Piston-Actuated Test Flange Assembly for High-Pressure Sealing
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Solution Overview
Problem
The existing methods for testing and certifying flanged connections, such as Christmas trees used in oil and gas wells, are time-consuming and labor-intensive due to the need for high torque application on numerous fasteners to achieve the required sealing force for high-pressure applications.
Innovation Solution
The test flange assembly comprises a flange body and a piston that is operatively coupled to the flange body, with a circular seal channel on the piston's outer surface and a larger inner surface area, allowing for pressurization to create a differential force that seals the flanged connection with reduced torque requirements, enabling efficient sealing and testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional blind flange testing methods are used with high torque on numerous fasteners, then reliable sealing is achieved, but time consumption and labor requirements increase significantly
Solution Approach 1:
The invention divides the sealing function into two independent parts: the seal structure itself and the force application mechanism. The piston assembly separately provides the sealing force through pressurization, while the fasteners only need to maintain positional alignment. This segmentation allows the sealing function to be achieved without requiring high torque on multiple fasteners, thereby reducing testing time while maintaining sealing reliability.
Solution Approach 2:
The piston assembly acts as an intermediary mechanism that translates fluid pressure into sealing force. Instead of relying directly on fastener torque to create sealing force, the piston mediates this process by using pressurized fluid to generate the necessary sealing force on the seal structure, significantly reducing the torque requirements on fasteners and thereby reducing testing time and labor.
2Reliability
If high torque is applied to numerous fasteners to achieve required sealing force, then adequate sealing is obtained, but operational effort and complexity increase
Solution Approach 1:
The invention uses hydraulic principles by introducing a piston assembly that utilizes pressurized fluid to generate sealing force. The fluid pressure acts on the piston surface area to create the necessary force on the seal structure, replacing the need for high mechanical torque on multiple fasteners. This hydraulic approach significantly reduces operational effort while maintaining adequate sealing force.
Solution Approach 2:
The invention substitutes the traditional mechanical torque-based sealing system with a pressure-based system. Instead of relying on mechanical torque applied to fasteners to create sealing force, the system uses pressurized fluid acting on the piston to generate the sealing force. This mechanical substitution reduces the complexity and effort of torque application while achieving the same sealing reliability.
3Strength
If multiple fasteners are used to secure blind flange, then connection strength is ensured, but device complexity and assembly time increase
Solution Approach 1:
The invention segments the functions of fasteners and sealing components. The fasteners are reduced in number and their function is limited to maintaining positional alignment and preventing lateral displacement. The sealing function is separately handled by the piston-actuated seal structure. This segmentation allows connection strength to be maintained with fewer fasteners while reducing device complexity.
Solution Approach 2:
The piston assembly serves as an intermediary that provides the sealing force without requiring multiple fasteners. By introducing this intermediate mechanism, the system achieves adequate connection strength and sealing with a reduced number of fasteners, thereby simplifying the overall device structure and reducing assembly 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
This solution significantly reduces the time and labor required for sealing and testing by applying a greater sealing force with less torque, effectively sealing flanged connections under high pressures with reduced operational effort.
Implementation Method 1
pressurizing a volume between the piston and the flange body so that the piston compresses the seal structure between the piston and the flanged component
Implementation Method 2
A portion of the outer surface radially inward from the circular seal channel has a surface area that is less than a surface area of the inner surface
Data Source
AI summary
Test flange assemblies comprise a flange body and a piston. The piston is configured to translate relative to the flange body and has an outer surface facing away from the flange body and an inner surface facing toward the flange body. The outer surface defines a circular seal channel for receiving a seal structure between the piston and a flange surface of a flanged component. The outer surface radially inward from the circular seal channel has a surface area that is less than a surface area of the inner surface. Methods of testing pressure containing structures comprise operatively positioning the test flange assembly, positioning a seal structure within the circular seal channel of the piston, coupling the flange body to a flanged component, and pressurizing a volume between the piston and the flange body so that the piston compresses the seal structure between the piston and the flanged component.