Testing Rod Seal Leakage of a 700 HP Reciprocating Compressor
Methane emissions from reciprocating compressors in the U.S. natural gas industry account for over 72.4 Bcf per year according to a 2006 statement by the United States Environmental Protection Agency. Methane also has a global warming potential 50 times greater than carbon monoxide. Reciprocating compressors are the machinery type with the highest contribution to methane emissions at natural gas transmissions stations. The largest contributing factor comes from the sealing components in the packing components around the piston rod. SwRI, therefore, designed and setup a test loop to perform baseline packing leakage measurements on a four stage 700 HP JGT/4 compressor. The goal was to improve upon current packing leakage models and to compare new seals vs. used seals. The test loop design is described including the limits of operation. The Data Acquisition System (DAQ), including data measurements, is also fully described. The project shows the results of the commissioning process that verified the operation of all the components. Once the loop was commissioned, SwRI performed baseline packing leakage for multiple pressure ratios on each of the four stages of the compressor. The data was collected to develop an analytical model of the packing leakage. Finally, similar testing was performed after replacing the typical rod seal packing with used packing. The used packing leakage was compared to the baseline packing leakage.