Flow Solutions Division

BW Seals
Durametallic Seals
 Pacific Wietz Seals
Pac-Seal

Plan 53B

Operation and Maintenance Manual

Flowserve B.V.
Borchwerf 20
4704 RG Roosendaal Revision 4, September 2004
The Netherlands
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Flow Solutions Division Operation and Maintenance Manual Plan 53B

Table of contents Page

1.0 INTRODUCTION 3

2.0 BRIEF DESCRIPTION 3

3.0 FUNCTION 4

4.0 SAFETY 4

5.0 TRANSPORT, STORAGE 5

6.0 INSTALLATION 5
6.1 Interconnecting Piping 5
6.2 Electrical Connections 7

7.0 SET-UP 7

8.0 START-UP AND OPERATION 8

8.1 Refilling 8

9.0 SYSTEM CHECK, PROBLEM SOLVING 8

10.0 MAINTENANCE 9

11.0 SHUT-DOWN, DISASSEMBLY 9

12.0 SPARE PARTS, REPAIR 10

ATTACHMENTS

1. System Assembly Drawing 11

2. Instrumentation 12

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

1.0 INTRODUCTION
All illustrations and details in these installation and operating instructions are subject to changes
that are necessary to improve product performance without prior notice.

The copyright of these instructions is the property of Flowserve. These instructions are intended for
Maintenance, Operating and Supervisory personnel and contain regulations and drawings of a
technical character that may not, in full or in part, be copied, distributed, used without authorisation
for competitive purposes, or given to others.

It should be understood that Flowserve does not accept any liability for instances of damage and/or
malfunctioning incurred through non-adherence to these installation instructions.

2.0 BRIEF DESCRIPTION

The system assembly drawing is included in this manual and can be found in attachment 1.

The system is delivered as a complete assembled unit. Depending on customer requirements the
system design and additional components may vary. For the exact execution of the system,
reference is made to the a.m. system assembly drawing. On the assembly drawing the design and
operating conditions of the system can be found (pressure, temperature and volume) as well as the
instrument settings.

The system assembly consists of the following components:

Accumulator
It contains the barrier fluid to lubricate and cool a pressurized dual mechanical seal.

Cooler
The cooler is part of the closed loop. The cooler is sized depending on the operating conditions.
The cooler can be finned tubing, a water cooler or a forced draft air cooler.

Hand pump (if applicable)

The hand pump is used to refill the system during operation.

Instrumentation
Various instruments can be fitted to the reservoir depending on the execution. Instrumentation is
used for measurements and detection of:
 Pressure: pressure indicator (PI), pressure switch (PS), pressure transmitter (PT);
 Flow: flow indicator (FI), flow switch (FS);
 Temperature: temperature indicator (TI).
The operating and installation instructions for adjustable instruments can be found in attachment 2.

Valves
Valves are used for draining and filling the system, isolation of the system from the mechanical seal
and for isolation of the instrumentation. A relief valve is used to protect the system against over-
pressurization. The assembly drawing indicates the position of the valves that are supplied with the
reservoir. The valves might also be part of the plant piping.

Circulation pump
Normally the seal will be equipped with an internal circulation device. If that is not possible an
external circulation pump will be part of the system.

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

3.0 FUNCTION
The function of a plan 53B system is:
 To provide a barrier fluid for lubrication and cooling of a pressurized dual seal arrangement.
 Pressurization of the barrier fluid with an accumulator.
 Cooling of the barrier fluid with a closed loop that includes a cooler.
 Monitoring of the mechanical seal performance by means of pressure, temperature and/or flow
indication.

Dual pressurized (or double) seals rely for their operation on the supply of a clean and suitable
non-hazardous, non-toxic barrier fluid to the cavity between the inner and outer seal, at a pressure
minimum 2 BarG higher than that of the sealed product. This ensures that both the inner and outer
seal faces are running on a film of clean fluid at a higher pressure than the seal chamber pressure,
which prevents leakage of the inflammable or toxic sealed fluid to atmosphere.

The inner seal and outer seal require a source of barrier fluid for cooling and lubrication. The
barrier fluid is therefore contained in an accumulator. The closed loop is piped to the cavity
between the seals, through the flow inlet and flow outlet connections on the seal flange(s). The
accumulator is pressurized with nitrogen.

The mechanical seal is executed with an integral pumping device or an external circulation pump,
which will circulate the barrier fluid, to enable cooling of the seal faces.

Under normal conditions the pressure will be maintained by the stored volume in the accumulator.
The pressure decreases in the closed loop, due to normal leakage of the mechanical seals. When
the pressure has dropped to the minimum barrier pressure as stated on the assembly drawing the
system needs to be refilled. The system must be refilled until the maximum barrier pressure as
stated on the assembly drawing is reached. Refilling can be done while the pump is in operation.

The system pressure should be checked on a regular base. The pressure can be checked by the
installed pressure indicator and pressure switch (if applicable).

Flowserve recommends installation of a low-pressure switch to detect refilling of the accumulator

with barrier fluid.

4.0 SAFETY
Please read these instructions carefully. Installation in accordance with the following instructions
will contribute to long and trouble free operation of the plan 53B.

For related mechanical seals, separate instructions are provided.

The ultimate user must ensure that personnel assigned to handle, install and operate the system
and related equipment is well acquainted with the design and operating requirements of such
equipment.

Damage to any of the systems components may result in unsatisfactory performance which can
eventually result in (excessive) seal leakage. The degree of hazard depends on the sealed product
and may have an effect on people and/or the environment.

Plant regulations concerning work safety, accident prevention and pollution must be strictly
adhered to:
 Wear designated personal safety equipment
 Isolate equipment and relieve any pressure in the system
 Lock out equipment driver and valves

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

 Consult plant Material Safety Data Sheet (MSDS) files for hazardous material regulations
 Installation in hazardous areas is dependant on the explosion protection of the instrumentation.
The ultimate user must judge in case of conflicting standards.

5.0 TRANSPORT, STORAGE

The plan 53B and related equipment must be transported and stored in the unopened, original
shipping box. The warehouse in which the system and related equipment are stored must be dry
and free of dust. Avoid exposing equipment to large temperature fluctuations, high humidity and
radiation.

Systems that have been dropped or have otherwise been subjected to heavy impacts during
transport must not be installed. An inspection by Flowserve or its appointed representative is
strongly advised

After a storage period of 3 years the system must be inspected for its “as new” properties. This
applies in particular to the instrumentation. An inspection by Flowserve is mandatory.

If the equipment is to be preserved with the system installed, the preserving medium must not
impair the function of the system by e.g. fouling and/or attack the secondary seals.

6.0 INSTALLATION (see figure 1)

Mount the stand firmly to the ground or equipment baseplate. Locate seal system as close to the
seal as possible, while leaving sufficient room for operation and maintenance.

System with water cooler:

To promote thermosyphoning in standby condition the cooler must be mounted above the seal.
For horizontal pumps the bottom of the cooler must be mounted 45 to 60 cm (18” to 24”) above the
shaft centerline, for vertical pumps 45 to 60 cm above the seal gland inlet or outlet connection,
whichever is the highest (unless otherwise specified)..

System with finned pipe cooler:

Unless otherwise specified the seal gland inlet or outlet connection, whichever is the highest,
should not be above the center of the finned tube section to promote thermosyphoning in standby
condition.

6.1 Interconnecting piping

In a plan 53B system, a pumping device, which is included in the seal design or an external
circulating pump generates the flow. The resistance in the system will determine the flow through
the system; therefore special attention must be paid to the execution of the interconnecting piping
between the system and the mechanical seal. Piping instructions are detailed on the system
assembly drawing.

Minimize restrictions (e.g. use full port valves, limit the number of fittings). Unless otherwise
specified, the minimum pipe size to be used is ¾”, schedule 80S maximum. Piping must be clean
and free of burrs.

Total pipe length and number of bends should be kept to a minimum. Use smooth, large radius
bends; do not use elbows, tees, etc. Pipe runs should be sloped continuously up or down to allow
adequate circulation, proper venting and draining. Make sure that the loop, including seal flange,
does not include vapor traps.

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

Figure 1: Interconnecting Piping

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

Where applicable the following connections should be made. Note that the name of the
connections on the seal /system assembly drawing may differ from those used in these
instructions. In case of doubt contact you Flowserve representative.

Barrier fluid supply line to mechanical seal

The to seal connection should be connected to tap BI (barrier fluid inlet) on the mechanical seal
flange.

Barrier fluid return line from mechanical seal

The from seal connection should be connected to tap BO (barrier fluid outlet) on the mechanical
seal flange.

Drain
Depending on the execution of the plan 53B, the drain connection should be connected to a drain
or a disposal point.

Cooling water connections coil Inlet and coil outlet

The cooling water inlet line should be connected to the cooling water in connection and the
cooling water outlet line should be connected to cooling water out connection.

6.2 Electrical connections (if applicable)

Electrical connections for instrumentation should be wired in accordance with the applicable
instrument and plant requirements. Power supply for the electric motor of a forced draft cooler or
circulation pump should be wired in accordance with the applicable electric motor and plant
requirements.

7.0 SET-UP
A plan 53B system is not self-venting like a reservoir type system. Air entrapped in the barrier liquid
will have a negative effect on the seal performance. During the set-up of the system venting is of
extreme importance.

 Check whether the block bleed valve to the instrumentation is open (if applicable).
 Check the pre-charge pressure of the accumulator. Charge with nitrogen pressure as stated on
the assembly drawing (typically 90% of the minimum barrier pressure).
 Check whether the block valve in the drain line is closed.
 Open the fill line and fill the system with clean barrier fluid until the maximum barrier pressure as
noted on the assembly drawing. Barrier fluid may be specified on the system assembly drawing.
Flowserve can supply information on barrier fluid, temperature and flow requirements based on
product type, seal size and product temperature. Ensure that the barrier fluid is clean and
compatible with the product.
 Close the block valve in the fill line (if applicable).
 Check for leakages at fittings and pipe work, rectify when necessary.
 Vent instrument lines with the bleed valves of the instrument valves.
 Vent the closed loop(s) by carefully opening the vent valve(s). The pressure in the system will
drop. Close the vent valve as soon as the pressure is reduced to the minimum barrier pressure
level as noted on the assembly drawing.
 As the pressure reduces during the venting procedure the pressure switch setting should be
checked (if applicable).
 Now refill the system again until maximum barrier pressure level.
 Repeat venting until all air has been removed from the system (normally 3 to 4 times).

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

8.0 START-UP AND OPERATION

 If a water cooler is installed, apply cooling water (typically 300 – 600 l/hr, or as per the cooler
manual).
 If a forced draft air cooler is installed, make sure the fan is running.
 Start the external circulation pump (if applicable).
 Dual pressurized (double) seals require the barrier fluid pressure to be maintained at least 2
bar or 30 psi) above the seal chamber pressure, unless otherwise specified. It is imperative to
pressurize the barrier liquid prior to pressurizing the equipment. Likewise, do not de-pressurize
the barrier system until the equipment has been fully isolated, de-pressurized and vented.
 Pressurize the equipment in which the seals are installed following the instructions supplied by
the equipment manufacturer.
 Check the seals, interconnecting piping and system for leakage, rectify when necessary.
 Start-up equipment in accordance with the equipment’s operating procedures unless
specifically requested otherwise by Flowserve. If the equipment is not operating properly (e.g.
seals and/or bearings running hot, cavitation, heavy vibration, etc.), shut down the equipment,
investigate and remove the cause.
 Shortly after the pump has been started the closed loop(s) should again be vented to remove
any residual air. Carefully vent the system whilst preventing that the barrier pressure drops
below the minimum barrier pressure. Refill until maximum barrier pressure.

8.1 Refilling
The system can be refilled during operation of the equipment and mechanical seal. A refill unit can
be a separate system that needs to be connected to the system or it can be a hand pump that is
supplied with the system.
 Open the shutoff valve in the connecting line between refill unit and system.
 Operate the hand lever, or operate the motorized refill unit, at the same time checking the
barrier fluid pressure by means of the pressure indicator.
 Refill the system until maximum barrier pressure has been reached.
 Upon completing the refill procedure, close the shutoff valve in the line between the refill unit
and the system.
 Disconnect the refill unit (if applicable)

9.0 SYSTEM CHECK, PROBLEM SOLVING

Checking of the system, limits itself to monitoring pressure, temperature, leakage and consumption
of barrier fluid.

 Check the barrier fluid pressure regularly (typically once a week). The barrier pressure must be
between minimum and maximum barrier pressure as noted on the assembly drawing.
 Check the seals, system and interconnecting piping for leaks, rectify when necessary.
 Check the barrier liquid on impurities by collecting a sample (typically once a month). If dirty,
drain the system to the minimum pressure level and refill with clean barrier liquid.
 Typically once per year the accumulator pre-charge pressure should be checked:
 Stop and de-pressurize the equipment in which the seal is installed.
 De-pressurize the plan 53B system by opening the drain valve.
 Install nitrogen charge unit on accumulator and check pressure.
 Follow set-up procedure and operational recommendations before re-starting the pump.
 Follow instructions as per paragraphs 7.0 and 8.0 prior to re-starting of the equipment.

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

Problem solving

PARAMETER INDICATION (1) POSSIBLE CAUSE SOLUTION

Pressure Fast increasing  Too high nitrogen pre-  Check accumulator pre-
during refilling charge pressure charge pressure
Fast increasing  Too high nitrogen pre-  Check accumulator pre-
after pump start-up charge pressure charge pressure
Reducing fast (2)  Too high seal leakage  Check seal condition (3)
 Leakage in the system  Check connections for
leakage
Temperature High  In-sufficient circulation  Check blockages in
system, contamination,
circulation pump
 Too high heat  Check seal condition
development of
mechanical seal
 Cooler not working  Check cool water, air
flow

Notes:
(1): Indication can be done with an indicator or with an alarm.
(2): The pressure drop should be monitored over time. A too fast drop in pressure compared to
previous measurements could be an indication for one of the mentioned possible causes.
(3): On a combined plan 53B system (one system for two seals) additional block valves
are installed to determine which inner seal (drive end or free end) is leaking
excessively. By closing one of the valves the accumulator function is isolated from one
loop (see also P&ID). If the pressure in that loop drops rapidly (visible on the pressure
gauge), the leaking inner seal is located on that end of the pump.

10.0 MAINTENANCE

Renewal of barrier fluid

 Stop the equipment in which the seals are installed and de-pressurize.
 De-pressurize the plan 53B system.
 Drain the system.
 Refill system with clean barrier fluid.
 Check all components for damage or leaks and replace or repair when necessary.
 Follow instructions as per paragraphs 7.0 and 8.0 prior to re-starting the equipment.

11.0 SHUT-DOWN, DISASSEMBLY

The equipment can be shut down at any time. Before the system can be removed the equipment in
which the seal is installed must be de-pressurized.

For (re)-installation, removal and maintenance work, the complete system must be de-pressurized
(and drained if required).

Product may be released during removal of the system. Safety measures and protective equipment
is required as per the plant’s safety regulations.

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

12.0 SPARE PARTS, REPAIRS

The system is designed to provide reliable operation under a wide range of operating conditions.
However, repairs will be necessary when components of the system reach the end of their normal
life expectancy or when the system has been operated outside of its design capabilities.

All liabilities and warranties to Flowserve for damage incurred through the use of non-original
replacement parts and accessories will be rendered null and void.

Please note that special manufacturing and delivery specifications exist for all parts of our products
manufactured or produced by ourselves and the replacement parts are always offered in
accordance with the latest technology and with the most current regulations and laws.

The information and specifications presented in this Operation and Maintenance Manual are
believed to be accurate, but are supplied for information purposes only and should not be
considered certified or as a guarantee of satisfactory results by reliance thereon. Nothing contained
herein is to be construed as a warranty or guarantee, express or implied, with respect to the
product. Although Flowserve Corporation can provide general application guidelines, it cannot
provide specific information for all possible applications. The purchaser/user must therefore
assume the ultimate responsibility for the proper selection, installation, operation and maintenance
of Flowserve products. Because Flowserve Corporation is continually improving and upgrading its
product design, the specifications, dimensions and information contained herein are subject to
change without notice.

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

ATTACHMENT 1

System Assembly Drawing

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Flow Solutions Division Operation and Maintenance Manual Plan 53B

ATTACHMENT 2

Instrumentation

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