Practical Leakage Testing of Compressor Valves a 1. Introduction 2.1 Flow Meter Testing Compressor valves should be flow- The leakage is determined by and the escaping air will blow out efficient and durable in service. subjecting the closed valve to a any small particles that might be Leakageis onecriteria thatimpacts “set air pressure of e.g. Shar (70 trapped between the sealing ‘on both of the above. Excessive PSI) and measuring the leakage surfaces and cause excessive leakage causes backflow of gas through the valve hy means of a leakage. when the valveis closed, raises the flow meter (fig. 1) This should be done with an temperatureofthe gas.andreduces Since small contaminants at times appropriate tool flat or sof-tipped) efficiency. Elevated temperatures can be caught between the valve so no damage is done to the valve also adversely affect valve lite. plate and seat lands, it is common plate or sealing element. Particular practice to "tap" the valve plate in cares called for when non-metallic For this reason, HOERBIGER's —_ several areas repeatedly. This will plates are used so no damage is quality assurance program dictates _brieflylitthe plate offthe seatlands done to these components. that all valves are subjected to a suitable leakage test. This policy covers newly made valves in our production plants and repaired valves in all our service centers. Ditterent geometry valves and | sealing elements made from steel ‘ornor-metallic material all undergo such rigorous testing, @ oe Test methods may vary but prefer- Poem cence ie given to those procedures that simulate the conditions as they " rt 2. Valve Testing Methods Soman There are 8 customary leakage test | ot procedures, and HOERBIGER | = recommends 2 of the testing methods. Lig HOERBIGER CORPORATION OF AMERICA, INC. 1981 S. W. 0th Avenue, Pompano each, Florida 33069 Phone (954) 974-5700 or Toll-Free (800) 327-8961+Fax (964) 974-0964 a VO15A. ‘AOVO1SA120X0002.2 Measuring Pressure Drop In this test method, leakage is ‘measured in pressure drop over time, using a fixed volume "V" (air supply is shut off) and measuring the time it takes for the pressure to drop trom pt to p2 (fig. 2). The time for the pressure drop to occur and parameter for acceptable leakage are dependenton the valve size, volume of the vessel and the selected pressures of p1 and p2 ‘The prior “tapping” of the vaive to blow out any impurities should be standard practice in this test procedure as well 2.3 Liquid Testing Test procedures as discussed under 21 and 22 are compatible and represent conditions as they prevail in the compressor cylinder The sealing element is “pressure loaded” much like it is in its operating environment when installed in a cylinder (the suction valve is kept closed by the cylinder pressure while the discharge vaive is under the influence of the line pressure). Frequently field people donothave access 10 leakage testers and resort to a simple "liquid testing* of the valve. Filling the seat ports of a valve with a fluid and observing the leakage rato of the fluid through the valve is ‘a common practice. Kerosene, Varsol and other light viscosity fluids (even water) are employed in such crude leakage tests. ‘Although the procedure is widely used, itis not withoutcontroversy as tothe viability ofits results. Contrary to the previously described methods of air pressure testing, the liquid test does not simulate conditions as found in the cylinder. The fluid pre-loads the sealing element towardsits opening ift, and test results can be distorted, especiallyifvalves use non-metallic sealing elements andif the pre-load of the springs used in the valve 1s very light. Certain valves, due to their design, cannot be tested at ll with the fluid method, and others will create the 9 — ee Raper ch, appearance of “leakers" when Uir sealing characteristic under air roseure ie perfectly acceptable. This test method, therefore, is controversial and should be avoided whenever possible. The cleaning process described in air testing cannot be applied in liquid tests, and any impurties in the sealing area will show as excessive leakage. Frequently, such liquid tests lead to unnecessary labor and repair of the valve which would possibly be termed fine under air tests. Itis recognized that proper testing of valves with air pressure is not always possible, but it remains the superior prodedure and should be adopted wherever possible.