STEM NUT THREAD WEAR ANALYSIS APPARATUS AND METHOD

Abstract

A method of quantifying stem nut thread wear in a valve having a valve stem that is positioned with a stem nut. A tool is mounted to, and rotates with, the stem nut, while simultaneously measuring stem displacement. The method of orienting the stem nut threads where one 360 rotation will capture all of the thread backlash in addition to any stem displacement. The measured stem displacement, including stem nut thread backlash, can then be used, with certain stem geometry parameters, to calculate stem nut thread wear percent and quantify remaining stem nut thread material.

Claims

1. A method of measuring stem nut thread wear in a valve having a threaded valve stem that is positioned with a threaded stem nut, comprising the steps of: a) gaining access to the top of the stem and stem nut area; b) mounting a tool apparatus atop the stem nut, wherein the it rotates with the stem nut; c) providing a method to measure 100% of stem nut thread backlash in 360 of stem nut rotation; d) mounting a tool apparatus to simultaneously measure valve stem axial movement and stem nut rotation; and e) providing a method to determine an amount of stem nut thread wear from the stem movement measured;

2. The apparatus of claim 1, wherein the tool body has a central opening and the valve stem extension rod is positioned in the central opening.

3. The apparatus of claim 1, wherein an indicator attached to the valve stem extension rod indicates rotation of the tool body.

4. The apparatus of claim 1, wherein the tool body has a marker to indicate the tool body has rotated 360.

5. The apparatus of claim 1, wherein there is an instrument attached to the tool body that quantifies axial stem movement.

6. The method of claim 1, wherein the stem nut threads are positioned in proximity to the valve stem threads where 360 rotation of the stem nut includes 100% of the thread backlash.

7. The method of claim 1, wherein the amount of stem nut wear is calculated using certain variables including stem Pitch, Lead, Stem Diameter, thread type and stem movement.

8. The method of claim 7, wherein remaining stem nut thread thickness and percent wear can be determined from the calculation.

9. The method of claim 3, wherein the instrument is mechanical.

10. The method of claim 3, wherein the instrument is a laser.

11. The method of claim 3, wherein the instrument is a digital rotary encoder.

12. The method of claim 5, wherein the instrument is mechanical.

13. The method of claim 5, wherein the instrument is digital.

14. The method of claim 5, wherein the instrument is a linear variable differential transformer.

15. The method of claim 5, wherein the instrument is a digital linear encoder.

16. The method of claim 5, wherein the instrument detects axial stem displacement.

17. An apparatus that indicates valve stem nut thread wear to an observer, comprising; a) a tool body having a lower portion adapted to connect to, and rotate with, a stem nut that is to be measured for thread wear, said tool body having an upper end portion comprised with a means of mounting instruments; b) an instrument that quantifies axial valve stem movement; c) an instrument that quantifies stem nut rotation relative to the valve stem; d) providing a method to capture 100% stem nut thread backlash in 360 of stem nut rotation; and e) providing a method to determine an amount of stem nut thread wear from stem movement measurement;

18. The apparatus of claim 17 wherein the upper portion is circular.

19. The apparatus of claim 17 wherein the tool body has an open center portion.

20. The apparatus of claim 17 wherein a valve stem extension rod extends through the open center portion.

21. The apparatus of claim 17 wherein the instrument used to quantify axial valve stem movement is a dial indicator.

22. The apparatus of claim 17 wherein the instrument used to quantify axial valve stem movement is digital.

23. The apparatus of claim 17 wherein the instrument used to quantify axial valve stem movement is an optical encoder.

24. The apparatus of claim 17 wherein the instrument used to quantify axial valve stem movement is a linear variable differential transformer.

25. The apparatus of claim 17 wherein the instrument used to provide a fixed position to quantify rotation is a mechanical pointer.

26. The apparatus of claim 17 wherein the instrument used to provide a fixed position to quantify rotation is at least in part a laser.

27. The apparatus of claims 25 and 26 wherein the pointer is affixed to the stem.

28. The apparatus of claims 25 and 26 wherein a stationary marker is affixed to the upper end portion to indicated when the stem nut has rotated 360.

29. The apparatus of claim 17 wherein the instrument used to provide a fixed position to quantify rotation is a rotary encoder.

30. The apparatus of claim 29 wherein the rotary encoder is connected on the upper end to the linear encoder stylus and the lower end is affixed to the valve stem.

31. The apparatus of claim 17 further comprising a pointer not attached to the tool body, which indicates rotation of the tool body.

32. The apparatus of claim 17, wherein the stem nut threads are positioned in proximity to the valve stem threads where 360 rotation of the stem nut includes all of the thread backlash.

33. The apparatus of claim 17, wherein the amount of stem nut thread wear is calculated using certain variables including stem Pitch, Lead, Diameter, thread type and stem movement.

34. The method of claim 32 wherein the calculations are performed and results documented in a report spreadsheet.

35. The method of claim 32 wherein the calculations are performed, and results documented, digitally.

36. The apparatus of claim 17 wherein the displacement measuring instrument includes a stylus that directly or indirectly contacts the stem to accurately measure axial stem movement.

37. The apparatus of claim 17 wherein the upper portion of the assembly has a means to temporarily and securely affix the displacement measurement instrument.

38. The apparatus of claim 17 wherein the lower portion of the tool body legs are adjustable to provide proper fit to stem nut.

39. The apparatus of claim 17 wherein the upper portion of the tool body is engraved a marker.

40. The apparatus of claim 17 wherein the upper portion of the tool body is affixed with a marker connected to and situated perpendicular to the upper portion surface to facilitate the pointer in measuring 360

41. The inventions substantially as shown and described herein.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0050] For a further understanding of the nature, objects, and advantages of the present invention, reference should be made to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

[0051] FIG. 1 is a cross section profile of a general purpose acme stem thread with a basic formula depicting how the formula calculates the stem nut thread base thickness;

[0052] FIG. 2 is a cross section profile of a general purpose acme stem thread mated with an unworn stem nut thread;

[0053] FIG. 3 is a cross section profile of a general purpose acme stem thread mated with a worn stem nut thread;

[0054] FIG. 4 is the general purpose acme calculation to find stem nut thread wear percent and remaining thread material;

[0055] FIG. 5 is the stub acme calculation to find stem nut thread wear percent and remaining thread material;

[0056] FIG. 6 is a typical report sheet used to automatically calculate and track/trend test results. This report will also extrapolate when the stem nut will reach a designated wear percent.

[0057] FIG. 7 is stem and stem nut test apparatus used to validate tool and process accuracy and repeatability.

[0058] FIG. 8 is the mold and measurement of the worn stem nut thread root used in the test apparatus (FIG. 7).

[0059] FIG. 9 is the lower portion of the Universal Tool Disk with adjustable rod-mounting bolts inserted into the adjustment grooves.

[0060] FIG. 10 is the lower portion of the Universal Tool Disk with the mounting rods spaced and secured for mounting on the test apparatus (FIG. 7).

[0061] FIG. 11 is the test assembly used to validate the accuracy and repeatability of the invention device and method for determining stem nut thread wear percent and remaining thread thickness.

[0062] FIG. 12 is the basic assembly of digital transducers used to simultaneously quantify axial and rotational parameters.

[0063] FIG. 13 is an excerpt from the table used to record the data taken from the test stand to validate accuracy and repeatability.

[0064] FIG. 14 is a schematic view of a basic embodiment of the apparatus of the present invention detached from the stem and stem nut;

[0065] FIG. 15 is a schematic view of a basic embodiment of the apparatus of the present invention connected to the stem and stem nut;

[0066] FIG. 16 is actual field installation of partial assembly on valve

[0067] FIG. 17 is a schematic view of a typical motor operated valve setup with apparatus and ready to perform test.

[0068] FIG. 18 is a picture of a typical stem nut locknut compression clamp used to secure the apparatus to valve stems that are not oriented pointing straight up.

[0069] FIG. 19 is a picture of an allen cap screw being tightened illustrating how the locknut compression clamp O-ring is compressed and correspondingly expanded to hold the inside diameter of the stem nut locknut.

[0070] FIG. 20 is a picture of how the apparatus is secured to the locknut compression clamp using the all-thread mounting rods.

DETAILED DESCRIPTION OF THE INVENTION

[0071] FIGS. 14, 15 and 17 show a preferred embodiment of the apparatus of the present invention, more clearly identified in FIG. 14 as the upper assembly prior to being mounted to the stem 4 and stem nut 5. The measuring apparatus is used to measure valve stem nut 5 thread wear on any rising stem valve having a threaded stem nut 5 that mates with and moves the threaded stem 4. The apparatus of the present invention can be used with any diameter stem 4. In FIGS. 9 and 10, the universal disk lower portion 1 shows how the mounting rods 7 can be adjusted to properly interface with a valve stem 4 and stem nut 5.

[0072] To perform the method of the present invention, the stem protector and indication rod (if installed) are removed. The apparatus is preferably mounted where it will rotate freely with the stem nut 5. The mounting rods 7, when connected to the disk lower portion 15 grooves can be adjusted to adapt the apparatus to interface with most stem 4 and stem nut 5 sizes. Various length mounting rods 7 can be used to adjust for different stem nut 5 depth requirements.

[0073] A displacement indicator 2 is used to detect axial stem movement in the setup shown in FIG. 15. However, any instrument capable of measuring axial stem movement may be used. A valve stem extension rod 8 and stylus contact button 11 will be required to allow the displacement indicator stylus 12 to contact the top of the valve stem 4. A stem contact button 13 is connected to the lower portion of the valve stem extension rod 8 and, using removable adhesive putty, press on to the center of the grease free valve stem 4. This will allow the valve stem extension rod 8 to remain stationary as the stem nut 5 rotates.

[0074] The pointer assembly 3 will be affixed to the valve stem extension rod 8 above the upper portion 14 of the universal tool disk 1, and positioned where it aligns with, and points to, the marker 9. The pointer 3 is installed where it is provided free travel axially as the valve stem 4 travels and rotationally as the stem nut 5 turns 360. The pointer 3, being indirectly connected to the valve stem 4, will nullify any valve stem 4 rotation that would otherwise induce an error.

[0075] FIG. 1 illustrates the profile of a typical general purpose acme thread to explain the basics of how the calculations are used to determine stem nut 5 thread wear from the backlash obtained from performing a test. Once the apparatus is properly installed, and the valve is in the fully closed position, the valve will then be positioned to where the test can be performed. Rotating the hand wheel 18 open will cause the stem nut 5 to rotate.

[0076] Universal tool disk 1 can be generally circular as shown in FIGS. 9 and 10 and have a central opening. The tool disk lower portion 15 provides three grooves to allow for three threaded bolts to freely slide. To properly adapt the tool disk 1 to the valve stem 5 and stem nut 6, two measurements will be required, stem nut locknut inside diameter and stem nut 5 depth from the top of the actuator housing. Three mounting rods 7 of the proper lengths will then be selected and screwed to the bolts slid into the lower portion 15 grooves. Divide the stem nut locknut inside diameter by two to find the radius then, using the measurement marks, slide and tighten the mounting rods 7 to where the outside of the rods 7 are just inside the measurement mark. It is best to have the mounting rods 7 rest on the stem nut 5 and have an interference fit with the stem nut 5 locknut.

[0077] Tool post 6 is threaded to and supported by tool disk 1. Tool post 6 supports displacement indicator 2 which can be any instrument that measures axial stem movement. Displacement indicator stylus 12 will rest on the stylus contact button 11 which is connected to the valve stem extension rod 8 mounted above the pointer 4.

[0078] Cleaning the valve stem 4 and the top of the stem nut 5 may be desirable to facilitate the apparatus installation. The apparatus contains a displacement indicator 2, or any similar instrument capable of detecting axial stem 4 movement.

[0079] The valve stem extension rod 8 will be required to allow the displacement indicator 2 to measure stem 4 movement. The top of the stem 4 needs to be clean of any oily substance to facilitate adhesion of the adhesive putty. Using reusable adhesive putty applied to the bottom of the stem contact button 13 securely press it onto the center of the is valve stem 4 top. Slide the universal tool disk 1 with mounting rods 7 secured, sub-assembly FIG. 10, to rest on top of the stem nut 5. Add enough valve stem extension rods 8 to extent through the universal disk upper portion 14 at least 1.5 FIG. 16. Slide the pointer assembly onto the valve stem extension rod 8 and allow it to rest on the disk upper portion 14. Install the stylus contact button 11 by screwing it to the top of the valve stem extension rod 8.

[0080] In FIG. 15, the apparatus sits atop the stem nut, and rotates therewith as the stem nut is rotated. The test begins with the stem nut 5 threads contacting the stem 4 threads in one direction; this ensures that when the stem nut 5 is rotated in the opposite direction, the 360 of stem nut 5 rotation will include 100% of the thread backlash. The larger diameter universal tool disk 1 has affixed in it a marker that indicates the starting and ending place to ensure exactly 360 of rotation in relationship to the stem-mounted pointer 3. Simultaneous to measuring stem nut 5 rotation, stem 4 displacement is being measured with the displacement indicator 2 through the valve stem extension rod 8. The test will begin with the pointer 3 pointing directly at marker 9 and the displacement indicator stylus 12 resting on the stylus contact button verifying that there is enough stylus 12 travel length to travel at least the distance of stem Lead. Once the universal tool disk 1 has traveled 360, record the displacement reading. Then, reset the displacement indicator 2 to zero and rotate the universal tool disk 1 in the opposite direction 360 and record the reading. If the two displacement reading are the same, enter the value into the Report Sheet FIG. 6. With the stem 4 Pitch, Lead and Diameter, data correctly entered, percent wear and remaining stem nut 5 thread thickness will be calculated.

[0081] Effective operation requires minimal training; however, having a basic mechanical understanding of valve designs would help the technician modify his technique to successfully perform the test. Certain dynamics that could make backlash measuring difficult are:

[0082] 1. Loose Stem Nut LocknutThis conditions is not relevant if the apparatus is resting directly on the stem nut 5; however, sometimes this is impossible and will have to be mounted to another component that rotates with the stem nut 5. If this alternate location is required, any axial stem nut 5 free play may mask the true backlash amount;

[0083] 2. System PressureDepending on valve design and packing loads, system pressure could make it difficult to find the backlash area due to the stem 4 ejection effect and low packing loads;

[0084] 3. Stem OrientationThe basic design of the present invention requires the valve stem to be oriented vertical up. Any other orientation will necessitate the tool to be mounted using a locknut compression clamp FIGS. 18-20.

[0085] 4. Thread ContaminationThe presence of hardened grease, broken thread material or any other solid contaminant between the threads may mask the true backlash measured by the present invention.

[0086] To perform the method of the present invention with the apparatus, one can perform the following steps:

[0087] With the apparatus in place on the stem nut 4 of a closed valve 17, declutch the actuator 16 if necessary, and rotate the hand wheel 18 open. The actuator 16 usually goes through a lost-motion region as the worm gear advances around the drive sleeve until it contacts lugs on the drive sleeve (referred to as hammer blow). The drive sleeve and stem nut 4 will then start turning. The stem 4, being in a compressed state, may appear to be moving as the mass of the stem 4 metal relaxes. Depending on the amount of valve T-bar slop, system pressure and packing tightness, the stem may continue to rise as the stem T-bar takes up the slop where it connects to the valve. The stem 4 should stop moving even as the stem nut 5 turns indicating stem 4 and stem nut 5 thread disengagement. Stop rotating the hand wheel 18 and reset the displacement indicator 2 where the indicator stylus 12 can travel a distance greater than the thread Lead measurement then, re-zero the displacement indicator 2 reading. Rotate the pointer 3 or universal disk assembly 1 where the pointer is aligned with the marker 9. Continue rotating the hand wheel 18 until the marker 9 on the universal disk 1 returns to where it is realigned with the pointer 3 and record the displacement indicator 2 reading. Then, reset the displacement indicator 2 reading to zero and rotate the hand wheel 18 in the closed direction until the universal disk rotates 360 where the marker 9 and pointer 3 are again aligned; record reading. During this rotation, a dead space should have been noticed where the stem 4 and stem nut 5 threads are disengaged, indicating thread backlash. If this backlash event is not seen, there may be excessive system pressure ejecting the valve stem 4 and disk assembly requiring a bleed-down of the line pressure. Once the line pressure is bled down, repeat steps going open, then closed until the displacement 2 readings agree.

[0088] The displacement 2 reading will then be entered into the Report Sheet FIG. 6 where it will be used with the stem 4 Diameter, Pitch and Lead to calculate the stem nut 5 thread wear percent and remaining thickness at the root of the worn stem nut 5 thread. The Report Sheet FIG. 6 will also allow the user to enter a desired percent wear amount and, based on the first and last data points taken, it will automatically extrapolate the date it is estimated it should reach that amount.

[0089] To eliminate stem 4 thread wear as the source of measured backlash, one should place a pitch gauge on the stem 4 threads to observe any detectable wear. Also, record on the Report Sheet, FIG. 6, stem Pitch, Lead and Diameter as these values will be required to perform the necessary calculations.

[0090] FIG. 14 is a drawing of a tool of the basic apparatus used to interface with a wide range of stem sizes. The tool can be used to measure stem nut thread wear on valves with general purpose and stub acme stems with diameters ranging from 1.125 to 8 with 1, 2, 3 and 4 thread starts. The apparatus, FIG. 14, can be used only on valve stems pointing straight up however, using a Locknut Compression Clamp, FIGS. 18, 19 and 20, the apparatus, FIG. 14, can be mounted to test many stem nuts driving stems in orientations other than straight up. The all-thread mounting rods 7 screw into the top of the clamps, FIG. 14

[0091] Over the next 12 months, further testing will be done to gain data from practical use and results may be included in the final patent application.

[0092] The following is a list of parts and materials suitable for use in the present invention:

TABLE-US-00002 Parts Number Description 1 Universal tool disk 2 Displacement indicator 3 Pointer 4 Valve stem 5 Stem Nut 6 Tool Post 7 Mounting rods 8 Valve stem extension rod 9 Marker 10 Indicator mounting clamp 11 stylus contact button 12 Displacement indicator stylus 13 Stem contact button 14 Universal tool disk (1) upper portion 15 Universal tool disk (1) lower portion 16 Motor operator (actuator) 17 Valve body 18 Actuator hand wheel 19 Digital Rotary Encoder

[0093] All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise.

[0094] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.