Professional Documents
Culture Documents
Aaron Rimpel
Tim Allison, Ph.D.
June 24, 2020
Outline
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SwRI is an Applied Research &
Development Company
Founded in 1947, based in San Antonio,
Texas
501 (c)(3) nonprofit corporation
– Internal Research
– New Laboratories
~$600M Annual revenue from contract
work for industry and government
clients
Over 2,600 employees
1,200-acre facility; 2.3 million square
feet of laboratories & offices
Flexible IP policy
Machinery Department: 70 employees,
5 labs with turbomachinery trains up
to 14 MW
Why is dry gas seal reliability important?
Minimize process gas leakage to
atmosphere
Prevent bearing oil migration
into process
Tight running clearance (3-10
microns)
– Low leakage
M. Klosek, "Short Course 4 on Dry Gas Seals," Turbomachinery – Sensitive to contamination
Symposium, Houston, 2003.
from process gas, seal supply
gas, lubrication oil
Understanding common DGS
failure modes and their
prevention can reduce frequency
and cost of DGS system failures
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Overview of DGS
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Most common seal in use:
Tandem Configuration
Primary and secondary (backup) seal in series
M. Klosek, "Short Course 4 on Dry Gas
Flow of sealing gas Seals," Turbomachinery Symposium,
Houston, 2003.
– Mostly leaks into process side
– Small amount goes through seal and primary vent
– Smaller amount goes through secondary seal and secondary vent
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Seal Gas Supply
Often taken from compressor discharge with a booster for transients
Higher pressure than required sealing pressure across compressor's operating range
– Including transients
– 50 psi above required sealing pressure usually sufficient[1]
Prevent condensation from water vapor and heavy hydrocarbons (C6+) with a
heater
– Largest pressure drop may be at seal faces
– Joule-Thompson effect will decrease temperature condensation
8
Gas Supply Control
DP control
– DP CV to keep seal gas pressure above a referenced sealing
pressure (typically 10 psi)[1]
Flow control
– Regulate gas flow through upstream orifice
– Flow control valve or needle valve
– Automatic control recommended
Recommended 32 ft/sec flow across inner laby[1]
Minimize seal gas consumption since most is recycled
– Very little flow required for seal
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Separation Seals
Labyrinth seals
– Least expensive
– Reliable
– Highest leakage
Contacting segmented carbon ring seals
– Wear service life of 3-5 years
– Low leakage
Noncontacting segmented carbon ring seals
– Indefinite service life
– Challenging operating conditions
10
Typical DGS Supply System Layout
Supply and vent locations at compressor (single seal)
Objective: Min 16 ft/s across process laby at 2x seal clearance
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Example DGS System
Filter DP
DP for Seal Gas Reference P
Control from
Seal Gas Compressor
Supply
Filter Seal Gas To Seal
Control Valve
Filter DP
LP Reference
Separation
Gas Supply HP Reference
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Typical Failure Modes
Process Supply Lube Oil Installation/
Contamination Contamination Contamination Geometry
15
Supply Gas Contamination:
Liquids in Vent Unable to be Drained
Causes
– No low point to drain liquid accumulation in vent
Symptom
– Liquid contamination in primary seal
Solution
– Have low point in primary vent line before flare to drain liquid
– Operator should check drain regularly
16
Supply Gas Contamination:
Other Contamination (28%)
Causes
– Contamination from a procedure (such as cleaning) where system
would be opened
– Other contaminates in lines are stirred up during transients (in seal gas
system and compressor operation)
– Upstream over-pressurization
Symptoms
– Contamination on gas side
– Oil contamination (from booster compressor)
– Solids in lines
Solution
– Flush & blow out upstream pipes
– Use stainless steel pipes instead of carbon steel to minimize corrosion
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Supply Gas Contamination:
Filter Overload or Degradation (8%)
Causes: Filter overload
– Operator not heeding alarms, not changing filter
– Collapses, sends large “clump” of debris through
Causes: Filter degradation
– Operator not heeding alarms, not changing filter
– Filter starts to allow larger particles through once clogged
Symptoms
– Vent pressure and vibration jump upward for a catastrophic, quick failure
(overload)
– Vent pressure trends upward to a gradual failure (degradation)
Solution
– Ensure operator heeds alarms related to filter and is trained to change filters
– Have duplex filter setup so filter can be changed while operating
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Filters in DGS Supply System
Filter DP
DP for Seal Gas Reference P
Control from
Seal Gas Compressor
Supply
Filter Seal Gas To Seal
Control Valve
Filter DP
LP Reference
Separation
Gas Supply HP Reference
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Coalescing Filter
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Other Failure Modes:
Improper Installation (38%)/Geometry (62%)
Causes
– Parts missing/not installed
– No axial movement on seal faces (were in contact)
– Drive pin too long or too short
Symptom
– Immediate failure on startup
– Misalignment (drive pin)
Solution
– Check drive pin dimensions prior to installation
– Check for proper installation
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Process Gas Contamination:
Cause
– Intermittently or continuously insufficient seal gas pressure (25%)
– Alarms and trips to not allow operation without sufficient seal gas pressure
– Provide gas supply during pressurized hold; provide adequate oil drainage
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Phase Map Analysis
Screen supply system with multiphase simulation tools
– Liquid dropout
– Solid formation
– Hydrate formation
Include system pressure drops and heat transfer
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Lube Oil Contamination (21%)
Causes
– Insufficient separation gas
– Inadequate separation seal design
– Lube oil flow too high, overcomes drains
Symptoms
– Wet oil on seal faces
Solution
– Increase separation gas pressure to upper design limit on seal[1]
– Note: excessive DP can accelerate wear of barrier seal
– Have minimum separation gas pressure as a start permissive for
lube oil
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Liquid Contamination Failure Mechanisms
Liquid droplets stick to faces and pull out material
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Liquid droplets stick to faces and pull out material
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Shear force breaks faces
Startup [OEM discussions]
Liquid accumulation in seal [OEM discussions]
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Faces overheat due to friction
High viscosity fluids [End-user discussions]
Flow rate dependence [OEM discussions]
Thermal deformations cause seal face rubs [OEM discussions]
Material failure at high temperatures [2, 3]
Results in shattered seal face
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Solid residue from liquid evaporation
Scoring on faces [4, OEM discussions]
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Grooves fill with liquid
Affects running gap, leads to poor hydrodynamic performance
[OEM discussions, 2]
May lead to face contact [OEM discussions, 2]
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Vaporization across seal faces
Rapid vaporization can shatter ceramics in seal [OEM
discussions]
“Puffing” due to vaporization [Pump seal discussions, 1]
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Hang-up due to liquid contamination
Affects tracking of seal faces
May result in face contact and high heat
Evidence of contamination or pitting
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Ongoing R&D efforts
GMRC-funded project to improve DGS reliability
– Better understand liquid contamination effects to improve
design, instrumentation, monitoring
– Develop analytical capability to predict failures
33
Rig for DGS liquid contamination testing
Back-to-back seal for thrust balance
3.5” shaft, 13,500 rpm
Vars: pressure, gas, liquid, LMF/LVF
Meas: flow, torque, temperature
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Two-phase CFD modeling of DGS
Eulerian-Lagrangian modeling approach
Discrete Phase Model (DPM)
Constant size droplets injected uniformly at the inlet of the geometry
(Sauter mean)
Spherical drag model
Taylor Analogy Breakup (TAB) model
Heat transfer through thermal system coupling approach
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Thank you!
Aaron Rimpel
aaron.rimpel@swri.org
Tim Allison
tim.allison@swri.org
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References
[1] J. S. Stahley, Dry Gas Seals Handbook, Tulsa: PennWell Corporation, 2005.
[2] M. Klosek, "Short Course 4 on Dry Gas Seals," in Turbomachinery Symposium, Houston, 2003.
[3] J. S. Stahley, "Design, Operation, and Maintenance Considerations for Improved Dry Gas Seal
Reliability in Centrifugal Compressors," in Proceedings of the 30th Turbomachinery Symposium,
Houston, 2001.
[4] American Petroleum Institute, API Standard 614: Lubrication, Shaft-Sealing, and Control-Oil
Systems and Auxiliaries for Petroleum, Chemical, and Gas Industry Services, 5th ed., Washington
D.C.: CSSinfo, 2008.
[6] J.M. Thorp, “Improving Dry Gas Seal Reliability”, API Spring Refining Meeting, New Orleans, April
15, 2008.
[7] M. Day and T. Allison, “Analysis of Historical Dry Gas Seal Failure Data in Natural Gas
Compressors”, Gas Machinery Conference, Denver, October 4, 2016. Also available as M. Day and T.
Allison, “Analysis of Historical Dry Gas Seal Failure Data”, ASME Turbo Expo, Seoul, South Korea, June
16, 2016.
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