Delayed Coker Isolation Valve Self-Cleaning Mechanism
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Solution Overview
Problem
Existing isolation valves in delayed coker unit operations are prone to coking up and oiling, leading to decreased performance over time, and often require frequent maintenance due to debris buildup, necessitating costly double block and bleed systems and labor-intensive decoking processes.
Innovation Solution
A bi-directional isolation valve system with a main body, valve closure, and bonnet design that allows for oscillation and self-cleaning, enabling extended operation without performance degradation, and allowing for inline serviceability and maintenance, reducing the need for double block and bleed systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional isolation valves are used in delayed coker unit operations, then initial isolation function is provided, but performance degrades over time due to coking and oiling
Solution Approach 1:
The valve incorporates a self-cleaning mechanism where the valve closure oscillates between seats during operation, automatically removing accumulated coke and oil deposits. This self-service function eliminates the need for external decoking processes and maintains reliable isolation performance over extended operational periods without manual intervention.
Solution Approach 2:
The valve closure is designed to oscillate dynamically between the first and second seats during normal operation rather than remaining statically closed. This dynamic movement prevents debris accumulation and maintains sealing surfaces clean, thereby extending the duration between maintenance cycles while preserving isolation reliability.
2Reliability
If double block and bleed system is used to ensure line isolation, then isolation reliability is improved, but system complexity and cost increase
Solution Approach 1:
The patent combines multiple isolation functions into a single valve unit by providing two sealing seats and a valve closure that can seal against either seat. This merged design eliminates the need for separate double block and bleed valve assemblies, reducing system complexity while maintaining the same level of isolation reliability through alternative technical means.
Solution Approach 2:
The valve closure serves multiple functions: it can seal against the first seat for normal isolation, seal against the second seat for maintenance isolation, and oscillate between seats for self-cleaning. This multi-functionality within a single valve replaces the need for multiple specialized valves in traditional double block and bleed systems.
3Ease of repair
If valve is removed from service for maintenance, then internal components can be accessed, but operational continuity is disrupted
Solution Approach 1:
The valve is segmented into modular components including the valve body, valve closure, bonnet, and seats. The bonnet can be removed independently to access internal components for inspection and maintenance, while the valve remains installed in the line. This segmentation enables maintenance without full valve removal, preserving operational continuity.
Solution Approach 2:
The bonnet is extracted as a separate removable component from the valve body, allowing access to the valve closure and seats for maintenance. This extraction approach enables internal component servicing while the valve remains in-place and connected to the piping system, minimizing disruption to operational continuity.
Data Source
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AI summary
The present invention provides more efficient, cost effective coke drum isolation valve devices and system as well as more efficient, cost effective methods for isolating the flow of matter from location to another in the delayed coker unit operation where the valve comprises a first seat; a second seat aligned with said first seat; a blind; a main body having an orifice dimensioned to align with an orifice in said line; wherein said main body is coupled to said line; an upper and lower bonnet coupled to said main body, wherein said bonnets may be removed in order to replace valve parts without separating the main body from the line; and a plate located inside a bonnet, wherein the plate comprises a planar surface that contacts a surface of the blind.