Note: Descriptions are shown in the official language in which they were submitted.
FILTER ELEMENTS, COALESCING BAFFLES, FILTRATION VESSEL
AND METHODS
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
FIELD OF THE INVENTION
[0001] This invention generally relates to filtration vessels,
coalescing baffles, and/or
filter elements and methods associated with the use.
BACKGROUND OF THE INVENTION
[0002] Filtration vessels and coalescers are generally known in the
prior art such as
shown in U.S. patent numbers 6,168,647 to Perry Jr. et al.; U.S. Publication
Number
2012/0210688 to Burns et al.; U.S. Publication Number 2013/0062273 to Burns
etal.; and
U.S. patent number 7,108,738 to Burns et al., the entire disclosures of each
of these
references being incorporated by reference as the different aspects of the
present invention
may be employed and improvements apply to these prior known filtration vessels
and
coalescing systems.
[0003] Certain aspects are also particularly applicable to a two stage
filtration system
such as shown in the '647 patent and the '688 publication. These particular
types of
filtration vessels are known and sold under the name GEMINI available from
PECOFacet
(US), Inc., a CLARCOR company located in Mineral Wells, Texas. Generally, in
these
types of systems, a gaseous fluid such as natural gas or other industrial
gases are forced
through different filter stage elements high pressure allowing for various
contaminant
removal from the gaseous fluid. Oftentimes, the removal involves removal of
oils and other
hydrocarbons including crude oil for example, that may be entrained as
droplets within the
gas stream. It is quite desirable to obtain a high efficiency of removal while
satisfying
sufficient flow and production rates through the vessel.
[0004] Currently, with many of the production sites, there are radical
hydrocarbons that
are a lot harder to coalesce such as in the fracking regions and certain oil
and gas production
regions. While GEMINI vessels existing such as covered by the aforementioned
'688 and
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'647 patents or publications provide for a certain amount of filtration and
capabilities,
further improvements are discussed herein.
BRIEF SUMMARY OF THE INVENTION
[0005] In one aspect the present invention provides for a tubular baffle
that comprises a
tubular extension. A plurality of pores is formed into the tubular extension.
At least one
drainage aperture is formed into the tubular extension. The tubular extension
comprises
regions of pores on opposed axial sides of the at least one drainage aperture.
Each drainage
aperture is larger in flow area than individual ones of the pores.
[0006] The at least one drainage aperture can include a plurality of
drainage apertures.
The tubular extension can include a series of drainage apertures arranged in
axial spaced
relation. This provides multiple opportunity for liquids to drain and exit the
larger drainage
apertures.
[0007] The tubular baffle may further include a downstream portion
comprising the
series of drainage slots and an upstream portion at least 1/5 of a length of
the tubular
extension that is free of the series of drainage apertures.
[0008] The porosity of the tubular extension may be between 20% and 40%
and further
can be between 28% and 35%.
[0009] In one embodiment, no louvers cover the pores.
[0010] The at least one drainage aperture may intersect and thereby may
connect
individual pores. However, this feature may also be applied to such louvered
applications
as in the prior art mentioned in the background.
[0011] The at least one drainage aperture can extend at least partially
along a
gravitational bottom of the tubular baffle as installed in a filtration
vessel.
[0012] In one embodiment, each drainage aperture may comprise a slot
having a length
between 1 to 4 inches and a width between 1/8 to 1/2 inches. The length of
each slot may
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extend circumferentially and the width of each slot may extend axially. For
many
production/industrial high pressure vessels, the tubular extension can have a
diameter of
between 3 and 8 inches and a length of at least 1 and 1/2 feet.
[0013] The tubular baffle may have at least one drainage aperture that
covers less than
1/3 a circumference of the tubular baffle.
[0014] The baffle may further comprise an orientation device orienting
the at least one
slot at a predetermined gravitational bottom relative to the orientation
device.
[0015] The tubular extension may comprise first and second open ends and
further
include a cap portion coupled to one open end. The cap portion can include an
end plate
with a post projecting from one side and a cup wall with windows projecting
from a second
opposite side. A porosity of the cup wall via the windows may be at least
twice as great as
a porosity of the tubular extension. This large flow capacity at the
downstream end can
encourage axial flow toward the downstream end and axial flow through the
element to the
downstream end.
[0016] The tubular baffle may further include a key arranged at a
predetermined
orientation relative to the at least one drainage aperture that orients the at
least one drainage
aperture at a predetermined gravitational bottom relative to the key. In an
embodiment, the
key may be formed into the post and may comprise an axially extending groove
formed into
the post.
[0017] The tubular baffle and/or a filter element may further include a
directional
indication formed on the end plate or end cap portion on the second opposite
side oriented
to indicate the predetermined orientation.
[0018] In another aspect the present invention provides for a filtration
assembly
incorporating such a tubular extension. The filtration assembly may further
include a filter
element that comprises a ring of filter media with an internal central flow
passage. The
filter element can have a first portion projecting into and received by the
tubular extension
and a second portion projecting outside of a first open end of the tubular
extension. The
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filtration assembly may further comprise a coalescing collection chamber
formed between
the filter element and the tubular extension. The filter element may include a
third portion
projecting through a second open end of the tubular extension.
[0019] Another aspect of the present invention is directed toward a
method of
coalescing using the filtration assembly. The method may comprise flowing a
gas stream
through though the filter element having entrained liquid droplets therein.
The method
further comprises flowing the gas stream radially outward through the ring of
filter media
while coalescing the entrained liquid droplets along the way. The flow of the
flowing gas
stream develops moving axially through the coalescing collection chamber and
drives the
entrained liquid droplets along the tubular extension toward the second open
end. The
method further includes draining the entrained liquid droplets through the at
least one
drainage aperture.
[0020] The method may include orienting the at least one drainage
aperture at a
gravitational bottom of the tubular extension and directing the flowing gas
stream to flow
axially along the first and second portions of the filter element.
[0021] In an embodiment, fifty percent to seventy percent of the flowing
gas stream
may exit from the first portion and thirty percent to fifty percent of the
flowing gas stream
may exit from the second potion. This can reduce radial flow velocity out
through the
element and/or baffle by spreading the radial flow over the length of the
element more
evenly. This reduced flow velocity prevents or reduces the likelihood of re-
entraining
droplets or atomizing of liquid droplets due to the slower more controlled
flow.
[0022] A series of drainage apertures may be aligned in axial spaced
relation along a
region of the tubular extension. As fluid flows along, there are then several
opportunities
for liquids to drain as opposed to flowing to the end where re-atomization may
occur.
[0023] In another embodiment the present invention provides for a
multiple stage filter
element assembly that comprises a filtration vessel that includes a partition
dividing the
filtration vessel into a first stage and a second stage. There may be at least
one opening in
the partition. The multiple stage filter element may further include an inlet
port in fluid
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communication with the first stage and an outlet port in fluid communication
with the
second stage. A filter element (e.g. one or more filter elements) may be
disposed in the
filtration vessel and extending through the partition. A tubular baffle can
surround the filter
element. The tubular baffle may comprise a non-louvered perforated extension
having a
plurality of pores.
[0024] Fluid flow in the multiple stage filter element may enter the
first stage through
the inlet port and pass radially inward through the filter element and along
an interior
chamber defined within the filter element. It may pass radially outward
through the filter
element and an intermediate chamber that may be defined between the tubular
baffle and
the non-louvered perforated extension. Thereafter it may flow to a low
pressure chamber
surrounding the tubular baffle. The low pressure chamber has a lower pressure
than the
intermediate chamber during use.
[0025] The multiple stage filter element assembly may have a porosity of
the non-
louvered perforated extension that is between 20% and 40% to provide a more
even flow
through the filter element over an extension of the filter element within the
second stage. It
may further have the porosity between 28% and 35%.
[0026] Further, the tubular baffle can include drainage apertures. Each
drainage
aperture may be larger in flow area than individual ones of the pores and may
connect
individual ones of the pores. In one embodiment, the drainage apertures extend
at least
partially along a gravitational bottom of the tubular baffle.
[0027] The multiple stage filter assembly may have pores that have a
pore size of
between .002 and .52 square inches. The pore size may be selected relative to
porosity to
control radial flow velocities and provide back pressure between the element
and the baffle
to control such velocities and spread fluid flow more evenly over the length
of the filter
element.
[0028] The non-louvered perforated tubular extension may comprise first
and second
open ends. There may be a cap portion coupled to one open end. The cap portion
may
include an end plate with a post projecting from one side and a cup wall with
windows
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projecting from a second opposite side. A porosity of cup wall via the windows
may be at
least twice as great as a porosity of the non-louvered perforated extension.
[0029] The non-louvered perforated extension can extend through the
partition. The
filter element may have a first portion projecting into and received by the
non-louvered
perforated extension. It may have a second portion projecting outside of a
first open end of
the non-louvered perforated extension. A coalescing collection chamber may be
formed
between the filter element and the non-louvered perforated extension. The
filter element
may further comprise a third portion that projects through the second open end
of the non-
louvered perforated extension.
[0030] In yet another embodiment or aspect the present invention
provides for keying.
In one embodiment, a tubular baffle that comprises a tubular extension with a
plurality of
pores formed into the tubular extension. The tubular extension comprises first
and second
open ends. A cap portion is coupled to one of the first and second open ends.
The cap
portion comprises an end plate with a post projecting from one side and a cup
wall with
windows projecting from a second opposite side. A porosity of the cup wall via
the
windows are at least twice as great as a porosity of the tubular extension. A
key is formed
on the cap portion.
[0031] In one embodiment, the key may be arranged at a predetermined
orientation
relative to the tubular extension. For example, the tubular extension may have
a bottom
portion with a greater drainage capability relative to a remainder of the
tubular extension.
[0032] The key can be formed into the post. The key may comprise a non-
circular
keyed structure formed along the post and extending axially. The keyed
structure may also
comprise an axially extending groove formed into the post.
[0033] Further, the post can define a cavity that is formed into the
second opposite side
for mounting a filter element. The keyed structure can extend into the cavity
as a projection
from a cylindrical surface of the cavity.
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[0034] The tubular baffle (or the filter element in an embodiment) may
further comprise
a directional indication that is formed on the end plate portion on the second
opposite side
and oriented to indicate the predetermined orientation.
[0035] The key may comprise a detent formed at a predetermined angular
position
relative to a central axis about which the tubular extension surrounds. The
post may
comprise a tapered tip and a cylindrical body. The key may extend axially into
the
cylindrical body and the tapered tip.
[0036] In yet another embodiment the present invention provides for a
multiple stage
filter element assembly that comprises a keyed tubular baffle. The multiple
stage filter
element assembly may further comprise a filtration vessel. A partition divides
the filtration
vessel into a first stage and a second stage. There is at least one opening in
the partition.
An inlet port is in fluid communication with the first stage. An outlet port
is in fluid
communication with the second stage. There is a filter element disposed in the
vessel and
extending through the partition. The tubular baffle surrounds the filter
element and is
secured by a support grid. The support grid provides a mounting opening to
receive the post
and a corresponding key keying with the key. The key may rotationally lock the
tubular
baffle relative to the filtration vessel and thus provide a predetermined
orientation to the
tubular baffle.
[0037] The multiple stage filtration vessel may further comprise
drainage apertures
formed along the tubular extension. The key may orient the drainage apertures
at a
gravitational bottom of the extension to facilitate drainage.
[0038] Alternatively or additionally, the key may also key with an end
cap of the filter
element and rotationally lock the filter element and the tubular baffle. The
corresponding
key may comprise a tab projecting from a circular surface of the mounting
opening.
100391 In still another embodiment the invention provides for a filter
element that
comprises a ring of filter media with an internal central flow passage. An end
cap closes an
end of the ring of filter media. The end cap comprises a mounting post and a
key is formed
along the mounting post.
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[0040] The mounting post may comprise a circular surface, and further
comprise a
detent formed into the mounting post that disrupts the circular surface and
extends axially
along the circular surface.
[0041] In one embodiment, the mounting post may comprise an axially
extending
groove to provide for the key. The mounting post may comprise a tapered tip
and a
cylindrical body and the key structure may extend axially into the cylindrical
body and the
tapered tip.
[0042] The key may provide means for keying with a tubular baffle having
a perforated
extension. Without the key, the filter element will not interfit and properly
mount with the
tubular baffle.
[0043] The ring of filter media may extend horizontally along an axis
and comprise an
upper half on one side of a horizontal plane and intersect the axis and a
bottom half on an
opposite side of the horizontal plane. The ring of filtration media of the
upper half and the
bottom half may be different with at least one different filtration,
coalescing or flow
characteristic.
100441 The key may be positioned at a predetermined position relative to
the upper half
and bottom half to locate the bottom half at a gravitational bottom when in
use. The
bottom half of the ring of filter media may comprise a treated region and the
upper half may
comprise an untreated region. The treated region may comprise a fluorocarbon
treatment.
The fluorocarbon treatment may include at least one of dipping, aerosol vacuum
application, vapor phase adhesion or plasma coating. The treated region can
additionally or
alternatively comprise an additional media to provide such a different
filtering
characteristic.
[0045] Another aspect of the present invention is directed toward a
method of using
such a keyed filter element. The method further comprises installing the
filter element into
a tubular baffle. The tubular baffle can include a tubular extension and a
plurality of pores
formed into the tubular extension. The method further comprises keying the
filter element
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to the tubular extension. The keying may rotationally lock the filter element
to the tubular
extension in an embodiment.
[0046] The method can further comprise installing the tubular baffle
into a support grid
in a filtration vessel, keying the tubular baffle to the support grid and
rotationally locking
the tubular extension to the support grid. The tubular baffle may comprise a
post having a
cavity receiving the mounting post of the filter element. The cavity may
include a circular
surface and a radially inward projecting detent.
[0047] The key of the filter element can include a clearance void formed
into the
mounting post to receive the projecting detent. For example, the clearance
void can
comprise a groove or a flat our other non-round key structure.
[0048] In still another embodiment the present invention provides for a
filter element
that comprises ring of filter media with an internal central flow passage. The
filter media
includes a treated region and an untreated region. The treated region has a
surface energy
different than the untreated region with an increased wettability for
hydrocarbons.
[0049] In one embodiment, the ring of filter media extends horizontally
along an axis
and comprises an upper half on one side of a horizontal plane intersecting the
axis and a
bottom half on an opposite side of the horizontal plane. The bottom half
comprises the
treated region. Greater than 50% of the upper half is free of the treated
region.
100501 For orientation of such an embodiment, the filter element may
further comprise
an orientation device at a predetermined angular orientation relative to the
treated region
adapted to locate the treated region along a gravitational bottom when
installed in a
filtration vessel.
[0051] The orientation device can include a key formed on an end cap of
the filter
element. The orientation device can additionally or alternatively include a
directional
indication marked on the filter element.
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[0052] The ring of filter media may comprise a tube wound depth media
surrounding an
axis having a plurality of layers. Alternatively or additionally, the ring of
filter media may
include a pleated ring portion.
100531 In another embodiment, the ring of filter media may extend
horizontally along an
axis and include a first stage portion and a second stage portion. The
portions may be
unitarily formed with each other or separate elements, with a seal element
separating the
first stage portion from the second stage portion. The treated region extends
primarily over
the second stage portion.
[0054] In a further such embodiment, the treated region may extend only
over a portion
of the second stage portion. The second stage portion can also include the
untreated region.
The treated region may be confined to one axial end portion of the second
stage portion. A
second axial end portion of the second stage portion may be only untreated and
form part of
the untreated region.
[0055] In an embodiment, the first stage portion can be free of the
treated region and
comprise only the untreated region. The treated region may cover less than
half of the
second stage portion. The first stage portion and the second stage portion may
be formed
integrally with each other as a tubular wrap of filter media comprising
multiple layers.
[0056] The filter element may further comprise a means for keying with a
tubular baffle
having a perforated extension. Further, it may be that without the means for
keying the
filter element will not interfit and properly mount with the tubular baffle.
The treated
region comprises a fluorocarbon treatment.
[0057] The fluorocarbon treatment may comprise at least one of dipping,
aerosol
vacuum application, vapor phase adhesion or plasma coating. Additionally, or
alternatively,
the treated region may comprise an additional filter media to provide the
treated region to
modify the surface energy along the treated region.
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[0058] Other aspects, objectives and advantages of the invention will
become more
apparent from the following detailed description when taken in conjunction
with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] The accompanying drawings incorporated in and forming a part of
the
specification illustrate several aspects of the present invention and,
together with the
description, serve to explain the principles of the invention. In the
drawings:
[0060] FIG. 1 is a side elevational view in partial section of a
preferred embodiment of
the multi-stage vessel and separator/coalescer filter element of the present
invention;
[0061] FIG. 2 is a side view of the separator/coalescer filter element
of FIG.1;
[0062] FIG. 2a, 2b, and 2c are similar views to FIG. 2 showing a side
elevation view of
a separator/coalescer filter element of FIG. 1 according to additional
embodiments of the
present invention, with FIG. 2a showing an embodiment where the filter media
of the filter
element includes a treated region on a lower horizontal half and an untreated
region on an
upper horizontal half of the filter element; FIG. 2b showing a treated region
on the second
stage portion of the filter element and an untreated region on the first stage
of the filter
element, and FIG. 2c showing a treated region on a downstream axial end
portion of the
second stage with untreated regions on an upstream axial end portion of the
downstream
region and an untreated region as well on the first stage.
[0063] FIG. 2d and 2e are further side elevation views of additional
embodiments of the
separator and coalescer filter element shown in FIG. 2, but with additional
keying system
and a treated region on the second stage and lower half in the filter element
of FIG. 2d, and
a multiple keying system and alternative different key structures being shown
in FIG. 2e.
[0064] FIG. 3 is an enlarged view of the chevron-type seal and seal
holder of the
separator/coalescer filter element of FIG. 2 taken at circle III;
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[0065] FIG. 4 is a partial cross-sectional view of the chevron-type seal
and the seal
holder of FIGS. 2 and 3; and
[0066] FIG. 5 is a perspective view of the basket cap portion for the
flow diffuser basket
of the multi-stage vessel of FIG.1.
[0067] FIG. 6 is a side view of the basket cap portion shown in FIG. 5;
[0068] FIG. 7 is an axial end view of the basket cap portion shown in
FIG. 5;
[0069] FIGS. 5a, 6a and 7a are similar figures to those shown in FIGS.
5, 6 and 7
respectively, but showing an alternative embodiment incorporating an
additional key
system;
[0070] FIG. 8 is a side view of an entire assembly of the tubular
impingement baffle
including the perforated extension and the basket cap portion, which is
employed in the
filtration vessel illustrated in FIG. 1, with the pore size being exaggerated;
[0071] FIG. 9 is an enlarged detail view of the perforated sheet metal
plate used in the
tubular baffle of FIG. 8 taken about detail A showing the perforated pores
better, again with
the pore size being enlarged for illustration purposes;
[0072] FIG. 10 is a side elevation view of the tubular extension
employing drainage
apertures, which may be in the form of slots that are sized larger than the
pores, the tubular
extension being used in the tubular baffle according to the embodiment of FIG.
8;
[0073] FIG. 11 is a bottom view showing the gravitational bottom of the
tubular
extension of FIG. 10.
[0074] FIGS. 12-14 are additional views of the basket cap portion used
in combination
with the perforated tubular extension shown in FIG. 8;
100751 FIG. 15 is an axial end view of the tubular baffle shown in FIG.
8;
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[0076] FIG. 16 shows a partially schematic and cut away from a bottom
view of a
filtration vessel incorporating the tubular baffle with slots according to the
embodiment of
FIG. 8 which schematic may represent that shown in FIG. 1;
100771 FIG. 17 shows an exploded assembly of a downstream support grid
including
straps carrying aperture, the basket cap portion of the coalescer and filter
element end cap,
all incorporating a keying system in accordance with an embodiment;
[0078] FIGS. 18-20 show perspective, end view and bottom elevation view
respectively,
of the inlet side end cap for the filter element, that may be used in
conjunction at the
opposite inlet end with the structure of FIG. 17 being employed at the outlet
end;
[0079] FIGS. 21-22 are opposed partially schematic axial end views taken
through cross
section of a filtration vessel with a filter element and coalescing tubular
baffle employing
the keying systems shown in FIGS. 17-20;
[0080] FIGS. 23-25 are isometric view of end portions of a filter
element interacting
with baffle and vessel components according to an alternative embodiment, with
the first
stage end portion of the filter element illustrated FIG. 23 and the second
stage end portion
being illustrated in FIGS. 24-25, which may be used as a retrofit, and which
filter element
and other components may be substituted or used in place of the corresponding
component
parts of FIG. 1, according to an embodiment of the present invention;
100811 FIG. 26, is an isometric view of an alternative embodiment of a
post having
instead a chevron-shape for the second stage end cap of the filter element to
be substituted
for the filter element end cap post shown in FIG. 17 (see also FIGS. 2d and
2e) that
similarly provides an axial clearance region arranged to clear the key
projection of the
keyed tubular baffle tubular baffle as illustrated and that may also provide a
keying
structure depending upon post configuration;
[0082] FIG. 27 is an isometric view of yet another alternative
embodiment of a post
having a rectangular shape for the second stage end cap of the filter element
to be
substituted for the filter element end cap post shown in FIG. 17 (see also
FIGS. 2d and 2e)
that also provides at least an axial clearance region arranged to clear the
key projection of
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the keyed tubular baffle tubular baffle as illustrated and that may also
provide a keying
structure depending upon post configuration;
[0083] FIG. 28 is an isometric view of yet another alternative
embodiment of a post
having a reduced diameter for the second stage end cap of the filter element
to be
substituted for the filter element end cap post shown in FIG. 17 (see also
FIGS. 2d and 2e)
that provides at least an axial clearance region arranged to clear the key
projection of the
keyed tubular baffle tubular baffle as illustrated, but this embodiment does
not provide
keying; and
[0084] FIG. 29 is an side view of the second stage end portion of a
filter element, that
may be used with the key tubular baffle as disclosed in other figures
according to yet
another alternative embodiment with the filter media tube being illustrated in
cross-section
and pored tubular extension removed for better illustration, with the second
stage filter
element end cap being postless so that the second stage of the filter element
may rest on the
keyed tubular baffle along the bottom as is illustrated, in which the postless
filter element
end cap provides for clearing the baffle key projection to allow the filter
element to still
interfit with the keyed tubular baffle.
[0085] While the invention will be described in connection with certain
preferred
embodiments, there is no intent to limit it to those embodiments. On the
contrary, the intent
is to cover all alternatives, modifications and equivalents as included within
the spirit and
scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0086] Referring to FIG. 1 of the drawings, the numeral 11 designates
the preferred
embodiment of a multi-stage vessel for simultaneously filtering solids,
separating liquids,
pre-coalescing liquids, and coalescing liquids out of a gas stream according
to the present
invention. This may generally be in accordance with that described in Patent
No. 6,168,647
to Perry Jr. et al. or U.S. Publication No. 2012/0210688 to Burns et al, or as
otherwise
incorporated into GEMINI brand filtration vessels available from PECOFacet
(US), Inc.
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[0087] The flow of the gas stream is indicated throughout as arrow G.
Multi-stage
vessel 11 has a generally tubular hull 12 having an initially open interior.
Hull 12 is
enclosed on an inlet end 12a by a conventional closure member 15, preferably a
releasable,
quick-opening closure. Hull 12 is permanently enclosed on an outlet end 12b by
a cap 13,
preferably elliptical. Closure member 15 consists of a conventional head
member 16 and a
conventional clamping member 17. Head member 16 is releasably sealed to multi-
stage
vessel 11 by clamping member 17. Clamping member 17 may be released and head
member 16 may be opened to allow access to the interior of hull 12. Clamping
member 17
provides a fluid-tight seal between hull 12 and head member 16, preferably
with a
conventional 0-ring (not shown). At least one and typically, a plurality of
separator/coalescer filter elements 18 are disposed within hull 12, although
one element 18
being shown in FIG. 1 to avoid confusion and too busy of drawings. For
example, multiple
filter elements, tubular baffles and holes in a partition of a two-stage
filtration vessel are
shown in the '688 publication to Burns.
[0088] In that regard, the vessel configuration, separator/coalescer
filter elements 18
may generally be any of those filter elements as disclosed in U.S. Patent No.
6,168,647 to
Perry Jr. et al. or U.S. Publication No. 2012/0210688 to Burns et al, both
assigned to the
present assignee. For example, the filter element 18 may comprise a single
continuous filter
media tube as in Perry Jr. or a combination or first stage and second stage
elements as in
various embodiments of Burns et al, that together can form the filter element
18 discussed
herein. However as shown in other figures and discussed, the filter element 18
preferably
includes a key such as a detent that can key a tubular baffle in an
embodiment. The detent
may also rotationally lock therewith an embodiment.
[0089] Hull 12 is supported by saddle supports 19. A plurality of
eyelets 20 are
permanently attached to hull 12 to aid in hoisting multi-stage vessel 11
during manufacture,
transportation, installation, and maintenance.
[0090] The interior of hull 12 is divided into a first stage 21a and a
second stage 21b by
a generally transverse partition 23. Partition 23 includes a plurality of
openings 25.
Although only a single separator/coalescer filter element 18 and filter guide
27 are shown, it
should be understood that openings 25 can be arranged, e.g., in rows on
partition 23. In a
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typical installation, four rows having two to four openings are present. A
tubular filter
guide 27 is aligned with each opening 25. Each filter guide 27 extends
longitudinally a
selected distance from partition 23 into first stage 21a. An inlet port 29 is
disposed on hull
12 and opens into first stage 21a. Inlet port 29 terminates with an inlet
flange 31. Inlet
flange 31 is adapted to allow multi-stage vessel 11 to be connected to a
conventional gas
pipeline. Inlet port 29 is located near partition 23 so that as a gas stream
flows through inlet
port 29 into first stage 21a, the gas stream impinges upon filter guides 27.
In this manner,
filter guides 27 aid in the removal of solids and free liquids from the gas
stream while
protecting separator/coalescer filter elements 18 from erosion. This, as well
as other
functions of filter guides 27, will be explained in more detail below. An
outlet port 33 is
disposed on hull 12 and opens into second stage 21b. Outlet port 33 terminates
with an
outlet flange 35. Outlet flange 35 is adapted to allow multi-stage vessel 11
to be connected
to a conventional gas pipeline. An annular collar 36 is aligned with outlet
port 33 and
extends into second stage 21b, thereby creating a barrier and preventing
liquids from
creeping along the interior surface of second stage 21 band escaping through
outlet port 33.
Multi-stage vessel 11 is preferably manufactured of steel materials which
conform to
published pressure-vessel standards, such as ASME Boiler and Pressure Vessel
Code,
Section 8, Division 1.
[0091] Disposed at an underneath portion 12c of hull 12 is a sump 39 for
collecting the
filtered solids, the separated liquids, the pre-coalesced liquids, and the
coalesced liquids that
are removed from the gas stream. Sump 39 is divided into a first-stage sump
39a and a
second-stage sump 39b by an impermeable sump partition 41. First-stage sump
39a is
generally tubular and is sealed on one end by a first-stage cap 37a.
Typically, first-stage
sump 39a collects separated liquids, pre-coalesced liquids, and solids not
filtered by
separator/coalescer filter element. Second-stage sump 39b is generally tubular
and is sealed
on one end by a second-stage cap 37b. Typically, second-stage sump 39b
collects coalesced
liquids.
[0092] A first-stage downcomer 43a provides fluid communication between
first stage
21a and first-stage sump 39a. First-stage downcomer 43a allows drainage of the
separated
solids, the filtered liquids, and the pre-coalesced liquids from first stage
21a into first-stage
sump 39a. A second-stage downcomer 43b provides fluid communication between
second
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stage 21 band second-stage sump 39b. Second-stage downcomer 43b allows
drainage of the
coalesced liquids from second stage 21b into second-stage sump 39b. A first-
stage sump
vent 45a provides fluid communication between first stage 21a and first-stage
sump 39a,
and acts as a gas vent. First-stage sump vent 45a allows gas displaced from
first-stage sump
39a to flow back into first stage 21a. A second-stage sump vent 45b provides
fluid
communication between second stage 21b and second-stage sump 39b, and acts as
a gas
vent. Second-stage sump vent 45b allows gas displaced from second-stage sump
39b to
flow back into second-stage 21b. A first-stage vent baffle 47a prevents solids
carried by the
separated liquids and pre-coalesced liquids from flowing into first-stage sump
39a. A
second-stage vent baffle 47b prevents mist from flowing back into second stage
21b from
second-stage sump 39b.
100931 Disposed on the upper side of hull 12 and in fluid communication
with first stage
21a is a first-stage pressure-gauge port 49a. First-stage pressure-gauge port
49a is adapted
to receive a conventional pressure gauge (not shown) for monitoring the
pressure in first-
stage 21a or the differential pressure. Likewise, located on the upper side of
hull 12 and in
fluid communication with second-stage 2Ib is a second-stage pressure gauge
port 49b.
Second-stage pressure-gauge port 49b is adapted to receive a conventional
pressure gauge
(not shown) for monitoring the pressure in second stage 21b or the
differential pressure.
100941 Continuing with reference to FIG. 1 in the drawings, first-stage
gauge glass
connections 51a and 51b are disposed opposite each other on the upper and
lower sides of
first-stage sump 39a and in fluid communication with first-stage sump 39a.
First-stage
gauge glass connections 51a and 51b are adapted to receive a conventional
gauge glass (not
shown) for monitoring the level of liquids and solids in first-stage sump 39a.
Similarly,
second-stage gauge glass connections 53a and 53b are disposed opposite each
other on the
upper and lower sides of second-stage sump 39b and in fluid communication with
second-
stage sump 39b. Second-stage gauge glass connections 53a and 53b are adapted
to receive
a conventional gauge glass (not shown) for monitoring the level of liquids in
second-stage
sump 39b. A plurality of first-stage sump connections 55, preferably operated
by valves
(not shown), for draining or siphoning solids, liquids, and pre-coalesced
liquids out of first-
stage sump 39a, are disposed on first-stage sump 39a. Similarly, a plurality
of second-stage
sump connections 57, preferably operated by valves (not shown), for draining
or siphoning
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coalesced liquids and fine liquids out of second-stage sump 39b, are disposed
on second-
stage sump 39b. In addition, first-stage sump connections 55 and second-stage
sump
connections 57 allow level control instruments and other measuring devices to
be inserted
into first-stage sump 39a or second-stage sump 39b, respectively.
[0095] A screen member 61, preferably made of a woven steel material, is
disposed in a
lower portion 63 of second stage 21b. Screen member 61 extends substantially
the entire
length of second stage 21 band acts as a barrier to prevent coalesced liquids
that have
collected in lower portion 63 from becoming re-entrained in the gas stream.
[0096] A grid that may have plurality of first-stage support straps 65
are disposed in
first stage 21a to support separator/coalescer filter elements 18. First-stage
support straps 65
generally extend transversely across first stage 21a, and are connected to the
interior of hull
12 by a snap fit or any suitable holding clip member (not shown) that does not
require tools
to release first-stage support straps 65. It should be understood that one or
more first-stage
support straps 65 may be connected together, or integrally connected, to form
a single
webbed network of first-stage support straps 65. First-stage support straps 65
are spatially
disposed within first stage 21a, such that the gas stream may flow unabated
around first-
stage support straps 65. First-stage support straps 65 include a plurality of
apertures 66 to
receive separator/coalescer filter elements 18. First-stage support straps 65
are preferably
made of rigid material, such as steel or metal. In addition, first-stage
support straps 65 hold
separator/coalescer filter elements 18 firmly in place, without longitudinal
compression,
thereby preventing longitudinal movement of separator/coalescer filter
elements 18 in
backflow situations.
[0097] Likewise, a grid comprising a plurality of second-stage support
straps 67 are
disposed in second stage 21b to support separator/coalescer filter elements
18. Second-
stage support straps 67 generally extend transversely across second stage 21
band are
connected to the interior of hull 12. As with first-stage support straps 65,
one or more
second-stage support straps 67 may be connected together, or integrally
connected, to form
a single webbed network of second-stage support straps 67. Second-stage
support straps 67
are spatially disposed within second stage 2 lb such that the gas stream may
flow unabated
around second-stage support straps 67 toward outlet port 33. Second-stage
support straps
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67 include a plurality of apertures 68 to receive separator/coalescer filter
elements 18 and
associated tubular baffles 71.
[0098] A plurality of generally basket-shaped tubular baffles 71 are
disposed in second
stage 21b to prevent coalesced liquids and fine liquids from becoming re-
entrained in the
gas stream as the gas stream flows through second stage 21b toward outlet port
33. A
separate tubular baffle 71 is associated with each separator/coalescer filter
element 18 and
each corresponding opening 25 in partition 23. Tubular baffles 71 are adapted
to be
inserted through tubular filter guides 27 from first stage 21a and into second
stage 21b,
where tubular baffles 71 are received and carried by second-stage support
straps 67. Thus,
once installed, tubular baffles 71 extend from second-stage support straps 67,
through
openings 25, past partition 23, and partially into filter guides 27. Tubular
baffles 71 may be
removed through filter guides 27 for cleaning, maintenance, and replacement.
[0100] Each tubular baffle 71 includes a perforated tubular extension 73
coupled to a
basket cap portion 75. It should be understood that perforated tubular
extension 73 and
basket cap portion 75 may be integrally connected. Perforated tubular
extension 73 is
adapted to allow the gas stream to flow through, but to prevent coalesced
liquids and fine
liquids from escaping and becoming re-entrained into the gas stream. In one
embodiment,
this may accomplished by a plurality of annular louvers (not shown) disposed
along the
extent of perforated tubular extension 73 such as shown in U.S. Patent
6,168,647. Louvers
may be employed with either or both of the keying aspects and/or the drainage
slot features.
More preferably in one embodiment, a non-louvered perforated extension 73 is
employed as
shown with a plurality of pores that provide a controlled backpressure.
[0101] Tubular baffle 71 with pores and/or drain apertures, along with
benefits will be
discussed in more detail herein, particularly with respect to FIGS. 8-12 and
16.
[0102] Referring now to FIG. 2 in the drawings, a typical
separator/coalescer filter
element 18 of the present invention is illustrated. Separator/coalescer filter
element 18 is
preferably a tubular filter element (that may be either cylindrical tube
and/or pleated having
a filter wall 81 and a hollow core 83. Filter wall 81 of separator/coalescer
filter element 18
preferably consists of multi-overlapped layers of non-woven fabric strips,
which provide an
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outer cylindrical surface in one embodiment. The selected density and porosity
of
separator/coalescer filter elements 18 prevent solids and pre-coalesced
liquids from passing
through separator/coalescer filter elements18 and into second stage 21b of
multi-stage
vessel 11. Thus, separator/coalescer filter elements 18 are of the same
general type as those
disclosed in U.S. Pat. No. 5,827,430, issued Oct. 27, 1998 to Perry, Jr., et
al, both references
of which are incorporated by reference. However, each separator/coalescer
filter element
18 of the present invention is circumscribed by an annular seal holder 85.
Seal holder 85 is
preferably made of polyester and is permanently sealed, or affixed, to filter
wall 81. Seal
holder 85 is sealingly bonded to filter wall 81 by a heat treatment, but it
should be
understood that seal holder 85 may be sealed to filter wall by other
conventional means,
such as glue or adhesive. It is preferable that seal holder 85 does not
compress the layers of
separator/coalescer filter element 18. Seal holder releasably carries an
annular seal 87,
preferably a chevron-type seal, as will be explained in more detail below.
Other seals and
seal arrangements may be employed in other embodiments, as well as alternate
filter
elements including those disclosed U.S. Publication No. 2012/0210688 to Burns
et al. A
filter element as used herein may itself comprise two or more end to end
elements as shown
in Burns et al.
101031 Seal
holder 85 and seal 87 separate separator/coalescer filter element 18 into two
portions: an inlet portion 89a (also referred to as first stage portion) and
an outlet portion
89b (also referred to as second stage portion). It is not necessary that inlet
portion 89a and
outlet portion 89b are of the same length. Indeed, depending upon the
application, it may be
necessary to offset seal holder 85 and seal 87 from the axial center of
separator/coalescer
filter element 18. It is important to note that both inlet portion 89b and
outlet portion 89b
are of generally homogenous construction and thus integral and continuous;
therefore, inlet
portion 89a and outlet portion 89b are functionally identical in one
embodiment, although
the lengths of inlet portion 89a and 89b may vary. In other embodiments, first
and second
stage portions are in whole or part functionally different. When seal 87 is a
chevron-type
seal, inlet portion 89a and outlet portion 89b are determined by the
orientation of seal 87, as
will be explained in more detail below. On the other hand, if seal 87 is an 0-
ring, or some
other type of seal whose functionality is independent of flow direction, then
inlet portion
89a and outlet portion 89b may be interchangeable. It should be understood
that due to
differences in the sealing characteristics between a chevron-type seal and an
0-ring type
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seal, the two seals may not be interchangeable for a given separator/coalescer
element 18.
0-rings or other seals may be employed through in some embodiments.
[0104] Inlet portion 89a terminates with a filter inlet cap 91a, and
outlet portion 89b
terminates with a filter outlet cap 91b. It is preferable that both filter
inlet cap 91a and filter
outlet cap 91b are identical, but for reasons explained below, filter inlet
cap 91a and filter
outlet cap 91b may be of varying configurations. Filter inlet cap 91a and
filter outlet cap
9 lb form a fluid-tight seal with separator/coalescer filter element 18, such
that all fluids in
the gas stream must pass through filter wall 81. Filter inlet cap 91a has a
filter inlet cap post
93a that protrudes longitudinally outward from separator/coalescer filter
element 18. Filter
inlet cap post 93a preferably tapers inwardly at its outermost extent. In a
similar fashion,
filter outlet cap 91b has a filter outlet cap post 93b that protrudes
longitudinally outward
from separator/coalescer filter element 18. Filter outlet cap post 93b
preferably tapers
inwardly at its outermost extent. Filter inlet cap 91a and filter outlet cap
91b are illustrated
having a filter inlet cap flange 95a and a filter outlet cap flange 95b,
respectively, although
filter inlet cap 91a and filter outlet cap 91b may also be flush with filter
wall 81.
[0105] Referring to FIG. 3 in the drawings, a blow-up view of circle III
of FIG. 2 is
illustrated. As mentioned above, inlet portion 89a and outlet portion 89b may
be
functionally identical. When seal 87 is a chevron-type seal, as is preferable,
the orientation
of seal 87 determines which portion of separator/coalescer filter element 18
represents inlet
portion 89a, and which portion of separator/coalescer filter element 18
represents outlet
portion 89b. Although the orientation of chevron-type seal 87 determines which
portion of
separator/coalescer filter element 18 represents inlet portion 89a, it should
be understood
that other means of ensuring proper installation of separator/coalescer filter
element exist.
For example, filter inlet cap post 93a and filter inlet cap post 93b may be of
different sizes
or shapes, or filter inlet cap flange 95a and filter outlet cap flange 95b may
be of different
sizes or shapes.
[0106] When seal 87 is a chevron-type seal, seal 87 includes a seal base
portion105, a
seal vertex portion 107, and a seal cone portion 109. Seal base portion 105
and seal cone
portion 107 are integrally joined together at seal vertex portion 107. Seal
cone portion 109
is preferably frusto-conical-shaped, having a small-diameter end 111, and a
large-diameter
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end 113. It is preferable that seal base portion 105 and seal cone portion 109
form an angle
a of about 60 . In order for seal 87 to operate properly, it is necessary that
seal 87 be
installed into seal channel 101 such that large-diameter end 113 extends in a
direction
opposite of the direction of flow of the gas stream. Because large-diameter
end 113 extends
downward in FIG. 4, the lower end of separator/coalescer filter element 18
becomes inlet
portion 89a, and the upper end of separator/coalescer filter element 18
becomes outlet
portion 89b. Large-diameter end 113 is flexible and can be compressed toward
seal base
portion 105. Thus, when separator/coalescer filter element 18 is installed
into multi-stage
vessel 11 (see FIG.1), large-diameter end 113 is compressed against filter
guide 27, thereby
forming a fluid-tight seal between first stage 21a and second stage 21b. Seal
holder 85 and
seal 87 allow individual tubular separator/coalescer filter elements 18 to
filter solids,
separate liquids, and pre-coalesce liquids as the gas stream flows through
filter wall 81 of
inlet portion 89a from outside to inside in first stage 21a, and
simultaneously coalesce fluids
and fine liquids as the gas stream flows back through filter wall 81 of outlet
portion 89b
from inside to outside in second stage 2 lb.
101071 Referring now to FIG. 5 in the drawings, basket cap portion 75 of
tubular baffle
71 is illustrated in a perspective view. Basket cap portion 75 is generally
cup-shaped with a
plurality of longitudinal windows 115 spatially arranged around a cylindrical
cup wall 117,
and which terminate at a plate provided by a flat cup lid 119. A hollow basket
cap portion
post 121, concentric with cup wall 117 protrudes axially away from cup lid
119. Basket cap
portion post terminates at a tapered end 123. Basket cap portion post 123 has
a central
cavity 125 extending through the plate or lid 119 that is configured to
matingly receive filter
outlet cap post 93b, when separator/coalescer filter element 18 is inserted
into tubular baffle
71 (see FIG.1).
101081 Referring back to FIG. 1, and especially FIGS. 8, 9, 10 and 11 in
accordance
with certain aspects and in one embodiment, the tubular baffle 71 and
specifically the
tubular extension 73 is shown to include a perforated sheet metal wrap 150
that is free of
and does not include louvers, but instead includes perforated pores 152 that
are preferably
round in one embodiment. Such pores can be punched out in press operations.
The sheet
metal wrap 150 is formed into a tubular shape and preferably cylindrical and
thereby
includes opposed ends including an open inlet end 154 and an open outlet end.
The open
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outlet end may be welded or otherwise secured to the rest of the cap portion
75 whereby a
large flow windows and openings are provided to facilitate fluid flow.
[0109] The perforations can better ensure evenness of the radial flow
through the filter
element, and/or control the fluid flow and liquid drainage in such a two stage
type vessel.
In particular, in one embodiment, the first half of the second stage filter
media and
collection chamber accounts for between about 50-70% of the gas stream exiting
through
the first half of the second stage filter media, while 30-50% of the gas
stream exits the filter
media and collections chamber in the second half of the filters second stage.
With pores, an
intermediate pressure chamber 158 in the form of a cylindrical chamber in one
embodiment
is formed radially between the outer periphery of the filter element 18 and
the inner
periphery of the tubular baffle 71. This can provide a backpressure to
encourage use of the
entire downstream second stage portion of the filter element reducing flow
velocity and
more controlled axial flow velocity through the baffle.
[0110] To achieve the more even flux and benefits and prevent virtually
all of the fluid
flow from flowing out say the first 3-6 inches of the second stage filter
media segment, the
pore sizes are tightly controlled, but yet more open than what is provided in
the previous
louvered baffle situation. Specifically, the porosity of the non-louvered
perforated
extension is between ("between" meaning including the end ranges) 20% and 40%,
and
more preferably between 28% and 35%. This porosity measure does not include
drain
apertures such as slots, which are discussed with association to additional
embodiments.
[0111] Further, the pores 152 can be smaller in size than louvers as per
the prior art,
with pore size preferably being between .002 and .5 square inches in flow
area. Preferably,
the pores are punched out as round pores having a diameter between .05 and .2
inch in
diameter.
[0112] Additionally, or alternatively, drainage apertures 160 are
provided along a
gravitational bottom 162 of the tubular extension 73. The drainage apertures
160 work in
synergy with the pores 152 to facilitate drainage due to the fact that an
axial flow of gas and
liquids moves axially along the intermediate pressure chamber 158 driving
liquids toward
the windows or open end proximate the basket cap portion 75. The drain
apertures 160 are
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large enough to facilitate drainage of liquid that is coalesced prior to
reaching the end to
prevent such liquids from being re-entrained or atomised due to gas flow
velocity through
the intermediate pressure chamber 158.
[0113] The drainage apertures are different than and larger in flow area
than individual
ones of the pores 152. Further, the drain apertures 160 may intersect (i.e.
larger than the
spaces between pore) and thereby connect with different ones of the pores 152.
[0114] The drainage apertures are located along the gravitational bottom
162 as liquids
drains down through gravity or otherwise and are thus located where drainage
can be
maximized. However, the drainage apertures are not so large as to create
unevenness in the
flow through the tubular baffle and ensure that the full length of the second
stage portion of
the filter element 18 is utilized with the goal of maintaining about even
radial flow outward
from the filter media along the entire length of the filter element in the
second stage. The
drainage apertures may each have a flow area of between .04 and .4 square
inches, more
preferably between .1 and .4 square inches.
[0115] In one embodiment, the drainage apertures comprise a plurality of
drain slots
that are arranged in a series 164 and axial spaced relation.
[0116] Further, tubular baffle may confine the drainage apertures to a
downstream
portion of the tubular extension 73 to keep higher backpressure at the
upstream region
and/or for structural integrity to drain liquids where most needed. The
downstream portion
166 being shown for example in FIGS. 10, 11 and 16. Further, an upstream
portion 168 of
the tubular extension 73 is provided that may be free of drainage apertures,
with the
upstream portion being at least 1/5 the length of the extension. In one
embodiment, by
restricting the drainage apertures to the downstream portion, this enables
liquid to coalesce
further along the upstream portion and also maintain their back pressure
towards the
upstream portion to ensure that more flow through the filter element occurs
over the entire
length more evenly.
[0117] In one embodiment, the drainage apertures are slots that have a
length of
between 1-4 inches and a width between 1/8 and 1/2 inches. The slots may
extend
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longitudinally axially, but preferably for strength purposes, the length of
each slot extends
circumferentially as shown with the width of the drainage slot extending
axially. This also
allows a greater span of the gravitational bottom. While slots are shown, and
are
advantageous, other shapes of drainage apertures may be used including simply
larger pore
openings that are sized substantially larger than those of the pores 152.
Again, these would
be provided preferably along the gravitational bottom, although some along or
around other
region are also envisioned.
[0118] Additionally, in an embodiment, the drainage slots are spaced
axially in the
series 164 at least 1 inch apart and more preferably, between 2 and 6 inches
apart. This
maintains sufficient strength and also maintains sufficient back pressure
within the
intermediate pressure chamber 158.
[01191 Typically, the tubular extension will have a diameter of between
3 inches and 8
inches and a length of at least 1-1/2 feet and typically between 2-4 feet for
most
embodiments, to provide reference relative to the pore size and drainage
aperture
arrangements discussed above.
[0120] It should be noted that the pores 152 and the drainage apertures
160 may be used
in different embodiments independent of each other or in an embodiment
combined as
shown for example in FIG. 1 and FIGS. 8-11. For example, the slots or other
drainage
apertures may be added to previous systems such as those shown in U.S. Patent
Number
6,168,674 to Perry Jr. employing a louvered opening arrangement in a baffle,
according to
one embodiment of the present invention.
[0121] While the porosity of the tubular extension is more limited, it
is noted that the
open end 156 of the tubular extension is not so limited, but opens into the
windows formed
within the basket cap portion 75 to prevent undue restriction at the far most
outlet end of the
baffle and filter element so that high flow rates can be ensured as opposed to
restricted. The
porosity through the windows of the basket cap portion 75 is at least twice as
large as the
porosity of the tubular extension, and typically at least 85%.
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[0122] It is also noted that the normal pore size 152 may be between
.0625 inch in
diameter to .2 inch in diameter. Drainage aperture 160 would be larger than
the pores and
in a range of between .2 inch and .5 inch in diameter, if round.
[0123] To orient the gravitational bottom 162 or otherwise to provide
for correct
compatibility to ensure that the proper baffle is being used or that the
proper filter element
is being employed, a keying system may be employed. The keying system is shown
for
example in FIGS. 17-22 and also in FIGS. 5a-7a as well as FIGS. 2d and 2e as
it relates to
the filter element.
[0124] As shown, the apertures 68 in the downstream support grid with
straps 67 may
include a key 170 in the form of a projecting tab 172 that projects radially
inward from the
otherwise circular surface of the apertures 68. Inlet grid 65 may or may not
have a similar
key system that keys with inlet/first stage end caps of the filter element.
Also, the tubular
baffle 71 along the post 121 may include formed therein a key 174 that is
complimentary to
key 170. This key 174 may take the form of an annular groove 176 along the
outer
periphery that extends axially along the post 121 and through the tapered end
123.
Additionally, internally, the annular groove 176 becomes a projecting rib 178
that extends
axially along the internal cavity 125 of the post 121 such that the key 174
may be provided
on one or both the outer periphery surface and inner periphery surface. The
key may also
be alternatively formed on a different portion of the tubular baffle such as
along the plate or
cup lid 119, along the cup wall 117 or other such portion. See FIG. 2e as an
example with
keys 194.
[0125] The filter element also includes a complimentary key 180 that
mates with the
key 174 of the baffle. Key 180 may be formed along the outlet side of post
93b, and may
take the form of a groove 182 that extends axially and through the tapered end
in one
embodiment.
[0126] Each of these keys are arranged at a predetermined orientation
relative to the
tubular extension 73 and particularly the drainage apertures 160 and
gravitational bottom
162 of the tubular extension. Specifically, the keys 170, 174 and 180 are all
provided to
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orient and arrange the drainage slots and at the gravitational bottom during
use to facilitate
such drainage.
[0127] While the projection and groove structure is particularly
beneficial and provide
for a detent structure to rotationally lock each of the keys 170, 174 and 180
to prevent
relative rotation between the tubular baffle and the vessel and prevent
relative rotation
relative to the filter element and the tubular baffle and/or for
compatibility, other such key
structures and orientation devices are also contemplated. For example, other
detent
structures may be employed. In one embodiment, and as shown in FIG. 2e, it may
comprise
a flat 184 form along the post and/or tabs 186 that are formed at a
predetermined angular
orientation relative to the post along the end caps of the filter elements.
Rather than being
tabs, receptacles may alternatively be used along the end caps that would be
received or
mate with corresponding tabs projecting axially from either the support grids
of the vessel
and/or the basket cap portion 75 of the tubular baffle 71. Such a keying
system may be used
additionally for filtration media characteristics to ensure that the proper
elements are being
in the right or correct vessels. Different filter media grades may be used or
different
efficiencies needed in different applications for such GEMINI vessels and such
a keying
system can be used to provide those features.
[0128] In the particular arrangement, it has the additional advantage of
assisting in
installation in that the filter element may be rotationally locked to the
tubular baffle and
installed together during axial installation to push the tubular baffle 71
into engagement and
keying relationship with the support grid 68 and the keyed aperture 68 shown
in FIG. 17.
[0129] Because the installation is done at the other opposite end, the
orientation device
may additionally or alternatively include in one embodiment a directional
symbol 188
formed upon the inlet end cap 91a such as an arrow pointing up when oriented
correctly.
This may be part of the post projection shaped in this format to include a
triangular post 190
and a vertical flange 192 vertically below the triangular post. This structure
itself may serve
as a key 194 and mate with a corresponding keyed aperture receptacle in the
inlet support
grid straps 65 and openings 66. The advantage of the directional arrow is that
it shows the
installation which way is up as the installation is largely done blind and the
installer can
then see which way the filter element needs to be installed to be properly
received without
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difficult into the tubular baffle 71. Specifically, with reference to FIG. 1
it can be seen that
the closure is only at the inlet end and at the other end through the
partition wall the outlet
side of where the keying structures are provided cannot readily be seen during
installation.
By providing a directional indication, this assists the service technician in
finding the
correct keying location. Alternatively, the service technician could operate
without such a
directional indication by rotating until the corresponding keys are found to
facilitate
rotational locking and installation.
[0130] Additionally, with reference to FIGS. 2a - 2d, various
embodiments are shown,
some of which may benefit from employing a keying structure to facilitate
proper
orientation of the filter element to arrange a treated region at a
predetermined angular
orientation with a certain portion of the outer cylindrical periphery of the
filter media being
located at a gravitational bottom. As mentioned above, the keying system may
also be used
to simply indicate whether a certain type of filter media or treated filter
media may be
installed or used and/or to orient the baffle. Any of the keying systems
described above
may be used in conjunction with these embodiments. Alternatively, it is also
possible that
the treated media embodiments discussed in FIGS. 2a - 2d may also be used
along without
such keying systems even though synergy exists using those systems together.
[0131] Turning then to FIGS. 2a - 2d, there is shown a filter element
18a - 18d, each of
which includes a treated region 200a - 200d, and an untreated region 202a -
202d. The
treated region provides a filtration characteristic that is different than the
untreated region.
Specifically, the treated region and untreated regions may be along different
outer
peripheral regions of the filter element. In one embodiment, the treated
region has a surface
energy that is different than the untreated region with an increased
wettability for
hydrocarbons. This may be done by way of a fluorocarbon treatment such as
plasma
fluorination or other chemical additives or coatings along the treated region.
The untreated
region, however, does not receive such treatment coatings or the like. The
untreated region
may have greater flow therefore, in some embodiments or a greater porosity.
For example,
the treated and untreated regions may also include some masking or additional
media
applied over a certain region.
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101321 In the embodiment shown in FIG. 2a, there is provided a filter
element 18a that
comprises filter media extending horizontally along the axis to include an
upper half 204
and a lower half 206. As shown, the bottom half comprises the treated region
200a. The
lower half may also partially incorporate part of the treated region 200a in
some
embodiments. Preferably, the upper half 204 comprises only the untreated
region 202a and
does not comprise any portion of the treated region. Preferably, at least half
of the upper
half is free of such treated region. With this arrangement, the wettability
and flow of liquids
along the gravitational bottom 208 is enabled or provided. The increased
wettability for
hydrocarbons facilitates additional flow of liquid through the filter element
at these regions.
Further, an orientation device such as those previously described including
keys for
example, may be employed and arranged at predetermined angular orientations to
locate the
gravitational bottom 208 of the filter element 18a at the appropriate
gravitational bottom
location when installed in the filtration vessel and in use.
101331 In the embodiment shown in FIG. 2b, filter element 18b instead
includes a
treated region 200b over the entire second stage 89b of the filter element
downstream of the
seal 87. In contrast, the upstream region along the first stage 89a may be
untreated and
form the untreated region 202b in whole or in part. The treated region 202b
may extend
partially into the first stage 89a in this filter element 18b. This is
particularly advantageous
when employing a unitary tube for the filter media that extends over both
first and second
stages 89a and 89b whereby the first and second stages are identical but for
the additional
treatment being formed along the second stage.
101341 Turning then to FIG. 2c, a further embodiment is shown where a
filter element
18c includes a treated region 200c restricted or confined only to an axial end
portion of the
second stage 89b. The second stage 89b also includes an upstream portion or
other axial
end portion comprising the untreated region 202c. The untreated region 202c
may also
extend over the first stage 89a in the filter element 18c. In this embodiment,
the treated
region 200c may also comprise some increased porosity to encourage additional
flow
toward the end of the filter element to prevent premature exiting of gaseous
fluid flow.
However, it may also comprise a fluorocarbon treatment to encourage liquid
droplet
formation at the axial end and closest to the window region 115 of the tubular
baffle when
employed in use (see other figures).
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[0135] Turning then to FIG. 2d, yet a further embodiment showing filter
element 18d is
shown with a treated region 200d along the bottom half of the filter element
at the
gravitational bottom like FIG. 2a, but also restricted primarily to the second
stage either
substantially or confined as in either of FIGS. 2b and 2c. As shown, the
untreated region
220 extends over the first stage in this embodiment. This arrangement and
enlarged image
also shows the keying system for orientation of gravitational bottom.
101361 From the above description, a recap and summary will be provided
additional
context relative to the additional coverage sought in this particular
continuation-in-part
application. From the above description and FIGS. 1-22, it is apparent there
is thus
provided a filter element 18 configured for use with a particular keyed
tubular baffle 71. By
configured for use it is meant that the filter element is usable with
therewith and will interfit
therewith such as in the claims appended hereto. But in such instances a
claimed a "filter
element configured for use with a tubular baffle" is directed to the filter
element (and is not
claimed in combination with the tubular baffle), whereas in contrast a claim
directed to "a
filter and baffle assembly" is directed to such combination by claiming
components
affirmatively in combination. The particular keyed tubular baffle 71 includes
a tubular
extension 73 and defines a plurality of pores 152 (that either may be louvered
or may not be
louvered), with the tubular extension 73 including first and second open ends
(e.g. to
receive the filter element therethrough as shown in FIG. 16), and with a cap
portion 75
coupled to one of the first and second open ends. The cap portion 75 comprises
an end plate
(see e.g. FIG. 17) with the post 121 projecting from one side that provides a
hollow receiver
(see e.g. the internal cavity 125 of the post 121), a key projection (e.g.
projecting rib 178
and/or groove 178) along the post 121 and projecting radially inwardly in the
hollow
receiver.
10137] According to an above disclosed embodiment, the filter element 18
comprises: (a) a tubular filter media extension with an internal central flow
passage (e.g. the
ring of filter media such as provided by the filter wall 81 that may have
hollow core 83, and
which may be either a continuous single unitary tube or multiple separate
elements) having
a first stage end provided (e.g. provided by first stage portion 89a) and a
second stage end
(.e.g. provided by second stage portion 89b), with the second stage end sized
to be received
within the tubular baffle; (b) a seal 87 disposed along the tubular filter
media extension
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between the first stage end and the second stage end to separate the first
filter stage 89a and
the second stage 89b; (c) with the first stage end cap 91a closing the first
stage end of the
tubular ring of filter media; (d) with the second stage end cap 91b closing
the second stage
end of the ring of filter media; and (e) a mounting post 93b provided by
second stage end
cap that is configured to be received within the hollow receiver of the
tubular baffle with an
axial clearance region arranged to clear the key projection of the tubular
baffle.
[0138] In an above embodiment, for example, the axial clearance region
of the filter
element is provided by the key 180 and/or an axially extending groove 182 such
as shown
in FIG. 17 (see also FIGS. 2D, 2E). As apparent, this structure (e.g. key 180
and/or an
axially extending groove 182) also provides means at the second stage end cap
91b for
clearing the baffle's key projection to allow the filter element to interfit
with the keyed
tubular baffle. Preferably, the axial clearance region is configured to key
with the key
projection for providing a predetermined angular orientation for use, with the
groove being
particularly advantageous. However other embodiments provide the axial
clearance region
and/or the means at the second stage end cap 91b for clearing the baffle's key
projection,
and are also shown and described in conjunction with alternative embodiments
in FIGS. 23-
29.
[0139] It is understood that the alternative embodiments filter elements
of FIGS. 23-29
are identical to the filter element 18 (e.g. same ring of filter media such as
provided by the
filter wall 81 that may the hollow core 83, and which may be a continuous
single unitary
tube or multiple separate elements; same seal 87 and seal holder 85), except
for an
alternatively configured second stage end cap and/or alternatively configured
first stage end
cap, such that the description above for earlier embodiments is equally
applicable to the
embodiments of FIGS. 23-29 unless expressly indicated to the contrary.
101401 Turning to FIGS. 23-25, in this alternative embodiment, a filter
element 218 is
illustrated including the same tubular filter media extension with an internal
central flow
passage much like the earlier embodiment (e.g. see references 81 and 83 in
FIG. 2) that is
also for use with the same keyed tubular baffle 71 (including drainage
apertures 160 are
provided along a gravitational bottom 162 of the tubular extension 73 ¨ see
e.g. FIGS. 1, 11
and 16). The keyed tubular baffle 71 provides the post 121 projecting from one
side that
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provides a hollow receiver (e.g. the internal cavity 125 of the post 121 as
shown in earlier
figures), and a key projection (e.g. projecting rib 178 and/or groove 176)
along the post 121
and projecting radially inwardly in the hollow receiver. The second stage end
cap 91b (see
earlier figures) is the same as the earlier embodiments and as such keys with
the keyed
tubular baffle 71 such as with key 180 (such as axial groove 182) to provide a
predetermined angular orientation between the baffle 71 and the filter element
218 and so
that if the filter element is rotated the baffle will also rotate. Rotation is
allowed here
because the second stage support grid 267 has a keyless aperture 268 which
receives the
post 121 of the baffle 218. The keyless aperture 268 is thus different that
the keyed aperture
68 (having key 170 in the form of projecting tab 172 shown in the earlier
embodiment of
FIG. 17). In this respect, this allows for a retrofit application in which the
improved tubular
baffle 71 with drainage apertures 160 may be installed into a keyless pre-
existing multiple
stage filter element assembly such according to those described an
incorporated by
reference in the Background Section above. Accordingly, when the keyed tubular
baffle 71
is installed with the keyed post 121 into the keyless aperture 268, and unlike
the earlier
embodiment, in this embodiment the tubular baffle 71 can freely rotate.
101411 However, in this embodiment of FIGS. 23-25, the first stage end
cap 291 is
different as shown in FIG. 23 and includes an alignment handle 293 that
projects axially
outward from a flat flange portion 295 of end cap 291. The first stage end cap
291 is
similar sealingly bonded to the first stage end of the tubular filter media
extension. Further
an alignment indicator such as directional symbol 288 may be used. The handle
293 is non-
circular and preferably has a longer dimension (than the width) that extends
vertically as
shown when in the proper position. As such the handle 293 provides an
indication of
alignment (with optional directional symbol 288). As a result, the filter
element 218
employ the key 180 and the handle 293 at opposite ends together provide means
for aligning
the tubular baffle 71 for a variety of purposes, such as for example to align
the drainage
apertures 160 at the gravitational bottom to make those function to facilitate
gravitational
drainage of coalesced liquids from a fluid stream. In particular, in a
retrofit application and
when the keyed tubular baffle 71 is installed with the keyed post 121 into the
keyless
aperture 268, the handle 293 can be rotated which in turn rotates the baffle
71 which is
rotationally locked thereto by keying so that the drainage apertures 160 can
be aligned
manually at the gravitational bottom to facilitate gravitational drainage.
Preferably, the
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angular orientation is such that when the handle is aligned in predetermined
alignment such
as vertical as such (and as may be indicated by the directional symbol 288),
the drainage
apertures 160 are aligned at the gravitational bottom. Further, a removable
and installable
inlet support grid 265 in this embodiment may also be modified relative to
that of FIG. 1
(and replaced in retrofit applications), in that the aperture 266 is non-
circular in this
embodiment such as shown as a vertical slot that closely receives and aligns
the handle 293
at the correct position such as vertically in this embodiment and that thereby
locks the
angular alignment when engaged and installed with the inlet grid 265. As such,
the inlet
support grid 265 can be new and retrofitted to replace conventional inlet
grids having
circular apertures or if otherwise do not provide for correct alignment.
[0142] Turning next to FIGS. 26 -29, these disclose alternative
embodiments of the post
structure of the second stage end cap that also provide for inter-fitting with
the keyed
tubular baffle. Other than the filter element second stage end cap post
configuration, these
embodiments can be identical to the earlier described embodiments (including
any of the
embodiments of FIGS. 1-25), such that the disclosure of FIGS. 1-25 are thereby
fully
applicable and vice versa to these embodiments other than for the distinctions
noted on the
post configuration.
101431 Referring to FIGS. 26 and 27, the mounting post can have a non-
circular
configuration comprising at least one of polygonal shape, rectangular shape
and chevron
shape. For example, FIG. 26 provides an alternative embodiment of a post 393
of the
second stage end cap that has a chevron shape, including a pair of wings 394
that together
define an axially extending V-shaped groove 382 that can provide a key
structure 380. The
chevron shaped post 393 can interfit with and provides clearance to receive
the key and rib
178 the keyed tubular baffle when received into the corresponding hollow
receiver of the
baffle post 121. Preferably, the chevron shaped post 393 is sized large enough
to only fit
one way into the receiver of the baffle post 121, and as such may be used for
providing for a
predetermined rotational orientation between the filter element and the keyed
tubular baffle.
To provide strength considering the smaller dimension, the post 393 and/or the
second stage
end cap may be made of steel or other stronger material including reinforced
materials than
conventional plastic employed in the second stage end cap in more typical
application. FIG.
27 shows an alternative embodiment of a post 493 of the second stage end cap
that has a
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rectangular shape, which is sized small enough to provide clearance for the
key and rib 178
of the keyed tubular baffle when received into the corresponding hollow
receiver of the
baffle post 121. Further, it the rectangular post 493 is not square and is
wider in one
dimension, the post 493 may only fit within the keyed tubular baffle in only
one of two
orientations, right side up or upside down. If used in conjunction with
directional indicia
288 at the first stage (see e.g. FIG. 23), this can also provide for
predetermined orientation
between the tubular baffle and the filter element. It may also be asymmetrical
relative to the
central axis of the filter element at least along portion.
[0144] Another embodiment is illustrated in FIG. 28, in which a circular
but smaller
post 593 is used that has a reduced diameter for the second stage end cap.
Neverthless, this
post is configured to be received within the hollow receiver with an axial
clearance region
arranged to clear the key projection, and thereby provides for compatibility,
although it is
less preferred in that this embodiment does not provide keying.
[0145] As apparent from FIGS. 26-28 embodiments, these alternative posts
393, 493
and 593 also provides means at the second stage end cap 91b for clearing the
baffle's key
projection to allow the filter element to interfit with the keyed tubular
baffle. Preferably,
the axial clearance region is configured to key with the key projection for
providing a
predetermined angular orientation for use as in the FIGS. 26 and 27
embodiments, with a
less preferred embodiment having a smaller diameter circular post 593 that
merely provides
clearance only for interfitting but no predetermined orientation feature in
the post 593
unlike other embodiments.
[0146] Turning next to FIG. 29, an alternative embodiment of a filter
element 618
having second stage filter element end cap 695 is illustrated being postless
so that the
second stage end portion of the filter element may rest on the keyed tubular
baffle along the
bottom as illustrated such as along cap portion 75 of keyed tubular baffle 71.
This also less
preferred and only provides compatibility and no orientation, but nevertheless
also similarly
provides the postless structure for clearing the baffle key projection to
allow the filter
element to still interfit with the keyed tubular baffle.
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[0147] All references, including publications, patent applications, and
patents cited
herein are hereby incorporated by reference to the same extent as if each
reference were
individually and specifically indicated to be incorporated by reference and
were set forth in
its entirety herein.
[0148] The use of the terms "a" and "an" and "the" and similar referents
in the context
of describing the invention (especially in the context of the following
claims) is to be
construed to cover both the singular and the plural, unless otherwise
indicated herein or
clearly contradicted by context. The terms "comprising," "having,"
"including," and
"containing" are to be construed as open-ended terms (i.e., meaning
"including, but not
limited to,") unless otherwise noted. Recitation of ranges of values herein
are merely
intended to serve as a shorthand method of referring individually to each
separate value
falling within the range, unless otherwise indicated herein, and each separate
value is
incorporated into the specification as if it were individually recited herein.
All methods
described herein can be performed in any suitable order unless otherwise
indicated herein or
otherwise clearly contradicted by context. The use of any and all examples, or
exemplary
language (e.g., "such as") provided herein, is intended merely to better
illuminate the
invention and does not pose a limitation on the scope of the invention unless
otherwise
claimed. No language in the specification should be construed as indicating
any non-
claimed element as essential to the practice of the invention.
[0149] Preferred embodiments of this invention are described herein,
including the best
mode known to the inventors for carrying out the invention. Variations of
those preferred
embodiments may become apparent to those of ordinary skill in the art upon
reading the
foregoing description. The inventors expect skilled artisans to employ such
variations as
appropriate, and the inventors intend for the invention to be practiced
otherwise than as
specifically described herein. Accordingly, this invention includes all
modifications and
equivalents of the subject matter recited in the claims appended hereto as
permitted by
applicable law. Moreover, any combination of the above-described elements in
all possible
variations thereof is encompassed by the invention unless otherwise indicated
herein or
otherwise clearly contradicted by context.
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