Hydrofoil Flapper Valve Assembly for Abrasive Frac Flow
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Solution Overview
Problem
Conventional high-pressure fluid transportation systems, particularly in the oil and gas industry, face challenges with abrasive and corrosive frac slurries that cause erosion and corrosion in zipper manifolds and valves, leading to increased maintenance costs and reduced system reliability due to the use of gate valves which are prone to seizing and require frequent greasing, and the need for improved components and methods to handle high-pressure and turbulent flows.
Innovation Solution
The development of pivot valves and flapper valves with novel designs that include a valve housing with a pivot or flapper mechanism, allowing for selective operation modes to manage flow direction and reverse flow, along with enhanced zipper manifolds and flowline fittings that incorporate rotatable elbows and spherical plenums to reduce erosion and corrosion, and methods for assembling these components using flange unions for improved flexibility and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If gate valves are used in high-pressure fluid transportation systems, then flow control capability is improved, but the valves are prone to seizing and require frequent greasing which increases maintenance costs and reduces reliability
Solution Approach 1:
The patent replaces traditional gate valve mechanisms with flapper valve mechanisms that use fluid pressure and hydrofoil lift forces instead of mechanical gating systems. This substitution eliminates the seizing problems associated with mechanical gate valves while maintaining flow control capability through the flapper's ability to pivot open and closed based on pressure differentials and hydrofoil aerodynamics.
Solution Approach 2:
The patent employs hydraulic principles through the use of hydrofoils that generate lift forces from fluid flow to automatically pivot the flapper open during normal operation. This hydraulic actuation eliminates the need for mechanical actuators and greasing mechanisms, thereby improving reliability while maintaining operational control through pressure-based actuation.
2Ease of manufacture
If conventional valve designs are used in abrasive frac slurries, then initial manufacturing cost is reduced, but erosion and corrosion increase leading to reduced component lifespan
Solution Approach 1:
The patent changes the geometric parameters of the valve components, specifically using streamlined flapper shapes and hydrofoil configurations that reduce turbulence and direct abrasive flow away from critical sealing surfaces. This parameter optimization maintains manufacturing simplicity while significantly reducing erosion rates and extending component lifespan in abrasive frac slurry environments.
3Adaptability or versatility
If zipper manifolds with multiple valves are used to control flow to multiple wells, then flow distribution capability is improved, but the complexity of assembly and maintenance increases
Solution Approach 1:
The patent designs universal flapper valve assemblies that can be installed in standardized configurations within zipper manifolds to control flow to multiple wells. Each flapper valve unit serves multiple functions including flow control, check valve operation, and pressure regulation, thereby achieving versatile flow distribution capability while maintaining relatively simple assembly through standardized interfaces and modular design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The novel valves and fittings provide enhanced operational reliability and reduced maintenance by allowing quick mode changes, minimizing grease usage, and reducing erosion and corrosion, thereby extending the lifespan of components and lowering operational costs in high-pressure fluid transportation systems.
Implementation Method 1
A hydrofoil extends from the flapper. The hydrofoil generates lift on the flapper to keep it elevated during forward flow.
Implementation Method 2
The flapper will pivot away from the seat in response to flow through the passage in a flow direction.
Implementation Method 3
The flapper will bear on the seat in response to flow through the passage in a reverse-flow direction.
Data Source
AI summary
Pivot valves have a valve seat and a valve closure mounted for pivoting movement through a closure chamber in a passage. The pivot valves may be selectively set in a check mode and an open mode. Flapper valves have a hydrofoil extending from a flapper. Valve assemblies comprise the pivot valves and flapper valves and have an open condition, a check condition, and a shut-off condition.