Removable Valve Insert for Safe Pipe Leak Testing
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Solution Overview
Problem
Current methods for testing pipework in buildings are unsafe for plumbers due to the risk of injury from water pressure and accidental discharge when removing plugs from inspection outlets during leak testing.
Innovation Solution
A valve assembly with a removable insert and control valve that seals the inlet when closed, allowing safe filling and inspection of pipework, and a cap to secure the insert, preventing water discharge until the control valve is opened for discharge, and a flow-through sleeve for sealing after removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug is used to seal the inspection outlet during pipework testing, then the pipework can be filled and inspected, but the plumber is at risk of injury from water pressure forcing the plug out and accidental discharge
Solution Approach 1:
The valve assembly is divided into separate functional components: an insert with sealing elements, a control valve mechanism, and a discharge pathway. This segmentation allows the sealing function to be independent from the discharge control, enabling safe pressure containment while maintaining controlled water release capability.
Solution Approach 2:
The control valve acts as an intermediary between the pressurized pipework system and the external environment. It mediates the water pressure by providing a controlled discharge pathway, preventing uncontrolled forceful ejection of water while allowing safe pressure release when needed.
2Ease of operation
If a plug is removed from the inspection outlet after testing, then the pipework can be accessed, but accumulated water discharges accidentally via the inspection outlet
Solution Approach 1:
The control valve is pre-configured with a discharge pathway before the insert is removed. This preliminary arrangement ensures that when the insert is removed for accessibility, any accumulated water can be safely discharged through the controlled valve mechanism rather than uncontrolled discharge from the inspection outlet.
3Ease of repair
If the insert is made removable for maintenance and replacement, then the valve assembly can be maintained, but the sealing and safety functions may be compromised
Solution Approach 1:
The valve assembly is designed with separable components including the insert, control valve, and housing. This segmentation enables the insert to be removed for maintenance while the control valve and housing remain in place. The standardized sealing interfaces ensure that replaced inserts maintain consistent sealing performance.
Solution Approach 2:
The insert is designed as a replaceable component that can be easily replaced when worn or damaged. This approach allows maintenance of the critical sealing function without requiring replacement of the entire valve assembly, ensuring consistent sealing reliability through periodic replacement of the insert component.
Data Source
AI summary
A valve assembly includes a valve housing having an inlet, an outlet and an opening, and an insert removably insertable in the opening. The insert has a first side facing upwards and a second side facing downwards when positioned in the opening. The first side and the second side have a conduit positioned therebetween, and a control valve located at least partially within the conduit and movable between an open position and a closed position. The control valve in the closed position stops fluid from passing through the conduit. When the insert is inserted in the opening and the control valve is in the closed position, the insert substantially seals the inlet and stops fluid flowing to the outlet.