How to eliminate process gas leakage in high-speed rotating equipment

Working around compressors? If so, you may have an idea of how critical sealing is, how a small gas leak can become a safety risk, and how it can affect your budget. The American Petroleum Institute developed API 692, a standard for dry gas sealing systems, because it recognizes the importance of sealing reliability in rotating machinery.

 

But what makes sealing challenging? 

Well, it’s the speed and pressure involved, and even tiny gaps can allow process gas to escape. 

That’s why modern plants are shifting to advanced solutions like: 

·         Dry gas seals

·         Mechanical seals

These solutions are designed to support mechanisms and keep the equipment running smoothly. In this blog, we will discuss how engineers eliminate process gas leakage in high-speed rotating equipment. 

 

Let’s start.                  



Seals for high-speed applications

When working with high-speed applications, dry gas seals are the most effective way to prevent gas leakage. Advanced seals operate with a thin gas film between the two seal faces, which prevents friction and reduces heat generation.

 

Unlike traditional seals, the dry gas seals do not rub continuously and last longer. This makes them compatible with high-speed compressors and other applications across industries. To improve reliability and reduce gas losses, one must shift from traditional sealing technologies to dry gas seals. 

 

Choose the correct mechanical seal design.

Mechanical seal is a crucial component for pumps handling volatile fluids. It prevents fluid from escaping by providing a tight seal between the rotating and stationary parts.

 

A well-designed pump seal allows smooth rotation and reduced leakage. But what’s the key?

Well, here’s what needs to be considered while selecting the correct design for your pump:

·         Pressure

·         Temperature

·         Process media

If the seal does not match the above process conditions, it can lead to overheating, wear, or leakage.

 

Seal support: Thermosiphon cooling

Heat generation around seals can:

·         Reduce lubrication

·         Increase wear

·         Cause leakage

That’s where a thermosiphon seal support system comes in. It supports the system by solving these problems by circulating cooling fluid between the seal chamber and a reservoir. This process acts naturally without a pump, stabilizes temperature, and helps maintain a fluid film to stop leakage. This also extends seal life and improves reliability. 

 

Compatibility

To eliminate leakage in high-speed rotating equipment, ensuring seal compatibility with the equipment is crucial.  

 

Seals such as the Grundfos seal are designed with specific parameters. This makes it essential to replace it with a correct replacement and maintain those parameters. A mismatch can lead to shaft misalignment, uneven loading, and eventual leakage.

 

Stable operating conditions

Want to eliminate gas leakage?

It’s simple, just maintain stable operating conditions.

 

Here are the factors that can damage a seal:

·         Sudden pressure fluctuation

·         Vibrations

·         Running equipment outside its design range

To avoid these and protect the sealing system, the rotating equipment must be:

·         Well aligned

·         Maintain clean process fluid.

·         Monitor vibration levels

When equipment operates within parameters, seals perform better.

 

FAQs

What is a dry gas seal?

Dry gas seals use a thin gas film between  seal faces to prevent friction, heat generation, and leakage in high-speed compressors. 

 

What is the role of the thermosiphon system in seal support?

It circulates fluid naturally between the seal chamber and reservoir for cooling the seal.

 

When to use dry gas seals?

Dry gas seals are used in high-speed applications where lubrication is not suitable. 

 

Final thoughts…

In high-speed rotating equipment, you cannot blame a single factor for causing leakage. What needs your attention is:

·         Improper seal selection

·         Inadequate sealing

·         Misalignments

·         Unstable operating conditions

Integrate your system with modern technologies such as:

·         Dry gas seal

·         Mechanical seal

·         Thermosiphon cooling system

·         Grundfos seals

With these advances, plants can significantly reduce leakage risks.

 

Are your pumps experiencing recurring leakages?

It’s time to connect with an expert team.

 

Trisun offers advanced sealing solutions designed to handle demanding industrial environments.

Contact us today to find the sealing solution that aligns with your system.

 

 

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