Hydraulic control valve systems and methods

Abstract

A subsea control valve is described having an improved hydraulic actuation system for movement of the gate and shear seal. The described valve also features a pressure monitoring arrangement for sensing pressure within portions of the valve. In a second described aspect, a control valve is provided with a segmented solenoid core actuator that allows for more certain actuation of the valve. In a further aspect, a valve system is described having a manifold with an improved fluid distribution system. In a further aspect, an exemplary valve is described having a pair of solenoid actuation coils. In still a further aspect, a solenoid actuated valve is provided with pulse-type actuation.

1 . A hydraulic control valve comprising: 
 a) a valve body having a function port, a supply port to allow for the supply of hydraulic fluid to the function port, and a vent port to allow fluid to vent from the function port;    b) a gate assembly having a gate moveably mounted within the valve body and a shear seal mounted within the gate, the gate assembly selectively directing hydraulic pressure to and from the function port by selectively alternating between a vent open-supply closed position and a vent closed-supply open position; and    c) a valve actuation assembly for moving the gate and shear seal between the positions.    
   
   
       2 . The hydraulic control valve of  claim 1  wherein the valve actuation assembly comprises a hydraulic actuation assembly having: 
 a) a hydraulic fluid chamber with an associated hydraulic fluid inflow line;    b) a hydraulic piston member retained within the chamber and moveable between distal and proximal positions in response to changes in pressure from the fluid inflow line; and    c) an actuation member extending between the piston member and the gate assembly to selectively move the gate assembly between said vent open-supply closed position and vent closed-supply open position.    
   
   
       3 . The hydraulic control valve of  claim 2  wherein the piston member presents distal and proximal pressure-receiving areas, the distal pressure receiving area being smaller than the proximal pressure-receiving area.  
   
   
       4 . The hydraulic control valve of  claim 2  further comprising a fluid passage interconnected with the hydraulic fluid chamber to provide vent pressure to a portion of the fluid chamber.  
   
   
       5 . The hydraulic control valve of  claim 4  further comprising a pair of annular fluid seals upon said piston member to define a vent-ported chamber therebetween.  
   
   
       6 . The hydraulic control valve of  claim 1  wherein the valve actuation assembly comprises a solenoid actuator assembly that is operably associated with the gate for selective movement of the gate.  
   
   
       7 . The hydraulic control valve of  claim 6  wherein the solenoid actuator assembly comprises: 
 a) a solenoid coil;    b) a fixed core element within the coil;    c) a plurality of moveable core elements within the coil and axially moveable therewithin, each of the moveable core elements being moveable with respect to the fixed core element and selectively engageable with an actuation member to cause movement of the gate.    
   
   
       8 . The hydraulic control valve of  claim 7  wherein the actuation member further comprises a stepped actuation rod having multiple rod portions of different diameters, at least one of the rod portions presenting a shoulder to engage a moveable core element.  
   
   
       9 . The hydraulic control valve of  claim 7  further comprising a pressure sensor assembly used as a wiring junction point where all wiring including the coil(s) and the pressure sensor are interconnected, as required, and terminated for connection to an external control source.  
   
   
       10 . The hydraulic control valve of  claim 6  wherein the solenoid actuator assembly comprises: 
 a) a moveable core element;    b) first and second independently energizeable solenoid coils, the first coil being selectively energizable to move the core element in a proximal direction, the second coil being selectively energizable to move the core element in a distal direction.    
   
   
       11 . The hydraulic control valve of  claim 10  wherein the first and second coils have windings in opposite radial directions.  
   
   
       12 . The hydraulic control valve of  claim 10  wherein the solenoid actuator assembly further comprises a pair of fixed core elements, each of which are located proximate an opposite axial end of the moveable core element to provide magnetic attraction to the moveable core element.  
   
   
       13 . A hydraulic control valve comprising: 
 a) a valve body having a function port, a supply port to allow for the supply of hydraulic fluid to the function port, and a vent port to allow fluid to vent from the function port;    b) a gate assembly having a gate moveably mounted within the valve body and a shear seal mounted within the gate, the gate assembly selectively directing hydraulic pressure to and from the function port by selectively alternating between a vent open-supply closed position and a vent closed-supply open position;    c) a valve actuation assembly for moving the gate and shear seal between the positions; and    d) a fail safe mechanism for allowing electrical pulse actuation to retain the valve in the vent closed-supply open position when electrical power is removed and further allow the valve to fail safe close upon loss of supply pressure.    
   
   
       14 . The hydraulic control valve of  claim 13  wherein the fail safe mechanism comprises a differential piston assembly disposed between the valve actuation assembly and the gate assembly and comprising: 
 a) a differential piston chamber that is ported to vent;    b) a differential area shuttle piston moveably retained within the differential piston chamber and having: 
 1) a body that presents a distal portion upon which supply pressure is applied and a radial shoulder that is exposed to vent pressure; and  
 2) a compressible portion that allows the body to be moved within the chamber in response to supply pressure.  
   
   
   
       15 . The hydraulic control valve of  claim 14  wherein the compressible solenoid actuated portion comprises a compressible spring.  
   
   
       16 . The hydraulic control valve of  claim 14  wherein the internal valve pressure activated compressible locking or holding portion comprises a Belleville washer.  
   
   
       17 . The hydraulic control valve of  claim 13  wherein the valve actuation assembly is controlled by electrical pulses provided by a remote controller, said electrical pulses being operable to move the valve between the vent open-supply closed position and the vent closed-supply open position.  
   
   
       18 . A valve system comprising: 
 a) a manifold with at least one valve operably associated therewith that utilizes hydraulic fluid;    b) the manifold further having a first plate member and a second plate member being affixed to one another; and    c) a hydraulic fluid communication system having at least one fluid pathway formed by an groove in at least one of the plate members for transmission of hydraulic fluid to or from the valve.    
   
   
       19 . The valve system of  claim 18  wherein the hydraulic fluid communication system further comprises: 
 a) a first annular groove operably associated with a fluid inflow line and the valve for supply of hydraulic fluid to the valve; and    b) a second annular groove operably associated with a fluid outflow line.