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
force

Gas is scooped into this

tight space forcing it to
overflow outwards into the
gap between the faces
forcing them apart

Spring tension

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

Low pressure
Low cost

Double Seal

Low pressure
Hazardous gas

Tandem Seal

Most popular seal

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

BEARING

SEAL

Axial thrust from high

discharge pressure

Low pressure suction

High pressure discharge

This pressure balancing

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

Balance drum

SEAL

BEARING

Balancing pressure
created by balance drum

6 centrifugal impellers

Pressure
balance drum

HP rotor & casing

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.

Bearing

HP

RO

SEPARATION SEAL GAS

Bearing

RO

Bearing

RO

Bearing

Burst disc

RO

LP

RO
PRIMARY SEAL GAS

RO
FC

FC

FC

FC

FC
SECONDARY SEAL GAS

SECONDARY SEAL GAS

PDT

PDC

N2
HP Fuelgas

Primary Gas

Primary Gas

Primary Vent

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.

Compressor
Suction
pressure

Atmospheric
pressure

Compressor
drive shaft

Bearing
housing

Secondary Gas

Compressor
Suction
pressure

Secondary Vent

Secondary Gas

Primary Gas

Primary Vent

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)

Atmospheric
pressure

Compressor
drive shaft

Bearing
housing

Separation Gas

Secondary Vent

Separation Gas

Compressor
Suction
pressure

Secondary Gas

Primary Gas

Primary Vent

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

system ensure separation
gas is on to keep the lube
oil out of the seal!!

Atmospheric
pressure

Compressor
drive shaft

Bearing
housing

Dry gas seal

assembly

Labyrinth ring
for separation
gas

John Crane
Dry gas seal
assembly

Sliding out

Keeper pin
Inserted to support
Assembly while
Sliding out

DP
ALARM

Typical control scheme:

FILTERS

DP
Seal gas pressure

A controller maintains a constant

differential pressure above suction
pressure, while the flows to each seal
are also monitored to check seal
integrity.

Suction pressure

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

HP Trip
P

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
start permissive for the compressor.
When the seal fails, the dP becomes
low, initiating a compressor trip.

RO
MARKS
PATENT
ORIFICE
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
isolation

Equilisation
valve

Filter B
isolation

Turning the valves in the correct

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
isolated

Filter B
in service

-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?

What must you do before starting the compressors lube oil system?
During normal running, where is primary seal gas supplied from?
What is the source of secondary gas?
How are the 2 seal faces prevented from touching during normal operation?
What is the purpose of separation gas?
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?
1.
2.
3.
4.
5.
6.

MAN

HELPER MOTOR

CENTRIFUGAL COMP

AXIAL COMP

GAS TURBINE