Valve Assembly Debris Flushing via Pressure Differential
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Solution Overview
Problem
Chemical injection valves are prone to clogging due to debris accumulation, and existing flushing systems are complex, vulnerable to clogging, and reduce flow rates, making them unreliable for sustainable oil and gas production.
Innovation Solution
A self-contained, autonomous valve assembly with multiple flow regulating units and spring elements that utilize pressure differences to automatically flush debris without external control systems, ensuring reliable and rapid cleaning without complex sensors or electric actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an internal control system with small measurement apertures is used to monitor flow and detect clogging, then clogging detection capability is improved, but the system becomes vulnerable to clogging itself and reduces flow rate
Solution Approach 1:
The invention extracts the measurement function from the main fluid passage by using a separate bypass line with a filter. The bypass line contains a differential pressure sensor that monitors flow conditions without being part of the main chemical injection path, thus avoiding clogging of the measurement system while maintaining detection capability.
Solution Approach 2:
A bypass line acts as an intermediary between the main fluid passage and the measurement system. This bypass line allows flow monitoring through a filter-equipped path that protects the differential pressure sensor from debris while still providing accurate flow measurement and clogging detection.
2Ease of operation
If an internal control system with moving parts (piston or motor) is used to open the throttling orifice for flushing, then flushing capability is improved, but the system complexity increases and reliability decreases
Solution Approach 1:
The system uses the existing inlet pressure to automatically drive the bypass valve open for flushing when clogging is detected. The differential pressure sensor triggers a valve that utilizes the same inlet pressure source to create a high-velocity flush flow through the filter, eliminating the need for separate motors or pistons.
Solution Approach 2:
The flushing mechanism uses hydraulic principles by directing high-velocity inlet pressure through the bypass line and filter to create a cleaning effect. The inlet pressure itself serves as the flushing medium, eliminating mechanical moving parts while achieving effective debris removal.
3Measurement precision
If small measurement apertures are used in the control system, then clogging detection precision is improved, but the flow range is reduced
Solution Approach 1:
The flow measurement function is segmented from the main chemical injection flow by creating a separate bypass line. This allows the measurement system to use small apertures for precise clogging detection while the main injection line maintains its full flow capacity without restriction from measurement apertures.
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 solution eliminates the risk of permanent clogging, maintains reliable fluid flow, reduces the need for complex monitoring systems, and allows for a larger flow range, simplifying documentation and storage while being cost-efficient.
Implementation Method 1
Each flow regulating unit has a spring element. The spring element regulates the opening in response to the pressure difference over the flow regulating unit.
Implementation Method 2
The inlet pressure of the valve assembly is larger than the outlet pressure of the valve assembly... equalizing the pressure over the other flow regulating unit(s) downstream and upstream to the flow regulating unit with clogged opening thereby providing a pressure difference across the flow regulating unit(s) where clogging occurs
Data Source
Figure 1~2A
Figure 2B
Figure 3~4
AI summary
The invention concerns a method for flushing of debris from a valve assembly arranged in a fluid line. The valve assembly comprises at least two flow regulating units arranged in series between an inlet and an outlet of the valve assembly. The inlet pressure is larger than the outlet pressure, and each flow regulating unit has a spring element and an opening is provided for each flow regulating unit which initially is set as a minimum opening allowing fluid to pass from one side of the each of the flow regulation unit to the other side of the flow regulation unit. The spring element regulates the opening in response to the pressure difference over the flow regulating unit. The method comprises the following steps in the case when at least one of the openings clogs: -equalizing the pressure over the other flow regulating unit(s) downstream and upstream to the clogged opening thereby -providing a pressure difference across the flow regulating unit where clogging occurs, which pressure difference exceeds the spring force and increases the opening for this flow regulating unit for flushing the debris. The invention also concerns a valve assembly, a use of the valve assembly and a fluid injection valve assembly.