Step by Step Dry Gas Seal Installation & Remove

DGS change-out activities are not a frequent event at site or

workshop. If you're reading this, I believe you have had or will have
experience in DGS installation and removal activity.
Normally, the DGS is installed, operated, maintained, removed or
repaired by authorized and trained personnel only. Failure to follow the
correct procedure will lead to seal malfunction or in worst case scenario,
the seal will be damaged.
The purpose of this writing is to share with the related technical
personnel out there on my way of practice on mounting and dismounting
of DGS from the compressor. This might be your checklist in planning
for next change-out activities.

*** Note: Different equipment will have different

configuration on seal fixation, so please study and evaluate the
situation (refer to manufacturer technical documents). ***

General Safety Note prior to installation or removal activities:

- Carefully study the installation drawing.
- Prioritize your safety.
- Pressure within compressor casing must be atmospheric without
differential pressure or vacuum.
- Make sure no hazardous or toxic gases/liquids present otherwise
decontamination procedures must be carried out.
- Kindly confirm with Electrical Team if the compressor casing
and shaft should be adequately earthed.
Preparation (Compressor)
Confirm the availability of special tools for DGS mounting and
dismounting.

- Backflush all pipe work to seals.

- Confirm the cleanliness of filters and they should be in excellent
condition.
- Clean the compressor’s cavity and shaft at which the DGS fits.
 - Check leading edge chamfers and the bore for burrs and sharp
edges that could damage the seal during installation.
- Find the rotor central running position (radial and axial).
- Ensure that the shaft is angularly aligned with the casing such
that any pin positions, keys, bolts or other features on the shaft and
casing are aligned with the corresponding features on DGS.
- Take a reference dimension (casing to rotor).
 - If any, check the installation drawing for any shims or spacers
requirement, calculate, alter and prepare these items accordingly
(sometimes these parts are installed after fitting in the DGS).
- With a proper method, slide in the dummy shaft into position
(normally provided by compressor manufacturer together with special
tools).
 - Lock the shaft axially at the drive end to prevent movement while
fitting the DGS.
 - It is suggested to mark the slots/pins on the shaft and
dummy/fitting sleeve as well as the vertical line on the housing.

- Apply a film of anti-seize compound onto the compressor shaft

and bore, sparingly.

Preparation (DGS)
- Check for correct shaft rotation.
- Check the cleanliness of the DGS. Normally up to this stage, the
DGS should remain packed (as supplied by OEM/ISP).
- Examine all the secondary seals (polymers or O-rings) for any
cuts or crushes. Should there is any damage, replace with new one as
supplied in installation kits.
 - Check the tolerance rings (applicable on certain designs) for any
damages and crushes. Replace accordingly if required.
- Exercise the DGS (support the rotating parts, remove the
installation plates, apply even hand pressure to seal stator, slowly release
the pressure once fully compressed, repeat minimum four times).
Caution: The stationary parts shall not be rotated during the procedure or
else the installation plate cannot be fitted or will be wrongly installed.
- Mark the keyways/pins positions on the installation plates.

- Measure the DGS length and check the working length. Normally
the tolerance on the installed working length is about ± 0.5 mm.
 - Sparingly apply the anti-seized compound on the DGS bore and
tolerance rings (if any).
- Lightly lubricate the outside diameter O-rings with silicon grease.
No lubrication on the polymer seals.

Fitting The DGS

- Use appropriate lifting equipment to position the gas seal on to
the shaft.
- Jack or lift the compressor’s shaft to radial running position using
appropriate method.
- Align any markings made for features (keyways, pins, slots, etc.)
within the seal with corresponding features sited within the compressor
casing and shaft.
 - Remove the lifting equipment.
- Push the DGS assembly for the first few mm movement.
- Using the fitting tools provided by the compressor manufacturer
(or suitable studding and jacking bar), carefully and evenly jack the gas
seal assembly into position by applying jacking force to the seal stator.

- When the gas seal is fully engaged home, the markings for DGS
and compressor’s casing should match and reference measurement is
still the same as there should be correct clearances.
- Remove all fitting tools.
- Remove the seal installation plates and their screws as per the
installation drawing.
 - Secure the seal stator into the compressor casing and the seal
rotor to the shaft using the ancillaries and locking devices as shown on
the installation drawing or if not shown as per the compressor’s manual
and documentation.

Remember
Take your time.
Constantly check seal is going in squarely.
Ensure all pins / keys are engaged.
STOP if anything feels tight.

DGS Removal
- Carefully study the installation drawing.
- All devices that secure the gas seal stator or rotor to the
compressor casing or shaft must be removed.
- Install the seal installation plates as identified on the installation
drawing.
- Install the special tools (removal purpose) as provided by the
compressor manufacturer.
- Fit any required lifting equipment.
- If any, fit in the dummy sleeve on the compressor’s shaft.
- Using these tools extract the gas seal cartridge from the
compressor housing by applying a jacking force to the seal stator.
- Using lifting equipment, remove the seal cartridge from the shaft.
Remember
Lubricants are not “fresh”.
Seal may have contaminants / dirt.
More difficult to remove than to install.
Greater care required.
The End.

"Mastering DGS Technology, Customizing DGS Refurbishment"