Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
  • F16K47/00—Means in valves for absorbing fluid energy
  • F16K47/04—Means in valves for absorbing fluid energy for decreasing pressure or noise level, the throttle being incorporated in the closure member
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T137/00—Fluid handling
  • Y10T137/8593—Systems
  • Y10T137/86493—Multi-way valve unit
  • Y10T137/86718—Dividing into parallel flow paths with recombining
  • Y10T137/86734—With metering feature
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T137/00—Fluid handling
  • Y10T137/8593—Systems
  • Y10T137/87917—Flow path with serial valves and/or closures
  • Y10T137/87981—Common actuator

Definitions

• This invention relates to fluid control devices, and certain embodiments relate to a multi-stage control valve having ceramic components.
• Some fluid systems use valves to control fluid flow.
• These fluid control valves may include a plug that is seated inside a valve housing.
• the plug can be moved within the valve housing to adjust the flow of fluid through the valve.
• notches or embedded corners on the plug surface interact with the fluid and affect the characteristics of the flow. For example, if a significant pressure drop is applied across the fluid control valve, a double-stage valve may be used to stage the pressure let down as the fluid passes over the plug. In such double-stage valves, the fluid flows over notches or embedded corners formed in the surface of the plug, which guide the fluid into a sequence of recovery cavities in the valve housing.
• valves may influence the materials and dimensions of the valve components.
• a high-temperature fluid including crude oil and erosive particulates, such as dirt and/or certain catalytic agents.
• the components may be subjected to temperatures in excess of 500 0 F and in extreme cases in excess of 1000 0 F and pressure differential across the valve greater than 3000 psi, which result in high fluid velocities at the control surfaces of the valve.
• a valve plug having specially-dimensioned notches or embedded corners may be used to stage the pressure drop across the valve.
• valve trim components is another factor to be considered in the design of fluid control valves.
• the erosion of valve components by high- temperature/high-pressure fluids may lead to significant problems.
• high-temperature crude oil with erosive particulates require replacement of valve plugs made from metal about every six months. Even if the metal can withstand the pressure differentials and tensile stress concentrations imposed at the embedded corners of the valve plug and seat, the erosive fluid can systematically wear away the control surfaces, thereby requiring replacement of the valve components. Rapid erosion of valve components results in significant maintenance and replacement costs.
• a fluid control valve having one or more ceramic components that operate substantially free of tensile stress concentrations.
• a fluid control valve includes a set of grooves formed on a ceramic plug such that the fluid flows over the plug's control surfaces in a direction substantially parallel to the control surfaces.
• the ceramic plug and other ceramic components may be manufactured using relatively simple machining techniques to reduce the overall production costs.
• a multi-stage flow control device includes a ceramic plug to control flow of fluid through a first and second staging portions.
• the device also includes a first set of control surfaces to contact the fluid in a first staging portion, and a second set of control surfaces to contact the fluid in a second staging portion.
• the control surfaces are formed in the ceramic plug such that, when the fluid flows through the first and second staging portions, the ceramic plug operates substantially free of tensile stress concentrations along the control surfaces.
• a flow control device in another illustrative embodiment, includes a valve body having an internal space and at least one plug guide disposed in the internal space.
• the device also includes a ceramic plug to control flow of fluid through the internal space.
• the ceramic plug is slidably engaged with the plug guide so as to reciprocate in a longitudinal direction from a first operative position to a second operative position.
• the device includes a plurality of grooves formed in an outer surface of the ceramic plug. The grooves extend in the longitudinal direction and define control surfaces such that, when the ceramic plug is in the first operative position, fluid flows in the grooves between the ceramic plug and the plug guide in a direction substantially parallel to the control surfaces.
• a fluid flow control valve having ceramic components may be relatively inexpensive to manufacture. For example, some ceramic components can be manufactured from relatively noncomplex base parts (e.g., cylinders, tubes, and the like) using a minimal number of machining operations.
• the fluid flow control valve may have an improved resistance to erosive conditions, thereby extending the service life of the valve. In some cases, fluid may flow between the ceramic plug and ceramic guide trim in a direction that is substantially parallel to the control surfaces. Such a configuration may provide a low angle of particle impingement, which can reduce the rate of erosive wear on the ceramic surfaces.
• the geometry of the ceramic components may be designed to reduce or eliminate tensile stress concentrations during operation of the valve, thereby decreasing the likelihood of catastrophic failure of a valve component.
• the ceramic plug may be configured to include no steps, flanges, or embedded corners that would cause tensile stress concentrations when fluid flows through the valve.
• the flow control valve may be assembled such that the ceramic components experience little or no tensile load during the assembly process.
• the ceramic components may be held in compression by carriers inside the valve body.
• Such designs utilize the enhanced toughness of ceramic materials when they are held in compression.
• FIG. 1 is a perspective exploded view of a flow control valve in accordance with a certain embodiments of the invention, with a section cut away to provide a view of the internal components;
• FIG. 2 is an enlarged perspective view of the assembled valve of FIG. 1, with a section cut away to provide a view of the internal components;
• FIG. 3 is another perspective view of the valve of FIG. 2, with a section cut away to provide a view of the internal components
• FIG. 4 is an enlarged partial perspective view of a portion of the valve of FIG. 2, with a section cut away to provide a view of the internal components
• FIG. 5 is another perspective view of the valve of FIG. 2, with a section cut away to provide a view of the internal components.
• a valve device 100 includes a valve body 110 that can be assembled from one or more portions.
• the valve body comprises an upper body portion 112 and a lower body portion 114.
• Both body portions 112 and 114 may comprise a high-strength metal material that is capable of withstanding the flow of high-temperature fluids.
• the upper body portion 112 and the lower body portion 114 are configured to mate with one another when a set of shafts 113 are inserted through a corresponding set of apertures 115 and engaged with a set of threaded nuts 116.
• Such a configuration provides for proper alignment of the upper and lower body portions 112 and 114.
• embodiments of the valve body 110 are not limited to the configuration depicted in FIGS. 1-2. Rather, the valve body 110 can be assembled in various ways such that the body portions are properly aligned.
• the plug 140 and/or the guides 160 and 170 may comprise a ceramic material or a similar material that is more brittle than ductile and sufficiently erosion-resistant.
• ceramic materials perform better under compressive stresses than in conditions where tensile stresses can cause crack propagation and fracture.
• ceramic materials may be more resistant to erosive fluids when the fluid flows substantially parallel to the ceramic surface (rather than flowing at a high velocity normal to the ceramic surface and impacting the ceramic surface). This erosion resistance characteristic may be more apparent when the fluid is a high-temperature, high-velocity fluid having erosive particulates.
• Certain embodiments of the flow control valve may utilize one or more of these or other characteristics of ceramic materials to provide a valve device that has a longer operation life and a reduced likelihood of catastrophic failure.
• each of the guides 160 and 170 may be retained in an associated carrier 162 and 172, respectively, which are also disposed in the internal space 120.
• the carriers 162 and 172 may have an outer circumferential surfaces 164 and 174, respectively, that engage a piloting surface 122 of the internal space 120.
• the guides 160 and 170 can be properly aligned for the plug 140 to extend axially through each of the guides 160 and 170.
• the valve body 110 may include at least one input port 124 and at least one output port 126.
• the input port 124 and output port 126 may be configured to mate with adjoining equipment.
• the input port 124 or the output port 126 may include internal or external threads to engage a tube, pipe, hose, or port from another piece of equipment.
• fluid is communicated through the input port 124 and into the internal space 120.
• the plug 140 may be positioned so that fluid flow is blocked (described in more detail below in connection with FIGS. 4-5).
• the input port 124 and output port 126 are not limited to the configuration and orientation shown in FIGS. 1-2. Rather, other types and orientations of ports may be used to permit fluid flow into and out of the internal space 120 of the valve body 110.
• the stem 130 may include an upper stem guide 136 that engages the outer circumferential surface of the upper stem portion 132.
• the stem guide 136 may comprise a metal material that is inserted into a bore of the upper valve body portion 112.
• the stem guide 136 includes an inner circumferential surface that slidably engages upper stem portion 132 such that the stem 130 may be moved in a longitudinal direction 105 relative to the valve body 110.
• the stem guide 136 is preferably produced with tight manufacturing tolerances so that the stem 130 is substantially restrained from swaying within the valve body 110.
• the stem guide 136 is spaced apart from the plug guides 160 and 170 such that any lateral swaying of the stem 130 proximal the stem guide 136 does not substantially interfere with the position of the of the plug 140 in the guides 160 and 170 (e.g., the manufacturing tolerances of the guides 160 and 170 and the plug 140 substantially prevent any swaying or lateral movement of the stem 130 that might otherwise be permitted by the stem guide 136).
• the stem 130 may comprise a metal material that can withstand the flow of high- temperature fluids.
• the stem 130 may comprise a high-strength, hardened steel material.
• some embodiments of the valve device may use the metal surface of the lower stem portion 134 to form a metal-on- metal seat that closes the fluid flow path.
• the lower stem portion 134 is shaped and configured to engage the plug 140.
• the lower stem portion 134 is sized to fit within an internal cavity of the valve body 110 and to move in the longitudinal direction 105 within that cavity.
• the plug 140 may comprise a ceramic material. Because the ceramic material may perform better under compressive conditions, the compression fit engagement between the lower stem portion 134 and the ceramic plug 140 eliminates or reduces any tensile stress concentrations that may be imposed on the ceramic material during assembly.
• a retaining wire may optionally be used as an alternate securing device.
• the plug's outer circumferential surface 141 and the stem's inner circumferential surface 137 may have opposing grooves formed therein to receive the retaining wire 139.
• the retaining wire 139 can be inserted through an aperture 138 in the lower stem portion 134 so that the retaining wire 139 is disposed between the lower stem portion 134 and the plug 140. While the compression fit (described above) serves to secure the plug 140 to the stem 130, the retaining wire 139 may serve as an alternate securing device in the event that the lower stem portion 134 heats up and expands to loosen the compression fit.
• the ceramic plug 140 includes a first set of grooves 142 formed in the outer circumferential surface 141.
• the grooves 142 are substantially parallel to one another and extend in the longitudinal direction 105.
• Each groove 142 defines one or more control surfaces 143, which are the surfaces that are exposed to the fluid flow along the valve trim where the fluid flow area is pinched (e.g., where the fluid velocity is substantially increased).
• the control surfaces 143 include those surfaces in the grooves 142 that are proximal to the ceramic guide 160.
• the fluid flows over the control surfaces 143 of the plug 140 in a direction that is substantially parallel to the control surfaces 143 (and the inner surface of the ceramic guide 160).
• ceramic materials may be more erosion resistant when the fluid flows substantially parallel to the ceramic surface.
• the ceramic plug 140 may increase the operational life of the valve device 100 while taking advantage of the erosion resistant characteristics of the ceramic material.
• the valve device 100 may be a multi-staging valve device that stages the pressure drop at different staging portions.
• the plug 140 may include a second set of grooves 144 formed in the outer circumferential surface 141. This second set of grooves 144 may provide a second staging portion in the valve device 100.
• the first carrier 162 When the first carrier 162 is cooled (e.g., to the estimated operating temperature or below), the first carrier 162 contracts to forms a compression fit along the outer circumferential surface 164 of the guide 160. A similar process may be performed to retain the second guide 170 in the second carrier.
• the stem 130 may be moved in the longitudinal direction 105 to adjust the longitudinal position of the plug 140 relative to the guides 160 and 170. If, for example, as shown in FIG. 5, the plug is moved to an open position, the fluid is permitted to flow through the first set of grooves 142, into the intermediate cavity 125, then through the set second set of grooves 144, and toward the output port 126.
• both the stem 130 and the first carrier 162 comprise a metal material, so the seat surfaces 135 and 165 (see FIG. 4) form a metal-on-metal seat.
• the ceramic plug 140 and guides 160 and 170 can be used to resist the effects of an erosive fluid without enduring impact loads at the seat when the plug 140 is moved into the closed position.
• the valve device 100 may be a single-stage or multi-stage device. In the embodiment shown in FIGS.
• valve device 100 shown as a double-stage device, but other embodiments may include a valve plug 140 having only one set of grooves 142 or 143 and one guide 160 such that the pressure drop across the valve is staged across only one staging portion.
• some embodiments may include a valve device having three sets of grooves (142, 144, or the like), three guides (160, 170, or the like), and two intermediate cavities 125 such that the valve device operates as a three-stage device. Similar designs can be implemented to created a valve device having four, five, or more stages.
• the valve device can be opened such that the fluid is permitted to flow between the input port 124 and the output port 126.
• the stem 130 may be moved in the longitudinal direction 105 relative to the valve body 110 so that at least a portion of the first set of grooves 142 are exposed to the fluid flow from the input port 124.
• fluid may be throttled through a first staging portion 148, which comprises the plug's control surfaces 143 proximal to first ceramic guide 160.
• the fluid flows through the grooves 142 between the control surfaces 143 and the first ceramic guide 160.
• the grooves 142 guide the fluid so that the fluid flows through the first staging portion 148 substantially in the longitudinal direction and substantially parallel to the control surfaces 143.
• the valve device 100 provides the valve designer with at least three ways to characterize the flow of fluid through the valve device 100.
• the flow characteristics through the valve device may be adjusted by changing the longitudinal position of the grooves 142, 144 on the plug 140 relative to the guides 160, 170.
• the fluid flow characteristics may be adjusted by changing the dimensions of the grooves 142 (e.g., width, depth, and the like) at the first staging portion 148.
• changing the dimensions of the grooves 144 at the second staging portion 149 may also adjust the flow characteristics through the valve device 100.
• the fluid flows through the staging portions 148 and 149 in a direction that is substantially parallel to the control surfaces 143 and 145.
• ceramic materials may be more erosion resistant when the fluid flows substantially parallel to the ceramic surface.
• the operational life of the valve device 100 may be increased while taking advantage of the erosion resistant characteristics of the ceramic material.
• the ceramic plug 140 and ceramic guides 160 and 170 operate substantially free of any tensile stress concentrations, thereby reducing the likelihood of crack propagation, fracture, and catastrophic failure.
• the valve device 100 is configured to be used in refining applications to control the flow of erosive fluid.
• some refining applications include an erosive fluid that comprises crude oil with erosive particulates (e.g., dirt and/or catalyzing agents).
• the valve device 100 may control this erosive fluid under conditions where the fluid is heated to a temperature of about 600 0 F to about 1,200 0 F and the pressure drop across the valve device could be in the range of about 1,000 psi to about 3,500 psi.
• the valve device 100 may have an input port size from about 1 to about 8 inches in diameter, and in some embodiments, the input port could be as large as 24 inches in diameter.
• certain embodiments of the ceramic plug may have a longitudinal length of more than 12 inches, and the internal space of the valve body 110 is sufficiently sized to house such a plug.
• the fluid may flow through the staging portions 148 and 149 in a direction that is substantially parallel to the control surfaces 143 and 145 of the ceramic plug 140, which can increase the operational life of the trim components in the valve device 100.

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• Engineering & Computer Science (AREA)
• General Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Lift Valve (AREA)
• Sliding Valves (AREA)

Priority Applications (3)

Applications Claiming Priority (2)

Publications (1)

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ID=35636899

Family Applications (1)

Country Status (5)

Cited By (1)

Families Citing this family (13)

Citations (3)

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• 2004
  • 2004-12-16 US US11/014,124 patent/US7363941B2/en not_active Expired - Lifetime
• 2005
  • 2005-10-03 CA CA 2590017 patent/CA2590017C/en not_active Expired - Fee Related
  • 2005-10-03 JP JP2007546644A patent/JP2008524525A/ja active Pending
  • 2005-10-03 EP EP20050805812 patent/EP1834120A1/en not_active Withdrawn
  • 2005-10-03 WO PCT/US2005/034919 patent/WO2006065319A1/en not_active Ceased

Patent Citations (3)

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