Auxiliary Systems for mechanical seals

Technical Manual
 Index

INDEX:

Introduction Page 3
API Plan Description Page 4
Flushing Fluid Selection Page 5
Standards Page 8
Instrumentation Page 9
Tests and Non Destructive Tests Page 10
8 Liters reservoir (Plan 52/53A) Page 11
12 Liters reservoir (Plan 52/53A) Page 12
24 Liters reservoir (Plan 52/53A) Page 13
Pressurization system by a bladder accumulator (Plan 53B) Page 14
External flushing unit (Plan 54) Page 15
Leakage detection system (Plan 65A/65B) Page 16
Gas Panel (Plan 72/74) Page 17
Leakage collection and detection system (Plan 75) Page 18
Gas leakage detection system (Plan 76) Page 19
Water cooler (Plan 21/23) Page 20
Air cooler (Plan 21/23) Page 22
Cyclone separator (Plan 31) Page 23
Flushing system from external source (Plan 32) Page 24
Static quench tank (Plan 51) Page 25
Accessories Page 26
API Plan selection form Page 28

2
Introduction

Mechanical seals are devices fitted on pumps, mixers or other rotating equipment op-
erating at heavy duty conditions and handling with highly toxic, flammable and le-
thal fluids. In pharma and food industry, mechanical seals must avoid emissions to atmos-
phere, but also prevent process fluid contamination coming from outside atmosphere.
To grant above mentioned conditions, mechanical seal has to be double type and flushed
or pressurized, which avoids process liquid leakage to atmosphere or atmosphere contami-
nants can come into process fluid (please see “Alfa seminar – double mechanical seals” section).

Together with double seal, an auxiliary system is properly designed

and sized according operating conditions, including instrumentation
for buffer / barrier fluid operating conditions, highlighting any
possible abnormal conditions. Some services working with
single mechanical seals require an auxiliary system to maintain
proper lubrication from cooling down process fluid or using an
external flushing media to maintain cleanliness into seal chamber.
Since 1962 Fluiten manufactures mechanical seals for
a wide range of markets and its technical department
designed and developed auxiliary systems solutions
customized in accordance with customer’s specifications.

Fluiten is a member of the European Sealing Association. One of the main issues under fo-
cus is related to the correct selection of mechanical seals fitted on equipment with rotating
shaft, especially pumps. The pump manufacturers' association is also sensitive to this topic, giv-
en wide use in various product sectors and applications. In a sample analysis, it has been seen
that the correct auxiliary system selection is very important in terms of energy savings. The graph
here below represents the relation between the API Plan selected and its Energy consumption.

3
 API Plan Description
SINGLE SEALS:

Plan 23 / Plan 21: Air or water heat exchanger is used to cool down process fluid to avoid its vaporization
between seal faces.

Plan 31: Cyclone separates solid / abrasive particles, to have clean flushing fluid cooling seal area for
lubrication purposes.

Plan 32: External flushing fluid flowing toward the process, whenever accepted by customer, maintain high
seal area cleanliness.

Plan 51: Static quench placed on seal atmospheric side prevents process fluid crystallization, maintaining
proper seal elasticity and operations.

Plan 65A / B: Pot detecting liquid phase process fluid leakages and highlighting any abnormal conditions by
means of level alarm.

Plan 66 A/B: Mechanical seal physiological leakage is highlighted by a pressure alarm connected to seal
atmospheric side.

UNPRESSURISED DUAL SEALS:

Plan 52: Reservoir containing buffer fluid, that limits process fluid emissions to atmosphere and improve
inner seal cooling performances.

Plan 55: A control unit promote buffer fluid circulation to limit process fluid emissions to atmosphere and
improve inner seal cooling performances.

Plan 72: Unpressurized inert gas (e.g. Nitrogen) dilutes process fluid leakages. Normally combined with Plan
75 or 76, to remove leakages and direct them to a safe area.

Plan 75: Liquid / gas leakages from process side are collected by a tank, which can be drained to collect
liquid phase process for its safe displacement and at the same time direct gas phase leakage toward flare or
gas treatment area.

Plan 76: Gas phase leakage is controlled and directed toward flare or gas treatment area.

DUAL PRESSURISED SEALS:

Plan 53A: Pressurized reservoir grants zero process fluid emissions to atmosphere, maintaining a cooled and
clean liquid between inner and outer seal faces.

Plan 53B: Pressurized bladder accumulator grants zero process fluid emissions to atmosphere and cooled
and clean liquid between inner and outer seal faces.

Plan 74: Pressurization by means of inert gas (e.g. Nitrogen) grants process fluid emissions to atmosphere
and proper double seal operations.

4
Flushing Fluid Selection
THE CHOICE OF AUXILIARY LIQUID

Pressurized flushing fluid (plan 32): pressurized clean fluid injected into stuffing box area

Buffer fluid: used in a dual mechanical seal configuration, unpressurized

Barrier fluid: used in a double mechanical seal configuration, pressurized

Quench: external flushing fluid injected at atmospheric pressure, normally water, dry steam or nitrogen

FLUSHING FLUID MUST NOT BE HARMFUL TO PEOPLE AND THE ENVIRONMENT, DANGEROUS, TOXIC OR
FLAMMABLE.

For proper cooling performances, promoting good lubrication and avoiding overheating, mechanical seal
must work with a liquid film between seal faces or gas in “gas lift-off” seals using Fluilift patented techno-
logy. Mechanical seals and auxiliary systems selections are based on operating conditions and process fluid
characteristics (i.e. toxicity, flammability). In case fluids are harmful for people and environment or opera-
ting conditions do not allow single seals to properly work, double mechanical seal must be selected (please
see “Alfa seminar”).
Characteristics of the auxiliary liquid:
• It shall not be dangerous for people or environment, hazardous, toxic or highly flammable.

• its lubricity properties must be good and they are affected by temperature and pressure.

• it shall not solidify or vaporize.

Its selection is made considering operating conditions and calculating heat genera- ted by seal faces.

• It shall not generate foam.

• It shall have a low gas solubility index (tip: Plan 53A nitrogen pressure should be limited to a maximum of
10 barg).

• It shall be compatible with process fluid and with material of mechanical seal and auxiliary system.
Final approval / selection of the same must be done by end user to certify its compatibility with process
fluid.

• Buffer / barrier fluid shall circulate through auxiliary system circuit to remove heat generated by seal faces.
For this reason its viscosity cannot be too high.

TYPE OF AUXILIARY LIQUID CIRCULATION VISCOSITY (cSt: 1 cSt=1 mm2/s)

Natural circulation "Thermosyphoning effect" Max 5 cSt @ 40°C
Forced circulation with pumping ring on the seal Max 14 cSt @ 40°C
( Plan 52, Plan 53 )
Forced circulation with external pump ( Plan 54 ) Max 32 cSt @ 40°C

In applications with rotation speeds higher than 20 m/s and pressures higher than 20 bar it is necessary to
limit the coefficient of friction and the heat generated, limiting the viscosity value of the barrier liquid keeping
it below 14 cSt. A low viscosity value prevents blistering on graphite. The pressurised solution with inert gas
(see "gas lift -off Fluilift" seals) is a very good alternative to "Wet" seals where operating conditions allow it.

5
 Fluishing Fluid Selection

LIQUID FEATURES APPLICATION USE &

PROCESS
TEMPERATURE
•Lubrication capacity: low •Low duty services, food and phar- 10 ÷ 80 °C
Water •Heat transmission: excel- ma industry.
Demi Water lent •Water pour point must be consid-
Deionized Water Not recommended when ered carefully when selecting it as
sliding face combination is flushing fluid.
hard Vs hard (i.e. both are
in silicon carbide or tung-
sten carbide.

•Lubrication capacity: •Medium duty services. -20 ÷ 100 °C

Water + good •Suitable as flushing liquid with (30%/70%)
Ethylene Glycol •Heat transmission: good light hydrocarbons.
•It is not recommended to select -35 ÷ 110 °C
To be used without addi- a glycol concentration above 50%, (50%/50%)
tives (fluids for car market since it increases flushing fluid
are not suitable), toxic if viscosity over suggested values.
ingested.
Not suitable for food and
pharma applications.

•Lubrication capacity: •Medium duty services. -15 ÷ 100 °C

Water + good •Suitable as flushing liquid with (30%/70%)
Propylene Glycol •Heat transmission: good light hydrocarbons.
•Food. -30 ÷ 110 °C
Not dangerous fluid, ac- •It is not recommended to in- (50%/50%)
cepted in food industry. crease the percentage of glycol
above 50% due to the excessive in-
crease in viscosity of the mixture.

Propanol / Ethanol •Lubrication capacity: low •Food and pharmaceutical. -110 ÷ 50 ° C

•Heat transmission: good •Low temperatures services. (Ethanol)
-120 ÷ 80 ° C
(Propanol)
Mineral Oil •Lubrication capacity: •Medium and heavy-duty services. 0 ÷ 120°C
excellent •Hydrocarbons services.
•Heat transmission: good •Recommended viscosity between
5 and 32 cSt.
Dearivates from distillation •Barrier fluid temperature should
and hydrogenation pro- be kept below 80°C.
cesses and represents the
highest quality for lubrica-
tion purposes products.
Mineral oil, if working for
long time at high tempera-
tures modifies its proper-
ties, being not suitable for
seal lubrication anymore.
Coking deposition on seal
atmospheric side can start
around 80°C.

6
Flushing Fluid Selection
LIQUID FEATURES APPLICATION USE &
PROCESS
TEMPERATURE
Synthetic Oil •Lubrication capacity: •Medium and heavy-duty 0 ÷ 150°C
good. services.
•Heat transmission: low •Applications with hydrocar-
bons (including high tempera-
Derivates from chemical tures).
synthesis normal- ly based •In case plan 53B is select-
on polyalphaole- fins (PAO). ed and content of additives
Characteristics comparable inside oil, it is recommended
to mineral oils, but with in- to verify its com- patibility
creased chemical stability. with seal gaskets and bladder
If it contains additives, de- accumulator.
gradation can start around •Recommended viscosity
120°C, creating particles between 5 and 32 cSt.
depositions in seal area. •Barrier fluid must be kept
below 120°C.

Diathermic Oil •Lubrication capacity: •Medium and heavy-duty 15 ÷ 400°C

good. services.
•Heat transmission: low •Applications with hydrocar-
Diathermic oil, when work- bons at high temperatures.
ing for long time at high •Barrier fluid must be kept
temperatures modifies its below 80°C.
properties, being not su-
itable for seal lubrication
anymore
Coking deposition on seal
atmospheric side can start
around 80°C

“White" oil for food •Lubrication capacity: •Food, cosmetic and pharma- 0 ÷ 60°C
use good ceutical services.
Heat transmission: low •Barrier fluid must be kept
below 60°C.
Derivates from paraffin oil
through refining process.
High purity and compa-
tibility grade, but limited
stability for temperature
fluctuations.

Not recommended flushing fluids are listed here below:

• Gas oil, Kerosene and Diesel, due to the high flammability and toxicity
• Methanol, due to low lubricating properties and high toxicity
• Oils for engines, gears and turbines, due to the high content of additives
• Automotive antifreeze fluids, due to the high content of additives
• Silicone oils, due to the additives or the formation of silicates that can damage the seal faces

7
 Standards
When designing auxiliary systems, several parameters must be considered, concerning correct
sizing and pressure vessels operating limits as stated into International or local standards and, finally,
specifications by customer.
It is possible to find here below a list of main Bodies that can be found on the market across the world:

ABS American Bureau of Shipping

ANSI American National Standards Institute

API American Petroleum Institute

ARH Algerian Hydrocarbon Regulation

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

ATEX 2014/34 /EU Equipment for potentially explosive atmospheres

BS British Standards

CENELEC European Committee of Normalization Electrotechnique

CRN Canadian Registration Number

CSA B51 Code sur les chaudières, les compareils et les tuyauteries sous pression (Canada)

DIN Deutsches Institut für Normung (Germany)

DOSH Department of Occupational Safety and Health (Malaysia)

EAC (TR-CU) Technical Regulation - Custom Union Certificates (Russia)

FM Factory Mutual

NACE National Association of Corrosion Engineers

NEMA National Electrical Manufacturers Association

DNV Det Norske Veritas

NR13 Boiler and Pressure Vessels (Brazil)

ISO International Standards Organization

KOSHA Korea Occupational Safety and Health Agency

PED 2014/68/EU Pressure Equipment Directive

POVERKA Metrology Certificate with Primary Calibration for Instruments (Russia)

SELO (CML) China Manufacturer License

INDUSTRY STANDARD LOCAL DIRECTIVES

8
Instrumentation

Instrumentation mounted on auxiliary systems is very important to monitor proper seal operation.
Working conditions can be controlled by means of transmitters, able to continuously measures physical
parameter and to set alarm levels.
Main instruments can be divided as follows:

PRESSURE GAUGES LEVEL INDICATORS

It is very important that readings is included Reflex:
between 20 and 80 % of instrument range. They can be welded or external with flanged
In case of high vibrations coming from the pump, connections. Borosilicate glass reflects light in a
they need to be filled with liquid. different way, indicating liquid level.

Magnetic:
Can be only external mounted, a floating
element inside a metallic tube giving a rotation
to flags of different coloured sides, indicating
the liquid level. Recommended whenever fluid is
harmful for operators.

MAGNETIC
EXTERNAL WELDED EXTERNALLY
REFLECTIVE REFLECTIVE MOUNTED

PRESSURE ALARMS LEVEL ALARMS

Pressure switches: Level switches:
They allow to set an alarm remotely. Can be ultrasonic, vibrating or floating types.
Transmitters: They allow to set an alarm remotely.
They can be analogue (4-20mA) or digital and can Transmitters:
continuously monitor the pressure. Currently, they They measure the liquid differential pressure and
are the basic solution required by API Standard can be analogue (4-20mA) or digital, continuously
682. monitoring the level. Currently, they are the basic
solution required by API Standard 682.
FLOW INDICATORS/ALARMS
They operate on the principle of a body floating
inside a pipe with variable section, gas control.
The graduated scale shown on the glass tube of the
instrument is calibrated to the gas operating
conditions therefore, when changed the
measure- ment is no longer correct. For variable
gas pressure conditions, the use of a mass flow
meter is recom- mended.

"Skin Type" gas expansion Bimetal thermometer with

thermometer thermowell

9
 Tests and Non Destructive Tests

Test to be carried out, including Non-Destructive Tests (NDT) are part of customer’s project specifications
and inside Calculation code applied to the selected auxiliary systems. Normally they include:

Hydrostatic: for components working under pressure

Air test: for fittings (Gas panel: Plan 72 or 74)

Functional: for flushing units (Plan 54)

PENETRATING LIQUIDS FOR CHECKING SURFACE DEFECTS ON WELDS

Advantages: relatively simple to carry out
Disadvantages: limited to surface defects and requires a considerable degree of cleaning.

X-RAYS
For in-depth control of full penetration welds.
Advantages: it is possible to record the results and consulting them later. Recommended for small thickness
and full penetration welding.
Disadvantages: It is not appropriate for detecting surface defects or large thicknesses. Risky for operators.
The result is two-dimensional, so cannot indicate the defect depth.

ULTRASOUNDS FOR WELDING

Advantages: can be used for very high thickness and highlights the defect in a very precise way, indicating
its position, size and type.
The necessary equipment is transportable, very sensitive, and does not require the use of other materials.
Disadvantages: traditional manual ultrasonic test does not allow to record results, so no possibility of
consulting them later, if computerized systems are not implemented. Very high experience and skills of the
operator are needed to analyse the results.

MAGNETIC PARTICLES FOR WELDING

Advantages: relatively simple to carry out
Disadvantages: the application is limited to ferromagnetic materials, such as iron, nickel and cobalt, and is
limited to examining the surface. Despite its simplicity, incorrect execution may will not disclose defects.

PMI (POSITIVE MATERIAL IDENTIFICATION)

To check the exact composition of the metal parts elements. There are two different types of analysis:
1. X-ray fluorescence analysis (XRF): X-rays hit the surface, which re-emits radiation depending on its con-
stituent elements. Metal surface is not damaged, but some elements are not detected (Carbon, Boron and
Silicon)
2. Spectrographic Analysis (OES): an electric arc is generated between the sample and a tungsten electrode,
the light spectrum of this arc identifies the elements, leaving a mark on the surface. It is used to detect ele-
ments such as Carbon, which are not detected by the XRF technique.

10
8 Liters Reservoir (Plan 52/53A)
DESCRIPTION
8 liters reservoir (Fluiten code SDPN16V08) can be used in two different configurations, based on the process fluid: Plan 52 or Plan
53A. If the process fluid atmospheric emissions of the process fluid must be reduced or diluted, Plan 52 should be considered.
If these are not acceptable, you must consider configuration with Plan 53A. In case process fluid emissions are not acceptable,
Plan 53A and barrier fluid must be considered, its design is very similar to Plan 52, but nitrogen must be injected into the reservoir
to pressurize barrier fluid.

PED CONSTRUCTION FEATURES

• Reservoir in AISI 316, for high corrosion resistance, even on
heavy duty services.
• Modular design: optional instrumentation available on
request.
• Integrated pipes for cooling water connection.
• MAWP: 16 barg.
• MAWT: 200 °C.

MAIN FUNCTIONS
• Sized to remove heat generated by the seal faces through
flushing fluid circulation, ensuring proper lubrication of the
sealing surfaces.
• Reduction of process fluid emissions to the atmosphere
(Plan 52): hazardous services, where emissions must be
limited.
• No emission of process fluid to the atmosphere (Plan 53A):
toxic services where emissions are not allowed.

CAUTION!
For Plan 53A solution, it is necessary to check the availability
of nitrogen in the plant at a pressure 1-2 bar higher than the
maximum stuffing box pressure.
Fluiten can suggest the type of flushing fluid (see page 5-7).

A) Auxiliary fluid inlet

B) Auxiliary fluid outlet
C) Charging line
D) Drain
E) Cooling water outlet
D) Drain
G) Pressure gas connection
V) Vent

11
 12 Liters Reservoir (Plan 52/53A)
DESCRIPTION
12 liters reservoir (Fluiten code SDP012) can be used in two different configurations, based on the characteristics of the process
fluid: Plan 52 or Plan 53A.
Plan 52 (reservoir at atmospheric pressure) is suitable where a reduced emissions are accepted, while Plan 53A (pressurized
reservoir) has to be considered when process fluid emission to atmosphere are not accepted (see Fluiten technical seminar).

PED CONSTRUCTION FEATURES

• Reservoir in AISI 316, for high corrosion resistance, even on
heavy duty services.
• Modular design: optional instrumentation available on
request.
• Integrated pipes for cooling water connection.
• MAWP: 16 barg.
• MAWT: 200 °C.

MAIN FUNCTIONS
• Sized to remove heat generated by the seal faces through
flushing fluid circulation, ensuring proper lubrication of the
sealing surfaces.
• Reduction of process fluid emissions to the atmosphere
(Plan 52): hazardous services, where emissions must be
limited.
• No emission of process fluid to the atmosphere (Plan 53A):
toxic services where emissions are not allowed.

CAUTION!
For Plan 53A solution, it is necessary to check the availability
of nitrogen in the plant at a pressure 1-2 bar higher than the
maximum stuffing box pressure.
Fluiten can suggest the type of flushing fluid (see page 5-7).

A) Auxiliary fluid inlet

B) Auxiliary fluid outlet
C) Charging line
D) Drain
E) Cooling water outlet
D) Drain
V) Vent

12
24 Liters Reservoir (Plan 52/53A)
DESCRIPTION
The 24 liters reservoir (Fluiten code SDP-024), designed according to the latest API 682 standard, works under the same principles
of 8 and 12 liters reservoirs, reducing emissions to the atmosphere when Plan 52 is considered, or eliminating them on 53A
configuration. Instruments included in the basic design are pressure transmitter, level transmitter and level indicator, which can
be locally checked by operators on-site.

API PED CONSTRUCTION FEATURES

• Reservoir in AISI 316.
• Welded level indicator (external flanged version also
available).
• Quick coupling, for fast refilling time.
• Integrated pipes for cooling water connection.
• Switches instead of transmitters availablility: low level,
high level, pressure switch. This solution can be provided if
accepted by the end user.

MAIN FUNCTIONS
• Sized to remove heat generated by the seal faces through
flushing fluid circulation, ensuring proper lubrication of the
sealing surfaces.
• Reduction of process fluid emissions to the atmosphere
(Plan 52): hazardous services, where emissions must be
limited.
• No emission of process fluid to the atmosphere (Plan 53A):
toxic services where emissions are not allowed.

CAUTION!
Plan 52 solution works effectively with fluids having a vapor
pressure higher than 1 bar, while it is not suggested if the
process fluid is very stable (vapor pressure lower than 1 bar),
in this case it will tend to settle in the tank, therefore a peri-
odic cleaning of the system itself is recommended.
Fluiten can suggest the type of flushing fluid (see page 5-7).

PLAN 53A
1) To flare system (Plan 52)
From to external pressure source ( Plan 53A )
2) Tank
3) Reintegrating buffer or auxiliary fluid
4) Flushing (F)
5) Barrier fluid outlet (LBO)
PLAN 52
6) Barrier fluid inlet (LBI)
7) Cooling water inlet
8) Tank drainage
9) Cooling water outlet
10) Barrier fluid drainage
11) Stuffing box
LI) Level indicator
LIT) Level transmitter with display
PIT) Pressure transmitter with display

11

13
 Pressurization system by a bladder accumulator (Plan 53B)
DESCRIPTION
Solution with accumulator and its elastomeric bladder pressurized by mean of nitrogen.
Barrier fluid circulation is promoted by mean the pumping ring integrated into seal design or through external circulating pump,
necessary to remove the heat generated by the seal faces, using water or air heat exchanger (finned pipes or forced draft cooler).
This solution must be used if no process fluid emissions to the atmosphere are permitted.

API PED CONSTRUCTION FEATURES

• Accumulator in painted carbon steel or AISI 316, for
corrosive environments.
• Water or air heat exchanger (finned pipes or forced draft
cooler).
• NBR, HNBR pr FKM.
• MAWP/MAWT depending on design conditions.
• Pressure switch instead of pressure transmitter available.
This solution can be provided if accepted by the end user.

MAIN FUNCTIONS
• No emission of the process fluid to the atmosphere.
• Volume calculated to ensure that the time between refilling
is in accordance with the API standard : 28 days
• Sized to remove heat generated by the seal faces through
flushing fluid circulation, ensuring proper lubrication of the
sealing surfaces: (see 8 liters).

CAUTION!
TIT mounted on accumulator is not mandatory in case a
fixed alarm strategy (according to API 682) is selected.
In case pumping ring cannot guarantee proper flow rate,
external circulating pump must be considered.
Fluiten can suggest the type of barrier fluid (see page 5-7).

1) Bladder accumulator charging connection

2) Bladder accumulator
3) Reintegrating barrier fluid
4) Flushing (F)
5) Barrier fluid outlet (LBO)
6) Barrier fluid inlet (LBI)
7) Stuffing box
8) Vent
9) Barrier liquid drainage
10) Valve (bladder accumulator integrity check)
PI) Pressure indicator
PIT) Pressure transmitter with display
TI) Thermometer
TIT) Thermometer with display

14
External flushing unit (Plan 54)
DESCRIPTION
A control unit equipped with circulating pump, designed and instrumented to circulate, pressurize and control barrier fluid to
the mechanical seals. Ideal solution when process fluid is toxic, contains solid particles, or if a high flow rate at high barrief fluid
pressures must be maintained during operation.

API PED CONSTRUCTION FEATURES

• Modular design.
• Tank sizes can be changed according to operating
conditions.
• Heat exchanger power, barrier fluid flow rate and pressure
designed to ensure proper seal faces lubrication.
• Wide range of construction materials according to involved
services type and the installation environment atmosphere.

MAIN FUNCTIONS
• No process fluid emissions to the atmosphere.
• Availability of high flow rates, for proper seal faces
lubrication.
• Very commonly used in remote location, whenever days
between refilling must be as much as possible.

CAUTION!
Barrier fluid pressure must be maintained at least 1.4 bar
higher than the maximum stuffing box pressure.
Fluiten can suggest the type of barrier fluid (see page 5-7).

I S I S S

15
 Leak detection system (Plan 65 A/B)
DESCRIPTION
Leakage detection system, normally used with single seals, to check the mechanical seal conditions. If the seal is damaged, level
inside the 5 liters tank increases in a shorter time than when the seal operates correctly, activating level alarm.
The system is equippped with an orifice (Plan 65A) or a normally closed valve (Plan 65B).

API PED CONSTRUCTION FEATURES

• Low space requirements thanks to its compact design.
• Integrated monitoring level, for reliable operation.
• By-pass line, to drain the flow in case of abnormal
leakage.
• Use of an orifice (Plan 65A) or a normally closed valve (Plan
65B).
• According to API 682, should be designed to withstand
pump MAWP.

MAIN FUNCTIONS
• Liquid phase leakage detection from the mechanical seal
atmospheric side, but also containment and collection to a
safe area.
• Normally used to detect leakages of finished products
therefore expensive for the plant.

CAUTION!
The leakage on the seal atmospheric side must condense
The tank must be placed at a lower level than seal drain
connection.

PLAN 65A

PLAN 65B

1) Valve ( normally open )

2) Drain valve ( Plan 65B ), Orifice ( Plan 65A )
3) To the exhaust collection system
4) Flushing (F)
5) Washing (Q)
6) Drainage (D)
7) Stuffing box
LIT) Level transmitter with display

16
Gas Panel (PLAN 72/74)
DESCRIPTION
Plan 72 uses a gas as flushing fluid (usually nitrogen) injected at atmospheric pressure between the two seals, in order to
dilute the process fluid emissions to the atmosphere and thus limit their impact. The inner mechanical seal works wet and is
lubricated by the process fluid, while the external seal works dry (technology developed by Fluiten, called Fluigrid).
This flushing plan can be used together with Plan 76 for fluids with vapor pressure higher than 1 bar, or with Plan 75 for fluids
with both gaseous and liquid phases once in contact with (due to the heat generated by the rotating sealing surfaces).
In case no emissions to atmosphere are permitted, Plan 74 must be considered.

PLAN 72/74 with container

CONSTRUCTION FEATURES
• Panel mounting size and position of the components can be
customized according to the customer's needs.
• Casing in AISI 316 (cabinet version).
• Equipped with double flow indicator (low and high) and
pressure switch, to allow better operations control.
• Pressure indicator promotes local control by plant
operators.
• Simple and compact design.

MAIN FUNCTIONS
• Dilution of process fluid leakage (Plan 72).
• Outer seal acts like a containment seal, working in wet
conditions in case of inner seal failure (Plan 72), limiting
process fluid emissions to atmosphere.
• No leakage of process fluid to atmosphere
(Plan 74)
PLAN 72/74 with panel • If barrier gas is not available at needed pressure, Fluiten
API can supply a booster device (Plan 74).

PLAN 72

PLAN 74

17
 Leakage collection and detection system (Plan 75)
DESCRIPTION
Collection and leakage control system, for process fluids having mixed phase in contact with the atmosphere, used when reducing
emissions level to the atmosphere is a must. Used in combination with a dual seal (2CW-CS), where the outer back-up dry
contacting seal is equipped with Fluigrid technology. Gaseous leakage is taken to the gas recovery system (usually represented by
the flare), while liquid leakage is collected into the tank. Flushing plan that can be used in combination with Plan 72.

API PED CONSTRUCTION FEATURES

• Tank material: AISI 316.
• Level indicator availability, for local control by operators.
• The pressure transmitter detects any abnormal gas flow
rate, indicating any critical points in the seal operations.
• Level transmitter indicates the presence of excessive liquid
in the tank.

MAIN FUNCTIONS
• Reduction of process fluid leakage to the atmosphere.
• Alternative to dual mechanical seal and reservoir (i.e. Plan
52).

CAUTION!
The tank must be placed at a lower level than mechanical
seal drain connection.

1) To the gas recovery system

2) To the liquid recovery system
3) Test connection
( If specified )
4) Flushing (F)
5) Containment seal vent (CSV)
6) Containment seal
drainage (CSD)
7) Buffer gas inlet (GBI),
plugged if not made with
PLAN 72
8) Stuffing box
LI) Level indicator
LIT) Level transmitter with display
PIT) Pressure transmitter with display
(a) If specified

18
Gaseous gas leakage detection system (Plan 76)
DESCRIPTION
Leakage detection system for fluids that evaporate in contact with the atmosphere.
Used with a dual seal (2CW-CS), where the external back-up dry contacting seal uses Fluigrid technology, directing process fluid
leakage to the gas recovery system.
Flushing plan that can be used in combination with Plan 72.

API PED CONSTRUCTION FEATURES

• Panel mounting.
• Pressure transmitter that, together with an orifice, allows
to detect a flow higher than normal and highlight any
damage to the mechanical seal on the product side.

MAIN FUNCTIONS
• Collection of gaseous leakage from the process fluid and
collect it to the gas recovery system. Typically selected with
fluids that vaporize in contact with the atmosphere, such as
Liquefied Petroleum Gas (LPG).
• Alternative to dual mechanical seal and reservoir (i.e. Plan
52).

1) To the gas recovery system

2) Pipeline
3) Pipeline
4) Flushing (F)
5) Containment seal vent (CSV)
6) Containment seal drainage (CSD),
7) Buffer gas inlet (GBI), plugged if not
made with PLAN 72
8) Stuffing box
PIT) Pressure transmitter with display

19
 Water Cooler (Plan 21/23)
DESCRIPTION
Water heat exchangers (Fluiten code CSW) are used to cool down the process fluid and ensure a stable, liquid-phase film
between the seal faces. In plan 23, thanks to a pumping ring integrated into mechanical seal, the process fluid flows through the
inner tube of the heat exchanger, while the cooling water flows through the shell, or through the outer tube for the tube in tube
version. Operating and environmental conditions, but also pumping ring performances are fundamental to properly evaluate
heat that can be removed by the heat exchanger.

TUBE-IN-TUBE
PED CONSTRUCTION FEATURES
• Designed according to different operating conditions, for a
wide range of operations.
FLANGED • Both water and the process sides can be easily vented and
drained.
• Special seamless design inside the heat exchanger.
• AISI 316 components: high corrosion resistance.
• Available with flanged, straight pipe or NPT connections.
STRAIGHT THREADED
• Compact design: very useful when available space is
limited.

MAIN FUNCTIONS
• Heat removal for proper mechanical seal lubrication.
• Highly recommended for boiler feed water pumps in power
generation plants, sometimes also accepted in Oil & Gas
plants.

SHELL & TUBE

API PED CONSTRUCTION FEATURES
• Designed according to pump MAWP and MAWT: suitable
for different operating conditions.
• Complete dismounting possibility: for an optimal and
simple piping cleaning.
• Both cooling and process sides can be completely vented
and drained.
• Shell in painted carbon steel, with option in AISI 316.
• Thermometer can be supplied, if required.

MAIN FUNCTIONS
• Heat removal for proper mechanical seal lubrication.
• Built according to API 682 specification, used in applications
for Oil & Gas plants.

CAUTION!
Use of the heat exchanger must be carefully evaluated,
especially when the process fluid has a high pour point.
The cooling efficiency can be increased by using a throat
bushing integrated into the mechanical seal design.

The heat exchanger should be placed 450 to 600 mm above

the pump centerline to promote thermosyphoning effect.

20
Water Cooler (Plan 21/23)
DESCRIPTION
Shell and tube water heat exchanger, for low duty services. Water heat exchangers (Fluiten code CSW) are used to cool down the
process fluid and ensure a stable, liquid-phase film between the seal faces. In plan 23, thanks to a pumping ring integrated into
mechanical seal, the process fluid flows through the inner tube of the heat exchanger, while the cooling water flows through the
shell, or through the outer tube for the tube in tube version. Operating and environmental conditions, but also pumping ring
performances are fundamental to properly evaluate heat that can be removed by the heat exchanger.

SHELL & TUBE

API PED CONSTRUCTION FEATURES
• Designed according to pump MAWP and MAWT: suitable
for different operating conditions.
• Complete dismounting possibility: for an optimal and
simple piping cleaning.
• Both cooling and process sides can be completely vented
and drained.
• Shell in painted carbon steel, with option in AISI 316.
• Flange rating: 600#
• Maximum heat removal: 2kW

MAIN FUNCTIONS
• Heat removal for proper mechanical seal lubrication.
• Particularly suitable for all applications in general industry,
chemical, petrochemical, pharmaceutical, food and where
there are no strict application specifications.

PLAN 21
1) From the higher pressure
pump area
2) Flushing (F)
3) Washing (Q)
4) Drainage (D)
5) Stuffing box
TI) Thermometer

PLAN 23
1) Flushing outlet (FO)
2) Flushing inlet (FI)
3) Washing (Q)
4) Drainage (D)
5) Stuffing box
6) Vent
(normally closed)
7) Drainage
(normally closed)
TI) Thermometer

21
 Air Cooler (Plan 21/23)
DESCRIPTION
When the process fluid between the seal faces must be cooled, but the cooling water is not available in the plant, air heat exchanger
must be considered as a necessary alternative. The simplest solution is with finned pipes (Fluiten code CSA), which work using natural
convection principle. The efficiency of this solution is promoted when installed in ventilated area and protected from direct sunlight.
Due to the low efficiency of natural convection effect, this solution is used when the operating conditions (operating temperature, shaft
rotation speed, shaft stuffing box pressure, etc.) are not heavy.
In case finned pipes cannot provide sufficient cooling, a solution with forced draft heat exchanger (motor-driven fan) must be considered.

NATURAL FINNED
API PED CONSTRUCTION FEATURES
• Finned pipes mounted with interference and large contact
surface area, for better heat transmission.
• Piping in AISI 316, fins in aluminum, with AISI 316 option
for corrosive environment.
• Modular design: the quantity and length of finned pipes
can be modified according to operating and environmental
conditions.
• Sunshades can be included in case reduced impact of solar
radiation is needed.
• Vertical installation.

MAIN FUNCTIONS
• Heat removal for proper lubrication of the mechanical seal.

FORCED DRAFT
API PED CONSTRUCTION FEATURES
• Different dimensions based on the heat load to be
removed.
• Different materials available in relation to the atmospheric
conditions into the plant.

MAIN FUNCTIONS
• Heat removal for proper mechanical seal lubrication.

22
Cyclone Separator (Plan31)
DESCRIPTION
Cyclone separator is a device used to supply a clean fluid to the seal in services where the process fluid contains solid particles.
It is mainly used in water-based services (e.g. wastewater circulation systems, seawater applications, etc.). A small part of the
flow from the pump discharge is directed to the cyclone separator and then splitted into two flows: clean one, which is directed
towards the stuffing box, and a "dirty" one, which is directed to pump suction.
The highest filtration efficiency is obtained when the specific gravity of solid particles is at least double than the one of the process
fluid and the differential pressure between the discharge and the stuffing box is high, but still within the recommended range.

CONSTRUCTION FEATURES
• Different materials available:
• 316
• Duplex
• Super Duplex
• Available in NPT or flanged version

MAIN FUNCTIONS
• Maintaining stuffing box cleanliness, while removing an
important amount of heat generated by the seal.
• It can be used for stuffing box venting purposes, thus
reducing the possibility of seal faces dry running (horizontal
pumps).
• It can help to maintain the correct stuffing box
pressurization level, reducing the chances of process fluid
vaporization between the seal faces.

CAUTION!
Solid particles specific gravity must be at least two times
than the one of the process fluid.
Minimum differential pressure between the discharge and
the stuffing box: 1,7 barg.
Stuffing box and suction pressure must be close.

1) From the clean product delivery of the

separator cyclone
2) Flushing (F)
3) Washing (Q)
4) Drainage (D)
5) Stuffing box

QA: Flow from pump discharge

QB: Clean product towards the stuffing box
QC: Dirty product directed towards the suction

23
 Flushing system from external source (Plan 32)
DESCRIPTION
Plan 32 (Fluiten Code AS-32) is a continuous clean fluid injection from an external source.
This solution is recommended if process fluids contain solid particles and contaminants, or whenever it is required to prevent air
entrance into the seal faces or vaporization of the process fluid between the seal faces.

API PED CONSTRUCTION FEATURES

• Wide range material availability
• Optional instrumentation available on request (as shown in
the diagram at the bottom of the page)
• Panel mounting, if required.

MAIN FUNCTIONS
• Prevent the seal rings from working dry in services with
high vapor pressure fluids or when the pump operates at
pressures below atmospheric one.
• Maintain proper seal faces lubrication.

CAUTION!
Plan 32 operating pressure must be kept 1-2 bar above the
maximum stuffing box pressure.
Plan 32 is not suggested to cool the stuffing box, due to its
high energy consumption
Required flow rate can be high; customer must be aware
that the flushing fluid can "contaminate" the process fluid in
a significant way.

1) From external source

2) Flushing (F)
3) Washing (Q)
4) Drainage (D)
5) Stuffing box
FI) Flowmeter
PI) Pressure indicator
TI) Thermometer
a) Optional

24
Static flushing tank (Plan 51)
DESCRIPTION
When continuous quenching is not available, static quench (Plan 51 according to API 682, Fluiten code SDP-003) can be an
alternative solution. This tank can be used to prevent ice formation in cryogenic services, salt deposition in salty water services
and air intrusion when the pump operates at pressures below atmospheric one.
This device must be connected to the Quench (Q) of the mechanical seal.

PED CONSTRUCTION FEATURES

• Material: AISI 316.
• 3 liters tank, for long operating time.
• Compatibility with a wide range of liquids.

MAIN FUNCTIONS
• Reduction or zero salt deposition or ice formation on the
seal atmospheric side.
• Preventing air entrance into equipment operating below
atmospheric pressure.
• Maintaining proper seal faces lubrication.

CAUTION!
Plan 51 should be combined with a segmental bushing or lip
seal mounted on the seal flange to reduce leakage to atmos-
phere, increasing the average time between refilling.

1) From the barrel

2) Washing (Q)
3) Drainage (D), plugged
4) Flushing (F)
5) Stuffing box
a) The elements below the line are supplied by the manu-
facturer. The elements above the line shall be borne by the
purchaser.

25
 Accessories

FILLING FUNNEL
Refilling method used in 12 liters reservoirs, including funnel,
lid, 3-liters auxiliary tank and double valve, necessary for
refilling during normal equipment operation.
The standard configuration for the 12 liters reservoir has a
½" connection, while the engineered solution for the 24
liters barrel is available with flanged connections.
• Material: AISI 316.

MANUAL REFILL PUMP

Manual pump used to refill the auxiliary systems. It can
be integrated directly on the system or transportable (by
Shoulder).

• Material: AISI 316

• Volume: size according to service conditions

EXTERNAL CIRCULATION PUMP

Magnetic driven pump used for 12 liters reservoirs.
Compatible with solvents, demineralized water and oil
• Capacity: 6 l/min
• Head: 35m
• Design temperatures: -15/+160 °C
• Design pressure: 20 bar
• Material: AISI 316
• Electric motor: 0.5 kW-230/400V-2.800rpm
• ATEX execution: II 2G EExd IIB T4

26
Accessories

NITROGEN PRECHARGE KIT

Nitrogen charging kit used for periodic pre-charge operations
or for the first start-up or following maintenance
operations.
• Design pressure: 360 bar
• Accumulator connection: 5/8” UNF
• Connecting to the nitrogen cylinder: W24.32 x 1/14'
The nitrogen bottle shall have a higher pressure than the
pre-charge value needed for the auxiliary system.
Different connections available on request, including
adapters for various sizes.

MOBILE CHARGING UNIT

Mobile refilling unit for barrier fluid, used on API PLAN
52, 53A and 53B. Trolley is equipped with double-acting
manual pump, check valve and related pressure gauge,
suction filter, welded level indicator, 5 meters long flexible
hose with ½" connection.

• Material: AISI 304 or AISI 316

• Maximum charge pressure: 100 bar (water/oil)
• Volume: 50lt
• For special versions please contact sales office

27
 API selection form

API PLAN : 21 23 31 32 51 52 53A 53B 53C

54 55 62 66A/B 65A/B 72 74 75 76

DESIGN CONDITION :
Pressure : barg
Temperature : °C
CERTIFICATION REQUIRED : APPLICABLE STANDARDS :
PED 2014/68/UE API 682 3rd edition
ATEX 2014/34/UE API 682 4th edition
ASME U-Stamp ASME code
TR CU 0012/2011 & 0032/2013 EN 13445
ARH Other:
SELO
Marine (ABS,DNV,…) : ATEX ZONE : GAS GROUP :
Other: TEMP. CLASS : PROTECTION TYPE : Ex-ia
IP : Ex-d
UTILITIES :
COOLING WATER AVAILABLE? YES STEAM AVAILABLE YES
NO NO
Temperature: °C min: barg
Temperature: °C
NITROGEN AVAILABLE ? YES
NO CONNECTED TO THE AVAILABLE TORCH
min: barg YES NO
CONDITIONS AT THE SITE:
ROOM TEMPERATURE RANGE: min °C INSTALLATION : CLOSED
MAX °C OPEN

TYPE OF ATMOSPHERE: INDUSTRIAL ELECTRIC: V Ph

MARINE Hz
ISTRUMENTATION :
FLUITEN STANDARD SWITCHES HART
ACCORDING TO SPECIFICATION N° : TRANSMITTERS FF

LEVEL INDICATOR: REFLEX WELDED

MAGNETIC EXTERNAL

TEMPERATURE PROBE : SKIN TYPE FLOATING ALARM STRATEGY (Plan53B) YES

WITH WELL NO

VALVES INSTRUMENTS : NEEDLE BLOCK&BLEED DOUBLE B&B

OTHER COMPONENTS :
ACCUMULATOR : C.STEEL HEAT EXCHANGER : TUBE-IN-TUBE
SS 316/L SHELL&TUBE
NATURAL AIR
FORCED AIR

CONNECTIONS : FLANGED ANSI DIN

THREADED NPT GAS

INTER_CONNECTION LINE : PIPING

TUBING
NOTES :

28
NOTES

29