Appendix K.

Distance Piece/Packer Venting For H2S

Contents Page

K1.0 Introduction K-2

K2.0 Section I: Vent/Purge System Designs K-3
K3.0 Section II: Basic Considerations K-7

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Appendix K Compressor Manual

K1.0 Introduction
Environmental protection and maintaining safety require close attention to contain-
ment of gas contaminated with hydrogen sulfide. Reciprocating compressors will
always have some gas leakage from the cylinders. The leakage occurs along the
piston rod and through the rod packer. This appendix outlines requirements for
preventing the escape of toxic, corrosive gas into the atmosphere or the compressor
crankcase. Leakage into the crankcase not only will result in atmospheric contami-
nation but, also, can result in crankcase explosions. The principles described herein
may also be applied to other compression services where controlled disposition of
leakage is required.

K1.1 Summary
Six designs for preventing the escape of gas from a compressor cylinder packer into
the atmosphere are discussed in Section I.
Designs 1 and 2 are conventional, non-purged arrangements which provide limited
protection. Designs 3 and 4 use purge gas to block the entry of gas into the distance
piece. Using a purge will prevent any leakage of H2S containing gas into the atmo-
sphere except when poor compressor rod or packer condition results in excessive
packer leakage. Designs 5 and 6, using expensive and space consuming double-
compartment distance pieces, will provide some additional protection in the event
of excessive packer leakage. However, the probability of needing this extra protec-
tion is low.
All designs require venting to a gas disposal system operating at a pressure less
than 10 psig and preferably, near atmospheric pressure.
Basic considerations and mechanical design features are discussed in Section II. It
must be emphasized that packer and wiper designs discussed in the following
require careful consideration of pressures to be encountered and of other applica-
tion details. Design must be a coordinated effort between the user, the compressor
manufacturer, and the packing manufacturer.

K1.2 Recommended Designs

Designs 3 or 4 are recommended where operation free from H2S odor is required or
where highly toxic H2S concentrations (500 PPM and over) of gas are being
compressed. Designs 1 or 2 are recommended for isolated compressors which are
handling lower H2S concentration gas. Shelters for such compressors should have
at least three open sides. Designs 5 or 6 are not recommended unless there is an
absolute need to prevent H2S gas escape even if an unlikely combination of poor
mechanical condition and system malfunction occurs.

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Compressor Manual Appendix K

K2.0 Section I: Vent/Purge System Designs

K2.1 Selection Tables

Figure K-1 lists factors which must be considered in the selection of a vent/purge
system. Figure K-2 lists the mechanical and system design details for specific
designs. The columns for each figure are headed by a system design number
ranging from one to six. The degree of protection provided, cost, and complexity
increase from a minimum for Design number 1 to a maximum for Design number 6.
Referring to Figure K-1, the governing factor for selecting a design is the permis-
sible concentration of H2S in the surrounding atmosphere. This allowable environ-
mental contamination depends upon the other factors listed in Figure K-1.

Fig. K-1 Guide to the Selection of Packer & Distance Piece Venting Systems for H2S Service (1 of 2)
Design No.
1 2 3 4 5 6
Governing Selection Factor
Allowable Atmospheric Contamination
(a) Continuous, Non-Toxic (odor ok) x
(b) None During Normal Operating x
(c) None, With Exceptions(1) x x
(d) None(2) x

Secondary Selection Factors

A. H2S Concentration In Gas
(a) Mildly Toxic, 100 PPM x x
(b) Toxic, 100-500 PPM x x
(c) Highly Toxic, 500 PPM (3) (3) x

B. Compressor Housing
(a) Open - 3 Side Minimum x x x x x x
(b) Closed (3) (3) x x

C. Environment
(a) Unpopulated Areas x
(b) In-Plant, Populated Areas x x x x x

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Appendix K Compressor Manual

Fig. K-1 Guide to the Selection of Packer & Distance Piece Venting Systems for H2S Service (2 of 2)
Design No.
1 2 3 4 5 6
Relative Ranking (A=Preferred, B=Acceptable, C=Undesirable)
D. Other Considerations
(a) Operator Safety C B A- A- A A
(b) Minimum Crankcase Contamination A B+ B+ B+ A- A
(c) Installed Cost A A- B B- C C
(d) Maintenance Effort A A- B B C C
(e) Equipment Space Required A A A A B B
(f) Purge Gas Use Rate - B- B C C C-
(g) Adaptability to Existing Compressors A B B B C C
(1) Some H2S escape permitted for short periods in the event of unforeseeable failures
(2) Least H2S escape possible under any circumstance
(3) Design not recommended unless safety devices recommended in Figure K-2 are used

Fig. K-2 Design Details, Packer & Distance Piece Venting Systems for H2S Service (1 of 2)
Design No.
1 2 3 4 5 6
(1) (1) (1) (2)
IB OB IB OB(1)
Distance Piece
No. of Compartments 1 1 1 1 2 2
Solid Access Covers R x x x x x x x
Cover Gaskets x x x x x x
Vent to Disposal System x x x
Vent to Atmosphere x x
Nitrogen Purge x x x

Rod Packer
Vent to Disposal System x x x x x x
Nitrogen Purge x x x
(2) (2)
Sweet Gas Purge
Preloaded Outer Rings R x x

Rod Wiper
Oil Control Rings x x x x x x
Preloaded Seal Rings x x x x
Code: x=required; R=recommended option. Superscripted numbers refer to footnotes.

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Compressor Manual Appendix K

Fig. K-2 Design Details, Packer & Distance Piece Venting Systems for H2S Service (2 of 2)
Design No.
1 2 3 4 5 6
(1) (1) (1) (2)
IB OB IB OB(1)

Nitrogen Purge (3)

Rod-Diaphragm Packer x x

Safety Devices
Dist. Piece Safety Valve (4) x (4) x x (4)

Dist. Piece Hi Press Alarm (5) R (5) x (5)

Packer Hi Temp. Alarm R R R R R R

Purge Gas Failure Alarm(6) R R R R

Indicators
Purge Gas Flow Rate R R R R R
Distance Piece Pressure (5) R (5) (5)

Code: x=required; R=recommended option. Superscripted numbers refer to footnotes.

(1) IB=inboard (compressor side) compartment; OB=outboard (cylinder side) compartment
(2) May be used if non-toxic and non-corrosive
(3) Recommended if normal distance piece venting pressure is over two psig or if frequent vent system pressure surges can cause back-
flow of hazardous gases into distance piece.
(4) Required if vent disposal system pressure can exceed distance piece maximum allowable internal pressure
(5) Recommended if PSV required per Note 4
(6) Can be actuated by purge gas supply low pressure or by low differential pressure between purge gas and vent gas system

The appendices in API 618 include figures that show the locations of vents and
purges for the designs discussed below.

K2.2 Design 1: Conventional for “Sweet Gas” Service

Design 1 is normally used for general service, sweet gas compressors. It can be
used in H2S services for unhoused compressors in a remote area where H2S odor
can be tolerated. However, if the concentration of H2S in the compressor gas is
highly toxic (500 PPM) or if the compressor is located in a fully enclosed room, the
possibility of injury to operating personnel is too great to allow the use of this
design. A poorly maintained packer or a sudden packer failure could release enough
H2S to pose a significant risk to personnel.

K2.3 Design 2: Purged Packer

Design 2 injects purge gas into the packer to block the escape of compression gas
into the distance piece. No compression gas will escape where the packer and rod

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Appendix K Compressor Manual

are in good condition, providing the purge gas pressure is always greater than the
packer vent system pressure. However, poor mechanical condition will probably
result in gas blowing through the distance piece and into the atmosphere. Failure of
the purge gas system will have the same result. Therefore, Design 2 should not be
used for compressors handling highly toxic concentrations of H2S, particularly if
the compressor is housed. It should not be used for any H2S service when odor
from escaping gas is highly objectionable.

K2.4 Design 3: Purged Packer, Pressure-Tight Distance Piece

Optional Purged Assembly
Design 3 provides additional protection over Design 2 by gasketing the distance
piece side covers and adding pressure seal rings to the crankcase wall rod wiper
assembly. The distance piece must be vented to a gas disposal system. This design
will prevent gas escape except when poor mechanical condition allows excessive
leakage through the packer and pressure seal rings in the wiper.
Wiper purging may be included in Design 3 where needed to more positively
prevent undesirable gas leakage into the crankcase. Such purging may be needed
where distance piece vent system pressure is normally above two psi or where pres-
sure surges in the vent system could cause frequent backflow of undesirable gases
from the plant vent system into the distance piece.

K2.5 Design 4: Purged Distance Piece

Design 4 is approximately equivalent to Design 3 in that it uses purge gas to block
the escape of packer leakage into the distance piece. However, the purge gas is intro-
duced into the distance piece rather than into the packer. Design 4 will use more
purge gas if the distance piece to cover gaskets leak and if the wiper seal rings are
worn. The design can be applied to existing compressors more easily than Design 3
since it does not require a special rod packer.

K2.6 Design 5 and 6: Double Compartment Distance Pieces

Designs 5 and 6 use double-compartment distance pieces. These are expensive and
require additional plot area. Their only advantage (other than for oxygen service
where they prevent the entrance of lube-oil into the compressor cylinder) is some
additional protection against the escape of H2S gas in very abnormal circumstances.
A sudden packer failure could result in relative high gas pressure in the distance
piece with Designs 3 and 4 if the packer and/or distance piece vent system capacity
is exceeded. H2S gas could leak through worn seal rings in the wiper, through the
crankcase and into the atmosphere. However, Designs 5 and 6 as well as Designs 3
and 4 will allow H2S leakage if the purge gas system fails. In addition, Designs 5
and 6 have only slightly higher reliability.

December 1988 K-6 Chevron Corporation

Compressor Manual Appendix K

K3.0 Section II: Basic Considerations

K3.1 Gas Leakage Paths

By design compressor rod packing always allows some gas leakage through the
packer assembly rings and cups. Normally, leakage rates will be less than 0.5 CFM.
Mechanical wear or damage to the packing or piston rod, or bad fouling deposits
can greatly increase the leakage rate up to 50 CFM. Gas leaking through the packer
must escape, either through a vent connection on the packer case or into the
distance piece, or both. Gas leaking into a closed distance piece, if not properly
vented, will be forced through the rod wiper assembly into the compressor crank-
case.
Leakage of gas contaminated with H2S into the crankcase has caused the following
mechanical, safety, and pollution problems:
• Corrosion of exposed machine parts;
• Reaction with the crankcase oil resulting in poor lubrication and/or crankcase
deposits;
• Crankcase explosions; and
• Gas escape into the atmosphere through crankcase breather vents, shaft oil
seals, or gasketed crankcase and cover joints.

K3.2 Packer Venting and Purging

Conventional rod packer designs generally include a venting connection at the first
(or second) cup of the assembly. Thus there are one (or two) packer rings separating
the vent connection space from the distance piece. Special packer designs (see
Figure K-3) can provide separate connections at two or more ring spaces at optional
locations. These designs allow purge gas injection between the packer vent connec-
tion ring and the first (or second) ring adjacent to the distance pieces. Purge gas
pressure must be at least two inches Hg higher than the vent line pressure to block
the leakage of compression gas into the distance piece. Both packer and distance
piece vent systems from each compressor should be designed to provide 50 CFM
per cylinder vent gas capacity.

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Appendix K Compressor Manual

Fig. K-3 Vented and Purged Packer Assembly

K3.3 Packer Ring Pre-loading

Packer ring sealing action depends, in part, on gas pressure holding the ring axially
against the cup's side mating surface. Rings adjacent to the distance piece which are
side-loaded only with pressure in the vent-cup space will not seal adequately if the
vent pressure is near atmospheric. Special pre-loaded designs must be used to
insure positive sideload on these rings.

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Compressor Manual Appendix K

K3.4 Crankcase Oil Wipers

Rod wiper assemblies attached to the crankcase wall are designed to minimize
transfer of crankcase oil into the distance piece. Double-action wipers also prevent
cylinder and packing lubricating oil from entering the crankcase. Neither of these
wiper assembly types are effective gas seals. However, they can be modified to seal
gas by adding one (or more) sealing rings (the same type used in packers). One
such modification is shown in Figure K-4. The sealing rings must be side-loaded
with springs for effective sealing if distance piece pressures are near atmospheric.

Fig. K-4 Two Cup Wiper Assembly with One Set of Seal Rings

K3.5 Distance Piece Types

Single compartment distance pieces are usually used. These are normally provided
with solid covers on the access openings, vent connections on the top, and drain
connections on the bottom.

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Appendix K Compressor Manual

Double-compartment distance pieces are generally used only for very hazardous
services, such as near 100% concentration of highly toxic or corrosive gases, or
oxygen. These distance pieces have a partition containing an auxiliary rod packer to
isolate the two compartments. Either or both compartments may have solid covers
and vent connections. Both compartments should have drain connections.

K3.6 Distance Piece Venting and Purging

Any compartment can be vented or purged, depending on the application. Where
positive pressure venting or purging is needed, the distance piece and access covers
must be able to contain the pressure. Typically, these parts are designed to with-
stand up to 10 psig internal pressure. However, their actual maximum pressure capa-
bility should be verified by the manufacturer. A pressure relief valve must be
installed to protect the distance piece if the maximum allowable pressure can be
exceeded in service.
Gasketed access covers are required where leakage is undesirable. The rod wiper
assembly in the crankcase wall must contain pressure seal rings (refer to “Crank-
case Oil Wipers”) where a single compartment is used. Pressure seal rings must
also be included when the inboard (crankcase side) compartment of a double-
distance piece is pressured.

K3.7 Wiper Assembly Purging

Additional protection against undesirable gas leakage into the crankcase can be
provided, where necessary, by introducing a suitable purge gas in between two pres-
sure sealing rings in the wiper assembly. The purge gas will block any flow through
the wiper assembly as long as the purge gas pressure is higher than the distance
piece internal pressure. Wiper assemblies must have at least one pressure sealing
ring on each side of the purge gas adaptor plate or entry port.

K3.8 Vent Gas Disposal

Packers and distance pieces must be vented to a lower pressure disposal system to
prevent escape of leakage gas into the atmosphere:
• Distance piece vents should be connected to a disposal system which operates
in a pressure range of zero psig (minimum) to the maximum internal pressure
rating of the distance piece (10 psig is typical). Ideally, a zero psig to two psig
vent system design range should be used. Normally, distance-piece vent-line
flow rates will be less than 0.5 CFM and venting to an atmospheric flare
system is economically acceptable.
• Packer vents can be connected to disposal systems which operate at a vacuum
or at pressures of 20 psig and higher. However, where vent system pressures
are outside of a 0-10 psig normal range, the packer design should be closely
reviewed. Packer vent gas flow rates normally are less than 0.5 CFM. Rates
may exceed five CFM with worn or damaged rods or packers. If this leakage
gas is usable for fuel it can be vented to a vapor recovery system.

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Compressor Manual Appendix K

• Distance piece and packer vents may be piped separately to different gas
disposal systems. They also can be connected to a single disposal system
through common piping outside of the compressor. In either case, it is essential
that the piping does not restrict the flow of vented gas. Any unnecessary restric-
tion will increase the gas pressure in the packer vent cup or in the distance
piece. Increased pressure in either will increase the possibility of leaking unde-
sirable gas to the atmosphere.

K3.9 Purge Gas

Nitrogen is preferred for purging. Other gases may be used for packer purging but
possible hazards should be carefully considered. The purge gas must not react unfa-
vorably with the compression gas or with the packing lubricant. Flammable purge
gases (such as sweet hydrogen or light hydrocarbon gases) may be usable in some
applications but should not be used for purging single compartment (or inboard side
of double compartment) pieces. Corrosive gases, including CO2, are not suitable for
packer or distance piece purging.

Chevron Corporation K-11 December 1988