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X perSEAL

X perSEAL. Customer Presentation 2013. Content. Introduction of X perSEAL Advantages Idea & concept Working principle (ring details, system design,…) System layout How to install X perSEAL ? X perSEAL in-house test capabilities Customer tests.

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X perSEAL

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  1. XperSEAL Customer Presentation 2013

  2. Content • Introduction of XperSEAL • Advantages • Idea & concept • Working principle (ring details, system design,…) • System layout • How to install XperSEAL? • XperSEAL in-house test capabilities • Customer tests XperSEAL

  3. Reciprocating Compressor – the chronic leakers! • Standard pressure packing causes the main gas leakage amount • Zero packing leakage not achievable with standard ring designs • Emission of greenhouse gases in public focus! • Several regional greenhouse gas initiatives (California, Northern Europe,....) • Gas smell of gas in public areas (CNG) • Increasing gas costs XperSEAL

  4. How to eliminate gas leakages? • XperSEALoffers… • Zero gas leakage • Gas tight static seal • No purge gas required • No water cooling required • No packing lubrication required • Monitored packing can be realized (status of seals) HOERBIGER’s breakthrough technology has a name… XperSEAL

  5. Specially designed “oil seals” pressurized oil poil pgas poil > pgas elasto – hydrodynamiceffects Idea and concept behind XperSEAL • Pressurized oil barrier poil>pgas • Oil barrier that make use of elasto-hydrodynamic effects  system withzero gas leakage Utilizing latest sealing technology & premium HOERBIGER material grades! XperSEAL

  6. pcyl poil >ps p pbuffer System layout / packing case XperSEAL case to fit in every machine! poil-in buffer volume pcyl oil wiper oil recovery Reduced loading on rings! dynamic gas seals poil-out HOERBIGER oil barrier seals XperSEAL

  7. In case of emergency stop • loss of oil pressure • automatic opening of vent line • continue operation (like standard packing) XperSEAL installation ZEP packing Poil out  vent existing packing oil- outlet oil- inlet oil drain vent  poil- out lube  poil- in • existing packing connection lube & vent to be used! • oil drain to be directly connected to crank case feedline poil return line vent oil drain XperSEAL

  8. Features of XperSEAL oil supply system • Plug & Play • Inherently safe system – ATEX certified • Designed for 2 - 4 pressure packings • Constant oil flow rate (~5,5l/min) • Pressure regulated by pressure control valve • Performance monitoring • oil level (oil leakage) • oil temperature • oil pressure • Option: control valve to switch between 2 pressure ranges XperSEAL

  9. XperSEAL system structure XperSEAL

  10. qualification process Test capabilities – XperSEAL (1) R&P tester • oil sealing behavior • generated frictional force (2) MultiPurposeTestCompressor – MPTC • full system tests • oil sealing behavior (3) Customer Test XperSEAL

  11. R&P Tester – friction force, oil leakage • Oil seal ring profile optimization • rod diameter 1 1/8” – 2” (exchangeable) • 360rpm up to 1400rpm • oil supply pressure up to 100bar • fully monitored test run (friction force, oil pressure, oil temperature,…..) Design of ring geometry based upon HOERBIGER calculation tool! XperSEAL

  12. In-house testing - MPTC • Operating conditions of in house compressor - MPTC • rod diameter 1 1/8” • 600rpm up to 1500rpm • various compression ratios (e.g. 30- 70bar) • oil supply pressure up to 120bar • fully controlled cycle XperSEAL

  13. Test results • Several tests were performed on our test compressor • Long term testing of main barrier seal • 1080rpm, oil pressure= 50…100bar, • running hours ~4000h • no critical wear detectable • constant and very low oil leakage (0,05-0,2 l/day) • Full system test showed • oil leakage level in the range of max. 0,2 l/day (rpm, oil pressure, oil temperature) • temperature can be controlled with oil throughput • dynamic gas pressure seals work as expected …reliable test results of XperSEAL system! XperSEAL

  14. Field Results • Customer:Öresundskraft • Location:Sweden, Helsingborg • Process:CNG bus refilling station • ITKK: / • Compressor:Ariel (JGQ/2) • Stages / Cylinders:4 / 2 • Pressures: 13 – 28 – 101 bar • Rod diameter:1.125” (28,58mm) • rpm / Stroke / Speed : 1400 ; 76,2mm ; 3,56m/s • Lubrication: full lube • Packing information: Cook, combined wiper pressure packing • 1xPB, 4x RTB, 1xTT, 1x 3RWS • General information: Bus engines have severe problems with oil contaminated gas. Customer is interested in reducing the overall oil consumption and wants to eliminate vent gas leakage. • Annual gas leakage reports! XperSEAL

  15. Field Results – Öresundskraft, Helsingborg Start ofXperSEAL in Feb. 23rd 2012 • Oil supply pressure – 70 bar • Return line temperature – 58 °C • Oil tank temperature – 46°C Inspection after 1 year of operation • rings are in good condition • system performs very well without any issues! No gas leakage detectable at vent! • cost savings (up to 600l/h measured before installation) No oil loss of XperSeal system detectable! • disconnection of packing lubrication • savings of 750ml oil per day! ~3,2k€ annual savings! • oil barrier sucks cylinder lubrication oil out of process! XperSEAL

  16. Field Results • Customer:NAM (Shell) • Location:Netherland, Den Helder • Process:Offshore gas – CH4 • ITKK: 104053 • Compressor:Howden Thomassen • Stages / Cylinders:2 / 2 • Pressures: 13 – 30 – 62 bar • Rod diameter:60mm • rpm / Stroke / Speed : 510 ; 125mm ; 2,1m/s • Lubrication: full lube (6 drops/min per packing ) • Packing information: Kranz, 1xPB, 5x Bridge Design • General information: Customer is interested to reduce overall oil consumption and to eliminate vent gas leakage. • (CH4 side products!) XperSEAL

  17. Field Results – NAM, Den Helder Start ofXperSEAL in April 2013 • Oil supply pressure – 55 bar • Return line temperature – 58 °C • Oil tank temperature – 46°C No gas leakage detectable at vent! • cost savings • no Benzene emissions (Carcinogen, Mutagen, Toxic) No oil loss of XperSeal system detectable! • disconnection of packing lubrication • savings of 850ml oil per day! ~3,5k€ annual savings! XperSEAL

  18. Field Results • Customer:Khalda Salam Gas Plant • Location:Egypt, Western Desert • Process:Propane (Refrigeration) • ITKK: 346601 • Compressor:Gardner-Denver • Stages / Cylinders:2 / 2 • Pressures: 4 – 10 – 18 bar • Rod diameter:2.25” (57,15mm) • rpm / Stroke / Speed : 750; 127mm ; 3,2m/s • Lubrication: full lube • Packing information: 6xTTRB • General information: Customer is interested to reduce Propane leakage. • Around 26 tonne of Propane losses per year. • Gas & Transportation costs per year ~ 95k€ XperSEAL

  19. Field Results – Khalda, Egypt Start ofXperSEAL in May 2012 • Oil supply pressure – 35 bar • Return line temperature – 84 °C • Oil tank temperature – 61°C No gas leakage detectable at vent! • maintenance people very impressed XperSeal system works as promised • no Propane losses (~95k€ savings per year) • disconnection of packing lubrication • savings of 2100ml oil per day! ~9,2k€ annual savings! XperSEAL

  20. Customer tests 1st XperSEALat Öresundskraft CNG refulling station • running since Feb.2012 without any issues • 2nd NAM / Den Helder, Netherland – running since April • natural gas, Thomassen compressor • 3rd Salam Gas Plant / Egypt – running since April • Gardner Denver, propane service, 2.25” rod diameter • 4th RAG / Haidach, Austria – installed end of June • natural gas, LMF compressor, • XperSeal system already on stock – clarification with TÜV • Repsol / Tarragona, Bilbao, Puertollano Spain - 2013 • two machines already defined for test • Hydrogen / H2S service • GWF Power and PG&E , California – both pending • natural gas XperSEAL

  21. Features of XperSEAL • Zero gas leakage during operation(gas costs) • Zero gas leakage during pressurized stand-still periods(no static seal) • No need of purge gas(cost savings of nitrogen) • No water cooling required • Efficiency improvement • Monitored packing can be realized(status of seals) • No gas smell • No packing lubrication required(overall oil consumption reduced) XperSEAL

  22. Field testing offer • R&D will be fully responsible for • production, installation and support. • R&D will deliver the complete system free of charge! • new cases • all packing internals (pressure seals, main seals, wiper) • assembling, mounting,… • XperSEAL system will be tested in-house before installation. • Full support during the testing period. XperSEAL

  23. Thanks • for • your • attention! XperSEAL

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