U.S. patent application number 16/272339 was filed with the patent office on 2020-01-16 for extreme service plug valve.
This patent application is currently assigned to GE Oil & Gas Pressure Control LP. The applicant listed for this patent is GE Oil & Gas Pressure Control LP. Invention is credited to Manuel Garibay, Rick C. Hunter, Robert S. Mckee, Chad Eric Yates.
Application Number | 20200018403 16/272339 |
Document ID | / |
Family ID | 56367251 |
Filed Date | 2020-01-16 |
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United States Patent
Application |
20200018403 |
Kind Code |
A1 |
Hunter; Rick C. ; et
al. |
January 16, 2020 |
EXTREME SERVICE PLUG VALVE
Abstract
A valve assembly for managing a flow of fluids in hydrocarbon
development and production operations includes a valve body having
an internal body cavity and a body bore intersecting the body
cavity. A valve plug is located within the body cavity and is
rotatable between an open position and a closed position. A sleeve
is located between the valve plug and the valve body and is
rotationally fixed to the valve body and remains rotationally
static relative to the valve body as the valve plug rotates. A seal
groove is located on a sidewall surface of the sleeve and
circumscribes one of the sleeve openings. A seal assembly has a
seal ring that is U shaped in cross section with an inner leg that
engages the seal groove and an outer leg that extends out of the
seal groove and engages one of the valve body and the valve
plug.
Inventors: |
Hunter; Rick C.; (Houston,
TX) ; Mckee; Robert S.; (Houston, TX) ;
Garibay; Manuel; (Houston, TX) ; Yates; Chad
Eric; (Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GE Oil & Gas Pressure Control LP |
Houston |
TX |
US |
|
|
Assignee: |
GE Oil & Gas Pressure Control
LP
Houston
TX
|
Family ID: |
56367251 |
Appl. No.: |
16/272339 |
Filed: |
February 11, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14992744 |
Jan 11, 2016 |
10203037 |
|
|
16272339 |
|
|
|
|
62102455 |
Jan 12, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16K 5/0471 20130101;
E21B 1/00 20130101 |
International
Class: |
F16K 5/04 20060101
F16K005/04; E21B 1/00 20060101 E21B001/00 |
Claims
1. (canceled)
2. A valve assembly for managing a flow of fluids in hydrocarbon
drilling, production and processing operations, the valve assembly
comprising: a valve body having an internal body cavity, a valve
aft opening, and a body bore extending through the valve body and
intersecting the body cavity; a valve plug located within the body
cavity, the valve plug having a plug through bore and being
rotatable between an open position where the plug through bore
registers with the body bore and a closed position where the valve
plug prevents a flow of a fluid through the body bore; a sleeve
located between the valve plug and the valve body, the sleeve
having a central bore and a pair of sleeve openings through a
sidewall of the sleeve that align with the body bore, the sleeve
being rotationally fixed to the valve body so that the sleeve
remains rotationally static relative to the valve body as the valve
plug rotates within the sleeve between the open position and the
closed position; a seal groove located on a sidewall surface of the
sleeve, the seal groove circumscribing one of the sleeve openings;
a valve aft cover to cover the valve aft opening, the valve aft
cover sealingly engaging the valve body; and a seal assembly
located within the seal groove, the seal assembly having a seal
ring being U shaped in cross section with an inner leg that engages
the seal groove and an outer leg that extends out of the seal
groove and engages one of the valve body and the valve plug.
3. The valve assembly according to claim 2, further including a
valve stem extending from the valve plug through the valve body,
the valve stem being a separate member from the valve plug, wherein
the valve plug is operable to float within the sleeve.
4. The valve assembly according to claim 2, further including a
bearing assembly, the bearing assembly circumscribing a valve stem
that extends from the valve plug through the valve body, the
bearing assembly being releasably secured to the valve body and
engaging a shoulder of the valve stem.
5. The valve assembly according to claim 2, further including a
coating on an outer surface of the sleeve, the coating varying in
thickness over a coverage area on the outer surface of the
sleeve.
6. The valve assembly according to claim 2, further including a
coating on an inner surface of the sleeve, the coating varying in
thickness over a coverage area on the inner surface of the
sleeve.
7. The valve assembly according to claim 2, wherein the seal
assembly includes a metallic seal in engagement with the seal ring,
the metallic seal having a polymer coating.
8. The valve assembly according to claim 2, wherein the sleeve is
expandable in a hoop direction, the sleeve having one or more
axially oriented cuts extending from a surface of the sleeve into
the sidewall of the sleeve.
9. A method of forming a valve assembly for managing a flow of
fluids in hydrocarbon drilling, production and processing
operations, the method comprising: using a valve body having an
internal body cavity, a valve aft opening, and a body bore
extending through the valve body and intersecting the body cavity;
using a sleeve having a central bore and a pair of sleeve openings
through a sidewall of the sleeve; forming a pair of seal grooves on
a sidewall surface of the sleeve, each seal groove circumscribing
one of the sleeve openings; locating a seal assembly within the
seal groove, the seal assembly having a seal ring that is U shaped
in cross section; locating a valve plug within the sleeve, the
valve plug having a plug through bore; passing the sleeve and the
valve plug through the valve aft opening; rotationally fixing the
sleeve within the valve body so that the pair of sleeve openings
align with the body bore, and so that an inner leg of the seal ring
engages the seal groove and an outer leg of the seal ring extends
out of the seal groove and engages one of the valve body and the
valve plug, and so that the valve plug is rotatable between an open
position where the plug through bore registers with the body bore
and a closed position where the valve plug prevents a flow of a
fluid through the body bore, the sleeve remaining rotationally
static relative to the valve body as the valve plug rotates within
the sleeve between the open position and the closed position; and
securing a valve aft cover to cover the valve aft opening, the
valve aft cover sealingly engaging the valve body.
10. The method according to claim 9, further comprising
circumscribing a valve stem that extends through the valve body
with a bearing assembly, the bearing assembly being releasably
secured to the valve body and engaging a shoulder of the valve
stem.
11. The method according to claim 9, further comprising coating an
outer surface of the sleeve with a coating, the coating varying in
thickness over a coverage area on the outer surface of the
sleeve.
12. The method according to claim 9, further comprising coating an
inner surface of the sleeve with a coating, the coating varying in
thickness over a coverage area on the inner surface of the
sleeve.
13. The method according to claim 9, further comprising providing
the sleeve with an area adjacent to the sleeve opening that
circumscribes the sleeve opening that has a reduced sidewall
thickness.
14. The method according to claim 9, further comprising providing
the sleeve that is unsymmetrical about a central axis, the sleeve
having multiple inner diameters.
15. The method according to claim 9, further comprising forming
axially oriented cuts in the sleeve, the cuts extending from a
surface of the sleeve into the sidewall of the sleeve, so that the
sleeve is expandable in a hoop direction.
16. A method of managing a flow of fluids in hydrocarbon drilling,
production and processing operations with a valve assembly, the
method comprising: using a valve body having an internal body
cavity, a valve aft opening, and a body bore extending through the
valve body and intersecting the body cavity; using a valve plug
within the valve body, the valve plug having a plug through bore;
using a valve aft cover to cover the valve aft opening, the valve
aft cover sealingly engaging the valve body; rotationally fixing a
sleeve in the valve body between the valve body and the valve plug,
the sleeve having a central bore, a pair of sleeve openings through
a sidewall of the sleeve, and a seal assembly located within each
of a pair of seal grooves on a sidewall surface of the sleeve, each
seal groove circumscribing one of the sleeve openings and, wherein
the seal assembly has a seal ring that is U shaped in cross section
with an inner leg of the seal ring engaging the seal groove and an
outer leg of the seal ring extending out of the seal groove and
forming a seal with one of the valve body and the valve plug; and
rotating the valve plug between an open position where the plug
through bore registers with the body bore and a closed position
where the valve plug prevents a flow of a fluid through the body
bore.
17. The method according to claim 16, further comprising
transferring an axial force of a valve stem that extends from the
valve plug through the valve body with a bearing assembly, the
bearing assembly being releasably secured to the valve body and
including a thrust bearing that engages a shoulder of the valve
stem.
18. The method according to claim 16, further comprising providing
a coating on an outer surface of the sleeve, the coating varying in
thickness over a coverage area on the outer surface of the
sleeve.
19. The method according to claim 16, further comprising providing
a coating on an inner surface of the sleeve, the coating varying in
thickness over a coverage area on the inner surface of the
sleeve.
20. The method according to claim 16, further comprising providing
an area of the sleeve adjacent to the sleeve opening that
circumscribes the sleeve opening with a reduced sidewall
thickness.
21. The method according to claim 16, further comprising providing
one or more axially oriented cuts in the sleeve, the cuts extending
from a surface of the sleeve into the sidewall of the sleeve so
that the sleeve is expandable in a hoop direction.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/992,744, titled "Extreme Service Plug
Valve," filed Jan. 11, 2016, now U.S. Pat. No. 10,203,037, issued
Feb. 12, 2019, and which claims priority to U.S. Provisional Patent
Application Ser. No. 62/102,455, titled "Extreme Service Plug
Valve," filed Jan. 12, 2015, the full disclosures of both which are
hereby incorporated herein by reference in its entirety for all
purposes.
BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure
[0002] This disclosure relates in general to valves for hydrocarbon
drilling, production and processing operations, and in particular
to plug valves used for managing fluids associated with hydrocarbon
drilling, production and processing operations.
2. Description of Related Art
[0003] Gate valves and ball valves can be used to manage fluids
relating to hydrocarbon drilling, production and processing
operations. However gate valves have cavities or voids which create
pockets for sand and debris accumulation, and ball valves generally
have open spaces around the ball. During operations of gate valves
and ball valves, solid matter can accumulate in such voids and open
spaces, which degrades their ability to seal or operate and
eventually leads to failure.
[0004] It can be difficult to manufacture advanced rigid high
pressure seals and some common valves instead currently use
primarily elastomeric seals due to their conformability. However
elastomeric seals alone can be both pressure and temperature
limited and will result in plug valve assemblies that are not
usually used in high pressure applications, in particular due to
the extrusion of the elastomeric seals during operation.
[0005] It is also difficult to achieve metal to metal sealing
around complex geometric shapes, such as a ball or cylinder. This
is because the manufacturing of these parts to achieve conforming
surfaces is more difficult, than say for flat gates and seats. As a
result these valves are generally not used in bi-directional
applications, or do not perform well at low pressures.
[0006] Furthermore, it is difficult to prevent sand or debris from
entering the dynamic sealing areas for all types of valves. The
ingress of sand or debris may prevent the valve from sealing
properly. Therefore it is beneficial to permit only very small or
zero clearances around the sealing surfaces.
SUMMARY OF THE DISCLOSURE
[0007] Embodiments described herein provide systems and methods for
a plug valve assembly that can provide open and close operation in
about half of the space and weight of a current gate valve. In
addition, valve assemblies of embodiments of this disclosure do not
have any large void areas where solid matter can accumulate, nor
permit sand to be entrained in the sealing areas.
[0008] Embodiments of this disclosure also provide a valve assembly
that can be used in bi-directional high pressure applications
without being prone to leakage. Furthermore systems and methods
described herein reduce the torque required to operate the valve
assembly.
[0009] In an embodiment of this disclosure, a valve assembly for
managing the flow of fluids in hydrocarbon drilling, production and
processing operations includes a valve body having an internal body
cavity and a body bore extending through the valve body and
intersecting the body cavity. A valve plug is located within the
body cavity. The valve plug has a through bore and is rotatable
between an open position where the plug through bore registers with
the body bore and a closed position where the valve plug prevents
the flow of a fluid through the body bore. A sleeve is located
between the valve plug and the valve body, the sleeve also having a
cross bore with a pair of sleeve openings through a sidewall that
align with the body bore. The sleeve is rotationally fixed to the
valve body so that the sleeve remains rotationally static relative
to the valve body as the valve plug rotates within the sleeve
between the open position and the closed position. A seal groove is
located on a sidewall surface of the sleeve, the seal groove
circumscribing one of the sleeve openings. A seal assembly is
located within the seal groove, the seal assembly having a seal
ring being U shaped in cross section with an inner leg that engages
the seal groove and an outer leg that extends out of the seal
groove and engages one of the valve body and the valve plug.
[0010] In an alternate embodiment of this disclosure, a method of
forming a valve assembly for managing a flow of fluids in
hydrocarbon development and production operations includes
providing a valve body having an internal body cavity and a body
bore extending through the body and intersecting the body cavity. A
sleeve having a central bore and a pair of sleeve openings through
the sidewall of the sleeve is provided. A pair of seal grooves are
formed on a sidewall surface of a sleeve, each of the seal grooves
circumscribing one of the sleeve openings. A seal assembly is
located within the seal groove, the seal assembly having a seal
ring that is U shaped in cross section. A valve plug is located
within the sleeve, the valve plug having a plug through bore. The
sleeve is located within the valve body so that the pair of sleeve
openings align with the body bore, and so that an inner leg of the
seal ring engages the seal groove and an outer leg of the seal ring
extends out of the seal groove and engages one of the valve body
and the valve plug, and so that the valve plug is rotatable between
an open position where the plug through bore registers with the
body bore and a closed position where the valve plug prevents the
flow of a fluid through the body bore, the sleeve remaining
rotationally static relative to the valve body as the valve plug
rotates within the sleeve between the open position and the closed
position.
[0011] In another alternate embodiment of this disclosure, a method
of managing a flow of fluids in hydrocarbon development and
production operations with a valve assembly includes providing a
valve body having an internal body cavity and a body bore extending
through the body and intersecting the body cavity. A valve plug is
provided within the valve body, the valve plug having a plug
through bore. A sleeve is rotationally fixed in the valve body
between the valve body and the plug, the sleeve having a central
bore, a pair of sleeve openings through the sidewall of the sleeve,
and a seal assembly located within each of a pair a seal grooves on
a sidewall surface of a sleeve, each the of the seal grooves
circumscribing one of the sleeve openings. The seal assembly has a
seal ring that is U shaped in cross section with an inner leg of
the seal ring engaging the seal groove and an outer leg of the seal
ring extending out of the seal groove and forming a seal with one
of the valve body and the valve plug. The valve plug is rotated
between an open position where the plug through bore registers with
the body bore, and a closed position where the valve plug prevents
the flow of a fluid through the body bore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] So that the manner in which the features, advantages and
objects of the disclosure, as well as others which will become
apparent, are attained and can be understood in more detail, more
particular description of embodiments of the disclosure briefly
summarized above may be had by reference to the embodiment thereof
which is illustrated in the appended drawings, which drawings form
a part of this specification. It is to be noted, however, that the
drawings illustrate only certain embodiments of the disclosure and
is therefore not to be considered limiting of its scope as the
disclosure may admit to other equally effective embodiments.
[0013] FIG. 1 is a perspective section view of a valve assembly in
accordance with an embodiment of this disclosure, shown along a
plane perpendicular to the body bore and with the valve plug in the
open position.
[0014] FIG. 2 is a section view of a valve assembly in accordance
with an embodiment of this disclosure, shown along a plane along
the body bore and with the valve plug in the open position.
[0015] FIG. 3 is a perspective partial section exploded view of a
valve assembly in accordance with an embodiment of this
disclosure.
[0016] FIG. 4 is a plan section view of a valve assembly in
accordance with an embodiment of this disclosure, shown with the
valve plug in the closed position.
[0017] FIG. 5 is a detail section view of an expansion section of
the sleeve of the valve assembly of FIG. 4.
[0018] FIG. 6 is a detail section view of a seal assembly of the
valve assembly of FIG. 4.
[0019] FIG. 7 is a plan section view of a valve assembly in
accordance with an embodiment of this disclosure, shown with the
valve plug in the closed position.
[0020] FIG. 8 is a detail section view of a seal assembly of the
valve assembly of FIG. 7.
[0021] FIG. 9 is a detail section view of an alternate seal
assembly of the valve assembly of FIG. 7.
[0022] FIG. 10 is a detail perspective section view of seal
assemblies of the valve assembly of FIG. 7.
[0023] FIG. 11 is a perspective partial section view of a sleeve of
a valve assembly in accordance with an embodiment of this
disclosure.
[0024] FIG. 12 is a plan section view of an alternate seal assembly
of a valve assembly in accordance with an embodiment of this
disclosure.
[0025] FIG. 13 is a top view of a valve plug in accordance with an
embodiment of this disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0026] The system and method of the present disclosure will now be
described more fully hereinafter with reference to the accompanying
drawings which illustrate embodiments of the disclosure. The system
and method of this disclosure may, however, be embodied in many
different forms and should not be construed as limited to the
illustrated embodiments set forth herein. Rather, these embodiments
are provided so that this disclosure will be thorough and complete,
and will fully convey the scope of the disclosure to those skilled
in the art. Like numbers refer to like elements throughout, and the
prime notation, if used, indicates similar elements in alternative
embodiments.
[0027] Looking at FIG. 1, valve assembly 10 includes valve body 12.
Valve body 12 has internal body cavity 14. Internal body cavity 14
is an open space within valve body 12 that can be centered around
axis Ax. Valve body 12 also has body bore 16 (FIG. 2) extending
through valve body 12 along axis Ay and intersecting body cavity
14. Valve body 12 can have any number of different outlet
connections depending on the application. As an example the outlet
connection can be a hammer union style connection, an API studded
connection, or a flanged connection. Valve body 12 can be made of
low alloy steels and may be cladded with a corrosion resistant
coating such as a nickel alloy or a polymer around the sealing
surfaces.
[0028] Valve assembly 10 can be associated with a wellhead assembly
that is disposed over a well (not shown). The wellhead assembly can
include a wellhead housing, a production tree over the housing and
flow lines connected to the tree or the wellhead assembly. The flow
lines and wellhead assembly can include embodiments of valve
assembly 10 described herein. Valve assembly 10 can also be used
for regulating fluids that communicate with the wellhead assembly,
or for regulating well and other fluids that are otherwise
travelling along a pipeline. As an example, valve assembly 10 can
be used as part of high pressure hydraulic fracturing
operations.
[0029] Valve assembly 10 can also include sleeve 18. Sleeve 18 is
located within body cavity 14 of valve body 12. Sleeve 18 has
central bore 20 and a cross bore that is generally orthogonal to
central bore 20. The cross bore includes a pair of sleeve openings
22 (FIG. 2) through a sidewall of sleeve 18 that align with body
bore 16. Sleeve 18 is rotationally fixed to valve body 12 so that
sleeve 18 remains rotationally static relative to valve body 12 so
that sleeve openings 22 remain aligned with and register with body
bore 16. As an example, looking at FIG. 2, sleeve pins 24 can
extend between valve body 12 and sleeve 18 and rotationally fix
sleeve 18 to valve body 12.
[0030] Sleeve 18 can be a generally cylindrical shaped member.
However, as discussed further herein, sleeve 18 may not be
cylindrical about central axis Ax and may instead for example, have
a constant outer diameter and a varying inner diameter.
Alternately, sleeve 18 can have multiple outer diameters. As an
example, sleeve 18 can have a tapered outer surface and a
cylindrical inner surface. Sleeve 18 can be a one piece design or
can alternately be a split member and formed of two or more
portions that allow some relative float to establish a uniform fit
when differential pressure is applied to valve assembly 10.
[0031] Looking at FIG. 1, valve assembly 10 can further include
valve plug 26. Valve plug 26 is located within central bore 20 of
sleeve 18 so that sleeve 18 is located between valve plug 26 and
valve body 12. Valve plug 26 has a cylindrical shape with plug
through bore 28 that extends through valve plug 26 along the axis
Ay that is generally perpendicular to central axis Ax. Valve plug
26 is rotatable between an open position where plug through bore 28
registers with body bore 16, and a closed position where valve plug
26 prevents the flow of a fluid through body bore 16. Looking at
FIG. 2, when valve plug 26 is in the fully open position, plug
through bore 28 is aligned with axis Ay. Looking at FIG. 4, when
valve plug 26 is in the fully closed position, plug through bore 28
is aligned with axis Az. Sleeve 18 remains rotationally static
relative to valve body 12 as valve plug 26 rotates within sleeve 18
between the open position and the closed position.
[0032] To fully close valve assembly 10, valve plug 26 is rotated
such that the plug through bore 28 is 90 degrees out of rotation
relative to body bore 16 and sleeve openings 22. Likewise, to fully
open valve assembly 10, valve plug 26 is rotated 90 degrees so that
plug through bore 28 aligns with body bore 16 and sleeve openings
22. Hence by a rotation of 90 degrees of valve plug 26, valve
assembly 10 can go from fully open to fully closed, or vice versa.
Valve assembly 10 can be bi-directional so that it can be used to
manage a fluid flow in either direction through valve body 12.
Therefore, when valve plug 26 is in the closed position, valve plug
26 is operable to block a pressurized fluid flowing in a first
direction through body bore 16 of valve body 12 and to block a
pressurized fluid flowing in a second direction through body bore
16 of valve body 12.
[0033] In order to rotate valve plug 26, valve stem 30 can be used.
Valve stem 30 extends from valve plug 26 axially through valve body
12. Valve stem 30 is a separate part from valve plug 26. This
allows valve plug 26 to float toward a downstream side of valve
body 12 when valve plug 26 is in the closed position, to provide a
higher rated seal between valve plug 26 and sleeve 18, and between
sleeve 18 and valve body 12. Sleeve 18, valve plug 26, an valve
stem 30 can be made from a variety of materials that meet the needs
of the nature of the fluids passing through valve assembly 10. As
an example, materials that form sleeve 18, valve plug 26, and valve
stem 30 can include low alloy steels, stainless steels, and highly
corrosion resistant alloys. Sleeve 18, valve plug 26, and valve
stem 30 can alternately be made of low cost steel and coated with a
corrosion resistant coating such as tantalum or tungsten carbide,
as is discussed further herein.
[0034] Valve stem 30 can have shaped end 32 that is in engagement
with stem profile 34 of valve plug 26 so that valve stem 30 is
axially unrestrained by valve plug 26. The interaction of shaped
end 32 and stem profile 34 can be capable of transferring very high
torques between valve stem 30 and valve plug 26 and yet allow for
floating of valve plug 26 along axis Ax. This also allows valve
plug 26 to float downstream to better engage the downstream
seal.
[0035] In order to prevent valve stem 30 from being pushed out of
valve body 12 by pressure from within valve body 12, a valve stem
restraining member can be used. In the example of FIGS. 1-2, valve
stem 30 has stem shoulder 36 facing away from body cavity 14. Valve
stem shoulder 36 is defined by an enlarged diameter of valve stem
30 so that valve stem 30 has a larger diameter at stem shoulder 36
than an inner diameter of opposite facing shoulder 38 in valve body
12. Valve stem 30 can then not be ejected when valve assembly 10 is
pressurized. This allows for certain testing of valve assembly 10
to be performed without the need to have the actuator attached to
valve assembly 10. The retention of valve stem 30 within valve body
12 is also a safety feature as the actuator connection with valve
body 12 is not a pressure containing connection. In addition,
should the actuator be severely impacted, there will be no pressure
released from valve assembly 10.
[0036] At an opposite end of valve stem 30 from shaped end 32 is
operating end 40. Operating end 40 can be a universal interface
that is engaged by an actuator to rotate valve stem 30, which in
turn will rotate valve plug 26 to move valve plug 26 between the
open position and the closed position and vice versa. The actuator
can be, for example, hydraulic or manual. Operating end 40 can be
configured so that it is possible to do factory acceptance testing
on valve assembly 10 with either a hydraulic or manual type
actuator. In alternate embodiments, an actuator with roller screw
devices can be used. Such an actuator can replicate the orientation
of the hand wheel that is sometimes used with gate valves that
embodiments of this application can replace. The roller screw (or
ball screw) device converts rotary motion of a hand wheel into a
linear motion. The linear motion then displaces a helical slot
mechanism which converts linear motion back into the needed rotary
motion. The tailored canted slot can leverage the input energy into
the break open and closed positions of the valve where the torques
are highest. In most valve designs, the "break open" torque is as
much as ten times greater than the "running" torque. Hence, by
optimizing the slot geometry (such as having 15 degrees for high
torque and 60 degrees for low torque, for example), the torque and
number of turns to operate the valve can be significantly reduced.
Alternately, a hydraulic or pneumatic piston coupled with a helical
slot mechanism, a compact quarter turn fluid-based actuator, a
helical spline actuator, and a rotary vane actuator can also be
used. Other types of quarter turn actuators such as scotch yoke,
rack and pinion, and hypoid can alternately be used as well.
[0037] At an interface between the actuator and valve assembly 10,
anti-vibration lock washers can be used to prevent threaded
connectors from backing off during the extreme vibrations involved
in certain hydrocarbon development operations. The anti-vibration
lock washers can mitigate the effects of vibration on valve
assembly 10. All threaded interfaces associated with valve assembly
10 can incorporate positive anti-vibration mechanisms.
[0038] In order to guide valve plug 26 as it rotates between the
open position and the closed position, and to provide stops for the
valve plug 26 in both the open position and the closed position and
vice versa, guide peg 42 can extend from valve body 12 and into
guide slot 44. The engagement of guide peg 42 and guide slot 44
provides a hard stop of valve plug 26 to reduce or eliminate
misalignment of plug through bore 28 with body bore 16. When fluid
that includes solid matter flows through valve assembly 10 at high
velocities, even the smallest amount of discontinuity between plug
through bore 28 and body bore 16 can result in erosion of the
components of valve assembly 10. By placing the hard stop directly
between the valve plug 26 and valve body 12, plug through bore
misalignment can be prevented.
[0039] Bearing assembly 46 can be used to accommodate axial thrust
of valve stem 30 and to reduce the torque required to rotate valve
stem 30. Bearing assembly 46 can be releasably secured to valve
body 12 and can engage bearing shoulder 48 of valve stem 30.
Bearing assembly 46 is used to transfer an axial force of valve
stem 30 to valve body 12. Bearing assembly 46 can include a low
friction bearing, such as roller bearings, to ease the rotation of
valve stem 30. Having bearing assembly 46 together with valve stem
30 being axially unrestrained by valve plug 26 can reduce or
eliminate binding of valve plug 26 and valve stem 30 within valve
body 12.
[0040] Stem penetration 50 extends through valve body 12 to
accommodate valve stem 30. Stem seal assembly 52 is located between
valve stem 30 and valve body 12 to prevent fluids from passing
between valve stem 30 and valve body 12. Stem seal assembly 52 can
include primary stem seal 54 and secondary seal assembly 56.
Primary stem seal 54 can be a dynamic seal that includes a member
that has an inner leg in sealing engagement with valve stem 30 and
an outer leg in sealing engagement with valve body 12. Primary stem
seal 54 can be made of a corrosion resistant material such as alloy
625 or 718, or can be coated with a corrosion resistant material.
Primary stem seal 54 can be coated with a relatively thick coating
of polyether ether ketone (PEEK), polyetherketoneketone (PEKK), or
other polymer of the polyaryletherketone (PAEK) family, or of a
phenolic material.
[0041] Secondary seal assembly 56 can be formed of a polymer and
include one or more seals that form redundant seals between valve
stem 30 and valve body 12. Secondary seal assembly can include a
spring energized polymeric jacket seal of Polytetrafluoroethylene
(PTFE) and its derivatives. Other seals for back-up or venting can
be provided in secondary seal assembly 56.
[0042] Looking at FIGS. 1-2, in order to assemble valve assembly
10, or perform maintenance on valve assembly 10, valve assembly 10
further includes valve aft opening 58. Valve aft opening 58 can be
sized so that after valve stem 30 is passed through valve aft
opening 58 and into stem penetration 50, sleeve 18 and valve plug
26 can be passed through valve aft opening 58 and into position
within body cavity 14. Valve aft cover 60 can then be secured to
valve body 12. Valve aft cover 60 can be removed to allow valve
plug 26 and sleeve 18 to be replaced for maintenance, and provides
for quick servicing of valve plug 26 and sleeve 18 in the field.
Seal ring 62 can form a seal between an outer diameter of sleeve
18, an inner diameter of valve body 12, and valve aft cover 60.
Seal ring 62 can be made of high strength steel and coated with a
low friction coating such as polyamide-imides (PAI), PEEK, or other
type of PAEK, with molybdenum disulfide (MoS2) or PTFE to reduce
assembly forces and increase the life of seal ring 62.
[0043] Because of the large diameter of valve aft cover 60 and the
need for adequate preload to energize seal ring 62, aft threads 64
are preferably a thread which reduces torque and wear on threads
64, such as, for example, a flex thread design. Valve aft cover 60
can be equipped with aft lubrication port 66. Additional
lubrication and test ports 68, 70 can be used alone or in
combination with aft lubrication port 66 to test and monitor
pressure valve body 12 or to monitor for leaks, such as with active
leakage monitoring methods.
[0044] Valve assembly 10 can include various coating and seal
arrangements. As an example, sleeve 18 can have a coating and be
equipped with a seal arrangement. The inner diameter of sleeve 18
can be cylindrical to maintain a balance of forces acting on valve
plug 26, and to facilitate methods of manufacturing sleeve 18 known
to be able to hold tight tolerances such as lathe machining,
honing, and grinding. A tapered outer surface of sleeve 18 allows
for tight fit to be achieved between sleeve 18 and valve body
cavity 14. This tight fit can be a reliable seal with sufficient
preload. The tapered geometry allows for a tight fit during
assembly where valve aft cover 60 is secured to valve body 12 while
driving sleeve 18 into a tight fit to valve body cavity 14. As this
may be a locking taper, disassembly tooling can be used to aid in
the retrieval of sleeve 18 from valve body cavity 14. Not all
embodiments of the present disclosure utilize an interference type
fit in order to achieve sleeve to body sealing. In alternate
embodiments, sleeve 18 can have cylindrical inner and outer
surfaces, or can have a varying inner diameter.
[0045] Sleeve 18 can have seal groove 72 located on a sidewall
surface of sleeve 18. Seal groove 72 can circumscribe one of the
sleeve openings 22. Seal groove 72a can be located on the outer
diameter surface of sleeve 18 and seal groove 72b can be located on
the inner diameter surface of sleeve 18. Seal assembly 74 is
located within seal groove 72. Looking at FIGS. 6, 8, and 9, seal
assembly 74 can include seal ring 76 that is U shaped in cross
section. Seal ring 76 can have an inner leg 78 that engages seal
groove 72 and an outer leg 80 that extends out of seal groove 72
and engages either valve body 12 or valve plug 26. Seal ring 76
will follow the contour of seal groove 72 and therefore have a
complex geometry. Seal ring can be formed with a 3-D printer in
order to enable fabrication of seal ring 76. Other members of seal
assembly 74 can also be printed with a 3-D printer. Seal ring 76
can be a metal member that is provided with a polymer coating to
provide a softer sealing interface. Surface finish improvements can
be made by various means prior to final coating if necessary. These
would include vibratory polishing, chemical and vibratory
polishing, electro-polishing, grit or bead blasting, or polishing
by hand.
[0046] In the embodiments of FIGS. 4 and 7, seal assembly 74 is
shown with legs 78, 80 pointing towards sleeve openings 22 so that
fluid pressure passing through body bore 16 will tend to force legs
78, 80 apart from each other. In alternate embodiments, legs 78, 80
of seal ring 76 can point away from sleeve openings 22. In such an
embodiment pressure can be allowed to seep past the upstream seal
assembly 74 so as to force legs 78, 80 apart from each other to
pressurize the downstream seal assembly 74.
[0047] Looking at the example of FIG. 6, seal ring 76 can work with
a separate seal member 82 that has an arm that is located between
the legs 78, 80 of seal ring 76. Seal member 82 can form a seal
between sleeve 18 and valve body cavity 14. In such an example,
seal ring 76 can act not only as a sealing member, but also as an
anti-extrusion ring, preventing seal member 82 from extruding past
seal ring 76 when seal member 82 is under pressure. Seal ring 76
has a base that engages seal groove 72. Seal ring 76 also engages
either valve body cavity 14 or valve plug 26. In the example of
FIG. 6, spring member 84 can be located between the legs 78, 80 of
seal ring 76 so that seal ring 76 remains in contact with seal
groove 72 and with valve body cavity 14 even when there is no
external pressure acting on seal ring 76. Spring member 84 can be
used for an initial preload of seal ring 76 to establish a low
pressure seal. Seal assembly 74 can be pressure energized at high
pressures and a pressure acts on seal member 82 and will also act
to further separate legs 78, 80 of seal ring 76, pushing inner leg
78 into tighter engagement with seal groove 72 and outer leg 80
into tighter engagement with valve body cavity 14. In alternate
embodiments, no spring member 84 is used and legs 78, 80 have
sufficient bias in a direction away from each other to form a low
pressure seal.
[0048] Seal assembly 74 in the example of FIGS. 4 and 6 can allow
sleeve 18 to float because of the ability of seal assembly 74 to
span a gap between sleeve 18 and valve body cavity 14, and between
sleeve 18 and plug 26. In certain embodiments of valve assembly 10,
at an upstream side, the separation between sleeve 18 and valve
body cavity 14 can be in the range of ten to fifteen thousandths of
an inch. In sealing high pressure and large bore plug valves with
elastomeric seal elements, current valve designs can require a zero
clearance extrusion gap in order to prevent extrusion and seal
failure. In embodiments of the current disclosure, seal ring 76
will prevent seal member 82 from extruding, even with a gap between
sleeve 18 and valve body cavity 14, and even at high pressures,
such as up to 20,000 psi. Seal ring 76 can be formed, for example,
of a metal or a plastic. Seal member 82 can be formed of, for
example, an elastomer that can allow seal member 82 to seal against
rough or uneven surfaces. Seal member 82 can be formed of a metal
and have a polymer coating.
[0049] In the example embodiment of FIG. 4, there is no seal groove
72b located on the inner diameter surface of sleeve 18. Instead,
the outer diameter of valve plug 26 can seal directly with the
inner diameter surface of sleeve 18. Such surfaces can be coated to
improve sealing and reduce friction between valve plug 26 and
sleeve 18, as further discussed herein.
[0050] In certain embodiments of valve assembly 10, at an upstream
side, the separation between sleeve 18 and valve plug 26 can be in
the range of one to five thousandths of an inch. Valve assembly 10
can be either upstream sealing or downstream sealing. In either
way, it is always best to reduce gap clearances to minimize sand
entering into the moving and sealing interface areas. In order to
help avoid a gap between sleeve 18 and valve plug 26, the inner
diameter sleeve 18 can be just slightly smaller than the outer
diameter of valve plug 26. In certain embodiments, this can result
in an interference fit between sleeve 18 and valve plug 26. This
would not normally work for all-metal components but it is possible
with thick and low-friction polymer coatings. Thick polymer
coatings, from 3 to 100 mils, can be applied to metal parts by
means of electrostatic coatings, by injection molding, or by cold
spray. By preloading valve plug 26 into sleeve 18 and by using the
advantage of the tapered sleeve-to-body interface, an interference
fit assembly can be made easily. If sufficient interference is
achieved at preload, or assembly, then the polymeric materials can
expand essentially elastically when applied pressure is expanding
the valve body. This approach may also be used for the interface
between sleeve 18 and valve body cavity 14 as erosion of the
coating is not a concern.
[0051] Alternately, looking at the example of FIGS. 4-5, sleeve 18
can be a flex-sleeve where flexure in sleeve 18 is provided by one
or more cuts 86. In certain embodiments, valve plug 26 can be
formed with an outer diameter that is larger than the inner
diameter of sleeve 18. Then when valve plug 26 is installed within
sleeve 18, valve plug 26 forces sleeve 18 to expand radially
outward by expanding at cuts 86. Alternately, valve plug 26 can be
formed with an outer diameter that is smaller than the inner
diameter of sleeve 18. Then after valve plug 26 is installed within
sleeve 18, sleeve 18 can be tightened, such as with threaded member
88 as discussed below, to minimize or eliminate any gap between the
inner diameter of sleeve 18 and the outer diameter of valve plug
26.
[0052] Cuts 86 extend the full height of sleeve 18 in a direction
generally parallel to axis Ax. Cuts 86 extend from a surface of
sleeve 18 into the sidewall of the sleeve 18. Cuts 86 can be
formed, for example, by wire electrical discharge machining or by
diamond wire saws. Cuts 86 will allow a portion of the diameter of
sleeve 18 to increase, so that sleeve 18 expands in a hoop
direction. The flexibility of sleeve 18 can be adjusted by
controlling the number of cuts 86 and the spacing between cuts 86.
Threaded member 88 can optionally be used to retain the integrity
of sleeve 18 at the location of cuts 86. Threaded member 88 can be
used to tighten cuts 86 of sleeve 18 so that the inner diameter of
sleeve 18 is decreased. Threaded member 88 can alternately be used
to loosen cuts 86 of sleeve 18 so that the inner diameter of sleeve
18 is increased. Threaded member 88 can also be used as a
manufacturing aid. In such an embodiment, threaded member 88 can be
adjusted so that the inner diameter of sleeve 18 can be used as a
template for forming an outer diameter of valve plug 26 that
precisely matches the inner diameter of sleeve 18.
[0053] The use of cuts 86 can eliminate any clearance gaps between
valve plug 26 and sleeve 18 while allowing for the use of hard
faced surfaces on both valve plug 26 and on the inner diameter
surface of sleeve 18, resulting in in a longer life design compared
to what can be achieved with soft seals or coatings. The
elimination of a gap between valve plug 26 and sleeve 18 promotes
initial low pressure sealing and minimizes ingress of sand or
debris between sleeve 18 and valve plug 26. In addition, the use of
cuts 86 can eliminate thermal lock, which occurs when an inner
valve member undergoes thermal expansion and becomes stuck within
an outer valve member. Instead, with the use of cuts 86, sleeve 18
is able to expand, as needed, if valve plug 26 experiences thermal
expansion.
[0054] Looking at the example embodiments of FIGS. 7-10, in
alternate embodiments, seal groove 72b can be located on an inner
diameter surface of sleeve 18. Seal assembly 74 that is located
within seal groove 72 can include seal ring 76 with outer leg 78
engaging seal groove 72b and inner leg 80 engaging valve plug 26.
In such embodiments, legs 78, 80 can be sufficiently biased away
from each other to provide a low pressure seal between sleeve 18
and valve plug 26. Alternately, spring member 84 can be located
between the legs 78, 80 of seal ring 76 so that seal ring 76
remains in contact with seal groove 72 and with valve plug 26 even
when there is no external pressure acting on seal ring 76. Looking
at FIG. 8, seal ring 76 can alternately itself act as a spring that
supports O-ring 90 so that O-ring 90 maintains a sealing contact
with seal groove 72.
[0055] Generally, the seal between valve plug 26 and sleeve 18 can
be more subject to contact with abrasive fluids and hence is
preferably made of harder materials. However, hard seal surface do
not seal well, and it can therefore be advantage to coat the seal
with a softer coating such as tantalum, silver, gold, indium, or
with a polymer such as PEEK, PEKK, PAEK or PTFE. Seal ring 76 in
the embodiment of FIG. 9 can be a spring energized polymer jacketed
seal made of polysulphones, PEEK, PEKK, or equivalent PAEK polymer
and composites of the same, including polybenzimidazole (PBI), with
dry lubricants as needed. Spring member 84 can be formed of Elgiloy
or other highly corrosion resistant material. The placement of seal
groove 72b on an inner diameter surface of sleeve 18 can be near or
away from plug through bore 28 depending on the design intent and
materials used.
[0056] The constant force of legs 78, 80 acting on sleeve 18 and
valve plug 26 will add torque to the operation of valve assembly
10, so the preload should be minimized and just enough to promote a
low pressure seal. The drag forces between sleeve 18 and valve plug
26 can be reduced by reducing the area in contact between sleeve 18
and valve plug 26. The drag is also minimized by the use of low
friction coatings between sleeve 18 and valve plug 26, such as
tungsten carbide (WC) with a diamond like coating (DLC).
[0057] Sleeve 18 may be made entirely from a polymeric material.
The use of high temperature polymers and their blends, can allow
sleeve 18 to withstand considerable temperatures and pressures. The
polymers of sleeve 18 could be made from PAEK or polysulphone type
polymers with additives such as PBI or glass/carbon fillers with
appropriate low friction additives such as PTFE and MoS2. In
alternate embodiments, sleeve 18 can be formed of a polymer
material on the outer and inner surfaces, and have a metal material
on the inside. This would provide a greater amount of compressions
and expansion of seals that are in contact with sleeve 18 and
provide an erosion resistance coating for the surface that slides
along valve plug 26, which is subject to the erosive fluids.
[0058] In the embodiment of FIG. 12, sleeve 18 can be formed of
materials that include a polymer so that seal assembly 74 includes
sealing legs 92 that are integrally formed as part of sleeve 18.
The outer lips of sealing legs 92 extend beyond the outer diameter
and the inner diameter of sleeve 18 to increase contact pressures
locally to promote sealing. If sleeve 18 is formed of metal, sleeve
18 may be selectively or entirely coated with a polymer coating for
enhanced seal performance at seal assembly 74.
[0059] In alternate embodiments, looking at FIG. 11, sleeve 18 can
be a split sleeve that can include at least two sleeve portions
18a, 18b. A split sleeve will allow the upstream portion of sleeve
18 to float in the downstream direction with pressure so as to
maintain a zero clearance between the upstream portion of sleeve 18
and an upstream surface of valve plug 26. This reduces the chances
of debris entering between sleeve 18 and valve plug 26 that would
otherwise cause sealing issues. The opposite effect occurs when the
pressure is applied in the reverse direction. The sleeve portions
18a, 18b can be placed in contact with valve plug 26 by the spring
action of seal assembly 74, and by the applied pressure which acts
across seal assembly 74.
[0060] Looking at FIG. 7, in alternate embodiments of sleeve 18,
sleeve 18 can be formed so that it is not symmetrical about axis Ax
(FIG. 1). Instead, sleeve 18 can have a constant outer diameter and
multiple inner diameters. In particular, offset grinding can be
used to form central bore 20 so that the sleeve 18 is unsymmetrical
about axis Ax and has multiple inner diameters. Offset grinding can
provide a central bore 20 that has a diameter or radius of
curvature at sleeve openings 22 that matches the outer diameter of
valve plug 26, but can have a size along axis Ay that is greater
than the outer diameter of valve plug 26. The size of central bore
20 along axis Az will match the outer diameter of valve plug 26.
This will result in a small gap 100 between the inner diameter of
sleeve 18 and the outer diameter of valve plug 26 at the location
of one or both of the sleeve openings 22. The depiction of gap 100
of FIG. 7 has been greatly exaggerated for visualization purposes.
In practice, the radial depth of wider region 100 can be on the
order of thousandths of an inch. The provision of gap 100 will
reduce the torque required to rotate valve plug 26, while
maintaining a tight fit between valve plug 26 and sleeve 18
adjacent to downstream sleeve opening 22 to maintain the integrity
of seal assemblies 74.
[0061] Coatings and surface finishes can be can be applied to valve
plug 26 and sleeve 18. Erosion and abrasion resistance, chemical
resistance, scratch resistance, and low friction are properties can
be achieved through such coatings and surface finishes. As an
example, the outer surface of valve plug 26 can have a hard erosion
resistant coating such a tungsten carbide, which can be applied by
thermal spray or vapor deposition. Other vapor deposited coating
choices for valve plug 26 could include titanium carbide (TiC),
titanium aluminium nitride (TiAlN), Titanium Nitride (TiN), DLCs,
diamond, and multilayered titanium and titanium aluminium nitride
(TiTiAlN) coatings. Diffusion coatings are also a viable a coating
technology for this application, such as trinitrotoluene (TNT), ion
nitriding, and boron nitride (BN). These coatings can also be used
together to achieve the desired combination of properties.
[0062] The inner diameter surface of sleeve 18 could include a low
friction coating, such as a combination of tungsten carbide and
DLC, or alternately TiC, TiAlN, TiN, DLCs, diamond, multilayered
TiTiAlN coatings, or a softer metal such as tantalum. Polymeric
materials such as PEKK with MoS2, and various PTFE derivatives can
alternately be used. The use of such coatings can reduce the
dependency on grease which is a common requirement of current high
pressure valve designs. Such valves must be re-lubricated in the
field, sometimes after only four cycles of the valve. The use of
friction-reducing coatings can reduce the torque on the valve, and
the need for re-greasing is greatly diminished or even
eliminated.
[0063] Coatings can be applied to inner and outer diameter surfaces
of sleeve 18 to affect the stresses acting on the inner and out
diameter surfaces of sleeve 18. Coatings can be applied in regions
where stresses that would otherwise act on uncoated surfaces can be
increased, and coatings can be absent in regions where stresses
that would otherwise act on uncoated surfaces are to be
decreased.
[0064] The forces acting on sleeve 18 can vary across the surfaces
of sleeve 18 and valve body 12. In order to redistribute such
forces more evenly across contact surface between sleeve 18 and
valve body 12 and to ensure there are no surfaces that are
subjected to forces above a desired threshold, the location and
thickness of coating 94 can be varied. Coating 94 can vary in
thickness over a coverage area, and the coverage area itself can be
optimized. As an example, the forces acting on sleeve 18 can be
highest adjacent to sleeve openings 22. Although regions of contact
between the outer diameter of sleeve 18 and the inner diameter of
valve body 12 are static, the flexibility of sleeve 18 will affect
the load path between sleeve 18 and valve body 12.
[0065] Looking at FIG. 11, coating 94 on an outer surface of sleeve
18 can be located in a region of sleeve 18 between seal groove 72
and sleeve opening 22, however, an area 96 adjacent to sleeve
opening 22 can free of the coating 94. This can reduce the
thickness of the sidewall of sleeve 18 proximate to sleeve opening
22 so that forces acting on area 96 adjacent to sleeve opening 22
are reduced by providing increased flexibility to sleeve 18. Sleeve
18 can also have coating 94 on the inner surface of sleeve 18.
Coating 94 on the inner surface of sleeve 18 can be spaced apart
from sleeve opening 22 so that the region adjacent to sleeve
opening 22 is free of coating 94.
[0066] Other regions of sleeve 18 that can be subjected to high
forces are located proximate to then ends of sleeve 18 that are
axially aligned with sleeve openings 22. As such, coating 94 can be
reduced or eliminated at edges 98, relative to the thickness of the
coating applied at other regions of sleeve 18.
[0067] Alternately, other steps can be taken to redistribute the
stresses more evenly across the surfaces of sleeve 18. As an
example, in order to reduce stresses acting on areas adjacent to
sleeve opening 22, an area of sleeve 18 adjacent to sleeve opening
22 that circumscribes sleeve opening 22 can have a reduced sidewall
thickness of the material that forms sleeve 18 before a coating, if
any, is applied.
[0068] In order to create finished surfaces for valve assembly 10
accurate grinding and lapping technology can be used to achieve the
finishes and flatness required for the interface between the
elements of valve assembly 10. A surface finish on the order of 5
micro-inches Ra is desired for the internal surface of sleeve 18,
and a finish of 5 micro-inches Ra is desirable for the outer
surface of valve plug 26.
[0069] Therefore embodiments of this disclosure provide systems and
methods for oil field applications and in particular for secondary
recovery operations such as hydraulic fracturing. Embodiments of
valve assembly 10 can be used for high pressure operations, such as
10,000 psi to 20,000 psi, and for extreme temperatures, such as
from -50 F to up to 450 F. In addition to uses for hydraulic
fracturing, embodiments of valve assembly 10 disclosed herein can
be used anywhere that gate and ball valves have been traditionally
used, including downstream oil and gas applications such as
refineries or production flowlines.
[0070] The terms "vertical", "horizontal", "upward", "downward",
"upstream", downstream", "above", and "below" and similar spatial
relation terminology are used herein only for convenience because
elements of the current disclosure may be installed in various
relative positions.
[0071] While embodiments of the disclosure have been shown or
described in only some of their forms, it should be apparent to
those skilled in the art that it is not so limited, but is
susceptible to various changes without departing from the scope of
the disclosure.
* * * * *