Abstract:
Systems and methods for assuring a safe working condition of a dry gas seal when a pump/compressor is in a standstill condition. A small booster compressor is added to boost the pressure of an intermediate buffer gas injected into the chamber between a primary seal and a secondary seal of the dry gas seal. Control components detect when the barrier gas pressure drops below a preconfigured value and when detected, closes a valve in a line to a flare safe area and turns on the compressor. The boosted intermediate buffer gas, Nitrogen or dry air, slows the flow of untreated process gas through the primary seal of the dry gas seal and prevents icing of the primary seal.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates generally to dry gas seals for compressors, pumps and, more specifically, to protect the integrity of the primary dry gas seal during standstill conditions. 
       BACKGROUND 
       [0002]    The application of dry gas seals to centrifugal compressor shaft sealing has dramatically increased in recent years for many reasons. The benefits offered by the use of dry gas seals on a centrifugal compressor include improved compressor reliability and the associated reduction of unscheduled downtime, elimination of seal oil leaking into the compressor and the associated process contamination, elimination of process gas contaminating the seal oil and requiring sour seal oil reclamation through degassing tanks, elimination of costs for replacement and disposal of sour seal oil, reduction of operating costs based on the greater efficiency of a dry gas seal, the reduction of maintenance costs for the simpler dry gas seal system and the reduction of process gas emissions. 
         [0003]    Dry gas seal installation is also adoptable for centrifugal pumps associated with liquefied gas. The many benefits of dry gas seals at the running conditions of centrifugal compressors and pumps mask problems associated with the use of dry gas seals on centrifugal compressors and pumps at other operating conditions such as the transient times of startup, shutdown and low-speed idle. The reason dry gas seals are problematic at these times is based on the requirement of a higher than suction pressure barrier gas to prevent contamination of the dry gas seal with particulate or liquid materials. The contamination can arrive, for example, from the untreated process gas or from bearing lubrication oil. 
         [0004]    A typical centrifugal compressor utilizing a dry gas seal will divert a portion of the process gas from the high-pressure discharge of the compressor then filter, dry and reduce the pressure of the gas. The clean and dry barrier gas is then injected upstream of the primary seal at a pressure slightly greater than the suction pressure of the compressor. The higher pressure barrier gas prevents the untreated process gas from entering the dry gas seal where contaminates can infiltrate the tight tolerances of the rotating dry gas seal surfaces and cause premature dry gas seal ring failure. 
         [0005]    During transient times of operation, the pressure of the process gas from the discharge of the compressor is reduced to the point where it is equal to the suction pressure of the compressor. Consequently, it is no longer possible to use the flow from the discharge of the compressor as a barrier fluid. Upstream of the primary seal, in the seal chamber, there is a pressure very close to the suction pressure of the compressor or pump. Downstream of the primary seal there is a pressure established by a buffer fluid, typically nitrogen or air available at a pressure of four to seven bar. Further, the higher pressure and un-treated process gas permeates the primary dry gas seal, transporting particulate and liquid contamination. This problem is emphasized with carbon dioxide (CO 2 ) as the process flow. The carbon dioxide (CO 2 ) expansion through the tight tolerances of the dry gas seal rings can form ice on the seal rings. Subsequently, when the compressor returns to normal operating conditions, the contamination between the dry gas seal rings results in premature wear and failure of the dry gas seal. 
         [0006]    Prior attempts to resolve this problem have centered on providing a booster for the process fluid to maintain the barrier gas at the conditions provided during normal operation of the compressor or pump. This solution requires the similar treatment of the process fluid with respect to filtering and heating to prevent contamination of the dry gas seal. Accordingly, market pressure is building for a system and method for preventing the backflow of process fluid, and the associated contaminates, through the dry gas seal during transient operating conditions. 
       SUMMARY 
       [0007]    Systems and methods according to these exemplary embodiment descriptions address the above described needs by providing a small secondary compressor for boosting the pressure of an intermediate buffer gas during operating conditions (i.e., startup, shutdown and low-speed idle) when the fluid pressure from the discharge of the pump is equal to the suction pressure of the area to be sealed by the dry gas seal. A simple control system detects a drop in barrier gas pressure in the dry gas seal (i.e., the trigger signal could be but is not limited to simply the “no running” condition of the turbomachinery) and protects the dry gas seal from icing by closing a valve between the dry gas seal and a flare-safe area and starting the secondary compressor to boost the intermediate buffer gas to a preconfigured pressure based on the pressure of the process fluid in the area to be sealed by the dry gas seal. 
         [0008]    According to an exemplary embodiment of a system for assuring a safe working condition of a dry gas seal during standstill operations, a barrier fluid pressure measuring system detects a drop in barrier fluid pressure. The exemplary embodiment continues with a valve connecting the chamber between primary and secondary seal with the flare. Further, the exemplary embodiment continues with a booster compressor for boosting the pressure of an intermediate buffer gas injected into the chamber between the primary and secondary seal. Next the exemplary embodiment comprises a control system for operating the booster compressor based on the measured pressure between the primary and secondary seal. 
         [0009]    According to another exemplary embodiment, a method for assuring a safe working condition of a dry gas seal installed on a liquefied gas pump when the pump is in a transient operating condition, is presented. Continuing with the first step of the exemplary method embodiment, the method detects the barrier gas pressure below a preconfigured value. In the next step of the exemplary method embodiment, the method closes a valve connected to the dry gas seal. Further in the exemplary method embodiment, starting a booster compressor associated with an intermediate buffer gas and maintaining said chamber pressure at a preconfigured value. 
         [0010]    In a further exemplary embodiment, a liquefied gas pump dry gas seal protection system is described. The exemplary embodiment includes a means to detect when the pressure of the barrier fluid drops below a lower limit. The exemplary embodiment further includes a means to regulate the flow from the dry gas seal to a flare-safe area. Continuing with the exemplary embodiment, included is a means to increase the pressure of an intermediate buffer gas injected into the dry gas seal. Continuing with the exemplary embodiment, included is a means to measure the pressure of the buffer gas. Next in the exemplary embodiment, a means to control the means to regulate flow and means to increase pressure based on the means to measure pressure and a preconfigured pressure value. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The accompanying drawings illustrate exemplary embodiments, wherein: 
           [0012]      FIG. 1  depicts a prior art cross-section view of a dry gas seal and the associated gas support system in an operating condition; 
           [0013]      FIG. 2  depicts a prior art cross-section view of a dry gas seal and the associated gas support system in a standstill condition; 
           [0014]      FIG. 3  depicts an exemplary embodiment cross-section view of a dry gas seal and the associated gas support system in an operating condition; 
           [0015]      FIG. 4  depicts an exemplary embodiment cross-section view of a dry gas seal and the associated gas support system in a standstill condition; 
           [0016]      FIG. 5  depicts an exemplary embodiment pressure-enthalpy diagram illustrating the gas leakage flow through the primary dry gas seal when the pump is in the operating condition; 
           [0017]      FIG. 6  depicts a prior art pressure-enthalpy diagram illustrating the gas leakage flow through the primary dry gas seal when the pump is in the standstill condition; 
           [0018]      FIG. 7  depicts an exemplary embodiment pressure-enthalpy diagram illustrating the gas leakage flow through the primary dry gas seal when the pump is in the standstill condition; and 
           [0019]      FIG. 8  is a flowchart depicting a method for maintaining sufficient pressure in the chamber between the primary and secondary dry gas seal to prevent contamination of the primary dry gas seal. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The following detailed description of exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. 
         [0021]    Looking to  FIG. 1 , a detailed diagram of a prior art exemplary embodiment of a dry gas seal (DGS) system  100  for a carbon dioxide (CO 2 ) pump is presented. It should be noted in the exemplary embodiment that any fluid in a supercritical state can be used as a barrier fluid in place of the exemplary carbon dioxide (CO 2 ). The exemplary embodiment reflects the behavior of the dry gas seal during operating conditions and includes a CO 2  pump  102  with its associated area to be sealed, a primary (inboard) seal  104  of a dry gas seal, a secondary (outboard) seal  106  of the dry gas seal, a process fluid filter  108 , a process fluid heater  110 , a valve and control element  112  for controlling the flow to a flare-safe area, an intermediate buffer gas filter  114 , intermediate buffer gas  116 , barrier fluid  118 , pressure reduction valve  120 , a primary dry gas seal chamber  122  and a secondary dry gas seal chamber  124 . 
         [0022]    In general, this exemplary prior art embodiment depicts process fluid, e.g. carbon dioxide, from the pump discharge being used as a barrier fluid. The pressure of the barrier fluid is reduced by a valve  120  and heated by a heater  110 . Continuing with the exemplary prior art embodiment, the barrier fluid is filtered by filters  108  and injected into the primary dry gas seal chamber  122 . In the exemplary embodiment, the pressure of the barrier fluid is higher than the suction pressure of the pump and therefore prevents the entry of any untreated process gas into the primary seal  104 . 
         [0023]    Continuing with the exemplary embodiment, the carbon dioxide (CO 2 ) barrier fluid flows partly into the pump through the inner labyrinth and partly to the primary vent through the primary dry gas seal. Next in the exemplary embodiment, the carbon dioxide (CO 2 ) that flows into the pump reaches a suction pressure that is higher than the critical pressure for carbon dioxide (CO 2 ) and accordingly will not experience icing or flushing. Further in the exemplary embodiment, the carbon dioxide (CO 2 ) that flows through the primary seal to the primary vent expands from P1 to a value established by the buffer gas (typically N 2 /air at 4-7 bar). It should be noted in the exemplary embodiment that the temperature of the carbon dioxide (CO 2 ) barrier fluid must be maintained, by a heater, to a value high enough to avoid, during the expansion, the risk of icing or flushing. 
         [0024]    Continuing with the exemplary embodiment, an intermediate buffer gas  116 , e.g. nitrogen or dry air is filtered by filters  114  and injected into the secondary dry gas seal chamber  124 . It should be noted in the exemplary embodiment that gases other than nitrogen or air are usable as a buffer gas. In the exemplary embodiment, the pressure of the intermediate buffer gas  116  is higher than the pressure of the barrier gas passing through the primary seal  104  and prevents the barrier gas from reaching the secondary seal  106 . In the exemplary embodiment, the mixture of barrier gas  118  and intermediate buffer gas  116  in the secondary dry gas seal chamber  124  passes through a valve  112  and flows to a flare-safe area. 
         [0025]    Looking now to  FIG. 2 , a detailed diagram of a prior art exemplary embodiment of a dry gas seal (DGS) system  200  for a carbon dioxide (CO 2 ) pump is presented. The prior art exemplary embodiment reflects the behavior of the dry gas seal during a transient, e.g. standstill, condition and includes a CO 2  pump  202  with its associated area to be sealed, a primary (inboard) seal  204  of a dry gas seal, a secondary (outboard) seal  206  of the dry gas seal, a process fluid filter  208 , a process fluid heater  210 , a valve and control element  212  for controlling the flow to a flare-safe area, an intermediate buffer gas filter  214 , intermediate buffer gas  216 , barrier fluid  218 , pressure reduction valve  220 , a primary dry gas seal chamber  222  and a secondary dry gas seal chamber  224 . 
         [0026]    Continuing with the prior art exemplary embodiment, the CO 2  pump is in a standstill condition and accordingly the discharge pressure from the pump is equal to the pressure in the area to be sealed  202 . When the pump is in a standstill condition, the pressure into the pump reaches a uniform value very close to the suction pressure, know as “settle out pressure”. It should be noted in the prior art exemplary embodiment that the result of the standstill condition is the process fluid from the pump discharge can no longer act as a barrier fluid to prevent the flow of untreated process fluid, from the area to be sealed  202 , into the primary seal  204 . Further in the prior art exemplary embodiment, the untreated process fluid is not heated or filtered and therefore contaminates can enter the primary seal  204  and icing can occur in the primary seal  204 . It should also be noted in the prior art exemplary embodiment that the pressure of the untreated process fluid is greater than the pressure of the intermediate buffer gas  216  therefore the intermediate buffer gas  216  cannot prevent the flow of untreated process fluid through the primary gas seal  204 . 
         [0027]    Continuing with  FIG. 3 , a detailed diagram of an exemplary embodiment of a dry gas seal (DGS) system  300  for a carbon dioxide (CO 2 ) pump is presented. The exemplary embodiment reflects the behavior of the dry gas seal during a operating, e.g. running, condition and includes a CO 2  pump  302  with its associated area to be sealed, a primary (inboard) seal  304  of a dry gas seal, a secondary (outboard) seal  306  of the dry gas seal, a flare valve  312 , and a control element for controlling the flow to a flare-safe area, an intermediate buffer gas filter  314 , intermediate buffer gas  316 , barrier fluid  318 , a primary dry gas seal chamber  322 , a secondary dry gas seal chamber  324 , a booster compressor  326  and, a booster compressor  326  discharge valve  328 , a booster compressor  326  inlet valve  330  and a booster compressor  326  bypass valve  332 . 
         [0028]    In a non-limiting exemplary embodiment, while the pump is in a running condition, the pressure in the area to be sealed  302  is lower than the pressure of the barrier fluid  318 , provided from the pump discharge, and while the barrier fluid pressure is higher than the pressure of the area to be sealed, flare valve  312  and booster compressor  326  bypass valve  332  are open, booster compressor  326  discharge valve  328  and booster compressor  326  inlet valve  330  are closed and booster compressor  326  is deactivated. Continuing with the exemplary embodiment, the pressure of the barrier fluid does not allow the process fluid to flow through the primary seal  304  and prevents contamination and icing of the primary seal  304 . 
         [0029]    Looking now to  FIG. 4 , a detailed diagram of an exemplary embodiment of a dry gas seal (DGS) system  400  for a carbon dioxide (CO 2 ) pump is presented. The exemplary embodiment reflects the behavior of the dry gas seal during a transient, e.g. standstill, condition and includes a CO 2  pump  402  with its associated area to be sealed, a primary (inboard) seal  404  of a dry gas seal, a secondary (outboard) seal  406  of the dry gas seal, a valve  412 , and control element, for controlling the flow to a flare-safe area, an intermediate buffer gas filter  414 , intermediate buffer gas  416 , barrier fluid  418 , a primary dry gas seal chamber  422 , a secondary dry gas seal chamber  424 , a booster compressor  426 , a booster compressor  426  discharge valve  428 , a booster compressor  426  inlet valve  430  and a booster compressor  426  bypass valve  432 . 
         [0030]    In a non-limiting exemplary embodiment, in “no running” conditions of the pump or compressor (trip, shutdown, startup, pressurized standstill, etc.), the pressure into the pump is uniform and is equal to the settle out pressure value and can no longer be used as a barrier fluid. In this exemplary embodiment condition, the flare valve  412  and the booster compressor  426  bypass valve  432  is closed, the booster compressor  426  discharge valve  428  and the booster compressor  426  inlet valve  430  is opened and the booster compressor  426  is activated. It should be noted in the exemplary embodiment that the booster compressor raises the pressure of the intermediate buffer gas  416 , injected into the secondary dry gas seal chamber  424 , to a predetermined pressure (P3) just below the pressure in the area to be sealed  402 . Continuing with the exemplary embodiment, the increased pressure of the intermediate buffer gas reduces the flow of process gas through the primary seal  404  and prevents contamination and icing of the primary seal  404 . The exemplary embodiment booster compressor  426  operates in a discontinuous fashion, performing ON/OFF cycles. Next, the exemplary embodiment booster compressor  426  is turned on and the pressure into the secondary seal chamber  424  rises until it reaches the pressure P3 and the booster compressor  426  is turned off. The exemplary embodiment continues with the pressure in the secondary seal chamber  424  slowly dropping, because of leakage of buffer gas through the secondary seal  406 . Continuing with the exemplary embodiment, when the pressure in the chamber  424  between the primary seal  404  and the secondary seal  406  drops below a predetermined value (P3−dP3), the booster compressor  426  is turned on. Further, it should be noted in the exemplary embodiment that when the pump returns to operating conditions and barrier fluid  418  pressure rises above the pressure in the area to be sealed  402  the booster compressor  426  is finally turned off 
         [0031]    Turning now to  FIG. 5 , in a pressure-enthalpy diagram  500  illustrated is the pressure reduction of the barrier fluid through the control valve  120 , the temperature rise of the barrier fluid through the heater  110  and the expansion of the treated leakage flow through the primary seal to the primary vent with the pump in running condition. The temperature in the exemplary embodiment is high enough to avoid flushing and icing during the expansion. 
         [0032]    Continuing now to  FIG. 6 , a carbon dioxide pressure-enthalpy diagram  600  of a prior art exemplary embodiment dry gas seal system in a standstill operating condition is presented. The prior art exemplary embodiment illustrates the pressure difference  602  occurring through the primary seal  604  during a standstill condition. In another aspect of the prior art exemplary embodiment, the enthalpy diagram  600  depicts the expansion  604  of the untreated carbon dioxide leakage flow through the primary seal and crossing the triple point  606  and the bi-phase zones of the diagram for carbon dioxide. Accordingly, the prior art exemplary embodiment indicates that icing will occur in and around the primary seal and will lead to premature failure of the primary seal. 
         [0033]    Looking now to  FIG. 7 , an exemplary embodiment of a carbon dioxide pressure—enthalpy diagram  700  of a dry gas seal system in a standstill operating condition is presented. The exemplary embodiment illustrates the pressure difference  702  occurring through the primary seal during a standstill condition. In another aspect of the exemplary embodiment, the enthalpy diagram  700  depicts the expansion  704  of the untreated carbon dioxide leakage flow through the primary seal and not crossing the triple point  706  and neither bi-phase zone of the diagram for carbon dioxide. Accordingly, the exemplary embodiment indicates that icing will not occur in and around the primary seal. 
         [0034]    Continuing now to  FIG. 8 , an exemplary method embodiment  800  for assuring a safe working condition of the dry gas seal and preventing flushing and/or icing when the pump or compressor is in a standstill condition is depicted. Starting at exemplary method embodiment step  802 , the pressure of the barrier fluid in the chamber upstream of the primary seal is measured. In this exemplary method embodiment, the measured barrier fluid pressure is compared to a preconfigured value and an indication is generated if the measured barrier fluid pressure is below the preconfigured value. 
         [0035]    Next at exemplary method embodiment step  804 , if the indication is presented that the barrier fluid pressure is below the preconfigured value then a valve associated with the dry gas seal and a flare-safe area is closed. In one aspect of the exemplary method embodiment, the valve prevents the exit of any gas from the chamber between the primary seal and the secondary seal except by passing through the secondary seal. In another aspect of the exemplary method embodiment, closing the valve reduces the volume of intermediate buffer gas required to maintain the desired pressure. Further in the exemplary method embodiment, the intermediate buffer gas can be, but is not limited to, Nitrogen or dry air. 
         [0036]    Next at exemplary method embodiment step  806 , a booster compressor is started to boost the pressure of the intermediate buffer gas injected into the chamber between the primary seal and the secondary seal. In another aspect of the exemplary method embodiment, the booster compressor is operated to maintain the pressure based on a preconfigured value for the chamber pressure that is near the value of the pressure of the process fluid in the area to be sealed by the dry gas seal. Continuing with the exemplary method embodiment, the preconfigured value can dynamically change based on changes in the pressure of the process fluid in the area to be sealed by the dry gas seal. It should be noted in the exemplary method embodiment that the process fluid can be, but is not limited to, carbon dioxide. 
         [0037]    Continuing with the exemplary method embodiment, at step  808  the rise in pressure in the chamber between the primary seal and the secondary seal is monitored until the pressure reaches a specified pressure (P3). Next, at step  810  of the exemplary method embodiment, when the pressure reaches pressure P3, the booster compressor is turned off. Further, at step  812  of the exemplary method embodiment, the pressure is monitored until it falls to a lower specified threshold and the method returns to step  806  and restarts the booster compressor. It should be noted that the exemplary method embodiment continues to cycle in this fashion until the pump/compressor returns to a running condition. 
         [0038]    The disclosed exemplary embodiments provide a system and a method for protecting a dry gas seal from at least icing conditions brought on by process fluid expanding through the primary seal of a dry gas seal. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details. 
         [0039]    Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein. 
         [0040]    This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.