Design, calculation & reverse engineering

Calculation of reciprocating compressors

• Thermodynamic and flow design of single- and multi-stage reciprocating compressors
• Pressures up to 500 bar
• All technical gases, including mixtures of up to 40 components
• Adaptation of existing compressors to new process conditions (gas, pressure, flow, speed)
• Material selection based on gas, pressure and temperature – including aggressive and corrosive gases such as sour gas containing H₂S

The software

Our design software is an in-house development by specialists in reciprocating compressor design. When designing a valve, we simulate its operation in the cylinder of the specific compressor.

The mathematical model describes the valve as a single-mass oscillator moving under gas forces and spring forces. It is based on the gas equations of state, the thermodynamics of systems with variable gas mass, unsteady gas flow and the dynamics of the sealing elements (valve plates).

The model allows us to:

• calculate the optimum gas-dynamic characteristics depending on the geometry of the flow passages and the lift of the valve plates,
• describe the motion of the valve plates based on the real spring stiffness, the mass of the moving parts and the crankshaft speed,
• determine pressure and power losses depending on the type of gas, the pressure ratio in the cylinder and the piston speed.

Own valve development – from operating point to finished valve

We develop compressor valves ourselves. The starting point is always the specific application: gas composition, pressures, temperatures, speed and capacity of your compressor. From this we use our own software to calculate the key parameters:

• Flow velocity and speed of sound in the valve
• Flow area and valve lift
• Spring forces and opening behaviour of the valve plates
• Pressure losses and efficiency

On this basis we design the valve, select the materials for plates, springs, seat and guard and prepare the manufacturing drawing. The result is a valve designed for your operating point, not just for the installation dimensions.

This applies to air as well as to demanding process gases, such as hydrogen-rich mixtures, where the low gas density calls for particularly precise matching of springs and lift.

• Redesign and optimisation: we improve existing valves in terms of efficiency, service life and ease of maintenance – e.g. by switching to PEEK valve plates where temperature and differential pressure allow.
• Costing and delivery: from a non-binding quotation to the ready-to-install valve, manufactured to our specifications.

Reverse engineering & custom parts

Your part is obsolete, the drawing is missing, the manufacturer no longer exists? We measure the sample, reconstruct the geometry, select the material and manufacture the part – technically improved on request.

1. Enquiry: sample, photos, dimensions, drawing or nameplate
2. Analysis & calculation: geometry, material, operating point
3. Design: manufacturing drawing to our own design or to your template
4. Manufacturing & delivery: single part, repair kit or ready-to-install assembly – with documentation in German, English or Russian

Matching reciprocating compressors of many manufacturers

We supply valves and spare parts to fit reciprocating compressors and valves from manufacturers including HOERBIGER, Ibach, Cozzani, Ariel, Atlas Copco and Borsig. They are based on samples, dimensions, drawings and your operating data.

We do not supply original parts. Mangione Consulting is not an authorised partner or service provider of the manufacturers named. The trademarks belong to their respective owners and are used solely to indicate what our parts are intended for.