PROBLEMS WITH GLAND PACKINGS

1. 2. 3. 4. 5. 6.

Excessive power consumption, More plant downtime, Atmospheric pollution, Effect on plant life, Loss of pumpage High maintenance cost.

II) 1)

INSTALLATION OF MECHANICAL SEAL

Lubricate shaft/sleeve and wedge/ o ring to assist installation. Note special care for EPR o ring should be taken by using glycerin / soap water / edible oil only. 2) Use sound judgement during installation. Never force parts during fitment. 3) Bleed all lines and seal chamber to prevent any air lock. 4) Connect all cooling and buffer fluid as per G.A. drawing. 5) Open all cooling and buffer fluid valves of the seal prior to start up of the equipment. 6) Mechanical seal should be pressurized prior to the equipment. 7) Maintain buffer fluid pressure 2kg/cm2 more than the reactor pressure. 8) Height of the thermosyphon should be 1.5 to 2 meters from the seal inlet to outlet of the thermosyphon pot. 9) Fill the buffer fluid (I.e. process compatible fluid or oil) in the thermosyphon system above the level of the inlet port of the buffer fluid )level can be seen through gauge glass). 10) Ensure the flow of cooling water 5-6 LPM in the cooling coils of thermosyphon system. Contd..

II) 11) 12)

INSTALLATION OF MECHANICAL SEAL

Contd..

Monitor the pressure and level of buffer fluid in the thermosyphon system. In case of leakage, buffer fluid pressure and level will go down. Check for seal failure :a) Inboard seal leakage Buffer fluid will go in the vessel b) Outboard seal leakage Buffer fluid will leak from the leak detection port. Lubricate the seal bearing periodically (greasing can be done on monthly basis). Periodical checking of bolts on the drive collar and pad plate nuts of the seal.

14) 15)

PREPARATION / CHECK POINTS FOR SEAL INSTALLATION

1) 2) KEEP THE AREA CLEAN CHECK THE PUMP PARAMETERS ARE WELL WITHIN LIMITS DO NOT ASSUME 3) OPEN THE SEAL PACKET JUST BEFORE INSTALLATION 4) ENSURE THAT WHEN YOU ARE INSTALLING SEAL OTHER PERSON IN SURROUDING DOES NOT CLEAN HIS AREA (SPECIALLY WITH COMPRESSED AIR) 5) ALL SHARP EDGES TO BE ROUNDED / DE BURRED 6) MAINTAIN SURFACE FINISH AT ELASTOMER AREA AS PER RECOMMENDATION 7) NO OIL WITH EPR ELASTOMERS 8) SEALS ARE DELICATE DONT USE HAMMER 9) USE GENUINE SPARES ONLY DO NOT MIX UP SPARES OF SAME MAKE TYPE / SIZE FOR DIFFERENT APPLICATION 10) DIRECTION OF SPRING FOR SINGLE SEAL

END PLAY : 0.1 mm MAX RADIAL MOVEMENT/ SHAFT WHIP : 0.08 mm MAX SHAFT RUNOUT : 0.08 mm MAX STUFFING BOX SQUARENESS OR : 0.08 mm MAX FOR 3000. rpm PERPENDICULARITY : 0.005 mm FOR 100,000 rpm CONCENTRICITY OF STUFFING : 0.13 mm MAX BOX BORE FOLLOWING PROBLEM MAY ARISE IF ABOVE ARE NOT IN LIMIT:1) SHAFT / SLEEVE FRETTING (MORE WITH TEFLON) 2) OVER COMPRESSION / UNDER COMPRESSION OF SEAL 3) CHATTERING / CHIPPING OF CARBON 4) PUMP VIBRATION 5) EXCESSIVE WEAR, DAMAGE TO SLIDING ELASTOMER 6) EXCESSIVE WEAR OF MATING FACES 7) WOBBING OF SEAL FACES 8) ERRACTIC FACE WEAR 9) THROTTLE BUSH, THROAT BUSH & IMPLLER WEARING OR INTER STAGE BUSH SEIZING.

TEN POINTS FOR SUCCESEFUL SEAL INSTALLATION. 1. THOROUGH READING AND FULL UNDERSTANDING OF SEAL INSTALLATION DRAWINGS IS THE KEY TO PROPER SEAL INSTALLATION. WORDS ARE AS IMPORTANT AS DIMENSIONS AND DIMENSIONS ARE AS IMPORTANT AS WORDS.

2.

KNOW THE MATERIALS YOU ARE WORKING WITH. CRITICAL SEAL COMPONENTS ARE OFTEN MADE FROM NON-DUCTILE SUBSTANCES THAT WILL CHIP, CRACK OR OTHERWISE BREAK, IF CARELESSLY HANDLED.
RESPECT THE PRIMARY SECONDARY SEALING AREAS. A LOT OF TIME HAS BEEN SPENT IN MAKING THE PRIMARY SEALING AREA FLAT AND SMOOTH. DONT SCRATCH OR, NICK, HANDLE AND GET THOSE AREAS DIRTY. SOMETIMES EVEN FINGERPRINT CAN CAUSE A SEAL TO LEAK. REMEMBER, THAT RUBBER, PTFE AND GASKETS CAN EASLY BECOME CUT TORN WITHOUT TOO MUCH ATTENTION TO THEIR WELL BEING. MAKE SURE THAT THE SHAFT SLEEVE IS FREE OF BURRS AND SHARP EDGES. IT MUST BE FINISHED TO THE APPROPRIATE SMOOTHNESS. IN CERTAIN CASES, SPECIFICATIONS WILL BE CALLED OUT ON THE INSTALLATION DRAWING. Contd..

3.

4.

ENVIRONMENTAL CONTROLS

TEN POINTS FOR SUCCESEFUL SEAL INSTALLATION. 5.

Contd..

ESTABLISH YOUR SEAL INSTALLATION REFERENCE POINTS AND MARK THEM CLEARLY AND PERMANENTLY IN THE EQUIPMENT. ALL SEAL INSTALLATION DRAWINGS GIVE THE REFERENCE DIMENSIONS. 6. USE SOUND JUDGEMENT DURING THE INSTALLATION. DONT OVER TIGHTEN BOLTS, ALIGN OR INSTALL WITH A HAMMER OR, IN ANY OTHER WAY, APPLY ANYTHING, EXCEPT PROFESSIONAL WORKMANSHIP TO THE JOB. 7. PIPING IS IMPORTANT TOO. INCORRECT CONNECTIONS, REVERSED FLOWS, DEAD ENDED LINES, ETC. WILL CAUSE PREMATURE SEAL FAILURE. DONT MIX UP THE WATER JACKET PORTS WTH THE SEAL CIRCULATION PORTS. TIME SPENT IN CAREFUL PIPING WILL BE TIME SAVED. 8. BLEED ALL THE GASEOUS ENTRAPMENT FROM THE SEAL CAVITY BEFORE START UP. IF YOU DONT, THE SEAL CAVITY MAY VAPOUR LOCK AND THE SEAL WILL BURN UP. 9. MAKE SURE VALVES ARE OPEN SO THAT THE SEAL IS ENSURED OF A POSITIVE FLOW OF LIQUID AT ALL TIMES. IN THOSE CASES WHERE THE SEALS REQUIRE AUXILIARY LINES, FLOWS HEATING OR COOLING BE SURE THAT THE SEAL IS PREPARED FOR OPERATION BEFORE THE PRIMARY EQUIPMENT GOES ON STREAM. 10. TURN THE EUIPMENT ON, AND ENJOY MAINTENANCE-FREE EQUIPMENT OPERATION.

APPLICATION OF MECHANICAL SEALS

1. 2. SEALINGS OF ALL TYPES OF GASES SEALINGS OF ALL TYPES OF LIQUID OF FOLLOWING CATEGORY A)ABRASIVE B)VISCOUS C)CORROSIVE D)TOXIC E)HAZARDOUS F)CRYSTALLIZING H)ALKALINE. SEALING OF ALL TYPES OF SLURRY MEDIA. SEALING OF LIQUIDS FROM CRYOGENIC ( SUB ZERO TEMP ) TO 4500 C TEMP SEALING OF LIQUIDS AT VACUM TO 100 BAR PRESSURE SEALING OF AGITATOR SHAFTS ( BOTTOM ENTRY, TOP ENTRY, SIDE ENTRY ). SEALING OF VARIOUS ROTARY EQUIPMENTS LIKE PUMPS, COMPRESSORS, MIXERS, TURBINES, GEAR BOXES, BLOWERS, ROTARY JOINTS, STATIC EQUIPMENTS LIKE VALVES. SEALING OF ROTARY EQUIPMENTS AT HIGH SPEED UPTO 20,000 RPM. SEALING OF MEDIA WITH POOR LUBRICATION PROPERTIES, HIGH FREEZING POINT LIQUIDS LIKE TAR DMT ETC. SEALING OF RADIOACTIVE WATER AND HEAVY WATER USED IN NUCLEAR POWER PLANTS.

3. 4. 5. 6. 7.

8. 9. 10.

INTERNALLY MOUNTED SEAL

EXTERNALLY MOUNTED SEAL

INTERNALY MOUNTED SEAL

1) 2) ALL PARTS COME IN CONTACT WITH THE MEDIA, HENCE THEY HAVE TO BE MADE OF COMPATIBLE MATERIAL. DIRTY PARTICLES ARE THROWN AWAY BECAUSE OF CENTRIFUGAL FORCE, HENCE THEY DONT DISTURB THE SEAL FACES. AS THE FACES WEAR, THE SECONDARY ELASTOMER MOVES TOWARDS CLEAN SURFACE. MORE LIFE & RELIABILITY. FLUID PR. HELPS SPRING FORCE, HENCE THE SEAL CAN BE USED FOR HIGHER PR. IF SEAL LEAKS, IT DOES NOT SPRAY OUT, BUT CAN BE COLLECTED THROUGH DRAIN PORT TO SAFER PLACE. NO ACCESS TO SEAL, HENCE NO ADJUSTMENTS ARE POSSIBLE. THE SEAL GETS ACCOMODATED INSIDE THE ST-BOX.

3)

4) 5) 6) 7)

EXTERNALY MOUNTED SEAL

1) 2) 3) 4) 5) 6) 7) 8) SUITABLE FOR EXTREMELY CORROSIVE LIQUIDS LIKE ACIDS WHERE SUITABLE MATERIAL IS NOT AVAILABLE. THE SEAL IS ACESSIBLE, HENCE ANY ADJUSTMENT IN SEAL WORKING LENGTH IS POSSIBLE. ADVANTAGEOUS WHERE FOOD PRODUCTS ARE BEING PUMPED AND CLEANLINESS IS OF UTMOST IMPORTANCE. AS THE FACES WEAR, SEAL RING MOVES TOWARDS DIRTY AREA. SOME AMOUNT OF SPRING FORCE IS EATEN AWAY BY LIQUID PRESSURE HENCE CANNOT BE USED FOR HIGH PR. DIRTY HEAVY PARTICLES TRY TO ENTER FACES BACAUSE OF CENTRIFUGAL FORCES. IF SEAL LEAKS, THE LEAKAGE IS SPRAYED OUT, UNLESS SPECIAL PROVISIONS ARE MADE. IT REQUIRES MORE SPACE OUT SIDE THE ST-BOX..

SINGLE SPRING SEAL

1) 2) 3) 4) 5) 6) THIS SEAL IS MOST SUITABLE FOR DIRTY MEDIA. THICKER SPRING WIRE DIA PROVIDES MORE CORROSION ALLOWANCE. MORE TOLERANCE ON OPERATING LENGTH OF SEAL HENCE EASY FOR INSTALLATION. FOR EACH SHAFT DIA DIFFERENT SPRING IS REQUIRED. THIS CAN BE USED FOR C.W. / C.C.W ROTATION. THE SPRING IS NOT SUBJECTED TO THE TORSIONAL LOAD, HENCE NO SLIPPING OF SPRING. BETTER PERFORMANCE & RELIABILITY.

MULTISPRING SEAL
1) SMALL SPRINGS ARE SPREAD OVER CIRCUMFERENCE EQUALLY THIS GIVES UNIFORM PRESSURE TO FACES. THE SEAL IS NOT SUITABLE FOR DIRTY LIQUIDS AS SPRINGS GET CLOGGED UP RESULTING INTO SEAL HANGUP. COMPACT, HENCE LOWER STUFFING BOX DEPTH IS ACCEPTABLE FOR DIFFERENT SIZES OF SEALS SAME SPRING CAN BE USED ONLY QTY. WILL VARY. WIRE DIA IS VERY SMALL. HENCE NO CORROSION ALLOWANCE IS AVAILABLE. WE HAVE TO GO FOR HIGHER ALLOYS LIKE HAST-C, ALLOY-20 ETC. COST OF MANUFACTURING IS HIGH BECAUSE OF MANY OPERATIONS, INVOLVED.

2)

3) 4) 5)

6)

BACK TO BACK SEALS

BACK TO BACK SEALS

1) TO SEAL MEDIA HAVING FOLLOWING PROPERTIESA) LOW LUBRICITY, B) TOXIC, HAZARDOUS GASES / LIQUID, C) SLURRY MEDIA, D) ABRASIVE & CORROSIVE MEDIA. IN CASE I/B SEAL FAILS, BARRIER FLUID BEING AT HIGHER PRESSURE, IT WILL MIX INTO PUMP MEDIA. METALLIC BELOW SEALS SHOULD NOT BE RECOMMENDED FOR BACK TO BACK ARRANGEMENT. PLEASE REMEMBER BARRIER FLUID PRESSURE MUST BE MAINTAINED AT 1 TO 1.5 kg / CM2 HIGHER THAN ST. BOX PRESSURE. IF ABOVE CONDITION CANNOT BE SATISFIED THEN I/B SEAL MUST BE REVERSE BALANCED. API PLAN 53/54 IS RECOMMENDED. AS PER API, FORCED CIRCULATION OF BARRIER FLUID IS MANDATORY EITHER BY PROVIDING PUMPING RING SYSTEM OR BY EXT. PUMP. SINCE THE WHOLE SYSTEM HAS TO WITHSTAND HIGH PRESSURE, SYSTEM COST IS MORE. SELECTION OF BARRIER FLUID IS USERS RESPONSIBILITY AS PER API.

2) 3)

1) 2) 3) 4) 5) 6)

TANDEM SEALS
(FACE TO BACK)

TANDEM SEALS
1) 2) 3) 4) 5) SECOND SEAL AS A SAFETY SEAL. IF QUENCH MEDIA IS EXPENSIVE, THEN TO SEAL THAT MEDIA. WHEN IT IS NOT ACCEPTABLE THAT BARRIER FLUID SHOULD MIX WITH THE PUMP MEDIA. TO SEAL MEDIA AT VERY HIGH PRESSURE BY SPLIT PRESSURE METHOD. FOR MEDIA WHICH HAVE LOW VAPOUR PRESSURE. PLEASE REMEMBER 1) BARRIER FLUID CIRCULATION NEED NOT BE AT HIGH PRESSURE EXCEPT FOR HIGH PRESSURE SPLIT PRESSURE APPLICATION. AS PER API, NOW IT IS MANDATORY TO HAVE POSITIVE CIRCULATION OF BARRIER FLUID EITHER BY PROVIDING PUMPING RING SYSTEM OR BY A SEPARATE PUMP. API PLAN 52 / 53 IS RECOMMENDED.

2)

3)

SEAL FLUSHING

1) 2) 3) 4)
5)

TO PROVIDE LUBRICATION. TO DISCIPATE HEAT EFFECTIVELY. TO KEEP LIQUID IN TURBULANCE. TO MAINTAIN STUFFING BOX PRESSURE ABOVE VAPOUR PRESSURE. TO KEEP SLURRY AWAY FROM SEAL (PLAN 32)

SEAL QUENCHING
1) 2) 3) 4) 5) TO KEEP ATMOSPHERE AWAY FROM SEAL FACES TO PROVIDE ADDITIONAL HEAT DISCIPTION. TO CARRY AWAY LEAKED LIQUID TO SAFER PLACE TO KEEP THE AREA BELOW SEAL FACES CLEAN. TO HELP INCREASED LUBRICATION TO SEAL FACES.

ADDITIONAL ADVANTAGES
FLUSHING A) IT PREVENTS FORMATION OF A VAPOUR TRAP AROUND SEAL FACES IN CASE OF VOLATILE LIQUIDS. B) IT DOES NOT ALLOW ABRASIVES TO REACH FACES. C) IT PREVENTS ACCUMULATION OF SEDIMENTS ON SEAL AREA. QUENCHING A) IT CARRIES AWAY LEAKED PRODUCT. B) IT PREVENTS LEAKED PRODUCT COMING IN CONTACT WITH ATMOSPHERE C) IT COOLS THE SEAL FACES FROM INSIDE. D) IT POVIDE LUBRICATION TO FACES WHEN ST. BOX IS UNDER VACUUM.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 01
Integral recirculation pump discharge to seal chamber. Recommended for clean pumpage only. Care must be taken to insure that integral recirculation is sufficient to maintain stable face conditions.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 02
Dead ended stuffing box with no circulation of flushed fluid. Jacketed stuffing box and throat bushing required when specified. Connection Fl plugged for possible future connection.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 11 Recirculation form pump discharge through a flow control orifice to the seal. The flow enters the seal chambers adjacent to the mechanical seal faces, flushes the faces, and flows across the seal back in to the pump suction. Connection Fl for flushing inlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 13 Recirculation form pump seal chamber through a flow orifice and back to pump suction. Mainly applicable for vertical pumps. Connection FO for flushing outlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 21

Recirculation from pump discharge through a flow control orifice and heat exchanger, then in to the seal chamber. Connection Fl for flushing inlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 23A

Recirculation from pumping ring in the seal chamber through a heat exchanger and back in to the seal chamber. This plan can be used on hot application to minimize the heat exchanger by cooling only the small amount of liquid that is recirculated. Connection Fl for flushing inlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 23B

Recirculation form Pumping ring in the seal chamber through a heat exchanger and back in to the seal chamber. This plan can be used on hot application to minimize the heat load on the heat exchanger by cooling only the small amount of liquid that is recirculated. Connection Fl for flushing inlet and FO for flushing outlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 31 Recirculation form pump discharge through a cyclon seperator delivering the clean fluid to the seal chamber. The abrasive solids are delivered to pump suction line. Connection Fl for flushing inlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 32

Flush is injected in to the seal chamber from on external source. Care must be exersized in choosing in choosing a proper source of seal flush and to avoid contamination of the fluid being pumped with the injected flush. Connection Fl for flushing inlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 41

Recirculation from pump discharge through a cyclon seperator delivering the clean fluid to a heat exchanger cooler and then to the seal chamber. The solids are delivered to the pump suction. Connection Fl for flushing inlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 51

External reservoir providing dead ended blanket for fluid to quench connection of the gland. Connection Fl for flushing inlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 52

External reservoir providing buffer fluid for the board seal. During normal operation, circulation is maintained by an internal pumping ring. The reservoir pressure is less than seal chamber. Connection Fl for flushing inlet, Bl for banner inlet and BO for barrier outlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 53

Pressurized external barrier fluid reservoir supplying clean fluid to the seal chamber. Circulation is by internal pumping ring. Reservoir pressure is greater than the process fluid being sealed. Connection Bl for barrier inlet and connection BO for barrier outlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 54

Pressurized external barrier fluid reservoir or system supplying to the seal chamber. Circulation is by an external pump or pressure system. Reservoir pressure is greater than the process pressure being sealed. Connection Bl for barrier inlet and connection BO for barrier outlet.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 61

Plugged connection for the purchasers use. Typically this plan is used when the purchaser is to provide fluid to an external sealing device such as water, gas or stream.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 62 External source providing a quench. The quench may be required to prevent solids from accumulating on the atmospheric side of the seal. Typically used with a close clearance throttle bush. Connection Fl for flushing inlet if required.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 71 Tapped connections for purchases use. Typically this plan is used, when the purchaser may use buffer gas in the future

FLUSHING PLANS AS PER API 682

Seal Flush Plan 72

Externally supplied gas buffer for arrangement 2 seals. Buffer gas may be used alone to dilute seal leakage or in conjunction with plan 75 or 76 to help sweep leakage in to close connection system. Pressure of buffer gas is lower then process side pressure of inner seal.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 74

Externally supplied barrier gas used to positively prevent fluid from leaking to atmosphere. Pressure of barrier gas is higher than process side of inner seal. Venting of seal chamber may be required prior to start up and operation to avoid the collection of gas in the pump.

FLUSHING PLANS AS PER API 682

Seal Flush Plan 75 Containment seal chamber drain for condensing leakage on arrangement 2 seal. Pump fluid condenses at ambient temperatures. Valves to be installed for operator use, relative to ground clearance and other obstructions.

FLUSHIING PLANS AS PER API 682

Seal Flush Plan 76

Piping / instrument harness shall be supported from overhead structure or side such that no strain is put on tubing connected to seal gland. Containment seal chamber drain from noncondensing leakage on arrangement 2 seal. pump fluid dose noncondensing at ambient temperatures.

SEAL FAILURE DUE TO :-

UNSTABLE OPERATING CONDITIONS

FAULTY INSTALLATION

59 %
24 %

IMPROPER SEAL SELECTION

MISC OTHER CAUSES

9%
8%

SEAL FAILS DUE TO : Coupling Misalignment Pump Cavitation Air Entrainment Over Pumping Excessive Heat Bearing Failure Pipe Strain Impeller Shaft / Sleeve Stuffing Box