Impulse Tolerant Valve Assembly for High-Pressure Pump Vibration
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Solution Overview
Problem
Reciprocating high-pressure pumps used in oil and gas fields, particularly those for fracking, experience significant vibration-induced issues due to high peak pressures, leading to rapid valve wear, corrosion fatigue, and structural failures, as conventional valve designs fail to manage the broad-spectrum high-frequency vibrations effectively.
Innovation Solution
An impulse tolerant valve assembly featuring a valve body with a nonlinear spring-mass damper immersed in a dilatant liquid, which reduces vibration energy transmission by tuning the damper to specific frequencies, incorporating an elastic valve body base plate and elastomeric seals to dissipate energy as heat, and utilizing a concave flexure to minimize wear and resonance excitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventionally-stiff valve body contacts a conventional frusto-conical valve seat, then valve closure force is sufficient to seal the valve, but broad-spectrum high-frequency vibration is generated causing damage to pump housing structures
Solution Approach 1:
A cushioning element is positioned between the valve body and valve seat to absorb impact energy before it propagates to the pump housing. This cushioning element deforms during valve closure to reduce the transmission of high-frequency vibrations while maintaining adequate sealing force.
Solution Approach 2:
An intermediary material or structure is introduced between the valve body and valve seat interface. This intermediary acts as a mediator that reduces the direct metal-to-metal contact, thereby dampening vibration transmission while preserving the sealing function.
2Reliability
If the valve body longitudinal movement stops abruptly during closure, then sealing is achieved, but kinetic energy is converted to high-amplitude closing energy impulse
Solution Approach 1:
A cushioning element is positioned between the valve body and valve seat to absorb impact energy before it propagates to the pump housing. This cushioning element deforms during valve closure to reduce the transmission of high-frequency vibrations while maintaining adequate sealing force.
Solution Approach 2:
The closure characteristics are modified by changing the compliance or damping properties of the valve assembly components. This allows the valve to maintain reliable sealing while reducing the peak closing energy impulse through controlled energy dissipation.
3Strength
If heavier and substantially more rigid valve bodies are used, then valve durability is improved, but vibration transmission to pump housing is increased
Solution Approach 1:
An intermediary material or structure is introduced between the valve body and valve seat interface. This intermediary acts as a mediator that reduces the direct metal-to-metal contact, thereby dampening vibration transmission while preserving the sealing function.
Solution Approach 2:
A sacrificial or replaceable cushioning element is used that absorbs vibration energy during valve operation. This element can be periodically replaced, allowing the use of durable valve bodies while managing vibration transmission through the consumable component.
4Power
If lighter valve bodies comprising interior cavities are used, then closing energy impulse amplitude is reduced, but valve structural rigidity is decreased
Solution Approach 1:
The valve body is constructed using composite materials or a hybrid structure combining lightweight materials with strategically placed reinforcement. This allows reduction of overall mass and closing energy impulse while maintaining sufficient structural rigidity for reliable operation.
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 solution effectively reduces the amplitude and duration of closing energy impulses, minimizing vibration-induced damage and corrosion susceptibility, thereby extending the lifespan of pump components and reducing maintenance costs in high-pressure applications.
Implementation Method 1
a valve body with a nonlinear spring-mass damper immersed in a dilatant liquid, which reduces vibration energy transmission by tuning the damper to specific frequencies
Implementation Method 2
a valve body with a nonlinear spring-mass damper immersed in a dilatant liquid, which reduces vibration energy transmission by tuning the damper to specific frequencies
Implementation Method 3
incorporating an elastic valve body base plate and elastomeric seals to dissipate energy as heat
Implementation Method 4
utilizing a concave flexure to minimize wear and resonance excitation
Data Source
AI summary
An impulse tolerant valve assembly comprises a valve body having a longitudinal axis and a central internal cavity, the cavity enclosing a nonlinear spring-mass damper optionally immersed in a dilatant liquid. The central internal cavity is enclosed by a proximal valve body portion and a distal elastic valve body base plate, the base plate having a peripheral valve seat interface. Impulse tolerance results in part from hysteresis heat loss due to compliance of the elastic valve body base plate, as well as from heat loss associated with operation of the nonlinear spring-mass damper. The combined heat loss is reflected in reduction of closing energy impulse amplitude and damping of induced valve body vibrations. Compliance of the elastic valve body base plate increases closing energy impulse duration and narrows the corresponding induced vibration spectrum. The valve body has at least one guide and at least one peripheral seal-retention groove.