Injection Fitting Check Valve Retrieval Under Pipeline Pressure
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Solution Overview
Problem
The existing methods for replacing a failed inner check valve in a double check valve injection fitting require system shutdown, leading to potential leaks, emergencies, and operational disruptions, as accessing and removing the inner check valve allows product to escape from the pipeline.
Innovation Solution
A system comprising a hollow isolation ball valve assembly and an extraction tool that allows for the removal and replacement of the inner check valve without shutting down the system, using a detachable first and second section with a relief valve and an elongated inner key to unscrew and remove the failed inner check valve safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the inner check valve is accessed and removed by shutting down the system, then the valve can be replaced, but the system must be shut down causing operational disruption and potential safety hazards
Solution Approach 1:
The tool is divided into multiple sections: a hollow isolation ball valve assembly with first and second detachable sections, an extraction tool, and an elongated inner key. This segmentation allows the tool to be assembled in stages and enables the replacement procedure to be performed on isolated segments while the rest of the system remains operational.
Solution Approach 2:
The hollow isolation ball valve assembly acts as an intermediary device that isolates the inner check valve replacement procedure from the main system. By installing this assembly and closing its ball valve, the tool creates an isolated workspace where the inner check valve can be removed and replaced without affecting system operation or causing product escape.
2Productivity
If the inner check valve is accessed without system shutdown, then operational continuity is maintained, but product may escape from the pipeline creating safety hazards
Solution Approach 1:
Before accessing the inner check valve, the hollow isolation ball valve assembly is installed and its ball valve is closed to prevent product escape. This preliminary isolation action counteracts the potential harmful effect of product leakage that would occur during valve replacement, allowing safe work to proceed while the system remains operational.
Solution Approach 2:
The extraction tool and elongated inner key are prepared and positioned in advance through the hollow isolation ball valve assembly before the actual inner check valve removal begins. This preliminary preparation ensures that all necessary tools are in place and the isolation system is ready, enabling the replacement to be completed efficiently without system shutdown or product escape.
3Reliability
If a leak-lock adapter is used to stop leakage, then the leak is temporarily sealed, but the inner check valve still cannot function properly for sealant injection
Solution Approach 1:
The failed inner check valve is completely removed from the system using the extraction tool and elongated inner key through the hollow isolation ball valve assembly. By taking out the defective valve entirely rather than attempting to seal around it, the tool restores full functionality for sealant injection while maintaining leak prevention through the isolation assembly's closed ball valve during the procedure.
Data Source
AI summary
A system for retrieving a failed inner check valve that is part of an injection fitting includes a hollow isolation valve assembly that includes a first section and a second section that is detachable from the first section. The first section includes a first valve and the second section including a relief valve. The first valve moves between a closed position in which the first section is completely occluded and an open position and can be in the form of a ball valve. The system also includes an extraction tool that is configured to be coupled to and advanced along the isolation valve assembly. An elongated inner key is configured to be received into and pass through the hollow isolation valve assembly. A distal end of the inner key is configured to engage and unscrew the failed internal check valve for removal thereof.