Pressure Switch Diaphragm and Dart Mechanism for Wide Range Operation
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Solution Overview
Problem
Existing pressure switch systems fail to operate effectively across a wide range of pressures, from low to high, in high-pressure environments, posing safety risks by allowing disengagement of remote connectors at hazardous pressurized conditions.
Innovation Solution
A fail-safe pressure switch assembly that includes a diaphragm, pin, dart, and sensor, which transitions between closed and open positions based on pressure thresholds, preventing disengagement of remote connectors from the wellhead across a pressure range of 30 PSI to 22,500 PSI, using a compression assembly and communication pathway to control hydraulic valve actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a pressure switch is designed to operate at high pressures, then it can function in high-pressure environments, but it fails to activate at low pressures within the same environment
Solution Approach 1:
The pressure switch is divided into separate functional components: a diaphragm for pressure sensing, a compression assembly with spring for force application, a dart for mechanical movement, and a sensor for detection. This segmentation allows each component to be optimized for its specific function, enabling reliable operation across both low and high pressure ranges
Solution Approach 2:
A compression assembly with a spring acts as an intermediary between the diaphragm and the dart. The spring compresses under diaphragm pressure and applies force to the dart, providing mechanical amplification that enables the switch to detect low pressures while remaining stable at high pressures
2Ease of operation
If the remote connector is allowed to disengage freely, then operation is simple and quick, but pressurized fluid may be released causing harm to personnel and equipment
Solution Approach 1:
The pressure switch is activated in advance before disengagement occurs. When pressure exceeds the safe threshold, the sensor detects this condition and prevents the remote connector from disengaging, thereby eliminating the hazard before it can manifest
Solution Approach 2:
The sensor provides continuous feedback about the pressure condition to the control system. This feedback loop enables real-time monitoring and automatic prevention of disengagement when unsafe pressure levels are detected, ensuring personnel and equipment safety
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
Ensures safe operation by preventing disengagement of remote connectors during high-pressure conditions, maintaining functionality at low pressures and providing a safety mechanism to prevent harm to personnel and equipment.
Implementation Method 1
transitioning the diaphragm to an energized position based on the first pressure to exert a force against the pin
Data Source
AI summary
A pressure switch system provides a safety mechanism for equipment at a well site environment to prevent the opening or release of certain components when an unsafe condition exists. A pressure switch assembly of the system includes a diaphragm that transitions to an extended position as pressure of a pressurized fluid is flowed through a fluid pathway of the assembly. The diaphragm couples to a pin that transitions along with a dart based on the pressure at the diaphragm. When pressure reaches or exceeds a threshold, the dart is transitioned to a location proximate to a sensor. The sensor triggers actuation of a switch to prevent release or opening of a remote connector of a hydraulics unit until the pressure is at or falls below the threshold. The threshold is set to a pressure based on the unsafe condition.