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    EAR 2011 Valve and Ring Leakage

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    ssmith2007
    This document summarizes ways to diagnose different types of leaks in compressor cylinders, including leaks from suction valves, discharge valves, piston rings, and late closing valves. It describes measurable characteristics for each type of leak such as changes in temperature readings, volumetric efficiencies, flow balance, and clearance volume calculations. Graphs are provided to illustrate pressure-volume and pressure-crank angle profiles with different leak types. The document provides a comprehensive overview of diagnosing leaks based on data analysis and aims to distinguish between leak sources.

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    EAR 2011 Valve and Ring Leakage

    Uploaded by

    ssmith2007
    72 views45 pages
    This document summarizes ways to diagnose different types of leaks in compressor cylinders, including leaks from suction valves, discharge valves, piston rings, and late closing valves. It describes measurable characteristics for each type of leak such as changes in temperature readings, volumetric efficiencies, flow balance, and clearance volume calculations. Graphs are provided to illustrate pressure-volume and pressure-crank angle profiles with different leak types. The document provides a comprehensive overview of diagnosing leaks based on data analysis and aims to distinguish between leak sources.

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    Compressor Valve and Ring Leakage

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    This document summarizes ways to diagnose different types of leaks in compressor cylinders, including leaks from suction valves, discharge valves, piston rings, and late closing valves. It describes measurable characteristics for each type of leak such as changes in temperature readings, volumetric efficiencies, flow balance, and clearance volume calculations. Graphs are provided to illustrate pressure-volume and pressure-crank angle profiles with different leak types. The document provides a comprehensive overview of diagnosing leaks based on data analysis and aims to distinguish between leak sources.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    72 views45 pages

    EAR 2011 Valve and Ring Leakage

    Uploaded by

    ssmith2007
    This document summarizes ways to diagnose different types of leaks in compressor cylinders, including leaks from suction valves, discharge valves, piston rings, and late closing valves. It describes measurable characteristics for each type of leak such as changes in temperature readings, volumetric efficiencies, flow balance, and clearance volume calculations. Graphs are provided to illustrate pressure-volume and pressure-crank angle profiles with different leak types. The document provides a comprehensive overview of diagnosing leaks based on data analysis and aims to distinguish between leak sources.

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    of 45

    GMRC 2011 Analyzer Workshop

    Diagnosing Leaking Valves and


    Rings Basic and Complex
    Warren Laible
    Windrock, Inc

    Valve Leakage

    Suction or discharge valve leakage occurs when gas


    passes by the closed sealing elements or the seat
    gasket while there is a differential pressure across
    the valve.
    The cylinder capacity is reduced and, in some cases,
    the required compression work load may remain the
    same or increase.

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Suction Cavity Temperature Increase
    As the gas is compressed in the cylinder end it is
    heated. This heated gas will leak into the suction
    cavity through the closed valve and raise the
    temperature in the suction cavity.
    The valve cap closest to the leaking valve may be
    the hottest.
    This heated gas is also made available to the
    other cylinder end that may be healthy.

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Discharge Temperature Increase
    Since the inlet gas to the cylinder is heated due
    to recycling across the leaking suction valve, the
    discharge temperature will also increase.
    Both ends of the cylinder will have an increase in
    discharge temperature.
    The cylinder end with the valve leakage will
    generally increase more.
    The temperature at the discharge nozzle is a
    blend of both cylinder ends.

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Discharge Delta Temperature Increase
    Discharge delta temperature is measured
    discharge temperature - theoretical discharge
    temperature.
    This delta temperature will generally increase as
    the suction leakage progresses.

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Indicated Suction Volumetric Efficiency Increase
    For a fixed pressure ratio, the measured

    suction volumetric efficiency will increase.


    Since high pressure gas is leaking out of the
    cylinder during the expansion event, the
    internal cylinder pressure will drop faster than
    normal and will reach suction pressure earlier
    in the stroke.
    The calculated suction flow rate will increase.

    Indicated Suction Volumetric


    Efficiency Increase

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Indicated Discharge Volumetric Efficiency Decrease
    For a fixed pressure ratio, the measured discharge
    volumetric efficiency will decrease.
    Since high pressure gas is leaking out of the cylinder
    during the compression event, the internal cylinder
    pressure will remain below discharge pressure for a
    longer percentage of the stroke.
    The calculated discharge flow rate will decrease.

    Indicated Discharge Volumetric Efficiency


    Decrease with Suction Leakage

    Pressure rise too


    slow
    Pressure drop
    too fast

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Calculated Flow Balance is Greater than 1.0
    Flow balance is the calculated suction flow rate
    divided by the calculated discharge flow rate. The
    average calculated flow rate may not appear to
    change much in the performance report; however,
    the externally measured flow rate may be
    significantly reduced.

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Reduction in the Calculated Clearance
    Volume From the Expansion Line
    If you are calculating cylinder clearance volume
    from the expansion line and suction volumetric
    efficiency, the clearance will appear less than
    when the cylinder was healthy.

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    Increase in the Calculated Clearance Volume
    From the Compression Line
    If you are calculating cylinder clearance
    volume from the compression line and
    discharge volumetric efficiency, the clearance
    will appear greater than when the cylinder was
    healthy.

    Measureable Suction Valve or Seat


    Leakage Characteristics:
    A defective valve leaks when it is closed; therefore,
    the ultrasonic traces will indicate leakage after the
    normal valve closure and will indicate greater leakage
    activity as the differential pressure increases.
    The leakage will stop when the valve re-opens.

    Head-End Pressure & Ultrasonic Vs. Crank-Angle

    Head-End Pressure Vs. Displaced Volume with


    Suction Valve Leakage

    Pressure rise
    too slow
    Pressure drop
    too fast

    Crank-End Pressure Vs. Crank-Angle


    With Suction Valve Leakage

    Crank-End PV With Suction Valve Leakage


    Actual compression
    slope goes up slower
    than the theoretical

    Pressure is leaking out of


    the cylinder all of the time
    that the suction valves are
    closed

    Actual expansion slope


    goes down faster than the
    theoretical
    CE PV

    Crank-End Cylinder Pressure


    With Packing Leakage
    Actual compression
    slope goes up slower
    than the theoretical

    Similar to suction leakage


    pattern except pressure is
    leaking out of the cylinder
    all of the time

    Discharge delta temperature does not increase

    Actual expansion slope


    goes down faster than the
    theoretical

    Head-End Suction Un-loader Leakage


    (Finger Type)

    Pressure is leaking out of


    the cylinder all of the time
    that the suction valves are
    closed

    Actual compression
    slope goes up slower
    than the theoretical

    Actual expansion slope


    goes down faster than the
    theoretical

    Un-loader fingers resting on valve plates

    Suction Valve Leakage Summary

    Flow balance greater than 1.00

    Suction cavity temperature increase

    Discharge temperature increase

    Measured suction volumetric efficiency increase

    Measured discharge volumetric efficiency decrease

    Discharge delta temperature increase

    Decrease in calculated clearance volume from the


    expansion event

    Increase in calculated clearance volume from the


    compression event

    N-ratio greater than 1.00

    Measureable Discharge Valve or


    Seat Leakage Characteristics
    Indicated Discharge Volumetric Efficiency Increase
    For a fixed pressure ratio, the measured discharge
    volumetric efficiency will increase.
    Since high pressure gas is leaking into the cylinder
    during the compression event, the internal cylinder
    pressure will increase at a faster rate and the
    compression event will end earlier in the stroke.
    The calculated discharge flow rate will increase.

    Indicated Discharge Volumetric Efficiency Increase


    Pressure
    rise too fast

    Pressure
    drop too
    slow

    Indicated Suction Volumetric Efficiency Decrease


    Pressure
    rise too fast

    Pressure
    drop too
    slow

    Measureable Discharge Valve or


    Seat Leakage Characteristics
    Calculated Flow Balance is Less Than 1.0
    Flow balance is the calculated suction flow rate
    divided by the calculated discharge flow rate. The
    average calculated flow rate may not appear to
    change much in the performance report; however,
    the externally measured flow rate can be
    significantly reduced.

    Measureable Discharge Valve or


    Seat Leakage Characteristics
    Reduction in the Calculated Clearance
    Volume from the Compression Line
    If you are calculating cylinder clearance volume
    from the compression line and discharge
    volumetric efficiency, the clearance will appear
    less than when the cylinder was healthy.
    Excessive discharge valve leakage can cause a
    negative clearance volume calculation

    Measureable Discharge Valve or


    Seat Leakage Characteristics
    Increase in the Calculated Clearance Volume
    From the Expansion Line
    If you are calculating cylinder clearance volume from
    the expansion line and suction volumetric efficiency,
    the clearance will appear greater than when the
    cylinder was healthy.

    Measureable Discharge Valve or


    Seat Leakage Characteristics
    A defective valve leaks when it is closed; therefore,
    the ultrasonic traces will indicate leakage after the
    normal valve closure and will indicate greater leakage
    activity as the differential pressure increases.
    The leakage will stop when the valve re-opens.

    Head-End Pressure & Ultrasonic Vs. Crank-Angle


    With Leaking Discharge Valve
    Discharge
    close
    leak

    Discharge
    open

    Head-End Pressure Vs. Displace Volume


    With Leaking Discharge Valve
    Pressure
    rise too fast

    Pressure
    drop too
    slow

    Crank-End Pressure Vs. Crank-Angle


    With Leaking Discharge Valve

    Crank-End PV With Slight


    Discharge Valve Leakage
    Actual compression
    slope goes up faster
    than the theoretical

    Pressure is leaking into the


    cylinder all of the time that
    the discharge valves are
    closed
    Actual expansion slope
    goes down slower than the
    theoretical

    Discharge Valve Leakage Summary

    Flow balance less than 1.00

    Discharge temperature increase

    Calculated suction volumetric efficiency decrease

    Calculated discharge volumetric efficiency increase

    Discharge delta temperature increase

    Increase in calculated clearance volume from the


    expansion event

    Decrease in calculated clearance volume from the


    compression event (may go negative)

    N-ratio below 1.00

    Ring Leakage
    Flow balance greater than 1 unless discharge leakage
    is also present
    Discharge temperature increase
    VEs generally increases
    VEd generally decreases but may remain fairly
    stable or even increase
    Discharge delta temp increase
    Calculated clearance from expansion may
    increase or decrease
    Calculated clearance from compression may
    increase or decrease
    N-ratio above 1

    Slight Ring Leakage


    Pressure is alternately
    leaking out of one cylinder
    end into the other end
    Actual expansion slope
    goes down slower than the
    theoretical
    Actual compression
    slope goes up faster,
    then slower than the
    theoretical

    Severe Ring Leakage

    Leak Index and Ring Leakage

    ???

    Multiple Leakages
    HE discharge
    valve &
    suction valve
    leak

    CE discharge
    valve leak

    Late Closures
    HE late
    suction and
    discharge
    valve closures

    CE late
    suction and
    discharge
    valve closures

    A leak for a short period


    of time right after
    closure causing a
    reduction in volumetric
    efficiencies

    Ring Leakage or Discharge Valves?

    Severe Discharge Valve Leakage

    Is There a Leakage Problem?

    Suction or Discharge Valve Problem?

    What Would You Call?

    Questions?

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