Multi-phase Sampling Valve with Orifice Mixing and Waste Re-injection
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Solution Overview
Problem
Conventional methods for sampling crude oil face challenges such as inefficient mixing at low fluid velocities, turbulence issues, and the risk of toxic gas release, particularly H2S, which complicates accurate sampling and increases waste.
Innovation Solution
A multi-phase sampling system utilizing a three-way four-port valve unit with a main valve body and orifices to create pressure drop and turbulence, ensuring homogenization of fluids and re-injecting waste back into the pipeline, thereby minimizing toxic gas release and improving mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a static mixer is used to mix the fluid before withdrawal, then mixing effectiveness is improved at high fluid velocity, but mixing fails during turndown or low velocity (laminar flow)
Solution Approach 1:
The patent employs dynamic mixing elements within the valve body that create turbulence and mixing through the valve operation itself rather than relying on static mixers. The fluid is forced through restricted passages and orifices during valve transitions, generating dynamic mixing action that remains effective across varying flow velocities including laminar flow conditions
Solution Approach 2:
The sampling system performs self-mixing through the valve operation. The actuation of the valve to switch between sampling positions automatically generates the mixing action needed to homogenize the fluid, eliminating the need for separate static mixing devices and ensuring mixing occurs regardless of flow velocity
2Ease of operation
If traditional sampling methods release gas and remaining fluid to atmosphere, then sampling simplicity is improved, but toxic gas release risk increases
Solution Approach 1:
The patent maintains the sampled fluid under pressure throughout the sampling process, keeping it in a closed system that prevents atmospheric release. The sample is collected in a pressurized container that matches the pipeline pressure, eliminating the need to vent to atmosphere and thereby preventing toxic gas release while maintaining sampling simplicity
Solution Approach 2:
The patent introduces a pressurized sampling container as an intermediary between the pipeline and the sampling analysis point. This container acts as a pressure-matched interface that allows sample withdrawal without pressure equalization to atmosphere, thereby preventing toxic gas release while maintaining ease of operation
3Ease of manufacture
If sampling waste is released to atmosphere, then waste disposal simplicity is improved, but environmental harm and safety risks increase
Solution Approach 1:
The patent recovers the sampling waste by reinjecting it back into the pipeline rather than discarding it to atmosphere. The valve system directs the waste fluid back into the main flow, simplifying waste disposal while eliminating environmental harm and safety risks associated with atmospheric release
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 effectively collects representative samples while minimizing waste and exposure to toxic gases, ensuring accurate phase mixing and reducing incidents related to unsafe sampling practices.
Implementation Method 1
The third valve opening is defined by a plurality of orifices for mixing incoming non-homogenous fluid to generate a mixed homogenous fluid
Implementation Method 2
the fourth valve opening has a lesser diameter that the third valve opening for increasing fluid pressure drop, fluid velocity, and fluid turbulence
Implementation Method 3
the fourth valve opening has a lesser diameter that the third valve opening for increasing fluid pressure drop, fluid velocity, and fluid turbulence
Data Source
AI summary
A multi-phase sampling collection system includes a three-way four-port valve unit that includes a valve housing having a first port, a second port opposite the first port, and a third port. The valve unit includes an inner valve member that is movably disposed within the valve housing between a plurality of positions. The inner valve member has a main valve body that has a first valve opening, a second valve opening opposite the first valve opening, a third valve opening and a fourth valve opening opposite the third valve opening. The third valve opening is defined by a plurality of orifices for mixing incoming non-homogenous fluid to generate a mixed homogenous fluid and the fourth valve opening has a lesser diameter that the third valve opening for increasing fluid pressure drop, fluid velocity, and fluid turbulence resulting in improved mixing of the non-homogenous fluid that exits through the fourth valve opening.