A new valve concept for high-speed gas compressors

For decades the HOERBIGER plate valve has been proving its advantages; namely, good flow characteristics, high reliability, long life, simple maintenance and the possibility to regulate the suction valve with flow efficient unloaders. The preceding features also typify the essential advantages of the plate valves versus ring valves. Correct valve operation for a given compression condition is a key to long life of all self-actuated sealing elements. The motion of a free-floating valve element is dependent on the following forces: 1. Gas flow force 2. Weight of the moving component 3. Friction involved in the opening and closing movement 4. The sticking effect 5. The spring force 1. The flow force is governed mainly by the thermodynamic events inside the cylinder and the momentary position of the sealing element in the overall motion cycle. Additional influence comes from the pressure patterns and/or pulsations of the manifold side of the valve. They will be discussed under the aspect of high clearance later on in this article. 2. Gas velocities frequently found in today's compression equipment are such that the weight of the moving valve element can be neglected, especially when the sealing element is of a low weight as on to plate valves. Needless to say, that in computer programs calculating valve motion the weight of the moving component can easily be considered. 3. Friction forces are non-existent with frictionless guided HOERBIGER valves. They are present in valve designs with sliding guidance but, generally, friction is so low that it can be ignored. An exception might be where side forces are present which result in higher friction forces in the valve movement.

4. The sticking effect and its resultant adhesive forces are normally encountered when liquids (e.g. lube oil, water or condensate) or other sticky contaminants are caught between the retainer or seat and the sealing elements. The sticking effect is detrimental because it is counteractive to normal valve motion. All other forces mentioned earlier act in the main continuously during the motion cycle onto the sealing element. The sticking effect tends to prevent the beginning of the motion until the gas force can overcome the adhesive reaction. As soon as the adhesive bond is broken, the sticking effect and its force is zero, and the increased gas flow force results in abnormally high acceleration of the moving valve component. The delayed valve action and subsequent acceleration results in heavier than normal impact of the valve element onto the seat. A similar effect can be experienced in the opening motion of the valve where sticking of the sealing element to the seat can occur. Figure 1 shows a valve motion diagram with a varying degree of heavy oil residue. The sticking effect has two elements: An adhesive counter-force which is time dependent; the shorter the time the greater the necessary force, the effect of which is more critical as the RPM of the compressor increases. The adhesive effect can be theoretically defined and corrective mathematical values can be used in calculations. Such values are generally derivatives of experience and empirical measurements.

closed
Valve lift

Crank angle

1 Valve in normal condition 2 Valve slightly overlubricated 3 Valve overlubricated

open

Fig.1: Plate motion of a suction valve plate

HOERBIGER CORPORATION OF AMERICA, INC.

3350 Gateway Drive, Pompano Beach, Florida 33069 Phone (954) 9 74-5700 or Toll-Free (800) 327-8961 Fax (954 ) 974-0964 Internet http://www.hoerbigercorp.com E-mail office@hoerbigercorp.com A0V016E01HZ10X

V016E

5. The spring force is correctly defined by taking into account, aside from other values, the four forces mentioned before. Modern computer programs based on a long history of experience assist in the proper selection of the spring force. One can now appreciate, that it is easier to apply the correct spring load to a webbed valve plate than to several individual rings. Each ring, in turn, would have to be individually and correctly spring loaded which is difficult simply from the point of the prevailing geometry of these components. Frequently, it is only possible by using a large number of springs which makes these valves service intensive and costly to maintain. A plate valve is also more conducive to later changes or tailoring of the spring force to cope with changes in the operating conditions. Many of today's valves are designed for minimum pressure loss by varying the number and shape of the seat and guard ports, the ports of the sealing element and by applying the highest acceptable valve lift. Brake horsepower is saved and the compressor efficiency is improved. Frequently, valve life is sacrificed in this effort. Extremely narrow valve rings or excessive valve lifts often result in premature valve failure. The resultant downtime and cost of repair often defeat the desired increase in efficiency. For considerable time, HOERBIGER has employed various principles of dampening the valve motion, and the product has been recognized for its excellent valve life. A new valve concept is introduced here which combines optimum flow with a new damping system; a valve design that can cope with today's challenges and design requirements. The new HOERBIGER-CT Valve series is the answer to the following performance requirements which are expected with increased frequency in today's market. The operating conditions of compressors are variable; RPM, pressures and gas composition fluctuate and valves cannot always be tailored to these variances. The presence of contaminants in the gas stream has increased. Gases contain liquids, elements of lubrication and even solids. Abnormally high clearance volumes are at times provided to allow reduced output even at low compression ratios. These high clearances often cause valve failures, especially in discharge valves, an effect which becomes obvious when pulsations in the valve pockets are taken into account. Figure 2 demonstrates such a condition where the valve motion of a discharge valve is calculated by means of a computer for 3 different clearances (10 %, 20 %, 50 %) without consideration of pulsations (above) and with consideration of a pressure pulsation of 2.5 % (below) in the valve chamber. The influence of the larger clearance volume on closing is substantial.

10 % Clearance volume 1,0 0,8 0,6

20 %

50 %

Valve lift

0,4 0,2 0,0 270 300 330 360 270 300 330 360 300 330 360 Crank angle Without pressure pulsation in valve chamber

10 % Clearance volume 1,0 0,8 0,6

20 %

50 %

Valve lift

0,4 0,2 0,0 270 300 330 360 270 300 330 360 300 330 360 Crank angle With pressure pulsation ( 2,5 %) in valve chamber

Fig.2: Diagrams of discharge valve lift at different clearance volumes

Figure 3 shows the basic design features of the CT valve which are described in more detail as follows: For reasons mentioned before the plate valve design was selected. A valve plate made from a high-temperature, highstrength polymer seals against the ports of the seat. A thin, steel cushion plate identical in port configuration to the non-metallic valve plate rests on the valve plate. The support plate can be flat or slightly dished in its free state. Both the valve plate and support plate cover a wider port on the outer perimeter of the valve. Coil springs are located only on this outer port and pre-load the plate evenly on the outer circumference. The inner sector of the valve plate and support plate comes in contact with a wafer-shaped cushion plate which is positioned against the retainer.

Suction
1 2 3
4 5

Discharge

1 Valve seat 2 Non-metallic valve plate 3 Steel plate 4 Coil springs 5 Wafer plate

Fig.3: Design of HOERBIGER-CT valves

This valve concept combines several advantages: Positioning the coil springs on the outer perimeter stabilizes the motion and reduces wobbling of the valve plate. Concentration of opening and closing impacts at a point on the outer edge of the sealing element is substantially reduced. Thermoplastic valve plates are generally able to hold up under high, localized stresses. They are known to absorb foreign particles effectively. They tend to be less tolerant to bending stresses, however, where steel generally outperforms non-metallic plates. The steel support plate enhances the non-metallic plate's capability to absorb bending stresses. Bending is caused by the dominant forces acting on the valve plate at two points offset from one another. Purposely employing a balanced elasticity of the non-metallic valve plate and its steel support plate can create an effect that brings on a phased motion of the inner versus the outer perimeter of the two plates. Figure 4 shows the time phase motion during the closing cycle of the valve. Similarly, it stands to reason that the flexibility of the plates is also advantageous to cope with the sticking effect caused from liquids or oil.

open
Valve lift

2 2 1
closed

1 Valve plate periphery (spring loaded) 2 Valve plate center

Fig.5: Typical assembly sequence for CT-Valve

TDC

Crank angle

Fig.4: Plate motion measured on a HOERBIGER-CT discharge valve

Summary: The valve concept demonstrated here using a nonmetallic sealing element and a steel support plate provides more elasticity than a solid steel plate of equal thickness. It has a greatly reduced tendency to wobble. It protects the sealing element from heavy impacts and supports the non-metallic valve plate in bending stresses. The sticking effect is virtually eliminated through features designed into the valve. This new valve design provides the optimum answers to today's requirements in high-speed compression equipment. Initially, tests were performed to substantiate the design objectives, and these tests were limited to in-house installations. Over the last two years, controlled tests were performed in real life conditions in the field which further confirm that the merits of the new HOERBIGER-design are very much evident.

It is easier to separate an elastic component from a flat and rigid surface than to do the same with two rigid parts. A minimum on elastic bend is adequate since the oil film that causes the bond is generally very thin. The wafer plate resting against the retainer cushions the opening impact of the inner sector of the valve plate against the retainer. It also substantially improves the separation of the plates upon their closing motion. The sticking effect is greatly reduced since the cross-section of the wafer plate is smaller than the width of the valve plate and support plate, and the waviness further minimizes the bond. The outer ring being wider than all the inner rings provides extra strength and resistance against impacts frequently found in this area.