Modular Stop for Ball Valve Wear Management
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Solution Overview
Problem
Current drill stem safety valve (DSSV) stop mechanisms are prone to premature failure due to low corrosion resistance and inability to withstand high torque, leading to overtravel and reduced valve life, as they either yield under load or require costly replacement of the entire valve body.
Innovation Solution
A modular stop system integrated into a removable stem insert made from more corrosion-resistant alloys, providing adjustable stopping power and allowing for easy inspection and replacement, which can be retrofitted into existing valves to extend their service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If stop rings are used to provide stopping surfaces, then the valve can be operated, but the low surface area causes yielding under torque load leading to overtravel and premature failure
Solution Approach 1:
The stop system is segmented into multiple independent stop elements (first stop and second stop) distributed around the valve body circumference. Each stop provides a localized stopping surface for the cam lobes, collectively providing sufficient stopping power while maintaining operational ease. This segmentation allows the load to be distributed across multiple contact points rather than concentrated on a single low-surface-area ring.
Solution Approach 2:
The invention transitions from a two-dimensional stop ring surface to a three-dimensional arrangement of multiple stops positioned at specific angular locations around the valve body. The stops extend radially inward and are positioned to receive cam lobes at approximately 45-degree angles, creating multiple stopping surfaces that collectively provide adequate stopping power without requiring a large single surface area.
2Strength
If the valve body is made from high strength carbon steel alloy to withstand high pressure and torque, then strength is improved, but corrosion resistance deteriorates and welding becomes impossible
Solution Approach 1:
The valve system is segmented into two distinct material systems: the valve body made from high-strength carbon steel alloy for pressure and torque resistance, and the stops made from corrosion-resistant materials (such as stainless steel, monel, or bronze) for corrosion resistance. This segmentation allows each component to be optimized for its specific functional requirements without compromising the other.
Solution Approach 2:
The invention employs composite material construction by combining high-strength carbon steel alloy for the valve body with corrosion-resistant materials for the stops. The stops are made from materials such as stainless steel, monel, or bronze that provide superior corrosion resistance while maintaining sufficient mechanical strength to withstand the operational loads transmitted from the stem and cam lobes.
3Manufacturing precision
If cam style stops are integrated into the valve body to improve stopping power, then alignment accuracy is improved, but repairability deteriorates as the stops cannot be replaced
Solution Approach 1:
The stops are extracted from the valve body as separate, removable components rather than being permanently integrated into the body structure. Each stop is positioned in a recess or cavity within the valve body and can be independently removed and replaced. This extraction maintains the precise alignment benefits of integrated stops while enabling easy replacement when wear occurs.
Solution Approach 2:
The stop system is made dynamic in terms of maintainability - while the stops are fixed in position during operation to provide precise alignment, they are designed to be easily removable and replaceable during maintenance. The stops can be accessed through openings in the valve body and replaced without requiring valve body replacement or complex disassembly procedures.
4Ease of repair
If stop rings are made replaceable to fix yielding issues, then repairability is improved, but the low surface area limits stopping power
Solution Approach 1:
The stop system is segmented into multiple independent stop elements positioned around the valve body circumference. Each stop provides a localized stopping surface for the cam lobes, and collectively they provide sufficient total stopping power. The segmentation allows each stop to be relatively small (maintaining replaceability) while the cumulative effect of multiple stops provides adequate stopping power to prevent overtravel.
Solution Approach 2:
Each stop is designed with localized quality - the stopping surface area of individual stops is optimized to receive the cam lobes at specific angular positions. The stops are positioned to provide optimal stopping power at the critical points in the valve rotation cycle, with the cam lobes contacting the stops at approximately 45-degree angles to maximize the stopping effect while minimizing wear.
Data Source
AI summary
A modular stop is provided for ball valves, such as those used as drill stem safety valves. The modular stop can be a replaceable component in valves for use with stems used to rotate a ball valve in the valve's body. The modular stop can bear the wear associated with the operation of ball valves and when the modular stop has exceeded its usable service life, it can be replaced without replacing the whole of the valve body. The modular stop can be used in new valve manufacture as well as in the retrofitting or remanufacturing of existing valves.