Tray Deck Orifice Repair Device Anti-Spin Tab
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Solution Overview
Problem
Fluid contact trays in petroleum and chemical processes experience wear due to rotating valves, leading to enlarged orifices that compromise mixing efficiency and pressure control, necessitating frequent replacement and increased maintenance costs.
Innovation Solution
A tray deck orifice device with a flat member and anti-spin tab is used to repair and prevent further wear on existing trays by aligning with and securing the orifices, allowing valves to fit snugly and preventing rotation, thus extending tray life and reducing maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tray decks are used with rotating valves, then flow control and mass transfer are achieved, but the orifices wear down and enlarge over time, compromising mixing efficiency and pressure control
Solution Approach 1:
The patent introduces an intermediary orifice repair device that fits within the enlarged orifice to restore the original flow control geometry. This mediator component prevents further wear and maintains proper flow characteristics without requiring replacement of the entire tray deck, thus resolving the contradiction between maintaining reliable orifice size and extending tray deck service life.
Solution Approach 2:
The patent recovers the functional integrity of worn orifices by installing repair devices that restore the original orifice dimensions. Instead of discarding the entire tray deck, the repair process recovers the lost functionality by replacing only the worn orifice surfaces with repair devices, thereby extending the overall service life of the tray deck.
2Productivity
If tray decks are replaced periodically to maintain efficiency, then process control is maintained, but maintenance costs and plant outage time increase
Solution Approach 1:
The patent segments the repair task from the entire tray deck replacement. By introducing a separate orifice repair device that can be installed independently within each enlarged orifice, the maintenance operation is divided into small, localized repairs rather than requiring complete tray deck replacement, thus reducing plant outage time while maintaining process efficiency.
Solution Approach 2:
The patent enables preliminary repair action on enlarged orifices before they severely compromise process efficiency. By installing orifice repair devices during scheduled maintenance periods rather than waiting for complete tray deck failure, the system maintains continuous productivity while minimizing unplanned outages and extensive maintenance operations.
3Ease of operation
If valves are allowed to rotate freely in orifices, then they can respond to flow rate changes, but the metal legs cut and enlarge the orifices, leading to uncontrolled openings
Solution Approach 1:
The patent introduces an intermediary orifice repair device that acts as a protective sleeve within the enlarged orifice. This mediator allows the valve to continue rotating and responding to flow rate changes while preventing the metal legs from further cutting into the orifice walls, thus maintaining both valve responsiveness and orifice dimensional control.
Solution Approach 2:
The patent applies beforehand cushioning by installing protective orifice repair devices that prevent further wear before the orifices become completely uncontrolled. The repair devices cushion against additional mechanical damage from valve rotation, preserving the original orifice dimensions and preventing catastrophic failure.
Data Source
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Figure 3~4
AI summary
The invention is directed to a tray deck orifice device for use with a tray deck in a vessel. The repair device comprises a flat member having a defined thickness and a void at a center thereof, and at least one anti-spin tab extending from an edge or edges of the flat member inwardly towards the void, wherein the repair device is designed to attach to the surface of the tray deck such that the void is aligned with a hole in the tray deck.