Rev.
March 2022 1
Application Notes: Mechanical Seals in Centrifugal Pumps for Oil & Gas / Process industry
In case of API 610 – the standard for centrifugal pumps, the 8th edition contained mechanical seal
plans, whereas in the 9th / 10th edition, the seal plans are left out. From then on, the design of mechanical
seals and seal plans are covered in API 682.
This note is in conjunction with API 610 and API 682. Seal plans refer to those specified in API 682 and
older versions of API 610, 5th, 6th, 7th and 8th edition.
Seal Chamber (also called stuffing box): The pump specification, API 610 covers seal chamer size, chamber
bore, total length, clear length and dimensional tolerances. In case of repetitive seal failures, verify that the
seal chamber is concentric to the shaft (total indicated runout is less than 125 microns) and seal chamber face
runout does not exceed 0.5 micron / mm. The seal chamber design (& size) should ensure stable film at the
seal faces. This is especially critical for liquids operating near their vapour pressure.
Seal function: The seal with rotating element, installed in centrifugal pumps, is typically called mechanical
seal. All seals (dry or wet) leak. Sealing is achieved by having the two sliding surface – one rotating and other
stationary sliding in close proximity. The leakage is controlled and is significantly lower than the conventional
packings; hence the ubiquitous use of the mechanical seals in centrifugal pumps. The leakage provides
lubrication, and removes the heat generated between the two closely spaced sliding faces, thereby extending
the operating life.
Typically, the rotating face may be spring loaded up to sliding speed of 25 m/s. At higher sliding speeds,
the stationary seal face (connected to the machine casing) is spring loaded.
Normally, the mechanical seals are externally pressurised, i.e. the leakage moves radially from outside to
inside. Essentially:
• the leakage movement inside the seal,
• the pressure in the seal chamber,
• the chemical properties of the pumped fluid,
• the generation of heat at the sliding seal faces and its removal, and
• the cleanliness of the pumped and sealing liquid
determine the selection of the seal type (single vs double) and the seal plan for the primary and the secondary
seals. The liquid that is being sealed, or the external liquid used for sealing, also determines the design and
the selection of other components in the mechanical seal, namely; the O-rings, Teflon seals, springs, throttle
bush, auxiliaries (orifice, cyclone separator, strainer, heat exchanger, coalescing filter, bladder accumulator,
and sealing fuid reservoir) and the various instrumentation installed in the seal condition monitoring system.
Seal selection: Key considerations when selecting the mechanical seals and its supporting seal plan are:
www.gl-mach.com , E: [email protected] , T: +61 456 980 655
Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia – Kota, India
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.
Rev. March 2022 2
1. Seal plans: API seal piping plans can be divided into four categories:
a. Process side: Plan 01, 02, 03, 11, 12, 13, 14, 21, 22, 23, 31, 32, and 41
b. Between seals:
i. Plan 52, 53A 53B, 53C, 54, and 55 for wet double seals
ii. Plan 71, 72, 74, 75, and 76 for the gas seals in the pumps
c. Atmospheric side: Plan 51, 61, 62, 65A, 65B, 66A, and 66B
d. Engineered seal: Plan 99
Seal plan 11, 13, 21, 23, 32, 41, 52, 53B, 61 and 62 are more commonly used.
2. Seal plan 11 is the most common seal plan for mechanical seals. Seal plan 21 and 31 are variations of the
seal plan 11; and seal plan 41 is a combination of seal plan 21 and plan 31.
3. A ready to assemble unit of mechanical seals is called a cartridge. They are easy to install, are generally
tested hydrostatically in the factory and the sliding surfaces are protected for transport. Ensure the
assembly locking feature is removed before commissioning the pump & the seal.
4. All meachnical seals leak from as low as 5 cc per hour (small pumps) to as much as 200 cc per hour (large
pumps of 1000s of kW duty). It depends on:
a. the mean radius of the sliding surface,
b. the thickness of the lubricating film and its dynamic viscocity,
c. the differential pressure to be sealed, and
d. the sealing radial width.
API standards (610 or 682) do not define the seal leakage rate or the seal acceptance criteria. Ask the seal
supplier to specify the seal leakage rate and its acceptance and replacement criteria at the time of the
order. Normally, this is jointly agreed with the seal supplier prior to the order. Seals are tested with the
pump. If the design is new, and the duty very onerous or critical, then the seals may be tested suitably in
the mechanical seal supplier’s shop prior to its installation in the pump.
5. In the case of boiling liquids or low specific gravity fluids, check the power consumption of the mechanical
seal (mainly the friction heat generated at the seal faces) and ensure that the seal plan selected is suitable
to prevent the vapourisation of the boiling liquid at the seal faces. In such cases, the seal plan selected
should cool the flushing liquid before it is introduced to the seal. Example, when pumping of propane.
6. In application where the seals with the circumfertential speed (at the mean sliding seal diameter) of 30
meters per second or more is required, ask the supplier to provide calcualtions to confirm that a stable
fluid film will be maintained between the rotating and stationary seal faces during operation.
7. Power generated at the seal faces is a multiple of surface pressure x sliding surface area x sliding speed x
coefficient of friction.
www.gl-mach.com , E:
[email protected] , T: +61 456 980 655
Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia – Kota, India
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.
Rev. March 2022 3
8. Pump vendors provide various means to reduce the pressure in the seal chamber where the mechanical
seal is located. Typically, the seal chamber pressure (thumb rule) considered by the seal suppliers is about
thirty percent (30%) of the pump discharge pressure.
9. In the case of multistage, between bearing pumps, a balance line may be used to ensure both seals, at
either end, are operating at slightly above the suction pressure. Ask seal supplier to provide calculations.
10. Engineered seals: Engineered seals are not required to meet any of the design or testing requirement of
API 682. Engineered seals are required in the following cases:
a. Seal surface speed above 23 meters / second, and/or
b. Pump shaft diameter at seal area is above 110 mm and/or
c. Pressure is above 4,100 kPag and/or
d. See section on, “Seal selection justification” of API 682 for acids and high temperature applications.
In such cases ask the supplier to justify their seal design. Establish the test acceptance criteria before the
placement of the order. Consider conducting full design review after the placement of order. This should
include review of the seal construction and the sizing of the auxiliaries.
11. It is common practice for the plant design engineer to obtain seal supplier selection / recommendations
through the pump supplier at the plant design stage, prior to the award of the pump order. Seal suppliers
use their previous experience to base their seal selection offer. Review the seal cross-section drawing and
the bill of material, both, prior to the award and during the design review cycle for known difficult seal
applications. Ask the seal supplier to provide their proven experience list. Judiciously, consider asking
contact details of other customers to obtain feedback on their field experience. Seal suppliers normally
provide this, when asked. Most customers provide feedback, when asked.
12. Clean air act (1990) of USA mandated lower hydrocarbon emissions. Suppliers recommended, and many
customers changed to double seals for the pumps in hydrocarbon or hazarduous services. Most plants
have closed blow down system and the small amount of hydrocarbon leakage from the seals can be easily
caught and recycled. Over engineering leads to many other wastes and poor equipment reliability /
availability. Application of double throttle bush can also be considered in place of double seals.
13. Balanced, single seals with throttle bush is most common seal type.
14. Consider double seals only if the seal reliability, safety risk or other environmental regulations justify their
use. In the case of double seals, the seal supplier may recommend that the throttle bush is not required.
However, in case of hazarduous duties the throttle bush may prevent massive leakage and hence should
always be installed.
15. Many customers insist on installing throttle bush (also referred as disaster bush) in all pumps, both with
single or double seals.
www.gl-mach.com , E:
[email protected] , T: +61 456 980 655
Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia – Kota, India
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.
Rev. March 2022 4
16. API 682 does not give the sizing criteria for the orifice, cyclone separators, strainers, heat-exchangers
(coolers), coalescing filters, reservoir, bladder accumulators and heat tracing elements. Their sizing and
selection depends on the properties of the pumped fluids, quality of the plant utilities (cooling water –
pressure, temperature and cleanliness; and pneumatic air pressure at the specific pump, pressure
variation and cleanliness) and ambient conditions (site temperature, temperature variation and moisture
content).
17. Check cooler sizing and its suitability for the site’s hottest ambient conditions. Consider specifying the
cooler be sized at least 20% larger than the required cooling surface. This would accommodate some
cooler fouling.
18. Check the design (sizing critieria) of the seal support auxiliary systems. It should be suitable for all
operating conditions. Seal flushing liquid reservoirs should be designed for at least 28 days (4 weeks) of
continuous operation. Generally operators bring the stand-by pump in operation every 28 days, and
hence the guideline.
19. Y-type strainers tend to clog and should be frequently cleaned. Consider coalescing filters for duties where
the strainers are the root cause of the seal problems.
20. Cyclone separators: Check the catalogue of the cyclone separator manufacturer for its design
requirements. Typically, a separator requires 100 kPa (14.5 psi) pressure differential between the its inlet
and stuffing box pressure to operate properly. They are commonly used with orifices to ensure the flow
rate remains in the design parameters of the cyclone separator, and to achieve good separation efficiency.
In the case of clogging, solidifying fluids, a PCV (pressure control valve) may be more suitable than orifice.
Recommendations: Based on the number of seals failed in a year, operating hours and the total number of
mechanical seals installed in a plant, calculate the mean time between failure (MTBF). Usually, in a well
maintained plant, this should be between 6 to 8 years. List all the bad actor pumps & mechanical seals of the
plant. These would be the pumps and the seals that lower the MTBF achieved. Generally, the failure to design
for the actual conditions encountered, namely; the pumped fluid properties, the site ambient conditions, the
site utilities and ambient conditions, results in poor seal reliability. Hence, a proper review of the seal selection
at the design stage is of critical importance. Consider, hiring a knowledgeable specialist, with design
experience, to guide during the design stage and/or plant wide review of bad actors to improve plant safety
and reliability.
www.gl-mach.com , E: [email protected] , T: +61 456 980 655
Global Machinery Consultants Pty. Ltd., A.C.N No. 094 649 699, A.B.N. 20 094 649 699. Perth, Melbourne, Australia – Kota, India
© This document is the property of Global Machinery Consultants Pty Ltd., Australia.
