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
Engine and Compressor
 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
Compressor Cylinder Cut Away
Standard Packing Case
Pressure Activates Packing
 Impediments to Proper Sealing
Ways packing case can leak What makes packing leak?
 Nose gasket (no crush)  Dirt or foreign matter (trash)
 Packing to rod (surface  Worn rod (.0015”/per inch dia.)
finish)  Insufficient/too much lubrication
 Packing to cup (lapped  Packing cup out of tolerance
surface) (+.002”/-.000”)
 Packing to packing  Improper break-in on startup
(dirt/lube)  Liquids (dilutes oil)
 Cup to cup (out of
 Incorrect packing installed
tolerance)
(backward or wrong type/style)
Typical Packing Leak Paths
 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
 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
 NNG Unit A/B Leakage Rates
350

300

250

200
Unit A
150 Unit B

100

50

0
1997 1998 1999 2000 2001 2002 2003 2004 2005 LEP
 NNG Packing Leakage
Economic Replacement Point
 Approximate packing replacement cost is
$3000 per compressor rod (parts/labor)
 Assuming gas at $5/MCF: 1CFM=28.316L
– 50 liters per min/28.316=1.766 scfm
– 1.766 x 1440min/day=2543 scf per day
– 2543/1000=2.543 MCF
– 2.543 x 365 days= 928MCF per year
– 928 x $5MCF=$4640 per year leakage
 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.
LEP Packing Configuration
Orientation in Cup
 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?
 What’s 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.
Reduce Fugitive Emissions
 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.
Questions?

Thank you!