Relief Valve Assembly for Hydraulic Fracturing Fluid Ends
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Solution Overview
Problem
In hydraulic fracturing, the buildup of pressurized fluid mixture due to proppants getting stuck in the fluid end of plunger pumps can lead to extreme pressure buildup, causing potential failure of the fluid end.
Innovation Solution
A relief valve assembly is introduced, featuring a housing with a chamber, a pilot inlet, an overpressure inlet, and a piston that separates the chamber ends, allowing fluid communication between the overpressure inlet and outlet when pressure exceeds a pilot pressure, redirecting the pressurized fluid back to the suction cavity for pressure relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If proppants are used in hydraulic fracturing, then production stimulation is achieved, but pressure buildup occurs due to proppants getting stuck in the fluid end
Solution Approach 1:
The relief valve assembly is pre-installed in the fluid end to prevent catastrophic pressure buildup before it occurs. The assembly includes a relief valve with a spring-loaded mechanism that automatically activates when pressure exceeds the spring force, creating a preliminary protective action against the harmful pressure buildup caused by proppant accumulation
Solution Approach 2:
The relief valve assembly converts the harmful effect of pressure buildup into a beneficial automatic safety mechanism. When proppants cause pressure to rise, the relief valve automatically opens to release the excess pressure, transforming the potential failure condition into a controlled pressure relief event that protects the system
2Reliability
If pressure relief mechanisms are added to prevent failure, then system reliability is improved, but device complexity increases
Solution Approach 1:
The relief valve assembly is integrated into the fluid end housing, merging the pressure relief function with the existing fluid end structure. The relief valve, spring, and associated components are combined into a single compact assembly that attaches to the fluid end, reducing the need for separate external pressure relief systems and minimizing overall device complexity
Solution Approach 2:
The relief valve assembly is designed to automatically activate and regulate pressure without external control or intervention. The spring-loaded mechanism self-regulates by opening when pressure exceeds the spring force and closing when pressure drops, providing self-service pressure management that improves reliability without requiring complex control systems
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 relief valve assembly effectively manages pressure by redirecting overpressurized fluid back to the suction cavity, preventing catastrophic failure and allowing for the recycling of the fluid mixture, thus maintaining system integrity and enabling continued operation.
Implementation Method 1
The piston may fluidly separate the first end from the second end
Implementation Method 2
The pilot inlet may be configured to provide a pilot pressure proximate the second end of the chamber
Data Source
AI summary
A relief valve assembly includes a housing assembly defining a chamber therein. The relief valve assembly includes a piston. The piston may be at least partially disposed within the chamber. The relief valve assembly includes a pilot inlet. The pilot inlet may be configured to provide a pilot pressure proximate a second end of the chamber. The relief valve assembly includes an overpressure inlet sealed from a first end of the chamber by the piston. The overpressure inlet may be configured to provide an inlet pressure which may actuate the piston when the inlet pressure exceeds the pilot pressure.