Grooved Relief Valve Disc Insert for Simmer Reduction
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Solution Overview
Problem
Conventional spring-operated pressure relief valves experience simmering, leading to increased time between crack and popping pressures, which requires higher overpressure to achieve rated capacity, and this can result in product loss and instability, especially at low set pressures operating with compressible or incompressible media.
Innovation Solution
Incorporating a disc insert with grooves or corrugation near the seat region to divert fluid flow into small chambers, converting fluid momentum into a supplemental upward force that reduces valve simmering without the need for a nozzle ring, thereby providing consistent force augmentation throughout valve lift and reducing manufacturing and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spring-operated pressure relief valves are used, then the valve structure is simple, but the valve experiences simmering leading to increased time between crack and popping pressures and requires higher overpressure to achieve rated capacity
Solution Approach 1:
The valve disc is segmented into a disc insert and disc holder, with the disc insert containing grooves that divide the fluid flow path. This segmentation allows the fluid flow to be redirected into the grooves, creating additional upward force on the disc insert to reduce simmering and decrease the time between crack and popping pressures.
Solution Approach 2:
The grooves are strategically positioned in specific locations on the disc insert to create localized fluid momentum conversion. The grooves are formed in the sealing surface region to divert fluid flow and generate supplemental upward force where it is most needed to reduce simmering and improve valve stability.
2Productivity
If conventional pressure relief valves are used, then manufacturing costs are lower, but higher overpressure is required to achieve rated capacity resulting in product loss
Solution Approach 1:
The grooves are pre-formed in the disc insert to proactively redirect fluid flow and generate supplemental upward force before the valve reaches full opening. This preliminary action reduces the overpressure needed to achieve rated capacity, minimizing product loss during the relief process.
3Reliability
If a nozzle ring is added to reduce simmering, then valve stability improves, but device complexity and manufacturing costs increase
Solution Approach 1:
The grooves are integrated directly into the disc insert, merging the simmer reduction function with the existing disc structure. This eliminates the need for a separate nozzle ring component while maintaining the valve stability and simmer reduction benefits, thereby reducing device complexity and manufacturing costs.
Solution Approach 2:
The disc insert serves multiple functions: it provides the sealing surface against the valve seat, structures the fluid flow path through the grooves to reduce simmering, and converts fluid momentum into supplemental upward force. This multi-functionality eliminates the need for separate components like nozzle rings.
4Ease of manufacture
If conventional valve designs are used, then manufacturing is simpler, but precise adjustment and additional mechanisms are needed to reduce simmering
Solution Approach 1:
The grooves in the disc insert automatically redirect fluid flow and generate supplemental upward force based on the valve's operational state. The system self-regulates to reduce simmering without requiring external adjustment mechanisms or precise manual calibration, simplifying both manufacturing and operation.
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 grooved disc insert design effectively reduces simmering by enhancing the force ratio and stability at lower lifts, minimizing overpressure and blowdown time, and eliminating the need for precise adjustment and additional mechanisms, thus improving the overall performance and reducing costs.
Implementation Method 1
directing the flow of process fluid into the groove to convert fluid momentum from the process fluid into an increased valve-opening force applied to the disc assembly to reduce valve simmer
Implementation Method 2
guiding the flow of process fluid in a direction opposite to the direction of the valve-opening force applied to the disc assembly via the disc holder
Data Source
AI summary
A spring-operated relief valve can include a biasing assembly, a valve inlet, a valve seat, a disc assembly that is biased toward the valve seat by the biasing assembly, and a disc insert secured to the disc holder. The disc insert can include a body, a sealing surface to seal against the valve seat, and a groove formed in the sealing surface of the disc insert, the groove to operate as a fluid guide to divert a portion of fluid flow during a relief event into the groove. The disc holder can extend past the sealing surface of the disc insert to direct fluid flow during a relief event.