Finite Element Analysis of Ring Type Compressor Valve Seat

ABSTRACT:
A compressor valve is a device that controls the flow of higher pressure gas from a reciprocating compressor cylinder. Normally, these valves open and close automatically, solely governed by the pressure differential. The reliability of reciprocating gas compressors depends upon the function of certain critical components. Among these components, compressor valves have become the focus for considerable development, both in design and analysis. In particular, the ring type valve is capable of operating in wide range parameters reaching temperatures up to 200C and pressure in excess of 400 bar. Nowadays, FEM is often used for analysis of valve components for optimum pressure differential. This paper highlights FEA of valve seat with the objective to predict the stresses induced in the valve seat at given operating pressure. Further, an analysis was carried out to determine the natural frequencies and respective mode shapes and also to determine whether the valve seat can operate safely for maximum pressure under consideration. The results obtained through modal analysis shows first mode shape in the form twisting and second mode shape in bending. Stress analysis showed the highest stress near the hub of the valve seat.

1.0 INTRODUCTION
The reciprocating compressor has long been acknowledged as the most efficient and flexible form of gas compression, covering virtually all types of gases, with working condition either lubricated or oil-free. Past concerns over the operating life of the critical components such as valves, packing and rings had provoked a surge of interest in other forms of compression like screw, centrifugal and turbo. However, strenuous efforts invested over recent years by product specialists have addressed most of these concerns, with the result that the reciprocating compressor is once again restored to its favored status and can stand scrutiny by users who rightly insist on consistent reliability and performance. Compressor valve is a device that controls the flow of higher pressure gas from a reciprocating compressor cylinder. In contrast to engine technology, compressor valves work on pressure difference, because the timing of opening and closing depends on the pressure ratio. If the pressure below the valve is greater than the pressure above the valve plus the spring force, it opens. Compressor valves have been acknowledged by most operators as the most frequent cause of unplanned compressor stoppages, since the traditional compressors work up to 1000 RPM and valves fitted to these compressors have to open and close up to half-a-billion times each year. Now with the advent of the higher-speed compact compressors, speed ranges have increased up to 1800 RPM, which means nearly one billion valve cycles per year. Thus there is a need for improved valve designs and materials. In order to avoid catastrophic failure of the valve and to make the compressor more reliable for use without stopping for valve changes at intervals of less than one year, valve designers have to focus on ways to make their valves, including seats, guards, sealing elements such as plates, rings or poppets, and the associated springs, sufficiently robust and resilient to be able to withstand the massively increased effect of impact loading and fatigue stresses.

2.0 VALVES USED IN RECIPROCATING COMMPRESSORS

The following are the types of valves used in reciprocating compressors define by shape of moving elements and damping used, and a brief description of each type is given.

2.1 Channel Valve

The channel element valve uses rectangular-shaped sealing elements. These valves are the feather valve, channel valve and the reed valve. These valves are applied to the industrial air machines for the most part.

2.2 Ported Plate Valve

The ported plate valve is similar to the concentric ring valve except that the rings are joined into a single element. The advantage is that the valve has a single element, making flow

control somewhat easier. Because of the single element, the number of edges available for impact is reduced.

2.3 Poppet Valve

The large seat and guard porting result in a valve that can be used effectively in applications in which debris or liquid is present. The poppet itself is designed to withstand high pressure differentials and high impact velocities, while providing a smooth, aerodynamic flow surface. Along with the large porting in the seat and guard, the poppets contribute to a low valve pressure drop.

2.4 Ring Valve

The valve assembly (figure 1) includes a ring valve having a fluid seal surface for selectively closing a fluid passage of a cylinder head and bias means for the ring valve urging in a first direction. The bias means include the outer peripheral edge region of the ring valve being secured between opposing upper and lower annular surfaces with a predetermined smaller clearance. The upper annular surface includes an outer edge and the lower annular surface includes an inner edge which defines a fulcrum radially inward of the outer edge. This type of compressor valves is recognised as outstandingly reliable in the oil, gas, petrochemical and air separation industries worldwide. The ring type valve is capable of operating across wide range parameters reaching temperatures of up to 200 C/390 F and pressures in excess of 400 bar / 6000 psi, and are suitable for sour gas applications. It has streamlined flow enabling free passage of entrained solids and liquids reducing risk of damage, thereby greatly improving reliability. Ring type valve has a wide range of operating conditions having durable thermoplastic discs with no seat damage or wear. As compared to other valves, it is simple in internal design-easy to service and suitable for both lubricated and nonlubricated applications. Also, it has increased efficiency and savings on power consumption with less back-flow and often lower process gas temperatures. The major disadvantage with this type is difficult to maintain uniform flow control with the independent rings.

3.0 FINITE ELEMENT ANALYSIS OF VALVE SEAT

To determine the stresses induced in ring valve, analysis is done by using finite element method tool. As an initial step with the given dimensions, the model is developed by using the modeling software CATIA V5R16. After doing the modeling of seat, it is imported in analysis software ANSYS 10.0 and then the FEM modeling is done, as shown in figure 2, meshing with three-dimentional-10 node tetrahedron elements.

3.1 Modal Analysis

With the FEM modeling free-free modal analysis was carried out to know the natural frequencies of valve seat and respective mode shapes. With this analysis, the first six modes were extracted. Figure 3a and 3b illustrate the first twisting and second bending mode shapes with first and second natural frequencies 87.57 Hz and 96.85 Hz respectively (Table 1).

S. No. 1 2 3 4 5 6

Table 1: Different mode Shapes at Respective Natural Frequencies Type of mode shape Max. Displacement Natural frequency Twisting 3.0 87.57 Bending 2.9 96.85 Axial distortion 3.8 206 Axial distortion 3.7 206.63 Distortion of slots near hub 1.88 238 Distortion of slots near hub 2.96 253

3.2 Stress Analysis

In order to determine the stresses induced in the valve seat, static stress analysis was carried out with imposing the boundary conditions. Since valve seat is held with valve stop, the nodes on inner cylindrical area at hub are constrained with all degrees of freedom with zero displacement. Another boundary condition is imposed by means of constraining the edge where valve seat is fastened to the cylinder head with displacement in all degrees of freedom zero. The valve seat is analyzed for maximum pressure developed by piston in operation, for this compressor under consideration it is 16.89 bar. Figure 4a illustrates the pressure loading on valve seat. With these boundary conditions and pressure loading, the solution was carried out and the results are shown in the following figures. Figure 4b shows the maximum deflection 0.0060 mm which was developed in valve seat under given operating condition. The results of stress analysis are depicted in figure 5 which shows the maximum stresses developed near the hub area and at the portion of the resting for the concentric rings.

3.3 Determination of Optimum Pressure

To predict the maximum pressure that valve seat can sustain, stress analysis was carried out by increasing the pressure loading by means of 5 bar. This procedure was repeated till the maximum stress induced in the valve seat exceeds one-third of the ultimate stress value of the material. The material used was AISI 410, the ultimate stress for which it was 485 N/mm2. Table 2 illustrates the values of stress analysis at different pressure loadings. The results clearly show that this valve seat can sustain maximum pressure up to 47 bar.

Table 2: Deflection and Stress results at Different Pressure Loading Conditions S. No. Pressure(Bar) Maximum deflection Maximum (mm) Stress(N/mm2) 1 16.89(Working) 0.0060 56.96 2 25 0.0088 84.24 3 30 0.0106 101.08 4 35 0.0124 117.93 5 40 0.0142 134.78 6 45 0.0160 151.63 7 47 0.0167 158.37 8 50 0.0170 168.42

4.0 CONCLUSION
In order to avoid catastrophic failure of the valve and to make the compressor more reliable for use, valve designers have to focus on ways to make their valves including seats, guards, sealing elements and the associated springs sufficiently robust and resilient. Finite element analysis is very much useful to design the components such as valve seat with complicated geometries.