Gate conduit apparatus

Abstract

A conduit apparatus with a body, a first surface, and a second surface opposite the first surface. The apparatus having a through bore providing a conduit between the first and second surfaces. A gate is disposed in a passage transverse to the through bore and configured for positioning with an opening on the gate coincident with the through bore. The gate opening is configured with a cutting surface, and the conduit body has an internal fluid passage to channel fluid to actuate the gate to move the cutting surface across the through bore. A method of operating a conduit.

Description

GATE CONDUIT APPARATUSCross Reference to Related Applications

[0001] Not Applicable.Background

[0002] This disclosure relates to fluid flow and pressure control devices. More specifically, the disclosure relates to a conduit device using a gate design for effective fluid control and pressure containment in general applications.

[0003] Valves to control the transmission and flow of fluids have been in use for centuries. Gate valves are well known and applied in various industries. Conventional gate valves are designed with a stem and stem packing configuration, which is less than ideal for use with extremely harsh fluids that significantly reduce the operational life of the gates.

[0004] Blowout preventers (BOPs) for oil and gas wells are used to prevent potentially catastrophic events known as blowouts, where high well pressures and uncontrolled fluid flow from a subsurface formation into the well can expel tubing (e.g., drill pipe and well casing), tools and drilling fluid out of the well. Blowouts present a serious safety hazard to drilling crews, the drilling rig, and the environment, and can be extremely costly. Typically, BOPs have “rams” that are opened and closed by actuators. The most common type of actuator pushes a closure element across a through bore in a BOP housing to close the well. In some cases, the rams have shears to cut through a drill string or other tools which may be in the well, and consequently in the through bore, at the time it is necessary to close the BOP. Conventional BOP systems utilize pressurized hydraulic fluid reservoirs known as accumulators to energize and actuate the ram, resulting in complicated, heavy units with numerous connections and controls that are prone to failure, especially in underwater applications.

[0005] A need remains for improved fluid control and pressure containment conduits.Summary

[0006] One aspect of the present disclosure is a conduit apparatus. The apparatus includes a main body having a through bore providing a conduit, a passage transverse to the through bore,and a gate disposed in the passage and configured for positioning with an opening on the gate coincident with the through bore. The gate opening is configured with a cutting surface, wherein the gate is configured for actuation via fluid pressure to move the cutting surface across the through bore.

[0007] Another aspect of the present disclosure is a conduit apparatus including a main body with a through bore providing a conduit, a passage transverse to the through bore, and a gate disposed in the passage and configured for positioning with an opening on the gate coincident with the through bore. The gate opening is configured with a cutting surface. The gate has at least one seal configured for actuation between an energized mode and a de-energized mode, wherein the seal is configured for energization and / or de-energization upon movement of the gate along the transverse passage.

[0008] Another aspect of the present disclosure is a method of operating an apparatus having a main body with a through bore providing a conduit and a passage transverse to the through bore. The method includes positioning a gate in the transverse passage, wherein the gate is configured for positioning with an opening thereon coincident with the through bore, wherein the gate has at least one seal configured for actuation between an energized mode and a de-energized mode. And actuating the gate in a first direction along the transverse passage to move a cutting surface on the gate opening across the through bore, wherein the seal is configured for energization and / or deenergization upon movement of the gate along the transverse passage.Brief Description of the Drawings

[0009] The following figures are included to further demonstrate certain aspects of the present disclosure and should not be used to limit or define the claimed subject matter. A more complete understanding of the present embodiments and further features and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numerals may identify like elements.

[0010] FIG. 1 shows a side perspective of a conduit embodiment according to this disclosure.

[0011] FIG. 2 shows an oblique view of a conduit embodiment according to this disclosure.

[0012] FIG. 3 shows a partially exploded side perspective of a conduit embodiment according to this disclosure.

[0013] FIG. 4 shows a cross section of a conduit as seen from one end of the conduit body according to this disclosure.

[0014] FIG. 5 shows an oblique view of a gate embodiment according to this disclosure.

[0015] FIG. 6 shows a close-up exploded view of a gate embodiment according to this disclosure.

[0016] FIG. 7 shows an oblique view schematic of a gate embodiment according to this disclosure.

[0017] FIG. 8 shows a cross section side view of a gate embodiment with a cutting surface according to this disclosure.

[0018] FIG. 9 shows an overhead cross section of a conduit embodiment in an open position according to this disclosure.

[0019] FIG. 10 shows an oblique view schematic of another gate embodiment according to this disclosure.

[0020] FIG. 11 shows a cross section side view of a gate embodiment with a solid surface according to this disclosure.

[0021] FIG. 12 shows an overhead cross section of a conduit embodiment in a closed position according to this disclosure.

[0022] FIG. 13 A shows a plan view of a gate embodiment according to this disclosure.

[0023] FIG. 13B shows a side view of the cutting surface blade embodiment of FIG. 13A.

[0024] FIG. 13C shows a cross section side view of the gate embodiment of FIG. 13 A.

[0025] FIG. 14 shows a cross section side view of a gate embodiment with a cutting surface according to this disclosure.

[0026] FIG. 15 shows a cross section side view of a gate embodiment with a cutting surface according to this disclosure.

[0027] FIG. 16 shows a cross section side view of a gate embodiment with a cutting surface according to this disclosure.

[0028] FIG. 17 shows an oblique view of a gate embodiment with a cutting surface according to this disclosure.

[0029] FIG. 18 shows a plan view of a gate embodiment with a cutting surface according to this disclosure.

[0030] FIG. 19 shows a plan view of a gate embodiment with a cutting surface according to this disclosure.

[0031] FIG. 20 shows a cross section side view of a gate embodiment with a cutting surface according to this disclosure.

[0032] FIG. 21 shows a cross section side view of a gate embodiment with a cutting surface according to this disclosure.

[0033] FIG. 22 shows a close-up perspective of a conduit embodiment according to this disclosure.

[0034] FIG. 23 shows an oblique exploded view of a conduit embodiment according to this disclosure.

[0035] FIG. 24 shows a cross section plan view of a conduit embodiment with a locking member according to this disclosure.

[0036] FIG. 25 shows a schematic of a conventional BOP in a side-by-side comparison to a conduit embodiment according to this disclosureDetailed Description

[0037] The foregoing description of the figures is provided for the convenience of the reader. It should be understood, however, that the embodiments are not limited to the precise arrangements and configurations shown in the figures. Also, the figures are not necessarily drawn to scale, and certain features may be shown exaggerated in scale or in generalized or schematic form, in the interest of clarity and conciseness.

[0038] While various embodiments are described herein, in the interest of clarity all features of an actual implementation may not be described in this specification. In the development of any such actual embodiment, numerous implementation- specific decisions may need to be made toachieve the design- specific goals, which may vary from one implementation to another. It will be appreciated that such a development effort, while possibly complex and time-consuming, would nevertheless be a routine undertaking for persons of ordinary skill in the art having the benefit of this disclosure. It will be understood that as used herein, the term “fluid,” in singular or plural form, defines a substance consisting of a liquid, a gas, or a combination thereof.

[0039] FIG. 1 shows a conduit 10 embodiment according to this disclosure. The conduit 10 has a body 12, a first end 14, a second end 16, a first surface 18, and a second surface 20 opposite the first surface. A through bore 22 traverses through the body 12, providing an open passage or conduit between the first surface 18 and the second surface 20. Although the embodiment of FIG. 1 shows the through bore 22 configured as a cylindrical opening, the bore may be configured in other geometrical shapes for the particular application (e.g., oval, octagonal, etc.). The body 12 may be formed of any suitable material depending on the application (e.g., metal, composites, synthetic materials, etc.). Although FIG. 1 shows an embodiment configured with a generally planar body 12 design, embodiments may be implemented with bodies comprising other geometrical designs more suitable for the desired application.

[0040] Some conduit 10 embodiments may be configured with threaded holes 23 formed on either or both surfaces 18, 20 to receive mounting bolts 24 for mounting of the conduit 10 onto a conventional fluid transmission system. The embodiment of FIG. 1 is shown configured with a flange 25 extending from the second surface 20. It will be appreciated by those skilled in the art that other embodiments may be configured for disposal of the conduit 10 onto fluid lines or systems in various fashions depending on the application (e.g., welded onto a line, affixed with clamps, etc.).

[0041] FIG. 2 shows an oblique view of a conduit 10 embodiment according to this disclosure. The conduit 10 is shown with a passage 28 formed transverse to the through bore 22. The transverse passage 28 extends across the body 12 from one end 14 to the other 16. The body 12 is implemented with slots or channels 30 formed transversely to the longitudinal axis of the body 12 on each end 14, 16. The channels 30 form part of a cover engagement system, as further described with respect to FIG. 3.

[0042] FIG. 3 shows a conduit 10 embodiment implemented with a pair of end covers 32. The end covers 32 are shown detached from the main body 12. Each end cover 32 has a slot or channel34 formed transversely to the longitudinal axis of the body 12. The channels 30 on the main body 12 and the channels 34 on the covers 32 are aligned with one another such that when the covers are respectively mated against the main body, an engagement bar 36 is used to maintain each cover in place. The embodiment of FIG. 3 shows the channels 30, 34 respectively formed with a series of teeth or projections running along the width of the body 12 and the covers 32. The engagement bars 36 are formed with a series of matching teeth or projections on each side for complementary engagement within the channels 30, 34 formed on the body 12 and covers. Each engagement bar 36 is inserted from one side of the body 12 to slide into place, securely locking the end cover 32 against the body 12. It will be appreciated by those skilled in the art that other embodiments may be implemented with the engagement bars 36 and channels 30, 34 formed with different complementary cross sections (e.g., I-beam, circular, semi-circular, stepped, etc.). Embodiments may also be implemented with conventional fasteners or adhesives disposed on the sides of the body 12 to secure the engagement bars 36 in place once the covers are mounted on the body.

[0043] A seal 38 (e.g., conventional fluid seal) is mounted in between each end of the main body 12 and each cover 32. Each cover 32 includes a groove 40 formed on the inner surface to receive the seal 38 when the cover is mounted on the main body 12. Each end of the main body 12 is also implemented with a groove 42 (see FIG. 4) to receive the seal 38 when the cover is mounted on the body.

[0044] FIG. 3 also shows a gate 44 disposed in the transverse passage 28 in accordance with embodiments of this disclosure. Aspects of the gate 44 are further described below. As shown in FIG. 3, when it is desired to inspect, repair, or replace the gate 44 (e.g., to replace all the seals), an engagement bar 36 is pulled out of a channel 30, 34 at either end of the body 12 to free the cover 32 for detachment to allow access to the gate via the passage 28. Once the end cover 32 is detached, the gate 44 can be removed and replaced while keeping the conduit 10 mounted in place. It will be appreciated by those skilled in the art that other detachable cover 32 configurations may be implemented with the conduits 10 using conventional hardware means and components.

[0045] FIG. 4 shows a cross section of a main body 12 from one end 12, 14 with the covers 32 removed. In this embodiment, the main body 12 includes a port 46 traversing the body from one side all the way into the transverse passage 28. The port 46 is pail of a gate 44 locking configuration further described below. Turning to FIG. 5, an embodiment of a gate 44 is shown. In thisembodiment, the gate 44 is configured as a rectangular-shaped planar body 45 with a first face 46 and a second face 48. The gate 44 has an opening 50 formed near a first end 52. The opening 50 is sized to coincide with the diameter of the through bore 22 formed in the conduit 10 body 12. The gate 44 provides a solid surface area 54 near a second end 56. FIG. 5 shows the opening 50 surrounded by a seal trench 58. The other end with the solid surface area 54 also has a seal trench 60 formed thereon. Although not shown in FIG. 5, the second face 48 of the gate 44 is configured with matching seal trenches 58’, 60’. In essence, the first face 46 of the gate 44 is a mirror image of the second face 48. Returning to FIG. 4, it can be seen that the transverse passage 28 is formed in the body 12 to match the longitudinal profile of the gate 44, which in the embodiment of FIG. 5 is in a geometric ellipsis form.

[0046] The gate 44 may be formed of any suitable material depending on the application (e.g., metal, composites, synthetic materials, etc.). As described with respect to the disclosed embodiments, the gate 44 is disposed in the transverse passage 28. The gate 44 is formed to fit within the passage 28 at a close tolerance yet allowing the gate to move within the passage as described herein. The gate 44 is configured for easy insertion and extraction from the passage 28, akin to a cartridge in a player. Some gate 44 embodiments may be implemented with one or more grooves 62A, 62B, 62C formed encircling the gate 44 surface near the center and near each end to receive and hold a band (e.g., an O-ring). Such bands function as a wiper for the internal surface of the passage 28 as the gate 44 moves back and forth therein. FIG. 5 shows a gate 44 embodiment configured with ports 64A, 64B, 66A, 66B, 66C. 66D at one end (further described with respect to FIG. 6). FIG. 5 also shows an embodiment implemented with a pair of orifices 68A, 68B formed on one side of the gate 44 (further described with respect to FIG. 24).

[0047] FIG. 6 shows a close-up of a gate 44 embodiment from the end near the solid surface area 54. Ports 64A and 64B are configured to respectively receive floating pistons 70A and 70B. Caps 71A and 7 IB are threadably engaged on the ports 64A, 64B to secure the pistons 70A, 70B and seal the ports. The pistons 70A, 70B and caps 71A, 7 IB may be fitted with seals (e.g., O-rings) to provide greater sealing integrity. Ports 66 A, 66B, 66C, and 66D are configured to respectively receive intensifier elements 73A, 73B, 73C, and 73D. Each intensifier element incorporates a threaded cap 74 with a hole 75, a plunger 76, and a spring 77. The plungers 76 include a body portion 78 affixed with an extending rod that passes through the hole 75 in the cap 74. The plunger76 body portions 78 and caps 74 may be fitted with seals (e.g., O-rings) to provide greater sealing integrity.

[0048] FIG. 7 shows a gate 44 embodiment of this disclosure. The gate 44 is implemented with the floating pistons 70A, 70B and intensifier elements 73A, 73B, 73C, 73D as described with respect to FIG. 6. As previously described with respect to FIG. 5, the gate 44 may be configured with mirroring seal trenches 58, 58’, 60, 60’ respectively formed on each face 46, 48. A first seal 80A is disposed around gate opening 50 in seal trench 58 and a second seal 82A is disposed around the solid surface area 54 in seal trench 60 (see FIG. 6). Although not depicted in FIG. 7 for clarity of illustration, a third seal 80B is disposed in mirroring seal trench 58’ formed on the second face 48 of the gate 44 surrounding the opening 50. Similarly, a fourth seal 82B is disposed in mirroring seal trench 60’ formed on the second face 48 of the gate 44 around the solid surface area 54.

[0049] FIG. 7 also shows the internal gate 44 passages for the fluid circuits between the seals 80A, 80B, 82A, 82B, the intensifier elements 73A, 73B, 73C, 73D, and the floating pistons 70A, 70B. Internal fluid channels Cl and C2 respectively traverse through the gate 44 body between seal trench 58 and intensifier elements 73A and 73B. Internal fluid channels C3 and C4 respectively traverse through the gate 44 body between seal trench 58’ and intensifier elements 73C and 73D. Internal fluid channels C5 and C6 respectively traverse through the gate 44 body to link internal passages Cl and C2 with floating piston 70A and internal passages C3 and C4 with floating piston 70B. All of the channels form internal closed fluid circuits in the gate 44.

[0050] Returning to FIG. 6, the closed fluid circuits of FIG. 7 are further described. Cap 71A seals channel C5, which is filled with inert gas (e.g., Nitrogen) under pressure. Cap 7 IB similarly seals channel C6, which is also filled with inert gas under pressure. The caps 74 of intensifier elements 73 A and 73B respectively seal channels Cl and C2, which are linked at the other end to seal trench 58. Channels Cl and C2 are filled with a semi-solid compound (e.g., high viscosity or thixotropic fluid, such as a suitable grease or other conventional semi-solid compound). Caps 74 of intensifier elements 73C and 73D respectively seal channels C3 and C4, which are linked at the other end to seal trench 58’ on the gate 44 (not shown in FIG. 7 for clarity of illustration). Channels C5 and C6 are respectively linked into channels Cl, C2 and C3, C4.

[0051] FIG. 8 shows a cross section side view of a gate 44 embodiment similar to the embodiment of FIG. 7. For clarity of illustration, only the section of the gate 44 with opening 50is shown in FIG. 8. Seal 80A resides in seal trench 58 on the first face 46 of the gate and seal 80B resides in seal trench 58’ on the second face 48. Each seal trench 58, 58’ is respectively configured with an orifice 81 A, 8 IB at the bottom of the trench. Internal fluid channel Cl runs between orifice 81 A and intensifier element 73A. Internal fluid channel C2 runs between orifice 81B and intensifier clement 73B. The gate 44 is shown with the seals 80A, 80B in a neutral or dc-cncrgizcd state. In this state, the seals 80A, 80B reside in the trenches 58, 58’ without any pressure from the intensifier elements 73A, 73B, 73C, 73D imposed upon them. As shown in FIG. 8, each trench 58, 58’ provides spacing 86A, 86B for the seals 80A, 80B to move slightly up or down within the trench. In the de-energized state, each intensifier element 73A, 73B plunger 76 extends out from the side of the gate 44 as shown in FIG. 8.

[0052] Turning to FIG. 9, a conduit 10 with a gate 44 embodiment similar to the embodiment of FIG. 8 is shown. In this overhead cross section view, the gate 44 is shown transitioned to an energized state, wherein seals 80A and 80B (see FIG. 8) are energized by the internal fluid circuits when the gate is positioned with the opening 50 coincident with the main body 12 through bore 22. In this embodiment, the cover 32 at the first end 14 includes a fluid port 88 leading to an internal fluid passage 89 that leads to a fluid feed into the transverse passage 28. The cover 32 at the second end 16 is also configured with a fluid port 90 leading to an internal fluid passage 91 that leads to a fluid feed into the transverse passage 28 at the other end of the gate 44. As shown in FIG. 9, the conduit 10 is in the open position. In this open position, any fluid traversing the through bore 22 from either the first surface 18 or the second surface 20 is free to flow through the gate opening 50 and in-out through the conduit 10. The gate 44 is set in the open position by maintaining a constant fluid pressure in the transverse passage 28 at the first end 14 via fluid passage 89, as depicted by the arrow in FIG. 9.

[0053] When the gate 44 is pushed via fluid pressure to the far end of the passage 28 (to the right in FIG. 9), the gate end abuts the inner surface of the cover 32 as shown in FIG. 9. The plunger 76 rods on the intensifier elements 73A, 73B are then pushed inward, overcoming the spring 77 force, and causing the plunger body portions 78 to move inward within the ports (see FIG. 6). The body portions 78 function as pistons, pressurizing the semi-solid compound within the channels Cl, C2. At the other end of the channels Cl, C2 the pressurized semi-solid compound exits the orifices 81 A, 8 IB in the seal trenches 58, 58’, energizing the seals 80A, 80B to engagewith the inner surfaces of the transverse passage 28. In this manner, the energized seals 80A, 80B provide an effective barrier to restrict fluids traversing the through bore 22 from seeping into the transverse passage 28.

[0054] Although the gate 44 embodiments of FIGS. 8 and 9 are shown without the floating pistons 70A, 70B for clarity of illustration, it will be appreciated that any gate embodiment of this disclosure may be implemented with or without such elements. Operation of the gate 44 of FIG. 9 is now considered with the embodiments of FIGS. 7 and 8. As described above, the floating pistons 70A, 70B cap internal gate 44 channels C5, C6 that are filled with an inert gas under pressure. As shown in FIG. 7, channels C5 and C6 respectively internally link into channels Cl, C2 and C3, C4. In this manner, the inert gas maintains a constant compressive pressure head on the semi-solid compound within the respective channels Cl, C2, C3, C4, which in turn maintains a constant pressure on the seals 80A, 80B. By maintaining a constant pressure on the seals 80A, 80B they remain in a semi-energized state and as the seals are extruded, they are fed over time to maintain a sealing pressure.

[0055] FIG. 10 shows another gate 44 embodiment of this disclosure. The gate 44 is implemented with the floating pistons 70C, 70D and intensifier elements 73E, 73F as disclosed with respect to the embodiment of FIG. 6. As previously described, the gate 44 may be configured with mirroring seal trenches 60, 60’ respectively formed on each face 46, 48. A first seal 82A is disposed around the solid surface area 54 in seal trench 60 (see FIG. 6) and a second seal 80A is disposed around the opening 50 in seal trench 58. Although not depicted in FIG. 10 for clarity of illustration, a third seal 82B is disposed in mirroring seal trench 60’ formed on the second face 48 of the gate 44 surrounding the solid surface area 54. Similarly, a fourth seal 82B is disposed in mirroring seal trench 58’ formed on the second face 48 of the gate 44 around the opening 50.

[0056] FIG. 10 also shows the internal gate 44 passages for the fluid circuits between the seals 82A, 82B, 80A, 80B, intensifier elements 73E, 73F, and the floating pistons 70C, 70D. Internal fluid channel C7 traverses through the gate 44 body between seal trench 60 and intensifier element 73E. Internal fluid channel C8 traverses through the gate 44 body between seal trench 60’ and intensifier element 73F. Internal fluid channel C9 traverses through the gate 44 body to link internal passage C7 with floating piston 70C and internal passage CIO with internal passage C8 with floating piston 70D. All of the channels form internal closed fluid circuits in the gate 44. Sealchannels C7 and C8 are filled with a semi- solid compound similar to the gate 44 embodiment of FIG. 7. Intensifier element 70C, 70D channels C9 and CIO are likewise filled with inert gas under pressure.

[0057] FIG. 11 shows a cross section side view of a gate 44 embodiment similar to the embodiment of FIG. 10. For clarity of illustration, only the gate 44 section with the solid surface area 54 is shown in FIG. 11. Seal 82A resides in seal trench 60 on the first face 46 of the gate and seal 82B resides in seal trench 60’ on the second face 48. Each seal trench 60, 60’ is respectively configured with an orifice 83A, 83B at the bottom of the trench. Internal fluid channel C7 runs between orifice 83A and intensifier element 73E. Internal fluid channel C8 runs between orifice 83B and intensifier element 73F. The gate 44 is shown with the seals 82A, 82B in a neutral or deenergized state. In this state, the seals 82A, 82B reside in the trenches 60, 60’ without any pressure from the intensifier elements 73E, 73F imposed upon them. As shown in FIG. 11, each trench 60, 60’ provides spacing 94A, 94B for the seals 82A, 82B to move slightly up or down within the trench. In the de-energized state, each intensifier element 73E, 73F plunger 76 extends out from the side of the gate 44 as shown in FIG. 11.

[0058] Turning to FIG. 12, a conduit 10 with a gate 44 embodiment similar to the embodiment of FIG. 11 is shown. In this overhead cross section view, the gate 44 is shown transitioned to an energized state, wherein seals 82A and 82B (see FIG. 11) are energized by the internal fluid circuits when the gate is positioned with the solid surface area 54 coincident with the main body 12 through bore 22. In this embodiment, the cover 32 at the second end 16 includes a fluid port 96 leading to an internal fluid passage 97 that leads to a fluid feed into the transverse passage 28. The cover 32 at the first end 14 is also configured with a fluid port 98 leading to an internal fluid passage 99 that leads to a fluid feed into the transverse passage 28 at the other end of the gate 44. As shown in FIG. 12, the conduit 10 is in the closed position with the gate 44 solid surface area 54 not permitting fluid flow through the through bore 22. The gate 44 is set in the closed position by maintaining a constant fluid pressure in the transverse passage 28 at the second end 16 via fluid passage 97, as depicted by the arrow in FIG. 12.

[0059] When the gate 44 is pushed via fluid pressure to the far end of the passage 28 (to the left in FIG. 12), the gate end abuts the inner surface of the cover 32 as shown in FIG. 12. The plunger 76 rods on the intensifier elements 73E, 73F are then pushed inward, overcoming thespring 77 force, and causing the plunger body portions 78 to move inward within the ports (see FIG. 6). The body portions 78 function as pistons, pressurizing the semi-solid compound within the channels C7, C8. At the other end of the channels C7, C8 the pressurized semi-solid compound exits the orifices 83A, 83B in the seal trenches 60, 60’, energizing the seals 82A, 82B to engage with the inner surfaces of the transverse passage 28. In this manner, the energized seals 82A, 82B provide an effective barrier to restrict fluids in the through bore 22 from seeping into the transverse passage 28.

[0060] Although the gate 44 embodiments of FIGS. 11 and 12 are shown without the floating pistons 70C, 70D for clarity of illustration, it will be appreciated that any gate embodiment of this disclosure may be implemented with or without such elements. Operation of the gate 44 of FIG.12 is now considered with the embodiments of FIGS. 10 and 11. As described above, the floating pistons 70C, 70D cap internal gate 44 channels C9. CIO that are filled with an inert gas under pressure. As shown in FIG. 10, channels C9 and CIO respectively internally link into channels C7 and C8. In this manner, the inert gas maintains a constant compressive pressure head on the semisolid compound within the respective channels C7, C8, which in turn maintains a constant pressure on the seals 82A, 82B. By maintaining a constant pressure on the seals 82A, 82B they remain in a semi-energized state and as the seals are extruded, they are fed over time to maintain a sealing pressure.

[0061] As disclosed herein, embodiments of the conduit 10 are configured to channel fluid to actuate the gate 44 from the open position to the closed position and vice-versa. It will be appreciated by those skilled in the art that gate 44 embodiments of this disclosure may be implemented with conventional seals, with energizable seals, or with a combination of conventional and energizable seals. It will also be appreciated that gate 44 embodiments may be implemented with zero, one, or multiple floating pistons as well as with zero, one, or multiple intensifier elements as disclosed herein.

[0062] An advantage of embodiments implemented with energizable seals as disclosed is the automatic and autonomous energization and de-energization of the seals upon transition of the conduit 10 from an open position to a closed position and vice-versa. The fluid ports 88, 90, 96, 98 providing the fluid pressure to move the gate 44 back and forth and the self-contained internal gate 44 fluid circuits in essence comprise a hydraulics-over-hydraulics closed system, which aidsin keeping the fluids free of contaminants. By maintaining a good seal while the conduit 10 is set in the open or closed position and while the gate 44 is moving, maximum protection is provided against contaminant migration as the gate transitions. For example, when flowing fluids with highly abrasive concentrations, energization of the gate 44 seals keeps the abrasive material in the through bore 22 from migrating into the conduit 10 body 12. By preventing such ingress of debris into the conduit 10 body the effective operational life of the conduit is extended. Usable seals that may be configured for / energization in accordance with the disclosed embodiments include those described in Inti. Pat. Apps. W 0 / 2021 / 142004 and WO / 2021 / I41999, both incorporated herein by reference.

[0063] In addition to providing effective sealing measures, the conduits 10 of this disclosure also provide the ability to shear objects in the through bore 22. Depending on the application, conduit 10 embodiments of this disclosure may be operated in environments where solid objects are disposed within or pass through the through bore 22 during operation of the conduit. In such circumstances, it may be necessary to clear the through bore by cutting through or shearing the solid objects in order to close the conduit via gate 44 actuation as disclosed herein. For example, in oil and gas applications the conduits 10 may be used to control wellbore pressure in lieu of or in combination with conventional BOPs equipped with shearing rams.

[0064] Returning to FIG. 7, a gate 44 embodiment is shown configured with a cutting surface 100 on the circumference of the opening 50. The cutting surface 100 may be formed in a halfmoon or crescent shape, with a projection 102 extending from the central portion of the surface to form a tip. The gate 44 embodiments of this disclosure may be configured with cutting surfaces 100 in several ways. The embodiments may be formed using conventional manufacturing techniques as known in the art (e.g., forging, machining processes, deposition layering, waterjet cutting, hot isostatic pressing processes, etc.). The gates 44 may also be formed from any suitable materials as known in the art. Some embodiments may be formed from suitable metals or metallic alloys (e.g., metal carbide such as tungsten carbide). Some embodiments may also be implemented with the cutting surface 100 having specialized coatings or compositions (e.g., infused with or coated with polycrystalline diamond, cubic boron nitride or other known “super hard” materials) as described herein.

[0065] Some embodiments may be implemented with the gate 44 having the cutting surface 100 formed thereon as a unitary structure. Some embodiments may be implemented with the cutting surface 100 formed as a separate element affixed to the gate 44 body 45. FIG. 13A shows a plan view of a gate 44 fitted with a blade 104. FIG. 13B shows a side view of the blade 104. FIG. 13C shows a cross section side view of the gate 44 of FIG. 13A with the blade 104 mounted within a receiving slot 106 formed in the gate 44 body. The blade 104 is inserted in the slot 106 through the opening 50 in the gate 44 body. A suitable adhesive may be applied to the slot 106 to aid in retention of the blade 104. With such embodiments, the blade 104 may be formed of a different material than the gate 44. For example, an embodiment may be implemented with a gate 44 body formed from a metal carbide and the blade 104 formed of high strength INCONEL™ 718. It will be appreciated that unitary gate 44 embodiments (with built-in cutting surfaces 100) and separate gate 44 / blade 104 embodiments may be implemented using any suitable materials known in the metallurgy arts.

[0066] Embodiments may be implemented with the cutting surface 100 having one or more projections 102 extending from the surface in various configurations. In some embodiments, the cutting surface 100 may be configured as a sloped ramp with a leading edge 110 extending downward from the first face 46 toward the second face 48 of the gate 44, as shown in cross section in FIG. 14. For clarity of illustration, only the gate 44 sections with the cutting surfaces 100 are shown in the following figures, without depiction of the seals, the solid surface area, or internal fluid circuits. FIG. 14 also shows a hard material 112, which may be made from a wear-resistant material, such as metal carbide (e.g., tungsten carbide), or “super hard” material, such as cubic boron nitride or polycrystalline diamond. The hard material 112 may be in the form of a coating on a substrate, that is a coating on the cutting surface 100 itself, or the hard material 112 may be a separate structure affixed to the substrate, i.e., the cutting surface 100. The hard material 112 may also be formed as one or more layers deposited onto the cutting surface 100 via conventional techniques as known in the art. The structure of the hard material 112 shown in FIG. 14 is only one example of a hard material forming part of the cutting surface 100 that first comes into contact with a device disposed in the through bore 22 when the gate 44 is actuated.

[0067] In some embodiments, the cutting surface 100 may be configured as a sloped ramp with a leading edge 110 extending downward from the first face 46 toward the second face 48 ofthe gate 44, as shown in cross section in FIG. 15. In some embodiments, the cutting surface 100 is configured with inclined faces 114 extending inward toward the center of the opening 50 in an arrowhead configuration, as shown in cross-section in FIG. 16. Some embodiments may be implemented with the inclined faces 1 14 having tapers respectively angled at approximately 10- 20 degrees from the first face 46 and the second face 48.

[0068] FIG. 17 shows a perspective view of another example gate 44 embodiment configured with a cutting surface 100. FIG. 18 shows a plan view of another example gate 44 embodiment configured with a cutting surface 100. In this embodiment, the cutting surface 100 may be configured with multiple tips, forming a serrated leading edge. FIG. 19 shows a plan view of another gate 44 embodiment with a cutting surface 100. In this embodiment, the opening 50 may be formed with angled side chamfers 116 extending from the cutting surface 100 side ends towards the center of the opening 50. The side chamfers 116 aid in centering and guiding an object in the through bore 22 to abut with the cutting surface 100 when the surface 100 is engaged as described herein.

[0069] As described herein, prior to actuation of the gate 44, the opening 50 with the cutting surface 100 is positioned in coaxial alignment with the through bore 22. Therefore, in operation the cutting surface 100 cutting edge may be exposed to fluids and materials (c.g., corrosive fluids, particulates, etc.) traversing the through bore 22 and past the cutting surface 100. Such material movement may cause fouling and damage to the cutting surface 100. As shown in FIG. 20, embodiments may be implemented with the cutting surface 100 configured with a protective layer 118 disposed over the cutting surface 100. The protective layer 118 may be disposed to form a planar face along the inner diameter of the opening 50. The protective layer 118 may be applied via well-known techniques, using conventional materials and compounds (e.g., resilient materials) to form the protective layer as known in the art (e.g., epoxies, elastomers, such as rubber and polyurethane, ceramics, thermoplastics). The protective layer 118 covers and seals the cutting surface 100, yet it is sufficiently brittle that it will shatter and not hinder the cutting surface upon contact with materials in the through bore 22 upon gate activation.

[0070] FIG. 21 shows a perspective view of another example gate 44 embodiment configured with a cutting surface 100. In some embodiments, one or more layers A, B of coatings may be applied to the cutting surface 100 to provide increased wear resistance, corrosion resistance, anti-galling, etc. Conventional materials may be used to form the coating(s) A, B as known in the art. For example, some embodiments may be implemented with a cutting surface 100 overlain with a first coating A, formed using a ceramic coating sold under product designation Tech 12, and a second coating B over the first coating A, formed using a ceramic coating sold under product designation Tech 22, both of which products arc made by Bodycotc PLC, Springwood Court, Springwood Close, Tytherington Business Park, Macclesfield, Cheshire, United Kingdom SK10 2XF. Some embodiments may be implemented with Tech 12 or Tech 22 ceramic coating applied to the cutting surface 100 and heat treated, such as in an oven. Repetition of this process may be implemented to produce coatings A, B that arc substantially free from porosity. Implementation of some cutting surface 100 embodiments may comprise coatings over the entire surface of the gate 44, which may provide a fully inert exterior surface that can protect against hydrogen embrittlement and sulfide stress cracking. In some embodiments, a very hard substrate may be used to form the gate 44 body. In some embodiments, the protective layer 118 may be applied over the one or more coatings A, B.

[0071] Turning to FIG. 22, a close-up view of another conduit 10 embodiment is shown. This embodiment includes a locking element 122 mounted on the gate 44. As previously described, during operation of the conduit 10 the gate 44 is positioned with the opening 50 located coincident with the through bore 22 to allow fluid passage therethrough. Also as previously described, in this position the gate 44 seals are energized to urge the respective seal faces against inner surface of the transverse passage 28. As such, the gate 44 is maintained in place until fluid pressure is applied to the gate 44 to transition to the closed position as described herein. The locking element 122 provides an added safety measure to maintain the gate 44 locked in either the open or closed position until actuation is desired.

[0072] FIG. 23 shows an exploded view of a locking element 122 in association with a conduit 10. The locking element 122 includes a cylindrical body 124 with an internal passage that houses a sliding piston with an elongated shaft 126 extending from one end of the body. A cap 128 covers the distal end of the cylindrical body 124. The cap 128 is secured to the body 124 via a plurality of external bolts 130 coupling the two components together. The cylindrical body 124 also includes a spring 132 disposed between the cap 128 and the internal piston. In a static mode, the spring 132 applies force against the internal piston to maintain the elongated shaft 126 in the extendedposition. A first fluid port 134 on the cap 128 provides an inlet for fluid (e.g., hydraulic fluid) to push the internal piston toward the conduit 10 wall, thereby fully extending the elongated shaft 126 from the cylindrical body 124. A second fluid port 136 on the cylindrical body 124 provides an inlet for fluid to push the piston from the other side, back into cylindrical body and thereby retracting the elongated shaft 126 from the conduit 10 wall. In this embodiment, the locking element 122 is mounted to one side of the conduit 10 body and affixed in place via a plurality of bolts 138 threaded into receptacles 140 formed on the side of the conduit.

[0073] The port 46 formed on the side of the conduit 10 (see FIG. 4) is configured to permit the elongated shaft 126 to pass into the through bore 28 when it is extended from the locking element 122. Returning to FIG. 5, gate 44 embodiments implemented with orifices 68 A, 68B formed on the side of the gate 44 are configured to receive the tip of the elongated shaft 126. As shown in FIG. 5, orifice 68A is located proximate the gate 44 opening 50 and 68B proximate the solid surface area 54. The orifices 68A, 68B are positioned on the gate 44 side such that when the gate 44 is in the open or closed position the positioned orifice aligns with the conduit 10 port 46 to receive the elongated shaft 126 extended through the port.

[0074] FIG. 24 shows a plan view cross section of a conduit 10 with the gate 44 in the open position. The locking clement 122 is shown actuated such that the elongated shaft 126 is extended through the port 46 to engage gate 44 orifice 68A. In this state, the locking element 122 retains the gate 44 in the open position. To close the gate 44, the locking element 122 is actuated to retract the elongated shaft 126, thereby freeing the gate 44 for movement within the passage 28. With this embodiment, the gate 44 remains securely in the open or closed position until the locking element 122 is actuated to retract the elongated shaft 126 to release the gate 44 as selected. It will be appreciated that conduit 10 embodiments may be implemented with the locking element 122 configured for actuation via means other than fluid pressure (e.g., electric servo, electromagnet solenoid, pneumatic, ROV actuation, etc.).

[0075] Fluids to actuate components of the disclosed conduits 10 may be provided by a separate or independent fluid supply linked to the conduits via suitable means as known in the art, such as tubing and hoses. Embodiments may also be implemented with a local fluid supply (e.g., coupled fluid reservoir and pump unit). Conduit 10 embodiments may also be implemented with conventional controls configured for selective actuation of the gate. The controls may be locallymounted or remotely linked with the conduits 10 as known in the art. It will be appreciated that the controls may comprise conventional electronics and processors programmed to actuate and operate the conduits 10 as described herein. In some embodiments, the controls can be programmed to perform automatic and autonomous operation of the conduits 10 to actuate the gates 44 as described herein.

[0076] Advantages of the disclosed conduit 10 embodiments include the implementation of a conduit that can be repaired / refurbished in the field, without needing to remove the unit from the operational system. Another advantage is the implementation of a conduit 10 with all the working components (e.g., cutting surface, seals) disposed in the gate 44, making it very easy and efficient to replace key components via a swappable gate cartridge. The disclosed conduits 10 do not require any packing or grease filling as used with conventional gate valve designs.

[0077] FIG. 25 shows a conventional BOP system 200 used in the oil and gas industry to control wellbore pressure. Such conventional BOP systems 200 require multiple pressurized accumulator tanks 201 to provide the energy to actuate the BOP rams. The accumulator tanks 201 are massive and take up a lot of volume, commonly adding approximately 200,000 Lb. (90718 Kg) to the overall weight of the structure. FIG. 25 also shows another conduit 10 embodiment of this disclosure. This conduit 10 has a main body 205 formed with an upper section 10A comprising a conduit with a gate 44 that operates as described herein relating to any of the disclosed embodiments. The main body 205 also has a lower section 10B comprising a pyrotechnically actuated BOP 207 as described in U.S. Pat. No. 11,028,664, incorporated herein by reference. The main body 205 is formed as a unitary structure with a single through bore 22 traversing the upper and lower sections 10A, 10B. As described in U.S. Pat. No. 11,028,664, the BOP 207 section 10B of this conduit 10 has its own internal passage transverse to the through bore 22 that permits a cutting element and / or a sealing element to pass into the through bore. This conduit 10 embodiment provides compact dual means for fluid pressure control, with redundant through bore 22 shearing capability. As depicted in FIG. 25, for oil and gas applications, this conduit 10 embodiment is substantially more compact compared to a conventional BOP system.

[0078] It will be appreciated that embodiments of the disclosed conduits 10 may be implemented for use in numerous applications and operations, in the oil and gas industry and in other fields of endeavor. For example, the disclosed conduit 10 embodiments may be deployed foruse at surface, above surface, subsurface, and under water. It will also be appreciated by those skilled in the art that embodiments of this disclosure may be implemented with conventional hardware components and parts formed of suitable materials depending on the application. Although only a few examples have been described in detail above, those skilled in the art will readily appreciate that many modifications arc possible in the examples. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.

Claims

ClaimsWhat is claimed is:

1. A conduit apparatus, comprising: a main body having a through bore providing a conduit; a passage transverse to the through bore; a gate disposed in the passage and configured for positioning with an opening on the gate coincident with the through bore; the gate opening configured with a cutting surface; and wherein the gate is configured for actuation via fluid pressure to move the cutting surface across the through bore.

2. The apparatus of claim 1 wherein the main body further comprises a second passage transverse to the through bore, the second passage configured to permit a cutting element and / or a sealing element to pass into the through bore.

3. The apparatus of claim 1 wherein the gate is configured for positioning the opening coincident with the through bore when the gate is in an open position and for positioning the opening offset from the through bore when the gate is in a closed position.

4. The apparatus of claim 3 wherein the main body is configured to channel fluid to actuate the gate from the open position to the closed position and vice-versa.

5. The apparatus of claim 3 wherein the gate is configured to restrict fluid passage along the through bore when the gate is in the closed position.

6. The apparatus of claim 1 further comprising at least one cover disposed on the main body to permit access to the transverse passage.

7. The apparatus of claim 1 wherein the gate comprises at least one seal to restrict fluid flow between the body through bore and the transverse passage.The apparatus of claim 7 wherein the at least one seal is configured for activation between an energized mode and a de-energized mode. The apparatus of claim 8 wherein the at least one seal is configured for energization and / or de-energization upon movement of the gate along the transverse passage. The apparatus of claim 9 wherein the gate is configured with a closed internal fluid circuit to energize and / or de-energize the at least one seal. The apparatus of claim 10 wherein the gate comprises at least one intensifier element to affect pressure of fluid in the internal fluid circuit. The apparatus of claim 1 further comprising a locking element to selectively retain the gate in an open position or a closed position within the transverse passage. The apparatus of claim 1 wherein: the gate comprises a plurality of seals configured for actuation between an energized mode and a de-energized mode; and the seals are configured for energization and / or de-energization upon movement of the gate along the transverse passage. A method of operating an apparatus having a main body with a through bore providing a conduit and a passage transverse to the through bore, comprising: positioning a gate in the transverse passage, wherein the gate is configured for positioning with an opening thereon coincident with the through bore, wherein the gate has at least one seal configured for actuation between an energized mode and a de-energized mode; and actuating the gate in a first direction along the transverse passage to move a cutting surface on the gate opening across the through bore,wherein the at least one seal is configured for energization and / or de-energization upon movement of the gate along the transverse passage. The method of claim 14 wherein actuating the gate along the transverse passage comprises applying fluid pressure to the gate in the first direction to move the cutting surface across the through bore and in a second direction to return the gate opening to the position coincident with the through bore.

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