High-Pressure Pump Valve Assembly With Dampener Disk Sealing
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Solution Overview
Problem
Conventional valves in high-pressure hydraulic fracturing pumps face challenges with leakage and premature failure due to exposure to corrosive and abrasive fluids at extreme pressures, requiring frequent maintenance and replacement.
Innovation Solution
A novel valve configuration featuring a dampener disk sandwiched between a top plate and a valve body, with pressure apertures that compress and expand the disk to seal the valve, minimizing direct fluid contact and reducing erosion, and utilizing a floating pressure plate to deflect fluid pressure onto the disk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional valves are used in high-pressure hydraulic fracturing pumps, then the valve structure is simple and easy to manufacture, but the valve suffers from erosion and leakage leading to premature failure
Solution Approach 1:
The valve is divided into separate functional components: a valve body, a dampener disk, and a pressure plate. The dampener disk is positioned within the valve body to provide sealing, while the pressure plate applies force to the dampener disk. This segmentation allows each component to be optimized for its specific function, improving overall reliability without requiring complete redesign of the entire valve system.
Solution Approach 2:
The valve employs a composite structure combining a rigid valve body with a flexible dampener disk made of elastomeric or polymeric material. This composite approach allows the rigid structure to provide structural integrity while the flexible material provides erosion-resistant sealing surfaces, thereby extending valve lifespan in corrosive and abrasive fluid environments.
2Reliability
If the valve sealing surface is directly exposed to high-pressure corrosive and abrasive fluids, then the sealing function is maintained, but the sealing surface suffers from erosion and premature failure
Solution Approach 1:
The dampener disk serves as an intermediary element between the high-pressure corrosive fluids and the valve body sealing surface. This intermediate component is made of erosion-resistant flexible material that directly contacts the abrasive fluids, protecting the valve body from erosion while maintaining effective sealing through its deformable nature.
Solution Approach 2:
The dampener disk is constructed from flexible elastomeric or polymeric material that can deform to conform to the valve seat geometry, creating an effective seal. This flexible membrane approach provides erosion-resistant sealing surfaces that maintain contact under high-pressure conditions without suffering from the same erosion problems as rigid sealing surfaces.
3Reliability
If frequent maintenance and replacement of valves is performed, then leakage and erosion problems are addressed, but maintenance time and costs increase
Solution Approach 1:
The dampener disk is designed to absorb and cushion the effects of high-pressure corrosive and abrasive fluids before they can damage the valve body. This protective cushioning effect extends the time between maintenance intervals by preventing erosion and leakage issues that would otherwise require frequent intervention.
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 solution extends the lifespan of valves by reducing erosion and leakage, allowing for longer service intervals and cost-effective maintenance, while maintaining effective sealing at high pressures.
Implementation Method 1
a dampener disk sandwiched between a top plate and a valve body, with pressure apertures that compress and expand the disk to seal the valve
Implementation Method 2
utilizing a floating pressure plate to deflect fluid pressure onto the disk
Data Source
AI summary
A valve assembly for a high-pressure fluid pump is described herein. The valve assembly includes a valve seat disposed in a cylindrical bore in a fluid end of the pump, and a valve body that includes: a top plate defining at least one pressure window, a lower sealing surface disposed below the top plate, and a dampener disk disposed between the top plate and the lower sealing surface, the dampener disk configured to expand in response to pressure exerted thereon via the top plate and through the at least one pressure window.