Wedge Plug Valve Extraction for Compact Pipeline Pressure Testing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gate valves used for pressure testing in pipelines face difficulties in manual removal, especially from larger diameter pipes, due to wedging and high removal forces, which complicates the process and increases the risk of damage to extraction mechanisms.
Innovation Solution
A plug assembly with a retaining ring and extractor plate that allows the retaining ring to rotate relative to the plug and extractor plate, enabling easier removal by utilizing a mechanical advantage through threaded engagement and wrenching surfaces, allowing the plug to be extracted from the fitting without extensive lateral extension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elongated linkages and screw shafts are used to extract the valve body completely from the fitting, then the valve body can be removed from larger diameter pipes, but the extraction mechanism extends laterally a considerable distance which subjects it to risk of damage and exposes it to environmental elements
Solution Approach 1:
The invention extracts only the essential function of lateral extension by removing it entirely. Instead of using elongated linkages and screw shafts that extend laterally, the patent uses a compact extraction mechanism where the retaining ring rotates in place within the fitting, eliminating the need for lateral space while maintaining the ability to extract valve bodies from larger diameter pipes
Solution Approach 2:
Instead of extending the extraction mechanism laterally to gain mechanical advantage, the invention inverts the approach by rotating the retaining ring axially within the fitting. This inversion transforms the extraction motion from a lateral pulling action to an in-place rotational action, significantly reducing lateral extension while maintaining extraction capability
2Adaptability or versatility
If elongated linkages and screw shafts are used to extract the valve body, then complete removal is achieved, but the cost of materials and labor to form these extended extraction mechanisms is considerable
Solution Approach 1:
The invention extracts and eliminates the costly elongated linkages and screw shafts, retaining only the essential rotational function of the retaining ring. This reduction in component size and complexity directly reduces material costs and manufacturing labor while maintaining complete valve body removal capability
Solution Approach 2:
The patent employs simpler, shorter retaining rings that are less expensive to manufacture compared to elongated linkages and screw shafts. These compact retaining rings achieve the same extraction function at lower material and labor cost, aligning with the principle of using simpler, more economical components
3Adaptability or versatility
If elongated linkages and screw shafts are used for extraction, then valve body removal is achieved, but the increased size limits the usefulness of the valve mechanism in compact applications
Solution Approach 1:
The invention removes the excessive length from traditional extraction mechanisms by eliminating elongated linkages and screw shafts. The retaining ring rotates in place within the fitting, reducing the extraction mechanism size to minimal dimensions while preserving complete valve body removal capability
Solution Approach 2:
Instead of using lateral extension to achieve extraction, the invention inverts the mechanism to rotate axially within the fitting. This inversion transforms a size-intensive lateral motion into a compact in-place rotation, dramatically reducing the length and overall size of the extraction mechanism
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
Facilitates safer, faster, and more efficient manual removal of valve bodies from fittings, reducing the complexity and cost of the extraction mechanism while maintaining a compact design suitable for larger diameter pipes.
Implementation Method 1
Threading engagement between the retaining ring and port allow the retaining ring to push the plug into the fitting in a first rotation direction while rotation in the opposite direction allows the retaining ring to push the extractor plate and the connected plug out of the fitting
Implementation Method 2
The plug has first and second opposing plug faces inclined relative to each other and are spaced further apart near the circular top flange and closer together at a distal end to form a wedge-shaped plug configured to fit into the wedge-shaped recess of the fitting
Implementation Method 3
a wedge-shaped plug configured to fit into the wedge-shaped recess and seal the flow passage between the fitting walls
Data Source
AI summary
A pipeline has a fitting with a wedge-shaped plug pressed into a wedge-shaped fitting recess by a retaining ring to block flow through the fitting for pressure testing. The plug has an extractor plate fastened to the plug through a center of the retaining ring so the retaining ring can rotate relative to the plug and extractor plate. But the extractor plate is a predetermined maximum distance from the plug and is larger than the center opening of the retaining ring to captivate the retaining ring between the plug and extractor plate. That limits the retaining ring motion along the port's axis. Threading engagement between the retaining ring and port allow the retaining ring to push the plug into the fitting in a first rotation direction while rotation in the opposite direction allows the retaining ring to push the extractor plate and the connected plug out of the fitting.