Emission control valve

An emission control valve is claimed which is used to control emissions into the atmosphere of a medium, such as liquids, gases, and/or solids, which is being regulated and transported. The apparatus generally comprises a valve body, a valve rack, a first and second valve member disposed within the body, disc means for allowing communication between the first and second valve members, and a pinion member for cooperating with the valve rack.

BACKGROUND OF THE INVENTION 
This invention relates to valves which are used to regulate the flow of 
gases, liquids, and/or loose materials through structures such as piping. 
More particularly, but not by way of limitation, this invention relates to 
valves which are used to control emissions into the atmosphere of the 
medium being regulated and transported. 
Valves are used in a wide range of industries, ranging from nuclear 
facilities to oil and gas refineries. Generally, a valve will be used to 
regulate the flow of gases, liquids, or loose materials, or a combination 
thereof, through structures, such as piping, or through apertures by 
opening, closing, or obstructing ports or passageways. The various gases, 
liquids, or loose material being regulating may contain elements which are 
considered hazardous to the environment and humans. 
Government agencies, on both a state and federal level, have begun to 
promulgate various regulations dealing with acceptable levels of emissions 
of hazardous gases, liquids or loose materials into the atmosphere. 
Valves, according to these new regulations, will contain seal means in 
order to prevent emission into the atmosphere of the materials being 
regulated. Valves containing actuator means, in order to remotely and/or 
automatically control operation of the valve, are particularly vulnerable 
to unexpected emission of the materials being transported because of the 
difficulty in creating a seal with the shaft of the actuator. 
Therefore, there is a need in the industry for a valve which is controlled 
by a remote actuator that wi 1 provide a sealing means which will prevent 
the medium being transported from being discharged into the atmosphere. 
Thus, an object of this invention is a novel sealing means to effectively 
seal a moveable actuator shaft member. 
Another object of the present invention is to have a back-up sealing 
chamber which will encapsulate the actuator shaft, and provide a secondary 
sealing means. 
SUMMARY OF THE INVENTION 
The present invention includes a valve with means for controlling emissions 
to the atmosphere. The valve includes a valve body with a first and second 
aperture defined therein, with the apertures being formed at perpendicular 
angles, and wherein the apertures intersect one another. 
The valve further includes a valve rack which is slidably disposed within 
the second aperture. A first valve member is disposed within the valve 
body, with the valve member having therein a plurality of ports. A second 
valve member is also disposed within the valve body, with the valve member 
also having a plurality of ports. 
A spherical, rotative disc means, which is located between the first and 
second valve members, are provided for allowing communication between the 
ports of said first and second valve member. A pinion member having the 
aforementioned disc means disposed therethrough is provided, with the 
pinion member cooperating with the rack so that as the rack moves in a 
longitudinal direction, the pinion member rotates allowing the openings 
contained on the disc means to become aligned with the ports on said first 
and second valve members. 
The valve can further comprise an actuating means for actuating movement of 
the rack in either an upward or downward longitudinal movement and 
encapsulating means, attached between said actuating means and said valve 
body, for encapsulating the rack and providing a seal so that the medium 
being transported or regulated by the valve is not released into the 
atmosphere. 
In one embodiment, the encapsulating means will include a seal body member 
having a first and second end and wherein said first end has defined 
therein a first port and the second end has defined therein a second port 
so that the rack is disposed therethrough. Also included will be first 
seal means, arranged about the rack in the first and second port, for 
sealing any emissions of the medium which is being regulated by the valve 
into the atmosphere. 
A feature of this invention is the rotative, spherical valve member which 
cooperates with a set of fixed disc valve members to provide for variable 
opening. Another feature includes fabrication of the rotative, spherical 
valve member and the fixed disc valve member from metal so that in 
operation the valve members provide a metal-to-metal seal. 
Yet another feature includes use of seal means, such as o-rings, with the 
aforementioned valve members to provide a sealing mechanism. Still another 
feature includes the ability of the variable opening valve members to open 
and close on solid materials and manufacturing the valve members so that 
the edges are grounded and tapered to mate with one another. This feature 
enables the valve members the ability of crushing loose material which may 
become lodged into the openings of the valve members. Further, this 
feature allows the operator the ability of variably opening the valve 
members to allow for incremental opening or closing, as deemed necessary 
and appropriate by the operator. 
Still another feature includes the use of the rack and pinion as a means 
which rotates the rotative, spherical valve member. Still another feature 
is the use of encapsulating means, which is also referred to as the 
encasing means, to provide a secondary sealing means for the actuator 
shaft. Another feature includes the use of an indication means, located on 
the actuator shaft, for determine the relative position of the valve 
members. Yet another feature includes the ability of the actuator to 
change action from air to open, or air to close by reversing the drive 
rack. 
Another feature includes a lockout to prevent relative movement of the 
actuator while the action is being changed from air to open or air to 
close. An advantage of the present invention is that the novel design 
allows for several tiers of sealing means, each a back-up to the others, 
in the event of failure of any of the seals. Another advantage is that the 
valve member construction will allow for the crushing of solids and loose 
materials which may become stuck in the valve. Another advantage allows 
for the use of this valve as an air to open, or alternatively as an air to 
close actuating valve. Yet another advantage is that the valve of the 
present invention meets the specifications of federal and state 
environmental agencies.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring to FIG. 1, the valve of the present invention is depicted. A 
controller operator valve 2, sometimes known as a diaphragm operated 
valve, has extending therefrom an actuator shaft 4 or rack which will be 
responsive to an air control signal. Thus, if the controller operator 
valve 2 is measuring a liquid level in a separator, and a predetermined 
level is sensed, a pneumatic controller will send a signal which will in 
turn cause the actuator shaft 4 to move in a lateral direction. It should 
be understood that while a pneumatic type of system is described, the 
actuator shaft 4 could be controlled by hydraulic and/or electrical 
operator means, and the valve of the present invention could still be 
employed. 
The rack 4 will have defined thereon teeth 6 which will cooperate with the 
pinion gear wheel 8, with the pinion gear wheel 8 also containing 
complementing teeth 10. The pinion gear wheel 8 will also contain a 
tubular shaft member 12 extending therefrom, this shaft member 12 having 
teeth 14, as seen in FIG. 2, defined thereon. Thus, as the rack 4 travels 
laterally, this movement will in turn impart rotational movement to the 
wheel 8, and shaft member 12. 
The longitudinal actuator shaft 16 is also depicted in FIG. 1. The shaft 16 
will contain defined thereon teeth 18 (not shown) which will cooperate 
with teeth 14 of shaft member 12. The shaft 16, the wheel 8 and rack 4, 
heretofore described, can be contained within an actuator cover means 20. 
The cover means 20 will be of a generally rectangular box configuration, 
and will have a first port 22, second port 24 and third port 26 defined 
thereon. 
Referring to FIG. 2, port 22 will have contained therein first tubular 
position sub 28 having on the outer diameter a shoulder 30, as seen in 
FIG. 2, which abuts the actuator cover means 20. Fastening means 32 (not 
shown) can also be employed for fastening the position sub 28 to the 
actuator cover means 20. On the outer diameter of the sub 28 there is 
contained thread means 34 which will threadedly mate with travel stop 
means 36. The travel stop means is utilized to limit the travel of 
actuator shaft 16 so that the travel means 36 can effectively stop 
movement of the shaft 16 and prevent the opening and/or closing of the 
valve elements, as will be further described hereinafter. 
A second tubular position sub 38 will be disposed within port 26. The 
second sub 38 will have on the outer diameter a first surface 40 which 
will terminate at shoulder 42, with shoulder 42 abutting the actuator 
cover means 20. The sub 38 will have in turn second surface 44 which will 
have defined therein a groove 46 for placement of o-ring 48. On the 
internal diameter, the sub 38 will have a bore 50 which will contain a 
groove 52 for placement of sealing means 54, which will sealingly engage 
the shaft 16. 
Referring to FIG. 1 again, a third tubular position sub 56 will be disposed 
within the port 24. The sub 56 will be similar to the previously described 
positioned sub 28, in that sub 56 will have on the outer diameter a 
shoulder 58 that will abut the actuator cover means 20, and also 
containing thread means 60 in order to threadedly engage travel stop 62 to 
the sub 56. Travel stop 62 will serve a similar purpose to travel stop 36, 
in that the travel stop 62 will limit the relative lateral movement of 
rack 4. 
As seen in FIG. 1, the actuator cover means 20 has attached thereto an 
encapsulating means 64, which will also be referred to as encasing means, 
for encapsulating the actuator shaft 16 and sealing the shaft from the 
atmosphere as the shaft 16 exits the valve body 66. The encapsulating 
means 64 will be of a general rectangular box configuration. In the 
preferred embodiment, at least one side 68 can be constructed of 
plexiglass so that an operator can determine the relative position of the 
longitudinal actuator shaft 16. 
The encapsulating means 64 is constructed so that in the event of a leak 
from the valve body 66, through the longitudinal actuator shaft 16, the 
leak will be contained within the encapsulating means 64 so that no 
emissions of the regulated medium is possible into the atmosphere. 
The encapsulating means 64 will be fastened to the actuator cover means 20 
by fastening means 70, not shown. Side walls 72 and 74 , and top ceiling 
76 can be constructed of metal, and the side walls and ceiling 76 can then 
be welded together. The plexiglass member will be attached by conventional 
fastener such as flush-bevelled socket head screws. Seal means, seen 
generally at 77, are provided for sealing emissions from the valve body 66 
along the longitudinal actuator shaft axis, as the shaft exits the valve 
body 66. 
Referring now to FIG. 3, the valve body 66 of the present invention is 
illustrated. The valve body 66 will contain a first aperture 78 and a 
second aperture 80, and wherein the first and second aperture, 78 and 80 
respectfully, intersect at substantially perpendicular angles. The valve 
body generally comprises a first portion 82 which will be attached to a 
second portion 84. The first portion 82 will contain a first opening 86 
and second opening 88 for the placement of securing means, to be described 
later, which will fasten the valve body 66 to the encapsulating means 64. 
The portion 84 will also contain a plurality of flange openings, shown 
generally at 90, for the placement of bolting means (not shown) for 
bolting the first portion 84 and second portion 82. Other flange openings, 
shown as 92, are for attaching the valve to the pipe 94, as also shown in 
FIG. 5, which is used to transmit the medium being transported. 
Referring to FIG. 4, the first 96, and second 98 valve member, along with 
the disc means 100 will now be discussed. The second aperture 80, which is 
also referred to as a passageway 80, will be in communication with the 
aforementioned pipe 9 such that the medium will flow through pipe 94 and 
into passageway 80. Disposed within said first valve body member 82, and 
in communication with passageway 80, will be the first valve member 96 
which is a tubular member having a flow face 102 which is essentially 
flat. Disposed on the second end of the first valve member 96 is concave 
surface 104. 
Disposed through the valve member 96 is a series of openings 106. In the 
preferred embodiment, the member 96 will contain a first three set 
arranged about the outer peripheral, and a second set contained within a 
larger set, as shown in FIG. 5. In the preferred embodiment, the first 
three set circle will be of larger diameter than the second three set 
circle. 
The second valve member 98 will also be disposed within said valve body 
member 82 and will contain a flow face 108 which is essentially flat. 
Referring to FIG. 5, extending on the opposite end of member 98 is concave 
surface 110. Member 98 will also contain a plurality of openings 112, 
identical in pattern as that of the openings 106 in the first valve 
member, i.e. a first three set openings on the outer peripheral, and a 
second set, three openings, with the second set being smaller in diameter 
as compared to the first set. 
The disc means 100 will now be discussed in more detail. Generally, the 
disc comprises a cylindrical member 114 with a first convex surface 116 
which mates and cooperates with the concave surface 104 of the first valve 
member 96. The convex surface 116 can also be seen in FIG. 5. Extending 
axially opposite convex surface 116 is convex surface 117, which will mate 
and cooperate with the concave surface 110. Disc means will also have 
contained therethrough a plurality of openings, which like the openings 
contained on the first and second valve members 96,98, have a first three 
member set contained thereon and a second-three member set, with the first 
member set being located on the outer periphery of the disc and the second 
set being located within, and with the first set having a larger diameter 
than the second so that the disc means openings 118 will align with the 
openings of the first and second valve members, 96, 98. 
The disc means 100 also will include a cylindrical gear wheel 118 as shown 
in FIG. 7, which will contain a plurality of teeth 120. The gear wheel 118 
will have contained therein the disc 100. Longitudinal actuator shaft 16 
will have contained on the lower end a plurality of cooperating teeth 122. 
Therefore, the longitudinal actuator shaft 16 and the gear wheel will 
cooperate similar to a rack and pinion gear wheel. 
The gear wheel 118 has disposed therethrough at least one threaded bore, 
and in the preferred embodiment will have two, 124 and 126, wherein two 
set screws 128 and 130 will be placed and secured against the disc means 
100 inner member. Therefore, as the shaft 16 moves in a longitudinal 
direction, the teeth 122 will engage and transmit force to the teeth 120. 
This will, in turn, cause the disc 100 to rotate. 
Referring again to FIG. 4, the cylindrical gear wheel 118 will have on the 
outer diameter, a first surface 132, which as disclosed earlier, will have 
defined therethrough at least one threaded bore 130. Extending radially 
inward, the wheel 118 will a have a first surface 134 which will have 
defined thereon a groove 136 for placement of sealing means 138. Surface 
134 terminates at radially flat shoulder 140, which in turns leads to 
second surface 142, with the second surface 142 having defined therein a 
first and second groove 144 and 146, for placement of sealing means 148 
and 150. The threaded bore 130 with the set screw 128 is also shown in 
FIG. 4. 
Continuing to refer to FIG. 4, the first portion 82 of the valve will now 
be described. The first portion 82 will contain a lateral wall 152, which 
is an essentially flat surface, with wall 152 terminating at perpendicular 
side wall 154, with side wall 154 having a first surface 156 terminating 
at radial shoulder 158. The shoulder 158 extends to second surface 160, 
With the surface 160 containing a plurality of threaded openings 162 for 
placement of threading means (not shown, but known by those of ordinary 
skill in the art) such as flanking nuts. The surface 160 concludes at 
radial shoulder 164. The surfaces 156, 160 will have placed thereon a 
flange face of a piping member, with the piping member being in 
communication with the passageway 80. 
Surface 150 terminates at lateral wall 166, which is an essentially flat 
surface, with wall 166 terminating at perpendicular side wall 168, side 
wall 168 including a first surface 170 having a plurality of threaded 
openings 172 for placement of threaded flanking bolts (not shown). The 
surface will terminate at inwardly extending radial shoulder 174, with the 
shoulder extending to surface 176. The surface 176 will have defined 
thereon main opening 80, as well as the radial shoulder 178. 
The first portion of the valve 82, as mentioned previously, will contain 
the main passageway 80. As contained within the valve, the passageway 80 
has a diameter which will be essentially equal to the internal diameter of 
the pipe to which the valve is coupled. The diameter of the opening 80 
will circumferentially increase to match the size of the gear wheel 118. 
The second portion of the valve 84 is generally of a rectangular case 
configuration. The lateral wall 180 terminates at side wall 182 and will 
have a first surface 184 that contains a plurality of openings 186 for 
placement of bolt securing means (not shown). The surface 184 will 
terminate at the radially extending shoulder 188, which in turn extends to 
second surface 190. Surface 190 terminates at another inwardly extending 
radial shoulder 192. The second portion of the valve 84 will contain a 
second lateral wall 194. 
Extending perpendicular to the wall 194 is the face 196 which will have 
defined thereon a first surface 198, with the surface 198 having disposed 
therethrough the aforementioned openings 186. The surface will extend to 
radial shoulder 200, with radial shoulder terminating at the second 
surface 202. Second surface 202 will conclude at radial shoulder 204, with 
shoulder continuing to the third surface 206. 
As seen in FIG. 4, the surface 206 has defined therein the passageway 80, 
which will be of a diameter of equivalent size as that of the pipe 
diameter, as previously expressed. The diameter of the opening 80 will 
circumferentially decrease to match the size of the gear wheel 118. 
Referring to FIG. 6, the mode of fastening the first portion of the valve 
body 82 with the second portion 84, as well as showing the seal means 77 
and piping 94 is shown. The disc means 100, as the disc means has been 
assembled, is shown in relation to the disc means, placement in between 
the valve portions 82, 84. Thus, the teeth 120 of the gear wheel 118 will 
be oriented so that the teeth 120 will intersect at least partially into 
the first aperture 78. 
Previously discussed longitudinal shaft 16, which is also known as the rack 
16, will now be described in greater detail. The rack 16 has a first end 
208 and a second end 210 which is best seen in FIG. 7, with the second end 
210 containing the previously described teeth 122. Turning back to FIG. 2, 
the rack 16 will comprise a first cylindrical surface 212 which will have 
an outer diameter which will be slidably disposed within the inner 
diameter of the tubular position sub 34. The first surface will terminate 
at the radial chamfered shoulder 214, which concludes at the second 
cylindrical surface 216 which will also contain teeth (not shown) which 
cooperate with the previously mentioned pinion gear wheel 8. The second 
surface terminates at the radial chamfered shoulder 218 with the surface 
218 concluding at the third surface 220, with the third surface having an 
outer diameter which will be slidably disposed within the tubular position 
sub 38 and rack 16 will be sealingly engaged with the seal means 54 so 
that any emissions within the encapsulating means will be precluded from 
entering the atmosphere. 
The third surface 220 will then conclude at radial chamfered surface 222 
which in turn extends to fourth surface 224 with fourth surface 224 
concluding at the previously described end 210. Surface 224 has delineated 
thereon the aforementioned teeth 122. 
Indicator means 226 will be disposed about the fourth surface 224 of the 
rack 16 and generally comprises a clamping device 228 fastened by a nut 
and bolt 230. Further, the nut can have a sharpened end 232 which acts as 
an indicator as to the relative position of the rack 16. An indication 
position means 234 can be placed on the yoke member for the operator to 
determine the relative position of the rack. 
The seal means 77 will now be described. Generally, the seal means is 
arranged about the shaft 16, sometimes known as the rack 16, in the first 
aperture 78. The seal means includes a plate structure 236 which has 
openings 238, 240, and 242 defined therein. The opening 240 will have the 
rack 16 slidably disposed therein, while the openings 238 and 242 will 
have securing mean 244 and 246? fitted therein for securing the plate 
structure 236 to the valve body 66. 
Packing element means 248, which in the preferred embodiment will be 
packing purchased under the trade name "Chevron Packing", will also be 
included, and the means 248 are positioned within first aperture 78. Thus, 
the packing element means 248 will also be disposed about the rack 16 so 
that the rack 16 sealingly engages the packing element means 248 and any 
emissions from the valve members 96 and 98 will be contained within the 
valve body 66. 
A second set of seals 250, and in the preferred embodiment known as 
o-rings, will also surround the rack 16 and also be placed within the 
aperture 78. 
A second plate structure 252 is also shown, with the plate 252 having 
openings 254, 256 and 258 which will correspond with the openings 238, 240 
and 242. In assembling the aforedescribed structure, it can be seen that 
the plate structures will be fastened to the valve body 66 by the securing 
means 244 and 246, thus compressing the seals 250 and 248 as seen in FIG. 
6. 
OPERATION 
The actuator rack 4 will move in a horizontal plane, in response to the 
diaphragm operator 2 signal. This movement will be transmitted to the 
pinion gear wheel 8 which will in turn rotate the wheel 8 and the shaft 
member 12. The teeth 14 will engage and transmit torque to the 
longitudinal shaft 16 which will in turn cause the shaft 16 (also known as 
rack) to move longitudinally upward. Note, that if the diaphragm is 
positioned opposite the position seen in FIG. 1, the rotation of wheel 8 
will be in an opposite direction, thus, changing the action from an 
air-to-open to an air-to-close valve. 
The upward movement will then be transmitted to the teeth 120 of the gear 
wheel 118. As noted earlier, disposed within the gear wheel is the disc 
means 100. Hence, as the wheel is rotated, the disc means will rotate 
allowing communication between the openings 112 on the member 110 and 
openings 106 on the member 96 through the openings 118 which are contained 
on the cylindrical member 114. 
As will be appreciated by those skilled in the art, as the rack 4 is 
retracted back into the diaphragm operator 2, an opposite rotation 
movement will be imparted to the pinion gear wheel 8, so that the shaft 
will move in an upward movement, and the disc means will rotate in an 
opposite direction, which will close openings 118 relative to openings 106 
and 112, and create a metal to metal seal the between the disc member 100 
and the members 110 and 96. Also, in the event a piece of loose solid 
material has become lodged within any of the openings, the hardened and 
sharpened metal edges contained on member 110 and 96 will act to crush the 
material. 
The operator will also be able to determine the relative position of the 
shaft 16 by comparing the position of the sharpened end 232 of the nut and 
bolt 230, and the indication position means 234 which can be a piece of 
metal strip with indentations marked in a suitable length of measurement 
thereon. 
Thus, it is seen that the apparatus of the present invention readily 
achieve the ends and objects mentioned as well as those inherent therein 
and not specially mentioned. While certain preferred embodiments of the 
invention have been illustrated and described for the purposes of the 
present disclosure, numerous changes in the arrangement and construction 
of parts and steps may be made by those skilled in the art, which changes 
are encompassed within the scope and spirit of the present invention as 
defined by the appended claims.