CA3135417A1 - Quarter turn hydraulic actuator for operation of large bore valves in high pressure implementations - Google Patents

Abstract

An actuator device for operation by differential pressure for rotational actuation of rotational valves in large high-pressure industrial applications. The embodiments presented are explosion resistant for implementation in zone 1 safety areas. They also incorporate high-visibility and monitor sensors to allow distant visual inspection or remote (non-line-of-sight) positional monitoring and actuation verification.

Description

Quarter Turn Hydraulic Actuator for Operation of Large Bore Valves in High Pressure Implementations Background of the Innovation Cross-Reference to Related Applications [0001] This application claims priority under 35 U.S.C. 119(e) from U.S.
Provisional Patent Application No. 62/977,525, by Adrian Bucciarelli, Et al, titled "Quarter Turn Hydraulic Actuator for Operation of Large Bore Valves in High Pressure Implementations"
filed 17 February 2020, which by this statement, is incorporated herein by reference for all purposes.
Statement Regarding Federally Sponsored Research or Development

[0002] Not Applicable Reference to Sequence Listing, a Table, or a Computer Program Listing Compact Disc Appendix

[0003] Not Applicable Background of the Invention

[0004] Many industrial operations are dependent on the ability to control fluid flow. Valves regulate the flow of gasses, liquids, or loose materials through apertures, such as pipes or passageways by opening, closing, or obstructing the fluid's progress. There is a multitude of valve types and designs satisfying one or more of these functions that can safely accommodate the wide variety of industrial applications.

[0005] Automation of valve operation is desirable for valves situated in inconvenient locations or requiring excessive operating forces. Automation is especially desirable for valves situated in hazardous environments where their operation places personnel at risk. Valves may bifurcate into small bore sizes (generally 2 inches or less), and commercial valves, above 2 inches in diameter (generally designated as Large Bore).

Date recue/date received 2021-10-22

[0006] Large bore applications commonly found in industrial applications may not be suitable for operation by traditional vane-type actuators due to the forces involved and the stresses on position arms. In the oil & gas industry, gate valves are a default selection, but there are situations where quarter-turn actuated valves may be preferred. For example, in situations requiring quicker cycling than possible with a gate valve.

[0007] Plug valves or ball valves are rotational motion valves used to stop or start fluid flow.
The name is derived from the shape of the disk, which resembles a plug. The simplest form of a plug valve is the petcock. The body of a plug valve is machined to receive the disk, a tapered, a spherical (ball), or cylindrical plug. The disk is a solid plug with a bored passage at a right angle to the rotational axis of the plug.

[0008] In the open position, the passage in the plug lines up with the inlet and outlet ports of the valve body. When the plug is turned 900 from the open position, the solid part of the plug blocks the ports and stops fluid flow. Plug valves are commonly available in either a lubricated or non-lubricated design and may have a variety of sealing designs to improve leak prevention or otherwise improve valve performance.

[0009] Quarter-turn operation valves offer tight seals and low turbulence in full-open or full-closed positions. But the limited rotary movement (angular displacements) are more difficult to automate. In the application of the preferred embodiment, control in high-pressure oil and gas (O&G) systems, the fluid pressures in a line can further hinder operations of typical actuators.
These demanding conditions include onshore and offshore drilling; production, pressure, and temperature extremes; and heavy oil, sour, and subsea applications, including hydraulic Date recue/date received 2021-10-22 fracturing operations incorporating pressure ratings in excess of 20,000 psi (pounds per square inch).
BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 shows a perspective view of an actuator in accordance with an exemplary embodiment of the innovation shown connected to a generic high-pressure large bore rotary valve with 1/4 turn actuation.

[0011] FIG. 2 is an exploded perspective view of an actuator in accordance with an exemplary embodiment of the innovation.

[0012] FIGS. 3A and 3B illustrates cut-away perspective diagrams of an actuator in accordance with an exemplary embodiment of the innovation shown in a first position and second position of typical operation.
Detailed Description of the Innovation

[0013] The innovation allows hydraulic/pneumatic power to actuate a rotational valve by translating linear action into rotational action. Linear actuators generally operate by changing the pressure on either end of a piston moving the piston to adjust the volume in response to the pressure differential.

[0014] The actuator comprises a plunger/piston which is moved in response to pressure. The plunger in the preferred embodiment is cylindrical, with a hollow center for accepting a cylindrical stem, and an enlarged top end serving as the plunger's piston.

Date recue/date received 2021-10-22

[0015] The plunger fits into a cylindrical actuator body with an internal diameter approximately equal to the outer diameter of the plunger piston. The actuator body's internal diameter is reduced at the lower end to approximately the outer diameter of the plunger's lower end and is capped at the distal end to form two cylindrical spaces, one above and one below the plunger's enlarged top (i.e., the plunger's piston).

[0016] By introducing a gas/fluid into the body cavity through a port that is above or below the plunger's enlarged top and venting fluid from the distal port, the plunger is moved up or down in attempts to equalize the pressure differential by relative volume changes of the upper and lower chambers. The cylindrical plunger and stem are co-axial.

[0017] While one skilled in the arts would appreciate the application of pneumatics to this innovation, the preferred embodiment of the inventor is hydraulic due to the efficiency of non-compressing fluids which can actuate large bore valves in high-pressure applications utilizing lower displacement volumes and pressures as a control medium.

[0018] In the preferred embodiment, a reduced diameter top of the stem extends through the plunger's piston end, and the upper body cavity to project through the cap of the actuator body.
Both pass-throughs sealed by 0-rings/gaskets, stem packing, etc. to maintain integrity of the upper chamber (i.e., upper portion of the divided body cavity).

[0019] The edge of the plunger piston is sealed in an equivalent manner to preserve the separation of the body cavity into upper and lower chambers. The lower end of the plunger is similarly sealed against the reduced internal diameter of the actuator body to maintain integrity of the lower chamber (i.e., lower portion of the divided body cavity).

Date recue/date received 2021-10-22

[0020] The stem's lower end has a spiral action channel, and the projecting top end is marked to indicate the orientation of the spiral action channel. The plunger and stem are mated together by an action rod passing from side to side of the plunger's internal space, through the stem's action channel across the central axis. In the preferred embodiment, the action rod is fitted with rollers on each end, retained with snap rings, which roll against the sides of the action channel to reduce frictional drag and wear.

[0021] Linear movement of the plunger translates to side pressure on the spiral action channel of the stem, resulting in rotational displacement of the stem and is indicated on the top position marking extending from the top end of the actuator body. The lower end of the stem is supported by racer bearings in a base of the actuator and has a mating port for attachment to a rotational actuated valve.

[0022] The actuator has a lower flange for securing it to the valve body and operationally mating with the valve's gate. The mating port of the actuator stem is connected to the stem (or other functional component) of the rotational valve and movement is translated thereto. The actuator body of the preferred embodiment has an adjustment gauge, and elongated bolt holes in the lower flange allowing adjustment of alignment between the actuator and the mated valve. This provides the opportunity to tune the actuator's extremes to be in concert with the valve's full-open and full-close positions.

[0023] The compact design allows for installation above the valve, usually within the same footprint of the valve body. The unique helical design of the action slot and roll incorporation into the action rod reduces frictional drag, allowing for double-acting implementation producing Date recue/date received 2021-10-22 sufficient torque in either direction for operation of large bore industrial valves, even against internal fluid resistance.

[0024] The preferred embodiment also includes an electronic sensor which can transmit the valve position similar to the visual indication available from the mark on the top end of the stem projecting through the upper end of the actuator. The following are in reference to the preferred embodiment and should not be taken as limiting of the innovation to other applications or designs, but merely as exemplary of how the teaching may be applied by one skilled in the arts.

[0025] Since this actuator is powered by pressure differentials it is suitable for use in explosive environments, or safety areas where ignition sources (including radio communications and electrical actuators) may be undesirable. The actuator's construction materials are selectable for durability and resistance to the desired environment of deployment and can be chosen to maximize equipment life and reduce required maintenance operations.

[0026] The position indicator, a slot across the stem's rotational axis in the preferred embodiment, can be tapped to secure a plate or other indicator that is visible at a distance (e.g., from outside the boundaries of a designated safety area). But the integrated position sensor can be monitored to signal operations beyond line-of-site, or to enable automated monitoring and responses.

[0027] While the preferred embodiment utilizes an action channel for quarter-turn operation, one skilled in the arts would appreciate the potential applicability of other embodiments that provide for half-turn operation, full-turn or multi-turn operations or more complex actions should a valve require such complexity. Care must be taken to balance the desired forces against any weaknesses that may be introduced by the shape of longer, more complex action channels.

Date recue/date received 2021-10-22 Detailed Description of the Drawings

[0028] FIG. 1 shows a perspective view of an actuator in accordance with an exemplary embodiment of the innovation shown connected to a generic high-pressure large bore rotary valve with V4 turn actuation. The actuator (100) is mounted on a rotary action valve (150).

[0029] An upper (130) and lower (140) hydraulic hose is connected to feed the actuator with pressurized fluids into an upper or lower piston chamber to position the valve as desired from a remote location.

[0030] FIG. 2 is an exploded perspective view of an actuator in accordance with an exemplary embodiment of the innovation. The actuator (200) is comprised of a body (210) with a mounting flange with elongated bolt holes (213). The bolt holes are elongated along the radius of the actuator (200) so the mounting can be rotated for adjustment by utilizing an adjustment gauge (215, not visible). The actuator (200) is then locked into position with a locking screw (217) to prevent rotation during actuation of the valve (150, not shown).

[0031] The actuator's (200) body (210) has a top cap (220) and a base (230) at distal ends, which together with various bearings, gaskets, and caps (290) seal against ends of the stem (250) to enclose and pressure seal the body's (210) internal cavity, supporting and/or guiding the stem's (250) movements within the actuator (200). The base (230) has a mounting flange (233) with elongated bolt holes matching the mounting flange (213) of the body (210) and being secured to the valve in the same manner.

[0032] The stem (250) has a mating port (257) at the end adjacent to the body's (210) and base's (230) mounting flange (213 & 233). The mating port (257) is supported by bearings and sealed with cap and gaskets (290) to be open at the bottom for mating the actuator (200) with the stem Date recue/date received 2021-10-22 (or other functional component) of the rotational valve (150 not shown) and transfer actuation movements thereto. The stem's (250) central body comprises an action channel (253), and a position indicator (255, not visible) extending through the body's (210) top cap (220) and sealed thereto with various gaskets and caps (290) as previously indicated.

[0033] The stem's (250) central body with the action channel (253) is encircled by the hollow body of a plunger (240). The plunger (240) has a top cap (243) at one end with a central opening through which passes the stem's (250) position indicator (255, not visible) and is slidably sealed thereto. The plunger's (240) top cap (243) has an external diameter substantially equal to the diameter of the body's (210) internal cavity and is slidably sealed thereto with 0-rings (245).

[0034] The plunger divides the body (210) cavity into two chambers, an upper and a lower that are respectively accessible by an upper hydraulic port (270A) and a lower hydraulic port (270B) extending through the outer wall of the actuator body (210). The plunger (240) has an action rod mount w/screws (247) which are secured to distal ends of an action rod (260) which passes through the action channel (253) of the stem (250).

[0035] The action rod (240) has optional rollers on each end to reduce friction against the action channel (253). As the plunger is moved up or down, the action rod (240) extending through the stem (250) causes the stem's mating port (257) to rotate. This rotation can be detected and monitored by a position sensor (280) for remote monitoring.

[0036] FIGS. 3A and 3B illustrates cut-away perspective diagrams of an actuator in accordance with an exemplary embodiment of the innovation shown in a first position and second position of typical operation. In FIG 3A, the actuator (320) is shown in a first position, where the plunger (240) has been forced down by adding fluid to the upper chamber (300) through the upper Date recue/date received 2021-10-22 hydraulic port (270A) and removing fluid from the lower chamber (310) through the lower hydraulic port (270B).

[0037] Expanding the upper chamber (300) forces the plunger (240) to move downward, while remaining sealed by the 0-rings (245). This movement forces the action rod (260), which is secured to the plunger's (240) action rod mount (247, not indicated), to move downward. The movement of the action rod (240) within the action channel (253) of the stem (250) translates the downward force into a counterclockwise rotary force. The rotary force of the action rod (240) on the action channel (253) causes the stem (250) to rotate to a first position, as indicated by the position indicator (255) extending through the top cap (220), operating the rotary valve secured to the base (230), and reported by the position sensor (280).

[0038] In FIG 3B, the actuator (330) is shown in a second position, rotated clockwise from the first position by one quarter-turn. One skilled in the arts would appreciate that obvious modification of the action channel (253) could change the direction and/or distance of such movements, and that such repositioning is well within the teaching presented here. In the illustrated second position, the plunger (240) has been forced down by adding fluid to the lower chamber (310) through the lower hydraulic port (270B) and removing fluid from the upper chamber (300) through the upper hydraulic port (270A).

[0039] Expanding the lower chamber (310) forces the plunger (240) to move upward, while remaining sealed by the 0-rings (245). This movement forces the action rod (260), which is secured to the plunger's (240) action rod mount (247, not indicated), to move upward. The movement of the action rod (240) within the action channel (253) of the stem (250) translates the upward force into a clockwise rotary force. The rotary force of the action rod (240) on the action Date recue/date received 2021-10-22 channel (253) causes the stem (250) to rotate to a second position, as indicated by the position indicator (255) extending through the top cap (220), operating the rotary valve secured to the base (230), and reported by the position sensor (280).

[0040] The diagrams in accordance with exemplary embodiments of the present invention are provided as examples and should not be construed to limit other embodiments within the scope of the invention. For instance, heights, widths, and thicknesses may not be to scale and should not be construed to limit the invention to the particular proportions illustrated. Additionally, some elements illustrated in the singularity may actually be implemented in a plurality.

[0041] Further, some element illustrated in the plurality could actually vary in count. Further, some elements illustrated in one form could actually vary in detail. Further yet, specific numerical data values (such as specific quantities, numbers, categories, etc.) or other specific information should be interpreted as illustrative for discussing exemplary embodiments. Such specific information is not provided to limit the invention.

[0042] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
Date recue/date received 2021-10-22

Claims (8)

Claims I claim:

1. An actuator for a rotary operation valve comprising:
a hollow cylindrical body comprising:
an internal diameter, and an external wall, a top cap sealing to one end, and a base sealing to the distal end;
a cylindrical stem coaxially aligned and centrally extending through the hollow cylindrical body, wherein the stem comprises:
a position indicator on one end extending through the top cap, and rotationally sealed thereto, a mating port at the distal end, extending through and opening external to the body's base, rotationally sealed thereto, and a channel extending through a portion of the stem, the channel spirally shaped in relation to, and intersecting the central axis of the stem body;
a hollow cylindrical plunger movably inserted in the body and encircling the stem, comprising:
a top cap closing one end and having an external diameter substantially equal to the actuator body's internal diameter, slidably sealed thereto dividing the actuator body into a first and a second chamber, and an axial opening, slidably sealed to the stem, and encircling the stem's channel;
an action rod extending through the stem's channel and mounted to the internal walls of the plunger's hollow the actuator body further comprising an first and a second port on the body wall positioned to respectively be in fluid connection with the first or the second port.

2. The actuator described in claim 1 further comprising an electronic position sensor for transmitting rotational position of the stem within the actuator body.

3. The actuator described in claim 1 wherein the plunger top cap further comprises grooves for 0-rings sealing the plunger top cap against the internal wall of the actuator body.

4. The actuator described in claim 1 wherein non-compressible fluid creates a pressure differential between the first and the second chamber.

5. The actuator described in claim 1 wherein a gas creates a pressure differential between the first and the second chamber.

6. The actuator described in claim 1 wherein the action channel is oriented clockwise.

7. The actuator described in claim 1 wherein the action channel is oriented counterclockwise.

8. The actuator described in claim 1 wherein the action channel comprises a plurality of joined channels.

Date recue/date received 2021-10-22