Plug Valve Assembly With Lubricant Channels for In-Line Servicing
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Solution Overview
Problem
Plug valves used in hydraulic fracturing applications face challenges due to harsh conditions such as high pressure, corrosive, and abrasive liquids, leading to short lifespan and frequent maintenance needs if not properly designed, while also being costly and difficult to install and service.
Innovation Solution
A plug valve assembly with a reduced weight and manufacturing cost, featuring a cylindrical plug body with lubricant channels and a grease port for easy maintenance, and compatibility with various actuation devices, allowing for in-line servicing and reduced personnel requirements during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plug valves are used in hydraulic fracturing applications, then they can handle high pressure and abrasive liquids, but they have short lifespan and require frequent maintenance
Solution Approach 1:
The valve body is divided into separate sections with replaceable liners that can be removed and replaced without replacing the entire valve. This segmentation allows critical wear surfaces to be renewed independently, extending the overall valve lifespan while reducing maintenance complexity
Solution Approach 2:
The patent modifies material parameters by using highly wear-resistant materials for the liners and sealing surfaces that can withstand abrasive liquids. This parameter change in material properties directly improves reliability under harsh hydraulic fracturing conditions
2Reliability
If traditional plug valves are designed for durability, then they can withstand harsh conditions, but they become costly and difficult to install and service
Solution Approach 1:
The valve assembly is segmented into modular components including removable liners and accessible sealing elements. This modular design maintains durability while enabling straightforward installation and maintenance operations without requiring complete valve replacement
Solution Approach 2:
The patent introduces intermediary components such as removable liners and seal cartridges that act as mediators between the harsh operating environment and the main valve body. These intermediaries protect the primary structure while being easily replaceable, thus maintaining reliability without increasing operational complexity
3Stress or pressure
If plug valves are designed with heavy-duty construction, then they can handle high pressure applications, but they require more personnel for installation and increase overall system weight
Solution Approach 1:
The valve is segmented into a stationary pressure-containing body and removable internal components. This allows the main body to be optimized for pressure handling while lighter-weight replaceable parts handle the abrasive fluid flow, reducing overall weight without compromising pressure capability
Solution Approach 2:
The patent employs composite construction with different materials optimized for specific functions: high-strength materials for pressure-containing surfaces and lighter wear-resistant materials for flow paths. This composite approach maintains pressure handling capability while reducing overall assembly weight
4Productivity
If traditional valve designs are used, then they provide basic functionality, but they require frequent shutdowns for maintenance and have longer downtime
Solution Approach 1:
The valve components are segmented to allow maintenance of critical parts without removing the valve from the pipeline. This enables quick replacement of liners and seals during scheduled maintenance windows, minimizing operational downtime and maintaining productivity
Solution Approach 2:
The patent incorporates preliminary design features such as pre-assembled seal cartridges and quick-connect components that allow maintenance personnel to perform repairs rapidly. These preliminary preparations reduce the actual maintenance time required, thereby reducing loss of operational time
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 new design achieves a 50% reduction in weight and manufacturing cost, simplifies installation and maintenance, and allows for easier adaptation to different actuation methods, enhancing operational efficiency and reducing downtime.
Implementation Method 1
Defined on the inward-facing surfaces of these inserts are channels 127 that allow a lubricant to be distributed around the plug body 116 to facilitate its rotation within the cavity of the valve body 102
Data Source
AI summary
A plug valve assembly has a valve body with an inlet and an outlet each defining a fluid passageway in fluid communication with a cavity defined within the valve body. The valve body further has a collar defining a service opening extending upward from the valve body. A plug with a spindle top and a plug body is disposed within the cavity. The plug has an opening that is operable to obstruct the fluid passageway when it is in a closed position and to connect the inlet to the outlet when it is in an open position. The spindle top of the plug has a hexagonal outer profile and a through opening and adaptable to engage with a variety of actuating devices. A threaded cap is removably engaged with the collar of the valve body and is operable to retain the plug within the valve body cavity.