Superhard Choke Cage Inserts for Erosion-Resistant Flow Control
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Solution Overview
Problem
Choke valves in petroleum and natural gas production experience wear and erosion due to high pressure, necessitating enhanced durability and wear resistance.
Innovation Solution
A choke valve design incorporating a ring made of sintered superhard material, such as polycrystalline diamond, secured within the conduits of the choke cage, which can be attached using various mechanisms like braze, adhesive, or friction, to enhance durability and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional materials are used in choke valve conduits, then manufacturing cost is reduced, but wear and erosion resistance deteriorates under high pressure
Solution Approach 1:
The patent applies composite materials by combining a substrate material with a sintered superhard material coating on the inner surface of the conduit. This composite structure provides superior wear and erosion resistance from the superhard material layer while the substrate provides structural support, resolving the contradiction between enhanced reliability and manufacturing ease.
Solution Approach 2:
The patent applies local quality by applying the sintered superhard material coating only to the inner surface of the conduit where wear and erosion occur, rather than making the entire conduit from superhard material. This localized application provides enhanced wear resistance at the critical interface while keeping the overall manufacturing cost manageable through selective material application.
2Reliability
If fully sintered superhard material rings are used in conduits, then wear resistance is maximized, but manufacturing cost increases significantly
Solution Approach 1:
The patent uses a composite construction with a substrate and a sintered superhard material coating, rather than using fully sintered superhard material throughout. This approach provides the necessary wear resistance at the wear interface while significantly reducing manufacturing cost compared to fully sintered rings, as the substrate can be made from more economical materials.
Solution Approach 2:
The sintered superhard material is applied locally as a coating on the inner surface where wear occurs, rather than using it for the entire ring structure. This localized application provides maximum wear resistance where needed while minimizing the amount of expensive superhard material required, thereby reducing overall manufacturing cost.
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 use of sintered superhard material rings significantly reduces wear and erosion, extending the useful life of the choke valves while being more economical than fully sintered rings.
Implementation Method 1
The relatively high pressure experienced by such choke valves may lead to wear, erosion and other degradation. Accordingly, choke valves designed to enhance durability and wear resistance may be desirable.
Implementation Method 2
A method for manufacturing such a choke cage may comprise subjecting grains of superhard material to high-pressure, high-temperature conditions sufficient to sinter at least some of the grains together.
Data Source
AI summary
A choke valve for regulating a flow rate, a pressure or other parameters of a fluid flow may comprise a choke cage comprising a passage therethrough and a choke plug slidable within the passage. At least one conduit may pass through a wall of the choke cage and into the passage such that as the choke plug slides it may at least partially cover the conduit. A ring comprising a sintered superhard material may be secured within the conduit enhancing durability and wear resistance of the choke cage. A method for manufacturing such a choke cage may comprise subjecting grains of superhard material to high-pressure, high-temperature conditions sufficient to sinter at least some of the grains together, hollowing out the sintered superhard material to form a ring, and securing the ring within a conduit.