Type 28 Gas Seals

Range introduction and operating principles

John Crane

Programme Overview
John Crane Introduction Dry Gas Seal Application Turbo-Machinery Brief History of Dry Gas Seals Seal Design & Operating Principles T28 Product Range T28 Gas Seal Configuration & Operation Control & Monitoring Systems Q&A

John Crane

John Crane Introduction

John Crane

Smiths Group plc

John Crane is a Division of Smiths Group plc 6,400 Employees 626 million sales 2008 Smiths Group plc is a forward-thinking, focused engineering company with worldwide market-leading positions in its four chosen areas of specialization Medical Detection John Crane Flex-Tek & Interconnect
John Crane

A Global Leader

For over 80 years John Crane has had a passion for innovation We are the acknowledged world leader and the largest developer, manufacturer and provider of:
Products: Engineered mechanical seals Sealing support systems Power transmission couplings Engineered bearings

Solutions: Service Reliability contracts Asset management solutions Oil & water chemistry consultancy

John Crane

Organisation
North America Europe Middle East Africa

Latin America

Asia Pacific

Americas

Europe Asia Africa

John Crane

Organisation
Sales 500M

Quebec Hamilton

Chicago

France Slough

Czech Rep. Germany Italy Madras

Tianjin

Washington Venezuela

Osaka

Mexico

Singapore

Sao Paulo Victoria 184 facilities in 43 countries 20 manufacturing plants JCMSD Development JCMSD Manufacturing JCMSD Sales/Service
John Crane

Sydney

Over 80 service centres 1350 customer support Ens.

John Crane Korea

John Crane KOREA 1988 John Crane 100% , Headquarter , Factory & Sales Office , Sales Office Sales Technical Engineer .

John Crane KOREA Engineering Expertise , Technical Service, Global Supply Channels , Contracted Seal Reconditioning , Alliance Capability .

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John Crane Korea Profile

Established in 1988 Wholly-owned Smiths subsidiary Headquarter in Seoul Factory & Sales office in Pusan Sales office in Yeochun Integrated Flexibox Korea in 1999

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Head Office in Seoul

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John Crane Facility in Busan

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Workshop in Busan

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Sales Offices

Sales in Busan

Sales in Yosu
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Value Added Solutions

Mechanical seals Power transmission couplings Sealing support systems Spares

Running spares Repair Retro-fit

Asset management Seal management Stock management

KNOWLEDGE

SERVICE

EXPERIENCE

John Crane has developed a world leading E-Business solution providing us and our customers with an opportunity to achieve mutual benefits
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Dry Gas Seal Application Turbo-Machinery

John Crane

Dry Gas Seal Applications

Extraction & Production Offshore Onshore Refineries Catalytic Reformer Hydrotreater Hydrocracker Fluid Catalytic Cracker GTL Petrochemical Plants Ethylene Methanol Butyl Polymers Organic Chemicals Ammonia Urea Acetyls Nitric Acid
John Crane

Gas Gathering & Transmission Gas Treatment Gas Storage Pipeline LNG GTL

Non-Contacting Seal Products

Type 28LD Type 28EXP Type 28XP Type 28AT Type 28GP Compressors Turboexpander Type 28GP/AT Mixers Blowers CK728/738 Type 5280

Type 28ST Steam Turbines Type 28SST Pumps

Type 28GT

Gas Turbines

Type 28LD Type 28SC

Type 28VL

Type 2800 Type 2800E

John Crane

Type 285

Type 5620USP

Gas Compressor Sealing

Type 28AT
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Turbomachinery Product
John Crane Dry Running Gas Seal

Compressors
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Dry Gas Seal Applications

A between bearings compressor normally contains two Type 28 gas seals

John Crane

Gas Seals in a Compressor

Gas Seal

Gas Seal

Compressor
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Typical Compressor
Man-Turbo Compressor

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Typical Compressor
Nuovo Pignone 2BCL

Diaphragm Bundle
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Compressor Train Nuovo Pignone

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Compressor Train - MHI

John Crane

DGS Benefits
Dry Gas Seal Benefits over Oil Seals:
- Increased safety - 98% power savings - 97% reduction in gas losses - Eliminate contamination - Considerable reliability improvement - Simple pipe work / support system - No seal oil consumption - $US500k

John Crane

Brief History of Dry Gas Seals

John Crane

Once Upon a Time ...

John Crane founded in 1917 Chicago, Illinois, USA Crane Packing Limited established in Slough, England, UK, in 1923, by Frank Payne - the Company President.

Frank Payne

Enlarged Berwick Avenue Works Slough 1936

John Crane

Type 28 Gas Seal Milestones

1968 1975 1981 1985 1985 1986 1991 1992 1994 1995 1997 1998 1998 2000 2002 2004 2005 2005 2005 2006 2007 2008 First patent First field applications First beam type compressor First steam turbine First offshore First H2 recycle compressor Bi-directional seal XP seal - 123 to 200 bar Type 82 separation seal introduced First H.P. re-injection Worlds Largest 330mm Gas Seal 400 bar seal test 100,000,000 Operating hours T28 EXP 350bar Tandem Seal First fully operation service centre commissioned Infrastructure investment for 500mm seal + 5 service centres operational 3m investment in testing and development facilities Reliability team founded 425 bar EXP seal with independently verified performance 5 new test rigs commissioned Global service centre network Next generation separation seals T83/T93FR launched
John Crane

Gas Seal Performance Progress

450 400 350 Pressure (Bar) 300 250 200 150 100 50 0 1985 1990 1995 2000 2005
AT m de n Ta
X em and PT
X le r ip PT

EX

le r ip TT

John Crane

(C r D ani C) te &

ad Qu P

m de n Ta

Type 28 Gas Seal Experience

John Crane invented the dry gas seal 30 years ago. Gas seals have revolutionised turbomachinery sealing Gas seals are installed in the majority of new centrifugal compressors Gas seals are fitted as standard by all major compressor OEMs Over 20,000 gas seals supplied Over 200 million operating hrs

John Crane

Manufacturing Sites - Dry Gas Seals

JC UK, Slough

JC Inc, Chicago JC Japan, Ritto

= Dry Gas Seal Manufacturing and Reconditioning

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Sales and Service Sites

JC Norway JC Russia JC Tianjin

JC Saudi Arabia JC Singapore

JC Brazil

= Regional DGS Repair & Test Centres

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Dry Gas Seal Operating Principles

John Crane

Operating Principles

Spiral Groove Comparison

UNIDIRECTIONAL SPIRAL GROOVE

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BIDIRECTIONAL SPIRAL GROOVE

Spiral Groove Dry Gas Seals

Features

Cartridge seal - relatively simple to fit No wet seal system Gas lubricated usually by the process gas Non-contacting faces

John Crane

Type 28 Principles of Operation

Primary Ring

Spiral Groove

Shaft
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Mating Ring

Spiral Groove Sealing Surface

Rotating Mating Ring
clockwise shaft rotation spiral groove Inner groove diameter

Sealing dam Opposing face inner diameter outer diameter

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Spiral Groove Pattern

The Spiral Groove pattern is uni-directional only
Direction of Rotation

Mating Ring

Gas is pumped inwards by rotating spiral grooves

Gas is compressed & Pressure increases to set gap

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Hydrodynamic Lift Optimisation Spiral Groove

Interface Pressure

Face ID
Groove Groove

Dam

D ace O F

Face Profile

Groove Groove

tion a R ot

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Spiral Groove Geometry

Optimised spiral grooves

Maximum lift pressure generated. CStedy bespoke design and analysis tool
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Hydrodynamic Lift

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Grooves for Dry Gas Seals

Rotating Seat with Recessed Grooves of Micrometers Depth Spring Loaded Carbon Face

Sealing Interface Film Thickness of Several Micrometers

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Dry Gas Seal Technology

Bi-directional Rotation Seal

John Crane Type 28ATBD / 28XPBD
High Performance BD Profile

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Bi-Directional Groove Pattern

Type 28BD Pattern

John Crane

Type 28 Principles of Operation Bi-Directional Spiral Groove

Direction of Rotation

Gas is induced towards the center.

Gas is Compressed & Pressure increases to set Gap. Sealing Dam

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Type 28BD Improved Groove

John Crane

Why Use Grooves?

The Opening Load is the summation of the Hydrostatic force and the Hydrodynamic force. Hydrostatic pressure is generated by an external source and controlled by the balance ratio of the seal. Hydrodynamic pressure is self-generated where the pumping and compression action is created by the rotating grooves. Hydrodynamic pressure increases the operating film thickness and the film stiffness of the sealing gap. Hydrodynamic pressure maintains the noncontacting sealing interface. Hence zero wear and low frictional heating.

John Crane

Spiral Groove Comparisons

SPIRAL GROOVE UNI-DIRECTIONAL SPIRAL GROOVE

John Crane

BI-DIRECTIONAL SPIRAL GROOVE

Spiral Groove Dry Gas Seals

Some of the Benefits Non-contacting no wear - life of equipment (refurb 3-5 years) increased reliability - less downtime reduced maintenance reduced heat generation - no cooling Gas lubricated no oil system - reduced weight, increased space, reduced maintenance low power consumption - typically <5kW improved operational safety.
John Crane

Spiral Groove Principles

The spiral grooves are the heart of the non-contacting design Precision depth grooves generate lift No wear or frictional heat generation Grooved component rotates in Type 28

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Sealing Interface (Normal Gap)

Approx. Gap = 0.003mm

Closing Force

Opening Force

Compression

Expansion Spring Load and Hydrostatics

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Sealing Interface (Reduced Gap)

Closing Force

Increased Opening Force

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Sealing Interface (Normal Gap)

Approx. Gap = 0.003mm

Closing Force

Opening Force

Compression

Expansion Spring Load and Hydrostatics

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Sealing Interface (Increased Gap)

Closing Force

Reduced Opening Force

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Sealing Interface (Normal Gap)

Approx. Gap = 0.003mm

Closing Force

Opening Force

Compression

Expansion Spring Load and Hydrostatics

John Crane

John Crane World Leader in Dry Gas Seal Technology

John Crane

T-28 Dry Gas Seal Design Future

John Crane

Type 28AT Design Features

Shrouded drive ring to contain rotating mating ring Mating ring positively driven on outside diameter

Distortion free Retainer with profile milled drive lugs.

John Crane

Type 28AT Design Features

Large diameter multiple springs prevent buckling Elastomer o-rings Controlled contact

Tolerance strip to centralise mating ring on support sleeve accommodating thermal, pressure and centrifugal effects.
John Crane

Type 28AT Tandem Seal

Secondary Vent Primary Vent Filtered Process Gas

Bearings

Process Gas

Tolerance Strips
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Centring Devices

Canted Coil

Standard Tolerance Strip

Finger Spring
John Crane

Type 28AT Design Features

Compliant balanced stationary carbon primary ring design providing maximum flexibility Logarithmic spiral or bi-directional grooves

Tungsten carbide or silicon carbide rotating mating ring

John Crane

Type 28AT Seal Design Features

Compliant balanced stationary carbon primary ring design providing maximum flexibility Logarithmic spiral or bi-directional grooves

Tungsten carbide or silicone carbide rotating mating ring

John Crane

T-28 Dry Gas Seal Product Range

John Crane

DGS Applications
A between bearings compressor typically comprises two type 28 Dry Gas Seal cartridges.

John Crane

DGS Application Range

John Crane DGS Operating Range

Temp: -140 to +315C Pressure: to 425 Barg Speed: to 200m/s Shaft: to 330mm

John Crane

Type 28 AT for duties up to 82 bar*

Carbon seal faces

Explosive decompression at High Pressure! Chemical Attack!

Elastomeric O Ring Secondary seal

John Crane

*some specific
designs to 120 bar

Seal Configuration & Operation Gas Seals

John Crane

Type 28AT Single Seal

Often external labyrinth

mainly to prevent ingress of bearing oil process gas is non-toxic

John Crane

Type 28AT Single Seal

Bearings

Process Gas Maximum Dynamic Pressure: 82 bar g

Single seal configuration is used mainly with non-hazardous gases such as air, nitrogen and carbon dioxide.
John Crane

Type 28AT Single Seal Cartridge

Filtered Process Gas

Simplest arrangement for lower cost sealing of non-hazardous process gases

John Crane

Type 28AT Tandem Seal

Flammable gases Hazardous gases Low toxicity gases 90 - 95% applications use tandem seals

John Crane

Type 28AT Tandem + Labyrinth

N2 Purge

Secondary Vent

Primary Vent

Filtered Process Gas

Bearings

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Type 28AT Tandem Seal Cartridge

Secondary Vent

N2 Purge

Primary Vent

Filtered Process Gas

Bearing

Proces s Gas

For sealing of non-hazardous process gases, with second seal for controlled shutdown in the event of seal failure
John Crane

Tandem with Labyrinth

Secondary Vent N2 Buffer Primary Vent Filtered Process Gas

Tandem seal with intermediate Labyrinth configuration is used with toxic, flammable and hazardous gases.
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Labyrinth

John Crane

Tandem Type 28AT with Intermediate Labyrinth

N2 Purge

Secondary Vent

N2 Purge

Primary Vent

Filtered Process Gas

For sealing of hazardous process gases, with controlled leakage to flare, atmospheric emissions limited to process gas combustion products
John Crane

Tandem with Labyrinth

Secondary Vent N2 Buffer Primary Vent Filtered Process Gas

Inboard seal failure will cause process gas leakage to atmosphere

John Crane

Tandem with Labyrinth + Type 82

N2 Buffer (2) Secondary Vent N2 Buffer (1) Primary Vent Filtered Process Gas

With external Type 82 or double purged labyrinth No process gas leakage to atmosphere
John Crane

Type 28AT - Double Seal

N2 Barrier at 2 bar above process pressure

Bearings

Process Gas

Used for highly toxic or abrasive process gases and compressors with very low suction pressures
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Type 28AT Double Cartridge

N2 Purge

Vent

N2 Buffer

Bearings

Process Gas

For sealing of hazardous process gases, with zero emissions to atmosphere

John Crane

Type 28AT / 82 - Double Seal

N2 Buffer

Vent

N2 Barrier at 2 bar above process pressure

Bearings

Process Gas

Used for highly toxic or abrasive process gases and compressors with very low suction pressures
John Crane

Type 28AT Tandem + Type 82

N2 Buffer

Secondary Vent

Primary Vent

Filtered Process Gas

Bearings

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Type 82 Barrier Seal

N2 at 0.4 bar differential

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Improved Product - Type 83 Barrier Seal

Type 82 Bushing Upgrade - the Type 83 Barrier Seal
Wave Spring Garter Spring

Carbon Segments
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Basic System

John Crane

Control & Monitoring System of Dry Gas Seals

John Crane

Control and Monitoring System

Dry Gas Seal Control System

Design - Engineering - Manufacturing - Test - All done in Singapore

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Typical Nuovo Pignone Panel

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Control and Monitoring System

Control & Monitoring System :

Filtration of Buffer Gas Regulation of Buffer Gas Monitoring of Seal Performance

John Crane

Key System Functions

Filter Control Measure

Measure

Control Measure

Bearing

John Crane

28XP Tandem Seal with Intermediate Labyrinth Gas Seal Flow Diagram
FILTERED SEAL GAS PRIMARY LEAKAGE

SEPARATION GAS SECONDARY LEAKAGE

N2 PURGE GAS

BEARING CAVITY

John Crane

PROCESS CAVITY

DGS Control System Tandem Seal with Intermediate Labyrinth

I/P PI
SEALING GAS FILTER 1

PDIT

FIL. 2

PDIT PIT
PDCV

PDIT SEPARATION / PURGE

FE

PURGE GAS PDCV FI FI FILTER 1

GAS FILTER 2

SEPARATION GAS PI PI PCV

SECONDARY LEAKAGE

SECONDARY LEAKAGE

PDIT

FE
COMPR. DISCH

FE

PDIT

PRIMARY LEAKAGE

PRIMARY LEAKAGE

John Crane

Gas Seal Support Systems

Primary Seal / Buffer Gas Supply Primary Seal Gas Leakage Secondary Seal Buffer Gas Supply Secondary Seal Leakage Separation Gas Supply

John Crane

DGS Control System - Seal Gas Supply

EXTERNAL GAS FILTER MODULE PROCESS GAS

Process Gas
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DGS Control System - Filtration

EXTERNAL GAS FILTER MODULE PROCESS GAS
FI FI

Filtered Process Gas

Process Gas
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DGS Control System - Primary Vent

EXTERNAL GAS FILTER MODULE PROCESS GAS
FI FI

Filtered Process Gas

Process Gas to Flare

PI FO FI PI FO FI

FLARE

Process Gas
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DGS Control System Buffer Gas (Nitrogen) Injection

EXTERNAL GAS FILTER MODULE PROCESS GAS
FI FI FI FI

Filtered N2 Buffer Gas Filtered Process Gas

PCV

N2 SECONDARY FILTER MODULE

Process Gas to Flare

PI FO FI PI FO FI

FLARE

Process Gas
John Crane

DGS Control System - Nitrogen Injection

EXTERNAL GAS FILTER MODULE PROCESS GAS
FO FI FI FI FI

Filtered N2 Secondary Gas Filtered Process Gas

FO PCV

N2 SECONDARY FILTER MODULE

Process Gas to Flare

PI FO FI PI FO FI

FLARE

Process Gas
John Crane

DGS Control System - Secondary Vent

EXTERNAL GAS FILTER MODULE PROCESS GAS
FO FI FI FI FI

Filtered N2 Secondary Gas Filtered Process Gas

FO PCV

N2 SECONDARY FILTER MODULE

Process Gas to Flare

PI FO FI PI FO FI

FLARE

VENT

Process Gas
John Crane

N2 to Atmosphere

Basic System
1. Basic System
Primary Seal / Buffer Gas Supply Primary Seal Gas Leakage Secondary Seal Buffer Gas supply Secondary Seal Leakage Separation / Barrier Gas Supply

John Crane

Basic System
System Functions
Provide clean seal gas
(during normal operation) Monitor Dry Gas Seal Performance (leakage flow / pressure & separation seal pressure / flow)

Seal / Buffer Gas Supply Module

Seal Leakage Monitoring Module

Secondary Seal Buffer Gas Module

Separation Gas Module

Functional Details Primary Seal / Buffer Gas Supply Module

Pressure / Flow Control Filter Particulate or Coalescing Filter

Primary Seal Leakage Monitoring Module

Monitors primary seal leakage and initiates alarm / shutdown

Secondary Seal Buffer Gas Supply Module (option)

Supplies a flow of clean dry nitrogen to the outboard seal

Secondary Seal Leakage Monitoring Module

Monitors secondary seal leakage and initiates alarm / shutdown

Separation Gas Module

Supplies a flow of clean dry nitrogen to the Separation Seal
(barrier seal) Monitors pressure or flow to the Separation Seal Initiates Alarm if it is low
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Basic

Primary Seal / Buffer Gas Supply Module

To Seal To Seal Flow Meter

Seal Gas Filter

PDCV Inlet
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Primary Seal Leakage Monitoring Module

To Flare

Pressure Transmitter

Flow Meter From Seal Leakage Block with Orifice

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Secondary Seal Buffer Gas Supply Module

To Seal

Flow Meter

Buffer Gas Filter Inlet

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Separation Gas Supply Module

To Barrier Seal Orifice Union

Separation Gas Filter

Pressure Regulator

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John Crane Dry Seal Control System INOVIT

John Crane