Hyper compressors are designed for LDPE production, compressing ethylene up to 3500bar with only two stages of compression, in order to reach conditions for the polymerization. The high operating and fluctuating pressure strongly impact design and life of all cylinder components.
The packing cups are among the most stressed components of a hyper compressor cylinder. They are particularly subjected to very high pulsating pressures, thus fatigue and wear. Therefore, they are periodically replaced during maintenance and are critical for availability of the hyper compressor.
A typical hyper compressor packing assembly contains 5 to 6 disc shaped packing cups that contain the plunger sealing rings at the internal diameter. The packing cups are provided with lube oil ducts to lubricate the sealing elements. Typically these ducts extend axially through the assembly to the injection points. For that purpose each packing cup could have a different number of lube oil passages. Moreover, at the external diameter are located passages for packing cooling oil. For these reasons each of the packing cups is a unique part with different machining features.
In order to optimize the availability of spare parts and standardize the product, a new design of hyper compressor packing cups has been evaluated, called further “all-purpose packing cup”. The idea was to make the packing cups all equal to each other, and potentially to reduce manufacturing and warehousing costs.
This idea has been realized by introducing in a single all-purpose cup, multiple sectors angularly offset with each other. Each sector contains the oil ducts required for a given cup position in the assembly. By rotating the cup about the plunger axis by e.g. 90° or 180° the desired sector can be activated (put in fluid communication with adjacent lube oil ducts). In this way the “all-purpose packing cup” can be mounted in each of the 5 to 6 different positions in the packing assembly.
The all-purpose cup design has been analyzed by a well validated FEA approach on the high cycle fatigue and flaw propagation safety margins. The analysis was performed considering all multiple possible load combinations where, depending on the assembly configuration, different active lube oil holes (holes that deliver oil to the plunger) were pressurized while all remaining ducts were left unpressurized.