Gas Seal Course Customer 112003 04a

Dry Gas Seals
Examples of
Your Seals
© 2003 John Crane EAA 1

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Dry Gas Seals

Dry Gas Seals
Commissioning
Procedure

Commissioning Procedure
■ General preparation
➤ Ensure free shaft rotation with coupling

disconnected
➤ Ensure Bursting Discs have been

replaced
➤ Check buffer gas system - is it on and

functioning?
21
■ Static Tests
➤ Inboard seal
◆ Open primary leakage line valve
◆ Pressurise casing incrementally to 5 bar g maximum
◆ Measure & record leakage at each increment (Page 23)
◆ Pressurise casing to 7 bar g (If below operating
pressure)
◆ Leakage should rise quickly – indicates static lift-off 
➤ Outboard seal
◆ Close valve in primary leakage line
◆ Pressurise casing to 5 bar g maximum
◆ Measure & record interspace pressure (Page 23)
❖ Will gradually rise if outboard seal operating correctly
◆ Depressurise outboard seal before compressor casing
22
■ Dynamic test
➤ Fully open primary vent valve
➤ Commence normal start-up procedures
➤ Gradually close primary vent valve to
obtain interspace pressure of 0.5 bar g
➤ Record inboard leakage rates (Page 25)
➤ Compare against guaranteed values (Page
8)
➤ Rejection criteria is 3 times guaranteed
➤ Continue recording leakage for 4 hours (at
half hour intervals) 23
■ Operation & Maintenance
➤ Virtually no maintenance required
➤ Continue monitoring leakage (daily)
➤ Check for oil in atmospheric vent lines

(monthly)
➤ During prolonged shutdown / staorage,

blank all connecting ports
24
Examination – Test Number 2
Time allowed: 45 minutes
■ And now for the
examination!
■ It is a multiple choice
test paper
■ Points
➤ 1
correct
➤ 0 don’t
know
➤ -1 incorrect
■ There may be more
than one correct
answer - tick them
25
all
Dry Gas Seals
Installation Test

Dry Gas Seal Installation - Test
1. What should be used to lubricate the
bore of the compressor housing?
A. Silicone grease
B. Anti-seize compound
C. Nothing
compressor shaft/rotor?
A. Silicone grease
C. Nothing
27
3. During installation, seal setting plate

screws should be:
A. Tight
B. Slackened by 1/8 turn
C. Very loose
D. Removed
4. Compressor rotor should be set:
A. In normal running position
B. Towards non-drive end
C. Towards drive end
28
5. The seal should be “exercised”
A. Before installation in compressor
B. After installation in the compressor
C. It must NOT be exercised
6. A reference dimension between
compressor rotor and compressor
casing should be taken or checked:
A. Before seal installation only
B. After seal installation only
C. Before, during and after installation
D. Reference dimension not important
29
7.If the installation tool jacking nuts
become tight:
A. Use a longer spanner to give better
leverage
B. Undo nuts and try to withdraw seal
C. Stop, think, investigate, then take
action
8. A failed seal should be:
A. Jacked out quickly as it is stopping
production
B. Removed with more care than with the
installation of a new seal. 30
Dry Gas Seals

1. What should be used to lubricate the bore
of the compressor housing?
A. Silicone grease
C. Nothing
A. Silicone grease
C. Nothing
32
A. Silicone grease
B. Anti-seize compound – very small
amount
C. Nothing
A. Silicone grease
C. Nothing 33
A. Silicone grease
amount
C. Nothing
A. Silicone grease
amount
34

screws should be:
A. Tight
C. Very loose
D. Removed
35

screws should be:
A. Tight
C. Very loose
D. Removed
36

screws should be:
A. Tight
C. Very loose
D. Removed
37
38
39
40
become tight:
leverage
action
production
become tight:
leverage
action
production
become tight:
leverage
action
production
installation of a new seal – it may stick! 43
Dry Gas Seals
Dismantling and
Re-assembling

Hands-on Exercise 3
S/38644 S/39397 S/38006 S/39923
T28AT+Laby T28AT Small T28AT T28XP
C D B A
1. Disassemble and re-assemble seal

(Only disassemble/clean/assemble
inboard seal unit)
2. Install one new tolerance strip in
bore of main sleeve
3. Re-assemble seal
45
Seal Failure
Analysis

Failure Statistics - Returned
Seals
■ 80% - significant contamination
➤ 50% - contaminant was hydrocarbon
◆ liquid from process gas
◆ lube oil from bearings
➤ 10% - solids / particulates

◆ from pipework
◆ from process gas (incorrect filtration)
➤ 4% - chloride based from the process

gas
➤ 2% - free water from the process gas
➤ 14% - unknown contaminants
47
Hydrocarbon Contamination
■ Oil from bearings
➤ Ensure barrier seal is fitted between seal
and bearings
➤ Ensure barrier gas is switched on before
oil system (30 minute delay)

➤ Ensure oil system is switched off before
barrier gas system (30 minute delay)

■ Problem
➤ High temperature from shearing liquid -
mating ring fracture
➤ Burnt oil deposits block grooves and/or
cause hang-up of balance diameter seal

48
Hydrocarbon Contamination
■ Hydrocarbons from Process Gas
➤ Efficient coalescing filters
➤ Heat the filtered gas to overcome the

Joule-Thompson effect
49
Other Contaminants
■ Water - corrosion of metal and carbide
➤ drop-out from process gas, often at
pressurised stand-still conditions
■ Chloride Corrosion
➤ salt water entrained in process gas
All can be designed for - these were all

unexpected contaminants
50
Liquid Contamination
51
Other Causes of Failure
■ Reverse Rotation
➤ face contact can occur
➤ bi-directional seal (Type 28BD) can be
supplied
➤ occasional low speed acceptable with
Type 28AT and Type 28XP

■ Reverse Pressure
➤ face contact can occur
➤ at high speeds - mating ring fracture
➤ can be designed for static reverse
pressure
➤ consider pressurised double seal
52
Other Causes of Failure
■ Incorrect Fitting
➤ axial alignment (working length ± 0.5
mm)
◆ rotor in correct position
◆ accurate shims
➤ contamination from fitting lubricants

➤ incorrectly fitted tolerance rings
➤ damaged o-rings / polymer rings
■ O-ring damage during running

➤ chemical attack
➤ thermal attack
➤ explosive decompression
53
Mating Rings
Contact Damage
Not acceptable.
Must be replaced.
Investigate HOW / WHY?
54
Mating Rings
55
Mating Rings
56
Mating Ring Contact - Causes
57
No lift Forced contact

58
Typical Example Start-up Misalignment
of a Failure procedures Buffer gas
Analysis Root supply & timing Thrust worn
Dirt
Causes Tree
Before start-up.
Settle-out pressure Clearances
Check control system
Bal. diameter wear
Why/How? Labyrinth or Type 82 Dew point

Thermal attack
Bal. diameter o-ring
Joule-Thompson?
Blocked filter
Wrong filter size Chemical attack
No filter Bearing Oil Condensate Bal. diameter o-ring
Dirt Coke Installation

(Exercise?)
Blocked grooves Hang-up

59
Typical Example Was rotor in running position Check flare pressure
of a Failure when seals were installed?
Analysis Root Check operating
Check DE/NDE bias procedures
Causes Tree
Check buffer
Check position
gas pressure
and condition Driver reversal
Shim size Seal at correct end? Turbining Wrong seal

& position
Thrust bearing
Assembly Thermal Growth
Installation Reverse rotation
Reverse pressure
Hang-up

60
Mating Rings
Chips x
Not acceptable, especially with Silicon Carbide.

Must be replaced.
61
Mating Rings
Heat Checking
Very rare, but can be

seen on tungsten
carbide. Not acceptable.
Must be replaced.
62
Mating Rings
63
Mating Rings
Pitting
Tungsten carbide can be

attacked by contaminants.
Can sometimes be re-
lapped.
In most cases, will have to
be replaced.
64
Mating Rings
Chloride attack on
Tungsten Carbide
65
Mating Rings - Chloride Attack
66
Mating Rings
Groove Deposits
Can be cleaned, but

usually needs re-lapping
and re-grooving.
Check for heat-crazing
and contact.
67
Cosmetic Marks
Again for comparison, surface marking of no significant depth,

which is cosmetic and acceptable
68
Primary Ring
Contact
Contact is unacceptable.
Can cause excessive heat,
melting the metal filler in
the carbon.
Must be replaced.
69
Primary Ring
Showing Inside Diameter Primary Ring/Mating Ring
Contact
Not acceptable. Replace Primary Ring.

70
Primary Ring Damage
Showing large particle marking. The face must be lapped back

to remove all trace, checked for thickness and re-processed.
Probably needs replacing.
71
Cosmetic Marks
Showing light gramaphoning with no depth, due to particles.

Cosmetic, and acceptable.
72
Primary Ring
Normal Wear
Acceptable
“scuffing” marks.
Radial scratches
must be lapped
out.
73
Cosmetic Marks
Showing light circumferential marks caused by particles

trapped between seal and face
74
Cosmetic Marks
This shows an exposed particle which has been pulled out

of the surface and has caused a ring of contact.
This is cosmetic and acceptable
75
Cosmetic Marks
Showing scuffing where particles have passed through the

seal.
This is acceptable.
76
Cosmetic Marks
Showing surface discolouration which is due to the manufacture

of the primary ring blank.
This is acceptable.
(Not to be confused with oil blistering).
77
Primary Ring
Radial Cracks
This is rare. Check that it

is a crack and not a
scratch. Must be
replaced.
78
Primary Ring
Chipping
Blend
Very small chips on the ID of the carbon are

acceptable provided they can be blended in.
Small chips on the OD are acceptable provided they

can be blended in.
Large chips require the primary ring to be replaced.

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Chips
Showing a small chip which may be blended out and accepted.
80
Chips
Showing a larger chip encroaching onto the sealing dam.

Primary Ring must be replaced.
81
Primary Ring
Oil Blisters
Not acceptable.
Must be replaced.
82
Labyrinth – Chloride Attack
83
Type 28XP Carrier - Contact
84
O-Rings
Nicks and Cuts
85
O-Rings
Explosive Decompression
86
O-Rings
Thermal Damage
87
O-Rings
Compression Set
(More common with Perfluoroelastomer
material)
(1 hour at 200°C)
88
Polymer Seals
Better explosive decompression and corrosion resistance
They require careful handling.
89
Polymer Seals
Sliding Damage
Typical of damage to
be found on seal OD
polymer rings in Type
28XP seals.
Must be replaced.
Investigate HOW /
WHY?
90
Polymer Seals
Damaged Spring
Spring holds seal open to
enable pressure to
energise the seal.
Must be replaced.
91
Metal Parts
Check critical areas
Scored Bore (o-ring grooves,
tolerance ring grooves
and landings).
Polish out marks with

fine emery paper, but
do not damage edges
of tolerance strip
grooves.
Check compressor
shaft and clean up
carefully.
Check that correct

lubricant is being used,
and used sparingly.
92
Metal Parts
Galling Often caused by

misalignment during
fitting or removal.
Check condition of
compressor shaft and
take remedial action.
Repair may be possible,

but distortion may
cause problem to re-
occur.
Replacement is
generally advised
93
Metal Parts
Dents, bumps, hammer marks, distortion
Parallel
Square
Bore must be
perfectly
round
94
Metal Parts
Fretting and Pitting
Contaminants in the gas can cause pitting.
The balance diameter is critical and pitting is not

acceptable.
Must be replaced.

95
Dry Gas Seals
Cleanliness
Accuracy
Time
96
Dry Gas Seals
When:
3. Installing a seal
4. Removing a seal
5. Disassembling a seal
6. Assembling a seal
STOP if anything starts to get tight

97
Dry Gas Seals
Cleanliness
Accuracy
Time
Stop!!
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Apply “CATS” and you can . . .
99
Produced by John Blaber
Technology
Developments
Materials

Cranite Primary Ring Material
Desirable Attributes Silicon Existing
Carbide Carbon
High Modulus  
Good dry friction  
Homogeneous material  
Good Thermal conductivity  
Lower internal stresses  
Higher Stability  
Fracture Toughness   Diamond like coating
102
Cranite Material - Attributes
■ Composite of Silicon Carbide & Carbon
■ High elastic modulus
➤ Reduced radial and toroidal deflections
■ High thermal conductivity
➤ Reduced thermal distortions
■ High stability
➤ Negligible residual distortion
■ Good dry friction
➤ Retains excellent carbon performance
103
Cranite 2000
Desirable Attributes Silicon Existing Cranite
Carbide Carbon 2000
High Modulus   
Good dry friction   
Homogeneous material   
Good Thermal conductivity   
Lower internal stresses   
Higher Stability   
Fracture Toughness    Diamond like coating
104
Cranite 2000 - Benefits
■ Higher pressure capability
➤ Controlled face distortion
➤ Controlled radial deflections
➤ Reduced operating gap
➤ Stiffer fluid film
■ Reduced leakage
➤ Highly stable, repeatable at any
pressure
■ Excellent stop/start face
performance
➤ No need for coating 105
CTrans Analysis
Static Leakage up to 250 bar
140
Pressure ( x 10 bar )
120
Leakage ( l/min );
100
80 Carbon
60
Cranite
40
Pressure
20
0
0 5 10 15 20 25 30
Time (sec)
106
Dynamic Tests - Leakage Comparison
Cranite 2000 Development

Dynamic IB leakages, cranite versus carbon faces @ 6000 rpm.
140
120
Leakages / l.min
-1
100 Carbon
80
60 Cranite 2000
40
20
0
20 40 80 120 160 200
Pressure / bar g.
107
Cranite / ADC Dynamic Test
250
Pressure ( bar ) ; Temp (C)
Pressure
200
Leakage ( l/min )
Temp
150
Leakage
100
50
Speed x 100
0
0 50 100 150 200 250 300 350
Time (min)
108
Cranite Stop-Start & Slow Roll
Tests
■ Over 2100 stop-start cycles ( spring
load )
■ Over 50 hrs slow-roll @ 100 rpm
4000
Speed (rpm)
3000
2000
1000
0
0 5 10 15
Time (min)
109
Improved Silicon Carbide
Material
■ Increased TRS - 25%
■ Increased fracture toughness - 40%
■ Improved availability
■ Adopted as Preferred Standard SiC Q1/99
110
Large Diameter Cranite Seal
Tests
■ 10.375” seal for Nam Groningen
> Cranite Faces

> Improved seat
material
111
Improved Carbon
■ 6 Month Development program
➤ Carbons tested to 250 bar
➤ Residual distortion measured
➤ Improved grade reduced distortion by 70
%
Residual distortion Level
5.437"
7.125"
Carbon 1 Carbon 2 Carbon 3 Original

Carbon
112
Improved Carbon Material
■ Improved processing
➤ Reduced Prepressurisation
■ Less residual distortion

➤ More uniform presentation angle
➤ Higher Stability
➤ Reduced sensitivity
■ Improved reliability
➤ More stable leakage
➤ Face shadowing eliminated
113
Improved Carbon
■ Tested on pilot jobs Q3/98
■ Introduced on high pressure jobs Q4/98
■ Adopted as standard for all

seals Q1/99
■ Improved production process

➤ Prepressurisation offline
➤ Cycle time reduced
from 3 days to 3 hours

114

Gas Seal Course Customer 112003 04a

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Dry Gas Seals

© 2003 John Crane EAA 1

© 2003 John Crane EAA 19

© 2003 John Crane EAA 20

➤ Ensure free shaft rotation with coupling

➤ Ensure Bursting Discs have been

➤ Check buffer gas system - is it on and

➤ Virtually no maintenance required

➤ Continue monitoring leakage (daily)

➤ Check for oil in atmospheric vent lines

➤ During prolonged shutdown / staorage,

© 2003 John Crane EAA 26

3. During installation, seal setting plate

© 2003 John Crane EAA 31

3. During installation, seal setting plate

3. During installation, seal setting plate

3. During installation, seal setting plate

© 2003 John Crane EAA 44

1. Disassemble and re-assemble seal

© 2003 John Crane EAA 46

➤ 10% - solids / particulates

➤ 4% - chloride based from the process

➤ 14% - unknown contaminants

oil system (30 minute delay)

barrier gas system (30 minute delay)

cause hang-up of balance diameter seal

■ Hydrocarbons from Process Gas

➤ Efficient coalescing filters

➤ Heat the filtered gas to overcome the

All can be designed for - these were all

Type 28AT and Type 28XP

➤ can be designed for static reverse

➤ contamination from fitting lubricants

➤ damaged o-rings / polymer rings

■ O-ring damage during running

No lift Forced contact

Why/How? Labyrinth or Type 82 Dew point

Dirt Coke Installation

Blocked grooves Hang-up

No lift Forced contact

Shim size Seal at correct end? Turbining Wrong seal

Assembly Thermal Growth

Installation Reverse rotation

No lift Forced contact

Not acceptable, especially with Silicon Carbide.

Very rare, but can be

Tungsten carbide can be

Can be cleaned, but

Again for comparison, surface marking of no significant depth,

Not acceptable. Replace Primary Ring.

Showing large particle marking. The face must be lapped back

Showing light gramaphoning with no depth, due to particles.

Showing light circumferential marks caused by particles

This shows an exposed particle which has been pulled out

Showing scuffing where particles have passed through the

Showing surface discolouration which is due to the manufacture

This is rare. Check that it

Very small chips on the ID of the carbon are

Small chips on the OD are acceptable provided they

Large chips require the primary ring to be replaced.

Investigate HOW / WHY?

Showing a small chip which may be blended out and accepted.

Showing a larger chip encroaching onto the sealing dam.