Monobore Choke Valve Assembly for Fast Fracturing Overpressure Relief
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Solution Overview
Problem
Existing hydraulic fracturing systems face mechanical failures and slow pressure relief response times due to overpressure events, leading to costly repairs, increased downtime, and safety risks.
Innovation Solution
Implementing a monobore assembly with a control module, pressure relief choke valve, and bleed choke valve that rapidly respond to overpressure by actuating within 0.4 seconds to prevent damage, using a dual controller to manage pressure relief and bleed operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If industry leading relief valves and bleed valves are used for overpressure protection, then pressure relief function is provided, but mechanical failures occur at high rates due to severe pressure conditions
Solution Approach 1:
The patent replaces traditional mechanical relief valves with a choke valve system actuated by hydraulic or electric actuators. The choke valve uses a controlled opening mechanism rather than purely mechanical spring-loaded operation, substituting mechanical reliability with controlled actuation systems that are less prone to mechanical failure under severe pressure conditions.
Solution Approach 2:
The patent employs hydraulic actuators to drive the choke valve for pressure relief. By using hydraulic actuation instead of traditional mechanical valve mechanisms, the system leverages fluid power to achieve reliable operation under high pressure conditions, reducing mechanical failure rates while maintaining effective pressure relief capability.
2Reliability
If traditional relief valves are used for overpressure relief, then pressure relief is provided, but response time is slow
Solution Approach 1:
The patent implements a dynamic choke valve system with adjustable opening degrees and variable flow characteristics. The valve can rapidly transition from closed to fully open position and modulate intermediate positions, providing fast response time while maintaining effective pressure relief. The dynamic control capability allows the valve to adapt to different pressure conditions and respond faster than traditional static relief valves.
Solution Approach 2:
The patent changes the operational parameters of the valve system by using a choke valve design that allows continuous adjustment of opening degree and flow rate. This enables rapid response to pressure changes while maintaining relief effectiveness, as the valve can quickly change its flow parameters rather than relying on slow mechanical displacement of traditional relief valve components.
3Reliability
If choke valves are used for overpressure relief, then response time is reduced and reliability is improved, but device complexity increases
Solution Approach 1:
The patent designs the choke valve system to perform multiple functions: overpressure relief, flow control, and pressure regulation. By making the valve multi-functional, the system reduces overall complexity compared to using separate dedicated components for each function. The same choke valve handles both normal flow control and emergency pressure relief, simplifying the overall system architecture.
Solution Approach 2:
The patent combines the pressure relief function with the existing choke valve infrastructure rather than adding separate relief valve systems. By merging the overpressure protection function into the existing flow control valve, the system achieves improved reliability and faster response without proportionally increasing device complexity, as it utilizes and enhances existing components rather than adding entirely new systems.
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
Enhances the reliability and response time of overpressure protection, reducing mechanical failures, downtime, and safety risks, thereby increasing operational efficiency and reducing costs.
Implementation Method 1
The pressure relief choke valve is configured to receive the output action from the control module to actuate the pressure relief choke valve from a closed position to a fully open position in less than 0.4 seconds, thereby to prevent damage from overpressure
Implementation Method 2
The pressure transducer is mounted to the pressure relief choke valve body and configured to receive the pressure from the pressure sensing aperture and transmit the pressure signal to the control module during operation
Implementation Method 3
The body has a choke bean positioned therein configured to reduce the pressure of the pressurized fluid, thereby to adjust a flowrate of the fluid during operation
Data Source
AI summary
The present disclosure provides embodiments of a monobore assembly to be positioned in a hydraulic fracturing manifold system to provide overpressure relief and bleed using choke valves. The monobore assembly includes a control module, a pressure relief choke valve, a pressure transducer, and a bleed choke valve. The control module has a controller configured to receive a pressure signal, from the pressure transducer, and upon determination the pressure is above a predetermined threshold, send an output action to relieve the pressure in a throughbore of the monobore assembly. The pressure relief choke valve is configured to receive the output action and open in less than 0.4 seconds, thereby to prevent damage from overpressure within a throughbore of a first monobore junction. The bleed choke valve is also configured to receive the output action to controllably evacuate pressure, or pressurized fluid, within a throughbore of a second monobore junction.