Tapered Rupture Disc Assembly to Resist Premature Breakage
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Solution Overview
Problem
Existing rupture disc systems in wellbore applications face challenges in withstanding high hydraulic pressures during casing placement, leading to premature breakage and increased operational costs due to the need for drilling out plugged ends, and there is a desire for systems that can adapt to various well conditions without introducing new steps or risks.
Innovation Solution
A rupture disc assembly with a shallow angle taper on its side surface, designed to mitigate tensile stresses through radial compression, allowing it to remain intact under normal operating pressures while breaking at higher pressures, reducing debris size and material costs, and featuring a disc failure activation mechanism to control the rupture process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rupture disc is made thicker to withstand high pressures during casing placement, then the pressure resistance is improved, but the debris size and material cost increase
Solution Approach 1:
The invention changes the geometric parameters of the rupture disc by introducing a shallow angle taper (5-15 degrees) on the side surface. This taper modifies the stress distribution within the disc, creating radial compression that counteracts tensile stresses during pressurization. The optimized taper angle represents a parameter change that allows the disc to withstand high pressures while maintaining thinner dimensions, thereby reducing both debris size upon rupture and material costs.
Solution Approach 2:
The invention applies local quality by creating a non-uniform geometry through the shallow angle taper on the side surface. This localized geometric modification concentrates radial compression forces in specific regions of the disc where tensile stresses are highest during pressurization. The taper is applied only to the side surface rather than the entire disc, optimizing strength where needed while minimizing overall material usage and potential debris.
2Reliability
If the rupture disc assembly is designed to withstand high hydraulic pressures, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The invention achieves enhanced reliability through a single parameter change - the shallow angle taper on the side surface. This geometric modification fundamentally alters the stress distribution mechanism, enabling the disc to withstand high hydraulic pressures during casing placement. The solution avoids complex multi-component assemblies by relying on this elegant geometric parameter optimization, thereby improving reliability without significantly increasing device complexity.
3Ease of manufacture
If a conventional rupture disc is used, then the manufacturing is simple, but the disc breaks prematurely under high pressure
Solution Approach 1:
The invention maintains manufacturing simplicity while dramatically improving pressure withstanding capability through the shallow angle taper design. The taper can be integrated into the disc forming process using standard manufacturing techniques such as CNC machining or mold design. This parameter change does not require complex multi-step manufacturing processes or specialized materials, allowing conventional manufacturing methods to produce a disc with enhanced structural performance that resists premature breakage under high pressure.
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 rupture disc assembly effectively withstands high hydraulic pressures during casing placement, reduces debris size and material costs, and simplifies the completion process by eliminating the need for drilling out plugged ends, enhancing the reliability and efficiency of wellbore operations.
Implementation Method 1
the engagement/contact/force transmission between the rupture disc and the mounting apparatus produces enough radial compression in the rupture disc due to the shallow angle taper to significantly mitigate or cancel tensile stresses in the rupture disc
Implementation Method 2
the rupture disc is operable to break upon the top surface of the rupture disc being subjected to a disc rupture pressure that is greater than the disc working pressure
Data Source
AI summary
Disclosed is a rupture disc assembly for use in making a temporary seal in a vessel such as a casing string. The rupture disc assembly may include a rupture disc having a side surface that has a shallow angle taper inward towards a bottom surface of the rupture disc, and a mounting apparatus to support the rupture disc so that the rupture disc forms the temporary seal. When a disc working pressure is applied to a top surface of the rupture disc, engagement/force transmission between the rupture disc and the mounting apparatus produces enough radial compression in the rupture disc due to the shallow angle taper to significantly mitigate or cancel tensile stresses thereby avoiding the rupture disc from breaking. The rupture disc may be configured to break when the rupture disc is subjected to a disc working pressure that is greater than the disc rupture pressure, thereby removing the temporary seal. An axial abutment surface feature may be provided which is configured and operable to limit downward axial movement of the rupture disc relative to said disc support mechanism and thus be operable to restrict the amount of compression said tapered wall surface of said disc support mechanism can exert on said at least a portion of said rupture disc when the top surface of the rupture disc is subjected to said hydraulic pressure within the well.