Insertion Valve Assembly With Linear Cutters for Hot Tapping
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Solution Overview
Problem
Conventional insertion valve assemblies require large coupons to be cut from the existing pipe, increasing size and weight, and necessitate shutting down fluid pressure for replacement, causing prolonged service interruptions.
Innovation Solution
A valve kit with an insertion valve assembly and cutting assembly that uses linear cutters to make two spaced cuts through the existing pipe, reducing the size of the removed coupon and allowing installation without depressurizing the pipe, and includes a check valve to prevent fluid escape during maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional insertion valve assemblies are used, then the valve can be installed in the pipe, but a large coupon must be cut from the existing pipe, increasing size and weight
Solution Approach 1:
The cutting operation is segmented into two separate linear cuts instead of one large circular coupon removal. The first linear cutter makes a cut at a first location, and the second linear cutter makes a cut at a second location, dividing the removal operation into manageable segments that reduce the size of individual coupons while maintaining overall functionality.
Solution Approach 2:
The cutting approach transitions from a circular/cylindrical coupon removal (conventional method) to linear cuts along the pipe axis. By changing the dimensional approach from radial/circular to linear/longitudinal, the patent achieves smaller removed sections while simplifying the cutting mechanism.
2Productivity
If conventional insertion valve assemblies are used, then the valve can be installed, but installation requires shutting down fluid pressure, causing prolonged service interruptions
Solution Approach 1:
The linear cutters are designed to create precise cuts and prepare the pipe sections in advance, with the first cutter making a preliminary cut at a first location before the second cutter operates at a second location. This preliminary action allows for controlled, staged removal that maintains pressure containment throughout the process, enabling installation without complete pressure shutdown.
Solution Approach 2:
The cutting and installation process is designed to maintain continuous fluid flow containment. The first linear cutter creates a sealed section, then the second linear cutter completes the removal while maintaining pressure integrity. This continuous containment allows the valve installation to proceed without interrupting service, eliminating the need for pressure shutdown and restoration cycles.
3Volume of moving object
If linear cutters are used to make two spaced cuts, then the coupon size is reduced, but the cutting assembly complexity increases
Solution Approach 1:
The cutting assembly is segmented into two independent linear cutter units, each capable of making a linear cut at a specific location. This segmentation allows each cutter to be simpler in design compared to a single complex circular cutter, while the modular nature enables independent operation and maintenance of each cutting unit.
Solution Approach 2:
The cutting assembly incorporates movable and adjustable components that allow the linear cutters to be positioned and operated dynamically. The first linear cutter and second linear cutter can be independently actuated and positioned, providing flexibility in the cutting process while maintaining a relatively simple overall assembly structure through standardized, reusable components.
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
Facilitates the installation of insertion valves without service interruptions by minimizing the size of the removed pipe section and ensuring fluid containment during maintenance, enabling hot tapping processes.
Implementation Method 1
the outer valve body second section is configured to be coupled to the outer valve body first section and around the existing pipe, with the pair of outer body valve seals compressed to seal between the outer valve body first section and the outer valve body second section on opposite sides of the existing pipe
Implementation Method 2
a first seal disposed between the first gland and the outer valve body first end, the first seal sized to sealingly engage with the existing pipe when compressed between the first gland and the outer valve body first end, and a second seal disposed between the second gland and the outer valve body second end, the second seal sized to sealingly engage with the existing pipe when compressed between the second gland and the outer valve body second end
Data Source
AI summary
Systems and methods for cutting an existing pipe carrying a fluid under pressure include using a cutting assembly having first and second linear cutters spaced by a lateral width. The cutters are moved from a retracted position to an extended position thereby to cut a coupon from the existing pipe. An insertion valve may then be installed on the existing pipe at the location where the coupon was removed. The insertion valve includes a valve element that is movable between open and closed positions. In some examples, the systems and methods include a check valve that moves from an open position to a closed position as the valve element moves from the closed position to the open position, thereby to facilitate repair and/or replacement of the insertion valve.