Replaceable Valve Body Saver for High-Pressure Seal Wear
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Solution Overview
Problem
High-pressure valves used in hydraulic fracturing operations experience rapid deterioration due to corrosion, erosion, and wear at the sealing insert to main body interface, leading to frequent replacements and costly intrusive repairs, as existing solutions fail to address the root cause of interface failure.
Innovation Solution
A removable annular body saver is introduced, which is rigidly fixed to the valve body with no mechanical gap, isolating erosion and corrosion damage to the body saver rather than the valve body, allowing for replacement without welding or machining, and extending the service life of the valve body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a gate or plug valve is designed with small gaps between internal sealing parts to allow movement, then the valve can operate smoothly without locking up, but the gaps allow abrasive particles to penetrate and cause rapid deterioration of the sealing interface
Solution Approach 1:
The valve body is segmented into a permanent outer body and a removable inner liner. The liner contains the sealing surfaces and can be replaced independently without replacing the entire valve body. This segmentation allows the sealing interface to be maintained or replaced without affecting the valve body structure, resolving the contradiction by protecting the sealing interface from abrasive damage while maintaining operational smoothness.
Solution Approach 2:
The removable liner is extracted as a separate replaceable component from the valve body. This extraction allows the liner to be removed and replaced when worn, without requiring intrusive repairs to the valve body. The liner contains all sealing surfaces and interfaces exposed to abrasive flow, isolating the permanent valve body from deterioration.
2Ease of repair
If the valve body is repaired using intrusive methods such as welding to restore deteriorated sealing surfaces, then the valve can be restored to service, but the repair process is time-consuming and requires specialized equipment
Solution Approach 1:
The valve is segmented into a permanent body and a removable liner. When the sealing surfaces deteriorate, only the liner needs to be replaced, not the entire valve body. This segmentation transforms a complex intrusive repair operation into a simple component replacement, dramatically reducing repair time and eliminating the need for welding or machining the valve body.
Solution Approach 2:
The deteriorated liner is extracted and replaced with a new one. This extraction approach allows rapid replacement of worn sealing surfaces without requiring time-consuming intrusive repairs to the valve body. The liner can be replaced in-field without specialized repair equipment, significantly reducing downtime.
3Reliability
If high viscosity sealing greases are injected frequently to force proppant out of interfaces, then sealing effectiveness is maintained, but the service life of moving sealing faces remains very limited and requires frequent replacement
Solution Approach 1:
The removable liner is extracted as a sacrificial component that contains all sealing surfaces exposed to abrasive flow. By isolating the sealing faces within the removable liner, the liner absorbs all wear from proppant particles and abrasive fluid. The liner can be replaced frequently without affecting the permanent valve body, allowing frequent replacement of worn sealing surfaces while maintaining sealing effectiveness.
Solution Approach 2:
The removable liner functions as a disposable or short-lived component that is intentionally designed to wear out and be replaced. All sealing surfaces are contained within this replaceable liner, which absorbs abrasive damage from proppant particles. The liner can be frequently replaced without requiring replacement of the entire valve assembly, effectively managing the limited service life of sealing faces.
Data Source
AI summary
A high pressure valve includes a valve body having a surface defining a corresponding portion of a conduit and a pocket. A removable insert is removably inserted into the pocket of the valve body and has surface defining a corresponding portion of the conduit. A seal insert is spaced from the valve body by the removable insert and has an interface with the removable insert. A moving member interfaces with the seal insert for selectively closing the conduit, the interface between the seal insert and the removable insert allows play between the seal insert and the removable insert in response to movement of the moving member.