API 682
A P I 682 Short Short Guide Most common plans and operational inormation inormation..
API 682 has emerged to become a worldwide accepted standard in today`s renery and hydrocarbon related applications. EagleBurgmann oers a wide range o high quality mechanical seals and supply systems which ully comply with this standard. From expert consulting and engineering up to modular TotalSealCare® service solutions or entire plants – EagleBurgmann is your reliable partner or sealing technology technology.. Please ask also or our API AP I poster, our detailed brochure brochure 58E and the API AP I 682 seal selection sotware on CD. Find your nearest contact at www.eagleburgmann.com/world. Important Note Operating manuals and plant guidelines must be strictly observed and are always to be ollowed prior to the inormation given in this short guide. Beore carrying out any regular inspection or repair work, shut down system and make sure the system is completely pressureless! Do not touch hot suraces! Use adequate temperature measuring device. Strictly ollow saety regulations! Terms used in this short guide Start-up procedures: assume that pump is reinstalled and put into operation ater overhaul. Shut-down procedures: assume a stopping o the pump and keeping the pump in standby mode. Regular inspections are conducted on the normal operator tours. Troublerouble-shooting shooting describes the most common ailures at mechanical seals and supply systems and how to cure them. Other causes, not mentioned in this guide, may be present – however these must be evaluated by consulting EagleBurgmann. Subject to change. 2
API 682 has emerged to become a worldwide accepted standard in today`s renery and hydrocarbon related applications. EagleBurgmann oers a wide range o high quality mechanical seals and supply systems which ully comply with this standard. From expert consulting and engineering up to modular TotalSealCare® service solutions or entire plants – EagleBurgmann is your reliable partner or sealing technology technology.. Please ask also or our API AP I poster, our detailed brochure brochure 58E and the API AP I 682 seal selection sotware on CD. Find your nearest contact at www.eagleburgmann.com/world. Important Note Operating manuals and plant guidelines must be strictly observed and are always to be ollowed prior to the inormation given in this short guide. Beore carrying out any regular inspection or repair work, shut down system and make sure the system is completely pressureless! Do not touch hot suraces! Use adequate temperature measuring device. Strictly ollow saety regulations! Terms used in this short guide Start-up procedures: assume that pump is reinstalled and put into operation ater overhaul. Shut-down procedures: assume a stopping o the pump and keeping the pump in standby mode. Regular inspections are conducted on the normal operator tours. Troublerouble-shooting shooting describes the most common ailures at mechanical seals and supply systems and how to cure them. Other causes, not mentioned in this guide, may be present – however these must be evaluated by consulting EagleBurgmann. Subject to change. 2
Connection codes on seal gland acc. to API 682, 3rd edition F = Flush FI = Flush IN (only plan 23) FO = Flush OUT (only plan 23) D = Drain Q = Quench V = Vent BI = Buer/Barrier IN BO = Buer/Barrier OUT LBI = Liquid Buer/Barrier IN LBO = Liquid Liquid Buer/Barrier OUT GBI = Gas Buer/Barrier IN GBO = Gas Buer/Barrier OUT CSD = Containment Containment Seal Drain CSV = Containme Containment nt Seal Vent Most common PID codes for supply system instrumentation PI = Pressu Pressure re Indicator TI = Temperature Indicator LS = Level Switch PS = Press Pressure ure Switch LG = Level Gauge PT/PIT PT/ PIT = Pressure Pressure Transmitter/ Pressure Indicator Transmitter TT = Temperature Transmitter PCV = Pressure Control Valve PSV = Pressure Saety Valve = Valve normally open (NO (NO)) = Valve normally closed (NC) = Orice = Strainer
3
Plan 02 Seal chamber cooling or heating and neck bush are necessary,, unless otherwise necessary specied. Dead end seal chamber with no circulation. Plugged connections or possible uture circulation and quench.
Media char characteristics acteristics Clean media is pumped at high temperature. Flushing is not desired or necessary necessary.. Start-up procedur proceduree No special procedures need to be ollowed. Shut-down procedure No special procedures need to be ollowed. Regular inspection No special procedures need to be ollowed.
4
2 0
Plan 02
1 1
3 1
2 2 , 1 2
3 2
Troubleshooting No special procedures need to be ollowed.
1 3
2 3
2 5
A 3 5
B 3 5
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
5
6 7
Plan 11 For general applications. Product pumped clean, good lubricating properties and heat removal rom the mechanical seal. Recirculation rom pump discharge through fow control orice to the seal.
Media characteristics For any moderatly clean and warm media. Start-up procedure The seal chamber must be lled with pumped media. I the seal chamber is not sel-venting chambers, trapped gas must be removed by venting. Check that piping and the appropriate orice is installed correctly. I valves are installed in the fush piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. Shut-down procedure No special procedures need to be ollowed. Regular inspection Check or any leakage and abnormal temperature gradient on the fush line (e.g. a healthy fow will display nearly equal temperature distribution on the total piping).
6
Plan 11
1 1
3 1
2 2 , 1 2
3 2
n
Troubleshooting Problem: Abnormal temperature gradient on the fush piping. Cause: Interrupted fow o fush stream (valve is closed or piping/ orice is clogged). Solution: Open valves and secure against accidental closing. Shut down pump and check piping/orice or clogging.
1 3
2 3
2 5
A 3 5
B 3 5
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
7
6 7
Plan 13 Used where the seal chamber pressure is at discharge pressure (mainly vertical pumps). Recirculation rom pump seal chamber through a fow control orice and back to the seal.
Media characteristics For any moderatly clean and warm media. Start-up procedure The seal chamber must be lled with pumped media. Trapped gas must be removed by thoroughly venting the seal housing. On vertical pumps a vent connection shall be supplied at the highest point o the seal chamber or seal housing. Check that piping and the appropriate orice is installed correctly. I valves are installed in the fush piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. Shut-down procedure No special procedures need to be ollowed. Regular inspection Check or any leakage and abnormal temperature gradient on the fush line (e.g. a healthy fow will display nearly equal temperature distribution on the total piping).
8
Plan 13
3 1
2 2 , 1 2
3 2
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Troubleshooting Problem: Abnormal temperature gradient on the fush piping. Cause: Interrupted fow o fush stream (valve is closed or piping/ orice is clogged or gas is trapped in the seal chamber o vertical pumps). Solution: Open valves and secure against accidental closing. Shut down pump, remove clogging rom piping or orice. Vent seal chamber thoroughly in vertical pumps.
1 3
2 3
2 5
A 3 5
B 3 5
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
9
6 7
Plan 21 (22) Used or hot applications or where the temperature and pressure in the seal chamber is close to the vapour curve o the product. Recirculation rom pump discharge through a fow control orice and cooler into the seal chamber.
Plan 21 = without strainer, Plan 22 = with strainer. Media characteristics The media is near to its vapourisation point. Media is pumped at high temperature. Start-up procedure The seal chamber must be lled with pumped media. Trapped gas must be removed by thoroughly venting the seal housing. Check that piping and the appropriate orice is installed correctly. The strainer must be clean (plan 22). I valves are installed in the fush piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. The cooling water supply must be connected, thoroughly vented and operative. Shut-down procedure Keep cooling water supply open at high temperatures. Regular inspection Check or any leakage and abnormal temperature gradient on the fush line (e.g. a healthy fow will display nearly equal temperature distribution on the total piping). Check cooling water temperature. Clean strainer (plan 22) at regular intervals.
10
Plan 21 (22)
2 2 , 1 2
3 2
n
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Troubleshooting Problem: Abnormal temperature gradient on the fush piping. Cause: Interrupted fow o fush stream. The valve is closed or piping/orice is clogged. The strainer is loaded with deposits. Solution: Open valves and secure against accidental closing. Shut down pump, remove clogging rom piping or orice. Clean strainer.
1 3
2 3
2 5
A 3 5
Problem: Abnormal temperature rise in the cooling water supply. Cause: Cooling water stream is interrupted. Solution: Open cooling water supply. Check i cooling water piping is clogged, remove clogging. Consider changing to plan 23 i possible.
B 3 5
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
11
6 7
Plan 23 Used or hot liquid applications or where the temperature and pressure in the seal chamber is close to the vapour curve o the product. Recirculation by means o a pumping ring in seal chamber through a cooler and back to seal chamber.
Media characteristics The media is near to its vapourisation point. Media is pumped at high temperature. Start-up procedure The seal chamber must be lled with pumped media. Trapped gas must be removed by thoroughly venting the seal housing. Piping shall be inclining upward and sel venting (no gas traps). Piping shall be arranged to provide lowest possible fow resistance (direct lines, avoid bends i possible, required bends with large radius) I valves are installed in the fush piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. The cooling water supply must be connected, thoroughly vented and operative. Shut-down procedure Keep cooling water supply open at high temperatures. Regular inspection Check or any leakage and abnormal temperature gradient on the fush line (e.g. a healthy fow will display nearly equal temperature distribution on the total piping). Check cooling water temperature.
12
Plan 23
3 2
n
n
Troubleshooting Problem: Abnormal temperature gradient on the fush piping. Cause: Interrupted fow o fush stream. The valve is closed or piping is clogged. Solution: Open valves and secure against accidental closing. Shut down pump, remove clogging rom piping. I pumped media is heavily loaded with solids, consider using alternative API plan.
1 3
2 3
2 5
A 3 5
Problem: Abnormal temperature rise in the cooling water supply. Cause: Cooling water stream is interrupted. Solution: Open cooling water supply. Check i cooling water piping is clogged, remove clogging.
B 3 5
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
13
6 7
Plan 31 Used in applications with suspended solids where the SG o the particles are 2x that o the liquid. Recirculation rom pump discharge through a cyclone separator, clean fuid to seal chamber, contaminated fuid to suction.
Media characteristics Media contains suspended solids. For optimum perormance, the density o solid particle shall be more than twice that o the liquid. Start-up procedure The seal chamber must be lled with pumped media. Trapped gas must be removed by thoroughly venting the seal housing. Check that piping and the cyclone separator is installed correctly. I valves are installed in the fush piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. Eventual orices or obstacles in any o the fow lines shall be removed as solid particle will accumulate here or reduce the eciency o the cyclone separator. Shut-down procedure No special procedures need to be ollowed. Regular inspection Check or any leakage and abnormal temperature gradient on the fush line (e.g. a healthy fow will display nearly equal temperature distribution on the total piping).
14
Plan 31
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Troubleshooting Problem: Abnormal temperature gradient on the fush piping. Cause: Interrupted fow o fush stream. The valve is closed, piping or cyclone separator is clogged. Solution: Open valves and secure against accidental closing. Shut down pump, remove clogging rom piping or cyclone separator. I an orice is in the line it is highly recommended to remove it. I the particle density is less than twice that o the liquid or i the piping gets clogged repeatedly, consider using an alternative API plan.
1 3
2 3
2 5
A 3 5
B 3 5
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
15
6 7
Plan 32 Used when the product being pumped does not have good lubrication properties, is dirty or hazardous. Flush injection o clean fuid into the seal chamber rom an external source.
Media characteristics Media contains suspended solids. Media has poor lubricity. Media is pumped at high temperature. Media is hazardous and/or harmul. Direct contact o the media with the seal is not desired. Start-up procedure Check that piping, instrumentation and strainer or orice (i installed) is installed correctly. I installed, the strainer or orice must be clean. Open main valve or external source o fushing liquid. The seal chamber must be lled with fushing liquid. Adjust fow rate by means o fow indicator and fow control valve as per instructions. Secure main valve and fow control valve rom alse operation (e.g. accidental closing). Shut-down procedure Shut down pump. Close main valve only ater pump has completely stopped, keep fow control valve open. Regular inspection Check or any visible leakage. Check or temperature rise in the fush line at point o entry into the seal. Clean strainer when pump is shut-down.
16
Plan 32
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Troubleshooting Problem: Temperature rise in the fush line near seal. Cause: The fush stream is interrupted, heat generated by the seal radiates into the fush line. Solution: Open main valve, check fow rate indicator, adjust fow rate with fow control valve. I this does not cure the problem shut down pump and check fush line or clogging. Clean strainer or orice.
2 3
2 5
A 3 5
B 3 5
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
17
6 7
Plan 52 Used where the pumped product is harmul / hazardous and / or buer fuid may not contaminate the product. External reservoir at pressure below seal chamber pressure providing buer liquid orced circulation.
Media characteristics Media is pumped at high temperature. Media is hazardous and/or harmul. Media may not be contaminated with barrier fuid. Media may not contain suspended solids and should have good lubricating properties. Start-up procedure Check that piping and the appropriate instrumentation is installed correctly. Piping shall be inclining upward and sel venting (no gas traps). The TS vessel must be at highest point. Piping shall be arranged to provide lowest possible fow resistance (direct lines, avoid bends i possible, required bends with large radius). Fill the TS Vessel with resh buer fuid to be above MIN, but well below MAX mark. Type and quality o the buer fuid shall be in accordance to the operation manual. Trapped gas must be removed by thoroughly venting the seal housing. Valves in the piping must be open at all times and alse operation (e.g. accidental closing) must be excluded. Valve to fare or sae vent line must be open. Do not pressurise the system. Shut-down procedure No special procedures need to be ollowed. Keep cooling water supply open at high temperature. Regular inspection Check the correct ll level o the TS vessel (between MIN and MAX mark). Exchange the buer fuid at regular intervals, as indicated in operation manual. A change o buer fuid colour is normal and does not in itsel indicate a seal ailure. Check or any visible leakage and abnormal temperature rise. The TI shall display the specied temperature range. The PI shall display a pressureless condition.
18
Plan 52
n
Troubleshooting Problem: Abnormal rise o fuid level and increase o pressure in TS Vessel. Cause: The product side seal is having an increased leakage. Solution: Shut-down pump and have mechanical seal inspected. 2 5
n
n
n
Problem: Abnormal all o fuid level in TS Vessel. Cause: The atmospheric side seal is having an increased leakage. Solution: Shut down pump and have mechanical seal inspected.
A 3 5
B 3 5
Problem: The temperature indicator shows abnormal rise o temperature in the buer system. Cause 1: The seal is overheating due to dry running or increased riction. Solution: Shut down pump and have mechanical seal inspected. Make sure seal is lubricated suciently by pump media. I this cannot be assured, consider changing to a system with pressurised barrier fuid. Cause 2: Insucient cooling by the water cooler in the TS vessel. Solution: Check cooling water supply.
C 3 5
4 5
2 6
5 6
Problem: Temperature rise between buer fuid out at TS vessel and buer fuid in at seal gland connection. Cause: Circulation o buer fuid is interrupted, heat generated by seal radiates into buer fuid line. Solution: Vent the buer fuid system acc. to instructions. Check circulation o buer fuid.
2 7
4 7
5 7
19
6 7
Plan 53A Used or hot applications or where products have low pressure and are harmul/ hazardous. External reservoir pressurized above seal chamber pressure providing barrier fuid to mechanical seals. Forced circulation.
Media characteristics Media contains suspended solids. Media has poor lubricity. Media is pumped at high temperature. Media is hazardous and/or harmul. Leakage o media to atmospheric side is not desired. The media is near to its vapourisation point. Start-up procedure Fill the TS Vessel with resh barrier fuid up to max. ll level mark. The barrier fuid shall be in accordance to the operation manual. Trapped gas must be removed by thoroughly venting the seal housing. Check that piping and the appropriate instrumentation is installed correctly. Piping shall be installed in an upward inclined way, and sel venting. Piping shall be arranged to provide lowest possible fow resistance (direct lines, avoid bends as ar as possible, required bends with large radius). Valves in the piping must be open at all times and alse operation (e.g. accidental closing) must be excluded. Apply barrier pressure at the specied value (usually 2 bar or min 10% above stung box pressure). Start-up pump. Shut-down procedure Shut o pump. Keep TS vessel pressurised. Keep cooling water supply open at high temperatures. Regular inspection Check the correct ll level o the TS vessel (between MIN and MAX mark). Check correct barrier pressure. The PI shall display the specied value. Check or any leakage and abnormal temperature rise. The TI shall display the specied value. Check or abnormal temperature gradient in circulation line.
20
Plan 53A
A
A N2
n
n
n
n
Troubleshooting Problem: Abnormal all o fuid level in TS Vessel. Cause: Either the product side or the atmospheric side seal is having an increased leakage. Solution: Shut-down pump and have mechanical seal inspected. Problem: The temperature indicator shows abnormal rise o temperature in the barrier system. Cause 1: The seal is generating excessive heat due to dry running or increased riction. Solution: Shut-down pump and have mechanical seal inspected. Make sure seal is lubricated suciently by barrier fuid. Cause 2: Insucient cooling o the TS vessel. Improve cooling capacity, or ensure cooling water circulation. Solution: Check cooling water supply.
A 3 5
B 3 5
C 3 5
Problem: Temperature rise between barrier out at TS vessel and barrier in at seal gland connection. Cause: Circulation o barrier fuid is interrupted, heat generated by seal radiates into barrier line. Solution: Vent the barrier fuid system acc. to instructions. Check circulation o barrier fuid.
4 5
2 6
Problem: Rise o barrier fuid level and simultaneous drop o indicated pressure. Cause: The barrier pressure has broken down. Solution: Check barrier pressure supply line. Ensure supply o sucient barrier pressure.
5 6
2 7
4 7
5 7
21
6 7
Plan 53B Used or applications where products have high pressure and are harmul/ hazardous. Pre-pressurized bladder accumulator provides pressure to circulation system. Heat removed by air/water heat exchanger. Forced circulation.
Media characteristics Media contains suspended solids. Media has poor lubricity. Media is pumped at high temperature. Media is hazardous and/or harmul. Leakage o media to atmospheric side is not desired. The media is near to its vapourisation point. Start-up procedure Pre charge accumulator to the specied pressure. Fill up circulation line acc. to instructions until barrier fuid exits at the vent. Trapped gas must be removed rom the system by venting at highest point o the system. Check that piping and the appropriate instrumentation is installed correctly. Piping shall be installed in an upward inclined way. Cooler must be higher than seal. Piping shall be arranged to provide lowest possible fow resistance (direct lines, avoid bends as ar as possible, required bends with large radius). Valves in the piping must be open at all times and alse operation (e.g. accidental closing) must be excluded. Open valve o accumulator to apply barrier pressure. Start-up pump. Shut-down procedure Shut o pump. No special procedures need to be ollowed. Regular inspection Check correct barrier pressure. The PI shall be within the specied value. Check or any leakage and abnormal temperature rise or gradient. The TI shall be within the specied value. I low pressure is indicated, rell system acc. to instructions.
22
Plan 53B
n
Troubleshooting Problem: Low pressure is indicated by PI. Cause: Barrier fuid level has dropped due to normal leakage. Solution: Rell barrier fuid acc. to instructions until correct pressure is indicated.
n
Problem: Ater relling barrier fuid, pressure cannot be maintained. Cause: Abnormal leakage o mechanical seal. Solution: Shut down pump and have mechanical seal inspected.
n
Problem: Temperature rise in barrier system. Cause: The seal is generating excessive heat or increased riction due to dry running. Solution: Achieve correct barrier fuid pressure by maintaining the correct barried fuid volume.
B 3 5
C 3 5
Cause 2: Insucient cooling at air/water coolers. Solution: Ensure that cooling is sucient by installing larger coolers, ensure cooling water circulation (water cooler) or make sure that air coolers are in a shaded area and ree o dust in hot climate. n
4 5
2 6
Problem: Temperature rise between barrier out at cooler and barrier in at seal gland connection. Cause: Circulation o barrier fuid is interrupted, heat generated by seal radiates into barrier line. Solution: Vent the barrier fuid system acc. to instructions.
5 6
2 7
4 7
5 7
23
6 7
Plan 53C Used or applications where products have high pressure and are harmul/ hazardous. Pressurization by reerence line rom seal chamber to a piston pressure booster provides pressurized barrier fuid to circulation system. Forced circulation.
Media characteristics Media has poor lubricity. Media is pumped at high temperature. Media is hazardous and/or harmul. Leakage o media to atmospheric side is not desired. The media is near to its vapourisation point. Start-up procedure Fill up piston transmitter with resh barrier fuid so that ll indicator is between specied MIN and MAX marks. Important: piston may not be below MAX mark (“on block”) to avoid excessive pressure build-up. Trapped gas must be removed by venting at highest point o the system. Check that piping and the appropriate instrumentation is installed correctly. Piping shall be installed in an upward inclined way. Cooler must be higher than seal. Piping shall be arranged to provide lowest possible fow resistance (direct lines, avoid bends as ar as possible, required bends with large radius). Valves in the piping must be open at all times and alse operation (e.g. accidental closing) must be excluded. Start-up pump. The reerence line rom the seal chamber will be sel-lling ater start-up. Remaining air bubbles can be tolerated. Shut-down procedure Shut o pump. No special procedures need to be ollowed. When water cooler is used, keep cooling water supply open at high temperatures. Regular inspection Check correct ll level o the barrier fuid. I piston reaches the TOP mark, then ll level is LOW and vice versa. Check or any leakage and abnormal temperature rise or gradient. The TI shall be within the specied value. I a strainer is installed in the reerence line, keep clean.
24
Plan 53C
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Troubleshooting Problem: The sight gauge shows that the piston is at top position. Cause: Barrier fuid level is low, allowing the reerence pressure to move the piston upward. Solution: Rell barrier fuid acc. to instructions until piston is between MIN and MAX mark.
n
Problem: Sudden rise o the piston over MIN mark. Ater relling, the level cannot be maintained, piston rises again. Cause: Abnormal leakage o mechanical seal. Solution: Shut o pump and have mechanical seal inspected. Rell barrier fuid.
n
Problem: Piston is below MAX mark and is pressed “on block”. Cause: Ater long pressureless standstill period, the piston may drop due to gravity. The piston transmitter has been overlled with barrier fuid. Caution: This is a critical operation condition! Pressure is trapped! Due to thermal expansion critical pressures can be reached causing seal and/or supply system destruction. Solution: Open vent valve at supply system and allow pressure/ barrier fuid to escape. Piston will rise to a normal value. Take caution when opening vent valve and observe saety instructions!
n
n
Problem: Abnormal temperature rise in barrier system. Cause: Insucient cooling at air n/water coolers. Solution: Ensure that cooling is sucient by installing larger coolers, ensure cooling water circulation (water cooler) or make sure that air n coolers are ree o dust and are installed in a shaded area and in hot climate regions. Problem: Temperature rise between barrier out at cooler and barrier in at seal gland connection, while the cooler itsel is cool. Cause: Circulation o barrier fuid is interrupted, heat generated by seal radiates into barrier line. Solution: Vent the barrier fuid system acc. to instructions or check barrier fuid piping or clogging. 25
C 3 5
4 5
2 6
5 6
2 7
4 7
5 7
6 7
Plan 54 Used in harmul/hazardous applications. Pressurized clean barrier fuid rom an external system. Fluid circulation by an external pump or pressure system.
Media characteristics Media contains suspended solids. Media has poor lubricity. Media is pumped at high temperature. Media is hazardous and/or harmul. The media is near to its vapourisation point. Leakage o media to atmospheric side is not desired. Start-up procedure Fill up barrier fuid tank with resh barrier fuid acc. to instructions. Check that piping and the appropriate instrumentation is installed correctly. Piping shall be installed in an upward inclined way. Piping shall be arranged to provide lowest possible fow resistance (direct lines, avoid bends as ar as possible, required bends with large radius). Valves in the piping must be open at all times and alse operation (e.g. accidental closing) must be excluded. Start-up barrier fuid system and adjust barrier pressure acc. to instructions. Start-up pump. Shut-down procedure Shut o pump. Regular inspection Correct ll level o the barrier fuid is surveyed by alarm protection. Check lters and strainers at the barrier fuid system acc. to instruction. Check bladder accumulator acc. to instructions. Check or any leakage and abnormal temperature rise or gradient. The TI shall be within the specied value.
26
Plan 54
n
Troubleshooting Problem: Barrier fuid level is at MIN value. Cause: Barrier fuid level is low. Solution: Rell barrier fuid acc. to instructions.
n
Problem: Ater relling, the level cannot be maintained. Barrier fuid level drops rapidly. Cause: Abnormal leakage o mechanical seal. Solution: Shut o pump and have mechanical seal inspected. Rell barrier fuid.
n
Problem: Abnormal temperature rise at seal. Cause: Circulation o barrier fuid is interrupted, heat generated by seal radiates into barrier line. Solution: Ensure that barrier fuid can circulated. Inspect strainers and lters at barrier fuid system.
4 5
2 6
5 6
2 7
4 7
5 7
27
6 7
Plan 62 Used to keep atmospheric side o seal clean. External source providing a fow-through quench to atmospheric side.
Media characteristics Media is pumped at high temperature. Leakage o media on atmospheric side may orm deposits, crystallise or oxidize. Start-up procedure Open valves or the nitrogen, steam, water or whatever quench media is used. I valves are installed in the quench piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. Adjust the desired fow o quench media (hint: usually low fow rates are sucient). Shut-down procedure No special procedures need to be ollowed. Regular inspection Check or abnormal leakage on atmospheric side o seal.
28
Plan 62
n
n
Troubleshooting Problem: Seal is showing increased leakage o pumped media on atmospheric side. Cause: Abnormal leakage o the seal. Solution: Shut o pump and have mechanical seal inspected. Problem: Seal is showing increased leakage o quench media on atmospheric side. Cause: Atmospheric seal ring (throttle bushing or lip seal) is leaking. Solution: Shut o pump and check seal ring or excessive wear.
2 6
5 6
2 7
4 7
5 7
29
6 7
Plan 65 Used or leakage detection on single seal. Atmospheric side leakage collection and monitoring in external vessel.
Media characteristics Can be used with any media which orm a liquid leakage (non-evaporating). Start-up procedure I valves are installed in the piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. Shut-down procedure No special procedures need to be ollowed. Regular inspection No special procedures need to be ollowed.
30
Plan 65 A
to drain
A Device to be located below pump shat
n
n
Troubleshooting Problem: Level-high alarm has been activated. Cause: Abnormal leakage o the mechanical seal. Solution: Shut o pump and have mechanical seal inspected. Problem: Level-high alarm has been activated but seal is o.k. Cause: The drain pipe o the system is clogged or drain valve closed. Solution: Remove clogging rom piping, clean orice or open drain valve.
5 6
2 7
4 7
5 7
31
6 7
Plan 72 Applicable with hydrocarbons, normally used in conjunction with plan 75 or plan 76. Externally supplied gas buer (pressure lower than seal pressure). Buer gas used to dilute seal leakage.
Media characteristics Media vapors are hazardous and/or harmul. Media vapors are purged to avoid combustable mixtures. Start-up procedure I specied, leakage collection systems plan 75 or 76 may be installed in connection with plan 72. I valves are installed in the piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. Check that piping and electrical equipment o the gas panel is installed correctly. Make sure that rotation direction o pump corresponds to rotation direction o gas seal (at unidirectional gas seal). Open main valve o buer gas line. Adjust gas fow acc. to instructions. Check pressure indicator: pressure shall remain near 0 bar [g] i pressure builds up, a valve is still closed. Start-up pump. Shut-down procedure Shut o pump. Gas buer supply may be shut o, i required. Regular inspection Check or abnormal gas consumption: fow indicator shall display specied value. Check buer gas pressure: it should be near 0 bar [g]. Check lter and replace lter elements at regular intervals (acc. to instructions).
32
Plan 72 A
B
C
A connect to plan 75
n
B connect to plan 76
C N2
Troubleshooting Problem: High level alarm o leakage collection system plan 75. Cause: High liquid leakage o product side mechanical seal. Solution: Shut o pump and have mechanical seal inspected.
n
Problem: High pressure alarm o vapour recovery system plan 76. Cause: High gas leakage on product side mechanical seal. Solution: Shut o pump and have mechanical seal inspected.
n
Problem: Ater start-up the pump runs in reverse mode. Cause: Ater installation, the pump has been connected in reversed polarity. Solution: Connect pump in correct polarity. In case o unidirectional seal, have seal inspected or damage.
n
Problem: Pressure indicator in gas supply system shows pressure increase. Cause: The valve to the fare line is closed or orice is clogged. Solution: Open valve to fare line, make sure the orice is clean. 2 7
4 7
5 7
33
6 7
Plan 74 Used in applications where the product is harmul/ hazardous. Externally supplied barrier gas used to positively prevent process fuid rom leaking to atmosphere.
Media characteristics Media has poor lubricity. The media is near to its vapourisation point. Media is hazardous and/or harmul. Media shall be ree o solids. Start-up procedure I valves are installed in the piping, they must be open at all times and alse operation (e.g. accidental closing) must be excluded. Check that piping and electrical equipment o the gas panel is installed correctly. Make sure that rotation direction o pump corresponds to rotation direction o gas seal (at unidirectional gas seal). Open main valve o barrier gas line. Set optimum barrier pressure to be above product pressure acc. to instructions. Adjust the set points o instruments acc. to instructions. Start-up pump. Shut-down procedure Shut o pump. Keep barrier gas supply open. Regular inspection Check or any abnormal gas leakage in piping (use adequate gas leak detecting device such as bubble spray etc.). Check or abnormal gas consumption: fow indicator shall display specied value. Check barrier pressure: PI shall display specied value. Check lter and replace lter elements at regular intervals (acc. to instructions).
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Plan 74
A
A N2
n
Troubleshooting Problem: Abnormally high gas consumption. Cause: High leakage o mechanical seal or leaking piping. Solution: Shut o pump and inspect the seal, check piping.
n
Problem: Abnormally low gas consumption. Cause 1: Barrier gas supply is insucient. Solution: Check barrier gas supply source. Ensure all valves are ully open. Check lter and replace lter element i necessary. Cause 2: Seal aces are running in contact. Solution: Have gas seal inspected.
n
Problem: Ater start-up the pump runs in reverse mode. Cause: Ater installation, the pump has been connected in reversed polarity. Solution: Connect pump in correct polarity. In case o unidirectional seal, have seal inspected or damage.
4 7
5 7
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6 7
Plan 75 Application when pump fuid condenses at ambient temperatures. Containment seal chamber drain or condensing leakage.
Media characteristics Media is hazardous and/or harmul. Media leakage o product side seal is liquid. Start-up procedure The plan 75 is commonly used in connection with plan 72, where leakage o the seal is liquid. Check that piping is installed correctly. Open valve o the fare line. Close valve o the liquid drain line. Start-up pump. Shut-down procedure Shut o pump. Keep fare line open and drain line closed. Regular inspection Check liquid level through sight glass or level indicator. The level shall be between MIN and MAX mark. Check position o valves. Flare line must be open, liquid drain must be closed. I high level alarm is triggered, drain the system by opening liquid drain line. Close valve aterwards.
36
to fare
Plan 75 A
to drain
A Device to be located below pump shat
n
n
Troubleshooting Problem: Ater drain, the liquid leakage collection system rells quickly. Alarm is triggered ater a short interval. Cause: Abnormal leakage o mechanical seal Solution: Shut o pump and inspect the seal. Problem: Liquid leakage at atmospheric side containment seal. Cause 1: Both valves to fare and drain are closed. Liquid leakage has lled entire seal and leakage collection system. Cause 2: The product side seal has increased leakage. Solution: Have mechanical seal inspected, make sure valves are in correct position.
5 7
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6 7
Plan 76 Application where pump fuid does not condense at ambient temperature. Containment seal chamber drain or non-condensing leakage.
Media characteristics Media is hazardous and/or harmul. Media leakage o product side seal is evaporated. Start-up procedure The plan 76 is commonly used in connection with plan 72, where leakage o the seal is vapour. Check that piping is installed correctly. Open valve o the fare line. Start-up pump. Shut-down procedure Shut o pump. Keep fare line open i possible. Regular inspection The drain valve o the leakage collection system can be opened occasionally to check or any liquid condensate. The system does not require regular maintenance.
38
Plan 76
n
to fare
Troubleshooting Problem: The high pressure alarm is triggered. Cause: Abnormal leakage o mechanical seal. Solution: Shut o pump and have mechanical seal inspected.
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