Control Valve Packing Adjustment for Fugitive Emissions Sealing
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Solution Overview
Problem
Control valves experience fugitive emissions due to insufficient sealing, which is exacerbated by aging assets, incorrect technology choice, and valve sizing, posing challenges for operators and regulators under ESG and regulatory pressures.
Innovation Solution
An electronically controlled packing load adjuster that monitors emissions and adjusts the packing load using a worm gear arrangement and electric motor to maintain optimal sealing pressure, reducing leaks and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fixed packing is used in control valves, then the structure is simple and ease of manufacture is improved, but sealing performance deteriorates over time due to aging assets and insufficient sealing
Solution Approach 1:
The patent implements a dynamic packing adjustment mechanism that allows the packing load to be varied over time. A motor-driven lead screw mechanism adjusts the position of a packing holder, applying varying loads to the packing material. This dynamic adjustment compensates for aging effects and maintains sealing performance throughout the valve's operational life, directly resolving the contradiction between simple manufacturing and long-term reliability.
2Reliability
If adjustable packing load mechanism is added to control valves, then sealing performance is improved by reducing emissions, but device complexity increases
Solution Approach 1:
The patent incorporates a control system that automatically monitors valve performance parameters and autonomously adjusts the packing load without requiring external intervention. The controller receives feedback from sensors and actuates the motor to maintain optimal sealing conditions, enabling the valve to self-regulate and compensate for wear or aging, thus maintaining high sealing performance while managing system complexity through automation.
3Object-generated harmful factors
If motor-driven packing adjustment system is implemented, then emissions are reduced through optimal sealing, but use of energy increases
Solution Approach 1:
The patent employs a control strategy that adjusts the packing load periodically or on-demand based on monitored valve parameters rather than maintaining continuous high-load sealing. The motor activates only when adjustment is needed, reducing energy consumption while maintaining effective sealing performance and minimizing emissions throughout the valve's operational cycle.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces emissions and leaks by dynamically adjusting the packing load, enhancing sealing performance while maintaining control valve functionality.
Implementation Method 1
A worm gear arrangement is provided to translate rotation of a motor into axial movement to adjust a packing load.
Implementation Method 2
An electronically controlled packing load adjuster that monitors emissions and adjusts the packing load using a worm gear arrangement and electric motor
Data Source
AI summary
An example apparatus is disclosed herein comprising a valve that includes a valve body defining a fluid passageway between an inlet and an outlet, a flow control member in the fluid passageway, a stem coupled to the flow control member, and a bonnet coupled to the valve body. The stem extends through a channel in the bonnet. A section of the channel forms a bore. The bore is threaded. The apparatus includes packing in the channel to form a seal between the bonnet and the stem. The apparatus includes a worm wheel nut threadably engaged with the bore. The stem extends through an opening in the worm wheel nut. The apparatus also includes a worm meshed with the worm wheel nut. The worm is to rotate the worm wheel nut to cause the worm wheel nut to move and adjust a load on the packing.