The present disclosure relates to apparatus, systems, and methods for maintaining valve components and, more particularly, to apparatus, systems, and methods for lapping a surface of a valve, such as a safety relief valve.
Valve lapping refers to a procedure that is used when sealing surfaces of a valve are machined to a smooth finish with the use of an abrasive object. Lapping is the finishing of a surface that has previously been subjected to grinding. The lapping process levels the surfaces where valve components are seated and contact each other. Surfaces where metal is in direct contact with metal tend to wear and it can be important that the seal between the surfaces is tight to prevent leakage of a fluid that circulates through the valve.
In an example implementation, a valve lapping system includes an electric motor at least partially enclosed in a housing; a hollow core coupled to the housing and including a threaded outer surface; a traveling block that includes a hub configured to thread onto the threaded outer surface of the hollow core and a plurality of arms that extend from the hub, with each arm including a channel configured to receive a portion of a valve; a threaded rod that extends through the hollow core and couples to the electric motor; and a bracket coupled to the threaded rod and including an opening sized to receive a lapping block that includes an abrasive surface configured to modify a sealing surface of the valve. The bracket and lapping block are configured to rotate or oscillate, in combination, based on operation of the electric motor to rotate or oscillate the threaded rod.
In an aspect combinable with the example implementation, the bracket further includes a lock assembly configured to secure the lapping block into the opening and to the bracket.
In another aspect combinable with any of the previous aspects, the portion of the valve includes a flange bolt.
Another aspect combinable with any of the previous aspects further includes a plurality of threaded nuts, each threaded nut configured to thread onto the flange bolt that extends through the channel to secure each arm to the valve.
In another aspect combinable with any of the previous aspects, each arm extends substantially linearly from the hub, or each arm includes an L-shaped arm that extends from the hub.
In another aspect combinable with any of the previous aspects, the hub includes a plurality of arc channels.
In another aspect combinable with any of the previous aspects, each arm is secured to the hub with a bolted connection at one of the arc channels.
In another aspect combinable with any of the previous aspects, each arm is secured to the arm at a radially adjustable location with the bolted connection and the arc connection.
In another aspect combinable with any of the previous aspects, the hub is configured to thread onto the threaded outer surface of the hollow core to adjust a distance between the hub and the housing based on a size of the valve.
Another aspect combinable with any of the previous aspects further includes a controller that includes the electric motor, the controller including a plurality of control buttons.
In another aspect combinable with any of the previous aspects, the controller is configured to perform operations including based on activation of a first control button, turning the electric motor on; and based on activation of a second control button, turning the electric motor off.
In another aspect combinable with any of the previous aspects, the controller is configured to perform operations including based on activation of a third control button, adjusting a rotational speed of the electric motor to adjust a rotational speed of the bracket and the lapping block, in combination, based on operation of the electric motor at the adjusted rotational speed to rotate the threaded rod.
In another aspect combinable with any of the previous aspects, the controller is configured to perform operations including based on activation of a fourth control button, adjusting a rotational direction of the electric motor to adjust a rotational direction of the bracket and the lapping block, in combination, based on operation of the electric motor at the adjusted rotational direction to rotate the threaded rod.
In another example implementation, a valve lapping method includes installing a valve lapping system onto a valve. The valve lapping system includes an electric motor at least partially enclosed in a housing, a hollow core coupled to the housing and including a threaded outer surface, a traveling block that includes a hub threaded onto the threaded outer surface of the hollow core and a plurality of arms that extend from the hub, with each arm including a channel through which a portion of the valve extends, a threaded rod that extends through the hollow core and is coupled to the electric motor, and a bracket coupled to the threaded rod and including an opening into which a lapping block that includes an abrasive surface is secured. The method further includes operating the electric motor to rotate or oscillate the bracket and lapping block, in combination, through rotation or oscillation of the threaded rod by the electric motor; and modifying a sealing surface of the valve with the rotating or oscillating lapping block.
An aspect combinable with the example implementation further includes securing the lapping block into the opening and to the bracket with a lock assembly of the bracket.
In another aspect combinable with any of the previous aspects, installing the valve lapping system includes installing the traveling block onto the valve such that flange bolts of the valve extend through respective channels of the arms; and installing a threaded nut onto each of the flange bolts to secure each arm to the valve.
Another aspect combinable with any of the previous aspects further includes selecting arms of the traveling block that extend substantially linearly from the hub based on a size of the valve, or selecting arms of the traveling block that each includes an L-shaped arm that extends from the hub based on the size of the valve.
In another aspect combinable with any of the previous aspects, the hub includes a plurality of arc channels, and each arm is secured to the hub with a bolted connection at one of the arc channels.
Another aspect combinable with any of the previous aspects further includes adjusting a radial location of each arm in a respective arc channel; and securing each arm to the hub at the location with a bolted connection through the arc channel.
Another aspect combinable with any of the previous aspects further includes threading the hub onto the threaded outer surface of the hollow core to adjust a distance between the hub and the housing based on a size of the valve.
Another aspect combinable with any of the previous aspects further includes activating a first control button to turn the electric motor on; and activating a second control button to turn the electric motor off.
Another aspect combinable with any of the previous aspects further includes activating a third control button to adjust a rotational speed of the electric motor to adjust a rotational speed of the bracket and the lapping block, in combination, based on operation of the electric motor at the adjusted rotational speed to rotate the threaded rod.
Another aspect combinable with any of the previous aspects further includes activating a fourth control button to adjust a rotational direction of the electric motor to adjust a rotational direction of the bracket and the lapping block, in combination, based on operation of the electric motor at the adjusted rotational direction to rotate the threaded rod.
Implementations according to the present disclosure may include one or more of the following features. For example, implementations of valve lapping systems and methods according to the present disclosure can improve a lapping quality of one or more sealing surfaces of a valve, such as a safety relief valve. As another example, implementations of valve lapping systems and methods according to the present disclosure can ensure a continuity of a lapping force applied to a sealing surface of a valve by a lapping block during a lapping operation. As another example, implementations of valve lapping systems and methods according to the present disclosure can minimize a time duration of lapping process. Also, implementations of valve lapping systems and methods according to the present disclosure can avoid human error during a lapping process. Further, implementations of valve lapping systems and methods according to the present disclosure can be more time and cost efficient compared to manual or other automated lapping processes.
The details of one or more implementations of the subject matter described in this disclosure are set forth in the accompanying drawings and the description. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
Example implementations of a valve lapping system such as the valve lapping system 100 include a motor (for example, an electric motor such as an adjustable speed motor) and a bracket that secures a lapping block within the system. The bracket is connected to the motor though a shaft and coupling, which can be enclosed within a hollow core and includes a bearing compartment to keep the shaft securely driven by the motor. The example of the valve lapping system 100 can be used in lapping operations on valves of different sizes and with lapping blocks of different sizes.
Utilization of the valve lapping system 100 (and other valve lapping systems described in the present disclosure) can expedite the lapping process as compared to conventional lapping operations. For instance, a relief valve with an imbedded disk requires lapping to even the level in order to repair scratches that could cause a leak. Manual lapping methods require an average of 18 accumulated hours from a technician to finish the lapping for each relief valve. In addition, the manual lapping by a technician may not be precise enough which might affect the repair of the sealing surface. In comparison, the valve lapping system 100, for example, can minimize a lapping operation to less than a fourth of the time of such conventional methods.
In the illustrated example of
As shown in this example (and also in
As shown in
As shown in
In this example, controller 101 includes a housing 102, an electric motor (not specifically shown here), a processing system (with motor controller), and a display 104 with control buttons (shown more fully in
A controller base 106 fits on a bottom side of the housing 102 to enclose the electric motor and other electronics. As shown in this example, a housing extension 110 is connected to the housing 102 (for example, to the controller base 106) and secures the controller 101 to the hollow core 105. For example, the hollow core 105 includes a threaded surface 114 onto which the housing extension 110 can be threaded to secure the controller 101 to the hollow core 105.
Continuing with
As shown, the bracket 125 is coupled to the threaded rod 135. The threaded rod 135 can be positioned to extend through the hollow core 105 to couple to the electric motor in the controller 101 (as shown in
As shown in these figures, the threaded rod 135 is coupled, through a bearing 124, to a motor coupling 108 (also shown in
As shown in
In this example, the controller 101 includes five control buttons 134a-134e. Control button 134a can be a direction control. For example, activation (or deactivation) of control button 134a can cause the electric motor 130 to switch from rotating in a first direction (thereby rotating the threaded rod 135, bracket 125, and lapping block 300 in the first direction) to rotating in a second, opposite direction (thereby rotating the threaded rod 135, bracket 125, and lapping block 300 in the second direction).
Control button 134b can be a speed increase control. For example, activation of control button 134b can cause a rotational speed of the electric motor 130 to increase, thereby increasing a rotational speed of the threaded rod 135, bracket 125, and lapping block 300. Similarly, control button 134c can be a speed decrease control. For example, activation of control button 134c can cause a rotational speed of the electric motor 130 to decrease, thereby decreasing a rotational speed of the threaded rod 135, bracket 125, and lapping block 300.
Control button 134d can be an off control. For example, activation of control button 134d can cease all rotational speed of the electric motor 130 (gradually or instantly), thereby also ceasing a rotational speed of the threaded rod 135, bracket 125, and lapping block 300. Control button 134e can be an on control. For example, activation of control button 134e can turn the valve lapping system 100 (or 200) on, either at a low rotational speed or no rotational speed of the motor 130 (which is then activated by control button 134b).
First, as shown in
Second, as shown in
Third, as shown in
Fourth, as shown in
To begin the lapping operation, the valve lapping system 200 can be turned on by activating the control button 134e. While on, the electric motor 130 in the controller 101 may be at no speed or a very low speed unsuitable for the lapping operation. Next, the rotational speed of the electric motor 130 can be increased by manipulation of the control button 134b. Rotation produced by the electric motor 130 is transferred to the lapping block 300 through the threaded rod 135 and bracket 125. Control buttons 134b and 134c can be manipulated until a desired rotational speed of the lapping block 300 is reached and then, subsequently adjusted as needed. Optionally, control button 134a can be manipulated to reverse a rotational direction of the electric motor 130 (and thus lapping block 300). Such a change of rotational direction can result in oscillating movement of the lapping block 300 on the valve surface. In some aspects, speed and direction control of the electric motor 130 can be programmed into the controller 101 and performed in an automated fashion once the valve lapping system 200 is turned on.
While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, example operations, methods, or processes described may include more steps or fewer steps than those described. Further, the steps in such example operations, methods, or processes may be performed in different successions than that described or illustrated in the figures. Accordingly, other implementations are within the scope of the following claims.