VALVE SEAT INSTALLATION TOOL SYSTEM

A valve seat installation tool is disclosed. The valve seat installation tool includes a force conversion shaft extending from a shaft front surface to a shaft rear surface along a central axis, a torque nut secured to the force conversion shaft adjacent to the shaft front surface, a head adjacent to the shaft rear surface and a pump adapter secured to the force conversion shaft between the torque nut and the head.

FIELD OF THE INVENTION

The present invention relates to installation tools for valve seats, and more particularly an installation tool for securing valve seats in their respective pumps.

BACKGROUND INFORMATION

Valve seats are often replaced in order to ensure proper pressure sealing during a pumping operation. Valve seats are often replaced using hydraulic insertion tools. Hydraulic insertion tools often require a significant amount of space and are difficult to utilize in the field. A mechanical insertion tool utilizing mechanical torque may allow for valve seat installation to occur at site of their respective pump, while also allowing for simplified installation with standardized torques.

SUMMARY OF THE INVENTION

The present invention provides a valve seat installation tool and a method of installing a valve seat. The valve seat installation tool includes a force conversion shaft extending from a shaft front surface to a shaft rear surface along a central axis, a torque nut secured to the force conversion shaft adjacent to the shaft front surface, a head adjacent to the shaft rear surface and a pump adapter secured to the force conversion shaft between the torque nut and the head.

An aspect of the present invention is to provide a valve seat installation tool including a force conversion shaft extending from a shaft front surface to a shaft rear surface along a central axis, a torque nut secured to the force conversion shaft adjacent to the shaft front surface, and a pump adapter secured to the force conversion shaft between the torque nut and the shaft rear surface.

Another aspect of the present invention is to provide a method of installing a valve seat including inserting the valve seat into a pump body. A head is then inserted into the valve seat. Next, a pump adapter is secured to a pump opening of the pump body. Then a force conversion shaft is secured to the pump adapter, wherein the force conversion shaft extends from a shaft front surface to a shaft rear surface along a central axis and the pump adapter is secured between the shaft front surface and the shaft rear surface. The force conversion shaft is then inserted into the pump body such that the force conversion shaft moves along the central axis relative to the pump adapter until the shaft rear surface comes in contact with the head. A socket of a torque wrench is attached to a torque nut, wherein the torque nut is secured to the force conversion shaft adjacent to the shaft front surface. Finally, the torque nut is rotated in a first direction with the socket.

DETAILED DESCRIPTION

The installation tool of the present invention addresses the issues mentioned above by providing a valve seat installation tool that can insert a valve seat through mechanical forces. The valve seat installation tool can be operated using standard torque wrenches.

The installation tool provides several benefits to the installation of valve seats. The installation tool can be operated without hydraulic equipment, resulting in a simpler installation. The installation tool also allows for calibrated installation such that valve seats can be installed with an adequate source for each valve seat type. The installation tool can also allow the same force regardless of the strength capabilities of the user. The simplified design also allows the installation to occur at the site of the respective pump.

Referring toFIGS.1-7, an installation tool10is shown including a force conversion force conversion shaft20, a torque nut40, a head50, a pump adapter70and a valve seat90.

The force conversion shaft20may extend along a central axis100from a shaft front surface22to a shaft rear surface24. The force conversion shaft20may be cylindrical in shape. The shaft outside surface26may include a shaft set of threads27around the outside circumference of the force conversion shaft20. The shaft set of threads27may extend axially down the entire length of the force conversion shaft20between the shaft front surface22and the shaft rear surface24, or down a partial length of the force conversion shaft20. The force conversion shaft20may be made of a steel material, such as a stainless steel, alloy steel or carbon steel, or other ductile material.

The shaft set of threads27may have a thread density of at least 2 threads per inch, for example, 3 threads per inch, 4 threads per inch, or 4.5 threads per inch. The shaft set of threads27may have a thread density of at most 7 threads per inch, for example, at most 6 threads per inch, at most 5.5 threads per inch, or at most 5 threads per inch.

The force conversion shaft20may have a shaft length Ls that is at least 6 inches, for example, at least 1.5 feet or at least 3 feet. The shaft length Ls may be at most 6 feet, for example, at most 5 feet or at most 4 feet. The shaft length Ls may range from 6 inches to 6 feet, for example, from 1.5 feet to 5 feet, or from 3 feet to 4 feet.

The force conversion shaft20may have a shaft outer diameter DSOthat is at least 1 inch, for example, at least 1.5 inches or at least 2 inches. The shaft outer diameter DSOmay be at most 4 inches, for example, at most 3 inches or at most 2.5 inches. The shaft outer diameter DSOmay range from 1 inch to 4 inches, for example, from 1.5 inches to 3 inches, or from 2 inches to 2.5 inches.

The force conversion shaft20may be structured and arranged to withstand the predetermined torque required to install the valve seat90. The predetermined torque may be at least 250 lbf-ft, for example, at least 500 lbf-ft, or at least 800 lbf-ft. The predetermined torque may be at most 6400 lbf-ft, for example, at most 4000 lbf-ft, or at most 1600 lbf-ft. The predetermined torque may range from 250 lbf-ft to 6400 lbf-ft, for example, from 500 lbf-ft to 4000 lbf-ft, or from 800 lbf-ft to 1600 lbf-ft. The force conversion shaft20may be structured and arranged to convert the torque force into a linear force applied through the shaft rear surface24.

A torque nut40may be secured to the force conversion shaft20adjacent to the shaft front surface22. The torque nut40may be structured and arranged to be rotated by a torque wrench. Rotation of the torque nut40may transfer the rotational force to the force conversion shaft20, causing the force conversion shaft20to rotate.

The torque nut40may extend from a nut front face42to a nut rear face44. The nut outside surface46may be located between the nut front face42and nut rear face44, and may be hex shaped, square shaped, triangular shaped and/or the like. The nut outside surface46may be structured and arranged to receive a socket of a torque wrench (not shown). The torque nut40may be structured and arranged on the force conversion shaft20such that the force conversion shaft20would not impede a torque wrench socket from attaching to the nut outside surface46.

The torque nut40may include a nut set of threads47on the nut inside surface48of the torque nut40that are structured and arranged to form a threaded connection with the shaft set of threads27. The nut set of threads47may have the same thread density (e.g., threads per inch) as the shaft set of threads27. The nut inside surface48may have nut inner diameter DNIthat is equal to or greater than the shaft outer diameter DSO. The nut outside diameter DNOmay be at least half an inch greater than the shaft outer diameter DSO, for example, at least ¾ inch, or at least 1 inch. The nut outside diameter DNOmay be at most 2 inches greater than the shaft outer diameter DSO, for example, at most 1.5 inches greater, or at most 1.25 inches greater.

The torque nut40may be initially secured to the force conversion shaft20by rotating the torque nut40in a clockwise or counterclockwise direction around the force conversion shaft20. The nut set of threads47may interact with the shaft set of threads27, pulling the torque nut40in the axial direction along the central axis100toward the shaft rear surface24.

The torque nut40may be welded to the force conversion shaft20to create a permanent connection between the torque nut40and the force conversion shaft20. The torque nut40may be welded to the force conversion shaft20through any welding means, such as arc welding, metal inert gas welding, laser welding and/or the like. The torque nut40may be welded at the nut front face42and/or the nut rear face44. A front weld joint43may be formed on the nut front face42. A rear weld joint45may be formed on the nut rear face44. The front weld joint43and/or the rear weld joint45may be formed around the entire outer circumference of the force conversion shaft20. The permanent connection of the torque nut40to the force conversion shaft20may allow the torque nut40to transfer rotational force to the force conversion shaft20. In some non-limiting embodiments or aspects, the torque nut40may be secured to the force conversion shaft20through other suitable means for forming a permanent connection. The torque nut40may be formed with the force conversion shaft20, such as through3D printing or through molding.

The torque nut40may be made of the same or different material as the force conversion shaft20. The torque nut40may be made of a steel, such as a stainless steel, alloy steel or carbon steel, or ductile material.

A pump adapter70may be secured to the force conversion shaft20between the head50and the torque nut40. The pump adapter70may be releasably attached to the force conversion shaft20. The pump adapter70may be cylindrical in shape and may extend from a pump adapter front surface72to a pump adapter rear surface74. The pump adapter front surface72may be oriented to face towards the shaft front surface22when the pump adapter70is secured to the force conversion shaft20. The pump adapter rear surface74may be oriented to face towards the shaft rear surface24when the pump adapter70is secured to the force conversion shaft20.

The pump adapter70may have a pump adapter center hole75structured and arranged to receive the force conversion shaft20. The pump adapter inner diameter DFIof the pump adapter70, defined by the pump adapter center hole75, may be equal to or greater than the shaft outer diameter DSO. The pump adapter inner diameter DFImay be the same as the nut inner diameter DNI. A pump adapter set of inner threads77may be arranged on the pump adapter inner surface76. The pump adapter set of inner threads77may be structured and arranged to engage with the shaft set of threads27. The pump adapter set of inner threads77may extend through the entire axial length or partial axial length of the pump adapter inner surface76.

The pump adapter70may be structured and arranged to connect to an opening, such as a pump body112. The pump adapter70may include a pump adapter set of outer threads79on the pump adapter outer surface78. The pump adapter set of outer threads79may be oriented in an opposite direction than the pump adapter set of inner threads77. The pump adapter outer diameter DFOmay be less than or equal to the diameter of the opening of the pump body112. The pump adapter set of outer threads79may be structured and arranged to make a threaded connection with a set of threads arranged on an inside surface of an opening of a pump body112. The pump adapter set of outer threads79may be buttress threading. The pump adapter set of outer threads79may extend along at least a portion of the axial length of the pump adapter70between the pump adapter front surface72and the pump adapter rear surface74.

The pump adapter70may include a pump adapter recess73on the pump adapter front surface72. The pump adapter recess73may be centered around the pump adapter center hole75. The pump adapter recess73may be structured and arranged to receive a tool bit to rotate the pump adapter70. The pump adapter recess73may be hex shaped, cross shaped, square shaped, star shaped or other geometric shape.

The pump adapter70may include one or more handles71on the pump adapter outer surface78. The handles71may be structured and arranged to receive the fingers or hands of a user to aid in lifting of the pump adapter70by the user. The handles71may be slots extending from the pump adapter outer surface78towards the pump adapter inner surface76. The handles71may extend a partial length around the circumference of the pump adapter outer surface78. When the pump adapter70is installed on the pump body112, the one or more handles71may extend outward of the pump body112such that the handles71remain accessible when the pump adapter70is fully installed.

The shaft rear surface24of the force conversion shaft20may be placed on a head50, shown without a valve seat90inFIGS.6and7. The force conversion shaft20may be inserted into a head recess59of the head50, the head recess59having a recess diameter DR that is greater than or equal to the shaft outer diameter DSO. The head recess59may extend along a head recess side surface58from the head front surface52toward the head rear surface54to a head recess bottom surface57. The shaft rear surface24may make contact with or be pressed against the head recess bottom surface57. A recess diameter DR being greater than the shaft outer diameter DSOmay allow for variation of the location of the shaft rear surface24against the head recess bottom surface57such that the shaft rear surface24need not be inserted into an exact position against the head recess bottom surface57, but instead may be placed anywhere within the head recess59. The head50may have various sizes corresponding to the valve seat90to be installed into the pump body112. For example, a larger valve seat90may result in a larger head50structured and arranged to secure the valve seat90.

In some non-limiting embodiments or aspects, the head50may be releasably or permanently secured to the force conversion shaft20. The head50may be secured to the force conversion shaft20by a threaded connection. The head50may be welded to the force conversion shaft20or may be formed as a single component with the force conversion shaft20.

The head50may be structured and arranged to receive a valve seat90. The head50may be cylindrical in shape. The head50may extend from a head front surface52to a head rear surface54. The head front surface52may be oriented to face the shaft front surface22when the head50is adjacent to the force conversion shaft20. The head recess59may be located at the center of the head front surface52. The head rear surface54may be oriented to face away from the shaft rear surface24when the head50is adjacent to the force conversion shaft20. The head50may extend along the central axis100. The head50may include a front end51adjacent to the head front surface52and a rear end53adjacent to the head rear surface54.

The front end51may have a head front end outer diameter DHFthat is the same as or greater than the head rear end outer diameter DHR. The head front end outer diameter DHFmay be less than the pump adapter outer diameter DFO. The rear end53may be structured and arranged to be inserted into the valve seat hole95of the valve seat90. The head rear end outer diameter DHRmay be equal to or less than the valve seat inner diameter DVI.

The head50may include a ring60. The ring60may be made of an elastic material, such as polyurethane, and may be cylindrical in shape. The ring60may be made of a material that has a hardness that is lower than the hardness of the valve seat90. The material of the ring60may be different than the material of the head50. The material of the ring60may be softer than the material of the head50. Using softer material for the ring60compared to the material of the head50and/or the valve seat90may reduce the likelihood of the valve seat90being damaged during installation, thus increasing the potential life of the valve seat90.

The ring60may be structured and arranged to receive the valve seat90and to fit the outside shape of the valve seat90. The ring60may be attached to the head50, and may be located between the front end51and the rear end53. The ring60may be located on a rear end outer surface56. The ring outside surface66may align with the front end outer surface55.

The ring60may extend from a ring front surface62to a ring rear surface64. The ring front surface62may face the shaft front surface22when the head50is installed on the force conversion shaft20. The ring rear surface64may be oriented to face away from the shaft rear surface24when the head50is secured to the force conversion shaft20. The ring inner surface67may be in contact with the rear end outer surface56. The ring front surface62may be adjacent to the front end51. The ring60may be secured to the head50through an adhesive, mold fit, threaded fit and/or the like.

The ring rear surface64may be structured and arranged to receive the valve seat90. The ring rear surface64may deform when coming in contact with the valve seat90. The ring rear surface64may deform to match the contour of the valve seat90, resulting in a tighter fit of the ring60to the valve seat90. The ring rear surface64may be conical in shape and may be angled to receive the valve seat90.

The valve seat90, shown inFIGS.1,3,4, and5, may be structured and arranged to be inserted into a valve, such as a frac valve. The valve seat90may be cylindrical in shape. The valve seat90may extend from a valve seat front surface92to a valve seat rear surface94. The valve seat90may extend in a radial direction from a valve seat inner surface96defined by a valve seat hole95to a valve seat outer surface97. The valve seat front surface92may be oriented to face the shaft front surface22when the valve seat90is secured to the installation tool10. The valve seat rear surface94may be oriented to face away from the shaft rear surface24when the valve seat90is secured to the installation tool10.

The valve seat front surface92may include a valve seat conical surface91centered around the valve seat hole95. The valve seat hole95may extend in the axial direction along the central axis100from the valve seat front surface92to the valve seat rear surface94. The valve seat conical surface91may be structured and arranged to be received by the ring rear surface64. A valve seat inner surface96is defined by the valve seat hole95. The valve seat inner surface96may be cylindrical in shape. The valve seat inner diameter DVIof the valve seat inner surface96may be less than or equal to the head rear end outer diameter DHR. When the valve seat90is installed on the head50, the valve seat inner surface96may form a friction fit with the rear end outer surface56of the head50. The valve seat outer diameter DVOmay be less than the pump adapter outer diameter DFOsuch that the valve seat90may fit within the pump body112.

The valve seat90may include a valve seat lip98located on the valve seat outer surface97proximate the valve seat front surface92. The valve seat lip98may extend in a radial direction outward from the valve seat hole95. The valve seat lip98may extend along a plane perpendicular to the central axis100.

The valve seat90may be inserted into a pump110, as shown inFIGS.9A-10B. The pump110may include a pump body112. One end of the pump body112may include a pump120. The pump120may include a pump opening122, the pump opening122being structured and arranged to receive a pump adapter70. The pump opening122may define a pump opening inner surface124. The pump opening inner surface124may be threaded and structured and arranged to form a threaded connection with the pump adapter set of outer threads79.

The pump body112may encase a pump chamber114, the pump chamber114being an open space located within the pump110. The pump chamber114may be in fluid communication with the pump opening122through a pump valve slot116. The pump valve slot116may extend from the pump chamber114to towards the pump opening122. The pump valve slot116may be defined by a pump valve slot wall118, the pump valve slot wall118may be cylindrical in shape and may be structured and arranged to receive a valve seat90. The pump valve slot116may end at a pump valve slot ledge117located at the end of the valve slot116closest to the pump opening122. The pump valve slot ledge117may be planar in shape and may be perpendicular to the central axis100. The pump valve slot ledge117may expand radially from the pump valve slot116.

The installation tool10may be used to install the valve seat90into a fluid body of a pump110using the following installation method820, as shown inFIG.8.

In step800, the valve seat90is placed through the pump opening122of the pump110. The valve seat90may be placed by hand through the pump opening122. The valve seat90may be oriented such that the valve seat rear surface94is facing away from the pump opening122and the valve seat front surface92is facing toward the pump opening122. The valve seat outer surface97may be inserted through the pump valve slot116such that the valve seat outer surface97is in contact with the pump valve slot wall118. When inserted, there may be a valve seat gap GVS, measured as the distance between the valve seat lip98and the pump valve slot ledge117. The valve seat gap GVSmay be at least 0.1 inches, for example, at least 0.2 inches, or at least 0.25 inches. The valve seat gap GVSmay be at most 0.5 inches, for example, at most 0.4 inches, or at most 0.3 inches. The valve seat gap GVSmay range from 0.1 inches to 0.5 inches, for example, from 0.2 inches to 0.4 inches or from 0.25 inches to 0.3 inches.

In step802, the head50is placed onto the valve seat90. The head50may be inserted through the pump opening122and oriented such that the rear end outer surface57is facing away from the pump opening122. The head50may be placed onto the valve seat90by moving the head50along the central axis100in the axial direction toward the valve seat hole95. The rear end53may be inserted into the valve seat hole95such that the valve seat inner surface96comes in contact with the rear end outer surface56. The head50may be moved in the axial direction until the valve seat conical surface91comes in contact with the ring rear surface64. The valve seat90and the head50may form a friction fit of the head50onto the valve seat90. The shape and size of the head50may be specific to the valve seat90to be installed. Different sized and shaped heads50may be used with the same force conversion shaft20and torque nut40.

In step804, the pump adapter70is secured to the pump opening122. The pump adapter70may be specific to the pump body112in which the valve seat90is to be installed. The pump adapter70may be secured to a pump opening122through a threaded connection. The pump adapter set of outer threads79may make a threaded connection with the threads of the pump opening inner surface124. The pump adapter70may be locked into position.

In step806, the force conversion shaft20may be threaded through the pump adapter70. The same force conversion shaft20may be used with different sized pump adapters70based on the pump body112. The shaft rear end24may be inserted into the pump adapter center hole75. The force conversion shaft20may be rotated to form a threaded connection between the shaft set of threads27and the pump adapter inner set of threads77. The force conversion shaft20may be rotated in a first direction. The first direction may be a clockwise or counterclockwise direction. The rotation of the force conversion shaft20within the pump adapter70will cause the force conversion shaft20to move in the axial direction relative to the pump adapter70as the shaft set of threads27interacts with the pump adapter set of inner threads77, pushing the shaft rear surface24further into the pump body112. The force conversion shaft20may be rotated until the shaft rear end24comes in contact with the head recess bottom surface57. The initial insertion of the force conversion shaft20may be completed by hand, wrench, torque wrench or other tool.

In step808, a socket of a torque wrench is attached to the torque nut40. The socket of the torque wrench may be attached to the torque nut40by moving the socket in the axial direction along the central axis100toward the nut front face42. The socket of the torque wrench may come in contact with the nut outside surface46. The socket of the torque wrench may be attached to a torque wrench set with a predetermined torque value. The torque wrench may include one or more torque multipliers.

In step810, the torque wrench is rotated in the first direction. As the torque wrench is rotated, it applies the rotational force to the torque nut40. The torque nut40then transfers the rotational force to the force conversion shaft20due to the torque nut40being welded to the force conversion shaft20. Due to the pump adapter70being secured to the pump opening122, as the force conversion shaft20rotates, the pump adapter70remains in place and the shaft rear end24continues to move in the axial direction towards the pump chamber114. The further axial movement of the force conversion shaft20after contact is made with the head recess bottom surface57causes the shaft rear surface24to apply a linear force on the head recess bottom surface57. The force on the head recess bottom surface57causes the head50to move in the axial direction, which then applies the force onto the valve seat90. The valve seat90may then move in the axial direction away from the pump opening122. As the valve seat90moves in the axial direction, the valve seat gap GSVbegins to decrease in size as the valve seat lip98moves towards the pump valve slot ledge117.

In step812, the torque wrench continues to rotate the torque nut40until the torque wrench measures a torque value that meets or exceeds a predetermined torque value. The predetermined torque value may be determined based on the properties of the pump body and/or valve seat90. The predetermined torque value may be determined based on the predetermined installation force of the valve seat90. The predetermined installation force may be at least 15,000 lbf, for example, at least 19,000 lbf, at least 22,000 lbf or at least 24,400 lbf. The predetermined installation force may be at most 200,000 lbf, for example at most 180,000 lbf, at most 140,000 lbf or at most 120,000 lbf. The predetermined installation force may range from 15,000 lbf to 200,000 lbf, for example, from 19,000 lbf to 180,000 lbf, from 22,000 lbf to 140,000 lbf, or from 24,400 lbf to 120,000 lbf. The valve seat gap GSVmay decrease to zero as the valve seat lip97comes in contact with the pump valve slot ledge117, as shown inFIGS.10A and10B.

The predetermined torque value may also be determined based on the physical properties of the force conversion shaft20, such as the friction coefficient, thread pitch, thread depth, helix angle, and normal thread angle. The predetermined torque may be based on previously completed testing of various torque values for various valve types. The predetermined torque may be at least 250 lbf-ft, for example, at least 500 lbf-ft, or at least 800 lbf-ft. The predetermined torque may be at most 6400 lbf-ft, for example, at most 4000 lbf-ft, or at most 1600 lbf-ft. The predetermined torque may range from 250 lbf-ft to 6400 lbf-ft, for example, from 500 lbf-ft to 4000 lbf-ft, or from 800 lbf-ft to 1600 lbf-ft. Once the predetermined torque value is reached, the valve seat90will be adequately secured to the pump body.

In step814, the force conversion shaft20is removed. The force conversion shaft20is rotated in a second direction, the second direction being opposite of the first direction. As the force conversion shaft20is rotated in the second direction, the force conversion shaft20moves in an axial direction out of the pump adapter70. The force conversion shaft20is rotated until the threaded connection between the force conversion shaft20and the pump adapter70is disconnected.

In step816, the pump adapter70is disconnected from the pump opening122. The pump adapter70may be disconnected from the pump opening122by rotation of the pump adapter70.

In step812, the head50is removed from the pump110. The head50may be removed by hand by a user. In some non-limiting embodiments, the installation method may be used to install both a valve seat90on the suction side126of the pump body112as well as the discharge side128of the pump body112. The valve seat90may be installed on the suction side126before a second valve seat is installed in the discharge side128. The suction side126may be separated from the discharge side128in an axial direction by the pump chamber114.

It should also be understood that some steps in the method may be completed in a different order than what is shown. For, example, in some non-limiting embodiments or aspects, prior to installation of the valve seat90, the pump adapter70may be threaded to the force conversion shaft20. The pump adapter70may be attached to the force conversion shaft20through a threaded connection. The pump adapter70may be inserted onto the shaft rear surface24by moving the pump adapter70along the central axis100in the axial direction toward the shaft rear surface24. The pump adapter70may be attached to the force conversion shaft20by rotating the pump adapter70in a clockwise or counterclockwise direction.

As used herein, “including,” “containing” and like terms are understood in the context of this application to be synonymous with “comprising” and are therefore open-ended and do not exclude the presence of additional undescribed or unrecited elements, materials, phases or method steps. As used herein, “consisting of” is understood in the context of this application to exclude the presence of any unspecified element, material, phase or method step. As used herein, “consisting essentially of” is understood in the context of this application to include the specified elements, materials, phases, or method steps, where applicable, and to also include any unspecified elements, materials, phases, or method steps that do not materially affect the basic or novel characteristics of the invention.

In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, in this application, the use of “or” means “and/or” unless specifically stated otherwise, even though “and/or” may be explicitly used in certain instances. In this application and the appended claims, the articles “a,” “an,” and “the” include plural referents unless expressly and unequivocally limited to one referent.