What are the most severe consequences of a leak in the inter-stage heat exchanger of a reciprocating compressor?
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One of the four-stage reciprocating compressors in our plant has leaks in both its primary and secondary coolers. Currently, the water in the secondary filler circulation system is entirely gas-filled, with a temperature of around 60 degrees. The flow rate at the primary outlet is 30 kilograms, while it’s 70 kilograms at the secondary outlet. What are the most serious consequences of continuing things this way?
The leakage is excessive; when heat exchange can no longer take place, the next stage of piston rings becomes overheated and deforms, the check valve ceases to function, and the heat exchanger is damaged.
Using combustible gases is unsafe; moreover, it reduces efficiency and increases power consumption
Poor heat exchange efficiency, pressure loss
How can an inter-stage cooler of a reciprocating compressor be connected to the stuffing box? Shouldn’t the cooling water used for filling come from the demineralized water in the tank?
Water cannot be compressed; what consequences do you think that will have? If the subsequent process is liquefaction, then ice blockage will occur
The phenomenon you mentioned is caused by contradictions: 1. Leakage in the inter-stage cooler cannot occur inside the packing; even if there is a leak, it can only occur from high pressure to low pressure systems. As a result, the combustible gas level at the top of the circulation tank will rise above acceptable levels, and in severe cases, there is a risk of flash ignition or explosion. 2. Leakage in the packing cooling water system indicates that either the sealing of the packing cooling system is inadequate or the water cooling system is blocked. In severe cases, this can lead to the packing becoming soft due to high temperatures, resulting in poor sealing and backflow of gases
Both the heat exchanger and the packing are cooled by circulating water
It can cause equipment damage in mild cases, and even lead to an explosion in severe cases; it’s essential to take this seriously! ! !