Segmented Valve Seat for Delayed Coker Thermal Stress
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Solution Overview
Problem
The thermal cycling in delayed coker unit operations causes significant stress and reduces the longevity of valve and seat components due to extreme heat variances, leading to frequent maintenance and reduced operational efficiency.
Innovation Solution
A preassembled cartridge seat system with a main body, upper and lower bonnets, and a steam purge system that allows for inline serviceability and maintains the valve in a partially open position, preventing coke and debris buildup, and includes a seat system that shears accumulated material upon actuation, ensuring reliable operation without frequent maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional valve seat components are used in delayed coker operations, then the valve can perform its basic function, but the components experience significant thermal stress and reduced longevity due to extreme heat variances
Solution Approach 1:
The valve seat is divided into multiple segments that can move independently relative to each other. This segmentation allows each segment to accommodate thermal expansion and contraction separately, reducing the cumulative thermal stress on the overall seat structure while maintaining sealing integrity under extreme heat variances
Solution Approach 2:
The valve seat transitions from a static structure to a dynamic one where segments can adjust their positions. The segments are designed to move dynamically in response to thermal changes, enabling the seat to adapt to expanding and contracting forces caused by extreme temperature variations, thereby improving reliability under thermal stress
2Reliability
If the valve is kept closed to prevent coke buildup, then sealing is maintained, but coke and debris accumulate inside the valve, requiring frequent maintenance
Solution Approach 1:
The valve incorporates a self-cleaning mechanism where the moving segments automatically shear off accumulated coke and debris during normal operation. The relative motion between segments creates shearing forces that prevent buildup, allowing the valve to maintain itself without external intervention and reducing maintenance frequency while preserving sealing performance
3Ease of repair
If the valve is kept partially open to prevent coke buildup, then maintenance needs are reduced, but the valve may not provide adequate sealing
Solution Approach 1:
The valve segments can dynamically adjust their positions to maintain both flow control and sealing. By allowing segments to move independently, the valve can operate in a partially open state for extended periods while the segments self-adjust to maintain adequate sealing, thus reducing maintenance frequency without sacrificing reliability
4Productivity
If multiple coke drums are used for continuous operation, then productivity is improved, but thermal cycling increases, causing more severe thermal stress on valve components
Solution Approach 1:
The segmented valve seat design allows each segment to independently accommodate thermal expansion and contraction. This segmentation distributes the thermal cycling stress across multiple smaller units rather than concentrating it on a single monolithic structure, enabling the valve to withstand the increased thermal cycling demands of continuous multi-drum operations
Solution Approach 2:
The valve segments are designed with the ability to change their physical parameters (position, spacing) in response to thermal conditions. This parameter adaptation allows the valve to maintain functionality under the extreme and varying thermal conditions generated by continuous operation across multiple coke drums, improving overall system reliability
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 extends the lifespan of valve components, reduces maintenance needs, and maintains high performance over extended periods by preventing coke and debris accumulation, ensuring continuous operation and minimizing thermal stress effects.
Implementation Method 1
a steam purge system that allows for inline serviceability and maintains the valve in a partially open position, preventing coke and debris buildup
Implementation Method 2
The heated residual byproduct utilized in coking operations comes into contact with not only the coke drum, but valve and seat components. This heating and subsequent cooling may result in expansion of various elements within a valve system
Implementation Method 3
when a vessel is being purged of its contents it will cool and return to a state of equilibrium
Data Source
AI summary
The present invention provides more efficient, cost effective coke drum valve devices and system as well as more efficient, cost effective methods for isolating the flow of matter in a delayed coker unit operation. Specifically, embodiments of the invention relate to various seat systems used in valves for delayed coking operations.