Comprehensive Solutions
TESCO Engineering’s facility is equipped with Cutting-Edge Tools and Testing Systems, supported by a team of Highly Skilled Engineers with extensive expertise in dry gas sealing technologies.
We offer solutions for all types of industrial equipment, regardless of OEM, addressing sealing challenges with Precision and Efficiency.
Below is an overview of our Dry Gas Sealing Capabilities.
Dry Gas Seal
The Dry Gas Seal Section is dedicated to the Precise Disassembly and Diagnostic Evaluation of Faulty Dry Gas Seals. Since Dry Gas Seals are highly precise components that require very careful handling during both assembly and disassembly, TESCO Engineering has developed Custom Tools specifically designed for the dismantling and assembly of DGS.
Our technicians conduct a Thorough Assessment of the seal’s structural and functional integrity, followed by methodical deconstruction to evaluate wear, material degradation, and damage caused by gases and pressure during operation.
A root cause failure analysis is Performed In Compliance with API 692 Standards to identify performance deficiencies. Each component is Serialized for Traceability, and Comprehensive Technical Documentation, including failure reports and engineering recommendations, is provided. These recommendations offer targeted solutions for Optimizing Seal Reliability, Performance, and Lifecycle Management.
Convex Lapping
TESCO Engineering is equipped with large 40-inch lapping cast tables and 40-inch polishing copper tables. These facilities are Capable Of Lapping and Polishing Carbon, Silicon Carbide (SiC), and Tungsten Carbide (TC) faces with an outer diameter of up to 400mm, utilizing the method of convex lapping.
Laser Texturing
Our Advanced Laser Texturing System performs High-Precision Seal Face Lift-Off on components up to 400mm in diameter. It utilizes a high-frequency Laser pulse up to 1000 kHz for rapid, accurate marking.
Capable of creating various texture geometries —constant depth, narrow profile, variable depth, and wavy—the system supports Unidirectional and Bidirectional Texturing, along with complex 3D Curvilinear Patterns. Integrated with CAD systems, it Ensures Precise Execution, with High-Speed Motion Capabilities of 300 mm/s (X/Y) and 500 mm/s (Z), significantly minimizing cycle times and maximizing efficiency.
Spin Testing
Most Rotating Seal Face Materials are made from powder-based substances, it is crucial to verify the Structural Integrity of the seal faces. This is done by Individually Spin-Testing the seal faces at speeds significantly higher than their intended operational conditions.
Speed-related failures are typically stress-induced, so the overspeed test is usually conducted at 122% of the Maximum Critical Speed (MCS), and Maximum Continuous Operating Speed (MCOS) up to 24,500 RPM. The in-house spin test machine developed by TESCO Engineering can accommodate seal face measuring up to Ø480mm and reach a maximum RPM of 30,000. It is equipped with a Fully Automated Control Panel, ensuring efficient and precise operation.
Dry Gas Seal Head Tester
The Dry Gas Seal Dismantling Section is dedicated to the Precise Disassembly and Diagnostic Evaluation of Faulty Seals. Since Dry Gas Seals are Highly Precise Components that require very careful handling during both assembly and disassembly, TESCO Engineering has developed Custom Tools specifically designed for the dismantling and assembly of DGS.
Our technicians conduct a Thorough Assessment of The Seal’s Structural and Functional Integrity, followed by methodical deconstruction to evaluate wear, material degradation, and damage caused by gases and pressure during operation.
A root cause failure analysis is performed in compliance with API 692 Standards to identify performance deficiencies. Each component is Serialized For Traceability, and Comprehensive Technical Documentation, including failure reports and engineering recommendations, is provided. These recommendations offer targeted solutions for Optimizing Seal Reliability, Performance, and Lifecycle Management.
Dry Gas Seal Rotor Balancing
Dry Gas Seal Rotating Assemblies must be balanced to ISO 1940-1, Grade 2.5 or better to ensure Optimal Performance and Prevent Premature Failure. Any modification or replacement of rotating components requires a complete rebalancing of the assembly.
TESCO Engineering’s Dry Gas Seal Rotor Balancing Machine is designed to handle Components With a Maximum Diameter Of 600 mm, a Length Of 1 Meter, and a weight range of 16 to 160 kg. It operates within a belt-driven RPM range of 200 to 2800, providing Precise Control for Accurate Balancing.
The machine adheres to ISO balancing tolerances from G0.4 to G100, Ensuring Minimal Vibration and Optimal Performance. Fully automated, it offers high efficiency and precision with minimal human intervention.
Dynamic Test Rig
TESCO Engineering's cutting-edge In-House Dry Gas Seal Dynamic Testing Facility exemplifies Advanced Engineering Capabilities, meticulously designed to evaluate the Performance and Reliability of dry gas seals under a wide array of operational conditions. This state-of-the-art test rig
The facility is equipped with Precision Instrumentation and Sophisticated Data Acquisition Systems that monitor critical performance parameters such as leakage rates, friction coefficients, thermal stability, pressure, temperature, rotational speed, and vibration, ensuring comprehensive and reliable test results.
The dynamic testing process adheres to API 692 standards and is Fully Automated to accommodate various seal configurations, including single, double, and tandem seals. Additionally, both the drive motor and test cell are equipped with specialized chillers to maintain Optimal Thermal Conditions, while a lube oil system ensures smooth operation of the motor bearings.
The facility’s ability to simulate compressor start-up and shutdown processes further enhances its testing fidelity. By offering Live Dynamic Test Witnessing via both a dedicated gallery and remote web viewer, TESCO Engineering Ensures Real-Time Oversight. This rigorous testing methodology ensures the dry gas seals’ adherence to the stringent performance and reliability standards demanded by critical industries such as oil and gas, power generation, and chemical processing, effectively minimizing downtime, Reducing Operational Costs, and Maximizing The Reliability of Rotating Equipment and Turbomachinery.
Manufacturing & Refurbishment of Dry Gas Seals (API 692)
Application
- Centrifugal Compressors
- Turboexpanders
- Gas Turbine Compressors
- High-Speed Integrally Geared Compressors
Types
- Single dry gas seal
- Double dry gas seal
- Tandem dry gas seal without intermediate labyrinth
- Tandem dry gas seal with intermediate labyrinth
- Tandem dry gas seal with prepositive labyrinth
Configuration
- Single seal
- Dual tandem arrangement
- Dual back-to-back arrangement
- Dual face-to-face arrangement
- Dual pusher containment seal
- Dual pusher non-contacting seal
- Dual bellow non-contacting seal
Scope of Work
- Inspection
- Failure Analysis or Root Cause Analysis
- Application Engineering
- 3D Scanning
- Fitment checking
- Dry gas seal selection
- Dry gas seal support system selection/filtration
- Material selection
- CFD analysis
- Detail Product Engineering
- GA drawing
- Bill of material
- Manufacturing
- Soft parts (carbon, silicon)
- Adaptive parts
- Heat treatment
- Laser texturing non-contacting seal
- Lapping & Assembly
- Integrity testing as per API 682 standard
- Qualification testing as per API 682 standard – only Category 3 & Engineered seals
- Packing with protective box
Partner with the Industry Leader
Need innovative engineering solutions? Reach out to TESCO Engineering for state-of-the-art products and expert support in the petrochemical and specialized industries.
Request a solution