Engeering Horizon

XPERSEAL – RELIABLE ROD SEALING FOR ZERO GAS LEAKAGE FROM RECIPROCATING COMPRESSORS

XPERSEAL – RELIABLE ROD SEALING FOR ZERO GAS LEAKAGE FROM RECIPROCATING COMPRESSORS

XPERSEAL – RELIABLE ROD SEALING FOR ZERO GAS LEAKAGE FROM RECIPROCATING COMPRESSORS
January 15
14:54 2015

By: Hoerbiger

One-of-a-kind sealing system for reciprocating compressors

We Set Standards.

HOERBIGER designs, manufactures and services pressure packings, piston rings and rider bands for original equipment

manufacturers and compressor operators. We design and test our sealing systems for the most challenging operating conditions. From chemically inert to highly reactive gases, at

temperatures from cryogenic to roasting, from bone-dry to wet, and from vacuum to high pressures – we have it covered. HOERBIGER has developed a new one-of-a kind rod sealing system for reciprocating compressors: XperSEAL.

What’s Behind XperSEAL?

The basic idea behind the XperSEAL is simple. A pressurized volume of oil surrounds the reciprocating rod and is kept in place by specially designed oil seal rings. This oil barrier prevents pressurized process gas from leaking along the rod as long as the oil pressure exceeds the process gas pressure.

The higher dynamic viscosity of oil as compared to gases and the use of elasto-hydrodynamic effects allow optimal rod sealing and packing lubrication, while keeping oil loss to a minimum.

The XperSEAL packing provides absolutely gas-tight sealing thanks to the pressurized oil barrier and specially designed oil rings. The required oil pressure for the packing is supplied

by a hydraulic unit. The power supply and control of the hydraulic unit are provided by the ExBox-S, a central control unit which can be mounted in the hazardous area. It also monitors oil level, temperature, and pressure.

MAKING YOUR COMPRESSOR GREEN, SAFE AND RELIABLE FOR THE FUTURE

Environmental Requirements

With rising environmental awareness and the need to lower

emissions, XperSEAL is an ideal way to:

Meet national and international greenhouse gas emission limits;

  • Eliminate the smell of gas in public areas (e.g. CNG );
  • Prevent emissions of toxic materials, VOCs, etc.

XperSEAL provides a foundation from which to reach

environmental targets:

 

  • Zero gas leakage through pressure packing during

operation;

  • Gas-tight static sealing during compressor standby.

 

Increased Reliability

 

XperSEAL’s smart system design means:

 

  • No more clogged cooling water lines – because XperSEAL needs no cooling water;
  • No contamination of cooling water with the process gas;
  • No unexpected shutdowns due to packing gas leakage;
  • No more issues with clogged, over- or under-lubricated packing;
  • Real-time information on packing status thanks to integrated monitoring.

 

 

 

 

 

 

Workplace Health and Safety

 

Keep the gas where it should be and avoid dangerous

situations. With zero gas leakage during both operation and

standby, XperSEAL can:

 

  • Prevent toxic emissions for a safe workplace;
  • Avoid explosive gas mixtures in the compressor distance

piece;

  • Prevent contamination of crankcase oil and hence any risk of consequential damage;
  • Educe the need for a flare gas compressor.

 

Efficiency Gains

 

XperSEAL can cut operating costs through savings on:

  • Process gas
  • Purge gas
  • Lubricating oil

 

XPERSEAL SYSTEM COMPONENTS

 

XperSEAL packing provides gas-tight sealing by creating an internal barrier of pressurized oil. Specially designed oil rings all but eliminate oil loss.

 

The power supply and control for the hydraulic unit are provided by the ExBox-S, which can be mounted in hazardous areas. The ExBox-S send signals for oil level, temperature and pressure to a DCS or PLC.

 

The hydraulic unit at the heart of the XperSEAL system provides the pressurized oil for the barrier. An integrated cooler keeps the packing at a constant temperature, while smart electronics monitor oil level, temperature, and pressure.

Technical Specifications:

Ex certification: ATEX, UL, intrinsically safe system

Up to six pressure packings

Ambient temperature: –4 °F / –20 °C up to 140 °F / 60 °C

Gas suction pressure: up to 1230 psi / 85 bar

Rod diameter: up to 4 inch / 101.6 mm

Piston speed: up to 19.6 ft/s / 6 m/s

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Engineering Horizons

Engineering Horizons

“Engineering Horizons” is the first & leading technical magazine of Pakistan covering Process, Mechanical, Metallurgical, Mining, Electrical & Electronics field under a single cover. We also feel pleasure in saying that this is the only magazine of its own kind & style, which is widely circulated in all Engineering Sectors of Pakistan.

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