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Overview
Introduction Background of Study Objective Mechanical Seal System Seal Design and Operation Parameters Replacement of Seal
Conclusion
Introduction
Background Polymerizers mechanical seals have been leaking for last 4 years Seal condition will drive the seal replacement job in T/A 2006 Objectives Present some facts about mechanical seal Maintenance teams capability to replace the seal
Engro Asahi Polymer & Chemicals Ltd.
Oil Circulation
Lubricate and seals the seal faces Seal box environmental control Barrier fluid
Telltale Hole
Engro Asahi Polymer & Chemicals Ltd.
Vessel
O-ring
Mating Ring (SS) Flushing Water, Pf = 10 kgf/cm2 ,telltale hole Seal Box Ps = 15 kgf/cm2
Telltale hole
Vessel outside
Failed Seal If a seal leaks before the carbon face is worn out because of misalignment, high vibration, high temperature or FP, its called Failed Seal 85% of Seals fail before wearing out
Engro Asahi Polymer & Chemicals Ltd.
Thermal expansion of the shaft or sleeve can break a stationary seal face The elastomer or rubber part can swell and breaks the face Fatigue of the springs caused by misalignment.
Barrier fluid
A hydraulic force is created any time there is fluid between the seal faces. A centrifugal force created by the action of the fluid being thrown outward by the rotation of the shaft. A hydrodynamic force created because trapped liquid is non compressible.
Rotary face
Spring Force
A Seal is considered as
Temperature
Heat can cause liquid to vaporize, blowing the lapped seal faces apart Heat will affect the elastomer in the seal reducing its life Lapped faces can go "out of flat" and critical tolerances change at elevated temperature
Pressure
Seal box pressure must not rise above recommended,
It will create higher differential pressure across the seal faces and thus seal face will wear out more rapidly It will disturb the hydraulic balance of the seal Generate high stresses on seal faces
20 15 10 5 0 Feb Apr 05 05 Jul 05 Aug Oct Nov Jan Feb Mar 05 05 05 06 06 06 Months Poly A Poly B
Is the seal system at risk? Yes. If the leakage is high enough to cause pressure drop in the seal box. Current Oil Leakage Rate Poly A: 5.6 ml/day Poly B: 16.5ml/day
Poly B
Ps > P f > P o
Where, Po: Vessel pressure Pf: Flushing water pres. = Po+ 1~2 Kgf/cm2 Ps: Seal box pres. = Pf + 2~5 Kgf/cm2
Engro Asahi Polymer & Chemicals Ltd.
Vibration Data
Vibration values are on the lower side Vibration data implies that mechanical seal and the agitator assembly are aligned properly. This also means that rotary faces of the seal are balanced
Vibration Data (Polymeriser B)
3.5 3 2.5 2 1.5 1 0.5 0
04 Ja n 0 Fe 5 b 0 M 5 ar 05 Ap r0 M 5 ay 05 Ju n 05 Ju l0 Au 5 g 0 Se 5 pt 05 O ct 0 No 5 v0 5 O ct
2 1.5 1 0.5 0 Oct Jan Feb Mar Apr May Jun Jul 04 05 05 05 05 05 05 05 Aug Sept Oct Nov 05 05 05 05 x y z
Displacement (um)
x y z
Conclusion
Bottom seals are leaking for last 3~4 years Mechanical Seal of Polymerizer B has completed six years of
operation. Benchmark period for seal replacement at other plant sites is 4~6 yrs Seal box pressure is maintained at 22 Kgf/cm2 instead of 15 Kgf/cm2 recommended by the vendor One seal was already serviced by Shinko Pantec Seal failure would cause a downtime of 6 days
Based on above maintenance team recommends seal replacement during T/A 2006.
our requirements for all the crafts Prepare test procedures based on the checklist for skill evaluation Develop a plan to test and certify contract employees Develop a scheme to implement skill certification plans in subsequent years
Engro Asahi Polymer & Chemicals Ltd.
is 100% compliance Invite only relevant people to training in order to increase training effectiveness Distribute training assignments equally to all the Engineers and Asst. Engineers for equal load sharing Not more than two trainings in a month Training section will prompt the trainer couple of months prior to the training and will facilitate the trainer to prepare his training documentation Training performance assessment will be done every quarter of the year More organized approach has helped Maintenance in increasing training hours.
Maintenance Training
Maintenance Training Plan
TNA of Employees
Skill Certification Plan
Performance