EagleBurgmann DGS
EagleBurgmann DGS
EagleBurgmann DGS
eagleburgmann.com
info@eagleburgmann.com 1
A B S D A B C S D
Labyrinth
Labyrinth
Bearing side
2 Secondary seal
Process side
Bearing side
Process side
1 2 3 1 2 3
3 Separation seal 1 Primary seal
2 Secondary seal
4
3 Separation seal
4 Intermediate
labyrinth
Tandem Dry Gas Seal (EagleBurgmann DGS) Tandem Dry Gas Seal with intermediate labyrinth (EagleBurgmann DGS)
2
from the normal seal behavior. If the dynamic critical temperature line (dew line) and turn it into
sealing element is prevented from moving freely to a vapor (dual phase). Apart from the
adjust for axial movements, this will affect the seal Joule-Thompson effect, the environment also
gap and lead to high seal leakage if the faces are influences the seal gas temperature. Ambient
kept open, or will cause primary seal failure in temperatures can cool exposed supply lines, which
case the faces stay in contact. will drop the temperature of the gas and change
Contaminated dynamic sealing element the gas conditions.
To avoid the above-mentioned scenarios, a supply
of clean gas must be provided to the primary seal Since gases can be made up of different
whenever the compressor is pressurized or in components, they can change the critical
operation. A reliable clean gas flow will prevent temperature (dew point) of a gas. For gas pipelines
contamination from the process gas from entering with methane as the major component, there are
the primary seal. also heavier hydrocarbons within the gas which
can dramatically change the critical temperature
In the next steps, proper filtration must be selected. (dew point). Even small differences in the gas
Typically, filter elements are selected to remove composition can make the difference whether
particles as small as 3 µm and sometimes even a gas remains gaseous or begins to form liquids or
1 µm. This ensures the removal of particles that are vapors.
Contaminated seal area behind the stationary face larger than the seal gap can tolerate, producing
a clean quality gas for the primary seal. Seal gas Component % mol
filters have high alarms on differential pressure to Methane 89.415
identify when filter elements require replacement. Ethane 7.0
Propane 1.095
The use of dual filter housings means that filter N-butane 0.121
elements can be replaced during compressor I-butane 0.094
operation without interrupting the seal gas flow. N-pentane 0.018
Filters supplied with seal gas systems have I-pentane 0.025
limitations on the volume and size of the liquids and Hexane+ 0.006
Nitrogen 0.80
particles they can manage. Higher levels of CO2 1.424
contaminants in the seal gas will require additional
filtration. This filtration pre-filters the gas and Typical natural gas pipeline gas composition
Damaged seal face generally contains some type of liquid knock out.
If liquids enter the gap between the rotating seat
and stationary face, this creates high shearing
Contamination by particles Contamination by liquids forces which generate heat. The generated heat
leads to gap instability, causing contact between
Particles present in the process gas can When a compressor is hot during normal operation, the rotating seat and stationary face, damaging the
contaminate the primary seal when the seal gas the operating temperature ensures the gaseous seal faces and resulting in a seal failure. If a failure
flow across the process side labyrinth is state is retained for most applications. So the gas does not occur during operation with the liquid
insufficient, or if the provided filtration or remains gaseous when the seal gas flows from the contamination, the seal will fail at the next
conditioning is inadequate for the seal gas to discharge tap through the seal gas system into the subsequent start due to increased shear forces.
produce the required quality of gas. primary seal cavity and through the seal - dropping
in pressure and temperature from discharge Many seals fail because of liquids in the gas during
In consequence, particles can enter the gas pressure down to atmospheric pressure. Examples normal or transient conditions. This is usually the
grooves on the rotating face and the sealing gap. If of applications where the gas always remains result of not considering the gas dew point – not
the particles are small enough, they will blow gaseous are pure ethylene or propylene completing a dew point analysis - or an inaccurate
through the seal. Larger particles will get trapped compressors, as these gases condensate at very gas composition is used to complete a dew point
inside the grooves or gap, causing negative effects low temperatures. For other applications, such as analysis. Both of these can result in liquid forming
to the sealing behavior or seal reliability. In wet gas pipeline, when the gas flows through the in the seal gas and a system design that does not
addition to the sealing gap, particles can also block seal gas system and seal it forms liquids. These meet the needs of a dry gas seal.
the dynamic sealing element. liquids are detrimental to the gas seal.
Several steps must be taken to identify and provide
The dynamic sealing element is an O-ring or When a gas drops in pressure it will change in the correct system to prevent liquids in seal gas.
elastomer free sealing device between the temperature. This is known as the Joule-Thompson The first step is to accurately analyze the gas
non-rotating seal face and the balance sleeve. effect. Control valves and orifices to manage composition to identify all the components in the
The non-rotating seal face must slide together with pressure and flow in a seal gas system will change respective gases being used for seal gas supply.
the dynamic sealing element on the balance the temperature of the gas. The seal gas also This includes any changes in the gas composition
sleeve, axially compensating for axial position or drops in pressure as it flows between the seal over time due to upset process conditions, and
movements of the compressor shaft in relation to faces, changing the temperature of the gas. For alternate gases used for seal gas. Most gas
the seal housing. The non-rotating face must also most gases this is a lower temperature, which will composition analyses do not include information
move freely to adjust for any movements resulting move the gas conditions and possibly cross the on components higher than C5 or C6.
3
80
70
60
60
50 50
40 40
30 30
Gas Lamination I3:I5 SOP conditions Gas Lamination I3:I5 SOP conditions
20 20
Temperature (°C )
Temperature (°C )
10 10
0 0
Safety margin
-10 Safety margin
-10
-20
Saturation curve -20
-30 Saturation curve
-30
-40
-40
-50
-60 -50
-70 -60
-80 -70
0 10 20 30 40 50 60 0 10 20 30 40 50 60 70 80
Pressure (bar ) Pressure (bar )
Pessure and temperature operating limits © EagleBurgmann Pessure and temperature operating limits © EagleBurgmann
Dew point curve during the project phase (example) Dew point curve with field gas composition project phase (example)
Process people are not concerned with trace Contamination during pressurized During a pressurized stand still condition, seal gas
components higher than C5 or C6. Some stand still conditions flow, (clean and quality seal gas to the primary
procedures also dry the gas sample before the seal), is only present when an alternate supply or
analysis is completed. This eliminates components Due to environmental concerns it is more difficult means of producing seal gas flow is provided. Seal
that turn to liquid and affect the operation of the to vent compressors to the atmosphere. If gas flow during normal operation is generated by
gas seal. Another concern is when the composition compressors are stopped after a certain period of the discharge pressure, as indicated previously,
of the process gas changes over time. Even minor time they will be depressurized, sending the gas to which is higher than the pressure at the seal. If
changes in the gas composition can significantly flare or atmosphere, resulting in emissions a higher pressure/flow cannot be provided during
change the dew point of a gas. It is therefore penalties or fines. Some situations can also require a pressurized hold, unconditioned process gas
elemental to provide an accurate and complete gas a pressurized compressure which ensures a quick from the compressor flows into the primary seal
composition when establishing the phase envelope response to demand. Having a gas seal fail on cavity via the process labyrinth, when the seal gas
to ensure a reliable result. Possible changes in gas a restarted compressor while supporting demands flow is lost. When the compressor is not or only
composition over time must be considered as well. does not result in reliable production, profits or slowly rotating but still pressurized, leakage still
reduced environmental concerns. As identified occurs through the gas seal. This means the gas
Taking this information as basis, the second step is above, particles in seal gas or primary seal cavity, leaking through the seal is unconditioned process
to produce the line for the seal gas dew point and or liquids that form in a seal gas are root causes gas from the compressor, allowing unconditioned
to identify at what temperature and pressure the for the majority of seal failures. To prevent these gas to enter the primary seal cavity and
components in the gas will turn to liquids. failures from occurring it is essential to ensure contaminating the primary seal.
Pressures and temperatures to the left of the dew a clean and quality seal gas for the primary seal.
line result in a dual phase gas; liquid in the gas. This maintains a reliable seal that will not fail
This is the area where the seal gas may not during standstill conditions and prevents failures
operate in. The third step is to plot the when restarting or shortly after restarting Process gas flow during
decompression curve with the minimum margin a compressor. pressurized stand still
from the dew line (industry standards have
identified the safety margin as 20 Kelvin). A B S D
FO
PDIT
4
2 3 4 5 6
7
HEATER 1 Gas IN
TE TE
1 2 Cooler
LIT FILTER FILTER PDIT TSHH TE RoTech
Booster
3 Separator
LIC
PIT TIC 4 Filter unit
LCV 5 Heating
6 RoTechBooster
7 Gas OUT - to primary
seal gas supply
As stated in the previous section on contamination If the line represents pressure and temperature correctly; a typical limit is 50 cycles / minute for
by liquid, the ambient temperature must be drops of the seal, then gas passes through or close reasonable life.
considered. The reason is that the compressor and to the dual phase envelope. There are a few
seals will be at an ambient temperature during possible solutions for this. The air driven boosters are positive displacement
standstill conditions. If unconditioned process gas piston type boosters, and the one used as an
is exposed to these conditions, the gas drops in An outside source can be used, but the same example will provide 1:1.78 pressure ratios. They
temperature and pressure when passing through analysis must be completed on an accurate incorporate many moving parts in the booster to
the seal face liquid forms and contaminates the dry composition of this gas. A concern with using an operate the unit. There are poppet valves, shuttle
gas seal. outside source is that gas volume is added to the valves, check valves, piston rod and pistons that all
compressor/process. This increases the pressure have seals and wearing parts. These require
in the compressor/process. As the pressure builds maintenance and affect the reliability of the unit.
in the system, the gas must be vented to maintain
the clean flow of gas to the gas seal. Due to The principle operation of the booster uses air as
stricter environmental regulations this is becoming the drive media. It is supplied through a shuttle
more difficult to do. valve to apply pressure on one or the other end of
the piston. The position of the shuttle valve spool is
The ideal solution is to circulate the gas within the controlled by pressure and determines which end
system. Dirty or wet gas is drawn out of the of the piston is applied with pressure.
compressor through a conditioning system to bring
it to the quality and temperature required for the The position of the spool is controlled by a pilot
Contaminated seal face gas seal and is pushed into the seal cavity. This system and spring and poppet valves. The poppet
ensures the gas seal is provided with a gas that valves control pressurization and depressurization
When liquids form between the seal faces while does not allow liquid to form between the seal of the pilot system. The spool movement is also
the compressor is not rotating, they may stick faces. assisted by a spring to move the spool when the
together. The flat surfaces of the stationary face pilot system is unpressurized. When the piston
and rotating seat are within two light bands of Conditioning a seal gas can require filtering the pushes against the poppet valve on right hand end
flatness. With such flat surfaces the liquid will gas using coalescing filters. Or, conditioning can of the cylinder, the pilot system is pressurized and
create a bond between the stationary face and the be as complex as cooling the gas to form the the shuttle valve spool is moved to the left,
rotating seat. This is good on the one hand liquid, a liquid knockout to remove liquid, a heater allowing air pressure to enter the drive cylinder and
because it will reduce or even totally eliminate the to provide minimum dew point margin, heat trace move the piston to the left.
seal leakage. On the other hand, the downside is for maintaining temperature, a booster to move the
that the strength of the bond is so great when gas, and final filtration to ensure nothing passes When the piston hits the poppet valve on the left
rotational force is applied to the seat that it will through to the seal. Proper analysis of the dew hand side, the pressure is vented from the pilot
damage the drive pins and the stationary seat. This point and operating conditions will define the system and the spring assists in moving the spool
causes high seal leakage during the start or restart required conditioning to ensure the right quality of to the right. This will vent the pressure in the
of a compressor, and identifies a seal failure with gas is available for the gas seal. cylinder on the right and pressurize the cylinder on
the requirement to replace the seal. the left. As the piston moves back and forth, check
The movement of the gas is one of the most valves on the process end open and close to draw
important requirements for providing reliability for pressure in from the suction on one side of the
a dry gas seal: circulating seal gas from the piston and push process gas out on the other side
compressor through the seal cavity. During normal of the piston. This produces the seal gas flow.
operation there is sufficient differential pressure
between compressor discharge and sealing These systems are complex not only for the
pressure. When sufficient differential pressure is booster itself but also for the system required to
not present, usually during a standstill , a booster ensure it operates the controls for the drive gas,
is required. Air-driven piston pumps are currently over pressure protection and monitors the wear of
being used for this application, but they have seals. With the many wear parts and additional
proven unreliable, especially when required to equipment to operate the unit, it becomes a very
Destroyed seal faces after startup with contaminated sliding faces operate for long periods of time or when not sized costly system and has many reliability concerns.
5
B A B B A B
6 1 2 3 4 7
open open
closed D
closed
closed 5
C C closed
open open
5 Spool
6 Check valve 1.1
7 Poppet valve
1.3 3
4
Dirt and debris in the shuttle valve, poor quality or 5
excessive cycling of poppet valves, ice buildup in
the shuttle valve spool, poor quality air and many
other issues have prevented these types of
boosters from operating reliably. Due to these
reliability issues, air driven boosters have not
performed well and are not the best option for long
periods of continuous operation.
Operation principle rotating type booster EagleBurgmann RoTechBooster
To ensure reliable operation of gas seals and Item Description Rotech © EagleBurgmann
compressors during standstill conditions, a reliable 1.1 Inner rotor two or even more of these units are needed; more
device to circulate the seal gas must be used. As 1.2 Outer rotor air volume is required to drive them. Using this type
rotating equipment is generally much more reliable 1.3 Can of booster requires accepting lower velocities or
than reciprocating equipment, the best booster 2 Motor higher air consumption with multiple units.
design will be a centrifugal type. 3 Bearing cartridge
4 Impeller To provide an idea of the requirements for a piston
Many booster designs require shaft seals, resulting 5 Pressure housing booster, an example for a pipeline application with
in additional leakage of gas. If a magnetic coupled the below conditions will be used:
or canned booster is used, this eliminates any The equipment used for circulating seal gas is
additional gas leakage; no gas to manage or used not only for standby conditions but anytime Shaft size: 150 mm (5.9")
leaking to atmosphere. One of the most important there is insufficient pressure across the Pressure: 70 barg (1,015 PSIG)
parts in a centrifugal design is the impeller. compressor to deliver adequate seal gas flow. Temperature: 23 °C (73.4 °F)
The impeller design must handle a wide range of When the correct circulation unit is provided, the Required flow for 5 m/s (16.4 ft/s) at twice the
operating pressures and varying gas. If the correct compressor can be placed in a pressurized hold for labyrinth clearance: 389 Nm3/h (229 SCFM)
impeller is not used, changing gas conditions can a nearly unlimited period of time. Continued supply Output of piston booster at 90 cycles/min.:
result in a booster failure. of clean dry gas to the gas seals will ensure the 332 Nm3/h (196 SCFM)
ideal conditions for the gas seal and guarantee Drive air required for one unit: 62.6 Nm3/h
Selecting a rotating, clean gas booster provides the a trouble-free start or restart of your compressor. (36.8 SCFM)
ability to use a standard reliable electrical motor.
The use of a variable speed drive provides the Piston type boosters are primarily designed to Based on the size and operating condition for the
capability to manage the varying gas density and generate pressure increase, allowing installation in above example, the required seal gas flow for each
wider range of operating pressures with lower line with pressure reduction elements such as seal is more than one piston booster can provide.
power consumption. This allows for minimal capital pressure control valves, flow control valves or To meet the recommended flow for two seals,
to install and operate the booster. The integration orifices. Although these units generate more than three boosters should be used for the application.
of an air-driven device, which is the standard for sufficient pressure boost, they are limited in the This would require almost 132.5 Nm³/h (78
piston type solutions, uses large volumes of air to flow produced. They therefore do not always SCFM) of air to provide the required flow for the
drive the units. This requires installation of other achieve the flow necessary to achieve minimum boosters cycling at 70 cycles a minute. Other
equipment just to support an air driven booster. velocity across the process labyrinth. To achieve boosters producing high pressure ratios will
the required velocity across the process labyrinth, consume even more air.
6
3.50
3.00
2.50
Head (bar) Required Performance of EagleBurgmann RoTechBooster Type 225H
2.00 225H
1.50 Power consumption: 6.7 kW
1.00 Running torque: 25.6 Nm
0.50 Estimated temperature rise: 20.2 °C (68.3 °F)
Estimated outlet temperature: 43.2 °C (109.8 °F)
0.00 Check bearing loads: OK
0.00 500.00 1000.00 1500.00 2000.00 2500.00
Flow (NCMH)
Conclusion
A B S D
Contamination is the leading cause for dry gas seal
failure. As identified in this article, if process gas or
inadequately conditioned seal gas is provided to
a dry gas seal, it will affect the reliability of the
PIT
seal. To prevent this from occurring requires an
FO accurate gas analysis, correct conditioning
FIT components and seal gas flow whenever pressure
is present in the compressor. When a compressor
PCV
is in pressurized standby, using an alternative gas
requires venting of gas pressure and leads to
environmental concerns. Incorporating a booster in
the system eliminates venting of process gas and
PDIT
FO
prevents contaminated process gas from entering
the primary seal. A reliable booster, like an
EagleBurgmann RoTechBooster, delivers the
recommended seal gas flow until the compressor
is restarted to prevent failures in standby situations
From discharge or a higher
during or shortly after compressor restarts.
stage of the compressor
7
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Article by Daniel Goebel, EagleBurgmann Germany with contribution of Glenn Schmidt, EagleBurgmann USA.
E150801 / E1 / 1.000 / 02.16/ 9.7.5 / © EagleBurgmann Group Marketing, Germany
EagleBurgmann is one of the internationally leading companies for industrial sealing technology. Our eagleburgmann.com
products are used everywhere where safety and reliability are important: in the oil and gas industry, info@eagleburgmann.com
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