Compressor Flange Fastening with Multi-Hole Washers for Leak Prevention
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Solution Overview
Problem
High-pressure high-temperature gas leakage from gaps between flanges in compressors due to pressure and thermal deformation, despite existing groove and protrusion designs, as the fastening force distribution is inadequate and limited to a narrow range.
Innovation Solution
A fluid device using a multi-hole washer shared by multiple fastening members to distribute fastening force over a wider area, ensuring the fastening force on mating surfaces is sufficient to prevent leakage, with at least part of the fastening members being stud bolts or through bolts, and the washer disposed on both ends of the through bolts for line-symmetric alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a washer is disposed between the bolt head and the flange to distribute fastening force, then the fastening force distribution is improved, but the distribution range is still limited to a narrow area close to the bolt shaft
Solution Approach 1:
Multiple washers from adjacent bolts are merged into a single continuous washer structure that spans across multiple bolt locations. This allows the fastening force to be distributed over a much wider area of the flange mating surface, combining the individual washer functions into a collective sealing system that addresses the limited distribution range problem.
Solution Approach 2:
The washer design transitions from individual circular washers centered on each bolt to an extended washer structure that spans radially and circumferentially across the flange. This dimensional expansion allows the fastening force to distribute over a larger surface area, moving beyond the narrow circular pattern of traditional individual washers.
2Force
If a through bolt is used to increase fastening force and distribution range, then the fastening force is improved, but it is still difficult to secure sufficient surface pressure over a wide range to prevent leakage
Solution Approach 1:
The through bolts are combined with extended washers that span multiple bolt locations, merging the fastening functions into a unified system. This combination allows the high fastening force of through bolts to be distributed over a much wider area, achieving both the force magnitude and the distribution width needed for reliable leakage prevention.
Solution Approach 2:
The extended washer acts as an intermediary between the through bolt and the flange mating surface. It receives the concentrated fastening force from the through bolt and redistributes it over a wide area, mediating between the point load of the bolt and the distributed pressure needed for sealing.
3Area of stationary object
If the washer thickness is increased to expand the fastening force distribution range, then the distribution area is improved, but the effect is still insufficient to prevent leakage
Solution Approach 1:
Instead of relying on increased thickness of individual washers, multiple washer functions are merged into a continuous extended structure. This lateral merging provides much greater distribution area than vertical thickening, effectively spreading the fastening force across the entire flange mating surface.
Solution Approach 2:
The solution shifts from increasing washer thickness (one dimension) to extending the washer radially and circumferentially across the flange (two dimensions). This dimensional transition provides significantly larger distribution area for the same material volume, achieving better leakage prevention.
Data Source
AI summary
Flanges of half bodies provided in a compressor casing are fastened by multiple bolts and a multi-hole washer shared by two or more adjacent bolts. When F is fastening force, T is a thickness of the washer, θ is a distribution angle of the fastening force, Rb is a radius of the bolt, R is a radius of a distribution range of the fastening force on a bearing surface, A is an area of the distribution range on the surface, a is an area of a distribution range of the fastening force on a mating surface of the flange, and R=Rb+T·tan θ and A=πR2 are established, F/A is lower than yield strength of each of a flange material and a multi-hole washer material, and F/a is equal to or higher than predetermined surface pressure determined based on pressure of fluid inside the casing.