RU240000U1 - Ball valve using spiral springs - Google Patents

Abstract

The utility model relates to pipeline valves intended for use as a device for changing the flow direction of the working medium in turbo-piston units included in systems for measuring the quantity and quality of oil and petroleum products. A ball valve using spiral springs contains at least three springs, which are located between the seat and the flange evenly around the circumference of the seats, pressing the seat against the plug. The technical result is increased reliability and durability due to the creation of a flow-through design by introducing a spring structure instead of a metal bellows, while the degradation time of the unit is up to 100,000+ cycles. The technical result is achieved by using a valve with a spring structure, in particular, from spiral cylindrical compression springs, which performs the function of separating media instead of a bellows in the closed position, and the function of passing steam in the open position, while the springs exhibit significantly less wear compared to a bellows, which together leads to a significant reduction in production costs, maintenance and repair costs. 6 z.p. f-ly, 4 ill.

Description

Field of technology

The utility model relates to pipeline fittings intended for use as a device for changing the direction of the flow of the working medium in turbo-piston units included in systems for measuring the quantity and quality of oil and petroleum products.

State of the art

A four-way valve is known (patent RU173352, priority date August 23, 2017). The four-way valve design utilizes a cast body with four ports, a shutoff valve assembly consisting of a conical plug with an L-shaped seal and an upper and lower stem attached to it, a damping device, an automatic pressure relief device, and a leak detection unit. A disadvantage of this solution is the use of metal structures at operating temperatures ranging from -40°C to +40°C, without taking into account thermal expansion. At temperatures close to the critical limits, the reliability of the pressure relief automation decreases. There is a high risk of depressurization after a period of operation. The non-dismountable design, long repair times, and short intervals between repairs also present challenges.

Also known from the prior art is a three- and four-way coking diverter valve, the Velan Coker Diverter Valve, information about which is published on the Internet (https://velan.com/products/coker-diverter-valves-three-and-four-way/ - access date 05/22/2025), containing a robust one-piece body, an annular seal with a steam block, the ability to purge the bellows and body with steam, while the design contains an electric, hydraulic or pneumatic drive, which function depending on the operating conditions.

A disadvantage of the known technical solution is the use of a metal bellows in the valve, which operates at high temperatures. This determines its limited service life due to cyclic loads, susceptibility to fatigue failure and loss of mechanical properties under the influence of thermal stress, as well as a high probability of corrosion and erosion, which leads to frequent failures and increased downtime for repairs.

A four-way valve is known, registered by Saudi Arabian Oil Company, Aramco Services Company (international application WO2016164442, priority date 06.04.2016) the four-way valve has a body with an inlet and an outlet, a first circulation port and a second circulation port, the four-way valve additionally has a valve plug located inside the valve body, with valve body seals that seal against the fluid between the valve body and the valve plug, the valve plug can rotate between a forward seat position for directing fluid from the inlet to the first circulation port and a reverse seat position for directing fluid from the inlet to the second circulation port.

The disadvantage of this solution is a complex and unreliable damping system that requires adjustment, low reliability, and the possibility of sudden failures due to the lack of a pressure relief device.

A coke chamber switching valve (patent RU 222265, priority date August 10, 2023) is proposed as the technical solution (prototype) closest to the claimed utility model. The valve design includes a body, a ball plug, seats securing the ball plug at three points, and purge nozzles. The valve serves as a distribution unit for high-temperature hydrocarbons obtained during the cracking of heavy petroleum residues. It is used to switch between storage chambers every 12-14 hours. A disadvantage of this solution is the use of a metal bellows due to its low durability, loss of mechanical properties due to fatigue failure, and long repair times.

A common, significant problem with these similar systems is the use of metal bellows in their design, which have a limited service life, are prone to fatigue failure, and loss of mechanical properties. Furthermore, bellows require regular maintenance and replacement, which increases operating costs. Repairs are often complicated by the need to dismantle structural components, further increasing costs and reducing the overall reliability of the system.

The technical challenge is to create an improved ball valve design without the use of a bellows, which, as a structural element, is susceptible to fatigue, corrosion, and mechanical failure, the likelihood of which increases during high-temperature processes. A bellows failure leads to leaks, reduced valve performance, and other problems. The bellows also complicates installation and repair.

The technical result is an increase in the reliability and durability of the ball valve by creating a design with the introduction of springs instead of a metal bellows, while increasing the degradation time of the unit to 100,000+ cycles.

Revealing the essence

This technical result is achieved by using springs in the ball valve, specifically helical cylindrical compression springs, which act as a medium separation mechanism instead of a bellows in the closed position and as a steam passage mechanism in the open position. The springs are located around the perimeter of the seat and press the seat against the plug, resting on the flange. This also compensates for thermal expansion of the metal components, maintains the required seat-to-plug contact force, and provides effective vibration isolation during equipment startup and shutdown. Furthermore, springs exhibit significantly less wear compared to bellows, which collectively leads to a significant reduction in production, maintenance, and repair costs.

The claimed utility model differs from its closest analogue in that it uses springs instead of a metal bellows, in particular spiral cylindrical compression springs of comparable rigidity to the bellows.

Brief description of the drawings

Fig. 1 - general view of the ball valve.

Fig. 2 - longitudinal sectional view of a ball valve with spiral springs.

Fig. 3 - passage of coke and steam flows in the body of the tap with spiral springs.

Fig. 4 - the course of the spiral spring: open and closed position,

where 1 is the body;

2 - spindle;

3 - medium outlet units with blow-out nozzles;

4 - tap plug;

5 - bushing;

6 - spiral spring;

7 - nozzle flange;

8 - housing cavity;

9 - saddle;

A - spiral spring in working condition (extension).

Implementation

The claimed utility model is implemented as follows.

A ball valve comprises a valve body 1, which serves as the main structural component of the device and ensures mechanical strength and tightness. It is made of durable materials, typically metal, that are resistant to external influences and provide adequate protection of the internal components from corrosion. Body 1 contains a cavity 8 containing a spindle 2 with a plug 4. The plug 4 is spherical and rotates within body 1, changing the direction of fluid flow. When the holes in the plug 4 align with the terminals in body 1, unimpeded fluid flow is ensured, allowing the fluid or gas to flow freely.

The movement of plug 4 is enabled by spindle 2, which is connected to an external control mechanism, allowing the operator to control the flow of medium in the ball valve. Sleeve 5 maintains plug 4 in the desired position and prevents wear by reducing friction between plug 4, springs 6, and body 1, as plug 4 rotates frequently and must remain sealed when opening and closing. Sleeve 5 also allows steam and coke to reach the springs.

Nozzle flange 7 is the component through which the fluid exits. It can have several configurations depending on the specific needs of the system. Nozzles integrated into fluid exit assemblies 3 ensure uniform flow distribution and can be adapted to optimize operation under various conditions. Seat 9 engages plug 4, which is acted upon by springs 6 evenly spaced around the circumference of the seats. This is the part of the design that determines the tightness and reliability of the ball valve.

Ball valve components operating at high temperatures are subject to thermal expansion. The formula for thermal expansion of the plug diameter is known:

D=D0*(1+α(T1-T0),

where D is the plug diameter at the calculated operating temperature;

D0 – plug diameter at a temperature of 20°C;

α is the coefficient of thermal expansion of the metal;

T0 - initial temperature of the plug (20°C);

T1 - maximum design temperature.

In this case, in the preferred embodiment, the plug diameter D = 675.5 mm * (1 + 10 1/(μ°C) (550°C - 20°C) = 678.5 mm.

After subtracting the original diameter from the obtained one, we get:

678.5 - 675.5 = 3 mm, which is the maximum expansion of the plug diameter and is taken as the calculated spring travel for the specific ball valve implementation under consideration. Moreover, it has been experimentally confirmed that, depending on the valve's design features, the material used, and its dimensions, the optimal spring travel in a ball valve is determined to be between 1 and 5 millimeters.

The spring stroke (Fig. 4) determines the difference in position between the “open” position of the springs, where the passage of steam and coke flows is ensured, and the “closed” position, where the separation of the media occurs due to the sealing of the internal cavity of the housing and the channel of the working medium, and the steam flows supplied through the nozzles.

Springs 6, evenly spaced around the circumference of the seats, are located at each outlet and functionally replace the bellows in known designs. They are installed in the valve to maintain pressure on plug 4, which facilitates improved sealing and closure, preventing fluid leakage. Depending on the flow rate in the valve, the spring can be positioned in various operating positions—open, closed, and intermediate—adapting it to system requirements. Specifically, when gas flows such as coke and steam pass through the valve, the spring can compress or expand to adapt to changing conditions, ensuring stable operation.

The embodiment comprises at least three springs, which are evenly spaced between seat 9 and flange 7 around the circumference of the seats, pressing seat 9 against plug 4, thereby ensuring uniform pressure distribution within the structure. It has been proven that fewer springs are prone to distortion, uneven pressure distribution within the assembly, and a high risk of spring breakage. In the preferred embodiment, the valve comprises eight springs, evenly spaced around the circumference of the seat, thereby ensuring an optimal balance of open and closed position performance.

Experiments have confirmed that the degradation time of a crane assembly using spiral springs increases to 100,000+ cycles compared to the average of 10,000-50,000 cycles for an identical crane using a bellows. Effective vibration isolation is achieved during start-up and shutdown modes of the equipment, while the springs exhibit significantly less wear compared to bellows. This increases the reliability and durability of the crane.

The preferred embodiment utilizes helical cylindrical compression springs. The spring travel, shown in detail view A (Fig. 4), corresponds to the expansion of the plug diameter for this implementation—3 mm. Thus, the spring travel accommodates any expansion of the seat-to-plug joint and compensates for thermal expansion of the metal components under both normal and high-temperature operating conditions. The required seat-to-plug contact force is maintained, effective vibration isolation is achieved during equipment startup and shutdown, and vortex shock damping occurs during petroleum product transportation.

There are also spring designs that involve rigid attachment by welding or other means at one or both ends of the spring to the rest of the structure. Full fixation: each spring is rigidly fixed at one end to the flange and the other end to the seat, ensuring the stability of the assembly and reducing the risk of loosening during cyclic use. Partial fixation: each spring is secured to the flange.

When the operator turns the spindle, the plug begins to rotate. Depending on the plug's position, the flow rate within the valve changes, allowing the fluid to be directed to the desired areas of the system. If the plug rotates 90 degrees, the flow is completely blocked, achieved by a tight seal between the plug and the seat. The springs are crucial in this regard, compensating for thermal expansion of metal components, maintaining the required seat-to-plug contact force, providing effective vibration isolation during equipment startup and shutdown, and damping vortex shocks that occur during petroleum product transportation. Furthermore, springs exhibit significantly less wear compared to bellows, and the seat design ensures easy spring installation during assembly, which collectively leads to a significant reduction in production, maintenance, and repair costs.

Thus, by creating a design with the introduction of springs instead of a metal bellows, the technical result is confirmed, namely, it increases the reliability and durability of the ball valve.

Claims (7)

1. A ball valve comprising a body made with inlet and outlet channels, in the cavity of which seats are placed, also containing a ball plug, a sleeve, a flange, characterized in that it contains springs that provide pressure on the plug in such a way that in the closed position separation of the media is achieved, and in the open position, passage of steam, wherein the springs are located between the seat and the flange evenly around the circumference of the seats. 2. A ball valve according to item 1, characterized in that spiral cylindrical compression springs are used. 3. A ball valve according to claim 1, characterized in that at least three springs are evenly distributed around the circumference of the seats. 4. A ball valve according to item 1, characterized in that eight springs are evenly distributed around the circumference of the seats. 5. A ball valve according to claim 1, characterized in that each of the springs is tightly secured to the flange. 6. A ball valve according to item 1, characterized in that each of the springs is tightly secured to the flange at one end and to the seat at the other end. 7. A ball valve according to item 1, characterized in that the working stroke of the spring is from 1 to 5 mm.