Safety Valve with Burst Disk for Overpressure Relief
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Solution Overview
Problem
Current hydraulic fracturing systems lack effective mechanisms to automatically detect and mitigate pressure spikes, which can lead to equipment damage and potential blowouts, posing risks to safety and the environment.
Innovation Solution
An overpressure safety system with a fluid control manifold assembly and safety valve that includes a movable valve member and burst disk, allowing for predictable and economical relief of excess pressure, alerting operators to shut down the pump and directing pressure to a containment tank, thereby preventing damage and blowouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual pressure monitoring and shutdown is used, then equipment damage can be prevented, but operational efficiency is reduced and response time is delayed
Solution Approach 1:
The pressure relief system automatically detects pressure spikes through pressure sensors and actuates the relief valve without human intervention. The system monitors pressure continuously and self-regulates by opening the relief valve when pressure exceeds the setpoint, eliminating the need for manual observation and shutdown decisions while maintaining equipment safety.
Solution Approach 2:
The system employs pressure sensors that continuously monitor fluid pressure and provide feedback to the control mechanism. When pressure exceeds the predetermined setpoint, the feedback signal triggers the actuator to open the relief valve, creating a closed-loop control system that automatically responds to pressure changes and maintains safe operating conditions.
2Object-affected harmful factors
If pressure relief system is installed at the pumping truck, then pressure can be relieved, but equipment damage may have already occurred by the time relief is achieved
Solution Approach 1:
The pressure relief valve is positioned upstream at the manifold location rather than downstream at the pumping truck. This preliminary positioning allows the system to relieve pressure at the source before it can propagate through the distribution lines and cause damage to downstream equipment such as wellbore injection equipment and valves.
Solution Approach 2:
The system introduces a dedicated pressure relief valve as an intermediary component between the pressure source and the distribution network. This intermediary device specifically targets and relieves pressure spikes before they can affect other system components, acting as a protective barrier that isolates the harmful pressure effects.
3Reliability
If automated pressure relief system is implemented, then response time is improved and equipment protected, but system complexity increases
Solution Approach 1:
The system replaces complex electronic control and automated actuation mechanisms with a simpler mechanical pressure-driven design. The pressure sensor provides the trigger signal, but the relief valve itself is actuated by the pressure differential across its diaphragm or piston, eliminating the need for powered actuators, control algorithms, and complex wiring while maintaining automated response.
Solution Approach 2:
The system employs a pressure sensor and relief valve assembly that can be easily replaced as a unit if needed. Rather than designing for complex repair of multiple components, the design accepts that these safety components may need periodic replacement, simplifying the overall system architecture by making the safety subsystem modular and easily maintainable.
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 system automates pressure control and relief, reducing equipment damage and environmental risks, allowing for safe and continuous operation of hydrocarbon production activities without the need for system shutdown or deconstruction.
Implementation Method 1
a burst disk in the safety valve blocks the flow of pressurized fluid through the safety valve until the pressurized fluid is at a pressure of at least a set overpressure and then the burst disk ruptures so that the pressurized fluid can flow through the safety valve
Implementation Method 2
a pressure sensor in communication with the safety valve and configured to detect a pressure spike in the pressurized fluid
Data Source
AI summary
An overpressure safety system for use with a distribution of pressurized fluid associated with hydrocarbon production operations includes a safety valve in fluid communication with a main bore of a fluid control manifold assembly. The safety valve has a blocking condition where the safety valve blocks a flow of pressurized fluid through the safety valve, and a venting condition where the safety valve provides a fluid flow path for the pressurized fluid at a set overpressure to pass through the safety valve. A valve member is moveable within the safety valve between a first position where a pressure side of the valve member blocks the flow of the pressurized fluid at a pressure below the set overpressure from passing through the safety valve, and a second position where the valve member provides a fluid flow path for the pressurized fluid at any pressure to pass through the safety valve.