Beruflich Dokumente
Kultur Dokumente
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Flushing
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Flushing
Benefits:
Provide lubrication.
Increase margin between the vapour pressure of the fluid and seal
chamber pressure.
Prevents abrasive particles from reaching the seal faces with external
liquid injection.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Quenching
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API Circulation Plans
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans
Why API Plans?
A significant number of the seal failures are attributed to unsuitable seal
environment. The environment in which the seal operates largely determines the
performance and the life of the mechanical seal.
API plans / systems / accessories are hence rightly called the support systems as
they support the seal to ensure a longer life.
Seal support systems are a combination of one or more instrument (s)/ piping /
device (s) that ensure that the mechanical seal gets a continuous desired flow of
flush fluid. It serves the function of removing heat from the seal area and lubrication
the seal faces.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans
Seal support plans / systems are broadly divided into two types :
Flushing Plan and Quenching Plan
Flush plans are defined as the sealing support systems which provide flush fluid to
the mechanical seal inside the seal chamber and directly affect the lubrication, heat
dissipation and longevity of the seal.
Quench plans on the other hand are support systems that are provided on the
atmospheric side of the seal. Quench plans do multiple functions including indirect
heat removal, cleaning up the debris from under the faces, maintaining a liquid barrier
between atmosphere and the seal faces etc.
Flush plans are further divided into several categories like Single seal plans, dual seal
plans, gas seal plans etc.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans
The API 610 & the API 682 standards recommend seal flush plans and seal quench plans to be used for
the single as well as dual mechanical seals for pumps.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans Overview
Plan Service Description
01
02
11
12
13 Use for clean Media
14 Flushing on Product side
21
22
23
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans Overview
53A
53B Pressurised Reservoir
53C Use for dangerous Pressurised System
54 fluids
61 Flushing on
62 atmospheric side
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans Overview
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API Plans
API-Plan 01
- Internal circulation from
pump discharge to seal
chamber
Use:
For clean media
in general service
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Plan 01
Integral (internal) re circulation is from discharge to seal. A connection
is made from an area behind the impeller, near discharge to seal
chamber. Recommended for clean fluids.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Plan 02
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Plan 02
The seal chamber / stuffing box is dead-ended (with no circulation of
fluid).
This plan is preferred plan for the clean and relatively cool liquids having
sufficient (at-least 1 kg/cm2) margin between vapour pressure and
stuffing box pressure.
Care should be taken to vent the stuffing box properly. One 5 mm
diameter hole at the topmost position of the throat should be provided for
venting purpose.
Depending on the requirement cooling or heating is provided in the
stuffing box jacket.
For liquids at self ignition temperature API Plan 02 is not recommended.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Plan 11
A line with flow control orifice is connected from the discharge side of
the pump into the gland flush connection. It is default seal flush plan.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans
API-Plan 12
- Seal flush for single seals
- Product flow from
discharge to seal
chamber through
- Orifice for flow restriction
- strainer
Use:
BURGMANN Product: for clean media in
SP24 Orifice general service
SP18 Strainer
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Plan 13
Horizontal Pump
Orifice
From Seal
Suction
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Plan 13
From Seal
Orifice
Vertical Pump
Suction
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Plan 13
In this plan liquid moves away from the seal face instead of impinging
on to it ( API Plan 11) and the stuffing box pressure reduces making
the seal more comfortable.
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Plan 14 r ge to se al chamber
c ha
Media from dis
thru orifice
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Plan 21
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Plan 21
A line with orifice is connected from the discharge side of the pump
through a flow control orifice and cooler into the seal chamber.
It provides cool flush to the seal. This plan is the best for liquids at self
ignition temperature. In the event of seal leakage, cool liquid will continue
to reach seal faces as long as the pump is running ,ensuring that hot
liquid does not come out.
The disadvantage is that heat loss is more, also cooling water
requirement is high.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Plans
API-Plan 22
- Seal flush for single seals
- Product flow from
discharge
TI - to seal chamber through
strainer
- Orifice for flow restriction
- Heat exchanger for
cooling
Use:
for clean media
BURGMANN Product:
in hot services
WDK / WED / WEL / WE
Heat exchanger
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Plan 23
Recirculation using a pumping screw/ring in the seal chamber through a
cooler and back into the seal chamber
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API Flushing Plan 31
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Cyclone Separator
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API Flushing Plan 32
Clean flush fluid is injected into the seal chamber from an external source
PRESSURE
GAUGE STRAINER
ORIFICE
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API Flushing Plan 32
It is also used to reduce flashing or air intrusion (in vacuum services) across
the seal faces by providing a flush that has a lower vapour pressure or that
will raise the seal chamber pressure to an acceptable level. The external flush
should be continuous and reliable even during non-standard situations such
as start-up or shutdown.
The external flush should also be compatible with the process stream because
it will flow from the seal chamber into the process fluid.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Flushing Plan 32
Plan 32 is not recommended for cooling only, as the energy costs can be very
high. Product degradation costs should be considered when using a Plan 32.
Pressure of the external flush should always be at least 2 bar above the seal
chamber pressure
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API Flushing Plan 41
Use:
EBI Product: Hot services containing solids
ZY Cyclon Separators
WDK / WED / WE / WEL Heat exchanger
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API Circulation Plan 51
Vent
Plugged Use:
Services where leakage to
atmosphere can not be
tolerated clean, non-
EBI Product: polymerizing products at low
QFT Qench fluid vessel temperature
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plans
Note on the use of single seals and need for dual seals
All the above mentioned plans are normally used for single seals (though they are
used for inboard seals of dual seals also).
Single seals are not recommended to be used for media which are toxic,
inflammable, hazardous, poisonous etc.
For all such applications, dual seals are used. API plans for dual seals start with the
digits 5 or 7
Dual seals use either a buffer fluid or a barrier fluid as a flushing media
Buffer fluid is an un-pressurized flush fluid and is used in plans 52 & 72.
Barrier fluid is a pressurized flush fluid and is used in plans 53A/B/C, 54 and 74
5 series plans are used for liquid buffer/barrier and 7 series are used for gas
buffer/barrier media
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API Circulation Plan 52
API seal configuration 2CW-CW Vent line
Pressure gauge
Instrument Use
Pressure switch
Refill connection LG Level indication
(mandatory)
Level switch
Level gauge PG Pressure indication
(mandatory)
LSL To detect leakage from outer
(mandatory) seal
LSH To detect inner seal leakage
(optional) (for non-flashing media)
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 52
Features
1. The pumped fluid does not get contaminated
2. The pumped media does not leak directly to atmosphere
3. No pressurization required for the reservoir as in case of a plan 53
Application areas
1. For clean, non-polymerizing, flashing services.
Can also be used for non-flashing services
2. For services where product dilution is not acceptable
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 53A
Pressure gauge
API seal configuration
Vent line
PG Pressure indication
(mandatory)
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 53A
API seal configuration : 3CW-FB / 3CW-BB / 3CW-FF
Instrument Use
LG Level indication
(mandatory)
PG Pressure indication
(mandatory)
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 53A
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API Plan 52 & 53A System
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API Circulation Plan 53B
Pre-charging connection
API seal configuration
Pressure gauge and
Pressure switch Bladder Accumulator
3CW-FB / 3CW-BB / 3CW-FF
Vent Cooler
Instrument Use
PG Pressure indication
Hand pump
(mandatory)
Temperature
TG Temperature
gauge (optional) indication
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 53B
API seal configuration
3CW-FB / 3CW-BB / 3CW-FF
Instrument Use
PG Pressure indication
(mandatory)
TG Temperature
(optional) indication
PSL To detect leakage
(mandatory) into inner as well as
from the outer seal
Hand Pump To refill barrier fluid
(mandatory) in the accumulator
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 53B
Pressurized barrier fluid circulation to the seal chamber through a bladder accumulator.
Circulation is maintained by a pumping ring in running condition and thermo siphon in standstill
condition.
Features
1. The barrier fluid and Nitrogen are separated by a bladder & hence no chance of N2 mixing with
barrier fluid.
2. The pumped fluid gets contaminated but never leaks to the atmosphere, unless the system
pressure is lost.
3. This is a standalone system and hence much more reliable than plan 53A
4. Heat is removed with the help of a water or an air cooler.
Application areas
1. For hazardous, toxic, inflammable, bad lubricity media & for services where product dilution is
acceptable.
2. For polymerizing and dirty media where media is unsuitable for flushing the inner seal faces.
3. For pressures above 16 bar, at which normally pressure source is not available at sites.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Deatails of Barrier/Buffer Fluid Resrvoir
Capacity of reservoirs: -
6 liters
8 liters
12 liters
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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 reservoir total
volume works out to 28 liters and is widely followed by all consultants for
refinery jobs.
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Reservoir Design
ASME Section VIII Div. 1
HT pressure 63 kg/cm2(g)
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API Circulation Plan 53C
Vent API seal configuration
Reference pressure line
3CW-FB / 3CW-BB / 3CW-FF
Vent
Cooler Pressure gauge Piston Accumulator
and Pressure
switch
Instrument Use
PG Pressure indication
(mandatory)
Temperature gauge
TG Temperature indication
(optional)
PSL To detect leakage into inner
(mandatory) as well as from the outer
seal
LSL To detect leakage into inner
(mandatory) as well as from the outer
seal
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 53C
Pressurized barrier fluid circulation to the seal chamber through a piston type accumulator.
Circulation is maintained by a pumping ring in running condition and thermo siphon in standstill
condition. The seal chamber reference pressure is magnified by a defined proportion in the
accumulator and this magnified pressure barrier fluid is then circulated through the seal chamber.
Features
1. No Nitrogen is used. Uses seal chamber pressure hence reliable. Thus independent of plant utility.
2. The pumped fluid gets contaminated but never leaks to the atmosphere, unless the system
pressure is lost
3. This is a standalone system and hence much more reliable than plan 53A
4. Heat is removed with the help of a water or an air cooler
Application areas
1. For hazardous, toxic, inflammable, bad lubricity media & for services where product dilution is
acceptable
2. For polymerizing and dirty media where media is unsuitable for flushing the inner seal faces
3. For applications with varying seal chamber pressures
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
DRU Pressure Booster System
DRU 2063
?
What is that
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Operation of DRU Unit
Buffer fluid
Piston
Ratio 1:1.1
or 1:1,5
Cooling
Seal Product pressure
From stuffing box
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Operation of DRU Unit
Leakage
No influence to the
Buffer pressure
Piston
Ratio 1 : 1.1
or 1 : 1,5
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Operation of DRU Unit
Refilling
No influence to
Piston
the Ratio 1:1.1
Buffer pressure or 1:1,5
Refill
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Commonly used Buffer / Barrier Liquid
Cooling Water
D. M. water
Lubricating oils
METHANOL
Thermic fluids
Synthetic oils
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
Levels in API Plans
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Instrument selection based on Vapor Pressure
INSTRUMENTS
PARAMETERS
LSL LSH PSH
1 bar A < V.P. < Flare back Press. (2.75 bar A max) Y Y Y
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Level Instrument
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Mounting of Level Switch
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Level Transmitter
Displacer Type Guided Wave Radar Type
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Weld Pad Level Gauge
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Screwed Connection Level Gauge
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Flanged Connection Level Gauge
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Pressure Instruments
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Pressure switch
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PRESSURE TRANSMITTERS
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Pressure Gauge
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Barrier Fluid System SPA Dedicated API Plan 54
Pressurized external barrier fluid system supplying barrier fluid to the dual seals.
Circulation is maintained by an external pump or pressure system.
Stand alone pressure system
mandatory instruments
Instrument Use
PG Pressure indication
TG Temperature indication
PSL To detect inner or outer
seal leakage
LSL To detect inner or outer
seal leakage
Filter/Strainer To remove suspended
particles
LG To indicate level in
reservoir
Cooler To cool the hot barrier
liquid returning from the
seal
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
SPA Flow Diagram ( Open System )
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Functions of SPA System
Pressurization
By gear pump in normal operation
Pressure retaining unit
with pump stopping accumulator maintains the pressure in the system
between the two check valves
Continous flow through the seal
no flow with pump idle
Relief of pressure into the tank
by hand possible during stand still
Cooling of flid in the tank
heat exchanger operating with water
Filter unit for cleaning the fluid
single or double filter
Supply of two seals possible
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Quenching Plan 61
Tapped & plugged connections for future use as plan 62 or as plan 65
Features
The Q & D connections when
piped, this plan can get
Quench - Q
converted to plan 62
When the D connection is piped
to a drain collection system, this
plan can be used as a plan 65
Normally used for single seals
Application areas
As plan 62 or 65, in future
Drain - D
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Quenching Plan 62
Supply of an external fluid to the atmospheric side of the seal faces using
the quench connections
Features
1. Uses water, steam or Nitrogen
2. The quench fluid cools the seal
faces & also reduces coking and
oxidation of the media by creating
a barrier between the seal faces
and the atmosphere
3. Flushes away built up material or
solids underneath the seal faces
Application areas
1. Caustic, crystallizing & oxidizing
services
2. Used with steam to avoid coking
The quench fluid can be clean water (1 lpm @ 0.5 kscg), 3. Hot hydrocarbons
steam (1 m3/hr @ 0.5 kscg) or low pressure Nitrogen. 4. Cryogenic services
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API Plan 65 Leakage Detection
Features
Drain A level switch gives an alarm in case of heavy
port
leakage
Drain
High level Has an overflow connection in the top half of the
Overflow line
Collection
switch pot
drain collector to drain excessive leakage
Orifice plate
Application areas
Single seals with plan 61 connection
Condensing leakages
To liquid collection
system
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Flushing Plans for CS & NC Seals
7 Series of Plans
Key Features
Instrument Use
PCV PG Pressure indication
Pressure control valve
PCV To maintain correct
buffer gas pressure
PSL To give an alarm for
Filter
drop in pressure
CSD containment seal drain
FSH To detect leakage
Note: Keep buffer gas pressure less than seal chamber and give an alarm
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulating Plan 72
Features
Is used together with a plan 75 or 76
The buffer gas in normally Nitrogen & acts as a cooling fluid
Nitrogen blanket reduces the explosion hazard arising out of the leakages from
the inboard seal
Application areas
For containment seals API configuration 2CW-CS where media is a flashing
hydrocarbon
May be used for non-flashing services also
Check points
Always ensure that the pressure of the buffer gas is lesser than the seal
chamber pressure.
Set the forward pressure regulator to min 0.4 bar above the flare back pressure.
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API Circulating Plan 74 FOR NF992
Pressurized barrier gas from external source to a dual pressurized non contacting seal
FSH
PG P
S
Flow meter API seal configuration 3-NC BB/FB/FF
GBI Gas barrier in
Control valve
ROP - Restriction
orifice plate
Isolation valve
FROM N2 SOURCE
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API Circulation Plan 75 FOR L9DTUE
Leakage from an inboard seal sealing a condensing media is directed to a leakage collection system.
flare
GBI Gas buffer
To
in
P P
G S
Instrument Use
PG Pressure indication
Test
connection (NC)
LG To view level of leakage
drain alarm
LSH To detect leakage & give an
Drain valve alarm
Note: Mount the pot below the pump centre line
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 75
Features
1. Avoids direct leakage of pumped media to the atmosphere
2. The collected fluid may be sent back to the process
3. This plan can be used with buffer gas (plan 72) or without buffer gas (Plan 71)
4. Liquid leakage gets collected in the pot and vapors pass to the collection system
Application areas
1. For condensing media
2. For configurations utilizing an outboard containment seal contacting or non-contacting type
3. May be used in non-condensing media in order to collect the condensate from the collection
system
Check Points
1. Set the PSH at a pressure of 0.7 bar g so as to trigger an alarm when the pressure in the pot rises
2. Ensure that the vent line is always open and an orifice is present to generate back pressure
3. Mount the pot below the pump centerline
4. Connect both level and pressure alarms so that the one which is reached first will indicate the
leakage
5. Use sloping lines from the CSD port to the pot
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API Circulation Plan 76
Non-condensing leakage from inner seal is directed to flare through containment seal vent connection.
To Flare
CSV containment seal vent
API Seal configuration
PG PS 2-CW CS, 2-NC CS
Primary flush
Drain valve
Instrument Use
PG Pressure indication
Note: Do not use for condensing media. Add an orifice to generate back pressure
Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July
API Circulation Plan 76
Features
1. Avoids direct leakage of pumped media to the atmosphere & ensures almost no leakage from the
outboard seal
2. The vapors are directed to the vapour collection system
3. This plan can be used with buffer gas (plan 72) or without buffer gas (Plan 71)
Application areas
1. For non-condensing media typically high vapour pressure flashing light hydrocarbons
2. For configurations utilizing an outboard containment seal contacting or non-contacting type and
handle toxic or hazardous media
Check Points
1. Set the PSH at a pressure of 0.7 bar g so as to trigger an alarm when the leakage rises
2. Ensure that the vent line is always open and an orifice is present to generate back pressure
3. Ensure a low point condensate drain
4. Check that the support to the harness piping is sufficient
5. Use a (13mm) tubing for the CSV line and ensure that the pipeline is continuously rising upwards
6. Do not use for condensing media
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Any
Question ?
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Corporate Training EagleBurgmann India Prepared by : Surajjit Rayy EagleBurgmann 2010 1st. July