Forward-Acting Rupture Disc Opening at Full Bore Diameter
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Solution Overview
Problem
Conventional rupture discs used in downhole applications often restrict fluid flow due to their design, which includes a smaller opening diameter than the tool or tubing bore, and may leave remnants that impede flow or tool passage, especially in horizontal or deviated wellbores where drag reduction techniques are employed.
Innovation Solution
A bulged, forward-acting rupture disc with a line of opening formed in the transition region between the bulged section and flange section, allowing the disc to tear and open to a diameter at least as large as the flange section, ensuring unimpeded fluid flow and tool passage, without introducing additional stress that would alter burst characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the line of opening is formed within the bulged section to minimize effect on burst pressure characteristics, then the burst pressure characteristics are maintained, but the opening diameter becomes smaller than the bore of the tool or tubing
Solution Approach 1:
The patent applies local quality by forming the line of opening specifically in the transition region between the bulged section and flange, rather than uniformly across the entire disc. This localized approach allows the opening to be positioned where it can achieve maximum diameter (matching the flange inner diameter) while the rest of the disc structure, particularly the bulged section, maintains its original integrity and burst characteristics. The line of opening is created only in the transition zone, leaving the bulged section's metal grain structure undisturbed.
2Ease of operation
If the line of opening is formed in the transition region to increase opening diameter, then the opening diameter matches the flange inner diameter, but the structural integrity of the transition region is compromised
Solution Approach 1:
The patent converts the potential harm of compromising transition region integrity into a benefit by deliberately using the transition region's inherent stress characteristics. The transition region already experiences stress concentration due to the geometry change from bulged to flange section. By forming the line of opening in this region, the patent harnesses these existing stress patterns to initiate controlled tearing at the desired location, achieving maximum opening diameter without requiring additional strengthening measures.
3Ease of operation
If material is removed from the transition region to form the line of opening, then the disc tears along the line of opening providing large opening, but the burst characteristics may be affected
Solution Approach 1:
The patent applies preliminary action by pre-forming the line of opening in the transition region during manufacturing, creating a predetermined weakness that will guide the disc's tearing behavior under pressure. This preliminary modification ensures that when the disc ruptures, it will tear along the pre-formed line in the transition region rather than unpredictably across the bulged section, providing consistent large opening diameter while maintaining control over the rupture characteristics.
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 forward-acting rupture disc effectively opens to match or exceed the internal diameter of the flange section, preventing flow restriction and ensuring unimpeded passage of fluids and tools, while maintaining predictable burst characteristics by concentrating stress without altering the metal grain structure.
Implementation Method 1
a line of opening that overlies the transition region. The line of opening comprises an area in which material making up the rupture disc has been removed thereby weakening the rupture disc such that when a pressure of a fluid acting upon a concave face of the dome reaches a predetermined threshold the rupture disc tears along the line of opening
Data Source
Figure 1~3
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AI summary
A bulged, forward-acting rupture disc (10) and a pressure relief device (38) incorporating a rupture disc (10), having a line of opening (28) formed in the transition region (26) of the disc between the bulged section (12) and flange section (14) are provided. The line of opening (28) is a stress-concentrating feature that, in conjunction with a stress-intensifying edge (68) located on an associated outlet ring (42), facilitates opening of the disc (10) when exposed to a predetermined pressure acting upon the concave face (20) of the bulged section (12).