# Absolute Energy Saving

Products and services to cut energy consumption for reciprocating compressorsEnergy balance for a typical (1 to 4 MW) reciprocating compressor operating in refinery. 2% - 7% friction losses valve losses leaks from piston rings and packings packing friction losses bypass energy losses

3% - 10% 0,5% - 1% 3% - 10% 12% - 50%



### indicated compression energyenergy used by the compressor 

# How can I save energy?

You can save energy by keeping your compressor in good running order, by using the best available technology for valves, rings and packings, and by choosing effective control strategies. This is easy to say, but how do you quantify these savings and make sure any improvements will be cost-effective?
What if you could benchmark your compressor’s performance against a large population of similar compressors? With HOERBIGER you can do just that. HOERBIGER’s proprietary system carries information from over 50,000 reciprocating compressors covering virtually every compressor type and gas service. Using our specialized tools as RecipCOM, we can audit your compressor’s performance and map it against other similar compressors. The audit may uncover opportunities for improving the maintenance or operation of your equipment. 

### If you operate reciprocating compressors, the chances are you’re sensitive to energy consumption. After all, your energy bill directly influences your production costs. The good news is that for large machines just a small improvement in efficiency - say 3% - means significant savings. As an independent service partner and technology leader for critical components and systems for reciprocating compressors HOERBIGER can bring you these savings and more. 

# Energy: more important than ever

Sources: Charles Bouché, Karl Wintterlin: Kolbenverdichter, Springer Verlag 

# Where can I save energy?

# What savings can I expect? Starting from a detailed compressor energy balance, HOERBIGER experts quantify the costs and benefits of upgrades to valves, rings, packings and compressor controls. The result is higher efficiency, energy savings and lower operating costs.
The potential reduction in power consumption multiplied by the number of running hours per year gives the energy saved per year. Using less energy can save you money in two ways: through lower electricity bills, and by cutting CO 2 emissions that are charged under emissions trading schemes (ETSs) or carbon taxes.
In short the mechanism works as follows: reduced electricity consumption requires less output from power plants. Less fuel is consumed, and less CO 2 emitted. This is good news for compressor operators, who can sell the resulting spare CO 2 emissions permits. 

### Forming the energy balance of a reciprocating compressor gives a comprehensive picture of the losses. HOERBIGER provides solutions for valves, cylinder rings & packing cases and compressor control systems to raise the efficiency of the machine. This leads to energy saving and CO 2 

### tax reduction.

power reduction [kW] x x x

x = =

= working hours [h]

energy price [ €

/kWh ] specific CO 2 emission* [t CO 2 /kWh] CO 2 certificate price [ € /t CO 2 ]

energy saving [kWh] money saving [ € ]

*Specific emission: the quantity of CO 2 emitted from a power plant for each unit of electricity produced. For example, a CHP (combined heat and power) plant with a gas turbine emits about 0.45 t CO 2 /MWh. The worksheet on the next page looks at the compressor energy balance in more detail

# General information Compressor operating hours per year: Electricity cost (typically 100 € /MWh) CO 2 specific emission (typically 0,45 t CO 2 /MWh for a CHP plant) CO 2 cost (~15 € /t for 2010 in the EU) 

# Compressor Valve: What type of valves are used?

How clean is the compressed gas?


# Main packing cases: How many packing cases are installed on the compressor? How many tangential radial rings pairs are in each packing case? What is the final discharge pressure?


# Control: What kind of control is used? range of control [0-100%] average load [0-100 %] 

# Energy saving form

Fill in the boxes to see how much energy you might save by updating your reciprocating compressor to the latest performance standards.

h € /MWh t CO 2 /MWh € /t CO 2

clean dirty

bypass plate valves ring valves profiled plate valves

on/off step control reverse flow clearance pockets

HOERBIGER Compression Technology is a business unit of HOERBIGER Holding AG, Zug / Switzerland. HOERBIGER is active throughout the world as a leading player in the fields of compression technology, automation technology and drive technology. In 2010, its 7,600 employees achieved sales of 950 million Euro. The focal points of its business activities include key components and services for compressors, gas engines and turbomachines, hydraulic systems and piezo technology for vehicles and machine tools, as well as components and systems for shift and clutch operations in vehicle drive trains of all kinds. Through innovations in attractive technological niche markets, the HOERBIGER Group sets standards and delivers cutting-edge solutions for the benefit of its customers.

This product brochure contains product specifications based on research and development on the one hand and on manufacturing on the other. Dependent on place of installation, operating conditions and specifications, several parameters of the described product may change. Thus, HOERBIGER assumes no liability or w arranty for the accuracy and completeness of the information covered in this brochure. 

### www.hoerbiger.com1803292 - Issue 09 2011

# Rings and packings: friction down 40% with HOERBIGER BCD
Compressor piston rings and packing rings contribute to energy losses through friction and leakage. On average, each set of standard tangential/radial packing rings accounts for losses of about 5 kW. Improved ring design can cut losses significantly. The HOERBIGER BCD (Balanced Cup Design) is a robust single-ring design with a pressure balancing groove that reduces leakage by 70% compared to a standard packing and friction losses by 40%. And not only do BCD rings save energy, they also last longer than conventional rings. 

# Valves: CP profiled plates cut losses by 40%
Energy losses from traditional flat-plate valves are typically in the range 3–10% of total compressor energy use. With their unique profiled rings and plates, HOERBIGER CM and CP valves provide larger flow areas for the same valve diameter. That means valve losses 40% lower than for standard valves. Compressors operating in challenging processes often face polymerisation or coking that can clog valves and seriously reduce efficiency. HOERBIGER’s professional valve repair services can restore original performance. 

# Control: HydroCOM avoids wasteful bypass
Capacity in reciprocating compressors is usually adjusted through a combination of step control (via suction valve unloaders and/or clearance pockets) and bypass control. Bypassing, which recirculates compressed gas, is particularly wasteful. HydroCOM is an efficient, stepless, fully automated control system that uses the principle of reverse flow to avoid compressing more gas than is actually needed. As a result, HydroCOM reduces energy consumption by 12-50% compared to step control systems. As well as greatly reducing costs for energy and CO 2 

# emissions, HydroCOM brings indirect financial savings through easier compressor operation.

A P

B C 0 50 100

0 0 1 2 3 4 5

10 20 30 40 50 60 70 6 7

50 100Indicated power %Indicated power %Friction losses [kW]



## Supply pressure [bar] Capacity % Equivalent energy savings BCD ring

Reverse-flow control (HydroCOM) Ideal control system Step-control 

# C r 

# D r 

# D 

# Absolute Energy Saving

Conventional tangential/radial ring

Energy savings