© 2018 IJRAR June 2018, Volume 5, Issue 2 www.ijrar.

org (E-ISSN 2348-1269, P- ISSN 2349-5138)

“SELECTION STRATEGY OF MECHANICAL SEAL

FLUSH PLAN FOR VARIOUS PLANTS”
Authors: Satinder Pal Singh1, Dr. Neel Kanth Grover2 & Dr. H.S. Bains3
1
Ph.D. Research Scholar, Department of Mechanical Engineering, I. K. Gujral Punjab Technical University, Punjab, India.
2
Associate Professor, Department of Mechanical Engineering, I. K. Gujral Punjab Technical University, Punjab, India.
3
Director, P.U. Swami Sarvanand Giri Regional Centre, Punjab, India.

ABSTRACT:

Pump mechanical seal failure incidents outnumber any other rotating component of a pump in a typical OG&C Plant. This is also well-
known fact that up to 70% of pump maintenance expenditure is responsible for seal repair/maintenance or replacements. This arises
the need for accurate selection of mechanical seal for given pump & particular service conditions.

As a standard industry practice, Pump Buyer usually follows Pump/Seal Vendor recommendation for final selection of Seal Plan.
Although the onus of deciding the seal plan and material selection is fairly & squarely on the Pump/Seal Vendor, however it is
recommended that Buyer shall also validate/verify the seal selection during bid evaluation stage himself (based on seal selection
guidelines). This will help in avoiding changes in seal plan during detailed engineering (after award) which otherwise led to
cost/schedule impact. Before selecting the seal material, type of seal the designer or pump manufacturer either needs to go through
exhaustively complete scope of API 682 and their field experience (operational experience of using Seal Type X in Pump Type Y with
process parameters Z).

This paper will illustrate the selection guidelines based on seal vendor recommendations, feedback from Plant Owner (Plant O&M
personals) and in-house lesson learnt. This paper will also discuss the work process diagram for the mechanical seal
selection/coordination for OG&C plant along with brief information on various Seal types for Pumps per API 682.

There is no doubt that the marginally higher cost for the better-quality seals will probably be recovered during the first year of operation
of pumps itself. Although this seal selection guideline is applicable for new installations/Procurement of Pumps, however this may be
extended for upgrading seals of Pumps in existing OG&C installations where frequent maintenance is encountered.

KEYWORDS:

Mechanical Seal
Seal Flush Plan
Selection Guideline
Pump/Seal Vendor
OG&C Plant
Work Process Diagram
Plant Owner
API 682

DEFINITIONS:

Pumps: refers to Centrifugal and Rotary pumps.

VOC: volatile organic compound as defined in the CAAA.
In VOC Service: means that the piece of equipment contains a process fluid (light liquid, heavy liquid or gas/vapor) that is at least5%
VOC by weight.
Light Liquid: liquid organic compound with a vapor pressure ≥ 0.044 Psia @ 70 deg F.
Heavy Liquid: liquid organic compound with a vapor pressure < 0.044 Psia @ 70 deg F.
HAP: Hazardous Air Pollutant.
Buffer Fluid: A fluid used as a lubricant or buffer between dual mechanical seals. The fluid is always at a pressure lower than the
pump process pressure being sealed.
Barrier Fluid: A fluid which is introduced between dual mechanical seals to completely isolate the pump process liquid from the
environment. Pressure of the barrier fluid is always higher than the process pressure being sealed
P&ID: Process & Instrumentation diagram.
O&M: Operation & Maintenance
OEM: Original Equipment Manufacturer
OG&C: Oil Gas & Chemical
LNG: Liquefied Natural Gas
API: American Petroleum Institute

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1.0 INTRODUCTION

Mechanical Seal is a device used to seal the interface between a rotating shaft and stationary housing Mechanical seals are used
throughout industry to minimize or eliminate leakage in the Pumps, Mixers and other rotating equipment’s. The ability of mechanical
seal to meet its performance objectives depends upon wide range of factors involving equipment design, operating conditions (process
parameters) and support system. Mechanical seals have gained success over the years for their ability to minimize or eliminate leakage
of process fluids to atmosphere. This has resulted in improved equipment reliability, reduced emissions and improved safety. While the
purpose of the seal appears to be simple enough however the design of seal components are significant engineering challenges.

However still LNG, Oil and Power plants are being confronted with several no. of available mechanical designs hence the end customer
should use inexpensive standard seal and exotic, highly engineered seal models.

Before selecting the seal material, type of seal; the designer or pump manufacturer either needs to go through exhaustively complete
scope of API 682 and their field experience (operational experience of using Seal Type X in Pump Type Y with process parameters Z).
To make the selection less complicated, selection guideline/strategy is illustrated in this paper below based on seal vendor
recommendations, feedback from Plant Owner (Plant O&M personals) and in-house lesson learnt (previous projects experience).

Selection strategy outline which makes the maximum use of capabilities of pump and seal manufacturer and Operational & Maintenance
personal in plants is presented here. This strategy will allow to selection of high-quality seal for given type of pump in given installation.

Principal features of optimum seals are also highlighted in this paper. This selection strategy provides a guideline for the selection of
mechanical seals and support systems for hydrocarbon services. Additional attention must be given to issues not covered by this paper
(i.e. selection guideline) like availability of auxiliary systems such as vapor recovery (flare) for a dual seal equipped with an API Plan
52, nitrogen for a dual seal equipped with an API Plan 53, cooling water, containment areas for seal leakage to reduce/ eliminate the risk
of environmental incidents, etc. Safety and environmental concerns should be evaluated on a case by case basis.

1.1API 682 4th Edition Seal Code Quick Reference

API 682 extract (refer Table D.1) below explains regarding Seal Code depicting various nomenclatures for the Seal Category,
arrangement, type and Design Options along with Size and Piping plans.

First Position: Seal Category (1, 2, 3)

Second Position: Seal Arrangement (1, 2, 3)

Third Position: Seal Type (A, B, C)

Fourth Position: Containment Device (P, L, F, C, S, X)

Example: P—plain gland with no bushing: this design can be used in Arrangement 2 or Arrangement 3 seals

Fifth Position: Secondary Sealing Element (Gasket) Material (F, G, H, I, R, X)

The available options are shown below:
F—FKM gaskets;
G—polytetrafluoroethylene (PTFE) spring energized gaskets;
H—nitrile gaskets;
I—FFKM gaskets;
R—flexible graphite (with spiral wound flexible graphite gaskets for gland gasket);
X—unspecified: the option for the secondary sealing element is unknown or not covered by the
standard options. This will be specified separately.

Sixth Position: Seal Face Material Combination (M, N, O, P, Q, R, S, T, X)

Example: M—carbon vs nickel bound tungsten carbide;

Seventh Position: Shaft Size in mm

Example: 25 mm is described as 025.

Eighth Position: Piping Plans

Example: A seal using a Plan 11 and a Plan 53A would be described as 11/53A

Examples of Finished Seal Codes

Example: 31B-LIN-075-53A

2.0 MECHANICAL SEAL SELECTION PROCEDURE-A

This seal selection procedure is used when service temperature and Vapor pressure of the Hydrocarbon is known. This procedure
provides a guideline for the selection of mechanical seals and support systems for new pumps, and seal upgrades of existing pumps.

Refer Table D.2 for selection of Mechanical seal of Pumps along with necessary notes. The “NOTES” sections at the bottom of this
procedure must be read prior to selecting any seal & seal support system.

Mechanical seals in light liquid VOC service containing 5% or more Hazardous Air Pollutants (HAP) by weight are treated as a separate
group as described in #1 in the “NOTES” section.

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TABLE D.2: Mechanical Seals for Pumps in Hydrocarbon Service - Selection Procedure
Hydrocarbon Services with Specific Gravity 0.7 and Seal Chamber Pressure 280 Psig
3.5” Maximum Sleeve or Shaft diameter
Emissions Target Control Level = 500 ppmv
Service Vapor Seal chamber pressure / Standard Seals Seal Primary Secondary Additional Information
Temp. Pressure vapor pressure ratio @ Arrangement Flush Flush
(degF) (Psia) service temp.
(calculated in Psia).
(1)
20 to 250 14.7 Pusher seal or Metal Special purpose 11, 13 or For new pumps, seal manufacturer to coordinate with
Bellows seal single balanced 14(1) pump OEM on primary seal flush selection (11,13 or 14)
cartridge seal and determine seal flush orifice size.
(2)
>14.7 1.5 Pusher seal Special purpose 11, 13 or Dry running secondary emission containment seals
single balanced- 14(1) and seals equipped with an API Plan 52 vented to a
cartridge seal vapor recovery system are not considered zero emission
seals, and must be approved by the owner.
>14.7 <1.5 Pusher seal Dual balanced 11, 13, 14(1) 52(2)
(3)
Barrier fluid compatibility with the process must be
cartridge seal or or evaluated.
(4)
23(7) 74(3,4,5,6) Preferred for continuous duty service
(5)
Select Plan 53 or 74 if difference between product
vapor pressure and seal chamber pressure is less than 25
psi.
(6)
53(3,5,6,8) Bellows type seals may be used in products with
or particulates present with owner approval.
(7)
74(3,4,5,6) API Plan 23 can be used as an option to obtain desired
vapor pressure margin.
(8)
250 to 450 >14.7 Pusher seal or Metal Special purpose 23 API Plan 53 is an option in locations where vapor
bellows seal single balanced- recovery system is not available or when flaring of seal
cartridge seal emissions or a product release into the flare (in the case
of a seal failure) is not allowed.
14.7 Pusher seal or Metal Special purpose 23
bellows seal single balanced-
11, 13 or 62
cartridge seal
14(1)

Hydrocarbon Services with Specific Gravity < 0.7 and Seal Chamber Pressure 280 Psig
3.5” Maximum Sleeve or Shaft diameter
Emissions Target Control Level = 500 ppmv
Service Vapor Seal chamber pressure / Standard Seals Seal Primary Secondary Notes /Additional Information
Temp. Pressure vapor pressure ratio @ Arrangement Flush Flush
(degF) (Psia) service temp.
(calculated in Psia).
20 to 450 Pusher seal (8) Dual balanced- 11,13 or 14 52(2)
(1)
For new pumps, seal manufacturer to coordinate with
(1)
cartridge seal pump OEM on primary seal flush selection (11,13 or 14)
and determine seal flush orifice size.
(2)
Dry running secondary emission containment seals and
seals equipped with an API Plan 52 vented to a vapor
recovery system are not considered zero emission seals,
and must be approved by the owner.
(3)
23(3) 52(2,6) API Plan 23 can be used as an option to obtain desired
vapor pressure margin.
(4)
53(4,5,6,7,8,9) API Plan 53 is an option in locations where vapor
or recovery system is not available or when flaring of seal
74 (5,7,8,9,10) emissions or a product release into the flare (in the case
of a seal failure) is not allowed.
(5)
Barrier fluid compatibility with the process must be
evaluated.
(6)
Based on seal heat generation calculations, seal
manufacturer to evaluate barrier fluid cooling
requirements and methods. Must be reviewed and
approved by owner.
(7)
API Plan 53 or 74 must be selected if specific gravity
is below 0.45
(8)
Bellows type seals may be used in products with
particulates present with owner approval.
(9)
Select Plan 53 or 74 if difference between product
vapor pressure and seal chamber pressure is less than 25
psi.
(10)
Preferred for continuous duty service

2.1 NOTES

 New pumps in light liquid service (Pv 0.044 Psia @ 70 deg F) that contain 5% VOC by weight AND 5% HAP by weight, must
be equipped with dual cartridge seals. API Plan 53 or 74 are the preferred secondary piping plan options for these services. Dry
running secondary emission containment seals and seals equipped with an API Plan 52 vented to a vapor recovery system (flare)
are not considered zero emissions seal systems and may be used only with approval of the owner.
 If the required Barrier fluid pressure in an API Plan 53 is above 150 Psi(g), the use of alternate technologies like pressure pistons
or API 53 modified reservoirs with bladders is required.
 Hydrocarbon services containing HF or H2S in hazardous concentrations are not covered by this procedure and must be
engineered in a combined effort between the owner, seal manufacturer and pump OEM.
 Services in pressure, temperature and size ranges not covered by this procedure must be engineered in a combined effort between
the owner, seal manufacturer and pump OEM.
 The use of alternative and new technologies is encouraged. Seals and seal support systems not covered by this procedure are
must be approved by the owner.
 If seals and seal support systems are used in a different way than the one described in this procedure, it must be approved by
the owner.
 This selection procedure assumes that low emission special purpose inside-mounted seals are utilized. Pusher and bellows seals
must be designed in accordance with the standard seals A, B and C types recommended on the API Standard 682 (First Edition,
October 1994). Any deviation must be approved by the owner.
 This selection procedure assumes that API 7th or 8th edition pumps will be used. If pump does not comply with API 7 th or 8th
edition, the seal and seal support system must be approved by the owner.
 Seals and seal support systems for non-API pumps must be approved by the owner.
 Primary and secondary support plan codes follow API Standard 682 (Current Edition) coding.
 Fluoroelastomer O-rings are the standard for all hydrocarbon services covered in this procedure with the exception of the
following services:
Hydrocarbons services above 350 deg F
Aromatic hydrocarbon services above 150 deg F
Hydrocarbon services with high concentration of H2S
 Perfluoroelastomer O-rings are the standard when fluoroelastomer O-rings are not an acceptable choice.
 The use of perfluoroelastomer O-rings as an alternative to fluoroelastomer O-rings is acceptable when it is justified by
standardization reasons.
 Metal bellows seals may also use flexible graphite secondary seals in place of fluoroelastomer or perfluoroelastomer O-rings.

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 Additional attention must be given to issues not covered by this procedure like: availability of vapor recovery systems (flare)
for a dual seal equipped with an API Plan 52, availability of Nitrogen for a dual seal equipped with an API Plan 53, availability
of cooling water, containment areas for seal leakage to reduce / eliminate the risk of environmental incidents, etc. EH&S
concerns should be evaluated on a case by case basis.
 For abrasive or corrosive services in which the process fluid cannot be utilized as flush for the inner seal, an external flush API
Plan 32 is an acceptable option. Cost of introducing an external product into the process stream and compatibility issues must
be evaluated in a case by case basis.
 Dry non-contacting gas seals with API 682 Plan 74 support system should not be used in the pump applications when available
Nitrogen pressure is less the 30 psig over maximum seal chamber pressure.

2.2 MECHANICAL SEAL SELECTION PROCEDURE-B

Another alternatively checking the right seal selection will be based on Service and Temperature range of Pumping. Table D.3 below
illustrates the selection procedure for primary and secondary seal type for a given pump with particular set of conditions (service type
and temperature range).

TABLE D.3: Mechanical Seals for Pumps in Hydrocarbon Service - Selection Procedure
Pumping API 682
Service Service Temperature Comments Seal Code
No Range Category Type Arrgm Config Primary Secondary Notes

1 Fresh water, condensate 0-100 °C 2 Aa 1 CW-FL 11 61M

2 Sea Water 0-80 °C 2 Aa 1 CW-FL 11 61M Note 62 May be
required
3 Boiler Feed Water 80-290 °C 2 Aa 2 CW-FL 23 61M

4 Sour Water H2S >50 0-80 °C 2 Aa 1 CW-FL 11 61M

ppm
5 Sour Water H2S >200 0-80 °C 2 Aa 2 CW-CW 2 52
ppm
6 Sour Water H2S >500 0-80 °C 2 Aa 3 CW-FB 2 53
ppm
7 Sour Water H2S >2000 0-80 °C 3 Aa 3 CW-FB 2 53
ppm

8 Brine 0-80 2 Aa 1 CW-FL 11 62

9 Oily Water - Sump VS4 Pumps 2 Aa 1 NC-FX 2 Packed Gland,

applications Dry Running
Contacting Seal
10 Storm Water - Sump VS4 Pumps 2 Aa 1 NC-FX 2 Packed Gland,
applications Dry Running
Contacting Seal
11 Sea Water - Sump VS4 Pumps 2 Aa 1 NC-FX 2 Packed Gland,
applications Dry Running
Contacting Seal
12 Hydrocarbon -Non VS4 Pumps 2 Aa 1 NC-FX 2
Flashing - Sump
applications
13 Hydrocarbon - Flashing 2 Aa 1 CW-BB 2 53
- Sump applications
14 Hydrocarbon - Non 2 Aa 1 CS-FX 2
Flashing with H2S (low
levels below 200 ppm)

15 Sea Water - Vertical Lift 1 Aa 1 CW-FL 32 Clean Water

flush

16 Cooling Water 0-80 °C 2 Aa 1 CW-FL 11 61M

17 Process Water 0-80 °C 2 Aa 1 CW-FL 11 61M

18 Hydrocarbons - Non -40 °C to -5 2 Aa 1 CW-FL 11 61M

Flashing °C
19 Hydrocarbons - Non -5 °C to 175 2 Aa 1 CW-FL 11 61M
Flashing °C
20 Hydrocarbons - Non 176 °C to 2 Ca 3 CW-BB 11 53
Flashing 259 °C
21 Hydrocarbons - Non >260 °C possibly 2 Ca 1 CW-BB 11 53
Flashing above auto
ignition
temperature
22 Hydrocarbons - Non to a max of Above auto 3 Ca 1 CW-BB 23 53
Flashing 450 °C ignition
temperature

23 Hydrocarbons - Flashing -5 °C to 59 2 Aa 2 CW-CS 11 76

°C
24 Hydrocarbons - Flashing 60 °C to 175 2 Aa 3 CW-BB 2 Note 53 Consider Plan
°C 23
25 Hydrocarbons - Flashing 176 °C to 2 Ca 3 CW-BB 2 Note 53 Consider Plan
259 °C 23
26 Hydrocarbons - Flashing >260 °C 2 Ca 3 CW-BB 23 53
27 Hydrocarbons - Flashing to a max of Above auto 3 Ca 3 CW-BB 23 53
450 °C ignition
temperature

28 Hydrocarbons Contaminated as a minimum follow Sour Water with ppm H2S or hydrocarbon
with H2S at operating temperature
29 Hydrocarbons Contaminated 2 Aa 3 CW-BB 2 53
with Benzene

Examples of
Hydrocarbo
n Services
30 Naphtha 0-80 °C 2 Aa 1 CW-CS 11 76 Check with
process for H2S
or Benzene
present
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31 Propane / Butane 0-80 °C 2 Aa 3 CW-FB 11 53
32 Crude Oil 0-80 °C 2 Aa 1 CW-FL 11 65
33 Crude Oil >200 °C Posibility of 2 Aa 3 CW-FB 2 53
Coking
34 Diesel Oil 0-80 °C 2 Aa 1 CW-FL 11 61M
35 Kerosene 0-80 °C 2 Aa 1 CW-FL 11 61M

36 Molten Sulphur 127 C 2 Aa 1 CW-FL 11 62 Steam Quench

37 Corrosive Acid 0-80 2 Aa 3 CW-FB 2 53

38 Sulphuric Acid 0-80 2 Aa 1 CW-FL 11 61
39 Hydrofluoric Acid 0-80 Work
with
Pump
Vendor /
Seal
Vendor
40 Caustic Acid (Low 0-80 2 Aa 1 CW-FL 11 62
concentrations)
41 Caustic Acid (High 0-80 2 Aa 3 CW-FB 2 53
Concentrations)

42 Benzene 2 Aa 3 CW-BB 2 53

43 Amines 0-240 °C 2 Aa 3 CW-BB 2 53

44 Lean MEG 2 Aa 3 CW-BB 2 53

45 Rich MEG 2 Aa 3 CW-BB 2 53

46 Slurries Work
with
Pump
Vendor /
Seal
Vendor

2.3 WORK PROCESS FLOW DIAGRAM- SEAL SELECTION/CO-ORDINATION

Work process flow diagram for the mechanical seal selection/coordination for OG&C plant along with brief information on various
Seal types for Pumps per API 682. TABLE D.4 below illustrates the Process Map which help in Mechanical Seal Selection/coordination
between the Pump/Seal vendor, End User and Design Department Interco-ordination (Engineering, Procurement), Process Safety and
Licensor (wherever applicable). Below notes are to be referred in line with Table D.4.

NOTES:

1.) Refer 1a) & 1b) below:

a) End User Inputs/Comments are required where applicable, per the prime contract applicable from project to project.
b) Review / comments from EPC Contractor/Consultants Sub-Disciplines shall be as-required based on document type and scope of seal
and auxiliaries specified.
2.) Specific fluid properties that must be advised shall be:
a) Specific Gravity
b) Specific Heat
c) Vapor Pressure
d) Viscosity (Including any significant viscosity increase when fluid is cooled)
e) Temperature – Minimum/normal/maximum
f) Potential for coking or crystallization when process fluid cools or reaches atmospheric pressure.
g) Whether fluid will completely flash or if condensable may be present.
h) Whether fluid is considered hazardous and/or flammable
i) Presence of hazardous components in fluid (e.g. H2S, caustic, etc.)
j) Properties of available flushing utilities (e.g. water, steam, nitrogen, etc.)
k) Compatibility of buffer/barrier fluids and Plan 32 flushing liquid with process fluid.
3.) Seal documentation deliverables for review (via the pump vendor) shall include at minimum:
i) Seal performance data included on Seal Data Sheet and/or Pump Data Sheet (Note 4)
ii) Seal Drawing with operating conditions complete (Including seal chamber pressures)
iii) Seal Flush (Including Auxiliary Flush Plan) Arrangement Drawings (Complete with flushing flow rates and pressures)
iv) Seal Flush P&ID for each service with instrument tags and alarm/set points
v) Seal IOM Manual (Marked specifically for the seal supplied for each service)
4.) Some projects combine seal data on the Pump Data Sheet and others require a separate Seal Data Sheet.
5.) Seal vendor shall recommend buffer and/or barrier flush fluid. Process and Project Engineering shall review and approve
recommended fluid.
6.) Seal flush P&ID’s shall detail field connections for vents and drains with their termination locations.
7.) Mechanical Seal Quote shall list all operating condition assumptions, as provided on pump/seal data sheets. Quote shall also include
Seal Chamber Pressure and Vapor Pressure Margin (or state N/A if not applicable) for each service to receive consideration as complete
bid.
8.) Start-up representative should be consulted at Hazop Review Stage (IFH) for lessons-learned / recommendations regarding:
a. Typical seal flush plan selections.
b. Spare mechanical seal quantities by service.

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D.4 PROCESS MAP- MECHANICAL SEAL SELECTION/ COORDINATION

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3.0 CONCLUSION:

Systematic efforts to upgrade seal selection are possible through increased involvement of experienced application engineer working for
capable seal manufacturers. These efforts are further assisted by a seal selection strategy presented in this paper which identifies those
design features which promise to lead to reduced failure risk, greater ease of maintenance, better understanding by operators and
mechanical work forces. It is believed that 98% of the pumps used in typical petrochemical plant can be assigned service severity
categories from 1 (least severe) to 9 (most severe). Selection of only 3 types to cover all 9 categories will accomplish the goals we have
set for ourselves. The selection strategy presented also outlines, which makes maximum use of the capabilities of knowledgeable seal
manufacturers and is perfect road map for ideal seal selection. Additionally, the Work process flow diagram depicted in this paper helps
in right path following for coordination between different parties while seal selection for the pumps in a typical plant.

4.0 REFRENCES:

1. Ingram, J.H., “Pump Reliability- Where do you start?” Paper presented at 37th Petroleum Mechanical Engineering Workshop and
Conference, Dallas (1981)
2. Bloch, H.P., “A User’s view of Fluid Sealing Economics,” Paper presented at 45 th Annual Meeting of Fluid Sealing Association, Sun
Valley (1978)
3. API Standard 682, 4th Edition- Pumps- Shaft Sealing Systems for Centrifugal and Rotary Pumps.
4. Day, Michael, “Hydrodynamic Sealing of Centrifugal Pumps- Keys to Success”, World Pumps (1995).
5. Huebner, Michael, “Material Selection for Mechanical Seals”, Flowserve Corporation, Deer Park.
6. Massaro, A.J., “The ‘Mating Pairs,’ Concept for Mechanical Seals,” Lubrication Engineering, pp. 436-446 (1988).
7. Heinz P. Bloch, “Selection strategy for Mechanical Shaft Seals in Petrochemical Plants”, Exxon Chemical Company, Baytown.

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