High pressure ball valve

1. A method comprising:

locating a flow control assembly in a portion of an axial fluid flow bore disposed through a valve body, the axial fluid flow bore having an inlet end located opposite an outlet end, the flow control assembly comprising a flow control element disposed between, and having an outer surface in sealing contact with an inner annular surface of an inlet valve seat and an inner annular surface of an outlet valve seat, wherein the flow control element is rotatable between an open and a closed position;

wherein at least a portion of the inner annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, or a combination thereof, comprise a sealing face dimensioned and arranged to sealingly engage a portion of the outer surface of the fluid flow control element;

wherein at least a portion of the inner annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, or a combination thereof, comprise a plurality of support surfaces dimensioned and arranged in physical contact with the outer surface of the fluid flow control element adjacent the sealing face;

wherein the inlet valve seat, the outlet valve seat, or a combination thereof comprise a plurality of vent grooves laterally disposed into the inner annular surface of the valve seat between the plurality of support surfaces;

rotationally engaging an inner end of a valve stem in a corresponding recess of the flow control element, the valve stem extending from an outer end through a packing bore disposed radially around the valve stem in the valve body to an inner end of the valve stem, wherein the inner end of the valve stem comprises a plurality of sides, the recess having a corresponding number of sides, wherein a distance between the sides of the recess are dimensioned relative to a distance between the plurality of sides of the first end of the valve stem to allow for an amount of lateral movement of the flow control element between the fluid flow bore inlet end and the fluid flow bore outlet end;

applying a pressurized fluid to the inlet end of the fluid flow bore to laterally move the flow control assembly towards the outlet end of the fluid flow bore in an amount sufficient to produce sealing contact between an outer annular surface of the outlet valve seat with a portion of the valve body;

applying a pressurized fluid to the outlet end of the fluid flow bore to laterally move the flow control assembly towards the inlet end of the fluid flow bore in an amount sufficient to produce sealing contact between an outer annular surface of the inlet valve seat and a portion of the valve body;

rotating the valve stem such that the flow control element is in the closed position prior to or after the application of the pressurized fluid to the inlet or outlet end of the flow bore, the pressurized fluid having a pressure of greater than 275.8 MPa (40,000 psi) and a temperature of greater than or equal to about 200° C.; and

maintaining the pressure of greater than 275.8 MPa (40,000 psi) and temperature of greater than or equal to about 200° C. for at least 1 hour, wherein the fluid is maintained by the valve without leaking past the flow control element into the respective inlet or outlet end of the fluid flow bore.

2. The method of claim 1 , wherein the sealing face and the support surfaces comprise a spray and fuse coating comprising metals from Groups 6-12 of the periodic table of the elements alone, or in compounds comprising elements from Groups 13-16 of the periodic table of the elements.

3. The method of claim 1 , further comprising:

locating a plurality of packing rings around the valve stem within an inner diameter of the packing bore;

locating an inner anti-extrusion ring in the packing bore between the packing rings and an inner end of the packing bore; and

locating an outer anti-extrusion ring in the packing bore between the packing rings and a packing gland.

4. The method of claim 1 , further comprising preventing blowout of the stem with a shoulder having an enlarged outer diameter formed on the valve stem wherein the outside diameter of the shoulder is greater than an inside diameter of a portion of the valve body, a portion of a bracket attached to the valve body, a bushing attached to the valve body, or a combination thereof disposed around the valve stem between the outer end of the valve stem and the shoulder.

5. The method of claim 1 , wherein the inlet valve seat, the outlet valve seat, or a combination thereof comprise an annular groove disposed into the inner annular surface of the valve seat between the sealing face and the plurality of support surfaces, to inhibit propagation of cracks from the support surfaces into the sealing face.

6. The method of claim 1 , wherein at least a portion of the outer surface of the fluid flow control element, the fluid flow bore, the inner annular surface of the inlet valve seat, the outer annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, the outer annular surface of the outlet valve seat, or a combination thereof includes a spray and fuse coating comprising metals from Groups 6-12 of the periodic table of the elements alone, or in compounds comprising elements from Groups 13-16 of the period table of the elements.

7. The method of claim 1 , further comprising attaching at least one of the inlet valve seat or the outlet valve seat to the valve body using a plurality of radially spaced threaded members engaged with an outer radial edge of the at least one of the inlet valve seat or the outlet valve seat and the valve body.

8. A bidirectional valve comprising:

a valve body comprising an axial fluid flow bore disposed therethrough having an inlet end located opposite an outlet end and a flow control assembly located within a portion of the fluid flow bore;

the flow control assembly comprising a flow control element disposed between, and having an outer surface in sealing contact with an inner annular surface of an inlet valve seat and an inner annular surface of an outlet valve seat, wherein the flow control element is rotatable between an open and a closed position;

wherein at least a portion of the inner annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, or a combination thereof, comprise a sealing face dimensioned and arranged to sealingly engage a portion of the outer surface of the fluid flow control element;

wherein at least a portion of the inner annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, or a combination thereof, comprise a plurality of support surfaces dimensioned and arranged in physical contact with the outer surface of the fluid flow control element adjacent the sealing face, and a plurality of vent grooves laterally disposed between each of the plurality of support surfaces;

wherein the inlet valve seat, the outlet valve seat, or a combination thereof comprise a plurality of vent grooves laterally disposed into the inner annular surface of the valve seat between the plurality of support surfaces;

a valve stem extending from an outer end through a packing bore disposed radially around the valve stem in the valve body to an inner end of the valve stem, wherein the inner end of the valve stem comprises a plurality of sides dimensioned and arranged to rotationally engage a corresponding recess having a corresponding number of sides disposed into the flow control element, wherein a distance between the sides of the recess are dimensioned relative to a distance between the plurality of sides of the first end of the valve stem to allow for an amount of lateral movement of the flow control element laterally between the fluid flow bore inlet end and the fluid flow bore outlet end such that a pressure applied to the inlet end of the fluid flow bore results in lateral movement of the flow control assembly towards the outlet end of the fluid flow bore in an amount sufficient to produce sealing contact between an outer annular surface of the outlet valve seat with a portion of the valve body, and such that a pressure applied to the outlet end of the fluid flow bore results in lateral movement of the flow control assembly towards the inlet end of the fluid flow bore in an amount sufficient to produce sealing contact between an outer annular surface of the inlet valve seat and a portion of the valve body, or a combination thereof.

9. The valve of claim 8 , wherein the sealing face and the support surfaces comprise a spray and fuse coating comprising metals from Groups 6-12 of the periodic table of the elements alone, or in compounds comprising elements from Groups 13-16 of the periodic table of the elements.

10. The bidirectional valve of claim 8 , wherein at least one of the inlet valve seat or the outlet valve seat is attached to the valve body using a plurality of threaded members radially spaced about and engaged with an outer radial edge of the at least one of the inlet valve seat or the outlet valve seat and the valve body.

11. The bidirectional valve of claim 8 , further comprising a valve stem packing system comprising:

a plurality of packing rings having an inner diameter dimensioned to be disposable around the valve stem, and an outer diameter dimensioned to be locatable within an inner diameter of the packing bore disposed radially around the valve stem in the valve body.

12. The bidirectional valve of claim 8 , wherein a fluid applied upstream or downstream to the fluid flow bore is maintained by the valve in the closed position without leaking downstream or upstream respectively past the flow control element for at least one hour, wherein the applied fluid has a pressure of greater than 275.8 MPa (40,000 psi) and a temperature of greater than or equal to about 200° C.

13. The valve of claim 8 , wherein the sealing contact between the outer annular surface of the outlet valve seat with the valve body, between the outer annular surface of the inlet valve seat and the valve body, or a combination thereof, are metal-to-metal.

14. The valve of claim 11 , further comprising an outer anti-extrusion ring disposed between the plurality of packing rings and a packing gland.

15. The valve of claim 14 , further comprising an inner anti-extrusion ring disposed between the plurality of packing rings and an inner end of the packing gland.

16. A valve comprising:

a valve body comprising an axial fluid flow bore disposed therethrough having an inlet end located opposite an outlet end and a flow control assembly located within a portion of the fluid flow bore;

the flow control assembly comprising a flow control element disposed between, and having an outer surface in sealing contact with an inner annular surface of an inlet valve seat and an inner annular surface of an outlet valve seat, wherein the flow control element is rotatable between an open and a closed position;

a valve stem extending from an outer end through a packing bore disposed radially around the valve stem in the valve body to an inner end of the valve stem, wherein the inner end of the valve stem comprises a plurality of sides dimensioned and arranged to rotationally engage a corresponding recess having a corresponding number of sides disposed into the flow control element, wherein a distance between the sides of the recess are dimensioned relative to a distance between the plurality of sides of the first end of the valve stem to allow for an amount of lateral movement of the flow control element laterally between the fluid flow bore inlet end and the fluid flow bore outlet end such that a pressure applied to the inlet end of the fluid flow bore results in lateral movement of the flow control assembly towards the outlet end of the fluid flow bore in an amount sufficient to produce sealing contact between an outer annular surface of the outlet valve seat with a portion of the valve body, and such that a pressure applied to the outlet end of the fluid flow bore results in lateral movement of the flow control assembly towards the inlet end of the fluid flow bore in an amount sufficient to produce sealing contact between an outer annular surface of the inlet valve seat and a portion of the valve body, or a combination thereof;

wherein the valve stem further comprises a shoulder with an enlarged outer diameter formed on the valve stem wherein the outside diameter of the shoulder is greater than an inside diameter of a portion of the valve body, a portion of a bracket attached to the valve body, a bushing attached to the valve body, or a combination thereof disposed around the valve stem between the outer end of the valve stem and the shoulder.

17. The bidirectional valve of claim 8 , wherein the inlet valve seat, the outlet valve seat, or a combination thereof comprise an annular groove disposed into the inner annular surface of the valve seat between the plurality of support surfaces and the sealing face.

18. A valve comprising:

a valve body comprising an axial fluid flow bore disposed therethrough having an inlet end located opposite an outlet end and a flow control assembly located within a portion of the fluid flow bore;

the flow control assembly comprising a flow control element disposed between, and having an outer surface in sealing contact with an inner annular surface of an inlet valve seat and an inner annular surface of an outlet valve seat, wherein the flow control element is rotatable between an open and a closed position;

a valve stem extending from an outer end through a packing bore disposed radially around the valve stem in the valve body to an inner end of the valve stem, wherein the inner end of the valve stem comprises a plurality of sides dimensioned and arranged to rotationally engage a corresponding recess having a corresponding number of sides disposed into the flow control element, wherein a distance between the sides of the recess and the first end of the valve stem is dimensioned to allow for lateral movement of the flow control element between the fluid flow bore inlet end and the fluid flow bore outlet end such that a pressure applied to the inlet end of the fluid flow bore produces sealing contact between an outer annular surface of the outlet valve seat with a portion of the valve body, and such that a pressure applied to the outlet end of the fluid flow bore produces sealing contact between an outer annular surface of the inlet valve seat and a portion of the valve body, or a combination thereof;

wherein at least a portion of the outer surface of the fluid flow control element, the fluid flow bore, the inner annular surface of the inlet valve seat, the outer annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, the outer annular surface of the outlet valve seat, or a combination thereof includes a spray and fuse coating comprising metals from Groups 6-12 of the periodic table of the elements alone, or in compounds comprising elements from Groups 13-16 of the period table of the elements.

19. The valve of claim 18 , wherein the spray and fuse coating forms an annular sealing face on the inner annular surface of the inlet valve seat, of the outlet valve seat, or a combination thereof, dimensioned and arranged to sealingly engage a portion of the outer surface of the fluid flow control element.

20. The valve of claim 19 , wherein the spray and fuse coating forms a plurality of support surfaces adjacent the sealing face dimensioned and arranged in physical contact with the outer surface of the fluid flow control element.

21. The valve of claim 20 , further comprising an annular groove separating the support surfaces from the sealing face.

22. The valve of claim 21 , further comprising a plurality of vent grooves laterally disposed between each of the plurality of support surfaces.

23. The valve of claim 22 , wherein the support surfaces and vent grooves are disposed between the annular groove and an outer radial edge of the valve seat.

24. The valve of claim 22 , wherein the plurality of support surfaces and vent grooves are disposed between the annular groove and an inner radial edge of the valve seat.

25. A valve comprising:

a valve body comprising an axial fluid flow bore disposed therethrough having an inlet end located opposite an outlet end and a flow control assembly located within a portion of the fluid flow bore;

the flow control assembly comprising a flow control element disposed between, and having an outer surface in sealing contact with an inner annular surface of an inlet valve seat and an inner annular surface of an outlet valve seat, wherein the flow control element is rotatable between an open and a closed position;

a valve stem extending from an outer end through a packing bore disposed radially around the valve stem in the valve body to an inner end of the valve stem, wherein the inner end of the valve stem comprises a plurality of sides dimensioned and arranged to rotationally engage a corresponding recess having a corresponding number of opposing sides disposed into the flow control element, wherein a distance between the sides of the recess are dimensioned relative to a distance between the plurality of sides of the first end of the valve stem to allow for an amount of lateral movement of the flow control element between the opposing sides of the inner end of the valve stem and the recess to produce sealing contact between an outer annular surface of the inlet valve seat and a portion of the valve body;

wherein at least a portion of the inner annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, or a combination thereof, comprise a sealing face dimensioned and arranged to sealingly engage a portion of the outer surface of the fluid flow control element, and wherein at least a portion of the inner annular surface of the inlet valve seat, the inner annular surface of the outlet valve seat, or a combination thereof, comprise a plurality of support surfaces dimensioned and arranged in physical contact with the outer surface of the fluid flow control element adjacent the sealing face, and a plurality of vent grooves laterally disposed between each of the plurality of support surfaces.