3 Valve Design

-/+0*.,+0 Compression Technology-/+0*.,+0 Compression Technology

Plate Valvesfor Piston Compressors


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Trained forCompetenceTrained for

Competence

Compressor ValvesGeneral

• Valve Characteristics

• Demands on a Compressor Valve1.2.0

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Competence

1.2.1

Valve Characteristicspv Diagram and Lift Diagram of Valve Plate

v

Motion of thevalve plate

Motion of thevalve plate

progressiveincrease

t

guard

seat2

lift diagram of a delivery valve

3

41delivery pressure

p2

suctionpressure

p1TDC BDC

pv diagram

displacement

guardlift

seat

clearance volume

guard lift

seat

lift diagram of a suction valvelift diagram of

a suction valve

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Competence

1.2.3

Valve CharacteristicsIndicated Power in the pv Diagram

A certain amount of indicated poweris lost due to valve losses

A certain amount of indicated poweris lost due to valve losses

0

5

10

15

20

25

30

35

0% 20% 40% 60% 80% 100%displacement [%]

pres

sure

[bar

]

Loss in suction valve

loss in delivery valve

Area borderedby the red line:

Indicated workof cylinder end

suctionpressure

deliverypressure

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Competence

1.2.4

Valve CharacteristicsChange of pv Diagram with Leaking Valves

Change due to leaking suction valves

good: sealing suction valvesbad: leaking suction valves

0% 20% 40% 60% 80% 100%

head end crank end

pres

sure

[bar

]

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Competence

1.2.5

Valve CharacteristicsValve Losses – Ventilation Losses

Valve losses are lossesincurred in the valve

Valve losses are lossesincurred in the valve

suction valve = intake

delivery valve = outlet

Ventilation losses are theoverall losses

incurred in:

Ventilation losses are theoverall losses

incurred in:

delivery chamberpiping

pulsation dampers

suction chamber

valve nestdelivery valve

suction valvevalve nest

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Competence

1.2.6

Valve CharacteristicsValve Losses – Ventilation Losses

The areas exceeding nominal delivery pressure show the different losses on the delivery side.

The total losses in the valve, in the valve nest, in the piping and also pulsation losses are called VENTILATION LOSSES.

Valve losses shown on delivery valve:Valve losses shown on delivery valve:

lossesin valvelosses

in valve

pipe andpulsation losses

nominaldelivery pressure

pulsating pressurein the pressure chamber

losses invalve nest

pv diagrampv diagram

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Competence

1.3.1d7d5d3d1

d2d4d6

h

Demands on a Compressor ValveLarge passage area fe

The passage area feis the smallest passage area in the valve

fe = (d1 + d2 + d3 + d4 + d5 + d6 + d7). π. h

d1 ... d7 seatingledgediameter

h ..... valve lift

π .................... 3,14159

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Competence

1.3.2

Demands on a Compressor Plate ValveOptimized Equivalent Area

1ζζζζ1

αααα1111 ====

1ζζζζ1

areas A1, A2pressures p0, p1, p2, p3

velocities υυυυ0000,,,, υυυυ1111,,,, υυυυ2222,,,, υυυυ3333

drag coefficient ζζζζ

coefficient of contraction

equivalent area φφφφ= . A1

φφφφ====

ΑΑΑΑ2222 ====

αααα1111 ⋅⋅⋅⋅ ΑΑΑΑ1111 ====

ΑΑΑΑ1111//// ζζζζ1111Phi value

υυυυ1

p2

υυυυ0

p0

A1

υυυυ2

A2

υυυυ3

p3p1

pipethrottling deviceorifice

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Competence

1.3.4

• Long valve life and reliability

• Low valve losses

– large passage areas

– good aerodynamic characteristics

• Low masses of moving parts

• Quick response to low differential pressure

• Low clearance volume

Demands on a Compressor Plate Valve

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Competence

2.0

Compressor Valve DesignContents

• Valve Types made by HOERBIGER• Plate Guidance

– centrally guided– frictionless guided

• Damping– principle of double damping– effect of double damping– impulse law– tumbling– measurement of tumbling Motion

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Competence

Plate Valve types made by HOERBIGEROverview

2.1.1

Valves with different types of sealing elements

Steel Plates Non-metallic Plates

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Competence

2.2.1

154F3d

9

286

4, 573

1

9

1374, 5

68

21 ... seat2 ... guard unit3 ... valve plate4 ... lift washer5 ... lift washer6 ... dampler plate7 ... closing springs8 ... damping springs9 ... nut

Plate GuidanceValves with Frictionless Guided Plates

suction valve delivery valve

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Competence

2.2.2

154F3d

Plate GuidanceFrictionless Guided Plates

Valve plate Damper plate

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Competence

2.2.3

Valve plate 134RDwg. No. 004658

double guide arm,hollow ground

Valve plate 134RDwg. No. 057303single guide arm

Damper plate 100FDDwg. No. 086355double guide arm

Damping plate 183RDwg. No. 099199single guide arm

Spring plate 109DIADwg. No. 448068Triple guide arm

Plate GuidanceFrictionless Guided Plates - Examples

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Competence

2.2.4

143CGd

8

1

35647

2

8

2

74563

1

Plate GuidanceValves with Centrally Guided Valve Plates

1 ... seat2 ... guard unit3 ... valve plate4 ... damper plate5 ... guide ring6 ... closing springs7 ... damping springs8 ... nut

Suction valve Delivery valve

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Competence

143CGd

2.2.5

Plate GuidanceCentrally Guided Plates

Valve plate Damper plate

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Competence

2.3.1

DampingPrinciple of Double Damping

h2

h1

h2

h1

h1 + h2

Advantage 1: Increase in spring loadAdvantage 2: Reduction of tumblingAdvantage 3: Reduction of opening impact

Spring load damping principle valve design

h 1h 2

valv

e lif

th =

h1

+ h 2

spring load

closing and damping springs

closing springsalone

closing and damping springs

closing springsalone

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Competence

2.3.2

DampingEffect of Double Damping

opening motionof the valveplate

0 - 25 ms

0123456

0 10 20 30 40 50 60 70 80 90 100 110 120 130

• reduction of opening impact • strong damping springs against sticktion on the guard• reduction of closing impact velocity• reduction of tumbling motion of valve plate

Time [ms]

measuring point 1measuring point 2cylinder pressuredead centre signal

Volts [V]

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Competence

2.3.3

DampingImpulse Law

vb

va

Impulse Law:

Before the impact:

damper plates notmoving, mass mdp

valve plate with mass mvp and velocity vb

After the impact:

plate pack moves with velocity va

( )mvpmvp + mdp

va = vb .

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Competence

2.3.4

vt

2 r

vt

k~ vt

v2

ωωωω

~ 0.12 ⋅⋅⋅⋅ d

The valve plate normally impacts at an angle onto the seat.

DampingTumbling

1st impact

guard

seat

center of impact

2nd impacton opposite side

vt ... Translatory speed of the centre of gravity of the plate = impact velocityof the 1st impact.

ωωωω ... Angular velocity of rotation caused by 1st impact.

With the first impact the velocityof the centre of gravity

is reduced, the plate starts torotate with angular velocity ω.ω.ω.ω.

The 2nd impact is harder than the first impact,

impact velocity: v2 ~ vt + ωωωω ⋅⋅⋅⋅ r

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Competence

• Traditional steel plate valves� type designation of steel plate valves� traditional steel plate valves

• Traditional valves with non-metallic valve plate (conversion)

• Valves with non-metallic sealing elements� valve vypes with plastic plate : CU, CS, CT

3.0

Introduction to Plate Valve TypesContents

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Competence

3.1.1

Type Designation of Steel Plate ValvesOverview

DIA DIA

Type designationconsists of:

design features1- 3 digits

or series designation of a type, e.g.:R Valves for high speed compressorsH 5 slot type with double damping

Other design features:formely letters, numbers - suffixed to main design features

Design features:Letters or combination of letters and numbers:• plate guidance C: centrally - frictionless: no indication• slot designation D E F G H J K L M N

number of slots 1 2 3 4 5 6 7 8 9 10 • double damping D

Size: diameter of theoutmost seating ledge

size1 - 3 digits

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Competence

3.1.2

CFD series 92CFDdouble damping

3 slots centrally guided (for lubricated operation)

sizeR-series 134R1

“version 1” (obsolete, on old drawings)high speed type

size H-series 213H2

“version 2” (obsolete, on old drawings)series (frictionless guided, 5 slots, double damping)

sizeHDS-series 92FD

double damping3 slots

frictionless guided valve plate and damper plate (non lubricated operation)

size

Type Designation of Steel Plate ValvesExamples

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Competence

3.2.0

R / RLX

DDHDS

CEDCFDCGDEDH

10R/37RLX88R / RLX

134R38DD92FD

92CFD52CED74CFD88CGD70ED213H

79R / RLX117R / RLX

214R64FD

254MD254CND65CED126CFD184CGD100ED371H

603025400

200 bis 400200 bis 400

400400

200 bis 40040060

1500150015001000100010001000100010001000700

...

...

...

...

...

...

...

...

...

...

...

Traditional Steel Plate ValvesValves for Process Compressors

Type

Series

Type

Size

Application

delivery pressurep2 max [bar]

compressor speedn [RPM]

Application of the R-series:R-types are used in air compressors or in the low pressure stages of O2-compressors. For non lubricated compressors and sizes smaller than 134R the types 37RLX to 117RX are used.

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Competence

3.2.1

P1P2

P3

Traditional Steel Plate ValvesSmall R-Types, up to 117R

Valves with spring plates

• up to size 117R• for lubricated and non lubricated

high speed air, refrigeration and gascompressors: “High speed”-valves

spring load P

lift h

1 sp

ring

plat

e2 s

prin

g plate

s

3 spring plates

spring load

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Competence

3.2.2

Traditional Steel Plate ValvesLarge R-Valves, above and including 134R

Frictionless guided valve plates

valve plate with single guide arm

middle lift washer

2 damper plates

upper lift washer

closing springs

• for lubricated and non lubricated high speed air, refrigeration and gascompressors: “High speed”-valves

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Competence

7.0

Concentric ValvesContents

• Concentric Valves - Designs

• Installation on Compressor

• Applications

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Competence

7.1.1

Concentric ValvesDesigns

inside outside

outside inside

ValveArrangement

FlowIN / OUT

downwards/upwards

downwards/sideways

upper body,lower body

concentric seat:“ring concentric”

“stacked”for small DIA

Seat (body)Arrangement

suctionvalve

deliveryvalve

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Competence

7.2.1Example:valve type 98R/165CEsuction valve insidedelivery valve outsidecooling water

water channels

Concentric ValvesAssembly

valve plate SV

cushion plate SV

spring plate SV

spring plates DV

valve plate DV

upper body

lower bodyassembly

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Competence

7.3.1

• Throttling in intake or outlet• Leakage due to incorrect clamping arrangement• Insufficient cooling, for example due to

- build (SV on outside)- shape of cylinder head (heating up of gas during intake)

Installation on CompressorPossible Problems

Concentric valvetype 105R/178CE

with DS3 unloadersuction valve

delivery valve

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Competence

Valve

7.3.2

Throttlingon intake or outlet affects:• volumetric efficiency• motion of valve plateThe inlet and outlet portsshould be larger than the passage area of the valve.

Cooling• insufficient cooling of cylinder• heating up of suction duct

Installation on CompressorPossible Problems

Leakage• between suction and

delivery chamber• between delivery chamber

and cylinder• inside the valve, between

suction and delivery side• due to incorrect clamping• upper/lower bodies too thin

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Competence

7.4.1

gasketdelivery side suction side

Ring as support for gasket

Application of Concentric ValvesExample of Low Pressure Application

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Competence

20

69

73.9

79.5 -0.3

310.2

50.7

13

4

3

44+0.15+0.06

M6

34

80 -0.19

M=4.1-5 Nm

2

7.4.2

Example:

Valve type : 42R/68CDDrawing No. : 441766Compressor : SF-125

starting air1500 RPM2nd stage

Types 30R2/54C to 194R2/296CF

Application of Concentric ValvesStandardized Sizes

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Competence

7.4.3

Customer : Tanabe, JapanCompressor : Type VHOS114, for

starting air, 1450 RPM 1st stage: 1 - 3.3 bar

Lubrication : non lubricatedCooling : water

Valve type : 174RX/274FDrawing No. : 550182Suction valve : insideDelivery valve : outsideUnloader type : DS Regulation : ON/OFF

Application of Concentric ValvesValve for Low Pressure Application

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Competence

18

9

36

16

24

66

70 -0.19(h11)

M6

27

18

M=4.1-5 Nm

7.4.4

Valve Type : 50CI / 24CDrawing No. : 442692Suction Valve : outside - 50CIDelivery Valve : inside - 24CCustomer : SAPIO, ItalyCompressor : SIAD, 93kW, 710 RPM

H2, pD,max 221 barLubrication : oilCooling : water

These concentric valves are always individually designed.

Application of Concentric ValvesValve for High Pressure Application

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Competence

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3 Valve Design

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