Abstract:
A solenoid-operated valve of the kind that is used in a subsea control pod comprises a valve assembly ( 2 ) and a solenoid assembly ( 1 ). The valve assembly ( 2 ) comprising has fluid ports (P, S, T) for the receipt and delivery of hydraulic control fluid and a valve element ( 37, 38, 39 ) that is actuable between open and closed positions in order to control the flow of hydraulic control fluid between the fluid ports. The valve element ( 37, 38, 39 ) is actuable by an actuating member of the solenoid assembly ( 1 ). The solenoid chamber (A) is filled with oil and sealed against ingress of hydraulic control fluid from the valve chamber ( 36 ) and from the ingress of oil and/or seawater from the control pod. A movable pressure balancing device ( 30 ) is provided in the solenoid assembly ( 1 ) so as to ensure that the internal pressure of the oil in the solenoid chamber (A) and the external pressure of the oil in the control pod are balanced.

Description:
BACKGROUND 
     The present invention relates to a solenoid-operated valve and more particularly, but not exclusively, to such a valve for use underwater in a control system of a subsea wellhead for the extraction of oil and/or gas. 
     In subsea drilling, large actuators or process valves associated with the wellhead are typically controlled by smaller main-stage valves and pilot-operated valves. These smaller valves are hydraulically and/or electrically-operated and may be housed within a subsea container known as a control “pod” so that they are protected from the surrounding environment. The pod is sealed against the ingress of sea water and has a one or more connectors for connection to a supply of hydraulic fluid and/or electric power for operation of the valves. The pod is typically filled with a suitable oil so that it immerses and enters the valves. The oil typically contains a corrosion inhibitor and serves as an electrical insulator. 
     Some valves may be designed such that they are sealed against the ingress of pod oil and are instead flooded with hydraulic control fluid. 
     In some instances it is possible for sea water to ingress into the pod. For example, the pod may develop a leak. In the instance where the valves are flooded with pod oil, the ingress of seawater into the pod can lead to seawater entering the valves which undesirable as it increases the risk of corrosion of valve parts. In the instance where valves are flooded with hydraulic control fluid there is still a risk of seawater entering the valve via connectors disposed on the pod for connection to corresponding connectors provided on the end of an umbilical (a collection of lines, hoses or tubes through which control fluid and electrical power may be supplied) that extends from a topside production platform or vessel. 
     The armature of a solenoid-operated valve is designed to have relatively high magnetic permeability so as to ensure that the force applied the actuator is sufficient for to move the valve member without unduly high electrical power being consumed. Such materials are vulnerable to corrosion and it is thus common to apply a suitable coating to the armature such as, for example, nickel plating. 
     It has been found that the oil or hydraulic control fluid that enters the solenoid cavity from the pod or the rest of the valve can cause the solenoid actuator to jam. In particular, over time the running gap between the solenoid actuator and the surrounding armature becomes filled with a sticky deposit or gum-like substance. It is thought that the problem may be caused by the corrosion inhibitor and/or other additives in the oil/control fluid chemically degrading the nickel plating on the armature. 
     The content of hydraulic control fluid is regulated by industry or government standards to avoid harmful substances being vented into the sea. Such control fluids have a high water content and the volume of additives is being increasingly restricted for environmental reasons. This increases the risk of corrosion of valve parts and, in particular, solenoid operators. 
     It is an object of the present invention to obviate or mitigate the aforementioned disadvantages. It is also an object to provide for an alternative or improved solenoid-operated valve. 
     SUMMARY 
     According to a first aspect of the present invention there is provided a solenoid-operated valve comprising a valve assembly and a solenoid assembly, the valve assembly comprising: a body with fluid ports for the receipt and delivery of hydraulic control fluid, a valve element disposed in a valve chamber, the valve element being actuable between open and closed positions in order to control the flow of hydraulic control fluid between the fluid ports, the valve element being actuated by a solenoid assembly; the solenoid assembly comprising at least one coil for generating a magnetic field and an actuating member disposed in a solenoid chamber for displacement by the magnetic field, the actuating member being coupled to the valve element, wherein the solenoid chamber is sealed against ingress of hydraulic control fluid from the valve chamber and from the ingress of fluid from the environment surrounding the solenoid assembly, and a movable pressure balancing device provided between the solenoid chamber and the surrounding environment, the balancing device having a first surface exposed to the internal pressure within the solenoid chamber and a second surface for exposure to the external pressure of the surrounding environment, the device being movable so as to ensure the forces acting on the first and second surfaces are balanced. 
     The external pressure of the surrounding environment will, in use, be the pressure of the oil within a control pod in which the valve is contained. The internal pressure will be that of the hydraulic fluid sealed within the solenoid chamber, such fluid being isolated from the hydraulic control fluid which, is use, is present in the valve chamber. 
     The isolation of the solenoid assembly prevents ingression into the solenoid chamber of any sea water that is present in the pod. It also prevents any seawater present in the hydraulic control fluid from entering the solenoid chamber. 
     The valve assembly is designed to selectively open and interrupt a hydraulic control fluid supply path that, in use, would extend between a source and an inlet of a fluid handing member that requires control such as, for example, a main-stage valve. 
     The pressure balancing device may take any suitable form. It may comprise a single component or may comprise an assembly of components. 
     In one preferred embodiment the pressure balancing device is in the form of a flexible diaphragm. The diaphragm may be retained in the solenoid assembly by a clamping arrangement. For example it may be clamped at its periphery so as to leave a region in-board of its periphery exposed to the respective fluids. The diaphragm deflects according to the forces applied by the prevailing pressures acting on each surface. 
     In another embodiment the pressure balancing device is a piston that is sealed to the housing. A first piston surface is exposed to the solenoid chamber and an opposed second piston surface is exposed to the pressure of the surrounding environment. 
     The clamping arrangement may be provided by a support member that is screwed into a housing of the solenoid assembly. The support member may define an annular shoulder against which the diaphragm is clamped by a clamping member. 
     The solenoid assembly may comprise a solenoid housing and the valve assembly may comprise a valve housing. The two housings may be integrally formed or may be separate components that are fixed together permanently or which may be separably connected together. 
     The actuator may be in the form of a push rod which may carry an armature member. 
     The solenoid assembly may further comprise one or more pole pieces in which the armature member is supported for sliding or floating movement. The pole pieces may be substantially cylindrical and disposed radially inboard of the at least one coil. The solenoid chamber may be defined at least in part by at least one bore in the pole pieces 
     There is preferably an isolating seal provided between valve chamber and solenoid assembly so as to prevent hydraulic control fluid from entering the solenoid assembly and in particular the solenoid chamber. The seal may be provided around the valve element of the valve assembly and/or around the actuator of the solenoid. 
     The valve element may comprise at least one substantially spherical element for sealing against a valve seat. The spherical valve element may be axially movable within the valve chamber between a closed position in which it seals against the seat and an open position in which it is displaced from the seat. The valve element may further comprise at least one actuating pin arranged coaxially with the valve seat for moving the spherical valve element to the open or closed position. The at least one actuating pin is preferably connected, directly or indirectly to the solenoid actuating member. 
     The housing may comprise at least first and second ports for the hydraulic control fluid. 
     A first fluid path may be defined between the first and second ports and passing through the chamber. 
     There may be a third port and a second path defined between the second and third ports with the chamber being disposed at the intersection of the first and second paths/The spherical member is moveable to open or close the first and second fluid paths. 
     In one embodiment there may be a second spherical valve element with a corresponding valve seat and a further actuating pin between the two spherical valve elements. The pins and spherical elements are arranged in the valve chamber such that when the first spherical valve element is displaced from its seat (so as to open the first fluid path) it moves the further actuating pin which in turn forces the second valve element on to its seat (so as to close the second fluid path). 
     There may be provided a biasing member that applies a force against the actuating member. 
     The valve assembly may be a two-position, three way valve. 
     According to a second aspect of the present invention there is provided a subsea control pod containing at least one solenoid-operated valve as defined above, the pod containing a first hydraulic fluid, the valve assembly being connectable to a source of hydraulic control fluid via a conduit provided in the pod for supplying hydraulic control fluid to the valve chamber, the solenoid chamber being filled with a second hydraulic fluid. 
     The first and second hydraulic fluids may be of the same type or may be different. They may be a suitable oil such as synthetic hydrocarbon based oil. The hydraulic control fluid may be, for example, a water based fluid containing, for example, ethylene glycol. 
     The pod preferably has a connector for connection to the source of hydraulic control fluid, the valve chamber being in fluid communication with the connector. 
     According to a third aspect of the present invention there is provided a method for operating a subsea solenoid-operated valve that comprises a valve assembly and a solenoid assembly, the method comprising connecting the fluid ports of the valve assembly into a hydraulic control fluid supply path that, in use, extends between a source of control fluid and an inlet to a fluid handling member that requires control, such that the control fluid enters a valve chamber of the valve assembly, providing a valve element that is actuable between open and closed positions in order to control the flow of hydraulic control fluid between the fluid ports, the valve element being actuable by a solenoid assembly; the solenoid assembly comprising at least one coil for generating a magnetic field and an actuating member disposed in a solenoid chamber for displacement by the magnetic field, the actuating member being coupled to the valve element, the method further comprising filling the solenoid chamber with a first hydraulic fluid and isolating the filled solenoid chamber by sealing it against ingress of hydraulic control fluid from the valve chamber and sealing the solenoid chamber from the ingress of fluid from the environment surrounding the solenoid assembly, providing a movable pressure balancing arrangement in the solenoid assembly, the balancing device having a first surface exposed to the internal pressure within the solenoid chamber and a second surface for exposure to the external pressure of the surrounding environment, the device being movable so as to ensure the forces acting on the first and second surfaces are balanced. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A specific embodiment of the present invention will now be described with reference to the accompanying drawings in which: 
         FIG. 1  is a longitudinal sectioned view of a solenoid-operated valve in accordance with the present invention; 
         FIG. 2  is a longitudinal section view according to  FIG. 1 , with a pressure diaphragm in a first position; 
         FIG. 3  is a longitudinal section view according to  FIG. 1 , with a pressure diaphragm in a first position 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to  FIG. 1 , the exemplary solenoid-operated valve has two principal sections: a solenoid assembly  1  and a valve assembly  2 . The solenoid assembly  1  is driven by electrical signals and serves to operate the valve assembly  2  so as to interrupt or allow the flow of hydraulic fluid. 
     The solenoid assembly  1  comprises a housing  3  in which there is a pair of axially arranged coils  4  supported on a hollow cylindrical holder  5 . The coils  4  are connected to an electrical supply (not shown) by a connector block  6  which will be very familiar to the skilled person and requires no further description. The holder  5  receives a pole piece  7 ,  8  at each end. Each pole piece  7 ,  8  has an end flange  9 ,  10  that extends radially outwards from a generally cylindrical body  11 . The flanges  9 ,  10  are fixed to the housing  3  and the bodies  11  are received in the holder  5 . The pole pieces  7 ,  8  are axially separated by a pressure tube  12  that is disposed radially inboard of the holder  5 . The region radially inboard of the pressure tube and the pole pieces  7 , 8  defines a solenoid chamber A which in use is filled with suitable hydraulic fluid such as oil. An O-ring seal  13  is provided in an annular groove in each cylindrical body  11  of the pole pieces  7 ,  8  and seals against the pressure tube  12  to prevent egress of the hydraulic fluid from the solenoid chamber A. 
     A solenoid actuator  14  is disposed concentrically with the coils  4  for axial movement as is well known in the art. In the embodiment shown the actuator  14  comprises a push-rod  15  on which a hollow cylindrical armature  16  is supported. There is a small annular clearance  17  between the outer surface of the armature  15  and the inner surface of the first pole piece  7  to allow for relative axial movement. This annular clearance  17  is commonly referred to as the “running gap”. A small axial clearance  18  between one end of the armature  16  and the adjacent second pole piece  8  allows the push rod  15  and armature  16  to travel in the axial direction relative to the pole pieces  7 ,  8 . The push rod  15  extends from the armature  16 , through a bore in the second pole piece  8 , towards to the valve assembly  2  where it terminates in an adapter  19  for connection to the valve assembly. On the solenoid assembly side, the adapter  19  defines a blind bore  20  for receipt of the push rod  15 . The end of the push rod  15  simply abuts a surface defined at the end of the bore  20 . The other side of the adapter  19  has a nipple  21  for connection to the valve assembly. 
     The end of the push rod  15  opposite the adapter  19  is fixed to the armature  16  by means of a fixing assembly that may take any suitable form. In the embodiment shown an externally threaded adjuster  22  is screw-fitted into a threaded bore in the end of the armature  16  and a set screw  23  on the end of the push rod  15  is screw-connected into the adjuster  22 . A locking nut  24  and washer  25  secure the connection. The threaded adjuster  22  allows adjustment of the axial position of the push rod  15 . 
     A plug  26  closes the hydraulic chamber A by virtue of it being received in the bore in the first pole piece  7  and itself defines an internal bore  27 . At one end, the internal bore  27  accommodates the fixing assembly  22 , 33 , 24 , 25  of the push rod  15 . At the other end the bore has a radially outward step  28  and the enlarged diameter of the bore  27  receives a closure member  29 . A flexible diaphragm  30  is mounted in the plug  26  such that it abuts the step  28  and closes the bore  27 . It is clamped at its periphery against the annular step by the closure member  29  which has a central port  31  for fluid communication with the external environment such that one surface of the diaphragm  30  is exposed to the pressure of the external atmosphere and the other side is exposed to the pressure within the solenoid housing  3 . The closure member  29  is generally cylindrical with an external thread for threaded connection with an internal thread defined in the plug  26 . The port has a divergent section so as to allow fluid to act on all the exposed surface of the diaphragm (i.e. that which is inboard of the clamped portion) 
     The valve assembly  2  in the exemplary embodiment shown is a two-position, three-way hydraulic valve assembly but it is to be understood that it may take any suitable form. A valve body  35  has three ports: pressure port P for connection to a supply of pressurised fluid, tank port T for connection to a tank or reservoir and service S for connection to a fluid circuit which may contain, for example, a main-stage valve that is opened or closed under the control of two solenoid-operated control valves of the present invention. The ports P, S, T are represented in dotted line for ease of reference as in practice they will angularly offset around the central longitudinal axis of the valve assembly  2 . 
     The valve body  35  has a central bore of circular cross-section that extends along a longitudinal axis and which defines a valve chamber  36  for receipt of a valve element that is divided into three segments  37 ,  38 ,  39 . Each valve segment is arranged for communication with one of the fluid ports P, T, S via a shallow annular groove  40 ,  41 ,  42  defined in its outer surface. The three segments are separated by a pair of O-rings  43  that are located in annular recesses in the exterior surface of the central segment such that it is sealed to the internal bore surface of the valve body  35 . The valve element is retained between bushes  44 ,  45  that are fixed to the valve body at each end. 
     Each of the valve element segments  37 ,  38 ,  39  has an axial central bore in which a respective metallic actuating pin  46 ,  47 ,  48  is free to slide in the axial direction. The three pins are separated by two precision formed spheres  49 ,  50  which may be produced from, for example, a ceramic or a suitable metal such as zirconium of aluminium alloy. The spheres  49 ,  50  are designed to seal against respective concave valve seats  51 ,  52  defined in the central segment  38  around the central bore. 
     Annular recesses  53  in the inner surfaces of the outer two valve segments  37 ,  39  provide annular clearances between the surface of the bore and the respective sphere  49 ,  50  so as to permit limited axial movement of the spheres within the segments. Each of the outer two valve segments  37 ,  39  has angled passages  54 ,  55  inclined to the central longitudinal axis which provide fluid communication between the respective shallow grooves  40 ,  42  and the region around the spheres  49 ,  50 . The central segment has angled passages  56  that extend from the shallow groove  41  to an annular clearance  57  between the central pin  47  and the bore in which it resides. 
     The two outer pins  46 ,  48  project into central bores in the guide bushes  44 ,  45  where they run in dynamic seals  58 ,  59  for reciprocating motion. The seal  59  in bush is provided by an elastomeric seal such as an O-ring with a back-up seal designed to avoid extrusion of the O-ring seal during its movement. 
     The end of the pin  48  nearest to the solenoid assembly  1  abuts the nipple  21  defined on the adapter  19 . 
     The pins and spheres  46 , 47 , 48 , 49 , 50  form an assembly which is axially movable by a small distance to displace one or other of the spheres  49 ,  50  from its respective valve seat  51 ,  52  as will be described in more detail below. One end of the pin and sphere assembly is axially loaded by the solenoid assembly  1  and the other end is acted on by a spring-loading assembly  60  that fits into a cavity in the valve body  35 . The spring-loading assembly  60  comprises a spring cap  61  for abutment with the end of pin  46 . A spring  62  is compressed between the cap and an adjustable retaining member  63  that is screw-connected and sealed to the valve body  35 . The retaining member  63  is generally cup-shaped to receive the spring  62 . 
     The solenoid and valve assembly housings  3 ,  35  are connected together such that the actuator  14  is axially aligned with the pin and sphere assembly  46 , 47 , 48 , 49 , 50 . In this way axial movement of the solenoid actuator  14  causes movement of the pin and sphere assembly (via the adapter  19 ) so as to change the state of the valve assembly  2 . 
     In operation, the coils  4  are energised appropriately by application of a suitable electrical current. This creates a magnetic field that is transmitted to the actuator  14  via the pole pieces  9 ,  10 . This causes the actuator  14  to move to the right (in the orientation of  FIGS. 1 to 3 ), carrying with it the adapter  19 . This in turn acts on the pin and sphere assembly  46 , 47 , 48 , 49 , 50  which moves to the right against the force applied by the spring assembly  62 . This movement serves to displace sphere  49  from its seat  51  thereby allowing hydraulic control fluid from the pressure port P to flow along from the inclined passages  54  in the outer segment  36 , between the sphere  49  and its seat  51 , along the annular clearance  57  between the pin  47  and the central segment  38  and out along the inclined passages  56  to the service port from where it flows, for example, to a main-stage valve. At the same time sphere  50  is forced against its seat  52  so as to prevent hydraulic control fluid from flowing to tank T. 
     When the coils  4  are de-energised, the solenoid actuator  14  is no longer driven by a force that moves it to the right. The spring return force acting on the spring cap  61  and the pin  46  biases the assembly  46 , 47 , 48 , 49 , 50 , the adapter  19  and the actuator  14  to move back to the left. This serves to displace sphere  50  from its valve seat  52  thereby allowing fluid communication between the tank and service ports T, S. At the same time sphere  49  is forced back on to its seat such that fluid is prevented from flowing from the pressure port P. 
     In the present invention the valve chamber  36  of the valve assembly  2  is flooded with hydraulic control fluid and sealed such that it is isolated from the solenoid assembly  2 . In particular, the O-ring and back up seal  59  in the bush  45  prevents control fluid from egressing from the valve chamber  36  into the solenoid assembly housing  3  and chamber A. 
     The solenoid assembly  1  contains a suitable oil and the solenoid housing  3  is sealed from the oil in the surrounding pod (not shown), thus providing an isolated solenoid-operated valve. Since the oil in the solenoid chamber A is isolated from its surroundings it can be selected to be one that is benign to the coating on the armature and thus the risk of the actuator jamming is considerably reduced. The isolation of the solenoid assembly  1  from the surrounding pod environment and the valve assembly  2  means that the risk of ingress of seawater into the solenoid housing  3  is considerably reduced. 
     The flexible diaphragm  30  ensures that the valve is pressure balanced. In particular, if the pressure within the solenoid assembly  1  is less than that in the surrounding pod the diaphragm  30  deflects inwardly as illustrated in  FIG. 2 , this pressuring the oil in the solenoid chamber A until is reaches the same pressure as the oil in the pod.  FIG. 3  illustrates the position of the diaphragm  30  in the event that the pressure of the oil in the solenoid assembly  1  is greater than that in the pod. It can be seen that the diaphragm  30  deflects outwardly thus reducing the pressure in the solenoid assembly  1 . 
     It will be appreciated that numerous modifications to the above described design may be made without departing from the scope of the invention as defined in the appended claims. For example, the pressure balancing may be performed by any suitable means as opposed to a flexible diaphragm, such as for example a sealed piston. In addition it is to be understood that the valve assembly may take any suitable form including, for example, a single sphere and two pin arrangement such as that described in our co-pending UK patent application No. 1013857.6. 
     The described and illustrated embodiments are to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the scope of the inventions as defined in the claims are desired to be protected. It should be understood that while the use of words such as “preferable”, “preferably”, “preferred” or “more preferred” in the description suggest that a feature so described may be desirable, it may nevertheless not be necessary and embodiments lacking such a feature may be contemplated as within the scope of the invention as defined in the appended claims. In relation to the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used to preface a feature there is no intention to limit the claim to only one such feature unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.