MOST COMMON COMPRESSOR VALVE FAILURES
CAUSE AND CORRECTIVE ACTIONS
RING OR PLATE FAILURES DUE TO DEBRIS RING OR PLATE FAILURES DUE TO LIQUIDS FAILURES DUE TO BLOCKED VALVES
n Source of debris are from the gas stream or broken valve
components
n Scarring can often be seen on the seat and guard as well
n It is common to see debris scars alongside other failure
modes so it is not necessarily the root cause of a failure
Remedy: Upgrade to Non metallic plates if possible.
Reevaluate valve design. Non metallic plates can
usually survive longer than metallic in the presence
of moderate debris.
RING OR PLATE FAILURES DUE TO
MISAPPLICATION
n Melted non-metallic sealing elements are normally
a sign that the compressor ran for an extended
period with leaking valves, was exposed to very high
temperature, or when a material selection for a specific
operating condition was incorrect
n Springs are often stuck in sealing element
n Air compressors tend to have surging in temperature.
Remedy: Upgrade to metallic sealing element. Reengineer
valves when process change occurred or a new duty has
been applied.
FAILURES DUE TO CHANGE IN
OPERATING CONDITIONS
Any changes in operating condition such as compressor
speed, operating pressure and gas composition will
affect valve performance. Valve inner components might
be damaged and consequently pre-mature valve failure
occurred.
Remedy: Re-evaluate valve performance before any changes
applied to the process.
HOERBIGER KT ASIA SERVICES PTE LTD
77 Joo Koon Circle, Singapore 629097 Tel: +65 6890 0770 Fax: +65 6890 8037 Email: info-asia@hoerbiger.com
n Valve plate failure due to liquid or condensate is a typical
process related issue
n Metallic sealing element will become rusty whenever
there is condensation, lifespan is then shortened.
n Liquids are generally driven to the center of the valve
by the gas flow
n Water hammer effect inflicted damage to the center of the
plate, innermost rings may be broken and do
seldom occur on the outside of the plate
n Springs may be collapsed
Remedy: Prevent condensation e.g. by insulating of suction
line, prevent liquid carry-over, suitable cooling rate for the
cylinder. Consider ring or profiled plate type valve.
SPRING FAILURES DUE TO DEBRIS
OR FATIGUE
n Sand or welding slag enters the spring pockets (Usually
a transient event and common after startups)
n Debris may scar the coils and provide a failure initiation
point
n Spring fatigue failure leads to high impact of the metallic
valve plate
n Outer section of valve plate starts failing
n One or multiple springs collapsed
Remedy: Re-engineering of spring load required. Reduction
of dynamic spring loading by using different spring type,
different spring pocket depths and / or lower valve lift.
RING OR PLATE FAILURES DUE TO
MOLDING DEFECTS
Generally, poor material quality could lead to longitudinal
cracks and jagged, crumbled, break surface indicate a
molding defects in the material.
Remedy: Selecting experienced supplied and improve
material selection.
n Blocked valves are mostly a result of the process and
are commonly seen in polyethylene plants or HDS or
CCR applications in refineries.
n Blocked valves will lead to high differential pressure
across the valve seat and could lead to cracks in the
seat. Blocked valves could result in safety issues as
they impact on rod load reversals if the gas cannot be
released to the discharge line.
n Sticky material can initially also lead to plate stiction
and high opening impact of valve plate.
Remedy: Besides improving process related equipment
upstream the compressor, a valve upgrade to ring type.
Profiled ring/plate type valves with anti-stiction designed
guard will make an improvement.
RING OR PLATE FAILURES DUE TO OVER
LUBRICATION
n Oil stiction effects leads to high impact of the
conventional valve plate, ring.
n Outer section of valve plate starts failing because of
imbalanced movement of sealing element
n Plate valves are vulnerable to excessive lube
If lube rates can’t be reduced, conversion to a profiled
n
geometry valve may minimise the issue
Remedy: Reduce cylinder lubrication rate (if possible),
increase spring force or change valve type or profiled ring/plate
in combination with profiled guard can improve reliability
FAILURE DUE TO IMPROPER
INSTALLATION AND REPAIR
n Broken guard: suction valve was loose in valve pocket
due to improper torque of valve covers which caused
damage to multiple elements
n Seat lands too wide outside of specs or plate was flipped
then reused
n Top locking nut not used or reused
Remedy: Follow HOERBIGER repair procedures and change
all required consumables during servicing!