John Crane Gas Seal Technology

约翰克兰干气密封技术
27th September, Singapore
JC Shanghai RO
This document contains information proprietary to John Crane. It must not be copied, disclosed or re-transmitted
without written permission of John Crane UK Ltd.
该资料内容为约翰克兰私有技术，未经约翰克兰书面同意不得复制和传播

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Gas Seal Milestones
And
Gas Seal Infrastructure

约翰克兰干气密封里程碑
和生产基地

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Gas Seal Milestones
约翰克兰干气密封里程碑
ƒ 1968 First patent
ƒ 1975 First field applications
ƒ 1981 First beam type compressor
ƒ 1985 First steam turbine
ƒ 1985 First offshore
ƒ 1985 First Mag brg / Dry seal
ƒ 1986 First H2 recycle compressor
ƒ 1991 Bi-directional seal
ƒ 1992 XP seal - 123 to 200 bar
ƒ 1994 Type 82 barrier seal introduced
ƒ 1995 First H.P. re-injection
ƒ 1997 Worlds Largest 330mm Gas Seal
ƒ 1997 Cranite 2000
ƒ 1997 500 bar test rig
ƒ 1998 400 bar seal test
ƒ 1998 100,000,000 Operating hours
ƒ 1999 £2M Investment in Infrastructure
ƒ 2000 T28 EXP 350bar Tandem Seal
ƒ 2001 T28 EXP 425bar Tandem Seal
ƒ 2002 First fully operation service centre commissioned
ƒ 2003 600 bar Development rig Commissioned
ƒ 2004 Infrastructure investment for 500mm seal + 5 service centres operational
ƒ 2005 £2m investment in testing facility

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
GAS SEAL INFRASTRUCTURE
生产基地
Slough UK
700 New Seals
600 Repairs
英国slough公司
年产700台新密封
修复600台旧密封

Ritto Japan
350 New Seals
100 Repairs
Morton Grove USA 日本Ritto公司
600 New Seals 年产350台新密封
600 Repairs Global Total 修复100台旧密封
美国Morton Grove公司 1650 New Seals
年产600台新密封 1300 Repairs
修复600台旧密封 全球总生产能力
年产1650台新密封
修复1300台旧密封
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Type 28 Principles of Operation
And
Seal Arrangement

28AT型干气密封
原理和结构形式

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28AT Seal Design Features
28AT型干气密封结构

Logarithmic spiral or
bi-directional
design.

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28 Principles of Operation
28型密封的工作原理 Mating Ring 旋转环
基面
LAND OUTER
DIAMETER 外径

螺旋槽 SPIRAL
GROOVE

GROOVE
DIAMETER 螺旋槽直径
INNER
DIAMETER

内径

ROTATION RELATIVE
TO PRIMARY RING

与动环相对转动
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28 Principles of Operation
Uni-Directional Spiral Groove单向螺旋槽
Direction of Rotation
旋向

Gas is induced
towards the
center.
气体沿槽流向中心

Gas is Compressed &

Pressure increases to
Sealing Dam set Gap.
密封坝 气体受到压缩，压力升高，
推开密封面，产生间隙
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Sealing Interface (Normal Gap)
正常间隙密封面

Approx. Gap = 0.003mm

Closing Force Opening Force

闭合力 开启力

Compression
压缩

Expansion
膨胀
Spring Load
and Hydrostatics
弹簧和流体的共同作用

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Sealing Interface (Reduced Gap)
密封面间隙被减小

Increased
Closing Force Opening Force
闭合力 开启力被增大

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Sealing Interface (Increased Gap)
密封面间隙被增大

Reduced
Opening Force
Closing Force 开启力被减小
闭合力

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28AT Single Seal Design Features
28AT型单密封的设计特点

Compliant stationary face design providing maximum

flexibility.
静止密封头设计确定了密封的最大适应能力

Logarithmic
spiral or bi-
directional
design.
对数螺旋槽或者
双向螺旋槽设计

Tungsten carbide
or silicone
Tolerance ring to centralise seat on sleeve allowing carbide rotating
thermal, pressure and centrifugal deflections. seat
在轴套上安装调心环，帮助静环中心定位。这种设计容 旋转环材料使用碳
许由于热、压力或者离心力造成的偏差。 化钨或者碳化硅
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28AT Double Seal Design Features
28AT型并联密封的设计特点

DOUBLE SEAL
并联密封

N2 Purge Vent 放空 N2 Buffer 隔离N2气

Bearings Process
Gas
轴承
工艺气

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28AT Tandem Seal Design Features
28AT型串联密封的设计特点

Vent to flare Process Gas

Vent 放空 N2 Buffer 隔离N2气 放火炬 工艺气

Pressure: Up To 83 bar Temperature: - 20 To + 205 °C Speed: Up To

180m/s.
压力：最高83bar 温度：- 20 ~ 205 °C 转速：至180m/s
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28XP High Pressure DGS 28XP高压干气密封
Typical Tandem Arrangement 典型的串联结构

Polymer Seals聚脂密封圈 L-Shaped carrier

Pressure: Up To 200 bar
design L形推环设计
Temperature: - 38 To + 315
°C
压力：最高200bar 温度：-38~315 °C
Speed:Up To 180m/s. Gases: All
转速：180m/s 气体种类：所有气体
Appropriate Design Gas Seals
合理设计的适应不同工况的干气密封

T28 - AT T28 - XP
•No explosive decompression problems associated with O-Rings
•没有快速减压造成O环爆裂问题
•Applications are not compromised by chemical compatibility of the O-Ring
密封圈不象O环可能被化学侵蚀（抗腐蚀性好）

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
DGS Applications
干气密封应用

ƒ A between bearings compressor typically

comprises two type 28 Dry Gas Seal
cartridges.双支撑压缩机配两个干气密封

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Type 28 Principles of Operation
Bi-Directional Spiral Groove双向螺旋槽
Deep 深槽

Direction of Rotation Gas is induced

Shallow 浅槽
旋向 towards the
center.
气体沿槽流向中心

Gas is Compressed &

Pressure increases to
Sealing Dam set Gap.气体受到压缩，压力升高，
密封坝 推开密封面，产生间隙
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Load Capacity Predictions气膜承载能力评估
- Spiral v BD 单向和双向螺旋槽比较
30
T28 Spiral
28型螺旋槽密封 Speed = 14,500 rpm
Improved
25 6.625 in O/B Seal
Non-Dimensional

BD
Load Capacity

改进型双向旋转
20
承载能力

Original T28 BD
15 以前的双向旋转28型密封
Closing
Load
10 闭合力

0
0 2 4 6 8 10
Min'm Film Thickness (um)
最小气膜厚度
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Film Stiffness Predictions 气膜刚度评估
- Spiral v BD 单向和双向螺旋槽比较

100
90 T28 Spiral Speed = 14,500 rpm
Film Stiffness (MN/m)

28型螺旋槽密封 6.625 in O/B Seal

80
70 Improved
BD
60
气膜刚度

改进型双向旋转
50
40
30 Original T28 BD
20 以前的双向旋转28型密封
10
0
0 2 4 6 8 10
Min'm Film Thickness (um)
最小气膜厚度
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
CSTEDY Predictions -
Improved T28 BD Profile 改进后双向槽的性能

10
Min'm Film Thickness (um)
6.625 in O/B Seal
JC Spiral Groove
8 螺旋槽

Improved BD
6 改进的双向槽

Original BD
4 双向槽
Rayleigh Pad
2

0
0 2000 4000 6000 8000 10000 12000 14000 16000
Speed (rpm)

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
DGS Application Range
干气密封的应用范围

John Crane DGS

Operating Range
干气密封运行范围

ƒ Temp: -140 to +315°C

ƒ Pressure: to 450 Barg
ƒ Speed: to 200m/s
ƒ Shaft: to 330mm

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28 Dry Gas Seals Features and Benefits
28型干气密封的特点和优点

ƒ Seal Lift off Pressure 密封开启力

• @0 RPM, approximately 100 PSIG (7 BarG)
• 转速为0时，大约7bar
ƒ Seal Lift Off Speed 密封开启速度
• At 0 pressure differential, lift off is approximately 2 Ft./Sec.(0.6
m/s), calculated from the shaft size.
• 压力差为零时，线速度大约是0.6 m/s
ƒ Seal Axial Shifts 轴窜
• + 0.125” (3 mm)
ƒ Seal Radial Shifts 轴跳
• + 0.025” (0.6 mm)

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Type 28 Standard Materials of Construction
28型密封的组成材料

ƒ Mating Ring 转动环

• Tungsten Carbide 碳化钨
• Silicon Carbide 碳化硅
ƒ Primary Ring 静止环
• Carbon 石墨
TM
• Cranite - T28EXP
ƒ Hardware 金属件
• 410 S.S. 410不锈钢
ƒ Rotating Parts 旋转部件
• 17-4 PH
ƒ Springs 弹簧
• Hastelloy C 哈氏C合金

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 John Crane Gas Seal
Design & Analysis
Tool
设计和分析工具

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Hydrodynamic Lift Optimisation -
Spiral Groove流体动压提升力的优化-螺旋槽

Interface Face ID
Pressure
密封面产 Groove
生的压力 OD
Face

Face Dam
Profile Groove

密封面槽形 n
a tio
Rot
Groove

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
CSTEDY / CTRANS Analysis
CSTEDY / CTRANS 分析

z Gas seal performance

prediction
气密封性能预测
z Utilising 使用产权软件
CSTEDY/CTRANS
proprietary software
z Steady state &
transient fluid film
modelling
模拟稳态和瞬态流体膜
z Real time gas seal
behaviour
干气密封的实时性能
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Summary
概述

ƒ CStedy and CTrans Provide:-

• Simulated seal performance 模拟密封的性能
• Under Realistic Operating Conditions
模拟实际工况
• Extended performance 提高密封的性能
• Reduces iterative testing 减少重复试验
• Quantifies transient effects 对瞬态影响进行量化分析
ƒ Spiral Groove Most Efficient in Generating
Load Capacity / Film Stiffness
螺旋槽能够产生足够的承载能力和气膜刚度
ƒ Improved Diagnostic / Customer Support
分析能力和客户支持都有改进
ƒ Improved reliability high performance sealing
改进的密封性能。
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Other Analysis Tools
其他分析工具

ƒ High Level of Investment in Computer Modelling,

including
在计算机模拟上的高水平投资，包括：
• Finite Element Analysis (FEA) 有限元分析
• Linear FEA 线性有限元分析
• SDRC Master Series

• Non-Linear FEA (Material & Geometric)

• 非线性有限元分析
» HKS ABAQUS

• Computational Fluid Dynamics 计算流体动力学

• CHAM Phoenics

• Gas Property Thermodynamic Data 气体热力学数据

• National Engineering Laboratory PPDS2

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Seal Performance Analysis
密封性能分析

Seal Size 162mm Pressure 0 bar

Speed 16,110 rpm Temperature 150 C

Leakage = 1.5 l/min

5 Microns/ div

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 John Crane System Design for
Maximum Reliability
约翰克兰最高可靠性的系统设计
80% of seals fail prematurely because of
contamination
80%的密封失效源于污染
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Clean Seal Gas Injection – Normal Operation
干净气体的注入 – 正常工况

EXTERNAL GAS
外部气源
Filtered Process Gas Flow path of
过滤后的工艺气
FILTER
MODULE
seal gas under
PROCESS GAS
normal dynamic
工艺气
FI FI
operating
conditions
正常工况时的气
体流向

Process Gas 工艺气

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 John Crane Turbomachinery
Ensure the OB seal is adequately
alarmed
确保外侧密封充分报警

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Ensure the IB/OB seal is adequately alarmed
确保密封遇险报警
EXTERNAL Filtered N2 Secondary Gas N2 SECONDARY
GAS FILTER MODULE
PCV
FILTER Filtered Process Gas
MODULE

PROCESS
GAS
ƒ Ensure OB seal is alarmed
FI FI FI FI
ƒ 保证外侧密封失效报警
• LP in PV = OB seal failure
• HP in PV = IB seal failure
Process + N2
Gas to Flare

PI PI

FO FO

FI FI
FLARE

Process Gas
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 John Crane Turbomachinery
Ensure adequate separation
from bearing oil
确保充分隔离轴承油

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Ensure adequate Barrier Seal Supply
确保隔离密封气的充足供应
EXTERNAL GAS Filtered N2 Secondary Gas 过滤过的N2 N2 SECONDARY
外部气源 FILTER MODULE
PCV 氮气过滤器
FILTER Filtered Process Gas
MODULE
过滤器 ƒ Ensure Barrier gas
PROCESS GAS supply pressure is
工艺气
PI FI FI FI FI PI adequately controlled
ƒ 隔离气压力要被充分控制
• Should be controlled
Barrier seal pressure
controlled with PCV’s to 0.3 to 0.5 bar
• Barrier Seal leakage
隔离气压力 changes with time
由PCV控制
PI PI

FO FO
Process + N2
Gas to Flare
FI FI
工艺气+N2 FLARE VENT放空
放到火炬
Process Gas
工艺气
N2 to Atmosphere 氮气去大气
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 John Crane Turbomachinery
- Create a clean environment for the
seal under all conditions
- 为密封在所有工况下创造一个洁净环境

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
No Seal Gas Flow at Settle-out Conditions
在滞止工况下密封气体不流动

Filter No Differential Pressure

= No Flow
没有压差 = 没有流动
FI FI

Seal contaminated
by Process Gas
Settle-out Conditions
密封被工艺气污染
(Pressurised standstill)
Can Lead to Seal Hang Up
on Start-up
能导致密封在再起动时呆滞

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Ensure the Gas is Clean and Dry
确保工艺气是干净干燥的
EXTERNAL ƒ For extended reliability clean / dry
GAS
外部气源 Filtered Process Gas seal gas is the MOST important
FILTER
MODULE过
过滤后的工艺气 ƒ 对于长远可靠性而言，干燥的密封
滤器 气是十分重要的
PROCESS • Gas should be filtered to around 3
GAS
工艺气
micron
FI FI
• 气体要被过滤到3微米左右
• Coalescing filters can be used to
dry the gas
• 复合过滤器可用于干燥气体
• Heaters can be used to provide
superheat
• 加热器可用于升温
• Heat tracing should be used to
prevent heat loss
• 保温将被用于防止热量流失
• SEPro type systems can be used to
provide static gas flow
Process Gas • SEPro 型系统能使静止的气体
流动
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
SEPro - the installation
SEPro – 结构
Monitoring Outputs Conditioned Gas Supply
监控输出
FIT
合格气体供给
Filter
过滤器
STATUS
PI PANEL

FI FI

N2 INLET CONTROL
PI
氮气入口 PANEL

HEATER
加热器
PI PI S
FILTER
PI 过滤器
TE

CIRCULATOR
循环器

Seal Protected
密封被保护

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
 Seal environment solutions from
密封环境解决方案

SEPro Flow Diagram

SEPro 流程图 MONITORING OUTPUTS

FIT

FROM MAIN SEAL GAS FILTERS FEED TO DRY GAS SEALS

STATUS
PI PANEL

PI

NC CONTROL
N2 PURGE MODULE

NC
VENT

HEATER
MODULE

PI PI S VENT

FILTER
AIR PI
SUPPLY NC

TE

NC
VENT

GAS BOOSTER

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
John Crane Gas Seals Offer :-

ƒ Experience 业绩
• More experience than the other gas seal vendors put together
多于其他干气密封厂家总和

ƒ Global service 全球服务

• Local experience and support
• 本地经验和支持
• Local repair service
• 本地维修服务
• All to a guaranteed global standard
全球标准品质保证
ƒ Technology 技术
• Proven high performance products specially selected for specific
requirements
已提供了众多的高性能产品特别是对特殊要求的特殊设计
© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
Experience in Refinery
炼油行业经验

MORE THAN 500 SEALS IN

OPERATION ON REFINERIES
CATALYTIC REFORMER 重整
20-110bar 28AT/XP Tandem
FLUID CATALYTIC CRACKER
0-5bar 28AT Double
HYDROCRACKER 裂解
To 190bar 28XP Tandem

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane
John Crane Gas Seals Control Panel
约翰克兰控制系统

© John Crane 2005 – Do not copy or reproduce without written permission of John Crane