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Excessive power consumption, More plant downtime, Atmospheric pollution, Effect on plant life, Loss of pumpage High maintenance cost.
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Lubricate shaft/sleeve and wedge/ o ring to assist installation. Note special care for EPR o ring should be taken by using glycerin / soap water / edible oil only. 2) Use sound judgement during installation. Never force parts during fitment. 3) Bleed all lines and seal chamber to prevent any air lock. 4) Connect all cooling and buffer fluid as per G.A. drawing. 5) Open all cooling and buffer fluid valves of the seal prior to start up of the equipment. 6) Mechanical seal should be pressurized prior to the equipment. 7) Maintain buffer fluid pressure 2kg/cm2 more than the reactor pressure. 8) Height of the thermosyphon should be 1.5 to 2 meters from the seal inlet to outlet of the thermosyphon pot. 9) Fill the buffer fluid (I.e. process compatible fluid or oil) in the thermosyphon system above the level of the inlet port of the buffer fluid )level can be seen through gauge glass). 10) Ensure the flow of cooling water 5-6 LPM in the cooling coils of thermosyphon system. Contd..
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Monitor the pressure and level of buffer fluid in the thermosyphon system. In case of leakage, buffer fluid pressure and level will go down. Check for seal failure :a) Inboard seal leakage Buffer fluid will go in the vessel b) Outboard seal leakage Buffer fluid will leak from the leak detection port. Lubricate the seal bearing periodically (greasing can be done on monthly basis). Periodical checking of bolts on the drive collar and pad plate nuts of the seal.
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END PLAY : 0.1 mm MAX RADIAL MOVEMENT/ SHAFT WHIP : 0.08 mm MAX SHAFT RUNOUT : 0.08 mm MAX STUFFING BOX SQUARENESS OR : 0.08 mm MAX FOR 3000. rpm PERPENDICULARITY : 0.005 mm FOR 100,000 rpm CONCENTRICITY OF STUFFING : 0.13 mm MAX BOX BORE FOLLOWING PROBLEM MAY ARISE IF ABOVE ARE NOT IN LIMIT:1) SHAFT / SLEEVE FRETTING (MORE WITH TEFLON) 2) OVER COMPRESSION / UNDER COMPRESSION OF SEAL 3) CHATTERING / CHIPPING OF CARBON 4) PUMP VIBRATION 5) EXCESSIVE WEAR, DAMAGE TO SLIDING ELASTOMER 6) EXCESSIVE WEAR OF MATING FACES 7) WOBBING OF SEAL FACES 8) ERRACTIC FACE WEAR 9) THROTTLE BUSH, THROAT BUSH & IMPLLER WEARING OR INTER STAGE BUSH SEIZING.
TEN POINTS FOR SUCCESEFUL SEAL INSTALLATION. 1. THOROUGH READING AND FULL UNDERSTANDING OF SEAL INSTALLATION DRAWINGS IS THE KEY TO PROPER SEAL INSTALLATION. WORDS ARE AS IMPORTANT AS DIMENSIONS AND DIMENSIONS ARE AS IMPORTANT AS WORDS.
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KNOW THE MATERIALS YOU ARE WORKING WITH. CRITICAL SEAL COMPONENTS ARE OFTEN MADE FROM NON-DUCTILE SUBSTANCES THAT WILL CHIP, CRACK OR OTHERWISE BREAK, IF CARELESSLY HANDLED.
RESPECT THE PRIMARY SECONDARY SEALING AREAS. A LOT OF TIME HAS BEEN SPENT IN MAKING THE PRIMARY SEALING AREA FLAT AND SMOOTH. DONT SCRATCH OR, NICK, HANDLE AND GET THOSE AREAS DIRTY. SOMETIMES EVEN FINGERPRINT CAN CAUSE A SEAL TO LEAK. REMEMBER, THAT RUBBER, PTFE AND GASKETS CAN EASLY BECOME CUT TORN WITHOUT TOO MUCH ATTENTION TO THEIR WELL BEING. MAKE SURE THAT THE SHAFT SLEEVE IS FREE OF BURRS AND SHARP EDGES. IT MUST BE FINISHED TO THE APPROPRIATE SMOOTHNESS. IN CERTAIN CASES, SPECIFICATIONS WILL BE CALLED OUT ON THE INSTALLATION DRAWING. Contd..
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ENVIRONMENTAL CONTROLS
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ESTABLISH YOUR SEAL INSTALLATION REFERENCE POINTS AND MARK THEM CLEARLY AND PERMANENTLY IN THE EQUIPMENT. ALL SEAL INSTALLATION DRAWINGS GIVE THE REFERENCE DIMENSIONS. 6. USE SOUND JUDGEMENT DURING THE INSTALLATION. DONT OVER TIGHTEN BOLTS, ALIGN OR INSTALL WITH A HAMMER OR, IN ANY OTHER WAY, APPLY ANYTHING, EXCEPT PROFESSIONAL WORKMANSHIP TO THE JOB. 7. PIPING IS IMPORTANT TOO. INCORRECT CONNECTIONS, REVERSED FLOWS, DEAD ENDED LINES, ETC. WILL CAUSE PREMATURE SEAL FAILURE. DONT MIX UP THE WATER JACKET PORTS WTH THE SEAL CIRCULATION PORTS. TIME SPENT IN CAREFUL PIPING WILL BE TIME SAVED. 8. BLEED ALL THE GASEOUS ENTRAPMENT FROM THE SEAL CAVITY BEFORE START UP. IF YOU DONT, THE SEAL CAVITY MAY VAPOUR LOCK AND THE SEAL WILL BURN UP. 9. MAKE SURE VALVES ARE OPEN SO THAT THE SEAL IS ENSURED OF A POSITIVE FLOW OF LIQUID AT ALL TIMES. IN THOSE CASES WHERE THE SEALS REQUIRE AUXILIARY LINES, FLOWS HEATING OR COOLING BE SURE THAT THE SEAL IS PREPARED FOR OPERATION BEFORE THE PRIMARY EQUIPMENT GOES ON STREAM. 10. TURN THE EUIPMENT ON, AND ENJOY MAINTENANCE-FREE EQUIPMENT OPERATION.
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MULTISPRING SEAL
1) SMALL SPRINGS ARE SPREAD OVER CIRCUMFERENCE EQUALLY THIS GIVES UNIFORM PRESSURE TO FACES. THE SEAL IS NOT SUITABLE FOR DIRTY LIQUIDS AS SPRINGS GET CLOGGED UP RESULTING INTO SEAL HANGUP. COMPACT, HENCE LOWER STUFFING BOX DEPTH IS ACCEPTABLE FOR DIFFERENT SIZES OF SEALS SAME SPRING CAN BE USED ONLY QTY. WILL VARY. WIRE DIA IS VERY SMALL. HENCE NO CORROSION ALLOWANCE IS AVAILABLE. WE HAVE TO GO FOR HIGHER ALLOYS LIKE HAST-C, ALLOY-20 ETC. COST OF MANUFACTURING IS HIGH BECAUSE OF MANY OPERATIONS, INVOLVED.
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TANDEM SEALS
(FACE TO BACK)
TANDEM SEALS
1) 2) 3) 4) 5) SECOND SEAL AS A SAFETY SEAL. IF QUENCH MEDIA IS EXPENSIVE, THEN TO SEAL THAT MEDIA. WHEN IT IS NOT ACCEPTABLE THAT BARRIER FLUID SHOULD MIX WITH THE PUMP MEDIA. TO SEAL MEDIA AT VERY HIGH PRESSURE BY SPLIT PRESSURE METHOD. FOR MEDIA WHICH HAVE LOW VAPOUR PRESSURE. PLEASE REMEMBER 1) BARRIER FLUID CIRCULATION NEED NOT BE AT HIGH PRESSURE EXCEPT FOR HIGH PRESSURE SPLIT PRESSURE APPLICATION. AS PER API, NOW IT IS MANDATORY TO HAVE POSITIVE CIRCULATION OF BARRIER FLUID EITHER BY PROVIDING PUMPING RING SYSTEM OR BY A SEPARATE PUMP. API PLAN 52 / 53 IS RECOMMENDED.
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SEAL FLUSHING
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TO PROVIDE LUBRICATION. TO DISCIPATE HEAT EFFECTIVELY. TO KEEP LIQUID IN TURBULANCE. TO MAINTAIN STUFFING BOX PRESSURE ABOVE VAPOUR PRESSURE. TO KEEP SLURRY AWAY FROM SEAL (PLAN 32)
SEAL QUENCHING
1) 2) 3) 4) 5) TO KEEP ATMOSPHERE AWAY FROM SEAL FACES TO PROVIDE ADDITIONAL HEAT DISCIPTION. TO CARRY AWAY LEAKED LIQUID TO SAFER PLACE TO KEEP THE AREA BELOW SEAL FACES CLEAN. TO HELP INCREASED LUBRICATION TO SEAL FACES.
ADDITIONAL ADVANTAGES
FLUSHING A) IT PREVENTS FORMATION OF A VAPOUR TRAP AROUND SEAL FACES IN CASE OF VOLATILE LIQUIDS. B) IT DOES NOT ALLOW ABRASIVES TO REACH FACES. C) IT PREVENTS ACCUMULATION OF SEDIMENTS ON SEAL AREA. QUENCHING A) IT CARRIES AWAY LEAKED PRODUCT. B) IT PREVENTS LEAKED PRODUCT COMING IN CONTACT WITH ATMOSPHERE C) IT COOLS THE SEAL FACES FROM INSIDE. D) IT POVIDE LUBRICATION TO FACES WHEN ST. BOX IS UNDER VACUUM.
Recirculation from pumping ring in the seal chamber through a heat exchanger and back in to the seal chamber. This plan can be used on hot application to minimize the heat exchanger by cooling only the small amount of liquid that is recirculated. Connection Fl for flushing inlet.
Recirculation form Pumping ring in the seal chamber through a heat exchanger and back in to the seal chamber. This plan can be used on hot application to minimize the heat load on the heat exchanger by cooling only the small amount of liquid that is recirculated. Connection Fl for flushing inlet and FO for flushing outlet.
Flush is injected in to the seal chamber from on external source. Care must be exersized in choosing in choosing a proper source of seal flush and to avoid contamination of the fluid being pumped with the injected flush. Connection Fl for flushing inlet.
Recirculation from pump discharge through a cyclon seperator delivering the clean fluid to a heat exchanger cooler and then to the seal chamber. The solids are delivered to the pump suction. Connection Fl for flushing inlet.
External reservoir providing buffer fluid for the board seal. During normal operation, circulation is maintained by an internal pumping ring. The reservoir pressure is less than seal chamber. Connection Fl for flushing inlet, Bl for banner inlet and BO for barrier outlet.
Pressurized external barrier fluid reservoir supplying clean fluid to the seal chamber. Circulation is by internal pumping ring. Reservoir pressure is greater than the process fluid being sealed. Connection Bl for barrier inlet and connection BO for barrier outlet.
Pressurized external barrier fluid reservoir or system supplying to the seal chamber. Circulation is by an external pump or pressure system. Reservoir pressure is greater than the process pressure being sealed. Connection Bl for barrier inlet and connection BO for barrier outlet.
Seal Flush Plan 71 Tapped connections for purchases use. Typically this plan is used, when the purchaser may use buffer gas in the future
Externally supplied gas buffer for arrangement 2 seals. Buffer gas may be used alone to dilute seal leakage or in conjunction with plan 75 or 76 to help sweep leakage in to close connection system. Pressure of buffer gas is lower then process side pressure of inner seal.
Externally supplied barrier gas used to positively prevent fluid from leaking to atmosphere. Pressure of barrier gas is higher than process side of inner seal. Venting of seal chamber may be required prior to start up and operation to avoid the collection of gas in the pump.
Piping / instrument harness shall be supported from overhead structure or side such that no strain is put on tubing connected to seal gland. Containment seal chamber drain from noncondensing leakage on arrangement 2 seal. pump fluid dose noncondensing at ambient temperatures.
59 %
24 %
9%
8%
SEAL FAILS DUE TO : Coupling Misalignment Pump Cavitation Air Entrainment Over Pumping Excessive Heat Bearing Failure Pipe Strain Impeller Shaft / Sleeve Stuffing Box