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 Compressor Components  (Download Literature for ExactoTorques, Pistons, Liners)


Compressor Valves

Valves 1 Valves 2 Valves 3 Valves 4 Valves 5

ACI offers a complete line of proprietary designed compressor valves. Valve type and internals are selected to provide optimized service and performance under varied operating conditions. Compressor valving is a science in itself and requires more detail than the below general outline provides. For detailed valve analysis, please contact ACI Services, Inc.
 
Plate Valves
  • Offered in damped, individual ring, and ported plate designs.
  • Damped plate valve employed in high pressure applications or where liquids and/or dirt are present, and endurance is the primary concern. Process applications are typical.
  • Ported plate valves offer a good selection for balance of efficiency and endurance. Gas gathering and storage service are areas of common applications.
Accu-Guide
Poppet Valve
  • Patented design concept that overcomes mechanical failure problems associated with many conventional poppets. Used in gas transmission, storage and process services where additional fixed clearance can be tolerated.
  • Click here for more details on this patented design.
Valve Styles -
Poppet and Plate
  • Single Deck: Used in cylinders with acceptable valve area to swept volume ratio -- minimal fixed clearance compared to other valve styles
  • Double Deck Opposed Flow: Utilized with valve cap unloaders or where additional free lift area, compared to single deck valves, is required. Fits into reasonable valve pocket depths.
  • Double Deck Parallel Flow: Same lift area as opposed flow valves, but higher fixed clearance. Requires generous valve pocket depths. More efficient gas flow than opposed flow valves.
  • Deck and One Half Parallel Flow: Greater plate lift area than other double decks and less fixed clearance than most multi-deck valves. Not usable with valve cap unloading equipment. Requires generous valve pocket depth.
Valve Styles -
Replications
  • Complete replacement valves for Cooper C5V single deck and C6V double deck valve series.

 
ExactoTorque

ExactoTorque™: A large number of rod failures are the result of inaccurate pre-stressing. ACI's ExactoTorque is the patented solution. It can be used for a wide variety of mounting and industrial attachments (flange bolting, foundation bolting, etc.), especially where precise alignment and space restrictions are a concern.

The Problem: Achieving proper torque.

  • Most piston rods need to be torqued to a pre-stress of 30,000 psi.
  • Conventional fasteners require unwieldy and occasionally hazardous application tools.
  • Galling between nut face and crosshead face often result from turning these faces against each other at the required torque levels.
  • These often lead to Piston Rod Failure, Thread Damage, and/or Excessive Rod Deflection.

The Proven Solution - ExactoTorque

  • Computer stress analysis assures proper quantity and size of jackbolts seated on individual bearing pads. Accurate preload is applied and face-to- face galling is eliminated.
  • The ExactoTorque pre-stresses the rod in the same manner as a conventional hex nut. Thread root area and bearing pad surface are equal to root and contact surface of conventional nut.
  • Mated spherical surfaces on pad and jackbolt allow perfect alignment of nut to crosshead face.
  • Designed for the specific application to fit rod load, gas load and space requirements.
  • Available for specialized applications such as piston end nuts, or designs to fit Cooper GMV compressors and others with air scavenger pistons.
  • Field proven for over 16 years..

Ease of Installation

  • Jackscrew pads are secured with seals to stay in place.
  • Normal multi-screw alternating sequence achieves a uniform torque.
  • Precise control of preloads with standard torque wrenches. Eliminates jacking wrenches, cranes and other inaccurate techniques.

Torque Requirement Comparisons
Rod Hex Nut ExactoTorque™ Jackscrews
Thread size
and pitch		 Torque Required
Ft-lbs		 Torque Required
Ft-lbs		 Number
Required		 Thread size
and pitch
2 - 10 2,200 125 6 7/8 - 14
2½ - 8 4,350 245 6 9/8 - 12
3 - 8 7,600 400 6 1¼ - 12
3½ - 8 12,250 660 6 1½ - 12
4 - 8 18,500 655 8 1½ - 12
5 - 8 36,700 700 12 1½ - 12

 
Compressor Pistons and Rods: Replacement pistons and rods are available in numerous sizes, configurations and materials. Replacement components can generally be categorized as replications or performance enhanced. Replicated components simply clone the original design, thus offering no design upgrade. Performance enhanced components provide redesigned concepts that optimize maintenance ease, service life and safety.
 
One Piece Pistons and
Thru-Bolt Rods
  • Rod and piston removal from cylinder required to service piston
  • Safety and torquing concerns with piston-to-rod spanner nut attachment
  • Limited rider ring radial thickness due to stretch over assembly
Segmental Pistons and
Thru-Bolt Rods
  • Piston segments and trim removable from cylinder without disturbing rod(s)
  • Existing rods reused for cost savings
  • Piston body is permanently attached to rod
  • Segments accurately torqued to piston body with multi-studs
  • Piston end clearances not disturbed
  • Heavy radial thickness rider rings for greater stability
  • Riders can be indexed to new angular running positions
Three-Piece Pistons and
Flanged Multi-stud Rods
  • Complete piston removal from cylinder without disturbing rod
  • Piston accurately torqued to rod flange with multi-studs
  • Piston end clearance not disturbed
  • Heavy radial thickness rider rings for greater stability, installed in open ended grooves
  • Riders can be indexed to new angular running positions
  • Cost effective, individual piston piece replacement if damage or wear occurs
Three-Piece Pistons and
Thru-Bolt Rods
  • Offer the same rider features as flanged multi-stud piston attachment
  • Piston serviceability limited
  • Safety and torquing limitation still a concern

 
Cylinder Liners: ACI Services, Inc. supplies one of the most complete liner inventories available on the market. Some of the basic styles are:
Wet Type Liners
  • A liner style used in valve-in-head cylinders
  • Liner body is made from a sand casting
  • Wet type denotes liner is part of the cylinder water jackets
  • Requires internal oil tubes to distribute lube oil to bore
  • Design is susceptible to water leaks at flange joints
Dry Type Liners
  • A liner used in valve-in-body cylinders, water or air cooled
  • Liner is a sleeve type made from centrifugally cast metal
  • Dry type denote liner is separate from water jackets
  • Available in interference-fit and slip-fit designs
Slip-fit Liners
  • Sleeve type liner installed in the cylinder with a slight clearance fit
  • Applications include relining for wear -- bore diameter change for performance reasons
  • Design allows quick, easy removal/installation of damaged liners
  • Liner clamped in place using front cylinder head bolt
  • Can be installed in existing wet liner bodies, lined and unlined cylinders
  • Initial installation may require preparatory machining to accept liner

 
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Last modified: March 18, 2008
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