How to Optimize Cylinder Valves Design (Print)

Page 1 of 3

How to Optimize Cylinder Valves Design

If diagnostic and service improve reciprocating compressors availability, a
clever design with an appropriate ratio among new technologies can
enhance the mechanical behaviour for a better reliability

Fig.1.: Compressor valve.

Authors: Enzo Giacomelli, Consultant Engineer, and Claudio

Vaglini, Customer Support Engineer
Reciprocating compressors are used in many services for Oil & Gas, with
special process requirements. The range of capacities, operating
conditions and molecular weights make the use of such machines very
flexible. There is a continuing focus to improve operation, maintenance
and consequently the availability of the plants that implies guidelines and
precautions to be considered since the first design of the machines. That
is important for the cylinders valves (Fig.1) as they are one of the most
critical part in a compressor.

Targeting Valves Reliability

The proper selection of technologies and design procedures helps for an
optimization of mechanical behaviour, a minimum energy consumption,
in compliance with the specifications, to cover the requirements.
In refinery, chemical, petrochemical, natural gas and other industrial
plants the operating conditions are different as a function of the
applications. The pressures can reach 350Mpa for LDPE production and
molecular weights are very variable. Reciprocating compressors
cylinders are lubricated but dry applications are also required to avoid
pollution of the product. The presence of dirt and liquids entrained by gas
influences the actual operation. In refinery H2 production process have
different degrees of cleanliness. For heavy duty services it is necessary a
wide capacity control of the compressor to adapt the operating conditions
according to process requirements.
The valve can be of different types like disk, ring type, poppet, with flat
surface or special profiles. Metallic shutters have been replaced by
plastic components, apart of low temperatures or very high pressures,
due to the great adaptability to non controllable conditions (dirty or liquid
presence). The materials of the valves for heavy duty applications in Oil
& Gas are subject to requirements API 618, additional specifications of
Engineering Companies and end users.

Design Modeling and Simulation

Valves design related to mechanical and fluid-dynamic aspects, affecting
the reliability of the machines, needs advanced methods, simulations,
technologies, high material quality.
Mathematical models are able to describe the pressure drop through the
valves and the plate motion in operation. The shutters are subjected to
the forces due to spring, fluid drag, inertia and damping. Many
parameters are involved and the main input data are cylinder geometry,
properties of gas (Molecular weight, Cp/Cv ratio), RPM, suction,
discharge temperature and pressure. The outputs are plate movement,
compression cycle, power loss at the valve, total power absorbed by the
compressor, pressure pulsations in plenum chambers, nozzles,
dampeners and piping.

http://www.pcne.eu/article/how-to-optimize-cylinder-valves-design/?a=print

26-08-2016

How to Optimize Cylinder Valves Design (Print)

Page 2 of 3

The lift is calculated for an adequate gas velocity, with consequent

evaluation of pressure drop and spring load, to compromise between
energy saving and valve mechanical behaviour.
Excessive fluttering may cause a reduction of the life of springs, with
consequent problems to the plates. For refinery applications, the gas
velocity is normally higher due to the small lift required, as the drag force
on the rings is low due to the low MW of the gas.
The life of the valves is greatly influenced by the movement of plate that
should reach the guard and keep the position till the closure starts, with
the condition to occur before the dead point. During the opening period
the fluttering should be minimised to reduce the fatigue effect on the
springs and multiple shock against the seat.
The valves are to withstand the operating conditions, environmental and
dynamic aspects, considering the corrosion, particularly for rings and
springs, undergoing fatigue stresses. FEM (Finite Elements Method) is
used for strength determination of bodies, plates and for the natural
frequency analysis (Fig.2).
The fluid-dynamic aspects are investigated with CFD (Computerized
Fluid Dynamics) to optimize the development of standard series of
valves.

Monitoring and Diagnostics

The instruments to control process parameters, such as temperature and
pressure in suction and discharge help to evidence abnormalities. In
addition the temperature of the cover surface can be measured to verify
the correct performance of the valves.
Monitoring and Diagnostics systems anticipate problems and eliminate
most of the risks. Failures affect operation and safety of personnel. In
addition, they determine equipment damages and production losses.
In a multistage compressor the inter-stage pressure variations are a
further help to give an identification of the origin of the problems.
The control of valve performance is made with the analysis of
thermodynamic parameters, with acoustic emission analysis and in more
detailed way by measuring the compression cycle and the pressure
upstream and downstream the valves. Suitable instrumentation can be
used for spot analysis or continuously with on-line monitoring.
The malfunction of the valves can be predicted and the most suitable
period selected for replacement, possibly combined with other
maintenance activities, thus reducing the risk of shutdown of the plant
and increasing the availability.

Maintenance and Service

The strategies of Preventive, Predictive or Proactive Maintenance
depend on the type of machines, criticality of the service and on the
possibility to count on "condition monitoring" or "diagnostic systems".
Machines and valves should restore the original performance (MTBF)
and keep the time for maintenance at the minimum, as directly affecting
the availability of plants.
Therefore to reduce the MTTR is necessary to:
replace immediately a valve with a spare
combine these interventions with other possible needs to stop the
machine
plan the activities with a general shut-down
Valves can run smoothly with very good results, by reaching operating
life of about 3 years or more depending on the applications. The
presence of dirt, liquid or other things in the gas are worsening the
operation.

http://www.pcne.eu/article/how-to-optimize-cylinder-valves-design/?a=print

26-08-2016

How to Optimize Cylinder Valves Design (Print)

Page 3 of 3

Experts of valves and compressors give Engineering Support,

Reconditioning and Upgrades and a more prompt solution to the ongoing
operation deviations.
High Quality valves are necessary to reach good performance and a
longer MTBF (Mean Time Between Failure), with consequent reduction
of maintenance interventions in heavy duty applications.
The valves are reconditioned by replacing the internal parts (rings and
springs), by the workshop of the plant or by external service shops. The
reconditioning has to be carried out by qualified personnel, respecting
strict repair and reconditioning procedures to have valve components of
excellent quality and as new.
R&D can improve valve life, reducing maintenance costs and increasing
the availability in case of dirty gas. Special plastic plugs avoid the relative
movement between metallic parts (Fig.3), avoiding wear of counter-seats
and springs.

Dott. Ing. Mario Cozzani Srl

PCN Europe Magazine

Published since 2004, PCN Europe has become a reference
publication in Europe covering the latest industry news, application
stories and product news from and for the processing world,
including the chemical and pharmaceutical, food and beverage, oil
and gas, as well as the rubber and the plastic industry. It is the
indispensable source of information for processing professionals to
get an update on what is happening in their industry.
All rights reserved 2016 - TIMGlobal Media
Contact us - Follow TIMGlobal Media on LinkedIn for company updates

http://www.pcne.eu/article/how-to-optimize-cylinder-valves-design/?a=print

26-08-2016