Differential Pressure Valve with Variable Restrictor for Piggable Leak Shutoff
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Solution Overview
Problem
Existing pipeline systems lack an effective mechanism to automatically detect leaks and prevent environmental damage by stopping the flow of materials in case of a rupture, while also being compatible with pigging operations for cleaning and inspection.
Innovation Solution
A differential pressure actuated valve system with a variable flow restrictor and primary flapper that automatically closes when a leak is detected, using pressure differentials to control the flow and maintain pipeline integrity, allowing for pigging operations by maintaining a standard pipeline diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a valve is designed to automatically detect leaks and stop flow, then pipeline safety and environmental protection are improved, but the device complexity increases due to the need for sensors and control systems
Solution Approach 1:
The valve uses the pipeline's own operating parameters (pressure differential) to trigger automatic closure. The differential pressure actuator senses leak conditions through natural pressure changes and autonomously actuates the flapper without external sensors or control systems, achieving self-diagnosis and self-protection
Solution Approach 2:
The differential pressure actuator serves as an intermediary mechanism that translates pressure differential changes into mechanical flapper motion. This intermediary converts subtle pressure changes into reliable valve closure action without requiring complex electronic sensing or control infrastructure
2Reliability
If a flow restrictor is added to create pressure differential for leak detection, then leak detection capability is improved, but the valve complexity and resistance to pig passage increase
Solution Approach 1:
The flow restrictor is designed with variable resistance capability, allowing it to dynamically adjust its flow restriction characteristics. This dynamic design enables the restrictor to provide sufficient pressure differential for leak detection during normal operation while minimizing resistance to pig passage during maintenance operations
Solution Approach 2:
The flow restrictor serves multiple functions: creating pressure differential for leak detection, maintaining flow control during operation, and allowing pig passage during maintenance. This multi-functionality reduces the need for separate components and simplifies the overall valve structure
3Adaptability or versatility
If the pipeline diameter is maintained for pigging operations, then maintenance capability is improved, but the ability to create sufficient pressure differential for leak detection deteriorates
Solution Approach 1:
The flow restrictor creates localized flow resistance at a specific point in the pipeline without reducing the overall pipeline diameter. This localized restriction generates the necessary pressure differential for leak detection while maintaining full pipeline capacity and pigging capability elsewhere in the system
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 system effectively prevents environmental damage by automatically stopping material flow upon leak detection, ensuring pipeline integrity and enabling safe passage of pigging devices for maintenance without external sensors or power.
Implementation Method 1
creating a pressure differential in the flow of material across the variable flow restrictor including relatively high-pressure material in the upstream portion and relatively low-pressure material in the downstream portion
Implementation Method 2
the primary flapper separates the relatively high-pressure material in the upstream portion from the portion of the relatively low-pressure material in the low-pressure chamber, is held in the first position by the pressure differential
Data Source
AI summary
A valve system for controlling a flow of material includes a pipeline including an upstream portion a downstream portion. The system includes a variable flow restrictor configured for providing a restrictive orifice within the pipeline and creating a pressure differential in the flow of material high-pressure material in the upstream portion and low-pressure material in the downstream portion. The system includes a low-pressure tube connected to the downstream portion and a low-pressure chamber connected to the tube and receiving low-pressure material. The chamber includes a secondary flapper configured for selectively blocking the tube. The system includes a primary flapper disposed between the upstream portion and the low-pressure chamber and configured to be disposed in one of a first and second position. The flapper is held in the first position by the pressure differential. The flapper moves to the second position blocking the pipeline when a leak occurs.