COMPRESSOR DRY GAS SEAL SYSTEMS

COURSE OUTLINE

I. INTRODUCTION
a. Overview
b. Function of Compressor Seals
c. Types of Compressor Seals

II. GAS SEAL SYSTEMS

a. Gas Seal Technology
b. System Requirements

III. SYSTEM DESIGN

a. Equipment
b. Seal Gas
c. Separation Gas

IV. OPERATION
a. Startup
b. Normal Operation
c. Shutdown
I. INTRODUCTION

The CPF Stage 2 Process Gas Compressors and Injection Gas Compressors are
equipped with Dry Gas Seal Systems, a relatively new technology in seal design. The
dry gas seal systems replace the conventional oil seal systems that are used on the
Train 1 compressors.

The main differences between dry gas seals and conventional oil seals are seal
barrier fluid and seal face geometry.

The dry gas seal system utilizes nitrogen and dry process gas in place of seal oil as the
barrier fluid to separate the gas spaces inside the compressor case from the oil-
lubricated bearings and the atmosphere.

The shape of the conventional oil seal is designed to create a balanced opening and
closing force to maintain just the right amount of seal face separation. The gas seal
depends upon the generation of a lifting force (gas pressure) to separate the seal faces.
This hydrodynamic lifting force is created by the seal face geometry (shape or
configuration).

FUNCTION OF COMPRESSOR SEALS

Think of a compressor as three separate parts. The first part is the main “barrel” or
“cylinder” of the compressor, which moves gas by converting energy supplied from the
driver to the compressor rotor, where the gas pressure is raised and thus forced to
move along the discharge piping. Next, there is the compressor “shaft”, which is the
conduit for transfer of energy from the driver to the compressor. The third part is the
“mechanical seal”, which allows the rotating shaft to pass into the pressurized
compressor cylinder without leaking hydrocarbon around the shaft.

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The compressor seals are critical components that prevent compressed gas from
leaking from the compressor case through the rotor shaft cavities. The choice of seals is
dictated by the process involved and the fluid handled.

TYPES OF COMPRESSOR SEALS

There are several types of compressor seals. This course will focus on three variations:

• Labyrinth Seals
The labyrinth seal is a non-contacting seal, consisting of a series of sealing strips, or
grooves, machined into a stationary insert. The insert is horizontally split and fitted
into the compressor barrel around the shaft. In some cases, sealing strips may also
be machined into the compressor shaft. The sealing strips provide the seal around
the shaft. The clearance between the labyrinth strip and the surface of the shaft is
very tight. The smaller the clearance, the more leakage is reduced. A “buffer” gas is
often used with the labyrinth seal to improve the sealing effect.

• Mechanical Contact Seals

The mechanical contact seal generally consists of a stationary carbon ring and a
rotating ring made of a high-quality material. The rotating ring turns with the
compressor shaft and mates in a sliding contact motion to the stationary carbon ring.
Seal oil, at a higher pressure than the compressed gas, is required with this type of
seal. A very thin film of seal oil is forced between the mating surfaces. This wets the
sliding surfaces and reduces wear. The seal oil also flushes and cools the seal ring
components. The stationary carbon ring is spring loaded to force it to remain in
sliding contact with the rotating ring. O-rings are used to provide sealing between the
laterally moving metal parts within the stationary seal housing.

• Mechanical Non-Contact Seals

The mechanical non-contact seal, or gas seal, is very similar in function and design
to the mechanical contact seal. Instead of seal oil, a small quantity of clean seal gas
is used. The seal faces do not contact each other. The seal gas separates the seal
faces less than a thousandth of an inch.
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II. GAS SEAL SYSTEMS

The use of dry gas seals has become the standard in the last decade for centrifugal
compressors in many applications. A gas seal system eliminates the bulky and
expensive arrangement of high-pressure pumps, filters, regulators, and reservoirs that
are required by the oil-film type seals of the past.

The advantages of a seal gas system over a conventional seal oil system are primarily
cost savings associated with reduced lube oil loss in the event of seal leakage and the
elimination of the power loss from oil shear and drag found in these systems. Dry gas
seals also improve compressor efficiency.

GAS SEAL TECHNOLOGY

The idea is very simple. Let the seal faces ride on a film of gas. Unlike liquids, gases
are compressible but you do generate a similar lifting force if the seal face geometry is
designed and built correctly. The idea is to direct the gas into some narrow channels
that will increase the gas pressure causing the face separation.

INBOARD CLEAN GAS INJECTION OUTBOARD

SEALING PRESSURE

GROOVES GAP

PROCESS GAS AT LEAKAGE FLOW TO

SEALING PRESSURE VENT OR ATMOSPHERE

FIGURE 1: Gas Seal Principle ( Courtesy of Dresser Rand )

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Hydrodynamic forces are generated by the viscous shear of the gas film when the
grooved face is rotating, so unlike the hydrostatic (oil) version, these seals operate
effectively only while the shaft is turning. This same phenomenon occurs when water
fills the tread of an automobile tire causing the car to actually lift off the road surface.

As discussed in the previous section, the gas seal is a mechanical non-contact seal,
very similar in design to the mechanical contact seal, but utilizing process gas as the
seal barrier fluid and a seal ring geometry configured to generate optimum pressure
distribution between the seal faces.

The Heart of the Seal

The heart of the gas seal is a pair of rings. A stationary ring is held against a rotating
ring by spring pressure. The contact face of the rotating ring incorporates special film-
riding geometry in the form of grooves or tapered lands on the outer portion. Filtered
compressor discharge gas, maintained at a pressure slightly above that of the process
gas to be contained, is introduced into the seal area.

As the gas pressure and shaft rotation interact in normal operation, the geometry on the
rotating ring creates a dynamic gas pumping or "lifting" effect which pushes the spring-
loaded stationary ring away from the rotating ring. A pressure dam effect created by the
rings functions as the primary seal and breaks down the gas pressure to just above
atmospheric pressure.

Figure 2: Grooves Pattern ( Courtesy of Dresser Rand )

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 Dresser-Rand Gas Seal Design

The Dresser-Rand Gas Seal is an << L >> Sleeve design. The “L” sleeve is the
component between the spring and the carbon ring in the stationary housing of the
mechanical seal. Remember that the spring applies the force that closes the seal
(pushes the stationary carbon ring against the rotating tungsten carbide ring fitted to the
compressor shaft). Since the “L” sleeve and carbon ring move laterally along the shaft
to mate with the rotating ring, friction forces can restrict that movement and result in
failure of the seal rings to close completely. This is referred to as the “hang-up
situation”. In the Dresser-Rand << L >> Sleeve design, two different O-rings are placed
in the “L” sleeve to minimize the risks of “hang-up”. One O-ring is installed between the
“L” Sleeve and the back face of the carbon ring. The other O-ring is installed between
the “L” sleeve and the seal housing.

Seal Gas Stationary Carbon Ring

Mechanical
Seal Housing

Spring

Rotating O-rings
Tungsten Carbide
Ring

“L” sleeve

FIGURE 3: Dresser-Rand << L >> Sleeve Design Gas Seal

( Courtesy of Dresser-Rand )

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SYSTEM REQUIREMENTS

The following requirements must be met to ensure the Seal Gas System will perform in
a satisfactory manner:
• Delivery of clean, dry gas for both seal gas and separation gas controlled at a rate
guaranteed to satisfy the requirement for the system.
• A continuous supply of Nitrogen to serve as Separation Gas.
• An avenue for any small amount of leakage flow to allow the system to perform at its
pressure design. Excessive backpressure will be harmful to the seals.
• Reliable utility service, (electrical, instrumentation, etc.) to allow the system to
operate in a trouble free manner.

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III. SYSTEM DESIGN

Technical Drawings:
• P&ID’s: HBNS2-PR-1835-1/3; HBNS2-PR-1865-1/3; HBNS-1866-1/3
• Vendor Diagrams: 345-868 (1-2); 345-831 (1-3); 345-893 (1-3); 345-831 (1-3)

GAS SEAL SYSTEM

Seal Gas supply is provided via a 2” line from the Fuel Gas Header in the case of the
Process Compressors or the 2” Injection Gas export line for the Injection Compressors.
The seal gas should be clean, dry and filtered to 10-micron particle (solids) and 99.97 %
liquid free of particles 3 micron and larger. Prior to entering the Compressor building
there is a solenoid activated Safety Shutdown Valve. Next is a Seal Gas filter pot to trap
particulate matter and liquid. The filter pot is equipped with a local pressure differential
gauge and alarm to alert the operator when filters require changing. A check valve is
located directly downstream of the SDV. The remainder of the system is located inside
the compressor building with all controls and much of the equipment on the Gas Seal
Control Panel.

FIGURE 4: Gas Seal Control Panel

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There is a PRV located upstream of the Pressure Differential Control Valve set at a
value to protect the system and discharging into the high- pressure flare line. After
passing the pressure differential control valve there is a second set of filters with their
piping arranged in such a way as to allow flow through either filter individually, or to be
used in parallel. The filters are equipped with a local pressure differential reading with a
high- pressure tap upstream of the filters and a low- pressure tap downstream. There is
an additional tap for instrumentation (discussed in the instrumentation section). The
stream of seal gas then splits into 2 streams with each passing through a flow restriction
orifice and enters the seal assemblies between the primary seal and the labyrinth at
both locations (inboard/ outboard or intake/ discharge seals). Between the flow orifices
and the seals there are pressure taps and drilled check valves on the seal gas
reference lines. This will be discussed further in the instrumentation section.

There are two primary vent lines (from inboard/ outboard or intake/ discharge seals),
which allow a path for the small amount of expected flow of seal gas. They are each
equipped with low point drains for the purpose of draining any accumulated liquids. The
normal flow values to the primary gas seal vents for individual systems will be provided
in tables in following sections. There is a high-pressure shutdown switch located
between the seal vent and the restriction orifices set at 1.0 BARG. Each primary vent
line is equipped with restriction type orifices and local pressure differential gauges. Both
primary vent lines are also equipped with PSV’s set to maintain a maximum seal
pressure not to exceed 0.34 BARG. The primary vents are routed to atmosphere above
the compressor building roof.

Note: It is important to limit the pressure in the vent lines at all times so that
maximum seal backpressure does not exceed 0.34 BARG. Excessive
backpressure can cause damage to seals.

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Separation Gas is clean, dry nitrogen supplied from a ¾” stainless steel tubing supplied
from plant utilities. The nitrogen will be delivered at approximately 6.6 BARG filtered to 3
micron absolute and 99.97% liquid free. The minimum pressure for the nitrogen is 2.8
BARG. Prior to entering the compressor building there is a solenoid activated Safety
Shutdown valve with a check valve situated directly downstream. There is a filter
equipped with a local differential gauge with pressure taps both up and downstream of
the filter. There is a Pressure Differential High Alarm (PDAH) on the filter to alert the
operators of a system problem. The nitrogen pressure is controlled by a regulator to
allow for a normal flow rate of 13 NM³/hr with a maximum of 16 NM³/hr. There is a local
pressure differential reading across the regulator. The separation gas piping splits into
two streams and enters the seal body between the carbon bushing seals at both
locations (inboard/outboard or intake/ suction seals).

The exit route for the separation/ seal gas is the secondary vent line, which discharges
to atmosphere outside the compressor building and is fitted with a flame arrestor. The
secondary vent line is supplied with a low point drain line to periodically drain
accumulated liquid.

Note: It is important to limit the pressure in the vent line at all times so that
maximum seal backpressure does not exceed 0.34 BARG. Excessive
backpressure may cause damage to seals.

Instrumentation

If the Seal Gas system is to operate properly, the system instrumentation must function
as designed. On the Seal Gas supply line there is a Pressure Differential Control valve
(PDCV) located at the front of the system. Its output is reset from the Pressure
Differential Indicator/ Controller (PDIC) which obtains a pressure differential reading
from pressure taps downstream of the inlet micron filters and the two seal gas reference
taps located directly downstream of the seal gas restriction flow orifices. The PDIC has
a setpoint of 0.69 BARG and a low alarm trip set at 0.21 BARG.
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Remember, this is a differential pressure controller, so if the reading is above 0.69
BARG the inlet control valve will open and if the reading is below 0.69 BARG the inlet
control valve will close to achieve the desired setpoint.

There are High Differential Pressure Switches (PDSH) located at the inlet micron filters
and on the flow orifices on each of the primary vent lines. These switches will activate
an alarm. High- High Pressure Switches (PSHH) are located on both primary vent lines
upstream of the restriction orifices. These switches activate a compressor shutdown.

There is a Low Differential Pressure switch in the same location as the PDIC. This
switch will activate an alarm.

On the separation gas piping there is a High Differential Pressure Switch (PDSH) at the
nitrogen inlet micron filter which when tripped will initiate an alarm. The Pressure
Differential Control Valve (PDCV) takes its signal from inlet (high) separation gas piping
and another signal off the secondary vent line (low). This same piping also has a Low
Differential Pressure Switch (PDSL) which triggers both the permissive to start (when
satisfied) and an alarm when abnormal reading is obtained.

Also included on the Seal Gas Panels are a Low Pressure Switch (PSL) and a
Shutdown (PSLL) for compressor lube oil. These two switches are not part of the Seal
Gas System, but as they are included on the control panel they are mentioned here.

The instrument tables on the following pages are specific to the separate panels
for the Process and Injection Compressors. The item numbers correspond to the
numbers found on the system diagrams to assist with identification of
components.

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 Process Compressors: K2-201, K8-201, K4-201, K3-201
Note: Refer to Vendor Diagram No. 345-868
Item Tag Number Description Range/Setpoint/
Number Alarm/ Trip Setting
956 N/A Piston check valve (inlet) N/A
983 PRV-640 Pressure relief valve at inlet of Seal Gas Set at 72.4 BARG
panel.
959 PDCV-605 Seal Gas Differential Pressure Control Valve. Resets from signal of
PDIC-605 to maintain
.69 BARG.
991/992 TE-606 Inlet temperature element and thermowell.
961 N/A (2) Seal Gas Inlet micron filters. 0.5 micron

Injection Gas Compressors: SK-K8-401, SK-K8-402, SK-K8-403- *D8R6S*

Note: Refer to Vendor Diagram 345-831
Item Tag Number Description Range/Setpoint/
Number Alarm/ Trip Setting

GAS SEAL DIAGRAM 345-831 PG. 1 / 3

966 PI-600 Local Pressure Gauge (inlet). 0-55 BARG

951 PDI-600 Local Pressure Differential Indication- across 0-3.4 BARG
inlet filters.
954 PDSH-600 High Differential Pressure Switch- across inlet Alarms @ 1.40 BARG
filters.
958 PDIC-605 Seal Gas Pressure Differential Indicator/ Resets PDCV 605 to
Controller. maintain .69 BAR.
955 PDSL-605 Low Seal Gas Differential Switch. Alarms @ .21 BARG
962 FO-610/ 620 Seal Gas restriction flow orifices. 0.3438” bore.
974 N/A Check valves (2) modified with bleed orifice 0.040” bore.
holes.
957 PSHH-613/ 623 Primary Vent Gas High- High Shutdown Shutdown @ 1.0 BARG
963 FE-611/ 621 Primary Vent Gas flow orifice plates. 0.3438” bore.
953 PDI-611/ 621 Primary Vent Gas Pressure Differential (local 0- 0.7 BAR
reading).
955 PDSH-611/ 621 High Differential Pressure Alarm Switch Alarms @ 0.07 BAR
Primary Vent Gas.
971 FL-639 Separation Gas micron filter. Liquids and solids 93%
@ .1 micron.
952 PDI- 639 Local Separation Gas Pressure Differential. 0- 0.3 BAR
954 PDSH-639 Separation Gas High Pressure Differential. Alarms @ 1.40 BAR
972 PDCV-630 Separation Gas Pressure Differential Control Controls Sep. Gas
Regulator. Pressure @ .21 BAR
982 PDI-631 Separation Gas Local Pressure Differential 0- .7 BAR

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 Item Tag Number Description Range/Setpoint/
Number Alarm/ Trip Setting
955 PDSL-631 Separation Gas Low Alarm (Permissive to Set @ 0.07 BAR
Start) Differential Pressure Switch.
956 N/A Piston check valves (2) Inlet Seal Gas and N² N/A
to inlet.
983 PRV-640 Pressure relief valve at inlet of Seal Gas Set at 72.4 BARG
panel.
959 PDCV-605 Seal Gas Differential Pressure Control Valve. Resets from signal of
PDIC-605 to maintain
.69 BARG
991/992 TE-606 Inlet temperature element and thermowell. N/A
961 N/A (2) Seal Gas Inlet micron filters. 0.5 micron

GAS SEAL DIAGRAM 345-831 PG. 2 / 3

956 N/A Piston check valves (2) Inlet Seal Gas and N² N/A
to inlet.
959 PCV-653 Seal Gas Pressure Control Valve. Resets from signal from
PIC-653 to maintain 131
BARG.
986 PRV-690 Seal Gas Pressure Relief Valve Set @ 152 BARG to
relieve to High Pressure
Flare.
960 PIC-653 Seal Gas Pressure Controller Resets PCV-653 to
maintain 131 BARG
974 PDCV-655 Seal Gas Differential Control Valve. Resets from PDIC-655
to maintain .69 BARG
991/ 992 TE-656 Temperature element and thermowell. N/A
961 N/A (2) Micron filters for Seal Gas. 0.5 micron
967 PI-650 Local Seal Gas Pressure indication. N/A
990 PDI-650 Local Seal Gas Pressure Differential N/A
indication.
954 PDSH-650 Seal Gas High Pressure Differential Alarm Set @ 1.40 BAR
Switch.
958 PDIC-655 Seal Gas Pressure Differential Controller Resets PDCV-655 to
maintain .69 BARD.
955 PDSH-650 Seal Gas High Pressure Differential Alarm Set @ .21 BARD.
Switch.
962 FO-660/ 670 Seal Gas/ Reference Gas restriction flow 0.3438” bore
orifices.
957 PSHH-663/ 673 Gas Seal Primary Vent High- High Pressure Set @ 1.0 BARG
shutdown switch.
963 FE-661/ 671 Gas Seal Primary Vent flow orifices. 0.3438 bore
955 PDSH-661/ 671 Seal Gas Primary Vent High Differential Set @ 0.07 BAR
Pressure Alarm Switch.
953 PDI-661/ 671 Seal Gas Primary Vent Differential Pressure 0- 0.07 BAR
Indication (local).

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 Item Tag Number Description Range/Setpoint/
Number Alarm/ Trip Setting
971 N/A Separation Gas Micron Filter Liquids and solids 93%
@ .1 micron.
952 PDI-689 Separation Gas Pressure Differential 0- 3.4 BAR
Indication (local).
954 PDSH-689 Separation Gas High Pressure Differential Set @ 1.40 BAR
Alarm Switch.
972 PDCV-680 Separation Gas Differential Pressure Control Controls Separation
Valve. Gas Pressure
Differential @ .21 BAR
982 PDI-681 Separation Gas Pressure Differential 0- 0.07 BAR
Indication (local).
955 PDSL-681 Separation Gas Low Alarm (Permissive to Set @ 0.07 BAR
Start) Differential Pressure Switch.

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SEAL GAS

The source of seal gas for the Process Compressors is a 2” branch off the Fuel Gas
Header Line Number 2”-GS-C-2-1851014. There is a root valve at the branch to isolate
this line from the fuel gas header. Seal Gas will be supplied at a pressure of
approximately 62.1 BARG and 32°C minimum temperature.

The source of Seal Gas for the Injection Compressors is a 2” branch off the Injection
Gas Export line. The line number is 2”-GS-FM-2-1864003. There is a root valve at the
branch to isolate this line from the injection gas export line. Seal Gas will be supplied at
a pressure of approximately 343 BARG and 71°C.

Specification

The specification for Seal Gas is: clean, dry filtered to 10-Micron particle (solids) and
99.97% liquid free of particles 3 Microns and larger.

SEPARATION GAS

The source of Separation Gas (Nitrogen) for the Process Compressors is a 1” branch
off the Nitrogen Header. The line number is 1”-NT-A-2-1879037. There is a root valve at
the branch to isolate this line from the nitrogen header. Separation Gas will be supplied
at a pressure of 2.8 BARG (minimum).

The source of Separation Gas for the Injection Compressors is a 1” branch off the
Nitrogen Header. The line number is 1”-NT-A-2-1879038. There is a root valve at the
branch to isolate this line from the nitrogen header. Separation Gas will be supplied at a
pressure of 2.8 BARG (minimum).

Specification

The specification for Separation Gas (nitrogen) is; clean, dry filtered to 3-Micron
Absolute and 99.97% liquid free.

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IV. OPERATION

STARTUP

1. Verify there is adequate communication between the field and the Control Room.

2. Check the entire system before attempting a startup. Watch for loose
connections and fittings, missing piping or instrument items, open bleeders, verify
all utilities (electricity, instrument air, high pressure flare system and nitrogen
supply) are ready for service and blinds that might be installed in the system
have been removed.

3. Ensure the upstream block valve and bypass is closed at the inlet filter pot
located outside the compressor building on both the Seal Gas and Separation
Gas streams.
4. To avoid the possibility of damaging instruments it is recommended they be
isolated and placed in service individually as the system is inventoried.

5. Stroke the PDCV for both Seal Gas and Separation Gas to check for smooth
travel.

6. Check that the valves directly upstream of the Micron Filters on both Seal Gas
and Separation gas are closed and the PDCV on each line is 100% open.

7. Reset the Nitrogen Emergency Shutdown Valve located outside the compressor
building.
8. Slowly crack open the root valve off the Nitrogen header and pressure to the
upstream block valve of the Nitrogen Filter using the ¾” bleed downstream of the
Emergency Shutdown Valve to displace air from the line. Note: A portable O2
analyzer may be used to monitor oxygen content. When a reading of <1% O2 is
observed move to the next step.
9. Open the high point vent on the Nitrogen filter then using the upstream block
valve slowly allow nitrogen to enter the filter and displace the oxygen from the
vent. Monitor with the oxygen analyzer as in Step 8.

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10. Place the Nitrogen filter PDI and PDSH in service by opening both the high and
low pressure taps. Check the low point drain on the filter pot for water and drain
until dry nitrogen is observed if water is present.
11. Slowly open the Nitrogen Filter Pot downstream block valve and allow the line to
displace oxygen by bleeding at the Separation Gas Micron filter. Again use the
portable O2 meter to monitor. When a satisfactory reading is observed, close the
bleeder and allow the system to continue to fill.

12. Place the Separation Gas Filter PDI and PDSH in service by opening the high
and low pressure taps.

13. Place the PDI and PDSL on the Secondary Vent in service by opening the high
and low pressure taps.
14. The Separation Gas System should now be in full service. Watch for a few
minutes to make sure the PDCV is controlling properly to maintain the system at
the desired pressure.

Note: Because the Seal Gas section of the system will be filled with gas it is very
important to ensure the piping has been properly air freed prior to introduction of
gas. The following steps 15 – 18 describe how to do this.

15. Ensure the root valve at the Gas Header is closed.

16. Reset the Seal Gas Emergency Shutdown Valve located outside the compressor
building and verify the downstream block valve and bypass at the Seal Gas filter
pot is closed and the high point vent on the pot is open.

17. Use a properly rated hose or piping (if available) to supply a source of nitrogen
into the Seal Gas piping.

18. Slowly begin a flow of nitrogen into the Seal Gas line while monitoring the bleed
from the Filter Pot vent with a portable O2 analyzer. When a reading of <1% O2
is observed proceed to the next step.

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19. Check the low point bleed on the Filter Pot for water. If dry proceed.
20. Place the PDI and PDSH for the Filter Pot in service by opening the high and
low- pressure taps.
21. Crack open the downstream block valve on the Filter Pot and allow a flow of
nitrogen through the PDCV up to the two Seal Gas inlet Micron filters. Check the
low point bleeds at the filters for water. When dry, proceed to the next step.
22. Place the PDI and PDSH for the two inlet Micron filters in service.

23. Slowly open the downstream block valves for the Micron filters. There are no
additional isolation points on the Seal Gas piping other than taps for
instrumentation.

24. Open the 2 valves on the Seal Gas reference lines, which provide the low-
pressure signal for the PDIC.

25. Line up the high- pressure tap to the PDIC. Once the PDIC is allowed to get a
signal it will begin sending signals to the PDCV which in turn will begin controlling
the system.

26. Make sure the two High-High Pressure Shutdown Switches on the Primary Seal
Gas Vent lines are properly lined up.

27. Make sure the PDI and PDSH on both Primary Seal Gas Vent lines are properly
lined up (both high and low- pressure taps).

28. Check the system in several places with a portable O2 analyzer to ensure the
oxygen reading is <1%.
29. When the system has been freed of oxygen shut down the flow of nitrogen and
slowly open the root valve for gas into the system.
30. Monitor the system to ensure all controllers are working properly. Consult the
tables in the previous section for the acceptable readings at the control panel.

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NORMAL OPERATION

The Seal Gas system is sufficiently automated and should not require a great deal of
special attention. The control panel provides critical indicators and most of the
equipment is located in a compact area. The individual items on the panel have been
identified with numbered labels to assist operators and maintenance technicians.

The following items should be monitored during normal operation:

• The operators and maintenance technicians should know and understand the piping,
controls and equipment in the system. Be sure to share problems and their solutions
with co-workers. This will quickly expand the base of knowledge and experience on
the system.

• The operators should look at the control panel during normal rounds to observe that
all readings are in the normal range. If an abnormal reading is observed investigate
the cause.

• The low point drains should be checked regularly for liquid.

• The filters should be watched closely. Note: A filter that shows a reading of no or
exceptionally low- differential pressure may have failed elements rendering it
ineffective. This condition should be reported or noted in the shift log. Low point filter
drains should be checked for liquid.

• Pay attention to the system primary and secondary vents. These can alert personnel
of a problem.

• Any alarms on the system should be investigated immediately. Alarms the operator
could expect to see would be “high differential” or “high primary vent gas shutdown”.
The vent gas high-pressure shutdown would indicate a gross seal failure or serious
problem with the seal gas system controls.

• System problems should be directed to the appropriate craft for attention.

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SHUTDOWN

The system should never be shut down under normal conditions while the compressor
is rotating. The result would be damage to seals. The following steps will explain the
shutdown of the system after the compressor has come to a full stop. The entire seal
gas system should always be shut down if the compressor barrel is to be depressurized.

1. Use the instrument setpoint of the Seal Gas PDIC to slowly force the PDCV into the
closed position. This will shut off the flow of Seal Gas.
2. It is recommended the Seal Gas Emergency Shutdown valve located outside the
compressor building is tripped closed. This will isolate the supply from the system.
3. Bleed the pressure from this section of the Seal Gas system between the two
blocked valves at the high point vent at the inlet filter pot located outside the
compressor building. This action will make a double block and bleed situation.
4. It is recommended the upstream block valves at the Seal Gas Micron filters are
closed.
5. It is recommended the Separation Gas Emergency Shutdown valve located outside
the compressor building is tripped closed. This will isolate the supply from the
system.
6. Isolate the nitrogen from the system by closing the valve directly upstream of the
Separation Gas Micron filter.
7. Bleed the pressure from this section of the Separation Gas system between the two
blocked valves at the high point vent at the inlet filter pot located outside the
compressor building. This action will make a double block and bleed situation.
8. Since the Primary and Secondary vents are routed to atmosphere no other steps
need be taken.

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