Ball valves and processes of using same
View Patent ↗Ball valves, ball elements used therein, and processes for using same in cutting operations and fluid or slurry flow regulation feature a second set of ball rotation pins that mount to a second piston that is hydraulically driven in the opposite direction of a first piston. In certain embodiments the pistons move perpendicularly to a direction of flow through the ball valve.
1 . A ball valve comprising:
a) a ball member ( 2 ) mounted within a carrier ( 32 ) and rotatable relative to upper and lower ball seats ( 28 , 30 ) about a left king pin ( 4 ) and a right king pin ( 6 ) between open and closed positions;
b) the ball member ( 2 ) comprising a sealing surface ( 36 ), a bore surface ( 38 ) defining the through bore, a leading edge surface ( 40 ) extending between the sealing surface ( 36 ) and the bore surface ( 38 ), the leading edge surface ( 40 ) being configured to cut a body extending at least partially through the through bore surface ( 38 ) upon closure of the ball member ( 2 );
c) the ball member ( 2 ) further comprising a left surface ( 42 ) and a right surface ( 44 ), an upper left pin slot ( 16 ) and a lower left pin slot ( 18 ) in the ball member left surface ( 42 ), and an upper right pin slot ( 20 ) and a lower right pin slot ( 22 ) in the ball member right surface ( 44 ), the upper left and lower left pin slots ( 16 , 18 ) accepting ends of a corresponding pair of upper left and lower left ball rotation pins ( 8 , 10 ), and the upper right and lower right pin slots ( 20 , 22 ) accepting ends of a corresponding pair of upper right and lower right ball rotation pins ( 12 , 14 );
d) the upper left and lower left ball rotation pins ( 8 , 10 ), and the upper right and lower right ball rotation pins ( 12 , 14 ) operated by upper and lower cylindrical operating pistons ( 24 , 26 ) such that when the upper and lower cylindrical operating pistons ( 24 , 26 ) are driven towards the ball member ( 2 ) in opposite directions, the ball member ( 2 ) rotates to the closed position.
2 . The ball valve of claim 1
a) the ball member ( 2 ) mounted within the cylindrical carrier ( 32 ) and being rotatable relative to the upper and lower ball seats ( 28 , 30 ) about the left king pin ( 4 ) and the right king pin ( 6 ) between open and closed positions;
b) the upper ball seat ( 28 ) and the lower ball seat ( 30 ) arranged in and secured to the cylindrical carrier ( 32 );
c) a cylindrical housing ( 34 ) in which is secured the cylindrical carrier ( 32 ).
3 . The ball valve of claim 2 wherein the respective through bores of the ball seat and the ball member define a flow path through the valve, wherein the ball member is rotated relative to the upper and lower ball seats to misalign the respective through bores to prevent or restrict flow through the ball valve, and is rotated relative to the upper and lower ball seats to align the respective through bores to permit or increase flow through the ball valve.
4 . A riser comprising one or more of the ball valves of claim 2 .
5 . The ball valve of claim 2 configured to contain pressure ranging from about 500 psi to about 15,000 psi.
6 . The ball valve of claim 2 having a service trim configured for use in a highly corrosive and high pressure environment, the cylindrical housing and the cylindrical carrier comprising a low carbon, heat-treat hardened chromium-molybdenum alloy steel having a density of 7.85 g/cm 3 (0.284 lb./in 3 ), and an alloy inlay throughout, wherein the alloy inlay is a nonmagnetic, corrosion-resistant and oxidation-resistant nickel-based alloy comprising a solid solution of columbium and molybdenum in a nickel-chromium matrix.
7 . The ball valve of claim 6 wherein the low carbon, heat-treat hardened chromium-molybdenum alloy steel consists essentially of:
Element
Percentage
Carbon
0.28-0.33
Chromium
0.8-1.1
Manganese
0.7-0.9
Molybdenum
0.15-0.25
Phosphorus
less than or equal to 0.035
Silicon
0.15-0.35
Sulphur
less than or equal to 0.04.
8 . The ball valve of claim 6 wherein the nonmagnetic, corrosion-resistant and oxidation-resistant nickel-based alloy consists essentially of:
Element
Percentage
Carbon
0.10 max.
Nickel
balance
Chromium
20.0-23.0
Iron
5.00 max.
Silicon
0.50 max
Manganese
0.50 max
Sulfur
0.015 max.
Phosphorus
0.015 max.
Molybdenum
8.00-10.0
Titanium
0.40 max.
Cobalt
1.00 max.
Columbium + Tantalum
3.15-4.15
Aluminum
0.40 max..
9 . The ball valve of claim 2 wherein the upper and lower ball seats, the upper left and lower left ball rotation pins ( 8 , 10 ), the upper right and lower right ball rotation pins ( 12 , 14 ), and the king pins comprise a low carbon alloy consisting essentially of:
Element
Percentage
Carbon
0.08 max.
Nickel + Cobalt
50.00-55.00
Chromium
17.00-21.00
Iron
balance
Silicon
0.35 max
Manganese
0.35 max
Sulfur
0.015 max.
Phosphorus
0.015 max.
Molybdenum
2.80-3.30
Titanium
0.65-1.15
Cobalt
1.00 max.
Boron
0.006 max.
Copper
0.30 max.
Aluminum
0.20-0.80.
10 . The ball valve of claim 2 , wherein the ball member through bore has a bore size of 7⅜ inches or greater.
11 . The ball valve of claim 2 configured to cut coiled tubing up to 2 inch diameter at 140 ksi, slick line of 5/16 inch diameter (braided or slick), and/or Eline of 7/32 inch diameter.
12 . A process of cutting a flow conduit or communications line, the process comprising:
(a) positioning a ball valve in a flow line, the ball valve comprising
(i) a cylindrical housing ( 34 ) in which is secured a cylindrical carrier ( 32 ), an upper ball seat ( 28 ) and a lower ball seat ( 30 ) arranged in and secured to the carrier ( 32 ); a ball member ( 2 ) mounted within the carrier ( 32 ) and being rotatable relative to the upper and lower ball seats ( 28 , 30 ) about a left king pin ( 4 ) and a right king pin ( 6 ) between open and closed positions; the upper and lower ball seats ( 28 , 30 ) and the ball member ( 2 ) defining respective through bores;
(ii) the ball member ( 2 ) comprising a sealing surface ( 36 ), a bore surface ( 38 ), a leading edge surface ( 40 ) extending between the sealing surface ( 36 ) and the bore surface ( 38 ) defined by the respective through bore, the leading edge surface ( 40 ) being configured to cut a body extending at least partially through the valve upon closure of the ball member ( 2 );
(iii) the ball member ( 2 ) further comprising a left surface ( 42 ) and a right surface ( 44 ), an upper left pin slot ( 16 ) and a lower left pin slot ( 18 ) in the ball member left surface ( 42 ), and an upper right pin slot ( 20 ) and a lower right pin slot ( 22 ) in the ball member right surface ( 44 ), the upper left and lower left pin slots ( 16 , 18 ) accepting ends of a corresponding pair of upper left and lower left ball rotation pins ( 8 , 10 ), and the upper right and lower right pin slots ( 20 , 22 ) accepting ends of a corresponding pair of upper right and lower right ball rotation pins ( 12 , 14 ); an upper cylindrical operating piston ( 24 ) connected to the upper left ball rotation pin ( 8 ) and to the upper right ball rotation pin ( 12 ), and a lower cylindrical operating piston ( 26 ) connected to the lower left ball rotation pin ( 10 ) and to the lower right ball rotation pins ( 14 );
(b) running a flow conduit or communications line through the through bore of the ball valve; and
(c) closing the ball valve by exerting force on the upper cylindrical operating piston and the lower cylindrical operating piston to close the ball valve and cut the flow conduit or communications line.
13 . The process of claim 12 wherein the running of the flow conduit or communications line through the through bore of the ball valve occurs during a managed pressure operation selected from the group consisting of surface backpressure MPD (SBP MPD), floating mud cap drilling (FMCD), dynamic mud cap drilling (DMCD), pressurized mud cap drilling (PMCD), Dual Gradient Drilling (DGD), underbalanced drilling (UBD).
14 . The process of claim 12 wherein the closing of the ball valve occurs during a managed pressure operation selected from the group consisting of surface backpressure MPD (SBP MPD), floating mud cap drilling (FMCD), dynamic mud cap drilling (DMCD), pressurized mud cap drilling (PMCD), Dual Gradient Drilling (DGD), underbalanced drilling (UBD), comprising controlling the subsea pressure management sub-system and the modified riser joint from the floating vessel via the use of one or more umbilicals.
15 . A process of regulating a flow in a conduit, the process comprising:
(a) positioning a ball valve in a flow line, the ball valve comprising
(i) a cylindrical housing ( 34 ) in which is secured a cylindrical carrier ( 32 ); an upper ball seat ( 28 ) and a lower ball seat ( 30 ) arranged in and secured to the carrier ( 32 ); a ball member ( 2 ) mounted within the carrier ( 32 ) and being rotatable relative to the upper and lower ball seats ( 28 , 30 ) about a left king pin ( 4 ) and a right king pin ( 6 ) between open and closed positions; the upper and lower ball seats ( 28 , 30 ) and the ball member ( 2 ) defining respective through bores;
(ii) the ball member ( 2 ) comprising a sealing surface ( 36 ), a bore surface ( 38 ), a leading edge surface ( 40 ) extending between the sealing surface ( 36 ) and the bore surface ( 38 ) defined by the respective through bore, the leading edge surface ( 40 ) being configured to cut a body extending at least partially through the valve upon closure of the ball member ( 2 );
(ii) the ball member ( 2 ) further comprising a left surface ( 42 ) and a right surface ( 44 ), an upper left pin slot ( 16 ) and a lower left pin slot ( 18 ) in the ball member left surface ( 42 ), and an upper right pin slot ( 20 ) and a lower right pin slot ( 22 ) in the ball member right surface ( 44 ), the upper left and lower left pin slots ( 16 , 18 ) accepting ends of a corresponding pair of upper left and lower left ball rotation pins ( 8 , 10 ), and the upper right and lower right pin slots ( 20 , 22 ) accepting ends of a corresponding pair of upper right and lower right ball rotation pins ( 12 , 14 ); an upper cylindrical operating piston ( 24 ) connected to the upper left ball rotation pin ( 8 ) and to the upper right ball rotation pin ( 12 ), and a lower cylindrical operating piston ( 26 ) connected to the lower left ball rotation pin ( 10 ) and to the lower right ball rotation pins ( 14 );
(b) flowing a fluid or slurry through the ball member through bore while the ball member is in an open position; and
(c) exerting force on the first and second pistons to close the ball valve and regulate the flow in the conduit partially or fully.
16 . The process of claim 15 wherein the flowing of the fluid or slurry through the ball member through bore while the ball member is in an open position is performed during a managed pressure operation selected from the group consisting of surface backpressure MPD (SBP MPD), floating mud cap drilling (FMCD), dynamic mud cap drilling (DMCD), pressurized mud cap drilling (PMCD), Dual Gradient Drilling (DGD), underbalanced drilling (UBD).
17 . The process of claim 15 wherein the exerting force on the first and second pistons to close the ball valve is performed during a managed pressure operation selected from the group consisting of surface backpressure MPD (SBP MPD), floating mud cap drilling (FMCD), dynamic mud cap drilling (DMCD), pressurized mud cap drilling (PMCD), Dual Gradient Drilling (DGD), underbalanced drilling (UBD).