API Piping Plan 53G (Gas Seals)

REV 1.0

Definition:
A secondary seal API piping plan, using nitrogen gas as the barrier medium, operated at a higher pressure than that of the primary seal chamber, to provide a barrier between the product in the pump and the atmosphere.

Objective:
The objective of API Plan 53G is to eliminate product leakage to atmosphere for compliance with EPA and internal safety regulations as well as increase the overall reliability of the sealing system for severe duty services. This piping plan will be found in a variety of services including products that are considered health hazards, auto-ignition/flashing, or too abrasive for acceptable seal life. Examples of products meeting this requirement are high concentration of known carcinogens, HF Acids, Caustics, hot hydro-carbons above the auto-ignition point. The secondary sealing system in this API piping plan is maintained at a higher pressure than the primary seal chamber. This provides a clean stable environment for both primary and secondary seals to operate while eliminating process contamination of the secondary sealing system or environment. The barrier gas must be compatible with the product since a small amount of this gas will migrate into the process stream. The barrier gas must also be environmentally safe according to EPA and internal safety regulations.

Line Up Procedure:
When dealing with a gas dual sealing system, there will be a seal gas panel charged from an external gas source, ( typically nitrogen ), that is compatible with the pumped product. The gas supplied to the panel is filtered at the panel using a coalescing filter. The pressure that the panel operates at will be adjusted via the regulator mounted on the panel. There is a pressure gauge on the panel that records the pressure on the seal. Open the regulator to the specified pressure is obtained on the pressure gauge. Once the seals are stable, the flow meter should drop to a range of 0-2 scfh. Plant standards for most services are available for review. In the event you are unsure of the proper selection, call your Reliability Engineer or BW/IP for verification.

Note: The gas pressure must be on the sealing system prior to lining up your pump for service. Always stabilize the gas sealing system prior to applying any pressure to the pump, and never de-pressure the gas sealing system prior to de-pressuring the pump. This will prevent damage to the seals during start-up and shut down procedures.
The following steps outline the checks required before, during, and after start-up of the equipment.
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Check to make sure the regulator on 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. Check to make sure the flow meter drops to 0-2 scfh. If not, proceed to the trouble shooting section below. Proceed with pump line-up procedure per plant specifications. Check for leaks around any valves. 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.

Preventive Maintenance and Troubleshooting:

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. There are a number of failure modes for this type of system. They are listed and discussed separately below. No or Low Gas Panel Pressure with Typical Flow Recorded on the Flow Meter No or low gas panel pressure is usually caused by one of four things. First, check to make sure the supply to the panel is fully open. Partially closed or closed supply valves can effect the supply to the regulator on the gas panel. Second, the regulator on the panel may not be adjusted properly. Third, the supply pressure to the gas panel may be varying. Last the filter element in the coalescing filter on the gas panel may be clogged. Solution Check to make sure the supply valve(s) to the gas seal panel is fully open. Check to make sure the supply pressure to the panel is at normal levels. Adjust the regulator toward the increasing pressure direction only to obtain the baseline pressure. 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. High Gas Panel Pressure with Typical Flow on the Flow Meter This normally occurs when the regulator on the panel has been set above the base pressure reading.

Solution

Adjust the regulator on the gas panel in the decreasing direction. When making the adjustment, do so slowly to avoid dropping the panel below the desired base pressure reading. High Flow reading on the Flow Meter High flow readings are typically considered flows in excess of 5-6 scfh. The causes of leakage can be a result of loose fittings located anywhere down stream of the flow meter, up to the connection on the seal flange. High flow rates can also be caused from damage to the seal faces within the seal assembly. Solution 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, as the flow meter is calibrated in SCFH. If all fittings are leak free, call your maintenance personnel to trouble shoot 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 run and an orderly shut-down be executed when it is appropriate.

Shut Down Procedure:

Once the suction and discharge lines have been blocked, and all the pressure on the pump case has been relieved, check the gauge on the gas panel. Block off the pressure source from the gas panel and allow the pressure to drop to atmospheric pressure. When the gauge reads 0 PSIG, isolate the gas panel from the seal flange, and prepare the pump for maintenance.