DGS Seal

ENGRO FERTILIZER LIMITED
DRY GAS SEALS

Presented By :
NDB , Rana Yousuf , Ahtsham Ahmad
Special Thanks :
ALQ , ZAA , Moghezz Butt , Tahir Lashari
ROLE OF MECHANICAL SEALS IN OUR DAILY LIFE
Every aspect of our life is influenced by mechanical seals.
Home Appliances - washing machines, overhead water tank
pumps, water well pumps, swimming pools pumps and sump
pumps.
Automobile Water body seal
Pharmaceutical products
Newspapers / Books - Dependent on pulp & paper
manufacturing.
What is a Seal ?
Seals are used to form a barrier between two spaces. Generally one of these
spaces contains process fluid at a pressure other than atmosphere pressure.
Static Seal:
In this type of seal, sealing takes place between the surfaces which do not more relative
to one another.

Example: Gaskets in pipe flange connections, cylinder covers. etc..
Dynamic Seal
In this type of seal, sealing takes place between the surfaces which have relative
movement.
Mechanical Seal with specialty of Dry Gas Seal
Labyrinth
Packing
What is a Mechanical Seal?
A mechanical Seal consists of two extremely smooth and flat
surfaces, called faces, held together to prevent fluid from
escaping. In a mechanical seal, one face must rotate with the
shaft and is commonly called the Rotary Face and the other
mechanical seal face is fixed and is called the Stationary Face.
Common parts of Mechanical seal
Springs
Allen
Screws
Case/Metal
Retainer
Rotary
Face
Stationary
Face
O-Rings
Gland Plate
(Stationary
Holder)
Early shaft seals were simple labyrinth seals, which oftentimes required complicated
ejector systems to deal with substantial gas leakage through the seals.
EARLY SEALS
FLOATING SEALS
The next" generation of compressor shaft seals was oil film floating ring seals. There are two sealing
surfaces in a typical floating ring oil seal, the inside diameter of the seal rings and the mating
surfaces between the seal rings and the seal housings.
Oil is injected into the seal at a pressure slightly higher than the process gas (sealing) pressure. This
high-pressure oil forms a seal against the process, and also serves to cool the seal components.
Both labyrinth and oil film floating ring seals are radial seals, sealing the radial space
created between a rotating shaft and a stationary seal. This limited the level of sealing that
could be obtained, because the parts had to operate at a clearance large enough to avoid
contact between the stationary and rotating parts
FLOATING SEALS
Mechanical Seals
During operation, seal oil is injected into the seal at a pressure slightly higher than the
process gas. This oil provides a seal against the process gas and is also required to cool the
seal components, which are subject to high heat generation caused by the contacting
design of the seal. During shutdown, the spring-loaded shutdown piston (held open by oil
pressure during operation) is held in contact with the contact ring, providing a gas-tight
seal.
Contact seals were end-face seals, meaning the actual sealing surface was located
between seal components Perpendicular to the compressor shaft, as opposed to radial
seals.
A portion of the seal oil can be lost into the compressor, causing process
contamination and oil consumption.

A portion of the seal oil comes in contact with the process gas. This sour oil
must be treated and reclaimed or disposed of. Disposal of sour ail requires
compliance with local environmental codes.

The seal oil systems require substantial maintenance and can be unreliable.

A safety concern exists because of oil flash point issue~, which occur when gas is
absorbed into seal oil.

There are substantial process gas losses be-cause of seal emissions, which,
again, must be handled in accordance with local environmental codes.
ITS & BUTS
The most difficult answer about seal to tell its operating life.
As per API, a seal average life should be 03 years.

But experiences tell us that most of seals do not achieve this life. In some cases seals last
more than 03 years. Because seal life depends upon various variables.
The only way to tell if you are getting satisfactory seal life is to look at the soft face.
If there is still plenty of Carbon you did not get Good Life.
If most of the Carbon has worn away you got Good Life.
Mechanical Seal life
Non-Contacting Hydrodynamic Gas seal Contacting Type hydrostatic Seals
Hydrodynamic or lift off seals that float on a
cushion of gas.
Hydrostatic seals where the seal faces are
separated by controlling the opening and
closing forces acting on the faces.
HYDRODYNAMIC AND HYDROSTATIC SEAL

Dry gas seals are
Gas-lubricated
Mechanical
Noncontactlng
End-face seals

Rotary Components are :
Mating Ring
Shaft sleeve
O-rings for secondary sealing

Stationary Components are :
Primary Ring
Springs
A pusher sleeve/Thrust Ring
Various O-ring
Housing that hold the Gas components
DRY GAS SEAL
Lets Identify Parts of DGS
Gas enters the groove moving towards the center; because of the volume
reduction at the tips,
Gas is compressed and pressure increases setting the gap between the rings.
How Gas Compresses in Grooves
During operation (rotation), injected sealing gas flows from the outside diameter of the mating ring
into the mating ring's grooves . The shape of the grooves is optimized to enhance seal performance,
and the grooves are machined only to the radial midpoint of the mating ring face to a depth of only a
few microns. The compression zone of the sealing gas is located at the "tips" of the grooves (nearest
to the inside diameter of the mating ring). The pressure dam developed at the grooves causes "lift
off", separation of the primary and mating rings by the desired running gap.
Gas Compression
Bidirectional
Gas flows into symmetrical T-Grooves
is pumped circumferientially toward
the edge of groove
Stagnation of flow at the edge builts pressure and
results in hydrodynamic lift-off, even at low peripheral
speed
Hard ring
Groove depth = 10 micron
Clearance during operation ~ 35 micron
Human hair diameter : 50 75 micron !!!
Depth of Grooves
Lift-off is most likely used because the first dynamic seal designs were for use in jet
engines
The equations that determine the separation force are the same as those used to
calculate hydro-dynamic forces for a liquid. While the calculations are the same, just with
different values for the fluid parameters, it would be a better description to call them
fluid-dynamic forces. Using hydro was most likely just an over simplification for
explaining the lift effect.
"lift off", just mean separation of the primary and mating rings by the desired running
gap.
WHY Questions
When the compressor is stopped (not rotating), the primary ring is held against the
mating ring with a series of springs. Because the grooves are not machined across the
entire face of the mating ring, the two rings are in tight contact over the dam area and
the running gap (and therefore seal leakage) is eliminated.
Why Lift-off ?
Why hydro-Dynamic lift ?
Gas enters the groove moving towards the center;
Gas is compressed and pressure increases setting the gap between the rings.
Static Pressure +
Spring Thrust
Dynamic
Pressurization
Process
Side
Stationary ring Rotating ring
Seal
gas
Seal
gas
The pressure profile at the
interface is self adjuxting to
restore to a position of
equilibrium
Pressure Profile in faces
Clearance variation due to axial shaft displacement
Normal gap
Increased gap
Reduced gap
Opening force
Opening force
Opening force
Closing force
Closing force Closing force
WHAT IF ROTOR MOVES AXIALLY
Force
FORCES VARITATION CURVE
If the running gap between the primary and mating seal rings increases during
operation because of axial rotor movement, the pressure at the mating ring groove
tips will be reduced as the volume increases. The gas forces acting on each-side of
the primary and mating seal rings will force the rings toward each other, thereby
restoring the running gap to the desired value.

Conversely, if the clearance between the seal rings decreases because of axial rotor
movement, the pressure at the mating ring groove tips will increase as the volume
decreases, overcoming the gas forces acting on the outside of the mating rings,
hence increasing the running gap to the desired value.
WHAT IF ROTOR MOVES AXIALLY
Opening Force
Closing Force
DISTORTION
IDEAL PROPERTIES REQUIRED DURING AXIAL MOVEMENT
When there is axial movement of the compressor rotor, the gas film between the mating
and primary seal rings must have sufficient stiffness to ensure that the rings do not come in
contact with each other, which can lead to catastrophic seal damage. A narrow running gap
presents increased risk of accidental contact between the primary and mating ring faces.
Therefore, a narrow running gap and the highest possible gas film stiffi1ess represent the
optimum combination
Gas stiffness
Pressure Profile
A uniform pressure distribution between the primary and mating ring faces is also
important, because it will reduce the local deformation (and therefore potential for the
seal rings to make contact) of the parts.
Balance of Forces
The hydrostatic and hydrodynamic forces acting on the seal control the position of the
primary ring. Hydrostatic forces are present whenever the seal is pressurized.
Hydrodynamic forces are present only during rotation of the mating ring.
BALANCING FORCES/Closing
BALANCING FORCES/ Opening
The opening force is much more difficult to calculate. The opening force is a complex
function of several parameters, which are not all independent of each other.

The opening force is a function of

1. Rotational speed
2. Gas pressures and
3. Temperatures
4. Groove geometry
5. The running gap

Therefore, the opening' force must be calculated by computer code. The computer code
typically calculates pressure, speeds, and temperature distributions at every point within
the seal ring interface.
1. The program will iterate until the optimum running gap-where the opening forces
exactly balance the dosing forces-is attained.
2. Different groove geometry can be analyzed and optimized to provide optimum gas
seal performance.
Dry Gas seal Leakage
Dry gas seal are not zero leakages seals, a small amount of gas is required to pass through
the seal to cool the rings, avoiding damages due to overheating.
1. When the compressor is stopped (not rotating), the primary ring is held against
the mating ring with a series of springs.
2. Because the grooves are not machined across the entire face of the mating ring,
the two rings are in tight contact over the dam area and the running gap (and
therefore seal leakage) is eliminated.
The gas seal leakage is directly proportional to the cube of the
running gap.
Gas sealing leakage is also directly proportional to sealing pressure
and the physical size (diameter) of the gas seal.

3. Therefore Static Balancing Force is most important. Thus Seal diameter.
DGS Required Characteristics of Material
High hardness
High modulus of elasticity
High tensile strength-to-mass-ratio
High thermal conductivity
Low coefficient of thermal expansion
DGS CONFIGURATIONS
Single gas seal
Tandem Gas seal
Tandem Gas seal with Intermediate Labyrinth
Double Opposed Seal
Comparison of Configurations
Single Seal
Tandem Seal

The addition of the secondary seal provides
1. A backup to the primary gas seal
2. Increases the operating safety of the compressor by providing an opportunity
for a controlled shutdown of the compressor should the primary seal be
damaged or otherwise fail.
Tandem With Intermediate Seal
when no seal gas leakage can be tolerated in the secondary vent.
To accomplish this, the intermediate labyrinth seal is typically buffered with an inert gas
injected into the port at a pressure slightly higher than the primary vent pressure. This
assures a positive flow of intermediate seal across the intermediate labyrinth toward the
primary vent. Thus, the flow through the primary vent (flare) is a combination of primary
gas seal leakage and intermediate seal gas leakage across the intermediate labyrinth.
More complex support system requirements.
Possible requirement for more axial space in the
compressor.
Increased difficulty in the accurate measurement of
primary gas seal leakage. This is caused by the
mixture of primary gas seal leakage and intermediate
labyrinth leakage in the primary vent. It is nearly
impossible to determine the proportion of primary
gas seal leakage to the overall gas flow through the
vent.
Increase in the mass on the compressor rotor

More complex seal design
More complex support system requirements
Requirement for more axial space in the compressor
Larger mass in the compressor rotor
Dis-advantages of Tandem seals as compared to the previous one
Arrow ??
Double Opposed
1. The inboard seal leakage flows across the inner labyrinth seal and into the process side of the
compressor
The flushing gas is supplied at a pressure slightly higher than the sealing pressure. This assures a
positive flow of clean, dry flushing gas across the inner labyrinth and into the process side of the
compressor.
Double opposed gas seals are used in process gas applications where it is necessary to
eliminate all process gas emissions, even to flare
1. The total seal gas consumption is very low
2. Seal gas leakage to the outboard vent is also very low, contains no process gas (zero
process gas emissions), and can be vented locally.
3. Plant nitrogen is typically very dean and dry, and, when used as sealing gas, greatly
reduces the potential for gas seal contamination (a major concern when sealing with
filtered process gas), thus increasing gas seal reliability.
4. There is no primary vent system, which simplifies the gas seal support system.
1. They are limited in their application by temperature. The extremely low flow of seal gas
through the double opposed gas seal provides very limited cooling
2. The double opposed gas seal is not a viable option at high sealing pressures. The
operating pressure limits of double opposed gas seals can vary depending on the seal
manufacturer and the specific application.
3. A very small amount of the inert sealing gas will leak into the compressor. Depending
on the application and the inert sealing gas employed, this could upset the process.
Pros & Cons. of Double Opposed
????
Barrier Seal
Avoid seal gas leakage into the
bearing chamber;

Avoid the lube oil entering the dry
gas seal.
Types of Barrier Seal
Stationary component is abraded by the
rotating part, which creates the tighter
clearances required for reducing gas
leakage.
The abradable labyrinth solution is retrofit-
table with no modification to existing
compressor parts.
The tertiary contact carbon rings sleeve
and housing was replaced by a toothed
sleeve and abradable stator components.
Types of Barrier Seal
Hardened sleeve on Shaft
N
2
Supply
If the gas leakage increase, the
differential pressure drops
down under 0,5 Bar
Bearing
side
To secondary
vent
0,5 barg
Carbon Ring Tertiary Seal Types
Hardened sleeve on Shaft
Carbon rings
Springs
N
2
Supply
Reduced N2 buffer consumption respect to
standard labyrinth seals
Improve compressor reliability compared to
contact carbon seals
Reduce buffer gas consumption.
Intermediate Labyrinth
Product side
Outboard seal
Inboard seal
Seal gas STREAM 1
Primary vent (leakage from inbord seal
+ intermediate buffer gas - to flare) STREAM 2
Intermediate buffer gas (N
2
)
STREAM 3
Secondary vent (leakage from Outbord seal
+ separation gas - atmospheric) STREAM 4
Separation gas (N
2
)
STREAM 5
Atmosphere
(Bearing chamber)
Separation seal Inner seals
Carbon rings
Face
Seat
Seat
Face
Tandem Seal
Process gas
side
Bearings
side
Buffer-Process gas
supply
Seal
gas supply
N
2
Seal gas
leakage
Separation gas
N
2
Inner seal Inboard seal Outboard seal Separation seal
Drawing Understanding
Compressor
Name
I/B O/B
Secondary seal Tertiary Seal Type Secondary seal Tertiary Seal Type
K-01 HP
NO Labyrinth NO
Labyrinth (But
simply screwed)
K-431 LP
YES Carbon Ring YES Carbon Ring
K-431 HP
K-441
ENCOP
YES YES
PLANT DGS
Primary Seal is present off course in all Below Compressors
Compressor
Name
I/B O/B
Intermediate Labyrinth Intermediate Labyrinth
K-01 HP
NO NO
K-431 LP
YES YES
K-431 HP
YES YES
K-441
YES YES
ENCOP
YES YES
Intermediate Labyrinth
DGS Support System
Provide clean, dry seal gas to the Primary gas seals
Provide clean, dry separation gas to the barrier seals
Monitor the health of the DGS and barrier seals
Seal Gas supply Source
Gas filters
Primary Vent & Their Instrumentation
Secondary Vent & Their Instrumentation
Inert Gas supply
Control System
Why Support System is necessary ?
What is included in Support System ?
Seal Gas Supply
The seal gas source must be available CONTINUOUSLY at a pressure slightly higher than the
required sealing pressure across the entire operating range of the compressor, including
transient conditions such as startup, shutdown, idle, and static (non-rotating).
From Compressor
Discharge
From External
Source
A second concern is the quality (cleanliness) of the seal gas. Gas seal manufacturers have
stringent requirements for seal gas quality, typically requiring the seal gas to be dry and filtered
of particles 3 Micro-meter (absolute) and larger.
The potential for liquid condensation within the gas seal system must be-thoroughly reviewed.
Heavy hydrocarbons & water vapor contained in the sealing gas have a tendency to condense as
the gas flows through the gas seal system. The various components of the gas seal system-filters,
valves, and orifices-cause seal gas pressure drops during operation. A seal gas heater can be
provided as part of the gas seal system
The American Petroleum Institute's standard API614 (1999) requires that the seal gas
temperature into the gas seal be at least 20"F above its dew point. This can be insufficient
in many cases.
Primary Seal Gas vent & Its Health
1. Flow Orifice
2. Pressure Gauge
3. Pressure Transmitter
4. Pressure Alarm
5. PSV/Rupture Disc
The separation gas is required for the barrier seals, which are intended to prohibit lube oil migration into
the gas seal. The separation gas is usually provided to the barrier seals through stainless steel tubing. Like the
primary seal gas, the separation gas must be available at sufficient pressure, as defined by the barrier seal
manufacturer, with enough safety margin to account for buildup of pressure drop through the gas seal system
components. It is very common to use plant instrument air as the separation gas medium. It is highly
preferable to use nitrogen source for separation gas.

Compared to the main seal gas supply, the quality and composition of the separation gas is of lesser
concern. The manufacturer's gas quality requirements for barrier seals are less stringent than for dry gas seals.
The-typical sources of separation gas (nitrogen or instrument air). are generally very clean in comparison to
seal gas sources.
Inert Gas supply & Its Health
Control Systems of DGS
The primary objective of the seal gas control system is to assure that sealing gas is injected
between the inner labyrinth seal and the gas seal at a rate sufficient to prevent reverse now of
unfiltered process gas across the inner labyrinth seal and into the gas seal.
1. A rate of 16 ft/s is an industry accepted standard for sealing with labyrinth seals based on
many years of experience with providing buffer gas to seals. This is considered the
minimum acceptable seal gas velocity for gas seal applications.
2. Therefore, to assure a positive flow of seal gas across the inner labyrinth seal, gas seal
systems should be designed to provide a minimum gas velocity of16 ft/s across the inner
labyrinth seal at all times.
3. The seal gas velocity across the inner labyrinth seal will vary with labyrinth clearance. To
maintain the minimum 16 ft/sec velocity across the inner labyrinth seal at increased
labyrinth clearance, the system should be designed to provide twice the seal gas velocity
(32 ft/s) at the inner labyrinth clearance.
The Data for the flow control was based on the constant gas velocity of 32 ft/s .
Why 02 Control Systems of DGS ?
Differential Pressure
Control System
Flow Control System
Compressor
Name
Control System
K-01 HP
K-431 LP
K-431 HP
K-441
ENCOP
PLANT DGS CONTROL SYSTEMS
Practical Parts of DGS seal
Shim Ring
Housing of Primary
Seal
Housing of
Secondary Seal
Housing of Tertiary
Seal
Sleeve of Tertiary
Seal
Sleeve of Secondary
Seal
Sleeve of Primary
Seal
Shim Ring To lock
the Seal
Closing Flange
of seal
Seal Locking
Nut
Maintenance of DGS
a) Review the operating trends of key gas seal performance indicators (e.g., seal gas and
separation gas supply flow or differential pressure and primary gas seal leakage).

b) Inspect the low point drains located in the primary and secondary gas seal vents and
filter housings for accumulated liquids. Remove any liquids that are present.

c) Inspect the differential pressure of the operating seal gas filter. If the differential
pressure exceeds that of a clean filter element by given psi, or if the differential
pressure alarm is activated, switch operation to the clean filter element following
manufacturer's instructions.
Good Practices
Seals Maintenance

Pre-setups for DGS Removal
Removal and installation measure before seals
Assembly/disassembly end labyrinth, dry gas seal and separation seal on BCL I
Assembly/disassembly end labyrinth, dry gas seal and separation seal on MCL

1. Disassembly coupling cover
2. Disassembly tube vent / drain
3. Disassembly spacer
4. Disassembly hub
5. Control distance between shaft ends
6. Disassembly proximity probes
7. Disassembly thermocouples
8. Disassembly proximity probe (axial displacement)
9. Disassembly active thrust bearing
10. Disassembly thrust collar
11. Disassembly inactive thrust bearing
12. Disassembly journal bearing
13. Disassembly (spacer ring)
14. Disassembly Dry seal
15. Disassembly end labyrinth seal
Pre-setups for DGS Removal
DBSE
The DBSE

Axial clearance of trust bearing

Reference distance shaft end casing
Opposite To Thrust Bearing

Reference distance shaft end casing
Thrust Bearing side

Distance from end shaft to thrust collar B

Measuring now from shaft end to shim ring A and the thickness of the collar C If B
measured = B calculated, mean that F = 0, therefore thrust collar is correctly installed
DGS
The external surface of the Shaft piece
to the DGS outer surface
Inner Labyrinth
DGS
Separation/Tertiary Seal
Shear Ring

Fix the axial rotor device
Place axially the rotor
When the correct position is found lock the rotor
Locking of Rotor Axially
Check the Direction of Rotation , Marked on the Seal
Sense of rotation :
CCW cartridge are provided with 3 grooves
CW cartridges are provided with 4 grooves
Why it is so important to know/Install Correct direction of Rotation ?
Install PVC pipes on shaft ravel distance of DGS
Insert labyrinth seal (with its dowel) with proper
extractors L
Insert retaining ring by proper pliers (standard tool)
Dowel
Retaining Ring
Assembly of End/inner Labyrinth seal of DGS
4/4 shear ring
Measure distance y and thickness y1
Measuring of distance for separation seal assembly
Shim Ring
Measure thickness x and thickness x1
Calculate Z
Z= ( Y-Y1) (X+X1)
Install Guide Rods on the casing Flanges
Tie DGS TO Bell Assembly
Bell Assembly
Setting Flange
Slide assembled group along the 4 studs
lift shaft using crane or hydraulic jack
Sliding DGS inside the Compressor
Sliding DGS inside the Compressor
BURGMAN dry gas De-coding
Compressor
Name
I/B O/B I/B & O/B
Seal Code Seal Code Tertiary Seal
K-01 HP
PDGS10/108-E1- L PDGS10/108-E1- R N/A
K-431 LP
DGS20/170-ZT2-L DGS20/170-ZT2-R CSE8-150-E5-U
K-431 HP
PDGS10/165-ZT8-L PDGS10/165-ZT8-R CSE8/150-E6-U
K-441
DGS21/150-ZT7-L-A1 DGS21/150-ZT7-R-A1 CSE8/140-E2-U-A1
ENCOP
Plant Data

DGS Seal

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DGS Seal

Uploaded by

Copyright:

Available Formats

ENGRO FERTILIZER LIMITED

DRY GAS SEALS

You might also like