API Plan 32 Troubleshooting in the Field Doesn’t Have to Be a Headache

A flush plan is essential to maintain proper lubrication, pressure, and temperature at a mechanical seal face. When the process fluid itself is too aggressive to use as a flush fluid, API Plan 32 protects the seal by injecting water or another external flush fluid into the seal chamber. 

API Plan 32 is common in Alberta oil and gas operations because it is simple, reliable, and effective for a wide range of fluid handling applications. However, it’s always possible that something can go wrong—especially in the field. Field Advisors and technicians must be familiar with all aspects of the system so they can respond to problems quickly and complete API Plan 32 troubleshooting to determine their root causes.

Below, we’ll look at common pressure, flow, and temperature problems you might encounter during API Plan 32 troubleshooting and what might be causing them. When in doubt, a local seal support systems supplier can help by providing an onsite evaluation and expert advice.

Common API Plan 32 Troubleshooting Problems

Flush Pressure

API Plan 32 requires the external flush fluid to be delivered at least 15 psi (1 bar) higher than the seal chamber pressure. If this pressure changes unexpectedly, some possible causes to look for are:

• Unexpected pressure changes upstream
• Leaks in the flush system or waterline
• Full or partial closure of the flush supply valve
• Crimped or damaged tubing supplying flush fluid to the seal chamber
• Clogged orifices or flow control valve
• Damaged or deteriorated throat bushing

Flush Flow

Changes in pressure affect flow, so follow the above troubleshooting guidelines for pressure problems first.

If pressure drop is not causing the flow problem, check the quality of the flush fluid. Plant water can contain minerals that can build up in flow control valves, obstructing flow over time. If the flush contains contaminants, they can clog flow control valves or flow meters.

If the flush fluid contains contaminants, consider preventive measures to prevent buildup. Accessible, easily maintained filters or strainers can reduce the risk of clog-related problems before they happen.

Flush Temperature

Keeping the seal chamber cool is critical to pump reliability. High temperatures will damage seals and other pump components, potentially causing a mechanical seal leak or other failures.

One of the flush fluid’s jobs is to prevent the seal faces from getting too hot. High seal chamber temperatures can be caused by insufficient flush flow or pressure. Also, check for changes or failures in upstream heat exchangers that could be causing the problem.

As for preventive measures, a temperature gauge on the tubing delivering flush to the seal chamber can identify temperature changes before they get out of control and damage the seal.

Best Practices to Improve API Plan 32 Reliability

Always follow best practices for startup, shutdown, and maintenance to protect your API Plan 32 system and prevent issues. A few best practices to keep in mind:

• Ensure the flow rate, pressure, and temperature of the flush are optimized for the pump’s standby, startup, and shutdown conditions.
• Whenever process conditions change, perform a risk assessment and make any necessary changes to the mechanical seal and seal support system.
• Schedule regular preventive maintenance to inspect seals for signs of damage or corrosion.

Of course, the best way to avoid API Plan 32 troubleshooting headaches is to start with a quality seal support system customized for your process.

Good Design Prevents API Plan 32 Troubleshooting Headaches

API Plan 32 systems are simple and reliable—when they’re designed well. A good design requires a thorough understanding of mechanical seal and throat bushing design, process fluid conditions, flush fluid conditions, and plant infrastructure.

An experienced seal support system supplier like Edmonton Valve & Fitting takes the time to consult onsite, understand your process and infrastructure, and account for any special problems or concerns you have. With this information, our Field Advisors can design and implement an API Plan 32 solution perfect for your needs.

Depending on your process, some examples of custom design elements may include:

• Flow meters to monitor flush flow and alert to changes
• Pressure gauges to monitor flush source pressure
• Thermowell pre-welded into tube fitting tee to reduce leak points
• Filters or strainers to prevent clogging by flush fluid contaminants
• Check valve to prevent process fluid from infiltrating flush fluid in the event of mechanical seal failure

When problems do arise, our local experts are available to help with API Plan 32 troubleshooting, provide ongoing technical support, and ensure you’re getting optimum performance from your seal support system.