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Compressors and seals are an integral part of all the compressor would lose efficiency and in the their capacity to simplify the seal control panel and
processes used to transform natural gas into LNG. worst case, suffer unscheduled shutdowns at great make it more reliable. In a high performance DGS,
Cooling gas below the dew point in the range of economic cost. That makes the choice of seals a the two sliding surfaces run one on top of the other
-160 C (-256 F) at ambient conditions typically key part of the total capital investment decision. separated by a film or cushion of gas that
is done stepwise in heat exchangers employing guarantees contactless running at speeds up to
refrigerants, usually methane, ethane and propane. EagleBurgmanns experience in LNG applications 20,000 min-1. The narrow, stable sealing gap
began in 1999. Today it is the market leader in results in relatively low gas leakage around the
The cooling media are compressed and then supplying gas seals used on LNG carriers. The compressor shaft and ensures the seal works
expanded to progressively cool down the natural extension of the companys product portfolio to without wear and with relatively low power input.
gas. Compressors circulate the refrigerants. The large diameter DGSs for LNG plants started in
latest generation of LNG vessels has on board 2005 with the development of a 390 mm seal While these seals may have some general
re-liquefaction units to decrease LNG losses from specific for low temperature applications. characteristics in common regardless of the
liquid returning to a gaseous state during manufacturer, a great deal of proprietary
transportation. These re-liquefaction units generally Extensive design verification and testing as well as knowledge and expertise goes into the design,
use centrifugal geared compressors, combined continuous product upgrading and operating range choice of materials, testing and manufacture of the
with the expansion turbine. extensions have resulted in these ultra-large seals latest certified LNG seals.
being certified for LNG operations by major
At onshore terminals, new, ultra-large capacity compressor manufacturers, allowing One cannot not take a DGS used in everyday
processing equipment is being used to increase EagleBurgmann to offer acomplete LNG product industry and simply upsize it for LNG compressors.
production rates and reduce the percentage of portfolio. The design and materials selection has to
natural gas diverted to power the liquefaction anticipate all operating conditions to which the
process. Compressors as large as 120 tonnes have seal will be exposed. Likewise, the testing and
Article by Daniel Goebel (EagleBurgmann Germany) and Francesco Grillo (EagleBurgmann Italy)
been developed. That, in turn, required the Dry gas seals most efficient and manufacturing is extremely demanding and critical
development of a 390 mm (15.35") gas seal to reliable compressor sealing solution to safety and reliable performance during extended
E120702 / E1 / 1.000 / 07.12 / 9.7.5 EagleBurgmann Group Marketing, Germany
Typical operating
DGSSingle conditions:
EagleBurgmann
Shaft diameter: approx. 60 ... 70 mm
(2.36" ... 2.76")
Sealed gases: N2
Typical operating parameters, Sealing pressure: 10 52 barg
390 mm terminal seals
PDGSTandem mit Labyrinth EagleBurgmann
(145 ... 754 PSIG)
Shaft diameter: 350 mm (13.78") Normal operating temperature:
Sealed gases: N2, CH4, C2H6, C 3H8 +40 C ... +50 C (+104 F ... +122 F)
Sealing pressure: 4 24 bar g (58 ... 348 PSIG) Speed: approx. 20,000 min-1
Normal operating temperature:
+30 C +50 C (+86 F ... +122 F) Typical seal design data:
Minimum gas inlet temperature: -100 C (-148 F) Pressure: 50 barg (725 PSI)
Speed: approx. 3,000 min-1 Temperature: -29 C +125 C (-20 F ... +257 F) EagleBurgmann PDGS seal
Materials selection criteria for low Optimizing seal performance Manufacturing considerations
temperature operations
Proper tapering of the seal face is another critical Very large seals like the 390 mm LNG seals are
EagleBurgmanns LNG selection criteria for all part of designing a DGS for extreme temperatures. the most challenging to manufacture because the
metal parts and secondary sealing elements It begins with predicting the seal face deformation. geometrical tolerances have to be the same as for
assures a reliable, long term operation and good The unique EagleBurgmann solution is to size the smaller seals. Geometrical tolerances like the
materials properties in temperatures as low as seal face taper at room temperature for optimal flatness imposed on seal faces have little to do
-196 C (-320 F). All secondary sealing elements geometry under ordinary operating conditions, with the size of the seal.
are made of polytetrafluoroethylene (PTFE) with applying the companys validated calculation codes
special filler material to withstand low and extensive experience to get the optimum result
temperatures. for extreme heat or cold temperatures, then fine- Field experience
tuning the result through extensive testing.
For the primary sealing elements, the rotating seat Since EagleBurgmann delivered its first 60-70 mm
and stationary face employ EagleBurgmanns The rotating seat of a DGS compressor seal is LNG seals for maritime transport applications in
proven standard solution used since 1992: silicon grooved to ensure the gas separation film forms 1999, it has built up an installed base of more than
carbide against silicon carbide. These faces are and stabilizes during dynamic operation, including 350 such seals worldwide.
especially large in a 390 mm seal, so compressor start-ups and coast down. These
compensating for temperature deformation is proven 3D grooves ensure optimal pressurization Then in 2005, it undertook to develop 390 mm
especially important. within the sealing gap (between rotating seat and cryogenic seals for onshore LNG operations for one
stationary face). EagleBurgmann engineers of the worlds leading compressor manufacturers.
The graphic below shows the seal core. simulated operating conditions to generate an As a result of that success, that OEM
The rotating seat is turning together with the optimum operational sealing gap below 5 m and commissioned the company to develop a version of
compressor shaft while the ceramic stationary face ensure reliability of the gap under all operating the same 390 mm design for a high temperature
is fixed by torque pins to the metal housing. conditions. environment a furnace gas recompression train
The balance sleeve is shrink-fitted to the housing. in a new cogeneration plant at a major steel mill in
EagleBurgmann uses tungsten carbide for both the Wuhan, China. The 390 mm seal underwent further
balance sleeve and supporting ring for the sealing Controlled testing of every seal type testing up to a +250C (+482 F) bulk seal
element, preferring it for low temperature temperature. With the design robustness and
coefficient and because, when polished, tungsten Every LNG seal type is subjected to rigorous particularly the sophisticated gap control solutions
carbide gives a very high quality, smooth surface. cryogenic testing under simulated operating of EagleBurgmann, no significant design
conditions at the EagleBurgmann test center. modifications for high heat were necessary.
The stationary face has to be sealed reliably Liquid nitrogen is used to cool down the seals to Those seals have been in continuous service since
against the balance sleeve to avoid any leakage -170 C (-274 F) prior to the dynamic test. The the cogeneration plant started up in 2009.
bypass and the stationary face must move axially master tests for each seal also simulate particular
to compensate for any shaft movements. During operational issues of LNG compressors that The feedback from the compressor OEM has been
extreme temperature fluctuation, the gap will vary represent major challenges for dry gas seals, like: very positive, a testament to the versatility of the
dramatically. If its too large, good sealing function original design to adapt to all temperature
is not ensured, and if it gets too small or even the impact of rotor deformation that might extremes and fluctuations. The result is a new
disappears, it loses axial flexibility. This required occur in variable or low-speed operations. generation of dry gas seals built to a high standard
special attention to cope with the temperature compressor coast down from shaft of safety and efficiency on which LNG operators
extremes and the -135 C (-211 F) standard misalignment, simulated by reproducing a can rely.
operating temperatures for expander seals. forced plant shutdown more than 120 times
References
[1]. Different, Thirty-Sixth Turbomachinery Symposium: Gas turbines and turbo compressors for LNG service, 2007
[2]. Dr. Shukri T.: LNG technology selection, 2004
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