eHydroCOM - Electric Stepless Capacity Control System

eHydroCOM – Electric Stepless Capacity Control System

Achieve precise and fast process control while saving energy

Solve stepless control tasks precise  and fast

Many reciprocating compressors need to deliver less than their rated capacity, and this typically requires excess compressed gas to be returned to the suction side via a recycle valve. When this happens, the energy used to compress this recycled gas is wasted. HOERBIGER’s eHydroCOM is an all-electric stepless volume control system available today for reciprocating compressors. The fully standardized, 100% oil-free system is the ideal way to achieve and maintain stable capacity control of dynamic processes. 

Precise capacity control
eHydroCOM continuously adjusts the compressor’s delivery rate to match the amount required by the downstream process. Precise control of the suction valves eliminates the need for a bypass valve. This not only saves energy and reduces CO2 emissions, but also improves your process controls at the same time.

eHydroCOM Sytem
One system – many possibilities

Conventional capacity control systems waste energy because they either require gas to be compressed unnecessarily (bypass valves) or cannot accurately match the required flow rate (stepwise capacity control, which is also time-consuming to adjust). eHydroCOM, in contrast, offers a wide and stepless control range, from below 10% (depending on the application) up to 100%. Delivery rate can be adjusted continuously and automatically, with no time lag. Together with the wide turndown, this means you can operate your compressors more flexibly, cover your  needs with a smaller fleet, react quickly and avoid overcapacity issues.

Test your energy savings here.

The best solution for your challenges

Standardized and ready for use immediately
The patented eHydroCOM actuator is a smart device that combines a range of electronic and electric drive technologies to increase the reliability, efficiency and lifetime of your compressor. With no hydraulic oil to leak, and a design that is almost wear-free in operation, eHydroCOM reduces potential points of failure and keeps downtime to a minimum.

Failure prevention through real-time monitoring of the actuator
Digital networking capabilities allow you to monitor your actuator in real time and thus detect failures early – or even avoid them altogether. And, thanks to our remote maintenance system, any problems that do arise can be quickly assessed by HOERBIGER experts if necessary. If spare parts are required, HOERBIGER always has semi-finished products ready, reducing or eliminating the need for you to carry spares.

Reduced operating costs with eHydroCOM  
Taking advantage of plug-and-play connections, eHydroCOM XD – our most powerful and compact system for extreme duties – can be easily retrofitted to your existing compressors with minimal downtime. The self-calibration feature means that even untrained personnel with less experience can install and commission eHydroCOM. In line with the motto “one size fits all”, it’s easy to replace the actuators. For you this means less inventory and less downtime. Your compressor is ready for use again immediately after maintenance.

With eHydroCOM, our employees – even those without years of operating experience – are able to start and stop the compressors. Thanks to the significantly more robust controls, pressure fluctuations in the hydrogen systems are almost imperceptible, and so we avoid unplanned downtime. The support through remote maintenance works perfectly.

Manager at a chemical park in Germany

Benefits at a glance

Saves energy and CO2 emission costs, while improving process control
Feature

Reverse flow control: The delivery rate of the compressor adjusts continuously to process requirements

Advantage
Smaller fleet footprint, fast response  to changes, and prevent overcapacity issues
Feature

Reverse flow control: Wider control range, and ability to assign new duties to individual compressors

Advantage
Better economics (ROI): Lower lifetime costs and sustainable production over a long service life
Feature

100% oil-free and all-electric operating principle

Advantage
Improved reliability, fewer compressor downtime and less waste due to fewer spare parts replacements (reduced OPEX)
Feature

Automatic wear compensation while compressor runs

Advantage
Reduced energy losses and minimal emissions, you can quickly return to normal operations
Feature

Standardized system: “One size fits all”

Advantage
Just-in-time order system cuts  inventory costs and warehouse requirements
Feature

Standardized system: “One size fits all”

Advantage
Failure avoidance through real-time monitoring of the actuator
Feature

Connectivity

Advantage
Minimizes energy use and reduces air pollution
Feature

Remote support

Advantage

Working principle of eHydroCOM

Working principle of eHydroCOM
eHydrocom
eHydroCOM HD

Electric Stepless Capacity Control System
Heavy Duty Single Stack Actuator

eHydroCOM HD at a glance:
Technical data
Actuator layout:
Single magnetic coil stack
Application limits:
Up to 2.5kN unloading foce, 800rpm,  70bara suction pressure 
Application range:
Majority of applications 
IP:
Actuator: IP65​
FPSU: IP65
Actuator height / weight:
267mm / 20.5kg (NACE 23.5kg) 
EX-certificates*:
ATEX Zone 1 IIC
Power supply:
Actuator: 60VDC
FPSU input: 3 x 400VAC
Electrical connections:
Terminals
Maintenance intervals:
<400rpm: 32,000 operating hours
400 to 800rpm: 24,000 operating hours
Standardization:
Same actuator for all stages / compressors
Automatic clearance compensation:
Yes
Automatic wear compensation while  compressor runs:
Yes
Separate enclosure required for FPSU / ePU:
No
*Status correct at the time of printing. Further approvals may already be available. Please contact us for details.
  • Field Power Supply Unit (FPSU)​
  • Digital Compressor Interface (DCI)​
  • Top Dead Center (TDC sensor)​
eHydrocom system layout
eHydrocom X
eHydroCOM XD

Electric Stepless Capacity Control System
Xtreme Duty Double Stack Actuator

eHydroCOM XD at a glance:
Technical data
Actuator layout:
Dual magnetic coil stack
Application limits:
Up to 6.5kN unloading foce, 1,200rpm,  160bara suction pressure
Application range:
All HydroCOM applications incl. dia 17mm  high force
IP:
Actuator: IP65​
FPSU: IP67
Actuator height / weight:
232mm / 20.0kg (NACE 23.0kg
EX-certificates*:
ATEX / IECx Zone 1 IIC, CSA C1/D2, TIIS, CCC
Power supply:
Actuator: 560VDC
ePU input: 3 x 400VAC
Electrical connections:
Ex-connector
Maintenance intervals:
<400rpm: 32,000 operating hours
400 to 800rpm: 24,000 operating hours
800 to 1,200rpm: 16,000 operating hours
Standardization:
Same actuator for all stages / compressors
Automatic clearance compensation:
Yes
Automatic wear compensation while  compressor runs:
Yes
Separate enclosure required for FPSU / ePU:
No
*Status correct at the time of printing. Further approvals may already be available. Please contact us for details.
  • ePU:  eHydroCOM Power Unit  
  • eCIU: Compressor Interface Unit  
  • TDC: Top Dead Center
  • JB: Junction Box
eHydrocom X system layout
eHydroCOM in the field
eHydroCOM

Brochure A4

Download now
PDF document 
- 720 KB
eHydroCOM

Brochure Letter Format

Download now
PDF document 
- 709 KB
Components for reciprocating compressors