New Approach Changes Fundamental Compressor Valve Design

“With our technology, we can go even further by eliminating the ‘valve’ completely and embedding just our modules directly in the cylinder in the location where it makes the most sense,” said Zahroof. “So, a set of modules could be embedded in the head of the cylinder radially to act as a suction valve and another set can be arranged axially to act as a discharge valve. This will greatly enhance the performance of the compressor beyond what we can do with just replacing existing valves in a conventional design – improving gas flow and efficiency and minimizing dead clearance, or increasing volumetric efficiency. This is possible because of all the wear elements are in the module and no machining is required for the housing of the valves, as is required in a conventional valve.”

Conventional valves need to be sent to a precision machine shop for the valve seat and guard to be refurbished. If it has already been machined a couple of times, they will have to be replaced with new ones, which requires time for measurement to detailed drawings. The internal components, the springs and sealing elements, are always replaced, just like Zahroof’s modules. The valves are assembled and then have to be leak tested to ensure that the machining and aligning of components are correct.

Instead of sending valves to be refurbished – in some cases, sent from one continent to another due to lack of machine shops nearby – Zahoof’s cartridges, or modules in the valves, are replaced.

Thinking outside the box led to development of Zahroof’s Straightflo valve.
Thinking outside the box led to development of Zahroof’s Straightflo valve. SOURCE: Zahroof Valves

“The wear parts are in the module, and by making them all the same dimensions across all our valves – 1.5-inches in diameter to more than 12 inches in diameter – we can apply economy of scale and offer the cartridges at a relatively low price, about $17 per module for our standard module.”

To replace the module, the valve is opened by unscrewing a couple of cap screws. The old modules are removed by pushing them out by hand. The valve seat and carrier may next be cleaned, but in most cases, is not required as the critical surfaces will be clean. A fresh set of modules are then installed by hand into the carrier, and the valve closed with the cap screws.

“The design is such that this can be done in a matter of minutes,” said Zahroof. Unlike conventional valves, Zahroof’s valves don’t need to be leak tested in the field because every new modules comes from the factory leak tested.

Zahroof is focused on the entire pipeline of onshore and offshore oil and gas activity, from gathering to transmission, processing, storage and injection. The company’s technology also has applications for carbon dioxide, as well as the refining and petrochemical industries, which Zahroof intends to enter, Gioffredi said. Zahroof also is working with compressed natural gas manufacturers and OEMs on several long-term projects.

 


The company’s also has been supplying its valves to HICOR for use in their compressor technology system. Zahroof said their valve is the only valve that can handle the liquid in the chamber.


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