Carbide seat remanufacturing

Abstract

Typically, a fluid used in a fracturing operation erodes a valve seat in a fluid end of a reciprocating pump. Thus, the valve seats must be frequently replaced with new valve seats. Thus, a remanufacturing process is disclosed that manually or mechanically continuously cleans and / or grinds at least a carbide insert from a used valve seat until the insert is reusable. This reduces material costs and improves efficiency and sustainability.

Description

Technical Field

[0001] Embodiments described herein relate generally to carbide valve seats and, more particularly, to a process for remanufacturing carbide valve seats. Background Art

[0002] In a fracturing operation, a reciprocating pump is used to fracture a subterranean formation. A reciprocating pump includes a power end and a fluid end. The power end drives the fluid end to pump fluid through the fluid end. During a fracturing operation, the pump can operate at a rate of up to 1,000 strokes per minute to generate pressures of up to 25,000 pounds per square inch (psi).

[0003] The fluid end of a reciprocating pump typically includes a plurality of valves that enable fluid to flow into and out of the fluid end. The fluid passing through these valves is typically an abrasive slurry of water and sand. Over time, the slurry will erode and / or dent the surface of the valve seat. By grinding the surface of the valve seat to smooth the surface again, the utility of such a valve seat can be extended. For example, U.S. Patents Nos. 7,861,738 and 7,216,427 disclose processes for grinding valve seats in fuel injectors and internal combustion engines, respectively.

[0004] The present invention is directed to overcoming one or more problems discovered by the inventors. Summary of the invention

[0005] In an embodiment, a remanufacturing method for a valve seat includes, for each of one or more used valve seats: receiving a used valve seat, wherein the used valve seat includes an insert, and wherein the insert includes a tapered surface and a shoulder surface; when the insert is recyclable, manually or mechanically cleaning the insert; when the cleaned insert is sufficient for reuse, pairing the insert with a first new body, the first new body having the same recess as a previous body that most recently used the insert; when the cleaned insert is insufficient for reuse, manually or mechanically grinding the tapered surface of the insert to a first depth such that at least a portion of the shoulder surface remains; when the ground insert is sufficient for reuse, pairing the insert with a first new body having the same recess; when the ground insert is insufficient for reuse, further manually or mechanically grinding the tapered surface of the insert to a second depth such that no portion of the shoulder surface remains; and when the further ground insert is sufficient for reuse, pairing the further ground insert with a second new body, the second new body having a shallower recess than the previous body.

[0006] In an embodiment, a remanufacturing method for a valve seat includes, for each of one or more used valve seats: receiving the used valve seat, wherein the used valve seat includes an insert, and wherein the insert includes a tapered surface and a shoulder surface; determining that the valve seat is recyclable; manually or mechanically cleaning the insert; determining that the cleaned insert is insufficient for reuse; manually or mechanically grinding the tapered surface of the insert to a first depth such that at least a portion of the shoulder surface remains; determining that the cleaned insert is insufficient for reuse; further grinding the tapered surface of the insert to a second depth such that no portion of the shoulder surface remains; and pairing the further ground insert with a new body having a shallower recess than a previous body that the insert was most recently used with.

[0007] In an embodiment, a remanufacturing method for a valve seat, for each of a plurality of used valve seats, the remanufacturing method comprising: receiving the used valve seat, wherein the used valve seat comprises an insert, and wherein the insert comprises a tapered surface and a shoulder surface; when the insert is not recyclable, manually or mechanically discarding the insert; when the insert is recyclable, cleaning the insert; when the cleaned insert is sufficient for reuse, pairing the insert with a first new body, the first new body having the same recess as a previous body that most recently used the insert; when the cleaned insert is insufficient for reuse, manually or mechanically replacing the insert with a new body; The method comprises grinding the tapered surface of the insert to a first depth so that at least a portion of the shoulder surface remains; when the ground insert is sufficient for reuse, mating the insert with a first new body having the same recess; when the ground insert is insufficient for reuse, further manually or mechanically grinding the tapered surface of the insert to a second depth so that no portion of the shoulder surface remains; when the further ground insert is sufficient for reuse, mating the further ground insert with a second new body having a shallower recess than the previous body; and when the further ground insert is insufficient for reuse, discarding the insert. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Details concerning the structure and operation of embodiments of the present invention may be gleaned in part by examination of the accompanying drawings, in which like reference numerals represent like parts, and in which:

[0009] Figure 1 shows a cross-sectional view of a fluid end of a reciprocating pump according to an embodiment;

[0010] Figure 2 shows a cross-sectional view of a valve seat according to an embodiment;

[0011] Figure 3 It shows that according to the embodiment Figure 2 A cross-sectional view of a portion of the valve seat in circle C in FIG.

[0012] Figure 4 A remanufacturing process of a valve seat according to an embodiment is shown. DETAILED DESCRIPTION

[0013] The detailed description set forth below in conjunction with the accompanying drawings is intended as a description of various embodiments and is not intended to represent the only embodiments in which the present invention may be practiced. In order to provide a thorough understanding of the embodiments, the detailed description includes specific details. However, it will be apparent to those skilled in the art that embodiments of the present invention may be practiced without these specific details. In some cases, known structures and components are shown in simplified form for brevity of description.

[0014] For clarity and ease of explanation, some surfaces and details may be omitted in this specification and the accompanying drawings. It should also be understood that the various components shown herein are not necessarily drawn to scale. In other words, the features disclosed in the various embodiments may be implemented within and between components using relative dimensions different from those shown in the accompanying drawings.

[0015] Figure 1 A cross-sectional view of a fluid end 100 of a reciprocating pump according to an embodiment is shown. Fluid can flow into an inlet 110 along a longitudinal axis L. The inlet 110 is separated from a pressure chamber 150 by a first valve, which includes a valve head 120A and a valve seat 200A. The valve head 120A is biased to a closed position by a spring 130A fixed to a mounting body 140A. When the spring 130A is compressed, the valve head 120A is separated from the valve seat 200A, so that fluid can flow from the inlet 110 into the pressure chamber 150 between the valve seat 200A and the valve head 120A. Over time, the fluid may erode the valve seat 200A.

[0016] Similarly, the pressure chamber 150 is separated from the outlet 190 by a second valve, which includes a valve head 120B and a valve seat 200B. The valve head 120B is biased to a closed position by a spring 130B fixed to the mounting body 140B. When the spring 130B is compressed, the valve head 120B is separated from the valve seat 200B, so that fluid can flow from the pressure chamber 150 between the valve seat 200B and the valve head 120B into the outlet chamber 190. Over time, the fluid may erode the valve seat 200B. It should be understood that the second valve can be the same as the first valve, so that the valve seat 200B is the same as the valve seat 200A.

[0017] The plunger 160 is driven by the power end of the reciprocating pump to translate along a radial axis R, which is perpendicular to the longitudinal axis L. In other words, during operation of the reciprocating pump, the plunger 160 continuously slides into the pressure chamber 150 during the downstroke and slides out of the pressure chamber 150 during the upstroke. These strokes create a pressure differential that drives the first valve and the second valve. For example, each upstroke can compress the spring 130A while the spring 130B is decompressed, so that the fluid flows from the inlet 110 into the pressure chamber 150. Conversely, each downstroke can compress the spring 130B while the spring 130A is decompressed, so that the fluid flows from the pressure chamber 150 into the outlet chamber 190.

[0018] The outlet chamber 190 can be in fluid communication with an outlet channel 195 that carries the fluid in the outlet chamber 190 along an axis perpendicular to the longitudinal axis L and the radial axis R. Typically, the fluid end 100 includes a plurality of Figure 1 In other words, the assembly shown can be replicated at different cross-sectional depths along the axis so that each of the plurality of plungers 160 pumps fluid from a corresponding inlet 110 to a corresponding outlet chamber 190, through a corresponding first valve and a second valve, and into an outlet channel 195. The fluid output by all of these assemblies can converge in an outlet channel 195, which can carry the fluid to an outlet of the fluid end 100.

[0019] As used herein, reference numerals with additional letters will be used to refer to specific components, and the same reference numerals without any additional letters will be used to refer to multiple components collectively or to refer to a general or arbitrary instance of a component. Thus, for example, the term "valve seat 200" collectively refers to the first valve seat 200A and the second valve seat 200B, and the term "valve seat 200" can refer to the first valve seat 200A or the second valve seat 200B.

[0020] Furthermore, as used herein, the terms “upstream” and “downstream” are relative to the direction of fluid flow through the fluid end 100. For example, the inlet 110 is upstream of the outlet chamber 190, and the outlet chamber 190 is downstream of the inlet 110.

[0021] Figure 2 A cross-sectional view of a valve seat 200 according to an embodiment is shown. Each valve seat 200 includes a body 210 and an insert 220. Both the body 210 and the insert 220 are annular about a longitudinal axis L with an open center such that a passage 205 is formed therethrough. The insert 220 is located within the body 210.

[0022] At all points, the outer diameter of the insert 220 can match the inner diameter of the body 210 from the support surface 224 to the height H of the insert 220 along the longitudinal axis L. Thus, the insert 220 fits tightly into the body 210. In an embodiment, the radially outwardly facing surface of the insert 220 along the radial axis R can form a friction fit with the radially inwardly facing surface of the body 210 along the radial axis R. Thus, the body 210 and the insert 220 can be joined by a press fit. Alternatively, the body 210 and the insert 220 can be joined by shrink fitting, bonding, sintering, welding, and / or the like.

[0023] The body 210 can include a groove 215 along an outer circumference of the body 210. The groove 215 can be positioned upstream of the support surface 224 and the insert 220. The groove 215 can be configured to retain an O-ring 230. When inserted with the fluid end 100, the O-ring 230 can be compressed within the groove 215 by the body of the fluid end 100, thereby sealing the area around the valve seat 200. The seal formed by the O-ring 230 prevents fluid from flowing through the valve seat 200 except through the passage 205.

[0024] In an embodiment, the insert 220 is made of a carbide material, which includes any binary compound of carbon and an element of lower or comparable electronegativity. Inserts 220 made of carbide materials tend to be very hard and wear-resistant. Examples of carbide materials include, but are not limited to, tungsten carbide, tungsten carbide nickel, tungsten carbide cobalt, titanium carbide, etc. Alternatively, the insert 220 can be made of another material, including another ceramic material, such as zirconium oxide, partially stabilized zirconium oxide, silicon nitride, sialon, etc. The body 210 can be made of the same material as the insert 220 (e.g., carbide) or a different material than the insert 220.

[0025] Figure 3 It shows that according to the embodiment Figure 22 is a cross-sectional view of a portion of the valve seat 200 in the circle C in FIG. The insert 220 is located on the support surface 212 of the body 210. The support surface 212 may include a first portion 212A, a second portion 212B, and a third portion 212C. The first portion 212A may be generally perpendicular to the longitudinal axis L and parallel to the radial axis R. The second portion 212B may taper radially outwardly downstream to the outer diameter of the support surface 212 at an angle A1 relative to the radial axis R from a specific diameter representing the radial outer end of the first portion 212A. The angle A1 of the tapered second portion 212B may be any suitable angle between 0 and 90 degrees relative to the radial axis R, but is generally in the range of 20-70 degrees, and is preferably 30 degrees or about 30 degrees (i.e., 60 degrees relative to the longitudinal axis L). In an alternative embodiment, the second portion 212B may be omitted. The third portion 212C may be generally parallel to the longitudinal axis L and perpendicular to the radial axis R. The downstream end of the third portion 212C can transition into a tapered surface 214, which can taper at the same angle A1 as the second portion 212B of the support surface 212 or at a different angle. The downstream end of the tapered surface 214 can transition into a shoulder surface 216, which can be substantially perpendicular to the longitudinal axis L and parallel to the radial axis R.

[0026] The insert 220 may include a supported surface 222 having a profile that matches the supporting surface 212. In other words, the supported surface 222 may have an outer diameter that is the same as, slightly larger than, or slightly smaller than the inner diameter of the supporting surface 212, such that a tight fit is formed between the supporting surface 212 of the body 210 and the supported surface 222 of the insert 220. The downstream end of the supported surface 222 transitions into a shoulder surface 226 that may be generally perpendicular to the longitudinal axis L and parallel to the radial axis R. The upstream end of the supported surface 222 transitions into an inner surface 228 that may be generally parallel to the longitudinal axis L and perpendicular to the radial axis R.

[0027] Insert 220 also includes a tapered surface 224 between shoulder surface 226 and inner surface 228. Tapered surface 224 may taper radially outward downstream at an angle A2 relative to radial axis R. Angle A2 may be the same as or different from angle A1. At the upstream end, tapered surface 224 may curve into inner surface 228.

[0028] There are many ways to grind the valve seat 200. In the first case, the tapered surface 224 of the insert 220 can be ground parallel to the axis G to any depth, shown in three examples: the depth D1 between the axes G and G1; the depth D2 between the axes G and G2, which corresponds to the tapered surface 214 of the body 210 and reaches but does not exceed the shoulder surface 226; and the depth D3 between the axes G and G3, which exceeds the shoulder surface 226. When the insert 220 is ground to a depth between 0 and D2 (i.e., not exceeding the shoulder surface 226), the height H of the insert 220 does not change (i.e., remains H1). On the other hand, when the insert 220 is ground to a depth greater than D2 (i.e., exceeding the shoulder surface 226), the height H of the insert 220 changes from H1 to H2. In addition to grinding parallel to the axis G, the shoulder surface 226 of the insert 220 can be ground, for example, parallel to the radial axis R. It is worth noting that this will reduce the height H of the insert 220. The tapered surface 214 of the body 210 may also be ground, for example, parallel to the axis G (eg, parallel to the axis G3), and / or the shoulder surface 216 of the body 210 may be ground, for example, parallel to the radial axis R.

[0029] Figure 4 A remanufacturing process 400 for a valve seat 200 is shown according to an embodiment. Although the process 400 is shown as having a certain arrangement and ordering of subprocesses, the process 400 can be implemented with fewer, more, or different subprocesses and different arrangements and / or orders of subprocesses. In addition, it should be understood that any subprocess that is not dependent on the completion of another subprocess can be performed before, after, or in parallel with the other independent subprocess, even if the subprocesses are described or shown in a particular order.

[0030] Process 400 may be implemented at a single service center or at multiple service centers. In the latter case, different subprocesses of process 400 may be performed by different service centers. For example, grinding may be performed at a service center (e.g., a service center of a supplier of valve seat 200) that is different from a service center that performs other subprocesses (e.g., a service center of a supplier of front end 100 or an entire fracturing pump). It should be understood that the description of each subprocess in process 400 is intended only to provide an example of how the subprocess may be implemented, and each subprocess is subject to many potential variations.

[0031] In subprocess 405, the valve seat 200 is received from the field. When the valve seat 200 requires maintenance, it is typically received from the field through a system process. For example, the valve seat 200 may be identified as requiring maintenance during a routine inspection or due to a reported problem. A maintenance team may then be dispatched to the field to retrieve the valve seat 200. The maintenance team ensures that the valve seat 200 is safely disconnected from the fluid end 100, taking necessary precautions to avoid any spills or leaks. The valve seat 200 may be packaged and labeled with relevant information, such as its identification number, location, specific instructions or observations noted during the inspection, and / or the like. The valve seat 200 is then transported to a maintenance center where the valve seat 200 may undergo a thorough evaluation and repair.

[0032] In subprocess 410, it is determined whether the valve seat 200 received in subprocess 405 is recyclable. Determining whether the valve seat 200 is recyclable may involve several processes and methods. A visual inspection may be performed to assess the overall condition of the valve seat. This includes inspecting the valve seat 200 for signs of wear, corrosion, pitting, cracks, or any other damage. Measuring tools such as calipers or micrometers may be used to assess the dimensions of the valve seat 200 components to ensure that they fall within acceptable tolerances. Non-destructive testing techniques, such as dye penetrant inspection or magnetic particle testing, may be used to detect surface cracks or defects. In addition, ultrasonic testing may be used to assess the thickness of the valve seat 200 and identify potential thinning areas. Based on the findings from these inspections, the technician may determine whether the valve seat 200 is recyclable. Factors such as the severity of the damage, the condition of the material, and the availability of repair technology may help make this decision. When it is determined that the valve seat 200 is not recyclable (i.e., "No" in subprocess 410), process 400 proceeds to subprocess 415. Otherwise, when it is determined that the valve seat 200 is recyclable (ie, “yes” in sub-process 410 ), process 400 proceeds to sub-process 420 .

[0033] In subprocess 415, the entire valve seat 200, including both the body 210 and the insert 220, is discarded. The valve seat 200, which may include both the body 210 and the insert 220, can be removed from the system and isolated to prevent any potential contamination or safety hazards. The valve seat 200 can then be thoroughly cleaned to remove any residual fluid, contaminants, or debris. The valve seat 200 can be disassembled to separate its various components, such as the body 210 and the insert 220. These components can be sorted and classified based on their material composition for recycling or proper disposal. For example, the insert 220 can be sent to a scrap metal facility for recycling. Non-metallic components, such as seals or gaskets made of rubber or synthetic materials, can be disposed of in accordance with local regulations or guidelines for hazardous waste.

[0034] In subprocess 420, the insert 220 is removed from the body 210 of the valve seat 200 received in subprocess 405, and the body 210 is discarded. As in subprocess 415, the components of the body 210 can be sorted and classified based on their material composition for recycling or appropriate disposal. For example, the body 210 can be sent to a scrap metal facility for recycling.

[0035] In subprocess 425, the insert 220 removed in subprocess 420 is cleaned. Cleaning the insert 220 may involve several processes and methods for effectively removing deposits and contaminants. The insert 220 may be removed from the body 210 to inspect any visible damage or wear. The insert 220 may be subjected to a combination of mechanical and chemical cleaning methods. Mechanical cleaning may involve the use of a wire brush, an abrasive pad, a scraping tool, and / or a light grind to remove stubborn deposits or scale accumulation. Chemical cleaning may involve the use of an appropriate solvent or detergent compatible with the material of the insert 220. These agents may be applied to dissolve or loosen deposits, which may then be rinsed away. Ultrasonic cleaning may also be used to effectively remove contaminants. In one embodiment, the cleaning process of the insert 220 may be automated using one or more automatic cleaning machines, such as an ultrasonic cleaner, an automatic solvent cleaner, a high-pressure water jet cleaner, and / or the like. After the cleaning process, the insert 220 may be thoroughly rinsed with clean water to remove any remaining detergent or residue.

[0036] In subprocess 430, it is determined whether the cleaning in subprocess 430 is sufficient. Subprocess 430 represents the first recycling opportunity of insert 220. Determining whether insert 220 has been sufficiently cleaned may include a thorough evaluation of several factors. Insert 220 may be visually inspected to ensure that there are no visible signs of deposits, scale, or contaminants on the surface of insert 220. Visual inspection of insert 220 may include manual direct visual inspection and / or automatic magnified visual inspection using tools such as magnifiers or microscopes, ultraviolet (UV) inspection using ultraviolet light to detect fluorescent deposits or contaminants, surface profiles that measure surface topography and identify irregularities, liquid penetrant inspections that use colored dyes to reveal surface cracks or defects, etc. Any remaining residue or deposits may indicate that cleaning is insufficient. Next, the smoothness and uniformity of the surface of insert 220 may be inspected. Rough or uneven areas indicate the presence of stubborn deposits that may require further cleaning. In addition, insert 220 may need to be free of any discoloration or stains that may indicate residual contaminants. Functional testing may be performed to verify the cleanliness of the insert 220. Subprocess 430 may involve checking the fit and alignment of the insert 220 with other valve seat 200 components, and performing leak or flow tests to ensure proper sealing and operation. A combination of visual inspection, surface evaluation, and functional testing can help determine whether the insert 220 has been sufficiently cleaned to meet the required standards to be considered reusable. Automated machines for visual inspection of the insert 220 can provide effective and reliable inspection capabilities. Examples of these machines include, but are not limited to, automated optical inspection (AOI) systems, machine vision systems, robotic inspection systems, laser scanning systems, coordinate measuring machine (CMM) systems, and the like. AOI systems utilize cameras and image processing algorithms to detect visual defects and contaminants that may be present on the surface of the insert 220. Machine vision systems employ cameras and image analysis techniques to capture and analyze images, enabling identification of specific features, measurements, and defects in the insert 220. Robotic inspection systems combine robots with machine vision systems for precise and repeatable inspections. Laser scanning systems use lasers to scan the surface of the insert 220 and create detailed 3D representations. The CMM system provides dimensional analysis regarding the surface quality of the insert 220. When it is determined that the cleaning is adequate (i.e., "yes" in subprocess 430), process 400 proceeds to subprocess 435. Otherwise, when it is determined that the cleaning is inadequate (i.e., "no" in subprocess 430), process 400 proceeds to subprocess 440.

[0037] In subprocess 435, the insert 220 cleaned in subprocess 430 can be paired with (e.g., installed into) a new body 210 having the same recess as the previous body 210 in which the insert 220 was most recently used. The body 210 having the same recess will have a support surface 212 of the same size as the body 210 discarded in subprocess 420. For example, the axial distance parallel to the longitudinal axis L between the most upstream end of the support surface 212 and the most upstream end of the tapered surface 214 will be equal to the height H of the cleaned insert 220. It should be understood that this axial distance represents the depth of the recess formed in the body 210.

[0038] In subprocess 440, the insert 220 may be ground to the end of the shoulder surface 226, but not beyond the end of the shoulder surface 226. For example, the tapered surface 224 of the insert 220 is ground parallel to the axis G to but not beyond the depth D2. In this case, the overall height H of the ground insert 220 remains the same (i.e., H1) after subprocess 440 as before subprocess 440. The angle A2 of the tapered surface 224 may also remain the same after subprocess 440 as before subprocess 440. However, in alternative embodiments, the angle A2 of the tapered surface 224 may be changed during grinding so that the angle A2 is different after subprocess 440 than before subprocess 440. It should be understood that the grinding in subprocess 440 removes a portion of the material forming the insert 220, while the cleaning in subprocess 425 removes debris from the surface of the insert 220 without removing significant material from the insert 220. Subprocess 440 may be completed by manual or machine automation. Robotic automation for grinding the insert 220 may include the use of specialized grinding machines, such as centerless grinders, cylindrical grinders, surface grinders, computer numerically controlled (CNC) grinders, tool and cutter grinders, and the like.

[0039] In subprocess 445, it is determined whether the cleaning in subprocess 440 is sufficient. Subprocess 445 represents a second recycling opportunity for insert 220. Subprocess 445 can be the same or similar to subprocess 430, and therefore, it is not described again herein. When it is determined that the cleaning is sufficient (i.e., "yes" in subprocess 445), process 400 proceeds to subprocess 435. Otherwise, when it is determined that the cleaning is not sufficient (i.e., "no" in subprocess 445), process 400 proceeds to subprocess 450.

[0040] In subprocess 450, the insert 220 is ground further, possibly beyond the shoulder surface 226. Subprocess 450 may be the same or similar to subprocess 440, and therefore, will not be described in detail herein. For example, the tapered surface 224 of the insert 220 is further ground parallel to the axis G beyond the depth D2 to a depth D3. As a result, the overall height H of the ground insert 220 is reduced from H1 to H2. As an example, the height H1 may be 0.450 inches (11.43 millimeters), and the height H2 may be 0.424 inches (10.78 millimeters). The height H2 and the corresponding depth D2 may be selected based on the size of the recess of the new body 210. For example, the recess of the previous body 210 in which the insert 220 was most recently used may have a height H1, and the recess of the new body 210 having a recess that is more recently shallow than the previous body 210 may have a height H2. In this case, the insert 220 may be intentionally ground to a depth D3 , and thus to a height H2 , even though this depth is greater than required to sufficiently clean the insert 220 so that the insert 220 may fit in the recess of the new body 210 .

[0041] In subprocess 455, it is determined whether the cleaning in subprocess 450 is sufficient. Subprocess 455 represents a third recycling opportunity for insert 220. Subprocess 455 may be the same or similar to subprocess 430 and / or 445, and therefore, will not be described in detail herein. When it is determined that the cleaning is sufficient (i.e., "yes" in subprocess 455), process 400 proceeds to subprocess 460. Otherwise, when it is determined that the cleaning is not sufficient (i.e., "no" in subprocess 455), process 400 proceeds to subprocess 465.

[0042] In subprocess 460, the insert 220 ground in subprocess 450 can be paired with (e.g., installed into) a new body 210 having a shallower recess than the previous body 210 that most recently used the insert 220. The body 210 having the shallower recess will have a support surface 212 that has different dimensions than the previous body 210 discarded in subprocess 420. In particular, at least the length of the third portion 212C of the support surface 212 of the new body 210 will be less than the length of the third portion 212C of the support surface 212 of the discarded body 210. For example, the height of the new body 210 can have the same height H2 as the additional ground insert 220.

[0043] In subprocess 465, the insert 220 may be discarded. At this point, the insert 220 has been ground to its minimum usable height H, but is still not clean enough to be recycled. Therefore, the insert 220 is discarded, which may include recycling the insert 220. The process 400 then ends.

[0044] In an embodiment, the insert 220 may be processed through more than one iteration of the subprocesses 450 and 455. In particular, there may be multiple models of valve seats 200, each with a different notch height. In this case, the insert 220 may be iteratively ground to each notch height associated with one of the multiple models of valve seats 200 until it is determined in subprocess 455 that the insert 220 is sufficiently clean, in which case the insert 220 may be paired with the body 210 of the model of valve seat 200 having the corresponding notch height in subprocess 460, or until the insert 220 is at the minimum notch height among the multiple models of valve seat 200 and is still not sufficiently clean, in which case the insert 220 should be discarded in subprocess 465. In other words, the insert 220 is ground to a continuously decreasing height, matching the notch height of the available body 210, until the insert 220 is sufficiently clean, or if sufficient cleanliness is never achieved, the insert 220 is discarded.

[0045] It should be understood that process 400 can be performed on batches of valve seats 200. Similarly, inserts 220 can be cleaned in batches in subprocess 425 and / or ground in batches in subprocesses 440 and 450. For example, a first quantity of valve seats 200 can be received in subprocess 405. The first quantity can be divided into a second quantity of inserts 220 that are cleaned in subprocess 425 (i.e., "yes" in subprocess 410) and a third quantity of inserts 220 that are discarded with their corresponding bodies 210 (i.e., "no" in subprocess 410). The second quantity of inserts 220 that are cleaned in subprocess 425 can then be divided into a fourth quantity of inserts 220 that are installed into new bodies 210 in subprocess 435 (i.e., "yes" in subprocess 430) and a fifth quantity of inserts 220 that are ground in subprocess 440 (i.e., "no" in subprocess 430). The fifth number of inserts 220 ground in the subprocess 440 may then be divided into a sixth number of inserts 220 installed in the new body 210 in the subprocess 435 (i.e., “Yes” in the subprocess 445) and a seventh number of inserts 220 ground in the subprocess 450 (i.e., “No” in the subprocess 445). The seventh number of inserts 220 ground in the subprocess 450 may then be divided into an eighth number of inserts 220 installed in the new body 210 in the subprocess 460 (i.e., “Yes” in the subprocess 455) and a ninth number of inserts 220 discarded in the subprocess 465 (i.e., “No” in the subprocess 455).

[0046] Although process 400 is described with respect to recycling insert 220, a similar process may be used to recycle body 210. In particular, tapered surface 214 may be cleaned in a manner similar to cleaning tapered surface 224 in subprocess 425. If cleaning is insufficient, tapered surface 214 may be ground parallel to axis G to a depth not exceeding shoulder surface 216 in a manner similar to grinding tapered surface 224 in subprocess 440. If the first grinding is insufficient, tapered surface 214 may be ground parallel to axis G to a new depth exceeding shoulder surface 216 in a manner similar to grinding tapered surface 224 in subprocess 450. If the second grinding is insufficient, body 210 may be discarded in a manner similar to discarding insert 220 in subprocess 465. In any case where body 210 is recycled, the recycled body 210 may be paired with an insert 220 having a height H that matches the depth of the recess after cleaning and / or grinding.

[0047] Industrial Applicability

[0048] The valve seat 200 within the fluid end 100 of a reciprocating pump may experience erosion when exposed to slurries or other fluids during fracturing operations. The erosive nature of these fluids, which often contain abrasive particles and chemicals, can gradually wear away the surface of the valve seat 200 over time. The high velocity and turbulence of the fluid exacerbate the erosion process, resulting in material loss and degradation of the surface of the valve seat 200. The combination of solid particles, chemicals, and mechanical forces creates a harsh environment that accelerates erosion, potentially compromising the function and sealing ability of the valve seat 200.

[0049] Thus, a remanufacturing process 400 for a valve seat 200 is disclosed. The process 400 can process the insert 220 of the valve seat 200 through sub-processes that gradually change the surface of the insert 220 until the insert 220 is considered recyclable. In other words, the process 400 provides multiple opportunities for recycling the insert 220. These sub-processes can begin with non-destructive cleaning of the insert 220 (e.g., sub-process 425), and if this is unsuccessful, the surface of the insert 220 is ground to increasing depths (e.g., not exceeding the shoulder surface 226 in sub-process 440, or not exceeding the shoulder surface 226 in sub-process 450) until the insert 220 can be recycled or further grinding will render the insert 220 unusable. Inserts 220 that are never considered recyclable can be discarded in sub-process 465.

[0050] The remanufacturing process 400 can provide significant cost savings. Instead of investing in a new insert 220, which may be expensive, the old insert 220 can be recycled through the process 400. In addition, the remanufacturing process 400 improves efficiency and sustainability. By extending the life of the insert 220, the need for new inserts 220 is reduced, thereby minimizing the consumption of raw materials and energy required for manufacturing. This is consistent with environmentally conscious practices and contributes to a more sustainable approach within the industry. Therefore, the remanufacturing process 400 not only provides economic benefits, but also helps to conserve resources and reduce the environmental impact associated with producing new parts.

[0051] It should be understood that the above benefits and advantages may relate to one embodiment or may relate to several embodiments. Aspects described in conjunction with one embodiment are intended to be usable with other embodiments. Any explanation in conjunction with one embodiment applies to similar features of other embodiments, and elements of multiple embodiments may be combined to form other embodiments. The embodiments are not limited to embodiments that solve any or all of the problems described or embodiments that have any or all of the benefits and advantages described.

[0052] The foregoing detailed description is merely exemplary in nature and is not intended to limit the invention or the application and use of the invention. The described embodiments are not limited to use in conjunction with a particular type of machine. Therefore, although for ease of explanation, the present embodiment is depicted and described as being implemented in the fluid end of a reciprocating pump for fracturing, it should be understood that it can be implemented in various other types of pumps and machines with valve seats and in various other systems and environments. In addition, it is not intended to be limited by any theory presented in any of the preceding sections. It should also be understood that these illustrations may include exaggerated dimensions and graphic representations to better illustrate the referenced items shown, and are not considered to be limiting unless explicitly stated.

Claims

1. A method for remanufacturing a valve seat, for each of one or more used valve seats, the remanufacturing method comprising: receiving the used valve seat, wherein the used valve seat comprises an insert, and wherein the insert comprises a tapered surface and a shoulder surface; When the insert is recyclable, manually or mechanically cleaning the insert; When the cleaned insert is sufficient for reuse, pairing the insert with a first new body having the same recess as a previous body of the insert that was most recently used; When the cleaned insert is insufficient for reuse, manually or mechanically grinding the tapered surface of the insert to a first depth such that at least a portion of the shoulder surface remains; When the ground insert is sufficient for reuse, pairing the insert with the first new body having the same recess; When the ground insert is insufficient for reuse, further manually or mechanically grinding the tapered surface of the insert to a second depth such that no portion of the shoulder surface remains; as well as When the further ground insert is sufficient for reuse, the further ground insert is mated with a second new body having a shallower recess than the previous body.

2. The remanufacturing method according to claim 1, further comprising: When the insert is not recyclable, the insert is discarded.

3. The remanufacturing method according to claim 1, further comprising: When the further ground insert is insufficient for reuse, the insert is discarded.

4. The remanufacturing method of claim 1, wherein the used valve seat further comprises the previous body, and wherein the remanufacturing method further comprises discarding the previous body.

5. The remanufacturing method of claim 1, wherein the used valve seat further comprises the previous body, the previous body comprising a tapered surface, and wherein the remanufacturing method further comprises cleaning or grinding one or both of the tapered surfaces of the previous body.

6. The remanufacturing method of claim 1, wherein the one or more used valve seats is a plurality of used valve seats, and wherein the cleaning, the grinding, and the further grinding are performed on batches of the inserts.

7. The remanufacturing method of claim 1, wherein in one or both of said grinding and said further grinding, said tapered surface is ground to an angle relative to the longitudinal axis of said insert that is equal to an angle of said tapered surface relative to said longitudinal axis before grinding.

8. The remanufacturing method of claim 1, wherein in one or both of said grinding and said further grinding, said tapered surface is ground to an angle relative to the longitudinal axis of said insert that is different from an angle of said tapered surface relative to said longitudinal axis before grinding.

9. The remanufacturing method according to claim 1, wherein the further grinding is iteratively performed to a plurality of second depths until the further ground insert is sufficient for reuse with a new body having a corresponding recess, or the further ground insert has been ground to a minimum usable height and is still insufficient for reuse.

10. The remanufacturing method of claim 1, wherein the insert is made of a carbide material.

11. The remanufacturing method of claim 1, further comprising determining whether the valve seat is recyclable.

12. The remanufacturing method of claim 1, further comprising determining if the cleaned insert is insufficient for reuse.

13. The remanufacturing method of claim 1, further comprising determining if the ground insert is insufficient for reuse.

14. The remanufacturing method of claim 1, further comprising determining whether the further ground insert is adequate for reuse.

15. The remanufacturing method of claim 1, wherein the previous body corresponds to a previous body that most recently used the insert.

Images