Bidirectional one piece metal seat for ball valve
The disclosure relates a metal seat for a ball valve, having a seating segment of the metal seat; a curved seating surface defined on the seating segment, wherein the curved seating surface is complementary to an outer surface of a ball of the ball valve; a primary spring unitary with the seating segment and the curved seating surface; and a base unitary with the primary spring, the seating segment, and the curved seating surface.
1 . A metal seat for a ball valve, comprising:
a seating segment of the metal seat;
a curved seating surface defined on the seating segment, wherein the curved seating surface is complementary to an outer surface of a ball of the ball valve;
a primary spring unitary with the seating segment and the curved seating surface;
a base unitary with the primary spring, the seating segment, and the curved seating surface;
a coating overlayed onto the curved seating surface, wherein a hardness of the coating is greater than a hardness of the seating segment;
wherein the primary spring is composed of a first material, the seating segment is composed of a second material, the coating is comprised of a third material and further wherein the first material, the second material and the third material are different;
wherein the primary spring defines an interstice, and further comprising a secondary spring inserted into the interstice;
wherein the primary spring forms a first caret shape in a cross sectional view of the primary spring; and
wherein the first caret defines a first vertex on an exterior surface of the primary spring.
2 . The metal seat according to claim 1 , wherein the primary spring forms a second caret shape in cross sectional view of the primary spring, and wherein the second caret is joined to the first caret and defines a second vertex on an interior surface of the primary spring.
3 . The metal seat according to claim 1 , wherein the seating segment, the primary spring, and the base are produced by a method of additive manufacturing.
4 . The metal se at according to claim 1 , further comprising a secondary spring inserted into the metal seat.
5 . A valve having a valve body comprising:
a ball within the valve body, wherein the ball defines an outer surface;
a first metal seat inserted into the valve body upstream of the ball;
a second metal seat inserted into the valve body downstream of the ball;
wherein each of the first metal seat and the second metal seat comprise:
a curved seating surface defined respectively on each of the first metal seat and the second metal seat complementary to the outer surface of the ball;
a primary spring unitary with each of the curved seating surface;
a base unitary with each of the primary spring and each of the curved seating surface;
a coating overlayed onto each of the curved seating surfaces; and
wherein each of the primary springs are composed of a first material, each of the curved seating surfaces are composed of a second material, and each of the coatings are comprised of a third material and further wherein the first material, the second material and the third material are different;
wherein the first metal seat and the second metal seat each comprise a gasket seal inserted between a back face of the base and the valve body.
6 . The valve of claim 5 , wherein each of the primary spring of the first metal seat and the second metal seat define an upper interstice bounded by the valve body, and further comprising a secondary spring inserted into the upper interstice.
7 . The valve of claim 5 , wherein each of the primary springs of the first metal seat and the second metal seat define a lower interstice open to a bore of the valve body, and further comprising a secondary spring inserted into the lower interstice.
8 . The valve of claim 5 , wherein the curved seating surface, the primary spring, and the base of each of the first metal seat and the second metal seat are produced by a method of additive manufacturing.
9 . The valve according to claim 5 , wherein a cross sectional view of each of the first metal seat and the second metal seat has a first side, and a second side opposite to the first side, and wherein each of the primary springs consists of a single caret shape in the cross sectional view at each of the first side and at the second side.
10 . The valve according to claim 9 , further comprising a secondary spring inserted into each of the first metal seat and the second metal seat.
11 . A method for use of a ball valve, comprising the following:
providing a ball within the ball valve, wherein the ball defines an outer surface;
providing a first metal seat upstream of the ball;
providing a second metal seat downstream of the ball;
wherein each of the first metal seat and the second metal seat comprise:
a curved seating surface defined on each of the first metal seat and the second metal seat complementary to the outer surface of the ball;
a primary spring unitary with each of the curved seating surface; and
a base unitary with each of the primary spring and each of the curved seating surface;
a coating overlayed onto each of the curved seating surfaces, wherein the coating resists erosion and wear;
wherein each of the primary springs are composed of a first material, each of the curved seating surfaces are composed of a second material, and each of the coatings are comprised of a third material and further wherein the first material, the second material and the third material are different;
preventing a leak path behind each of the first metal seat and the second metal seat via a unitary connection of the curved seating surface, the primary spring, and the base of each of the first metal seat and the second metal seat; and
wherein the step of preventing a leak path behind each of the first metal seat and the second metal seat is further via a bellows unitary with the primary spring and curved seating surface.
12 . The method of claim 11 further comprising the steps of: additive manufacturing said first metal seat prior to said step of providing said first metal seat; and additive manufacturing said second metal seat prior to said step of providing said second metal seat.
13 . The method of claim 11 , further comprising the steps of torquing consistently; reducing torque; and providing a Class VI shutoff rating per ANSI/FCI 70-2.
14 . The method according to claim 11 , wherein a cross sectional view of each of the first metal seat and the second metal seat has a first side, and a second side opposite to the first side, and wherein each primary spring consists of a single caret shape in the cross sectional view at each of the first side and at the second side.
15 . The method of claim 13 , further comprising the step of maintaining a seal between the ball and each of the curved seating surfaces defined on each of the first metal seat and the second metal seat without reliance on a line pressure.
16 . The method of claim 15 , wherein the primary spring of the first metal seat and the second metal seat provides consistent spring loading on both sides of the ball; and further comprising the step of wearing the ball valve in a consistent wear pattern.
17 . A method of manufacturing for a ball valve, comprising the steps of:
depositing one or more layers of material to produce a unitary seat having a seat base, a primary spring segment, and a seating segment; and
mate-lapping a surface of the unitary seat;
wherein the step of depositing one or more layers of material comprises the steps of depositing a first set of layers of a first material via additive manufacturing, then depositing a second set of layers of a second material via additive manufacturing, and then depositing a third set of layers in a third material, wherein the first material, the second material and the third material each have a different composition of metals.
18 . The method according to claim 17 , wherein the third set of layers is a coating having a hardness greater than the material of the unitary seat and is deposited via additive manufacturing.
19 . The method according to claim 18 , wherein the surface of the unitary seat is defined on an interior surface of the seating segment and is arced to be complementary to a ball of the ball valve.
20 . The method according to claim 19 , further comprising the step of assembling the ball and the unitary seat in an unpressurized condition.
21 . The method according to claim 18 , wherein a cross sectional view of the unitary seat has a first side, and a second side opposite to the first side, and wherein each of the primary spring segments consists of a single caret shape in the cross sectional view at each of the first side and at the second side.
22 . The method according to claim 21 , further comprising the step of inserting a secondary spring into the unitary seat during the step of depositing one or more layers.