Seal Gas Switchover Control for Contamination-Free Dry Gas Seals
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Solution Overview
Problem
Gas seals in rotating equipment fail due to contamination, leading to process fluid leakage, which can harm people and the environment and cause system shutdowns.
Innovation Solution
A dual-seal gas supply system with sensors and automatically actuated valves that switch between clean and contaminated gases to ensure contaminant-free seal gas is supplied to rotating apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single seal gas supply system is used, then the device complexity is low, but the reliability of seal gas supply deteriorates due to contamination risk
Solution Approach 1:
The seal gas supply system is divided into multiple independent supply lines (first seal gas supply line, second seal gas supply line), each with its own solenoid valve and CPC sensor. This segmentation allows the system to switch between different gas sources, improving reliability by ensuring that if one supply line becomes contaminated, the other can take over without affecting the overall seal functionality.
Solution Approach 2:
The system monitors particle count parameters in the seal gas using CPC sensors and automatically switches between different gas supply lines when contamination thresholds are exceeded. This parameter-based control mechanism enables dynamic adaptation to changing gas quality conditions, maintaining seal reliability while managing system complexity through automated decision-making.
2Measurement precision
If seal gas is monitored continuously, then the measurement precision of contamination is high, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The system incorporates CPC sensors that continuously monitor particle count in the seal gas and provide feedback to the control system. When the particle count exceeds predetermined thresholds, the system automatically triggers a switch between seal gas supply lines. This feedback mechanism enables precise contamination detection while maintaining manageable complexity through automated response protocols.
Solution Approach 2:
The monitoring and control system operates autonomously, with CPC sensors automatically detecting contamination levels and the control system independently making switching decisions between gas supply lines. This self-service capability eliminates the need for manual monitoring and intervention, achieving high measurement precision without proportionally increasing operational complexity.
3Productivity
If automatic switchover between seal gas supplies is implemented, then the productivity is maintained by preventing shutdowns, but the device complexity increases due to multiple valves and control mechanisms
Solution Approach 1:
The system performs preliminary monitoring of seal gas quality using CPC sensors before contamination affects the seal. When particle counts approach critical thresholds, the system proactively switches between gas supply lines before actual seal failure occurs. This preliminary action prevents productivity loss from shutdowns while managing complexity through preventive rather than reactive control.
Solution Approach 2:
The system replaces manual monitoring and manual switching operations with automated electronic control. CPC sensors electronically detect particle counts, and solenoid valves are actuated by electronic control signals based on predetermined thresholds. This substitution of mechanical/manual processes with electronic automation maintains productivity through continuous operation while managing complexity through standardized control architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents process fluid leakage by maintaining a contaminant-free seal gas supply, reducing the risk of environmental harm and system downtime.
Implementation Method 1
a first CPC sensor configured to measure a particle count in the first gas
Implementation Method 2
a first solenoid valve coupled to the first seal gas supply line and having an open position and a closed position, wherein the open position hydraulically connects the first seal gas supply line to the seal gas inlet pipe
Data Source
AI summary
A system includes a seal gas (comprising a first gas or a second gas), a seal gas inlet pipe, a first seal gas supply system, a second seal gas supply system, and a computer processor. The first seal gas supply system comprises a first seal gas supply line configured to transport the first gas from a first seal gas supply to the seal gas inlet pipe, a first solenoid valve, and a first CPC sensor configured to measure a particle count in the first gas. The second seal gas supply system comprises a second seal gas supply line configured to transport the second gas from a second seal gas supply to the seal gas inlet pipe, and a second solenoid valve. The computer processor is coupled to the first CPC sensor, the first solenoid valve, and the second solenoid valve.