compressor safety valve leaking quotation

A leak in the compressor service valve can lead to shorter cycling of the refrigerant which increases the discharge temperature. With the cycles becoming shorter and shorter, the discharge temperatures will begin to increase since they are subjected to the heating cycle more frequently. An increase in the discharge temperature is one of the best indicators of a leak in the service valve. Monitoring these temps on a daily basis is a great way to uncover potential refrigerant leaks.

Any type of leak in the compressor service valve will cause most of the active refrigerant to remain in either the condenser or the receiver, or both. Over time, this will cause higher subcooling in the condenser and prevent the refrigerant from traveling throughout the system. While this may not seem out of the ordinary, over time, it can start to damage the system.

A suction valve is used to remove excess superheat. If the valve is not seated correctly and the heat remains, the suction pressure will begin to rise. This can also cause refrigerant to leak from the compressor"s cylinder back into the suction line. As more and more of the refrigerant is displaced or drawn back into the suction lines of the system, the higher the suction pressure.

With small refrigerant leaks, superheating may not become a problem. However, if the leak continues to increase, major problems can occur. Extreme superheating, or an excessive amount of vapor which goes far beyond its boiling point, is caused by insufficient refrigerant flow as it travels through the system. If the flow of the refrigerant is not sufficient when it gets to the thermostatic expansion valve, it can cause extreme superheating.

A leak in the compressor service valve is often detected during an inspection of the system and can be repaired rather quickly. These tips are a great way to identify the problem if it happens to occur between regular inspections. If a leak is detected or if you suspect one may be compromising your system, call a professional HVAC technician and have them take a look at your system. The sooner it"s fixed, the quicker your system will be up and running at maximum efficiency.

If the diagnosis determines that a replacement refrigeration compressor may be necessary, Compressors Unlimited has a wide selection of remanufactured compressors that are not only cost-effective, but superior quality with a warranty included.

Water entering the PRV is constricted and pushed into the valve’s inner chamber. The chamber is controlled by a spring-loaded diaphragm and disk. When water pressure fluctuates, the PRV helps maintain a constant flow and safe water pressure.

PRV valve leaking usually means there’s a hole in your valve. If you see pressure relief valve leaking, flooding, or if you hear strange noises coming from your PRV, it’s time for a replacement.

CPV Manufacturing has the best PRVs on the market to fit your individual or company needs. Check out our PRVs or head over to our news blog for more information about machined valves and fittings.

We provide onsite safety relief valve diagnostic testing and repair services while helping you manage your overpressure protection assets for regulatory compliance.

You need your air compressor to be ready to work when you are. By familiarizing yourself with common issues with this type of equipment, you can learn how to address minor repairs before they become costly.

Air leaks are one of the most common problems associated with air compressors. You should actively pay attention to weak spots and potential holes in your air hoses and valves.

Any time you notice the gauge indicating lower pressure after deactivating the air compressor when the tank is full, you are likely dealing with an air leak.

Use liquid soap:You can apply a thin layer of liquid soap on your air compressor’s connections, including the equipment’s power switch and couplers. Any holes will bubble as the air escapes.

Air leaks can also happen when a tank check valve is not completely closed. Anytime you notice the pressure gauge dropping when you’ve turned off the tank, take a closer look at the valve’s condition. You may need to clean or replace it to fix the leak.

Starting failure is another common issue associated with air compressors. Equipment not powering up could be due to a few different causes, so you’ll want to examine every potential issue to find the root of the problem and adequately address it.

If the power connection and settings are all good, your compressor is likely failing to start because it lacks sufficient air pressure compared to cut-in pressure.

A compressor’s cut-in pressure should be lower than its cut-out pressure. If it is not, the machine will start and stop continuously. To fix the problem, adjust your pressure set points accordingly.

Your air compressor could also fail to start because of a lack of oil. Follow a regular maintenance schedule to change your equipment’s fluids and avoid an empty oil compartment.

Another common problem with air compressors is failing to shut down. Your equipment should stop running when the tank pressure reaches the cut-out point. If your equipment continues operating after turning it off, it could be due to a faulty pressure release valve or power switch.

A faulty pressure release valve could keep your motor from shutting down. In this case, the valve is not releasing the pressure effectively, and the compressor is too pressurized to turn off. If you do not address this issue, it can cause serious damage to your machine.

Unloader valve:Your problem may be due to the air compressor’s unloader valve. You can test this by opening the tank drain and allowing the air to escape to simulate its function and remove water. To test the valve, close the drain and power up the compressor. Replace the valve if the compressor runs up to cut-out pressure.

Splitting the power supply:Another culprit could be your power supply. Using an extension cord that’s too small or plugging too many appliances into the same circuit can bog down your compressor.

Identifying pressure and flow problems with your air compressor can be more challenging than other common issues. The machine may appear to be working properly at first glance. However, if you notice your equipment is reaching too much or too little pressure, your compressor may need some attention. To identify flow issues, inspect the following components:

You are likely familiar with the typical sounds and vibrations associated with your air compressor. If you notice the machine is louder than usual when you power it up or it is reverberating more than normal, explore the possible causes.

Improper mounting: If your equipment is improperly mounted, your compressor can rattle when in use. You may need to refasten boots or add vibration pads to correct mounting errors.

It’s best to take problems relating to your air compressor’s oil very seriously. Ignoring them can cause significant damage, and you may have to replace your machine entirely. Expired fluids and dispersion are two of the most common oil issues.

Dispersed oil can cause cracking and swelling in your compressor’s seals. To get to the root of the problem, closely inspect your compressor. Look for the following causes of dispersed oil:

Tending to oil issues as soon as possible is critical to minimizing the damage they can cause to your machine. The sooner you address oil problems with your air compressor, the better you can maintain your equipment and keep it running smoothly.

Limited air intake:When the air intake on your compressor is obstructed or not ventilated properly, the machine has to work extra hard and can generate overly hot air.

Lack of air pressure is a significant issue with any compressor. When your equipment doesn’t build up enough pressure, you should inspect it thoroughly. You can conduct a pump test by emptying the air tank and timing how long it takes for your machine to reach a certain pressure starting from zero. Your compressor should reach the desired pressure in a specific time frame outlined by the manufacturer.

Gasket:The gasket between the high- and low-pressure compartments in your compressor may cause problems with your air intake pump and lead to inadequate air pressure.

The exact tools you’ll need will depend on your specific air compressor’s model and manufacturer. You’ll also need high-quality replacement parts compatible with your existing compressor.

Before investing in new parts, check out your warranty.If your air compressor is still under warranty, the manufacturer may pay for replacement parts. You may also need to turn to a professional for help to ensure your machine’s repairs are effective and secure.

Knowing how to replace parts on your air compressor is a handy skill for all owners and operators. Explore the different steps to swap out worn or damaged parts for new ones.

If your regulator’s internal components are worn and starting to fail, you may need a replacement. Use these steps to install a new one on your air compressor:

Open the drain valve on your air tank and allow all the air to empty before getting started. You can close the drain valve once all the pressure is removed.

If your compressor won’t turn on or runs until its safety valve opens, you likely need to replace the pressure switch. To do so, follow these easy steps:

Recent repairs:If your equipment has not had costly maintenance within the last year, you may financially benefit from buying new parts and tuning up your current air compressor.

Operating conditions:You want your machine to work quickly and be energy efficient. If your compressor operates at over 60% of its capacity, you can likely fix your equipment with new repair parts.

The following are circumstances when it may be advantageous to replace your air compressor with a new model instead of using replacement parts for a repair:

Age:If you have been running your air compressor for more than 10 years, your equipment could be very worn and inefficient. You are likely ready for a newer model.

Operating conditions: Look at your current equipment’s energy efficiency and operating conditions. You may want to replace your compressor if it runs at less than 60% of its capacity.

Availability of replacement parts:If you experience a breakdown with your machine and have difficulty finding replacement parts for your system components, replacing your air compressor entirely may be a better option.

When you need high-quality air compressor replacement parts for your machine, turn to Quincy Compressor. We have the services and parts you need to keep your equipment performing at its best.

Our team of knowledgeable air experts is here to help you maintain your air compressor. We want to help you extend its life by easily making necessary repairs and replacements. Count on us to keep your operations up and running.

Are you interested in learning more about around-the-clock assistance from our service technicians? Explore services from Quincy Compressor, or contact us today!

Conventionally when we talk about oil lubricated screw air compressor maintenance, it is mostly about replacing consumables such as filters and lubricant on time. While these consumables have a defined usable life and have a direct effect on the efficiency and the life of the air compressor itself when not replaced on time, there are a few critical valves in the air compressor that require maintenance as well. Compressor valves directly affect the efficiency, safety, and the functionality of the screw air compressor. Let us understand some of the commonly available valves in a screw air compressor, why they need maintenance, and discuss some of the frequently asked questions about screw air compressor valves.

A screw air compressor is very similar to a human heart. While a human heart has tricuspid, pulmonary, mitral, and aortic valves, a screw air compressor has four critical valves namely air inlet, minimum pressure, blow down, and safety valves.

Air inlet valve is also commonly known as the ‘Intake valve’ which is typically assembled on the airend’s intake. The air inlet valve of a conventional fixed speed screw air compressor controls the air intake into the compressor. It remains closed when the compressor starts to lower the starting load on the main motor and when the desired working pressure is attained in the compressed air circuit and thus enabling the compressor’s motor to run without any load. In some compressors that are capable of providing a variable output by modulating the amount of air it sucks in, the inlet valve holds various opening positions to regulate the volume of air entering the compressor. The effective performance of the inlet valve directly affects the compressor’s capacity and its power consumption during load and no-load conditions.

The minimum pressure valve is typically assembled on the exit of the air-oil separation tank of a compressor. The minimum pressure valve acts as a check valve preventing back flow of compressed air into the airend, retains a minimum pressure in the compressor system for lubrication, offers a restriction to avoid a collapse of the air-oil separation filter, and ensures a suitable velocity of flow across the air-oil separator that ensures efficient air-oil separation. The effective performance of the minimum pressure valve directly affects the compressor’s lubrication, air-oil separation efficiency, and power consumption during load and no-load conditions.

The blow down valve is typically found on a dedicated exhaust line from the air-oil separation tank. The blow down valve evacuates the compressed air in the air-oil separation tank each time the compressor runs on a no-load and when the compressor shuts down to ensure there is no back pressure when the compressor starts to load next time. The blow down valve of a conventional screw compressor is typically actuated by a solenoid valve. The effective performance of the blow down valve affects the compressor’s power consumption during un-load, capacity of the compressor when running on load, and the life of the motor.

The safety valve is typically mounted directly on the air-oil separator tank. The only function of the safety valve is to blow off the compressed air in the air-oil separation tank when the pressure in the air-oil separation tank exceeds the set pressure of the safety valve and there by prevents the tank from cracking under high pressure. A malfunctioning safety valve affects the safe operation of the air compressor or results in leakage of compressed air continuously.

Though each compressor manufacturer has their own unique valve design, compressor valves in general contain moving parts such as springs, valve plates, and plungers that affect the opening and closing of the valves and rubber seals / seats that offer perfect sealing when the valves remain closed. These moving parts wear or lose their mechanical properties over a period of time and the sealing components typically ‘age’ over time and lose their effectiveness and will need to be replaced.

Compressor manufacturers typically design these components to operate efficiently for several thousand or millions of operation cycles. However, several factors such as variability in the demand pattern, sizing of the air compressor against a certain air demand, the environment in which the air compressor operates, promptness of preventive maintenance, etc. determine how long these valves efficiently operate.

Many times, it is difficult to identify a malfunctioning valve or a valve operating with worn-out parts as the compressor continues to generate air. The typical symptoms of a malfunctioning valve are loss in compressor"s capacity, increase in power consumption during load or/and unload, drop in discharge pressure, increase in oil carry-over and more load on motor. These symptoms are either difficult to notice or have other frequently common assignable causes such as air leak before suspecting the compressor valves.

Case studies show that operating a screw air compressor with a worn-out / malfunctioning valve could increase its overall power consumption by 10 - 15%. Power cost contributes to more than 75% of the compressor’s total life cycle cost over ten years and hence this is a significant impact. Unserviced valves also lower the life span of downstream accessories by half. In some cases, a malfunctioning safety valve may result in a catastrophe.

Air compressor manufacturers typically offer convenient valve maintenance kits for customers that contain the internal parts of the valve that wear or age out. Changing the valve kits is a much more sensible and economical option than changing the complete valve.

It is difficult or almost impossible to identify a malfunctioning valve unless it is opened for inspection. Hence it is absolutely mandatory that these valves are inspected for effectiveness every year and the internal moving parts replaced as a part of preventive maintenance once every year or two depending on the operating conditions of the air compressor. It is typical for compressor manufacturers to mandate a valve kit replacement once every two years as a proactive measure.

In particular, the safety valve must be inspected and certified every year per the local safety laws to ensure they are functional and efficient. Sometimes, replacing the safety valve entirely with a valid certificate for one year is more economical as the certification procedures could be equally expensive on an existing valve.

As stated before, it is challenging to identify a valve that is worn out unless it is opened and inspected, but there are a few indicators that a qualified compressor technician can use to deduct a malfunctioning valve.

Low duty cycle operation: A sophisticated screw air compressor in today’s day and age carries a convenient microprocessor-based human-machine interface that keeps track of operating hours of the compressor under load and un-load conditions and the number of load/unload counts the compressor is subjected to over a period of time. A higher un-load hours and load/unload count indicates that the air compressor is oversized against the actual air demand. This in turn indicates the air compressor ‘cycles’ frequently between load and un-load mode as opposed to running continuously on load. Every time a compressor ‘cycles’, the inlet valve, blow down valve, and minimum pressure valve is brought into play where their internals ‘actuate’. Frequent actuation of these valves results in a faster wear of the internals and hence results in shorter life.

High operating temperature: A compressor that runs on a high operating temperature affects the life of the valve’s sealing components, which causes them to ‘age’ fast.

Compressor not building pressure: If the air demand has not changed over time and the facility is relatively free of any air leakage, the air compressor is probably not delivering the rated output. There is a high probability that there is a malfunctioning valve.

Increase in compressor’s power consumption: An increase in the air compressor’s power consumption profile over a period of time where there has been no abnormal change in the air demand and usage pattern indicates an increase in either the load or un-load power. There is a high probability that this is because of a malfunctioning valve.

Based on the design philosophy adopted by the air compressor manufacturer, the oil lubricated screw air compressors could have a few more valves that are critical to functional performance that must be maintained as well. Some of the other valves frequently used in an air compressor are as follows:

Temperature control valve (also known as thermal valve) is used to regulate the flow of oil through the oil cooler based on the operating temperature.

Drain valves are used to drain lubricant at the time of lubricant change over or cleaning. Air compressors equipped with a moisture trap at the outlet of the after cooler also has a drain valve (automatic or timer based) to discharge water collected

The presence or absence of one of these valves and the type of actuation of these valves (electronic / mechanical) depends on air compressor’s design architecture. The Operation and Maintenance Manual (OMM) and the Piping and Instrumentation Diagram (P&ID) supplied by the air compressor manufacturer are excellent resources that explain the purpose, functioning, and maintenance requirements of these valves.

Many of the air compressor valves are highly specialized and exclusive. Their designs are usually complex and some even need special tools to service them. The internal components" build quality and material selection are extremely important and proprietary. Hence it is highly critical that only genuine valve kits issued by the air compressor manufacturer are used to maintain the valves. An inferior after-market replacement will most certainly compromise the performance of the entire compressor, void the original manufacturer"s warranty of the compressor, cause consequential damage to other parts of the compressor, and above all, be a safety hazard.

In conclusion, while it is important to change the screw air compressor"s filters and lubricants on time, it is equally important to perform preventive maintenance on these critical valves in a screw air compressor as recommended by the air compressor manufacturer. While the intake valve, minimum pressure valve, safety valve, and blowdown valve are critical to the performance and safety of the compressor, there could be other valves in the compressor that are critical and need maintenance. The air compressors sizing and the environment in which it operates are crucial factors that affect the life of the air compressor. Finally, it is critical to proactively service these valves using genuine kits issued by the compressor manufacturer to enable the air compressor performs efficiently and safely.

We also provide on-site electronic testing of your safety valves while your plant operates as an option. IVI is cognizant of the need to complete safety valve projects within a designated time frame. We pride ourselves on meeting critical deadlines during outages/shutdowns. We attribute this success to the planning of the projects and attention to detail by our project managers. In addition, IVI can provide technical support and maintenance coordination for all your valve repairs - during outages as well - and will have you back online with the least amount of downtime. This ensures that you will attain an extensive reduction in operating costs resulting in greater profits.

Safety is of the utmost importance when dealing with pressure relief valves. The valve is designed to limit system pressure, and it is critical that they remain in working order to prevent an explosion. Explosions have caused far too much damage in companies over the years, and though pressurized tanks and vessels are equipped with pressure relief vales to enhance safety, they can fail and result in disaster.

That’s also why knowing the correct way to test the valves is important. Ongoing maintenance and periodic testing of pressurized tanks and vessels and their pressure relief valves keeps them in working order and keep employees and their work environments safe. Pressure relief valves must be in good condition in order to automatically lower tank and vessel pressure; working valves open slowly when the pressure gets high enough to exceed the pressure threshold and then closes slowly until the unit reaches the low, safe threshold. To ensure the pressure relief valve is in good working condition, employees must follow best practices for testing them including:

If you consider testing pressure relief valves a maintenance task, you’ll be more likely to carry out regular testing and ensure the safety of your organization and the longevity of your

It’s important to note, however, that the American Society of Mechanical Engineers (ASME) and National Board Inspection Code (NBIC), as well as state and local jurisdictions, may set requirements for testing frequency. Companies are responsible for checking with these organizations to become familiar with the testing requirements. Consider the following NBIC recommendations on the frequency for testing relief valves:

High-temperature hot water boilers (greater than 160 psi and/or 250 degrees Fahrenheit) – pressure test annually to verify nameplate set pressure. For safety reasons, removal and testing on a test bench is recommended

When testing the pressure relief valve, raise and lower the test lever several times. The lever will come away from the brass stem and allow hot water to come out of the end of the drainpipe. The water should flow through the pipe, and then you should turn down the pressure to stop the leak, replace the lever, and then increase the pressure.

One of the most common problems you can address with regular testing is the buildup of mineral salt, rust, and corrosion. When buildup occurs, the valve will become non-operational; the result can be an explosion. Regular testing helps you discover these issues sooner so you can combat them and keep your boiler and valve functioning properly. If no water flows through the pipe, or if there is a trickle instead of a rush of water, look for debris that is preventing the valve from seating properly. You may be able to operate the test lever a few times to correct the issue. You will need to replace the valve if this test fails.

When testing relief valves, keep in mind that they have two basic functions. First, they will pop off when the pressure exceeds its safety threshold. The valve will pop off and open to exhaust the excess pressure until the tank’s pressure decreases to reach the set minimum pressure. After this blowdown process occurs, the valve should reset and automatically close. One important testing safety measure is to use a pressure indicator with a full-scale range higher than the pop-off pressure.

Thus, you need to be aware of the pop-off pressure point of whatever tank or vessel you test. You always should remain within the pressure limits of the test stand and ensure the test stand is assembled properly and proof pressure tested. Then, take steps to ensure the escaping pressure from the valve is directed away from the operator and that everyone involved in the test uses safety shields and wears safety eye protection.

After discharge – Because pressure relief valves are designed to open automatically to relieve pressure in your system and then close, they may be able to open and close multiple times during normal operation and testing. However, when a valve opens, debris may get into the valve seat and prevent the valve from closing properly. After discharge, check the valve for leakage. If the leakage exceeds the original settings, you need to repair the valve.

According to local jurisdictional requirements – Regulations are in place for various locations and industries that stipulate how long valves may operate before needing to be repair or replaced. State inspectors may require valves to be disassembled, inspected, repaired, and tested every five years, for instance. If you have smaller valves and applications, you can test the valve by lifting the test lever. However, you should do this approximately once a year. It’s important to note that ASME UG136A Section 3 requires valves to have a minimum of 75% operating pressure versus the set pressure of the valve for hand lifting to be performed for these types of tests.

Depending on their service and application– The service and application of a valve affect its lifespan. Valves used for clean service like steam typically last at least 20 years if they are not operated too close to the set point and are part of a preventive maintenance program. Conversely, valves used for services such as acid service, those that are operated too close to the set point, and those exposed to dirt or debris need to be replaced more often.

Pressure relief valves serve a critical role in protecting organizations and employees from explosions. Knowing how and when to test and repair or replace them is essential.