Piston compressor air valves often get damaged
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Class 3 piston compressor, medium: hydrogen, discharge pressure: 17 MPa; the suction valves on the 3rd stage are frequently damaged. It can be used for about a week. The damage is as shown in the attachment. It has a unloader and forced lubrication; however, the amount of oil accumulation is not significant, and carbon buildup is not severe. The valve disc has been replaced individually, as well as new complete sets. Could everyone please help analyze the reasons for the valve disc damage and the key points for inspection? Thank you
If it’s not due to overuse, this is likely a problem with the equipment design or the material used in the parts manufactured by the manufacturer. Also, check whether the spring of the pressure control valve disc is too stiff; for all these issues, technical support should be sought from the equipment manufacturer.
There’s definitely no overload issue. The condition of the spring hasn’t been checked yet, but this is a fully replaced valve seat and the spring is also brand new. I’m trying to figure out what else I can check on my own; I plan to examine the rod of the unloader. If I can’t find anything, I’ll have to contact the manufacturer
Inspect the spring, check the quality of the valve disc, and verify whether the flow channel in the inlet buffer tank is aligned properly. Are the baffle plates in good condition?
What about changing the style of the air valve, such as switching to a hole-type valve?
I think: unstable pressure is also a factor; there may be reasons related to fluid accumulation, as well as the material of the valve disc and springs, along with the pattern and spacing of holes in the valve disc. The installation method and accuracy, etc., need to be carefully checked.
Could the design style lead to stress concentration, making it prone to damage?
I really don’t understand design; I’ve had little exposure to piston engines anyway.
I’ve checked the curve for unstable pressure; there’s no issue. This machine is equipped with forced lubrication. When it was disassembled earlier, an excess amount of lubricant was found, and fluid accumulation was suspected; the flow rate of the oil injector was then adjusted. During this latest malfunction, almost no fluid accumulation was detected. Regarding the design aspect, we can only wait for the manufacturer to take a look.
The spring is brand new; this is a completely new set of valves, so it hasn’t been disassembled for inspection yet. No visual abnormalities were observed in the flow channel of the inlet buffer tank. Are baffle plates used in heat exchangers? What does this have to do with the malfunction? Please give some guidance.