API Piping Plan 31

REV 1.0 Definition:

A primary product seal flush plan that originates at the discharge, or a pressure point on the pump higher than that of the stuffing box pressure, of the pump and is piped through a cyclone separator delivering clean process liquid to the seal flush port and process liquid with solids back to the pump suction.

Objective:
The objective of API Plan 31 is to clean the process liquid going to the seal chamber using a cyclone separator. The process liquid typically originates at the pump discharge line and is piped to the side of a cyclone separator. This device, installed properly, uses a vortex action to separate solids from the process liquid. These solids are piped back to the pump suction off the bottom of the cyclone separator. The clean process liquid is taken from the top of the cyclone and piped to the seal flush port, and used to lubricate the primary product seal and dissipate heat generated by this seal. This plan can also be used to raise the pressure in the stuffing box when the required product vapor suppression margin required is not present (suction pressure is at or near the vapor pressure of the liquid). Note: There should be no valves or orifices in the lines coming to or leaving the cyclone separator. If they are present request they be removed at the first possible outage.

Line Up Procedure:
The following steps outline the checks required before, during and after start-up of the equipment. 1) Check to make sure any valves in the seal flush line are open. These lines should be free of valves, if possible. Otherwise, any valves in this line must remain open until the pump is pulled for repair. See note above. 2) Proceed with opening all valves for service. 3) Check for leaks around any valves and connections in the seal flush line. 4) Start pump per normal procedures. 5) Once running, check to make sure the seal flush line is the same temperature from its origin through the cyclone separator to the primary seal flush port on the primary seal flange and back to suction of the pump. It should be the same temperature as the pump case. [Caution: Do not touch the seal flush line if the pumping temperature is above 150F.]

Preventive Maintenance and Troubleshooting:

The primary seal flush line should be checked on normal operator rounds. Check the seal flush lines with a temperature indicator. The seal flush line should be the same temperature as the pump case from its origin through the cyclone separator to the flush port on the primary seal flange. The

line from the cyclone back to suction should also be the same temperature. [Caution: Do not touch the seal flush line if the pumping temperature is above 150F.]

The typical modes of failure in this flush plan are a clogged cyclone separator, a clogged line from the cyclone to suction, or a closed valve in the seal flush line. During these modes, you will find the following when you check the seal flush line on a particular piece of equipment.

A Hot Service
When the cyclone separator is clogged in a hot service, you will find all three lines at the cyclone cold. Moving towards the origin, towards the flush port on the primary seal flange, and towards the suction line away from the cyclone, you will find the lines become hot just before the connections at each location. When the line from the cyclone separator to suction is clogged, you will find the cyclone itself hot as all the flow from the discharge of the pump will be diverted to the seal flush port on the primary seal flange. The line to suction will become cool some distance from the cyclone and become hot again at the pump suction connection. In the event a valve in the line to the cyclone is closed, heat will radiate back up the line from the flush port on the primary seal flange. The cyclone may still be hot as flow can reverse itself in this line and go back to pump suction. When a closed valve between the cyclone and the pump suction line is closed, this line will become cool some distance between both connections. A closed valve in the line between the cyclone and the seal flange will result in heat radiating up the line from the seal flush port on the primary seal flange. The cyclone will be hot as all flow will be diverted back to pump suction.

A Cold Service
When the cyclone separator is clogged in a cold service, you will find the line hotter at the seal flush port connection on the primary seal flange. The line will cool as move toward the origin of the seal flush line (i.e.. the cyclone, back to the discharge/suction of pump, etc..). The heat that is radiating up the seal flush line and is generated by the mechanical seal. In other words, there is no flow in this line and therefore, heat is backing up through the line. When the cyclone separator to suction line is clogged in a cold service, there are no physical indicators. Shortened seal life from solids entering the seal chamber will be the only evidence. In the event a valve in the seal flush system is closed on the inlet to the cyclone, heat will radiate back up the line from the seal flush port on the primary seal flange. This heat may only be evident for a short distance or it may actually reverse flow in the line and go back to the pump suction. If a valve is closed between the cyclone and pump suction, physical evidence will be hard to identify. A closed valve between the cyclone and the primary seal flange will result in heat radiating up the line from the seal flush port on the primary seal flange.

Solution
Upon finding the above situation, you should check for closed valves in the seal flush lines. If no valves are present or they are open, tap on the cyclone separator to see if it will open and flow properly. If the above attempts are unsuccessful, begin procedures to shut the equipment down in an orderly manner.

Shut Down Procedure:

Once the equipment has been prepared for maintenance, remove the seal flush line and check for foreign matter clogging the line. This matter will usually be found in the cyclone separator or the line going to pump suction. In the event you cannot find a problem, contact your maintenance or BW/IP personnel for further assistance.