Sie sind auf Seite 1von 25

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Best Practices For Mechanical Seals and Sealing Systems for Centrifugal & Rotary Pumps
Please send your comments and suggestions to the author. This document is intended for guidance purpose and may be adopted with minor modifications by any functional department within RIL group of companies. Reproduction of this document or parts thereof in not allowed unless written permission is obtained from the Approving authority.

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 1 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

INDEX
TOPIC
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0

DESCRIPTION
Scope Definition Applicable Standards Purpose Seal Categories Seal Types Seal Designs Seal Arrangements and Configurations Seal Accessories Seal Piping Plans Seal Selection Procedure Seal Maintenance and Best Practices Seal Documentation References Appendix-1 Seal Types Drawings Appendix-2 Seal Piping Plan Flowchart

PAGE NO.
3 4 4 4 4 5 6 6 7 9 19 20 22 23 24 25

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 2 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

1.0 SCOPE This document covers best practices for mechanical seals and sealing systems installed in centrifugal and rotary pumps with an aim to achieve a minimum of 3 years of seal life. The scope of the document is to provide guidelines and best practices on seal selection and maintenance. This document is best used in conjunction with API 682.

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 3 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

2.0

DEFINITION:

A mechanical seal is a device which prevents leakage of fluids along rotating shafts. Primary seal function is at right angles to the axis of rotation between one stationary ring and one rotating ring. The associated sealing systems are provided for the principal purpose of cooling and lubricating the seal faces. 3.0 APPLICABLE STANDARDS:

The primary standards applicable to seals and sealing systems for pumps are; API 610 - Centrifugal Pumps for General Refinery Service, 10th Edition API 682 - Shaft Sealing Systems for Centrifugal and Rotary Pumps, 2nd Ed. 2002 ISO 21049:2004 Pumps -- Shaft sealing systems for centrifugal and rotary pumps 4.0 PURPOSE:

The purpose of this document is to detail best practices with regards to the design, selection, operation and maintenance of mechanical seals and sealing systems for centrifugal and rotary pumps. The document is intended for; 1. Field Maintenance Personnel 2. CES (Functional) Engineers 3. Project Engineers 4. Planning and Materials Engineers 5.0 SEAL CATOGORIES:

A seal category is intended to cover the proposed pump, its operating window, materials of construction, design features and documentation requirements for the seal. API 682 has listed three categories (see Table 1) and has provided specifications for each category. The code has standardized on face materials of Silicon carbide (SiC) and Carbon. However tungsten carbide maybe be an option for face material in non-API pumps handling a service that is neither hazardous nor toxic (defined in Section 11.0).

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 4 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

TABLE 1: SEAL CATEGORIES API 682 2ND EDITION

6.0 SEAL TYPES: (REFER APPENDIX -1 FOR IMAGES) The code has classified the seals in three types. Type A is a pusher seal with rotating flexible element. Face materials: Silicon Carbide and Carbon Metal Components: SS 316 Springs: Hastalloy C-276 O-Rings: Fuoroelastomers Type B is a bellow seal with rotating flexible element. Face materials: Silicon Carbide and Carbon Diaphragms: Hastalloy C-276 Metal Components: SS 316 O-Rings: Fuoroelastomers / Flexible Graphite * Note: Fluoroelastomers shall not be used at a temperature beyond 175 deg.C and Perfluoroelastomers shall not be used in seals operating at pumping temperatures greater than 240 deg.C

Type C is a bellow seal with stationary flexible element. Face materials: Silicon Carbide and Carbon Diaphragms: Inconel 718 Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 5 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited


SS 316 Flexible Graphite

Copyright: Reliance Industries Limited, India

Metal Components: Secondary Seals: 7.0 SEAL DESIGNS:

Mechanical seals designs are typically of the wet contact seal faces (designated as CW) type. The API code has now included two additional seal designs and these are as follows; Containment Seals (designated as CS): These are seals typically used as backup seals in a dual unpressurized seal arrangement. These operate at a pressure of 0.7 bar under normal conditions. When the inner seal fails, this seal is designed to operate under full pressure conditions for a minimum of eight hours. Non Contact Seals (designated as NC): In this design of seals, the contact face maybe profiled to achieve a hydrodynamic lift so as to create a separation of the faces. These are typically used in dual pressurized seal arrangements. These maybe considered for liquid and mixed phase applications.

8.0

SEAL ARRANGEMENTS and CONFIGURATIONS:

The seal arrangement defines the number of seals in the cartridge and the seal housing pressures. These are categorized as below; Arrangement 1: This is the conventional one seal per cartridge assembly. Arrangement 2: This is a dual seal cartridge assembly with outboard seal is at a pressure lower than the seal housing pressure (outboard seal could be a containment seal) Arrangement 3: In this arrangement, dual seals are supplied with an external barrier fluid which is at a pressure higher than the sealing pressure. Refer the chart below.
Nomenclature: FB: BB: FF: FX: FL: Face Back Back Back Face Face Fixed bushing Floating bushing

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 6 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

TABLE 2: SEAL ARRANGEMENTS AND CONFIGURATIONS API 682 2ND EDITION

9.0 9.1

SEAL ACCESSORIES: SEAL COOLERS:

Seal coolers maybe specified to increase the vapor pressure of the fluid or improve its lubricating properties. The seal cooler sizing shall be adequate for the required removal of heat. The following shall be ensured; 1. Buffer/Barrier fluid temperature does not reach boiling point. A margin of 15deg.C is recommended between the maximum anticipated temperature and the boiling point. 2. Barrier/Buffer fluid temperature should not exceed allowable limits of the materials of construction. 3. The temperature rise of the fluid should be restricted to 20deg.C. To meet the above conditions, it maybe necessary to ensure that the inlet temperature to the coolers is atleast 35deg.C below its boiling point. Additional minimum design criteria is specified as follows; The process shall be on the tube side and the cooling media shall be on the shell side. It should be possible to drain both the shell and tube sides. Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 7 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Shaft seal size < 2.500 inches Minimum tube size Minimum Tube thickness 0.065 Shaft seal size > 2.500 inches Minimum tube size Minimum Tube thickness 0.095 9.2 Barrier/Buffer Reservoirs:

The minimum design criteria sizes of the reservoirs have been specified in the code. The minimum volume for these reservoirs is indicated as; Shaft seal size < 2.500 inches Volume: 3 gallons Shaft seal size > 2.500 inches Volume: 5 gallons Reservoirs for atmospheric or low pressure buffer liquid and accumulators for pressurized barrier liquid shall be sized for a manual refill interval time of at least 25 days based on the seal leakage rate specified by the seal manufacturer without compromising the specified seal life time. 9.3 Condensate Collection Reservoir:

The condensate collection reservoir is a vessel used to collect leakage from a Plan 75 system. This reservoir collects the leakage and is a place for liquid and gas phase leakage to separate and be piped to the appropriate recovery system. The reservoir maybe instrumented to monitor inner seal leakage. The standard provides details of the construction for this vessel. 9.4 Buffer / Barrier Gas Supply Panels:

Gas supply panels are used on Plan 72 and Plan 74 systems to provide a filtered regulated inert gas to the mechanical seals. The supply panels must have, at a minimum, a pressure regulator, coalescing filter, flow meter, low pressure switch, pressure gauge, check valve, and isolation valve.

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 8 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

10.0

SEAL PIPING PLANS:

Primary seal plans, such as 11, 13, 21, 23 and 32, shall be executed in piping with welded or flanged connections. The use of strainers or cyclone separators to trap sealant particulates is not recommended. Standard seal flush plans 12, 22, 31 and 41 shall not be used. A brief discussion on the various seal piping plans is included to aid the selection process; Plan 01: Internal seal chamber flush from pump discharge Purpose: Heat removal from seal housing Venting of seal housing Reduce risk of freezing / polymerizing fluid in exposed and external piping of Plan 11. Application Clean and medium fluid temperatures Single seals Limitation: Flush cannot be directed over the seal faces. Plan 02: Dead ended seal chamber with no flush. Purpose: Simple, low cost Application Clean and medium fluid temperatures Single seals Limitations: Flush cannot be directed over the seal faces With higher fluid temperatures cooling water jacket is required for seal housing. Construction Features: Throat bush is removed. Plan 11: Default seal piping plan. Seal flush from pump discharge through an orifice. Purpose: Heat removal from seal housing Venting of seal housing in horizontal pumps Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 9 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Increases seal chamber pressure and raises vapor pressure margin Application Clean service and medium fluid temperatures Single and dual seals Limitations: Failure mode is due to chocking of orifice. Regular field checks to include monitoring of temperatures upstream and downstream of orifice. Plan 13: In this plan, there is a recirculation from seal chamber back to pump suction through an orifice. The orifice ensures seal chamber pressure greater than suction pressure. Purpose: Heat removal from seal housing Venting of seal housing in vertical pumps Application Clean service and medium fluid temperatures Single and dual seals Vertical pumps Limitations: Failure mode is due to chocking of orifice. Regular field checks to include monitoring of temperatures upstream and downstream of orifice. Construction Features: Need a vent in piping loop for venting prior to starting in vertical pumps Plan 14: In this plan, there is a seal flush from pump discharge through an orifice and a recirculation from seal chamber back to pump suction through an orifice. Purpose: Heat removal from seal housing Continuous venting of seal housing in vertical pumps Increase seal pressure chamber and fluid vapor pressure margin Application Clean and medium fluid temperatures Single and dual seals Vertical pumps Limitations: Failure mode is due to chocking of orifice. Regular field checks to include monitoring of temperatures upstream and downstream of orifice. Construction Features: Need a vent in piping loop for venting prior to starting in vertical pumps Prepared by: Paresh Girdhar Page: 10 of 25 Group Manufacturing Services Engineering Services Dept Date: 9-Mar-07 Checked by : K Gopalakrishnan DOC. No: GMS/RP/26 Revision no.: 0.0 Approved by : A Venkatraman

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Plan 21: In this plan, there is a seal flush from pump discharge through an orifice and a cooler. Purpose: Cooling of seal Reduce fluid temperature to raise fluid vapor pressure margin Reduce coking Application Clean and high temperature service, typically between 80 deg.C to 175 deg.C Single and dual seals Limitations: Failure mode is due to chocking of orifice. Regular field checks to include monitoring of temperatures upstream and downstream of orifice. Construction Features: Seal coolers and piping need vents at highest elevation for venting before start Plan 23: In this plan, the flush is circulated by an internal pumping device to the cooler in a closed loop. This lowers the cooling duty of the cooler and may allow lower flush temperatures. Purpose: Cooling of seal Reduce fluid temperature to raise fluid vapor pressure margin Reduce coking Application Clean and high temperature service, typically between 80deg.C to 175deg.C Single and dual seals Limitations: Seal coolers and piping need vents at highest elevation for venting before start Failure mode is due to chocking of orifice. Regular field checks to include monitoring of temperatures upstream and downstream of orifice. Construction Features: Seal housing requires close clearance throat bush to keep away the process liquid Tangential seal gland taps shall enter at bottom and exit at top Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 11 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Plan 32: In this plan, the seal flush is provided from an external source. Purpose: Cooling of seal Reduce fluid temperature to raise fluid vapor pressure margin Prevent entry of dirty, polymerizing or solid particulate matter in the seal housing Application Service that maybe dirty, polymerizing, oxidizing or has particulate matter. High temperature service Single seals Limitations: External barrier liquid has to be available and compatible with the process liquid Regular monitoring required to ensure supply of correct quantity of flush at the specified pressure Construction Features: Throat bushing needs to be sized to hold pressure or maintain flow velocity Plan 52: In this plan, the unpressurized barrier liquid is circulated through the reservoir. Leakage of the inner and outer seals is monitored. Purpose: To provide a backup seal for the primary seal To provide seals with zero emissions, especially in applications of light hydrocarbons Applications where no process contamination is allowed Application Plan is used for dual seals in face to back arrangement High temperature, hazardous or toxic service Limitations: The required instrumentation raises the cost of the plan Construction Features: Piping loop needs to self vent to vapor recovery system near atmospheric pressure Buffer liquid to be compatible with process liquid and should preferably have a good specific heat Inboard and outboard seal leakages are known by increase in reservoir pressure and reservoir level respectively Prepared by: Paresh Girdhar Page: 12 of 25 Group Manufacturing Services Engineering Services Dept Date: 9-Mar-07 Checked by : K Gopalakrishnan DOC. No: GMS/RP/26 Revision no.: 0.0 Approved by : A Venkatraman

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Plan 53 - A: In this plan, the pressurized barrier liquid is circulated through the reservoir. Barrier liquid is circulated by pumping ring. Barrier liquid is pressurized in the reservoir by gas which is in direct contact with a liquid. Leakage of the inner and outer seals is monitored. Purpose: To provide a backup seal for the primary seal To provide seals with zero emissions, especially in applications of light hydrocarbons (having high vapor pressure) No process contamination is allowed Application Plan is used for dual seals in face to back arrangement High temperature, dirty, polymerizing, oxidizing, hazardous or toxic service Limitations: Requires regular monitoring of the reservoir pressure. Plan 53 A as pressurizing gas is in contact with the barrier liquid; gas pressure can drop due to absorption Gas charging arrangement is required Construction Features: Piping loop needs to self vent to vapor recovery system near atmospheric pressure Buffer liquid to be compatible with process liquid and should preferably have a good specific heat Inboard and outboard seal leakages are known by reservoir level alone. Plan 53 - B: In this plan, the pressurized barrier liquid is circulated through the reservoir. Barrier liquid is circulated by pumping ring. A bladder in the reservoir separates the gas from the barrier liquid. Leakage of the inner and outer seals is monitored. Purpose: To provide a backup seal for the primary seal To provide seals with zero emissions, especially in applications of light hydrocarbons (having high vapor pressure) No process contamination Need higher pressure than in Plan 53A Application Plan is used for dual seals in face to back arrangement where charge gas in reservoir can be absorbed by the buffer liquid. Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 13 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

High temperature, dirty, polymerizing, oxidizing, hazardous or toxic service Limitations: Requires regular monitoring of the reservoir pressure. Gas charging arrangement is required Construction Features: Piping loop needs to self vent to vapor recovery system near atmospheric pressure Buffer liquid to be compatible with process liquid and should preferably have a good specific heat Inboard and outboard seal leakages are known by reservoir level alone. Plan 53 - C: In this plan, the pressurized barrier liquid is circulated through the reservoir. Barrier liquid is circulated by pumping ring. The reservoir has a piston accumulator. The barrier liquid is pressurized by the process liquid from the pump discharge. Leakage of the inner and outer seals is monitored. Purpose: To provide a backup seal for the primary seal To provide seals with zero emissions, especially in applications of light hydrocarbons (having high vapor pressure) No process contamination Need higher pressure than in Plan 53A Dynamic tracking of system pressure Application Plan is used for dual seals in face to back arrangement High temperature, dirty, polymerizing, oxidizing, hazardous or toxic service Limitations: Reference line can get chocked. Construction Features: Piping loop needs to self vent to vapor recovery system near atmospheric pressure Buffer liquid to be compatible with process liquid and should preferably have a good specific heat Inboard and outboard seal leakages are known by reservoir level alone. Plan 54: In this plan, external pressurized barrier liquid is provided for dual seals in back to back or face to face arrangements. Purpose: Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 14 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

To provide seals with zero emissions, especially in applications of light hydrocarbons (having high vapor pressure) Isolate the process liquid Application Plan is used for dual seals in back to back or face to face arrangement High temperature, dirty, polymerizing, oxidizing, hazardous or toxic service Seal cannot induce circulation Limitations: Availability of reliable source of compatible barrier liquid at the required pressure Circulating system must be pressurized and energized at all times Construction Features: Piping loop needs to self vent to vapor recovery system near atmospheric pressure Buffer liquid to be compatible with process liquid and should preferably have a good specific heat Inboard and outboard seal leakages are known by circulating system level gauge. Plan 62: This plan provides external quench on the process side of the seal. Purpose: Prevent solid build up or icing on atmospheric side of the seal. This prevents seal hang-up situations Application Used typically in single seal arrangements with self flush Service that can cause polymerizing, oxidizing, coking, icing, crystallizing in atmospheric conditions Limitations: Need continuous supply and drain of quench media Needs monitoring of choking of supply or drain connections of quench media Construction Features: Quench side pressure to be limited to 0.3 bar (2 psi) Plan 65: This plan is designed to detect seal failures by directing atmospheric leakage to a small collection vessel. Purpose: Detect seal leakage and prevent leakage of seal to atmosphere Application Maybe used in single and back to face seal arrangements Prepared by: Paresh Girdhar Page: 15 of 25 Group Manufacturing Services Engineering Services Dept Date: 9-Mar-07 Checked by : K Gopalakrishnan DOC. No: GMS/RP/26 Revision no.: 0.0 Approved by : A Venkatraman

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Limitations: Need periodic checking of the drain line for choking Requirement of close clearance throttle bushing may require extended gland Construction Features: Requires a close clearance throttle bushing to aid directing leakage to the collection vessel Plan 71: This plan provides supply of gas buffer for dual gas seals and containment seals. Purpose: Provide for low pressure containment seal with gas buffer as backup for primary seal. Application Typical application is in face to back seal arrangement where outboard seal is a containment seal in dead ended seal cavity. High temperature, hazardous or toxic service Limitations: Gas buffer supply pressure to monitored on a regular basis Construction Features: With containment seals gas buffer pressure is limited to 0.7 bar (10 psi) Plan 72: This plan provides supply of gas buffer for dual gas seals and containment seals. This is selected when it is beneficial to sweep the containment seal cavity with an inert gas. Purpose: Provide back up for primary seal using a low pressure containment seal with gas buffer Application Typical application is in face to back seal arrangement where outboard seal is a containment seal. High temperature, hazardous or toxic service Limitations: Gas buffer supply pressure to monitored on a regular basis Used in conjunction with Plan 75 or Plan 76 where sweep of buffer gas and seal leakage is led to a closed collection vessel

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 16 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Construction Features: With containment seals gas buffer pressure is limited to 0.7 bar (10 psi) Plan 74: This plan provides supply of pressurized barrier gas for dual gas seals. Purpose: To provide seals with zero emissions, especially in applications of light hydrocarbons (having high vapor pressure) Isolate the process liquid Application Where liquid barrier for seals cannot be used Plan is used for dual seals in back to back or face to face arrangement High temperature, dirty, polymerizing, oxidizing, hazardous or toxic service Moderate temperatures Limitations: Clean and reliable supply of barrier gas supply is required. Construction: Barrier gas supply is typically 1.75 bar above the seal chamber pressure Gas flow meters indicate leakages of the inner and outer seals Bottled gas supply system maybe required as an emergency backup system Plan 75: This plan provides for collection of drain from containment seal cavity. The drain may then be led to a liquid collection system and/ or for vapor recovery. Purpose: Leakage collection for zero/low process emissions Safety indicator for primary seal Application Used alone or with Plan 72 Fluids that may condense in ambient conditions Service that maybe hazardous or toxic or with high vapor pressure Clean, non-polymerizing, non-oxidizing fluids Limitations: Regularly monitor liquid level, valve settings and low vent pressure. Construction Features: Collection reservoir is located below seal drain and downward sloped piping Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 17 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Hook up vent collection reservoir to low pressure vapour recovery system or flare system Primary seal leakage is indicated by increase in level / increase in vent pressure

Plan 76: This plan provides for vent from seal cavity of containment seal to vapor recovery. Purpose: Leakage collection for zero/low process emissions Safety indicator for primary seal Application Used alone or with Plan 72 Fluids that do not condense in ambient conditions Service that maybe hazardous or toxic or with high vapor pressure Clean, non-polymerizing, non-oxidizing fluids Limitations: Regularly monitor liquid level, valve settings and low vent pressure. Construction: Collection reservoir is located below seal drain and downward sloped piping Hook up vent collection reservoir to low pressure vapour recovery system or flare system Primary seal leakage is indicated by increase in level / increase in vent pressure

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 18 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

11.0

SEAL SELECTION PROCEDURE:

The following criteria maybe be considered for seal selection; Dual seals shall be applied in the following services: Hazardous services Hazardous services shall be defined on the following basis o Category 1: Liquids containing hydrogen sulphide in concentrations above 600 mg/kg. Liquids consisting of or containing lethal substances as indicated in the data/requisition sheet.
Examples of lethal substances include but are not limited to: HF acid, phenol, concentrated sulphuric or nitric acid.

o Category 2: Liquids consisting of or containing very toxic substances These are substances with TLV-TWA rating of 5 ppmv and lesser The value maybe extended to TLV-TWA rating of 20 ppmv if the location / site of the pump is frequently visited by personnel Liquids that are known to be proven carcinogens and or have been to known to be causing cancer in animal experiments. Hydrocarbon liquids at an operating temperature above their auto-ignition temperature. o Category 3: Hydrocarbon liquids with a seal chamber vapour pressure higher than 5 bar (abs). Hydrocarbon services of butane (C4) or lighter. Services in which the required three year operation cannot be ensured with a single seal application due to the physical or chemical properties of the liquid to be sealed. Services in which it is not permitted for the pumped liquid to enter the flare or atmosphere. In this case, dual pressurized seals shall be applied.

Seals and seal arrangements and seal harnesses shall be selected in accordance with Seal Piping Plans as described in 10.0 The following applications need the specific approval of the Principal: Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 19 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

Plan 54 for dual seals in Category 1 liquid services Dual unpressurized face to back seals with Plan 52 in Category 2 services Single seals with Auxiliary seals, other than dry gas seal types A wet contact seal with containment seal may be considered only for liquids specified under Category 3 and are not classified as hazardous or toxic as per the definitions in Category 1 and 2.

Dual pressurized non-contact (NC) (dry gas) seal arrangements with a pressurized nitrogen barrier are recommended for liquids that are not classified as hazardous and have a maximum vapor pressure at pumping temperature of 1.05 bar (abs). Careful attention shall be paid in this application to ensure a reliable nitrogen supply system. Non-contacting primary seal with containment seals in a face to back configuration maybe considered for fluids in supercritical state or vaporizing liquids after validating that the design ensures vaporization of liquid before it enters the seal faces and also that it does not condense or cause icing as it expands to a lower pressure. 12.0 12.1 SEAL MAINTENANCE and BEST PRACTICES: Observation Maintenance: Temperature monitoring of seals and sealing systems is most effective. Use of IR thermometers should be encouraged to record temperature of seal housing of pumps and ensure these are same or lower than the pump inlet or suction casing. It is a good practice to record differences in temperature on seal flush lines that are installed with orifices. This is applicable for seal piping plan 11, 13, 14 and 21. Difference in temperature can detect clogged orifices which is the most common failure mode. Temperature measurement of flush lines downstream of cooler in Plan 21, 23, 52, 53 will highlight the condition of the coolers. Vibration and noise due to cavitation or bearing damage are indications of causes that can affect seal life and need immediate reporting and action. Regular level monitoring of reservoirs of Plan 52, 53, 75 and 76 can provide early information of seal failures. Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 20 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

All pumps provided with quench should be checked for proper supply and drain of quench media. 12.2 Preventive Maintenance: The following activities are suggested during the normal PM schedules of the pump. Opening and cleaning of sealant lines, orifices, vents and drains especially for unclean services Back flush or cleaning of seal coolers. Ensuring adequate cooling water supply and return Calibration of instrumentation for Plan 32, 52, 53, 72, 74, 75, 76 12.3 Corrective Maintenance: The recommended practice is the use of seal cartridges in all applications. These cartridges maybe be restored and tested in-house or by the seal vendor. In any case, the following shall be the guidelines for repair as a minimum. 1. Surface Finish: The seal faces shall be lapped and finished to a maximum tolerance of 3 light bands or 0.87 microns The surface finish of the sleeve shall be a minimum of 0.8 microns Ra Surface finish of the seal housing face shall be 1.6 microns Ra The seal housing bore shall be machined to a finish of 3.2 microns Ra

2. Geometric Tolerances: Shaft/sleeve runout at seal face area should be within 0.05 mm Radial shaft deflection at seal face area should be within 0.05 mm Squareness of the seal housing (dial base on shaft and pointer in axial direction on face of seal housing) shall be within 0.05 mm Concentricity of the bore of seal housing (dial base on shaft and pointer in radial direction on bore of seal housing) with shaft shall be limited to 0.07 mm Seal Testing: All wet contact seals shall be subjected to a hydrostatic test. The test pressure shall be the higher of the pressures the seal

3.

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 21 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

maybe subjected to during static (shutdown) and dynamic (operating) conditions of the pump. 12.4 Spare parts Management: 1. A master list of all installed seals shall be maintained indicating their interchangeability 2. Seal cartridges or spares maybe categorized as consumable or durable spares Their reorder level and reorder quantity shall be determined accordingly. Ordering information on slow or nonmoving seal spares shall be reviewed annually. 3. All seal components shall have the information about their shelf life and storage instructions. It is recommended to store all elastomers in low temperature and humidity free environments 4. There shall be annual inspection of the condition of the stocked seal parts. 13.0 DOCUMENTATION AND RECORDS: For effective maintenance and troubleshooting, it is essential to have the following documentation for mechanical seals and sealing systems; Original seal specification document Seal cross-section drawing with dimensions and tolerances. It should also include bill of materials indicating MOC, installed quantity and OEM part number Seal piping plan details, documents and drawings Seal and seal plan manufacturing and testing records Repair / refurbishing procedures and check sheets with protocol values.

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 22 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited

Copyright: Reliance Industries Limited, India

14.0

REFERENCES:

API 610 - Centrifugal Pumps for General Refinery Service, 10th Edition API 682 - Shaft Sealing Systems for Centrifugal and Rotary Pumps, 2nd Ed. 2002 Shell DEP - Shaft Sealing Systems For Centrifugal And Rotary Pumps: DEP 31.29.00.33-Gen. - July 1998 Overview of API 682 and ISO 21049 Michael B Huebner Proceedings of 21st International Pump Users Symposium 2004 Overview of API 682 Second Edition - Michael B Huebner Proceedings of 20th International Pump Users Symposium 2003 Advances in Mechanical Sealing An introduction to API 682 Second Edition M.B.Huebner, J.M.Thorp, G.S.Buck, C.L.Fernandez Proceedings of 19th International Pump Users Symposium 2002 Containment Seals for API 682 Second Edition P.E.Bowden, C.J.Fone Proceedings of 19th International Pump Users Symposium 2002 Use of Non-Contacting Seals in Volatile Services B.Goodenberger, D.E.Barron, J.Marquardt - Proceedings of 20th International Pump Users Symposium 2003 Understand Mechanical Seals A.S.Godse Hydrocarbon processing April 1995 Mechanical Seal Piping Plans Flowserve Document FTA160 Rev 12/03 Flowserve Solutions Division Advanced Gas Sealing Systems for Hydrofluoric Acid Alkylation and Other Extremely Hazardous Duties D. Kozlowski, E.Jahromi. J.R.WasserProceedings of 20th International Pump Users Symposium 2003 Burgmann Mechanical Seals Catalogue

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 23 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited


Appendix 1.0

Copyright: Reliance Industries Limited, India

Seal Type A and its Alternative

Seal Type B and its Alternative

Seal Type C and its Alternative

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 24 of 25 Date: 9-Mar-07 Revision no.: 0.0

For Internal Circulation Only

Reliance Industries Limited


Appendix 2.0

Copyright: Reliance Industries Limited, India

MECHANICAL SEAL PIPING PLANS


Single Seals Optional Fluid Quench Flush Type ? Plan 62 Self Flush Dead Ended Plan 02 Sealant is dirty/solids/ polymerizing ?
No Normal
A

Multiple Seals Seals Face to Back (FB) External flush Plan 32 Back to Back (BB) / Face to Face (FF)

Wet Contact Seals

Wet / Non Contact + Containment Seal Inboard Seal - Wet

Non Contact Seals External Pressurized Barrier Gas Plan 74 Outboard Seal

Wet Contact Seals External Pressurized Barrier liquid Plan 54

Positive Pressure Difference

Inboard Seal Outboard Seal

Inboard Seal - NC
Yes

External Pressurized Barrier liquid Plan 54 Induced Circulation

External Unpressurized Buffer liquid Induced Circulation

Pressurized Barrier Gas Plan 74

Product Temperature ? Plan 52 Plan 01 Plan 11


High

Unperssurized Buffer Gas Dead Ended Plan 71 Gas Supply System Plan 72 Drain-Mixed Phase Plan 75

Sealant Cooler Induced Circulation Vertical Pump? Needs venting ?

Plan 21

Possibility of Gas absorption?


No Yes

Plan 23

Plan 53-A Drain-Completely Dry Plan 76

Plan 13 Plan 14
No

Need dynamic tracking of system pressure? Plan 53-B


Yes

Plan 53-C

Prepared by: Paresh Girdhar Checked by : K Gopalakrishnan Approved by : A Venkatraman

Group Manufacturing Services


Engineering Services Dept

DOC. No: GMS/RP/26

Page: 25 of 25 Date: 9-Mar-07 Revision no.: 0.0