Reciprocating compressor valve damage estimation under varying speeds through the acoustic emission technique

Purpose The purpose of this paper is to examine the effect of reciprocating compressor speeds and valve conditions on the roor-mean-square (RMS) value of burst acoustic emission (AE) signals associated with the physical motion of valves. The study attempts to explore the potential of AE signal in the estimation of valve damage under varying compressor speeds. Design/methodology/approach This study involves the acquisition of AE signal, valve flow rate, pressure and temperature at the suction valve of an air compressor with speed varrying from 450 to 800 rpm. The AE signals correspond to one compressor cycle obtained from two simulated valve damage conditions, namely, the single leak and double leak conditions are compared to those of the normal valve plate. To examine the effects of valve conditions and speeds on AE RMS values, two-way analysis of variance (ANOVA) is conducted. Finally, regression analysis is performed to investigate the relationship of AE RMS with the speed and valve flow rate for different valve conditions. Findings The results showed that AE RMS values computed from suction valve opening (SVO), suction valve closing (SVC) and discharge valve opening (DVO) events are significantly affected by both valve conditions and speeds. The AE RMS value computed from SVO event showed high linear correlation with speed compared to SVC and DVO events for all valve damage conditions. As this study is conducted at a compressor running at freeload, increasing speed of compressor also results in the increment of flow rate. Thus, the valve flow rate can also be empirically derived from the AE RMS value through the regression method, enabling a better estimation of valve damages. Research limitations/implications The experimental test rig of this study is confined to a small pressure ratio range of 1.38–2.03 (free-loading condition). Besides, the air compressor is assumed to be operated at a constant speed. Originality/value This study employed the statistical methods namely the ANOVA and regression analysis for valve damage estimation at varying compressor speeds. It can enable a plant personnel to make a better prediction on the loss of compressor efficiency and help them to justify the time for valve replacement in future.