Valve failure in compressors

Valve failures account for 41% of the problems associated with reciprocating machinery. Valve failure is the single most reason for a scheduled or unscheduled shut down of reciprocating compressors.

FUNCTIONS
A compressor valve acts as a check valve in inlet and discharge passage to the cylinder bore, The inlet valve will allow the gas being compressed to enter the cylinder on the suction stroke and will then close to prevent the back flow of gas into the inlet passages on the compression stroke. The discharge valve opens so that opens so that the gas can be forced out of the cylinder at an elevated pressure on the compression stroke and then closes to keep the gas from re-entering the cylinder on the suction stroke. Any leakage past the close valve whether inlet or discharge will reduce the efficiency of the compressor.

CAUSES Faulty seat gasket Inadequate setscrew tightening Worn Valve seat, channels Or plates, Improper valve assembly channels sticking in guides Accumulation of carbon particle due failure of piston and rider rings.

EFFECTS during the compression stroke some of the some of the normally displaced gas will leak or blow by the suction valve to the suction side of the piston the volume of gas actually displaced will decrease capacity loss can often be attributed to problems with valves as the compressor hot gases passes over the valve in the wrong direction ,the valve heats up. The inlet temp of gas on the suction side of the gas goes up, thus reducing the volumetric efficiency. Carbon build up occurs in the valves and leakage becomes even worse. Moving parts like strips channels or plates may distort due to warpage. Thermal expansion occurs; hence clearance decreases due to high temperature. SYMPTOMS

LOG CHART

MAINTANANCE PROCEDURE

SUGGESTION FOR BETTER PERFORMANCE Use of non-metallic plate valves Using valves with excellent flow geometry for low lift applications Poppet valves

Cop valves

COP valve.

The COP Valve is a poppet type valve that does not require any rework of the seat. The actual valve seat is the seat plate that is replaced when worn. Therefore, the overhaul of a COP valve is very simple: Cleaning and replacing parts is all that is needed. The wear parts, poppets, springs, lift washers and seat plates are easy to stock and not expensive. The seat plate does not have to be replaced at each overhaul. This valve is truly field repairable.