Loadless Start Valve for Reciprocating Compressor

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Solution Overview

Problem

Existing compressor start-up methods require significant power and incur high costs due to the need for specific compressor designs or solenoid valves with timer relays to unload the compressor, leading to inefficient power usage during startup.

Innovation Solution

A start-up valve with a valve body, plunger, and spring that diverts compressor discharge to atmosphere during startup, reducing motor load, and automatically unloads the compressor when shut down, allowing for a loadless start-up without requiring special compressor designs or solenoid valves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a reciprocating compressor is started from standstill, then the compressor can begin operation, but the motor consumes maximum power due to inrush current and compression of residual air pressure

Engineering Contradiction:

Improvemotor power consumptionVSAvoidstart-up difficulty

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The start-up valve performs preliminary unloading action before the compressor reaches full operating speed. By diverting compressed air to atmosphere during the start-up phase, the system prepares for loadless operation before the motor needs to deliver full power, thereby reducing peak power consumption during start-up.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention extracts and removes the harmful load (compressed air pressure) from the system during start-up by diverting it through the start-up valve to atmosphere. This separation allows the motor to start without the burden of compressing air against existing system pressure, reducing inrush current and peak power demand.

Inventive Principle:

Principle #2Taking out (Extraction)

2Power

If solenoid valves with timer relays are used to unload the compressor, then the compressor can be unloaded during start-up, but the system cost increases significantly

Engineering Contradiction:

Improvestart-up power consumptionVSAvoidsystem cost

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The start-up valve is designed to automatically control its own operation through the interplay between spring force and gas pressure. The valve opens during start-up when pressure is low and closes when pressure builds up, eliminating the need for external control systems like solenoid valves and timer relays, thereby significantly reducing system cost while maintaining the unloading function.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The spring acts as an intermediary element that mediates between the gas pressure and valve plunger. Instead of using expensive electronic control components, the spring provides a simple mechanical means to translate pressure changes into valve position changes, achieving automatic unloading control without additional costly components.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Power

If specific compressor designs are used for unloading, then the compressor can be unloaded, but the design complexity and manufacturing cost increase

Engineering Contradiction:

Improvestart-up power consumptionVSAvoidmanufacturing cost

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The start-up valve is designed as a universal component that can be attached to the discharge side of any reciprocating compressor regardless of the specific compressor design. This multi-functional approach allows a single valve design to work with various compressor types, eliminating the need for expensive compressor-specific unloading designs and simplifying manufacturing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention separates the unloading function from the compressor design itself by making the start-up valve an independent, attachable component. Rather than requiring the compressor to be specially designed with integrated unloading features, the function is segmented into a separate valve assembly that can be added to standard compressors, reducing manufacturing complexity and cost.

Inventive Principle:

Principle #1Segmentation

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 solution reduces the power required for starting the compressor, lowers costs, and provides a compact, cost-effective means to manage compressor unloading, enabling efficient and economical operation by diverting discharge to atmosphere during startup and unloading pressure during shutdown.

Implementation Method 1

a spring provided within the internal passageway and connected to the valve plunger. As the compressor starts-up and gas flow increases, the spring is compressed until the valve plunger abuts the internal passageway

Methodology Applied

Scientific EffectSpring compression: Spring

Data Source

PatentUS11204029B2Loadless start valve for a compressor

Publication Date: 2021.12.21 QUINCY COMPRESSOR LLC

AI summary

A compressor installation having a reduced load at start-up, including a gas compressor having an inlet and an outlet and a start-up valve connected to the outlet of the compressor. The start-up valve includes a valve body having an inlet and an outlet, a valve plunger connected to the inlet of the valve body, a spring connected to the valve body and the valve plunger, and a muffler. The start-up valve is configured to discharge the compressed gas through the muffler to atmosphere to reduce the load on the motor at start-up. After starting the compressor, the spring in the start-up valve is compressed after pressure is increased by the compressor and the discharge through the start-up valve to atmosphere is closed.