Pakistan Customers Training API Plan & Seal Failure-Madhavan PDF

API Piping Plans
©John Crane Inc. 2006

Sealing Support Plans
Supply Cooling & Lubrication To Seal Faces
API Piping Plan Numbers.
Ø 01 and 02: Internal circulation for single seals.
Ø 11, 12, 13 and 14: Simple recirculation systems for single seals.
Ø 21, 23, 31 and 41: Recirculation systems with auxiliary equipment for single seals.
Ø 32 and 62: External injection systems.
Ø 52, 53 (A, B, & C), 54 and 74: External systems for dual seals.
Ø 72, 75, 76: External systems for containment seals.

Plan 02 - Dead Headed
Seal Gland Connections

Plugged For Pos sible
Future Cooling Needs
Typical arrangement stuffing box

may be shouldered, tapered flow
modified or a through bore (open).

Plan 11 - Return From Discharge
Arrangement widely used on

clean fluids. Higher stuffing box
pressure prevents fluid flashing at
seal faces & promotes circulation / cooling.
Plan 13 - Return To Suction
Used on vertical pumps to vent

stuffing box or when the box
pressure is near discharge pressure.

Plan 21 - Heat Exchanger
Via Pump Discharge
Vent
Orifice
Goal: flow
to seal to be
~ 140°F - 180°F
(~ 60°C - 82°C)
Plan 23 - Heat Exchanger
Via Seal Chamber
Vent
Orifice
Typical Internal Pumping Ring

arrangement on
Boiler Feedwater
Pump seals.
Pumping Rings
Radial Flow Dri lled Vane Holes
Axial Flow
Radial Flow Paddle Wheel

Heat Exchangers
Water Cooled Air Cooled
High efficiency heat transf er No cooling water needed

Compact Remote location use
Water required Lower heat transfer

Plan 31 - Cyclone Separator
Clean fluid to seal
Process
fluid
Arrangement can be used in

place of Plan 11. Cyclone
Abrasives to suction
separator is used to remove
solids in fluid pumped.
Plan 32 - Flush, External Source
Flow
Meter Clean external
Check source of flush fluid
Valve P
Valve
When process fluid is too hot

or dirty and an external source
can be used. Typical packing
and single seal support method.
Plan 32 - Flush, Single Seal
Flush
Fluid
Stuffing
Box
Pressure
Box Flush
Atmosphere Flush pressure 5 psi min.
Pressure Pressure
higher than max. box press.

Plan 62 - Quench, External Source
Used to prevent coking or

crystallization of process fluid on
the atmospheric side of the seal
faces in a single seal.
Plan 62 - Quench, External Source
Quench Low pressure

Fluid restriction dev ice
Stuffing
Box
Pressure
Quench
Box Pressure Atmosphere Quench pressure 5 psi max.
Pressure

API PLAN - Dual Seals
§ Unpressurized Dual Wet Seals

• Plan 52
§ Pressurized Dual Wet Seals

• Plan 53A
• Plan 53B
• Plan 53C
• Plan 54
• Dual Gas Seals

• Plan 74

Buffer / Barrier Fluid
What is the stuff between the two seals?
§ Buffer fluid (unpressurised dual seal)

A fluid which is at a pressure less than the seal
chamber pressure (typically at atmospheric
pressure)
§ Barrier fluid (pressurised dual seal)

A fluid with is at a pressure greater than the seal
chamber pressure

Plan 52

Plan 52

Plan 53A

Plan 53A

Plan 53B

Plan 53B

Plan 53C

Plan 53C

Plan 54 - Pressurized Barrier
Arrangement normally used

when process will not allow
introduction of external flush.
Also used on vacuum services.
Plan 54

Plan 54

Plan 54 - Pressurized Barrier
Double Seal
Pressurized Barrier
Barrier Seal Support
Fluid
Stuffing
Box
Inboard Seal Outboard Seal

Pressure
Box Barrier
Atmosphere Barrier pressure 15 psi min.
Pressure Pressure
higher than max. box press.
Higher pressure barrier fluid acts as the

lubricating film across inboard seal faces
Sealing Water Regulator Systems
Complete Systems To Control

Sealing Water Flow & Pressure
Monitor Water Supply &
Indicate Trouble
Alarm If Low / No Flow
Use With:
Ø Packing
Ø Single seals
Ø Quench seals
Ø Double seals
Clean In Place Features

During Operation

Plan 74
API PLAN 74
Systems that provide pressurized gas (N2 or steam) at a pressure higher
then stuffing box pressure to avoid pumped fluid leakage to
atmosphere

Plan 74

Secondary Containment Plans
Purpose:
§ Direct the flow of Volatile Organic Compound (VOC) and other
hazardous substances leaking past the primary seal faces for
safe disposal.
• Plan 72
• Plan 75
• Plan 76

Plan 72
• API PLAN 72
Systems that provide gas at low pressure pressure to reduce fugitive
emission and prevent icing on cold applications

Plan 72

Plan 75
API PLAN 75
Systems that collect both liquid and gas leakages

Plan 75

Plan 76
API PLAN 76
Systems that collect gas leakages

Plan 76

Comparisson Plan 72 v 74
• API PLAN 72
Systems that provide gas at low pressure pressure to
reduce fugitive emission and prevent icing on cold
applications
• API PLAN 74
Systems that provide pressurized gas (N2 or steam) at a
pressure higher then stuffing box pressure to avoid
pumped fluid leakage to atmosphere

Plan 75 and Plan 76 Main Components
Components Plan 75 Plan 76

Tank for liquid
Reservoir No
collector
Pressure Gauge Yes Yes
Pressure Sw itch (*) Yes (high) Yes (high)
Level Gauge Yes No
Level Sw itch (*) Option (high) No
Orifice Yes Yes
NOTE:
(*) Pressure and Level Transmitter can be adopted instead of
Pressure and Level Sw itch

Coffee Break

Seal Failure
Analysis
A brief overview

What is a failed seal?
Leakage of the pumping fluid thru the sealing components,

which causes
§ Dilution of the process stream
§ Poisoning of the environment
§ An Immediate safety Hazard.

Seal Leakage
§ All mechanical seals will leak to some extent

during operation.
§ If the seal is operating correctly then the

leakage should be extremely low, to the point
where it may not be noticed or visible.

Leakage Rates
Fluid film thickness is very important

too thin - wear, causing early seal failure
too thick - visible leakage

Acceptable Leakage Rates
§ Varies depending on application

• Environmental considerations/legislation
• High hazard or pollution risk
Increasing leakage.
• Process contamination
• Minimum levels of cleanliness
• Economic considerations
Note :
Leakage rate vary depending on the size, seal type, application
Depending upon the properties of the sealed fluid the leakage may
be liquid or a gas.

Leakage rate for Fluids
Diameter (mm)
100 Speed (rpm)
80
00
15
60
30 0 0
18
00
00
40
36
30
20
.
Pressure (bar g) L e a k a g e ( m l/h )
0 2 4 6 8 10 12 1 4 1 6 1 8 20 0.01 0.1 1 10 100

Balanced Seal Unbalanced Seal

Normal Operational Life of the Seal
Normal Operational Life of the Seal
First Few
Hours
Incidence of Failures
Time
.
What is an Acceptable Seal Life?
§ API 682 States the design is to have “High

probability of meeting the objective of at least 3
years of uninterrupted service while complying
with Emissions Regulations.”

Sources of Seal Unreliability
I.Mech.E Chemical Co. PP & JC

Seal selection & design
Design 28% 15% 4%*
Pump selection, design
& suction circuitry.
Installation, alignment,
bearing & pump condi tion
Maintenance 24% 20% 47%
Seal & system fitting &
installation functions
Process upsets,off-duty
operating, primi ng,
mal-operation.
Operation 48% 65% 49%
Seal flushing, cooling,
quenching.
* No Data included for Pump Design unreliability data
Leak Path

Preparation for Improving Seal Reliability
Where do I start? - The Statistician
Data Segregation
Seal or Bearing Reliability?
Macro Survey Operational Life?
Process Criticality?
Hazard or Pollution Risk?

What’s The Problem? - The Detective
The Duty & Equipment Specification
Seal Design Arrangement & Materials
Information Failure Description
History
Seal Component condition

Seal Component condition
• Record Condition as Removed from Equipment.

• Record ALL Visible Effects (Compared to As New).
• Examine ALL Parts & Their Relative Positions.
• Check Functional Flexibility.
• Rubbing Surfaces Require Detailed & x5 Mag.
• Store Failed Parts for Statistical Examination.
THIS IS YOUR ONLY RELIABLE INFORMATION EVERYTHING

ELSE MUST EXPLAIN IT.

Common Sources of Seal Unreliability
§ Failure Analysis
How Can This Happen?

Visible Evidence on Seal Components
§ Rubbing Face Condition
• Wear level
• Contact Level and breakdown of material structure
• Chipping on track or edges
• Cracking of section (dynamic or static?)
• Rubbing, abrasion or corrosion
• Heavy ID damage, OD or both.
• Uneven damage circumferentially
• Eccentric or overlapped tracking

Rubbing Face Condition
Carbon Graphite Face operating under high contact stress

Carbon Graphite Face operating under excessive contact stress

Carbon Graphite Face with ‘edge chipping’
ID
OD

Antimony impregnated carbon graphite with melted film of Antimony
ID
OD

Carbon Graphite Face with abrasive damage and erosion

Carbon Graphite primary ring

(metal bellows) abrasive
damage and erosion Corresponding Mating Ring
May be caused by Catalyst Fines

Carbon Graphite Face with damage caused by

polymerisation
OD
ID
‘Blistering’

Detail of blister on Carbon Graphite Face

Thermal Crazing of track

Tungsten Carbide Face with hydropads

Thermal Crazing
ID
OD
Hydropad

Mating Ring damage in SiC - Blistering

Mating Ring damage in SiC – Thermal Cracking

Primary Ring in Sic/Graphite Composite - Blister damage

Primary Ring in Sic/Graphite Composite - Blister damage

Uneven Contact Circumferentially - 2 point

Uneven Contact Circumferentially - 3 point

Vaporisation Damage

Primary / Mating Ring Condition
• Drive wear or damage

• Edge chipping
• Erosion or polishing on rear surface
• Localised rubbing/polishing
• Radial Sectional crack
• Circumferential crack
• Process surface erosion
• Spinning of inserted designs

Primary Ring Condition



Radial Sectional
Fracture

Circumferential Sectional Fracture

Bellows Condition
Over pressurised from OD
Normal
Over pressurised from ID

Bellows Condition
Failed Seal New Seal

Secondary Seal Condition
• Cuts or slicing damage

• Wear or abrasion on the rubbing surface
• Twisting of the section
• Hardness of the elastomer
• Extrusion
• Blistering of surface on process side
• Change in section or diameter

Extrusion
• A thin lip has formed on the entire ID or OD of the O-ring.

Some materials may exhibit a shredded appearance.
• Often caused by an application where pressure is beyond the

design limitations for the material in use. Also, will result
from thermal expansion of the material if groove width is too
narrow,
or from swell caused by chemical interaction with material.
Normal
Lip
Ring
Shredding

O-ring sliding damage
Damaged Surface Edge View

Hard or cracked Elastomer
• The part is hard and has several cracks, it is easily broken

when bent by hand. Damage may be on process side,
atmospheric side, or only in areas in contact with a specific
part.
• Temperature too high for material in use. Possible chemical

attack if the damage is evident only on the process side of
the part.
Normal Flat Cracks

Ring Surfaces

Compression Set
• The part is permanently deformed with flat sides on the

sealing surfaces.
• Caused by improper design of parts which houses the O-ring

resulting in over compression of the material or by chemical
attack (swelling) of the material while in service.
• Compression set is a common cause of O-ring failure.

If it occurs on a dynamic O-ring the ability of a primary ring
to track will be impaired.
Normal
Ring Flat
Surfaces

Blistered and ruptured elastomer
• Many small blisters and ruptures throughout the part caused

by explosive decompression.
• A fluid which is a gas at atmospheric pressure, is being
sealed under high pressure and over time is absorbed into
the elastomeric material. When the pressure is released too
quickly
the fluid which is trapped in the elastomer expands rapidly
resulting in damage to the part.
Blister Rupture

Case Study - Recent Example (Abu Dhabi)
§ Pressurised dual metal

bellows seal found
contaminated with
process fluid

Recent Example (Abu Dhabi)
§ Inspection of the IB
bellows shows:

§ That explains the contamination
§ But, how did that happen?

LBI

The evidence:

The evidence:
§ Light grooving on inboard

primary ring
§ Possible comet trails may

indicate vaporisation

The evidence:
§ Mating Ring in good

condition
§ No sign of high heat
generation

The evidence:
§ Heavy coke formation

on OB primary ring
§ This is coked barrier § This requires face
fluid! temperatures above
150°C

The evidence:
§ Once cleaned, the OB faces

are in excellent condition
§ No sign of high heat
generation at the faces

§ From the evidence, it is likely that the following

sequences of events occurred:
§ At some time, possibly for a prolonged period,

the barrier fluid has been allowed to become
very hot (in excess of 130 ° C) This is clear from
the coking observed on the atmospheric side of
the OB seal. Note that the good condition of the
OB faces indicates normal level of heat
generation.

§ Barrier fluid degrades, and high stuffing

box temperature, high barrier fluid
temperature plus degraded oil lead to
vaporization of fluid on IB seal faces

§ Vaporisation leads to
micro-movement causing
fatigue failure of the IB
bellows assembly at the
weld.

§ Bellows failure allows contamination of the seal and seal

system with process fluid

Thank you
Any Questions??

Pakistan Customers Training API Plan & Seal Failure-Madhavan PDF

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API Piping Plans

©John Crane Inc. 2006

Supply Cooling & Lubrication To Seal Faces

API Piping Plan Numbers.

Ø 01 and 02: Internal circulation for single seals.

Ø 32 and 62: External injection systems.

Ø 72, 75, 76: External systems for containment seals.

©John Crane Inc. 2006

Seal Gland Connections

Typical arrangement stuffing box

©John Crane Inc. 2006

Arrangement widely used on

Used on vertical pumps to vent

©John Crane Inc. 2006

Typical Internal Pumping Ring

Radial Flow Dri lled Vane Holes

©John Crane Inc. 2006

Water Cooled Air Cooled

High efficiency heat transf er No cooling water needed

©John Crane Inc. 2006

Clean fluid to seal

Arrangement can be used in

When process fluid is too hot

©John Crane Inc. 2006

Used to prevent coking or

Quench Low pressure

©John Crane Inc. 2006

§ Unpressurized Dual Wet Seals

§ Pressurized Dual Wet Seals

• Dual Gas Seals

©John Crane Inc. 2006

What is the stuff between the two seals?

§ Buffer fluid (unpressurised dual seal)

§ Barrier fluid (pressurised dual seal)

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

Arrangement normally used

©John Crane Inc. 2006

©John Crane Inc. 2006

Inboard Seal Outboard Seal

Higher pressure barrier fluid acts as the

Complete Systems To Control

Clean In Place Features

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

©John Crane Inc. 2006

Components Plan 75 Plan 76

©John Crane Inc. 2006