Replacement Valve Assembly for Pressurized PCCP Insertion

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Solution Overview

Problem

Existing methods for replacing valves in prestressed concrete cylinder pipes (PCCP) are inefficient, requiring complex setups and risking pipe rupture due to the need to strip wire reinforcements, and existing valve designs lack retraction capabilities, necessitating pipeline shutdown for repairs.

Innovation Solution

A replacement valve assembly that uses a temporary enclosure for precise and controlled movement of a cut-covering assembly, allowing for easy insertion and retraction, and includes a linkage system that expands to fit larger diameters for corroded pipes, enabling valve installation without disrupting the pipe's internal pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the valve isolator uses a one-way pushing movement to insert the cut-covering assembly into the pipe, then the valve replacement can be performed, but the sealing mechanism cannot be retracted and pipeline shutdown is required for corrections

Engineering Contradiction:

Improvevalve replacement operationVSAvoidsealing mechanism correction

Core Design Contradiction:

Ease of operationVSEase of repair

Solution Approach 1:

The linkage assembly converts the rotational movement of the valve isolator into reciprocating linear movement, enabling the cut-covering assembly to both advance into and retract from the pipe. This dynamic bidirectional movement allows the sealing mechanism to be retracted for corrections without pipeline shutdown, resolving the one-way movement limitation.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the cut-covering assembly has a larger diameter to accommodate corroded pipes, then it can fit larger internal diameters, but it becomes difficult to insert into existing pipe ends

Engineering Contradiction:

Improveaccommodation of corroded pipesVSAvoidinsertion into pipe ends

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The cut-covering assembly is designed with expandable elements that allow it to be inserted in a collapsed, compact state through the pipe end, then expanded once inside to accommodate larger internal diameters and corroded pipe conditions. This dynamic size change resolves the contradiction between insertability and adaptability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cut-covering assembly employs a nested structure where the sealing elements and support structures are collapsed within the insertion tool during insertion, then deployed outward once positioned. This nesting allows easy insertion while providing the necessary adaptability for corroded pipes.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Manufacturing precision

If the linkage assembly uses intermediate moving parts to control cut-covering assembly movement, then precise and controlled advancement and retraction is achieved, but the device complexity increases

Engineering Contradiction:

Improvecut-covering assembly positioningVSAvoidlinkage assembly structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The linkage assembly replaces complex multi-stage hydraulic or electronic positioning systems with a mechanical conversion system that uses the existing rotational movement of the valve isolator to drive the reciprocating movement of the cut-covering assembly through intermediate linkages. This substitution achieves precise control while managing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables safe and efficient valve replacement in PCCP pipelines by maintaining internal pressure during operations, preventing pipe rupture and allowing for quick issue reversal, while accommodating various pipe materials and internal corrosion.

Implementation Method 1

The linkage includes intermediate moving parts that collaborate to hold, advance and retract the cut-covering assembly in precise movements as the valve's isolator is rotated between the closed and open positions

Methodology Applied

Scientific EffectMechanical linkage: Four-Bar Linkage

Implementation Method 2

Movement of the valves isolator activates the linkage to mechanically press the cut-covering assembly against the inside pipe wall by expanding the cut-covering assembly to fit a larger inside diameter than the cut-covering assembly

Methodology Applied

Scientific EffectMechanical expansion: Mechanical Force

Data Source

PatentUS11892115B2Valve insertion tool

Publication Date: 2024.02.06 MAICHEL JEFFREY L

AI summary

A method of cutting and removing a section of prestressed concrete cylinder pipe and then installing a replacement valve while the pipeline is fully pressurized uses a replacement valve body with two cylinders that match the openings of the cut pipe. Inside each of the two cylinders is a cut-covering assembly which includes a cylindrical elastomeric seal and a mechanical linkage to move the seal in and out of the cut pipe. The replacement valve body further includes a rotatable valve in a central portion of the valve, and when the cylinder ends of the replacement valve body are positioned adjacent the bores of cut pipe ends, the valve can be rotated to move linkage assemblies that control the elastomeric seals in and out of each of the cut-covering assemblies into the bores of the cut pipe ends, thereby covering gaps created when the pipe was cut and placing the pipe ends in fluid-tight engagement with the replacement valve body.