Valves Overview Service En

7/27/2019 Valves Overview Service En

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Compressor valves

Engineered or better efciency

and reliability


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Reliable compressor operation or every industryReciprocating compressor valves work under demanding conditions. They are crucial to your compressors availability,

efciency and reliability.

Operators o reciprocating compressors

still suer more shutdowns than theyneed to. Studies show that valves which

are poorly engineered or o outdated de-

sign cause breakdowns and unnecessary

maintenance.

HOERBIGER compressor valves oper-

ate completely automatically, with high

eciency, long service lie and ideal fow

behaviour.

Our wide variety o designs covers:

High and low pressures

Lubricated and non-lubricated com-

pressors

Light gases (hydrogen) and heavy

gases (air)

Humid and bone-dry gases

Corrosive and contaminated gases

HOERBIGER compressor valves

are proven perormers in industriesincluding:

Process industries

Rening

Petrochemicals

Chemicals

Oil and gas production

Gas lit and re-injection

Gas gathering

Gas transportGas storage

LNG terminals

CNG

Industrial gases

Syngas: hydrogen, carbon monoxideAir separation: oxygen, nitrogen

Specic gases: argon, helium

Food industry

PET bottle blowing

Industrial air

Industrial rerigeration

Utilities

Cogeneration (combined heat and

power)

BiogasWater treatment

Transport

Automotive

Railways

Shipbuilding


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Innovation: a HOERBIGER traditionProven and unique designs

For more than a century HOERBIGER

has developed designs and materials toimprove the eciency and reliability o

compressors. From standard applications

to the most challenging specials, every

HOERBIGER solution encapsulates all

our expertise in the complex relation-

ships within the compressor, as well as

on external benchmarks and standards.

This experience allows us to provide what

our customers need. We support com-pressor manuacturers in the early stages

o developing new models, and we create

spare parts to squeeze the last drop o

perormance out o old machines.

HOERBIGER product development

standards

To create the best products or our

customers we ollow a development proc-

ess that is imaginative and fexible, yettightly structured:

Systematically examine undamental

chemical and physical relationships

Use these ndings to develop better

materials and products

Run thorough tests in our laboratories

and on our own test compressors

Work with selected customers on an

intensive reerence phase


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Country:Number:Name:

Customer

ITKK PrintOut - Performance

0000006933

PK-101CE

Tag:

Performance

85600Nm3/h

38900kg/hr

1380 kW

HE CE

77.5C 76.9C

89.5% 89.6%

91.4% 92.7%

1.8% 1.5%

9.02% 7.51%

65.1kW 49.4kW

Valves1x186CGE-F2

1x186CGE-F21x186CGE-F2

1x186CGE-F2

152.1

152.1

39.931.9

39.931.9

57.471.8

52.465.5

2.463.1

2.042.58

1.382.11

1.151.76

0.6231.34

0.5181.12

Qad:

Qind:

Mad:

Mind:

Nad:

Nind:

T2V:

:

Q:

:

Total Loss:

Total Loss:

Type:

Lift:

Flow Area:

GasVelocity:

q Value:

T:

dpdOT:

3.545.48

2.954.56

6.399.87

4.857.49

0.5580.862

0.4640.718Loss

Percentage:

Loss Power:

LossP ressure:

Eff. Flow Area:

725.23

725.23

12%12%ClVol HE/CE:

80mm0 mmRod HE/CE:

NoneLubrication:

320mmStroke:

270 mmBore:

4xST1/CYL1Name:

1 Hydrogen(H2)85.530%

2 HydrogenChloride(HCl)

8.000%

3 Propane(C3H8)

5.990%

4 HydrogenSulfide(H2S)

5.000 %

5 Methane(CH4)3.760%

6 Ethane(C2H6)2.680%

7 n-Butane(C4H10) 1.717%

8 Benzene(C6H6)0.320%

Gas Analysis

Cylinder

84200 Nm3/h

38300 kg/hr

1490 kW

HE SVHE DV C

E SV CE DV

Reference2:Reference1:

375 rpm

4GM16-45/35-55CM2

Compressor

Manufacturer:

Speed:

Model:

19.5bar(a)1.57

1.354

1.015

71.4C

53.8bar (a)

P2-P1:

P2/P1:

K2:

Z2:

T2:

P2:

0.454 kg/m310.3g/Mol1.362

1.003

35C

34.3bar(a)

:

MW:

K1:

Z1:

T1:

P1:

2007-12-17Name:

Operating Condition

mm

cm2

cm2

m/sec

%

%

kW

bar( a)

C

bar (a)

Pocket Factor:

11

11

PLEASE NOTE:

The performance calculations do not includein

takeo rpi pe losses.

313692ITKK Number:

11.08.2010Printed by Herve Ferra

ris on11/

Scarcely any two o our compressor

valves work under exactly the same

conditions. A wide variety o processesrequires an equally wide variety o valve

designs, materials, sizes and congura-

tions. Process operators trust us to tailor

valves to their highly specic demands.

Compressor manuacturers rely on our

expertise to optimise their designs, help-

ing them to provide reliable and ecient

perormance or decades to come.

Long beore computers, we used indexcards to capture every detail o our

technical knowledge o valve design and

operation. Now, HOERBIGER application

engineers can draw on customised de-

sign sotware and on-line databases that

are always available, consistent, accurate

and up-to-date.

The right valve at the right time in the right placeCustomised or every application

Every HOERBIGER valve is precisely

tailored in design, dimensions and

materials to the process and the machine

in which it operates. First we pre-select

one or more valve types to provide higheciency and long service lie based on

eatures such as suction and discharge

valve motion, pressure drop and gas

velocity. Next, our application engineers

use HOERBIGERs proprietary simula-

tion tools to carry out a comprehensive

dynamic study under actual operating

conditions. Valve seats and guards are

designed using state-o-the-art nite ele-

ment methods.


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Our valve materials must meet

special requirements including

stability at very high or low

temperatures, resistance to corrosive

gases, extremely high impact

resistance, and reliability under a

wide range o operating conditions.

All the ollowing materials have been

specically developed by HOERBIGER

or valves and are manuactured in our

own plants.

Standard materials

PK is the standard HOERBIGER material

based on the polymer PEEK. It is oten

used as a benchmark against which to

measure other materials. PK remains in

our extensive material portolio or its

temperature tolerance.

MC is a material developed or light gasapplications and or ring valves. MC is

impact-tolerant and has optimum sealing

behaviour.

PC is a specic carbon-lled PEEK that

provides reliable service in high-tempera-

ture environments.

The ideal material or every applicationA complete selection o materials to meet every requirement

Impact-resistant materials 3X

MTX sets a new standard or the workinglie o valve plates. It is especially suit-

able or high-stress conditions.

HTCX perorms well or medium to heavy

gases at medium and high temperatures.

Carbon reinorcement and excellent seal-

ing properties make HTCX ideal or ring

valves.

For corrosive, cryogenic and other

challenging applications

HP is a truly unique material or both

plate and ring valves. This compression-

moulded polymer reinorced with long

carbon bres resists chemical attack

over an exceptionally wide tempera-

ture range (200C to +230C). HP is

particularly suited to corrosive gases like

ammonia and chlorine, to cryogenic ap-

plications such as LNG boil-o gas and

ethylene, and to pure oxygen.

Proper material selection or gas com-

pression equipment can only be made

by qualied technical personnel. Please

consult an authorised HOERBIGER rep-

resentative to ensure that you receive the

correct material or your compressors

operating conditions.


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CE valveHighly efcient ring valve or all

process applications

Ideal or heavy duty

Low energy consumptionCovers wide ranges o pressure and

other operating conditions

Reliable operation in dicult appli-

cations like humid or contaminated

gases

Easy to repair

Characteristics

Proled guard stops oil stickingWide fow openings or high eciency

Carbon-bre-reinorced HTCX and

HP rings withstand the most violent

impacts

Spring saver technology

10 mm ring width

Maximum speed 1200 rpm

Size range 48314 mm

Suitable or HydroCOM control

Typical applications

Hydrocracking

LDPE

CX valveRobust valve or hydrogen and light

gases

Very robust design

Extremely long lieEasy to repair

Characteristics

Proled guard prevents oil sticking

Carbon-bre-reinorced HTCX rings

withstand the most violent impacts

16 mm ring width


Size range 60310 mmSuitable or HydroCOM control

Typical application

Hydrodesulphurisation

CM valveReliable, efcient ring valve or high

pressures

Higher power and compression density

Reliable operation at extreme pres-sures

The standard or high-pressure and

high-speed compressors

Characteristics

Proled guard prevents oil sticking

Drilled seat is stable at high pressure

Wide fow openings or high eciency

Carbon-bre-reinorced HTCX ringswithstand the most violent impacts

Synchronising plate ensures uniorm

movement o rings

7 mm ring width


Size range 72192 mm


Typical application

Natural gas storage


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CP valveGreater efciency and reliability

or both standard and extreme

conditions

Ideal or high compression density andhigh speed

Cuts valve energy losses by up to 40%

Longer mean time between repairs

Better availability due to ewer un-

scheduled shutdowns

Characteristics

Extremely ecient proled plate

designHP material with low thermal expan-

sion is suitable or temperatures

rom 200C to 200C and corrosive

environments

Integrated anti-rotation device ensures

reliable operation when unloaded

Special springs provide maximum

dynamic reliability


Size range 79212 mmSuitable or HydroCOM control


PET bottle blowing

Air separation (oxygen)

LNG boil-o

HYCO processes

CT valveHigh-perormance valve or high-

speed compressors

Suitable or high-speed compressors

Better availability due to ewer un-scheduled shutdowns

Easy to repair

Characteristics

Non-metallic plate valve

Circumerential springs stabilise plate

motion

Good eciency

Suitable or both lubricated and non-lubricated compressors

Patented design helps eliminate oil

sticking


Size range 64220 mm


Typical application

Gas lit

CS valveProven perormance at low and

medium pressures

Standard design

Easy to repair

Characteristics

Non-metallic valve plate

Proled guard reduces oil sticking

Suitable or both lubricated and non-

lubricated compressors

Size range 90320 mm

Typical application

Industrial air


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R valveThe senior valve or industrial air

compressors

R valves have a worldwide reputation or

reliability under the most severe oper-

ating conditions in small short-strokeindustrial air compressors. In lubricated

service, the robust design gives long and

trouble-ree operation with minimum

maintenance. These valves and HOER-

BIGER reed valves are still an economi-

cal solution or small serial compressors.

Characteristics

Available or both lubricated and non-

lubricated compressorsLow to medium pressures

High fow

Low clearance volume

Strong seat

Coil springs, spring plates or guided

ring design

Metallic or non-metallic valve plate


Industrial air compressorsBrake compressors

Starter compressors

ConcentricFor lube and non-lube compressors

A concentric valve integrates the suc-

tion and discharge valves in a single

valve body. In single-acting compres-sor cylinders, this makes ideal use o

the available space. Concentric valves

are customised or each application to

achieve optimal integration with the

cylinder head. Features include:

Low clearance volume

Low fow resistance

Long service lie

Compact, space-saving designAvailable in metallic and non-metallic

versions


Rerigeration

Industrial air

CNG (compressed natural gas)

HDS valveTraditional design or heavy gases

HDS valves were previously used or

heavy gases and high-pressure applica-

tion. Most o these valves have now beenconverted to non-metallic designs, which

are more reliable and reduce the risk o

secondary damage caused by broken

metal valve plates.

Characteristics

Reliable and long-lived

Double-damping design reduces open-

ing and closing impactsDrilled seat to withstand high

pressures


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Visual checking

First o all, our specialists examine each

valve careully to spot any problems

and their possible causes or the nal

repair report. They decide whether the

valve can be repaired economically, and

i so, they give it a preliminary clean in

preparation or dismantling.

Dismantling

For dismantling, the valve is rst sprayed

with solvent. It is then clamped in a

special jig which stops it rotating and

prevents damage when the screw is

removed.

Washing and shot-peening

All the valve components are cleaned

with the help o a shot-peening machine,which removes even the most persistent

layers o contamination.

Crack checking

Next, each component is inspected or

signs o atigue, cracks and breakage.

Small cracks can be repaired, but deep

tears or breaks in the seat or guard

require the valve to be replaced. On the

whole, the valve will need replacing i

more than 10% o the thickness o the

sealing elements has been lost.

Seat machining

Seat surace quality is critical to valve

tightness. We use high-precision ma-

chine tools to turn and grind valve seats

to agreed standards.

Assembly

Due to the highly specic and individual

nature o each compressor valve, assem-

bly requires as much care and accuracy

as dismantling. Our specialists use only

HOERBIGER spare parts when they

replace plates, rings and springs. They

take care to tighten the central nut to the

exact torque required, whilst ensuring

that the valve plates have ree movement

and the correct lit.

Leak testing and conditioning

Finally, the valve is checked thoroughly

on a dedicated test rig. We insist on the

same stringent tightness standards or

reconditioned valves as or new valves.

All values are documented on a certi-

cate that is included with the analysis

report. The valve is wrapped in specialpaper or long-term storage.

The best valve service now on your doorstepState-o-the art compressors equipped with HOERBIGER valves require only a minimum o valve maintenance.

Nevertheless, compressor reliability and saety depend on carrying out this limited maintenance thoroughly.


10/12

Valve retaining system stops leaks

On older compressors, the seal around each valve cover can bea signicant source o gas leakage. HOERBIGERs Eliminator

valve retaining system virtually eliminates leaks, and can be

retrotted to any compressor that uses valve cover gaskets.

Benefts

Even load distribution through multiple jackbolts

Eliminates misalignment problems

Unique captive jackbolt design

Tubular valve chairEliminates leakage

Solutions to get the best rom your valvesTo back up its proven valve designs HOERBIGER oers a sae, leak-ree mounting system and a simple yet eective

method o capacity control

Diaphragm cylinders or stepwise control

HOERBIGER diaphragm cylinders act in conjunction with valve

unloaders to provide stepwise control o compressors. Their

advantages compared to other unloader systems are:

Applicable to any compressor

Exact matching o the valve, unloader and diaphragm cylin-

der creates a system solution

Suitable or almost any gas, thanks to the use o corrosion-proo materials

Direct- or reverse-acting

Rapid response, with no stick-slip eect

Optional bellows version guarantees zero leakage or critical

applications

Serial inert gas connection or purging, i required

Low consumption o compressed air or other control media

Service-riendly

Sae and environmentally riendly

Lower lie-cycle costs


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HydroCOM capacity control systemsHOERBIGER control systems or higher efciency, better process control and lower operating costs

Many reciprocating compressor

applications require a fner degree

o capacity control than is possible

through simple stepwise unloading.

Unortunately, most o the available

capacity control systems are slow,

inaccurate, and wasteul o energy.

HOERBIGERs HydroCOM system is

dierent.

HydroCOM is the most ecient continu-

ous control system available or recipro-cating compressors.

HydroCOMs stepless control stabi-

lises compressors that are subject to

fuctuating loads

Reducing or eliminating the need to

recycle or vent gas allows maximum

energy savings

Can be ully integrated into distributed

control systems (DCSs) and otherplant automation systems

Shares a common platorm with

HOERBIGERs RecipCOM continuous

compressor monitoring and protection

system

How HydroCOM works

When the compressor is required to oper-ate at less than ull load, during part o

each compression stroke the HydroCOM

controller sends a signal to an actua-

tor connected to a valve unloader. The

unloader holds the suction valve open

until the required volume o gas has been

pushed back into the suction chamber

again. At that point the suction valve

closes and the gas remaining in the cylin-

der is compressed.

Why invest in HydroCOM?

Continuous control via HydroCOMprovides large energy savings, since the

compressor handles only the volume o

gas that is actually required. HydroCOMs

ability to adapt smoothly to load changes

helps to optimise the perormance o the

whole plant, and simplies process start-

up and shutdown.

HydroCOM supports complete

system integration

Clear interaces permit simple integration

o HydroCOM into both new and existing

compressor plants.


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www.hoerbiger.com

[email protected]

The advantages o HOERBIGER valves or yourcompressor

Benefts

Energy savings and higher eciencyProblem-solving know-how to achieve outstanding runtime

Easy and proessional repairs thanks to our more than 60

service companies in close proximity to you

In-house or outsource

Reduction o unscheduled shutdowns, especially in combina-

tion with HOERBIGERs RecipCOM monitoring and protection

system

Excellent controllability with the HydroCOM control system

Customised unctionality covers both standard and excep-

tionally demanding operating conditions

Main eatures

Well-proven and robust ring designInnovative and extremely ecient proled plate design

Broad product line o careully designed valves

Backed by intensive research and development

Comprehensive competence in material selection and design

Proven material quality, with complete quality control at

every process stage

AKT3

SER013BE

201009

HOERBIGER Compression Technology is a business unit o HOERBIGER Holding AG, Zug / Switzerland. HOERBIGER is active

throughout the world as a leading player in the elds o compression technology, automation technology and drive technology. In

2009, its 6,500 employees achieved sales o 772 million Euro. The ocal points o its business activities include key components

and services or compressors, gas engines and turbomachines, hydraulic systems and piezo technology or vehicles and machine

tools, as well as components and systems or shit and clutch operations in vehicle drive trains o all kinds. Through innovations in

attractive technological niche markets, the HOERBIGER Group sets standards and delivers cutting-edge solutions or the benet o

its customers.

This product brochure contains product specications based on research and development on the one hand and on manuacturing on the other hand. Dependent

on place o installation, operating conditions and specications, several parameters o the described product may change. Thus, Hoerbiger assumes no liability or

warranty or the accuracy and completeness o inormation covered in this brochure

Valves Overview Service En

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