Valve Insert System for Gate Valve Wear Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Proppant in frac fluid can enter the interior volume and interfaces of gate valves, causing wear and reducing their useful life, and existing methods to mitigate this, such as lubricant injection, are time-consuming and resource-intensive.
Innovation Solution
A valve insert system that guides and focuses lubricant flow to remove proppant from the interior volume and interfaces of gate valves, reducing the size of the lubricant volume needed and directing it to areas that benefit most, thereby reducing wear and maintenance time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lubricant injection is used to mitigate proppant wear, then wear protection is improved, but maintenance time and resource consumption increase
Solution Approach 1:
The valve insert system performs preliminary protective action by providing a proppant-free flow path that prevents proppant from reaching critical valve interfaces in the first place. This preliminary protection eliminates the need for subsequent lubricant injection and maintenance interventions, directly resolving the contradiction between wear protection and maintenance time
Solution Approach 2:
The valve insert system extracts or removes proppant from the critical flow path by providing a separate proppant-containing flow path. This extraction prevents proppant from contacting valve interfaces, providing wear protection without requiring lubricant injection or increasing maintenance time
2Reliability
If lubricant is injected into the entire interior volume, then wear protection is improved, but lubricant consumption increases
Solution Approach 1:
The valve insert system applies local quality by providing protection only where it is most needed - at the valve interfaces and critical components. The proppant-free flow path is specifically designed to protect these local areas from proppant exposure, eliminating the need for blanket lubricant injection throughout the entire interior volume, thus reducing lubricant consumption while maintaining wear protection
3Productivity
If proppant-containing fluid flows through the entire valve interior, then flow capacity is maintained, but valve wear increases
Solution Approach 1:
The valve insert system segments the flow path into two distinct channels: a proppant-containing flow path for bulk fluid transport and a proppant-free flow path for protecting critical valve interfaces. This segmentation allows the valve to maintain full flow capacity through the proppant-containing path while protecting valve life by directing proppant away from critical components through the segmented proppant-free path
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 valve insert system effectively reduces proppant-related wear, decreases lubricant usage, and shortens maintenance time by focusing lubricant flow to critical areas, enhancing the operational life and efficiency of gate valves during fracing operations.
Implementation Method 1
A valve insert system that guides and focuses lubricant flow to remove proppant from the interior volume and interfaces of gate valves
Data Source
AI summary
A system including a valve, including a valve body having an interior volume and a bore along a first axis, a stem extending along a second axis, and a flow control element coupled to the stem, wherein the stem is configured to selectively move the flow control element through the interior volume between a closed position and an open position relative to the bore, and a valve insert system configured reduce a size of the interior volume and to guide a lubricant to reduce wear on the flow control element.