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Intermediate Packing
Contents
Main Pressure Packing Intermediate Packing
Basic Understanding Ring Theory Housing Theory Leakage Control Cooling Systems for Packings Typical Packing Types Associated Products - Piston Rods
Basic Understanding
Crosshead
Crankcase
Intermediate Packing
Intermediate Packings seal the first distance piece to the second distance piece in the area of the piston rod. Usually they are not lubricated and not water cooled.
Flange Ring sets
Piston rod
radial clearance
axial
piston rod
lateral
piston rod
The rings segments are held together by garter springs until the gas pressure is such that they are forced on to the rod to create the seal. Sealing rings are pegged together so that the gaps between the ring segments of one ring are covered by the ring segments of the other to reduce leakage. Rings can float axially and radially in the grooves of the cups to compensate for rod movement.
Axial and radial clearance allow the rings to float in the housing , thus leakage is prevented by always maintaining a positive seal.
If lip seals were used they would not conform to the rod as it would not compensate for the rod movement. For this reason segmental rings are used.
Gaps of one ring are covered by the face of the other ring. Rings are positioned by a pin
End clearance between ring segments allows worn rings to compensate for wear automatically. Tangential cut rings act like a camera lens.
Gaps of one ring are covered by the face of the other ring. Rings are positioned by a pin
discharge pressure
Piston rod
The last sealing ring group is responsible for the leakage to the outside.
Rule of the thumb for packings: Each recess of a new packing will reduce the pressure by half. If one ring pair is worn, the pressure has to be reduced by the remaining ring pairs. The pressure profile will differ then from the pictured profile.
Design Criteria
Differential pressure Temperature Speed of the rod Gas type and gas condition Lube Rod material Rod surface Customers demand Expected life time Costs
- Number of ringsets, with or without cooling - Cooling, ring material - Cooling , ring material - Vent, ring type,ring material - ring material, number of lube points - ring material - ring material - materials and design - material, design - design and material
4 sets
5 sets
6 sets
7 sets
5 sets
6 sets
7 sets
8 sets
All packings above 70 bar whether vented or unvented must be cooled and should be lubricated.
4 sets
5 sets
6 sets
7 sets
8 sets
9 sets
5 sets
6 sets
7 sets
8 sets
9 sets
10 sets
1 lube point
2 lube points
Plates Plates
Crank end
Cylinder end
etc.
etc.
O-Rings O-Rings
Soft Soft metal metal gasket gasket (joint) (joint) to to seal seal on on stuffing stuffing box box
Contents
Function Single Acting Ring Groups Double Acting Ring Groups Side Loaded Ring Groups Special Rings Pressure Breakers Clearance figures
Tangent cut ring gaps are sealed by radial cut ring Axial movement of piston rod
tangential ring
Crank end
Side clearance in the cups and radial cut ring gaps avoid gas traps. They allow the gas inside the cups to return to the cylinder.
Cylinder end
Crank end
Pressure
gap
gap
Rings located relative to each by a peg in tangential cut ring mating hole in radial cut ring. By this gaps of tangential cut rings are covered by radial cut ring. Seals only, when the crank end of the cylinder is compressing gas Standard ring set for low to medium pressures
Task: Application:
Pressure
Radial cut ring combined with 6 piece design, instead of 3-piece design tangential cut ring. Tangential cut is continued across the segment creating Bridge Pieces for brittle ring materials , for pressures above 150 bar with metal Bridge Pieces
Pressure
Description:
Single acting standard ring pair with backup ring. Backup ring is bored to have 0.1 to 0.2 mm clearance on the piston rod and hence no gaps when fitted. Standard ring group for pressures above 21 bar
Application:
Cylinder end
On reverse stroke gas is sealed in the same manner as described for the crank stroke. Axial movement of piston rod
Cylinder end
Crank end
Pressure
Description:
2 tangential cut rings pegged together in such a way that the segments of one ring mask the end gaps of the other ring. Seal in both strokes of the compression cycle. Low pressures or vacuum, Intermediate Packing, pulsation seal in Wiper Packings, final or vent seal in Main Pressure Packings.
Task: Application:
Pressure
Description: Application:
Double acting ring set with backup ring Standard set for pressures of less than 12 bar and higher temperatures
Pressure
Description:
Double acting ring pair consisting of two 4-segment radial cut rings pegged together, so that the segments of one ring masks the end gaps of the other. Where brittle materials must be used, e.g. carbon sturdy parts, frequently used with brittle materials no wear limit, difficult to install
Pressure
Pressure
Radial cut ring with Tangential cut chamfered boss ring with peg
always maintains a seal between tangential cut and container sealing face due to the inclined nature of the faces of the 2 radial cut rings and garter spring load. Main Packings at low pressure side near vent and purge, also in Intermediate (Partition) Packings and Oil Tight Packings.
Application:
Pressure
Pressure
Single acting tangential cut ring without wear restriction Description: Application: Disadvantage:
No direct leakage path beween the segments, needs no further ring for proper sealing. Where small containers must be installed. No wear restriction; possibility of damage to inboard feather edges if rod is inserted into assembled packing.
Pressure
Pressure
Single acting ring with relief slots in the middle of segments and chamfers on joint
Reduce pressure and throttle gas pressure pulsations but not to seal. Pressures greater then 20 bar, used on their own filling a recess, or with backup ring when non metallics (PTFE).
Recess dia
Containers
Other Parts
Tie rods - O-rings - Static Sealing
Flanges
Containers (cups) Spigotted Flange HRP Standard Containers (cups) Recessed Flange cannot be lapped
T-Container (cup)
L-Container (cup)
Plate
Containers
for purge
vented plain
Plate :
Contains the holes for vent. Masks the milled cooling water grooves. Compensates the thickness reduction of containers after reconditioning (by installing a thicker plate). Dimensions: Dimensions of flanges, containers, plates are according to HRP standard TDSM 182
or
Spigot dia. as Container (cup) outer diameter Recess dia = Stuffing box nom. bore +0 to 0.15 mm As recesses cannot be lapped effectively, recessed type flanges should be avoided.
SEALING FACES on Containers, Flanges and Plates Surface finish and Flatness : low pressure: < 70 bar uncooled Packings
0.4 &
0.002
Materials
Standard :
Specials :
As required by customers
Tie rod
The joint forms the only static seal as part of the main pressure packing, which seals against the bottom of the stuffing box in the compressor. It is important that the static seal is flat and parallel. It is also important that there is a good surface at the bottom of the stuffing box with no contamination. This is as important a seal as any of the sealing rings.
the discharge pressure of the compressor, the size of the piston rod the molecular weight of the gas any lubrication.
Secondary factors include surface finish of the rod and the containers, gas contamination and machine misalignments.
if operated at very low pressures, if running at partial or off-load, if (new) packings have not bedded in.
Nitrogen IN
Cylinder side
Nitrogen
Nitrogen
Dangerous gas
Oil drain
Vent and Purge System, Pressures, Leakage flows to API 618 Vent Pressure
- up to1.5 barg maximum to API 618, Appendix 1 depends on both the leakage flow escaping past the packing rings and the back pressure and flow restriction from vent / flare line system. If the vent line back pressure and restriction remains constant, then an increasing vent line pressure indicates increasing packaging leakage.
Modular construction, up to 4 cylinders per cabinet Satisfies emissions legislation to API618 & NACE Optional flow controlled purge for valve unloaders, intermediate & wiper packings
G1
Vent flow F1 V5
NITROGEN SUPPLY
max. 16 bar typ. 10 bar
V1 Shut Off Regulator Gauge F1: Flowmeter (metallic type) Flow range 10 30 l/min F2: Flowmeter (rotameter) Flow range 0 10 l/min
For lower pressures water cooling is necessary only under special conditions.
water inlet
water outlet
Better coolant flow with reduced losses Meets API 618 revision 4 by eliminating O rings which surround the piston rod Easier to change packing rings without removing the piston rod Cooling passages can be cleaned by removal of plugs
Main Characteristics Typical Pressure Packing Types HRP Stationary Gas Seal Features of HRP Pressure Packings Testing of Pressure Packings
Characteristics
The main characteristics of Pressure Packings are:
lube or non-lube with or without cooling with or without vent with vent and with or without purge
discharge pressure differential temperature. piston speed customer specification process requirements
Non lube, uncooled, not vented, not purged, for discharge pressures less than 10 bar
Cylinder end
Crank end
Non lube, uncooled, not vented, not purged, for discharge pressures less than 30 bar
Pressure Breaker Ring Single acting ring groups
Cylinder end
1302
0310
0304
0306
0310
Crank end
Lube, Lube uncooled, not vented, not purged, for discharge pressure from 30 bar to 70 bar
Pressure Breaker Ring Single acting ring groups
oil
from cylinder lube pump
Cylinder end
1302
0310
0304
0306
0310
Crank end
Cylinder end
O-rings are used to prevent the process gas from entering the water channels and to also prevent water from leaving the water channels
Crank end
Cylinder end
gas
The mixture of dangerous gas and purge gas is piped to the vent collection
HRP Design
Segmental Packing Rings only seal during dynamic reciprocating action. Stationary Gas Seal energises when the compressor is stopped
Pneumatically operated externally, when the rod is stationary to prevent cylinder gas emission
Cylinder end
STATIC
ROD CONTACT
Piston energised
HRP Design
Cartridge unit fitted to existing Packing increasing length
Segmental packing rings only seal during dynamic reciprocating action. For standstill additional parts are necessary
Distance piece
Cylinder end
Application Features
Face & outside dia connections make flange more serviceable. Thermocouple to detect increases in temperature
Detachable flange to aid assembly Vent connection can be fitted with an off-line flow measurement device TYPICAL WATER COOLED PRESSURE PACKING
Design Features
`O'-Ring design can be captive, totally eliminating possibility of gas leakage into water channels Fully lapped faces with O-Rings eliminate static leakage
Spiral wound Gasket, optional, to reduce static leakage Milled groove Coolant Channels to reduce pressure drop to a minimum Tee shaped Cup complete with`SLP' Rings & purge (API618) allows for sealing faces to be machine-lapped TYPICAL WATER COOLED PRESSURE PACKING
Pressurised air (6 bar) is connected to cooling water inlet. Air inlet valve will be closed. Pressure drop is checked at the closed volume
Piston Rods
Piston Rods
Surface Finish
higher value of Ra preferred - hardened rods
- coated rods
Coating
for reducing rod wear and/or reconditioning
- Chromium oxide - Ceramics (Metco P130), produced with plasma gun method (HVOF) - Tungsten Carbide produced with plasma gun (HVOF) or Detonation Gun method
Materials
Lube air compressor Process gas compr. Coated rods - unhardened 30 HRC, cut threads - Induction hardened (occasionally nitrided) 50 to 55 HRC, rolled threads - Thermal plasma sprayed, mostly to 65 - 70 HRC
End
of the Training File
Pressure Packings