Insertion Valve Assembly for Small-Coupon Pipe Tapping
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Solution Overview
Problem
Conventional insertion valve assemblies require a large coupon 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 minimize the size of the coupon removed and includes a check valve to prevent fluid escape during maintenance, allowing installation and maintenance without pressure shutdown.
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 pressurized pipes, but a large coupon must be cut from the existing pipe, increasing size and weight
Solution Approach 1:
The cutting assembly uses multiple linear cutters (first linear cutter and second linear cutter) spaced apart to make sequential linear cuts through the pipe, dividing the cutting process into segments that create a smaller coupon compared to conventional single-cutter methods
Solution Approach 2:
The invention transitions from conventional circular/cylindrical cutting paths to linear cutting paths by using linear cutters that move in straight lines through the pipe, changing the dimensional approach to cutting and resulting in a smaller coupon volume
2Productivity
If conventional insertion valve assemblies are used, then the valve can be installed in pressurized pipes, but replacement requires shutting down fluid pressure, causing prolonged service interruptions
Solution Approach 1:
The insertion valve assembly is designed to be installed and replaced in pressurized pipes without requiring shutdown of the fluid system, maintaining continuous useful action of fluid flow through the pipe during maintenance operations
Solution Approach 2:
The valve assembly incorporates dynamic sealing capabilities with glands and seals that can accommodate pressure variations and maintain sealing effectiveness during installation and operation in pressurized conditions, enabling maintenance without pressure shutdown
3Quantity of substance
If conventional insertion valve assemblies are used, then the valve can function in pressurized pipes, but the assembly size and weight increase
Solution Approach 1:
The cutting assembly divides the cutting function into multiple linear cutters working in sequence, removing material more efficiently and creating a smaller coupon volume relative to the assembly size compared to conventional single-cutter designs
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
Reduces service interruptions by enabling installation and maintenance of insertion valves in pressurized pipes with minimal fluid loss and without depressurizing the system.
Implementation Method 1
first and second linear cutters spaced by a lateral distance, wherein the first and second linear cutters are mounted to a carriage translatable between a retracted position, in which the first and second linear cutters are disposed within the cutting assembly chamber, and an extended position, in which the first and second linear cutters project from the cutting assembly housing by a cutting distance sufficient to extend entirely through the existing pipe
Implementation Method 2
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
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.