Flowserve Pump Gas Seals

Dual Gas Seals for Pumps
Flow Solutions Division
Advantages of Dual Gas Seals

No product emissions
gas pressure provides barrier to product leakage
No product contamination
uses inert barrier gas such as nitrogen
No seal face wear

noncontacting APGS face technology
Protected from off-design pump operation

tolerant of vibration, cavitation, dry running
Advantages of Dual Gas Seals

Minimal power consumption, no heat generation
15-20 times less energy loss than liquid seals
Simplified barrier support system

unitized control panel dead-ended gas supply no external cooling required
Low total operating cost

no routine maintenance inexpensive barrier gas
Liquid Seal Support System

Pressure gage, regulator, barrier fluid, pressure supply, compatible barrier fluid, supply tank, cooling water, circulating device, barrier piping loop, inner seal flush, routine supply tank filling, disposal of used barrier fluid
Typical Gas Seal Applications

Where VOCs Why no product emissions
Cavitating pumps
Batch operations Replace single seal Replace dual seal
vibration, dry running

dry running emissions, dry running product contamination, total operating cost
Technology Considerations
Groove pattern design - film stiffness, low speed lift-off, gas consumption Secondary seal drag - seal face hang up Operating conditions - seal face distortion, vibration, batch operation Product effects - solids, polymers, etc. Gas reliability - barrier system design Safety during upset events - pressure reversal, reverse rotation, slow speed
Advanced Pattern Groove System

Shallow Tapered Spiral Groove
Land
Shallow Annular Groove

Sealing Dam
Advantages of APGS Technology

Patented tapered depth and tapered width spiral grooves with unifying circumferential groove High film stiffness with low gas leakage Adaptable to various application types:
high speed, high pressure compressors low speed mixers variable speed pumps
Over 2500 installations in pump gas seal and compressor services

Flowserve Pump Gas Seals

GF-200
Face to face pusher design Fits large bore seal chambers only High pressure capability Extensive exotic materials availability
GX-200
Common rotor welded metal bellows design Fits both small bore and large bore seal chambers Solids resistance features Pressure reversal product containment

2) Gas is compressed through narrowing spiral grooves 1) Gas enters wide and deep grooves at OD
2 3 1
3) Gas pressure is equalized through circumferential groove

GF-200 Hydraulic Principles

Opening Forces, Fo
h
Closing Forces, Fc
Spring
Hydrostatic h 0.0001 (2.54 m) Fo1 > Fo > Fo2 h1 < h < h2
Static: Dynamic: Upset:
Fo < Fc, seal faces closed Fo = Fc, seal faces separated by gap, h Fo1 > Fc, faces separated by new gap, h1 < h
APGS film stiffness provides stability to upset conditions.

Robust Seal Face Geometries

Flat reaction surface Uniform drive load Flat spring retainer
Premium quality materials
Designed with custom analytical techniques and proven by extensive correlation testing and field experience, seal face deflections are minimized for reliable performance.
Patented LoDrag O-ring Design

Canted coil spring Dynamic O-ring
Highly polished sleeve
Canted coil spring positioned above dynamic O-ring compensates for thermal expansion and chemical swell, providing consistent loading and low friction drag to reduce seal face hang-up.
GF-200 Design Features

Dead-ended barrier gas Requires large bore seal chamber
Simple installation cartridge seal is 100% static tested at the factory

Solids Handling
Self-cutting labyrinth bushing
Teeth built into cartridge sleeve
Integrating a bushing into the product end of the cartridge can reduce the opportunity for solids from the process stream to enter the seal area and cause secondary seal hang-up or erosion.
GF-200 Operating Limits

Product Pressure: Barrier Pressure: Temperature: Minimum Speed: Maximum Speed: Seal Sizes: 500 psig (34.5 bar) 25 psi (2 bar) minimum over product pressure -40 to 500 F (-40 to 260 C) 500 ft/min (2.5 m/sec) 7000 ft/min (25 m/sec) 1.000 to 6.000 (25.4 mm to 150 mm)
GF-200 Estimated Gas Consumption

8
Total Gas Consumption (SCFH) = CF x RPM / 1000 Total Gas Consumption (NL/hr) = CF x RPM / 35.31
Consumption Factor (CF)
1.125" (28 mm) 5 1.375" (35 mm) 1.625" (40 mm) 4 1.875" (48 mm) 2.375" (60 mm) 3 2.750" (70 mm) 4.750" (121 mm) 2
0 0 100 200 300 400 500

Seal Chamber Pressure (psig)
Barrier Gas Pressure = Seal Chamber Pressure + 50 psig
GX-200 Gas Barrier Seal
GX-200 Design Features

Patented overall design Stationary carbon faces Mounts completely outside seal chamber
Inboard seal
Outboard seal
Common rotor silicon carbide with APGS


2) Gas is compressed through narrowing spiral grooves 1) Gas enters wide and deep grooves at OD
2 3 1
3) Gas pressure is equalized through circumferential groove

GX-200 Hydraulic Principles

Closing Forces, Fc Opening Forces, Fo
h
Hydrostatic Spring
h 0.0001 (2.54 m)
Fo1 < Fo < Fo2 h1 > h > h2
Static: Dynamic: Upset:
Fo < Fc, seal faces closed Fo = Fc, seal faces separated by gap, h Fo1 < Fc, faces separated by new gap, h1 > h
APGS film stiffness provides stability to upset conditions.

Robust Seal Face Geometries

Rectangular cross sections Tangential drive loads Premium quality materials
Uniform hydraulic and spring load
Flat reaction surface
Designed with custom analytical techniques and proven by extensive correlation testing and field experience, seal face deflections are minimized for reliable performance.
Welded Metal Bellows

Bellows closes off during upset pressure reversals
Interchangeable inboard and outboard capsules No drive torque through bellows
Patented, unitized welded metal bellows eliminate dynamic secondary seals for excellent seal face tracking and solids resistance. With an upset pressure reversal, inboard seal faces contact to contain product.
Solids Resistance
Redirected process solids
Tapered retaining plate ID
Patent pending tapered retaining plate protects bellows ID and seal face region by redirecting process solids toward the seal chamber. The bellows remain clean with no opportunity to hang-up.
GX-200 TARSEx Bushing

Radial vanes throw solids toward the OD Bushing can be separate addon or unitized into cartridge
Sealing dam aids static solids restriction
The TARSEx bushing restricts solids from the seal area by creating a static and dynamic barrier through cooperation with the tapered retaining plate. TARSEx stands for Tapered Annulus Radial Solids Exclusion.
GX-200 Design Features

Dead-ended barrier gas Fits any size seal chamber
Simple installation cartridge seal is 100% static tested at the factory

GX-200 Operating Limits

Product Pressure: Barrier Pressure: Temperature: Minimum Speed: Maximum Speed: Seal Sizes: 200 psig (34.5 bar) 25 psi (2 bar) minimum over product pressure -40 to 500 F (-40 to 260 C) 500 ft/min (2.5 m/sec) 7000 ft/min (25 m/sec) 1.000 to 3.000 (25.4 mm to 76 mm)
GX-200 Estimated Gas Consumption

2.5 Total Gas Consumption (SCFH) = CF x RPM / 1000 Total Gas Consumption (NL/hr) = CF x RPM / 35.31 2 Seal/Shaft Size 1.5 1.125" (28 mm) 1.375" (35 mm) 1.625" (40mm) 1.875" (48 mm) 2.125" (53 mm) 2.375" (60 mm) 2.750" (70 mm)
Consumption Factor (CF)
0.5
0 0 25 50 75 100 125 150 175 200 psig
6 8 Seal Chamber Pressure
10
12
14 bar
Barrier Gas Pressure = Seal Chamber Pressure + 50 psig (4 bar)
Barrier Gas System

Pressure gage
Regulator
Flow meter 5 micron filter
Options:
Pressure alarm Check valve Orifice Booster pump 3-way valve
From gas header

To seal
Application Considerations
Barrier Gas Reliability
Pressure reversals are a primary reason for seal upset Install alarms and emergency backup supply
Fluids with Solids

Gas seals are not slurry seals - product at seal face ID Gas may cause dissolved solids to come out of solution Use bushings to keep solids from seal faces
Reverse Rotation of Pumps

APGS gas seal faces contact when reverse rotated Check piping, shutdown procedures, and motor wiring
Application Considerations
Transient Slow Speed Cycles
Check all equipment cycles for minimum speeds Minimize start and stop parameters on VFDs
Stand-by Pumps
Small static gas leakage can accumulate over time Properly vent pump before start-up
Low Flow / Low Suction Head Pumps

Centrifugal pumps can tolerate 1-2% entrained gas Gas leakage expands in low pressure suction Evaluate gas percentage at lowest pressure point
GX-200 Case History

US Navy - Fuel oil and lube oil vertical pumps
Problem: Single seals on US Navy ships could not maintain zero emissions with dry running at startup and 0.035" axial shaft movement. Solution: Standard GX-200 satisfied all requirements including military shock and vibration testing. Shock testing simulated the shock wave of a conventional or nuclear weapon upon explosion - a 400 lb hammer dropped 5 feet imparting 500 gravities. Vibration testing looked for resonant frequencies from 5-50 Hz at amplitudes up to 0.030 (0.76 mm).
Conclusions
Flowserve Flow Solutions Division GF-200 and GX-200 noncontacting seal face gas barrier seals provide extended pump reliability solutions using proven, patented technologies. Zero product emissions, no contamination of the product, no seal face wear, tolerance of offdesign pump operation, negligible energy consumption, simple installation, and low maintenance requirements add up to low total operating costs.
Conclusions
APGS face design produces a stable gas film for consistent loading, early face separation, high film thickness, and low gas leakage. The GF-200 is a face to face pusher design using LoDrag energized O-rings to minimize secondary seal drag. Fitting only on large bore seal chambers, it is capable of sealing 500 psi (34.5 bar) with a variety of optional materials of construction.
Conclusions
The GX-200 is a common rotor design which eliminates secondary seal drag altogether with Alloy C-276 or Alloy 718 bellows. It fits any seal chamber size by mounting entirely outside and has standard solids tolerance features. Ask Flowserve for information about gas seal solutions for other equipment such as mixers, compressors, or steam turbines where low speed, high pressure, and/or high temperature create difficult sealing environments.
Other Flowserve Gas Seals
Flowserve Gas Seal Products

Product GSD GSL GB-200 GF-200 GX-200 GF-300 GTS GSS Gaspac VRA ML-200 Technology Contacting Wavy Hydropads APGS APGS APGS Wavy Wavy APGS, T-groove Contacting APGS Arrangement Backup Backup Double Double Double Tandem Single All All Single/Double Double Equipment API API ANSI big bore ANSI big bore ANSI small bore API Sundyne Compressor Mixers Mixers Special Feature Emergency containment High duty containment Pressure reversals Low drag O-rings Metal bellows Flashing hydrocarbons High speed, small size High speed, large size Low speed Low speed
Steam Turbine High temperature steam

Flowserve Pump Gas Seals

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Dual Gas Seals for Pumps

Flow Solutions Division

Advantages of Dual Gas Seals

No seal face wear

Protected from off-design pump operation

Flow Solutions Division

Advantages of Dual Gas Seals

Simplified barrier support system

Low total operating cost

Flow Solutions Division

Liquid Seal Support System

Typical Gas Seal Applications

vibration, dry running

Flow Solutions Division

Advanced Pattern Groove System

Shallow Annular Groove

Advantages of APGS Technology

Over 2500 installations in pump gas seal and compressor services