September 1995

Process Industry Practices Machinery

REEP001 Seal Flush and Lubrication Guidelines for Centrifugal Pumps

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3208 Red River Street, Suite 300, Austin, Texas 78705. PIP member companies may copy this practice for their internal use.

3pr96 Minor format changes. 2pr96 Minor format changes. Not printed with state funds.

September 1995

Process Industry Practices Machinery

REEP001 Seal Flush and Lubrication Guidelines for Centrifugal Pumps

Table of Contents
1. Introduction ..................................2
1.1 Purpose .............................................2 1.2 Scope ................................................2 3.14.4 Seal Pot Pressure Switch....... 8 3.14.5 Seal Pot Level Switches......... 9 3.14.6 Buffer Fluid ............................ 9 3.15API Plan 53 ....................................... 9 3.15.1 General.................................. 9 3.15.2 Seal Pot Low Level Switch... 10 3.15.3 Seal Pot Low Pressure Switch.................................. 10 3.16 API Plan 54 .................................... 10 3.17 API Plan 61 .................................... 10 3.18 API Plan 62 .................................... 11

2. References....................................2
2.1 Industry Codes and Standards ...........2

3. Seal Flush Plans...........................2

3.1 General..............................................2 3.2 API Plan 1 .........................................3 3.3 API Plan 2 .........................................3 3.4 API Plan 11........................................3 3.5 API Plan 12........................................4 3.6 API Plan 13........................................4 3.7 API Plan 21........................................5 3.8 API Plan 22........................................5 3.9 API Plan 23........................................5 3.10 API Plan 31.......................................5 3.11 API Plan 32.......................................6 3.12 API Plan 41.......................................6 3.13 API Plan 51.......................................7 3.14 API Plan 52.......................................7 3.14.1 General ..................................7 3.14.2 Seal Pot .................................7 3.14.3 Auxiliary Piping/Tubing...........8

4. Lubrication Methods for Bearings...................................... 11

4.1 General ........................................... 11 4.2 Product Lubricated Bearings............ 11 4.3 Lubrication of Antifriction Bearings .. 11 4.3.1 General .................................. 11 4.3.2 Grease Method ....................... 11 4.3.3 Wet Sump Method.................. 12 4.3.4 Dry Sump Method................... 14 4.4 Pressure Fed Lubrication................. 14 4.5 Lubricant Contamination Considerations................................. 15

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1.

Introduction
1.1 Purpose
The purpose of this Practice is to provide designers with seal flush and lubrication guidelines for centrifugal pumps for chemical plant and refinery applications.

1.2

Scope
This Practice covers guidelines for application of seal flush plans and lubrication considerations for centrifugal pumps.

2.

References
The following references contain additional information that may be useful to the designer:

2.1

Industry Codes and Standards

American Petroleum Institute (API) Std. 610 - Centrifugal Pumps for Refinery Service Std. 682 - Shaft Sealing Systems for Centrifugal and Rotary Pumps

American Society for Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section II - Materials Section VIII, Division 1 - Pressure Vessels In this Practice the ASME Boiler and Pressure Vessel Code is referred to as the ASME Code for convenience. B73.1 M - Specification for Horizontal End Suction Centrifugal Pumps for Chemical Process B73.2 M - Specification for Vertical In-Line Centrifugal Pumps for Chemical Process

3.

Seal Flush Plans

3.1 General
Shaft sealing systems are discussed in API Std. 682 in general terms. Additional information on shaft sealing systems is available in Appendix D of API Std. 610. Seal life can be extended by designing systems that provide cool and clean fluids to the seal cavity and by using bearings and a shaft stiffness that minimize motion of the seals.

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PIP REEP001 Seal Flush and Lubrication Guidelines for Centrifugal Pumps

Seal flush guidelines in Sections 3.2 through 3.18 of this Practice are provided to assist in the selection of standardized seal flush plans as defined in Appendix D of API Std. 610 and in Figure A2 of ASME B73.1M and ASME B73.2M. Selection of an appropriate seal flush plan must take into consideration normal and transient operating conditions, including standby condition in which pumps with recirculating flush system have no flow through the seal chamber. Seal materials must be suitable for expected temperatures and pressures during standby and warm-up (or cool-down). A continuous flush from an external source may be required if seal components cannot tolerate anticipated conditions in the seal chamber when the pump is idle.

3.2

API Plan 1
API Plan 1 (ASME Plan 7301) takes fluid from the pump discharge, reduces the pressure as it passes through an orifice, and injects the fluid into the seal cavity (seal face) area through an internal passageway. The fluid then flows from the seal cavity to the back side of the impeller and then back into the process stream. The purpose of API Plan 1 is to keep fluid from stagnating in the seal cavity. Stagnation may result in excessive seal cavity temperature rise and buildup of contaminants from normal wear. API Plan 1 should not be used with dirty fluids.

3.3

API Plan 2
API Plan 2 (ASME Plan 7302) has a dead-end seal chamber with no circulation of flushing fluid, but it has plugged connections in the seal chamber for possible future circulating fluid. A water-cooled stuffing box jacket may be specified to provide cooling. API Plan 2 can be used with clean fluids with high specific heats, such as water, in relatively low speed pumps. Extreme caution should be used if API Plan 2 is used in light hydrocarbon services with low specific heats because of excessive seal cavity temperature rise that can cause vaporization of the fluid. API Plan 2 should not be used with dirty fluids.

3.4

API Plan 11
API Plan 11 (ASME Plan 7311) takes fluid from the pump discharge, reduces its pressure as it passes through an orifice, and injects it into the seal cavity (seal face) area through external piping or tubing. Fluid then flows from the seal cavity to the back side of the impeller and then back into the process stream. The purpose of API Plan 11 is to provide cooling by keeping fluid from stagnating in the seal cavity. Stagnation may result in excessive seal cavity temperature rise and buildup of contaminants from normal wear. API Plan 11 should not be used with dirty fluids.

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3.5

API Plan 12
API Plan 12 (ASME Plan 7312) is identical to API Plan 11 except for an additional Y-strainer upstream of the orifice and the seal cavity. Comments on API Plan 12 are the same as those on API Plan 11 with the additional comment that the coarse filtration provided by a Y-strainer may be of little or no value for protecting the seal, other than keeping the orifice from plugging. Note: API Plan 12 has been deleted in API Standard 610, 8th edition.

3.6

API Plan 13
API Plan 13 (ASME Plan 7313) provides circulation from the seal cavity through an orifice back to the pump suction. The most commonly used function of API Plan 13 is to reduce pressure in the seal cavity on pumps that generate high seal cavity pressures, such as a vertical turbine pumps that have discharge pressure on the throat bushing directly under the seal cavity. In order to get flow through the seal cavity, it is imperative to bleed off the seal cavity pressure through an orifice back to the pump suction. On vertical turbine pumps, API Plans 1, 11, 12, 21, 22, 31, or 41 must be used in conjunction with API Plan 13. Caution must be taken when using API Plan 13 not to reduce the seal cavity pressure below the process fluid vapor pressure. API Plan 13 is also useful in high-head pumps in which the use of an API Plan 11 requires a small orifice [less than 3 mm (1/8-inch)] that can be easily plugged or produces an excessive flush flow rate. In pumps that have discharge heads greater than 300 meters (1,000 feet), the use of multiple orifice breakdown that increases orifice sizes, may be desirable. The use of multiple orifice breakdown also reduces noise and provides less orifice wear than the smaller single orifice. API Plan 13 should not be used on pumps in which specific impeller designs cause seal chamber pressure to approach or fall below the suction pressure of the pump. Typical of this design is the reverse vane impeller. Under these conditions there may be inadequate differential pressure to cause flow sufficient to cool the seal assembly, resulting in mechanical damage to the seal faces. When pumping light hydrocarbons or steam condensate at low flow rates, much of the driver power heats the process fluid due to pump inefficiency. Heating of the process fluid can cause vapor formation and possible vapor locking of the pump. A modified version of API Plan 13 (referred to as API Plan 14 in the 8th edition of API Std 610) that takes seal cavity fluid through an orifice back to the vapor portion of the suction vessel provides even better protection for the seal. The seal cavity bypass provides a greater flow rate, and this improves the potential for vapor removal. API Plan 14 is also often used successfully for highly volatile fluids in systems with marginal net positive suction head available (NPSHA) which will otherwise not operate due to cavitation. If it is not possible to install a line back to the suction vessel, injecting into suction piping at least 5 meters (15 feet) upstream of the inlet flange at a

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point above the seal cavity elevation may be an acceptable alternative. This alternative may allow time for the vapor to condense.

3.7

API Plan 21
API Plan 21 (ASME Plan 7321) takes fluid from the pump discharge through an orifice and heat exchanger and then injects the fluid into the seal cavity. This is basically an API Plan 11 with the addition of the heat exchanger. The purpose of API Plan 21 is to provide a cooled flush to the seal. The need for a cooled seal flush can vary greatly depending on the process fluid, type of seal used, and materials of construction for the seal. Pump and seal manufacturers should be consulted for specific recommendations. When pumping hot water at sea level, a cooled seal flush is recommended for pumping temperatures above 66C (150F). This temperature should be adjusted for higher elevations to maintain the temperature in the seal chamber approximately 39C (70F) below the atmospheric boiling temperature of water. The heat exchanger may use water as a cooling medium or an air fin convective/air fin-fan if water is scarce. Alternatively, the exchanger may use a suitable process fluid as the cooling medium.

3.8

API Plan 22
API Plan 22 (ASME Plan 7322) is identical to API Plan 21 except for an additional Y-strainer upstream of the orifice. Comments to API Plan 22 are the same as those on API Plan 21, with the additional comment that the coarse filtration provided by a Y-strainer may be of little or no value for protecting the seal other than keeping the orifice from plugging. Note: API Plan 22 has been deleted in API Standard 610, 8th edition.

3.9

API Plan 23
API Plan 23 (ASME Plan 7323) incorporates a pumping ring on the seal that provides recirculation of the process fluid from the seal cavity through a heat exchanger and back to the seal. API Plan 23 has an advantage over API Plan 21 because slightly less power is consumed, but more importantly, the cooled seal flush fluid does not go back into the process stream. Another advantage over API Plan 21 is that less cooling water is required because the cooler removes only seal face generated heat, plus heat conducted from the pump casing by the shaft and seal chamber.

3.10

API Plan 31
API Plan 31 (ASME Plan 7331) takes dirty process fluid from the pump discharge into an inertial separator. Clean fluid comes off the top of the inertial separator, through the orifice, to the seal cavity, to the back side of the impeller, and then back into the process stream. Dirty fluid comes off the bottom of the inertial separator into the pump suction.

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If the process stream is very dirty or is a slurry, API Plan 31 typically is inadequate and is not recommended. (See Section 3.11 of this Practice.) Also, some solids with a density less than twice that of the process fluid do not centrifuge out of suspension effectively, thus making the inertial separator ineffective. Some pump manufacturers offer an optional internal inertial separator with internal passageways that eliminates costly external piping/tubing, and can be used in lieu of API Plan 11 (ASME 7311). An external separator may be the best choice if contaminants are excessive or extremely abrasive, resulting in the need for periodic cleaning or replacement of the separator. Below is typical internal inertial separator particle removal performance:
PARTICLE SIZE 2.5 micron 5.0 micron 8.5 micron PERCENT REMOVED 87 94 96-99

3.11

API Plan 32
API Plan 32 (ASME Plan 7332) is used to inject an external source of clean and/or cooled fluid into the seal cavity. This seal flush fluid goes from the seal cavity to the back side of the impeller and then into the process stream. Requirements/conditions under which API Plan 32 should be used are as follows:
Requirement for a clean flush to the seal if the process fluid is extremely dirty or is

a slurry that prohibits the use of API Plan 31.

Requirement for a cooled flush to the seal if the process fluid is too hot or if cooling

water is not available for an API Plan 21.

Requirement for a non-corrosive seal flush to provide a buffer zone in the seal

cavity to prevent corrosive process fluid from damaging the seal. An example is an isobutane flush into a hydrofluoric acid pump.
Requirement for reduction of flashing or air intrusion (in vacuum service) across

seal faces by providing a flush that has a lower vapor pressure or that raises the seal chamber pressure to an acceptable level. Caution: The seal flush pressure must be greater than the seal cavity pressure. The pump manufacturer should be consulted for recommendations. Also, the fluid flush must be compatible with the process fluid because it will leak into the process fluid.

3.12

API Plan 41
API Plan 41 (ASME Plan 7341) is the same as API Plan 31 except that a heat exchanger is used to cool the flush going to the seal cavity. If cooling water is not available, an air cooled heat exchanger may be used. Occasionally, a cool process stream is used as the cooling fluid. Caution: Proper selection of heat exchanger materials, pressure ratings, and temperature ratings is required.

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PIP REEP001 Seal Flush and Lubrication Guidelines for Centrifugal Pumps

3.13

API Plan 51
API Plan 51 (ASME 7351) is most effectively applied to vertical pumps. API Plan 51 provides for a non-pressurized, dead-end blanket of buffer fluid on the outboard side of the mechanical seal. Some type of auxiliary sealing device is necessary to keep the buffer fluid from leaking to the atmosphere or on the ground. API Plan 51 is typically used with single seals. API Plan 51 is used to:
Prevent formation of ice on the outboard side of the mechanical seal that can cause

problems with the seal faces. This is required for cryogenic and many light hydrocarbon services at start-up below 0C (32F). Methanol is frequently used as a buffer fluid. Special attention is needed when using methanol or ethanol because they evaporate through any vent to the atmosphere or to a low pressure area.
Prevent formation of crystals on atmospheric or outboard side of the mechanical

seal. With certain fluids, such as caustic, crystals form on the atmospheric side of a seal when normal seal leakage comes into contact with air. By providing a blanket of buffer fluid such as glycol, air is prevented from reaching the outside of the seal, thus preventing crystal formation. Note: API Plan 51 has been deleted in API Standard 610, 8th edition.

3.14

API Plan 52
3.14.1 General API Plan 52 (ASME Plan 7352) is typically used with a tandem seal arrangement and allows a buffer fluid to provide lubrication and cooling to the secondary (outboard) seal. 3.14.2 Seal Pot A non-pressurized seal pot with a capacity of 8 to 20 liters (2 to 5 gallons) is connected to the seal housing with supply and return piping or tubing. The piping/tubing should be arranged to allow the buffer fluid to thermosiphon and the tandem seal design should provide pumping action (centrifugal or axial flow pumping ring) to cause forced circulation of the buffer fluid in order to remove heat generated by the seals. Certain applications may require a heat exchanger either in the supply line or as cooling coils in the seal pot to cool the buffer fluid and enhance thermosiphoning. The seal pot should be high enough to provide a minimum level of buffer fluid of 30 cm (1 foot) above the seal. However, the recommended level is 1 meter (3 feet). Additionally, the supply and return piping/tubing from the seal pot to the seal should be adequately sized and arranged to minimize head losses. Piping/tubing must also be arranged to avoid a vapor trap in the return line from the seal to the seal pot.

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Pressurized seal pots (greater than 15 psig) with an inside diameter greater than 15 cm (6 inches) shall be designed and constructed in accordance with ASME Code Section VIII using the material properties from ASME Code Section II, Part D. All seal pots require ASME Code Stamping unless exempted by a local jurisdiction or governing agency. The buffer fluid level in the seal pot must be maintained above the return line entry position in the seal pot to achieve and maintain the thermosiphon effect. If the fluid falls below this level, and if circulation is dependent only on the thermosiphon effect, flow will stop, and cause seal damage. A means of monitoring this low critical level must be provided in the seal pot and may be a local sight glass or a remote low level alarm system. If the primary (inboard) seal leaks, the process fluid leaks into the buffer fluid. A pressure switch or a high level switch in the seal pot can be used to detect this leakage. 3.14.3 Auxiliary Piping/Tubing A flow indicator is sometimes specified in the return line to the seal pot to ensure that circulation is occurring. In general, flow indicators are not recommended because they cause extra pressure drop, thus impeding flow. The return line to the seal pot should be noticeably warmer to the touch when compared to the supply line to the mechanical seal. 3.14.4 Seal Pot Pressure Switch For process fluids with vapor pressure greater than atmospheric pressure, a pressure switch is typically used to detect pressure buildup in the seal pot. The seal pot is usually vented to a flare through an orifice that is typically 3 mm (1/8-inch) in diameter. Normal seal leakage vaporizes and vents through this orifice, but if excessive leakage cannot vent fast enough, the pressure buildup in the seal pot will be detected by the pressure switch. For most light hydrocarbon applications, the pressure switch should be set 100 - 200 kPa (15 - 30 psig) above the flare system pressure. The pressure switch could be set higher, but more leakage would occur before detection. Field adjustable pressure switches are recommended. A block valve between the seal pot and the orifice allows the operator to stop leakage to the flare and to keep the pump running on the secondary seal until the pump can be scheduled for maintenance. Seal pots and seal flush tubing/piping that can be blocked from atmospheric venting should be designed for maximum pump discharge pressure. A pressure gauge should be provided on the seal pot to determine the internal pressure. Seal pot pressure must be vented before depressurizing the pump, or back pressure on the primary seal can cause the primary seal faces to open up and dump buffer fluid into the pump.

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PIP REEP001 Seal Flush and Lubrication Guidelines for Centrifugal Pumps

3.14.5

Seal Pot Level Switches For process fluids with vapor pressures lower than atmospheric pressure or for process fluids with entrained gases, (for example, carbon dioxide, amine) that vaporize with leakage across the seal, a high level switch in the seal pot is typically used to detect seal leakage. If the buffer fluid level reaches the high level switch, the operator can lower the level, and then determine how long it takes for the level to build back up. Build up frequency is the basis for deciding when to conduct maintenance. Because of the low vapor pressures, a pressure gauge on the seal pot may not be necessary. Some purchasers specify a low level switch on the seal to detect a loss of buffer fluid. Loss of buffer fluid typically occurs across the secondary (outboard) seal. Buffer fluid can also be lost past an o-ring in the gland plate, through a leaking piping/tubing fitting, through a leaky drain valve, etc. Loss of the buffer fluid causes failure of the secondary (outboard) seal.

3.14.6

Buffer Fluid It is the purchaser's responsibility, not the pump vendor's, to select a buffer fluid that is compatible with the process fluid and that has lubricating properties for the secondary (outboard) seal. The buffer fluid should be noncorrosive to the seal pot and piping, should not be too viscous, and should not freeze in cold weather.

3.15

API Plan 53
3.15.1 General API Plan 53 (ASME Plan 7353) is typically used with double seals and is similar to an API Plan 52 except that it is a pressurized system with a minimum blanket pressure 140 kPa (20 psi) higher than the zone between the primary (inboard) seal and the back side of the impeller. Occasionally, if process pressures vary significantly, the blanket pressure is set at the relief valve setting. If process pressure exceeds 3,500 kPa (500 psig), setting the blanket pressure at the relief valve setting results in unnecessary secondary seal stress and reduced reliability. A more effective way to minimize stress on the secondary (outboard) seal is by the application of a controlled differential blanket pressure at a level 140 kPa (20 psig) higher than the zone between the primary (inboard) seal and the back side of the impeller. API Plan 53 provides lubrication and cooling for both the primary (inboard) and secondary (outboard) seals. Supply and return piping/tubing should be arranged to allow the buffer fluid to thermosiphon. The double seal design should provide pumping action to cause forced circulation of the buffer fluid in order to remove heat generated by the seals. Certain applications may require an exchanger in the supply line or cooling coils in the seal pot to cool the buffer fluid and enhance thermosiphoning. A sight flow indicator in the

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return line to the seal pot is not recommended. Occasionally, a separate pump is used to provide positive circulation. 3.15.2 Seal Pot Low Level Switch A low level switch in the seal pot detects a loss of buffer fluid from leakage across the primary and/or secondary seals, or leakage through some other path, such as loose fittings. A means of adding make-up buffer fluid under pressure to the seal pot while the pump is running is necessary, or the pump must be shutdown and depressurized, and the seal pot depressurized. The make-up buffer fluid is then added, the seal pot repressurized, and finally the pump is repressurized and restarted. 3.15.3 Seal Pot Low Pressure Switch A low pressure switch in the seal pot is used to detect loss of pressurization of the buffer system. Loss of buffer fluid pressure can upset the primary (inboard) seal, thus allowing process fluid to flow into the API Plan 53 system. Typically, a constant external pressure source prevents loss of proper pressurization.

3.16

API Plan 54
API Plan 54 (ASME Plan 7354) is typically used with double seals and allows for circulation of a clean high pressure fluid from an external system to supply lubrication and cooling for both the primary (inboard) and secondary (outboard) seals. API Plan 54 does not have instruments for detection of seal leakage. Leakage of the secondary (outboard) seal can be detected visually by leakage to the atmosphere. API Plan 54 is also used occasionally with tandem seals with a low pressure clean fluid being used to provide lubrication and cooling of the secondary (outboard) seal. Leakage across the primary (inboard) seal is more difficult to detect than when using an API Plan 52. Careful consideration should be given to the reliability of the barrier fluid source. If the barrier fluid source is interrupted or contaminated, expensive seal failures may occur. Occasionally, if process pressures vary significantly, the seal flush pressure is set at the relief valve setting. If process pressure exceed 3,500 kPa (500 psig), setting the seal flush pressure at relief valve setting results in unnecessary secondary seal stress and reduced reliability. A more effective way to minimize stress of the secondary (outboard) seal is by application of a differential back pressure controlled at a level 140 kPa (20 psig) greater than the zone between the primary (inboard) seal and the back side of the impeller.

3.17

API Plan 61
API Plan 61 (ASME Plan 7361) provides plugged connections in the gland plate to allow for future use as an API Plan 62.

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3.18

API Plan 62
API Plan 62 (ASME Plan 7362) allows an external fluid quench (steam, gas, water, etc.) between the outboard seal and the throttle bushing or auxiliary sealing device. Applications include steam quench on hot oil pumps to prevent coking, water quench on caustic or salt pumps to prevent contact with air (thus preventing the formation of crystals on the outboard side of the seal), and nitrogen quench (purging) to carry certain vapors away that may leak across seal faces.

4.

Lubrication Methods for Bearings

4.1 General
Lubrication method used for centrifugal pump bearings depends on the type of bearing, the size of the pump, and cost considerations.

4.2

Product Lubricated Bearings

Product lubricated bearings are typically used in vertical and sealless pumps that have sleeve bearings. The product is used as a hydrodynamic fluid for centering the pump shaft within one or more sleeve bearings. Except for sealless pumps, sleeve bearings are typically made of rubber, carbon, carbon filled PTFE, or metal, often bronze. Compatibility of the pumped fluid with the bearing material is critical to the success of product lubricated bearings. If the pumped fluid is chemically active or contains solids, special consideration is required for materials. In some cases, an external source of clean product may be required for the lubrication of the bearings. Product lubricated bearings may have axial or helical grooves.

4.3

Lubrication of Antifriction Bearings

4.3.1 General Lubrication methods for antifriction bearings include grease, wet sump, and dry sump. The reliability of antifriction bearings is heavily influenced by the bearing fit, alignment, and the temperature and cleanliness of the lubricant. Consequently, the lubricant should be maintained uncontaminated and at a temperature low enough to preclude its deterioration. 4.3.2 Grease Method The grease lubrication method is typically limited to non-critical pumps that operate at relatively low speeds and temperatures, and that have a driver power of 7.5 kW (10 hp), or less, for horizontal pumps, and 45 kW (60 hp), or less, for vertical pumps.

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The grease lubrication method is used more often in vertical pumps than in horizontal pumps. Grease may be packed in the bearing and sealed at the factory or it may be in the bearing housing surrounding the bearing. If the grease is in the bearing housing, whether on the pump or driver, the bearing vent plug should be removed and the vent left open until the pump has operated at a stable temperature. This procedure minimizes the common tendency to over grease the bearing. 4.3.3 Wet Sump Method 4.3.3.1 General The wet sump lubrication method is the most common in centrifugal pumps. This method is also referred to as oil flooded. Variations of the wet sump method are the simple-wet-sump method, the wet-sump-with-ring-oil method, the wet-sump-withflinger method, and the wet-sump-with-purge-mist method. 4.3.3.2 Simple-Wet-Sump Method In the simple-wet-sump lubrication method, the lower section of the bearing housing serves as a small sump. The sump oil level should be maintained at the centerline of the lowest roller element in the bearing. This is accomplished by a constant level oiler with a typical capacity of 100 cc (4 ounces). Problems encountered with the simple-wet-sump method are the following:
If the oil level is high, frothing and foaming may occur.

Unnecessary heat will be generated and additional power is required.

Proper level is confined to a small range. If the oil level falls

below the lower rolling element, no further lubrication is possible.

With vented bearing housings, there is a tendency for water

vapor to condense inside the bearing housing, particularly on standby units. Water condensate displaces the lubricant and causes pitting of the lower rotating elements, resulting in shortened bearing life. The simple-wet-sump method is the standard lubrication method on many ASME B73.1 pumps. If contamination or heat buildup is possible, other lubrication methods should be considered to improve reliability. 4.3.3.3 Wet-Sump-With-Ring-Oil Method In the wet-sump-with-ring-oil method, a ring rides on the top of the shaft and within the oil sump. The ring is not attached and

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merely rests on top of the shaft. The ring typically rotates at about 50% of the shaft speed. The oil level must be maintained so that the bottom of the ring is immersed in the oil sump, thus lifting and distributing the oil as the ring turns. One advantage of the wet-sump-with-ring-oil method, as compared to the simple-wet-sump method, is that the oil level is below the lowest rolling element, thus eliminating frothing and reducing heat and energy requirements. Maintenance of the proper oil level is critical to reliable operation. The ring bore should be immersed in the oil 6 mm to 9 mm (1/4-inch to 3/8-inch). Problems can be encountered on startup or in cold climates if the oil in the sump is too viscous. If the oil is too viscous, the ring may rotate at a considerably reduced speed and may be unable to provide oil to the rolling elements. 4.3.3.4 Wet-Sump-With-Flinger Method In the wet-sump-with-flinger method, a flinger (disc) is attached to the pump shaft. A flinger works better than a ring when the oil is very viscous. The flinger must be immersed in the oil in the same manner as in the ring oil method. The wet-sump-with-flinger method is the standard lubrication method for most API single stage overhung pumps. This method is generally more reliable than the simple-wet-sump method. 4.3.3.5 Wet-Sump-With-Purge-Mist Method The wet-sump-with-purge-mist method incorporates a variety of features from the other wet sump methods, plus an oil mist purge that is typically supplied from a central oil mist generating console. The main advantage of the wet-sump-with-purge-mist method is the elimination of atmospheric contamination. This increases the mean time between failure of bearings. The wet-sump-with-purge-mist method does not take full advantage of the energy savings that can be attributed to the dry sump method. Drain cups should be installed with the wet-sump-with-purgemist method because the sump oil level increases gradually.

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4.3.4

Dry Sump Method The dry sump lubrication method (pure oil mist) uses a central oil mist generator that provides compressed dry air, saturated with oil mist, directly to the bearing housing. The main advantages of the dry sump method are as follows: The central oil mist generator that serves several pumps requires less manpower for routine maintenance servicing. Since the lubricating oil is once through, bearing wear particles are washed out and not recycled. The need for oil changes is eliminated. Antifriction bearings tend to operate at a cooler temperature compared to sump oil systems. By adding a transparent collection chamber at the bottom of the dry sump, oil mist condensate can be collected and examined for color changes or spectrometric examination. Thus, early detection of bearing distress is possible. 50% less lubricating oil will be consumed compared to the wet sump method, even with the once through oil. Less energy is consumed compared to the wet sump method. The positive pressure within the bearing housing precludes ingress of atmospheric contaminants, thus reducing the potential for corrosion or wear from atmospheric contaminants. Reduction of bearing failures and maintenance costs.

4.4

Pressure Fed Lubrication

Pressure fed lubrication may be used for pumps with hydrodynamic radial or thrust bearings. The pressure fed lubricant acts both as a coolant and a lubricant. This type of lubrication system is almost never used for pumps with driver power less than 225 kW (300 hp). Hydrodynamic bearings are more commonly used on horizontal between-bearing type pumps. They are seldom used on overhung type pumps. Hydrodynamic bearings are typically lined with bearing babbitt. Babbitt materials lose strength rapidly with increasing temperature. The oil film in pressure fed lubrication may be as thin as 0.005 mm (0.0002-inch). Therefore, the oil should be filtered to remove particles larger than the minimum oil film thickness. Because the oil also serves as a coolant, pressure fed lubrication should have oil coolers. The coolers are typically water cooled or fin fan. API Std.610 should be used as a guide for long life pumps in main process stream services that use pressure fed lubrication. Large utility pumps, intermittent duty pumps, or pumps with integral speed increasing gear boxes may use a manufacturers

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Process Industry Practices

September 1995

PIP REEP001 Seal Flush and Lubrication Guidelines for Centrifugal Pumps

standard force fed lubrication system if it has filtration, cooling, prelube pump, and indications of pressure and temperature.

4.5

Lubricant Contamination Considerations

Pumps that are outdoors, especially standby pumps, can have problems with contamination of the bearing lubricant. For new facilities with many pumps, it may be economically feasible to use the wetsump-with-purge-mist lubrication method (4.3.3.5) or the dry sump lubrication method (4.3.4) to assist in keeping the bearing lubricant uncontaminated. These lubrication methods can be used with standard lip seals for bearing isolation. For facilities with only a few pumps, it is probably more economical to use the simplewet-sump lubrication method (4.3.3.2) , the wet-sump-with-ring-oil lubrication method (4.3.3.3), or the wet-sump-with-flinger lubrication method (4.3.3.4). If these lubrication methods are used, they should be used in conjunction with the following features for bearing isolation: Labyrinth-type bearing isolation seals that provide a positive static seal or magnetic-type bearing isolation seals. These types of bearing isolation seals provide a tight seal that precludes the ingress of atmospheric contaminants. Some labyrinth-type bearing isolation seals do not provide an atmospherically tight seal in static conditions. A diaphragm expansion chamber, occasionally referred to as a vent, that is typically cylinder shaped and has an internal elastomeric diaphragm that precludes the ingress of atmospheric contaminants. A bullseye-type level gauge to observe bearing oil level and eliminate the constant level oiler. The constant level oiler does not function properly with diaphragm expansion chamber and bearing isolation seals that provide tight sealing of the bearing housing. Internal pressures vary from slightly positive to slightly negative as the operating temperatures vary throughout the day.

Process Industry Practices

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