Reciprocating compressor valve replacement: from monthly to annual maintenance

In a letter of appreciation dated 18 February 2009, a petrochemical company in Shanghai reported that replacing compressor valves and components with Chinese-made alternatives from RONDER had extended the maintenance interval in its olefins unit from monthly to annual. Maintenance and spare-parts procurement costs had also fallen.

Valve replacement on GEMINI compressors

The olefins unit had two US-made GEMINI reciprocating compressors, tagged 11-C-2501AX/BX and originally fitted with HOERBIGER valves. Following startup in May 2005, frequent valve plate and spring failures meant the compressors needed maintenance in less than a month.

In July 2005, the customer began using Chinese-made springs and PEEK compressor valves supplied by RONDER. Some complete valve assemblies were also replaced with domestically manufactured units.

Figure 1. Replacement timeline summarized from the customer letter.

Maintenance interval record

By February 2009, the customer had used the locally manufactured valves for nearly four years. Converting the reported monthly and annual intervals to a yearly basis, maintenance frequency fell from approximately 12 times per year to once per year. The letter described the changes in maintenance interval and costs:

“The maintenance interval has changed from once a month to once a year, saving us substantial maintenance labor and resources and greatly reducing machine maintenance and spare-parts procurement costs.”

PEEK valve plates on hydrogen compressors

The same letter described another application in the plant’s styrene unit. Two hydrogen compressors manufactured by Shenyang Gas Compressor Factory used RONDER’s ring-shaped PEEK valve plates with conical sealing surfaces, with a reported service life of more than one year and two months.

Figure 2. The two applications recorded in the letter.

Discuss a valve replacement with RONDER

If your compressor has recurring valve plate or spring failures, or needs frequent valve maintenance, email the following information to sales@ronder-valve.com to discuss replacement options, including Chinese-made alternatives:

Compressor manufacturer, model, stage and rotational speed;
Gas composition, suction and discharge pressures and temperatures;
Current valve configuration, maintenance intervals and the main components that have failed;
Valve documentation, maintenance records or photographs of failed components that you are able to share.

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