Pipeline Isolation Plug With Ball-Joint Seal Modules
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Solution Overview
Problem
Existing pipeline isolation tools face limitations in providing reliable double block and bleed isolation, particularly in requiring trapped pressure for self-energization of secondary seals and lacking redundancy in lock arrays, which can lead to risks associated with single seal isolation and limited testing of lock arrays.
Innovation Solution
A pipeline isolation plug design featuring a first seal module with a single seal element and a second seal module with axially spaced seal elements, both configured to be self-energized by fluid pressure differentials, allowing for dual lock array redundancy and venting of the annulus between the second and third seal elements to ambient, ensuring continued sealing engagement even if external actuation fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single seal module with one seal element is used, then the device complexity is reduced, but the reliability of isolation is insufficient
Solution Approach 1:
The plug is divided into multiple seal modules (first seal module with first seal element, second seal module with second and third seal elements) that can be independently actuated. This segmentation allows each module to provide independent sealing capability, thereby improving overall isolation reliability while maintaining manageable device complexity through modular design.
Solution Approach 2:
Different seal modules are positioned at different locations along the plug body with specific seal elements at specific positions. The first seal module provides sealing at one location while the second seal module provides sealing at another location, creating localized quality improvements that collectively enhance overall isolation reliability.
2Reliability
If trapped pressure is used to provide self-energization of secondary seal, then the seal engagement is improved, but the risk from single seal isolation increases
Solution Approach 1:
The system prepares multiple seal elements (second and third seal elements in the second seal module) in advance, all capable of self-energization. This beforehand cushioning ensures that if one seal fails, other seals are already in place to maintain isolation, thereby reducing the harmful effect of single seal isolation failure while maintaining reliable seal engagement through self-energization.
Solution Approach 2:
The patent utilizes fluid pressure differential as a parameter to self-energize multiple seal elements. By changing the pressure parameter across the seal modules, the system activates multiple seals simultaneously or sequentially, improving reliability while distributing the risk rather than relying on a single seal.
3Reliability
If two lock arrays are added for redundancy, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The lock and seal functionality is segmented into separate modules (first seal module with first lock element, second seal module with second lock element). Each module contains its own lock and seal elements, providing redundancy while keeping each module's complexity manageable. This modular segmentation allows for easier assembly, testing, and maintenance compared to a fully integrated complex system.
Solution Approach 2:
The coupling between seal modules allows for relative movement and dynamic configuration. The modules can be assembled and disassembled independently, and their relative positions can be adjusted during operation. This dynamic capability simplifies the overall system complexity by allowing flexible configuration while maintaining the redundancy benefits of multiple lock arrays.
4Ease of operation
If modular seal and lock units are used for ease of assembly, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The plug is segmented into standardized modular units (seal modules with integrated lock elements) that can be independently manufactured, tested, and assembled. This segmentation improves ease of operation by allowing simple modular assembly while the standardization of each module keeps the individual component complexity manageable.
Solution Approach 2:
Each seal module is designed as a universal unit that combines seal and lock functionality. The modules can be used in different configurations and positions, providing multi-functionality that simplifies operation and assembly while avoiding the need for multiple specialized components, thereby controlling overall device complexity.
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 design provides enhanced reliability and safety by maintaining self-energization of multiple seal elements, facilitating double block and bleed isolation with reduced risk from single seal isolation, and enabling effective verification of lock integrity through pressure differentials and monitoring mechanisms.
Implementation Method 1
The first seal module is configured such that a fluid pressure differential across the module tends to actuate the first seal element
Implementation Method 2
The second seal module is configured such that a fluid pressure differential across the module tends to actuate the second and third seal elements
Data Source
AI summary
A pipeline isolation plug for location in a section of pipe has two seal modules coupled together by a ball joint. The first module has a mandrel defining a pressure head which, in use, is exposed to the pipeline pressure. A seal element is mounted behind the pressure head and is radially extendable to engage a pipe inner wall. The second module has a mandrel defining a pressure head which, in use, is exposed to the fluid pressure between the first and second modules. Two axially spaced seal elements are mounted on the mandrel behind the pressure head and are radially extendable to engage the pipe inner wall.