Modular Flow Trim Valve for Erosion-Resistant Severe Service
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Solution Overview
Problem
Conventional valves used in severe conditions, such as the oil and gas industry, face issues with erosion, corrosion, and operational challenges due to exposure to solids, brine, and acids, leading to reduced durability and efficiency.
Innovation Solution
A modular valve design with a rotatable disk mechanism, protected by a top mounting pad and interior sleeve, featuring a groove to prevent fluid pressure impact, and removable components for easy maintenance, along with a wear disc and sensor port for monitoring wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional valve assemblies are used in severe conditions, then they can control fluid flow, but they suffer from erosion, corrosion, and reduced durability
Solution Approach 1:
The valve is divided into modular components including a replaceable flow trim assembly, seat rings, and disk assembly that can be independently serviced. This segmentation allows critical components exposed to erosion and corrosion to be replaced without replacing the entire valve, thereby improving durability and reliability in severe service conditions
Solution Approach 2:
The valve design incorporates adjustable flow trim configurations and interchangeable seat rings that can be selected based on specific service conditions. By changing parameters such as trim geometry, material composition, and seat configuration, the valve can be optimized for different erosion and corrosion scenarios, enhancing its reliability
2Ease of operation
If multiple-port-disk flow trims are used to control fluid flow, then flow rate adjustment is achieved, but operational challenges and maintenance complexity increase
Solution Approach 1:
The valve employs a dynamic flow trim system where the movable disk can be positioned at multiple angles to control flow rate. This dynamic adjustment capability provides precise flow control while the modular design simplifies maintenance by allowing the entire flow trim assembly to be quickly replaced as a single unit, reducing operational complexity
Solution Approach 2:
The flow trim assembly is designed as a universal module that can be applied across different valve sizes and configurations. The standardized design allows the same basic assembly to serve multiple functions and be used in various service conditions, simplifying both operation and maintenance while providing effective flow control
3Reliability
If valves are designed for severe service conditions, then they can withstand harsh environments, but component replacement and maintenance become difficult
Solution Approach 1:
The valve is segmented into easily removable components including the flow trim assembly, seat rings, and disk that can be independently accessed and replaced. This segmentation enables maintenance personnel to service critical components without specialized tools or extensive disassembly, making repair easy while maintaining the ability to withstand severe service conditions
Solution Approach 2:
Critical components such as the flow trim assembly and seat rings are designed to be extractable from the valve body without removing the entire valve from the pipeline. This extraction capability allows for quick in-line maintenance and replacement, improving ease of repair while the robust design of these extracted components ensures they can withstand severe service conditions
Data Source
AI summary
A valve having a flow trim assembly that can be quickly and efficiently removed and repaired or replaced. A body section having a central through bore that defines an inlet, an inner chamber or space, and two selectable outlets. Further the selectable outlets can direct flow in either a 90 degree “angle” orientation or at straight “in-line” orientation. An actuator stem extends into the inner chamber. A first (movable) trim member is attached to the rotator, and can be selectively rotated relative to a second (fixed) trim member. The first and second trim members cooperate to adjust flow opening through the valve. A valve bonnet that allows direct coupling of an actuator to the valve.