Installation & Troubleshooting Guidelines For API Seal Flush Plans

1
Installation & Troubleshooting

Guidelines for API Seal Flush Plans
API Piping Plans

Review of Piping
Plan Schematics
Installation & Troubleshooting Guidelines
for API Seal Flush Plans-Introduction
End face shaft seals consist of

 A set of faces, one flexibly mounted and one
rigidly mounted
 springs or metal bellows to provide flexibility
 secondary sealing members one of which must
provide flexibility
 adaptive hardware to hold the parts in an
assembly
2
Springs Secondary
Sealing
Secondary
Members
Sealing
Members
Adaptive
Hardware
Dynamic Secondary Flexibly Rigidly

Sealing Member Mounted Mounted
Face Face
3
The faces provide for the dynamic sealing

of the fluid in the pump
The flexibly mounted face moves during
pump operation to maintain a narrow
sealing gap to the rigidly mounted face
4
 The size of the sealing gap

must be carefully
controlled
 To provide for acceptable
leakage of the pump
product to atmosphere
 To provide load support to
Sealing
the faces as well as Gap
lubrication to prevent face
damage and excess wear so
that adequate seal life is
maintained
5
The seal faces and the seal assembly

generate heat in the seal chamber due to
 liquid turbulence in the seal chamber
 liquid shear in the sealed fluid between the seal
faces
 mechanical motion in the seal assembly
 occasionally bumping or touching of the seal
faces
6
 This heat must be removed in most applications to

maintain stable operation
 In high temperature applications the opposite
may be true. The heat in the seal chamber must
be maintained to provide a stable operation
 To control the temperature in the seal chamber
and to provide adequate lubrication for the seal
faces, a seal flush is required for the vast majority
of applications
7
 A variety of seal flush arrangements may be used
depending on
 pump construction
 the type of seal assembly being used
 the seal chamber pressure
 fluid properties
 operating conditions such as temperature, viscosity, etc.
 It is essential that the correct seal flush arrangement
be installed and operated properly
8
The various seal flush arrangements have

been categorized by API
The plans are numbered and identified as
API Piping Plan XX
A brief overview of the various piping plans
commonly encountered follows
We will discuss each in more detail with a few
exceptions as indicated
9
 API Piping Plan Summary (* = not covered)
 01*,02*………Pump feature flush plan
 11,12*,13,14…By pass Flush- Flush plans intended to keep the
seal area clean and remove seal generated heat
 21,22*,23…….Cooling Flush plan - Flush plans intend to cool
the seal area
 31,32,33*…….Slurry Flush Plan - Flush plan intended to keep
the slurries away from the sealing area.
 41*…………....a combination plan for cooling and slurry
 51*,52,53……..Dual Seal Flush plans
 61,62………….Atmospheric flush plans to provide for a
suitable atmosphere outside the seal area or
behind the primary seal faces-Quench
1
Orifice
API Piping Plan 11

Line from discharge through
orifice to seal flange
1
Pressure
Block Valve Gauge
Orifice
Gauge
Valve
API Piping Plan 11

Line from discharge
through orifice to seal flange
1
Line Up Procedure-API Plan 11

 Check to make sure any valves in the seal flush line
are open (caution-if the flush source is taken from
past the block valve on the pump discharge header
the suction valve must be open or the pump and seal
chamber will be subject to full pump discharge
pressure)
 Proceed with opening all valves for service
 Check for leaks around valves and the orifice in the
flush line
1
Line Up Procedure-API Plan 11 Continued

 Start pump per normal procedure
 Once running check to make sure the seal
flush line is the same temperature from its
origin to the primary seal flush port on
the primary seal flange or seal chamber
connection. The line should be the same
temperature at both ends.
1
 Preventive Maintenance and Troubleshooting-

Plan 11
 The seal flush line should be checked
regularly with a temperature indicator.
It should be the same temperature at
both ends of the line.
 The typical mode of failure is a clogged
orifice or a closed valve.
1
 Preventive Maintenance Orifice

and Troubleshooting-Plan
11
 Hot Service-seal flush line
plugged. When the seal
flush line is plugged in a hot
service the line will be cold.
It may be hot at the origin
and at the seal, but it will
become cold as you move
away from the connections API Piping Plan 11
Line from discharge
1
 Preventive Maintenance Orifice

11
 Cold Service-seal flush line
clogged. When the seal
flush line is clogged on a
cold service, you will find
the line hotter at the seal
connection. The line will
become cooler as you move
away from the seal toward API Piping Plan 11
the pump case.
Line from discharge
1
Orifice
API Piping Plan 13

Line from seal flange through
orifice to pump suction
1
Pressure
Block Valve Gauge
Orifice
Gauge
Valve
API Piping Plan 13

Line from seal flange
through orifice to pump
suction
1
 Line Up Procedure-API Plan 13

 Check to make sure any valves in the seal flush line are
open
flush line
 Open the vent line (if there is one) on the seal flush line
to vent any air or vapor that is in the primary seal
chamber. (Primarily for vertical pumps)
 Close the vent line when a good liquid flow is obtained
2

flush line is the same temperature from its
origin to the primary seal flush port on
the primary seal flange or seal chamber
connection. The line should be the same
temperature at both ends.
2

Plan 13
 The seal flush line should be checked
It should be the same temperature at
2
 Preventive Maintenance and Orifice

Troubleshooting-Plan 13
plugged. When the seal
flush line is plugged in a hot
service the line will be cold.
It may be hot at the origin
and at the low pressure
point (near the pump case),
but it will become cold as
you move away from the
connections
API Piping Plan 13
2

clogged. When the seal
flush line is clogged on a
cold service, you will find
the line hotter at the seal
connection. The line will
become cooler as you move
away from the seal toward
the pump case. API Piping Plan 13
2
Orifice
Orifice
Rotameter
API Piping Plan 14

Line from seal flange through orifice to pump suction and line
from pump discharge to seal flange or seal chamber tap
2
Orifice
Orifice
Gauge
Block Valve Pressure
Valves Pressure Gauge
Gauge
Rotameter
API Piping Plan 14

Line from seal flange through orifice to pump suction and line
from pump discharge to seal flange or seal chamber tap
2
 Line up procedure-API Plan 14

open
flush line
 Open the vent line (if there is one) on the seal flush line
to vent any air or vapor that is in the primary seal
chamber. (Primarily for vertical pumps)
 Close the vent line when a good liquid flow is obtained
2
Line up procedure-API Plan 14

flush lines are the same temperature
from their respective origins to their
respective connections. The lines should
be the same temperature at both ends.
2
Line up procedure-Plan 14
 The line from discharge should be the same
temperature from the connection at the pump case to
the primary seal flush port on the primary seal flange
or the seal chamber tap.
 The line to suction should be the same temperature
from the seal flush port on the primary seal flange to
the suction connection.
 Both lines should be the same temperature as the
pump case
2

Plan 14
 The seal flush lines should be checked
They should be the same temperature at
3
 Preventive Maintenance and
Troubleshooting-Plan 14 Orifice
 Cold Service
 Line from discharge-when the seal flush
line is clogged in a cold service, you will Orifice
find the line hotter at the seal flush port
connection on the seal flange or seal
chamber tap. The line will cool as you
move toward the origin of the seal flush.
The heat you measure at this point is
radiating up the seal flush line and is
generated by the mechanical seal. This
differential may be quite small for plan 14
is the seal chamber pressure is high
enough to generate some flow through the API Piping Plan 14
line to suction. Line from seal flange through
orifice to pump suction and line from
pump discharge to seal flange or seal
chamber tap
3
Orifice
 Cold Service
 Line to suction-if the line from
discharge is operating properly, it
may not be possible to detect that
this line is plugged. If vapors
are accumulating at the top of the
seal chamber, the line will be
warmer at the primary seal flange
and cool as you move away from it
toward the suction connection due
to heat generation at the seal.
Otherwise a flow indicator is
helpful to detect failure of this line.
API Piping Plan 14
orifice to pump suction and line from
pump discharge to seal flange or seal
chamber tap
3
 Hot Service
 Line from discharge-when the Orifice
seal flush line is clogged in a hot
service, you will find the line cold.
It may be hot at the origin and
also at the flush port connection
on the seal flange or seal chamber
tap, but it will become cold as you
move away from the connections.
API Piping Plan 14

Line from seal flange through orifice to
pump suction and line from pump
discharge to seal flange or seal chamber tap
3

 Hot Service
 Line to suction-When the
seal flush line is clogged in
a hot service, you will find
the line cold. It may be hot
at the origin and also at the
flush port connection, but
it will become cold as you
move away from the
connections
API Piping Plan 14
Line from seal flange through orifice to pump
suction and line from pump discharge to seal
flange or seal chamber tap
3
Orifice
Heat Exchanger
API Piping Plan 21

orifice and cooler to seal flange
3
Pressure
Block Valve Gauge
Orifice
Gauge
Valve
Heat Exchanger
API Piping Plan 21

3

 Check to make sure any valves in the seal flush
line are open (caution-if the flush source is
taken from past the block valve on the pump
discharge header the suction valve must be
open or the pump and seal chamber will be
subject to full pump discharge pressure)
 Check to make sure the cooling water lines to
the heat exchanger are open
3
 Line Up Procedure-API Plan 21 Continued

 Open the case drain on the heat exchanger to
clear debris from the cooling water system and
check for flow
 Check for leaks around valves and the orifice in
the flush line
3

 Once running check to make sure product is flowing
through the heat exchanger to the primary seal flush
port. This can be confirmed by checking for a
temperature drop across the heat exchanger
 Once running check to make sure the cooling water is
flowing through the case side of the heat exchanger.
This can be confirmed by checking for a temperature
rise across the heat exchanger.
3
 Preventive Maintenance and Troubleshooting-Plan 21

 The seal flush line should be checked regularly with
a temperature indicator. When the pump is
running the outlet of the seal cooler should be
noticeably cooler than the inlet
 The cooling water lines should be checked regularly
with a temperature indicator as well. The outlet
cooling water line should be warmer than the inlet
cooling water line.
4

 The typical modes of failure are
 clogged orifice or a closed valve
 loss of cooling water flow
 missing or oversized orifice
 The body of the heat exchanger should be warm while
the pump is in operation
 The heat exchanger case drain should be opened
periodically to purge the heat exchanger of
accumulated solids and debris
4
Orifice
Troubleshooting- Plan 21
 Clogged or closed seal flush
line-when the seal flush line
is clogged or closed, you will Heat Exchanger
find the seal flush line and
heat exchanger cold. The
seal flush line may be hot at
the origin and at the flush
port connection, but it will
become cold as you move
away from the connections. API Piping Plan 21
4
Orifice
 Loss of cooling water flow-if
cooling water flow is lost,
the seal flush line will be hot Heat Exchanger
throughout its entire length.
The cooling water lines will
be hot near the heat
exchanger and become
cooler as you move away
from the heat exchanger. API Piping Plan 21
4
Orifice
 Preventive Maintenance
21
 Missing or oversized orifice-if
Heat Exchanger
the orifice is oversized or
missing, the temperature
drop in the flush line across
the cooler will be inadequate.
The temperature rise in the
cooling water lines across the
cooler will be excessive and
the heat exchanger case will
be hot API Piping Plan 21
Line from discharge through orifice
and cooler to seal flange
4
Vent Valves
API
PIPING
To suitable drain
or disposal system
Long radius
PLAN 23
tubing bends Line from seal
required for Heat to cooler
all elbows Exchanger and back to
seal flange
18-24”
4

 Check to make sure any valves in the seal flush
circulation lines are open. There should not be any
valves in the seal flush circulation lines for a Plan 23
under normal circumstances however.
 Check to make sure the cooling water lines to the heat
exchanger are open
 Open the case drain on the heat exchanger to clear
debris from the cooling water system and check for flow
4

 Open the vent valve(s) in the seal flush
circulation lines. A full product stream to grade
should be obtained before the vent valve is
closed. This will insure the seal is immersed in
liquid prior to pump operation
 Check for leaks around valves in the flush line
circulation lines
4

 Once running check to make sure product is
flowing to and from the heat exchanger to the
flush ports. This can be confirmed by checking
for a temperature drop across the heat exchanger
 Once running check to make sure the cooling
water is flowing through the case side of the heat
exchanger. This can be confirmed by checking
for a temperature rise across the heat exchanger.
4

 The seal flush line should be checked regularly with a
temperature indicator. When the pump is running the
outlet of the cooler should be slightly cooler than the
inlet. The outlet should be only 20-30 oF above the
cooling water temperature and the inlet should be only
30-40 oF above the outlet.
 The cooling water lines should be checked regularly with
a temperature indicator as well. The outlet cooling water
line should be warmer than the inlet cooling water line.
4

 The typical mode of failure are an unvented system,
a closed valve in the seal flush circulation lines, or
loss of cooling water flow
 The body of the heat exchanger should be warm
while the pump is in operation
 The heat exchanger case drain should be opened
periodically to purge the heat exchanger of
accumulated solids and debris
5
 Unvented or closed valve in the
seal flush circulation lines-if the
system is not properly vented or a
valve is closed in the seal flush
circulation lines you will find the
seal lines and heat exchanger 18-24”
cold. The flush lines may be hot
at their origin, but will become
cold as you move away toward
the heat exchanger. The body of
the heat exchanger may also be
cold. API PIPING PLAN 23
Line from seal to cooler
and back to seal flange
5
 Clogged or closed cooling water
system-if the cooling water system is
inoperable, you will find the process
lines entering and exiting the heat
exchanger at the same temperature.
The body of the heat exchanger will 18-24”
also be very hot. The cooling water
lines entering and exiting the heat
exchanger will be very hot at the
cover and both lines will cool as you
move away from the heat exchanger. API PIPING PLAN 23
Line from seal to cooler
and back to seal flange
5
API Piping Plan 31

and cyclone separator to seal flange
5
Pressure
Block Valve Gauge
Gauge
Valve
API Piping Plan 31

5

open (caution-if the flush source is taken from past the
block valve on the pump discharge header the suction
valve must be open or the pump and seal chamber will
be subject to full pump discharge pressure)
 Check for leaks around valves, connections in the seal
flush line, the cyclone separator, and the orifice in the
flush line
5
 Line Up Procedure-API Plan 31Continued

 Once running check to make sure the seal flush line is
the same temperature from its origin through the
cyclone separator to the primary seal flush port on the
primary seal flange or seal chamber connection . Also
check the line from the cyclone separator back to the
suction connection. The line should be the same
temperature at all locations throughout its length.
5

 The seal flush line should be checked regularly
with a temperature indicator. It should be the
same temperature as the pump case throughout
its entire length.
 The typical mode of failure is a clogged orifice,
a closed valve, a clogged cyclone separator, or a
clogged line from the cyclone separator back to
suction.
5
for API Seal Flush Plans

plugged. When the cyclone
separator is plugged in a
hot service all three lines
will be cold. It may be hot
at the origin, at the suction
connection, and at the seal,
API Piping Plan 31
connections Line from discharge through orifice
5
 Hot Service-seal flush line plugged.
When the line from the cyclone
separator to suction is clogged, you
will find the cyclone itself hot and the
line to the seal flange. The connection
at the suction may be hot near the
pump case but will become cooler as
you move away from the connection.
The seal may leak erratically due to a
high flush rate. It will fail quickly
since it is being subjected to all the
API Piping Plan 31
abrasives present in the system. Line
from discharge through orifice
5
plugged. If the orifice is
plugged the line from the
pump case to the cyclone
will be cold. The lines to the
seal and the suction
connection may be hot since
fluid is flowing from the seal
back to the cyclone and then API Piping Plan 31
to suction. Line from discharge through orifice
6
plugged. Finally, if a valve is
closed in the line from the
cyclone to the seal, this line
will be cold but may be hot at
the seal connection or the
cyclone. The lines from the
pump case to the cyclone will
be hot since liquid is flowing API Piping Plan 31
from discharge to the cyclone Line from discharge through orifice
and then back to suction. and cyclone separator to seal flange
6
 Cold Service-seal flush
line plugged. When the
cyclone separator is
clogged in a cold service,
the line to the seal will be
hotter than the rest of the
line at the seal connection.
The lines will be cool in
all other locations
API Piping Plan 31
6
plugged. If the line from the
cyclone to pump suction is
clogged, there will be no
physical evidence. The lines
will be the same temperature
in all locations since fluid is
flowing to the seal. The seal
may exhibit erratic leakage
due to the presence of solids API Piping Plan 31
and a high flush rate. Line from discharge through orifice
6
plugged. If the orifice is plugged,
there will be no physical evidence.
All lines will be cool since there is
flow from the seal to the cyclone
and then back to suction. The seal
may be operating fine unless there
is no enough differential pressure
between the seal chamber and
suction to provide adequate flow.
Then the connection at the seal
flange may be warm. API Piping Plan 31
6
plugged. A closed valve
between the cyclone separator
and the seal flange will result in
no flow to the seal. The
connection at the seal flange
may be warm. The lines will be
cool at all other locations since
there will be flow from pump
discharge to the cyclone and
back to suction. API Piping Plan 31
6
Check Valve
Pressure
Indicator
Block
Flow Indicator
Pressure Valve
or Flow
Regulator
Pressure
Indicator External Source
of Clean Fluid
API Piping Plan 32

Flush from External Source
6

open (caution-if the flush source is taken from a very high
pressure source the suction valve must be open or the pump
and seal chamber will be subject to the full pressure)
 Check the gauge on the seal flush line to make sure there is
pressure in the line
 If there is a flow indicator in the flush line check to make
sure a flow is established
6

 Check for leaks around valves and the orifice in
the flush line
 Once running check to make sure the seal flush
line is the same temperature from its origin to
the primary seal flush port on the primary seal
flange or seal chamber connection. The line
should be the same temperature at both ends.
6

 The seal flush line should be checked regularly
with a temperature indicator. It should be the
same temperature at both ends of the line.
 The typical mode of failure is a clogged orifice,
a defective flow or pressure controller, loss of
pressure in the line, or a closed valve.
6

 Hot Service-seal flush
line plugged. When the
seal flush line is plugged
in a hot service the line
will be cold. It may be
hot at the seal connection,
connection
API Piping Plan 32
7

 Cold Service-seal flush
line clogged. When the
seal flush line is clogged
on a cold service, you will
find the line warmer at
the seal connection. The
line will become cooler as
seal connection.
API Piping Plan 32
7
Orifice To Suitable
Block and Vapor Recovery
Pressure Bleed Valve System
Gauge Fill Connection
Pressure High Level Switch Low Level
Switch Switch
Long Radius Temperature
Tubing Bends Indicator
Cooling
Required
Water Drain 18-24”
Connections Valve
API Piping Plan 52

Circulation of clean unpressurized
buffer fluid from seal to external
reservoir and back to seal 7
 Check to make sure the level of buffer fluid in
the seal reservoir is at the base level reading
 Check to make sure there are no visible buffer
fluid leaks at the seal or fittings in the secondary
sealing system
 Check to make sure that any valves from the
flare connection port on the seal reservoir to the
flare header or low pressure point are open.
7
 Check the gauge on the reservoir. There should
be no pressure (or the pressure reading should
be less than or equal to the flare header pressure
or the system to which the reservoir is vented).
 Check for leaks around valves and connections
in the flare connection line
7

 Once running check to make sure your
base level and pressure readings in the
tandem seal reservoir are still holding
 the reservoir should also begin to warm as
the secondary seal circulates buffer fluid
to and from the secondary seal chamber
7

 The tandem seal reservoir should be checked on
normal operator rounds on a regular basis. The base
level should be checked for fluid loss or gain. The base
pressure of the system should also be monitored. The
temperature of the reservoir should be checked.
 A pressure increase in the reservoir is an indication of
a primary seal leak. Small fluctuations are acceptable
since the pressure in the flare header system is also
variable.
7

 When a pressure increase is observed also check the
flare header line leaving the reservoir. It may be closed
or blocked. If it is cold, this is an additional sign of a
leaking primary seal in light hydrocarbon. If it is hot, it
may be a sign of a leaking primary seal in a hot service.
 A level increase in the reservoir is also a sign of a leaking
primary seal. A slowly increasing level is a normal
symptom when the primary seal leakage does not
vaporize at the reservoir temperature.
7

 When a level increase is observed, also check
the pressure reading.
 A level decrease in the reservoir is a
symptom of a leaking secondary seal. Check
all the seal circulation piping and
connections. Make sure the drain valve is
closed.
7

 A fugitive emission failure usually occurs when the
primary seal leakage does not vaporize at the reservoir
temperature. Over a period of time it may accumulate
in the reservoir even though a level increase is not
observed. This is due to the fact that the secondary seal
may leak at almost exactly the same rate as the
primary seal. When this happens, the fluid in the
reservoir should be drained, the reservoir flushed out,
and then refilled with fresh buffer fluid.
7

 Level Increase-Block in the
reservoir and observe how
rapidly the pressure
increases. If it raises only a
few pounds in 15 minutes,
this is probably normal
accumulation of primary
seal leakage. If it rises
rapidly, a primary seal API Piping Plan 52
failure has occurred Circulation of clean unpressurized
reservoir and back to seal
8

 Level Decrease-check all the
piping and fittings for leaks.
Block in the reservoir. If
the pressure does not rise
gradually there is a leak
somewhere in the system.
Check the drain valve.
Block in the cooling water
lines. There may be a leak API Piping Plan 52
in the cooling water coil. Circulation of clean unpressurized
8
52
 Pressure Increase-check to
make sure the line to the
flare header is not closed or
blocked. Block in the
cooling water and drain off
a small amount of buffer
fluid to check for water. API Piping Plan 52
The cooling coil may be Circulation of clean unpressurized
leaking.
8

 Fugitive Emission
Failure-wash down the
surrounding area.
Check all the flush lines
and pump connections
for leaks. Drain the
reservoir, flush it out, API Piping Plan 52
and refill with fresh Circulation of clean unpressurized
buffer fluid. buffer fluid from seal to external
8
Source of gas
or clean liquid Check Valve
Fill Connection
Block Pressure
Valve Regulator
Pressure Low Level
Block and
Switch Switch
Bleed Valve
Pressure Long Radius
Indicator Temperature
Tubing Bends Indicator
Required
Cooling Water Drain
Connections 18-24”
Valve
API Piping Plan 53

Circulation of Clean Pressurized
Barrier Fluid from Seal to
Reservoir and back to Seal 8
 Check to make sure the level of barrier fluid in the seal
reservoir is at the base level reading
 Check to make sure there are no visible barrier fluid leaks
at the seal or fittings in the secondary sealing system
 Note: Depending on the system pressure the next
two steps may need to be implemented after the
pump valves are opened
 Check to make sure that any valves from the pressure
source to the seal reservoir are open.
8

 Check the gauge on the reservoir. Make sure the
reservoir is pressurized to the required set point.
 If the reservoir cooling coil is piped to a water
supply, open the cooling water lines
 Check for leaks around valves and connections
in the reservoir system
8

 Once running check to make sure your base
level and pressure readings in the double seal
reservoir are still holding
 The reservoir should also begin to warm as
the secondary seal circulates buffer fluid to
and from the secondary seal chamber
8
 The double seal reservoir should be checked on normal
operator rounds on a regular basis. The base level should
be checked for fluid loss or gain. The base pressure of the
system should also be monitored. The temperature of the
reservoir should be checked.
 A pressure loss in the reservoir may be an indication of
either a primary or secondary seal leak. Small
fluctuations are acceptable since the supply pressure to
the pressure controller may also be variable. A pressure
loss can also be due to a defective controller.
8

Plan 53
 A pressure increase in the reservoir is usually due to a
malfunction in the pressure controller. High pressure
services will normally have a bias regulator. Tap on
the regulator to see if it is stuck. If the pressure
increases or becomes erratic, shut down the pump in an
orderly manner for maintenance. The regulator may
need to be replaced or recalibrated. If it is a bias
regulator, the pressure sensing line may be clogged.
8
 A level loss in the reservoir is also a sign of a leaking
primary or secondary seal. A slowly decreasing level is
a normal symptom since both seals will have normal
leakage.
 When a level loss is observed, also check the pressure
reading.
 A level decrease in the reservoir may not be due to seal
leakage. Check all the seal circulation piping and
connections. Make sure the drain valve is closed.
9

 A level increase in the reservoir can only occur when the pressure
in the reservoir is lost. In this case the primary seal is leaking
product into the reservoir. Restore pressure to the reservoir. If
the pumpage is toxic or hazardous, the pump should be shut down
in an orderly manner for maintenance. The barrier fluid in the
reservoir and seal chamber should be drained and replaced.
 A small increase in the reservoir level will be observed shortly
after startup due to the heating of the barrier fluid by the seal.
Small fluctuations in the level are normal and should not be a
cause of concern.
9

 A fugitive emission failure usually occurs when
the pumpage has accumulated in the reservoir
for some reason. Usually there will have been a
loss of pressure for some time period for this to
occur. When this happens, the fluid in the
reservoir should be drained, the reservoir
flushed out, and then refilled with fresh buffer
fluid.
9
 Pressure Loss-check to make
sure the line from the pressure
source is not closed or blocked.
Block in the cooling water and
drain off a small amount of
buffer fluid to check for water.
The cooling coil may be
leaking. Check the pressure
controller. Check all lines and
connections for leaks. Make
API Piping Plan 53
sure the drain valve is closed. Circulation
of Clean Pressurized
Reservoir and back to Seal
9
53
 Pressure rise-the pressure
regulator is either stuck or
defective. Tap on the
regulator to see if the
pressure will drop to the base
level. If not it must be
replaced or recalibrated. If a
bias regulator is being used,
API Piping Plan 53
the pressure sensor line may Circulation of Clean Pressurized
be plugged Barrier Fluid from Seal to
9
 Level increase-the system has lost
pressure and pump product is
leaking into the barrier fluid past
the primary seal. Restore the
pressure to the reservoir. Check
the air or liquid supply line to
make sure there is pressure and
all valves are open. If the
pumpage is hazardous or toxic,
drain the reservoir and the seal
chamber and replace the barrier
API Piping Plan 53
fluid. Circulation
of Clean Pressurized
9
 Level Loss-Refill
reservoir and monitor
level closely. If rapid loss
occurs a leak is present.
Check all piping and
connections for leaks.
Make sure the drain valve
is closed. Block in the
cooling water. The API Piping Plan 53
cooling coil may have a
leak.
9

 Fugitive Emission Failure-
wash down the
surrounding area. Check
all the flush lines and
pump connections for
leaks. Drain the reservoir,
flush it out, and refill with
fresh buffer fluid.
API Piping Plan 53
9
External Nitrogen
Flow
Pressure Source
Meter
Pressure Gas Control Panel
Pressure P.I. Switch
Regulator Flow
Switch Barrier Inlet
Check
Valve
Coalescing
Filter
Ball Valve
API Piping Plan 53 (Gas)

9
 Line-up procedure-Plan 53 Gas

 The gas pressure must be on the sealing system prior to
lining up the pump for service
 Always stabilize the gas sealing system prior to
applying any pressure to the pump
 Never de-pressure the gas sealing system prior to de-
pressuring the pump
 Maintaining the proper seal pressure at all times is
critical to avoid damage to the seals during the start-up
and shut down procedure
9
Line-up procedure-Plan 53 Gas continued

 Check to make sure the regulator o the gas panel
is turned all the way to decreasing
 Open the supply gas pressure to the gas panel
 Know your baseline secondary sealing system
pressure!
 Turn the regulator adjustment knob towards
increasing until the baseline pressure is obtained
1

 Check to make sure the flow meter drops to 02
scfh. If not, proceed to the trouble shooting
section below (note: the flow meter should
stabilize in less than 5 minutes)
 Proceed with pump line-up per plant
specifications
 Check for leaks around any valves
1

 Start pump per normal procedures
 Once running, check to make sure your panel
pressure and flow readings in the secondary
sealing system are stable and at the baseline
readings
1
Preventive Maintenance and

Troubleshooting-Plan 53 Gas
 The seal system should be checked on normal
operator rounds
 The gas panel should be checked for proper
pressure and gas flow readings. Significant
changes in these readings can indicate the
primary and/or secondary seal is beginning to
leak and should be monitored carefully
1
Preventive Maintenance and

 No or low gas panel pressure with typical flow
recorded on the flow meter is usually caused by
one of four things
 Partially closed or closed supply valves-check to
make sure the supply valves to the gas seal panel is
fully open
1
Preventive Maintenance and Troubleshooting-

Plan 53 Gas
recorded on the flow meter is usually caused by
one of four things
 Improperly adjusted regulator-adjust the regulator
toward the increasing pressure direction only to obtain
the baseline pressure.
 Variable supply pressure-check to make sure the supply
pressure to the panel is at normal levels
1

Plan 53 Gas
recorded on the flow meter is usually caused by one of
four things
 Clogged filter element in coalescing filter-in the event these
attempts are unsuccessful, decommission the pump and take
the gas panel out of service and check the coalescing filter.
Proceed through the start-up procedure for the gas panel. If
you are still unsuccessful, contact maintenance for assistance
1
Plan 53 Gas
 A high gas panel pressure with typical flow on the
flow meter normally occurs when the regulator on
the panel has been set above the base pressure
reading -adjust the regulator on the gas panel in
the increasing direction. When making the
adjustment, do so slowly to avoid dropping the
panel below the desired base pressure reading
1
 Preventive Maintenance and Troubleshooting-Plan 53 Gas
 High flow readings in excess of 5-6 scfh can be caused by
loose fittings downstream of the flow meter or damage to
the seal faces
 The first step is to leak check all fittings down stream of the flow
meter on the gas panel. A very small leak can cause a high flow
reading. If the fittings are leak free, call your maintenance
personnel to troubleshoot the mechanical seal assembly. A high
flow under these conditions usually means the seal is damaged in
some way.
 Providing you can maintain the base pressure on the panel and an
elevated leak rate is not affecting process conditions, the pump can
continue to be operated until an orderly shut-down can be executed.
1
 Preventive Maintenance and External Nitrogen Flow
Pressure Source Meter
 No or low gas panel pressure with Pressure Gas Control
typical flow recorded on the flow meter Switch Panel
Pressure P.I.
 Partially closed or closed supply valves- Regulator Flow Barrier
check to make sure the supply valves to Switch Inlet
the gas seal panel are fully open
 Improperly adjusted regulator-adjust
the regulator toward the increasing Check
pressure direction only to obtain the Valve
Coalescing
baseline pressure. Filter
 Variable supply pressure-check to
make sure the supply pressure to the Ball Valve
panel is at normal levels
API Piping
Plan 53 (Gas)
1
External Nitrogen Flow
 Preventive Maintenance and Pressure Source Meter
 No or low gas panel pressure with Pressure Gas Control
Switch Panel
typical flow recorded on the flow Pressure P.I.
meter Regulator Flow Barrier
 Clogged filter element in coalescing Switch Inlet
filter-in the event these attempts
are unsuccessful, decommission the
Check
pump and take the gas panel out of Valve
service and check the coalescing Coalescing
filter. Proceed through the start-up Filter
procedure for the gas panel. If you Ball Valve
are still unsuccessful, contact
maintenance for assistance
API Piping
Plan 53 (Gas)
1
Pressure Gas Control
 A high gas panel pressure with Panel
Switch
typical flow on the flow meter Pressure P.I.
Regulator Flow
normally occurs when the Barrier
Switch Inlet
regulator on the panel has been
set above the base pressure
reading -adjust the regulator on Check
the gas panel in the increasing Valve
Coalescing
direction. When making the Filter
adjustment, do so slowly to avoid
Ball Valve
dropping the panel below the
desired base pressure reading
API Piping
Plan 53 (Gas)
1
Pressure Gas Control
 High flow readings in excess of 5-6 Switch Panel
scfh can be caused by loose fittings Pressure P.I.
Regulator Flow Barrier
downstream of the flow meter or Switch Inlet
damage to the seal faces
 The first step is to leak check all fittings
down stream of the flow meter on the Check
gas panel. A very small leak can cause a Valve
high flow reading. If the fittings are leak Coalescing
free, call your maintenance personnel to Filter
troubleshoot the mechanical seal Ball Valve
assembly. A high flow under these
conditions usually means the seal is
damaged in some way.
API Piping
Plan 53 (Gas)
1
Troubleshooting-Plan 53 Gas Pressure Gas Control

Panel
 High flow readings in excess Switch
Pressure P.I.
of 5-6 scfh can be caused by Regulator Flow Barrier
loose fittings downstream of Switch Inlet
the flow meter or damage to
the seal faces Check
 Providing you can maintain Valve
the base pressure on the panel Coalescing
Filter
and an elevated leak rate is not
affecting process conditions, Ball Valve
the pump can continue to be
operated until an orderly shut-
down can be executed. API Piping
Plan 53 (Gas)
1
Orifice Normally
Pressure or .125” typical open
To flare
flow indicator or vapor
or switch Check Valve
1-2 psi opening recovery
maximum
P.I.
Normally
.250” closed
min To drain or suitable
enclosed recovery
Sump w/liquid system
level indicator
or switch API Piping Plan 61
Vent to Closed Vapor System
1

 Check to make sure any valves from the flare connection
port on the secondary seal flange to the flare header or low
pressure point are open
 Check the gauge on the line to the flare header or low
pressure point. It should read no pressure or less than or
equal to the flare header pressure
 If the pumpage becomes a liquid at atmospheric conditions
a drain leg should be included. Make sure the drain valve is
closed.
1

line to the flare header
 Once running check to make sure that the pressure on
the line to the flare header is zero or less than or equal
to the flare header pressure. Also make sure that there
is no ice forming on this line (for light hydrocarbons)
and that the line is cool (for hot services)
1

 The line to the flare header should be checked
regularly. The pressure in the line should be zero or
less than or equal to the flare header pressure. It
should not be cold (for light hydrocarbons) or warm
(for hot services)
 The typical mode of failure is a clogged orifice, an open
drain valve, a stuck check valve, or a closed valve in the
flare line.
1
 Pressure Reading on gauge in flare
line-check for cold line (light
hydrocarbons). Make sure the valve is
open to the flare header. Open the
drain valve to relieve pressure and
observe how quickly the pressure
reading returns. If the pressure builds
quickly (more than 2 psi in 5 minutes),
a seal leak has occurred. If the
pressure builds slowly, this is due to
normal seal leakage. The the flare line API Piping Plan 61
is probably blocked. Vent to Closed Vapor System
1

 Liquid accumulation in
drain line-drain the line and
close the drain valve. Block
in the flare line and observe
the pressure. If it rises
slowly, (2 psi or less in 5
minutes ) normal leakage
has occurred. If it rises
rapidly, a seal leak may API Piping Plan 61
have occurred. Vent to Closed Vapor System
1
API Piping Plan 62 Block
Liquid or Gas Quench To Valves
Atmospheric Side of Seal Faces
Pressure Steam or
Regulator Other Gas
Or Liquid
Quench Supply
Connection
Drain Block
Connection Valve
To Drain or Trap
Suitable
Recovery System
1
Pressure Regulator
Steam or
Block Other Gas
Quench
Valves Or Liquid
Connection
Block Supply
Wrap Copper Line
Valve
Around Suction or
Discharge Nozzle
and Insulate Trap
Drain To Drain or Suitable
Connection Recovery System
API Piping Plan 62

Liquid or Gas Quench To Atmospheric Side of
Seal Faces-Alternate For Wet Steam
1
Pressure Steam or
Regulator Block
Other Gas
Valves
Or Liquid
Supply
Quench API Piping Plan 62

Connection Block Liquid or Gas Quench To
Valve Atmospheric Side of Seal
Drain
Faces-Alternate for Wet Steam
Connection
Route Quench Trap
Line Through
seal chamber To Drain or Suitable
Water Jacket Recovery System
1
Line Up Procedure-API Plan 62-Steam

Quench
 If a blow down line is included in the
steam quench system open it until all
condensate has been evacuated.
 Open the line to the steam trap
1
 Line Up Procedure-API Plan 62-Steam Quench Continued
 Open the block valve for the steam quench. If a regulator and
gauge are used make sure the gauge shows the proper steam
pressure. If a needle valve is used, open the needle valve until
condensation is observed at the bushing or drain port on the seal
flange. Then start closing the needle valve until steam condensate
can be observed on a cold object (such as channel locks or a
mirror) held near the drain port. Note that it is common to see
some condensation dripping out of the seal flange at this point
since the pump is not up to full operating temperature
1
 Line Up Procedure-API Plan 62-Steam Quench Continued
 Check for leaks around valves, fittings, and the orifice if used in
the quench line
 Once running check to make sure the steam quench is still in
operation. Any condensation previously observed should
disappear as the pump comes up to full operating temperature
except for cold service pumps such as caustic service where there
will always be condensate present.
1
 Preventive Maintenance and Troubleshooting-Plan 62-Steam
Quench
 The steam quench should be checked regularly. If
a pressure gauge is used, it should be checked to
make sure the set point has been maintained.
Steam condensate should be visible on a cold object
held near the drain port.
 The typical mode of failure is a clogged orifice, a
defective pressure controller, loss of pressure in the
line, or a closed valve.
1

Troubleshooting-Plan 62-Steam
Quench
 Steam quench not operable-
Check all valves to make
sure they are open. Check
steam source. If orifice is
used, block in system and
check for clogged
conditions. Open blow
down line to make sure API Piping Plan 62
system is not filled with Liquid or Gas Quench
condensate.
To Atmospheric Side
of Seal Faces
1

Troubleshooting-Plan 62-Steam
Quench
 Excessive Condensate-Open
blow down line. Reduce
steam to desired level. It
may be necessary to
insulate steam system. For
cold service pumps such as
caustic service there will
always be condensate API Piping Plan 62
present. Liquid or Gas Quench
To Atmospheric Side
of Seal Faces
1
 Line Up Procedure-API Plan 62-Water Quench

 Open the line from the water source.
 Open the block valve for the water quench. If a
regulator and gauge are used make sure the
gauge shows the proper pressure. If a needle
valve is used, open the needle valve until the
desired amount of drippage is observed at the
bushing or drain port or line on the seal flange.
1
 Line Up Procedure-API Plan 62-Water Quench

Continued
 Check for leaks around valves, fittings, and the orifice if
used in the quench line
 Once running check to make sure the water quench is
still in operation. All water should be coming out of the
drain port or line. There should not be any water
visible on the pump shaft.
1
 Preventive Maintenance and Troubleshooting-Plan 62-Water

Quench
 The water quench should be checked regularly. If
a pressure gauge is used, it should be checked to
make sure the set point has been maintained.
Water drippage should be visible at the drain port
or line.
 The typical mode of failure is a clogged orifice, a
defective pressure controller, loss of pressure in
the line, or a closed valve.
1
 General Comment-Steam & Water Quench
 The steam or water quench should be put in
service before the pump is put in service. It is not
a good practice to put a quench system in
operation while the pump is running or when it
has been prepared for service. It is possible to
shock a mechanical seal under these conditions
and cause a catastrophic seal failure. The
operator may be put at risk when this event
occurs

Installation & Troubleshooting Guidelines For API Seal Flush Plans

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Installation & Troubleshooting Guidelines For API Seal Flush Plans

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1

Installation & Troubleshooting

API Piping Plans

End face shaft seals consist of

Dynamic Secondary Flexibly Rigidly

The faces provide for the dynamic sealing

 The size of the sealing gap

The seal faces and the seal assembly

 This heat must be removed in most applications to

The various seal flush arrangements have

API Piping Plan 11

API Piping Plan 11

Line Up Procedure-API Plan 11

Line Up Procedure-API Plan 11 Continued

 Preventive Maintenance and Troubleshooting-

 Preventive Maintenance Orifice

 Preventive Maintenance Orifice

API Piping Plan 13

API Piping Plan 13

 Line Up Procedure-API Plan 13

Line Up Procedure-API Plan 13 Continued

 Preventive Maintenance and Troubleshooting-

 Preventive Maintenance and Orifice

 Preventive Maintenance and Orifice

API Piping Plan 14

API Piping Plan 14

 Line up procedure-API Plan 14

Line up procedure-API Plan 14

 Preventive Maintenance and Troubleshooting-

API Piping Plan 14

 Preventive Maintenance and Orifice

API Piping Plan 21

API Piping Plan 21

 Line Up Procedure-API Plan 21

 Line Up Procedure-API Plan 21 Continued

 Line Up Procedure-API Plan 21 Continued

 Preventive Maintenance and Troubleshooting-Plan 21

 Preventive Maintenance and Troubleshooting-Plan 21

 Line Up Procedure-API Plan 23

Line Up Procedure-API Plan 23 Continued

Line Up Procedure-API Plan 23 Continued

 Preventive Maintenance and Troubleshooting-Plan 23

 Preventive Maintenance and Troubleshooting-Plan 23

API Piping Plan 31

API Piping Plan 31

 Line Up Procedure-API Plan 31

 Line Up Procedure-API Plan 31Continued

 Preventive Maintenance and Troubleshooting-Plan 31

 Preventive Maintenance and

API Piping Plan 32

 Line Up Procedure-API Plan 32

Line Up Procedure-API Plan 32 Continued

 Preventive Maintenance and Troubleshooting-Plan 32

 Preventive Maintenance and

 Preventive Maintenance and

API Piping Plan 52

Line Up Procedure-API Plan 52 Continued

 Preventive Maintenance and Troubleshooting-Plan 52

 Preventive Maintenance and Troubleshooting-Plan 52