Valve Failure Poster

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 n Valve plate failure due to liquid or condensate is a typical n Blocked valves are mostly a result of the process and
components process related issue are commonly seen in polyethylene plants or HDS or
CCR applications in refineries.
n Scarring can often be seen on the seat and guard as well n Metallic sealing element will become rusty whenever
n It is common to see debris scars alongside other failure there is condensation, lifespan is then shortened. n Blocked valves will lead to high differential pressure
modes so it is not necessarily the root cause of a failure n Liquids are generally driven to the center of the valve across the valve seat and could lead to cracks in the
by the gas flow seat. Blocked valves could result in safety issues as
they impact on rod load reversals if the gas cannot be
n Water hammer effect inflicted damage to the center of the released to the discharge line.
plate, innermost rings may be broken and do
seldom occur on the outside of the plate n Sticky material can initially also lead to plate stiction
and high opening impact of valve plate.
n Springs may be collapsed
Remedy: Upgrade to Non metallic plates if possible.

Reevaluate valve design. Non metallic plates can Remedy: Prevent condensation e.g. by insulating of suction Remedy: Besides improving process related equipment
usually survive longer than metallic in the presence line, prevent liquid carry-over, suitable cooling rate for the upstream the compressor, a valve upgrade to ring type.
of moderate debris. cylinder. Consider ring or profiled plate type valve. Profiled ring/plate type valves with anti-stiction designed
guard will make an improvement.
RING OR PLATE FAILURES DUE TO SPRING FAILURES DUE TO DEBRIS RING OR PLATE FAILURES DUE TO OVER
MISAPPLICATION OR FATIGUE LUBRICATION
n Oil stiction effects leads to high impact of the
n Melted non-metallic sealing elements are normally n Sand or welding slag enters the spring pockets (Usually conventional valve plate, ring.
a sign that the compressor ran for an extended a transient event and common after startups)
period with leaking valves, was exposed to very high n Outer section of valve plate starts failing because of
temperature, or when a material selection for a specific n Debris may scar the coils and provide a failure initiation imbalanced movement of sealing element
operating condition was incorrect point
n Plate valves are vulnerable to excessive lube
n Spring fatigue failure leads to high impact of the metallic
n Springs are often stuck in sealing element If lube rates can’t be reduced, conversion to a profiled
valve plate n
n Air compressors tend to have surging in temperature. geometry valve may minimise the issue
n Outer section of valve plate starts failing
n One or multiple springs collapsed
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
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.
Remedy: Upgrade to metallic sealing element. Reengineer
valves when process change occurred or a new duty has
been applied.
FAILURES DUE TO CHANGE IN RING OR PLATE FAILURES DUE TO FAILURE DUE TO IMPROPER
OPERATING CONDITIONS MOLDING DEFECTS INSTALLATION AND REPAIR
Any changes in operating condition such as compressor Generally, poor material quality could lead to longitudinal n Broken guard: suction valve was loose in valve pocket
speed, operating pressure and gas composition will cracks and jagged, crumbled, break surface indicate a due to improper torque of valve covers which caused
affect valve performance. Valve inner components might molding defects in the material. damage to multiple elements
be damaged and consequently pre-mature valve failure
occurred. n Seat lands too wide outside of specs or plate was flipped
then reused
n Top locking nut not used or reused
Remedy: Re-evaluate valve performance before any changes

applied to the process.
Remedy: Selecting experienced supplied and improve

material selection.
HOERBIGER KT ASIA SERVICES PTE LTD Remedy: Follow HOERBIGER repair procedures and change
all required consumables during servicing!
77 Joo Koon Circle, Singapore 629097 Tel: +65 6890 0770 Fax: +65 6890 8037 Email: info-asia@hoerbiger.com

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MOST COMMON COMPRESSOR VALVE FAILURES

CAUSE AND CORRECTIVE ACTIONS

Remedy: Upgrade to Non metallic plates if possible.

Remedy: Reduce cylinder lubrication rate (if possible),

Remedy: Re-evaluate valve performance before any changes

Remedy: Selecting experienced supplied and improve

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