Rupture Disc Assembly Withstand High Back Pressure
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Solution Overview
Problem
Existing rupture disc units fail to reliably withstand extremely high differential back pressures and consistently operate across a wide temperature range while being selectively openable under lower activation pressure, especially in harsh oil field conditions.
Innovation Solution
A rupture disc unit with a bulged disc and a self-releasing conical plug, where the plug is designed to support the disc under high pressure and release to allow rupture at a lower activation pressure, using a tapered fluid passage and a capture mechanism to ensure reliable operation, constructed from materials like stainless steel and Inconel to withstand corrosive conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rupture disc is designed to withstand high differential back pressure, then the disc thickness and strength must be increased, but this makes the disc difficult to rupture at lower activation pressures
Solution Approach 1:
The system is divided into two functional components: a support structure (housing with tapered passage) that withstands high back pressure, and a rupture disc that is optimized for selective rupture at activation pressure. The conical plug acts as a pressure-distributing element that separates the back pressure load from the rupture disc, allowing the disc to be thin and easily rupturable while the housing structure handles the high pressure containment.
Solution Approach 2:
The conical plug serves as an intermediary element between the high back pressure environment and the rupture disc. It distributes the back pressure forces around the rupture disc perimeter rather than concentrating them on the disc surface, enabling the disc to remain thin and easily rupturable while the system withstands high differential pressures.
2Ease of operation
If the rupture disc is made thinner to allow easy rupture at activation pressure, then selective opening becomes easier, but the disc cannot withstand high differential back pressures
Solution Approach 1:
The system separates the pressure-withstanding function (handled by the housing and conical plug structure) from the rupture function (handled by the thin disc). This segmentation allows the disc to be optimally thin for easy activation while the surrounding structure provides the necessary back pressure containment capability.
Solution Approach 2:
The conical plug acts as a mediator that intercepts and redistributes back pressure forces before they reach the thin rupture disc. By positioning the plug in the tapered passage, it creates a mechanical advantage that allows the thin disc to rupture selectively at activation pressure while the system as a whole withstands high differential pressures.
3Ease of manufacture
If conventional rupture disc designs are used, then manufacturing is simple, but they fail to reliably withstand extremely high differential back pressures while being selectively openable
Solution Approach 1:
The conical plug design utilizes dynamic pressure distribution - at high back pressure, the plug expands to fill the tapered passage and distribute forces uniformly around the rupture disc perimeter. At activation pressure, the force distribution changes, allowing localized rupture. This dynamic response enables reliable operation across different pressure conditions while maintaining manufacturing simplicity.
Solution Approach 2:
The system changes the pressure distribution parameters around the rupture disc through the conical plug geometry. The tapered passage and conical plug create a specific force distribution pattern that enhances back pressure withstand capability while preserving selective rupture characteristics, improving reliability without complicating manufacturing.
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 unit effectively withstands high differential back pressures up to 50,000 psig and operates reliably across a 40°F to 350°F temperature range, withstanding 100 cycles of pressure without fatigue, and is economical to manufacture and install, ensuring reliable operation in oil field applications.
Implementation Method 1
A conical, self-releasing plug is complementally received in the tapered passage with the largest end face in conforming engagement with the concave surface of the bulged section of the rupture disc. The plug is of sufficient mass to support and prevent rupture of the disc under a high differential back pressure applied against the rupture disc
Implementation Method 2
A tapered, generally conical, self-releasing solid plug is complementally received in the tapered passage with the largest end face in conforming engagement with the concave surface of the bulged section of the rupture disc
Data Source
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AI summary
An activation rupture disc unit is provided that is capable of withstanding a substantially higher back pressure than its burst activation pressure. The unit includes a tubular housing having a fluid passage. Tapered wall structure defines at least a portion of the passage with the fluid outlet thereof being of greater area than the fluid inlet. A rupture disc is carried by the housing and has a central bulged section in fluid-blocking relationship to the passage. A tapered, self-releasing solid plug is positioned in and conforms to the tapered portion of the passage. The plug has a curved surface conforming to and positioned in full supporting relationship to the central section of the rupture disc. The plug is of sufficient mass to prevent rupture of the central section of the disc under a back pressure substantially greater than the activation pressure of the disc.