Sealing-Refinery applications.

Sealing Hydrocarbons

What does a oil refinery do ???

Crude oil is a cocktail of various different hydrocarbons.

The typical compound of crude oils is:
83 - 87 wt % Carbon
11 - 15 wt % Hydrogen
0,1 - 7 wt % Sulphur
0,06 - 1,5 wt % Oxygen
0,1 - 0,5 wt % Nitrogen and other compounds

Crude oil cannot be used directly in modern applications

>>> it needs to be refined!
Sealing Hydrocarbons

What does a oil refinery do ???

Refineries transform crude oil into different end-products
by applying physical, physical-chemical and chemical processes.

The long molecule chains of crude oil are split (cracked) into shorter
molecule chains or are re-arranged to form new products.
Principle of a refinery

Main units of a refinery

Crude oil storage tanks

Distillation

Crackers

De-sulphurisation

Naphta Reformer

LPG units

Ready products
Principle of a refinery

Crude Oil tank farm

Storgage of the incoming crude oil

De-salination, pre-heating of crude oil

Transport to first process stage: atmospheric + vacuum distillation

Principle of a refinery

Atmospheric + Vacuum distillation

Seperating the crude oil in:

light >>> LPG, gas

middle >>> Oil, Naptha
heavy >>> Bitumen, tar
...fractions by means of :

high temperature and atmospheric pressure (atm. distillation)

and

moderate temperature and reduced pressure (vacuum distillation)

Principle of a refinery

Thermo - Catalytic - Hydro Crackers

Separated fractions + heavy fractions from the distillation are split

(cracked) into finer sub-fractions be means of:

Thermal cracking >>> high temperatures, no longer common

Catalytic cracking >>> high temperatures + catalysator powder

which has semi-liquid (fluid) characteristics
(FCC = Fluid Catalytic Cracking)
Good yield of high-octane fuel

Hydrocracking >>> moderate temperatures + Hydrogen

Most sophisticated crack-process
Principle of a refinery

De-sulphurisation

Sulphur is an undesired compound in mineral-oil based

hydrocarbons. It can be found in elementary form or as H2S.

It must be removed from the hydrocarbons to receive pure end-

products. Modern environmental protection laws e.g. require low-
sulphur fuels.
H2S is extremely toxic and must be removed.
Principle of a refinery

Naptha Reformer

The pre - stage of gasoline is called Naptha. Naptha or crude

Benzine is not yet suitable to run modern gasoline engines as it
contains a very low octane rate.

Modern gasoline needs to have an octane rate of 91 -98. This is

achieved in Naptha Reformer units.

Katalytic reforming is commonly applied today. Platinium is used as

catalyst - hence the idiom Platforming is commonly used.
Principle of a refinery

Waste products

Refineries produce considerable amounts of non-desired waste

products, which need to be disposed, transformed processed.

Waste gas: characteristic for all refineries are the burning flare
stacks. Here, waste gas is being burnt.

Coking: The residue products (bottom product) is coked

which means superheating under high pressure and
no oxygen. Coke can be used as solid fuel material.

Calcination: Coke can be fully incinerated - creating calcinate.

This material is used in the electronics industry to
make electrodes etc.
Sealing Hydrocarbons

How to seal
Hydrocarbons
mechanical seals - principles

Most common seal types in refineries:

puscher type seals with spring Burgmann

loaded unit and dynamic o-ring
H75

Burgmann
metal bellows seals for
high temperature applications MFL85N
MFLWT80

but:
a refinery also offers low-duty applications where standard cartridge seals
such as Cartex or Mtex are perfectly suitable.

> so: dont forget to look out for these opportunities!

mechanical seals - principles

basic seal arrangements and layouts:

single seal

single seal with quench

double seal unpressurised buffer fluid

double seal pressurised barrier fluid

whatever seal arrangement they all have one thing in common:

> all seals are desigend as ready-to-install cartridge seals !

basic seal arrangements and layouts:

Single seal flush connection +

multipoint injection

balanced seal design

dynamic o-ring

low emission principle:

V means support ring
under the carbon face
basic seal arrangements and layouts:
same design features as
Single seal with quench single seal + additionally:

quench connection port

floating throttle bushing

basic seal arrangements and layouts:

Single seal with quench

purpose of a quench:
- dilute and remove leakage
- prevent deposits on atmospheric side of the seal
-keep away air (oxygen) from leaked media in order to prevent oxidizing
(e.g.: hot oil will create coke sediments when in contact with air)
- keep the seal cool or hot

Typical quench media in refineries:

Purpose Quench media
Prevent coking of hot oil Nitrogen or steam
Cooling the seal Cool liquid, diesel, oil
Heating the seal Hot steam
Removing deposits, cleaning the seal Clean liquid which will dilute the deposits
basic seal arrangements and layouts:

Double Seal
flush connection + buffer fluid IN
multipoint injection buffer fluid OUT

product side (inboard) seal atmospheric side (outboard) seal

basic seal arrangements and layouts:
Double seal unpressurised buffer fluid
higher product lower buffer atmospheric
pressure (p1) pressure (p3) pressure (p2)

p3 = p2

leakage of media into the buffer fluid

leakage of buffer fluid into the atmosphere

Consequences:
- media will accumulate in the buffer fluid
-TS vessel level will rise
- Traces of media will get contact with the atmosphere
basic seal arrangements and layouts:
Double seal pressurised barrier fluid
product higher barrier atmospheric
pressure (p1) pressure (p3) pressure (p2)

p1 < p3 >p2 p3 = p2

leakage of barrier fluid into media

leakage of barrier fluid into the atmosphere
Consequences:
- barrier fluid will escape into the media
-TS vessel level will drop
- Visible leakage on atmospheric side
will be only clean barrier fluid
no secret: the most common API Plans in refineries

API Plan 11 Description: Flush

Layout: Pipe from pump discharge

through 3 mm orifice to
stuffing box chamber

Purpose: Cooling, diluting gas ring,

preventing vaporisation

Common applications:
Flashing hydrocarbon
Media which tends to
vaporise
Generally recomended
no secret: the most common API Plans in refineries

API Plan 02 Description:Dead End

Layout: Connection port, plugged

Purpose: For customers determination

Common applications:
where plan 11 will cause
problems:
high temperature and
high content of solids
no secret: the most common API Plans in refineries

API Plan 62 Description: Quench

Layout: Introduction of clean fluid between

atmospheric end of seal and throttle
bushing

Purpose: Diluting and removing leakage

deposits
Cooling & heating of seal
preventing coking of hot oil

Common applications:
Hot oil
Bitumen / tar
media with solids
no secret: the most common API Plans in refineries

API Plan 52 Description: Pressureless buffer fluid

Layout: Circulation of buffer fluid through

a pressureless TS vessel

Purpose: Lubricating the 2nd backup seal

Diluting leakage
Monitoring seal behaviour
(leakage, failure)
Improving lubrication of seal

Common applications:
Media with poor lubricity
Harmful media
no secret: the most common API Plans in refineries

API Plan 53A Description: pressurised barrier fluid

circulation through TS
vessel

Layout: TS vessel pressurised

with Nitrogen

Purpose: Media may not leak towards

the atmosphere. Media must be
kept inside pump

Common applications:
Media with high content of solids
Dangerous Media
Media with very poor lubricity
no secret: the most common API Plans in refineries

API Plan 53B Description: pressurised barrier fluid

circulation through TS
vessel

Layout: TS vessel pressurised

with bladder accumulator

Purpose: Media may not leak towards

the atmosphere. Media must be
kept inside pump

Common applications:
Media with high content of solids
Dangerous Media
Media with very poor lubricity
no secret: the most common API Plans in refineries

Description: pressurised barrier fluid

circulation through pressure
API Plan 53C
transmitter (DRU)

Layout: seal pressurised

by DRU pressure transmitter

Purpose: Media may not leak towards

the atmosphere.
Pressure difference between
product and atm. side very high

Common applications:
Media with high content of solids
Dangerous Media
Very high pressure
no secret: the most common API Plans in refineries

API Plan 54 Description: pressurised barrier fluid

circulation through external
supply system

Layout: Seal connected with external

supply system (SPA)

Purpose: Media may not leak towards

the atmosphere. Media must be
kept inside pump

Common applications:
Media with high content of solids
Dangerous Media
Media with very poor lubricity
materials for refinery seals

Seal Faces
Clean medium:
Carbon, antimony impregnated <> Silicon Carbide
(Buko 03 <> Buka 22)
Medium containing solids:
Silicon Carbide <> Silicon Carbide (Buka 22 <> Buka 22)

Secondary Sealing Elements

Chemical resistance > usually Viton is suitable for most HC.
However, never use EPDM (not resistent to mineral oils)!
Temperature range. Most Elastomers are limited at 180C - 200C.

Construction Materials
Standard is 1.4571 or 1.4462 CrNiMo-steel
Seal selection in refineries

1) knowing the media:

name,
vapour pressure,
density (spec. gravity),
viscosity,
hazards,
solids,
corrosive?
Seal selection in refineries

2) Temperature range

< - 40C: Metal bellows seal with Graphite

secondary seals (MFLCT80)

- 40C to + 220C : Pusher-type o-ring seal (e.g. H75)

+ 220C to + 300C: Standard metal bellows seals

(e.g. MFL85, Mtex)

> +300C : Metal bellows seal with Graphite

secondary seals (MFLWT80)
Seal selection in refineries

3) Pressure

suction, discharge, stuffing box

the margin between stuffing box pressure and vapour pressure

of media shall be approx. 2 bar

H75 type seals have a pressure limit of approx. 40 bar

MFL type seals are limited to 25 bar.
Seal selection in refineries

4) density spec. gravity spec. weight > lubricity

is the media in liquid phase at all times or is there a risk of dry

running?
If vapour pressure is not indicated, this will give a rough
estimation, which seal arrangement is suitable:
Density kg/m Seal Type
> 750 Single
750 650 Single, with multipoint injection (Plan 11)
650 550 Double seal, pressureless buffer fluid (Plan 52)
< 550 Double seal, pressurised barrier System (Plan 53)
Seal selection in refineries

5) sliding velocity
most process pumps in refineries have a speed of approx. 2950 rpm.
More important than the rpm is the resulting sliding velocity of the
mechanical seal.
calculating the sliding velocity in m/s:

mean diameter of the seal face X rpm X 3,14

60.000

> In most cases, seal max. velocity is 25 m/s

 ISO/NP21049
(API 682, 2nd Edition)
Scope ISO / NP 21049 - General

ISO / NP 21049

is a guideline

for the minimum requirement for

Shaft Sealing Systems

for Centrifugal and Rotary Pumps

used in petroleum , natural

gas and chemical industry
Scope ISO / NP 21049 - General

ISO / NP 21049 covers seals for shaft diameters

from 20 mm (0,75 in)

to 110 mm (4,3 in)

Scope ISO / NP 21049 Seal categories

Category 1
For non - ISO 13709 Seal Chambers

Temperatures from -40 C (-40 F) to 260 C (500 F)

Absolute Pressures up to 22 bar (315 psi )

Scope ISO / NP 21049 Seal categories

Category 2
For ISO 13709 Seal Chambers (Table 1 only)

Temperatures from -40 C (-40 F) to 400 C (750 F)

Absolute Pressures up to 42 bar (615 psi )

Scope ISO / NP 21049 Seal categories

Category 3
Must meet full specification (incl. documentation)

For ISO 13709 Seal Chambers (Table 1 only)

Temperatures from -40 C (-40 F) to 400 C (750 F)

Absolute Pressures up to 42 bar (615 psi )

Scope ISO / NP 21049 Seal types

Type A

Balanced
internally
- - mounted
cartridge
pusher
multiple springs
flexible element rotating
secondary sealing by elastomer o-rings
Scope ISO / NP 21049 Seal types

Type B

Balanced
internally- mounted
cartridge
non - pusher ( metal bellows )
flexible element rotating
secondary sealing by elastomer o-rings
Scope ISO / NP 21049 Seal types

Type C

Balanced
internally - mounted
cartridge
non - pusher ( metal bellows )
flexible element stationary
secondary sealing by flexible graphite
Scope ISO / NP 21049 Seal arrangements

ISO / NP 21049 covers 3 Arrangements:

Arrangement 1: one seal per cartridge assembly

Arrangement 2: two seals per cartridge assembly

with a containment seal chamber at pressure less
than the seal chamber pressure

Arrangement 3: two seals per cartridge assembly

with externally supplied barrier fluid
Scope ISO / NP 21049 Sealing methods

ISO / NP 21049 covers 3 Designs:

Contacting Wet Seals (CW)

Non-contacting Seals (wet or dry, NC)

Containment Seals
(contacting or non-contacting, CS)
Scope ISO / NP 21049 Sealing methods

ISO / NP 21049 covers 3 orientations for

Arrangements 2 & 3:

Face-to-Back
(arr.2 default selection & arr. 3 wet seals)

Back-to-Back
(arr. 3 default for gas seals; option for wet seals)

Face-to-Face
(arr.3 optional selection for wet or gas seals)
 ISO / NP 21049 design requirements

Materials
Category 1 Category 2 Category 3
Mech. Seal Face Carbon Carbon Carbon
Mating Ring SSSiC RBSiC RBSiC
(Buka 22) (Buka 20) (Buka 20)
Hard / Hard SSSiC/ RBSiC/ RBSiC/
SSSiC RB SiC RBSiC
Secondary elements Fluoroelastomer
Perfluoroelastomer
(altern.: TFE, Nitrile ..)
Flexible graphite
Springs Alloy C-276 or Alloy C-4
(single: SS 316 or 1.4571)
Bellows Alloy C.276 (Type B)
Alloy 718 (Type C)
Sleeves SS 316 or 1.4571
Housing SS 316 or 1.4571
BURGMANN Mechanical Seal Type

H75 Type A Arrangement 1

API 682 Code: C2A1A1161

Pressure: 0... 42 bara /

580 psia
Temperature : -40 C .. + 180 C
-40 F.. + 350 F
Speed: 20 m / 65,6 ft.
per second
BURGMANN Mechanical Seal Type

H75K & H75F Type A Arrangement 2 or 3

API 682 Code: C2A2A1152 or
C2A3A1153

Pressure 0... 42 bara /

580 psia
Temperature : -40 C .. + 180 C/
-40 F.. + 350 F
Speed: 20 m / 65,6 ft. per
second
BURGMANN Mechanical Seal Type

MFL85N Type B Arrangement 1

API 682 Code: C2A1B1161

Pressure : 0... 25 bara / 365 psia

Temperature : -40 C / + 180 C

-40 F / +350 F

Speed : 20 m / 65 ,6 ft. per sec.

BURGMANN Mechanical Seal Type

MFL85N + MFL85F Type B Arrangement 2 and 3

API 682 Code: C2A2B1152 or

C2A3B1153

Pressure: 0... 25 bara

0 .. 365 psia

Temperature : - 40 C .. + 180 C
- 40 F.. + 350 F

Speed: 20 m/s
65 ,6 ft. per sec
BURGMANN Mechanical Seal Type

MFL65 Type C Arrangement 1

API 682 Code: C2A1C0262

Pressure: 0... 25 bara/

362,5 psia

Temperature : -20C / +400C

-4F / 752F

Speed: 50 m /164 ft. per sec.

MFL

MFL
MFL

Design of a MFL-seal
While common pusher-seals are built-up by a large number
of single parts, the MFL-Seal contains only very few
components:

Bellows unit stationary seat

Bellows unit
sec. seal
Stationary seat
Secondary seals

set screw secondary seal

MFL

Design of a Bellows Unit

bellows carrier metal bellows seal face housing seal face

MFL
Advantages

No blocking of the shaft seal

The spring-loaded mechanical seal is The MFL-Seal is equipped with a static

blocked by deposits at the dynamic shaft seal. Therefore no blocking of the
O-ring and therefore unable to self-align. rotating seal due to deposits will occur.

No wear of the shaft

Self-cleaning bellows
Balanced arrangement
High-temperature applications
Compact design
MFL

Bellows - Types

Membrane bellows (lamella bellows)

Unlike rolled metal

bellows, membrane
bellows consist of multiple
membrane leaves which
are welded at the inner
and outer diametric
edges.

Cross-section of a Burgmann
membrane bellows
MFL
Balanced at Internal & External Pressurization

AH Dual Operation
A internally pressurized
p3 > p1
Hi
d

AH Tandem or single
operation
A
externally pressurized
p3 < p1
Ha
d

The MFL tandem dual seal is either used with pressurized barrier
fluid or with unpressurized buffer fluid
The seal remains closed even if barrier pressure breaks down
Advantage: max. operational reliability is provided in case barrier
pressure break down is not discovered at once
MFL Seal Classification

MFL Seals

Rotating bellows unit Stationary bellows unit

standard engineered standard engineered

MFL85N
MFLS (low temperature)
MFLWT80S MFL65

MFLWT80 (MFLW80) MFLCT80

(high temperature) (low temperature)
MFLW81S MFLS
(shaft sealing) (Aerospace)

MTEX
MTEX - Cartridge Concept

MTEX
MTEX - Cartridge Concept

MTEX - SO x

x Single seal
Balanced
Independent of direction
of rotation
Cover without supply
connections ("dead-end")
Sturdy design
Burgmann Total Seal Care Program Middle East References

1. ARAMCO - Riyadh Refinery, KSA

2. ISO Octane Refinery Dubai
3. KNPC MAB Refinery, Kuwait
4. ADCO Abu Dhabi
5. Total E&P Qatar
6. Maersk Oil Qatar
7. Borouge- Abudhabi
8. Sohar Refinery.

Note : Scope of the contract is suited to the needs / wants of the

Customer.