Gate valves, assemblies, seats and seals, kits, and associated methods to enhance operating life of gate valves

Abstract

The present disclosure provides embodiments of gate valves, gate valve assemblies, gate valve seats and seals, kits, and associated methods to enhance gate valve operational performance. In an embodiment, a gate valve has an actuator, a gate connected to the actuator, a valve body, a valve seat, a seat pressure seal, and a debris protection seal. The valve seat is positioned in a valve seat recess of the valve body and is configured to contact the gate during operation and substantially align with an inner diameter of a throughbore of the valve body. The seat pressure seal is positioned on a first portion of the valve seat to sealingly contact the valve seat recess when the gate compresses against the valve seat. The debris protection seal is disposed within the valve seat to prevent debris from compromising the seat pressure seal.

Description

GATE VALVES, ASSEMBLIES, SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVESInventors: Jacob Cox; Sean Gajic; Nicholas Peter GetteCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 575,485, filed April 5, 2024, titled “GATE VALVES, GATE VALVE ASSEMBLIES, GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” and U.S. Provisional Application No. 63 / 715,394, filed November 1, 2024, titled “GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” the disclosures of which are incorporated herein by reference in their entireties. This application is also a continuation-in-part of and claims the benefit of U.S. Non -Provisional 19 / 087,153, filed March 21, 2025, titled “GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” which claims priority to and the benefit of U.S. Provisional Application No. 63 / 575,485, filed April 5, 2024, titled “GATE VALVES, GATE VALVE ASSEMBLIES, GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” and U.S. Provisional Application No. 63 / 715,394, filed November 1, 2024, titled “GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” the disclosures of which are incorporated herein by reference in their entireties.TECHNICAL FIELD

[0002] The present disclosure generally relates gate valves and methods for increased gate valve operational performance and service life. More specifically, the present disclosure relates to embodiments of gate valves and associated methods to reduce risk of particle invasion into interior portions of gate valves, gate valve assemblies, and gate valve seats that damage seals.BACKGROUND

[0003] Gate valves contain several components that are potential sources of valve leaks in dirty service operations, such as, for example, slurries in fracturing operations. In particular, gate valve seats have been known to cause leaks as the associated seals may experience an invasion ofgranular particles to damage or significantly reduce a sealing power of the gate valve seats within the gate valve pockets. Conventional gate valves also may implement grease to prevent seizing of the valve while capturing any particles near the seat seal area. The grease, however, has been known to fail as it may dry or retain many particles causing damages to the valve. Efforts have been implemented to reduce the amount of grease necessary for proper valve operation while maintaining proper sealing. However, Applicant has recognized that the implementation of conventional seals has not achieved the desired longevity of the valve, and thus, frequent grease and seal replacement often is required for continued operation.SUMMARY

[0004] There remains a need for increased gate valve operational performance and service life. Applicant has recognized that invasion of granular particles between a valve seat and a throughbore of the gate valve that may cause damage or significantly reduce a sealing power of the gate valve seats within gate valve pockets, thereby causing valve failures, e.g., valve leaks or valve seizure, and necessitating damage repair. Embodiments of the present disclosure reduce, or eliminate, usage of grease that is known to accumulate granular particles causing damage, e.g., scoring of surfaces that would otherwise be smooth for sealing purposes.

[0005] Embodiments of the disclosure, for example, include gate valves and methods to increase gate valve performance and service life. In an embodiment, a gate valve includes a valve body with a throughbore extending through the valve body, a cavity with a bore positioned transversely to and in fluid communication with the throughbore, and a profile at a connection of the throughbore and the cavity. The profile includes a first bore connected to the cavity and concentrically aligned with the throughbore, a second bore concentrically aligned with the first bore, and a tapering portion positioned to extend from the first bore to the second bore. The gate valve further includes a valve seat positioned in the second bore and has a seat pressure seal in abutting contact with the valve body. Further, the gate valve includes a debris protection seal positioned to abutting contact a distal end of the second bore.

[0006] In another embodiment of a gate valve, the gate valve includes a valve actuator, a gate connected to the valve actuator so that the valve actuator actuates the gate during operation, a valve body, a valve seat, a seat pressure seal, and a debris protection seal. The valve body includes a first end and a second end opposite the first end, and the valve body further includes a throughbore extending through the valve body and has a first diameter extending from the first end to the secondend. The valve body also has a cavity disposed in the valve body and also has a bore positioned transversely to and in fluid communication with the throughbore. The bore is configured to receive the gate, thereby to position the gate to reduce or increase a fluid flow through the throughbore when in operation. In an embodiment, the valve body additionally has one or more valve seat recesses having a second diameter greater than the first diameter of the throughbore and disposed between and in fluid communication with the cavity and the throughbore. The valve seat is positioned in the one or more valve seat recesses. The valve seat, in an embodiment, has an annular body with a proximate surface, a distal surface, an inner surface, and an outer surface. Further, the proximate surface is configured to contact the gate when in operation. The distal surface is disposed opposite the proximate surface and configured to contact the valve body, thereby to reduce the fluid flow that bypasses the gate when the gate valve is in a closed position. The inner surface is substantially aligned with an inner diameter of the throughbore of the valve body. The outer surface further has a first portion with a first outer diameter less than a second outer diameter of a second portion. The first portion abuttingly contacts the distal surface, and the second portion connects to the first portion. The seat pressure seal is positioned on the first portion of the valve seat and further includes a first male spreader ring, a second male spreader ring, and a first female seal member having a first opening configured to receive and contact the first male spreader ring, thereby to sealingly contact the first female seal member against a recess surface of the one or more valve seat recesses when the gate compresses against the valve seat. A second female seal member has a second opening configured to receive and contact the second male spreader ring, thereby to sealingly contact the second female seal member against the recess surface of the one or more valve seat recesses when the gate compresses against the valve seat. The first opening and the second opening are positioned to be opposite facing such that the first male spreader ring abuts the valve body, the second male spreader ring abuts a substantially vertical wall of the valve seat, and the first female seal member abuttingly contacts the second, female seal member. The debris protection seal is disposed in a recess within the valve seat, thereby to prevent debris from bypassing the debris protection seal.

[0007] In another embodiment, a seat pressure seal for a gate valve has a first male spreader ring, a second male spreader ring, and a first female seal member having a first opening configured to receive and contact the first male spreader ring, thereby sealingly to contact the first female seal member against a recess surface of one or more valve seat recesses when the gate compressesagainst the valve seat. The seat pressure seal also has a second female seal member having a second opening configured to receive and contact the second male spreader ring, thereby sealingly to contact the second female seal member against the recess surface of the one or more valve seat recesses when the gate compresses against the valve seat. Further, the first opening and the second opening are positioned opposite facing such that the second male spreader ring is configured to abut a valve body. The first male spreader ring also is configured to abut a substantially vertical wall of the valve seat, and the first female seal member abuttingly contacts the second female seal member. Embodiments of a gat valve kit, for example, may be used for retrofitting portions of preassembled gate valves or when constructing or manufacturing a new gate valve.

[0008] Also, in another embodiment, a gate valve seat kit for use within a valve includes a container and a valve seat, a seat pressure seal, and a debris protection seal each positioned within the container. The valve seat has an annular body with a proximate surface, a distal surface, an inner surface, and an outer surface. Further, the proximate surface of the valve seat is configured to contact a gate when positioned in a gate valve and during operation. The distal surface is disposed opposite the proximate surface and is configured to contact a valve body to reduce fluid flow that bypasses the gate when a gate valve is in a closed position when in operation, and the inner surface is configured to be substantially aligned with an inner diameter of a throughbore of the valve body when in operation. The outer surface of the valve seat further has a first portion with a first outer diameter less than a second outer diameter of a second portion, and the first portion abuttingly is connected to the distal surface. The second portion is coupled the first portion by a substantially radial wall. The seat pressure seal has a first male spreader ring, a second male spreader ring, a first female seal member having a first opening configured to receive and contact the first male spreader ring, thereby sealingly to contact the first female seal member against a recess surface of the one or more valve seat recesses when the gate compresses against the valve seat, and a second female seal member having a second opening configured to receive and contact the second male spreader ring, thereby sealingly to contact the second female seal member against the recess surface of the one or more valve seat recesses when the gate compresses against the valve seat. Further, the first opening and the second opening are positioned opposite facing such that the second male spreader ring is configured to abut the valve body, the first male spreader ring abuts a substantially vertical wall of the valve seat, and the first female seal member abuttingly contacts the second female seal member. The debris protection seal is configured to be positionedin a recess within the valve seat, thereby to reduce debris from bypassing the debris protection seal that may otherwise compromise sealing ability or power of a seat pressure seal.

[0009] In yet another embodiment, a debris protection seal includes an annular body having a proximate surface extending axially to a distal surface disposed opposite the proximate surface, an outer surface, and an inner surface parallel to the outer surface. The outer surface has outer radial slot cuts evenly spaced apart beginning from the proximate surface. The inner surface also has inner radial slot cuts evenly spaced apart beginning from the proximate surface. The outer radial slot cuts and the inner radial slot cuts are spaced apart substantially evenly between each other such that the cuts alternate, straddle, and are substantially parallel to each other beginning from the proximate surface.

[0010] In still another embodiment, a method to machine a gate valve body of a gate valve includes machining a seat recess into a throughbore of a valve body, thereby to define a profile. Further, the profile includes a first radial recess wall having a second diameter greater than a first diameter of the throughbore, a second radial recess wall having a radially outward extending slope beginning from the first radial recess wall at an angle of about 15 degrees to about 75 degrees, and a third radial recess wall having a third diameter greater than the second diameter of the first radial recess wall. The second recess radial is positioned to connect the first radial recess wall to the third radial recess wall. The first radial recess wall has a length longer than a total length of the second radial recess wall and the third radial recess wall combined, and a lip fluidly connects the cavity to the third radial recess wall of the valve body. The seat recess, for example, may define a valve seat for the gate valve.

[0011] In yet a further embodiment, a method to retrofit a gate valve to enhance gate valve performance includes disassembling a preassembled gate valve by removing internal component portions to expose a throughbore within the valve body such that the throughbore is accessible for machining, machining a portion of the throughbore of a valve body, thereby to define a machined profile positioned adjacent to a cavity of the valve body configured to house the internal component portions of the gate valve so as to define a machined portion of the gate valve, positioning a valve seat having a seat pressure seal and a debris protection seal within the machined portion, and reassembling the gate valve with the internal component portions, thereby to define a retrofitted gate valve.

[0012] Aspects and advantages of these exemplary embodiments and other examples, are discussed in detail herein. Moreover, it is to be understood that both the foregoing information and the following detailed description provide merely illustrative examples of various aspects and embodiment and are intended to provide an overview or framework for understanding the nature and character of the claimed aspects and embodiments. Accordingly, these and other objects, along with advantages and features of the present disclosure, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood by those skilled in the art that the features of the various embodiments described herein are not mutually exclusive and may exist in various combinations and permutations.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the many ways in which they may be practiced. According to common practice, as will be understood by those skilled in the art, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to illustrate embodiments of the disclosure more clearly.

[0014] FIG. 1 is a perspective view of an embodiment of a gate valve having portions broken away for clarity, according to an embodiment of the disclosure.

[0015] FIG. 2A is an exploded sectional view of a gate valve body having a seat assembly, according to an embodiment of the disclosure.

[0016] FIG. 2B is an enlarged view of a valve body seat profile taken along the lines FIG. 2B of the gate valve body of FIG. 2A, according to an embodiment of the disclosure.

[0017] FIG. 3A is a sectional view of an integrated gate valve body and seat, according to an embodiment of the disclosure.

[0018] FIG. 3B is an enlarged view of the valve body seat profile taken along the lines of FIG. 3B of the gate valve body of FIG. 3A, according to an embodiment of the disclosure.

[0019] FIG. 4A is a sectional view of a gate valve seat having seals thereon taken along the lines of FIG. 4A of the sectional view of FIG. 3 A to clarify seal positioning, according to an embodiment of the disclosure.

[0020] FIG. 4B is a sectional view of a gate valve seat without the seals of FIG. 4A, according to an embodiment of the disclosure.

[0021] FIG. 5A is a sectional view of a gate valve seat having seals thereon taken along the lines of FIG. 5 A of the perspective view of FIG. 1, according to an embodiment of the disclosure.

[0022] FIG. 5B is a sectional view of a gate valve seat without the seals of FIG. 5 A, according to an embodiment of the disclosure.

[0023] FIG. 6A is an enlarged sectional view of an embodiment of a debris protection seal taken along the lines of FIG. 6A of the sectional view of a gate valve seat having seals of FIG. 4A, according to an embodiment of the disclosure.

[0024] FIG. 6B is an enlarged perspective sectional view of an embodiment of a debris protection seal taken along the lines of FIG. 6B of the exploded sectional view of FIG. 2A, according to an embodiment of the disclosure.

[0025] FIG. 6C is a perspective sectional view of another embodiment of a debris protection seal taken along the lines of FIG. 5A of the sectional view of a gate valve seat of FIG. 5A, according to another embodiment of the disclosure.

[0026] FIG. 7A is a sectional view of an additional embodiment of a debris protection seal having a grooved pattern, according to another embodiment of the disclosure.

[0027] FIG. 7B is a perspective view of an embodiment of a debris protection seal having a grooved pattern of FIG. 7A with a spiral shape, according to one embodiment.

[0028] FIG. 8 is a sectional perspective view of an embodiment of a seat pressure seal taken along the lines of FIG. 8 of the exploded sectional view of FIG. 2A, according to an embodiment of the disclosure.

[0029] FIG. 9 is a flow chart of a method for machining a gate valve, according to an embodiment of the disclosure.

[0030] FIG. 10 is a flow chart of a method to retrofit a gate valve for increased valve performance, according to one embodiment of the disclosure.

[0031] FIG. 11 is a perspective view of a valve seat kit, according to one embodiment of the disclosure.

[0032] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated into other embodiments without further recitation.DETAILED DESCRIPTION

[0033] The present disclosure describes various embodiments related to a gate valve and methods for increased gate valve performance and service life by significantly reducing particles from damaging gate valve seals, such a seat pressure seal. Gate valves contain several components that are potential sources of valve leaks in dirty services, such as, for example, slurries in fracturing operations. The dirty services may contain a high number of particles that migrate between several adjoining valve components leading to valve failure, such as valve seizure and / or leaks. These problematic failures necessitate routine service and maintenance which increase operational costs or may lead to process downtime which reduces revenue and product.

[0034] Gate valve seats have been known to cause leaks as the associated seals may experience an invasion of granular particles to damage or significantly reduce a sealing power of the gate valve seats within the gate valve pockets and / or seize the valve which may necessitate a replacement valve. Conventionally, the grease utilized to lubricate the valve seat is known to saturate with captured granular particles near the seat seal area creating a stoppage of the valve or a failed seat seal. Efforts have been implemented to reduce the amount of grease necessary for proper valve operation while maintaining proper sealing. However, the implementation of conventional seals has not achieved the desired longevity of the valve and, thus, frequent grease replacement is required for continued operation. As such, the present disclosure enhances valve operating performance and service life by reducing particle migration to the valve seat pressure seal.

[0035] The description may use the phrases “in certain embodiments,” “in various embodiments,” “in an embodiment,” “in one embodiment, or “in example,” which may each refer to one or more of the same or different embodiment. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous. The term “plurality” as used herein refers to two or more items or components. The terms “about” or “approximately” are defined as being close to as understood by one ofordinary skill in the art. Tn one non-limiting example, these terms are defined to be within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

[0036] The terms “removing,” “removed,” “reducing,” “reduced,” or any variation thereof, when used in the claims and / or the specification includes any measurable decrease of one or more components in a mixture to achieve a desired result. The use of the words “a” or “an” when used in conjunction with any of the terms “comprising,” “including,” “containing,” or “having,” in the claims or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The terms “wt. %”, “vol. %”, or “mol. %” refers to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, which includes the component. In a nonlimiting example, 10 grams of a component in 100 grams of the material is 10 wt. % of the component.

[0037] FIG. 1 is a perspective view of an embodiment of a gate valve 100 having portions broken away for clarity, according to an embodiment of the disclosure. The gate valve 100 includes a seat assembly 126 discussed below. The depicted gate valve 100 includes a valve body 102 connected and fastened to a valve bonnet 104 with bolts 103, thereby defining a gate cavity 138, and further connected to a flange 124. The valve bonnet 104 may be fastened to the valve body 102 in a variety of manners, such as, but not limited to, a threaded connection, a stud and nut connection, a weld, a pressure seal, and / or other like connections. The valve body 102 may include multiple flanges 124 to fluidly connect the gate valve 100 to a network of pipes (not shown) configured to flow a fluid through the gate valve 100, as will be understood by those skilled in the art. In one embodiment, the flange 124 may include a compression flange, a threaded or a welded connection, or the like, to fluidly connect to adjacent pipes (not shown). The valve bonnet 104 houses a valve stem 106 that connects a handwheel 108 to a gate 110 disposed in the gate cavity 138. The gate cavity 138 may be a wet area that routinely contacts a valve fluid and houses the gate 110. In embodiments, the valve stem 106 may be a rising or a non-rising stem type, for example, as will be understood by those skilled in the art. While the gate valve 100 is illustrated as a manually operated gate valve 100 by handwheel 108, it is contemplated a mechanical, electrical, or pneumatic actuator (not shown) may be used in place of, or in addition to, the handwheel 108, thereby to rotate the valve stem 106 to stroke, or actuate the movement of, the gate 110 towardsan open or closed position initiated from a location site away from the valve, such as an operator station, or a control panel.

[0038] The gate 110 is configured to abut a valve seat 112 and compress a seat pressure seal 114 and a debris protection seal 116 disposed on the valve seat 112 into a seat recess 118 defined into the valve body 102. The compression of the seat pressure seal 114 allows the valve seat 112 to seal against the seat recess 118 to prevent leaks from an upstream end 120, through the gate 110 and bypassing the seat pressure seal 114, and into a downstream end 122. In one embodiment, the valve may be bi-directional fluid flowing, and the upstream end 120 and the downstream end 122 may be positioned opposite facing as illustrated in FIG. 1. The gate 110 may be a solid taper wedge, a split wedge, a flexible wedge type, or the like, as will be understood by those skilled in the art. Furthermore, the gate valve 100 may be a wafer gate, a spring-loaded valve, a ball gate valve, a diaphragm gate valve, a swing gate valve, or the like, as will be understood by those skilled in the art. Each of the seat pressure seal 114 and the debris protection seal 116 will be discussed in further detail below. Several minor operational components, such as, packing glands, bushings, a yoke, guides, bearings, and the like, as will be understood by those skilled in the art are excluded from the drawings and not described further herein but may be incorporated in an embodiment of a gate valve 100.

[0039] FIG. 2A is an exploded sectional view of a gate valve body having a seat assembly 226, in a full-bore embodiment of the disclosure. FIG. 2B is an enlarged view of a valve body seat profile taken along the lines FIG. 2B of the gate valve body of FIG. 2A. The following will disclose physical relationships for components of the gate valve 100. It is to be understood the central reference point for the terms “distal” and “proximate” is the gate 110. The gate valve body 202 illustrates an example of a half of the valve body 202 with a throughbore 248 having an inner diameter 244 that substantially matches an inner diameter surface 246 of the annular valve seat 212, commonly known as a full-bore. It is contemplated a reduced bore gate valve may also implement the gate valve embodiment disclosed herein, as will be understood by those skilled in the art. Further, it is to be understood that the half of a gate valve body 202 illustrated may be the upstream end 120 or the downstream end 122 as shown in FIG. 1. While the gate valve body 202 is illustrated to be a globe shape, the valve body 202 may be a cube shape as the valve body 102 shown in FIG. 1, cylindrical shape, or other customary shapes known and understood by those skilled in the art to be a gate valve and associated gate valve body.

[0040] The valve body 202 includes the flange 224 and the seat recess 218. The seat recess 218 is configured to tightly receive a first outer diameter surface 228 of the valve seat 212 to position the valve seat 212 therein. The seat recess 218 includes a first radial recess wall 230, a second radial recess wall 232, and a third radial recess wall 234 with a lip 236. In one embodiment, the third radial recess wall 234 defines a first bore in the valve body 202, the first radial recess wall 230 defines a second bore in the valve body 202, and the second radial recess wall 232 defines a tapering portion positioned to extend from the first bore to the second bore. The first radial recess wall 230 has a first end 230a and a second end 230b positioned on the proximate and distal portions of the second bore defined by the first radial recess wall 230, respectfully. The second end 230b of the first radial recess wall 230 is connected to the throughbore 248 by a distal radial wall 250 defining an end of the second bore. In one embodiment, the distal radial wall 250 has a plane that is substantially radially disposed to a Center Line (“C / L”). The first end 230a of the first radial recess wall 230 is connected to a second end 232b of the second radial recess wall 232. The second radial recess wall 232 has a first end 232a that is connected to a second end 234b of the third radial recess wall 234. A first end 234a of the third radial recess wall 234 is connected to the lip 236 that directly connects a radial cavity wall 240 of a gate cavity 238 and the third radial recess wall 234. The gate cavity 238 is configured to receive any internal components of the gate valve 100, such as, for example, the gate 110, and may be a bore, transversely positioned to and fluidly connected to the throughbore 248. In one embodiment, the bore may be a cross-bore, a y-bore, or other type bores commonly used in the valve industry.

[0041] The first radial recess wall 230 is substantially parallel with the inner diameter 244 of the throughbore 248. The third radial recess wall 234 is substantially parallel with the inner diameter 244 of the throughbore 248. The first radial recess wall 230 has a diameter less than a diameter of the third radial recess wall 234. The second radial recess wall 232 is disposed between and links the first radial recess wall 230 and the third radial recess wall 234 at a slope. The slope has an angle 252 that is about 15 degrees to about 75 degrees, such as about 15 degrees to about 70 degrees, such as about 15 degrees to about 65 degrees, such as about 15 degrees to about 60 degrees, such as about 15 degrees to about 55 degrees, such as about 15 degrees to about 50 degrees, such as about 15 degrees to about 45 degrees, such as about 20 degrees to about 40 degrees, such as about 25 degrees to about 35 degrees, such as about 27 degrees to about 33 degrees, such as about 30 degrees. The angle 252 is advantageous as the first outer diametersurface 228 of the valve seat 212 is guided by the angle 252 to insert the tight fitting valve seat 212 within the seat recess 218 with minimal damage to the lip 236, a known failure point for leaks on conventional valves, and with minimal damage to an outer edge 256 on a distal surface 254 of the valve seat 212, a known particle ingress location causing damage to the seat pressure seal 214. Stated differently, conventional valves experience damage at multiple connection sites between a gate cavity and a throughbore by improper installation, for example, entry of the valve seat within a seat recess. By the addition of the profde described above for the seat recess 218 to the valve body 202, the third radial recess wall 234 is sufficiently large enough to position the outer edge 256 on a distal surface 254 of the valve seat 212 within the seat recess 218 wherein further inserting the valve seat 212 is guided by the angle 252 to properly install the tight fitting first outer diameter surface 228 of the valve seat 212 into contact with the first radial recess wall 230 with significantly reduced damage to known failure points of conventional valves. Therefore, the angle 252 significantly reduces installation error as precisely cut components, such as the valve seat 212 and the seat recess 218, are integrated with increased confidence of reduced damage.

[0042] The seat assembly 226 includes the valve seat 212, a debris protection seal 216, and the seat pressure seal 214. In one embodiment, the seat assembly 226 may be available in a replacement kit available for replacement. In one embodiment, the valve seat 212 has a first outer diameter surface 228 greater than a second outer diameter surface 258 of the valve seat 212, thereby defining a shoulder 259. In one embodiment, the second outer diameter surface 258 is configured to receive the seat pressure seal 214 thereon and abut the shoulder 259. In one embodiment, the seat pressure seal 214 is an annular seal including multiple sealing members, discussed below. In one embodiment, the seat pressure seal 214 may include a single sealing member, such as an O-ring type seal with various cross-sectional shapes, as will be understood by those skilled in the art, thereby to allow for custom sealing for different operating conditions, such as high pressure or high temperature operations. The debris protection seal 216 is configured to fit within a step 260 on the distal surface 254 of the valve seat 212. Further, the debris protection seal 216 is configured to reduce the number of particles, such as sediment or sand within the valve fluid, to ingress toward the seat pressure seal 214, discussed in more detail below.

[0043] FIG. 3A is a sectional view of an integrated gate valve body 202 with a valve seat 212, including a debris protection seal 216 positioned within the seat recess 218, according to an embodiment of the disclosure. Stated differently, the valve seat 212 may be positioned in thesecond bore defined by the first radial recess wall 230 of the valve body 202. FIG. 3B is an enlarged view of the valve body seat profile taken along the lines of FIG. 3B of the gate valve body of FIG. 3 A. The valve seat 212 is tightly positioned within the seat recess 218 such that the distal surface 254 of the valve seat 212 abuts the distal radial wall 250 of the seat recess 218, thereby to establish a metal-to-metal contact to reduce particle infiltration from the fluid within the throughbore 248 to the seat pressure seal 214. In one embodiment, the valve body 202 includes stainless steel, such as 316, 316L, 304, 304L, or super duplex stainless steel. In one embodiment, the valve seats 212, or 512, includes stainless steel, such as 316, 316L, 304, 304L, or super duplex stainless steel.

[0044] The unification of the valve seat 212 into the seat recess 218, as illustrated from the positions in FIG. 2A to the integrated positions in FIG. 3A, creates an air flow as the volume of air is displaced between the distal surface 254 of the valve seat 212 and the distal radial wall 250 of the seat recess 218. For example, as the valve seat 212 is placed and slid into the seat recess 218, the seat pressure seal 214, having a slightly greater radial thickness 362 as compared to the difference between the first outer diameter surface 228 and the second outer diameter surface 258 of the valve seat 212, pushes air flow towards the throughbore 248. Prior to contact between the distal surface 254 and the distal radial wall 250, the debris protection seal hinders the air flow 216 contacting the distal radial wall 250, therefore creating an air pocket disposed between the seat pressure seal 214, distal surface 254, the distal radial wall 250, and the debris protection seal 216. Thus, the air pocket is trapped therein upon installation.

[0045] Conventionally, air pockets have been problematic as retraction of the valve seat 212 to remove the valve seat 212 from the seat recess 218 creates a suction at the site of the air pocket, thus making the removal challenging. Furthermore, air pockets hinder a desired metal-to-metal contact between the distal surface 254 and the distal radial wall 250. In more extreme scenarios, the trapped air pocket may cavitate under pressure exerted onto the valve seat 212 from a gate, such as the gate 110 of FIG. 1, causing damage to the valve body 202 or the valve seat 212 and, therefore, an increased risk of leaks, repairs, or replacements that increase the cost of operation and lost production. To overcome this challenge, the debris protection seal 216 advantageously allows air pockets to escape into the throughbore 248. In one embodiment, as further described below, the debris protection seal 216 has legs which expand laterally and into abutting contact with the distal radial wall 250 when the valve seat 212 is installed within the valve body 202. The orientation of the legs of the debris protection seal 216 allows the air pocket to flow out and intothe throughbore 248 while preventing reverse flow up towards the seat pressure seal 214 during operation.

[0046] In one embodiment, during operation, the air pocket, discussed above, is purged into the throughbore 248 because of a gate, such as gate 110 of FIG. 1, pushing the valve seat 212 in a direction 360. The pushing the valve seat 212 in the direction 360 may exert an even force across the valve seat 212 which will allow any retained air pocket to purge through the debris protection seal 216 and into the throughbore 248, thereby allowing the desired metal -to-metal contact between distal surface 254 and the distal radial wall 250 to significantly seal the valve seat 212 to the valve body 202 to prevent leaks or bypassed fluids to bypass the gate 110.

[0047] The valve body 202 includes valve dimensions discussed below in reference to a 7.063 + / - 0.001-inch bore, full bore gate valve. In one embodiment, the valve bore dimensions may range from 1.813 + / - 0.001 inch bore to 7.063 + / - 0.001-inch bore, full bore gate valves. It is contemplated the dimensions and their associated ratios disclosed may be utilized to scale embodiments of a gate valve to varied sizes that would be appropriate for each operating scenario under various fluid services, as will be understood by those skilled in the art. In one embodiment, for example, the third radial recess wall 234 has a length of about 0.135 + / - 0.005 inch, such about 0.135 + / - 0.003 inch, such as about 0.135 + / - 0.001 inch. In another embodiment, for example, the third radial recess wall 234 has a diameter of about 9.600 + / - 0.006, such as about 9.600 + / - 0.004 inch, such as about 9.600 + / - 0.002 inch. In yet another embodiment, for example, the distal radial walls 250 of each of the seat recess 218 are spaced apart at a length 364 of about 14.129 + / - 0.005 inch, such as about 14.129 + / - 0.003 inch, such as about 14.129 + / - 0.001 inch. In a further embodiment, for example, the first radial recess wall 230 has a diameter of about such as about 9.410 + / - 0.006, such as about 9.410 + / - 0.004 inch, such as about 9.410 + / - 0.002 inch. In still another embodiment, the first radial recess wall 230 may be machined finished to have a roughness average (“Ra”) of about 32 Ra. In an embodiment, for example, the distal radial wall 250 of the seat recess 218 may be machined, as will be understood by those skilled in the art, and finished to have a roughness average of about 32 Ra. In an embodiment, the intersection of the first radial recess wall 230 and the second radial recess wall 232, at either the first end 230a of the first radial recess wall 230 or the second end 232b of the second radial recess wall 232, may be machined to have a radius of curvature of about 0.05 inch. In one embodiment, the intersection of the first radial recess wall 230 and the distal radial wall 250 of the seat recess 218, at the second end 230b, maybe machined to have a radius of curvature of about 0.039 inch. In one embodiment, when installed, the valve seats 212 may be separated by a length 368 of less than about 7 inches, such as less than about 6 inches, such about 5 inches, to accommodate and contact a gate 110.

[0048] FIG. 4A is a sectional view of a gate valve seat 212 having seals thereon taken along the lines of FIG. 4A of the sectional view of FIG. 3A to clarify seal positioning, according to an embodiment of the disclosure. FIG. 4B is a sectional view of a gate valve seat without the seals of FIG. 4A. The valve seat 212, as illustrated, has an annular body 400 defined by a proximate surface 266, the distal surface 254 disposed opposite the proximate surface 266, the inner diameter surface 246, the first outer diameter surface 228, the second outer diameter surface 258, the shoulder 259 that connects the first outer diameter surface 228 and the second outer diameter surface 258, the outer edge 256 that connects the second outer diameter surface 258 and the distal surface 254, and the step 260 that connects the distal surface 254 and the inner diameter surface 246. The second outer diameter surface 258 is able to tightly receive the seat pressure seal 214. Details of the seat pressure seal 214 will be discussed below. In one embodiment, the second outer diameter surface 258 has a diameter slightly greater than the seat pressure seal 214 inner diameter whereas the seat pressure seal 214 is expanded to receive the valve seat 212 to be positioned onto the second outer diameter surface 258 of the valve seat 212, thereby to establish a tight seal between the seat pressure seal 214 and the second outer diameter surface 258. Similarly, as discussed within the details of FIG. 3A above, the seat pressure seal 214 has a slightly greater radial thickness 362, as compared to the difference between the first outer diameter surface 228 and the second outer diameter surface 258 of the valve seat 212. Stated differently, the seat pressure seal 214 has a slightly greater outer diameter than the diameter of the second outer diameter surface 258, thereby creating a tight seal between seat pressure seal 214 and the first radial recess wall 230. Together, a tight seal may be continuous across the first radial recess wall 230 of the seat recess 218 positioned in the valve body 202 and the second outer diameter surface 258 of the valve seat 212 when positioned and installed within the seat recess 218. Furthermore, in one embodiment, when in operation, the seat pressure seal 214 is configured the contact the distal radial wall 250 of the seat recess 218 via the second side surface 860 (as shown in FIG. 8). The first side surface 836, opposite the second side surface 860 (as shown in FIG. 8), of the seat pressure seal 214 is configured to have a gap 402 of less than about 0.09 inch, such as less than about 0.08 inch, such as less than about 0.07 inch, such as less than about 0.06 inch, such as lessthan about 0.05 inch, such as less than about 0.04 inch, such as about 0.03 inch wherein fluid from the gate valve 100 is able to enter the throughway 872, as shown in FIG 8 below, thereby allowing the legs 814UPPER, 814LOWER of seat pressure seal 214 to radially expand to produce a high pressure and tighter seal between the first radial recess wall 230 of the seat recess 218 positioned in the valve body 202 and the second outer diameter surface 258 of the valve seat 212. Relatedly, the second legs 816UPPER, 816LOWER of the seat pressure seal 214 also are expanded radially by the axial force exerted by the contact of the distal radial wall 250 and the seat pressure seal 214 on the second side surface 860.

[0049] The step 260 is configured to position a debris protection seal 216 therein. The step 260 has a surface 260a with a diameter slightly lesser than an outer diameter the debris protection seal 216, thereby to allow the debris protection seal 216 to tightly fit within the step 260 and prevent migration of any fluid particles from bypassing the debris protection seal 216 between the surface 260a and the outer diameter of the debris protection seal 216.

[0050] The annular body 400 includes valve dimensions discussed below in reference to a 7.063 + / - 0.001-inch bore, full bore gate valve. In one embodiment, the valve bore dimensions may range from 1.813 + / - 0.001 inch bore to 7.063 + / - 0.001-inch bore, full bore gate valves. It is contemplated the dimensions and their associated ratios disclosed may be utilized to scale the gate valve 100 to varied sizes that would be appropriate for each operating scenario under various fluid services. The valve seat 212 has a length 404 of about 4.500 + / - 0.001 inch extending from the proximate surface 266 to the distal surface 254. In one embodiment, the inner diameter surface 246 has a diameter 410 of about 7.085 + / - 0.005 inch. The first outer diameter surface 228 has a length 408 of about 3.495 + / - 0.006 inch. The second outer diameter surface 258 has a length 418 of about 1.000 + / - 0.01 inch. The proximate surface 266 has a length 406, corresponding to the thickness of the valve seat 212 of about 1.158 + / - 0.003 inch. The distal surface 254 has a length 412 of about 0.844 + / - 0.002 inch. The step 260 has a radial length 414 of about 0.139 + / - 0.004 inch. The step 260 has an axial length 416 of about 0.100 + / - 0.001 inch. The dimensions disclosed advantageously allow the seat pressure seal 214 to define a tight seal across the first radial recess wall 230 of the seat recess 218 positioned in the valve body 202 and the second outer diameter surface 258 of the valve seat 212 when positioned and installed within the seat recess 218 and when the gate valve 100 is in operation, such as rotating the valve stem 106 to stroke, or actuate the movement of, the gate 110 towards an open or closed position causing the valve seat 212 tomove in a direction 360 to create the desired metal -to-metal contact between the distal surface 254 and distal radial wall 250 to prevent valve 100 leaks and any fluid particles from migrating to the seat pressure seal 214.

[0051] FIG. 5A is a sectional view of a gate valve seat 512 having seals thereon taken along the lines of FIG. 5 A of the perspective view of FIG. 1, according to an embodiment of the disclosure. FIG. 5B is a sectional view of a gate valve seat 512 without the seals of FIG. 5A. FIG 5A illustrates an embodiment of the valve seat 512 having an annular body 500 defined by a proximate surface 566, a distal surface 554 disposed opposite the proximate surface 566, an inner diameter surface 546, a first outer diameter surface 528, a second outer diameter surface 558, a third outer diameter surface 572 positioned between a first flange 568 and a second flange 570, a berm 574 that connects the second flange 570 to the proximate surface 566, a shoulder 529 that connects the first outer diameter surface 528 and the second outer diameter surface 558, the outer edge 556 that connects the second outer diameter surface 558 and the distal surface 554, and a seal recess 560 positioned on the distal surface 554 creating a ledge 562 disposed and connecting the distal surface 554 to the inner diameter surface 546. The third outer diameter surface 572 is straddled by the first flange 568 and the second flange 570 and is configured to receive a field tool (not shown) to pry the valve seat 512 away from the seat recess 218 for maintenance. Conversely, the third outer diameter surface 572 may be utilized by a field tool (not shown) to guide the valve seat 512 into the seat recess 218 during installation, as will be understood by those skilled in the art. The seal recess 560 is configured to receive a debris protection seal 516 therein so as to position one or more legs 606 of the debris protection seal 516 (as shown in FIG. 6A) to each abuttingly contact the distal radial wall 250 of the seat recess 218 when the valve seat 512 is installed or the valve 100 is in operation. The second outer diameter surface 558 is able to loosely receive the seat pressure seal 214. Details of the seat pressure seal 214 will be discussed below.

[0052] In an embodiment, the second outer diameter surface 558 has a diameter slightly less than an innermost diameter of the seat pressure seal 214 whereas the seat pressure seal 214 easily slides onto the valve seat 512 to be positioned onto the second outer diameter surface 558 of the valve seat 512, thereby reducing the usage of grease to integrate the components together. In one embodiment, the length 518 of the second outer diameter surface 558 is shorter than an overall length of the seat pressure seal 214; therefore, when installed or in operation, the seat pressure seal 214 is compressed between the shoulder 559 and the distal radial wall 250 of the seat recess 218,thereby to expand the legs of the seat pressure seal 214 to tightly seal across the first radial recess wall 230 of the seat recess 218 and the second outer diameter surface 558 of the valve seat 512.

[0053] The distal surface 554 includes a bump or bulbous feature 578 configured to abut and contact the distal radial wall 250 when the valve 100 is in operation. While the bump feature 578, as illustrated, includes three contact sites 580 to create a metal-to-metal contact between the valve seat 512 and the distal radial wall 250, more or less contact sites 580 are contemplated. In one embodiment, the bump feature 578 is configured to create at least one particle cavity 576, or indentation, configured to capture and retain any fluid particle, such as sand, which bypasses the debris protection seal 516 in a direction towards the seat pressure seal 214. In one embodiment, the particle cavity 576 may be concentrically aligned with the valve seat 512 with a central diameter less than the diameter of the second outer diameter surface 558 but with a central diameter greater than the diameter of the inner diameter surface 546 such that the particle cavity 576 has a constant volume formed in the distal surface 554. Stated differently, the particle cavity 576 is an enclosed volume disposed between at least two of the contact sites 580 positioned on the distal surface 554.

[0054] The contact sites 580 define a plane 586 that radially align with each other. The ledge 562 extends from the annular body 500 and towards the plane 586. However, the ledge 562 does not align, meet, or cross the plane 586 to allow for air displacement, as discussed above in reference to air pockets, into the throughbore 248.

[0055] The debris protection seal 516 is similar to the embodiment of the debris protection seal 216 as shown in FIG. 2A-4B; however, the orientation of the debris protection seal 516 faces the distal radial wall 250 of the seat recess 218 rather than facing the throughbore 248 as does the debris protection seal 216. In one embodiment, the one or more legs 606 of the debris protection seal 516 (as shown in FIG. 6A) each contact the distal radial wall 250 of the seat recess 218 when the valve seat 512 is installed or the valve 100 is in operation while also having sufficient flexibility to allow an air pocket to purge in to the throughbore 248 and prevent the reverse flow up towards the seat pressure seal 514 during operation. Stated differently, the one or more legs 606 of the debris protection seal 516 which contact the distal radial wall 250, flap in radially inward direction to allow any air pocket to displace into the throughbore 248 while simultaneously creating a seal to prevent or significantly reduce particles from migrating from the throughbore 248 and towards the seat pressure seal 214. In one embodiment, the debris protection seal 516 is an enlarged debrisprotection seal 216, in a different facing orientation as discussed above, as the seal recess 560 may be deeper than an axial length 416 of the debris protection seal 216 configured to fit the valve seat 212 of FIG. 4B.

[0056] The first flange 568 has a distal wall 568a that faces the radial cavity wall 240 of the gate cavity 238 when the valve seat is installed in the seat recess 218. The distal wall 568a is configured to position an annular compression spring 140, as shown in FIG. 1, to retract the valve seat 512 away from the seat recess 218 during operation. Furthermore, the annular compression spring 140 creates separation between the valve seat 512 and the seat recess 218 wherein any particles that may be retained in the particle cavity 576 during operation, may be induced to fall or move toward the throughbore 248 by a venturi effect from fluid flow within the throughbore 248. For example, a pressure loss, and / or high velocity flow, as will be understood by those skilled in the art, from an initial opening of the gate 110 may cause the fluid to flow through an orifice smaller than the throughbore 248, thereby to cause a suction toward the pressure loss gradient and / or high velocity flow and induce the particles within the particle cavity 576 to move toward the throughbore 248. In one embodiment, the annular compression spring 140 is a multi-wave, or multi-turn, compression spring type. In one embodiment, the annular compression spring 140 has a diameter greater than a diameter 584 of the first outer diameter surface 528 and a diameter less than an outermost diameter of the first flange 568.

[0057] The annular body 500 includes valve dimensions discussed below in reference to a 7.063 + / - 0.001-inch bore, full bore gate valve. In one embodiment, the valve bore dimensions may range from 1.813 + / - 0.001 inch bore to 7.063 + / - 0.001-inch bore, full bore gate valves. Is it contemplated the dimensions and their associated ratios disclosed may be utilized to scale the gate valve 100 to different sizes that would be appropriate for each operating scenario under various fluid services. The valve seat 512 has a length 504 of about 4.495 + / - 0.001 inch extending from the proximate surface 566 to the distal surface 554. In one embodiment, the inner diameter surface 546 has a diameter 524 of about 7.080 + / - 0.000 inch. The first outer diameter surface 528 has a length 518 of about 0.927 + / - 0.000 inch and a diameter 582 of about 8.983 + / - 0.002 inch. The second outer diameter surface 558 has a length 508 of about 0.713 + / - 0.000 inch and a diameter 584 of about 9.400 + / - 0.002 inch. The first flange 568 has a length 590 of about 0.500 + / - 0.000 inch. The third outer diameter surface 572 has a length 592 of about 1.715 + / - 0.001 inch with a diameter 526 of about 9.000 + / - 0.000 inch. The first flange 568 has a length 594 of about 0.340+ / - 0.000 inch. The berm 574, positioned toward proximate surface 566 from the second flange 570, has an axial length 596 of about 0.300 + / - 0.000 inch. The proximate surface 566 has a total profde height 522 of about 1.697 + / - 0.000 inch. The distal surface 554 has a total profde height 598 of about 0.952 + / - 0.002 inch. In one embodiment, the length 518, between the plane 586 of the contact sites 580, is about 0.005 + / - 0.000 inch. The seal recess 560 has a depth 520 into the valve seat 512 of about 0.325 + / - 0.000 inch. Each end of the contact sites 580 that align with the plane 586 have a flattened width portion of about 0.020 + / - 0.000 inch. The flattened width portion of the contact sites 580 advantageously enable various metal-to-metal contacts between the distal surface 554 and the distal radial wall 250, thereby providing redundant contact locations further providing enhanced protection from migration of the particles toward the seat pressure seal 214 and thus, preventing frequent valve leaks or failures.

[0058] The dimensions disclosed above for valve seat 512, advantageously allow the seat pressure seal 214 to slip onto the first outer diameter surface 528 with reduced or eliminated need for grease, allow for air pockets to exhaust into the throughbore 248 when the valve seat 512 moves, allow for springs to be in positions to create a phenomena to reduce the amount of particles held within the particle cavities 576, allow for redundant metal-to-metal contacts between the distal surface 554 and the distal radial wall 250, thereby to provide enhanced protection from leaks or valve failure and while providing an ease of installation, and reduced particle migration toward the seat pressure seal 214, among other features described and discussed above.

[0059] FIG. 6A is an enlarged sectional view of an embodiment of a debris protection seal 216, or 516 taken along the lines of FIG. 6A of the sectional view of FIG. 4A, according to an embodiment of the disclosure. The debris protection seal 216, 516 includes a body 602 and a leg portion 604. The debris protection seal 216, 516 each include polyether ether ketone (“PEEK”). The leg portion 604 includes one or more legs 606 that extend away from the body 602. The body 602 has a thermal mass greater than the one or more legs 606 such that the body 602 is more rigid as compared to the one or more legs 606. Each of the one or more legs 606 extend away and outward beyond the width 608, of the body 602 in a symmetrical manner across a debris Center Line (“C / Ld”). Further, each of the one or more legs 606 have an outer sidewall 614 at an angle 612 of about 170 degrees between the body 602 and the leg 606. The positioning of the one or more legs 606 define an angle 618 of about 20 degrees between each of the inner sidewalls 616. In one embodiment, the width 608 of the body 602 is about 0.095 + / - 0.002 inch. In oneembodiment, the width 610, defining the maximum width of the leg portion 604, is about 0.125 + / - 0.002 inch. Each of the one or more legs 606 has a thickness 620 of about 0.016 + / - 0.002 inch. Each of the one or more legs 606 is configured to flap, thereby being able to move upon an exerted force on either the outer sidewall 614 or the inner sidewall 616. As discussed above, an air pocket may be trapped between the seat pressure seal 214, distal surface 254, 554, the distal radial wall 250, and the debris protection seal 216, 516. As the gate valve 100 closes, the air pocket pressure is increased as the valve seat 212, 512, is pushed in the direction 360. The increased pressure is evenly exerted on all confining walls however only the one or more legs 606 is configured to flap to exhaust the increase pressure into the throughbore 248, thereby to allow the metal-to-metal seal between the valve seat 212, 512 and the distal radial wall 250 of the seat recess 218.

[0060] In the embodiments of FIG. 3A and 4A, the debris protection seal 216 is oriented such that only one the one or more legs 606 contacts the distal radial wall 250 and the other of the one or more legs 606 contacts the step 260. In one embodiment, when installed, each of one or more legs 606 point toward the throughbore 248 and are compressed together by the dimensions of the step 260 and the distal radial wall 250 such that each of the one or more legs 606 firmly expands against the distal radial wall 250 and the step 260 to create a seal that allows pressure to be exhausted in a radial inward direction on at least the one or more leg 606 contacting the distal radial wall 250 while preventing particle migration to the seat pressure seal 214.

[0061] In the embodiment of FIG. 5A, the debris protection seal 516 is oriented such that each of the one the one or more legs 606 contacts the distal radial wall 250 while the body 602 is inserted in a depth 520 of the seal recess 560. In one embodiment, when installed, each of one or more legs 606 point toward the distal radial wall 250 and are compressed together by the dimensions of the seal recess 560 such that each of the one or more legs 606 create a seal that may flap to allow pressure to be exhausted in a radial inward direction while preventing particle migration to the seat pressure seal 214. The dimensions for the debris protection seal 516 may be scaled up from the dimensions of the debris protection seal 216 to desirably fit the depth 520 of the seal recess 560 while still maintaining the intended pressure relief function as discussed above in reference to the air pocket trapped between the seat pressure seal 214, distal surface 554, the distal radial wall 250, and the debris protection seal 516.

[0062] FIG. 6B is an enlarged perspective sectional view of an embodiment of a debris protection seal 216 taken along the lines of FIG. 6B of the exploded sectional view of FIG. 2A, and FIG. 6C is a perspective sectional view of another embodiment of a debris protection seal 516 taken along the lines of FIG. 5A of the sectional view of FIG. 5A, according to another embodiment of the disclosure. FIG. 6B illustrates the debris protection seal 216 utilized in the step 260 of FIGS. 2A, 3A, 4A wherein the one or more legs 606 point inward and toward the throughbore 248. FIG. 6C illustrates the debris protection seal 516 utilized in the seal recess 560 of FIG. 5A wherein each of the one or more legs 606 point toward the distal radial wall 250 in the direction 360 and are configured to extend beyond the plane 586.

[0063] FIG. 7A is a sectional view of an additional embodiment of a debris protection seal 716 including PEEK, or other like materials, and having a grooved pattern, according to one embodiment. FIG. 7B is a perspective view of an embodiment of a debris protection seal 716 having a grooved pattern of FIG. 7A with a spiral 750, according to one embodiment. The debris protection seal 716 may be used within the valve seat 512 as illustrated in FIG. 5 A and 5B. The debris protection seal 716 includes an annular body 702 having a proximate surface 704 extending axially to a distal surface 706 disposed opposite the proximate surface 704, an outer surface 708, and an inner surface 710. The outer surface 708 has outer radial slot cuts 712 that are evenly spaced apart beginning from the proximate surface 704. The inner surface 710 has inner radial slot cuts 714 that are evenly spaced apart beginning from the proximate surface 704. The outer radial slot cuts 712 and the inner radial slot cuts 714 are evenly spaced out between each other such that the cuts alternate and straddle each other beginning from the proximate surface 704. Stated differently, the positioning and spacing of the cuts 712, 714 may be referenced from proximate surface 704 such that the cuts 712, 714 are parallel, straddle, and evenly spaced to each other. The outer radial slot cuts 712 and the inner radial slot cuts 714 define a cross-sectional serpent-like pattern 756 on the annular body 702. The serpent-like pattern 756 may be compressible and have the behavior of a compression spring such that an elastic potential energy of the serpent-like pattern 756 will return to the uncompressed position. In one embodiment, the annular compression spring 140 may be positioned within the PEEK material, inserted within the outer radial slot cuts 712, and / or inserted within inner radial slot cuts 714 of the debris protection seal 716 such that the serpent-like pattern 756 enables the debris protection seal 716 to behave as a spring. The distal surface 706 includes a grooved pattern 718 configured to capture sand andrelease pressure. In one embodiment, the grooved pattern 718 is a single spiral 750 winding from the inner surface 710 to the outer surface 708, or vice versa. The spiral 750 defines an elongated path for particles to migrate to the seat pressure seal 214, thereby reducing the likelihood of the particles accessing and thus impeding the sealing power of the seat pressure seal 214.

[0064] In one embodiment, the annular body 702 has a length 722 of about 0.351 + / - 0.005 inch and a width 732 of about 0.220 + / - 0.005 inch. In one embodiment, the outer radial slot cut 712 nearest the distal surface 706 has a length 720 of about 0.240 + / - 0.005 inch from the proximate surface 704. In one embodiment, the outer radial slot cut 712 nearest the proximate surface 704 has a length 726 of about 0.120 + / - 0.005 inch from the proximate surface 704. In one embodiment, the inner radial slot cut 714 nearest the distal surface 706 has a length 724 of about 0.180 + / - 0.005 inch from the proximate surface 704. In one embodiment, the inner radial slot cut 714 nearest the distal surface 706 has a length 728 of about 0.060 + / - 0.005 inch from the proximate surface 704. The one embodiment, the outer radial slot cuts 712 and the inner radial slot cuts 714 are spaced apart a distance of about 0.060 + / - 0.005 inch from each other and each have a depth 730 of about 0.180 + / - 0.005 inch and a width 742 of less than about 0.031 + / - 0.005 inch. The grooved pattern 718 on the distal surface 706 may include one or more cavities 734 having a depth 736 of about 0.042 + / - 0.005 inch from the distal surface 706. Furthermore, the one or more cavities 734 may have an angle 738 of about 60 degrees such that the grooved pattern 718 defines a tapering entry into the depth 736 wherein the depth 736 closes with a radius of curvature of about 0.010 + / - 0.005 inch. In one embodiment, the depth 736 of each of the one or more cavities 734 are centrally spaced apart a distance 740 about 0.0650 + / - 0.005 inch. Furthermore, the proximate surface 704 has an outer edge 746 and inner edge 744 that each have a cutaway of about 45 degrees resulting in a flat surface with a length 748 of about 0.015 + / - 0.005 inch. The dimensions for the debris protection seal 716 above are advantageous as the distal surface 706 sealingly abuts the distal radial wall 250 of the seat recess 218 when installed, to define a long spiral 750 volume which relieves pressure from the operation of a gate valve 100, as discussed above, and significantly reduces particle migration to the seat pressure seal 214. For example, a particle that migrates into the spiral 750 of the debris protection seal 716 must traverse a long spiral path rather than a direct radial direction to access the seat pressure seal 214. Moreover, the serpent-like pattern 756 keeps a constant contacting force on the distal surface 706 towards the distal radial wall 250 to enable an effective seal of the distal surface 706 on the distal radial wall 250 of the seat recess 218.Therefore, the debris protection seal 716 is simultaneously capable to relieve pressure while prolonging the time for a particle to migrate to the seat pressure seal 214, thereby elongating the life of the valve 100 without mechanical failure, such as leaks and / or premature wear.

[0065] FIG. 8 is a sectional perspective view of an embodiment of an annular seat pressure seal 214 taken along the lines of FIG. 8 of the exploded sectional view of FIG. 2A, according to an embodiment of the disclosure. The seat pressure seal 214 includes an annular first female seal member 802 with a first opening 806 and an annular second female seal member 804 with a second opening 808 facing opposite the first opening 806, an annular first male spreader ring 810, and an annular second male spreader ring 812. In one embodiment, the first female seal member 802 includes PEEK and the second female seal member 804 includes polytetrafluoroethylene (“PTFE”). In another embodiment, the first female seal member 802 and the second female seal member 804 each include PTFE. In one embodiment, the second female seal member 804 further includes a spring therein constructed with at least stainless steel. In one embodiment, the seat pressure seal 214 has a length 862 of about 0.940 + / - 0.005 inch. The first opening 806 and the second opening 808 face opposite of each other such that the first male spreader ring 810 faces the shoulder 259, or 529, and the second male spreader ring 812 abuts and / or faces the distal radial wall 250 of the seat recess 218 on the valve body 202. The first opening 806 is configured to receive the first male spreader ring 810 to seal the first female seal member 802 against the valve seat 212, or 512, and the valve body 202. The second opening 808 is configured to receive the second male spreader ring 812 to seal the second female seal member 804 against the valve seat 212, or 512, and the valve body 202 when the gate 110 compresses against the valve seat 212, or 512. Moreover, the first female seal member 802 and the second female seal member 804 each have a backside surface 846, 848 that abut each other to establish an X-shape defined by the seat pressure seal central portion 850. The backside surfaces 846, 848 directly contacting each other are advantageous as the seat pressure seal 214 provides a sturdy construction able to endure prolonged operation with significantly reduced fatigue and / or failure as the valve 100 may be bidirectional and able to seal in either flow orientation. In one embodiment, the first female seal member 802 and the second female seal member 804 have the same dimensions and have a cross- sectional profile that is symmetrical.

[0066] The first opening 806 is defined and partially enclosed by a first upper leg 814UPPER, further including a first end 814a directly connected to a first female seal member body 818 and asecond end 814b positioned away from the first female seal member body 818, and by a first lower leg 814LOWER, further including a first end 814c directly connected to the first female seal member body 818 and a second end 814d positioned away from the first female seal member body 818. In one embodiment, the first female seal member body 818 and the first legs 814UPPER, 814LOWER together have a length 864 of about 0.335 + / - 0.005 inch. In one embodiment, the first female seal member body 818 has a height 866 of about 0.174 + / - 0.005 inch. In one embodiment, the first female seal member body 818 has an outer surface 868 having a diameter of about 9.396 + / - 0.005 inch and an inner surface 870 having a diameter of about 9.048 + / - 0.002 inch.

[0067] The second opening 808 is defined and partially enclosed by a second upper leg 816UPPER, further including a first end 816a directly connected to a second female seal member body 820 and a second end 816b positioned away from a second female seal member body 820, and by a second lower leg 816LOWER, further including a first end 816c directly connected to a second female seal member body 820 and a second end 816d positioned away from the second female seal member body 820.

[0068] The first male spreader ring 810 includes a male extension 822 that centrally extends away from a first male spreader ring body 824 defined by a first outer diameter surface 832, a first inner diameter surface 834, and a first side surface 836. In one embodiment, the first male spreader ring 810 has a length 842 of about 0.307 + / - 0.005 inch and the first male spreader ring body 824 has a length 844 of about 0.125 + / - 0.005 inch. In one embodiment, the first male spreader ring 810 includes PEEK or similar material. In one embodiment, the first male spreader ring 810 includes one or more throughways 872 equally spaced about the first male spreader ring 810. For example, in an embodiment where four throughways 872 are present, the first male spreader ring 810 will have one throughway 872 positioned in every quarter of the first male spreader ring 810. In those examples, the throughway 872 has a diameter 874 of about 0.063 + / - 0.005 inch. The throughways 872 advantageously allow pressure to pass through to enable a radial expansion to sealing contact the seat pressure seal to the valve body 202 and the valve seat 212, 512. An upper shoulder 826a connects the first outer diameter surface 832 and the male extension 822 and a lower shoulder 826b connects the first inner diameter surface 834 and the male extension 822. In one embodiment, the first outer diameter surface 832 has a diameter of about 9.394 + / - 0.005 inch, the first inner diameter surface 834 has a diameter of about 9.048 + / - 0.005 inch, and the distance 838 between the first outer diameter surface 832 and the first inner diameter surface 834 is about 0.173+ / - 0.005 inch. The male extension 822 is configured to enter the first opening 806 of the first female seal member 802. In one embodiment, the male extension 822 has a thickness 840 of about 0.096 + / - 0.005 inch. The upper shoulder 826a is configured to contact the second end 814b of the first upper leg 814UPPER. The lower shoulder 826b is configured to contact the second end 814d of first lower leg 814LOWER. In one embodiment, the shoulders 826a, 826b push against the second ends 814b, 814d when the valve 100 is in operation such that the first legs 814UPPER, 814LOWER each bow in a radial direction to tightly seal against the valve body 202 and tightly seal against the valve seat 212, or 512. In one embodiment, the second end 814b has an outermost diameter of about 9.454 + / - 0.005 inch and the second end 814d has an innermost diameter of about 8.988 + / - 0.005 inch to define a distance 852 of about 0.233 + / - 0.005 inch.

[0069] The second male spreader ring 812 includes a male extension 828 that centrally extends away from a second male spreader ring body 830 defined by a second outer diameter surface 856, a second inner diameter surface 858, and a second side surface 860. In one embodiment, the second male spreader ring 812 has the same dimensions as the first male spreader ring 810 discussed above. In one embodiment, the second male spreader ring 812 includes PTFE or similar material. In one embodiment, the second male spreader ring 812 and the second female seal member 804 includes 5% moly modified PTFE. In one embodiment, the second male spreader ring 812 includes PEEK. An upper shoulder 854a connects the second outer diameter surface 856 and the male extension 828, and a lower shoulder 854b connects the second inner diameter surface 858 and the male extension 828. The male extension 828 is configured to enter the second opening 808 of the second female seal member 804. The upper shoulder 854a is configured to contact the second end 816b of the second upper leg 816UPPER. The lower shoulder 854b is configured to contact the second end 816d of second lower leg 816LOWER. In one embodiment, the shoulders 854a, 854b push against the second ends 816b, 816d when the valve 100 is in operation such that the second legs 816UPPER, 816LOWER each bow in a radial direction to tightly seal against the valve body 202 and tightly seal against the valve seat 212, or 512. In one embodiment, the first male spreader ring 810 and the second male spreader ring 812 each include PEEK and extend into the first female seal member 802 and the second female seal member 804 each including PTFE, respectively, to restrict axial movement and thereby protect the annular compression spring 140 from being overly compressed and cause deformation.

[0070] FIG. 9 is a flow chart of a method for machining a gate valve to define a recess for a valve seat, according to one embodiment. The method details operations that may occur to obtain a desired seat recess 218 for a valve seat within a valve body. It is to be understood, that alternate methods may be utilized to obtain the seat recess 218 described above for the valve seat on the valve body as understood by those skilled in the art.

[0071] The method 900 begins at block 902 where a user obtains a valve body. The valve body, such as valve body 202, may be obtained from a preassembled gate valve, such as an old gate valve needing repair from damage from service fluids, a gate valve that may be under performing in the intended service, or a new valve body for assembling a gate valve. In one embodiment, the method 900 may be used to retrofit an existing preassembled gate valve having face seals to a gate valve with diametric seals, as discussed above in reference to the seat pressure seal 214. In one embodiment, the valve body may be obtained by removing the internal and any external components associated with an operating gate valve, as will be understood by those skilled in the art.

[0072] At block 904, the valve body is positioned for machining the seat recess 218 for the valve seat by use of machining tools, as will be understood by those skilled in the art. The valve body, from block 902, may be transported to, for example, a tool shop capable of machining the valve body. In one embodiment, a service technician may travel to a site where the valve was in service to perform a local machining process.

[0073] Once the valve body is in position for machining, the valve body may be machined from the cavity, such as gate cavity 138, 238, or from the upstream end, or downstream end, accessing the lip 236 through the throughbore 248 to define the first radial recess wall 230 at block 906. The first radial recess wall 230, defining the second bore, may be machined into the valve body 202 with a centrally aligned bit such that the first radial recess wall 230 is concentrically aligned with the throughbore 248. As discussed above, the first radial recess wall 230 has a diameter greater than the inner diameter 244 of the throughbore 248 and is configured to receive and contact at least a portion of the first outer diameter surface 228 of the valve seat 212, 512.

[0074] In a response to a determination of whether the machining of the first radial recess wall 230 meets intended specifications, at block 908, the method 900 may proceed to block 910 for machining the third radial recess wall 234 if the first radial recess wall 230 meets intended specifications. The method 900 necessitates further machining if the first radial recess wall 230does not meet intended specifications by repeating the method of block 906. In one embodiment, the bit used to machine the valve body 202 may be worn from overheating, or overuse, and may produce a surface that is not within the intended specification. In one embodiment, the valve body 202 may have shifted from the positioning of block 904.

[0075] At block 910, the valve body may be machined to define the third radial recess wall 234. The third radial recess wall 234, or the first bore, may be machined into the valve body 202 with a centrally aligned bit such that the third radial recess wall 234 is concentrically aligned with the throughbore 248. As discussed above, the third radial recess wall 234 has a diameter greater than the diameter of the first radial recess wall 230 and is configured to receive the valve seat 212, 512 for installation.

[0076] In a response to a determination of whether the machining of the third radial recess wall 234 meets intended specifications, at block 912, the method 900 may proceed to block 914 for machining the second radial recess wall 232 if the third radial recess wall 234 meets intended specifications. The method 900 necessitates further machining if the third radial recess wall 234 does not meet intended specifications by repeating the method of block 910.

[0077] At block 914, in an embodiment, the valve body 202 may be machined to define the second radial recess wall 232. The second radial recess wall 232 may be machined into the valve body 202 with a centrally aligned bit such that the second radial recess wall 232 is concentrically aligned with the throughbore 248, for example. The second radial recess wall 232 is machined to define a truncated conical shape extending from the first radial recess wall 230 to the third radial recess wall 234 such that the widest portion of the conical shape is nearest the third radial recess wall 234. In one embodiment, the bit may begin to machine the second radial recess wall 232 at the third radial recess wall 234 and in a motion extending towards the gate cavity 238, the bit may exert a greater pressure, or expand a machining diameter, to machine an expanding conical shape extending from the first radial recess wall 230 to the third radial recess wall 234. As discussed above, the second radial recess wall 232 has a slope with an angle 252 configured to guide the valve seat 212, 512 to properly install the tight fitting first outer diameter surface 228, 528 of the valve seat 212, 512 into contact with the first radial recess wall 230 with significantly reduced damage to known failure points of conventional valves, thereby significantly reducing installation error as precisely cut components, such as the valve seat 212, 512 and the seat recess 218, are integrated with increased confidence of reduced damage.

[0078] In a response to a determination of whether the machining of the second radial recess wall 232 meets intended specifications, at block 916, the method 900 may proceed to block 918 for a measurement of surface roughness. The method 900 necessitates further machining if the second radial recess wall 232 does not meet intended specifications by repeating the method of block 914.

[0079] At block 918, the machined profile of the seat recess 218 may be measured for the existing surface roughness, also known as roughness average (“Ra”). The Ra may be objectively measured with a profilometer, a laser scanner, or a similar tool, to obtain an Ra value of the machined profile. In one embodiment, as discussed above, the first radial recess wall 230 may be machined finished to have a roughness average (“Ra”) of about 32 Ra. Similar specifications may be implemented on the entire machined profile of the seat recess 218.

[0080] In a response to a determination of whether the Ra of the machined profile of the seat recess 218 does not meet intended specifications, at block 920, the method 900 proceeds to block 922 for polishing. At block 922, the machined profile is polished. In one embodiment, the polish is performed by a machine to provide a reduced surface roughness to advantageously enhance the sealing capabilities of the seat pressure seal 214 and the debris protection seal 216, 516. After completion of a polishing cycle, method 900 proceed to block 918, to measure the existing surface roughness.

[0081] Alternatively, in a response to a determination of whether the Ra of the machined profile of the seat recess 218 meets intended specifications, at block 920, the method 900 also includes a valve body 202 having a seat recess 218 machined into the throughbore 248 of the valve body 202 through the throughbore 248 or through a gate cavity 238 defined by a bore positioned transversely to and in fluid communication with the throughbore 248, thereby to define a profile, e.g., a machined profile, as will be understood by those skilled in the art. The profile includes a first radial recess wall having a second diameter greater than the first diameter of the throughbore, a second radial recess wall having a radially outward extending slope beginning from the first radial recess wall at an angle of about 15 degrees to about 75 degrees, and a third radial recess wall having a third diameter greater than the second diameter of the first radial recess wall. The second recess radial is positioned to connect to the first radial recess wall and the third radial recess wall. The first radial recess wall, in an embodiment, has a length longer than a total length of the secondradial recess wall and the third radial recess wall combined, and a lip positioned adjacent the cavity to allow fluid to flow to the third radial recess wall of the valve body.

[0082] The method 900, discussed above, provides an embodiment of a method of machining of a valve recess. In another embodiment, the third radial recess wall 234 is bored before the first and second radial recess walls, as understood by those skilled in the art. In another embodiment, the second radial recess wall 232 is bored before the first and third radial recess walls, as understood by those skilled in the art.

[0083] The valve 100 may be assembled using the valve body 202 resulting from method 900, the valve seat 212,512, the seat pressure seal 214, the debris protection seal 216, 516, the gate 110, the valve stem 106, and other valve components for operation in during service, where dirt and debris consistent or often arise, as will be understood by those skilled in the art, with enhanced operational performance and extended service life, as discussed above.

[0084] FIG. 10 is a flow chart of a method to retrofit a gate valve for increased valve performance, according to one embodiment. The method 1000 details operations that may occur to obtain a desired valve body profile defined by the seat recess 218, discussed above, for a valve seat within a preassembled, or pre-used, gate valve body.

[0085] The method 1000 begins at block 1002 where a user obtains a preassembled gate valve for retrofitting the valve body of the gate valve 100. The valve body, such as valve body 202, may be obtained from an old gate valve needing repair from damage from service fluids, a gate valve that may be under performing in the intended service, or an unused preassembled gate valve. In one embodiment, the method 1000 may be used to retrofit an existing gate valve having face seals to a gate valve with diametric seals, as discussed above in reference to the seat pressure seal 214.

[0086] At block 1004, the preassembled gate valve is disassembled, or stripped, of internal components by removing any internal component portions of the gate valve to expose the throughbore of the valve body. In one embodiment, the internal component portions may be positioned in the cavity 238 of the gate valve 100. As discussed above, the internal components may include the gate 110, seats, seals, packing glands, bushings, a yoke, guides, bearings, and the like. Upon removal of the internal components, the valve body 202 may expose the throughbore 248 in preparation for machining, or re-tooling, of the valve body 202.

[0087] At block 1006, the valve body 202 is positioned for machining a portion of the throughbore 248 of the valve body 202, thereby to define profile, e g., a machined profile in anembodiment, positioned adjacent a cavity 238 of the valve body 202 configured to house the internal component portions of the gate valve so as to define a machined profile in the throughbore 248. As discussed in FIG. 9, the portion of the throughbore 248 which is machined may be positioned and fluidly connected to the cavity 238 of the valve body 202. In one embodiment, the profile is defined by a first radial recess wall 230, a second radial recess wall 232 extending and conically expanding from the first radial recess wall 230 to a third radial recess wall 234. In one embodiment, the third radial recess wall 234 is positioned closely adjacent or so as to abut the cavity 238 and has a diameter greater than the diameter of the first radial recess wall 230. In one embodiment, the first radial recess wall 230 has a diameter greater than the throughbore 248. In one embodiment, as discussed above, the second radial recess wall 232 has a slope with an angle 252. Stated differently, the machined profile includes a lip 236 in fluid communication and connecting the throughbore 248 with the cavity 238, a first bore concentrically aligned with throughbore 248 and defined by the third radial recess wall 234, a tapering portion concentrically aligned with the first bore and defined by the second radial recess wall 232, and a second bore concentrically aligned with the first bore and defined by the first radial recess wall 230.

[0088] Upon performing the machining of the valve body 202, as understood by those skilled in the art, the method 1000 proceeds to block 1008 where the gate valve 100 is reassembled with at least a valve seat having one or more valve seals, thereby to define a retrofitted gate valve. Reassembling of the gate valve 100 may be performed by inserting a valve seat 212, 512, having the seat pressure seal 214 and the debris protection seal 216, 516, into the cavity 238 and within the third radial recess wall 234. Further the valve seat 212, 512 may be slid, or guided, along the second radial recess wall 232 and into the first radial recess wall 230. Once the valve seat 212, 512 is fully inserted, the distal surface 554 of the valve seat 212, 512 may contact the distal radial wall 250 of the seat recess 218 for used in operation of the gate valve 100. Furthermore, reassembling of the gate valve 100 may include positioning any internal component portions, as will be understood by those skilled in the art, back into the cavity 238 or onto the valve body 202 for a completely assembled gate valve 100. Stated differently, the valve 100 may be reassembled using the valve body 202 resulting in an embodiment of a method 1000, the valve seat 212,512, the seat pressure seal 214, the debris protection seal 216, 516, the gate 110, the valve stem 106, and other valve components for operation such as in a dirty service, as will be understood by thoseskilled in the art, with enhanced operational performance and extended service life, as discussed above.

[0089] FIG. 11 is a perspective view of a valve seat kit 1100, according to one embodiment of the disclosure. In all embodiments, the valve seat kit 1100 includes a container 1102. The container 1102 may be a wrapper, a wooden or plastic box, a crate, or a pallet, wherein the container is configured to house or keep the components within the valve seat kit 1100 together or in a specific position. In one embodiment, the container 1102 has a locking feature or a tamperresistant feature to reduce unauthorized or inadvertent opening of the container 1102.

[0090] FIG. 11 illustrates an embodiment of a valve seat kit 1100 for a gate valve and includes the valve seat 212, the valve seat 512, the debris protection seal 216, the debris protection seal 516, and the seat pressure seal 214. In one embodiment, the seat pressure seal 214 includes annular first male spreader ring 810, the annular second male spreader ring 812, the first female seal member 802 and the second female seal member 804 in a disassembled manner. In one embodiment, the valve seat kit 1100 includes more components as illustrated in FIG. 11 such as, for example, the annular compression spring 140 as discussed above. In one embodiment, the valve seat kit 1100 includes fewer components as illustrated in FIG. 11. Further, it is to be understood by those skilled in the art that the valve seat kit 1100 also may include instructional manuals, video tutorials, degreaser packages, grease, cleaning wipes or cloth, and the like positioned with the container such as for use during or instructions for installation, as will be understood by those skilled in the art. The components as illustrated within the valve seat kit 1100 of FIG. 11 are not representative of the actual size but rather are enlarged to view component details and numerals.

[0091] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 575,485, filed April 5, 2024, titled “GATE VALVES, GATE VALVE ASSEMBLIES, GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” and U.S. Provisional Application No. 63 / 715,394, filed November 1, 2024, titled “GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” the disclosures of which are incorporated herein by reference in their entireties. This application is also a continuation-in-part of and claims the benefit of U.S. Non-Provisional 19 / 087,153, filed March 21, 2025, titled “GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATEDMETHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” which claims priority to and the benefit of U.S. Provisional Application No. 63 / 575,485, filed April 5, 2024, titled “GATE VALVES, GATE VALVE ASSEMBLIES, GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” and U.S. Provisional Application No. 63 / 715,394, filed November 1, 2024, titled “GATE VALVE SEATS AND SEALS, KITS, AND ASSOCIATED METHODS TO ENHANCE OPERATING LIFE OF GATE VALVES,” the disclosures of which are incorporated herein by reference in their entireties.

[0092] Other objects, features, and advantages of the disclosure will become apparent from the foregoing figures, detailed description, and embodiments. It should be understood, however, that the figures, detailed description, and embodiments, while indicating specific embodiments of the disclosure, are given by way of illustration only and are not meant to be limiting. Additionally, it is contemplated that changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from the detailed description. In further embodiments, features from specific embodiments may be combined with features from other embodiments. For example, features from one embodiment may be combined with features from any of the other embodiment. In further examples, additional features may be added to the specific embodiment described herein.

Claims

CLAIMSWhat is claimed is:

1. A gate valve compri sing : a valve body having a throughbore extending through the valve body, a cavity having a bore positioned transversely to and in fluid communication with the throughbore, and a profile at a connection of the throughbore and the cavity, the profile including a first bore connected to the cavity and concentrically aligned with the throughbore, a second bore concentrically aligned with the first bore, and a tapering portion positioned to extend from the first bore to the second bore; and a valve seat positioned in the second bore and having a seat pressure seal abutting contact the valve body and a debris protection seal positioned to abutting contact a distal end of the second bore.

2. The gate valve of claim 1, wherein the seat pressure seal comprises a male portion engaged with a female portion in abutting contact to compress axially to sealingly expand radially, and wherein the tapering portion has a slope with an angle of about 15 degrees to about 75 degrees.

3. The gate valve of claim 2, wherein the male portion of the seat pressure seal includes a first male spreader ring and a second male spreader ring, and wherein the female portion includes a first female seal member having a first opening configured to receive the first male spreader ring to sealingly abut the first female seal member to the second bore and the valve seat, and a second female seal member having a second opening configured to receive the second male spreader ring to sealingly abut the second female seal member to the second bore and the valve seat, the first female seal member abuttingly and directly contacting the second female seal member.

4. The gate valve of claim 1, wherein the second bore has a diameter less than the first bore, and wherein the distal end of the second bore fluidly connects the profile to the throughbore.

5. The gate valve of claim 4, wherein the debris protection seal further comprises a seal body having an inner leg extension abutting contact the valve seat and an outer leg extension abuttingly contacting the distal end of the second bore.

6. The gate valve of claim 1, wherein the debris protection seal further comprises a seal body having leg extensions that each abutting contacts the distal end of the second bore.

7. The gate valve of claim 1, wherein the debris protection seal further comprises an annular body having a proximate surface extending axially to a distal surface disposed opposite the proximate surface, an outer surface, and an inner surface parallel to the outer surface, the outer surface having outer radial slot cuts evenly spaced apart beginning from the proximate surface, the inner surface having inner radial slot cuts evenly spaced apart beginning from the proximate surface, the outer radial slot cuts and the inner radial slot cuts being evenly spaced out between each other such that the cuts alternate, straddle, and are parallel to each other beginning from the proximate surface.

8. The gate valve of claim 7, wherein the outer radial slot cuts and the inner radial slot cuts of the debris protection seal define a cross-sectional serpent pattern on the annular body, wherein the serpent pattern on the annular body of the debris protection seal is compressible and keeps a constant contacting and sealing force via the distal surface onto the distal end of the second bore, wherein the distal surface of the debris protection seal has a grooved pattern positioned therein, and wherein the grooved pattern comprises a single spiral that winds from the inner surface to the outer surface such that the single spiral defines an elongated path for particles to migrate to a seat pressure seal.

9. The gate valve of claim 13, further comprising one or more additional internal components positioned in the cavity.

10. A gate valve compri si ng : a valve actuator; a gate connected to the valve actuator so that the valve actuator actuates the gate during operation; a valve body having a first end and a second end opposite the first end, the valve body further including: A) a throughbore extending through the valve body and having a first diameterextending from the first end to the second end, B) a cavity disposed in the valve body and having a bore positioned transversely to and in fluid communication with the throughbore, the bore configured to receive the gate, thereby to position the gate to reduce or increase a fluid flow through the throughbore when in operation, and C) one or more valve seat recesses having a second diameter greater than the first diameter of the throughbore and disposed between and in fluid communication with the cavity and the throughbore; a valve seat positioned in the one or more valve seat recesses, the valve seat having an annular body with a proximate surface, a distal surface, an inner surface, and an outer surface, the proximate surface configured to contact the gate when in operation, the distal surface disposed opposite the proximate surface and configured to contact the valve body to reduce the fluid flow that bypasses the gate when the gate valve is in a closed position, the inner surface is substantially aligning with an inner diameter of the throughbore of the valve body, the outer surface further having a first portion with a first outer diameter less than a second outer diameter of a second portion, the first portion abuttingly connected to the distal surface, the second portion coupled the first portion by a substantially radial wall; a seat pressure seal positioned on the first portion of the valve seat, the seat pressure seal including a first male spreader ring, a second male spreader ring, a first female seal member having a first opening configured to receive and contact the first male spreader ring, thereby to sealingly contact the first female seal member against a recess surface of the one or more valve seat recesses when the gate compresses against the valve seat, and a second female seal member having a second opening configured to receive and contact the second male spreader ring, thereby to sealingly contact the second female seal member against the recess surface of the one or more valve seat recesses when the gate compresses against the valve seat, the first opening and the second opening being opposite facing such that the first male spreader ring abuts the valve body, the second male spreader ring abuts a substantially vertical wall of the valve seat, and the first female seal member abuttingly contacts the second female seal member; and a debris protection seal disposed in a recess within the valve seat to prevent debris from bypassing the debris protection seal and compromising a sealing power of the seat pressure seal.11 . The gate valve of claim 10, wherein the recess housing the debris protection seal is disposed in the inner surface of the valve seat and positioned in a shoulder connecting the inner surface and the distal surface of the valve seat.

12. The gate valve of claim 11, wherein the debris protection seal further comprises a seal body having an inner leg extension and an outer leg extension, the inner leg extension laterally contacting the valve seat and the outer leg extension laterally contacting the valve body, thereby to provide a redundant seal to prevent debris from bypassing the valve seat.

13. The gate valve of claim 10, wherein the recess has the debris protection seal positioned therein is disposed in the distal surface of the valve seat, and wherein the distal surface includes an indentation configured to retain debris that inadvertently bypassed the debris protection seal from accessing the seat pressure seal, thereby to reduce risk of impact to the sealing power of the seat pressure seal.

14. The gate valve of claim 13, wherein the distal surface has the indentation and includes two or more sealing surfaces abuttingly contacting the valve body when in operation such that a second redundant seal is defined by the contact of each of the two or more sealing surfaces and the valve body, wherein the valve body comprises a metal, wherein the valve seat comprises a metal, and wherein each of the two or more sealing surfaces define a metal-to-metal seal between the distal surface of the valve seat and the valve body, thereby to prevent debris that inadvertently bypassed the debris protection seal from accessing the seat pressure seal when in operation.

15. The gate valve of claim 10, wherein the bore of the cavity includes a radial cavity wall connected to a lip of each of the one or more valve seat recesses, the lip has a first end of a first radial recess wall having a third diameter greater than the second diameter of each of the one or more valve seat recesses, a second end of the first radial recess wall is connected to a linking wall extending between and connected to a second radial recess wall, the second radial recess wall has the second diameter of each of the one or more valve seat recesses, and the linking wall has a radially inward extending slope from the second end of the first radial recess wall.

16. The gate valve of claim 15, wherein the radially inward extending slope of the linking wall has an angle in a range of about 15 degrees to about 75 degrees and defines a tapering portion.

17. The gate valve of claim 10, wherein the debris protection seal further comprises an annular body having a proximate surface extending axially to a distal surface disposed opposite the proximate surface, an outer surface, and an inner surface, the outer surface having outer radial slot cuts evenly spaced apart beginning from the proximate surface, the inner surface having inner radial slot cuts evenly spaced apart beginning from the proximate surface, the outer radial slot cuts and the inner radial slot cuts positioned spaced apart evenly between each other such that the cuts alternate, straddle, and are parallel to each other beginning from the proximate surface.

18. The gate valve of claim 17, wherein the distal surface of the debris protection seal has a grooved pattern configured to capture fluid particles and to relieve a trapped pressure, wherein the grooved pattern comprises a single spiral that winds from the inner surface to the outer surface such that the single spiral defines an elongated path for particles to migrate to the seat pressure seal, thereby to reduce risk of the particles accessing and thus impeding the sealing power of the seat pressure seal.

19. A seat pressure seal for a gate valve comprising: a first male spreader ring; a second male spreader ring; a first female seal member having a first opening configured to receive and contact the first male spreader ring, thereby to sealingly contact the first female seal member against a recess surface of one or more valve seat recesses when a gate compresses against a valve seat; and a second female seal member having a second opening configured to receive and contact the second male spreader ring, thereby to sealingly contact the second female seal member against the recess surface of the one or more valve seat recesses when the gate compresses against the valve seat, the first opening and the second opening being opposite facing such that the second male spreader ring is configured to abut a valve body, the first male spreader ring is configured to abut a substantially vertical wall of the valve seat, the first female seal member abuttingly contacts the second female seal member.

20. The seat pressure seal of claim 19, wherein the first female seal member and the second female seal member each further comprise a backside surface, the backside surface of the first female seal member and the backside surface of the second female seal member physically and directly contact each other, thereby flush aligning an upper surface of the first female seal member and an upper surface of the second female seal member.

21. The seat pressure seal of claim 20, wherein the first male spreader ring comprises a first male extension configured to enter the first opening to cause the contact between the first female seal member against the recess surface of the one or more valve seat recesses, wherein the second male spreader ring comprises a second male extension configured to enter the second opening to cause the contact between the second female seal member against the recess surface of the one or more valve seat recesses, wherein the first male extension has one or more holes positioned from a proximate surface of the first male spreader ring to a distal surface of the first male spreader ring, the holes configured to allow pressure to pass through, and wherein the first female seal member and the second female seal member each comprise flexible legs configured to bow in a radial direction upon a forcible contact from the first male spreader ring or the second male spreader ring to cause the sealing between the first and second female seal member against the recess surface of the one or more valve seat recesses and against the valve seat.

22. A seat kit for use within a valve, the kit comprising: a container; a valve seat positioned in the container, the valve seat having a body with a proximate surface, a distal surface, an inner surface, and an outer surface, the proximate surface configured to contact a gate when in operation, the distal surface disposed opposite the proximate surface and configured to contact a valve body of a gate valve when positioned therein, thereby to reduce a fluid flow that bypasses the gate when a gate valve is in a closed position, the inner surface is configured to be substantially aligned with an inner diameter of a throughbore of the valve body, the outer surface further includes a first portion having a first outer diameter less than a second outer diameter of a second portion, the first portionconnects to the distal surface, the second portion is connected to the first portion by a substantially radial wall; a seat pressure seal positioned in the container, the seat pressure seal having a first male spreader ring, a second male spreader ring, a first female seal member having a first opening configured to receive and contact the first male spreader ring, thereby to sealingly contact the first female seal member against a recess surface of one or more valve seat recesses when the gate compresses against the valve seat, and a second female seal member having a second opening configured to receive and contact the second male spreader ring, thereby to sealingly contact the second female seal member against the recess surface of the one or more valve seat recesses when the gate compresses against the valve seat, the first opening and the second opening being opposite facing such that the second male spreader ring is configured to abut the valve body, the first male spreader ring abuts a substantially vertical wall of the valve seat, the first female seal member abuttingly contacts the second female seal member; and a debris protection seal positioned in the container and configured to be disposed in a recess within the valve seat to reduce debris from bypassing the debris protection seal.

23. The valve seat kit of claim 22, wherein the debris protection seal further comprises a seal body having an inner leg extension and an outer leg extension, the inner leg extension laterally contacting the valve seat and the outer leg extension configured to laterally contact the valve body, and wherein the recess housing the debris protection seal is disposed in the distal surface of the valve seat.

24. The valve seat kit of claim 22, wherein the distal surface includes an indentation configured to retain debris that inadvertently bypassed the debris protection seal from accessing the seat pressure seal, thereby not impacting the sealing power of the seat pressure seal, and wherein the distal surface having the indentation includes two or more sealing surfaces configured to abuttingly contact the valve body when in operation such that a second redundant seal is defined by the contact of each of the two or more sealing surfaces and the valve body.

25. The valve seat kit of claim 22, wherein the debris protection seal further comprises an annular body having a proximate surface extending axially to a distal surface disposed opposite the proximate surface, an outer surface, and an inner surface, the outer surface having outer radial slot cuts evenly spaced apart beginning from the proximate surface, the inner surface having inner radial slot cuts evenly spaced apart beginning from the proximate surface, the outer radial slot cuts and the inner radial slot cuts being evenly spaced out between each other such that the cuts alternate, straddle, and are parallel to each other beginning from the proximate surface, wherein the distal surface of the debris protection seal has a grooved pattern configured to capture fluid particles and to relieve a trapped pressure when installed, and wherein the grooved pattern comprises a single spiral that winds from the inner surface to the outer surface such that the single spiral defines an elongated path for particles to migrate to the seat pressure seal, thereby reducing a likelihood of the particles accessing and thus impeding the sealing power of the seat pressure seal.

26. A debris protection seal comprising: an annular body having a proximate surface extending axially to a distal surface disposed opposite the proximate surface, an outer surface, and an inner surface parallel to the outer surface, the outer surface having outer radial slot cuts evenly spaced apart beginning from the proximate surface, the inner surface having inner radial slot cuts evenly spaced apart beginning from the proximate surface, the outer radial slot cuts and the inner radial slot cuts being evenly spaced out between each other such that the cuts alternate, straddle, and are parallel to each other beginning from the proximate surface.

27. The debris protection seal of claim 26, wherein the outer radial slot cuts and the inner radial slot cuts define a cross-sectional serpent pattern on the annular body, and wherein the serpent pattern is compressible and configured to keep a constant contacting force via the distal surface on a seat recess of a valve body to effectively seal the distal surface onto the seat recess.

28. The debris protection seal of claim 26, wherein the distal surface has a grooved pattern configured to capture fluid particles and to relieve a trapped pressure, wherein the grooved patternis a single spiral that winds from the inner surface to the outer surface such that the single spiral is configured to define an elongated path for particles to migrate to a seat pressure seal.

29. A method to machine a gate valve body to define a recess for a valve seat, the method comprising: machining a seat recess into a throughbore of a valve body through the throughbore or through a cavity defined by a bore positioned transversely to and in fluid communication with the throughbore to have a profile, the profile including: a first radial recess wall having a second diameter greater than a first diameter of the throughbore, a second radial recess wall having a radially outward extending slope beginning from the first radial recess wall at an angle of about 15 degrees to about 75 degrees, a third radial recess wall having a third diameter greater than the second diameter of the first radial recess wall, the second radial recess wall connecting the first radial recess wall to the third radial recess wall, the first radial recess wall having a length longer than a total length of the second radial recess wall and the third radial recess wall combined, and a lip fluidly connecting the cavity to the third radial recess wall of the valve body.

30. The method of claim 29, wherein the valve body comprises a metal configured to contact a metal valve seat to create a metal-to-metal seal the metal valve seat and the valve body to prevent debris that inadvertently bypassed a debris protection seal from accessing a seat pressure seal when in operation, and wherein the slope of the second radial recess wall has an angle in a range of about 15 degrees to about 45 degrees.

31. A method to retrofit a gate valve for enhanced valve performance, the method comprising: disassembling a preassembled gate valve by removing internal component portions to expose a throughbore within a valve body such that a throughbore is accessible for machining; machining a portion of the throughbore of the valve body, thereby to define a profile to be positioned adjacent a cavity of the valve body and configured to house the internal component portions of the gate valve so as to define a machined portion;positioning a valve seat having a seat pressure seal and a debris protection seal within the machined portion; and reassembling the gate valve with the internal component portions and with, thereby to define a retrofitted gate valve.

32. The method of claim 31, wherein the cavity is defined by a bore positioned transversely to and in fluid communication with the throughbore, and wherein the seat pressure seal further comprises a first male spreader ring, a second male spreader ring, a first female seal member and a second female seal member each having an opening configured to receive and contact the first and second male spreader ring, thereby to sealingly contact each of the female seal members against a first radial recess wall when a gate compresses against the valve seat,33. The method of claim 32, wherein each of the openings of the first female seal member and a second female seal member are opposite facing such that the first female seal member physical and directly abuts the second female seal member along a backside surface of the first female seal member.

34. The method of claim 31, wherein a second radial recess wall has a slope with an angle of about 15 degrees to about 75 degrees, and wherein the profile is defined by a first radial recess wall, a second radial recess wall extending and conically expanding from the first radial recess wall to a third radial recess wall, the third radial recess wall abutted to the cavity and having a diameter greater than the diameter of the first radial recess wall, the first radial recess wall having a diameter greater than the throughbore.

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