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OIL FREE SCREW COMPRESSOR

NONCONTACTING, LOWLEAKAGE SEALS

AUTHORS:
JOHN JUSTAK CYRILLE DOUX

Problem Statement
Existing g oil f free screw compressor p seals are wearing. g Seal wear results in a loss of efficiency (increased power) and ultimately loss of capability to produce required pressure.

Existing Ring seals

Application Requirements
Design Conditions
16500 rpm (female rotor) 22000 rpm (male rotor) Max. temp. 200 deg. C Discharge pressure 41 bar, abs Suction pressure 12 bar, abs Rotor static deflection, , 0.004 4 Dynamic (1/rev) deflection <0.001 Lifetime for seal >20000 hours
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12 bar seal (suction)

Resonant Frequencies: 1st1488 Hz 2nd 2790 Hz 3rd 4088 Hz 4th 7829 Hz

Noncontacting Compliant Hydrostatic Advanced Lowleakage Seal

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12 Bar Seal w/pockets

Hydrostatic pocket pocket seals with square

labyrinth teeth mounted in soft radial support pp to allow 0.004 4 radial movement. Installed with 0.0075 radial clearance

41 bar(discharge) sealbeam & pocket designs

Prediction
Based on Static rig Tests and Analysis

12 bar beam
5shoe design @ 12 bar =10.2 scfm

12 bar Pocket
5pocket design @12 bar = 8.2 scfm

41 bar beam
41 mm beam b @ 41 b bar = 17 scfm f 45 mm beam @ 41 bar = 12 scfm

41 bar Pocket
41 mm pocket @ 41 bar = 14.5 scfm 45 mm pocket @ 41 bar = 15 scfm
( pocket k seals l and d 41bar b seals l were installed ll d with h 0.0075 radial d l gap)
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Discharge/Suction seal Installation

Test results

Beam Seal Test Results

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Posttest Discharge seal area Female rotor / Male rotor

Rotors were coated with dryfilm lubricant prior to runin

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Posttest Female/Male Discharge Seal Closeup

Dryfilm lubricant debris

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Female/Male seal Suction side

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Suction Rotor surface

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Orifice feed residue (suction)

Noted: rustlike material residue in orifice feeds

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Seal shoes, Male/Female suction seal

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Conclusion

; ; ; ;

Seal Test objectives 1 Survive test (limited to no wear) 1. 2. Targeted leakages (meet predictions) 3 Noncontacting during 0.004 3. 0 004 offsets 4. Maintain low leakage thru endurance testing

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Recommendations
Rerun 2 new sets of seals

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Change 5 shoes to 3shoe seals suction, suction wmultiple shoed

seals in series (23) on the discharge side.

Reduce installation gap from 0.004 gap to 0.001 gap & change from 2 tooth to 3 tooth design. This should reduce suction leakage from 10 scfm to 7.
Pocket seals both suction and discharge Modify design to insure pocket pressure feed Decrease installation gap from 0.0075 to 0.0005, this will reduce discharge seals from 15 scfm to 8 scfm and suction seals from 810 scfm to 6 scfm. Silicon Oring temp limit is 230C (450F) Replace problem orings with Kalrez is good to 324C (615F) Remove material from seals to improve p heat conduction
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