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ENGRO FERTILIZER LIMITED

DRY GAS SEALS

Presented By :NDB , Rana Yousuf , Ahtsham Ahmad

Special Thanks :ALQ , ZAA , Moghezz Butt , Tahir Lashari

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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 sumppumps.

Automobile Water body seal

Pharmaceutical products

Newspapers / Books - Dependent on pulp & papermanufacturing.

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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 relativeto one another.

Example: Gaskets in pipe flange connections, cylinder covers. etc..

Dynamic SealIn this type of seal, sealing takes place between the surfaces which have relativemovement.

Mechanical Seal with specialty of Dry Gas Seal Labyrinth

Packing

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What is a Mechanical Seal?

A mechanical Seal consists of two extremely smooth and flatsurfaces, called faces, held together to prevent fluid fromescaping. In a mechanical seal, one face must rotate with theshaft and is commonly called the Rotary Face and the othermechanical seal face is fixed and is called the Stationary Face.

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Common parts of Mechanical seal

Springs

AllenScrews

Case/MetalRetainer

RotaryFace

StationaryFace

O-Rings

Gland Plate(Stationary

Holder)

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Early shaft seals were simple labyrinth seals, which oftentimes required complicatedejector systems to deal with substantial gas leakage through the seals.

EARLY SEALS

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FLOATING SEALS

The next" generation of compressor shaft seals was oil film floating ring seals. There are two sealingsurfaces in a typical floating ring oil seal, the inside diameter of the seal rings and the matingsurfaces 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. Thishigh-pressure oil forms a seal against the process, and also serves to cool the seal components.

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Both labyrinth and oil film floating ring seals are radial seals , sealing the radial spacecreated between a rotating shaft and a stationary seal. This limited the level of sealing thatcould be obtained, because the parts had to operate at a clearance large enough to avoidcontact between the stationary and rotating parts

FLOATING SEALS

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Mechanical Seals

During operation, seal oil is injected into the seal at a pressure slightly higher than theprocess gas. This oil provides a seal against the process gas and is also required to cool theseal components, which are subject to high heat generation caused by the contactingdesign of the seal. During shutdown, the spring-loaded shutdown piston (held open by oilpressure during operation) is held in contact with the contact ring, providing a gas-tightseal.

Contact seals were end-face seals, meaning the actual sealing surface was locatedbetween seal components Perpendicular to the compressor shaft, as opposed to radial

seals.

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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 oilmust be treated and reclaimed or disposed of. Disposal of sour ail requirescompliance 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 isabsorbed 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

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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 lastmore 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

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Non-Contacting Hydrodynamic Gas seal Contacting Type hydrostatic Seals

Hydrodynamic or lift off seals that float on acushion of gas.

Hydrostatic seals where the seal faces areseparated by controlling the opening andclosing forces acting on the faces.

HYDRODYNAMIC AND HYDROSTATIC SEAL

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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

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Lets Identify Parts of DGS

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Gas enters the groove moving towards the center; because of the volumereduction at the tips,Gas is compressed and pressure increases setting the gap between the rings.

How Gas Compresses in Grooves

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During operation (rotation), injected sealing gas flows from the outside diameter of the mating ringinto 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 afew microns. The compression zone of the sealing gas is located at the "tips" of the grooves (nearestto the inside diameter of the mating ring). The pressure dam developed at the grooves causes "liftoff", separation of the primary and mating rings by the desired running gap.

Gas Compression

Bidirectional

Gas flows into symmetrical T-Grooves

is pumped circumferientially towardthe edge of groove

Stagnation of flow at the edge builts pressure andresults in hydrodynamic lift-off, even at low peripheralspeed

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Hard ring

Groove depth = 10 micron

Clearance during operation ~ 35 micron

Human hair diameter : 50 75 micron !!!

Depth of Grooves

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Lift-off is most likely used because the first dynamic seal designs were for use in jetengines

The equations that determine the separation force are the same as those used tocalculate hydro-dynamic forces for a liquid. While the calculations are the same, just withdifferent 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 forexplaining the lift effect.

"lift off", just mean separation of the primary and mating rings by the desired runninggap.

WHY Questions

When the compressor is stopped (not rotating), the primary ring is held against themating ring with a series of springs. Because the grooves are not machined across theentire face of the mating ring, the two rings are in tight contact over the dam area andthe running gap (and therefore seal leakage) is eliminated.

Why Lift-off ?

Why hydro-Dynamic lift ?

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Gas enters the groove moving towards the center;Gas is compressed and pressure increases setting the gap between the rings.

Static Pressur e +Spr ing Thrus t

DynamicPressur iza t ion

Process

Side

Stationary ring Rotating ringSealgas

Sealgas

The pressure profile at theinterface is self adjuxting torestore to a position ofequilibrium

Pressure Profile in faces

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Clearance variation due to axial shaft displacement

Normal gap

Increased gapReduced gap

Opening force Opening force

Opening forceClosing force

Closing force Closing force

WHAT IF ROTOR MOVES AXIALLY

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Force

FORCES VARITATION CURVE

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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 groovetips will be reduced as the volume increases. The gas forces acting on each-side ofthe primary and mating seal rings will force the rings toward each other, therebyrestoring 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 volumedecreases, 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

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DISTORTION

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IDEAL PROPERTIES REQUIRED DURING AXIAL MOVEMENT

When there is axial movement of the compressor rotor, the gas film between the matingand primary seal rings must have sufficient stiffness to ensure that the rings do not come incontact with each other, which can lead to catastrophic seal damage. A narrow running gappresents 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 theoptimum combination

Gas stiffness

Pressure ProfileA uniform pressure distribution between the primary and mating ring faces is alsoimportant, because it will reduce the local deformation (and therefore potential for theseal rings to make contact) of the parts.

Balance of ForcesThe hydrostatic and hydrodynamic forces acting on the seal control the position of theprimary ring. Hydrostatic forces are present whenever the seal is pressurized.Hydrodynamic forces are present only during rotation of the mating ring.

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BALANCING FORCES/Closing

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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 speed2. Gas pressures and

3. Temperatures4. Groove geometry5. The running gap

Therefore, the opening' force must be calculated by computer code . The computer codetypically calculates pressure, speeds, and temperature distributions at every point withinthe 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.

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Dry Gas seal Leakage

Dry gas seal are not zero leakages seals , a small amount of gas is required to pass throughthe seal to cool the rings, avoiding damages due to overheating.

1. When the compressor is stopped (not rotating), the primary ring is held againstthe 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.

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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

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DGS CONFIGURATIONS

Single gas seal

Tandem Gas seal Tandem Gas seal with Intermediate Labyrinth Double Opposed Seal

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Comparison of Configurations

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Single Seal

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Tandem Seal

The addition of the secondary seal provides1. A backup to the primary gas seal2. Increases the operating safety of the compressor by providing an opportunity

for a controlled shutdown of the compressor should the primary seal bedamaged or otherwise fail.

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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 gasinjected into the port at a pressure slightly higher than the primary vent pressure. Thisassures a positive flow of intermediate seal across the intermediate labyrinth toward theprimary vent. Thus, the flow through the primary vent (flare) is a combination of primarygas seal leakage and intermediate seal gas leakage across the intermediate labyrinth.

d f d l d h

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More complex support system requirements.

Possible requirement for more axial space in thecompressor.Increased difficulty in the accurate measurement ofprimary gas seal leakage. This is caused by themixture of primary gas seal leakage and intermediatelabyrinth leakage in the primary vent. It is nearlyimpossible to determine the proportion of primarygas seal leakage to the overall gas flow through thevent.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

A ??

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Arrow ??

D bl O d

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Double Opposed

1. The inboard seal leakage flows across the inner labyrinth seal and into the process side of thecompressor

The flushing gas is supplied at a pressure slightly higher than the sealing pressure. This assures apositive flow of clean, dry flushing gas across the inner labyrinth and into the process side of thecompressor.

Double opposed gas seals are used in process gas applications where it is necessary toeliminate all process gas emissions, even to flare

P & C f D bl O d

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1. The total seal gas consumption is very low2. Seal gas leakage to the outboard vent is also very low, contains no process gas (zeroprocess gas emissions), and can be vented locally .

3. Plant nitrogen is typically very dean and dry, and, when used as sealing gas, greatlyreduces the potential for gas seal contamination (a major concern when sealing withfiltered 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 gasthrough the double opposed gas seal provides very limited cooling

2. The double opposed gas seal is not a viable option at high sealing pressures. Theoperating pressure limits of double opposed gas seals can vary depending on the sealmanufacturer and the specific application.

3. A very small amount of the inert sealing gas will leak into the compressor. Dependingon the application and the inert sealing gas employed, this could upset the process .

Pros & Cons. of Double Opposed

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????

B i S l

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Barrier Seal

Avoid seal gas leakage into thebearing chamber;

Avoid the lube oil entering the drygas seal.

Types of Barrier Seal

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Stationary component is abraded by therotating part, which creates the tighterclearances required for reducing gasleakage.

The abradable labyrinth solution is retrofit-

table with no modification to existingcompressor parts.

The tertiary contact carbon rings sleeveand housing was replaced by a toothedsleeve and abradable stator components.


Carbon Ring Tertiary Seal Types

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Hardened sleeve on Shaft

N2 SupplyIf the gas leakage increase, thedifferential pressure dropsdown under 0,5 Bar

BearingsideTo secondaryvent

0,5 barg

Carbon Ring Tertiary Seal Types

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Hardened sleeve on Shaft

Carbon rings

Springs

N2 Supply

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Reduced N2 buffer consumption respect tostandard labyrinth sealsImprove compressor reliability compared tocontact carbon seals Reduce buffer gas consumption.

Tandem Seal

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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

FaceSeat Seat Face

Tandem Seal

Drawing Understanding

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Process gasside

Bearingsside

Buffer-Process gassupply

Sealgas supply

N2

Seal gasleakage Separation gas

N2

Inner seal Inboard seal Outboard seal Separation seal

Drawing Understanding

PLANT DGS

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CompressorName

I/B O/BSecondary seal Tertiary Seal Type Secondary seal Tertiary Seal Type

K-01 HPNO Labyrinth NO

Labyrinth (Butsimply screwed)

K-431 LPYES Carbon Ring YES Carbon Ring

K-431 HP YES Carbon Ring YES Carbon Ring

K-441 YES Carbon Ring YES Carbon Ring

ENCOP YES YES

PLANT DGS

Primary Seal is present off course in all Below Compressors

Intermediate Labyrinth

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CompressorName

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

te ed ate aby t

DGS Support System

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pp y

Provide clean, dry seal gas to the Primary gas sealsProvide clean, dry separation gas to the barrier sealsMonitor the health of the DGS and barrier seals

Seal Gas supply SourceGas filtersPrimary Vent & Their InstrumentationSecondary Vent & Their InstrumentationInert Gas supplyControl System

Why Support System is necessary ?

What is included in Support System ?

Seal Gas Supply

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pp y

The seal gas source must be available CONTINUOUSLYat a pressure slightly higher than the

required sealing pressure across the entire operating range of the compressor, includingtransient conditions such as startup, shutdown, idle, and static (non-rotating).

From CompressorDischarge

From ExternalSource

A second concern is the quality (cleanliness) of the seal gas. Gas seal manufacturers havestringent requirements for seal gas quality, typically requiring the seal gas to be dry and filteredof 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 asthe 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 beprovided as part of the gas seal system

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The American Petroleum Institute's standard API614 (1999) requires that the seal gastemperature into the gas seal be at least 20"F above its dew point. This can be insufficientin many cases.

Primary Seal Gas vent & Its Health

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y

1. Flow Orifice2. Pressure Gauge3. Pressure Transmitter4. Pressure Alarm5. PSV/Rupture Disc

Inert Gas supply & Its Health

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The separation gas is required for the barrier seals, which are intended to prohibit lube oil migration intothe 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 sealmanufacturer, with enough safety margin to account for buildup of pressure drop through the gas seal systemcomponents. 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 lesserconcern. 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 toseal gas sources.

pp y

Control Systems of DGS

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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 ofunfiltered 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 onmany 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 innerlabyrinth seal at all times.

3. The seal gas velocity across the inner labyrinth seal will vary with labyrinth clearance . Tomaintain the minimum 16 ft/sec velocity across the inner labyrinth seal at increasedlabyrinth clearance, the system should be designed to provide twice the seal gas velocity(32 ft/s) at the inner labyrinth clearance.

Why 02 Control Systems of DGS ?

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The Data for the flow control was based on the constant gas velocity of 32 ft/s .


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Differential PressureControl System


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Flow Control System

PLANT DGS CONTROL SYSTEMS

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CompressorName Control System

K-01 HP Differential Pressure

K-431 LP Differential Pressure

K-431 HP Differential Pressure

K-441 Differential Pressure

ENCOP

Practical Parts of DGS seal

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Shim Ring

Housing of PrimarySeal

Housing ofSecondary Seal

Housing of TertiarySeal

Sleeve of TertiarySeal

Sleeve of SecondarySealSleeve of Primary

Seal

Shim Ring To lockthe Seal

Closing Flangeof seal

Seal LockingNut

Maintenance of DGS

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a) Review the operating trends of key gas seal performance indicators (e.g., seal gas andseparation 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 andfilter housings for accumulated liquids. Remove any liquids that are present.

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

Good Practices

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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

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1. Disassembly coupling cover2. Disassembly tube vent / drain3. Disassembly spacer4. Disassembly hub5. Control distance between shaft ends6. Disassembly proximity probes7. Disassembly thermocouples8. Disassembly proximity probe (axial displacement)9. Disassembly active thrust bearing10. Disassembly thrust collar11. Disassembly inactive thrust bearing12. Disassembly journal bearing13. Disassembly (spacer ring)14. Disassembly Dry seal15. Disassembly end labyrinth seal

Pre-setups for DGS Removal

Removal and installation measure before seals

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DBSEThe DBSE

Axial clearance of trust bearing


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Reference distance shaft end casingOpposite To Thrust Bearing

Reference distance shaft end casingThrust Bearing side


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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 Bmeasured = B calculated , mean that F = 0, therefore thrust collar is correctly installed


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DGSThe external surface of the Shaft pieceto the DGS outer surface

Inner Labyrinth

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y

DGS

Separation/Tertiary Seal

Shear Ring

Locking of Rotor Axially

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Fix the axial rotor device Place axially the rotor When the correct position is found lock the rotor

Check the Direction of Rotation , Marked on the Seal

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Sense of rotation :CCW cartridge are provided with 3 groovesCW cartridges are provided with 4 grooves

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Why it is so important to know/Install Correct direction of Rotation ?

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Install PVC pipes on shaft ravel distance of DGS

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Assembly of End/inner Labyrinth seal of DGS

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Insert labyrinth seal (with its dowel) with properextractors L

Insert retaining ring by proper pliers (standard tool)

Dowel

Retaining Ring

Measuring of distance for separation seal assembly

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4/4 shear ring

Measure distance y and thickness y1

Shim Ring


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Measure thickness x and thickness x1


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Calculate ZZ= ( Y-Y1) (X+X1)

Install Guide Rods on the casing Flanges

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Tie DGS TO Bell Assembly

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Bell Assembly Setting Flange

lift shaft using crane or hydraulic jack

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Slide assembled group along the 4 studs

lift shaft using crane or hydraulic jack

Sliding DGS inside the Compressor

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Sliding DGS inside the Compressor

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BURGMAN dry gas De-coding

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Plant Data

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CompressorName

I/B O/B I/B & O/BSeal Code Seal Code Tertiary Seal

K-01 HP PDGS10/108-E1- L PDGS 10/108-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

dgs seal

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