Patent ID: 12259055

DETAILED DESCRIPTION

Certain examples are shown in the above-identified figures and described in detail below. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic for clarity and/or conciseness. Additionally, any features from any exemplary embodiment may be included with, a replacement for, or otherwise combined with other features to form other embodiments.

In the embodiments described below, any feature or structure described with respect to a single embodiment in a figure may be combined and arranged with any other embodiment illustrated in any other figure, or in any non-illustrated embodiments constructed in accordance with the teachings of the disclosure.

Turning now toFIG.1, a modular valve assembly1000includes a bonnetless main core1010comprising a main core housing1012having a main core inlet1016and a main core outlet1014. In other embodiments, the main core inlet1016and the main core outlet1014may be reversed. A first releasable connection1022is disposed proximate the main core inlet1016and a second releasable connection1024is disposed proximate the main core outlet1014.

A first inlet end connection1030is releasably attached to the first releasable connection1022. The first inlet end connection1030comprises a first inlet end connection housing1032and a first inlet end flow passage1034through the first inlet end connection housing1032. The first inlet end flow passage1034includes a curved portion1036that changes a direction of the first inlet end flow passage between 30 and 120 degrees as measured between a longitudinal axis A of the main core housing1012, and a direction of flow B that enters the first inlet flow passage1034. In the embodiment illustrated inFIG.1, the flow passage changes direction by approximately 90 degrees.

A first outlet end connection1040comprising a first outlet end connection housing1042and a first outlet end flow passage1044through the first outlet end connection housing1042. The first outlet end flow passage1044includes an angled portion1046.

When the first inlet end connection1030is releasably attached to the first releasable connection1022and the first outlet end connection1040is releasably attached to the second releasable connection1024, the first inlet end connection1030, the bonnetless main core1010and the first outlet end connection1040form an in-line valve configuration. An in-line valve configuration is defined herein as a valve configuration where any change in flow direction measured between incoming flow at an inlet1038of the first inlet end connection and outlet flow at an outlet1048of the first outlet end connection is 10 degrees or less.

The first releasable connection1022includes an external flange1050and the second releasable connection1024also includes an external flange1052. Similarly, the first inlet end connection1030includes an external flange1054and the first outlet end connection1040also includes an external flange1056. The external flanges1050,1052,1054,1056, advantageously allow the first inlet end connection1030and the first outlet end connection1040to be held in a fluid tight releasable connection against the bonnetless main core1010.

An inlet external clamp1060releasably secures the external flange1054of the first inlet end connection1030against the external flange1050of the first releasable connection1022. Likewise, an outlet external clamp1062releasably secures the external flange1056of the first outlet end connection1040against the external flange1052of the second releasable connection1024. An optional sealing ring1064may be clamped by the second releasable connection1024to enhance fluid sealing. While not illustrated inFIG.1, a similar sealing ring may be located in the first releasable connection1022.

The bonnetless main core1010includes a stem opening1070. A stem1072may extend from an actuator (not shown) to a valve plug1074. The valve plug1074is moved within the bonnetless main core1010to control fluid flow through the bonnetless main core1010. A valve trim, such as a cage1076is also disposed in the bonnetless main core1010and cooperates with the valve plug1074to control the flow of fluid through the bonnetless main core1010. In the embodiment ofFIG.1, the cage1074is a clamped cage that includes an outer sealing flange1078at one end of the cage1074. The outer sealing flange1078is captured by the first releasable connection1022to secure the clamped cage1076in the bonnetless main core1010.

Turning now toFIG.2, a modular valve assembly2000includes the bonnetless main core1010ofFIG.1. Any features discussed above with respect to the bonnetless main core1010ofFIG.1apply equally to the embodiment ofFIG.2and are not discussed again for the sake of brevity.

A second inlet end connection2030is releasably attached to the first releasable connection1022. The second inlet end connection2030comprises a second inlet end connection housing2032and a second inlet end flow passage2034through the second inlet end connection housing2032. The second inlet end flow passage2034is substantially straight and aligned with the longitudinal axis A of the main core housing1012. Substantially straight and aligned is defined as deviating 10 degrees or less from the longitudinal axis A.

A second outlet end connection2040is releasably attached to the second releasable connection1024. The second outlet end connection2040comprises a second outlet end connection housing2042and a second outlet end flow passage2044through the second outlet end connection housing2042. The second outlet end flow passage2044is substantially straight and perpendicular to the longitudinal axis A of the main core housing1012. Substantially straight and perpendicular is defined as deviating less than 10 degrees along the second outlet end flow passage2044and being oriented between 80 degrees and 100 degrees relative to the longitudinal axis A.

When the second inlet end connection2030is releasably attached to the first releasable connection1022and the second outlet end connection2040is releasably attached to the second releasable connection1024, the second inlet end connection2030, the bonnetless main core1010and the second outlet end connection2040form an angled valve configuration. An angled valve configuration is defined herein as a valve configuration where any change in flow direction measured between incoming flow at an inlet2038of the second inlet end connection2030and outlet flow at an outlet2048of the second outlet end connection2040is 30 degrees or more, for example approximately 90 degrees as illustrated inFIG.2.

By changing the first and second inlet end connections1030,2030and the first and second outlet end connections1040,2040, the bonnetless main core1010may be rapidly reconfigured from an in-line valve to an angled valve. The disclosed modular valve assembly therefore produces multiple and flexible valve configurations with fewer parts that can be rapidly changed in the field to accommodate changing needs.

Turning now toFIG.3, a modular valve assembly3000includes the bonnetless main core1010ofFIG.1. Any features discussed above with respect to the bonnetless main core1010ofFIGS.1and2apply equally to the embodiment ofFIG.3and are not discussed again for the sake of brevity.

In the embodiment ofFIG.3, an auxiliary core3080is removably attached to the first releasable connection1022. The auxiliary core3080includes an auxiliary core inlet3086, a first auxiliary core outlet3084and a second auxiliary core outlet3085. The first auxiliary core outlet3084is located adjacent to the bonnetless core inlet1016proximate the first releasable connection1022. The second auxiliary core outlet3085is located opposite the first auxiliary core outlet3084. The auxiliary core3080also includes a third releasable connection3025.

A third inlet end connection3030is releasably attached to the third releasable connection3025. The third inlet end connection3030comprises a third inlet end connection housing3032and a third inlet end flow passage3034through the third inlet end connection housing3032. The third inlet end flow passage3034includes an angled portion3037.

A third outlet end connection3040is releasably attached to the second releasable connection1024. The third outlet end connection3040comprises a third outlet end connection housing3042and a third outlet end flow passage3044through the third outlet end connection housing3042. The third outlet end flow passage3044includes an angled portion3046.

In other embodiments, the first, second, and third inlet connections1030,2030,3030, may be substituted for one another to achieve a desired flow configuration. Similarly, the first, second, and third outlet connections1040,2040,3040, may be substituted for one another to achieve a desired flow configuration.

When the auxiliary core3080is releasably connected to the bonnetless main core1010, a three-way valve configuration is advantageously produced. In the embodiment ofFIG.3, a clamped cage3076extends through both the bonnetless main core1010and through the auxiliary core3080. The clamped cage3076includes an external flange3078that is captured by the first connection1022to locate and secure the clamped cage3076within the bonnetless main core1010and within the auxiliary core3080.

Referring now toFIGS.1-3, any of the embodiments described above may be configured and reconfigured rapidly by changing or adding parts as described below. The bonnetless main core1010is the base element for all configurations. As described above, when the first inlet end connection1030is releasably connected to the first releasable connection1022, and the first outlet end connection1040is releasably connected to the second releasable connection1024, an in-line valve is produced as illustrated inFIG.1.

To reconfigure the valve assembly into an angled valve assembly, the first inlet end connection1030and the first outlet end connection1040are removed from the first releasable connection1022and the second releasable connection1024, respectively. Then, the second inlet end connection2030is releasably connected to the first releasable connection1022and the second outlet end connection2040is releasably connected to the second releasable connection1024, and an angled valve assembly is formed, as illustrated inFIG.2.

To reconfigure the modular valve assembly into a three-way valve, the second inlet connection2030is removed from the first releasable connection1022and the second outlet connection2040is removed from the second releasable connection1024. The auxiliary core3080is releasably connected to the first releasable connection1022. This alone forms a three-way valve, as illustrated inFIG.3. However, one or more inlet and outlet end connections may be added to adapt the three-way valve to needed configurations.

Returning now toFIG.1, the bonnetless main core1010may optionally include a substantially flat top mounting surface1086. The substantially flat top mounting surface advantageously provides space and stability for mounting monitoring or control elements, such as a centralized data acquisition system1088. Alternatively sensors, could be mounted on the substantially flat top mounting surface.

The modular valve assemblies described above may advantageously be quickly modified to include optional internal components, such as cavitation protection, orifice plates, flow straightening devices, etc. The bonnetless main core described above may also be combined with other end connections, such as varied size end connections, expanded outlet end connections, angle bodies, globe bodies, articulating joints.

The modular valve assembly described above may be advantageously configured or reconfigured into different types of valves, rapidly and in the field without special tools. In some examples, the modular valve assembly may be used to form high flow/low flow valves, as described below.

Turning now toFIG.4, a first embodiment of a high flow/low flow valve10is illustrated. The high flow/low flow valve10comprises a valve body12, which may comprise multiple interchangeable segments12a,12b,12c,12d. The interchangeable segments12a,12b,12c,12d, may include outwardly curved flanges that cooperate with flanges on other segments to form a continuous valve body12when connected with one another, for example with brackets (not shown inFIG.1). As a result, individual segments12a,12b,12c,12d, may be substituted or interchanged without the need for replacing the entire valve body12.

The valve body12includes a fluid inlet16and a fluid outlet14connected to one another by a fluid passageway18. In other embodiments, the fluid inlet and fluid outlet may be reversed. The fluid passageway18in the illustrated embodiment may include a first inlet branch18aand a second inlet branch18b.

A low flow valve seat20is disposed in a low flow port23of the fluid passageway18. A high flow valve seat22is disposed in a high flow port21of the fluid passageway18, and the high flow valve seat22is separated from the low flow valve seat20within the fluid passageway18. In the illustrated embodiment ofFIG.4, the high flow valve seat22may be part of an integrated high flow trim assembly24that also includes a high flow clamped cage26. In other embodiments, the high flow trim assembly24may include other types of cages, seat rings, plug guides, etc.

A low flow valve plug30is disposed in the fluid passageway18upstream of the low flow valve seat20. The low flow valve plug30cooperates with the low flow valve seat20to control fluid flow through the low flow valve seat20. A low flow trim assembly32may include, for example, the low flow valve seat20and a post guide34. In other embodiments, other types of trim may be included in the low flow trim assembly32. While the high flow trim assembly24and the low flow trim assembly32are illustrated in the current embodiments as being different structures, in some embodiments similar types of trim assembly structures may be employed between the high flow trim assembly24and the low flow trim assembly32. For example, in some alternate embodiments, both the high flow trim assembly24and the low flow trim assembly32may comprise cages.

A high flow valve plug36is disposed in the fluid passageway18upstream of the high flow valve seat22. The high flow valve plug36cooperates with the high flow valve seat22to control fluid flow through the high flow valve seat22.

A low flow actuator50is operatively connected to the low flow valve plug30, the low flow actuator50moving the low flow valve plug30relative to the low flow valve seat20to control fluid flow through the low flow valve seat20. The low flow actuator50is configured to move the low flow plug30independently of the high flow valve plug36.

Similarly, a high flow actuator52is operatively connected to the high flow valve plug36, the high flow actuator52moving the high flow valve plug36relative to the high flow valve seat22to control fluid flow through the high flow valve seat22. The high flow actuator52is configured to move the high flow valve plug36independently of the low flow valve plug30.

The high flow/low flow valve10described above may be used to control a wide range of fluid flow conditions through the valve body12. For example, when only a relatively low flow rate is needed, and/or one which requires precise control, the low flow valve plug30and the low flow valve seat20are ideally suited for fluid control. Initially, the high flow valve plug36is positioned relative to the high flow valve seat22at between 5% and 20% of the fully open high flow valve plug36travel. In some embodiments, the high flow valve plug36is positioned relative to the high flow valve seat22between 5% and 15%, and more particularly about 10%, of the full high flow valve plug36travel. Thereafter, the low flow valve plug30may be moved relative to the low flow valve seat20to precisely control low levels of fluid flow through the low flow valve seat20. When downstream flow requirements require near maximum flow through the low flow valve seat20, the low flow valve plug30may approach a fully open position to maximize fluid flow thorough the low flow valve seat20. As the low flow valve plug30approaches fully open, the high flow valve plug36may be moved relative to the high flow valve seat22to increase overall fluid flow through the valve body12to greater than the maximum fluid flow through the low flow valve seat20alone. In other embodiments, the high flow valve plug36begins in a closed position (preventing fluid flow through the high flow valve seat22) and the low flow valve plug30controls fluid flow until downstream requirements exceed the maximum flow rate through the low flow valve seat20, at which point the low flow valve plug30is positioned fully open and the high flow valve plug36and the high flow valve seat22control fluid flow above the maximum low flow rate.

In the illustrated embodiment ofFIG.4, low flow valve seat20defines a low flow restriction (e.g., a maximum low flow port fluid flow) in the low flow port23and the high flow valve seat22defines a high flow restriction (e.g., a maximum high flow port fluid flow) in the high flow port21, and the maximum low flow port fluid flow is between 5% and 25%, preferably between 10% and 20%, and more preferably about 15%, of the maximum high flow port fluid flow. The disclosed relative sizing between the maximum low flow port fluid flow and the maximum high flow port fluid flow advantageously produces a crossover band of fluid flow before the low flow port reaches 100% fluid flow and the high flow port begins opening to take over when the low flow port reaches its maximum fluid flow. This crossover band reduces chattering of the low flow valve plug30if a control signal cycles around the crossover band.

Turning now toFIG.5, a second embodiment of a high flow/low flow valve110is illustrated. Elements of the embodiment ofFIG.5that correspond to identical elements in the embodiment ofFIG.4are numbered exactly 100 greater that the embodiment ofFIG.4. For example, the valve body ofFIG.5is numbered112, while the valve body ofFIG.4is numbered12.

The high flow/low flow valve110illustrated inFIG.5includes a valve body112having a fluid inlet114and a fluid outlet116connected to one another by a fluid passageway118. In other embodiments, the fluid inlet114and the fluid outlet116may be reversed. The valve body112may comprise multiple interchangeable segments112a,112b,112c,112d. The interchangeable segments112a,112b,112c,112d, may include outwardly curved flanges that cooperate with flanges on other segments to form a continuous valve body112when connected with one another, for example with brackets (not shown inFIG.5). As a result, individual segments112a,112b,112c,112d, may be substituted or interchanged without the need for replacing the entire valve body112. The valve body112includes a fluid inlet114and a fluid outlet116connected to one another by a fluid passageway118.

A valve seat119is disposed in the fluid passageway118. The valve seat119includes a high flow side122and a low flow side120. In the illustrated embodiment ofFIG.5, the valve seat119may be part of an integrated high flow trim assembly124that also includes a high flow clamped cage126. In other embodiments, the high flow trim assembly124may include other types of cages, seat rings, plug guides, etc.

A low flow valve plug130is disposed in the fluid passageway118downstream of the valve seat120. The low flow valve plug130cooperates with the low flow side120of the valve seat119to control fluid flow through the valve seat119. A low flow trim assembly132may include, for example, a post guide134. In other embodiments, other types of trim may be included in the low flow trim assembly132. While the high flow trim assembly124and the low flow trim assembly132are illustrated in the current embodiments as being different structures, in some embodiments similar types of trim assembly structures may be employed between the high flow trim assembly124and the low flow trim assembly132. For example, in some alternate embodiments, both the high flow trim assembly124and the low flow trim assembly132may comprise cages.

A high flow valve plug136is disposed in the fluid passageway118upstream of the valve seat119. The high flow valve plug136cooperates with the high flow side122of the valve seat119to control fluid flow through the valve seat119.

A low flow actuator150is operatively connected to the low flow valve plug130, the low flow actuator150moving the low flow valve plug130relative to the valve seat119to control fluid flow through the valve seat119. The low flow actuator150is configured to move the low flow plug130independently of the high flow valve plug136.

Similarly, a high flow actuator152is operatively connected to the high flow valve plug136, the high flow actuator152moving the high flow valve plug136relative to the valve seat119to control fluid flow through the valve seat119. The high flow actuator152is configured to move the high flow valve plug136independently of the low flow valve plug130.

The high flow/low flow valve110described above with respect toFIG.5, may be used to control a wide range of fluid flow conditions through the valve body112. For example, when only a relatively low flow rate is needed, and/or one which requires precise control, the low flow valve plug130and the low flow side120of the valve seat119are ideally suited for fluid control. Initially, the high flow valve plug136is positioned away from the high flow side122of the valve seat119to a position that matches a crossover capacity of the low flow side120, which in the illustrated embodiment is between 80% and 100% of the low flow valve plug130travel. This crossover capacity advantageously allows for a smooth transition between the low flow side120and the high flow side122. Thereafter, the low flow valve plug130may be moved relative to the low flow side120of the valve seat119to precisely control low levels of fluid flow through the valve seat119. When downstream flow requirements require more flow than the maximum flow controllable by the low flow valve plug130, the low flow valve plug130approaches a fully open position to maximize fluid flow thorough the valve seat119. Once the low flow valve plug130approaches the fully open position, the high flow valve plug136may be moved relative to the high flow side122of the valve seat119to increase overall fluid flow through the valve body112to greater than the maximum fluid flow controllable by the low flow valve plug130alone.

Turning now toFIGS.6and7, a third embodiment of a high flow/low flow valve210is illustrated. Elements of the embodiment ofFIGS.6and7that correspond to identical elements in the embodiment ofFIG.4orFIG.5are numbered exactly 100 or 200 greater that the embodiment ofFIG.4orFIG.5. For example, the valve body ofFIG.6is numbered212, while the valve body ofFIG.4is numbered12and the valve body ofFIG.5is numbered112.

The high flow/low flow valve210comprises a valve body212having a fluid inlet214and a fluid outlet216connected to one another by a fluid passageway218. In other embodiments, the fluid inlet214and the fluid outlet216may be reversed. The valve body212may comprise multiple interchangeable segments212a,212b,212c,212d. The interchangeable segments212a,212b,212c,212d, may include outwardly curved flanges that cooperate with flanges on other segments to form a continuous valve body212when connected with one another a mechanical joint retention mechanism, for example by clamps or brackets213. As a result, individual segments212a,212b,212c,212d, may be substituted or interchanged without the need for replacing the entire valve body212.

A valve seat219is disposed in the fluid passageway218. The valve seat219includes a high flow side222and a low flow side220. In the illustrated embodiment of FIG.6, the valve seat219may be part of an integrated high flow trim assembly224that also includes a high flow clamped cage226. In other embodiments, the high flow trim assembly224may include other types of cages, seat rings, plug guides, etc.

A high flow valve plug236is disposed in the fluid passageway218proximate valve seat219. The high flow valve plug236cooperates with the high flow side222of the valve seat219to control fluid flow through the valve seat219. The high flow valve plug236includes a hollow passageway237that forms part of the fluid passageway218. An opening239of the hollow passageway237forms a low flow valve seat221.

A low flow valve plug230is disposed in the fluid passageway218proximate the valve seat219. The low flow valve plug230cooperates with the low flow valve seat221to control fluid flow through the hollow passageway237. A low flow trim assembly232may include, for example, the low flow valve plug230and the low flow valve seat221. In other embodiments, other types of trim may be included in the low flow trim assembly232, such as plug guides, cages, etc. While the high flow trim assembly224and the low flow trim assembly232are illustrated in the current embodiment as being different structures, in some embodiments similar types of trim assembly structures may be employed between the high flow trim assembly224and the low flow trim assembly232. For example, in some alternate embodiments, both the high flow trim assembly224and the low flow trim assembly232may comprise cages.

A low flow actuator250is operatively connected to the low flow valve plug230, the low flow actuator250moving the low flow valve plug230relative to the low flow valve seat239to control fluid flow through the low flow valve seat239. The low flow actuator250is configured to move the low flow plug230independently of the high flow valve plug236.

Similarly, a high flow actuator252is operatively connected to the high flow valve plug236, the high flow actuator252moving the high flow valve plug236relative to the valve seat219to control fluid flow through the valve seat219. The high flow actuator252is configured to move the high flow valve plug236independently of the low flow valve plug230.

The high flow/low flow valve210described above with respect toFIG.6, may be used to control a wide range of fluid flow conditions through the valve body212. For example, when only a relatively low flow rate is needed, and/or one which requires precise control, the low flow valve plug230and the low flow valve seat221are ideally suited for fluid control. Initially, the high flow valve plug236is positioned against the valve seat219. Thereafter, the low flow valve plug230may be moved relative to the low flow valve seat221to precisely control low levels of fluid flow through the opening239and thus through the hollow passageway237. When downstream flow requirements require more flow than the maximum flow controllable by the low flow valve plug230, the low flow valve plug230may be positioned in a fully open position. Once the low flow valve plug230is fully open, the high flow valve plug236may be moved relative to the valve seat219to increase overall fluid flow through the valve body212to greater than the maximum fluid flow controllable by the low flow valve plug230alone.

Although certain high flow/low flow valves have been described herein in accordance with the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, while the invention has been shown and described in connection with various preferred embodiments, it is apparent that certain changes and modifications, in addition to those mentioned above, may be made. This patent covers all embodiments of the teachings of the disclosure that fairly fall within the scope of permissible equivalents. Accordingly, it is the intention to protect all variations and modifications that may occur to one of ordinary skill in the art.