Compressor Manturbo
Compressor Manturbo
Compressor Manturbo
Usually, compressor modifications are carried out because of adaptations to new operating parameters. However, in cases of ongoing operational difficulties or problems in procuring components of auxiliary systems, modernizations are playing an important role to keep plant reliability as high as possible. With the focus on technical and economical efficiency, as well as reliability and safety, MAN PrimeServ was able to supply a customer in a petrochemical application with a modernization of the obsolete oil-lubricated shaft sealing system to a state-of-the-art dry gas sealing system.
Project goals
Two compressor trains in a hydrogen-recycle and a carbon monoxide gas application had to be modernized. The original oil-lubricated shaft sealing system from the early 70s had to be replaced. Due to increased maintenance expenditure and difficulties in procuring spare parts for the existing instrumentation and components such as pumps, valves, filters and seals, MAN PrimeServ was entrusted to supply a new
and reliable solution. Other important considerations included the environment and the customers technical and economic expectations.
convert the compressors from the old wet shaft sealing system to state-of-the-art dry gas seals (DGS) due to reliability and health, safety & environmental (HSE) considerations. The complete scope of supply included the tandem dry gas seal (DGS) cartridges with accessories and one DGS instrumentation and monitoring panel per compressor train. Furthermore, complete detail engineering, all necessary modifications of the casing and the compressor rotor including inspection and high-speed balancing, were provided. The modifications of the compressor rotors were carried out on the spare rotors just before the plant shutdown to minimize the risk of plant shutdown without spare part coverage. The available time frame to convert the four compressors from wet seals to dry gas seals was a 4-week plant shutdown. Within this time frame, the casing modifications were carried out, redundant piping and parts of the shaft sealing systems had to be removed and the new dry gas seal instrumentation and monitoring rack had to
be installed. Additionally, a general overhaul of the compressors and the plant was performed.
necessary
ments. The control and safety functions as well as the monitoring and alarming of the various measured parameters are performed by a control/monitoring system (PLC or DCS) located in a remote panel (preferably in a safe area).
process gas leakage flows to a safe location in case of an inner seal failure or a total seal failure. An uncontrolled process gas flow to the vent or, even worse, via the separation seal to the oil system is prevented.
Overhead vent
The buffer gas and a part of the bearing separation gas is collected in chamber F and fed via a common pipe to the overhead vent. During normal operation of the intact DGS, the gas flows to the vent will be pure nitrogen.
Technical Data
Seal type Double Tandem Tandem Static (bar) 25/30 60/82 300/350 Dynamic (bar) 20/25 60/82 240/300 1 1 2, 3 Max. pressure rating per seal cartridge operation/test Notes
Notes 1_Seal cartridge with elastomer seals 2_Seal cartridge with elastomer-free seals 3_Given pressure ratings may differ depending on gas compositions (dew point, MW, density, water content etc.) and technical development
Compressor F G E D C B A B C D E F G
A B C D E F G
Balance piston chamber Seal gas chamber Inner leakage chamber Buffer gas chamber Pressure control chamber Outer leakage chamber Bearing buffer chamber
Standard P&I diagram of a dry gas shaft sealing system (tandem seal nitrogen buffered)
Overhead vent Flare PSV PI FI H FO H.L PCV PDI PI L Dry and clean nitrogen
Switch function
L.H.
Alarm
LL.HH
Shutdown
L.LL
FO PI H.HH PI
LC
FO H.HH PI
LC
Pressure control
Vent F D B
TI
Note 1) Seal gas is tapped on compressor discharge or after 1st or 2nd stage impeller Note 2) Filter is only required if buffer gas contains particles bigger than 5 microns Note 3) Location of rupture disks not shown
Copyright MAN Diesel & Turbo Subject to modification in the interest of technical progress. D02081040EN Printed in Germany GMC-OBH06100.5
MAN Diesel & Turbo Schweiz 8005 Zurich, Switzerland Phone +41 44 278 3303 Fax +41 44 278 3302 [email protected] www.mandieselturbo.com 24/7 Hotline: +49 208 692 9000