Reducing Vent Gas Emissions with New Rod Sealing Solutions for Reciprocating Compressors. Jack Schwaller Hoerbiger Corporation of America

Transcription

1 Reducing Vent Gas Emissions with New Rod Sealing Solutions for Reciprocating Compressors Jack Schwaller Hoerbiger Corporation of America

2 The HOERBIGER Group headquartered in Zug, Switzerland, is a global leader in the fields of compression technology, drive technology, and hydraulic systems. Over 7,000 employees worldwide. Over 1 billion euros sales. Innovated solutions for compressors, industrial engines and turbines.

3 Performance of Rod Packing in a Reciprocating Gas Compressor GHG Regulations Sealing Solutions

4 Here is a cutaway of a typical reciprocating compressor cylinder. We see how the inlet gas enters the cylinder, is compressed and is then discharged downstream. The contained compressed gas will seek atmosphere by migrating down the moving rod that powers the piston. The Rod Packing Assembly will prevent this escape.

5 A close-up of this assembly a series of individual pressure activated seals to reduce cylinder pressure to atmosphere each seal must float to allow the rod and piston to move independently. this will cause a small amount of leakage with each compression stroke.

6 Acceptable leakage of 12 cfh(cubic feet per hour per cyl.) = *1720 cfday(cubic feet per day per compressor.033 tonnesch4 per day <12 tpy(year) *6 cylinder compressor

7 Failed Rod packing might see ten times that leakage..33 tonnesch4 per day <120 tpyear per compressor Potential leak paths: 1. Around the gasket or between gland components 2. Around worn Seals and inner gland faces 3. Or down the worn Rod

8 The EPA recognizes Recips as a major source 2015 Oil and Natural Gas Sector: Emission Standards for New and Modified Sources 40 CFR Part 60 --includesboth(ghg)methaneand VOC gases Calls for Recip compressors to 1. change-out seals every 36 month(26000 hours) or less 2. routine leakage checks 3. annual reporting of change-outs. Carbon offsets required by some states. Voluntary efforts to reduce GHG losses

9 Compliance with Federal or Local Regulations 2015 Many sites will have to upgrade their seals and maintenance practices. This starts with a survey and gap analysis for each affected site. Rod Packing assemblyto achievethe 3 years, requiresqualitysealdesigns Case assembly rebuild and test program evaluated. Evaluate cylinder rebuild and Rod Packing installation procedures. Seal vent leakage measure procedure established Reporting process upgraded.

10 Quality Rod Seal Performance BCD SealRing with an innovative 2015 geometry to improve rod contact reduced loading/frictional heat = achieve the 36 month life very low leakage < 12scfh simple and robust one-ring design easy to install

11 Quality Rod Seal Performance BCDSeal Ring 2015 Hundreds of applications: Natural gas applications wellhead to CNG to 2500PSI Process Refinery, Air Reduction, Refrigeration CO 2 Injection Flash-Gas Compressor

12 Continuous sealing -SBS(Stand-by Seal) Compressor is 2015 shutdown and pressurized will still leak! Minimize the number blow-downs Reduce leakage to near zero (in standby) Reduce gas loss via leaking yard valves special sealing cartridge added to the seal assembly SBS and the XperSEALfor continuous sealing to be available early next year activated hydraulically.

13 Certified replacement or new Seal Assemblies for 36 month replacement 2015cycle reconditioned back to as new condition tested and certified to zero leakage

14 Best practices installation 2015 Proper installation of seal assembly and alignment for minimal rod and piston runout 1. New gasket contacting a renewed inner cylinder surface 2. Proper torqueing of bolts 3. Old snoop/bubble test vs OGI Optical Gas Imaging or Parts per Million detectors.

15 Summary New low leakage seal performance requires new Technologies and methods BCD High performance seals are part of the solution SBS to offer near zero stand-by sealing Certified zero leakage cases Special installation care to pass new field tests for leakage.