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1
ปั! มชนิดนี" ถ่ายเทพลังงานจากเครื องยนต์ตน้ กาลั ่
ํ งหรื อมอเตอร์ไฟฟ้าให้แกของเหลวที ถูกดูดเข้าตรงจุด
ศูนย์กลางของใบพัด การหมุนของใบพัดจะเหวียงของเหลวออกสู่ปลายใบพัดทําให้เกดการไหลในแ ิ นว
่
ของแรงลัพธ์ระหวางแรงในแนวรั ศมีและแรงในแนวสัมผัส แรงเหวียงนี" เรี ยกแรงหนีศูนย์กลาง เมือ
ของเหลวเคลือนทีไปสู่ปลายใบพัด ความกดดันของของเหลวจะเพิมขึ" นเรื อย ๆ และมีค่ามากทีสุดเมืออยู่
่ ดศูนย์กลางของใบพัดมากทีสุด เมือมีความเร็ วมากพอแรงเหวียงนี" จะทําให้เกดสภาวะศู
หางจุ ิ นย์กลางที
ตําแหนงดุ่ มของใบพัดซึงเอื"อให้ของเหลวจํานวนใหมถู่ กดูดเข้ามาแทนในตําแหนงศู ่ นย์กลางใบพัดนี"
และถูกเหวียงออกไปเรื อย ๆ ตอเนื ่ องเมือของเหลวทีถูกดูดเข้าไปทีศูนย์กลางถูกเหวียงออกไปด้านนอก
ทุกทิศทางในแนวของใบพัดเพือให้ของเหลวทีสะสมอยูโ่ ดยรอบมีเพิมขึ" นได้ จึงต้องติดตั" งใบพัดให้เยื"อง
ศูนย์ มีจุดทีปลายใบพัดแทบจะแตะเรื อนปั! มตําแหนง่ ตําแหนงนี่ " เรี ยกวา่ “ลิน" ของเรื อนปั! ม”, Tong of the
casing จากตําแหนงลิ ่ "นของปั! มไปทางด้านทางออกปริ มาตรจะเพิมเรื อย ๆ เพือรองรับของเหลวทีเพิมขึ" น
และถูกขับออกไปทางด้าน
่ (Discharge opening)
จาย
2
Axial Flow
่
แบงตามทิ ศทางการไหลของ ของไหล
3
Mixed Flow & Radial Flow
4
Mixed Flow
Volute
5
Mixed Flow
Diffuser
6
Radial Flow
Volute
ปั! มแบบหอยโขง่
7
Radial Flow
Diffuser
แบบมีครี บผันนํ" า (Diffuser) ปั! มแบบนี" มีลกั ษณะของเรื อนปั! มและใบพัดเหมือนแบบ Volute
่ แตภายในเพิ
type ทุกอยาง ่ มเติมครี บผันนํ" าติดอยูก่ บเรื
ั อนปั! มเพือชวยปรั
่ บทิศทางให้ของเหลวทีถูกดั
ออกมาเข้าสู่ทิศทางไปสู่ช่องทางเดินทีเป็ นสวนโค้
่ งรอบนอกได้เร็ วขึ" น ทําให้มีการสูญเสี ยพลังงาน
น้อยลงทําให้การเปลียนพลังงานจลน์มาเป็ นพลังงานศักย์ในรู ปของความดันมีประสิ ทธิภาพดีข" ึน
8
Peripheral ; Turbine,Vertex,Regenerative
่
แบบเทอร์ไบน์ (Turbine Type) ปั! มแบบนี" บางครั" งเรี ยกวาแบบ Vertex, periphery หรื อ
่
Regenerative Turbine ลักษณะเดนของมั ่
นคือตัวใบพัดจะเป็ นแผนแบบกลม มีความหนา ครี บของ
ิ ั ่
ใบพัดเกดจากการกดเซาะรองบนของของแผนใบพั ่ ิ นแผนครี
ด เกดเป็ ่ บแคบ ๆ และลิน" ในแนวรัศมี เมือ
ของเหลวจากทางดูดสู่ช่องวางระหวางครี
่ ่ บของใบพัด มันจะถูกเหวียงออกด้วยแรงหนีศูนย์กลาง แต่
เนืองจากผนังของเรื อนปั! มปิ ดกนอยู " ั ม่ นั ไปไหนตอไมได้
่ ่ กจะถู็ กบังคับให้ตอ้ งย้อนกลับเข้าสู่ช่องวาง
่
่ บและถูกเหวียงกลับออกไปอีก ขบวนการนี" เกดซํ
ระหวางครี ิ " าไปมาจนกวาจะเคลื
่ อนทีถึงทางออกทําให
มี พลังงานเพิมขึ" นเรื อย ๆ ตามจํานวนครั" งของการเดินทางไปมาระหวางครี ่ บ และขอบใบพัด ซึงอาจมี
จํานวนครั" งตั" งแต่ 2 ถึง 50 ยิงจํานวนครั" งมากพลังงานศักย์ของๆเหลวกจะเพิ
็ มมากขึ" น
9
10
11
Types of Impeller
ลักษณะใบพัดของปัมแบบเซนตริฟูกอล
เนืองจากทิศทางการไหลของของเหลวถูกบังคับด้วยลักษณะของใบพัดและจานประกับ(Shroud) หลาย
รู ปแบบด้วยกนั คือ
ใบพัดเปิ ด (Open Impeller) เป็ นแบบทีตัวใบพัดยืนยาวออกจากแผนประกบหรื
่ ั อรัศมีของจานประกบั
่ ศมีของใบพัด
เล็กกวารั
ใบพัดกึงเปิ ด (Semi-open Impeller) แบบนี" จานประกบมี
ั รัศมีเทาใบพั
่ ดแตมี่ จานประกบเพีั ยงด้านเดียว
ใบพัดปิ ด (Closed Impeller) แบบนี" จานประกบมี
ั รัศมียาวเทาใบพั
่ ดและปิ ดอยูท่ " งั สองด้าน มีท" งั แบบทาง
ดูดด้านเดียวและสองด้าน (Closed - Single suction impeller) และ(Closed-Double suction impeller)
Paper Stock Impeller มีใบพัดออกแบบให้เหมาะสําหรับการปั! มของทีมีความข้นสูงเนืองจากเดิมมีใช้
ในอุตสาหกรรมเยือกระดาษ ดังนั" นแม้ต่อมาจะถูกใช้กบของเหลวอื
ั นกยั็ งคงมีชือเหมือนเดิม คือ Paper
Stock Impeller
Propeller ใบพัดแบบนี" บงั คับการไหลให้อยูใ่ นทิศทางการไหลเข้าสู่ใบพัดเพียงอยา่ งเดียวไมมี่ แรงหนี
ศูนย์กลางเรี ยกตามทิศทางไหลของๆเหลววา่ Axial Flow Type
Mixed Flow แบบนี" ของไหลเข้าสู่ใบพัดขนานกบแกนเพลา
ั แตมี่ ใบพัดบังคับให้ไหลออกทํามุม 45° ถึง
ั ศทางเดิม แรงขับเป็ นผลรวมของแรงขับดันในทิศทางของเพลาและแรงหนีศูนย์
80° กบทิ
Radial Flow เป็ นใบพัดชนิดทีบังคับของไหลให้ออกจากปั! มด้วยแรงเหวียงหนีศูนย์กลางเพียงอยางเดี ่ ยว
12
13
14
15
16
Types of shell
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
่ ี แตเอารู
อันนี" ไมเกยว ่ ปมาชวยอธิ
่ บาย
33
34
35
36
37
38
39
40
Test
41
Test
42
Test
43
Test
44
45
Wear ring
Shaft Sleeve
Balance Force
Radial thrust
Axial thrust
Seal
Packing
Mechanical seal
Trobleshooting of mechanical seals
Pump system
Water hammer
Hydraulic Transient Analysis
Surge
NPSH+CAVITATION
ALIGNMEMT
LOAD REJECTION
่
การตอขนาน+อนุกรม
Megnetic Bearing
Intake & Suction piping
Intake piping
Traveling Screen
Suction piping
Strainer
Damage Mechanisms
Wear Mechanisms
15 INSTALLATION,OPERATION, AND MAINTENANCE 15.19
Spares !commended
See
Part Note Start-up Normal Maintenance
Number of identical pumps 1-3 4-6 7+ 1-3 4-6 7-9 10+
Cartridge 1 1 1 1
Element 1 1 1 1
Rotor 1 1 1 1
Case 1
Head (case cover and seal 1
chamber)
Bearing bracket 1
Shaft (wlkey) 1 1 2 N13
Impeller 1 1 2 N13
Wear rings (set) 1 1 1 1 1 2 N13
Bearings complete (rolling 1 1 2 1 2 N13 N13
element, radial)
Bearings complete (rolling 1 1 2 1 2 N13 N13
element, thrust)
Bearings complete 1 1 2 1 2 N13 N13
(hydrodynamic, radial)
Bearing pads only 1 1 2 1 2 N13 N13
(hydrodynamic, radial)
Bearing complete 1 1 2 1 2 N13 N13
(hydrodynamic, thrust)
Bearing pads only 1 1 2 1 2 N13 N13
(hydrodynamic, thrust)
Mechanical seallpacking 1 2 N13 1 2 N13 N13
Shaft sleeve 1 2 N13 1 2 N13 N13
Gaskets, shims, O-rings (set) 1 2 N13 1 2 N/3 N13
Add for vertical pump
Bowls N13 N13
Spiders (set) 1 1 1 N13 N13
Bearings, bushings (set) 1 1 2 1 1 N13 N13
Add for high speed integral gear
Gear box 1 1 1 1 1 N13
Diffuser and cover 1 1 1 1 1 1 N13
Splined shaft 1 1 1 1 1 1 N13
Gear box housing 1 1 1 n13
Oil pump, internal 1 1 1 1 1 N13
Oil pump, external 1 1 1 1 1 N/3
Oil filter 1 2 N13 1 2 3 N13
Notes:
N = Number of identical pumps
(1)Horizontal pumps only
(2)Vital service pumps are generally unspared, partially spared, or multistage. When a vital
machine is down, production loss or violation of environmental permits results.
(3)Essential service pumps are required for operation and have an installed spare. A produc-
tion loss will occur only if main and spare fail simultaneously.
(4) Cartridge type mechanical seals shall include sleeve and gland.
( 5 ) Cartridge consists of assembled element plus discharge head, seal(s), and bearing housing(s).
(6) Element consists of assembled rotor plus stationary hydraulic parts (difiseds) or volute(s)).
(7) Rotor consists of all rotating parts attached to the shaft.
(8) Normal wear parts
(9) Per pump set
Symptom Cause
Wear on one or two rings next to Improper packing installation
packing gland; other rings OK
Wear on O.D. of packing rings Packing rings rotating with shaft sleeve or
leakage between rings and I.D. of box. Wrong
packing size or incorrectly cut rings
Charring or glazing of inner Excessive heating. Insufficient leakage to
circumference of rings lubricate packing or unsuitable packing
I.D. of rings excessively Rotation eccentric
increased or heavily worn on
part of inner circumference
16 INSTALLATION, OPERATION, AND MAINTENANCE 15.23
FURTHER READING
American Petroleum Institute. “Centrifugal Pumps for Petroleum, Petrochemical and Nat-
ural Gas Industries”,API Standard 610,lOth ed., 1220 L Street, Washington, DC, 20005,
2004, www.api.org.
American Petroleum Institute. API Recommended Practice 686 (PIP REIE 686), “Recom-
mended Practices for Machinery Installation and Installation Design.” 1st ed., 1220 L
Street, Washington, DC, 20005,1996, www.api.org.
Dufour, J. W., and Nelson, W. E. Centrifugal Pump Sourcebook. McGraw-Hill, Inc., New
York, 1992.
Heald, C. C., and P e w , D. G. “Design and Operation of Pumps for Hot Standby Service.” 5th
International Pump Users Symposium, Texas A&M, Houston, TX 1988.
Hydraulic Institute ANSI/HI 2000 Edition Pump Standards, Hydraulic Institute, Parsip-
pans NJ, www.pumps.org.
Karassik, I. J.Centrifugal Pump Clinic. Marcel Dekker, New York, 1981.
การประหยัดพลังงาน
การควบคุมการไหลโดยการปรับความเร็ วรอบ
การควบคุมการไหลโดยการหรี วาล์ว
การเปลียนความเร็ วรอบ
่ นย์กลางของใบพัด
การเปลียนเส้นผาศู
1
2
Pump vibration trobleshooting list
3
Pump vibration trobleshooting list
4
Pump vibration trobleshooting list
5
Pump vibration trobleshooting list
6
Pump vibration trobleshooting list
7
⌫
Frictionless Compressors
สรุ ป
คอมเพรสเซอร แบบไรแรงเสี ยดทานถือเป นอีกเทคโนโลยี หนึ่ งที่ รวมเอาแบริ่ งแบบแม เหล็ กและคอมเพรสเซอร
แบบแรงเหวี่ ยงเขาไวดวยกัน ทําใหสามารถขจัดปญหาการสู ญเสียพลังงานเนื่องจากแรงเสียดทาน และการสั่นสะเทือน
Å ´ µ é¹ · Ø
¹ ã ¹ ¡ Ò Ã Ê Ã éÒ § á Å Ð º Ó Ã Ø
§ Ã Ñ
¡ É Ò à ¤ Ã ×
èÍ § · Ó ¤ Ç Ò Á à Â ç¹ ä ´ é
à » ç¹ Í Â èÒ § ´ Õ Í Õ
¡ · Ñ
é§ ¤ Í Å ì à Â ç¹ Ê Ò Á Ò Ã ¶ ¶ è
Ò Â à · ¤ Ç Ò Á Ã Í
é ¹
ä ´ é
Í Â Ò
è § à µ Á
ç » Ã Ð Ê ·Ô ¸ Ô
À Ò ¾ à ¹ Í
è
× § ¨ Ò ¡ à ¤ Ã è
Í
× § · Ó ¤ Ç Ò Á à Â ¹
ç ä Á èÁ Õ
à Рº º Ë Å è
Í Å ×
è¹ ´ Ñ
§ ¹ Ñ
é¹ ¤ Í Á à ¾ Ã Ê à « Í Ã ìá º º ä Ã é
á Ã § à Ê Õ
 ´ · Ò ¹
¨ §
Ö Ê Ò Á Ò Ã ¶ · Ó § Ò ¹ ä ´ Í
é Â Ò
è § Á Ê
Õ Á Ã Ã ¶ ¹ Ð · Ê
è
Õ Ù
§ á Å Ð Á µ
Õ ¹
é · Ø
¹ ã ¹ ¡ Ò Ã Ê Ã Ò
é § á Å Ð º Ó Ã §
Ø Ã ¡Ñ É Ò à ¤ Ã è
Í
× § · Ó ¤ Ç Ò Á à Â ¹
ç · Õ
µ
è Ó
è Í ¡Õ ´ Ç
é Â
เอกสารอางอิง
[1] Turbocor, 2004, Frictionless Compressor, www.turbocor.com, 4p.
[2] HVAC&R Engineering Update, 2004, Magnetic Bearings Enhance Centrifugal Compressor Efficiency and
Operation, www.york.com, 4p
[3] International institute of Refrigeration Newsletter, 2004, Magnetic Bearing Centrifugal Compressor
เอกพจน ตันตราภิวัฒน
• Sliding Bearing
– Journal Bearing
– Bushing
• Rolling Bearing
– Ball Bearing
– Roller Bearing
• Fluid Bearing
– Air Bearing
– Hydrostatic Bearing
• Special Bearing
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 2
แบริ่งแบบผิวถูกัน (Sliding Bearing)
• มีลักษณะความเสียดทานที่ต่ํามาก
• การทํางานมีลักษณะเปนแบบ active และมีราคา
คอนขางสูง
• ใชสําหรับงานเฉพาะที่มีคุณลักษณะพิเศษ
• มีขอ จํากัดในการใชงานซึ่งจะเหมาะสมกับอุปกรณในแต
ละแบบนัน้ ๆ
Jewel Bearing
Active Magnetic Bearing
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 5
แบริ่งแบบลูกกลิ้ง Rolling Bearing
อาศัยหลักการสัมผัสแบบกลิ้งเพื่อลด
แรงเสียดทานระหวางชิ้นสวนที่มี
การเคลื่อนที่สัมพันธกันภายใตแรง
กระทํา (load)
ใชสําหรับยึดเพลาหมุนเพื่อรับแรง หรือ
ภาระในแนวรัศมี และแนวแกน
• Ball Bearings
• Roller Bearings
– Cylindrical Roller Bearing
– Needle Roller Bearing
– Tapered Roller Bearing
– Spherical Roller Bearing
• Thrust Bearings
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 10
บอลแบริ่ง (Ball Bearing)
• สามารถรับแรงไดทั้งในแนวรัศมีและแนวแกน แตภาระหลักจะเปนในแนวรัศมี
• สัมประสิทธิ์ความเสียดทานต่ํากวา rolling bearing อื่นๆ
• รับภาระไดนอย หรือปานกลาง
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 11
แบริง่ ลูกกลิ้ง (Roller Bearing)
Needle Roller
โดยทั่วไปความสัมพันธ
ของอายุการใชงาน
bearing บนกราฟ Log
จะมีลักษณะเปนเชิงเสน
ตัวอยางเชน L50 จะมี
อัตรารอดของ bearing ที่
ระยะเวลาประมาณ 5
เทาของ L10
ลักษณะความสัมพันธของการใชงานเกินกวาภาระที่
ออกแบบของ bearing และ อายุการใชงานที่ออกแบบ
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 21
ความสัมพันธของอายุ และภาระแบริ่ง
3
Ball Bearings: ⎛C ⎞
L=⎜ ⎟
⎝P⎠
10 / 3
Roller Bearings: ⎛C ⎞
L=⎜ ⎟
⎝P⎠
เพื่อความสะดวกอาจจะแสดงอายุแบริ่งเปนชั่วโมง
10 / 3
L2 ⎛ F1 ⎞
Roller Bearings: = ⎜⎜ ⎟⎟
L1 ⎝ F2 ⎠
From SKF
Catalog
Fe = XVFr + YFa
Fe = equivalent load
X = a radial factor
V = 1 for inner race rotation and 1.2 for outer race rotation
Fr = applied constant radial load
Y = a thrust factor
Fa = applied constant thrust load
Fa
ในบางกรณีที่ ≤ e กําหนดให X=1 และ Y=0
VFr
Note: Bearing บางชนิดไมสามารถรับโหลดในแนวแกนได
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 27
ตัวอยางการหาคา X&Y Factors (ใช table 11-1ในหนังสือก็ได)
1/ 3
⎡ 3 ⎤
3 / 10
⎡ j 10 / 3 ⎤
j
⎢ ∑ Ti ⋅ ni ⋅ Fe,i ⎥ ⎢ ∑ Ti ⋅ ni ⋅ Fe,i ⎥
Fe = ⎢ i =1 j ⎥ Fe = ⎢ i =1 j ⎥
⎢ ⎥ ⎢ ⎥
⎢ ∑ i i ⎥T ⋅ n ⎢ ∑ i i ⎥T ⋅ n
⎣ i =1 ⎦ ⎣ i =1 ⎦
Roller Bearings:
3 / 10
⎡ 1 φ 10 / 3 ⎤
Fe = ⎢ ∫ Fc dθ ⎥
⎣φ 0 ⎦
• ยึดแบบสวมแนน
• ใชเสื้อยึด
• ใช clips หรือ Rings
• ใช set screws
• ใชรูปรางของ
เพลา และอุปกรณ
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 34
การหลอลื่น
• หนาที่โดยหลัก
– แบงแยกผิวสัมผัสไมใหเกิดการขัดถูกันโดยตรงซึ่ง
กอใหเกิดการสึกหรอ
– ลดแรงเสียดทาน
– ลดความรอน
– รักษาผิวไมใหเกิดการกัดกรอน
• ชนิดแบงโดยสถานะ
– ของแข็ง (Solid Lubricants)
– ของเหลว (Liquid Lubricants)
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 35
สารหลอลื่นแบบแข็ง
• ใชสําหรับงานที่สารหลอลื่นเหลวไมสามารถใชงาน
ได
• ใชกับวัสดุที่มีความตานทานแรงเฉือนต่ํา low
shear stress
• บางกรณีเปนเพียงแคการเคลือบ
• อาจใชในการผสมกับเจลหรือของเหลวอื่นๆ
F du
τ = =μ
A dy
Types:
– Hydrostatic
– Hydrodynamic
• วัสดุมีความสําคัญมาก
– Bronze Bronze . copper with tin, lead, zinc, or
aluminum alloying elements
– Babbit Babbit . lead or tin with copper and antimony
alloying elements
– Aluminum Aluminum
– Powdered Metals Powdered Metals (Sintered metals)
– Polymers Polymers (plastics)
การออกแบบเครื่องจักรกล (Machine Design), อ.เอกพจน ตันตราภิวัฒน, ภาควิชาวิศวกรรมเครื่องกล สถาบันเทคโนโลยีพระจอมเกลาเจาคุณทหารลาดกระบัง 47
PV factor
P = Force/Projected Area
V = Velocity
Unstable
สมมุติฐาน
1. Lubricant is a Newtonian fluid
2. Inertia forces of the lubricant are
negligible
3. Incompressible
4. Constant viscosity
5. Zero pressure gradient along the
length of the bearing
6. The radius of the journal is large
compared to the film thickness
π 2 ⋅ d 3 ⋅η ⋅ l ⋅ N
T= ηN r
c f = 2π 2
T = f ⋅W ⋅ r = 2 ⋅ r 2 f ⋅ l ⋅ P P c
ηN
2
⎛r⎞
S =⎜ ⎟
⎝c⎠ P
1 r
S= f
2π 2 c
สมมุติอุณหภูมิน้ํามันเพิ่ม 34 F
η = 2.2μreyn
www.aesseal.com
The API Plans elaborated in this section are as defined by API 682 3rd edition / API 610 10th
edition. These are standardized flushing piping arrangements that are widely used in the
industry. Customer specific variants of these plans are possible.
01 02 11 12 13 14 21
22 23 31 32 41
51 61 62
65 71
72 74
Conserve
Water
•
0.6%
“Of all the worlds water 97.4% is salt water,
2% is solid in ice caps and only 0.6% is suitable
for industrial use and human consumption.”
PRIMARY FLUSH PLANS
01
Features
1. Minimizes risk of freezing / polymerizing of fluid in flush piping plans exposed to atmosphere.
2. Removes heat from the seal chamber as well as acting as a vent connection in horizontal pumps.
Use
1. Recommended in clean fluids.
2. Recommended for fluids which thicken at ambient temperature.
Caution
1. Ensure that the recirculation is sufficient for seal heat removal.
02
API PLAN 02
Description
Dead ended seal chamber with no flush fluid circulation.
Features
1. Applicable to low seal chamber pressure and process temperature.
2. Can be used with tapered seal chambers, especially for slurries.
3. Normally is used along with a jacketed seal chamber.
Use
1. In cool clean fluids with high specific heat, such as water, in relatively low speed pumps.
Caution
1. To avoid flashing, process fluid temperature must be taken into consideration.
2. Avoid use without cooling / heating jacket (for cylindrical chambers).
3. Ensure top point vent in throat bush (for cylindrical chambers in horizontal pumps).
11
Flow control
orifice
API PLAN 11
Description
Product recirculation from pump discharge to seal through a flow control orifice.
Features
1. Prevents product from vaporizing by maintaining positive pressure above vapor pressure.
2. Becomes a self-venting plan for horizontal pumps.
3. Default API Plan for most single seals.
Use
1. In general, applications with clean non-polymerizing fluids with moderate temperatures.
Caution
1. Calculation of recirculation flow rate, heat removal and orifice size are required.
2. Orifice size should be at least 1/8” (3.2mm).
3. Check the margin between discharge pressure & seal chamber pressure to ensure proper flow of fluid.
4. Do not use with media containing solids & abrasives.
12
Y strainer
Flow control orifice
API PLAN 12
Description
Product recirculation from pump discharge through a Y strainer and a flow control orifice to seal chamber.
Features
1. Becomes a self-venting plan for horizontal pumps.
2. Can handle dirty liquids to some extent.
Use
1. In general used in slightly dirty and non-polymerizing fluids.
Caution
1. Always ensure that orifice is placed after the Y strainer.
2. This plan is normally discouraged due to non-reliability of Y strainer.
3. Calculation of recirculation.
13
Features
1. Provides continuous vent for vertical pumps.
Use
1. Wherever Plan 11 is not usable due to low-pressure margin between discharge & seal
chamber pressure.
2. Used in vertical pumps.
Caution
1. Check margin between seal chamber pressure & suction pressure.
2. Orifice size should be at least 1/8” (3.2mm).
14
Flow control
orifice
API PLAN 14
Description
Product recirculation from pump discharge to seal chamber through a flow control orifice and seal
chamber back to suction through another flow control orifice.
Features
1. Ensures product recirculation as well as venting.
2. Reduces seal chamber pressure.
Use
1. Used in vertical pumps.
2. Used in light hydrocarbon services.
Caution
1. Check for pressure margin between discharge to seal chamber pressure and seal chamber to
suction pressure.
21
Flow control
orifice Cooling
water out
Heat exchanger
Cooling
water in
Temperature indicator
T
API PLAN 21
Description
Product recirculation from discharge through flow control orifice and heat exchanger to seal chamber.
Features
1. Improves pressure margin over vapor pressure.
2. Improves temperature margin to meet secondary sealing element limits, to reduce coking or
polymerizing & to improve lubricity.
3. Self venting plan.
4. Provides sufficient pressure difference to allow proper flow rate.
Use
1. For high temperature applications e.g. hot water application (temperature > 80ºC), hot
hydrocarbons etc.
2. In hot non-polymerizing fluids.
Caution
1. Always ensure that cooler is placed after the orifice.
2. Check pressure difference between discharge and seal chamber.
3. Cooler duty is high leading to fouling on waterside.
4. Potential plugging on process side if fluid viscosity gets high quickly.
22
Flow control orifice
Y strainer
Cooling water
out
Heat exchanger
Cooling water in
Temperature indicator
T
API PLAN 22
Description
Product recirculation from pump discharge through a Y strainer, a flow control orifice and a heat
exchanger to seal chamber.
Features
1. Improves pressure margin over vapor pressure.
2. Improves temperature margin to meet secondary sealing element limits, to reduce coking or
polymerizing & to improve lubricity.
3. Self venting plan.
4. Provides sufficient pressure difference to allow proper flow rate.
Use
1. For high temperature applications with slightly dirty liquid.
Caution
1. Always ensure that cooler is placed after the orifice.
2. Check pressure difference between discharge and seal chamber.
3. Cooler duty is high leading to fouling on waterside.
4. This plan is normally discouraged due to non-reliability of Y strainer.
23
Cooling water
out
Heat
exchanger
Cooling
water in
Temperature
indicator
Pumping
T
ring
API PLAN 23
Description
Product recirculation from seal chamber to heat exchanger and back to seal chamber.
Features
1. Circulation is maintained by pumping ring.
2. In idle condition heat transfer is maintained by thermosyphon effect and in running condition by a
pumping ring.
3. Lower product stabilization temperature is achieved.
4. Establishes required margin between fluid vapor pressure and seal chamber pressure.
Use
1. In hot and clean services e.g. in boiler feed water and hot hydrocarbon services.
Caution
1. Maintain maximum 0.5m horizontal distance from seal chamber to heat exchanger.
2. Vent valve required at highest point of piping system.
3. Ensure that pump has a close clearance throat bush.
4. Ensure that the seal outlet connection is in the top half of the gland.
5. Ensure that the cooler is mounted above the pump centre line.
6. Vent the system fully before start up.
31
Cyclone Separator
Clean mechanical
seal flush fluid
Product return to
pump suction
API PLAN 31
Description
Product recirculation from discharge through a cyclone separator, which directs clean fluid to the seal and
solids back to pump suction.
Features
1. Removes entrained solids from the process fluid.
2. Particles from cyclone separator are returned to suction.
Use
1. Used in media with suspended solids.
Caution
1. Pump throat bushing is recommended.
2. Ensure use for services containing solids with specific gravity twice or more than that of process fluid.
Control valve
Pressure indicator
32
P
Temperature indicator
10
5
Flow meter
T
1
Y Strainer
Seal Customer
vendor
API PLAN 32
Description
Injection of clean or cool liquid from external source into the seal chamber.
Features
1. Reduces flashing or air intrusion across seal faces by providing a positive flush.
2. Maintains vapor pressure margin.
3. Always provided at a pressure greater than seal chamber pressure.
4. If maintained properly the best of all single seal plans (subject to acceptance of contamination).
Use
1. Dirty or contaminated fluids.
2. High temperature applications.
3. Polymerizing and oxidizing fluids.
4. Media with poor lubrication properties.
Caution
1. External source should be continuous and reliable at all times, even during start up & shut down.
2. Flush fluid must be compatible with process fluid due to product contamination.
3. Product degradation can occur.
4. Ensure use with close clearance throat bushing to maintain pressure in stuffing box & control the rate
of contamination of pumped media.
5. Careful selection of flush fluid required to ensure that it does not vaporize on entering the seal chamber.
Cooling water out
41
Cyclone separator
Heat exchanger
Cooling water in
API PLAN 41
Description
Product recirculation from discharge through a cyclone separator and a heat exchanger to seal chamber.
Features
1. Improves pressure margin to vapor pressure.
2. Improves temperature margin to meet secondary sealing element limits, to reduce coking or
polymerizing & to improve lubricity.
3. Removes entrained solids from the process fluid.
4. Particles from cyclone separator are returned to suction.
Use
1. In hot services containing suspended solids.
Caution
1. Pump throat bushing is recommended.
2. Ensure use for services containing solids with specific gravity twice or more than that of process fluid.
3. Cooler duty is high leading to fouling on waterside.
Water
Savings
•
19 billion
liters
“AESSEAL® Seal Support Systems currently
save global industry in excess of
5 billion gal (US) / 19 billion liters of water per year.”
SECONDARY FLUSH PLANS
Vent (normally open)
Isolation valve
51
Pot
Isolation valve
Quench
Drain (plugged)
API PLAN 51
Description
External reservoir providing a dead-ended blanket for fluid to the quench connection of the gland.
Features
1. No direct process leakage to atmosphere.
2. No need to maintain pressure system as in Plan 53A.
Use
1. Preferred for clean, non-polymerizing media with vapor pressure higher than buffer fluid pressure.
Caution
1. Keep pot vent continuously open, which is necessary to maintain buffer fluid pressure close to
atmospheric pressure & vent the vapors to flare.
2. Should not be used in dirty of polymerizing products.
3. Never run the system with level in the sealant vessel being at low level as marked on the level gauge.
4. Vent the system properly before start up.
Level switch
Vent (normally open)
Pressure gauge
Restriction orifice
Pressure
switch
Buffer out
Liquid filling
connection
(normally closed)
Level gauge
Drain
Cooling water in
Buffer in
API PLAN 52
Description
Depressurized buffer fluid circulation in outboard seal of a dual seal configuration through a seal support
system. Circulation is maintained by using pumping ring in running condition and by thermosyphon effect
in stand still condition.
Features
1. No process contamination.
2. No direct process leakage to atmosphere.
3. No need to maintain pressure system as in Plan 53A.
Use
1. For media where product dilution is not allowed but leakage to atmosphere in diluted form may be
allowed.
2. Preferred for clean, non-polymerizing media with vapor pressure higher than buffer fluid pressure
(Is also used for lower vapor pressure media).
Caution
1. Keep the sealant vessel vent continuously open, which is necessary to maintain buffer fluid pressure
close to atmospheric pressure & vent the vapors to flare.
2. Should not be used in dirty or polymerizing products.
3. A restriction orifice is necessary in vent line to maintain back pressure in pot and facilitate quick
release of vapors to flare.
4. Pressure switch setting should be done above minimum flare back pressure in order to avoid false alarms.
5. Never run the system with level in the sealant vessel being at low level as marked on the level gauge.
6. Check for temperature difference in inlet and outlet lines to ensure that circulation is on.
7. Vent the system properly before start up.
Level switch
External nitrogen pressure Pressure gauge
source (normally open) Pressure
switch
Barrier out
Liquid
filling
connection
(normally closed)
Level gauge
Drain
Cooling water in
Barrier in
API PLAN 53A
Description
Pressurized barrier fluid circulation in outboard seal of dual seal configuration through a seal support
system. Circulation is maintained by using pumping ring in running condition and with thermosyphon
effect in stand still condition.
Features
1. In no case media leakage to atmosphere (Provided the seal support system pressure is not lost).
2. Clean fluid film formation between the inboard seal faces gives better seal life.
3. Works as a Plan 52 arrangement if barrier fluid pressure is lost.
Use
1. Applications where no leakage to atmosphere can be tolerated e.g. hazardous, toxic,
inflammable media.
2. For dirty, abrasive or polymerizing products where media is unsuitable as a lubricant for
inboard seal faces.
Caution
1. There will always be some leakage of barrier fluid in to the product. Check compatibility of
barrier fluid with product.
2. Always ensure that the pressure source maintains higher pressure at the seal support system so
that process does not dilute the barrier fluid.
3. Vent the system properly before start up.
4. In certain cases the inert gas can dissolve in the barrier media.
5. Product quality can deteriorate due to barrier fluid contamination.
Nitrogen precharge
connection
(normally closed)
Cooling water out
Bladder
accumulator
Vent (normally closed)
Cooling water in
Barrier in
API PLAN 53B
Description
Pressurized barrier fluid circulation in outboard seal of dual seal configuration. Circulation is maintained by
using pumping ring in running condition and with thermosyphon effect in stand still condition. The pressure
is maintained in the seal circuit by a bladder accumulator.
Features
1. Keeps barrier fluid and pressurized gas (inert gas) separate by using a bladder.
2. Heat is removed from the circulation system by an air-cooled or water-cooled heat exchanger.
3. Being a stand-alone system does not rely upon a central pressure source. Hence much more reliable
than a Plan 53A.
4. In no case media leakage to atmosphere.
5. Clean fluid film formation between the inboard seal faces gives better seal life.
Use
1. Applications where no leakage to atmosphere can be tolerated e.g. hazardous, toxic, inflammable media.
2. For dirty, abrasive or polymerizing products where media is unsuitable as a lubricant for inboard
seal faces.
Caution
1. There will always be some leakage of barrier fluid in to the product. Check compatibility of barrier fluid
with product.
2. Low volume of barrier fluid in system, hence heat dissipation is totally dependent on cooler efficiency.
3. Always recharge bladder to 0.9 times the working pressure.
4. Vent the system properly before start up.
5. Product quality can deteriorate due to barrier fluid contamination.
6. Can not be used where seal chamber pressure varies. Use Plan 53C for such applications.
Vent normally closed
Reference Pressure
pressure line relief valve Piston type
accumulator
Pressure gauge
LSL
Barrier out
Level switch (low)
Pressure switch
Cooling water in
Barrier in
API PLAN 53C
Description
Pressurized barrier fluid circulation in outboard seal of dual seal configuration. Circulation is maintained by
using pumping ring in running condition and with thermosyphon effect in stand still condition. The pressure
is maintained and fluctuations are compensated in the seal circuit by a piston type accumulator.
Features
1. There will always be some leakage of barrier fluid in to the product. Check compatibility of barrier fluid
with product.
2. Vent system properly before start up.
3. Heat is removed from the circulation system by an air-cooled or water-cooled heat exchanger.
4. In no case media leakage to atmosphere.
5. Clean fluid film formation between the inboard seal faces gives better seal life.
Use
1. Applications where no leakage to atmosphere can be tolerated e.g. hazardous, toxic, inflammable media.
2. For dirty, abrasive or polymerizing products where media is unsuitable as a lubricant for inboard seal faces.
3. Where pump pressure varies during operation needing an auto setting of barrier fluid pressure, thus
maintaining the same differential throughout.
Caution
1. Always connect reference pressure line from seal chamber to accumulator and keep it open.
2. There will always be some leakage of barrier fluid in to the product. Check compatibility of barrier fluid
with product.
3. Vent the system properly before start up.
4. Product quality can deteriorate due to barrier fluid contamination.
To external
pressure source
Barrier out
From external
pressure source
Barrier in
API PLAN 54
Description:
Pressurized external barrier fluid circulation from a central pressure source or by a stand alone pumping unit
(e.g. AESSEAL® PUMPPAC™).
Features:
1. Ensures higher flow rate, better heat dissipation & positive circulation of barrier fluid.
2. If maintained properly, is the most reliable pressurized plan for dual seals as compared to Plan 53 A/B/C.
3. Can also be given as a stand alone unit per pump.
Uses:
1. Applications where no leakage to atmosphere can be tolerated e.g. hazardous, toxic, inflammable.
2. For dirty, abrasives or polymerizing products where media is unsuitable as a lubricant for inboard
seal faces.
3. For media with high pressure and / or high temperature and / or high heat generation between faces.
4. Wherever Plan 53 A/B/C circulation is insufficient to dissipate heat.
Caution:
1. Carefully consider the reliability of barrier fluid source, if a central source is used.
2. Expensive system, proper engineering required.
3. Circulating system must be pressurized at least 1.5 bar greater that the pressure in the seal chamber.
4. Product contamination does occur. Barrier fluid selected should be compatible with the process fluid.
5. Always check filter / strainer in the system for any possible blockages.
6. Loss of pressure in system can lead to entire barrier liquid contamination.
7. Product quality can deteriorate due to barrier fluid contamination.
61
API PLAN 61
Description
Plugged connections for future use for Plan 62 or Plan 65.
Features
1. The drain connection can be piped in order to collect leakage and use as Plan 65.
2. Both quench & drain can be piped and used as quench in and out connection as Plan 62.
Use
1. For future provision.
Caution
1. Always keep ports plugged.
62 Pressure indicator
Control valve
Y strainer
Quench
Drain
API PLAN 62
Description
An external fluid stream is brought to atmospheric side of the seal faces using quench and drain
connections.
Features
1. The quench fluid acts as barrier in between atmosphere and process fluid.
2. The quench fluid reduces oxidation and cocking of product & also cools seal faces.
3. Flushes away undesirable material build up under seal faces.
4. Can be used with water, steam or an inert gas.
Use
1. In caustic or crystallising fluids.
2. In oxidising fluids or hot hydrocarbons.
3. Can be used to purge steam in hot applications especially for stationary bellows to avoid coking.
Caution
1. Ensure availability of continuous supply of low-pressure quench fluid limited to maximum 1 bar.
2. Use of throttle bushing on atmosphere side is mandatory.
3. Use proper bearing isolators to ensure that the quench fluid does not enter the bearings.
Environmental
Benefit
•
Charity registration
number 288701
www.wateraid.org
Pressure
Control control Restriction
valve valve orifice
API PLAN 65
Description
Leakage from seal faces is collected via the drain port & directed to a liquid collection system via
a vessel equipped with a high-level alarm.
Features
1. The quench fluid acts as barrier in between atmosphere and process fluid.
2. The quench fluid reduces oxidation and cocking of product & also cools seal faces.
3. Flushes away undesirable material build up under seal faces.
4. Can be used with water, steam or an inert gas.
Use
1. In services where seal leakage is condensing.
2. Used for single seals.
Caution
1. Vent connection should always be plugged.
2. Orifice downstream of the level switch should be located in vertical piping leg to avoid
accumulation of fluid in drain piping.
3. Shut down the pump as soon as high-level alarm is activated & attend the seal.
71
API PLAN 71
Description
Plugged connections for future provision to supply a buffer gas to a dual containment seal.
Features
1. Vent port can be piped to use as ‘CSV’ in Plan 76.
2. Drain port can be piped to use as ‘CSD’ in Plan 75.
3. GBI port can be piped to use as in Plan 72.
Use
1. For future provisions for API Plans 72, 75 and 76.
Caution
1. Always keep the ports plugged.
Used for: 2CW-CS.
Containment seal vent (CSV)
Pressure switch high
Gas buffer in (GBI)
Flush
Pressure gauge To flare
Customer
PSH
Seal vendor
Restriction
orifice plate
Isolation valve
Test connection
(normally closed)
Level LSH
switch high Level gauge
Gas barrier
out (GBO)
Control valve
Features
1 Can be used with Plan 72 with buffer gas or with Plan 71 without buffer gas systems.
2. Collection can be redirected to process fluid by using separate pumping device.
3. Can be used in single containment seal also.
4. Test connection is provided to check the inner seal by closing the block isolation valve while pump is
in operation and noting the time / pressure build-up relationship in the collector.
Use
1. Duties with condensing leakages.
2. Hazardous, toxic fluids.
3. May also be used for non-condensing leakages. In such cases, the collector can help in collecting
condensate from the vapor recovery system.
Caution
1. Ensure that collection system is located below the seal drain with sloping pipelines.
2. Drain port should be at bottom of containment seal to allow the leakage to flow to the collection system.
3. Collection system should always be vented releasing vapors of process liquid to vapor recovery system.
4. Valves that are installed should be accessible to operator relative to ground clearance and other
obstructions.
5. A flow control orifice is required to create back pressure on collection system and to have effective
condensation of vapors.
6. Pressure switch should be set at a gauge pressure of 0.7 bar.
Isolation valve
Customer (normally open)
Pressure
Seal vendor switch high
Flush
Drain valve
API PLAN 76
Description
Vapor leakages from inboard seal of dual containment seal are directed to a vapor recovery system via a
vent connection.
Features
1. Can be used with Plan 72 with buffer gas or with Plan 71 without buffer gas system.
2. Vapor leakage collection ensures zero to very low process emissions from out board containment seal.
Use
1. For high vapor pressure fluids, light hydrocarbons.
2. In hazardous or toxic media.
Caution
1. Do not use for condensing media.
2. Ensure continuous vent to low pressure vapor recovery or flare system.
3. Tubing shall be 13mm (1/2”) minimum diameter and shall rise continuously from the CSV connection
to the piping / instrumentation harness.
4. A flow control orifice is required to generate back pressure.
5. Ensure proper support to harness piping.
6. Ensure a low point drain in the piping loop.
Reliability
Source: Stephen Flood, Performance Plus Ltd - “Mechanical Seal Reliability - What Realistically Can Be Achieved?”
Enhancement
•
Seal System - 22%
Operations - 37%
Bearing - 13%
presented at The Mechanical Sealing Technology Seminar, I Mech E, London, April 07
Workshop - 07%
Install / Align - 05%
Process - 12%
Seal - 04%
72 Flow meter
FSH
valve
Features
1. Used in conjunction with API Plan 75 and / or 76.
2. Nitrogen provides cooling to seal faces.
3. Nitrogen blanket reduces the explosion hazard in high vapor pressure liquids.
4. This plan is used in conjunction with Plan 75 and 76.
Use
1. For flashing hydrocarbons.
Caution
1. Always ensure that buffer gas pressure is less than seal chamber pressure.
2. Set the forward pressure regulator at minimum 0.4 bar above flare back pressure.
Pressure switch
Pressure gauge Flow switch high
74 Flow meter
FSH
10 Pressure
Control control valve
Gas barrier in (GBI) Valve 5
Isolation valve
Filter
Restriction
orifice
Valve
Gas barrier out (GBO)
API PLAN 74
Description
Externally pressurized barrier gas through gas control system to a dual seal arrangement. An inert gas is
used as a barrier gas.
Features
1. Media leakage to atmosphere is eliminated.
2. Obtain very high reliability, as solids or other materials, which can lead to premature seal failure cannot
enter the seal faces.
Use
This plan is intended to be used for dual pressurized non-contacting gas seals.
1. Used in services which are not hot (within elastomer temperature limit) but which may contain toxic or
hazardous material whose leakage to atmosphere can not be tolerated.
2. In case of solids or other material present in sealing media.
3. Where process contamination is allowed but process liquid leakage to atmosphere is not allowed.
Caution
1. Always ensure barrier gas pressure is higher than seal chamber pressure.
2. Causes media contamination due to high-pressure nitrogen entering the pump.
3. Back pressure regulator should be set at least 1.7 bar greater than the seal chamber pressure.
4. Carefully consider the reliability of barrier pressure source, if central pressure issued.
5. Always check filter for any possible blockage.
6. Do not use for sticking or polymerizing media.
API PLANS & SYSTEMS PRODUCT GRID
CYCL™ Seal FLOWTRUE® SWM™ SW Range SWFF-TF™ SWC™ PP/W1™ SP
Cooler & SWP™ Range
Plan 21 •••••
Plan 22 •••••
Plan 23 •••••
Plan 31 •••••
Plan 32 •••••
Plan 41 •••••
Plan 52 •••••
Plan 53A ••••• ••••• ••••• ••••• •••••
Plan 53B
Plan 54 ••••• •••••
Plan 62 •••••
Plan 65
Plan 72
Plan 74
AES-15™ AES-FV™ AES-28™ PP/SOU™ PP/O1™ Plan 53B Plan 65 Plan 75 Gas
Panel
Plan 21
Plan 22
Plan 23
Plan 31
Plan 32
Plan 41
Plan 52 ••••• ••••• •••••
Plan 53A ••••• ••••• •••••
Plan 53B •••••
Plan 54 ••••• •••••
Plan 62
Plan 65 •••••
Plan 72 •••••
Plan 74 •••••
Plan 75 •••••
WATER MANAGEMENT SYSTEMS
CYCL™ SEAL COOLER
31 41 21 22 23
WATER MANAGEMENT SYSTEMS
FLOWTRUE® SWM™ & SWP™
32 62
WATER MANAGEMENT SYSTEMS
SWFF-TF™
SW2™
WATER MANAGEMENT SYSTEMS
SWC™ PUMPPAC™ W1
CONDENSATE SYSTEM
O IL SYSTEMS
AES-15™
SP2™
O IL SYSTEMS
AES-FV™ AES-28™
O IL SYSTEMS
PUMPPAC-SOU™ PUMPPAC™ O1
H IGH END SYSTEMS
COMPACT 107 API PLAN 65 - LEAKAGE
DETECTION VESSEL (LDV)
A PI PLAN SPECIFIC SYSTEMS
BESPOKE PLAN 53B SYSTEM
PUMPPAC™ SYSTEM
G AS SYSTEMS
GAS16-P1™
74
72
A PI PLAN SPECIFIC SYSTEMS
PLAN 75 SYSTEM
Our Purpose:
‘To give our customers such exceptional service that they need never consider alternative sources of supply.’
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AESSEAL® Global Locations
AESSEAL plc, Rotherham, UK Tel: +44 (0) 1709 369966 rotherham@aesseal.com
AESSEAL (MCK) Ltd, Lisburn, UK Tel: +44 (0) 2892 669966 salesmck@aesseal.co.uk
AESSEAL Ireland Ltd, Co Cork, Eire Tel: +353 (0) 214 633477 sales.ireland@aesseal.com
AESSEAL Inc, Rockford, TN, USA Tel: +1 865 5 310192 knxadmin@aesseal.com
AESSEAL ALAA, Dammam, Saudi Arabia Tel: +966 3 847 0033 sales.aesseal@afi.com.sa
AESSEAL Argentina SA, Buenos Aires, Argentina Tel: +54 11 4744 0022 aesseal@aesseal.com.ar
AESSEAL Australia Pty Ltd, Seventeen Mile Rocks, Australia Tel: +61 7 32791 144 customer.service@aesseal.net.au
AESSEAL Benelux BV, Breda, Holland Tel: +31 (0) 76 564 9292 seal@aesseal.nl
AESSEAL Brasil Ltda, São Paulo, Brazil Tel: +55 11 5891 5878 aessealbrasil@aesseal.com.br
AESSEAL Canada Inc, Vancouver, Canada Tel: +1 604 535 7512 vanadmin@aesseal.com
AESSEAL Chile SA, Providencia Santiago, Chile Tel: +56 2 2343022 aesseal@aesseal.cl
AESSEAL China Ltd, Ningbo, China Tel: +86 (0) 574 8823 2888 service@aesseal.com.cn
AESSEAL Colombia SA, Bogota, Colombia Tel: +57 (1) 634 9095 info@aesseal.com.co
AESSEAL Danmark, A/S, Køge, Denmark Tel: +45 56 64 14 00 mail@aesseal.dk
AESSEAL Deutschland AG, Bad Orb, Germany Tel: +49 (0) 6052 918810 info@aesseal.de
AESSEAL Deutschland GmbH, Kronau, Germany Tel: +49 (0) 7253 8090 gmbh@aesseal.de
AESSEAL France SARL, Nieppe, France Tel: +33 320 172850 aes.info@aesseal.fr
AESSEAL India PVT, Ltd, Pune, India Tel: +91 2113 302222 aesseal@aesseal.in
AESSEAL Italia SRL, Gallarate, Italy Tel: +39 0331 799 952 info@aesseal.it
AESSEAL Malaysia, SDN BHD, Selangor, Malaysia Tel: +603 806 21233 selangor@aesseal.com.my
AESSEAL Mexico, S de RL de CV, Mexico City, Mexico Tel: +52 833 266 9551 info-support@aessealmx.com
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AESSEAL Russia, Koroliov City, Moscow, Russia Tel: +7 495 777 4011 info@aesseal.ru
AESSEAL Pty Ltd, Durban, South Africa Tel: +27 (0) 31 903 5438 durban@aesseal.co.za
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AESSEAL® is a Registered Trademark of AESSEAL plc Copyright © 2009 AESSEAL plc Ref: L-UK/US-PIPINGPLAN-05 AES/DOC/IN 5080 06/09
Troubleshooting of Mechanical Seals -1-
1.1 General 3) Static secondary seal leakage is also visible at
A mechanical seal is expected to achieve its maximum the point where the shaft exits the gland or at the
performance and life when it is operated within its drain connections.
design specifications. A seal is considered to have 4) Gland gasket leakage is visible at the gland seal
failed when leakage exceeds environmental or plant chamber interface.
site operating limits. The failure may occur before or
1.4 Seal Failure Analysis
after the seal has achieved its designed life expectancy.
A failure of a seal may be a major contributor to rotary Much can be learned by a complete documented
equipment failure and downtime. analysis including the following:
An understanding of the mode of seal failure can lead to z Inspect the rotary equipment before shutdown and
extending the life of rotary equipment by improving seal record:
design and material selection, installation and operating - equipment inlet and outlet pressures
procedures, and environmental controls. - pump flow vs curve best efficiency point (BEP)
- equipment history
1.2 Causes of Mechanical Seal Failure
- product and seal chamber temperatures
The failure of a seal may be the result of: - leakage points, see 1.3
z Incorrect selection of seal design or materials for the - leakage rates
application temperature, pressure, speeds, and fluid - type of leakage (product or flush)
properties. - flush flow, pressure, and temperature
z Abuse of the seal components before installation - noise type and intensity
including chipping, scratching, nicking, or allowing - vibration levels
parts to become dirty. z Inspect the rotary equipment during disassemble
z Erroneous installation including assembly, seal and record:
setting, or placing of components in the chamber. - equipment type, model, and serial number
z Improper startup, dry running, or failure of - evidence of pitting (cavitation) in pump bowl
environmental controls. - condition of bearings
z Improper pump operation. - alignment measurements
z Contamination of the sealing fluid with abrasive or - condition of seal chamber, deposits, wear
corrosive materials. - condition of shaft (sleeve), fretting corrosion
z Equipment with excessive shaft run out, deflection, z Inspect the mechanical seal during disassembly of
vibration, or worn bearings. the rotary equipment and record:
z Worn-out seal. The seal achieved its normal life - seal manufacturer, type, and identification
expectancy. - seal history
1.3 Possible Seal Leakage Points - condition of the seal, discoloring, corrosion
- buildup of sediments, product, coke, etc.
A single stage mechanical seal may leak along one of z Decontaminate any seal that is to be returned to the
four paths. See Figure 1. manufacturer for analysis or reconditioning and
include the above information.
z Inspect the seal components during disassembly of
the seal and record observations detailed in the
following portions of this section.
1.4.1 Seal face wear patterns may often explain the
causes of seal failure. Most seal face assemblies have
one narrow face and one wide face. The narrow face
creates a circular mark called a wear pattern on the
Figure 1. Possible Seal Leakage Points wide face.
1) Seal face leakage is visible at the point where the z Normal wear patterns, Figure 2, are concentric with
shaft exits the gland or at the drain connections. the outer and inner diameters and are the same
2) Dynamic secondary seal leakage is also visible at width as the narrow face. Contact is light, even, and
the point where the shaft exits the gland or at the consistent.
drain connections.
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Troubleshooting of Mechanical Seals -2-
face is only touching the wide face off and on.
Ensure that the seal faces are flat, check the
flatness of the chamber face, tighten gland bolts
evenly, and make sure that the stationary is not
cocked. Consider a seal design with a flexibly
mounted stationary.
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Troubleshooting of Mechanical Seals -4-
chamber dimensions, seal design, installation,
set screw settings, temperature limits, product
buildup, and vibration levels. Change seal
metallurgy.
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Troubleshooting of Mechanical Seals -5-
evident on the parts, the body of drive casing (Figure
25), or shaft (sleeve). Check equipment alignment,
runout of shaft, vibration, and torque limitations of
seal design.
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