Top-Entry Ball Valve Maintenance Without Pipeline Shutdown
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Solution Overview
Problem
Existing ball valve maintenance requires shutting down pipelines, disassembling components, and reassembling them after replacement, leading to increased downtime, costs, and inefficiencies due to the difficulty in replacing components while the valve is in the pipeline.
Innovation Solution
A top entry ball valve assembly with a camming action and seat tools that allow for the removal and reinstallation of ball valves while still connected to the pipeline, enabling the disassembly and reassembly of components without shutting down the pipeline, using a seat stopping tool to prevent seat movement and a cam to disengage seat assemblies for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional ball valve maintenance is performed by shutting down pipelines and disassembling components, then component replacement can be completed, but downtime increases and operational efficiency decreases
Solution Approach 1:
The ball valve is divided into separable components (ball, seats, seals) that can be independently removed and replaced. The body remains in the pipeline while internal components are accessed through the top opening, allowing segmented maintenance without full disassembly
Solution Approach 2:
The ball and seat assemblies are extracted from the valve body through the top opening. Specialized tools remove the ball by extracting it upward through the opening, and seats are similarly extracted for replacement without removing the valve body from the pipeline
Solution Approach 3:
Specialized maintenance tools act as intermediaries to facilitate component removal and installation. The ball removal tool, seat installation tool, and other specialized devices enable component replacement through the top opening without requiring pipeline shutdown or valve body disassembly
2Loss of time
If ball valve components are replaced while connected to the pipeline, then downtime is reduced, but the complexity of the maintenance process increases
Solution Approach 1:
The valve is designed with a top opening and internal features (such as ball removal holes and seat installation features) prepared in advance to facilitate maintenance. The cam mechanism is pre-positioned on the ball to enable automatic seat engagement during the maintenance process
Solution Approach 2:
The cam mechanism on the ball automatically engages with the seats during the maintenance process. When the ball is rotated or positioned, the cam automatically pushes the seats into place, reducing the need for manual intervention and simplifying the overall maintenance procedure
3Ease of repair
If specialized tools are used for component removal and installation, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The maintenance tools are designed to perform multiple functions. The ball removal tool can both extract the ball and facilitate seat installation, while the seat installation tool can both install seats and verify their proper positioning. This multi-functionality reduces the total number of different tools required
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
This method reduces downtime and costs by allowing for the replacement of ball valve components and seals while the valve body remains connected to the pipeline, streamlining maintenance processes and improving operational efficiency.
Implementation Method 1
a cam mounted to said ball, said cam being moveable with rotation of said ball to a position to engage and urge said seat member away from a valve centerline
Data Source
AI summary
A top entry ball valve a pipeline mainly used in Oil and Gas Industry, Chemical and pharmaceutical Industries. The system allows for replacing all the ball valve components and seals while the valve body is still in the pipeline. The ball valve assembly has four main components: the body, gearbox, ball, and seats. Disassembly and reassembly may be performed utilizing various tools to allow removal and reinstallation of the ball, seats, seals, or other components therein without the need to remove the ball valve assembly from a pipeline.