Electro-Hydraulic Plug Valve Pressure Relief for Fast Wellbore Response
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Solution Overview
Problem
Existing pressure relief valve systems in high-pressure fluid injection operations, such as those in well sites, are slow to open and require multiple revolutions, posing risks during lubrication and maintenance, and often rely on gate valves that are prone to erosion and slow cycling.
Innovation Solution
An electronically controlled pressure relief valve system with two rotatably-actuated plug valves in series, actuated by electro-hydraulic actuators, which can open rapidly with less than one complete revolution, and includes pressure transducers for real-time pressure monitoring and a programmable controller to manage pressure thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If gate valves are used in pressure relief systems, then the system structure is simple, but the valve opening speed is slow and requires multiple revolutions
Solution Approach 1:
The patent replaces the traditional mechanical gate valve with a plug valve actuated by an electro-hydraulic actuator. This substitution enables rapid valve opening (in less than one complete revolution) by using electro-hydraulic power instead of manual or slow mechanical actuation, directly resolving the contradiction between opening speed and actuation complexity.
Solution Approach 2:
The patent employs electro-hydraulic actuators to drive the plug valves. The hydraulic system provides high-speed actuation capability, allowing the valve to open rapidly in less than one complete revolution. This hydraulic actuation mechanism resolves the speed limitation of traditional gate valves while maintaining controlled operation.
2Reliability
If traditional pressure relief valve systems are used, then the system design is conventional, but the valve is prone to erosion and slow cycling
Solution Approach 1:
The patent changes the valve design parameters by using a plug valve instead of a gate valve. The plug valve geometry and electro-hydraulic actuation provide both faster cycling capability and improved resistance to erosion from high-pressure fluids. This parameter change simultaneously addresses both reliability and productivity concerns.
Solution Approach 2:
The patent introduces dynamic actuation through electro-hydraulic actuators that can rapidly cycle the plug valves. The system enables quick opening and closing operations, improving valve cycling speed while the plug valve design inherently provides better erosion resistance compared to static gate valve designs.
3Reliability
If rapid valve opening is implemented, then safety is improved, but the actuation system becomes more complex
Solution Approach 1:
The patent replaces simple mechanical actuation with an electro-hydraulic actuation system that enables rapid valve opening for safety. While this increases system complexity, it provides the critical safety function of quickly isolating high-pressure zones during maintenance operations, prioritizing safety over simplicity.
Solution Approach 2:
The electro-hydraulic actuator serves as an intermediary between the control system and the valve mechanism. It translates electrical signals into rapid hydraulic actuation, enabling safe and quick valve operation. This intermediary component manages the complexity while delivering the safety benefit of rapid response.
4Loss of time
If plug valves with less than one complete revolution are used, then maintenance time is reduced, but the actuator design becomes more sophisticated
Solution Approach 1:
The patent replaces traditional multi-revolution valve actuation with an electro-hydraulic actuation system that opens the plug valve in less than one complete revolution. This substitution dramatically reduces maintenance time by enabling rapid valve operation, while the sophisticated actuator design is the trade-off for achieving this time reduction.
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 enables rapid pressure relief, reducing the risk of screen-out and erosion, and allows for quick maintenance with valves opening in less than 0.5 seconds, enhancing safety and efficiency in high-pressure fluid injection operations.
Implementation Method 1
two rotatably-actuated plug valves in series, actuated by electro-hydraulic actuators, which can open rapidly with less than one complete revolution
Implementation Method 2
includes pressure transducers for real-time pressure monitoring and a programmable controller to manage pressure thresholds
Implementation Method 3
The actuation of the plug valves redirects flow of the fluid to relieve pressure in the fluid injection system below the threshold level
Data Source
AI summary
A pressure relief valve system for a fluid injection system is provided. The PRV system comprises one or more pressure transducers configured to sense fluid pressure within the fluid injection system. The transducers then generate electrical signals representative of fluid pressure readings within the fluid injection system in real time. Signals are received by a controller which compares pressure readings with a stored pressure threshold. An actuation signal is sent upon detecting a signal representative of a pressure that exceeds the stored pressure threshold, causing an electraulically-actuated valve to rotatably move to an open position. The PRV system includes a bypass feature that allows the operator to manually open or close a valve when the stored pressure threshold is reached. A method of controlling pressure during a wellbore operation is also provided.