FLEXI-POWER^TM
High Pressure Gas Compressors

Hydro-Pac
FLEXI-POWER^TM High-Pressure Gas Compressors are manufactured to meet the requirements of many industries. These FX compressors are available in powers to 200 hp and for pressures to 60,000 psi and even higher.

Because numerous industry applications involve pressurizing closed vessels, Hydro-Pac developed a new generation of compressors that fully utilizes the power supply.

Compressor Design

FLEXI-POWER^TM High-Pressure Gas Compressors have two basic components, an intensifier and a hydraulic power unit.

The Intensifier, mounted on top of the console, is made up of first and second-stage gas cylinders and a hydraulic drive cylinder. Each cylinder contains a piston.

Tie-rods attach the gas cylinders to the hydraulic cylinder. A hydraulic flange and isolation spacer between each gas cylinder and hydraulic cylinder separate the hydraulic fluid from the process cylinders.

The Hydraulic Power Unit, contained within the console, is made up of an electric motor, hydraulic pump, oil reservoir, directional control valve and other hydraulic components.

The power unit provides pressurized hydraulic oil to the intensifier. The intensifier uses this pressurized hydraulic oil to compress gas.

The four-way valve controls the direction of hydraulic oil flow to and from the intensifier.

HOW COMPRESSORS WORK

Advances

Increased Capacity at Lower Operating Pressure

FX compressors adjust their stroke rate automatically according to the operating conditions.

This increase in stroke rate makes full use of available horsepower and results in higher capacity when the discharge pressure is low. For batch process applications, a higher capacity can significantly reduce the compression time.

Variable Inlet Pressure

FX compressors efficiently accommodate a wide range of inlet pressures. It is usually unnecessary to provide an expensive pressure regulator. In addition, operation with the highest available inlet pressure increases the capacity of the machine.

FLEXI-POWER^TM Compressor Efficiency

Conventional, fixed-displacement compressors produce a near constant flow of gas when operating at fixed inlet conditions, regardless of the discharge conditions. When process pressures are low, a relatively small percentage of available horsepower is utilized by the compressor. These compressors waste power and time.

FLEXI-POWER^TM compressors use most of their power, even when discharge pressures are low. At low discharge pressures, the intensifier strokes faster displacing more gas.

As pressure increases, FLEXI-POWER^TM compressors slow down to produce a higher pressure and corresponding maximum flow-rate. At the maximum discharge pressure, the Flexi-Power^TM compressor displaces the same amount of gas as a conventional fixed-displacement compressor.

Intensifier Design Features

Near-Isothermal Compression

The long, slow stroke of Hydro-Pac compressors allows heat removal during the compression cycle. This near-isothermal compression cycle requires less power than the faster compression cycle of a diaphragm or crank-driven machine.

The near-isothermal compression cycle of Hydro-Pac compressors consumes less energy and requires less power to pressurize a given volume.

Patented Free-Piston Design

Hydro-Pac's patented free-piston design allows replacement of the high-pressure packing in minutes without major disassembly of the intensifier. These pistons are pressure energized allowing them to adjust automatically for wear. The pistons are non-lubricated unless specifically requested by the user.

Fail-Safe Freedom from Contamination

Hydro-Pac compressors are non-lubricated eliminating lubrication contamination of the gas. In addition, a vented isolation chamber separates the gas cylinder from the hydraulic drive cylinder.

For applications requiring ultra-pure gas, optional full-length isolation spacers are available that do not allow entry of the oil-wetted portion of the plunger rod into the gas cylinder.

Check Valves

Inlet and discharge check valves are housed in a check valve body. The valve seats are reversible. The poppet, guide and spring are a cartridge. The guide accurately aligns the poppet with the seat. Large ports allow free flow of gas and reduce pressure drop.

Hydraulic Drive System Features

An advanced hydraulic drive system powers the Hydro-Pac FLEXI-POWER^TM compressor.

• Easily removable, sound-dampening panels enclose the hydraulic drive system.
• The hydraulic drive system allows the machine to be started under full load. Special unloading devices are not required.
• The slow operating speed and low inertia load eliminate the need for special foundations.
• Hydraulic oil is cooled and constantly filtered.
• Oil reservoir is baffled for cooling and foam dispersion, and is furnished with a clean-out cover.

Applications

FLEXI-POWER^TM High-Pressure Gas Compressors are ideally suited for:

• Hot isostatic pressing
• Supercritical extraction
• Pneumatic testing
• Shock tube pressurization
• Wind tunnel storage pressurization
• Calibration of transducers and other instruments
• Gas transfer and circulation
• High-pressure chemical reactions
• Well injection
• Material testing
• Gas leak testing

Safety

FLEXI-POWER^TM High-Pressure Gas Compressors are designed and built for maximum safety. Some of the specific safety features are:

• An interstage relief valve protects the interstage and first stage of the compressor from over-pressurization.
• A pressure-compensated hydraulic pump and back-up hydraulic relief valve provide redundant protection against over-pressurization of the hydraulic system.
• Protective panels shield the hydraulic drive system and electric motor.
• Leak-before-failure design of the high-pressure seals enhances safety.

Hydro-Pac Quality

We are committed to providing the best compressor possible. Some of the many steps taken to ensure the quality of Hydro-Pac compressors are:

• Careful, conservative engineering of all equipment
• Hydrostatic pressure testing of all gas cylinders prior to assembly.
• All machines run at maximum-rated conditions prior to shipment.

Service and Spare Parts

• Trained service technicians are available for field repair.
• We provide training on the operation and maintenance of our products.
• Complete product overhaul and rebuild can be done at our facility.
• Our computer based inventory allows parts shipment from stock.

Standard Equipment

FLEXI-POWER^TM High-Pressure Gas Compressors are furnished as complete units.

• Gas intensifier with inlet, interstage and discharge check valves.
• Electric motor, 230/460V, 3 ph, 60 Hz, TEFC
• Hydraulic power unit with pump, directional control valve and filter
• Gauges for oil pressure, level and temperature
• Sensors for low oil level and high oil temperatures
• Interstage relief valve
• Heat exchanger for hydraulic oil
• Interstage gas cooler
• Instruction manual with parts list

Standard Gases

• Argon
• Nitrogen
• Helium
• Carbon Dioxide
• Dry air
• Mixtures of 20% oxygen and other inert gas
• Methane
• Other inert gases

Options are available for Compressing

• Hydrogen
• Ethylene
• Other gases

Optional Equipment

• Spare parts kit
• Enclosure for intensifier
• Motor starter
• Pressure gauges for suction, interstage and discharge
• Relief valves for gas inlet and discharge lines
• Aftercooler
• Coolant-flow sensor
• Gas piston lubrication
• Heater for oil reservoir
• Explosion-proof motor and controls
• Special motor and control power
• Complete compressor packages
• Installation assistance

Utilities

• Electrical: 230/460V, 3 ph, 60 Hz (Other voltages available)
• Cooling water is required. The amount depends on the machine.

Selecting a Compressor

The selection of a FLEXI-POWER^TM compressor for a batch process requires the solution of a first-order differential equation.

Hydro-Pac has developed a computer program for this solution which uses actual gas data to model the changing capacity of a FLEXI-POWER^TM compressor.

Hydro-Pac can optimize compressor selection - a task best accomplished by our computer.

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