Planes API

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Installation & Troubleshooting Guidelines for API Seal Flush Plans
API Piping Plans

Review of Piping Plan Schematics
Installation & Troubleshooting Guidelines for API Seal Flush Plans-Introduction End face shaft seals consist of
A set of faces, one flexibly mounted and one rigidly mounted springs or metal bellows to provide flexibility secondary sealing members one of which must provide flexibility adaptive hardware to hold the parts in an assembly
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Installation & Troubleshooting Guidelines for API Seal Flush Plans-Introduction

Springs Secondary Sealing Members Secondary Sealing Members
Adaptive Hardware
Dynamic Secondary Sealing Member
Flexibly Mounted Face
Rigidly Mounted Face
Installation & Troubleshooting Guidelines for API Seal Flush Plans-Introduction The faces provide for the dynamic sealing of the fluid in the pump The flexibly mounted face moves during pump operation to maintain a narrow sealing gap to the rigidly mounted face

The size of the sealing gap must be carefully controlled
To provide for acceptable leakage of the pump product to atmosphere To provide load support to the faces as well as lubrication to prevent face damage and excess wear so that adequate seal life is maintained
Sealing Gap
Installation & Troubleshooting Guidelines for API Seal Flush Plans-Introduction The seal faces and the seal assembly generate heat in the seal chamber due to
liquid turbulence in the seal chamber liquid shear in the sealed fluid between the seal faces mechanical motion in the seal assembly occasionally bumping or touching of the seal faces
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This heat must be removed in most applications to maintain stable operation In high temperature applications the opposite may be true. The heat in the seal chamber must be maintained to provide a stable operation To control the temperature in the seal chamber and to provide adequate lubrication for the seal faces, a seal flush is required for the vast majority of applications
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A variety of seal flush arrangements may be used depending on
pump construction the type of seal assembly being used the seal chamber pressure fluid properties operating conditions such as temperature, viscosity, etc.
It is essential that the correct seal flush arrangement be installed and operated properly
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Installation & Troubleshooting Guidelines for API Seal Flush Plans-Introduction The various seal flush arrangements have been categorized by API The plans are numbered and identified as API Piping Plan XX A brief overview of the various piping plans commonly encountered follows We will discuss each in more detail with a few exceptions as indicated
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API Piping Plan Summary (* = not covered)
01*,02*Pump feature flush plan 11,12*,13,14By pass Flush- Flush plans intended to keep the seal area clean and remove seal generated heat 21,22*,23.Cooling Flush plan - Flush plans intend to cool the seal area 31,32,33*.Slurry Flush Plan - Flush plan intended to keep the slurries away from the sealing area. 41*....a combination plan for cooling and slurry 51*,52,53..Dual Seal Flush plans 61,62.Atmospheric flush plans to provide for a suitable atmosphere outside the seal area or behind the primary seal faces-Quench
1 0

Orifice
API Piping Plan 11

Line from discharge through orifice to seal flange
1 1

Block Valve
Orifice Pressure Gauge
Gauge Valve
API Piping Plan 11

1 2

Line Up Procedure-API Plan 11
Check to make sure any valves in the seal flush line are open (caution-if the flush source is taken from past the block valve on the pump discharge header the suction valve must be open or the pump and seal chamber will be subject to full pump discharge pressure) Proceed with opening all valves for service Check for leaks around valves and the orifice in the flush line
1 3

Line Up Procedure-API Plan 11 Continued Start pump per normal procedure Once running check to make sure the seal flush line is the same temperature from its origin to the primary seal flush port on the primary seal flange or seal chamber connection. The line should be the same temperature at both ends.
1 4

Preventive Maintenance and TroubleshootingPlan 11
The seal flush line should be checked regularly with a temperature indicator. It should be the same temperature at both ends of the line. The typical mode of failure is a clogged orifice or a closed valve.
1 5

Preventive Maintenance and Troubleshooting-Plan 11
Hot Service-seal flush line plugged. When the seal flush line is plugged in a hot service the line will be cold. It may be hot at the origin and at the seal, but it will become cold as you move away from the connections Orifice
API Piping Plan 11

1 6

Cold Service-seal flush line clogged. When the seal flush line is clogged on a cold service, you will find the line hotter at the seal connection. The line will become cooler as you move away from the seal toward the pump case. Orifice
API Piping Plan 11

1 7

Orifice
API Piping Plan 13

Line from seal flange through orifice to pump suction
1 8

Block Valve Pressure Gauge
Orifice
Gauge Valve
API Piping Plan 13

Line from seal flange through orifice to pump suction
1 9

Check to make sure any valves in the seal flush line are open Proceed with opening all valves for service Check for leaks around valves and the orifice in the flush line Open the vent line (if there is one) on the seal flush line to vent any air or vapor that is in the primary seal chamber. (Primarily for vertical pumps) Close the vent line when a good liquid flow is obtained 2 0

Line Up Procedure-API Plan 13 Continued Start pump per normal procedure Once running check to make sure the seal flush line is the same temperature from its origin to the primary seal flush port on the primary seal flange or seal chamber connection. The line should be the same temperature at both ends.
2 1

The seal flush line should be checked regularly with a temperature indicator. It should be the same temperature at both ends of the line. The typical mode of failure is a clogged orifice or a closed valve.
2 2

Preventive Maintenance and Troubleshooting-Plan 13 Hot Service-seal flush line plugged. When the seal flush line is plugged in a hot service the line will be cold. It may be hot at the origin and at the low pressure point (near the pump case), but it will become cold as you move away from the connections Orifice
API Piping Plan 13

Line from seal flange through orifice to pump suction 2 3

Preventive Maintenance and Troubleshooting-Plan 13 Cold Service-seal flush line clogged. When the seal flush line is clogged on a cold service, you will find the line hotter at the seal connection. The line will become cooler as you move away from the seal toward the pump case. Orifice
API Piping Plan 13

Line from seal flange through orifice to pump suction 2 4

Orifice
Orifice
Rotameter
API Piping Plan 14

Line from seal flange through orifice to pump suction and line from pump discharge to seal flange or seal chamber tap 2 5

Orifice Orifice
Block Valves
Gauge Valve
Pressure Gauge
Pressure Gauge
Rotameter
API Piping Plan 14

Line from seal flange through orifice to pump suction and line from pump discharge to seal flange or seal chamber tap 2 6

Line up procedure-API Plan 14
Check to make sure any valves in the seal flush line are open Proceed with opening all valves for service Check for leaks around valves and the orifice in the flush line Open the vent line (if there is one) on the seal flush line to vent any air or vapor that is in the primary seal chamber. (Primarily for vertical pumps) Close the vent line when a good liquid flow is obtained 2 7

Line up procedure-API Plan 14 Start pump per normal procedure Once running check to make sure the seal flush lines are the same temperature from their respective origins to their respective connections. The lines should be the same temperature at both ends.
2 8

Line up procedure-Plan 14
The line from discharge should be the same temperature from the connection at the pump case to the primary seal flush port on the primary seal flange or the seal chamber tap. The line to suction should be the same temperature from the seal flush port on the primary seal flange to the suction connection. Both lines should be the same temperature as the pump case
2 9

The seal flush lines should be checked regularly with a temperature indicator. They should be the same temperature at both ends of the line. The typical mode of failure is a clogged orifice or a closed valve.
3 0

Preventive Maintenance and Troubleshooting-Plan 14 Cold Service
Line from discharge-when the seal flush line is clogged in a cold service, you will find the line hotter at the seal flush port connection on the seal flange or seal chamber tap. The line will cool as you move toward the origin of the seal flush. The heat you measure at this point is radiating up the seal flush line and is generated by the mechanical seal. This differential may be quite small for plan 14 is the seal chamber pressure is high enough to generate some flow through the line to suction.
Orifice
Orifice
API Piping Plan 14

Line from seal flange through orifice to pump suction and line from pump discharge to seal flange or seal chamber tap
3 1

Preventive Maintenance and Troubleshooting-Plan 14 Cold Service
Line to suction-if the line from discharge is operating properly, it may not be possible to detect that this line is plugged. If vapors are accumulating at the top of the seal chamber, the line will be warmer at the primary seal flange and cool as you move away from it toward the suction connection due to heat generation at the seal. Otherwise a flow indicator is helpful to detect failure of this line.
Orifice Orifice
API Piping Plan 14

3 2

Preventive Maintenance and Troubleshooting-Plan 14 Hot Service
Line from discharge-when the seal flush line is clogged in a hot service, you will find the line cold. It may be hot at the origin and also at the flush port connection on the seal flange or seal chamber tap, but it will become cold as you move away from the connections.
Orifice
Orifice
API Piping Plan 14

3 3

Preventive Maintenance and Troubleshooting-Plan 14 Hot Service
Line to suction-When the seal flush line is clogged in a hot service, you will find the line cold. It may be hot at the origin and also at the flush port connection, but it will become cold as you move away from the connections
Orifice Orifice
API Piping Plan 14

Line from seal flange through orifice to pump suction and line from pump discharge to seal 3 flange or seal chamber tap

Orifice
Heat Exchanger
API Piping Plan 21

Line from discharge through orifice and cooler to seal flange
3 5

Block Valve Orifice Gauge Valve Pressure Gauge
Heat Exchanger
API Piping Plan 21

Line from discharge through orifice and cooler to seal flange
3 6

Line Up Procedure-API Plan 21 Check to make sure any valves in the seal flush line are open (caution-if the flush source is taken from past the block valve on the pump discharge header the suction valve must be open or the pump and seal chamber will be subject to full pump discharge pressure) Check to make sure the cooling water lines to the heat exchanger are open
3 7

Line Up Procedure-API Plan 21 Continued Open the case drain on the heat exchanger to clear debris from the cooling water system and check for flow Proceed with opening all valves for service Check for leaks around valves and the orifice in the flush line Start pump per normal procedure
3 8

Line Up Procedure-API Plan 21 Continued
Once running check to make sure product is flowing through the heat exchanger to the primary seal flush port. This can be confirmed by checking for a temperature drop across the heat exchanger Once running check to make sure the cooling water is flowing through the case side of the heat exchanger. This can be confirmed by checking for a temperature rise across the heat exchanger. 3 9

Preventive Maintenance and TroubleshootingPlan 21 The seal flush line should be checked regularly with a temperature indicator. When the pump is running the outlet of the seal cooler should be noticeably cooler than the inlet The cooling water lines should be checked regularly with a temperature indicator as well. The outlet cooling water line should be warmer than the inlet cooling water line.
4 0

Preventive Maintenance and Troubleshooting-Plan 21 The typical modes of failure are
clogged orifice or a closed valve loss of cooling water flow missing or oversized orifice
The body of the heat exchanger should be warm while the pump is in operation The heat exchanger case drain should be opened periodically to purge the heat exchanger of accumulated solids and debris 4 1

Preventive Maintenance and Troubleshooting- Plan 21 Clogged or closed seal flush line-when the seal flush line is clogged or closed, you will find the seal flush line and heat exchanger cold. The seal flush line may be hot at the origin and at the flush port connection, but it will become cold as you move away from the connections. Orifice
Heat Exchanger
API Piping Plan 21

Line from discharge through orifice and cooler to seal flange 4 2

Orifice Preventive Maintenance and Troubleshooting-Plan 21 Loss of cooling water flow-if cooling water flow is lost, the seal flush line will be hot throughout its entire length. The cooling water lines will be hot near the heat exchanger and become cooler as you move away from the heat exchanger.
Heat Exchanger
API Piping Plan 21

Line from discharge through orifice and cooler to seal flange 4 3

Orifice

Missing or oversized orificeif the orifice is oversized or missing, the temperature drop in the flush line across the cooler will be inadequate. The temperature rise in the cooling water lines across the cooler will be excessive and the heat exchanger case will be hot Heat Exchanger
API Piping Plan 21

Line from discharge through orifice 4 and cooler to seal flange

Vent Valves
To suitable drain or disposal system
Long radius tubing bends required for all elbows
API PIPING PLAN 23

Heat Exchanger
18-24
Line from seal to cooler and back to seal flange
4 5

Check to make sure any valves in the seal flush circulation lines are open. There should not be any valves in the seal flush circulation lines for a Plan 23 under normal circumstances however. Check to make sure the cooling water lines to the heat exchanger are open Open the case drain on the heat exchanger to clear debris from the cooling water system and check for flow Proceed with opening all valves for service
4 6

Open the vent valve(s) in the seal flush circulation lines. A full product stream to grade should be obtained before the vent valve is closed. This will insure the seal is immersed in liquid prior to pump operation Check for leaks around valves in the flush line circulation lines Start pump per normal procedure
4 7

Once running check to make sure product is flowing to and from the heat exchanger to the flush ports. This can be confirmed by checking for a temperature drop across the heat exchanger Once running check to make sure the cooling water is flowing through the case side of the heat exchanger. This can be confirmed by checking for a temperature rise across the heat exchanger.
4 8

Preventive Maintenance and Troubleshooting-Plan 23 The seal flush line should be checked regularly with a temperature indicator. When the pump is running the outlet of the cooler should be slightly cooler than the inlet. The outlet should be only 20-30 oF above the cooling water temperature and the inlet should be only 30-40 oF above the outlet. The cooling water lines should be checked regularly with a temperature indicator as well. The outlet cooling water line should be warmer than the inlet cooling water line. 4 9

Preventive Maintenance and Troubleshooting-Plan 23 The typical mode of failure are an unvented system, a closed valve in the seal flush circulation lines, or loss of cooling water flow The body of the heat exchanger should be warm while the pump is in operation The heat exchanger case drain should be opened periodically to purge the heat exchanger of accumulated solids and debris 5
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Preventive Maintenance and Troubleshooting-Plan 23 Unvented or closed valve in the seal flush circulation linesif the system is not properly vented or a valve is closed in the seal flush circulation lines you will find the seal lines and heat exchanger cold. The flush lines may be hot at their origin, but will become cold as you move away toward the heat exchanger. The body of the heat exchanger may also be cold.
18-24
API PIPING PLAN 23

Line from seal to cooler and back to seal flange 5 1

Preventive Maintenance and Troubleshooting-Plan 23 Clogged or closed cooling water system-if the cooling water system is inoperable, you will find the process lines entering and exiting the heat exchanger at the same temperature. The body of the heat exchanger will also be very hot. The cooling water lines entering and exiting the heat exchanger will be very hot at the cover and both lines will cool as you move away from the heat exchanger.
18-24
API PIPING PLAN 23

Line from seal to cooler and back to seal flange 5 2
API Piping Plan 31

Line from discharge through orifice and cyclone separator to seal flange 5 3

Block Valve Pressure Gauge
Gauge Valve
API Piping Plan 31


Check to make sure any valves in the seal flush line are open (caution-if the flush source is taken from past the block valve on the pump discharge header the suction valve must be open or the pump and seal chamber will be subject to full pump discharge pressure) Proceed with opening all valves for service Check for leaks around valves, connections in the seal flush line, the cyclone separator, and the orifice in the flush line 5 5

Line Up Procedure-API Plan 31Continued
Start pump per normal procedure Once running check to make sure the seal flush line is the same temperature from its origin through the cyclone separator to the primary seal flush port on the primary seal flange or seal chamber connection . Also check the line from the cyclone separator back to the suction connection. The line should be the same temperature at all locations throughout its length. 5 6

The seal flush line should be checked regularly with a temperature indicator. It should be the same temperature as the pump case throughout its entire length. The typical mode of failure is a clogged orifice, a closed valve, a clogged cyclone separator, or a clogged line from the cyclone separator back to suction.
5 7

Preventive Maintenance and Troubleshooting-Plan 31 Hot Service-seal flush line plugged. When the cyclone separator is plugged in a hot service all three lines will be cold. It may be hot at the origin, at the suction connection, and at the seal, but it will become cold as you move away from the Line from discharge through orifice connections
API Piping Plan 31
and cyclone separator to seal flange 5 8

Hot Service-seal flush line plugged. When the line from the cyclone separator to suction is clogged, you will find the cyclone itself hot and the line to the seal flange. The connection at the suction may be hot near the pump case but will become cooler as you move away from the connection. The seal may leak erratically due to a high flush rate. It will fail quickly since it is being Line from discharge through orifice subjected to all the abrasives and cyclone separator to seal flange present in the system.
API Piping Plan 31
5 9

Preventive Maintenance and Troubleshooting-Plan 31 Hot Service-seal flush line plugged. If the orifice is plugged the line from the pump case to the cyclone will be cold. The lines to the seal and the suction connection may be hot since fluid is flowing from the seal back to the cyclone and then to suction. Line from discharge through orifice
API Piping Plan 31
and cyclone separator to seal flange 6 0

Preventive Maintenance and Troubleshooting-Plan 31 Hot Service-seal flush line plugged. Finally, if a valve is closed in the line from the cyclone to the seal, this line will be cold but may be hot at the seal connection or the cyclone. The lines from the pump case to the cyclone will be hot since liquid is flowing from discharge to the cyclone Line from discharge through orifice and then back to suction. and cyclone separator to seal flange
API Piping Plan 31
6 1

Preventive Maintenance and Troubleshooting-Plan 31 Cold Service-seal flush line plugged. When the cyclone separator is clogged in a cold service, the line to the seal will be hotter than the rest of the line at the seal connection. The lines will be cool in all other locations
API Piping Plan 31


Preventive Maintenance and Troubleshooting-Plan 31 Cold Service-seal flush line plugged. If the line from the cyclone to pump suction is clogged, there will be no physical evidence. The lines will be the same temperature in all locations since fluid is flowing to the seal. The seal may exhibit erratic leakage due to the presence of solids and a high flush rate.
API Piping Plan 31


Preventive Maintenance and Troubleshooting-Plan 31 Cold Service-seal flush line plugged. If the orifice is plugged, there will be no physical evidence. All lines will be cool since there is flow from the seal to the cyclone and then back to suction. The seal may be operating fine unless there is no enough differential pressure between the seal chamber and suction to provide adequate flow. Then the connection at Line from discharge through orifice the seal flange may be warm. and cyclone separator to seal flange
API Piping Plan 31
6 4

Preventive Maintenance and Troubleshooting-Plan 31 Cold Service-seal flush line plugged. A closed valve between the cyclone separator and the seal flange will result in no flow to the seal. The connection at the seal flange may be warm. The lines will be cool at all other locations since there will be flow from pump discharge to the cyclone and back to suction.
API Piping Plan 31

Line from discharge through orifice and cyclone separator to seal flange 6

Pressure Indicator Pressure or Flow Regulator Check Valve Block Valve
Flow Indicator
Pressure Indicator
External Source of Clean Fluid
API Piping Plan 32

Flush from External Source
6 6

Check to make sure any valves in the seal flush line are open (caution-if the flush source is taken from a very high pressure source the suction valve must be open or the pump and seal chamber will be subject to the full pressure) Check the gauge on the seal flush line to make sure there is pressure in the line Proceed with opening all valves for service If there is a flow indicator in the flush line check to make sure a flow is established
6 7

Check for leaks around valves and the orifice in the flush line Start pump per normal procedure Once running check to make sure the seal flush line is the same temperature from its origin to the primary seal flush port on the primary seal flange or seal chamber connection. The line should be the same temperature at both ends.
6 8

The seal flush line should be checked regularly with a temperature indicator. It should be the same temperature at both ends of the line. The typical mode of failure is a clogged orifice, a defective flow or pressure controller, loss of pressure in the line, or a closed valve.
6 9

Preventive Maintenance and Troubleshooting-Plan 32 Hot Service-seal flush line plugged. When the seal flush line is plugged in a hot service the line will be cold. It may be hot at the seal connection, but it will become cold as you move away from the connection
API Piping Plan 32

7 0

Preventive Maintenance and Troubleshooting-Plan 32 Cold Service-seal flush line clogged. When the seal flush line is clogged on a cold service, you will find the line warmer at the seal connection. The line will become cooler as you move away from the seal connection.
API Piping Plan 32

7 1

Orifice Pressure Gauge Pressure Switch
Block and Bleed Valve

High Level Switch Long Radius Tubing Bends Cooling Required Water Connections
To Suitable Vapor Recovery System Fill Connection Low Level Switch Temperature Indicator Drain Valve 18-24
API Piping Plan 52

Circulation of clean unpressurized buffer fluid from seal to external reservoir and back to seal 7 2

Line Up Procedure-API Plan 52 Check to make sure the level of buffer fluid in the seal reservoir is at the base level reading Check to make sure there are no visible buffer fluid leaks at the seal or fittings in the secondary sealing system Check to make sure that any valves from the flare connection port on the seal reservoir to the flare header or low pressure point are open.
7 3

Line Up Procedure-API Plan 52 Continued Check the gauge on the reservoir. There should be no pressure (or the pressure reading should be less than or equal to the flare header pressure or the system to which the reservoir is vented). Proceed with opening all valves for service Check for leaks around valves and connections in the flare connection line Start pump per normal procedure
7 4

Line Up Procedure-API Plan 52 Continued Once running check to make sure your base level and pressure readings in the tandem seal reservoir are still holding the reservoir should also begin to warm as the secondary seal circulates buffer fluid to and from the secondary seal chamber
7 5

Preventive Maintenance and Troubleshooting-Plan 52 The tandem seal reservoir should be checked on normal operator rounds on a regular basis. The base level should be checked for fluid loss or gain. The base pressure of the system should also be monitored. The temperature of the reservoir should be checked. A pressure increase in the reservoir is an indication of a primary seal leak. Small fluctuations are acceptable since the pressure in the flare header system is also variable. 7 6

Preventive Maintenance and Troubleshooting-Plan 52 When a pressure increase is observed also check the flare header line leaving the reservoir. It may be closed or blocked. If it is cold, this is an additional sign of a leaking primary seal in light hydrocarbon. If it is hot, it may be a sign of a leaking primary seal in a hot service. A level increase in the reservoir is also a sign of a leaking primary seal. A slowly increasing level is a normal symptom when the primary seal leakage does not vaporize at the reservoir temperature. 7 7

When a level increase is observed, also check the pressure reading. A level decrease in the reservoir is a symptom of a leaking secondary seal. Check all the seal circulation piping and connections. Make sure the drain valve is closed.
7 8

Preventive Maintenance and Troubleshooting-Plan 52 A fugitive emission failure usually occurs when the primary seal leakage does not vaporize at the reservoir temperature. Over a period of time it may accumulate in the reservoir even though a level increase is not observed. This is due to the fact that the secondary seal may leak at almost exactly the same rate as the primary seal. When this happens, the fluid in the reservoir should be drained, the reservoir flushed out, and then refilled with fresh buffer fluid. 7 9

Preventive Maintenance and Troubleshooting-Plan 52 Level Increase-Block in the reservoir and observe how rapidly the pressure increases. If it raises only a few pounds in 15 minutes, this is probably normal accumulation of primary seal leakage. If it rises rapidly, a primary seal Circulation of clean unpressurized failure has occurred
API Piping Plan 52
buffer fluid from seal to external reservoir and back to seal 8 0

Preventive Maintenance and Troubleshooting-Plan 52 Level Decrease-check all the piping and fittings for leaks. Block in the reservoir. If the pressure does not rise gradually there is a leak somewhere in the system. Check the drain valve. Block in the cooling water lines. There may be a leak Circulation of clean unpressurized in the cooling water coil.
API Piping Plan 52

Pressure Increase-check to make sure the line to the flare header is not closed or blocked. Block in the cooling water and drain off a small amount of buffer fluid to check for water. The cooling coil may be Circulation of clean unpressurized leaking.
API Piping Plan 52

Preventive Maintenance and Troubleshooting-Plan 52 Fugitive Emission Failure-wash down the surrounding area. Check all the flush lines and pump connections API Piping Plan 52 for leaks. Drain the reservoir, flush it out, Circulation of clean unpressurized buffer fluid from seal to external and refill with fresh reservoir and back to seal buffer fluid. 8 3

Source of gas or clean liquid Block Valve Pressure Switch Pressure Indicator Check Valve
Pressure Regulator
Block and Bleed Valve Long Radius Tubing Bends Required
Fill Connection Low Level Switch Temperature Indicator
Cooling Water Connections
Drain Valve
18-24
API Piping Plan 53

Circulation of Clean Pressurized Barrier Fluid from Seal to Reservoir and back to Seal 8 4

Check to make sure the level of barrier fluid in the seal reservoir is at the base level reading Check to make sure there are no visible barrier fluid leaks at the seal or fittings in the secondary sealing system
Note: Depending on the system pressure the next two steps may need to be implemented after the pump valves are opened
Check to make sure that any valves from the pressure source to the seal reservoir are open. 8 5

Line Up Procedure-API Plan 53 Continued Check the gauge on the reservoir. Make sure the reservoir is pressurized to the required set point. If the reservoir cooling coil is piped to a water supply, open the cooling water lines Proceed with opening all valves for service Check for leaks around valves and connections in the reservoir system
8 6

Line Up Procedure-API Plan 53 Continued Start pump per normal procedure Once running check to make sure your base level and pressure readings in the double seal reservoir are still holding The reservoir should also begin to warm as the secondary seal circulates buffer fluid to and from the secondary seal chamber
8 7

Preventive Maintenance and Troubleshooting-Plan 53 The double seal reservoir should be checked on normal operator rounds on a regular basis. The base level should be checked for fluid loss or gain. The base pressure of the system should also be monitored. The temperature of the reservoir should be checked. A pressure loss in the reservoir may be an indication of either a primary or secondary seal leak. Small fluctuations are acceptable since the supply pressure to the pressure controller may also be variable. A pressure loss can also be due to a defective controller.
8 8

A pressure increase in the reservoir is usually due to a malfunction in the pressure controller. High pressure services will normally have a bias regulator. Tap on the regulator to see if it is stuck. If the pressure increases or becomes erratic, shut down the pump in an orderly manner for maintenance. The regulator may need to be replaced or recalibrated. If it is a bias regulator, the pressure sensing line may be clogged.
8 9

Preventive Maintenance and Troubleshooting-Plan 53 A level loss in the reservoir is also a sign of a leaking primary or secondary seal. A slowly decreasing level is a normal symptom since both seals will have normal leakage. When a level loss is observed, also check the pressure reading. A level decrease in the reservoir may not be due to seal leakage. Check all the seal circulation piping and connections. Make sure the drain valve is closed.
9 0

A level increase in the reservoir can only occur when the pressure in the reservoir is lost. In this case the primary seal is leaking product into the reservoir. Restore pressure to the reservoir. If the pumpage is toxic or hazardous, the pump should be shut down in an orderly manner for maintenance. The barrier fluid in the reservoir and seal chamber should be drained and replaced. A small increase in the reservoir level will be observed shortly after startup due to the heating of the barrier fluid by the seal. Small fluctuations in the level are normal and should not be a cause of concern.
9 1

A fugitive emission failure usually occurs when the pumpage has accumulated in the reservoir for some reason. Usually there will have been a loss of pressure for some time period for this to occur. When this happens, the fluid in the reservoir should be drained, the reservoir flushed out, and then refilled with fresh buffer fluid.
9 2

Preventive Maintenance and Troubleshooting-Plan 53 Pressure Loss-check to make sure the line from the pressure source is not closed or blocked. Block in the cooling water and drain off a small amount of buffer fluid to check for water. The cooling coil may be leaking. Check the pressure controller. Check all lines and Circulation of Clean Pressurized connections for leaks. Make Barrier Fluid from Seal to sure the drain valve is closed.
API Piping Plan 53

Reservoir and back to Seal
9 3

Pressure rise-the pressure regulator is either stuck or defective. Tap on the regulator to see if the pressure will drop to the base level. If not it must be replaced or recalibrated. If a bias regulator is being used, the pressure sensor line may be plugged
API Piping Plan 53


Level increase-the system has lost pressure and pump product is leaking into the barrier fluid past the primary seal. Restore the pressure to the reservoir. Check the air or liquid supply line to make sure there is pressure and all valves are open. If the pumpage is hazardous or toxic, drain the reservoir and the seal chamber and replace the barrier Circulation fluid.
API Piping Plan 53

of Clean Pressurized Barrier Fluid from Seal to Reservoir and back to Seal 9 5

Preventive Maintenance and Troubleshooting-Plan 53 Level Loss-Refill reservoir and monitor level closely. If rapid loss occurs a leak is present. Check all piping and connections for leaks. Make sure the drain valve is closed. Block in the cooling water. The cooling coil may have a leak.
API Piping Plan 53


Preventive Maintenance and Troubleshooting-Plan 53 Fugitive Emission Failure-wash down the surrounding area. Check all the flush lines and pump connections for leaks. Drain the API Piping Plan 53 reservoir, flush it out, Circulation of Clean Pressurized and refill with fresh Barrier Fluid from Seal to buffer fluid. Reservoir and back to Seal 9 7

External Nitrogen Pressure Source Flow Meter Pressure Switch Flow Switch Gas Control Panel
Pressure P.I. Regulator
Barrier Inlet
Coalescing Filter
Check Valve
Ball Valve
API Piping Plan 53 (Gas)

9 8

Line-up procedure-Plan 53 Gas
The gas pressure must be on the sealing system prior to lining up the pump for service Always stabilize the gas sealing system prior to applying any pressure to the pump Never de-pressure the gas sealing system prior to depressuring the pump Maintaining the proper seal pressure at all times is critical to avoid damage to the seals during the start-up and shut down procedure 9 9

Line-up procedure-Plan 53 Gas continued
Check to make sure the regulator o the gas panel is turned all the way to decreasing Open the supply gas pressure to the gas panel Know your baseline secondary sealing system pressure! Turn the regulator adjustment knob towards increasing until the baseline pressure is obtained
1 0 0

Check to make sure the flow meter drops to 02 scfh. If not, proceed to the trouble shooting section below (note: the flow meter should stabilize in less than 5 minutes) Proceed with pump line-up per plant specifications Check for leaks around any valves
1 0 1

Start pump per normal procedures Once running, check to make sure your panel pressure and flow readings in the secondary sealing system are stable and at the baseline readings
1 0 2

Preventive Maintenance and Troubleshooting-Plan 53 Gas
The seal system should be checked on normal operator rounds The gas panel should be checked for proper pressure and gas flow readings. Significant changes in these readings can indicate the primary and/or secondary seal is beginning to leak and should be monitored carefully
1 0 3

No or low gas panel pressure with typical flow recorded on the flow meter is usually caused by one of four things
Partially closed or closed supply valves-check to make sure the supply valves to the gas seal panel is fully open
1 0 4

Improperly adjusted regulator-adjust the regulator toward the increasing pressure direction only to obtain the baseline pressure. Variable supply pressure-check to make sure the supply pressure to the panel is at normal levels
1 0 5

Clogged filter element in coalescing filter-in the event these attempts are unsuccessful, decommission the pump and take the gas panel out of service and check the coalescing filter. Proceed through the start-up procedure for the gas panel. If you are still unsuccessful, contact maintenance for assistance
1 0 6

A high gas panel pressure with typical flow on the flow meter normally occurs when the regulator on the panel has been set above the base pressure reading -adjust the regulator on the gas panel in the increasing direction. When making the adjustment, do so slowly to avoid dropping the panel below the desired base pressure reading
1 0 7

Preventive Maintenance and Troubleshooting-Plan 53 Gas High flow readings in excess of 5-6 scfh can be caused by loose fittings downstream of the flow meter or damage to the seal faces
The first step is to leak check all fittings down stream of the flow meter on the gas panel. A very small leak can cause a high flow reading. If the fittings are leak free, call your maintenance personnel to troubleshoot the mechanical seal assembly. A high flow under these conditions usually means the seal is damaged in some way. Providing you can maintain the base pressure on the panel and an elevated leak rate is not affecting process conditions, the pump can continue to be operated until an orderly shut-down can be executed.
1 0 8

Preventive Maintenance and Troubleshooting-Plan 53 Gas No or low gas panel pressure with typical flow recorded on the flow meter
Partially closed or closed supply valves-check to make sure the supply valves to the gas seal panel are fully open Improperly adjusted regulatoradjust the regulator toward the increasing pressure direction only to obtain the baseline pressure. Variable supply pressure-check to make sure the supply pressure to the panel is at normal levels
External Nitrogen Pressure Source
Flow Meter Pressure Switch Flow Switch
Gas Control Panel
Barrier Inlet
Check Valve Coalescing Filter Ball Valve
1 0 9

Preventive Maintenance and Troubleshooting-Plan 53 Gas No or low gas panel pressure with typical flow recorded on the flow meter
Clogged filter element in coalescing filter-in the event these attempts are unsuccessful, decommission the pump and take the gas panel out of service and check the coalescing filter. Proceed through the start-up procedure for the gas panel. If you are still unsuccessful, contact maintenance for assistance
Gas Control Panel
Barrier Inlet
1 1 0

Preventive Maintenance and Troubleshooting-Plan 53 Gas A high gas panel pressure with typical flow on the flow meter normally occurs when the regulator on the panel has been set above the base pressure reading -adjust the regulator on the gas panel in the increasing direction. When making the adjustment, do so slowly to avoid dropping the panel below the desired base pressure reading
Gas Control Panel
Barrier Inlet
1 1 1

The first step is to leak check all fittings down stream of the flow meter on the gas panel. A very small leak can cause a high flow reading. If the fittings are leak free, call your maintenance personnel to troubleshoot the mechanical seal assembly. A high flow under these conditions usually means the seal is damaged in some way. External Nitrogen Pressure Source
Gas Control Panel
Barrier Inlet
1 1 2

Providing you can maintain the base pressure on the panel and an elevated leak rate is not affecting process conditions, the pump can continue to be operated until an orderly shut-down can be executed. External Nitrogen Pressure Source
Gas Control Panel
Barrier Inlet
1 1 3

Pressure or flow indicator or switch Orifice .125 typical Normally open To flare or vapor recovery
P.I.
Check Valve 1-2 psi opening maximum
.250 min
Sump w/liquid level indicator or switch
Normally closed
To drain or suitable enclosed recovery system 1 1 4
API Piping Plan 61

Vent to Closed Vapor System

Check to make sure any valves from the flare connection port on the secondary seal flange to the flare header or low pressure point are open Check the gauge on the line to the flare header or low pressure point. It should read no pressure or less than or equal to the flare header pressure If the pumpage becomes a liquid at atmospheric conditions a drain leg should be included. Make sure the drain valve is closed. Proceed with opening all valves for service
1 1 5

Check for leaks around valves and the orifice in the line to the flare header Start pump per normal procedure Once running check to make sure that the pressure on the line to the flare header is zero or less than or equal to the flare header pressure. Also make sure that there is no ice forming on this line (for light hydrocarbons) and that the line is cool (for hot services) 1 1 6

Preventive Maintenance and Troubleshooting-Plan 61 The line to the flare header should be checked regularly. The pressure in the line should be zero or less than or equal to the flare header pressure. It should not be cold (for light hydrocarbons) or warm (for hot services) The typical mode of failure is a clogged orifice, an open drain valve, a stuck check valve, or a closed valve in the flare line. 1 1 7

Preventive Maintenance and Troubleshooting-Plan 61 Pressure Reading on gauge in flare line-check for cold line (light hydrocarbons). Make sure the valve is open to the flare header. Open the drain valve to relieve pressure and observe how quickly the pressure reading returns. If the pressure builds quickly (more than 2 psi in 5 minutes), a seal leak has occurred. If the pressure builds slowly, this is due to normal seal leakage. The the flare line is probably blocked.
API Piping Plan 61

Vent to Closed Vapor System 1 1 8

Preventive Maintenance and Troubleshooting-Plan 61 Liquid accumulation in drain line-drain the line and close the drain valve. Block in the flare line and observe the pressure. If it rises slowly, (2 psi or less in 5 minutes ) normal leakage has occurred. If it rises rapidly, a seal leak may have occurred.
API Piping Plan 61

Vent to Closed Vapor System 1 1 9

API Piping Plan 62
Liquid or Gas Quench To Atmospheric Side of Seal Faces Block Valves
Pressure Regulator
Quench Connection Drain Connection To Drain or Suitable Recovery System
Trap
Steam or Other Gas Or Liquid Supply
Block Valve
1 2 0

Pressure Regulator Quench Connection Wrap Copper Line Around Suction or Discharge Nozzle and Insulate Drain Connection
Block Valves
Block Valve Trap
Steam or Other Gas Or Liquid Supply
To Drain or Suitable Recovery System
API Piping Plan 62

Liquid or Gas Quench To Atmospheric Side of Seal Faces-Alternate For Wet Steam 1 2 1

Pressure Regulator Block Valves Steam or Other Gas Or Liquid Supply
Quench Connection
API Piping Plan 62

Block Valve Liquid or Gas Quench To Atmospheric Side of Seal Faces-Alternate for Wet Steam
Trap To Drain or Suitable Recovery System
Drain Connection
Route Quench Line Through seal chamber Water Jacket
1 2 2

Line Up Procedure-API Plan 62-Steam Quench
If a blow down line is included in the steam quench system open it until all condensate has been evacuated. Open the line to the steam trap
1 2 3

Line Up Procedure-API Plan 62-Steam Quench Continued
Open the block valve for the steam quench. If a regulator and gauge are used make sure the gauge shows the proper steam pressure. If a needle valve is used, open the needle valve until condensation is observed at the bushing or drain port on the seal flange. Then start closing the needle valve until steam condensate can be observed on a cold object (such as channel locks or a mirror) held near the drain port. Note that it is common to see some condensation dripping out of the seal flange at this point 1 since the pump is not up to full operating temperature 2 4

Line Up Procedure-API Plan 62-Steam Quench Continued
Check for leaks around valves, fittings, and the orifice if used in the quench line Proceed with opening all valves for service Start pump per normal procedure Once running check to make sure the steam quench is still in operation. Any condensation previously observed should disappear as the pump comes up to full operating temperature except for cold service pumps such as caustic 1 service where there will always be condensate present. 2 5

Preventive Maintenance and Troubleshooting-Plan 62-Steam Quench
The steam quench should be checked regularly. If a pressure gauge is used, it should be checked to make sure the set point has been maintained. Steam condensate should be visible on a cold object held near the drain port. The typical mode of failure is a clogged orifice, a defective pressure controller, loss of pressure in 1 the line, or a closed valve.
2 6

Preventive Maintenance and Troubleshooting-Plan 62-Steam Quench Steam quench not operableCheck all valves to make sure they are open. Check steam source. If orifice is used, block in system and check for clogged conditions. Open blow down line to make sure system is not filled with condensate.
API Piping Plan 62

Liquid or Gas Quench To Atmospheric Side of Seal Faces 1 2 7

Preventive Maintenance and Troubleshooting-Plan 62-Steam Quench Excessive Condensate-Open blow down line. Reduce steam to desired level. It may be necessary to insulate steam system. For cold service pumps such as caustic service there will always be condensate present.
API Piping Plan 62

Liquid or Gas Quench To Atmospheric Side of Seal Faces 1 2 8

Line Up Procedure-API Plan 62-Water Quench Open the line from the water source. Open the block valve for the water quench. If a regulator and gauge are used make sure the gauge shows the proper pressure. If a needle valve is used, open the needle valve until the desired amount of drippage is observed at the bushing or drain port or line on the seal flange.
1 2 9

Line Up Procedure-API Plan 62-Water Quench Continued
Check for leaks around valves, fittings, and the orifice if used in the quench line Proceed with opening all valves for service Start pump per normal procedure Once running check to make sure the water quench is still in operation. All water should be coming out of the drain port or line. There should not be any water visible on the pump shaft.
1 3 0

Preventive Maintenance and Troubleshooting-Plan 62Water Quench
The water quench should be checked regularly. If a pressure gauge is used, it should be checked to make sure the set point has been maintained. Water drippage should be visible at the drain port or line. The typical mode of failure is a clogged orifice, a defective pressure controller, loss of pressure in the line, or a closed valve.
1 3 1

General Comment-Steam & Water Quench
The steam or water quench should be put in service before the pump is put in service. It is not a good practice to put a quench system in operation while the pump is running or when it has been prepared for service. It is possible to shock a mechanical seal under these conditions and cause a catastrophic seal failure. The operator may be put at risk when this event occurs
1 3 2

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Installation & Troubleshooting Guidelines for API Seal Flush Plans

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API Piping Plan 14

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API Piping Plan 14

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Installation & Troubleshooting Guidelines for API Seal Flush Plans

API Piping Plan 21

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API Piping Plan 21

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Installation & Troubleshooting Guidelines for API Seal Flush Plans

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API Piping Plan 21

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