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API PLANS

API 682 Flushing & Quenching Plan

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Why API Plans?

Definition how to operate the seal


Communication between Customer,
Engineering Company, OEM
and seal supplier
Description of minimum requirements
for the system design

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Flushing Plans


In flushing, fluid is introduced into the seal chamber on the
process fluid side in close proximity to the seal faces and
typically used for cooling & lubricating the seal faces.
Benefits:
Removal of heat generated between the seal faces Cooling.
Provide lubrication.
Increase margin between the vapour pressure of the fluid
and seal chamber pressure.
Keeps the liquid inside the seal chamber in constant
circulation.
Prevents abrasive particles from reaching the seal faces
with external liquid injection.
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Circulation Plans

Seal faces generate heat and require cooling


& lubrication while sealing.
These plans/systems are used to dissipate this
generated heat and lubricate the seal faces
thus extending the seal life.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Quenching Plans


A neutral fluid, usually water, steam or nitrogen, introduced
on the atmospheric side of the seal for:
Absorption or removal of leakage by quench fluid.
Monitoring of the leakage by measurement
Lubrication and cooling of secondary seal
Exclusion of air
Protection against dry running
Stabilisation of lubricating film
Heating
Icing protection

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plans Overviews


Plan
01
02
11
12
13
14
21
22
23
31
32
41
API PLANS

Service

Description

Use for clean Media


Flushing on Product side

Use for fluids


containing Solids

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plans Overviews


Plan
51

Service
Use for fluids
containing Solids

52
53A
53B
53C

Use for dangerous


fluids

Description
Quench, Circulation
pressureless

Pressurised Reservoir
Pressurised System

54
Flushing on
atmospheric side

61
62

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plans Overviews

Plan
71

72

74
75
76

API PLANS

Service

Use for gaseous


media
Use for liquid/
degassed or
gaseous media
which could
containing solids
or is dangerous

Ashutosh Chirmule

Description
Tapped connections for
customer use
External supplied pressureless gas connection
External supplied barrier
gas connection
Containment seal for
condensing leakage
Containment seal for
non-condensing leakage

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 11

- Seal flush for single


seals
- Product flow from
discharge to seal
chamber
- Orifice for flow restriction
Use:
for clean media in general
service

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 12

- Seal flush for single seals


- Product flow from
discharge to seal
chamber through
- Orifice for flow restriction
- strainer
Use:
for clean media in
general service

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 13

- Seal flush for single


seals
- Product flow from seal
chamber to suction
- Orifice for flow restriction
Use:
for clean media,
often in vertical pumps

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 14

- Seal flush for single


seals
- Product flow from seal
chamber to suction as
well as discharge to seal
chamber
- Orifice for flow restriction
Use:
for clean media,
often in vertical pumps

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 21

- Seal flush for single


seals
- Product flow from
discharge
- to seal chamber
- Orifice for flow restriction
- Heat exchanger for
cooling

TI

Our Products : Heat exchanger


WE, WDK, WED etc.

API PLANS

Ashutosh Chirmule

Use:
for clean media
in hot services

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 22

TI

Our Products : Heat exchanger


WE, WDK, WED etc.

API PLANS

Ashutosh Chirmule

- Seal flush for single seals


- Product flow from
discharge
- to seal chamber through
strainer
- Orifice for flow restriction
- Heat exchanger for
cooling
Use:
for clean media
in hot services

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 23

TI

- Circulation from pumping


device through cooler
back into seal chamber
- Heat exchanger for
cooling
Use:
for clean media
in hot services minimizing
the heat load on the
cooler

Our Products : Heat exchanger


WE, WDK, WED etc.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plan 23

- Circulation from pumping


device through cooler
back into seal chamber

Use:
for clean media in hot
services minimizing the
heat load on the cooler
Caution:
Unlike Plan 21, Plan 23 does not have an orifice in its loop.
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 31

- Seal flush for single seals


- Product flow from
discharge through
cyclone separator
- Clean fluid to seal
chamber
- Solids to pump suction
line

Cyclon

Use:
services containing solids
Our Products : Cyclone
ZY61, ZY62, ZY203.

API PLANS

Ashutosh Chirmule

Separators

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plan 31 - Cyclone Separator

Schematic
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plan 31 - Cyclone Separator

Process liquid from discharge of the pump is recirculated


through a cyclone separator to the seal. Solid particles are
centrifuged through cyclone separator and sent back to suction.
The Plan is specified for services containing solids.
The efficiency of the Cyclone Separators depends on the
specific weight of the solid particles. The specific weight of the
particles should be at least twice or more than that of carrier
liquid. It also depends on the size of the particles and pressure
difference at inlet and outlet of the cyclone separator.
The Cyclone Separator has to be installed in vertical position
only.
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 32

FI
PI
TI

If specified

- Seal flush from


external source for
single seal
- normally used with a
closed clearance
throat bushing
Use:
services containing solids
or contaminants

Our Product : Water supply unit

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plan 32

PRESSURE
GAUGE

STRAINER

EXTERNAL FLUSH
TO SEAL

ORIFICE

Caution:
THE EXTERNAL FLUSH TO SEAL MUST BE COMPATIBLE WITH THE PUMPED MEDIA.
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 41

Cyclon

TI

Our Products:
Cyclon Separators ZY 61,62,602

- Seal flush for single seals


- Product flow from
discharge through cyclone
separator and
- heat exchanger
- cooled, clean fluid to seal
chamber
- Solids to pump suction
line
Use:
services containing solids

Heat exchanger WE, WDK, WED


Etc.
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plan 41 (Plan 21 + 31)

- Seal flush for single seals


- Product flow from discharge
through cyclone separator
and
- heat exchanger
- cooled, clean fluid to seal
chamber
- Solids to pump suction line

Use:
Hot services containing
solids

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API Plans Tandem / Dual Seals


Digit 5 stands for
Dual seals with liquid buffer OR barrier.

Digit 2 stands for


Arrangement 2 i.e. tandem un-pressurized.

Digit 3 stands for


Arrangement 3 i.e. tandem pressurized or
Double Back to Back pressurized. Circulation
within close loop.
Digit 4 stands for
Arrangement 3 i.e. tandem pressurized or
Double Back to Back pressurized. Circulation
from external system.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

BUFFER LIQUID
All fluids used at pressures lower than the box pressure or at atmospheric
pressure are called BUFFER LIQUID.
They are used in conjunction with Plan 52.
The liquid along with the O/B seal act as a buffer to take care of leakage after
the I/B fails and hence is called BUFFER.
A Buffer fluid lubricates the O/B seal.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

BARRIER LIQUID

All fluids used at a pressure higher than box pressure are called BARRIER
FLUIDS.
They are used in conjunction with plans 53A, 53B, 53C and 54.
Since the liquid acts as a barrier between the pumped fluid and the
atmosphere, it is called BARRIER FLUID.
A Barrier fluid lubricates both the I/B and O/B seals.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Typically used BUFFER & BARRIER FLUIDS


Cooling Water
D. M. water

METHANOL

50% Water + 50% Ethylene Glycol


Lubricating oils
Thermic fluids
Synthetic oils

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Levels in API Plans


NLL The normal liquid level.
The system maintains this level in the pot during normal operation of the seals.
LLL The Low liquid level.
When the O/B seal in Plan 52 or 53 leaks or the I/B seal in a Plan 53 leaks, the level
in the pot drops. The lowest level to which it drops to give an alarm is the LLL.
HLL The High liquid level.
When the I/B seal in Plan 52 leaks, the level in the pot increases. The highest level
to which it rises to give an alarm is the HLL.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Why 28 liters ?
The API 682 calls for a 20 liters volume of buffer / barrier liquid at the
NLL.
Also it recommends use of a 8 schedule 40 pipe as a minimum.
With this and the dimensions given in the EIL sketch, the pot total
volume works out to 28 liters and is widely followed by all consultants
for refinery jobs.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

POT DESIGN
ASME Section VIII Div. 1
Design pressure 42 kg/cm2(g) or = flange rating of pump
HT pressure 63 kg/cm2(g)
8 sch 40 ASME B 16.5 class 300 flanges
8 sch 80 ASME B 16.5 class 600 flanges
8 sch 160 ASME B 16.5 class 900 / 1500 flanges
Accordingly, height of the pot increases since with increase in
Schedule the ID of pot decreases, OD remains 219.1 mm only.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Instrument selection based on Vapor Pressure

INSTRUMENTS
PARAMETERS
LSL

LSH

PSH

V.P. < 1 Kg/cm2(a)

1 Kg/cm2(a) < V.P. < Flare back Press.

V.P. > Flare Back Press.

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

LEVEL INSTRUMENTS

API PLANS

Level Sensing

Level Indicating

Level Switches
&
Level transmitters

Level Gauges

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

PRESSURE INSTRUMENTS

API PLANS

Pressure Sensing

Pressure Indicating

Pressure Switches
&
Pressure Transmitters

Pressure Gauges

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

When to select which Plan ?


APPROPRIATE PLAN

PARAMETERS

52

53A

53B

53C

54

No media contamination allowed

No leakage to atmosphere allowed

Media contamination acceptable.

Diluted leakage to atmosphere allowed

Pump pressures varying. Duty point variation

Central pressure source reliable

Central pressure source not reliable

Insufficient central pressure source

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 52
Vent
PI PS

MAX

MIN

Our Product :
Thermosiphon Systems
API PLANS

Ashutosh Chirmule

- External reservoir
providing buffer fluid
- Unpressurized
- Product leakage in to
buffer fluid
- vaporizing leakage
escapes through vent
line
Use:
Services where leakage
to atmosphere can not be
tolerated clean, nonpolymerizing products

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 53A
External
pressure source

PI

PSL

LG
MAX

MIN

Our Product :
Thermosiphon Systems
API PLANS

Ashutosh Chirmule

LSH
LSL

- External reservoir providing


buffer fluid for dual
mechanical seal
- Barrier fluid pressure 2 bar
above sealed pressure
- pressurized with nitrogen Barrier fluid leakage into
product
Use:
Services with abrasive,
dirty, or polymerizing
products

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Limitation of TS-System Due to Gas Absorption

The absorption depends on

- Fluid
- Pressure
- Temperature
- Gas ( e.g.. N2 or Air )

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Limitation of TS-System Due to Gas Absorption

Degassing process
is influenced by:

Heat transfer

; rising temperature
; dropping pressure
; fluid is in motion
Turbulence
Via shaft, flange and housing

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

Friction

8th Sep. 2010

API-Plan 53B

PI

- Circulation with bladder


accumulator and cooler,
pressurized.
- Forced circulation by
pumping ring or circulation
pump.

PSL

TI

API PLANS

Ashutosh Chirmule

Use:
When using abrasive,
contaminated
or polymerizing
Media

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 53B
Different Design Possibilities

API PLANS

Cooler
Fin Tube Cooler or Water Cooler
Different Cooling Capacities

Accumulator
Different Volume and Material

Connections
Flanges or Twin ferrule Fittings

Instrumentation
Switches or Transmitters
EEx i or EEx d
Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 53C
LI
LSL

Our Product : SPO9050

PI

- Circulation with pressure


booster (DRU) and cooler,
Pressurized by Reference
- pressure of seal chamber.
- Forced circulation by
pumping ring or
Circulation pump.
- Pressure ratio
1:1,1 resp. 1:1,5

PSL

TI

API PLANS

Ashutosh Chirmule

Use:
When using abrasive,
contaminated
or polymerizing
Media

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

DRU Pressure Booster System

DRU
What is that

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

DRU Pressure Booster System


A system for fluctuating product pressures
Pressurization
via the piston ratio above the
product pressure in stuffing box
Pressure level
can change during operation
but is always higher than product
Circulation
by circulation pump, pumping screw
Leakage compensation
with in the volume covered by the piston range
Cooling
by integrated heat exchanger
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Operation of DRU Unit


Bufferfluid

Piston
Ratio 1:1.1
or 1:1,5

Cooling
Product pressure
from stuffing box

Seal

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Operation of DRU Unit


Leakage
No influence to the
Bufferpressure
Piston
Ratio 1 : 1.1
or 1 : 1,5

When seal leaks,


Piston moves up
Seal

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Operation of DRU Unit


Refilling
No influence to
the
Bufferpressure

Piston
Ratio 1:1.1
or 1:1,5

Refill

Piston moves down


when buffer fluid
is refilled

Seal
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Special attention for operation and start up

API PLANS

Vacuum operation
Dirty products
Venting of the system
Position of the piston
Level switch ( min. / max. )
Safe operation

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 54

Barrier
system

Our Product :

- System supplying clean


barrier fluid to dual
mechanical seal
- Barrier fluid pressure 2
bar above sealed
pressure
- Barrier fluid leakage into
product
Use:
Services with abrasive,
dirty, or polymerizing
products

SPA Barrier Fluid System


API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Barrier Fluid System SPA Dedicated API Plan 54

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

SPA Flow Diagram ( Open System )

To seal

From seal

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

Functions of SPA System


Pressurisation
via the gear pump in normal operation
Pressure retaining unit
with pump stop the accumulator keeps the pressure
between the two check valves
Continous flow through the seal
no flow with pump stop
Relief of pressure into the tank
by hand possible during stand still
Cooling of fluid in the tank
heat exchanger operating with water
Filter unit for cleaning the fluid
single or double filter
Supply of two seals possible
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API-Plan 62

- External source providing


a quench ( steam,
nitrogen, water )
Use:
for clean media in service
where the presence of
oxygen or air should be
avoided
Drain

Our Product:
Water supply unit
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API PLAN 62
EXTERNAL FLUID AT ATMOSPHERIC SIDE

SCHEMATIC ARRANGEMENT
API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010

API PLANS

Ashutosh Chirmule

EagleBurgmann India Pvt. Ltd. 2012

8th Sep. 2010