OIL & GAS

Dry gas seal systems - part 3

BEST PRACTICES FOR INTERMEDIATE AND SEPARATION GAS SYSTEMS, DGS MONITORING AND PROTECTION OPTIONS
R. J. AIMONE, W. E. FORSTHOFFER AND R. M. SALZMANN

o far in this series we have discussed seal selection, seal gas conditioning, seal gas control and primary vent systems. We encourage readers to visit www.turbomachinerymag.com to obtain the previous two articles in this series. This final article will discuss best practices for: Intermediate labyrinths for tandem Dry Gas Seal (DGS) systems Vent systems between the seal cartridge and separation seal Separation seal systems DGS system monitoring and protection options

Specifying nitrogen use

In most cases, nitrogen is used as the intermediate and separation seal gas. If a site N2 source is not available, another alternative is to manufacture a low-grade, non-cryogenic N2 gas (minimum N2 content of 95%), using instrument or plant air. Process designs and commercial units for N2 production are available and have been used successfully. Regardless of the gas used, the best practice is to filter all the gas for both systems using dual coalescing filters (5 micron absolute), to assure that there is no free moisture. If cryogenic nitrogen (N2 that has been liquefied) is used, carbon face damage on the DGS can occur during slow-speed operation when the faces are in contact, or damage to radialcontact carbon seals can result (part 2, p. 24, March/April 2007). The best practice is to condition the N2 upstream of the coalescing filter system and raise its dew point to -30C (22F) or higher. Specific details of the plants nitrogen system should be discussed with seal suppliers in the pre-feed project phase if contact-type separation seals are used, or if extended periods of turning gear operation are anticipated. Intermediate labyrinths for tandem DGS systems: Since double seal applications use N2 as the seal gas (Figure 1), only N2 will flow through the atmospheric side seal. Therefore, an intermediate seal is not required. As stated in part 1 of this series (p. 20,
24 Turbomachinery International May/June 2007

Figure 1: An intermediate seal is not required for double seal applications as they use N2 as the seal gas and only N2 will flow through the atmospheric side seal

Jan./Feb. 2007), an intermediate labyrinth is always recommended for tandem DGS applications. The intermediate labyrinth assures that N2 is always present between the seals, and limits the flow of process gas to the secondary seal in the event of a primary seal failure. The best practice is to use flow control, complete with local flow indicator, to each seal. The goal is to achieve a velocity of 50 ft/sec through the intermediate labyrinth, without masking the primary seal leakage (Figure 2). Vent systems between the DGS cartridge and separation seal: Usually referred to as the secondary vent, its purpose is to direct the gas present between the DGS (tandem or double arrangement) and the separation seal to a safe location. Most importantly, conditions in this vent can provide information on the health of the outer seal (secondary seal for tandem arrangements and atmospheric seal for double seals) and the separation seal. The majority of installations do not specifically monitor the condition of the secondary or outer seal. Undetected failure of the secondary or the outer seal

exposes the plant to a process gas release in the event of primary or inner seal failure. If process gas can blow through the separation seal and into the bearing housing, a catastrophic equipment failure could occur. Therefore, the best practice is to monitor the condition of the secondary or outer seal by measuring one of the following (Figures 1, 2): High pressure in the secondary vent suggested setting: 1 kpag - 2 kpag (5 inches - 10 inches water column) Low pressure differential between the separation seal inlet and secondary vent pressure (if the separation gas is controlled at a fixed pressure) Low pressure in the primary seal vent this assumes that a pressure of 30 kpag - 40 kpag (5 psig) is normally maintained between the primary and secondary seals (see part 1) The decision to alarm or trip will depend on the application and the potential daily revenue loss of the plant. Since this vent can also contain oil or oil mist in the event of a separation seal system malfunction, the best practice is to monitor the effectiveness of the separation seal by locating the vent in the seal chamber at the low point (6 oclock position), and installing a device to indicate oil contamination (level glass as a minimum), with a drain valve to a safe location in the vent line. Separation systems: Regardless of the type of seal configuration (double or tandem), the function of the separation system is to prevent process gas from entering the bearing housing in the event of a seal failure, and oil from entering the seal cartridge (See Figures 1, 2 for system details). Entrance of process gas into the bearing housing exposes the plant to catastrophic consequences and extended downtime. There are several types of separation seals. The choice depends on the availability of the separation gas (usually N2). The alternatives, arranged in order of highest usage of separation gas, are: Labyrinth seals Abradeable labyrinth seals Non-contact carbon seals Segmented carbon contact seals The best practice is to use labyrinth or abradeable labyrinth separation seals, if sufficient N2 is available. This recommendation is based on the reliability of
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of critical importance to plant safety and reliability, and will require a HazOp review for each application.

Defining the seal system

In concluding this series, the following guidelines are recommended to promote DGS system safety and reliability. Always use a proactive approach as early as possible in the project. Completely define the entire system during the pre-feed phase of the project (using data sheets or a P&ID) to all quoting suppliers. Work as a team with the compressor and seal suppliers. Listen to their recommendations and consider action based on lessons learned. We sincerely hope that the DGS discussion and best practices presented in this series will be helpful in anticipating potential problems, and assuring optimum safety and reliability for all DGS installations. TI Footnotes:
No responsibility is assumed by the authors for any injury and/or damage to persons or property as a matter of product liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in these articles. Figure 2: Flow control should be used to achieve a velocity of 50 ft/sec through the intermediate labyrinth, without masking the primary seal leakage

Authors:
Robert Aimone has 47 years experience in the machinery field; in operations, maintenance, design, specification and troubleshooting. He spent over 30 years on the technical staff of Mobil Oil Corporation and the last six years as president of his own consulting firm REMO. William Forsthoffer has over 36 years experience in the turbomachinery industry as a designer (DeLaval), facilities engineer (Mobil), and field troubleshooter and trainer. In 1990, he founded Forsthoffer Associates Inc., (FAI), a turbomachinery consulting firm. Dick Salzmann has 44 years in the turbomachinery field, including 36 years with Delaval Turbine Inc. and its successors. His experience covers machinery application, design, testing, training and troubleshooting. Salzmann has been consulting for the last 6 years with FAI.
May/June 2007 Turbomachinery International 25

labyrinth-type seals compared to carbon seals, and the fact that the differential pressure across labyrinth seals is not limited, as is the case for most carbon ring seals. If carbon ring seals are used, the control system must limit the differential pressure to the design maximum. In addition, if carbon contact seals use cryogenic N2, the best practice is to condition the N2 (described in part 2). Experience shows that in the case of a catastrophic seal failure, there is a possibility that process gas could enter the bearing housing through the separation seal. For this reason, the best practice is to individually vent each of the bearing housings to a safe location. The method of separation gas control depends on the type of seal selected. For labyrinth and abradeable labyrinth seals, the best practice is to use differential pressure control seal supply pressure minus secondary vent pressure to each seal. For carbon ring seals, pressure control could limit the maximum differential pressure across the carbon rings. The condition of each separation seal can be determined by monitoring and alarming on low differential pressure for labyrinth and abradeable labyrinth seals. For carbon ring seals, monitoring and alarming on low pressure is recommended. These parameters should be used as
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permissive signals to prevent starting the oil system if N2 gas is not being supplied to the separation seals.

Monitoring and protection

The majority of current DGS installations trip on primary seal failure by measuring primary vent pressure or flow. In the case of a high-value product, where availability of the plant is critical, operations may choose to continue running for short periods after the primary seal fails, while preparing for shutdown. In this case, the recommendation is to trip on indicated primary AND secondary seal failure (atmospheric side for double seals). Trip options are based on the type of seal configuration and secondary seal. They are: Tandem seals trip on high-high primary seal flow or pressure AND high secondary vent pressure Tandem seals with carbon contact separation seal trip on high-high primary seal flow or pressure AND low N2 separation gas supply minus secondary vent pressure Double seals trip on high-high seal gas supply flow AND vent high-high pressure For any of the above options, instruments associated with the shutdown circuit should be triple modular redundant. The final decision regarding unit trips is