An integrated pilot-operated safety valve for ultra-high pressure vibration conditions

Abstract

An integrated pilot-operated safety valve for ultra-high pressure vibration conditions includes a main valve and a pilot valve connected by a pipeline. The main valve and pilot valve share a single valve body, featuring an integrated structural design. The connecting pipelines for the main valve, pilot valve, and chambers are all located inside the valve body. The upper part of the valve disc and the lower part of the valve disc plug of the main valve are designed with a spherical structure, allowing for a certain amount of oscillation and enabling automatic alignment of the valve disc during reseating. The guide ring and guide sleeve of the main valve are designed separately, facilitating adjustment of the alignment between the medium channel and the main valve chamber after the guide sleeve is installed. This invention avoids the risk of loosening or leakage of external connecting pipelines and joints under frequent vibration, enhancing the reliability of the valve.

Description

Technical Field

[0001] This invention relates to an integrated pilot-operated safety valve for ultra-high pressure vibration conditions, belonging to the field of overpressure protection devices. Background Technology

[0002] Ultra-high pressure pilot valves are commonly used in typical applications such as overpressure protection of gas injection compressors in gas storage facilities, overpressure protection of gas injection and oil production compressors in oil fields, and overpressure protection of compressors on offshore platforms. These high-pressure compressors typically require four to six stages of pressurization to reach the required pressure, and each stage of the compressor outlet requires a safety valve for overpressure protection. The maximum pressure of the required pilot-operated safety valve exceeds 100 MPa.

[0003] Currently, in the field of high-pressure safety valves, only spring-loaded safety valves suitable for small compressors exist. However, limited by their relatively small displacement capacity, they are ill-suited for the high-flow-rate requirements of high-pressure compressors. Furthermore, spring-loaded safety valves are insufficiently adaptable to harsh operating conditions where the working pressure is very close to the set pressure. Traditional pilot-operated safety valves, due to their typically external pipeline connection structure, suffer from problems such as limited pipeline pressure under high pressure, easy loosening and leakage under vibration conditions, and easy breakage of joints. These issues prevent them from meeting the requirements of ultra-high pressure vibration conditions. Therefore, a more advanced and reliable innovative pilot-operated safety valve technology is urgently needed to lead a new round of technological innovation in the field of ultra-high pressure safety protection. Summary of the Invention

[0004] The technical problem solved by this invention is to overcome the shortcomings of the prior art and provide an integrated pilot-operated safety valve for ultra-high pressure vibration conditions. This solves the problem that conventional pilot-operated safety valves are not suitable for ultra-high pressure vibration conditions due to the limited pressure of the external pipeline, and greatly expands the application range of pilot-operated safety valves.

[0005] The technical solution of this invention is: an integrated pilot-operated safety valve for ultra-high pressure vibration conditions, comprising: a main valve and a pilot valve, connected by a pipeline, wherein:

[0006] The main valve includes: valve body, valve seat, valve disc, valve disc plug, guide sleeve, main valve spring, guide sleeve ring, and cover plate; the connection method of each structure in the main valve is as follows:

[0007] The valve seat is installed into the valve body, and the valve disc is screwed into the valve disc plug through a threaded release mechanism. The valve disc plug is installed into the guide sleeve, and the guide sleeve and guide sleeve ring are installed into the valve body in sequence. The main valve spring is located in the guide sleeve and guide sleeve ring, with one end located in the valve disc plug and the other end contacting the cover plate. The cover plate is pressed and fixed on the valve body to ensure a seal between the valve seat and the valve body, and between the valve seat and the valve disc.

[0008] The pilot valve shares a valve body with the main valve. The pilot valve also includes: valve body, valve cover connector, valve cover, valve cap, adjusting screw, pilot valve spring, outlet valve seat, valve shaft, inlet valve seat, feedback piston, and piston sleeve. The connection method of each structure in the pilot valve is as follows:

[0009] The valve cover connector is fixed to the valve body by threads; the valve cover is fixed to the valve cover connector; the pilot valve spring is located inside the valve cover, one end of the pilot valve spring acts on the feedback piston through the spring seat, and the other end of the pilot valve spring is connected to the lower end of the adjusting screw through the spring seat; the valve cap is fixed above the adjusting screw; the adjusting screw is located on the upper part of the valve cover and inside the valve cap.

[0010] The outlet valve seat, valve shaft, inlet valve seat, feedback piston, and piston sleeve are located in the valve body. The piston sleeve is fitted around the feedback piston. The inlet valve seat and outlet valve seat are sequentially installed at the lower end of the feedback piston. The valve shaft passes through the outlet valve seat and inlet valve seat from bottom to top.

[0011] The pipeline includes a first channel, a second channel, and a third channel. The first channel connects the main valve inlet and the pilot valve inlet. The second channel connects the pilot valve inlet seat and the main valve air chamber. The third channel connects the pilot valve outlet and the main valve outlet. The main valve inlet is located below the valve seat, the main valve outlet is located on the valve body, the pilot valve inlet is located below the valve shaft, and the pilot valve outlet is located on the outlet valve seat and connected to the main valve outlet. The main valve air chamber is a cavity composed of a guide sleeve, a guide sleeve ring, a valve disc plug, and a cover plate.

[0012] Preferably, the upper part of the valve disc and the lower part of the valve disc plug are both designed as spherical structures, with the valve disc plug using a large spherical surface and the valve disc using a relatively small spherical surface, so that the valve disc and the valve disc plug have a certain amount of swing, which is used for the automatic alignment of the valve disc when the valve reseating.

[0013] Preferably, the valve body and the guide sleeve, the guide sleeve ring, and the valve disc plug and the guide sleeve are sealed by O-rings.

[0014] Preferably, the pipelines containing the first, second, and third channels are all located inside the valve body.

[0015] Preferably, four through holes are designed at the position where the inlet valve seat connects to the second channel of the valve body. During installation, one of the through holes can be aligned with the second channel of the valve body by simple adjustment.

[0016] Preferably, the guide ring is designed with through holes for alignment and connection with the second channel. The guide ring and guide sleeve are designed separately, which facilitates the adjustment of the alignment and connection between the second channel and the main valve air chamber after the guide sleeve is installed.

[0017] Preferably, the main valve utilizes the medium pressure and forms a metal-to-metal self-sealing structure through the area difference between the lower part of the valve disc and the upper part of the valve disc plug.

[0018] Preferably, the main valve structure has an opening height limit structure design between the valve disc plug and the guide sleeve: the valve disc plug and the guide sleeve adopt a stepped structure combination. When the valve is closed, there is a certain distance between the stepped surfaces of the valve disc plug and the guide sleeve. When the valve is open, the two stepped surfaces are in contact. The distance when closed is the valve opening height. The high limit structure design allows the valve opening height to be within a certain range, and the height of the limit structure can be adjusted by adjusting the throat diameter of the integrated pilot-operated safety valve.

[0019] Preferably, the guide sleeve acts directly on the valve seat, and both the valve seat and the valve disc mate with the guide section of the inner hole of the guide sleeve. The guide section of the inner hole of the guide sleeve mates with the valve seat and the valve disc in one operation, which ensures the guidance and centering of the main valve and achieves good sealing of the valve under high pressure.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] This invention addresses the overpressure protection requirements in ultra-high pressure vibration environments. Through an integrated main valve structure design, a special pipeline design, a main sealing structure design, and a split guide sleeve design, it solves the pressure and vibration problems faced by high-pressure pilot valves, improves the sensitivity of the main valve response, the reliability of its action and sealing, reduces the complexity of installation, and successfully realizes the application of pilot valves in ultra-high pressure vibration environments. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a conventional pilot-operated safety valve.

[0023] Figure 2 This is a schematic diagram of an integrated pilot-operated safety valve for use in ultra-high pressure vibration conditions.

[0024] Figure 3 A schematic diagram of an automatic valve disc alignment scheme;

[0025] Figure 4 This is a schematic diagram of a split-type guide sleeve design. Detailed Implementation

[0026] An integrated pilot-operated safety valve for ultra-high pressure vibration conditions mainly consists of a main valve and a pilot valve, and has the following three characteristics:

[0027] 1) Integrated main valve structure and special pipeline design:

[0028] Because compressors vibrate frequently and operate at extremely high pressures, higher requirements are placed on the connecting pipes and fittings of high-pressure pilot valves in terms of pressure resistance and vibration resistance. Loosening or leakage can easily lead to shutdowns and production stoppages. Conventional pilot-operated safety valves have their connecting pipes and fittings located outside the valve body. However, integrated pilot-operated safety valves for ultra-high pressure and vibration conditions feature a single integrated design for the main valve and pilot valve. The main valve and pilot valve share a single valve body, and the connecting pipes for the main valve, pilot valve, and chambers are all designed inside the valve body. This design is significantly more advanced than conventional pilot-operated safety valves (such as...). Figure 1 (As shown) This structure saves cost and installation space while significantly improving safety. Furthermore, the integrated design solves the problem of limited pressure resistance in the connecting pipes and fittings between the main valve and the pilot valve, ensuring pressure resistance consistent with the valve body and meeting the requirements of ultra-high pressure conditions. It also avoids the risk of loosening or leakage in external connecting pipes and fittings under frequent vibration, enhancing valve reliability. The integrated pilot-operated safety valve structure for ultra-high pressure vibration conditions is shown below. Figure 2 As shown.

[0029] For ultra-high pressure vibration conditions, the integrated pilot-operated safety valve and its main valve connection pipeline are both designed within the main valve body. Figure 2 The pipeline consists of a first channel, a second channel, and a third channel. The first channel is composed of two sections, a horizontal and a vertical channel, which connects the main valve inlet and the pilot valve inlet. The second channel is an oblique channel that connects the pilot valve inlet seat 16 and the main valve air chamber. The third channel is a horizontal channel that connects the pilot valve outlet and the main valve outlet. The main valve inlet is located below the valve seat 2, the main valve outlet is located on the valve body 1, the pilot valve inlet is located below the valve shaft 15, the pilot valve outlet is located on the outlet valve seat 14, and the main valve air chamber is a cavity composed of a guide sleeve 5, a guide sleeve ring 7, a valve disc plug 4, and a cover plate 8. Before the system pressure reaches the set point, the system pressure enters the valve shaft 15 through the first channel from the main valve inlet, and flows into the second channel through the channel between the outlet valve seat 16 and the piston sleeve 18, communicating with the main valve chamber. The inlet valve seat 16 is designed with four through holes at the position where it connects to the second channel of the valve body 1. During installation, simple adjustment can align the through holes of the inlet valve seat 16 with the second channel of the valve body 1, ensuring that the system pressure can enter the main valve chamber in a timely manner. At this time, the pressure between the main valve inlet and the main valve chamber is the same. Due to the difference in sealing area between the main valve inlet and the main valve chamber, the main valve is sealed. When the main valve inlet pressure reaches the set pressure, the pilot valve opens. The pressure in the main valve chamber enters the pilot valve through the second channel, then enters the pilot valve channel formed by the outlet valve seat 16 and the valve shaft 15 through the outlet valve seat 16, and is then released from the main valve outlet through the third channel. At this time, the chamber pressure decreases, and the medium force above the main valve disc plug 4 is lower than the medium force below. The main valve disc plug 4 then moves upward, and the main valve opens.

[0030] The first, second, and third channels are relatively short and have few bends inside the valve body, resulting in a short flow path. This allows for rapid decompression of the main valve chamber and a fast response when the main valve opens and closes.

[0031] 2) Main Sealing Structure Design: By rationally designing the structure of the contact area between the valve disc plug 4 and the valve disc 3, the reliability of its operation is improved. Both the upper part of the valve disc 3 and the lower part of the valve disc plug 4 are designed as spherical structures. The contact surface between the lower part of the valve disc plug 4 and the upper part of the valve disc 3 is a high-gloss double-spherical design. The valve disc plug 4 uses a large spherical surface, while the valve disc 3 uses a relatively smaller spherical surface. This structure allows the valve disc 3 and valve disc plug 4 to have a certain amount of swing, enabling automatic alignment of the valve disc 3 during valve reseating. This design not only facilitates the swing of the valve disc 3 and the alignment of the overall structure but also improves the stability of the structure. The specific structural scheme is as follows: Figure 3 As shown:

[0032] 3) Split-type guide sleeve design: The conventional integrated guide sleeve structure is designed as a split structure of guide sleeve ring 7 and guide sleeve 5. The upper end is designed as guide sleeve ring 7, with through holes for alignment and connection with the second channel. The split design of guide sleeve ring 7 and guide sleeve 5 facilitates the alignment and connection of the second channel with the main valve air chamber after guide sleeve 5 is installed. This easy adjustment solves the problem of alignment between the main valve air chamber and the pilot valve air path; it also facilitates installation and adjustment, saving processing costs. The lower guide sleeve works in conjunction with the valve seat guide surface, ensuring good alignment of the valve body, valve disc plug 4, valve disc 3, and valve seat 2, guaranteeing excellent sealing performance of the main valve. See the specific solution below. Figure 4 .

[0033] like Figure 2 As shown, an integrated pilot-operated safety valve for ultra-high pressure vibration conditions consists of a main valve and a pilot valve. The main valve is composed of a valve body 1, a valve seat 2, a valve disc 3, a valve disc plug 4, a guide sleeve 5, a main valve spring 6, a guide sleeve ring 7, and a cover plate 8. After the main valve components are installed, the cover plate 8 is bolted to the main valve body 1. The valve seat 2 is installed into the valve body 1, and the valve disc 3 is screwed into the valve disc plug 4 using a threaded release mechanism. The valve disc plug 4 is installed into the guide sleeve 5. The guide sleeve 5, guide sleeve ring 7, and main valve spring 6 are sequentially installed into the valve body 1. The main valve spring 6 is located in the guide sleeve 5 and guide sleeve ring 7, with one end installed in the valve disc plug 4 and the other end contacting the cover plate 8. The cover plate 8 is bolted and tightened onto the valve body 1 to ensure a seal between the valve seat 2 and the valve body 1, and between the valve seat 2 and the valve disc 3. The valve body 1 is sealed with the guide sleeve 5 and the guide sleeve ring 7, and the valve disc plug 4 is sealed with the guide sleeve 5 by O-rings.

[0034] Because this structure is an integrated main valve structure, the main valve body is also the pilot valve body. The pilot valve mainly consists of valve body 1, valve cover connector 10, valve cover 9, valve cap 12, adjusting screw 13, pilot valve spring 11, outlet valve seat 14, valve shaft 15, inlet valve seat 16, feedback piston 17, piston sleeve 18, etc. The valve cover connector 10 is fixed to the valve body 1 by threads; the valve cover 9 is fixed to the valve cover connector 10 by threads; the pilot valve spring 11 is located inside the valve cover 9, one end of the pilot valve spring 11 acts on the feedback piston 17 through the spring seat, and the other end of the pilot valve spring 11 is connected to the lower end of the adjusting screw 13 through the spring seat; the valve cap 12 is fixed above the adjusting screw 13; the adjusting screw 13 is located on the upper part of the valve cover 9 and inside the valve cap 12. The outlet valve seat 14, valve shaft 15, inlet valve seat 16, feedback piston 17, and piston sleeve 18 are installed in the valve body 1. The valve shaft 15, feedback piston 17, and piston sleeve 18 are connected by threads. Specifically, the piston sleeve 18 is fitted around the feedback piston 17. The inlet valve seat 16 and outlet valve seat 14 are sequentially arranged at the lower end of the feedback piston 17. The valve shaft 15 passes through the outlet valve seat 14 and inlet valve seat 16 from bottom to top.

[0035] Conventional pilot-operated safety valves typically use non-metallic soft seals made of fluoroplastics or rubber for their main seals. Under ultra-high pressure vibration conditions, pilot-operated safety valves require higher performance in terms of long-term sealing and erosion resistance. Therefore, ultra-high pressure pilot-operated safety valves utilize the medium pressure and the area difference between the lower part of the valve disc (3) and the upper part of the valve disc plug (4) to form a metal-to-metal self-sealing structure. This structure provides better long-term sealing and erosion resistance under high pressure conditions than non-metallic soft seals, resulting in a longer service life. See details... Figure 4 .

[0036] The main valve structure features a height limit mechanism between the valve disc plug 4 and the guide sleeve 5, which can be seen in detail below. Figure 4 The valve disc plug 4 and guide sleeve 5 adopt a stepped structure combination. When the valve is closed, there is a certain gap between the stepped surfaces of the valve disc plug 4 and guide sleeve 5. When the valve is open, the two stepped surfaces are in contact. The gap when closed is the valve opening height. This opening height limit structure design can ensure that the valve opening height is within a certain range. The height of the limit structure can be adjusted by adjusting the throat diameter of the integrated pilot-operated safety valve.

[0037] The guide sleeve 5 acts directly on the valve seat 2. Both the valve seat 2 and the valve disc 3 mate with the guide section inside the guide sleeve 5. The guide section between the inner bore of the guide sleeve 5 and the valve seat 2 and valve disc 3 is machined in one piece. This structure ensures excellent guidance and centering of the main valve, enabling good sealing under high pressure. See details... Figure 4 .

[0038] Based on the market demand for overpressure protection of high-pressure compressors, this invention has made structural innovations in the design of integrated main valve structure, special pipeline structure, main sealing structure, and split guide sleeve structure. This valve type is suitable for ultra-high pressure vibration conditions.

[0039] The contents not described in detail in this specification are existing technologies known to those skilled in the art.

Claims

1. An integrated pilot-operated safety valve for ultra-high pressure vibration conditions, characterized in that... include: The main valve and pilot valve are connected by a pipeline, wherein: The main valve includes: valve body (1), valve seat (2), valve disc (3), valve disc plug (4), guide sleeve (5), main valve spring (6), guide sleeve ring (7), and cover plate (8); the connection method of each structure in the main valve is as follows: The valve seat (2) is installed in the valve body (1), and the valve disc (3) is screwed into the valve disc plug (4) by a threaded release type. The valve disc plug (4) is installed in the guide sleeve (5). The guide sleeve (5) and the guide ring (7) are installed into the valve body (1) in sequence. The main valve spring (6) is located in the guide sleeve (5) and the guide ring (7), with one end located in the valve disc plug (4) and the other end contacting the cover plate (8). The cover plate (8) is pressed and fixed on the valve body (1) to ensure a seal between the valve seat (2) and the valve body (1) and between the valve seat (2) and the valve disc (3). The pilot valve shares a valve body (1) with the main valve. The pilot valve also includes: valve body (1), valve cover connector (10), valve cover (9), valve cap (12), adjusting screw (13), pilot valve spring (11), outlet valve seat (14), valve shaft (15), inlet valve seat (16), feedback piston (17), and piston sleeve (18). The connection method of each structure in the pilot valve is as follows: The valve cover connector (10) is fixed to the valve body (1) by threads; the valve cover (9) is fixed to the valve cover connector (10); the pilot valve spring (11) is located inside the valve cover (9), one end of the pilot valve spring (11) acts on the feedback piston (17) through the spring seat, and the other end of the pilot valve spring (11) is connected to the lower end of the adjusting screw (13) through the spring seat; the valve cap (12) is fixed above the adjusting screw (13); the adjusting screw (13) is set on the upper part of the valve cover (9) and inside the valve cap (12); The outlet valve seat (14), valve shaft (15), inlet valve seat (16), feedback piston (17), and piston sleeve (18) are located in the valve body (1). The piston sleeve (18) is sleeved around the feedback piston (17). The inlet valve seat (16) and outlet valve seat (14) are arranged sequentially at the lower end of the feedback piston (17). The valve shaft (15) passes through the outlet valve seat (14) and inlet valve seat (16) from bottom to top. The pipeline includes a first channel, a second channel and a third channel. The first channel connects the main valve inlet and the pilot valve inlet. The second channel connects the inlet valve seat (16) of the pilot valve and the main valve air chamber. The third channel connects the pilot valve outlet and the main valve outlet. The main valve inlet is located below the valve seat (2), the main valve outlet is located on the valve body (1), the pilot valve inlet is located below the valve shaft (15), and the pilot valve outlet is located on the outlet valve seat (14) and connected to the main valve outlet. The main valve air chamber is a cavity composed of a guide sleeve (5), a guide sleeve ring (7), a valve disc plug (4) and a cover plate (8).

2. The integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: The upper part of the valve disc (3) and the lower part of the valve disc plug (4) are both designed with spherical structures. The valve disc plug (4) adopts a large spherical surface, while the valve disc (3) adopts a relatively small spherical surface, so that the valve disc (3) and the valve disc plug (4) have a certain amount of swing, which is used for the automatic alignment of the valve disc (3) when the valve reseating.

3. The integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: The valve body (1) is sealed with the guide sleeve (5) and the guide sleeve ring (7), and the valve disc plug (4) is sealed with the guide sleeve (5) by O-rings.

4. The integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: The pipelines containing the first, second, and third channels are all located inside the valve body (1).

5. The integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: Four through holes are designed at the position where the inlet valve seat (16) connects to the second channel of the valve body (1). During installation, one of the through holes is aligned with the second channel of the valve body (1) by simple adjustment.

6. The integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: The guide ring (7) is designed with through holes for alignment with the second channel. The guide ring (7) and the guide sleeve (5) are designed separately, which makes it easy to adjust the alignment of the second channel with the main valve chamber after the guide sleeve (5) is installed.

7. An integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: The main valve utilizes the medium pressure and forms a metal-to-metal self-sealing structure through the area difference between the lower part of the valve disc (3) and the upper part of the valve disc plug (4).

8. An integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: The main valve structure has a height limit structure design between the valve disc plug (4) and the guide sleeve (5): the valve disc plug (4) and the guide sleeve (5) adopt a stepped structure combination. When the valve is closed, there is a certain distance between the stepped surfaces of the valve disc plug (4) and the guide sleeve (5). When the valve is open, the two stepped surfaces are in contact. The distance when closed is the valve opening height. The height limit structure design allows the valve opening height to be within a certain range. The height of the limit structure can be adjusted by adjusting the throat diameter of the integrated pilot-operated safety valve.

9. An integrated pilot-operated safety valve for ultra-high pressure vibration conditions according to claim 1, characterized in that: The guide sleeve (5) acts directly on the valve seat (2). The valve seat (2) and the valve disc (3) both cooperate with the guide section of the inner hole of the guide sleeve (5). The guide section of the inner hole of the guide sleeve (5) and the valve seat (2) and the valve disc (3) is formed in one operation, which ensures the guidance and centering of the main valve and achieves good sealing of the valve under high pressure.

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