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Reciprocating Compressor Seals Partner Savings From Compressor Rod Packing

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Reciprocating Compressor Seals Partner Savings From Compressor Rod Packing Presented to 2005 EPA Star Conference - Midland June 8, 2005 Jim Rauh, Compressor Engineering – PowerPoint PPT presentation

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Title: Reciprocating Compressor Seals Partner Savings From Compressor Rod Packing


1
Reciprocating Compressor Seals Partner Savings
From Compressor Rod Packing
  • Presented to
  • 2005 EPA Star Conference - Midland
  • June 8, 2005
  • Jim Rauh, Compressor Engineering
  • Rick Loveless, Northern Natural Gas

2
Engine and Compressor
3
Discussion Points
  • Standard packing cases
  • How packing works
  • Impediments to proper sealing
  • Packing case leaks
  • Northern Natural case histories
  • Low Emission Packing (LEP)
  • Summary/Q and A

4
Compressor Cylinder Cut Away
5
Standard Packing Case
6
Pressure Activates Packing
7
Impediments to Proper Sealing
  • Ways packing case can leak
  • Nose gasket (no crush)
  • Packing to rod (surface finish)
  • Packing to cup (lapped surface)
  • Packing to packing (dirt/lube)
  • Cup to cup (out of tolerance)
  • What makes packing leak?
  • Dirt or foreign matter (trash)
  • Worn rod (.0015/per inch dia.)
  • Insufficient/too much lubrication
  • Packing cup out of tolerance (.002/-.000)
  • Improper break-in on startup
  • Liquids (dilutes oil)
  • Incorrect packing installed (backward or wrong
    type/style)

8
Typical Packing Leak Paths
9
Leakage Rates
  • Packing is designed to restrict leakage
  • Fugitive natural gas emissions result in
    significant loss of revenue/greenhouse gas
  • Average rod leak rate is .98 to 1.86 scfm (28-53
    liters/minute) based on Pipeline Research
    Committee findings

10
Northern Natural/CECO Historical Data on Units A/B
  • Monitored emission units are methane leakage in
    liters/minute for two locations
  • Testing is still in progress, current 3 months
    leak rate shows zero leakage
  • Unit A leakage as high as 301 liters/min
  • Unit B leakage as high as 105 liters/min

11
NNG Unit A/B Leakage Rates
12
NNG Packing Leakage Economic Replacement Point
  • Approximate packing replacement cost is 3000 per
    compressor rod (parts/labor)
  • Assuming gas at 5/MCF 1CFM28.316L
  • 50 liters per min/28.3161.766 scfm
  • 1.766 x 1440min/day2543 scf per day
  • 2543/10002.543 MCF
  • 2.543 x 365 days 928MCF per year
  • 928 x 5MCF4640 per year leakage

13
Here Is the Solution
  • Low emission packing (LEP) overcomes low pressure
    to prevent leakage.
  • The side load eliminates clearance and maintains
    positive seal on cup face.
  • LEP is a static seal, not a dynamic seal. No
    pressure is required to activate the packing.
  • This design works in existing packing case with
    limited to no modifications required.

14
LEP Packing Configuration
15
Orientation in Cup
16
Reasons to Use LEP
  • Upgrade is very inexpensive.
  • Significant cost savings and reduction of
    greenhouse gas are major benefit.
  • Refining, petrochemical and air separation plants
    have used this design for many years to minimize
    fugitive emissions.
  • Should the natural gas industry follow suit?

17
Whats in Your Packing Case?
  • Consult with operations to verify your current
    packing case configuration.
  • What are the current leak rates?
  • Typical LEP conversion is around 125 and with
    gas at 6 MSCF, packing case leakage should be
    identified and fixed.
  • Monitoring emissions reduces greenhouse gas
    release.

18
Reduce Fugitive Emissions
19
Summary
  • Packing is a dynamic seal designed to restrict
    leakage.
  • Verify your current leakage rate.
  • Low Emission Packing (LEP) is an inexpensive
    conversion to reduce fugitive emissions.

20
Questions?
  • Thank you!
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