How to Troubleshoot Common Issues with Dry Gas Seals

Dry gas seals are an essential component of rotating equipment which is extensively used in the oil and gas industry. These seals are designed to contain the gas within the equipment, prevent contamination, and reduce emissions. However, like any mechanical system, dry gas seals can experience problems that can lead to downtime, decreased efficiency, and an increased risk of failure. This article will cover some of the common issues that arise with dry gas seals, and provide tips on how to troubleshoot them.

Understanding Dry Gas Seals

Before delving into common issues, it is essential to have an understanding of how dry gas seals work. These seals consist of two main parts: the primary seal and the secondary seal. The primary seal is in direct contact with the gas and rotates with the shaft, while the secondary seal is stationary and prevents gas from escaping.

The primary seal is typically made up of a set of rings that are in direct contact with the shaft. This seal is in contact with a mating ring that is spring-loaded and located in a stationary housing. The mating ring provides a dynamic seal but can also move independently, making it less prone to damage from shaft misalignment.

The secondary seal consists of a set of barrier seals, which are in contact with the primary seal, and a backing seal, which prevents gas from leaking out of the housing. The barrier seals create a static seal, while the backing seal provides redundancy against leakage.

Common Issues with Dry Gas Seals

1. Contamination

Contamination is a common issue that can occur with dry gas seals. It can be caused by a variety of factors, including poor installation, improper maintenance, and excessive wear and tear. Contamination can result in seal failure and can cause significant downtime and costly repairs.

Contamination can be prevented by implementing a proper maintenance program, performing regular visual inspections, and ensuring that gas is clean and meets the required specifications. If contamination occurs, it is essential to investigate the source and take corrective action to prevent reoccurrence.

2. Shaft misalignment

Shaft misalignment can cause significant problems with dry gas seals, as it can lead to premature wear and damage to the seals. Shaft misalignment can be caused by improper installation, inadequate or improper lubrication, and excessive wear and tear.

To prevent shaft misalignment, it is essential to ensure that the equipment is correctly installed and maintained. Regular inspections of the equipment and bearings can help detect any issues early before they lead to seal failure.

3. Installation errors

Installation errors can lead to a variety of problems with dry gas seals, such as improper clearances, inadequate lubrication, and poor alignment. These issues can result in premature wear and failure of the seals.

To prevent installation errors, it is essential to follow the manufacturer's guidelines and best practices for installation. Ensure that the equipment is correctly positioned, and the clearances are within specifications.

4. High temperatures

High temperatures can cause significant problems with dry gas seals, as they can lead to premature wear of the seals, contamination, and decreased efficiency. High temperatures can be caused by a variety of factors, including high rpm, poor lubrication, and inadequate cooling.

To prevent high temperatures, it is essential to ensure that the equipment is properly lubricated and cooled. Regular inspections of the equipment can help detect any issues early and prevent seal failure.

5. Low temperatures

Low temperatures can also lead to problems with dry gas seals. Cold temperatures can cause the seals to become brittle and lead to premature failure. Low temperatures can also cause the lubricant to become thick, leading to reduced efficiency and increased friction.

To prevent low temperatures, it is essential to ensure that the equipment is properly insulated and heated. Regular inspections of the seals and lubrication system can help detect any issues early before they lead to seal failure.

Conclusion

In summary, dry gas seals are critical components of rotating equipment that must be maintained and operated correctly to prevent downtime, decreased efficiency, and an increased risk of failure. By understanding the common issues that arise with dry gas seals and following best practices for troubleshooting, you can help ensure that your equipment operates efficiently and reliably. Maintaining a proper maintenance program, performing regular inspections, and utilizing the latest technology can help detect issues early before they lead to costly repairs and downtime.