A system containing high durability seat and disc surface specific to steam process for globe type manual and fully automatic control valves

Abstract

The invention relates to a system significantly increasing flow control performance, durability, and sealing properties for globe type valves.

Description

[0001] A SYSTEM CONTAINING HIGH DURABILITY SEAT AND DISC SURFACE SPECIFIC TO STEAM PROCESS FOR GLOBE TYPE MANUAL AND FULLY AUTOMATIC CONTROL VALVES

[0002] Technical Field

[0003] The invention relates to a system significantly increasing flow control performance, durability, and sealing properties for globe type valves.

[0004] Prior Art

[0005] Globe valves traditionally have hard metal alloy seating surfaces. These surfaces encounter problems such as wear, corrosion, and internal leakage in long-term use. In prior arts, various coating methods and material combinations have been used to eliminate these problems. However, these methods cannot reach the desired performance level. Traditional coating methods cannot sufficiently reduce the surface pressure forces and water hammer resistance on the seating surfaces, and therefore cannot provide optimal performance.

[0006] Globe valves are subjected to high temperature and pressure in steam applications. Therefore, the materials to be selected for seating and disc surfaces are required to be high strength, have high wear resistance, and be resistant to thermal expansion. These materials are also required to provide corrosion resistance, since the chemical components found in steam corrode the material over time. It is difficult to find materials robust enough to withstand high temperatures and pressures. At the same time, materials capable of providing all of the properties such as being resistant to corrosion and stable against thermal expansion are generally expensive and difficult to process.

[0007] The seat and disc surface design must be designed by being optimized with good engineering knowledge. The design is required to ensure fluid passage with minimum pressure drop and at the same time to ensure perfect sealing in closing and opening operations. Providing this balance presents a quite complex engineering problem.

[0008] High-strength materials are generally materials difficult to process. Therefore, special manufacturing techniques and equipment are required when working with these materials. Surface treatments, coating technologies, and precision machining methods have critical importance. Errors that may occur in the manufacturing process will negatively affect the performance of the valve.

[0009] In steam applications, valves are frequently subjected to high temperature changes. This situation leads to thermal expansion problems. In the case where seating and disc surfaces are made of different materials, the expansion coefficients of these materials are required to be compatible. Otherwise, the performance of the valve decreases due to thermal stresses, and sealing problems arise.

[0010] Particles and corrosion within the steam cause wear on the seating and disc surfaces over time. The selection of materials having high wear resistance is critical for extending the life of the valve.

[0011] The patent document numbered US3257095A discloses a valve configuration, particularly of a packed or sealed feature.

[0012] The patent document numbered US5288054A discloses a globe valve and its method of construction.

[0013] The patent document numbered CN117425789A discloses a fluid metering valve.

[0014] When the studies existing in the prior art are examined, a need has been felt for the development of the system subject to the invention significantly increasing flow control performance, durability, and sealing properties for globe type valves.

[0015] Objectives of the Invention

[0016] The object of this invention is to develop a system significantly increasing flow control performance, durability, and sealing properties for globe type valves. Another object of this invention is to develop a system increasing resistance against adverse conditions such as water hammer and sudden pressure increase.

[0017] Detailed Description of the Invention

[0018] The system implemented to achieve the object of this invention is shown in the attached figures.

[0019] These figures;

[0020] Figure 1: The cross-sectional view of the system subject to the invention.

[0021] Figure 2: The cross-sectional view of the system subject to the invention from a different angle.

[0022] Figure 3: The view of the sealing elements located in the system subject to the invention.

[0023] The parts located in the figures are individually numbered, and the counterparts of these numbers are given below.

[0024] 1. Valve body

[0025] 2. Valve bonnet

[0026] 3. Main stem

[0027] 4. Disc upper cover

[0028] 5. Seat ring

[0029] 6. Teflon protection part

[0030] 7. Lower cage

[0031] 8. Main stem balance tip

[0032] 9. Upper cage

[0033] A system significantly increasing flow control performance, durability, and sealing properties for globe type valves, and comprises;

[0034] - a valve body (1), a valve bonnet (2) closed onto the valve body (1), a main stem (3) extending from inside the valve bonnet (2) towards the valve body (1),

[0035] - a disc upper cover (4) located at the tip of the main stem (3),

[0036] - a seat ring (5) located inside the valve body (1),

[0037] - a Teflon protection part (6) located under the seat ring (5) and ensuring the prevention of steam-induced wear,

[0038] - a lower cage (7) located inside the seat ring (5) and ensuring the increasing of the sealing life,

[0039] - a main stem balance tip (8) connected to the main stem (3) and ensuring the movement balance inside the valves in cases where the main stem (3) and the parts on it are fully open or fully closed,

[0040] - an upper cage (9) located inside the valve body (1) and ensuring the increasing of the sealing life.

[0041] In the system subject to the invention, the assembly of the valve body (1) and the valve bonnet (2) to each other is performed by means of a gasket. The main stem

[0042] (3) performs linear movement inside both parts. Sealing is provided with the contact of the seat ring (5) mounted on the valve body (1) and the disc upper cover (4) attached onto the main stem (3) with each other. For the development of this sealing life and increasing the life, the Teflon protection part (6), the lower cage (7), and the upper cage (9) are mounted on the main stem (3). Movement balance inside the valves is ensured with the main stem balance tip (8) in cases where the main stem (3) and the parts on it are fully open or fully closed.

[0043] The impact resistance of the newly developed seat ring (5) and disc upper cover

[0044] (4) located in the system subject to the invention has been increased by being mounted at the lower part with a composite material resistant to wear and corrosion. This material provides superior performance by combining the advantages of both metal and polymer components. The lower cage (7) and upper cage (9) parts have been formed by welding two different filter-shaped parts between the seat and disc surfaces. Even if the valve is fully open, fully closed, or open at proportional levels, the cage system operates as a mechanism showing resistance against the flow, especially in a sudden pressure increase. In traditional designs, the welding of the cage system only up to half of the surroundings of the disc cannot prevent water hammer damages, especially in proportional controls and high-pressure superheated or critical steam processes.

[0045] With the new design, the disc and the seating surface are not subjected to blockage, and opening and closing are performed in a sounder manner with the ease of flexing originating from the filter holes. As a third measure, a protection part (6) has been attached under the disc to prevent steam-induced wear. This part, added to the design by means of a smart screw, has been designed in a manner not to pose a leakage risk.

[0046] The protection part (6) has primarily increased wear and water hammer resistance. Furthermore, it has raised the sealing class of the valve due to the sealing class of metal surfaces being lower compared to polymer materials. The valve has been upgraded from the metal-to-metal sealing class to the soft type sealing class. Although the caged structure has not changed or improved the permeability of the valve, it has increased the flow resistance of the valve. This situation can be defined as high flow strength belonging to the valve obtained without changing the external dimension compared to other valves of standard dimensions. This resistance minimizes the damage caused by aggressive fluids to the valves, especially.

[0047] The innovative seat and disc surface design located in the system subject to the invention will significantly increase the durability of globe valves, especially in steam systems operating under high temperature and pressure. Compared to conventional materials, the advanced technology materials used in this project (for example, high-temperature resistant alloys or ceramic coatings) will ensure the seating and disc surfaces to be more resistant against extreme temperatures, pressure, and chemical corrosion. Thus, the service life of the valves will be extended, and maintenance costs will decrease. Another important advantage is the improvement in the sealing performance of globe valves. The microstructural properties of the developed surfaces will provide perfect sealing by preventing the escape of steam. This situation will increase process efficiency by reducing energy losses. Furthermore, the prevention of steam leaks will increase occupational safety and contribute to the reduction of harmful emissions to the environment.

[0048] With the system subject to the invention, globe valves will be ensured to exhibit excellent performance under high temperature and pressure. For example, thermal barrier coatings used on seat and disc surfaces will provide high temperature resistance and reduce thermal fatigue. Thus, the trouble-free operation of the valves in long-term high-temperature applications will be possible. Furthermore, a structure resistant against sudden pressure changes that may occur in steam systems will be provided.

[0049] High-hardness materials and coatings having high wear resistance used on seat and disc surfaces will significantly reduce wear and tear. Especially in particulate fluids (for example, solid particles carried within the steam), the wear resistance of these surfaces has critical importance. Materials providing high temperature resistance, corrosion and wear resistance are preferred in such applications. For example, nickel-based alloys (Inconel) and stainless steels containing high chromium (316L) are widely used in steam applications. In a study, it was stated that Inconel 718 alloy exhibited excellent mechanical properties under high temperature and pressure.

[0050] Increasing wear and corrosion resistance by improving the surface properties of valves is of critical importance. Advanced technologies such as plasma spray coating and High Velocity Oxy-Fuel (HVOF) coating increase surface hardness and durability. In a study, it has been shown that HVOF coatings significantly increased wear resistance in valves used in steam applications.

[0051] The system subject to the invention will make flow control more precise by optimizing the passage of the fluid through the valve. Design optimizations performed using Computational Fluid Dynamics (CFD) analyses minimize pressure drops and improve the flow pattern. This provides a significant advantage especially in applications where energy efficiency is critical. Low pressure losses will reduce energy consumption and increase system efficiency.

[0052] Advanced manufacturing techniques make it possible to work with high-strength materials. Especially 3D printing (additive manufacturing) and precision casting methods enable the production of high-performance valves having complex geometries. In a study, it was stated that 3D printing technology was successful in the production of globe valve components with Inconel 718 material and provided high mechanical strength.

[0053] The innovative seat and disc surfaces developed within the scope of the invention will be able to be used not only in steam systems but also in various industrial applications such as chemical, petrochemical, power generation, and water treatment plants. This flexibility increases the applicability of the valves in a wide range and raises their commercial value. Furthermore, it offers a design capable of adapting to different fluid types and operating conditions.

[0054] High-performance and durable valves significantly reduce energy losses and operating costs. Since it will perform the opening and closing operation at lower torque values, it will provide air and electrical energy savings. With reduced sealing losses and optimized flow control, energy efficiency will increase. This will reduce the carbon footprint by lowering the energy bills of businesses. Although innovative materials increase initial investment costs, they provide an economic advantage since they reduce maintenance and replacement costs in the long run.

[0055] The system subject to the invention targets the design and manufacturing of seat and disc surfaces used in steam applications of globe type valves. These valves are used as critical components in various industries such as power generation plants, chemical factories, petrochemical plants, paper mills, and water treatment plants. The high-strength and wear-resistant innovative surfaces developed in the project will significantly increase the performance and life of these valves. This will find a wide field of application in the industry by increasing energy efficiency, reducing maintenance and replacement costs, and increasing safety.

Claims

CLAIMS1. A system significantly increasing flow control performance, durability, and sealing properties for globe type valves, characterized in that it comprises;- a valve body (1),- a valve bonnet (2) closed onto the valve body (1),- a main stem (3) extending from inside the valve bonnet (2) towards the valve body (1),- a disc upper cover (4) located at the tip of the main stem (3),- a seat ring (5) located inside the valve body (1),- a Teflon protection part (6) located under the seat ring (5) and ensuring the prevention of steam-induced wear,- a lower cage (7) located inside the seat ring (5) and ensuring the increasing of the sealing life,- a main stem balance tip (8) connected to the main stem (3) and ensuring the movement balance inside the valves in cases where the main stem (3) and the parts on it are fully open or fully closed,- an upper cage (9) located inside the valve body (1) and ensuring the increasing of the sealing life.

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