THE PREFERRED CHOICE IN COMPRESSION
PDC Machines has been manufacturing industrial diaphragm gas compressors since 1977. We have developed an extensive line of diaphragm compressors and fully automated turnkey diaphragm process gas compressor systems with installations around the globe.
Our diaphragm compressors are the preferred choice for high purity and leak tight gas compression applications. We design basic- to fully-instrumented leak-free, non-contaminating reciprocating diaphragm gas compression systems in accordance with customer specifications and API 618 (some exceptions/deviations, see Specifications). Our compressors range in size from 3 hp(2 kW) to 200 hp(150kW). Discharge pressures range from 50 psi to as high as 15,000 psi (1,100 bar) and typical flow rates based on compression ratio to 500 Nm3/hr.
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Serving Many Industries
Our leak free and oil free, gas, non-lubricated reciprocating diaphragm compressors are found in virtually every industry worldwide. These include:
- Alternative Energy/Hydrogen refueling stations
- Chemical and Petrochemical (CPI)
- Oil & Gas
- Specialty Gas
- Power Generation
- Pharmaceutical
- Semiconductor
- Food & Beverage
- Research & Development
- General Industrial requirements worldwide
Containerization
At the request of our customers, PDC Machines can package our compressors and customers equipment and instrumentation inside a container.
Highly reactive gases service
For compression of oxygen, fluorine, silane, phosphine and other highly reactive gases, PDC Machines performs rigorous cleaning procedures in a clean, dust-free environment. We use fire-resistant oil for the hydraulic system. We construct the process side diaphragm as well as the inner and outer check valve components.
Why PDC Machines’ Diaphragm Compressors
Non-contaminating Gas Compression
The triple diaphragm set ensures that the process gas is completely isolated from the hydraulic oil. The compressor does not use dynamic seals eliminating the potential for seal particulate to be imparted to the gas stream. Filters and oil removal systems are not necessary – Hydraulic oil cannot migrate into the process gas.
High Compression Ratio
Our metallic diaphragm compressors can achieve typical compression ratios up to 10:1 for certain models.
Superior & Extended Diaphragm Life
All aspects of diaphragm compressor design are intended to enhance component life, improve operability and reduce and simplify maintenance.Diaphragm cavity contours, which control stress in the diaphragms, are carefully controlled to provide uniform stress distribution. Special manufacturing processing is used on the diaphragm surfaces to enhance fatigue life.
Many of our customers have experienced continuous running times of 10,000 to 40,000 hours between routine maintenance minimizing the need for spare parts replacement.
Variable Suction Pressure
PDC compressors are capable of sub atmospheric as well as high suction pressures. Compressors can be used in in applications requiring low or high compression ratios. And for applications requiring intermittent or continuous service duty.
Many of our customers have experienced continuous running times of 10,000 to 40,000 hours between routine maintenance minimizing the need for spare parts replacement.
Unique Oil Distribution System
The hydraulic system is designed in such a way as to assure uniform diaphragm deflection, prevent knocks, vibration, cavitation and yield smooth, quiet compressor operation.
Fast Acting Leak Detection System
To detect and indicate diaphragm and seal failure.
Safety Interlocks
The compressor will be completely instrumented for safe and automatic operation.
Environmentally Safe
Our diaphragm compressors use static seals. There is no migration of gas to the crankcase as such the crankcase does not require purging or venting. The gas system integrity is monitored to preclude leakage of gas to the atmosphere.
Safe Compression of Corrosive Gases
We use non-flammable hydraulic fluid and all process-wetted components which are constructed from corrosion-resistant materials for processing of corrosive or oxidizing gases for safe operation and which will prolong the life of maintenance components.
High Discharge Pressure
PDC’s gas diaphragm gas compressors are capable of providing discharge pressures to 15,000 psig/1,000 barg and beyond.
Automatic Unloading System
The compressor is automatically re-primed at start-up. Manual start-up requires an experienced compressor technician to be present all the time to re-prime the compressor. Incorrect priming will cavitate the compressor and damage the heads, bolts, diaphragms, o-rings, process and hydraulic system.
Quiet Operation
Below 85 dBA @ 1 meter without sound-proofing enclosure.
Low Maintenance
Typically, only routine oil changes are necessary.
Low Energy Costs
PDC compressors use a heavy flywheel to provide energy. In addition, Duplex and two-stage diaphragm compressors can be horizontally opposed designs to further reduce horsepower requirements and energy usage.
International Standards Compliance
PDC’s’ diaphragm compressors can be designed and certified to comply with Canadian, European, South Korean, Japanese, North American and other international codes and standards.
ISO 9001 Quality Management
PDC is certified according to ISO 9001 standards for quality management of production and services.
Diaphragm Compressor Components
Oil Regulating Valve
The oil relief valve limits maximum hydraulic (and thus gas) pressure and assures that the diaphragms completely “sweep” the upper and lower cavity contours to maximize displacement.
Priming Pump
We provide an automatic, positive displacement gear pump. Priming is crankshaft driven and automatic upon start up. This eliminates priming problems that are typically associated with gravity fed pumps.
Injection Pump
PDC Machines provides a plunger type injection system on all motor driven diaphragm units. The injectors are also crank driven and precisely meter hydraulic fluid flow during the operation of the compressor.
Cavity Design
The deflection and resultant stresses in the metal diaphragms are controlled by carefully designed cavity contours. We use state of the art design and analysis tools as well as cutting edge programs to model these.
Process Head
At PDC Machines we machine process heads from a variety of materials for process gas compatibility. 300 series stainless steel is the standard used for most applications.
Triple Diaphragm Construction
The diaphragm set consists of three plates. The upper or process side, the lower or hydraulic side and the middle diaphragm. The middle diaphragm is brass to preclude galling. The upper and lower are typically 301 SST for most applications. However, the upper diaphragm material can be supplied in alternate materials, such as Inconel 718, for process compatibility.
Process Contacting Seals
We offer an extensive variety of static elastomeric O-ring seals for process gas compatibility, options include Buna-N, Viton, and Teflon encapsulated Viton and Kalrez.
Leak Detection System
Included with every PDC Machines diaphragm compressor is a leak detection system. This system detects diaphragm or seal failures. Our leak detection system monitors the gas and hydraulic sides of the compressor and will alarm and or shutdown the compressor when an anomaly is detected. Proper maintenance, operation and clean/dry process gas promotes component operating life.
Process Inlet and Outlet Check Valves
Compressor process check valve design is dependent on operating conditions and the process gas itself. PDC compressors typically utilize cartridge or plate style check valves. Valves and valve pockets are designed for easy removal and maintenance.
Automatic Unloading System
The compressor is automatically hydraulically re-primed at start-up and unloaded upon shutdown. This process is an important procedure which will not only provide for maximum efficiency but also eliminates the need for an operator to start-up/re-prime the compressor.
Hydraulic Oil System
The hydraulic system is designed to assure uniform diaphragm deflection, prevent knocks, vibration, cavitation and yield smooth, quiet compressor operation. Unique oil distribution techniques are employed to eliminate pressure differentials and gradients. The system utilizes an automatic priming pump, positive displacement high-pressure injection pump and oil relief valve with bypass valve for smooth, easy starting.
Safety Interlocks
Features include shutdowns for low suction pressure, high discharge pressure, low oil pressure, low water coolant and diaphragm or O-ring failure. Audible and visual annunciators can be supplied for an added level of protection. The compressor can be completely instrumented for automatic operation.