Profiled plate valve

Fluid handling – Line condition change responsive valves – Direct response valves

Reexamination Certificate

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Details

C137S516130, C137S516210, C251S333000

Reexamination Certificate

active

06510868

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to a plate valve for use with reciprocating compressors, and more particularly to, a valve having a sealing plate with contoured sealing surfaces.
2. Background of the Related Art
Reciprocating compressors are positive-displacement machines which generally include a piston, a piston rod, a cylinder, at least one suction valve and at least one discharge valve. In reciprocating compression, a medium, usually gas or air, is compressed by trapping the medium in an enclosed cylinder and then decreasing its volume by the action of a piston moving inside the cylinder. The medium is compressed to a pressure sufficient to overcome the spring tension holding a discharge valve closed, at which time the discharge valve opens and allows the compressed medium to leave the cylinder.
Because of the nature of the reciprocating piston, compression ceases at the limits of its stroke, the discharge valve again closes due to the action of the springs on the valve, the piston reverses direction, and a small amount of medium remaining in the cylinder expands, increasing in volume and decreasing in pressure. When the inlet pressure is higher than the pressure inside the cylinder and the spring tension holding the suction valve closed, the suction valve then opens, allowing the medium to flow into the cylinder. At the opposite limit of the piston stroke, the suction valve closes due to the springs acting on the valve, the piston again reverses direction, and the compression cycle begins anew.
Of the many components in a reciprocating compressor, none work harder nor serve a more important function than the suction and discharge valves. In fact, compressor efficiency is determined by the performance of the valves more than any other component. For optimum compressing efficiency to be achieved, these valves must be configured to provide a maximum flow area while at the same time, the medium flow through the valve must meet with a minimum resistance. In addition, it is critical that valve closure prevent leakage of gas or air in either direction.
Many compressors are run at peak loads for weeks or months at a time with no relief. In a typical 1000 rpm compressor, the valves which operate automatically with every stroke of the piston, open and close almost three million times a day. Therefore, in order to achieve optimum compressor efficiency, valve design must meet the above-mentioned objectives of efficient medium flow and control.
Generally, a compressor valve (discharge or suction) is composed exteriorly by two components, namely a valve seat and a valve guard. The valve seat provides inlet flow ports for the medium. The interior surface of the valve seat defines what is traditionally termed the seating surfaces. The valve guard defines outlet flow ports and is typically secured to the valve seat by bolts or a central stud and is spaced therefrom. Internally, the compressor valve is composed of a sealing plate or a series of rings and biasing elements such as helical springs. The sealing plate is disposed in the space between the valve seat and valve guard and is axially movable therein. The surfaces of the plate or rings which are located adjacent to the valve seat are termed sealing surfaces. These surfaces are designed to be engaged with corresponding seating surfaces of the valve seat. A biasing element is disposed between the valve guard and the sealing plate, urging the sealing plate sealing surfaces into a sealing engagement with the seating surface of the valve seat. In this biased position, the medium is prevented from flowing through the valve. As mentioned previously, when the operation of the compressor is such that sufficient pressure exists to overcome the force applied to the sealing plate by the biasing element, the valve will open allowing medium to flow into or out of the compressor cylinder.
The configuration of the sealing plate sealing surfaces and their engagement with the valve seat can have a dramatic impact on the flow of medium through the valve. In the compressor valves commonly in use today, there is an appreciable velocity head loss occasioned by problems in moving the fluid through the valve at high velocity. The problems are largely caused by energy losses resulting from extreme changes in flow direction, frictional interference and turbulence by the fluid as it passes through the compressor valve, around the sealing surfaces. These problems are especially critical in attempting to obtain optimum efficiency and capacity in high speed compressors undergoing 800 to 4000 strokes of the piston per minute.
In addition, configuration of the sealing plate sealing surfaces and their engagement with the valve seat can significantly impact the ability to prevent leakage of medium in either direction when the valve is in the closed position. Performance of the compressors, which by their nature have a very short stroke, requires valves which not only permit flow of the fluid or gases to and from the cylinder with a minimum of pressure loss and at a high velocity, but which will also seat rapidly and positively during the critical pressure reversals which take place at the beginning and end of the intake and discharge strokes.
Traditionally, a sealing plate for a compressor valve consisted of a circular plate that had opposed planar surfaces with flow ports extending between the opposed surfaces. For these valves the seating surfaces were planar and did not protrude into the flow ports of the valve seat, but merely covered the ports. U.S. Pat. No. 3,123,095 to Kohler discloses a plate valve with a sealing plate having planar seating surfaces. A disadvantage to this configuration, as well as others having planar sealing surfaces, is that flow through the valve tends to be turbulent resulting in increased pressure loss across the valve. The turbulence is caused by the rapid change in the direction of flow through the valve. In compressor valves, the flow ports of the sealing plate and the valve guard are aligned, but for obvious reasons these ports are offset from the inlet ports of the valve seat. As a result, the flow proceeds into the valve through the valve seat and must rapidly change direction in order to traverse to the ports in the sealing plate. This rapid change in direction results in the turbulent flow.
In an effort to improve the flow through the valve, sealing plates were furnished with profiled sealing surfaces which facilitate the flow through the valve by providing a smoother transition from the inlet flow ports of the valve seat to the flow ports of the sealing plate and valve guard. U.S. Pat. Nos. 3,536,094 to Manley discloses a prior art compressor valve having a sealing plate or rings with profiled sealing surfaces. The sealing surfaces in the Manley patent have a convex spherical cross-section which engages in concave spherical seating surfaces in order to interrupt the flow through the valve.
U.S. Pat. Nos. 4,924,906 and 5,052,434 to Harbal and Bauer receptively, also disclose valves with profiled sealing surfaces. Both of these patents disclose sealing surfaces that can be provided in a variety of cross-sections and engage in corresponding recesses in the valve seat. The Hrabal patent uses sealing rings which have a profiled cross-section and a support plate as the means for restricting and directing flow through the valve. The Bauer patent uses two piece rings of various cross-section to facilitate valve flow and closure.
The disclosures in the Manley, Harbal and Bauer patents attempt to provide a compressor valve that minimizes the velocity and pressure loss through the valve and increase the compressor efficiency by profiling the sealing surfaces. A disadvantage to these configurations is that the improvement in flow through the valve is achieved at the expense of valve seating performance. As noted, the optimum performance of the compressor requires valves which not only permit flow of the fluid or gases to and from the cylinder at a high velocity with a minimum amount of p

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