API Plan All

Circulation Systems
For Single and Multiple

Seal Arrangements
John Crane
Training Center
Copyright 2001 John Crane
Published by John Crane
6400 West Oakton St., Morton Grove, Illinois 60053 U.S.A.
All right to illustrations and text reserved by John Crane. This work may not be copied, reproduced, or trans-
lated in whole or in part without written permission of John Crane, except for brief excerpts in connection
with reviews or scholarly analysis. Use with any form of information storage and retrieval, electronic adapta-
tion or whatever, computer software, or by similar or dissimilar methods now known or developed in the
future is also strictly forbidden without written permission of John Crane.
Printed in the United States of America

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
How to use this Booklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Advantages and Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
System Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Flush Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Pumping Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Thermosyphon Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Buffer & Barrier Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Quenches for High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Determining the Quench Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Recommended Quench Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Controlling the quench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Secondary Containment Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Purge Rates for Secondary Containment Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Influence of Static and Dynamic Dual Gas Seal Leakage on Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Static Gas Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Dynamic Gas Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Notes and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Plan 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Sizing and Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Plan 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Plan 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Plan 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Plan 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Plan 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Plan 21/22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Plan 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Plan 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Plan 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Plan 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Plan 52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Pressurized Dual Seal Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Plan 53A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Plan 53B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Controling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Plan 53C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Controling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Plan 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Plan 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Plan 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Plan 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Plan 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Controlling and General .50
Plan 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Plan 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Disadvantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Controlling & General (Plans 72, 75, and 76) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Addendum 1- Buffer and Barrier Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Introduction
The American Petroleum Institute (API) created a numbering system for a variety of seal flush plans. The
API flush plans are now located in API Standard 682 and the corresponding ISO standard, ISO 21049. The
American National Standard Institute (ANSI) has adopted a slightly different designation system. At the time
of this publication the ANSI plans are not up to date with the API/ISO plan designations.
Table 1 - Summary of Flush Plans and Numbering

API/ISO ANSI General Description
01 7301 Internal recirculation from pump discharge.
02 7302 Dead-ended, no circulation.
11 7311 By-pass from discharge to seal chamber.
12 7312 By-pass from discharge thru strainer to seal chamber.
13 7313 Recirculation from seal chamber to pump suction.
14 7314 By-pass from discharge to seal and back to pump suction.
21 7321 By-pass from discharge thru cooler to seal chamber.
22 7322 By-pass from discharge thru strainer, orifice, cooler to seal chamber Not
shown. Similar to Plan 21 with addition of a strainer.
23 7323 Recirculation from pumping ring thru cooler to seal chamber.
31 7331 By-pass from discharge thru cyclone separator to seal chamber.
32 7332 Injection from external source to seal chamber.
41 7341 By-pass from discharge thru cyclone separator and cooler to seal chamber.
52 7352 Nonpressurized external reservoir with forced circulation.
53A 7353 Pressurized external reservoir with forced circulation.
53B -- Pressurized external bladder type reservoir with forced circulation. Has been
known as Plan 53 Modified.
53C -- Pressurized external piston type reservoir with forced circulation. Has been
known as Plan 53 Modified.
54 7354 Circulation of clean fluid from external system.
61 7361 Tapped connections only. Usually used for Plan 62 later. Not shown.
62 7362 Quench fluid from external source.
65 -- Single seal leakage alarm for high leakage.
71 -- Tapped connections only. Usually used for Plan 72, 75, 76 later Not shown.
72 -- External buffer gas purge for secondary containment seals.
74 -- Pressurized external barrier gas for Dual Gas Seals.
75 -- Secondary containment seal drain for condensing leakage.
76 -- Secondary containment seal drain for non-condensing leakage.
The ISO and ANSI standards are not synchronized at the time of this publication.
1 Circulation Systems
How to use this Booklet
The introduction contains an overview of the various piping plans. This provides general information and
some "Rules of Thumb" that can be utilized. There are also individual sections dealing with each of the
piping plans. These sections can be used as stand-alone guides without referencing the other sections in
the booklet. Within these individual sections there may be some information repeated as the
advantages/disadvantages and/or controls are similar for similar plans, such as 11, 12, 13, and 14.
General Information
These plans are utilized to provide the seal with the proper environment depending upon the type of
equipment used and the application that the seal is exposed to. In this booklet the basic flush plans are
discussed providing some general guidelines to be used along with the advantages/disadvantages of the
plans, and where appropriate information on sizing and proper control of the system.
The various flush plans can be grouped by a variety of categories. One method to group the plans is as
follows:
API Plan Description

01, 02 Internal system for single seals
11, 12, 13, 14 Simple recirculation system for single seals
21, 23, 31, 41 Recirculation systems with auxiliary equipment for single seals
52, 53A-C, 54, 74 External systems for dual seals
32, 62 External injection systems
72, 75, 76 External control system for containment seals
These groups can have similarities in advantages / disadvantages, sizing of the system, and system
controls.
Advantages and Disadvantages

Flush Plans 11, 12, 13, 14, 21, 23, 31, and 41 have the advantage that the flush source is coming from the
pumpage and going back to the pumpage, so that no product contamination occurs. In addition, these flush
plans unlike an external flush do not require any reprocessing of the product.
These same flush plans share the disadvantage that if the product being pumped is not a good face
lubricant, the seal can become damaged or clogged. Similarly, with the addition of flush plan 31 the flush
has to be recirculated. Circulation from the pump discharge back to pump suction will decrease pump
efficiency and increase power required for the application. Usually the volume of flush is very small
compared to the capacity of the pump and therefore the efficiency effect is very small.
Sizing
For flush plans 11, 12, 13, 14, 21, 31, and 41 the determination of the flush flow rate uses similar logic.
Generally the flush rate must be calculated based on service conditions, pump speed, and seal size. See
the "Flush Rates" section (page 3) for more details.
System Control
The flow in flush plans 11, 12, 13, and 14 is generally controlled by an orifice in the flush line(s). The
orifices should not be less than 1/8 inch (3 mm) unless the product is very clean and customer approval is
obtained. Many small or low speed pumps have a low differential pressure and no orifice would be required
in the piping. On the other hand, when the differential pressure is high, a single 1/8 inch orifice would allow
for more flow than desired. This can be addressed in two ways. One option is to use two or more 1/8 inch
orifices in series. The number is dependent upon the differential pressure. The second option is to use a
"choke tube". Usually this is a piece of 1/4 inch heavy wall tubing. The length of the tubing is calculated
using a piping pressure drop calculation such that the pressure drop across the tubing is equal to the
difference between the discharge pressure and the seal chamber at the flow desired.
Circulation Systems 2
Flush Rates
With few exceptions any flush system works hand in hand with the hardware and seal components. If the
seal is set up with a Distributed or Extended Flush, and/or an enlarged bore seal chamber, the effectiveness
of the system will be better and the seal will run cooler no matter how much or little the flush flow rate is.
Flush requirements for seals should be given in terms of a minimum and a recommended flow rate. Some
seals can actually operate satisfactorily without a flush. Such applications usually involve non-volatile fluids
at low pressures and low speeds. Heat is transferred from the faces, through the liquid and into the metal
surrounding the seal chamber. Analysis of these cases is beyond the scope of this booklet.
The minimum flush rate is necessary to obtain the performance rating given by the product technical
bulletin; it is determined by an energy balance computation. The assumption is that heat generated
between the seal faces is absorbed by the flush through ideal mixing. This raises the temperature of the
flush. Typically, an increase of 15F (8C) for water and low volatility hydrocarbons, 30F (16C) for lube oils,
and 5F (3C) for volatile hydrocarbons is allowed. Frequently, the minimum flush rate is relatively low, often
less than one gpm (4 l/m).
Field experience indicates and laboratory tests confirm that seal performance generally improves when the
flush rate is greater than the minimum. In particular, heat transfer usually improves and the average
temperature around the seal decreases with increased flush rate; as a result, the face temperature and wear
rate decreases. The recommended flush rate promotes these benefits.
The recommended flush rate should be based on experience with similar applications. Some considerations
include performance goals and fluid properties as well as the design and interaction of the seal chamber,
gland, flush plan and seal. In the absence of specific experience, a simple rule of thumb is: the
recommended flush rate is the larger of one gpm per inch (0.16 l/m per mm) of seal size or the minimum
flush rate.
Questions are sometimes asked about the maximum flush rate. Although increasing the flush rate beyond
the recommended value may produce further improvements, by definition this effect is rapidly diminishing
beyond that point. Unless close clearances are involved, there is probably no detrimental effects from flush
rates up to 25 gpm (100 l/m). Above this rate erosion can occur unless flush distribution decreases the
velocity of the flush.
As an example, when sealing water at 250 psig (17 barg) using a balanced 2" seal at 3600 rpm, the
minimum flush rate might be computed as 0.4 gpm (1.6 l/m) based on an allowable temperature rise of 15F
(8C). The rule of thumb yields 2 gpm (8 l/m) for a 2" seal. Therefore the recommended flush rate would be
2 gpm (8 l/m). On the other hand, when sealing propane under the same conditions, the minimum flush rate
is computed as 2.5 gpm (10 l/m) based on an allowable temperature rise of 5F (3C). Therefore, for
propane the recommended flush rate would be 2.5 gpm (10 l/m). (Note: Testing in propane under these
conditions, good performance was obtained using 2" Type 1648 seals flushed at 2 gpm (8 l/m); however,
other seal types may require higher flush rates.)
Pumping Rings
Pumping rings are used in closed loop sealing systems such as Plans 23, 52, and 53A-C to produce flow
through coolers and reservoirs. There are two basic pumping ring designs: radial flow and axial flow.
Either design can be effective. Just as the performance of a centrifugal pump is a function of the impeller
and volute, the performance of the pumping ring depends on the design of the seal chamber. In particular,
the design, size and placement of the inlet and outlet ports are crucial to the performance of the pumping
ring.
The first rule for pumping rings is to make the diameter of the inlet and outlet ports as large as possible.
This includes the pipe tap and the final drill through. There is no particular reason to make the outlet port
smaller than the inlet port unless there is not enough space for both to be large.
For radial flow pumping rings, a tangentially directed outlet port is absolutely essential. This requirement
applies to all variations of radial flow pumping rings, including those with vanes, drilled holes, slots, paddle
wheels, knurled surfaces, etc. According to simple theory, there is no reason to expect any flow through a
radially directed outlet port. In actual practice, a small flow rate, usually about 1/4 the amount expected
from a tangential outlet, is produced by a radial outlet providing that the outlet port is large. Flow can be
enhanced by exiting from an annulus about 0.2" (5 mm) in radial section.
For axial flow pumping rings, the inlet and outlet ports must not be directly over the vanes of the pumping
ring. There should be an inlet and outlet region at the ends of the pumping ring to assure even distribution
of the liquid. Although a tangential outlet is not essential for axial flow pumping rings, significant
performance improvements are realized when the outlet is tangential. In effect, an axial flow pumping ring
with a tangential outlet becomes two pumping rings in series.
Unlike outlet ports, inlet ports can, and should, be radially directed. Just as is the case for centrifugal
pumps, a tangential inlet would cause pre-rotation of the liquid, which would adversely affect performance.
In general, the pressure and flow from a pumping ring increases with diameter and shaft speed. Pressure
and flow decrease with increased radial clearance; however, good flow rates are definitely possible with the
1/16" radial clearance required by API 682/ISO 21049.
The circulation rate in a seal system is a function of the fluid properties and system piping as well as the
pumping ring. Small piping and viscous liquids result in low flow rates. The procedure for estimating the
circulation rate is to first construct a piping system curve and then superimpose the pumping ring
performance curve. The intersection of these curves defines the circulation rate. John Crane engineering
has pre-engineered many such systems and can assist with the design and evaluation of both the system
and the pumping ring.
When both the pumping ring and the system are properly designed, circulation rates of about 1/2 to 1-1/2
gpm per inch of seal size are easily attainable.
Thermosyphon Systems
A thermosyphon is a closed loop system in which fluid flow is produced by gravity through the effects of tem-
perature on density. This natural circulation results from the differential head that exists between the cold
and hot sections of the system. The cold fluid has the greater density and displaces the hot fluid. The say-
ing, "warm air rises" is better described as "cold air sinks".
Thermosyphons can provide cooling for liquid sealing systems; however, great care must be taken because
thermosyphon flow rates are small and easily stopped by bubbles from vaporization or dissolved gases. A
single bubble about the same diameter as the piping can stop flow; this is called vapor-locking. To prevent
vapor-locking and maximize flow, large diameter piping, connections, and drill throughs should be used.
The cooler or reservoir should be two to three feet (1 m) above the seal chamber. Liquid should flow "in the
bottom and out the top" of the seal chamber. The system must be periodically, or continuously, vented. To
assist in the thermosyphon effect the return or hot piping leg should be insulated so that no cooling occurs in
this line.
Because of the quirky and sensitive nature of thermosyphons, most specifications require a positive
circulation using some type of pumping ring. Even so, the effects of thermosyphoning should always be
considered when designing seal circulation systems. That is, the system should always be designed to
promote thermosyphoning.
Buffer & Barrier Fluids

For information on Buffer and Barrier Fluids see Technical Report TRP-001, on page 54.
Quenches For High Temperature
A quench, as defined by API 682, is "a neutral fluid, usually water or steam, introduced on the atmospheric
side of the seal to retard formation of solids that may interfere with seal movement." Nitrogen is another
popular quench medium.
In high temperature services, a steam quench may provide several benefits:

1. Retard formation of solids
2. Wash away solids that do form
3. Provide cooling during normal operation
4. Provide heating before startup
Nitrogen quenches, based upon general observations, are not as effective as steam for quenching high
temperature seals. Product decomposition ("coking") is related to temperature. Not only does coke form
more quickly in hot pumps, but it also forms more quickly around seals that run hot because of heavy load
or inadequate flushing.
Steam quenches can be used with either rotating seal heads or stationary (RS) designs. Quenches on
rotating seals, sometimes called a "steam blanket" is not particularly effective because very little steam is
circulated within the quench area. Depending upon the type of bushing used, the steam can even be
directed towards the pump bearings. A steam quench used with an RS design such as the Type 1604
(metal bellows seal), is more effective. The steam must enter underneath the bellows assembly, between
the bellows and the anti-coking baffle, and is guided around the seal to wash away the leakage from the
seal faces. Care should be taken to make the drain port as accessible as possible with as large a "drill thru"
as possible to prevent the drain hole in the gland from clogging up with coke. On a design like the Type
1604, if a quench is not going to be used then the baffle should be removed or modified as this will provide
additional clearances to counteract the accumulation of solids.
Determining the Quench Rate

There are four considerations for determining the recommended quench rate:
1. Is a quench required to improve MTBPM?
2. Minimum rate to purge the quench volume of the gland.
3. Minimum rate based on velocity to wash away leakage.
4. Minimum rate for cooling leakage below decomposition temperature.
Is a quench required to improve MTBPM? Typically on the services below, a quench will provide
extended MTBPM:
Crude oil above 350F (175C)
Mixed refinery hydrocarbons above 350F (175C)
Distillation tower bottoms above 350F (175C)
Heat transfer fluids above 350F (175C)
The relative effectiveness will depend upon many variables, but quenches used on lower temperature
services will have a reduced effect on extending MTBPM, other things being equal.
Minimum Rate for Purging

There are two considerations for purging:
1. A "Rule of Thumb" for purging a vessel is that the purge should replace the vessel fluid 5 times per
minute.
2. Another consideration is that the quench rate should be high enough to dilute seal leakage on a
weight basis of 10:1.
A "typical" quench rate based on #1. above is approximately 0.003 CFM / inch of seal size (0.0015 l/s per 25
mm) for a rotating seal head or 0.01 CFM / inch of seal size (0.005 l/s per 25 mm) for an RS seal.
Seal leakage is unpredictable to a point. A simple rule for determining quench rate is to use 300 grams/hr
per inch of seal size (300 grams /hr per 25 mm), which is about 0.7 lb/hr (0.32 kg/hr). In other terms, this is
0.3 CFM per inch of seal size (0.14 l/s per 25 mm) for steam or 0.2 CFM (0.094 l/s) for nitrogen.
Minimum Quench Rate Based on Washing

This is based upon the quench rate with a certain velocity thru the quench area. The velocity should be in
the range of 10 - 15 fps (3 - 4.5 m/sec) thru the flow area to be effective. For Type 1604 designs a flow rate
of approximately 1 CFM per inch of seal size (0.5 l/s per 25 mm) should be sufficient. This criteria does not
apply to a rotating seal without a baffle.
Minimum Quench Rate Based on Cooling

Table 2 below compares the heat transfer capabilities of water, nitrogen and steam. While water is a much
better fluid for removing heat, thermal distortions due to temperature differences at high temperatures makes
it undesirable. Based upon heat transfer coefficient, nitrogen should be better than steam at
removing heat. This apparent advantage is due to the fact that nitrogen at 100F (38C) is more dense than
steam at 250F (120C). However, due to the lower specific heat of nitrogen it will increase more in
temperature as it removes heat. If both nitrogen and steam are supplied at the same temperature they
should have essentially the same performance. Since nitrogen is usually supplied at a lower temperature
than steam, less nitrogen will be required, if the purpose is to cool.
Table 2 - Typical Properties of Water, Steam, and Nitrogen
Physical Property Water Steam Nitrogen

(100F) (250F) (100F)
Density, lb/cubic ft 62 0.036 0.069
Thermal conductivity, Btu/hr ft F 0.36 0.015 0.015
Specific heat, Btu/lb F 1 0.45 0.25
Typical convective heat transfer coefficient, Btu/hr cubic ft F 4000 9 11
Physical Property Water Steam Nitrogen

(38C) (120C) (38C)
Density, kg/m3 993.1 576 1.105
Thermal conductivity, W/cm C 6.23x10-3 2.59x10-4 2.59x10-4
Specific heat, J/kg C 4184 188.3 1046
Typical convective heat transfer coefficient, W/m2 C 8.172x107 1.838x105 2.247x105
Steam is usually readily available in plants and the flow rates are typically not regulated very closely due to
the availability. In part this is also due to the cost versus other quench media. The relative cost of quench
media is:
Water = 1 (datum) Steam = 0.005
Plant Nitrogen = 0.006 Bottled Nitrogen = 1.4
The cooling effect of gases such as steam and nitrogen on the face temperature of hot seals is small. The
order of magnitude is less than 500 Btu/hr (146 watts) removed from the seal faces. If the quench rate is
too small the temperature of the quench will heat up to nearly the pump temperature and allow
decomposition and coking to occur. To prevent this the average temperature in the quench volume can be
estimated from an energy balance using the seal leakage rate, quench flow rate and heat soak from the
surrounding metal. By constraining this average temperature to be less than some critical "coking"
temperature, the quench rate can be computed. Table 3 (page 7) shows the results for nitrogen and steam,
based upon a critical temperature of 350F (175C).
Table 3 - Quench Rates to Keep Temperatures Below 350F
Steam Requirement Nitrogen Requirement

(250F (120C) (100F (38C) Supply)
Saturated Steam)
Pump
Temperature CFM (l/s) lb/hr kg/hr CFM (l/s) lb/hr kg/hr
F (C)
400 (205) 0.5 (0.24) 1.0 (0.45) 0.2 (0.09) 0.9 (0.41)
500 (260) 1.5 (0.71) 3.1 (1.41) 0.7 (0.33) 2.8 (1.27)
600 (315) 2.4 (1.13) 5.2 (2.36) 1.1 (0.52) 4.6 (2.09)
700 (370) 3.4 (1.6) 7.4 (3.36) 1.6 (0.76) 6.5 (2.95)
Note: Rate is volume per inch (25mm) of seal size.
Recommended Quench Rate

After all the above considerations, the recommended quench rate is the largest of the values. For most
pump seals the recommendation can be simplified per Table 4 below.
Table 4 - Quench Rates for Typical High Temperature Pumps
Steam Requirement Nitrogen Requirement

(250F (120C) (100F (38C) Supply)
Saturated Steam)
Pump
Temperature CFM (l/s) lb/hr kg/hr CFM (l/s) lb/hr kg/hr
F (C)
400 (205) 0.3 (0.14) 1.0 (0.45) 0.2 (0.09) 1.0 (0.45)
500 (260) 0.8 (0.38) 1.5 (0.68) 0.4 (0.19) 1.0 (0.45)
600 (315) 1.2 (0.57) 2.4 (1.09) 0.6 (0.28) 1.1 (0.50)
700 (370) 1.7 (0.80) 3.4 (1.54) 0.8 (038) 1.6 (0.73)
Note: Rate is volume per inch (25mm) of seal size.
As a practical matter, it will be difficult to control the quench rate to less than 1 CFM (0.5 l/s). As a "Rule of
Thumb", a quench rate per inch (25 mm) of seal size of 1 CFM for a 400F (205C) pump plus 1 CFM for
each additional 100F ( 38C) of pump temperature (for steam). Nitrogen should be half the rate above,
with a minimum of 1 CFM per inch of seal size.
Controlling the quench

The recommended quench rates are low enough that the flowrate may be somewhat difficult to control with
any accuracy. Especially with steam, there is little need for precision. Table 5 (page 8) shows the
approximate flow rate through a simple orifice, for steam and nitrogen.
Table 5 - Approximate Flow Rates Through Orifices
Steam Flow, ACFM Nitrogen Flow, ACFM
Orifice Size, inch Orifice Size, inch
Differential
Pressure, psi 1/16 3/32 1/8 3/16 1/16 3/32 1/8 3/16
1 0.4 0.9 1.6 3.6 0.3 0.6 1.1 2.5
2 0.6 1.2 2.2 4.9 0.4 0.8 1.5 3.4
3 0.7 1.5 2.7 6.2 0.5 1.0 1.9 4.3
4 0.8 1.7 3.1 6.8 0.6 1.2 2.1 4.7
8 1.2 2.5 4.4 9.9 0.8 1.7 3.0 6.8
16 1.5 3.6 6.2 14.0 1.0 2.4 4.3 9.7
ACFM = Actual Cubic Feet per Minute
Steam Flow, ALPS Nitrogen Flow, ALPS

Orifice Size, mm Orifice Size, mm
Differential
Pressure, bar 1.6 2.4 3.2 4.8 1.6 2.4 3.2 4.8
0.07 0.19 0.42 0.76 1.70 0.14 0.28 0.52 1.18
0.14 0.28 0.57 1.04 2.31 0.19 0.38 0.71 1.60
0.21 0.33 0.71 1.27 2.93 0.24 0.47 0.90 2.03
0.28 0.38 0.80 1.46 3.21 0.28 0.57 0.99 2.22
0.55 0.57 1.18 2.08 4.67 0.38 0.80 1.42 3.21
1.1 0.71 1.70 2.93 6.61 0.47 1.13 2.03 4.58
ALPS = Actual Liters per Second
Secondary Containment Seals

Plans 71, 72, 75, and 76 are new plans for dry running secondary containment seals used in conjunction
with a liquid lubricated primary seal. As illustrated, the process, or inner seal, of the dual unpressurized
arrangement usually has its own flush plan. For example, the flush plans for a dual unpressurized seal
arrangement with a dry running secondary containment seal might be written as Plan 11/71, 11/71/75,
11/71/76, or as noted below 11/72/75 or 11/72/76. The Plan 11 for the inboard seal can be any of the plans
normally associated with a single mechanical seal.
A secondary containment device is a means of containing and controlling the primary seal leakage from a
mechanical seal. In contrast to a dual liquid lubricated mechanical seal, which operates in a buffer or barrier
fluid, a secondary containment device operates primarily in the leakage from the process seal although
purges may be added. There are many different types of secondary containment devices. Simple and
complex bushings, packing, lip seals and even mechanical seals can be used to provide secondary
containment. Leakage rates for the various secondary sealing devices can vary by several orders of
magnitude. Selection of the secondary containment device and system will depend on the level of leakage
to atmosphere that is considered acceptable as well as performance requirements for normal operation,
upsets, and in the event of process seal failure.
By definition, the secondary containment device does not necessarily have the performance or rating of the
primary seal; however, it may be able to temporarily tolerate seal cavity pressure and fluid in the event of a
failure of the primary seal. Large clearance devices like fixed bushings have the highest leakage rates,
floating bushings with reduced clearance are much better. Floating segmented bushings have still lower
leakage rates. Lip seals have very low leakage rates at low pressures. Dry running mechanical seals, both
contacting and non-contacting, may also be used as secondary containment devices and can approach the
level of performance of a dual unpressurized liquid lubricated seal arrangement. While the API plans noted
are normally associated with secondary containment mechanical seals they can also be used on the other
devices noted above.
Purge Rates for Secondary Containment Seals
API Plan 72 is designed to have an inert gas purge through the containment seal area with the intent to
control (reduce) emission levels to the atmosphere. The purge gas mixes with leakage from the primary
seal thereby reducing the concentration of the hazardous fluid (liquid or gas). Leakage rates from the
various types of containment devices will vary from high rates with bushings to low leakage rates with
contacting face seals. Leakage to atmosphere will also have a wide variation depending upon operating
conditions, length of time in service and equipment conditions, as well as a myriad of other lesser
considerations. When deciding on the purge rate consideration should be given to the type of containment
device, the flow rate past the orifice, the fact that excessive purge rates can dry out the sealing cavity and
possibly decrease the life of contacting face seals, and that excessive containment seal cavity pressures
can decrease the life of the containment sealing device with the possible exception of non-contacting
containment seals.
A simple "Rule of Thumb" is to have a flow rate on the order of 0.5 to 0.6 SCFM to the containment seal
cavity. This relates to the rough flow rate for a 5 psi differential pressure across a 1/16" (1.6mm) orifice.
This rate can be adjusted upwards or downwards depending upon the specific application.
Influence of Static and Dynamic Dual Gas Seal Leakage

on Pumps
Even though leakage from dual gas seals is normally very low, the following issues related to pump design
and installation may require attention, depending upon the seal duty:
1. Static gas leakage can displace the liquid in the pump and prevent start up. This is particularly relevant
in the case of vertical standby pumps.
2. Dynamic pump performance can also be affected by a loss of pump efficiency, differential head and
increased NPSHR (Net Positive Suction Head Requirements).
Summarized below are the background and recommendations to eliminate these potential problems.
Static Gas Leakage

Inboard static gas barrier leakage may be at a minimal rate i.e. < 40 ml/min, but in a vertical pump in a
standby condition, or stationary in a stop/start batch process, barrier gas can collect in the pump casing and
disable the ability of the impeller to prime on start-up. Some exceptional horizontal installations also suffer
the same circumstance when suction pipework originates from below the shaft centerline. Not all vertical
pumps are vulnerable, as the sensitivity is dependent on the relative positions of the impeller and the suction
inlet. Some in-line units using a Plan 13 flush (in conjunction with a Plan 74 for the dual gas seals) have the
ability to naturally vent through the suction valve, if the piping orientation permits.
It is customary to leave suction valves on standby pumps open and static barrier gas leakage will eventually
vent through this opening. On vertical pump installations this venting is liable to occur in sudden and
significant volumes when meniscus forces are broken. In these instances, there is a possibility that the
volume of gas entering the main pump suction, can be sufficient to affect the operation of the main pump, if
it is of a low enough flow rating.
To accommodate these issues, in vertical pump installations or horizontal pumps with non-venting suction
lines, a provision for manual or continuous automatic venting of seal chambers must be incorporated within
the total pump installation.
If for operational or hazard reduction reasons it is required to shut both the suction and the discharge valves
and isolate a standby pump it can be expected, as with any dual pressurized seal, that the pump casing
stands the risk of becoming pressurized to the same pressure as the gas barrier source. Depending upon
the effectiveness of the valve seats, the casing pressure could also rise to that of the pump discharge
manifold, which might be in excess of the barrier gas pressure. Even though the dual gas seal may have a
reverse pressure design feature, on horizontal units, it is possible that a small quantity of process fluid may
contaminate the gas barrier chamber. This is not detrimental to the seal (unless the process crystallizes or
hardens), but when restarting the pump there is a risk that this small volume of process fluid will be pumped
through the outer seal to the atmosphere.
On horizontal installations requiring zero atmospheric emissions, and which may be required to operate in a
standby mode with the pump suction and discharge valves closed, it is necessary to connect the casing to a
low pressure environment.
Dynamic Gas Leakage

Barrier gas leakage across the inner seal face during dynamic operation will eventually mix with the process
flow. Depending on the seal size, operating conditions, pump size, pump design, and operation this leakage
can affect the seal's performance. This may be an increase in the NPSHR, a reduction in differential head,
and in extreme cases a loss of prime. At normal leakage levels this may not be an issue, but when leakage
levels approach a condition when failure is deemed imminent, the affect on pump operation should be
minimized. The seal size, shaft speed, barrier gas pressure, pump flow capacity, impeller design, and level
of operational flow compared to the pump's design BEP (Best Efficiency Point) are all factors that determine
the affect on normal pump operation.
To prevent the likelihood of dual gas seal leakage in dynamic operation affecting the design pump
performance, screening by John Crane personnel is advised on pumps operating between 10 m3/h (44
gpm) and 20m3/h (88 gpm), when operating at less than 50% of its BEP.
At high vacuum suction conditions the affect of dual gas seal leakage into the process fluid is exaggerated
because the gas expands at the low pressure. This is not a normal pump operating condition, but on pump
NPSHR proof testing it may occur. The normal measurement criteria of a loss of 3% in the head generated
can be created by gas entrainment. In an NPSHR proof test with a low capacity pump design and dual gas
seals, a conservative and inaccurate value may be indicated.
It is advised that if NPSHR proof tests are applied to pumps with a BEP capacity less than 10 m3/h (44
gpm), the influence of gas seal leakage must be evaluated and if necessary use an alternate seal design.
Notes and Symbols
The symbols and notes below are used in the plan schematics that follow.
Table 6 - Symbols Used for Pump & Seal Gland Connections and Ancillary Equipment
Symbol Connections or Ancillary Equipment

CSD Containment Seal Drain
CSV Containment Seal Vent
D Drain
F Flush
FI** Flush Inlet or Flow Indicator
FIL Coalescing Filter
FO Flush Outlet
FM** Flow Meter
FSH Flow Switch High
GBI Gas Barrier/Buffer Inlet
GBO Gas Barrier/Buffer Outlet
HCI Heating/Cooling Inlet
HCO Heating/Cooling Outlet
I Inlet
LBI Liquid Buffer/Barrier Inlet
LBO Liquid Buffer/Barrier Outlet
LG Level Gauge
LI Level Indicator
LSH Level Switch High
LSL Level Switch Low
PCV Pressure Control Valve
PI Pressure Indicator
PS Pressure Switch
PSH Pressure Switch High
PSL Pressure Switch Low
Q Quench
QO Quench Outlet
TI Temperature Indicator
V Vent (if required)
** On Plans 72 and 74 the Flow Meter "FM" used to be shown as a Flow Indicator "FI".
Plan 01
Figure 1 - Seal Flush Plan 01
Plan 01 is an integral (internal) recirculation from the pump discharge to the seal chamber, which is typically
at a pressure slightly above pump suction pressure. It is similar to Plan 11 in that it uses the pressure
differential between pump discharge and pump suction to develop flow, but is different in that there are no
external lines (piping or tubing) on the pump. It is recommended for clean pumpage only and is typically
limited to pumps with a Total Discharge Head of less than 125 feet (38 m).
Advantages
1. No product contamination. The flush source is coming from the pump and going back to the pump.
2. No reprocessing of product. Unlike an external flush, the product does not have to be reprocessed.
3. Simplified piping. There is no external piping on the pump.
4. Useful arrangement on fluids that are highly viscous at normal ambient pumping temperatures so as
to minimize the risk of freezing if exposed to low temperatures in external piping plans, such as a
Plan 11.
Disadvantages
1. Must be used for clean pumpage only as dirty pumpage could easily clog the passageway and it
would require pump disassembly to repair.
2. Flush has to be repumped. The circulation from pump discharge back to pump suction will
decrease pump efficiency and increase power required for the application. The volume of the flush
is based upon the pump OEM's design and the pressure differential.
3. There is no external way to control flow. Unlike Plan 11 that can have an externally replaceable
orifice to control flow, the internal design of a Plan 01 eliminates this possibility.
4. The flush is not usually directed right at the faces, but may come in over the seal head.
Sizing and Controlling

The flow rate is dependent upon the pressure differential in the pump and the design of the line running
internal to the pump casing. Changing the impeller design can affect the pressure differential and thus the
flush rate. The pump OEM should be contacted to ensure that the flow rate is adequate to maintain a stable
condition at the seal faces.
General
This flush system can perform its function well when used properly. Changes in pump impellers, or
changing seal designs that can move the seal faces away from the flush hole can cause problems that
result in seal failures. This system is not recommended on vertical pumps.
Plan 02
Plan 02 is a non-circulating flush plan. In Plan 02 the process is not directed into or out of the seal
chamber. Seal generated heat is removed by convection and conduction to the process fluid, pump
components, and the surrounding environment. Also, some seal chamber designs promote cooling, by
mixing of process fluid between the pump cavity and seal chamber. Often, this plan is used in conjunction
with API Plan 62 and/or the optional use of a cooling jacket, which will provide some additional cooling. This
plan should only be used for services where adequate vapor suppression can be assured, so that
vaporization of the process in the seal chamber or at the seal interface does not occur. Plan 02 is often used
with a self venting, open seal chamber, i.e. no throat bushing.
Advantages
1. No external hardware required.
2. Solids are not continually introduced to the seal environment.
3. Pump efficiency is not affected, as there is no recirculation of pumped or externally supplied fluid.
4. Natural venting occurs with an open chamber throat.
Disadvantages
1. Success of this plan can be difficult to predict, reliance on previous experience with a specific
process or pump design is often required.
2. If the fluid in the seal chamber vaporizes, the life of the seal will be drastically reduced.
3. Fouling of the cooling jacket, if so equipped, over time will reduce its effectiveness resulting in
higher seal chamber temperatures.
4. Careful design of impeller/chamber interaction is necessary on low head pumps to prevent air
ingression.
General
Low duty, chemical service pumps are often a prime candidate for Plan 02. In these services, it is also
advantageous to apply Plan 02 in conjunction with a large (open bore) or taper bore seal chamber. Often, in
these services, suspended solids may be included in the process stream. In these cases, devices which
encourage seal chamber circulation, while excluding solids from the seal chamber, are available and offered
by many OEM and after market suppliers. Applications where these devices have been applied often work
well with Plan 02.
Hot, refinery and petrochemical heavy oil services, can be successfully sealed with Plan 02. Often, these
services congeal or become highly viscous at ambient conditions. This can result in fouling and plugging of
the recirculation plans, such as Plan 11, 13, 23 and their derivatives, unless effective temperature control
schemes are employed. In these services, Plan 02 offers a relatively simple, cost effective way to obtain rea-
sonable seal life. Only Plans 32 or 54 may be found to provide superior seal life. Use of Plan 02 in hot oil
applications normally requires the use of Plan 62, using steam or nitrogen. In most cases, use of a seal
chamber cooling jacket is helpful.
Successful use of Plan 02, as with other plans, is dependent on maintaining a lubricating film between the
seal faces. This can be accomplished only if vapor formation in the seal chamber can be adequately sup-
pressed. Plan 02, with no forced circulation through the seal chamber, requires thorough venting. This can
be accomplished before startup (after pump inventory) or on a continuous basis by means of a self venting
seal chamber design. Further, this Plan should be used with caution if the process has entrained gas or
other components, which may vaporize easily. This plan is not recommended for vertical pumps.
Plan 11
Plan 11 is the most common flush plan in use today. This flush plan simply takes an appropriate amount of
fluid from the discharge of the pump (or the discharge of one of the intermediate stages if applicable) and
puts it into the seal chamber to provide cooling and lubrication to the seal faces.
Advantages
3. Simplified piping. Piping consists of only pipe (or tubing) and an orifice, if required.
4. With a properly sized orifice and throat bushing that results in a higher seal chamber pressure the
vapor pressure margin can be increased.
Disadvantages
1. If the product in the pump is not a good face lubricant or is dirty, the seal can become damaged or
clogged.
2. Flush has to be re-pumped. Circulation from the discharge back to the pump suction will decrease
pump efficiency and increase power required for the application. Usually the volume of flush is very
small compared to the capacity of the pump and therefore the efficiency effect is very small.
Sizing
Generally the flush rate must be calculated based on service conditions, pump speed and seal size. The
rule of thumb is for not less than 1 GPM per inch (0.16 l/m per mm) of seal size, but the flush requirement
may be greater if the pressure or speed is high. For application above 3600 RPM or box pressures above
500 psig (35 barg) the flush rate should be calculated to avoid excessive heat at the seal.
Controlling
The flush flow rate is usually controlled by an orifice in the flush line. Orifices should not be less than 1/8
inch (3 mm) unless the product is very clean and customer approval is obtained. Many small or low speed
pumps have a low differential pressure and no orifice is required in the piping.
One of the interesting challenges that arises is when the differential pressure is high and a 1/8 inch orifice
allows for more flow than is desired. This can be addressed two ways. One option is to use two or more
orifices in series. The number is dependent on the differential pressure. The other way is to use a "choke
tube". This is a piece of tubing generally 1/4" heavy wall. The length of the tubing is
calculated using a piping pressure drop calculation such that the pressure drop across the tubing is equal to
the difference between the discharge pressure and the seal chamber pressure at the flow rate desired.
General
Any flush system works hand in hand with the hardware and seal parts. If the seal is set up with a
distributed or extended flush, the effectiveness of the system will be better and the seal will run cooler no
matter how much or little the flush flow rate.
Plan 12
Plan 12 is similar to a Plan 11 except that a strainer or filter is added to the flush line. (See other discussions
of Plan 11). This plan has limited usage, but can be successfully applied if adequate precautions are taken.
Advantages
3. Solids are removed from flush stream keeping the seal clean.
Disadvantages
1. If the product in the pump is not a good face lubricant the seal can become damaged.
3. Strainer or filter will plug over time. If the strainer plugs, flush flow will be lost and the seal can
become damaged due to overheating. This can be avoided by the use of a differential pressure
indicator or flow indicator.
Sizing
Controlling
inch unless the product is very clean and customer approval is obtained. Many small or low speed pumps
have a low differential pressure and no orifice is required in the piping. Maximum allowable pressure drop
across the strainer or filter must be taken into consideration in sizing the orifice.
Plan 12 should not be used without some form of indication that the strainer or filter is plugging. This can be
a differential pressure indicator or alarm, or it can be a flow indicator or alarm. This information will alert the
operator that there is inadequate flush to meet the needs of the seal.
Plan 13
Plan 13 is similar to a Plan 11 except that the flow comes out of the seal chamber and goes back to the
pump suction. Typically Plan 13 is used on vertical pumps since the vertical pump has the discharge at the
top of the pump where the seal is. This also helps the seal to vent gas out of the seal chamber.
Advantages
3. Helps to reduce the stuffing box pressure.
4. Useful on high pressure differential pumps where a Plan 11 would require the use of multiple orifices
in series or very small orifices that could become clogged.
Disadvantages
clogged.
3. Due to flow patterns, Plan 13 is not as efficient as a Plan 11. There is no velocity of flow impinging
on the faces. Generally the flow rates must be increased to make up for the decrease in
performance of the flush.
Sizing
may be greater if the pressure or speed are high. For application above 3600 RPM or box pressures above
Controlling
inch unless the product is very clean and customer approval is obtained. Many small or low speed pumps
have a low differential pressure and no orifice is required in the piping.
Often the throat bushing in the top of the pump controls the flow rate at a flow below what the seal needs. If
this is the case, a Plan 14 should be considered.
Plan 14
Plan 14 is a combination of a Plan 11 and a Plan 13. The flush is taken off of the pump discharge, sent to
the seal, then piped back to the pump suction. Often used in vertical pumps to provide adequate flush flow
and vapor pressure independent of the bushing in the pump. Also used in viscous products to provide a
flow path out of the box in addition to the throat bushing that can be restrictive.
Advantages
3. Optimized cooling. The flush flow can be controlled so that the cooling is directed at the faces and
adequate flow is maintained.
4. Allows complete automatic venting of the seal chamber provided that the "FO" port is properly
located.
5. With a properly sized orifice and throat bushing that results in a higher seal chamber pressure the
vapor pressure margin can be increased.
Disadvantages
clogged.
Sizing
Controlling
The flow rate is usually controlled by an orifice in the flush line. Orifices should not be less than 1/8 inch (3
mm) unless the product is very clean and customer approval is obtained.
One of the interesting challenges that arises is when the differential pressure is high and a 1/8 inch orifice
allows for more flow than is desired. This can be addressed two ways. One option is to use two or more
orifices in series. The number is dependent on the differential pressure. The other way is to use a "choke
tube". This is a piece of tubing generally 1/4" heavy wall. The length of the tubing is calculated using a pip-
ing pressure drop calculation such that the pressure drop across the tubing is equal to the difference
between the discharge pressure and the stuffing box pressure at the flow rate desired.
Plan 21/22
Plan 21 is a cooled version of flush Plan 11. In Plan 21 the product, from pump discharge, is directed
through an orifice, then to a heat exchanger to reduce the temperature before being introduced into the seal
chamber. A temperature indicator should be included on the process side of the exchanger, normally on the
downstream side. Additional temperature indicators are used in some installations to monitor cooling water
and process temperature on both sides of the exchanger.
Advantages
1. Process fluid is used to cool and lubricate the seal, i.e. no dilution of process stream.
2. Provides cooled process to the seal environment, thus improving lubricity and reducing the
possibility of vaporization in the seal chamber.
3. Can be applied to any pump where Plan 11 can be applied.
Disadvantages
1. Depending on the temperature of the process, the heat load on the heat exchanger can be very
high, resulting in high operating costs for the cooling water and/or fouling of the heat exchanger.
2. Calculation of flow rate through the Plan 21 circuit must be carefully performed, so as not to place
excessive load on the heat exchanger.
3. Some fluids may congeal or become highly viscous, during idle periods, if flow is not maintained
through the heat exchanger.
4. Flush has to be re-pumped. Circulation from pump discharge, back to suction, will slightly decrease
pump efficiency.
Sizing
The flow rate should be determined in a similar manner to that done for Plan 11. Next, depending on the
process fluid, a desired injection temperature should be determined. For hydrocarbon based fluids, 100 to
150F (50 to 80C) below the vapor point is a good target. For water and other aqueous solutions, most
seals require that the temperature of the flush being introduced to the seal chamber be maintained below
180F (80C), 140F (60C) is a good target. Finally, a heat exchanger can be sized, based on the
capabilities of the exchanger cooling circuit.
Controlling
The flow rate should be controlled by an orifice located in the flush line. API standards show the orifice
being located upstream of the exchanger. However, with process fluids that are near their vapor pressure,
improved results can be realized by locating the orifice between the exchanger and the seal chamber.
General
Plan 21 is not a preferred plan, either by the API or many users. This is due to the high heat load that is put
on the heat exchanger in this plan. High heat load results in, wasted energy, and a high rate of fouling of the
heat exchanger, which often results in shortened seal life. Fouling normally occurs on the water side of
cooling tower based cooling systems. This can be averted, to some degree, by maintaining a velocity, which
is sufficient to resist the deposit of cooling water sediment on the coils. On many systems this is difficult to
do. In order to monitor the condition of the heat exchanger, it is highly recommended that a temperature
indicator be installed, in the process stream, on the downstream side of the heat exchanger.
On cooled flush plans it is often helpful to include a close clearance, floating throat bushing. Such a bushing
will reduce the detrimental effects of heat soak and slightly increase the seal chamber pressure on Plan 21.
Use of this bushing will result in further suppression of vapor formation in the seal chamber.
Finally, a cooled flush plan, such as Plan 21, should never be used for the purpose of allowing the use of
materials with lower high end temperature limits. The materials used, throughout the seal, should be
designed to withstand the full range of process temperatures.
Note: Plan 22 is a Plan 21 with the addition of a strainer, located before the orifice. Plan 22 should
be used with caution as strainers can clog and result in seal failure.
Plan 23
Plan 23 is a closed loop circulation system used on hot applications for flushing and cooling single seals. In
Plan 23, a pumping ring in the seal chamber circulates product through a heat exchanger and back to the
seal chamber. A throat bushing is used to isolate the cool seal chamber from the hot pump. This bushing
may be nothing more than the pump manufacturers standard design.
General
Plan 23 has been the circulation plan of choice for hot water services, particularly high pressure boiler
feedwater, for many years. Recently, Plan 23 has been used to provide efficient cooling in hydrocarbon
services. Typically, the temperature in the closed loop system of Plan 23 is much less than the operating
temperature of the pump. The heat load on the cooler is minimized because it consists only of heat soak
from the pump and heat generated by the seal faces. The pumping ring and seal head also generate heat
from churning the fluid in the seal chamber, but this energy is small compared to the above two heat load
inputs.
Advantages
1. The process fluid is used to cool and lubricate the seal and there is no dilution of the process
stream.
2. The reduced operating temperature improves lubricity and reduces the possibility of vaporization in
the seal chamber.
3. Plan 23 is very efficient, therefore it is sometimes possible to use a smaller heat exchanger for Plan
23 than for Plan 21; however, in practice, this is not usually done.
4. The cooler is less likely to scale or foul, because the operating temperatures and heat duties are
low.
5. Less direct cooling of process fluid than Plan 21.
6. Can provide a cooled seal chamber thru effective thermosyphon effects when the pump is idle.
Disadvantages
1. The initial cost is more than Plan 21, because Plan 23 includes a pumping ring, throat bushing and
additional piping,
2. Plan 23 is not used for fluids with high freeze points or for viscous fluids because the pumping ring
may not be able to force circulation.
3. Venting is essential for Plan 23; vapor locking may occur if gases collect near the pumping ring.
4. Selection, design and location of the pumping ring along with inlet and outlet ports is crucial to the
successful operation of Plan 23.
5. The pumping ring requires energy and therefore reduces total pump efficiency; however, this is a
small effect and, in practice, no debit is taken.
Controls
Plan 23 systems are usually not controlled directly. The circulation rate depends on the performance of the
pumping ring within the particular closed loop system. The pumping ring, heat exchanger and piping are
selected to produce the desired operating conditions. Heat soak as well as heat generation must be
considered in determining the desired circulation rate. The heat exchanger is located as close as possible
to the seal. The general rule of thumb is that the heat exchanger should be elevated about three to five feet
(1 - 1.5 m) and located within a plot plan radius of about three feet (1 m). Piping should be large in diameter
and minimum length with long radius bends to minimize pressure drop and promote flow. To prevent vapor
locking, the piping should slope up from the gland to the heat exchanger. Most heat exchangers for Plan
23 systems use coiled tubing to provide heat transfer area. The process fluid is flowing inside the tubing so
the diameter and length of tube have a direct effect on pressure drop, and therefore flow rate, as well as
heat transfer.
Plan 31
Plan 31 is a variation to Plan 11, where an abrasive separator is added to the flush line. In Plan 31 the
product is introduced to the abrasive separator from the discharge of the pump. The clean fluid is routed out
the top of the separator and into the seal chamber, while the process with the heavier solids are routed back
to suction. This Plan should only be used for services containing solids that have a specific gravity at least
twice that of the process fluid. Throat bushings are a requirement when using this flush plan. An orifice is
sometimes required to control the flow into the separator.
Advantages
1. Solids are removed from the flush stream keeping the seal clean.
2. Unlike a strainer or filter the abrasive separator does not have to be cleaned.
Disadvantages
1. It is sometimes difficult to obtain the desired pressure differential required for the abrasive separator
to operate efficiently. Exceeding the published differential pressure will cause the separator to not
function properly.
2. Improper piping will cause the separator to not operate efficiently. Unless the pressure differential
from the two discharges to the final sources are almost the same the separator can either starve the
seal or allow abrasives to flow into the chamber.
3. The abrasive separator and the piping in the dirty outlet leg can become worn over time from the
abrasives spiraling down the coned shaped bore.
4. Not advisable on low vapor margin applications as vapor bubbles have a more natural inclination to
be channeled into the seal flush connection.
Sizing
Generally the flush rate sizing will be the same as a Plan 11 keeping in mind that only the clean fluid flows
to the seal. Various models or sizes of separators are available to provide different flow rates depending
upon the pressure differential available.
Controlling
The flow rate can be controlled by an orifice in the line running from the pump discharge to the inlet of the
abrasive separator. This orifice should not be less than 1/8 inch (3 mm) and should usually be larger
depending upon the size and the concentration of the particles being removed. Either multiple orifices or a
"choke tube" can be used to control the flow. On vertical pumps where the seal chamber is at discharge
pressure a separate line needs to be added going from the bushing at the bottom of the seal chamber back
to suction to reduce seal chamber pressure to allow the clean fluid to enter the seal cavity. On small or low
differential pumps no orifices are required.
It is important that the lines running from the clean outlet at top of the separator and the dirty outlet at the
bottom be at similar pressures to obtain proper separation and flow rates. It may be necessary to vary the
length of tubing or piping in one or both discharge lines to get the proper flow established.
General
The proper installation of the abrasive separator is a necessity for this flush plan to work. Typically the
separator needs to have a minimum of a 15 psi (1 bar) differential to operate properly. The maximum
particle size should be less than 1/4 the size of the inlet orifice. Also, to operate properly the system should
be vented. If air is trapped in the top of the separator it will not work. To vent the system use a tee fitting at
the clean outlet at the top of the separator. From the tee fitting the piping goes to the seal chamber. Off the
side of the tee fitting use a valve to vent off any trapped air.
An alternate solution may be to run two hard faces and allow the seal to operate with abrasives present.
This should be evaluated on a case-by-case basis.
Plan 32
In Plan 32, the flush stream is brought in from an external source . This plan is almost always used in
conjunction with a close clearance throat bushing. The bushing can function as a throttling device to
maintain an elevated pressure in the stuffing box or as a barrier to isolate the pumped product from the seal
chamber. Plan 32 is used when a process stream is difficult to condition in a way that will provide adequate
cooling and lubrication to the mechanical seal. In addition, it is often employed when a process stream
includes components, which may either result in abrasive wear or will impede free movement of critical seal
components. The design of a Plan 32 flush system involves application of hardware and logic that will
provide the seal with an environment conducive to long term service, while not compromising the operation
and profitability of the process stream.
Advantages
1. The external flush fluid, when selected and applied properly, can result in vastly extended seal life,
resulting in improved MTBPM for the pump system.
Disadvantages
1. Product degradation or dilution will occur when using this plan (though some process streams may
actually benefit).
2. Depending on overall system design, introduction of an external fluid to the process stream can
result in increased energy and reprocessing costs.
3. Support system costs can be very high and adds additional equipment to the system, which must be
in operation whenever the involved pump is on line.
Sizing
The flush rate is critical to any seal, but takes on another dimension when Plan 32 is involved. When an
outside flush source is used, concerns regarding product dilution, and/or economics almost always will
surface. For these reasons it is imperative that the seal supplier be adequately informed with regards to any
limitations that will be placed on the flush rate. With respect to the flush rate, three common scenarios
should be considered. In all cases the flow rate required to cool the seal should take precedence.
1. Exclusion of process from the seal chamber is the primary objective. In this case, a close-
clearance, floating throat bushing should be placed in the back of the seal chamber. The flow rate
which will normally achieve solids exclusion is 15 fps (feet per second), 5 m/s.
2. The process is at or near its boiling point and other flush plans are not practicable. Processes
in this category are often hot, thus heat soak is also a consideration. When calculating the flow rate
required one should not allow more than 1/4 of the available flush fluid-temperature margin to be
used.
3. The process is not at its boiling point, though it has properties which adversely affect seal
life. This scenario is common in process streams which have a tendency to polymerize, congeal, or
set up at various stages in a batch process. In this situation, simply diluting the process is often all
that is required to maintain reliable seal operation. The required flush rate may be quite low, and
often actual flush rate determination may be derived more from experience. In this case, knowledge
of the process and its interaction with the flush stream are key to success.
Controlling
Conditioning and controlling the rate of flush in a Plan 32 system can range from simple and inexpensive to
elaborate and costly. Simpler is usually better whenever possible. Finally, the device selected to control the
rate of flush is the most critical decision to be made, some methods are;
1. A drilled orifice or choke tube is the simplest device and will normally be the least costly. However,
careful attention must be paid to protecting the orifice from plugging, particularly if the size is less
than 1/8" (3 mm). Also, if the supply pressure and/or box pressure are not well determined, or are
variable, accurate sizing may not be attainable.
2. A manually adjustable needle or globe valve with flow indicator can be employed, thus allowing "on
the fly" control of the flush rate. This approach will allow accurate tuning of the flush rate, though
consistent monitoring is required.
3. A control valve is the ultimate control of flow rate, though cost can be substantially higher to
purchase and maintain such a device.
General
Communication between the seal company, and the end user is key to success of Plan 32. As with any
application, the fluid properties and service conditions of the process stream must be established in order to
provide a successful seal design. However, to insure success on Plan 32 applications, fluid properties of the
external flush stream should also be presented with the main process details
When Plan 32 is applied to process streams which are hot, the flush liquid may have a higher vapor
pressure than the process fluid when at the same temperature. In short, the introduction of a lower boiling
point liquid into the process stream will lower the NPSHA to some degree and will have a negative effect on
pump capacity as the liquid vaporizes in the pump. In the worst case, the pump may vapor lock or be
damaged by the resulting disturbances. In this case the flush rate is often "fine tuned" in a way that provides
adequate seal cooling and minimizes vaporization within the pump. Plan 32 is not recommended for cooling
only, as the energy costs can be very high. Further, material selections made for the seal should be made
based on the extremes of the process fluid conditions and the external flush fluid, not the flush by itself.
Plan 41

Plan 41 is a combination of flush Plans 21 and Plan 31. In Plan 41 the product, from pump discharge, is
first put through an abrasive separator to eliminate solid particles, and then it goes to a heat exchanger to
reduce the temperature before being introduced into the seal chamber. Optional accessories are an orifice
to control the flow and a temperature indicator on the product outlet side of the heat exchanger. In some
installations temperature indicators are also used to monitor cooling water temperatures. This Plan should
only be used for services containing solids that have a specific gravity at least twice that of the process fluid.
Throat bushings are a requirement when using this flush plan.
Advantages
1. Solids are removed and product temperature is reduced to enhance the seals environment.
2. Unlike a strainer or filter the abrasive separator does not have to be cleaned.
Disadvantages
1. This plan is not suitable for very low head services as the pressure drop thru both the abrasive
separator and heat exchanger may be too great.
2. Piping this arrangement to get the proper pressure drops in order to get efficient operation of the
abrasive separator and the correct flow through the heat exchanger is difficult. Exceeding the
published differential pressure will cause the separator to not function properly.
3. Depending upon the temperature of the process the heat load on the heat exchanger can be high,
resulting in high operating costs for the cooling water and/or fouling of the heat exchanger.
Controlling
The flow rate can be controlled by an orifice in the line running from the discharge to the inlet of the abrasive
separator. This orifice should not be less than 1/8 inch (3 mm) and should usually be larger depending upon
the size and the concentration of the particles being removed. Either multiple orifices or a "choke tube" can
be used to control the flow. On vertical pumps where the seal chamber is at discharge pressure a separate
line needs to be added going from the bushing at the bottom of the seal chamber back to suction to reduce
seal chamber pressure to allow the clean fluid to enter the seal cavity. However, in some cases, the pump
manufacturer uses the top bushing as a balance piston, so the pump manufacturer should be consulted. On
small or low differential pumps no orifices are required.
It is important that the lines running from the clean outlet at top of the separator and the dirty outlet at the
bottom be at similar pressures to obtain proper separation and flow rates. It will be necessary to vary the
length of tubing or piping in the dirty discharge from the abrasive separator back to pump suction to obtain
the same pressure drop produced by the heat exchanger.
General
This flush plan is very difficult to pipe properly to obtain the correct flow rate through the abrasive separator
and the heat exchanger. As such it is a flush plan that has not been that popular.
Typically the separator needs to have a minimum of a 15 psi (1 bar) differential to operate properly. The
maximum particle size should be less than 1/4 the size of the inlet orifice. Also, to operate properly the
system should be vented. If air is trapped in the top of the separator it will not work. To vent the system use
a tee fitting at the clean outlet at the top of the separator. From the tee fitting go to the seal chamber. Off
the side of the tee fitting use a valve to vent off any trapped air.
Plan 52
Plan 52 uses an external reservoir to provide buffer fluid for the outer seal of an unpressurized dual seal
arrangement. During normal operation, circulation is maintained by an internal pumping ring. The reservoir
is usually continuously vented to a vapor recovery system and is maintained at a pressure less than the
pressure in the seal chamber. As illustrated, the process, or inner seal, of the dual unpressurized
arrangement usually has its own flush plan. For example, the flush plans for a dual unpressurized seal
arrangement might be written as Plan 11/52.
Reservoirs are usually made of pipe and piping components with an internal coil of tubing to remove heat.
Unlike the heat exchangers used in Plan 23 systems, cooling water flows through the coils; the buffer fluid
flows over the exterior of the coils. It is important to realize that Plan 52 systems incorporate a vented reser-
voir.
Advantages
1. Plan 52 is a necessity for dual unpressurized seals using a liquid buffer fluid. In comparison to
single seals, the dual unpressurized seal can provide reduced net leakage rates as well as
redundancy in the event of a main seal failure.
2. The buffer fluid should not enter the process stream and contaminate the process fluid, because it is
unpressurized
3. The buffer fluid can serve as a contained quench for the process seal.
4. If there is enough heat transfer to the buffer fluid, the pressure rating for a dual unpressurized seal
can be greater than that of a single seal.
Disadvantages
1. Plan 52 (and any multiple sealing system) is more complex and more expensive than any single
seal and piping system.
2. There will always be some leakage from the process seal into the buffer system; therefore, the
buffer system is contaminated by the process fluid. Buffer fluids must be selected with great care.
It is possible with heavier process fluids to displace the buffer fluid resulting in the area between the
two seals to be completely filled with process fluid thereby losing a buffer between the product and
atmosphere.
3. If the process fluid has a low vapor pressure margin the heat from the outer seal can further reduce
the margin causing the inboard seal to run with partial to full vapor between the sealing faces. In
these cases a dry running containment seal is recommended using a Plan 76.
4. Venting is essential for Plan 52; vapor locking may occur if gases collect near the pumping ring.
5. Selection, design and location of the pumping ring along with inlet and outlet ports is crucial to the
successful operation of Plan 52.
Controls
Plan 52 systems are usually not controlled directly. The circulation rate depends on the performance of the
pumping ring within the particular closed loop system. The pumping ring, reservoir and piping are selected
to produce the desired operating conditions. Heat soak as well as heat generation must be considered in
determining the desired circulation rate. The reservoir is located as close as possible to the seal. The John
Crane recommendation is that the bottom of the reservoir be 18 to 30 inches (0.5 to 0.75 m) above the
centerline of the pump. Many customers require that the liquid level provide at least three feet (1 m) of
static head to the outer seal. The general rule of thumb is that the reservoir should be located within a plot
plan radius of about three feet (1 m). Piping should be large in diameter and minimum length with long
radius bends to minimize pressure drop and promote flow. To prevent vapor locking, the piping should
slope up from the gland to the reservoir.
In the event that the process, or inner, seal fails, there will be a pressure and/or level increase in the
reservoir, which produces an alarm. When this occurs, the reservoir is blocked in by closing the valve near
the top of the reservoir. As the process seal continues to leak, pressure and fluid level in the reservoir
increases further. The reservoir can potentially reach the same pressure as the process seal chamber. For
all practical purposes, the outer seal takes over the full sealing duty. For these reasons, the recommended
operating procedure is to begin planning an orderly shutdown and repair as soon as possible after failure of
the process seal.
General
In the past, most reservoirs for Plan 52 were vented to atmosphere and the main purpose of the outer seal
was to be a backup for the main seal; these were called tandem seals. Today the preferred term is dual
unpressurized seal to de-emphasize the physical orientation of the components. Plan 52 is used for both
non-volatile and volatile process services. Although the leakage rate across the main, or process, seal is
the same as for a single seal, the leakage is directed into the reservoir of the dual unpressurized seal. In
non-volatile services, the leakage from the process seal increases the liquid level in the reservoir. In volatile
services, the leakage from the process seal vaporizes and separates from the buffer fluid inside the
reservoir. If the reservoir is connected to a vapor recovery system, the actual emission rate can be very low.
PRESSURIZED DUAL SEAL PLANS
Plan 53A was formally recognized as Plan 53. European and other countries in the Middle East used a
piping plan that was unofficially called "Plan 53 Modified". This will become more universally recognized as
Plan 53B as API 682 2nd Edition gets wider exposure. Plan 53C is a variation of this that has also been
used in the past and is now formally recognized. The major difference in the plans is that Plan 53A uses an
external reservoir, while Plans 53B and 53C run within a closed loop system with a make-up system piped
to it for replenishment of the barrier fluid.
As illustrated in the plans below, the inner seal of the dual pressurized arrangement can have its own flush
plan. For example, the flush plans for a dual pressurized seal arrangement might be written as Plan 11/53A;
however, the need for a separate flush on the inner seal varies with the seal type and physical orientation.
The older traditional back-to-back seal arrangement usually does not require a separate flush for the inboard
seal. There may be cases where a Plan 32 is used as the pumpage may be extremely hazardous, contain
abrasives or the pumpage may polymerize easily, but these are a very low percentage of the applications.
The dual pressurized face-to-back seal arrangement eliminates some of the potential problems associated
with the back-to-back design. The new design also incorporates a reverse pressure capability that was not
a default with the back-to-back design. Also, there is no longer a dead zone underneath the inboard seal
that can become clogged and lead to seal hang-up. However, the face-to-back arrangement is not a cure
all. With the product on the seal O.D. and with it being used on API pumps that still incorporate throat
bushings, it is advantageous to provide a flush for the inboard seal on a number of applications. Abrasives
can accumulate in the more closed API type seal chambers compared to the newer generation chemical
duty pumps with large cylindrical bore or tapered bore chambers. The use of a Plan 11 or similar by-pass
type flush for the inner seal has advantages. It can help keep the seal chamber clean. It also has an
improved overall heat transfer setup versus just using a Plan 53 system alone. This is especially true on
higher temperature applications where the whole seal head is immersed in the process fluid with the face-to-
back design compared to just the I.D. of the seal faces, with the back-to-back design. Enhancing the seals'
environment will result in extended MTBPM.
Advantages
1. Plan 53A/B/C or 54 is a necessity for dual pressurized seals using a liquid barrier fluid.
2. In comparison to Plan 54, Plan 53A/B/C is usually less complex and less expensive.
3. With Plan 53A/B/C, both inner and outer seals are lubricated by the barrier fluid which can be
selected for optimum seal performance. Therefore, Plan 53A/B/C is usually selected for dirty,
abrasive or polymerizing process services which might be difficult to seal directly with single seals or
with dual unpressurized seals using Plan 52.
Disadvantages
1. Plan 53A/B/C (and any multiple sealing system) is more complex and more expensive than any
single seal and piping system.
2. There will always be some leakage of barrier fluid across the inner seal and into the process.
3. Venting the seal chamber is essential for Plan 53A/B/C; vapor locking may occur if gases collect
near the pumping ring. Proper venting can be accomplished by having continuously rising piping to
the reservoir. Selection, design and location of the pumping ring along with inlet and outlet ports is
crucial to the successful operation of Plan 53A/B/C.
Plan 53A
Figure 13 - Seal Flush Plan 53A
Plan 53A uses an external reservoir to provide barrier fluid for a pressurized dual seal arrangement.
Reservoir pressure is produced by a gas, usually nitrogen, at a pressure greater than the maximum process
pressure being sealed. During normal operation, circulation is maintained by an internal pumping ring.
Reservoirs are usually made of pipe and piping components with an internal coil of tubing to remove heat.
Unlike the heat exchangers used in Plan 23 systems, cooling water flows through the coils; the barrier fluid
flows over the exterior of the coils.
Advantages (vs other Plan 53 systems)

1. Least expensive of the various Plan 53 systems.
2. Should the loop be contaminated for any reason, the contamination is isolated to a single
installation.
3. Wear particles that are heavier than the barrier fluid will settle to the bottom of the reservoir. The
outlet to the seal should be located at least 2" from the bottom of the reservoir.
4. The volume of fluid is dependent upon the size of the reservoir. Larger flow rates can utilize larger
reservoir sizes so that retention time in the reservoir is maximized.
Disadvantages (vs other Plan 53 systems)

1. The barrier fluid in Plan 53A is subject to gas entrainment due to direct exposure to the pressurizing
gas.
2. Heat dissipation capacity is limited to the coiling coils unlike Plan 53B/C, which have separate and
potentially larger capacity.
3. Limited to a single pump installation, overhung or between bearing. For a large number of
installations a Plan 53A can be more expensive than Plan 53B/C.
Controls
The circulation rate in a Plan 53A systems is usually not controlled directly; it depends on the performance
of the pumping ring within the particular closed loop system. The pumping ring, reservoir and piping are
selected to produce the desired operating conditions. Heat soak as well as heat generation must be
considered in determining the desired circulation rate. The reservoir is located as close as possible to the
seal. The John Crane recommendation is that the bottom of the reservoir be 18 to 30 inches (0.5 to 0.75 m)
above the centerline of the pump. Many customers require that the liquid level provide at least three feet (1
m) of static head to the outer seal. The general rule of thumb is that the reservoir should be located within a
plot plan radius of about three feet (1 m). Piping should be large in diameter and minimum length with long
radius bends to minimize pressure drop and promote flow. To prevent vapor locking, the piping should
slope up from the gland to the reservoir.
By definition, Plan 53A is pressurized above the process pressure. The usual guideline is to operate at least
10% above the process pressure but a minimum of 20 to 50 psi (1.4 to 3.5 bar) above the maximum
process pressure. The most common means of pressurizing a Plan 53A system is with pressurized nitrogen.
Although high pressure nitrogen bottles have been used as a source, the preferred source is a plant wide
distribution system. API 682 cautions against using gas pressurization in direct contact with the barrier fluid
when the reservoir pressure is above 150 psig (10 barg). The concern is that gas is absorbed into the
barrier fluid but the API recommendation is overly conservative. Based on field experience and tests, the
John Crane recommendation is that direct contact gas pressurization can be used up to 300 psig (21 barg)
as long as the barrier fluid temperature is less than 250F (120C). Alternately a bladder or piston type
accumulator can be used in conjunction with the Plan 53A reservoir to eliminate the potential gas
entrainment on high pressure applications, but this has rarely been done.
General
Plan 53A systems are very similar to Plan 52 systems except that Plan 53A is pressurized whereas Plan 52
systems are usually vented. In Plan 53A systems the static pressure and elevation do not contribute to
pressure losses or pumping ring requirements. All pressure losses are due to the friction that is produced as
the fluid is flowing.
In the past, most seals used with Plan 53A were placed in a back-to-back orientation; these were called dou-
ble seals. Today the preferred term is dual pressurized seal to de-emphasize the physical orientation of the
components. Plan 53A is used with both liquid and gas process services. The leakage from the inner seal
enters the pump; the leakage from the outer seal is to the environment.
Plan 53B
Figure 14 - Seal Flush Plan 53B

Plan 53B is a modified version of Plan 53A. Unlike a Plan 53A that incorporates a pressurized reservoir
within the circulation loop, Plan 53B has only the piping and an air or water cooled heat exchanger within
the closed loop circuit. Some installations have used finned tubing as the "heat exchanger". Feed to this
circuit is a pre-pressurized bladder accumulator to maintain the barrier pressure within the closed loop
circuit. The basic setup is comprised of two parts; the closed loop circulating system and the make up
system. Flow in the circulating system is usually induced by an internal pumping device. The make up
system can be configured a number of ways based upon the customer's preference, ranging from a simple
hand pump to an elaborate pumping system feeding multiple pumps/seals.

1. Should the loop be contaminated for any reason, the contamination is contained within the closed
circuit.
2. The make up system can supply pressurized barrier fluid to multiple dual pressurized sealing
systems with either like or unlike pressure conditions.
3. The make up system pressurizing the barrier fluid is not subject to nitrogen or air entrainment as
with a Plan 53A.

1. The volume of fluid within the closed loop circuit is very limited and as such gets thermally cycled on
a frequent basis, so the service life of the fluid is reduced.
2. The finite volume of the accumulator requires a designed pressure operating range between refills
(in excess of that required for a Plan 53A) and this must be built into the pressure rating of the
seals.
3. The separate heat exchanger introduces additional flow resistance to the piping system and will
have a lower flow rate than an otherwise identical Plan 53A.
Controlling
The flow rate of the circuit is controlled by the pumping ring design, peripheral speed, barrier fluid viscosity,
and resistance of the piping circuit. If the equipment allows, tangential outlets should be used to enhance
the flow rate from the pumping ring. The sizing of the heat exchanger depends upon the heat load of the
system. The heat exchanger tubes should be as large as practical to minimize resistance and increase the
flow rate.
Plan 53C
Figure 15 - Seal Flush Plan 53C
Plan 53C is another modified version of Plan 53A. Unlike a Plan 53A that incorporates a pressurized
reservoir within the circulation loop, Plan 53C has only the piping and an air or water cooled heat exchanger
within the closed loop circuit. Some installations have used finned tubing as the "heat exchanger". This
plan also has a reference line from the seal chamber to a piston accumulator teed into the closed loop
system that provides a constant pressure to the loop above the seal chamber pressure. The basic setup is
comprised of two parts; the closed loop circulating system and the make up system. The make up system
can be configured a number of ways based upon the customer's preference, ranging from a simple hand
pump to an elaborate pumping system feeding multiple pumps/seals.

1. Should the loop be contaminated for any reason, the contamination is contained within the closed
circuit.
2. The make up system can supply pressurized barrier fluid to multiple dual pressurized sealing
systems with either like or unlike pressure conditions.
3. The make up system pressurizing the barrier fluid is not subject to nitrogen or air entrainment as
with a Plan 53A.

1. The volume of fluid within the closed loop circuit is very limited and as such gets thermally cycled on
a frequent basis, so the service life of the fluid is reduced.
2. The separate heat exchanger introduces additional flow resistance to the piping system and will
have a lower flow rate than an otherwise identical Plan 53A.
3. Pressure spikes or drops in the system (and the seal chamber) vary the pressure of the outer seal.
Tracking pressures can always be subject to delays that can cause a temporary loss of positive
pressure across the inboard seal.
Controlling
The flow rate of the circuit is controlled by the pumping ring design, peripheral speed, barrier fluid viscosity,
and resistance of the piping circuit. If the equipment allows, tangential outlets should be used to enhance
the flow rate from the pumping ring. The sizing of the heat exchanger depends upon the heat load of the
system. The heat exchanger tubes should be as large as practical to minimize resistance and increase the
flow rate.
Plan 54
Plan 54 utilizes an external source to provide a clean pressurized barrier fluid to a dual pressurized (double)
seal. The Plan 54 "system" supplying the barrier fluid can range from a process pump in the unit providing
clean cool lubricant under pressure, to a simple lubrication system with minimal components, to an elaborate
large system with many ancillary components and redundant systems to safeguard and alarm against
malfunctions and process upsets to a controlled process stream. API Standard 614 defines a large number
of variants that can be used to engineer these systems.
Advantages
1. The barrier fluid is typically one that has good to exceptional lubricating properties that when applied
properly can result in extended MTBPM for the seal.
2. When properly instrumented the system can safeguard the seal against pump upset conditions.
3. The mechanical seal is exposed to a neutral fluid, with the exception of parts of the inboard seal, so
that corrosion and other chemical related problems are eliminated.
4. Positively eliminates leakage of harmful and fugitive emissions to the atmosphere.
5. Can provide pressurized flow to multiple seal installations with one system to reduce costs.
6. Is not constrained by nitrogen ingress into the barrier fluid as in a Plan 53A.
Disadvantages
1. Systems can be costly compared to other flush plans depending upon the number and type of
redundant and safeguard systems utilized.
2. The system usually is dependent upon a separate pumping system (pump and motor) that can
cause seal failure if power to the "system" is lost.
3. Damage to the inboard seal can result in contamination of the process from barrier fluid leakage.
4. If used on multiple seal installations, the failure of one can have an affect on all of the other
installations unless proper precautions are taken to isolate the failed seal.
5. Dependent upon a reliable electrical supply.
Sizing
The flush rate for the system must take into account not only energy from the mechanical seal (heat soak,
seal generated heat, and turbulence), but must consider the heat added to the barrier fluid from the pump
supplying the barrier fluid. On low pressure/flow systems this is minimal, but can become significant on
larger systems operating at high pressures and flows. The system reservoir should be sized for a retention
time of 5 minutes, so if the flow rate is 3 gpm (12 l/m) the reservoir size should be a minimum of 15 gallons
(60 l).
Controlling
The flow rate is usually controlled by the size of the pump on the system. In applications where one system
is supplying barrier fluid to multiple seal chambers flow can be controlled with simple manually adjustable
needle or globe valves to control valves utilizing a variety of mechanical or pneumatic systems.
General
The pressure supplied to the dual pressurized mechanical seal is often stated as just being 25 psi (2 bar)
over the maximum pressure in the pump seal chamber. For lower pressure applications (less than 200
psig/14 barg) this is normally sufficient. For higher pressure applications the pressure should be at least
110% of the maximum pressure that the seal can see from the process due to variations in process
pressures. The complexity of the system should be in-line with the importance of the equipment to the
overall process and the associated hazards of the pumpage. When the Plan 54 system is supplying multiple
seal chambers precautions should be taken so that a failure of one seal will not drain the entire system
causing a chain reaction. Precautions should also be taken to prevent contamination of the barrier fluid
should one seal fail.
Plan 62
Plan 62 is a common flush plan to improve the environment on the atmospheric side of single seals.
Typically, this is either low pressure steam or nitrogen to prevent coke formation on hot hydrocarbon
services or water to prevent the formation of crystalline substances on fluids with solids in solution. It is
typically used with a floating or segmented bushing to limit the leakage of the quench fluid to atmosphere,
but can be used with a fixed bushing if the application permits. Quenches can also provide some cooling.
Advantages
1. Low cost alternative to tandem seals to improve condition on low pressure side of process seal.
Disadvantages
1. Leakage of process past primary seal is not contained except with the throttle bushing. Leakage
can then leak to atmosphere or go to a drain.
2. Improper control of steam can allow condensation to form that can boil and cause seal damage on
hot processes.
3. Poor steam control can lead to a reverse pressure on the seal and/or bearing oil contamination.
Sizing
Steam or nitrogen are the two media used on hot services to retard the formation of coke, with steam being
the most popular and economical. A "Rule of Thumb" for the quench rate for steam (250F/120C) is {1 lb/hr
(0.5 kg/h) for 400F (200C) product temperature + 1 lb/hr (0.5 kg/h) for each additional 100F (60C)} times
the seal size. For a 3 inch seal at 650F (343C) the rate would be 10.5 lb/hr (5 kg/h). The "Rule of Thumb"
for nitrogen (100F/38C) is 1 CFM (28 l/m) per inch of seal size + CFM (14 l/m) for each
additional 100F (60C) above 400F (200C).
Water quenches are typically used to retard the formation of crystalline solids on the atmospheric side of a
single seal. The flow rate is not important unless the process is hot and could cause the water to boil.
Otherwise the flow rate should be just sufficient to make up leakage past the bushing. Segmental bushings
provide the lowest leakage rate while fixed bushings will leak the most.
Controlling
Since steam is normally readily available it is not that important to control the flow. Control can be
accomplished with an orifice or gate valve. A steam trap is always recommended to remove entrained
water. Pressure of the steam should be less than 1 psig (0.07 barg). The line should be insulated or can be
wrapped around the pump discharge to maintain steam temperature in the range of 250F (120C).
Nitrogen would normally be controlled by a pressure regulator and appropriate block valves, flow meters and
a needle valve. A trick to preserve nitrogen in the cavity between the seal and the bushing is to create a
"U" on the gland outlet and fill the bottom of the "U" with approximately 2 inches (50mm) of liquid.
General
Steam quenches have been used with both rotating and stationary seal heads. Quenches on rotating seals
are not particularly effective because very little steam is circulated within the quench area. On stationary
seal heads the steam should be directed underneath the seal (usually a metal bellows seal) between the
bellows and an anti-coking baffle to wash away any leakage from the seal. The drain port should be as
large as practical to prevent clogging with coke.
PLAN 65
Plan 65 is a leakage detection plan that is normally utilized with a single seal. This should be used on appli-
cations where the seal leakage would normally be in a liquid state. From the gland drain connection leak-
age is directed past or through a reservoir containing a level switch, through an orifice and finally into either
a sewer or liquid collection system. If the leakage from the seal is excessive the orifice downstream from
the reservoir restricts the flow allowing the level in the reservoir to rise setting off an alarm. The downstream
orifice should be located in a vertical leg to avoid accumulation of leakage in the pipe. This system should
have a line running from the upper section of the reservoir connected to the piping downstream of the orifice
to excessive leakage to drain.
The selection of a proper throttle bushing is important. A fixed bushing, especially on larger size seals incor-
porating larger clearances, can allow leakage to leak past the bushing. This can contaminate the surround-
ing area or even spray the area in the case of a severely damaged seal. If axial space is available, it is rec-
ommended that either a floating or segmented bushing be used with this plan.
Advantages
1. Provides an indication of excessive seal leakage without manual inspection.
2. Can provide an automatic shutdown of equipment.
Disadvantages
1. Cost of system.
2. Leakage levels have to be relatively high to set off the alarm.
Plan 72
Plan 72 uses an external low pressure buffer gas, usually nitrogen, that is regulated by a control panel and
then injected into the outer seal cavity. The control panel may contain a pressure control valve to limit buffer
gas pressure in order to prevent reverse pressure on the inboard seal and/or limit pressure applied to the
secondary containment seal followed by either an orifice or needle valve to control the gas flow rate. To
constrain flows to realistic rates John Crane's panel is constructed with a needle valve. The control panel
may also have a coalescing filter to prevent solids and/or liquids within the buffer gas from contaminating the
secondary containment seal. A very important feature of this plan is that the gas purge is introduced close
to the seal faces whereas the vent and drain are away from the seal faces; in API 682 2nd edition a bushing
is required to physically separate the buffer inlet and the vent/drain. Plan 72 would ordinarily be used in
conjunction with Plan 75 for primary seal leakage that is condensing or Plan 76 for non-condensing leakage
to help minimize process fluid affecting the containment seal faces and dilute leakage to the atmosphere. It
is recommended a Plan 72 not be used in a dead-ended containment chamber.
The gas pressure regulator should control the pressure upstream of the flow control system to slightly less
than the Plan 75 or 76 alarm setting to ensure buffer flow over the complete system operational range. The
minimum gas flow rate for dry containment seals should be 3 to 6 SCFH (1.5 to 3 l/m), which will give
adequate product leakage dilution at normal leak rates (gas flow rates at this level can only be controlled by
a needle valve). If dilution is still required at Plan 75 or 76 alarm points and/or a flow control orifice is
specified by the purchaser, buffer gas flow rates are likely to be in excess of 20 SCFH (10 l/m).
Advantages
1. Protects the outer containment seal.
2. Reduces fugitive emissions.
3. Prevents icing in cryogenic services.
4. Introduction of nitrogen keeps the outer seal chamber cooler. This is an advantage where the
process fluid has a low vapor pressure margin.
5. Temporary loss of nitrogen should not affect the performance of the containment seal.
6. Lower maintenance and operating costs than a Plan 52 system.
Disadvantages
1. Temporary loss of nitrogen can result in temporary increase in fugitive emissions.
2. Contacting containment seals run better with the moisture from the process vapor leakage. A dry
nitrogen purge reduces the moisture in the containment seal chamber and can decrease the
operating life of the containment seal.
Plan 74
Plan 74 is a new plan for dual gas seals. All pressurized dual seal arrangements have a barrier fluid at a
pressure greater than the process pressure being sealed. Dual Gas Seals differ from other pressurized
multiple seal arrangements in that they do not have circulation of a fluid between the seals, but rely upon an
external source of inert gas to pressurize the seal cavity provided by the seal cartridge. Flow into the seal
cavity is the result of leakage of the inert gas past both the outboard seal faces and to a lesser extent the
inboard seal faces. Typically the external source is a pressurized nitrogen line within the plant. In some very
special cases the nitrogen source can be a nitrogen bottle or a bank of nitrogen bottles. This can be an
expensive, unreliable system and the maintenance is high, to ensure that the bottles have sufficient
pressurized gas at all times. The alternative is to use a gas pressure booster (amplifier).
Advantages
1. Lower cost system than liquid dual pressurized systems, especially for between bearing pumps.
2. Lower maintenance requirements and associated cost compared to dual liquid systems that utilize a
pressurized reservoir (Plan 53).
3. Leakage from the inboard seal into the process is an inert gas and is easily separated from the
process downstream.
4. Barrier fluid leakage to atmosphere is an inert gas. Drainage and cleanup is not an issue as with
dual liquid systems.
Disadvantages
1. Entrained gas in the pumping system can be a problem with multiple dual gas seals in a particular
unit and especially on closed loop systems.
2. Gas entrainment problems can cause pump performance problems on some installations with both
low suction head and low flow conditions. (See Introduction: pages 9 - 10)
3. Entrained gas under certain conditions can influence net positive suction head testing at the pump
OEM level. (See Introduction: page 10)
4. Not recommended for services containing sticky or polymerizing agents or where dehydration of the
pumpage causes solids buildup.
Controlling and General

In Plan 74 the pressurized source goes through a control panel. This panel acts to remove moisture, filter
and regulate the pressurized nitrogen (or other inert gas). The panel also contains a low pressure alarm
and flow meters. Flow alarms to warn against problems with the gas supply are an option. It is not
recommended to just hook the inert gas line directly to the seal cartridge. This is very unreliable and
prevents regulation of pressure and can allow for contamination of the seal faces and result in seal
performance problems. Plan 74 shows two connections, gas barrier inlet and outlet. The outlet is normally
closed as flow is not required for these seals.
The nitrogen source in a typical plant has pressure on the order of 100 psi (7 barg). If the Dual Gas Seal is
sealing product pressures in excess of 75 psi (5 barg), then a higher pressure source is required. A
pressure amplifier can be utilized in these installations to boost main system pressure. The pressure
amplifier uses a pump that has pistons of differing size. The pressure increase is possible due to the drive
piston, using supply air pressure being larger than the delivery piston. Typically, the high pressure gas is
fed into a receiver of suitable capacity as the piston pump is not designed for continuous operation.
Plan 75
Plan 75 is intended for use when the process sealed by the primary seal will condense at lower
temperatures or is always in a liquid form. In this arrangement the drain is located at the bottom of the outer
seal gland and is routed to a reservoir. Liquid leakage is collected and the gaseous portion is further routed
through an orifice to a flare or vapor recovery system. The reservoir does contain a pressure gage and a
high pressure switch to indicate a build up in pressure in the reservoir from excessive primary seal gaseous
leakage or a primary seal failure of some magnitude. Some users prefer to isolate the secondary
containment device with valves to the reservoir in the event of a primary seal failure. A level switch to warn
of excessive liquid leakage is optional on the reservoir.
The secondary containment seal can be subject to clogging in this arrangement. Some sort of baffle or
close clearance between the seal and gland should be used to isolate the containment seal from the
leakage of the primary seal. As noted above Plan 75 can be used in conjunction with a gas purge from Plan
72. Typically, contacting secondary containment seals are used with this plan.
Advantages
1. Lower initial cost alternative to liquid dual unpressurized seals using a Plan 52.
2. Lower maintenance requirements and associated costs compared to liquid dual unpressurized seals
that utilize reservoirs (Plan 52).
Disadvantages
1. The secondary containment seal may not be capable of running for extended periods of time in the
event of a primary seal failure. This depends upon the operating conditions.
2. The secondary containment seal can become clogged with debris if the primary seal leakage is a
heavy fluid that can coke or crystallize upon exposure to air. This can be improved upon thru the
use of Plan 72 and a bushing that directs the fluid away from the seal and seal faces.
3. All of the primary seal leakage will not always go to the disposal system and can leak past the
secondary containment seal faces to atmosphere.
Plan 76

Plan 76 is intended for use when the process sealed by the primary seal will not condense at lower
temperatures or pressures. In this arrangement the vent is located at the top of the outer seal gland and is
routed to a flare or vapor recovery system through an orifice, with an upstream pressure alarm switch. API
requires a minimum orifice diameter of 1/8" (3 mm) but smaller sizes may be necessary to provide a realistic
leakage alarm point. It is recommended that the high pressure alarm switch be set at 7 psi (0.5 bar) above
the mean operating condition in the flare or vapor recovery system.
The piping should continually rise from the vent to the piping/instrument harness and should be properly
supported so as not to impart strain to the gland. A drain connection in the piping is advisable in order to
safely dispose of process fractions that may have condensed. A block valve is standard on this arrangement
to isolate the containment seal in the event of a primary seal failure. Pressure gages and a high pressure
switch is standard on this arrangement.
While the secondary containment seal is less subject to clogging in this arrangement the leakage from the
primary seal may be a combination of a condensing and non-condensing fluid. When this is the case the
addition of a Plan 72/76 is highly recommended.
Advantages
1. Lower initial cost alternative to liquid dual unpressurized seals using a Plan 52.
2. Lower maintenance requirements and associated costs compared to liquid dual unpressurized seals
that utilize reservoirs (Plan 52).
Disadvantages
1. The secondary containment seal may not be capable of running for extended periods of time in the
event of a primary seal failure.
2. The secondary containment seal can become clogged with debris if the primary seal leakage
contains a heavy fluid that can coke or crystallize upon exposure to air. This can be improved upon
thru the use of Plan 72 and a bushing that directs the fluid away from the seal and seal faces.
3. Should some of the primary seal leakage condense and accumulate in the seal chamber the
containment seal will generate more heat that can potentially cause coking of the product and
shorten seal life.
4. All of the primary seal leakage will not go to the disposal system and can leak past the secondary
containment seal faces to atmosphere.
Controlling & General (Plans 72, 75, and 76)

There are two basic types of secondary containment systems: unpiped and piped. The simplest system,
unpiped, is essentially no system at all. Leakage from the primary seal is contained by the secondary
containment device within its performance capabilities. Bushings and non-contacting containment seals are
usually the only acceptable designs in these cases. The secondary containment device usually has a higher
leakage rate than the primary seal and all leakage from the primary seal readily escapes through the
secondary containment device.
In the event of a primary seal failure, there are several scenarios with respect to leakage from the secondary
containment device. If the secondary containment device is piped to a disposal system then most leakage
from the primary seal is routed to the disposal system. There will always be some leakage from the
secondary containment device but because pressures are usually low for piped systems, the secondary
sealing device leakage rate is also low. With an unpiped or blocked in secondary containment device, there
will be a pressure build up in the sealing interspace. The degree of this pressure build up is a function of
the leakage rate from the (failed) primary seal and the leakage rate of the secondary containment device to
atmosphere. This means that leakage is reduced but the point of escape is still at the seal gland.
Many end users prefer that the secondary sealing device use a different principle from the primary seal. For
example, the primary seal might be a mechanical seal (with radial leakage path) but the secondary
containment device be a floating segmented bushing that uses an axial leakage path. This preference is
based on the feeling that any upsets or mechanical problems affecting the primary seal will have a less
significant effect on the secondary containment device.
Secondary containment seals may also be used as a means of controlling a quench fluid for the primary
seal. Typical quench fluids are steam, nitrogen, and water.
Prepared by: Gordon Buck, Ralph Gabriel, Bob Goodenberger, Ken Laplant, and Chris Fone.
April 2005
Addendum No. 1
TECHNICAL REPORT
TRP-MS060
November 1996
Buffer and Barrier Fluids
by Gordon Buck, Anne-Laure Louarn,
Joe Sehnal, Florian Wisniewski
Increasingly restrictive regulations on leakage and safety may be added on the reservoir to keep the fluid at
have resulted in an increase in the number of multiple process temperature and eliminate cold starts.
seal arrangements. All wet multiple seals use an external If the fluid is being exposed to a wide temperature
fluid in addition to the process fluid that is to be sealed.
range, its viscosity index should be maximized to
The terms 'buffer fluid' and 'barrier fluid' are used to
ensure a stable viscosity.
describe these fluids. As defined in API 682, a buffer fluid
is used in unpressurized dual seals (traditional tandem
B. A good buffer or barrier fluid should be a good
seal arrangements). A barrier fluid is used in pressurized
heat transfer fluid.
dual seals to isolate the pump process liquid from the
environment. Gases may be used as buffer or barrier flu- The buffer/barrier fluid should remove heat generated at
ids depending on the design of the mechanical seals. The the faces very quickly. The physical properties of a fluid
following information focuses on liquid buffer or barrier that reflect this ability are thermal conductivity and specif-
fluids. The first part of this paper defines the properties ic heat. The higher the process temperature, the higher
and families of buffer and barrier fluids. The second part these values should be. Water has a very good heat
discusses circulation systems, an essential consideration transfer ability. The specific gravity should be at least at
for the reliable operation of sealing systems. 0.7 at process temperature. A higher specific gravity
decreases the required flow rate and allows better heat
removal.
I - Selecting a Buffer/Barrier Fluid
C. A good barrier or buffer fluid should not present
Several critical properties should be looked at when
any potential danger whether equipment is run-
selecting a barrier or buffer fluid. Following are a few
ning or stationary.
guidelines aimed at a better understanding of what a
good lubricant should be. The words in italic are defined Safety should be a top priority when selecting a fluid. It
in the appendix of this paper. should first not be a listed VOC (Volatile Organic
Compound) or VHAP (Volatile Hazardous Air Pollutants)
A. One of the most important properties of a good and second not be flammable in the considered applica-
buffer or barrier fluid is its viscosity. tion.
The fluid should be thick enough to separate surfaces,
A process temperature at or above boiling point would
prevent wear, yet thin enough to allow free movement,
cause the formation of vapor on and around the sealing
carry away heat and avoid carbon blistering if a carbon
faces on the atmospheric side. It would not only promote
ring is being used. As a general rule, the following limita-
shortened seal life or catastrophic failure, but formed
tions are proposed:
vapor could be a fire risk. The buffer fluid frequently oper-
At process temperature, the viscosity should stay ates near atmospheric pressure but can potentially reach
below 150 cSt (695 SUS) to provide adequate flow the same temperature as the pump it serves. Therefore
rates, and should not exceed 100 cSt (462 SUS) the atmospheric boiling point must be considered and
when lubricating a carbon ring to avoid carbon blis- should be at least 50F (27.8C) above the process tem-
tering. perature.
The lower viscosity limit is 1cSt (31 SUS).
Flash point, and of course fire point must be at least
At start-ups, when the buffer/barrier fluid is at ambi- 20F (11.1C) above process service temperature to
ent temperature, the pump may overheat due to the avoid any vapor flammability risks. Vapor pressure and
high viscosity of the fluid (the viscosity will then volatility should be checked at ambient temperature and
decrease with increasing temperature). The needed pressure.
shear force and heat generation may be so high
that it could damage the seal. According to API 682, Refer to the MSDS sheet for proper handling and stor-
the maximum viscosity at minimum temperature age.
should be 500 cSt (2310 SUS). Minimum tempera-
ture should be at least 5F (2.8C) above pour
point, and of course above freezing point. A heater
The last issue that needs to be addressed is the impor-
D. The fluid must be compatible with the tance of the size of the inlet/outlet ports and piping diame-
metallurgy, elastomers and other materials ters (see part III). Big diameters will allow air bubbles to
of the sealing system. move away and prevent them from stopping the fluid cir-
Lubricants are generally non-corrosive to hardware and culation, unlike smaller diameters that will trap bubbles
faces. Attention needs to be focused on the elastomeric along the walls of the tube or pipe.
parts of the seal that are more susceptible to chemical
reaction. G. Fluid stability must be ensured for a longer
maintenance cycle time.
The compatibility of a synthetic rubber with an oil is
The greater the stability of the fluid, the longer the mainte-
dependent on the value of the aniline point of the oil. A
nance interval. Fluids exposed to oxygen must resist oxi-
low aniline point causes high to extreme swelling of the
dation at operating and static conditions. The oxidation of
elastomer. It results in softening of the elastomer that may
the fluid causes the formation of acids and carbonized by-
permit extrusion of the secondary seal under high pres-
products. This results in carbon deposit on the faces (cok-
sure, overdampening of the primary ring, and interface
ing), viscosity change, and loss of sealing and heat trans-
fluid film depletion. Ultimately, the faces may burn up or
fer properties. The oxidation resistance of a fluid is indi-
the seal rings may crack under tensile loads.
cated by its total acid number.
On the other hand, if the aniline point of the oil is too
Synthetic oils are more susceptible to acid formation than
high, it will cause the secondary seals to shrink and hard-
hydrocarbons.
en, leading to secondary seal failure.
Unpressurized buffer fluids may loose volatile materials,
Table 1 on page 46 gives a brief overview of fluid/
causing an adverse effect on their original performance
elastomer compatibilities.
characteristics. Highly volatile fluids may cause as well
dangerous conditions and pressure drop. Fluids with low
E. The fluid should also be highly compatible with
vapor pressure are essential to keep the volume of the
the process pumpage being sealed.
lubricant constant.
This compatibility is desired whether a buffer or barrier
fluid is being considered. Situations that tend to cause To summarize, an ideal buffer/barrier fluid would have
any reaction are to be avoided. the following properties:
The formation of gases, particles, high viscosity liquids or safe to use, handle, store
vapors as a consequence would disturb the fluid flow, not a VOC, VHAP or other regulated compound
nonflammable
plate the seal faces or cause wear and leakage. Each
good lubricity
fluid must be individually considered based on its chemi-
good heat transfer properties
cal compatibility with the process stream. Consult a
compatible with process fluid
process engineer at the customers facility. compatible with seal materials
Caution: The barrier or buffer fluid slightly contaminates good flow qualities at very low temperatures
the process stream. Therefore it is important that the cho- remains a stable liquid at ambient temperatures
sen barrier fluid meets the requirements of the end users, non-foaming when pressurized
i.e. those who will buy the pumpage. John Crane cus- low solubility of gas
tomers should also consult with their clients regarding the inexpensive
chemical compatibility of the barrier/buffer fluid with their Restrictions on use of some chemical compounds has
end product. caused users and manufacturers of mechanical seals to
review their recommendations on buffer or barrier fluids.
F. Foaming risks are to be avoided. As a result, some traditional and readily available fluids
In pressurized systems, the barrier fluid is often pressur- are no longer recommended. For example, the higher vis-
ized by using a gas blanket (usually nitrogen) per API cosity lubricating oils are likely to cause blistering of a
flush plan 53. In this case, problems can occur when the carbon seal face. Automatic transmission fluid and auto-
gas is absorbed into the barrier fluid. As pressure is motive antifreeze contain additives that form deposits on
relieved or temperatures rise, gas may be released from the seal faces. Methanol and ethylene glycol are regulat-
the fluid. This release of gas can cause foaming, resulting ed VHAP.
in loss of lubrication, heat transfer and circulation.
John Crane's policy is a maximum of 450 psig and a tem- II - John Crane Barrier/Buffer
perature limit of 250F (139C) when nitrogen is used to Fluid Families
pressurize a system. This limit should be adjusted
depending upon the barrier fluid used. If its gas solubility To aid in the selection of buffer and barrier fluids, John
is high, the limit should be lowered. API 682 does not rec- Crane has established six groups or families, where flu-
ommend pressurization above 150 psig with a gas blan- ids of like composition and/or properties are classified:
ket. At higher pressure, a circulating system that does not A. glycol solutions and water
put the gas in direct contact with the lubricant should be B. alcohols
used, such as a piston pressurization or an oil/air circulat- C. kerosenes and diesel fuels
ing pump. In the case of a buffer fluid vented to atmos- D. petroleum based hydraulic and lubricating oils
phere, a good choice is to use a lubricant with a low gas E. synthetic hydraulic oils
solubility and a low vapor pressure. F. heat transfer fluids
Following is a discussion on some commonly used fluids mended. Actual experience has generally been that auto-
in each family: matic transmission fluid is a poor barrier fluid; the
assumption is that the various additives are the problem.
A. Glycol Solutions and Water
Automotive anti-freeze is not recommended. E. Synthetic Based Hydraulic and Lubricating Oils
A number of synthetic lubricants have been developed in
Water. Water can be a good barrier/buffer fluid. Viscosity recent years.
is generally around 1 cSt (31 SUS) at modest tempera-
tures; however, the viscosity is low at 212 F (100C) -- There are numerous synthetic lubricants available in the
which is also the atmospheric boiling point. Also, in many marketplace. A number of these are under evaluation.
climates, water may freeze at ambient conditions.
Royal Purple Barrier Fluid 22. Royal Purple Barrier
Ethylene glycol/water. A 50/50 mixture has been suc- Fluid 22, as an example, was developed specifically for
cessfully used as a buffer fluid for tandem seal arrange- buffer/barrier fluid FDA service and has proven to be a
ments in many services. However, ethylene glycol is now very effective buffer or barrier fluid both in laboratory tests
classified as a VHAP and is being replaced by propylene and in the field.
glycol.
Propylene glycol/water. A 50/50 mixture has become a F. Heat Transfer Fluids

recommended buffer fluid for many services. Heat transfer fluids that have the ability to provide ade-
quate lubrication throughout a wide range of tempera-
tures and pressures can be used as buffer or barrier flu-
B. Alcohols ids. This class encompasses a broad spectrum of chemi-
Caution: Alcohols can have a high rate of evaporation. cal families (water, steam, inorganic salts, certain lique-
Frequent re-fills may be required on a plan 52 (unpres- fied metals, organic class fluids,...)This paper addresses
surized buffer fluid). Check the properties of the alcohol the use of organic class heat transfer fluids. They fall into
type that is being considered. two categories:
Methanol. Although methanol has been used in the past Petroleum based fluids called 'hot oils'
as a buffer fluid for tandem seals in low temperature ser-
Synthetic aromatic fluids, such as Dowtherm HT.
vices, it is a VHAP and is not recommended. In addition
to being toxic, methanol has a low boiling point and low They offer higher thermal stability, broader working
viscosity. It is not a good seal face lubricant. temperatures range and are more effective than
petroleum 'hot oils'.
Propanol. 1-Propanol, or n-propyl alcohol, has replaced
methanol as a buffer fluid for low temperature services. It Dowtherm. Dowtherm is a family of synthetic heat trans-
has become one of the recommended buffer fluids for low fer fluids manufactured by Dow Chemical Company.
temperature applications. Dowtherm types are A, G, LF, J, HT, and Q. Dowtherm HT
is the recommended type for buffer or barrier fluid.
C. Kerosene and Diesel Fuel
General Guidelines for John Crane
The viscosity of diesel fuels and deodorized kerosenes
Buffer/Barrier Fluid Families
can provide adequate seal face lubrication through a wide
Table I shows general guidelines of the John Crane
temperature range. Although not a flashing hydrocarbon
Buffer/Barrier Fluid Families. Use of a fluid from these
according to API 682, diesel fuels and kerosenes may be
families does not necessarily ensure successful operation
classified as volatile organic compounds (VOC), especial-
of a sealing system. The temperature range of each fami-
ly at higher temperatures.
ly covers all temperature ranges of each fluid included in
this family. For a temperature range specific to a fluid,
D. Petroleum Based Hydraulic and Lubricating Oils use Table II on page 49.
Lube oils. Although turbine oils have been used exten-
sively in the past, experience is that the anti-wear/oxida- Caution: Check the allowable temperature range of
tion resistant additives plate out on the seal faces. elastomers before using them. Table I on
Reference temperatures of 40C (104F) and 100C page 46 addresses only chemical compati-
(212F) are conventions used in measuring properties of bility. The temperature range for a fluid fami-
lube oils. For example, an ISO grade 68 oil has a viscosi- ly might not be the same as the listed com-
ty of approximately 68 cSt at 40 C. John Crane's experi- patible elastomers.
ence is that the lower viscosity grades, (less than Grade
32) provide better performance. Paraffinic based oils Details of flow, temperature rise, etc. must be checked for
seem to be better than napthenic oils. Blistering of carbon each application. Fluids in each family may be used in
seal faces is common when lube oils are used as services more severe than indicated by the family specifi-
buffer/barrier fluids -- especially ISO grades 32 and high- cation providing that the properties and qualifications of
er. Experience has shown that synthetic oils perform bet- the particular fluid are deemed suitable after appropriate
ter than conventional turbine oils; this may be partially engineering review.
due to the (generally) lower viscosity of the synthetics.
Automatic transmission fluid. Automatic transmission
fluid has the proper range of viscosities but is not recom-
Practical Limit Vent
(Fluid temperature)
Fluid level to be
Family Minimum Maximum Elastomer maintained above
F C F C return line
Glycols -20 -29 185 82 E, X18, X48
3 feet minimum
Reservoir
Alcohols -191 -85 157 70 B, E, X18, X48
Kerosene/Diesel 0 -18 180 82 X18, B, X, X48
F BI BO
Lube Oils -20 -29 300 150 X18, N*, B, X, X48
Synthetic Oils -25 -32 480 249 N*, B , X, X48
Heat Transfer Fluids 0 -18 650 340 Check compatibility

for each fluid
Notes: Elastomer material codes are:

B = Buna-N X = Fluoroelastomer
E = Ethylene propylene N = Neoprene Figure 2. Seal Chamber for Plan 52
X48 = Perfluoroelastomer X18 = Aflas
* Select appropriate compound based on aniline point of fluid. maintained at a pressure less than the pressure in the
seal chamber.
Check compatibility with formulation.
Table 1. For Plan 52, the reservoir is located as close as possible

Guidelines for John Crane Buffer/Barrier Fluid Families to the seal. The John Crane recommendation is that the
bottom of the reservoir be 12 to 30 inches above the cen-
terline of the pump, and be within three feet (horizontally)
of the seal. API 682 requires that the liquid level provide
at least three feet of static head to the outer seal.
III - Piping Systems and Circulation
The performance of a barrier/buffer fluid depends on its Plan 53 uses a pressurized external barrier fluid reservoir
properties, but is also closely linked to the performance of to supply clean fluid to the seal chamber. Circulation is by
the pumping ring and the design of the piping system. an internal pumping ring or a thermosiphon. Reservoir
The following information gives a broad overview of circu- pressure is greater than the process pressure being
lation systems and fluid flow rates. sealed.
API Plan 52 and 53 Plan 53 systems are very similar to Plan 52 systems
except that Plan 53 is pressurized whereas Plan 52
Figures 1-4 show the API schematics for API Plans 52
system is usually vented.
and 53, but cannot be used to predict the circulation rate.
More details are required.
Plan 52 uses an external reservoir to provide buffer fluid External Pressure

for the outer seal of an unpressurized dual seal arrange- Source
ment. During normal operation, circulation is maintained
by an internal pumping ring. The reservoir is usually
PS PI
continuously vented to a vapor recovery system and is Normally open
When
Vent specified
PS PI
Normally open
When Reservoir
specified
FI
Reservoir
BO
BO BI
BI
Figure 3. Plan 53
Figure 1. Plan 52
To external Fluid level to be 5 shows that to produce a flowrate of two gpm of lube oil,
pressure source maintained above the pumping ring must put up around 19 feet of head.
return line This compares to 8 feet of head when water is the fluid.
Reservoir
Figure 6 shows system curves for a typical Plan 52 or 53
system. These curves, based on water, are approximately
true for viscosity less than 3 cSt (36 SUS). This figure
illustrates the importance of using large diameters. For
example, to circulate two gpm in 1/2" tubing requires a
differential head of 15 feet (6.5 psi of water) but only 3
feet of head is required for 3/4" tubing.
1/2 16 Ga Tubing
25
Figure 4. Seal Chamber for Plan 53 20 1/2 SCH 80
Differential Head (ft)

System Curves
15
A system curve shows the relationship of flow and pres- 3/4 16 Ga Tubing
sure. As an example, in order to produce more flow, addi- 10
tional pressure (really pressure difference) is required.
Figure 5 shows an example of a system curve for water 3/4 SCH 80
and lube oil. The relationship between required differen- 5
tial head and flow rate depends on the considered sys-
tem. 0
0 1 2 3 4 5
In Figure 5, the vertical axis is the head (or pressure) that Flowrate (gpm)
is required to produce the flow rate on the horizontal axis.
For example, if a flowrate of 2 gpm of water is desired, Figure 6. Plan 52 System Curves for Water
then the pressure difference in the system must be about
8 feet of liquid (3.5 psi of water). The pumping ring cre- Pumping Rings
ates the pressure difference (exit pressure from the Any rotating component can produce some pressure from
pumping ring minus entrance pressure to the pumping centrifugal effects. Even a smooth disk will act like a
ring). If the pumping ring is not capable of providing 3.5 pump to some degree. Naturally, the pumping effect is
psi at the two gpm flow rate, then the flow through the less than would be obtained from a true impeller; howev-
system will not be two gpm. er, it may still be adequate. This pumping effect is greatly
enhanced if the rotating element is placed near a tangen-
25
tially directed outlet port.
rte
20 The pumping effect is increased when the clearance

Wa
between the rotating element and outlet port is

il
eO
15 decreased. Keeping this effect in mind helps to empha-

Lub
size that the clearance between any rotating component

10 and the inlet port should be greater than the clearance at
the outlet port. Alternately, the inlet port can be made tan-
gentially (but opposite to the outlet). Testing has shown
5 that increased radial clearances improve flow on paddle
wheel (radial flow) pumping ring.
0
0 1 2 3 4 5
Figure 7 shows the measured performance curve for a 2-
Flowrate (gpm) 5/8" Type 8B-1 seal at 3600 rpm. Outlet ports were tan-
gential and 3/8" in diameter. Performance is shown with
Figure 5.
and without the axial flow pumping ring. Pumping rate is
Comparison of System Curves for Water and Lube Oil
much lower without an axial flow pumping ring; however,
in many cases even this reduced performance may be
adequate.
Some of the variables that affect the system curve are:
pipe size, pipe length, number of fittings, type of fitting,
static head and type of fluid. Although the specific gravity
of the fluid has some affect on the system curve, viscosity
is the most significant fluid property. In particular, lubricat-
ing oils with viscosities greater than around 6 cSt (45.5
SUS) require more head to produce a given flow. Figure
25 IV - Recommended Buffer and
Barrier Fluids
20 With Axial Flow
Pumping Ring John Crane Testing

15 John Crane has conducted a number of tests on various
Seal Head buffer and barrier fluids. Three types of tests have
10 Only been used to determine recommendations for using
these fluids.
5
The first test was a simple screening test designed to
0 select candidates for further testing with seals. The sec-
0 1 2 3 4 5 ond test was carried out with a complete mechanical seal
Flowrate (gpm) and sealing system on several selected fluids. The last
series of tests has been conducted on a sealing system
Figure 7. Performance Curve for a 2-5/8 Type 8B1 conforming to API 682. Barrier and buffer fluids were
at 3600 rpm on water. Tangential exit used 3/8 evaluated in a 100 hours sequence on a cartridge seal.
diameter ports. Pre and post test face measurements were taken, and
critical operating conditions, such as temperatures, pres-
sures, and horsepower were monitored. The process fluid
Combined Pumping Ring and System Curves was propane at ambient temperature. When a barrier fluid
The actual circulation rate depends on both the pumping was tested, the outboard seal was pressurized 25 psi
ring performance curve and the system curve. In fact, the above process pressure.
circulation rate is determined by the intersection of these
two curves. Figure 8 shows the performance of a 2-1/4" A post test review and interpretation of test results con-
axial flow pumping ring in water. The radially directed cludes the following :
ports were 1/2" diameter. Figure 8 shows that the expect-
ed circulation rate at 3600 rpm would be around 5.6 gpm White mineral oils and silicon based oils produced
for the standard Plan 52 system using 3/4" tubing. The very high torque and coefficient of friction in simple
circulation rate is reduced to around 2.1 gpm when 1/2" screening tests. Based on this result and poor field
tubing is used. For this particular situation, either size tub- experience, these fluids were not tested further and
ing allows a reasonable circulation rate. are not recommended.
L Grade ISO
1
32 oils have shown mixed results: In gen-
1/2 16 Ga Tubing
eral PAO based oils did not provide the best lubricity
25 and caused significant wear on the faces. The higher
viscosity of ISO 32 oils is likely to cause carbon blis-
20 tering, requires a higher horsepower and generates
more heat. ISO 32 PAO-Based Synth-1 failed twice

3/4 16 Ga Tubing causing a high seal leakage and coking on the faces,
15
when tested as a barrier fluid. Therefore this oil is not
3600 rpm
recommended for use as a barrier/buffer fluid.
10
ISO 32 PAO-Based Synth-2 generated a high horse-
5 power while demonstrating poor heat transfer and
1800 rpm high face temperature. Based on these tests and field
0 experience viscosity grades higher than 32 are not
0 1 2 3 4 5 6 recommended unless dictated by high temperature
Flowrate (gpm) applications.
Figure 8. Performance of 2-1/4 axial flow pumping J Kerosene K1 successfully completed the test as a
buffer and barrier fluid. Its low viscosity allowed low
ring in Plan 52 systems. Radially directed ports are horsepower, low head pressure, and good heat
1/2 diameter. removal capability showed by low faces temperatures.
Face conditions were good after the test. It is there-
fore recommended as a buffer/barrier fluid.
Kerosenes grades higher than K3 are not recom-

mended either as a barrier or buffer fluid due to their
higher viscosity.
1 PAO: Poly Aliphatic Olefin. Defines the molecular structure of the organic fluid. Molecules are unsaturated (olefin) straight chains
(aliphatic) of carbon atoms.
J Synth-3 and Synth-4 low viscosity synthetic Conversion Data
hydrocarbons gave excellent results and did not
require a horsepower as high as ISO 32 oils due to Kinematic Viscosity Conversion Table
their lower viscosity. They demonstrated good heat To obtain the Saybolt Universal Viscosity equivalent to the
transfer capabilities. Conditions of faces were excel- viscosity in cSt at a determined temperature of t F, multi-
lent. ply the equivalent Saybolt Universal viscosity at 100F by
[1 + (t -100) * 0.000064].
L Synth-5, with a viscosity equivalent to an ISO 32
grade, had disappointing results. It generated high e.g: 10 cSt at 210F are equivalent to 58.8 * 1.0070, or
face temperature and wear. This oil may be suggest- 59.2 SUS at 210F.
ed for high temperature applications.
Centi- SUS Centi- SUS Centi- SUS at
J Diester-based oils such as Synth-6 performed well. stokes at 100F stokes at 100F stokes 100F
In general, diester fluids demonstrate a better lubricity 1 31.0 12 65.9 32 149.7
than PAO based oils. However, performance varied
widely among different manufacturers. Diester-based 2 32.6 14 73.4 35 164.2
Synth-7 generated some grooving on the primary ring 3 36.0 16 81.1 40 185.7
and high heat at the faces. Reasons for these results 4 39.1 18 89.2 45 199.2
are under review. 5 42.3 20 97.5 50 231.4
6 45.5 22 106.0 60 277.4
Conclusion: Oil-synthetics (non PAO) ran better, cooler
than ISO 32 oils, and would provide a 7 48.7 24 114.6 70 323.4
longer seal life. 8 52.0 26 123.3 80 369.6
9 55.4 28 132.1 90 415.8
Recommended Barrier and Buffer Fluids 10 58.8 30 140.9 100 462.0
Based on tests, fluid properties and field experience, the Table III. Kinematic Viscosity Conversion Table
buffer and barrier fluids listed in Table II are recommend-
ed. Please refer to the customer's process engineers to
check compatibility with processed fluid. Temperature Conversions
t(F) = t(C) * 9/5 + 32
t(C) = [t(F) - 32] * 5/9
Sp @ Viscosity, cSt/SUS Specific Thermal Pump Temperature

Family Fluid Name 60F @ temperature, F/C Pour Boiling Heat @ Conductivity Range, F/C
Point Point 60F @ 60F
104/40 212/100 F/C F/C Btu/lbF Btu/hr ftF Min Max
Glycols Ethylene glycol 1.07 2.5/34.3 0.8/30.7 -30/-34 225/107 0.78 0.22 -20/-29 165/74
and Water in water (50% vol)
Propylene glycol 1.05 2.6/34.0 0.7/30.5 -28/-33 222/106 0.79 0.21 -20/-29 170/77
in water (50%vol)
Water 1.00 0.68/30.5 0.29/29.9 32/0 212/100 1 0.34 40/4.4 160/71
Alcohols n-Propyl-Alcohol 0.81 1.5/31.8 0.45/30.2 -195/-126 207/97 0.53 0.09 -191/-124 157/69
Kerosenes K-1 Kerosene 0.83 1/31.0 -20/-29 300/149 0.46 0.086 -10/-23 250/121
and diesels K-2 Kerosene 0.85 1.4/31.24 0.6/30.3 -30/-34 350/177 0.46 0.086 -20/-29 270/132
D-1 Diesel 0.83 1.4/31.24 0.6/30.3 -30/-34 350/177 0.46 0.086 -20/-29 300/149
D2-Diesel 0.86 2.7/35 1.0/31.0 -75/-59 360/182 0.46 0.086 10/-12 180/82
Lube oils Lube-1 0.86 13.9/75.8 5.1/43.2 -75/-59 219/104 ~0.5 ~0.08 -20/-29 169/76
Lube-2 0.85 9.5/59.4 2.6/34.0 10/-12 335/168 ~0.5 ~0.08 20/-6.7 285/140
Lube-3 0.89 9.5/57.1 2.3/33.5 -58/-50 >300/>149 ~0.5 ~0.08 20/-6.7 275/135
Synthetic Synth-3 0.80 7/48.7 1.5/31.8 -80/-62 700/371 0.555 0.089 -25/-32 430/221
Lube oils Synth-4 0.82 22/106.0 3.3/36.9 -80/-62 700/371 0.569 0.085 25/-4 440/227
Diester-Based 0.96 37.2/173 5.35/43.4 -58/-50 493/256 0.528 0.079 62/17 440/227
Synth-6
Heat
transfer Aromatic-1 1.01 29/135 4/39.1 25 /-4 650/343 0.35 0.071 55/13 600/316
fluids
Table II. Recommended Buffer and Barrier Fluids
Appendix
Critical properties definitions of barrier and buffer fluids and related ASTM tests
Property Definition Standard Comment
Flash Point, in F Temperature at which a fluid gives off ASTM D92

enough flammable vapor to flash in the
presence of a flame. The temperature
varies with different fluids. Flash point is
a critical factor in evaluating fire hazards,
and should be higher than service
temperature if in contact with oxygen.
Pour Point, in F Lowest temperature at which a fluid will ASTM D97

flow or pour before turning into a gel. Pour
point is an important consideration with low
temperature applications and refrigerants,
and should be at least 5F above minimum
temperature at which fluid is exposed.
Viscosity, in SUS, It is the measure of a relative resistance to ASTM D2270 The viscosity grade to be chosen
cSt, or cPs a fluid to flow. Low viscosity fluids flow ASTM D2161 depends on the temperature and the
freely, high fluids flow sluggishly. Units are pressure range of the application.
cSt (centistoke), cPs (centipoise) or SUS High viscosity grades are suitable for
(Saybolt Universal Seconds). very high temperatures.
Viscosity Index The viscosity index of a fluid indicates the ASTM D2270
degree of variation of viscosity with
temperature. The higher the index, the
more stable the viscosity with temperature
change.
Specific Gravity The specific gravity of a liquid is the ratio ASTM D1250
of its density at specified temperature to ASTM D287
that of water at 60F. A higher Sg
decreases the required flow rate and
allows a better flow.
Specific Heat in Ability to absorb heat

BTU/lbF
Thermal Ability to transfer heat

Conductivity
in BTU/Hr. FtF
Aniline Point, The aniline point is the minimum ASTM D611

in F temperature at which two equal volumes of
aniline and fluid are miscible. It appears to
characterize the swelling action of a
petroleum oil on synthetic rubber.
Corrosivity Ability of the fluid to interact chemically ASTM D130 This ASTM test measures the
with metal parts of the sealing system. ASTM D665 corroding action of petroleum products
on metal. A copper strip is immersed
in the tested fluid in presence of
oxygen and metal catalyst. Its color
after removal is ranked from 1
through 4. The higher the index, the
more corroded the state. The index
should be low (1a, 1b). Corrosion rate
of 0.002"/ yr is sought.
Property Definition Standard Comment
Total Acid The TAN (Total Acid Number) in mg KOH/g ASTM D943
Number indicates the degree of oxidation of the oil.
The test assesses the oxidation stability of
inhibited oils by evaluating the number of
hours required to reach 2.0 mg KOH/g in
presence of oxygen and a metal catalyst.
Foam Dispersion of gas in the fluid under the ASTM D892 The test measures the volume of
foam form of microscopic bubbles. right after fluid has
been blown by air
for 5mn, and later,
after having
allowed it to settle for
10 mn.
Repeated 3 times
(75F, 200F, 75F)
Gas Solubility Ability of the fluid to absorb and blend ASTM D2780
uniformly with gas. Should be minimum.
Volatility Loss of mass by evaporation of a ASTM D972

lubricating oil as a percentile of its total
mass, in fixed conditions.
Water Separability High demulsibility ability allows a lubricant ASTM 1401 The test must be passed.
to separate from water if contaminated
when it stands in the reservoir. It facilitates
the drainage.
Carbon Blistering Carbon blisters are eruptions which

occasionally occur on the rubbing face of
carbon rings used in systems containing oil.
Oil from the hydrodynamic films enters into
the pores of the carbon running face. A
rapid rise in temperature causes this oil
under the surface to expand. When the oil
cannot come out rapidly enough, a
subsurface pressure occurs, leading to
local cracking of the carbon.
Wear Damage resulting from friction. ASTM D4172 The test is called 4 ball wear test:
A steel ball is pressed and rotated on
three other clamped balls covered
with lubricant. The average size of the
scar diameters on the 3 lower balls is
used to compare lubricants. The scar
diameter should be as small as
possible. Lubricants must have good
anti-wear properties in order not to
damage the sealing faces and
cause leakage.
References
John Crane Lemco. John Crane Lemco Fluid Control Systems Pressure Reservoir Plan 52 and Plan 53 Instruction
Manual, Tulsa, OK: John Crane Lemco 1996.
Ciffone, John. Mechanical Seal Face Lubrication Mechanical Seal Installation Lubrication General Lubrication, Arlington
Heights, IL: John Crane Mechanical Maintenance Training Center 1994.
Europe Latin America Middle East, Africa, Asia North America
Slough, UK So Paulo, Brazil Dubai, United Arab Emirates Morton Grove, Illinois USA
Tel: 44-1753-224000 Tel: 55-11-3371-2500 Tel: 971-4-3438940 1-800-SEALING
Fax: 44-1753-224224 Fax: 55-11-3371-2599 Fax: 971-4-3438970 Tel: 1-847-967-2400
Fax: 1-847-967-3915
For your nearest John Crane facility, please contact one of the locations above.
If the products featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should be consulted prior to their selection and use.
In the interest of continuous development, John Crane Companies reserve the right to alter designs and specifications without prior notice. It is dangerous to smoke while handling
products made from PTFE. Old and new PTFE products must not be incinerated.
2001 John Crane Print 04/29/05 www.johncrane.com ISO-Certified QS 9000 MMTC-602-3

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Table 1 - Summary of Flush Plans and Numbering

API Plan Description

Advantages and Disadvantages

Buffer & Barrier Fluids

In high temperature services, a steam quench may provide several benefits:

Determining the Quench Rate

Minimum Rate for Purging

Minimum Quench Rate Based on Washing

Minimum Quench Rate Based on Cooling

Table 2 - Typical Properties of Water, Steam, and Nitrogen

Physical Property Water Steam Nitrogen

Physical Property Water Steam Nitrogen

Steam Requirement Nitrogen Requirement

Recommended Quench Rate

Table 4 - Quench Rates for Typical High Temperature Pumps

Steam Requirement Nitrogen Requirement

Controlling the quench

Steam Flow, ALPS Nitrogen Flow, ALPS

Secondary Containment Seals

Influence of Static and Dynamic Dual Gas Seal Leakage

Static Gas Leakage

Dynamic Gas Leakage

Symbol Connections or Ancillary Equipment

Figure 1 - Seal Flush Plan 01

Sizing and Controlling

Figure 2 - Seal Flush Plan 02

Figure 3 - Seal Flush Plan 11

Figure 4 - Seal Flush Plan 12

Figure 5 - Seal Flush Plan 13

Figure 6 - Seal Flush Plan 14

Figure 7 - Seal Flush Plan 21

Figure 8 - Seal Flush Plan 23

Figure 9 - Seal Flush Plan 31

Figure 10 - Seal Flush Plan 32

Figure 11 - Seal Flush Plan 41

Figure 12 - Seal Flush Plan 52

Figure 13 - Seal Flush Plan 53A

Advantages (vs other Plan 53 systems)

Disadvantages (vs other Plan 53 systems)

Figure 14 - Seal Flush Plan 53B

Advantages (vs other Plan 53 systems)

Disadvantages (vs other Plan 53 systems)

Figure 15 - Seal Flush Plan 53C

Advantages (vs other Plan 53 systems)

Disadvantages (vs other Plan 53 systems)

Figure 16 - Seal Flush Plan 54

Figure 17 - Seal Flush Plan 62

Figure 18 - Seal Flush Plan 72

Figure 19 - Seal Flush Plan 74

Controlling and General

Figure 20 - Seal Flush Plan 75

Figure 21 - Seal Flush Plan 76

Controlling & General (Plans 72, 75, and 76)

Propylene glycol/water. A 50/50 mixture has become a F. Heat Transfer Fluids

Glycols -20 -29 185 82 E, X18, X48

Synthetic Oils -25 -32 480 249 N*, B , X, X48

Heat Transfer Fluids 0 -18 650 340 Check compatibility

Notes: Elastomer material codes are:

Table 1. For Plan 52, the reservoir is located as close as possible

Plan 52 uses an external reservoir to provide buffer fluid External Pressure

Figure 4. Seal Chamber for Plan 53 20 1/2 SCH 80