Mark Dye

2009
 Principle of
operation:

Pressure

Rotating ring Stationary ring

Leak off

Seal Gap only 5 microns/ 0.2 mils

Principle of
operation:
Hydro-dynamic pressure
Tiny grooves cut into the face of the rotating ring scoops gas in
between the seal faces creating enough pressure to over come the
tension of the spring holding the faces together.

Hydro-dynamic Spring tension

force

Gas is scooped into this

tight space forcing it to
overflow outwards into the
gap between the faces
forcing them apart
 The seals are kept from touching by the generation of hydro-dynamic pressure, created by
small grooves cut into the face of the rotating ring which draw gas into the seal, forcing
the two surfaces apart.
Because the space between the seals is less than a human hair, the sealing gas used must
be completely dry and free from grit, dust or moisture.

An external source of sealing gas is therefore used to ensure cleanliness

The tandem seal system is designed so that after failure of the primary seal,
the machine can be safely shutdown using the containment provided by the
secondary seal without hazardous release of gas to the atmosphere.
Single Seal Double Seal Tandem Seal

Low pressure Low pressure Most popular seal

Low cost Hazardous gas Multiple arrangements

Although these dry gas seals are able to handle high levels of vibration
without damage, reverse rotation of the shaft at high speeds will damage the
seals as they are not able to develop the hydro-dynamic pressure required
to push the sealing faces apart.
A supply of filtered buffer gas is injected into the cavity between the primary
gas seal and inboard labyrinth. This supply of gas will leak past the inboard
labyrinth back into the compressor which will ensure that the cavity is free
from liquids or particles that could damage the gas seal. The supply gas will
also leak past the primary gas seal, into the cavity between the primary and
secondary gas seals which is directed to an approved vent or flare system.

Seal gas

Leak off to
vent system
Leak off into
compressor
suction
Labyrinth seals are used in conjunction with dry gas seals
in order to restrict the leakage between chambers around
the seal
A labyrinth seals works like a maze, creating a torturous path which
the fluid needs to flow through in order to escape

Lubricating oil from the compressor bearings is prevented from

entering the dry gas seal by the use of a simple labyrinth seal supplied
with separation gas to create a barrier to the migration of lube oil.

The labyrinth seals is a non

contact type of seal with very fine
clearances. Using a system of
notches and grooves, the pressure is
broken down little, by little so that
leakage is minimised (not stopped)
 The thrust created by the high pressure discharge pushing the compressor rotor back
towards the suction is cancelled by creating opposing thrust using a balance drum.
Pressure balance line
Gas that leaks into here is passed
back to the suction, so the pressure
here always going to be the same
as suction pressure

Balance drum

Balancing pressure Axial thrust from high

BEARING

BEARING
SEAL
SEAL

created by balance drum discharge pressure

High pressure discharge

This pressure balancing

Low pressure suction

system also means the
compressor seals are only
ever exposed to suction
pressure!
 6 centrifugal impellers

HP rotor & casing

Pressure
balance drum
Primary gas start up supply

Flow
controllers

Gas filters

Secondary
gas supply
Vent system
pressure
monitoring
Primary seal gas is supplied from HP
fuelgas for start up, then automatically
changed over from compressor
discharge. It is vented back to the low
pressure flare system.
(Backup supply for process
compressors is defrost gas)

Secondary and separation gas is

supplied from the nitrogen system
and vented to a safe location on the
roof of the building.
 RO RO RO RO
Burst disc

Bearing

Bearing
Bearing

Bearing
HP LP

SEPARATION SEAL GAS RO

PRIMARY SEAL GAS

RO
FC FC FC FC
FC

SECONDARY SEAL GAS SECONDARY SEAL GAS

PDT

PDC

N2

HP Fuelgas
 ga s skid
ea l
LP s

a s sk id
P seal g
H or
es s
pr
P com
L

ssor
pre
c o m
HP
 Primary Gas
Primary gas is injected in front of the seal to create a positive flow. It is used to ensure the gas
entering the seal is completely dry and clean, completely free from dirt, dust and moisture.

Primary Vent
Primary Gas

Compressor
Suction Atmospheric
pressure pressure

Compressor Bearing
drive shaft housing
 Secondary Gas
Secondary gas is nitrogen used to provide a clean source of gas to the secondary seal faces. The 2
seals are separated by another labyrinth and the leakage gas is lead to an atmospheric vent in a
safe location (above the building)

Secondary Vent
Secondary Gas
Primary Vent
Primary Gas

Compressor
Suction Atmospheric
pressure pressure

Compressor Bearing
drive shaft housing
 Separation Gas
Separation gas is nitrogen used to keep lube oil from the adjacent bearing housing
from leaking into the dry gas seal system
Before starting lube oil

Secondary Vent

Separation Gas
Secondary Gas
Primary Vent
system ensure separation
Primary Gas
gas is on to keep the lube
oil out of the seal!!

Compressor
Suction Atmospheric
pressure pressure

Compressor Bearing
drive shaft housing
 Dry gas seal
assembly

Labyrinth ring
for separation
gas
 Keeper pin
Inserted to support
John Crane Assembly while
Dry gas seal Sliding out
assembly

Sliding out
 DP

ALARM

Typical control scheme:

FILTERS

A controller maintains a constant

differential pressure above suction DP Suction pressure

pressure, while the flows to each seal

Seal gas pressure

are also monitored to check seal
integrity. P

P
The vent system is kept under a back pressure by passing
the flow through a restriction orifice. A secondary path is
opened by bursting a rupture disc to safely vent the higher
flows caused by seal failure.
Vent/Flare
A differential pressure transmitter
monitors the pressure between seal
supply and the low pressure vent.
When the seal is healthy, this dP is high
(Primary Seal Gas supply pressure on
one side and Flare pressure on the
other side). This high dP is used as a
HP Trip start permissive for the compressor.
P When the seal fails, the dP becomes
low, initiating a compressor trip.
RO
ORIFICE

MARKS
PATENT
PLATE

In addition we measure the pressure in

the vent line, upstream of the orifice. In
the event of seal failure this pressure
becomes high due to the increased flow
to flare. This high pressure alarm is also
used to trip the compressor.
It is extremely important the seal gas is
clean and dry. A 2 micron fine filter is
fitted with a standby element ready for
change over.
A smart ring sequencing system is
used to prevent mal-operation of filter
valves.

Filter A Equilisation Filter B Turning the valves in the correct

isolation valve isolation sequence will firstly de-isolate A filter,
then equalise so both filters are in
service, and the third valve will isolate
B filter for element replacement.

Filter A Filter B
isolated in service

A B
 -Control room
DCS

Filter
Dirtydirty
filteralarm
alarm Gas flow is
controlled from 3 DP
transmitters routed
through a high
selector to the valve
output

Rupture disc
Failure alarm

XA-032 XA-033
 -Quiz Can you
answer the following
questions?
1. What must you do before starting the compressors lube oil system?
2. During normal running, where is primary seal gas supplied from?
3. What is the source of secondary gas?
4. How are the 2 seal faces prevented from touching during normal operation?
5. What is the purpose of separation gas?
6. True or False?
The seal at the low pressure end of the compressor casing has an easier job than
the seal on the high pressure end.
7. If the compressor is accidentally turned backwards by the reversal of gas flow,
the seals will be damaged. Explain why?
8. True of False?
Some of the seal gas will leak back into the compressor casing.
9. Where is secondary gas vented to?
10. When a high Pressure is detected in the vent system, what is the most likely
cause?

MAN

HELPER MOTOR CENTRIFUGAL COMP AXIAL COMP GAS TURBINE