Reverse-Acting Rupture Disc for Hydraulic Fracturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic fracturing systems face pressure spikes that can lead to piping failure due to fatigue, and existing pressure relief solutions are inefficient, requiring frequent disc replacements and experiencing flow resistance issues.
Innovation Solution
A pressure relief device with a reverse-acting rupture disc and a straight vent path, designed to withstand high cycles without fatigue and provide unimpeded flow, using a thicker dome wall rupture disc and a weld-based sealing mechanism without elastomers, allowing for efficient pressure relief and quick replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional rupture disc with elastomer seals is used, then sealing is achieved, but flow resistance increases and replacement frequency increases
Solution Approach 1:
The patent removes elastomer seals entirely from the rupture disc assembly, extracting the harmful sealing component that caused flow resistance. The sealing function is replaced by a weld-based system using filler metal, eliminating the need for elastomers that impeded fluid flow while maintaining reliable sealing.
Solution Approach 2:
The patent replaces the mechanical elastomer seal system with a welding-based sealing mechanism. Instead of using elastomer materials that create flow resistance, the invention uses filler metal deposited through welding to create seals, substituting a mechanical sealing approach with a metallurgical bonding approach that reduces flow resistance.
2Ease of operation
If a rupture disc with thin dome wall is used, then ease of rupture is improved, but durability and fatigue resistance worsen
Solution Approach 1:
The patent applies local quality by concentrating the rupture initiation function in a specific localized area (the scored portion of the dome) while maintaining thicker walls in the overall dome structure for durability. The scoring creates a weak point for controlled rupture initiation, while the thicker dome wall provides overall structural strength and fatigue resistance.
Solution Approach 2:
The patent applies preliminary action by pre-scoring the dome wall during manufacturing to create a controlled weak point. This scoring is done in advance to ensure consistent rupture behavior at the desired pressure point, while the overall thicker dome wall structure is already in place to provide fatigue resistance before operation begins.
3Reliability
If frequent disc replacements are performed, then pressure relief functionality is maintained, but system downtime increases
Solution Approach 1:
The patent applies the disposable principle by making the entire rupture disc assembly a replaceable unit that can be quickly swapped out. The rupture disc with its scored dome is designed as a cost-effective disposable component that, when it fails, can be rapidly replaced without complex disassembly or specialized tools, minimizing system downtime despite frequent replacements being necessary.
Solution Approach 2:
The patent applies segmentation by designing the rupture disc as a separate, modular component that can be independently replaced from the rest of the pressure relief valve assembly. This segmentation allows the rupture disc to be swapped out quickly without affecting other components, reducing replacement time and system downtime.
4Volume of moving object
If a bent vent path is used, then device compactness is improved, but flow resistance increases
Solution Approach 1:
The patent applies inversion by reversing the conventional approach to vent path design. Instead of bending the vent path to achieve compactness, the invention uses a straight, unbent vent path that prioritizes flow efficiency. The device accepts a larger footprint as a trade-off for maximizing venting capacity and minimizing flow resistance through the straight path.
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 effectively manages pressure spikes, reducing the need for frequent replacements and minimizing flow resistance, enabling the system to operate safely and efficiently with reduced downtime, capable of handling up to 3.5 million cycles without failure.
Implementation Method 1
the disc is scored on its concave side to burst at a predetermined pressure
Implementation Method 2
a weld-based sealing mechanism without elastomers
Data Source
AI summary
A pressure relief device and a hydraulic fracturing system having a pressure relief device are provided. In one form, the pressure relief device has a valve body with a linearly extending throughbore between the inlet and outlet thereof. A rupture disc is secured in the valve body so that a frangible dome wall portion thereof has a reverse-acting orientation in the valve body bore. The hydraulic fracturing system includes a pump and a delivery line that receives pressurized fracturing fluid from the pump and delivers it to a well. A pressure relief device is installed along the delivery line. A sensor detects fluid flow downstream of the pressure relief device which allows the pump to be shut down when the downstream fluid flow is detected. The pressure relief device can have a body with a domed rupture disc and the sensor therein.