OIL & GAS

Dry gas seal systems

BEST PRACTICES FOR DESIGN AND SELECTION, WHICH CAN HELP PREVENT FAILURES
R. J. AIMONE, W. E. FORSTHOFFER AND R. M. SALZMANN

ry Gas Seal (DGS) systems have been used for the past two decades, and are specified by many endusers as the seal of choice for most compressor applications. One would therefore think that seal and system designs are well-known and proven. However, experience shows that failures are still quite common. For instance, last year, the authors dealt with nearly 50 DGS failures. These failures raise several questions. Are they all caused by foreign material contamination or ingestion? Are they connected with improper seal selection or unreliable system hardware? Who is responsible: seal vendors, compressor vendors, or end-users? In reviewing DGS failures experienced in 2006 and previous years, our conclusion is that in a majority of cases, the root cause is that the seal and system configuration were not designed to handle all the actual site operating conditions, including startup, shut-down and upsets that should and could have been anticipated. The end-user has the most complete knowledge of the process and plant operating procedures. Therefore, he or she needs to be proactive in terms of project DGS requirements, and specify the type of seal and system most suited to the plant and application, based on his or her knowledge and experience. Seal and compressor vendor input and experience are obviously required, but neglecting to evaluate the proposed system in detail against all operating modes subjects the user to the risk of unacceptable downtime and revenue losses, particularly in the mega plants (see p.8, Sept./Oct. 2004)) being built today. This series of three articles will offer guidelines, based to assist in establishing the best practices for DGS installations in critical machinery. The series can be a starting point for a proactive plan that could be included in the Invitation To Bid (ITB) package. The format for such a plan can be as simple as a designated seal configuration on the data sheet, with system requirements, or a Process & Instrumentation Diagram designed specifically for the application, prepared
20 Turbomachinery International January/February 2007

Figures 1, 2: Above are a double dry gas seal (left) and a tandem dry gas seal (right). These seals have been used for over twenty years, yet failures are common

by the end-user. A detailed component Design Audit and HazOp (Hazard & Operability) review are also absolute requirements. The series will focus on unspared and special-purpose compressor applications, as generally defined by API 617, 7th Edition, Chapter 2. It is in these critical hydrocarbon services that many of the DGS failures have occurred. The suggestions and recommendations can be applied to new equipment or retrofits, where possible. They are intended to help end-users think through the seal requirements for a specific compressor installation. Topics covered in this series include: DGS selection and design features Seal gas conditioning and control sytems Primary vent systems Intermediate seal gas systems Secondary vent systems Separation seals and systems

Seal selection
The purpose of any shaft-end seal is to effectively contain the process gas in the compressor case, and to prevent the uncontrolled escape of toxic or flammable gas to the surrounding atmosphere. The first step in achieving a safe and reliable DGS installation is selecting the best seal configuration for the specific compressor application. There are three common DGS arrangements single, double and tandem. Double and tandem arrangements (Figures 1, 2) are most prevalent in the class of machinery described above. Traditionally, the majority of compressors in all services have used tan-

dem seals (two single seals in series). The inboard primary seal essentially does the entire job of sealing the process gas, except in a few high-pressure applications. The outboard secondary or tandem seal is a back-up to seal the process gas in the event of a primary seal failure. While tandem seals are appropriate choices in many situations, double seals can be preferable in hydrocarbon services where: An inert gas, typically N2, that will not contaminate the process can be used as the primary seal gas The maximum process gas pressure to be sealed is relatively low (below 400 kPag), and is exceeded by the pressure available from the inert gas (N2) system For refinery, petrochemical and gas plant services, such as wet gas units, cokers, gas concentration units and other process gases, the double DGS is often the best seal choice. The system design, as we shall see in a later article, can be greatly simplified, as compared to tandem seals. Nitrogen is the preferred seal gas, since these machines do not operate in a closed loop. Suction pressures are generally below 400 kPag (~60 psig) and can be covered by most N2 supply systems, which are typically designed to deliver 500 kPag (~75 psig) or more at the point of use. Total seal gas flow is very low for double seals, and gas differential pressure can be set at a level high enough to prevent the maximum flare pressure from causing a reverse seal differential. Since the process gas in these services is often sour, the use of a sweet buffer gas, injected upstream of the labyrinth located inboard of the DGS (Figure 1), is the best practice. The buffer gas flow
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should be sufficient for a minimum velocity of 15 m/s (50 ft/s) across the labyrinth, at maximum design clearance. This will prevent the sour gas from contacting and potentially fouling DGS components that affect the ability of the stationary seal faces to follow and maintain their location relative to the rotating faces. Compressors in hydrocarbon refriger-

intermediate labyrinth will assure that there will normally be no hydrocarbon content in the gas flow through the secondary seal and in the secondary vent. Intermediate labyrinths typically run on the outside of the secondary seal rotating element, or down on the seal sleeve. The latter provides better clearance control and reduced N2 flow. It also minimizes any risk of damage to the secondary

A tandem dry gas seal is the best choice for most refrigeration services Double seals are preferable in hydrocarbon services where an inert gas can be used as seal gas
ation services pose a difficult problem for DGS selection. From the standpoint of system simplicity and the normally low, or sub-atmospheric, pressures to be sealed, one might wish to consider a double DGS. However, since refrigeration systems are closed-loop, N2 cannot normally be used as the seal gas, since it will build up during operation and reduce refrigeration capacity. Using the refrigerant as the seal gas would leave only the separation seal to contain the hydrocarbon in the event of a DGS failure, which is not recommended. Therefore, choosing a tandem DGS for most refrigeration services should continue to be the best practice, based on the fact that the secondary or back-up seal is provided. However, it should be noted that it is rare to operate on a secondary seal for a significant amount of time after a primary seal failure. Significantly, it is machines in refrigeration services that have experienced many of recent DGS problems. Many, if not the majority, of these failures most likely resulted from a lack of attention to the details of systems supporting the seals [1]. For high-pressure compressor services, including syngas, reinjection and hydrogen recycle, tandem DGS should continue to be the best practice selection. The pitfalls associated with low-pressure services are generally not concerns for operation at levels above 400 kPag (~60 psig). However, some machines start-up or operate for short periods at low pressure. These conditions must be accounted for in the system design details. Finally, we recommend that an intermediate labyrinth should be included between the two face seals in all tandem DGS for hydrocarbon service [2]. The injection of an inert gas, usually N2, between the secondary seal and the
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labyrinths are used, the N2 flow required is significantly (up to ten times) higher than for carbon-ring seals. If carbon-ring seperation seals are selected, either because of limited N2 capacity or cost, there are some additional considerations. Carbon ring seal designs vary widely in their ability to accept elevated differential pressure. Therefore the selected design must be capable of accepting the maximum anticipated differential for a sufficient period to safely shut down and secure the machine. Also, carbon-ring seals may exhibit excessive wear if the seal gas has a low dew point. Maintaining a minimum dew point of -30C (-34F) is recommended. Footnote:
[1] The next article in this series will focus on the best practices to prevent problems in machines with tandem seals in services with low and sub-atmospheric suction pressures. Details of seal gas supply and primary vent system designs will also be discussed. [2] Control of the intermediate flow will be discussed in the third article. TI

seal elements in the event of contact. Locating the labyrinth on the seal sleeve may add to the length to the seal, and could affect the rotordynamic analysis. For new machinery, single DGS are normally considered only for inert gas services. However, it should be noted that relatively few inert gas machines use DGS unless the loss of process gas from conventional labyrinth seals is excessive and too expensive to justify their use. If cleaned-and-dried process gas cannot be used as the seal gas, or the seal gas usage must be minimized, double (back-to-back) seals can be selected where the inert seal gas is injected between the seals. This minimizes total seal gas flow.

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, and as an associate of FAI. 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.
January/February 2007 Turbomachinery International 21

Using separation seals

Most DGS installations also include a separation seal between the DGS and the bearings. This prevents oil from the bearing housing from migrating into the DGS area. Labyrinths (metallic or abradeable) or carbon-ring seals are typically used for the separation seal, with nitrogen injected between two seal elements. The best practice is to control the nitrogen differential pressure over the adjacent DGS vent pressure. This provides a final barrier against the uncontrolled release of hydrocarbon gas, in the event of a complete DGS failure and increasing pressure in the adjacent vent. For maximum pressure capability and service life, labyrinths or abradeable seals are the separation seals of choice. They can easily handle the maximum pressure from most N2 supply systems, and take advantage of that capability to retain process gas in an emergency situation. Abradeable labyrinths, with reduced clearance, are often used to minimize N2 consumption. However, even if abradable

OIL & GAS

Dry gas seal systems - part 2

BEST PRACTICES FOR DESIGN AND SELECTION, WHICH CAN HELP PREVENT FAILURES
R. J. AIMONE, W. E. FORSTHOFFER AND R. M. SALZMANN

he first article in this series (p. 20, Jan./Feb. 2007) discussed best practices for Dry Gas Seal (DGS) selection and design. This article will cover: Seal gas conditioning Seal gas control Primary vent systems The source of seal gas may be the compressor discharge, an intermediate pressure point, or an external process or inert gas, or the compressor discharge. For the majority of applications, the seal Gas Conditioning Unit (GCU) will consist only of filtration (5 microns absolute) and moisture-removal equipment. The best practice is to use dual coalescing filters and automatic drainers with high level alarms. However, two special situations may require additional gas conditioning.

available at sufficient pressure. Reciprocating piston or diaphragm compressors are currently the most common choice, however small dry rotary screws have been used successfully and are potentially more reliable. In mega-plant applications, or where justified by potential revenue loss, dual amplifier units are recommended.

Seal gas control

The DGS control system design depends on the type of seal being used, and must consider all the anticipated operating conditions. This section will focus on double and tandem DGS applications (Figures 1, 2 are not complete P&IDs). Regardless of the design of the seal gas control system, the option to trip the machine based on monitored seal parameters and other parameters depends on the HazOp review, and economic evaluation of the consequences of the shutdown for each plant. Double seals can help simplify the seal gas control system, minimize the quantity of seal gas, and optimize system reliability. As noted in the previous article, double seals are normally applied where an inert seal gas (usually N2), which is compatible with the process, is available at a pressure exceeding the maximum process pressure at the seal interface (to prevent a seal pressure reversal). If N2 from a regulated system is used, the seal gas control valve can be eliminated (Figure 1). If the process gas is sour, a sweet buffer gas must be injected between the process labyrinth and DGS to prevent sour gas contact and potential DGS fouling. Differential pressure control is typically used. Flow control is also an acceptable option, provided the flow is sufficient to maintain a velocity of 15 m/sec (50 ft/sec) through the process labyrinth at twice the maximum design clearance. Tandem seals are the most common DGS application, and are required when an inert gas is either not available at sufficient pressure or not compatible with the process. The traditional control arrangement is to maintain a differential of 35 kPa - 70 kPa (5 psid -10 psid) over the balance or equalization chamber pressure, using one Pressure Differential Control Valve (PDCV). This arrangement is adequate when the sealing pressure is greater than the maximum pressure that can occur in the primary seal vent cavity. However, this control scheme can expose the primary seal to possible pressure reversals
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Seal gas conditioning

Cryogenic nitrogen (N2 that has been liquified) can damage the carbon stationary faces during slow-speed operation turning gear ratcheting or slow roll when the faces are in contact. Cryogenic N2 is typically very dry, with a dew point as low as -90C (-130F). But the selflubricating quality of carbon is based on the ability of its crystalline structure to adsorb and hold certain gases, including water vapor, which significantly reduce rubbing friction [1]. In the absence of water vapor, carbon has poor lubricating properties, and can wear rapidly. Therefore, dew point conditioning is required whenever carbon stationary elements are used in either face or circumferential seals, when rubbing contact is anticipated for extended periods. For large steam or gas turbinedriven compressors that require slow roll for extended periods below the DGS liftoff speed, the best practice is to condition the N2 upstream of the coalescing filter system, raising its dew point to 30C (-22F), or higher. Methods to increase N2 dew point include mixing saturated nitrogen from a bubbler chamber with cryogenic nitrogen in an appropriate ratio, or mixing moist air with cryogenic nitrogen, keeping the oxygen content below 5%. A dew-point monitor and low-dew-point alarm are
24 Turbomachinery International March/April 2007

Figure 1: Above is a best practice double DGS system. Differential pressure control of the buffer gas is used. A seal gas control valve is not required because the system N2 header pressure is regulated

required for safe operation. Saturated seal gas, either in the system or entering downstream of the GCU, exposes the DGS to liquid condensation and carryover into the seal chamber and between the DGS faces. The risk of seal damage is high when liquid enters the area between the faces. The best practice is to assure that the gas is superheated to approximately 15C (27F) above the gas condensing temperature at the lowest operating pressure in the primary vent. The addition of a heater to the GCU may be sufficient for this purpose. However, if the required temperature rise could cause polymerization, a cooler, separation vessel and re-heater may be required [2]. If the seal gas contains C6+ components, they must be identified and individually considered in determining saturation conditions. Regardless of the application, an alternate source of seal gas is required during start up or shut down, when the process compressor is not delivering sufficient pressure, or to back up the independent seal gas source. This alternate seal gas must meet all of the requirements enumerated above for the primary seal gas. N2 may be used if the system can tolerate it. If N2 is not acceptable, an amplifier unit (pressure booster) may be necessary when process gas is not

Figure 2: Tandem seal systems can be designed to avoid failures due to sub-atmospheric suction pressures

in low-pressure services, where the maximum cavity pressure of the primary vent can exceed the sealing pressure. While the flare header pressure is normally low (7 kPag - 21 kPag or 1 psig -3 psig), the maximum design flare pressure that can exist during a major upset, or during an Emergency Shut Down (ESD) can range from 140 kPag - 340 kPag (20 psig - 50 psig). Therefore, the maximum pressure in the primary seal vent cavity can be equal to the maximum flare pressure plus losses through check valves, orifices, and piping in the vent line. For services with low, or sub-atmospheric suction pressures, even normal conditions in the primary vent can cause a reverse differential on the primary seal, unless the system design precludes this possibility. A significant number of DGS failures in recent years have occurred in low-suctionpressure refrigeration, and other services. Figure 2 shows a system that has been used successfully in applications with low suction pressure. A PDCV at each seal controls the seal gas pressure to the inlet cavity at a nominal value of 35 kPa -70 kPa (5 psi - 10 psi) above the higher of the following values; reference gas pressure and primary seal vent cavity pressure measured upstream of the vent orifice. This is accomplished through the use of a high signal selector device at each seal, which assures that the primary seal will always have a positive differential of at least 35 kPa - 70 kPa (5 psid - 10 psid), even if the primary vent pressure increases significantly during an upset or ESD. Another approach that has been used
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successfully for large machines, where the seal gas flow represents a relatively small recirculation loss, is to use one PDCV for both seals. In this scheme, the sensing point for the primary seal vent pressure is moved to a location in the primary vent that is common to both seals. The differential pressure controlled by the PDCV is then set high enough (typically 200 kPa - 350 kPa or 30 psid - 50 psid) to assure that it will always be greater than the maximum pressure drop across the orifice, piping, and any other component between the sensing point and the primary seal-vent cavity. This pressure also provides for the maximum allowable primary seal gas leakage flow. Regardless of whether one or two PDCVs are used, the best practice is to assure that the control valve always operates within the acceptable valve coefficient known as CV range. For large units where seal gas flows can vary widely, an orifice can be installed in parallel with the PDCV for normal flow conditions. In this arrangement, the PDCV will remain closed unless flow conditions dictate otherwise, and the smaller valve will always operate in the acceptable CV range (10% - 90%). The key element in low-pressure service is to

compressor for the longest possible time, and safely shut down the compressor when a dangerous condition exists. Below are best practices for the primary vent: Locate the primary seal chamber vent at the bottom (6 oclock) position on the seal cartridge, with a low point drain in the vent piping adjacent to the machine. This will permit checking for liquids in the primary vent chamber. The required piping configuration, and when the drain will be opened, should be determined during the HazOp review. Intermediate labyrinths with N2 injection are recommended for all tandem seals. To prevent masking the primary seal leakage, flow control of intermediate N2 is the best practice. (Details concerning the N2 injection system for the intermediate seal labyrinth will be covered in the next article.) A flow measuring device is recommended in the primary vent to monitor flow. The device may be an adjustable orifice but tamper-proof, with a set point lock or cover or a fixed orifice. Orifice sizing is to be based on the expected leakage from the primary seal plus the intermediate labyrinth flow. Measuring primary

In low-pressure service the seal gas pressure should be controlled to ensure that a primary seal pressure reversal is not possible . . .
monitor the primary seal differential, as well as the process labyrinth differential, and control the seal gas pressure based on the higher of the two values to assure that a primary seal pressure reversal is not possible under any anticipated circumstances. vent flow to facilitate troubleshooting is always recommended, regardless of what parameters will be used for alarm and trip (flow or pressure). Use low-pressure, loss-flow elements that measure loss of low pressure to monitor seal leakage and intermediate labyrinth flow rates. Piping should be generously sized to minimize primary vent cavity pressure in the event of a primary seal failure. Seal cavity vent openings, internal to the compressor, should be checked so that they are not undersized. If a complete primary seal failure can cause the pressure in the primary vent cavity to exceed the pressure that can be delivered by the N2 system, the best practice is to relieve the vent pressure below the N2 system pressure. A weight-loaded, stem-guided, full-flow disc valve is recommended. A rupture disc can randomly fail and will require a unit shutdown for replacement. A spring-loaded check valve is recommended in the piping at the flare header connection. This prevents the back flow of flare gas into the primary vent chamber, and maintains a positive pressure differential across the secondary seal. The check valve is normally designed to exert a minimum back pressure of 35 kPag (5 psig) in the primary vent cavity, assuring a minimum 35 kPad (5
March/April 2007 Turbomachinery International 25

Primary vent systems

The term primary vent has traditionally been applied to tandem seal applications. For double seals, there is only one vent between the DGS and the separation seal (Figure 1). Since this vent will normally not contain hydrocarbons, it is generally not connected to the flare system, and may not always be monitored. Therefore, for double seal applications, the best practice is to monitor and alarm, or trip the system if N2 inlet flow to the seal assembly increases. Operators of large, high-revenue plants may decide to trip only when outer seal failure is imminent. High N2 flow plus high outer seal flow may be used to trip these units. For tandem seals, the primary vent, which normally contains hydrocarbons, is connected to the flare system and is instrumented to monitor the health of the primary seal (Figure 2). This system must provide the operating team with sufficient information to monitor the condition of the primary seal, maintain safe operation of the

psid) positive differential over the secondary seal. However, the required secondary seal pressure differential should be determined by the seal vendor, based on anticipated turning gear operation and seal lift-off speed. Primary vent systems have traditionally been provided with pressure or flow instrumentation usually Triple Modular Redundant (TMR) to trip the compressor unit on a significant increase in pressure or primary vent flow rate. With the increase of process unit size, and corresponding increase of daily revenue loss, many end-users are reconsidering this approach. Decisions regarding machinery trips must ultimately be made by the operating team for each plant as early as possible in the project (preFront End Engineering Design phase). The goal is to avoid spurious trips and unscheduled shutdowns, while maintaining the safety of the plant and the integrity of the machinery.

Specifying shutdowns
DGS are precision components, and significant transient variations can occur in monitored parameters. Therefore, the best practices for shutdown are: Set trip levels as high as reasonably possible, but below the minimum available N2 pressure Always use TMR (including wiring and logic) for trip functions Consider requiring more than one parameter to exceed allowable settings to initiate an automatic trip Require provisions for monitoring the condition of the secondary seal, as well as the primary seal, to permit action in the event of its deterioration or failure References:
[1] Paxton, R. Robert, "Manufactured Carbon: A Self-Lubricating Material for Mechanical Devices," CRC Press, Inc., 1979. [2] Forsthoffer, W.E., "How to prolong dry gas seal life", Turbomachinery International, Sept./Oct. 2005

Footnotes:
The next article will focus on the best practices for intermediate and separation gas systems and discuss best practices for condition monitoring of DGS systems. 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. TI

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
26 Turbomachinery International March/April 2007
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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