Compressor Valve Seat With Kidney-Hole Clusters for Low Pressure Drop
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Solution Overview
Problem
Reciprocating gas compressor valves face challenges with high differential pressures, leading to sealing element deterioration, leakage, and reduced structural integrity due to large seat holes, which compromise efficiency and reliability, and result in costly overhauls.
Innovation Solution
A reciprocating gas compressor valve design featuring a seat with clusters of kidney-shaped holes and a sealing element with a tubular section and specialized profiles to enhance flow efficiency while maintaining structural integrity, reducing clearance, and minimizing pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If large holes or slots are used in the seat to handle proper gas flow, then gas flow capacity is improved, but structural integrity of the seat deteriorates
Solution Approach 1:
The seat is divided into multiple clusters of holes rather than using large single holes. Each cluster contains multiple smaller holes arranged in a pattern, which collectively provide sufficient gas flow capacity while the distributed structure maintains better structural integrity compared to large concentrated openings
Solution Approach 2:
The hole distribution is optimized locally with clusters positioned to maximize flow while maintaining structural strength in critical areas. The varying density and arrangement of holes in different clusters allow tailored flow characteristics in different regions while preserving overall seat strength
2Strength
If height of the seat is increased to compensate for loss of structural integrity, then seat strength is improved, but clearance space increases
Solution Approach 1:
Instead of increasing overall seat height, the solution segments the flow path into multiple clusters of holes that provide sufficient flow capacity at reduced height, eliminating the need for excessive seat height compensation
Solution Approach 2:
The design transitions from relying on increased height (vertical dimension) to achieving flow capacity through optimized hole cluster patterns (horizontal/planar arrangement), effectively moving the solution to another dimensional approach
3Loss of energy
If lift of the sealing element is increased to minimize pressure drop, then flow efficiency is improved, but area for lift and diameter for holes must be enlarged
Solution Approach 1:
The flow path is segmented into multiple clusters of holes that collectively provide large effective flow area without requiring any single hole to be large, enabling efficient flow with moderate sealing element lift
Solution Approach 2:
Multiple smaller holes in each cluster are combined to function as a single large flow passage, achieving the flow capacity of large holes while maintaining smaller individual hole dimensions that reduce sealing element wear and extrusion risk
4Quantity of substance
If large area holes are used, then gas flow capacity is improved, but extrusion of sealing element occurs at high differential pressures
Solution Approach 1:
Large area flow capacity is achieved through multiple clusters of smaller holes rather than few large holes, distributing the pressure load across more contact points and preventing sealing element extrusion while maintaining flow capacity
Solution Approach 2:
The hole size and distribution are optimized locally in each cluster to balance flow requirements with sealing element protection, creating regions with appropriate pressure distribution that prevent extrusion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design improves flow efficiency, reduces clearance, and increases the valve's reliability by maintaining structural integrity, resulting in higher throughput and lower energy consumption, with a significant reduction in clearance volume and operational costs.
Implementation Method 1
The sealing element and a spring are contained in a valve assembly with the seat and a guard. During operation, high pressure gas forces are placed on the sealing element, thus opening the valve. At the end of a cycle, the sealing element is pushed towards the seat often due to spring force, resulting in the seat surface being sealed
Implementation Method 2
At the end of a cycle, the sealing element is pushed towards the seat often due to spring force, resulting in the seat surface being sealed and the valve in a closed position
Implementation Method 3
During operation, high pressure gas forces are placed on the sealing element, thus opening the valve. The sealing element then moves reciprocally between the seat and a stop surface to an open position where gas passes over the sealing element
Data Source
AI summary
A reciprocating gas compressor valve having a plurality of clusters of kidney shaped holes positioned along a common circular or annular locus in the main body and a sealing element with a top portion, a bottom portion and a tubular section. The tubular section is integrally connected to the top portion and bottom portion. In an open position, a flow pathway is provided through the clusters of kidney shaped holes and the tubular section and the bottom profile abuts a stop surface of the valve. In a closed position, the top profile abuts the seat for sealing gas flow within the valve.