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<p>The choke valve is a critical component in natural gas production, responsible for pressure reduction and flow regulation. Wear-induced failure of its transmission mechanism can lead to a significant increase in operating torque, thereby compromising operational safety and efficiency under ultra-high-pressure and extreme temperature conditions. In this study, the transmission pair of a cage-type choke valve with a rated working pressure of 175&#xa0;MPa was investigated to elucidate its wear characteristics and torque behavior across a temperature range of − 46 to 180&#xa0;°C. Full-scale cyclic opening and closing tests under 175&#xa0;MPa were conducted to identify the optimal material combination for the transmission pair. The results demonstrated that pairing a 42CrMo transmission rod with a high-beryllium-copper transmission nut effectively mitigates wear and reduces the risk of functional failure. Subsequently, thermo-mechanical coupled finite element analyses were performed under − 46&#xa0;°C, 20&#xa0;°C, and 180&#xa0;°C at 175&#xa0;MPa, yielding simulated torques of 209 N m, 164 N m, and 120 N m, respectively. Real-time torque measurements from full-scale experiments showed corresponding values of 200 N m, 145 N m, and 110 N m, which were slightly lower than the simulated results, confirming the reliability of the modeling approach. This study demonstrates that rational material pairing can substantially reduce wear-induced failure risks in ultra-high-pressure choke valve transmission mechanisms. The findings provide both theoretical insights and experimental validation for material selection and torque control strategies, offering practical guidance for preventing transmission mechanism failures in extreme operating environments.</p>

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Mitigation of Wear-Induced Torque Failures in a 175-MPa Choke Valve: Experimental and Numerical Insights

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • Bao Zhang,
  • Hao Zhang,
  • Hongtao Jing,
  • Junhui Wei,
  • Chunyu Feng

摘要

The choke valve is a critical component in natural gas production, responsible for pressure reduction and flow regulation. Wear-induced failure of its transmission mechanism can lead to a significant increase in operating torque, thereby compromising operational safety and efficiency under ultra-high-pressure and extreme temperature conditions. In this study, the transmission pair of a cage-type choke valve with a rated working pressure of 175 MPa was investigated to elucidate its wear characteristics and torque behavior across a temperature range of − 46 to 180 °C. Full-scale cyclic opening and closing tests under 175 MPa were conducted to identify the optimal material combination for the transmission pair. The results demonstrated that pairing a 42CrMo transmission rod with a high-beryllium-copper transmission nut effectively mitigates wear and reduces the risk of functional failure. Subsequently, thermo-mechanical coupled finite element analyses were performed under − 46 °C, 20 °C, and 180 °C at 175 MPa, yielding simulated torques of 209 N m, 164 N m, and 120 N m, respectively. Real-time torque measurements from full-scale experiments showed corresponding values of 200 N m, 145 N m, and 110 N m, which were slightly lower than the simulated results, confirming the reliability of the modeling approach. This study demonstrates that rational material pairing can substantially reduce wear-induced failure risks in ultra-high-pressure choke valve transmission mechanisms. The findings provide both theoretical insights and experimental validation for material selection and torque control strategies, offering practical guidance for preventing transmission mechanism failures in extreme operating environments.