CASE STUDY: GAS COMPRESSOR SERVICE

SERVICE OFFERING: J
 OHN CRANE TURBOMACHINERY SERVICES
R E L I A B I L I T Y A N D E N G I N E E R I N G C O N S U LTA N C Y

John Crane Solves Gas Compressor

Reliability Problem for East Coast
U.S. Electric Power Company

BAC KG R O UND
John Crane reliability
Industry: Electric Generation and
Natural Gas and engineering
Site: Combined-Cycle, Electric experts performed a
Generation Plant top-to-bottom root
Location: East Coast, United States cause analysis on the
End Product: Electricity mechanical and
operational functions
of the compressor.

CU S TO ME R N E E D HI G HLI G HT S
• The reliability of the high-speed (600 psi / 41 bar g) compressor, one of • A large U.S. power company
three combined-cycle trains at one of the United States largest power found that a high-speed, combined-
conglomerates, located on the East Coast, was critical to a major cycle compressor at one of its
metropolitan area generation stations had unexplained
• Recently the generation site discovered one of its 35,000 to 45,000 rpm reliability issues linked to DGS failure
gas compressors experienced unexplained dry gas seal (DGS) failures • Design issues in the compressor caused
• Conversely, initial John Crane analysis showed the seals were performing high frequency axial movement causing
flawlessly and the incoming gas composition was acceptable the DGS-related disruptions

• For years, John Crane seals on the low- and high-pressure sections of • On recommendation from a turbo-
the multistage bull gear compressor operated without interruption or machinery consultant, the compressor’s
needing repair gears were redesigned, and slight
modifications made to the DGS
• The power plant looked to John Crane for a complete review of the
mechanics and overall operation of the compressor to solve the seal • After nearly two years, the compressor
failure question remains in operation and the John Crane
seals have performed perfectly

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CASE STUDY: GAS COMPRESSOR SERVICE

APPL I CAT I ON RE S ULT S

• A team of John Crane reliability and engineering experts, from
the company’s Turbomachinery Services, conducted an exhaustive • Since early 2018, when the
root cause analysis on the mechanical and operational functions improvements were made, both
of the compressor John Crane DGS have operated
without interruption
• After verifying the existing John Crane seals and incoming gas
composition were not the cause of the failures, the analysis pointed • The high frequency axial movement
to high frequency axial movement and an unexpected high axial and an unexpected high axial
runout at the sealing faces during operation runout at the sealing faces during
operation have been eliminated
• After presenting the findings to the power company’s management,
the John Crane team called in a well-respected turbomachinery • The plant has stocked additional
consultant to confirm the findings John Crane replacement DGS
to ensure reliability and low
• The consultant concluded that the high frequency axial movement cost of ownership
was linked to a design flaw in the compressor that lacked a thrust
bearing to dampen rollers
• The consultant also made recommendations to the John Crane
team to make slight modifications in the DGS design to help it
correct the excessive axial runout

S O LUT I ON
• Following the recommendations of the turbomachinery consultant,
the compressor was redesigned with a new gear system
• A thrust bearing was installed in the compressor to reduce and
control the high frequency axial vibration
• The two John Crane DGS installed in the compressor were modified,
including changing the mating ring material from tungsten to silicon
carbide to improve the rotor dynamics of the units
• The control system’s transmitter was adjusted to improve gas flow
• Back pressure was introduced to compensate for the axial movement
and provide cushioning and dampening across the seal faces
• The team also increased the buffer gas temperature close to the seal
to avoid process condensate forming at the seal faces in extreme
weather conditions

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