Multi-Orifice Choke Valve Layout to Reduce Erosion
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Solution Overview
Problem
Conventional choke valves used in high-pressure hydrocarbon wells tend to erode prematurely due to turbulent and abrasive fluid flows, leading to reduced durability and increased maintenance costs.
Innovation Solution
The development of an orifice valve with multiple, elongate flow orifices configured at an angle or tapering towards each other, combined with a wear sleeve and flow restrictor, which reduces the likelihood of fluid jets impinging on the valve components, thereby minimizing erosion and enhancing resistance to wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a conventional choke valve is used to achieve high pressure drop, then the pressure reduction function is achieved, but the valve erodes prematurely due to turbulent and abrasive fluid flow
Solution Approach 1:
The single large flow passage is segmented into multiple smaller flow passages (e.g., 2, 4, 6, or more passages arranged radially or in parallel). This segmentation distributes the high-velocity fluid flow across multiple smaller channels, reducing the erosive impact on any single passage wall while maintaining the overall pressure drop function. The segmented design allows the valve to achieve the required pressure reduction without the premature erosion that plagues conventional single-passa
2Stress or pressure
If the flow passage is reduced to achieve pressure drop, then the pressure reduction is achieved, but the fluid velocity increases causing more erosion
Solution Approach 1:
By dividing the flow into multiple parallel passages, the velocity in each individual passage is reduced compared to a single passage design. The total pressure drop is achieved through the combined effect of multiple passages, each operating at lower velocities that minimize erosive forces.
Solution Approach 2:
The flow passages are arranged in multiple spatial dimensions (radial arrangement around a central axis, or parallel stacking), transforming a one-dimensional flow path into a multi-dimensional flow distribution system. This dimensional expansion allows the fluid to be distributed across multiple pathways, reducing velocity in each path while maintaining overall pressure drop performance.
3Reliability
If a wear sleeve is added to protect against erosion, then the resistance to wear is improved, but the device complexity increases
Solution Approach 1:
The valve incorporates a wear sleeve made from erosion-resistant materials (such as hardened steel, ceramic-coated materials, or other composite materials) that line the flow passages. This composite construction combines the pressure control functionality of the valve body with the erosion resistance of specialized materials, protecting the valve components from abrasive damage while maintaining a relatively simple overall structure.
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 orifice valve achieves a high pressure drop while reducing the risk of erosion, extending the valve's lifespan and improving operational safety and efficiency by distributing fluid jets in a manner that minimizes contact with valve components.
Implementation Method 1
The orifice valve achieves a high pressure drop while reducing the risk of erosion
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
An orifice valve as disclosed herein produces a high pressure drop in a flowing fluid. A valve body includes a flow restrictor with multiple flow orifices or ports. The flow ports produce fluid jets. The flow ports may be angled relative to the axial centerline of the valve body.