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compressor packings
Reciprocating compressors continue to play a vital role in both refineries
and gas transport operations. A revolutionary new technology that replaces
R
eciprocating compressors are an essential
part of the hydrocarbon supply chain. Their
ruggedness, flexibility, and ability to be
driven directly from engines running on natural
gas makes them valuable in gas production, gas
re-injection, and pipeline transport. In refineries,
recips high energy efficiency and ability to gener-
ate pressures of 3,000 psi and above are key to
the safe and economic handling hydrogen and
hydrogen-rich gas mixtures.
In the wider process industries recips are
appreciated just as highly: the last ACHEMA, for
instance, featured no fewer that 17 companies
exhibiting under the heading piston Figure 1 Conventional rod packings made from solid
compressors. materials will always show some degree of gas leakage
Compared to turbocompressors, recips are
inherently long-lived thanks to their robust ings. The new XperSEAL rod sealing system uses
construction and low operating speeds (typically pressurised oil to keep the gas in place, ensuring
a few hundred RPM). Fitted with the latest genuinely leak-free sealing for the lifetime of the
valves, sealing components, and capacity control compressor. This radically new sealing system is
systems, properly maintained recips boast effi- fail-safe, can be retrofitted easily to existing
ciencies that will surprise anyone who thinks of compressors, and uses no more oil than a
them as old technology. conventional lubricated packing.
With todays emphasis on minimising emis- The new sealing system has been tested
sions to atmosphere, however, there is one aspect successfully at three plants handling natural gas.
of recips that operators must consider seriously: In each case, XperSEAL was able to eliminate gas
the need for piston rod seals (Figure 1). Thanks leakage. The amount of oil used was no higher
to modern materials and computer-aided design than that required for conventional rod packings.
techniques, high-performance rod packings such
as HOERBIGERs BCD can achieve practically Conventional packings eventually leak
zero gas leakage when they are new. Over time, High-performance conventional rod seals are
however, wear is inevitable and with wear made from materials such as filled PTFE, graph-
comes leakage that can have significant financial ite, bronze, and elastomers. These work very
and environmental consequences. well, but their more-or-less rigid components can
Thanks to recent developments at never conform perfectly to the surface of the
HOERBIGER, it is now possible for the first time piston rod, while sliding contact means that some
to completely eliminate gas leaks from rod pack- wear is inevitable over time. The result is gas
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Figure 5 Normal operation (top) and failsafe mode (above). In failsafe mode category: Rotating Equipment
the system operates as a conventional vented packing, with purge if required