PROJECT EQUIPMENT MODEL

560MW Bin Qasim Combined Cycle Power Project Karachi Natural Gas Compressor(Ⅰ) MCL526+MCL457

Dry Gas Seals Manual

DRY GAS SEALS MANUAL

Sichuan Nikki Seals Co., LTD
Aug. 2010

TABLE OF CONTENTS
1 2 3 4 5 6

INTRODUCTION……………………………….……….……….… 3 STRUCTURE SPECIFICATION……….………....…………….. 7 CONTROL SYSTEM……..……………………………..….………9 INSTALLATION / REMOVAL……………………………..….…..20 OPERATION / MAINTENANCE…………………………………..25 SHIPMENT / STORAGE……………………………………………28

Appendix 1 :

Assembly Drawing CW (LP)

Drawing No: SNS0920-051-00-CW

Appendix 2 :

Assembly Drawing CCW (LP)

Drawing No: SNS0920-051-00-CCW

Appendix 3 :

Assembly Drawing CW (HP)

Drawing No: SNS0920-052-00-CW

Appendix 4 :

Assembly Drawing CCW (HP)

Drawing No: SNS0920-052-00-CCW

Appendix 5: Dry Gas Seal Control System P&ID (LP)
Drawing No: SNS0920-051-XT

Appendix 6: Dry Gas Seal Control System P&ID (HP)
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Sichuan Nikki Seals Co., LTD china.com

Tel:(028)85369013 Fax:(028)85366222 Home Site:www.sns-

DRY GAS SEALS MANUAL
Drawing No: SNS0920-052-XT

Appendix 7: Installation And Removal Drawing (LP-CW)
Drawing No: SNS0920-051-AZ-00-CW

Appendix 8: Installation And Removal Drawing (LP-CCW)
Drawing No: SNS0920-051-AZ-00-CCW

Appendix 9: Installation And Removal Drawing (HP-CW)
Drawing No: SNS0920-052-AZ-00-CW

Appendix 10: Installation And Removal Drawing (HP-CCW)
Drawing No: SNS0920-052-AZ-00-CCW

Appendix 11: Installation And Removal Instruction (LP-CW)
Drawing No: SNS0920-051-ZC-CW

Appendix 12: Installation And Removal Instruction (LP-CCW)
Drawing No: SNS0920-051-ZC-CCW

Appendix 13: Installation And Removal Instruction (HP-CW)
Drawing No: SNS0920-052-ZC-CW

Appendix 14: Installation And Removal Instruction (HP-CCW)
Drawing No: SNS0920-052-ZC-CCW

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Sichuan Nikki Seals Co., LTD china.com

Tel:(028)85369013 Fax:(028)85366222 Home Site:www.sns-

it does not need lubricants or lubrication control system.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.DRY GAS SEALS MANUAL 1. Long life and stable performance. By now. LTD china. its gas control system is less complicated than ordinary mechanical seals’ lubrication system. 1. A dry gas seal is suitable for any gas-delivering system. Invention of dry gas seal has been a breakthrough in sealing technology. Second.1 PRINCIPLES OF DRY GAS SEALS The main difference between a dry gas seal and a mechanical seal is there are equally spaced hydrodynamic grooves on one sealing face of dry gas seal. Lower maintenance cost. Third. Comparing with ordinary oil seal. gas flows into the grooves and compressed. economic and practical is better. First.sns- . Results have shown that dry gas seals compare favorably with ordinary oil seals in many ways. After several years of research and test.. it is non-contact and therefore there is hardly any restriction to its PV value. John Crane put out the world’s first dry gas seal into industrial use. Low power. high pressure or large centrifugal compressors than contact mechanical seals. Greatly reduced the maintenance expense and shutdown times. it is widely used on centrifugal compressors in China’s petrochemical. a new conception of “gas sealing” with no leakage has replaced the traditional “fluid sealing”. a dry gas seal has many merits:        Economize the extra power spent on driving the system. it is more suitable as shaft seals for high speed. to form a high-pressure part and -4- Sichuan Nikki Seals Co. chemical engineering and pharmacy industry. Its invention is based on gas-lubricated-bearing theory since the 60s of last century. As a result of the combination of dry gas seal and block sealing theory. Avoiding the possibility that process gas is polluted by oil Low leakage of the sealing gas. INTRODUCTION Dry Gas Seals is a type of newly developed non-contact shaft seal. When operating. oil refining.

open force will increase and the gas film will return to normal thickness for keeping force balance. It always exists whether the shaft is rotating or not. The rigidity of the gas film (Fv/Tv. Fig.. However. In normal conditions. Dry gas seal would always return to its working clearance after the disturbance is eliminated in the scope of design.1 typical spiral grooves Sichuan Nikki Seals Co. the sealing gas is pulled into the spiral grooves by viscous tangential force generated by the rotating ring. Tv: variation of thickness of the gas film) is an index usually used to judge -5- Fig.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.Fv: variation of acting force on the sealing face. When the seal operates. the opening force is equal with the closing force.1 shows a typical spiral grooves on the stationary ring: The depth of spiral grooves on a sealing face (Fig. The high pressure lead to the sealing faces to open and there becomes a gas film between the faces. Therefore. if comes a disturbance (processing or operating wave) which reduces the thickness of the gas film. the gas is driven to move toward the center but blocked by the sealing dam. if the disturbance causes increase thickness of gas film. Both the springs and the sealed fluid provide static pressure loaded on the sealing face. the tangential force will reduce and spiral groove of produce kinetic pressure will also reduce to cause the gas film pressure reduce then the opening force will drop and the gas film will return to normal thickness. the tangential force will grow and spiral groove of produce kinetic pressure will also grow to cause the gas film pressure increase . In the grooves. LTD china. Fig. The balance between the opening force by film and the closing force by spring and medium acting force makes non-contact operating of the seal possible.1) is within 8~15μm. therefore the gas is compressed and form a high-pressure zone. Gas film has certain rigidity to ensure stable working of a seal and lubricant function.sns- .2 is a force diagram of a spiral groove dry gas seal which shows how the rigidity of the gas film is formation and how does it guarantee the stable performance of the seal. On the contrary.DRY GAS SEALS MANUAL the sealing face begins to work.

Make sure the seal is at best working condition and give out alarms when the seal fails.2 Seal Type And Monitoring System For different kinds of working condition. there are various types of seals to choose. we can see whether the seal is operating normally.sns- . it monitoring the seal’s working condition. tandem seals and tandem seals with intermediate labyrinth. the value bigger is better. Usually. on the other hand. To ensure stable operation of dry gas seal. our workers can deal with the problem as soon as possible.2 force diagram of spiral groove dry gas seal 1. The control system gives out alarms when the flow or pressure value is abnormal (too high or too low). the seal might have failed and the system will interlock shut down.DRY GAS SEALS MANUAL the stability of a seal. -6- Sichuan Nikki Seals Co. relative monitor and control system is provided with the seal system. Fig. LTD china. By means of measuring the flow of gas leakage and monitoring relative pressure . If the gas leakage exceeds trip value.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. dry gas seals can be classified as single end face seal.. the system provides clean and dry gas to the seal. On one hand. double end face seal.

.DRY GAS SEALS MANUAL -7- Sichuan Nikki Seals Co.sns- . LTD china.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.

1 Features Of Dry Gas Seal . Code: H1191. which usually works under lower pressure difference. LTD china. which are of high safety and reliability. Model: MCL526 ( LP ) +MCL457 ( HP ) .27barg Discharge Temperature: 158.6 Discharge Pressure: 29barg Discharge Temperature: 147.DRY GAS SEALS MANUAL 2. and the seal face operates at a non-contacting state to avoid abrasion. When primary seal failed.sns- .6 Discharge Pressure: 10..4 oC Process Gas: Natural Gas Suction Pressure: 10. This structure can ensure that process gas will not leak into atmosphere. and the injected gas (N2) will not leak into the compressor.0barg Suction Temperature: 28oC Shaft Speed : 9934 rpm MCS 2) HP: Molecular Weight: 18. The operating condition is as following: 1) LP: Process Gas: Natural Gas Suction Pressure: 2.. Primary seal bear major pressure difference. Tandem Gas Seal is comprised of two single end face seals in a tandem arrangement. 2, 3, 4 Reference: APPENDIX 1, The GCTL01/L-152 and GCTL01/L-133 gas seals are Tandem Gas Seal with Labyrinth.02barg Suction Temperature: 45oC Shaft Speed : 9934 rpm MCS 2.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. STRUCTURE SPECIFICATION This natural gas compressor used on 560MW Bin Qasim Combined Cycle Power Project Karachi is a multistage compressor manufactured by Shenyang Blower Works Group Co. and excessive leakage gas can be avoided by secondary seal. Ltd. The barrier -8- Sichuan Nikki Seals Co.9 oC Molecular Weight: 18. Secondary dry gas seal is an auxiliary safety seal. secondary seal can bear major pressure difference to ensure the compressor be shut down safely.

General -9- Sichuan Nikki Seals Co. Because of slight abrasion during start-up/shut-down process.2 Performance Criteria Expected value of the seal under normal condition (1 suit): 1) LP Leakage rate of processing gas: less than 2 Nm3 / h Consumption rate of secondary seal gas(N2): less than 16 Nm3 / h Consumption rate of barrier gas (N2): less than 40 Nm3 / h Power: less than 3kw 2) HP Leakage rate of processing gas: less than 4 Nm3 / h Consumption rate of secondary seal gas(N2): less than 16 Nm3 / h Consumption rate of barrier gas (N2): less than 40 Nm3 / h Power: less than 3kw 3. axial installing precision and avoids outside dust and impurity affecting the performance of the seal.1.DRY GAS SEALS MANUAL seal on the atmospheric side can prevent lubricant oil enter to the sealing area and provide a clean and dry operation environment. The dry gas seal is assembled structure to prevent any damage by transport. realize the non-contact state. Meanwhile. when rotation. Open force and close force dynamic balance. CONTROL SYSTEM 3. The rotating ring has a series of spiral grooves on its running faces.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. LTD china. high rigidity gas film is formed in between the rotating and static ring. the rotating ring is made of Tungsten Carbide with high rigidity. the setting plates should not be taken off until the seal is installed onto the device with an installation tool. while the stationary ring is made of Carbon with self-lubricating.sns- . Make seal face separate 3 ~ 5 u m.. 2.

The piped Nitrogen is separated into two lines after filtered and decompressed. The leakage mixed with secondary seal gas (nitrogen). The purpose of the system is to provide clean and dry gas for the seal. as the primary seal gas leakage.5bar). work as barrier gas. goes through a flow control orifice and throttle valve before entering the seal chamber. will be vent. Start the barrier gas -10- Sichuan Nikki Seals Co. cooled and dehumidified process gas from discharge side works as primary seal gas . and to monitor the working condition of the seal. The working process of the system is: When the seal is normally operating. which based on proper pressure.sns- . The other line of nitrogen. only a little of this line gas will leak from the secondary seal face and this little gas is mixed with part barrier gas which leaks from process side of labyrinth.. the mixed gas is secondary seal gas leakage. The other part.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. there becomes a stable gas film between the faces. The secondary seal work as assistant seal.The gas is introduced into the seal chamber by filter and diff pressure control valve according to setting pressure (the pressure difference for primary seal gas and process gas at secondary balance pipe more than 1. One part of the gas is discharged into bearing case through the labyrinth seal. The majority of this line gas after going though middle labyrinth is mixed with leakage from the primary seal face and then vented. Though this seal did not bear the main pressure. Only a few of the seal gas (less than 2Nm3/h/ per set) may leak through the sealing faces of the main seal. to prevent unclean process gas entering the sealing area and this value is measure by a differential pressure transmitter and transmitted to the control room DCS/ITCC. one line gas as secondary seal gas. Its pressure must be controlled at 3bar higher than the process gas at the balance pipe. is led into the labyrinth seal after controlled by flow control orifice and throttle valve.DRY GAS SEALS MANUAL Special monitoring and controlling system is designed for the seal (SEE APPENDIX five and six). LTD china. primary seal gas leakage piped go back to controlling panels to measure its pressure and flow and then vented . The majority of primary seal gas introduced into the seal chamber goes back into the casing by labyrinth sealing at the end of the shaft. mixed with the leakage form secondary seal faces as the secondary seal gas leakage. the leakage is vented though pipe.

com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. if secondary seals fails.OR1. FL1. dehumidified process gas from filter discharge side is introduced into the dry seal system . Its pressure should be maintained at 0. Its value is measured by flow meter and transmitted to the control room.DRY GAS SEALS MANUAL before starting the lube system. V2. FL2 ( FL3 、 FL4 standby ) . V5.The process gas. if primary seals fails.7barg and then separated into two lines after going through V19. LTD china. At the same time the flow which enters into YAEKD91CF501 、 controlled at 40 Nm3/h by adjusting V13 , 2) Secondary Seal Gas V16 by hand. V20. YAEKD91CF502 is Nitrogen ( about 6barg ) , work as secondary seal gas. ( FL6 as a standby) . One line goes into the secondary seal chamber of the suction side through V27 、 YAEKD91CF503 、 V28 、 V30. its pressure is decompressed to 0. primary leakage flow and pressure will increase quickly . Another line goes -11- Sichuan Nikki Seals Co. primary leakage flow and pressure will decrease quickly and when it reaches the set value will send alarm and trip. FL5.1.V10.sns- . is divided into two lines after going through V1. 3. The control signal of diff pressure control valve YAEKD91 ZZ001 is measured by diff pressure transmitter and transmitted to the DCS/ITCC and then output to diff pressure control valve.03MPa to form a reliable blocking seal and to prevent the lubricant steam from entering the dry gas seal faces. The primary seal gas leakage flow is used to judge whether the seal is working normally. The other line goes into the seal chamber of the discharge side (drive end) through V16 、 YAEKD91CF502 、 V17. work as primary seal Gas.1 LP Control System of the Seal 1) Primary seal Gas When the seal is normally operating.YAEKD91ZZ001 and V11. Therefore the pressure after control valve is controlled at 3 bar higher than the process gas at the secondary balance pipe.V24. One line goes into the seal chamber of the suction side (non-drive end) through V13 、 YAEKD91CF501 、 V14.V21. However. V6..

another line goes though flange D1 at discharge side (drive end). The secondary seal leakage gas will be vented to safety zone though flange pipe joint.sns- .DRY GAS SEALS MANUAL into the secondary seal chamber of the discharge side through V31 、 YAEKD91CF504 、 V32 、 V34. Attention: Start the barrier gas before starting the lubricant system. The pressure of another line Barrier Gas is decompressed to 0. Nitrogen for compressor staring -12- Sichuan Nikki Seals Co. The pressure of one line Barrier Gas is decompressed to 0. but need check it at regular intervals.3barg after going through V39 、 OR3 . LTD china. the drain should be closedown. 7) Drain In order to prevent large oil drops from entering the dry gas seal area and polluting the gas seal when the compressor is at commissioning , oil cycle or oil pressure undulate. (One line goes though flange D2 at suction side (non-drive end). And shut down the barrier gas after the lubricant system is stopped ten minutes! 4) Drive gas Diff pressure control valve YAEKD91ZZ001 use filtered Instrument air as power supply. 3) Barrier Gas Nitrogen after filter.. When the compressor is normally operating.This line of piped Nitrogen goes into the barrier seal chamber of the suction side (non-drive end) through V36 、 V38. is separated into two lines. 5) Primary seal leakage gas The primary seal leakage gas of suction side (non-drive end) is vented after going through V43 、 V44 、 YAEKD91CF001 、 V45 、 V47.This line of piped Nitrogen goes into barrier seal chamber of the discharge side (drive end) through V40 、 V42.3barg after going through V35 、 OR2 .com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. the drain should be open. The primary seal leakage gas of discharge side (drive end) is vented after going through V48 、 V49 、 YAEKD91 CF002 、 V50 、 V52 。 6) Secondary seal leakage gas The component of secondary seal leakage gas is nitrogen. work as barrier gas.

YAEKD91CF505 is controlled at 40 Nm3/h by adjusting V59 , 2) Secondary Seal Gas V59 by hand. dehumidified process gas from HP discharge side is introduced into the seal system . LTD china. its pressure is decompressed to 0.DRY GAS SEALS MANUAL The pressure of discharge side do not rise to normal condition at the moment of compressor staring. is divided into two lines after going through V1.1. Nitrogen ( about 6barg ) , work as secondary seal gas. Therefore the pressure after control valve is controlled at 3 bar higher than the process gas at the secondary balance pipe. The control signal of diff pressure control valve YAEKD91 ZZ002 is measured by diff pressure transmitter and transmitted to the PLC and then output to diff pressure control valve.YAEKD91ZZ002 and V54. 3. The pressure of nitrogen is controlled at 0. ( FL6 as a standby) . FL5. Therefore we use nitrogen to replace process gas from discharge side to work as primary seal gas. Another line goes into secondary seal chamber of the discharge side through V69 、 YAEKD91CF508 、 V70 、 V72.2MPaG higher than casing inside.7barg and then separated into two lines. One line goes into the seal chamber of the suction side (non-drive end) through V56 、 YAEKD91CF505 、 V57. work as primary seal Gas.The process gas. so the pressure difference between suction side and discharge side is very low and the primary seal gas may can not introduce into seal chamber. FL2 ( FL3 、 FL4 as a standby ) . V6. V2. V20.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.OR4.sns- . FL1. At the same time the flow which enter into YAEKD91CF501.V62. One line goes into the secondary seal chamber of the suction side through V65 、 YAEKD91CF507 、 V66 、 V68 .2 HP Control System of the Seal 1) Primary seal Gas When the seal is normally operating.V53. 3) Barrier Gas -13- Sichuan Nikki Seals Co. V5. after going through V19.V21. The other line goes into the seal chamber of the discharge side (drive end) through V59 、 YAEKD91CF506 、 V60..

The pressure of another line Barrier Gas is decompressed to 0.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. And shut down the barrier gas after the lubricant system is stopped ten minutes! 4) Drive gas Diff pressure control valve YAEKD91ZZ002 use filtered Instrument air as power supply.. the drain should be close. The secondary seal leakage gas will be vented to safety area though flange pipe joint. another line goes though flange D3 at discharge side (drive end). When the compressor is normally operating.3barg after going through V73 、 OR5 . (One line goes though flange D4 at suction side (non-drive end). the drain should be open. The pressure of one line Barrier Gas is decompressed to 0.3barg after going through V77 、 OR6 .This line of Nitrogen goes into the barrier seal chamber of the discharge side (drive end) through V78 、 V80. -14- Sichuan Nikki Seals Co. but need check it at regular intervals Nitrogen for compressor staring The pressure of discharge side do not rise to normal condition at the moment of compressor staring-up.DRY GAS SEALS MANUAL Nitrogen after filtered work as barrier gas is separated into two lines. 7) Drain In order to prevent large oil drops from entering the dry gas seal area and polluting the gas seal when the compressor is at commissioning , oil cycle or oil pressure undulate.sns- . The primary seal leakage gas at discharge side (drive end) is vented after going through V86 、 V87 、 YAEKD91 CF004 、 V88 、 V90 。 6) Secondary seal leakage gas The component of secondary seal gas leakage is nitrogen. Attention: Start the barrier gas before starting the lubricant system. 5) Primary seal leakage gas The primary seal leakage gas at suction side (non-drive end) is vented after going through V81 、 V82 、 YAEKD91CF003 、 V83 、 V85.This line of piped Nitrogen goes into the barrier seal chamber of the suction side (non-drive end) through V74 、 V76. LTD china. so the pressure difference between suction side and discharge side is very low and the primary seal gas may can not be introduced into seal chamber.

2) Filter Blockage Diff pressure transmitter YAEKD91CP051 is to measure the pressure difference on the two sides of the primary seal gas filter.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. Alarm And Interlock LP Casing 1) The pressure difference for primary seal gas and process gas at the secondary balance pipe Diff pressure transmitter YAEKD91CP052 is to measure the pressure difference for primary seal gas and process gas at the secondary balance pipe. Diff pressure transmitter YAEKD91CP053 is to measure the pressure difference on the two sides of nitrogen filter. The normal value is 6bar.5bar is a precondition for the lube oil pump startup.08MPa. High-pressure alarm is 0. FL6 discharge condensate automatically by floating balls.2 Measuring. 4) Pressure of Primary seal leakage gas Pressure transmitter YAEKD91CP002 、 YAEKD91CP003 are to measure the Pressure of Primary seal leakage gas on both the suction side (non-drive end) and the -15- Sichuan Nikki Seals Co. The normal value is N=3bar.sns- . condensate of primary seal gas filter FL1 、 FL2 、 FL3 、 FL4 is controlled by valve V9 and discharge to container though flange N3 at regular intervals . The pressure difference higher than 1.5bar is a precondition for the compressor startup. High-pressure alarm is 0. 3) Pressure of Barrier Gas Pressure transmitter YAEKD91CP001 is to measure the pressure of barrier gas.2. Low PD alarm is given at L=1bar.08MPa.1..DRY GAS SEALS MANUAL Therefore we use nitrogen to replace process gas from discharge side to work as primary seal gas.5bar. Low pressure alarm is 3. 3. LTD china.2MPaG higher than pressure of casing inner. The nitrogen filters FL5. The pressure higher than 4. The pressure of nitrogen is controlled at 0. 3.

HH pressure alarm is 2 bar. High flowrate alarm is 17Nm3/h. The normal value is 3bar. 2) Pressure of Primary seal gas leakage Pressure transmitter YAEKD91CP004 、 YAEKD91CP005 are to measure the Pressure of Primary seal gas leakage on both the suction side (non-drive end) and the discharge side (drive end).. LTD china. Low flowrate alarm is 4Nm3/h.6bar.2 HP Casing 1) The pressure difference for primary seal gas and process gas at the secondary balance pipe Diff pressure transmitter YAEKD91CP054 is to measure the pressure difference for primary seal gas and process gas at the balance pipe. High pressure alarm is 1bar.6bar. Low pressure nitrogen is used as gas source for Secondary seal gas and Barrier Gas. HH pressure alarm is 2bar.5Nm 3/h. The normal value is 0.sns- . another line is Nitrogen for compressor start-up.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.HH flowrate alarm is 24Nm3/h. The normal value is 6Nm3/h.2. The normal value is 0. -16- Sichuan Nikki Seals Co.HH flowrate alarm is 34Nm3/h. 3) Flowrate of Primary seal leakage gas Metallic float flowmeter YAEKD91CF003 、 YAEKD91CF004 are used to measure the Flowrate of Primary seal gas leakage on both the suction side (non-drive end) and the discharge side (drive end). Instructions For Operating the Control System There are two lines work as Primary seal gas: one line is dehumidified process gas from NG station filter outlet. High flowrate alarm is 12Nm3/h.3. 5) Flowrate of Primary seal leakage gas 、 YAEKD91CF002 are used to Metallic float flow meter YAEKD91CF001 measure the Flowrate of Primary seal leakage gas on both the suction side (non-drive end) and the discharge side (drive end). High pressure alarm is 1bar. The normal value is 8.DRY GAS SEALS MANUAL discharge side (drive end). 3. The pressure difference higher than 1. Low PD alarm is 1bar. Low flowrate alarm is given at L=3Nm3/h. 3.5bar is a precondition for the lube oil pump startup.

sns- . YAEKD91CF501 、 adjusting V13 YAEKD91CF502 on two side of LP is controlled at 40 Nm3/h by 、 V16 by hand.5Nm3/h. Check the readings of the flowrate transmitters. 5) If there is no problems in static sealing . 4) the V46 Verify if all the stages above is finished and open valves V1.1 Seal Control System 1) Open valve V5 、 V6 、 V10 、 V11 、 V13 、 V14 、 V15 、 V16 、 V17 、 V18 、 V20 、 V21 、 V24 、 V25 、 V27 、 V28 、 V29 、 V31 、 V32 、 V33 、 V35 、 V36 、 V39 、 V40 、 V44 、 V45 、 V46 、 V49 、 V50 、 V51 、 V53 、 V54 、 V56 、 V57 、 V58 、 V59 、 V60 、 V61 、 V62 、 V63 、 V65 、 V66 、 V67 、 V69 、 V70 、 V71 、 V73 、 V74 、 V77 、 V78 、 V82 、 V83 、 V84 、 V87 、 V88 、 V89 and all the valves of the instrument and all the three-valve group (close the balance-valve between the high pressure end and the low pressure end).com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.DRY GAS SEALS MANUAL 3. Attention: Adjust the valve V43 、 the condition of system V48 、 V81 、 The V86 in according to flowrate of operation. the seal might have problems in static sealing. 3) Power on all the pressure and pressure difference transmitters. close transmitters system. V3 supply gas to no abnormal 、 situation 、 occurs V89 after and two minutes flowrate later. until the problem solving. close V15 、 V18 、 V58 、 V61 and flowmeters YAEKD91CF501 、 YAEKD91CF502 、 YAEKD91CF505 、 YAEKD91 CF506 will start to work. LTD china. valve V1 、 V3 、 V19 、 V7 、 V8 、 V12 、 V22 、 V23 、 V26 、 V37 、 V41 、 V55 、 V64 、 V75 、 V79. The flowrate of YAEKD91CF505 、 adjusting V56 、 2) Close YAEKD91CF506 on two side of HP is controlled at 90 Nm3/h by V59 by hand. pressure switches and flowrate transmitters. if the flowrate exceeds 0. analyze reason. Now open V19 and close V29 、 V33 、 V67 、 V71 , the -17- Sichuan Nikki Seals Co. If 、 V51 V84 YAEKD91CF001 、 YAEKD91CF002 、 YAEKD91CF003 、 YAEKD91CF004 will start to work..3.

isolating valves and pressure -18- Sichuan Nikki Seals Co. LTD china.V21. but must make sure the speed be no less than 1000rpm. slowly open valve V7. V6 or V20. Argon-arc welding should be adopted.5bar. Discharge condensate need changeover to standby condition. should check them periodically. flowrates and pressure values will remain stable. This period of testing time should be as short as possible.5 bar and the readings of pressure transmitter YAEKD91CP001 higher than 4. FL2. 3. FL3. 2) Polish all the trimmed edges before welding and inject argon into the pipes and tubes to work as a protection.DRY GAS SEALS MANUAL flowmeters YAEKD91CF503 、 YAEKD91CF504 、 YAEKD91CF507 、 YAEKD91 CF50 will start to work. The nitrogen filters (FL5. FL6) are floating values (discharge condensate automatically by floating balls). Attention: Primary seal gas filters (FL1. if any value reads high or even alarms occur. changeover to filters FL3.. If the readings of the pressure difference transmitter YAEKD91CP052 、 YAEKD91CP054 higher than 1. FL4 or FL6 and change the original filter element. Meanwhile. adjusting V13 、 V16 by hand to make sure The flowrate of YAEKD91CF501 、 YAEKD91CF502 on two side of LP is controlled at 40 Nm3/h and adjusting V56 、 V59 by hand to make sure The flowrate of YAEKD91CF505 、 YAEKD91CF506 on two side of HP is controlled at 90 Nm3/h.sns- . 6) If the readings of pressure difference transmitter for filter YAEKD91 CP051 or YAEKD91 is at the high alarm H=0. If the compressor is running normally. at now the compressor is allowed to start-up. However. V8 or V22 、 V23 and close valve V5.4.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. 1) On Site Piping & Tubing Material for newly connected pipes and tubes should be stainless steel. 3) Check if condensate drain valves are needed on pipelines connected to sharing utilities. and FL4) discharge condensate by hand. it is necessary to checking position of all the valves and readings of all instrument to analyzing the problem.8barg. for convenient operating and monitoring.

8) Put a clean white cloth or linen (silk) at one end of the pipe and sweep the pipe with air. 9) After pipe arrangement.. it is recommended to do pressure test and flaw detection to the high-pressure pipelines. 4) Newly added pipelines should be disassembled without interference to each other or the original pipelines. acid-wash the pipes and then sweep them with high-pressure steam before air-drying.sns- . Check if all the pipes are correctly connected according to the LIST OF CONNECTIONS OF SEALING FLANGES and CONECTION LIST from the compressor manufacturer. 6) The newly arranged pipes should be wash and blown separately before connect them to the flanges and onto the system. See if there is any dust or dirt on the cloth. Time length of the sweeping should be no less than 1 hour. Attention: Before connecting all the pipes. Gaskets are needed between flanges. 5) After all the pipelines are arranged.DRY GAS SEALS MANUAL gauges should be added to the near spot of the control system.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. -19- Sichuan Nikki Seals Co.5MPa) and its cleanliness no less than 10μm. make sure to take off the blind plates on the flanges. LTD china. Use white clean cloth to wipe the inside of the pipes and make sure there is no smear or stain on the cloth. 7) The sweeping air should be clean and dry (pressure no less than 0.

sns- . LTD china..DRY GAS SEALS MANUAL -20- Sichuan Nikki Seals Co.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.

If the seal moves freely. when there is no assembly or mechanical problem of the compressor. the seal gas supply flow must be sufficient enough during air tightness test and other tests. LTD china. Professional -21- Sichuan Nikki Seals Co. flat table with the setting plates facing down. It does not need to be dissembled before installation. Lightly rotate the sleeve in the direction marked on rotor.. Attention: It is recommended that site installation of the seal be arranged after load-less test of the compressor. 2) Turn over the seal cartridge with the setting plates facing up.1. See Assembly Drawing (APPENDIX 1. Use installation kit to put the seal into seal chamber from end of the shaft and remove the setting plates. INSTALLATION / REMOVAL Dry gas seal is a precision part. 3) 4) Remove the setting plates. The whole process is convenient and precise. 4. 2 , 3, 4) 4. It is in cartridge assembled. Remove the socket head cap screws and the shipping plate.1 Exercising the seal Exercising the seal helps to eliminate possible “sticking” of the dynamic o-ring due to long periods of storage. Meanwhile. It is recommended that the seals should be fitted by a Sichuan Nikki trained engineer or certified designee when first installing. Support the retainer inner so that the rotor is off the tabletop.DRY GAS SEALS MANUAL 4. The seal is comprised of seal cartridge and separation seal.1 1) Rotating Examination Place the seal cartridge on a clean. Any incorrect installation or removal operation could cause damage to the seal or affect longevity. it is qualified.sns- . with setting plates to connect the rotating part and the stationary part. If not. there might be steam or oil in the sealing faces.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.

fit the setting plates again. 4) After examination.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. 2) Clean the entire area into which the seal fits.DRY GAS SEALS MANUAL engineer is needed to clean the seal. 3) Slowly release and repeat 4 or 5 consecutive times. the seal must be dissembled to further check. If the seal rotor returns to its original position rapidly. Support the retainer outer so that the rotor is off the tabletop. Rectify as necessary. -22- Sichuan Nikki Seals Co. 4. rust or greasy dirt is allowed. Sweep the pipes related to the dry gas seal (especially pipes at the gas inlets to the seal) to prevent dusts or welding slag from getting into the seal chamber. 4) Carefully check the o-rings at outer surface of the seal and inside of the sleeve.2 1) Floatability Examination Slowly turn over the seal cartridge again.1. The springs are compressed at the stage. No scratch. 3) Make sure that all the lead edges on bore and shaft over which the seal passes have the required chamfers.2 Compressor Preparation 1) Check if all the pipes are connected.. 2) Grasp the sleeve and evenly press on the top until it can no longer be pressed down. 4. burr or other flaws is allowed.sns- . If no. LTD china. the seal is qualified. No dust.

Therefore. Install the adjusting ring first. take off the radical bearing bush and fix the axial and radical position of the rotator according to the case.3 Installation ATTENTION: In the process of installation. 9) Without removing them from their grooves. The other seal is installed after installation of the thrust collar.. lightly lubricate “0-rings” with silicon grease (not other grease or lubricant). 8) Check whether the direction marked on the seal casing is in accordance with the shaft rotation of the compressor. 7) Verify the installation dimension as shown on the drawing. Measure to verify the axial position of the shaft to compressor casing. Please refer to the INSTALLATION AND REMOVAL DRAWING (APPENDIX 7-10) and INSTALLATION AND REMOVAL INSTRUCTION (APPENDIX 11-14). the shaft must be fixed in its axial operating position. Wipe off excessive grease. -23- Sichuan Nikki Seals Co.sns- . It is recommended that the thrust end gas seal be installed first. the shaft must be lifted and centered in the seal housing by special tools during the installation process. Adjust the adjusting ring when needed. 1) 2) Fix the shaft in its radical operating position.DRY GAS SEALS MANUAL Replace any flawed or damaged parts 5) Axial location of shaft: During the installation process. LTD china.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. 4. 6) Radical location of shaft: The bearing bush must be removed when installing or removing the seal. Press the shaft to its working position. or it might get into the sealing area. and that might cause eccentricity of the shaft and the seal housing.

8) thread. It may cause damage to the O-ring..sns- . When rotating the nuts. End if the dimensions are Install split ring. 4) Connect the installation plates and screws to the setting plate Outer (APPENDIX 11-14). and then raise the rotator and make sure it remains at the center position. or scratches on the seal casing and the seal may occur. When installing. Especially avoid the O-ring from contacting the thread on the shaft. Check the installation dimensions of the seal again. Dust is not allowed to fall into the inner surface of the shaft sleeve. the shaft should always be kept at the axial center. and then put the Labyrinth components into the seal casing. 6) Rotate the locknut onto the thread of the rotator and Pre-tightening torque should be maintained at 400N. for it might scratch the shaft sleeve when installing. Remove locknut. Push the seal onto the shaft sleeve shoulder. 10) Repeat the steps above to install the seal on the other side. Don’t forget washers. Apply lock jam to the thread. ATTENTION: While pushing the seal cartridge. and remove the Inner/ Outer setting plates on the seal cartridge. Avoid any bruise or dust getting into the shaft sleeve. then remove Labyrinth components by screws.DRY GAS SEALS MANUAL 3) Place the seal cartridge onto the shaft. and tighten socket head cap screws.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. LTD china. Make sure the radical operating position to ensure socket head cap screws fit the Labyrinth. -24- Sichuan Nikki Seals Co. avoid impact or collision between the shaft sleeve and the shaft. Apply lock jam to the 4. 5) Remove the installation plates and screws. it is necessary to apply even force on both sides. 9) correct.M. Rotate the nuts on the screws to push the cartridge SLOWLY and SQUARELY into the compressor.4 1) Removal Remove split ring. 7) Lightly lubricate outside “0-rings” with silicon grease.

or scratches on the seal casing and the seal may occur. the disassembly would not proceed successfully. If the seal needs to be return to the Sichuan Nikki Seals Co. Make sure the shaft remains at the center position. When rotating the nuts. 4. After installation. it is necessary to apply even force on both sides. please put the installation tools and the packing box into careful storage. and installation tools. 5) Maintain the coaxially between the rotator and the seal case and fix the rotator. -25- Sichuan Nikki Seals Co. please put on the locating plates or damage might occur to the seal. 2) Inner/Outer setting plates are needed for transportation. LTD china. Add an adjusting ring gasket if necessary. 5) Remove the seal cartridge from the compressor. 4) Dry gas seal has high requirements for relative positions between the seal casing and the shaft. 6) Usually.. Check the installation dimensions before running the machine. Rotate the nuts on the screws to pull the cartridge SLOWLY and SQUARELY out of the compressor.DRY GAS SEALS MANUAL 2) 3) 4) Install the Inner/ Outer setting plates on the seal cartridge.sns- . 3) After installation. precision. Ltd.5 1) Notes The customer is not recommended to disassemble the seal because of the seal’s high requirements for complicated assembling. the side with a thrust collar is installed first to guarantee the precise installation of the seal on the other side.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.. cleanliness. Connect the installation plates and screws to the setting plate Outer. installation and disassembling of the seal. the plates should be put into careful storage. Without the locating plates.

the displacement allowed for the rotator should be no more than 2..com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. 9) After the seal is installed and the setting plate is taken off. -26- Sichuan Nikki Seals Co. LTD china. 8) Use silicone grease for lubrication and no other grease are permitted.5mm.DRY GAS SEALS MANUAL 7) Thoroughly clean the seal chamber and all the inlet/outlet pipelines.sns- .

Oil cycle: If there isn’t pressure in the shell . If there is return oil. LTD china. 4) After passed the static test. 2) Close the discharge valve of compressor.5Nm3/h. the primary seal gas should be put into firstly. Start the compressor according to the operating instructions.sns- .3bar.1 1) Starting Process of the Seal Put into Rules Start up: First put into the seal’s control system.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. If they are normal. close the barrier gas.check the pressure of YAEKD91CP506 、 YAEKD91CP507 、 YAEKD91 CP510 、 YAEKD91CP511 is 0. Check the instruments’ readings at each point.. and at last the primary seal gas. 5) 6) Start the lube oil system according to the operating instructions. Note : that the speed of the compressor should be no less than 1000rpm. the primary seal gas and the secondary seal gas should not be cut off until it isn’t pressure. -27- Sichuan Nikki Seals Co. If there is pressure in the shell. following the secondary seal gas. then the lube oil system.5bar. the primary seal gas and the secondary seal gas could be closed and only the barrier gas is needed. analysis reason 3) Make sure the pressure of barrier gas is maintained at higher than 4.DRY GAS SEALS MANUAL 5. OPERATION / MAINTENANCE 5. Adjust orifice bypass valves V37 、 V41 、 V75 、 V79 until the pressure returns to normal value if there is any deviation. put into the systems following step 1. Meanwhile. the leakage rate will increase until the compressor reaches stable state. following the secondary seal gas and then the barrier gas.1. put into the primary seal gas firstly and close the secondary seal gas to do static test on the primary seal. Note: that in the seal’s control system. Shut Down: Shut down the lube oil system firstly. If the flowrate is higher than 0. the seal system are ready to work. the flowrate transmitters YAEKD91CF001 、 YAEKD91CF002 、 YAEKD91CF003 、 YAEKD91CF004 should read 0.

temperature. it is possible the seal might fail. Please check the condensate drain at regular intervals. Notice the followings: 1) The seal is forbidden to running in an opposite direction. 2) Ensure stable flowrate and pressure of the primary seal gas. If it tends to grow. However. 5) The condensate drain should be open when the compressor is at normal running or oil cycle. drain of gas pipes (nitrogen and process gas) firstly and make sure there isn’t condensate before starting the seal’s control system. start-up again. Check the primary seal gas leakage flowrate everyday. Temporary rise of leakage does not mean failure of the seal. to prevent oil pressure variation or other fault lead to lube oil through the barrier seal into the sealing area.2 1) Note for Start-up Because of tandem dry gas seal. etc. 4) If the pressure difference of filter reaches alarm value. the condensate might get into the sealing faces and cause damage to the seal. 2) If the compressor is shut down. if the leakage rises continuously. the compressor in the shell must have pressure. Stable and continuous primary seal gas is the basic requirement for the normal operation of the dry gas seal. 6) Shut down the dry gas seal system at least 10 minutes after totally shutdown -28- Sichuan Nikki Seals Co. There are various reason affect the leakage rate. it is necessary to changeover the filter. 5. Primary seal gas leakage affect the working condition of dry gas seal. for example: process gas undulate.sns- .3 Regular Maintenance Dry gas seal is designed for wide range of services and usually it does not need to be maintained. pressure. LTD china.com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.. it is possible the seal is failing. 3) Monitoring the primary seal gas leakage rate. speed. Avoiding long time operation under low speed operation. the pressure don’t less than 2bar.DRY GAS SEALS MANUAL 5.

DRY GAS SEALS MANUAL of the compressor and lubricant system.sns- . -29- Sichuan Nikki Seals Co. LTD china..com Tel:(028)85369013 Fax:(028)85366222 Home Site:www.

rotate the shaft by hand to see if it moves smoothly.sns- . springs and tension spring need to be examined. it is possible that grease or steam might get into the sealing faces. cleanliness. If the compressor’s been shutdown for a long time with the seals inside. Therefore. If it is for long-term storage. Protecting hood is placed on the fluid side to keep away dust and to protect the rotary ring. Service life of dry gas depends on the time of storage. SHIPMENT / STORAGE The whole cartridge of seal should be placed in a customized firm box and set up by foamed plastic. Ambient humidity should be below 75% and desiccant is needed for transportation..com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. Please send the whole cartridge back to the vendor. Or. Oil residue is not allowed to contact the seal. seal all the connection points on the compressor. Other spare parts should be packed and put into the inner space of the shaft sleeve to avoid damage. It is recommended the ambient temperature for storing the seal be 15~25℃ and avoid heat sources like boiler.DRY GAS SEALS MANUAL 6. After verify that the inside of the shell is dry. LTD china. use elastic PE gaskets to seal the box. special setting plates are designed for the whole cartridge of seal for its transportation and storage. heat exchanger or direct sunshine. Check if there is oil inside the separation gas inlet pipeline. and installation tools. it is necessary to fix the shaft to prevent the seal from possible damage. Note: Do not use greasy cloth or paper as waterproof package. working and working condition. In better occasion. Another function for setting plate is to prevent relevant movement between the stationary parts and the rotary parts and their collision with each other. the -30- Sichuan Nikki Seals Co. The customer is not recommended to uninstall the seal because of the seal’s high requirements for complicated assembling. precision. Only trained specialists are allowed to disassemble the seal and perform cleaning operation. parts like elastomers. After designed period. If the seal is placed inside a shutdown compressor for more than 60 days.

com Tel:(028)85369013 Fax:(028)85366222 Home Site:www. frequent start-shut operation. vibration. -31- Sichuan Nikki Seals Co.. excessive axial slinger. unclean pipelines could all be reasons for short service life of dry gas seal.sns- . However. LTD china.DRY GAS SEALS MANUAL seal could work continuously for 3 years.

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