EagleBurgmann Compressor Seals

► Dry Gas Seal Upgrades

Content

 Oil seal types and system characteristics

 Why industry is looking for an upgrade
 Justification process for an upgrade
 Different types of upgrades
 Our approach to upgrade opportunities
 History and experience of EagleBurgmann on example of EBME
 What information is required to quote an upgrade
 Case study and real benefit
Sealing Compressors

 Clearance Seals (Dry seal)

 Labyrinth (specified where the process to be sealed is at low to moderate pressure and relatively high leakage flows
are tolerable even none flammable and hazard gases)

 Restrictive carbon ring

 Oil Seals (Wet seals / Liquid film seals)

 Oil bushing seals / Floating ring (axial sealing)
 Mechanical seal (radial sealing)
 Iso-carbon seals (radial sealing)

 Dry Gas Seals

Oil seal types
Typical Seal Oil System

Gas
LT
Oil
LSH LAH
Oil & Gas LSLL
LC
LALL
PDAH LSL LAL

PDISH PDISL Overhead Tank

PDCV
PI PDAL
Duplex Filter
Bank
TAH TI
TSH
Coolers
Compressor

FG FG
PI PAH
PI
LAL
Main & Standby PSH
Pumps
LG
LG Oil Traps
LG
TI TSHL
Reservoir LG

Degassing Unit
Typical Common Lube and Seal Oil System
Oil seal to Dry Gas Seal

Radial oil ring seal / dry gas seal

Compressors with previous installed oil ring seal usually need some modifications to housing,
rotor and supply channels.

Oil ring seal Dry Gas Seal

Clean process gas Leakage to flare Gas to vent Separation Gas

Process side Bearing side Process side Bearing side

Why Dry Gas Seal / Why Change? (The Pros)

Benefits: Dry Gas Seal vs. Oil Seal

 High level of safety (personnel, equipment, fire, gas)

 Environmental concerns (no oil usage, process gas losses, H2S)
 High reliability (Non contact, simple set-up, not )
 Reduced operating costs
 Operating simplicity
 Improved efficiency
 Maintenance costs
Why Change? (The Cons)

 Necessity of compressor heads machining

 Changes in compressor rotor dynamics

 Higher initial prices! (see next slides)

Justification Process

TANGIBLE FACTORS:
 Oil consumption
 Maintenance and downtime: 50 % up to 80% of compressor downtime was are directly related to oil
systems
 Energy costs: Oil seal power loss (10-30 HP )+ unit driven pumps (20-100 HP) which is from 0.5 to 1%
of unit HP while gas seal power loss is 1-2 HP
 Process gas leakage: Gas leakage/emission for oil seal typicaly ranged from 40 to 200 SCFM & higher
while for gas seal is less than 2 SCFM. Most of these emissions occur when the circulating oil is stripped
of the gas it absorbs at the high-pressure seal face.
 Fines and carbon taxes

INTANGIBLE FACTORS:
 Lost production due to contamination
 Compressor and auxiliary efficiency: Oil contamination in pipeline and cooler cause
 loss in pipeline efficiency and radiant heat efficiency losses
 Safety and asset risk management
 Reduced insurance policy due to new equipment
Return of investment

 A dry seal can save about 100.000,- € per year and pay for itself in as little as 18 months

 One Natural Gas STAR partner who installed a dry seal on an existing compressor, for example, reduced emissions
by 97 percent, from 75 to 2 Mcf per day, saving almost $80,000 per year in gas alone.

 Note that in ROI study initial CAPEX for seal oil system is considered as zero. Our assumption is that customer paid
this amount some years back. Just good to know that initial CAPEX motley is double of gas seal requirements,
which is for seal oil pumps, blower, degassing unit, seal oil traps, seal oil reservoirs, overhead seal oil vessels,
connecting piping and a control and monitoring panel
Different types of upgrade

Type Scope Risk

Type 1 Supply of hardware only (Seal + SMS) Low risk
Type 2 Engineering Medium risk
Rotor study
Supply of hardware (Seal + SMS + Bearing?)
Type 3 Engineering Medium to High risk
Rotor study Modification issues
Equipment modification could increase the risk
Supply of hardware (Seal + SMS + Bearing?)
Type 4 Engineering High risk
TK Rotor study Not only technical even
(Turn Key) Equipment and plant modification profit control due to
Supply of hardware (Seal + SMS + Bearing?+ …) large outsourcing
Full turnkey including piping, electrical, instrumentation,
mobilization, lube oil modification (if required), demolishing
and civil work
Buying Process and length

You raise the

?
Interest/Concern!
How to success selling upgrade:
Interest / Concern
Realize at which step of buying process end-
user is
Analysis / Budget
Discover what client consider in justification
process and target it
Justification
Process Build up relationship

Fund Approval
Our strategy:
Tendering
Be partner during justification
Final firm Offer
Minimize plant modification
Employ latest technologies .
Order Award

Executation
Steps to execute a job

1. Feasibility study“ (creates prior costs!)

- Verification of all dimensional drawings, driver information and operating conditions
(if no dimensional drawings are available dimensions must be taken)
- Definition of required modifications (rotor, housing, labyrinth…)
- Rotor dynamic analysis (done by a turbo machinery specialist)

2. If upgrade is feasible end-user places PO to EagleBurgmann local organisation as prime

vendor and subcontracts necessary works
EagleBurgmann as prime vendor to end users

or
EagleBurgmann as prime vend End-user
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Local organization for complete re Upgrade breakout:
Contract management
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Material procurement
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Modifications
Installation
Interferences Supervision
Compressor End-user known Commissioning
specialist contractors Training
Our Advantage: History and Experience

History:
• Compressor upgrade to dry gas seal technology for more than one decade
• Upgrade world toughest application (high pressure and light gas)
• Leader to establish regional teams capable to handle upgrades

Experience with OEM:

• Siemens
• TSH
• GE-Nuovo Pignone
• Dresser Rand
• Ingersoll-Rand
• Elliot-Ebara
• Tomassen Compression System

Industry sector:
• Refinery
• Petrochemical
• Pipeline
Pipeline •
Our Advantage: Leading technology appropriate for upgrade

• Properties of face materials:

• Excellent chemical resistance

• Minimized influence on rotor
• High rigidity (function of E-modulus and Spec. Mass)
• Minimized thermal stress
• High degree of thermal conductivity
• Dry running properties for starts/stops

• Gas film stiffness with 3D V-groove, U-grove design

• Self cleaning 3D grooves
• Torque transmission and centring of the rotating seat
• The PTFE solution for high pressure
• Safety – containment of seat in case of fracture / cupped retainer
• New coating technologies

• New technologies (RoTechBooster/CobaSeal/Diamondface)

Our DGS Test Facilities Worldwide

Houston, USA Zavolzhe, Russia

Dalian, China

Eurasburg,
Germany
Wolfratshausen,
Germany
Niigata, Japan
Niigata, Japan

Mexico City, Mexico

Pune, India
Dubai, UAE (2011) (2010)

Sao Paulo, Brazil

Edenvale, South Africa
(2010)

DGS Global Technology Center

DGS Center of Competence (design adaptations, dynamic testing facilities) Dynamic Test Facilities Worldwide

DGS Service Center (static testing facilities) API DGS Mech. Seal

API Testing Center for Pump Seals 4 12 95

18
E. g. Middle East Regional Extensive Upgrade Experience

C-602 HP C- C1/2-602 HP C1/2-251 LP 02K-1203 HP C-14-101/102 02K-1202 LP

Refinery Aramco-Berri Esfahan Oil Esfahan Oil SCOP-East KNPC SCOP-East
Nov.2009 Aug.2004 Ref. Ref. Export Ref. Export
(Saudi) Jul.2006 May.2006 Dec.2010 Mar.2011 Nov.2010
(Iran) (Iran) (Iraq) (Kuwait) (Iraq)

Upgrade type Level 3 Level 1 Level 3 Level 3 Level 2 Level 1 Level 2

Compressor Nuovo Thomassen/ Dresser Rand Dresser Rand Ingersoll-Rand MAN Turbo Ingersoll-Rand
OEM Pignone Elliot
Compressor 1 2 2 2 2 4 2
Quantity
Seal Type PDGS-TA-L/R DGS-TA-U PDGS-TA-L/R DGS-TA-L/R DGS-TL-U DGS-TL-U DGS-TL-U
+CSE +CSR +CSE +CSE +CSE +CSE +CSE
Sealing 185 barg 1 barg 195 barg 24 barg 19 barg 60 barg 6.75 barg
Press.
MCS (rpm) 14300 5523 10080 7525 13527 10000 13527

Sealed Gas H2, HC Propane H2, HC H2, HC Natural Gas H2, HC Natural Gas

Barrier Gas Air N2 Air Air N2 N2 N2

Information required to quote

Minimum Requirements for Budget Quotations:

 Shaft size
 Application data
 Start-stop procedure (pressurization curve, what pressure for start-up,
rundown curve, post shutdown, slow roll should taken into account)
 Client specs for systems & Dry Gas Seals
 OEM layout drawing of compressor
 Plant P&ID
 OEM Bearing & Wet Seal Assembly Drawings
 Rotor drawing
 Compressor cavity drawing
 Scope of work
 Oil system P&ID

* Any possibility to measure the machine should be kept

Tools and programs

 Labyrinth calculation software

 Design figures excel sheet
 Orifice calculation software
 Barrier seal leakage program/chart
 Gas quality analysis software
 Leakage flow calculation program for DGS
 Seal data sheets

 Rotor Dynamic Analysis (Partner)

Data required for the preliminary study

Item Remarks
Compressor data Machine type and model
Application data
Actual gas composition
Shaft size at seal place
Clearance data sheet
Driver data Type and start-stop procedure
Drawings Compressor sectional
Layout drawing of compressor
Bearing & wet seal assembly drawings
Lube Oil and Seal Oil P&ID
Seal Cavity Drawing
Scope and specification Client specification for systems & Dry Gas Seals
Scope of work
Availability of following items Spare Rotor 
to be checked Spare Oil Seal 
Spare Bearing 
Spare coupling 
Utility:
Instrument Air / Plant Air 
Nitrogen 
Flare 
Safe atmospheric vent 
Upcoming overhaul plant Measuring and confirming the drawings
Date (__/__/____)
Rotor Dynamic Analysis data required:

Item Remarks
Dimensional rotor drawing Impeller dimensions for calculating inertia of impellers. (if possible shaft
showing geometry of shaft diameter under impellers)
and added elements Geometry, weight and material properties of all components (trust disk,
lock nuts, balance drum, sleeves and any attached deflectors.
Centre line of the radial probe axial location (Nice to have)
Dimensional drawing existing Including curvature radius of pads if possible Types, location and design of bearings
bearings (including length of bearing,
Cross-sectional drawings Bearing and oil seal arrangement
Including seal details: number of rotating and stationary teeth and material
Indicating clearances
Rotor weight If not indicated on drawings, have to weigh

Complete datasheets Including minimum operating speed and MCS, etc.

Photographs Nameplate

Coupling drawing Including weight and inertia and location centers of gravity.

Lube oil data Oil type, flow, supply temperature and pressure. (For bearing calculations)

Drawings of new gas seals Including mass and inertia data

Complete list of all rotor For making comparison existing and new situation.
modifications for DGS
Original RDA Nice to have
Rotor and Components

ROTOR*:

* Siemens compressor
What document we are providing
Case Study

Upgrade of Hydrogen Recycle Gas Compressor in TZORC

Single Contractor EBIR (January 2009)

Scope of supply:
DGS+SMS engineered, manufactured and tested
Rotor dynamic analyses
Modification drawing and integration
Bearings
Rotor repair & modification
On site support

Delivery: 2009 October

Start up: 2009 November
Upgrade onsite process

 Contract management (Daily MoM, Project plan follow-up)

 Rotor dynamic analyses (Partner)

 Design of new bearings (Partner)

 Modification of rotor for DGS installation (Partner)

 Rotor repair (?) (Partner)

 Re-machining compressor head-covers & bearing housing(?)

 Compressor final assembly

 Final adjustment

 Seal Installation and bearing Installation

 Workshop static test

 Compressor final installation adjustment

 Panel Installation on platform / pipe routing

 Preparing power supply for panel and cabling/connectivity

 Installation of recording system and alarms/trip functions

 Support for start up the panel and monitor performance

 Training maintenance, process and instrument

Project payback

 Saving 300 barrel oil per year

 10% power saving = 5,000 ton steam per year
 Maintenance costs: Man Power / Spare parts / Time / … = (1/4)
 Renovation / Increasing efficiency. After upgrade, plant reached to 100% nominal production.
(not reachable before, due to seal oil auxiliary system limitations)
 %51 of compressor down time addressed to oil seal problem. Loss of production is 150k
Euro/day and twice a year addressed directly to oil seal problem and taken 2 days to rectify.
(300k euro/year)
Intangible 350,000
Tangible 150,000
Total savings per year 500,000
Overall Pay Back < 1 year

 The compressor could be kept pressurized during shutdown and reduce flaring the gas.
 Note that need changes in piping/valve arrangement including blow down to take advantage of pressurized holding.
 Design pressure review of upstream equipment that may be subject to settle out pressure.
Physical change (Before and after upgrade)
EBI - Dry Gas Seal -> Why to choose EBI Dry Gas Seals?

 Leading in technology (high pressure, large sizes)

 Well prepared for future challenges by continuous R & D
 Globally well established
 Global service network

Thank you for your attention!