TECHNICAL

ALERT
CONSULTING SERVICES DEPARTMENT
SUBJECT:
GAS RELEASE DUE TO FAILURE OF
CENTRIFUGAL GAS COMPRESSOR SEALS

ALERT NO.
001/02

DATE:
01/29/02

SUMMARY
Failure of centrifugal compressor seals can result in process gas entering the
bearing housing cavity. From this cavity, the gas can be released to atmosphere
through the bearing-housing vent and/or can travel with the oil return to the oil
reservoir. Excessive gas release at these vents presents a danger of fire,
and/or personnel hazard due to H2S poisoning if the process gas is sour.
Gas accumulation in the reservoir can produce an explosive gas mixture,
which has the potential to explode and cause serious damage to plant and
personnel. One incident where gas accumulated in the reservoir and
subsequently exploded, occurred on a compressor skid in Safaniya in
1991.
Two recent cases of excessive gas accumulation in the reservoir have occurred,
one with dry gas seals, and one with oil seals. In both cases, blockages in vent
lines prevented gas venting, causing it to flow to the bearing housings and
subsequently to the reservoir, and giving false indications that the seals were
operating satisfactorily since leakage rates to the vent would appear low. In both
cases the free space above the oil in the reservoirs was composed of 100% gas,
thus not explosive, and so fortunately no explosion or damage occurred. On the
unit fitted with oil seals, gaseous vapor could be seen coming from the bearing
housing vents. The vapor found no source of ignition within the immediate area
and so again it was quite fortunate that no explosion or damage occurred.
RECOMMENDATIONS
Faulty compressor seals should be replaced immediately. Lube and seal oil
reservoirs and bearing housing vents should have regular gas tests performed,
using a suitable gas tester, to identify any gas leakage. As additional protection,
and to eliminate the possibility of human error, it is recommended to install
permanent gas detection devices should be installed, where possible, and fitted
with alarms, to continuously monitor these areas. This is now a standard
requirement for new equipment.

In addition, compressor seal systems should be regularly monitored/inspected to

ensure that all components of the system are in good condition and operating
satisfactorily.
For compressors fitted with oil seals, the systems / items to be inspected include
the following:

Leakage detection systems, transmitters, switches, etc.

Seal oil trap check valves, drain valves, orifices, level switches/gauges,
and automatic drainers
Buffer gas control valves
Seal oil supply system, filters, pressure gauges, switches, transmitters,
etc.

For compressors fitted with gas seals, the systems / items to be inspected
include the following:

Leakage detection systems, flow meters/transmitters, pressure

switches/transmitters, etc.
Nitrogen supply system to the tertiary seals
Gas detectors in the vent lines
Vent line orifices, check valves, rupture discs, pzvs, etc.

If you have any questions regarding this technical alert, please contact E.W.
Brown at 874-6154.

____________________________
S.A.Al-ZAID, Manager (A)
Consulting Services Department