DRY GAS SEAL SYSTEM

Design Consideration & Troubleshooting

Dresser-Rand Asia Pacific
Kuala Lumpur, April 07

2007
Field Solutions Asia Pacific
Summary
‹ Design Requirements
‹ Seal Gas Supply

‹ Seal Gas Supply Controls

‹ Dry Gas Seal Primary vent

‹ Dry Gas Seal Secondary vent

‹ Enrichment Line

‹ Alarm, S/D and Interlock Conditions

‹ Transient Operations / Start Up

‹ Gas Seal System Failures & Troubleshooting

2
Design Requirements

The purpose of the gas seal system is:

‹ To provide clean, dry sealing gas to the faces

of the dry gas seals

‹To provide clean, dry separation gas to the

barrier seals

‹To monitor the "health" of the dry gas seals

and barrier seals
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Gas Seal System P&ID

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•© 2000 by Dresser-Rand
Seal Gas Supply
‹ .. can be an inert gas, sweet gas, or process gas
coming from a steady and continuous source, which
meets the cleanliness and temp requirements ( supply
temp shall be limited to a maximum of 250ºF /121 C)
‹This gas should be filtered to 2 micron to remove solid
particles from the gas stream
‹When moisture is present in the seal gas supply, a
coalescing element is recommended
‹ A duplex or stand-by filter assembly enables the
operator to change the dirty filter without system S/D.
D-R's standard arrangement is duplex filter assembly with
a stainless steel housing

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Seal Gas Supply – Filter Arrangement

discharge

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Seal Gas Supply – Filter Arrangement

discharge

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Seal Gas Supply

‹To evaluate potential liquid condensation, a phase map

shall be used to look at all operating conditions (design
pressure to atmospheric pressure) including pressurized
shutdowns and settle out conditions

‹ Depending on the quality of the seal gas and the result

of the phase map analysis, it may be required to provide
special liquid separation and filtration equipment, and
supplemental heating of the sealing gas
discharge
‹If the ambient temperature can fall below the seal gas
dew point, all seal gas supply piping shall be heat traced
supply
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Seal Gas Supply – Phase Envelope
DEW POINT
PHASE ENVELOPE - SEAL GAS SUPPLY Critical Point
SEAL GAS SUPPLY
2000

1800

1600

1400

1200
Pressure, PSIA

1000

800

600

400

200

0
0 20 40 60 80 100 120 140 160 180 200
Temperature, F C21983 New Gas

2000

1800

1600

1400

1200
Pressure Psig

Dew Points
1000 Seal Gas
Seal Gas fromDischarge
discharge 800

600

400

200

0
supply 0 50 100 150 200 250
Temperature F
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Seal Gas Supply – Diff Press Control
A1
D1
C1 B1 B1 C1

E1 E1
FO FO

A2 A2
C2 C2

D1: Seal Ref. port A1: Seal gas injection

A2: Drain B1: Primary seal vent
C1: Secondary seal vent C2: Drain
E1: Separation gas injection FO: Seal inlet flow restriction orifice

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Seal Gas Supply – Flow Control

discharge

supply
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Primary Vent Line
‹ Monitoring the gas seal leakage through the primary
vent = method of assessment of the condition of the dry
gas seal. Monitoring the differential pressure across a
restriction orifice in the primary vent piping fitted with an
indicating, differential pressure transmitter
‹ If the primary vent is connected to a flare system, a
check valve is required to prevent any potential reverse
flow in the vent which could cause damage to the gas
seal
‹ The primary vent shall be provided with a low drain
point valve to allow drainage of any potential liquid build-
discharge
up, which could contaminate the primary seal. Periodic
removal of any accumulated liquids is required
supply
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Primary leakage – proper monitoring
equip & safety devices

Rupture disc: unload the seal & release the pressure to

vent / flare in case of a primary seal failure / PCV failure
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 Rupture Sensor

‹ The plastic film with the printed silver circuit lies between two
armored graphite gaskets
‹ There is no contact to the rupture disk
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Secondary Vent
‹The secondary seal is intended to act as a backup in
case of primary seal damage, providing the necessary
shaft sealing until the unit can be safely SD and
depressurized

‹The compressor shall operate on the secondary seal

only for a controlled S/D

‹ The secondary vent shall be provided with a low drain

point valve to allow drainage of any potential liquid build-
up, which could contaminate the secondary seal. Periodic
discharge
removal of any accumulated liquids is required

supply
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Separation Gas Supply
‹N2 source is recommended to be employed for
separation gas. Alternate solution, use of instrument air
as the separation gas medium

‹The separation gas shall be free of solid particles 3

microns and larger, 99.97 percent liquid free, and a
maximum of 120 F (49 C) at the gas seal control panel
connection point

‹ A separation gas filter is provided at the gas seal

control panel inlet. D-R's standard arrangement is to
discharge
provide a duplex filter with non-ferrous housing

supply
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Separation Gas Supply

The supply of separation gas to the barrier seals is controlled using a

differential
discharge pressure control valve that regulates the separation gas
pressure to a predetermined value [< 15 PSI (<103 KPa)] above the
secondary vent pressure

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Separation Gas Supply – Alarms &
S/D
‹Alarm: is provided in the event the differential pressure
between the separation gas supply and the secondary
vent falls below a predetermined level

S/D: If proper separation gas pressure is lost during

operation of the compressor, S/D is initiated after 30
minutes (After the compressor case has been vented, lube oil
flow to the bearings shall be stopped)

Note: If proper separation gas pressure is lost while the

compressor
discharge is S/D depressurized, lube oil pump shall be
stopped except if the rotor system includes an active
turning gear
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 Permissive & Interlock Conditions

‹ Proper separation gas differential pressure

shall be confirmed before energizing the lube oil
pumps

‹ Permissive to start: provides an interlock for

the lube oil pump logic in the unit control panel

‹ Permissive to start: provides an interlock for

the rupture sensor (hard wired to the unit control
discharge
panel

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 Explosive Mixture
‹When air is used as the separation gas medium, the gas
seal system shall be evaluated for the possible occurrence
of explosive air / gas mixture in the secondary vent, under
all operating and static conditions

‹The system can be designed to create a "lean" or "rich"

environment in the secondary vent

‹ If the primary vent is connected to a flare system, the

secondary vent is only permitted to employ a rich mixture
design. Flame arrestors shall be provided (optionally by
discharge
D-R) for secondary vents to atmosphere employing
separation air
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Explosive Mixture
‹ “lean” mode: a quantity of air is injected into the
secondary vent to insure that the gas to air mixture
is below the lower explosive level of the gas. (This is
accomplished by bypassing separation air from the supply
piping directly into the secondary vent piping)

‹“rich” mode: a quantity of process gas is injected into

the secondary vent such that the gas to air mixture is
above the upper explosive level of the gas. (This is
accomplished by bypassing process gas from the seal gas supply
piping directly into the secondary vent piping)
discharge

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Gas Seal Control Panel
Alarm, S/D & Interlock Conditions
Parameter Alarm Shutdown Permissive
Condition Condition Start
Filter differential pressure (all) High

Seal gas supply orifice DP or seal gas DP Low DP Note **

Primary vent differential pressure High High

Intermediate gas orifice DP Low DP or Low DP Required

High DP
Separation gas supply / secondary vent Low Low Required
differential pressure (30 minute
delay)
Primary Vent Rupture Disc burst sensor Closed

Note **:
discharge A seal gas loss of supply shutdown is only required for toxic
gas service

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Gas Seal Control Panel – Operator Interface
Mimic Screen (Flow Control)

discharge

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Gas Seal Control Panel – Operator Interface
Mimic Screen (DP control)

discharge

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Start Up - Apliflow
Provides pressure boost to seal supply gas to ensure
filtered gas to the seals during start-up or times of low
pressure differential

Manual Operation - Set by discharge pressure

Automatic Operation
a) Begins operation at low differential pressure
b) Continues operation until sufficient pressure
discharge

differential re-established

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Start Up - Apliflow (FLOWSERVE)
Vent

Drive Air Out

DRY SEAL
PANEL

AMPLIFLOW Drive Air In

SYSTEM

Filtered Boost
Gas In Gas Out
discharge
Compressor Boosted Supply Gas
Discharge Gas to Dry Seals

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Ampliflow (Flowserve) P&ID

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Example: How Flowserve Ampliflow
Works
Seal Supply Flow for Diameter 3/32" Orifice
Based On Last TCPL Panel Design
Based on :
Start Psuction=700psig
115.00
Pdischarge=880psig
Pseal=Psuction

95.00 Pressurization
Flowrate (SCFM per Seal)

75.00 Normal Operation

Idle

55.00

Unit Ramp-up
35.00
Dry Seal Supply Flow With AMPLIFLOW
(Conservative Estimate)
15.00 AREA OF NO
SEAL SUPPLY Dry Seal Supply Flow Without
AMPLIFLOW
-5.00
0 5 10 15 20 25 30 35 40 45 50
Time (minutes)

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 Ampliflow Benefits

‹ Ensure positive flow of filtered gas to the dry

gas seal port (boost up the gas pressure)
‹ Prevent contamination of the seals during start-
up or times of recycle
‹ Extend the dry gas seal life (less chance of
failure due to contamination during start up /
idle)

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 DRY GAS SEAL
FAILURES & TROUBLESHOTING

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How does the contaminant enter the seal ?

Seal Supply Flare Separation

Gas System Gas

Process Bearing
Gas Oil

INBOARD OUTBOARD

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If foreign particles enter the seal

Consequences :

‹ Erosion of the faces

‹ Clogging of the grooves
‹ Fretting / Seizing of seal sleeve

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Origin of particles

‹ Unclean piping
‹ Corrosion
‹ Debris in the gas stream
‹ Lack or poor filtration
‹ Improper preservation
procedures

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Contamination with solid particles
Compressor head seal gas supply port

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Erosion of the faces

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Erosion of the faces

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Clogging of the grooves

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Clogging of the grooves

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Fretting / Seizing of seal sleeve

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Fretting / Seizing of seal sleeve

pitting and fretting on the balance Ø)

pitting and fretting on the balance

diameter and o'ring groove

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If liquid enters the seal

Consequences :
‹ Blistering of the carbon ring face
‹ Corrosion (ex: sea water)
‹ Heat generation (parts
deformation, O ring extrusion)
‹ Thermal shock (Tungsten ring
rupture)

41
Source of liquid ?

‹ Lube oil (defective barrier)

‹ Condensate (at operating conditions)
‹ Liquid carry over in the gas stream
‹ Improper filtration of the seal gas supply

42
Primary Vent Line Piped to Flare Without
Check valve

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Improper Preservation

44
Improper Preservation

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Blistering of the carbon ring face

46
Blistering of the carbon ring face

47
Corrosion

48
Corrosion

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Corrosion

50
Thermal shock

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Thermal shock

52
Thermal shock

53
Thermal shock

54
Lube oil (defective barrier)

55
Lube oil (defective barrier)

56
Lube oil (defective barrier)

57
Liquid Contamination

58
Condensate

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Improper filtration of the seal gas
supply

60
Improper filtration of the seal gas
supply

61
Improper filtration of the seal gas
supply

62
Improper filtration of the seal gas
supply

63
Other failure Causes

‹ Improper installation
‹ Excessive Pressure
‹ Excessive Temperature
‹ Combination of the above factors

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Improper installation

65
Improper installation
Head
Fond

Head
Fond
SHAFT
ARBRE

Static Part

Rotating Part

SHAFT
ARBRE
66
Typical list of questions

‹ Operating data (rpm, pressure, temperature,

gas composition, …)
‹ No of running hours
‹ No of Start/Stop
‹ Sequence of events
‹ Maintenance procedures (i.e. filters,
secondary vent low drain point checks )

67
Site Inspection (prior to seal removal)
‹ Check for liquid / particles at all drain points:
• Primary vent
• Secondary vent
• Casing
• Gas panel
‹ Try and identify (color, aspect,.), take samples
‹ Check gas seal filters

68
Site Inspection (during seal removal)
‹ Record installation data ( Seal S/N, shim
thickness, rotor S/N, shaft position, …)
‹ Check for liquid / particles / debris /dirt. (Gas
seal , barrier seal, inner laby, ports, …)
‹ Inspect and identify (color, aspect,.), take
samples, take pictures
‹ Visual inspect barrier seal

69
Return the Seal to Manufacturer for
Inspection & Repair
‹ Use initial boxing
‹ Return complete set of parts with same S.N.
• Gas seal
• Setting plate
• Shear rings
• etc …
‹ Return one pair of seals (not only one end)
70
Gas Seal System – Operation &
Maintenance
Seal gas supply shall be clean & dry and available at
sufficient pressure to cover the entire operation range

PCV shall provide >10 psid diff

press across the gas seal labyrinth

Gas seal condition is determined

by the primary & sec leakage rate 71
 Gas Seal System – Operation &
Maintenance

Monitor / service the

seal gas supply filters

Monitor / service the

buffer gas supply filters

Inspect the secondary &

primary low drain points
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Gas Seal System – On Condition
Service Strategy

Gas seal replacement is dictated by:

1) the primary vent leakage rate;
2) secondary vent (primary) low drain point liquid
accumulations;
3) vibration caused by unbalance (seal sleeve);

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