API 682 - Shaft Sealing Systems for Centrifugal and Rotary Pumps

5-Day Professional Training Course

Course Overview

This intensive 5-day API 682 training course provides comprehensive knowledge of mechanical seal systems for centrifugal and rotary pumps according to API Standard 682 (5th Edition). The course covers seal design, selection, installation, operation, troubleshooting, and maintenance of shaft sealing systems in process industries.

Target Audience: Mechanical engineers, reliability engineers, maintenance engineers, pump engineers, rotating equipment specialists, seal technicians, plant engineers, and professionals responsible for pump sealing systems in oil & gas, petrochemical, chemical processing, and power generation industries.

Day 1: Fundamentals and API 682 Overview

Morning Session (0900-1230)

Module 1: Course Introduction & Sealing Fundamentals

• Course objectives and structure

• Introduction to shaft sealing technology

• History and evolution of mechanical seals

• Why seals fail: common causes and statistics

• Economic impact of seal failures

• Safety and environmental considerations

Module 2: API 682 Standard Overview

• API 682 5th Edition (2021) structure and scope

• Purpose and applicability

• Key changes from 4th Edition

• Integration with API 610 (Centrifugal Pumps)

• Integration with API 676 (Rotary Pumps)

• Terminology and definitions

• Compliance requirements

• Documentation and data sheets

Afternoon Session (1330-1700)

Module 3: Mechanical Seal Design Principles

• Basic seal components and nomenclature

• Seal face materials (carbon, silicon carbide, tungsten carbide, ceramics)

• Secondary sealing elements (O-rings, gaskets, wedges)

• Seal face loading mechanisms

• Balance ratio and closing forces

• Heat generation and dissipation

• PV (Pressure-Velocity) limits

• Lubrication regimes (boundary, mixed, hydrodynamic)

• Face geometry and flatness requirements

Module 4: Seal Configuration Types

• Single seals: Inside/outside mounted, pusher/non-pusher

• Dual seals: Back-to-back, face-to-face, tandem arrangements

• Cartridge seals: Benefits and applications

• Component seals vs. cartridge seals

• Split seals for repair without pump disassembly

• Mixing device seals

• Seal selection criteria based on service conditions

Day 2: API 682 Seal Arrangements and Plans

Morning Session (0900-1230)

Module 5: API 682 Seal Arrangements

• Arrangement 1: Single seal - unpressurized

• Arrangement 2: Single seal - pressurized

• Arrangement 3: Dual seal - pressurized barrier fluid

• Arrangement 4: Dual seal - unpressurized buffer fluid (API 682 5th Edition)

• Selection criteria for each arrangement

• Application guidelines

• Advantages and limitations

• Cost-benefit analysis

Module 6: API 682 Piping Plans (Part 1)

• Overview of API 682 piping plans

• Plan 01: Recirculation from seal chamber

• Plan 02: Dead-ended seal chamber

• Plan 11: Recirculation from pump discharge

• Plan 13: Recirculation from pump discharge with cyclone separator

• Plan 14: Recirculation with external heat exchanger

• Plan 21: Recirculation from seal chamber with heat exchanger

• Plan 23: Recirculation from pump discharge with heat exchanger

• Plan 31: Recirculation with internal cyclone separator

Afternoon Session (1330-1700)

Module 7: API 682 Piping Plans (Part 2)

• Plan 32: External flush from external source

• Plan 41: Circulating throat bushing

• Plan 52: Unpressurized buffer fluid for dual seals (Arrangement 4)

• Plan 53: Pressurized barrier fluid with bladder accumulator (Arrangement 3)

• Plan 54: Pressurized barrier fluid with external reservoir (Arrangement 3)

• Plan 72: Quench/steam connections

• Plan 74: Vent/drain connections

• Piping plan selection methodology

• Fluid compatibility considerations

• Material selection for plan components

Workshop 1: Seal Arrangement and Piping Plan Selection Exercise

• Given process conditions, select appropriate arrangement

• Design piping plan for specific applications

• Calculate flow rates and heat loads

Day 3: Design, Materials, and Installation

Morning Session (0900-1230)

Module 8: Seal Support Systems Design

• Heat exchangers: Sizing, selection, tube vs. plate type

• Reservoirs/accumulators: Volume calculations, level monitoring

• Cyclone separators: Function and sizing

• Thermosiphon systems: Natural circulation principles

• Pumped circulation systems: External pumps

• Control and monitoring instrumentation:

  • Pressure gauges and transmitters

  • Temperature sensors

  • Flow indicators

  • Level switches

  • Barrier/buffer fluid quality monitoring

Module 9: Materials Selection

• Seal face materials:

  • Carbon grades (resin impregnated, antimony, metal filled)

  • Silicon carbide (reaction bonded, sintered, converted)

  • Tungsten carbide (nickel binder, cobalt binder)

  • Ceramics (alumina, zirconia)

  • Material pairing compatibility

• Elastomers and secondary seals:

  • Nitrile (NBR), FKM (Viton), EPDM, Kalrez, PTFE

  • Chemical compatibility

  • Temperature limits

• Metallic components: Stainless steels, Hastelloy, titanium, Monel

• Material selection based on process chemistry

Afternoon Session (1330-1700)

Module 10: Installation and Commissioning

• Pre-installation inspection checklist

• Seal installation procedures

• Critical installation parameters:

  • Seal chamber dimensions and tolerances

  • Shaft runout and end play limits (API 610 requirements)

  • Seal face perpendicularity

  • Compression settings for pusher seals

  • Torque specifications

• Support system installation

• Pressure testing procedures

• Flushing and priming systems

• Pre-commissioning checks

• Start-up procedures and monitoring

• Run-in period considerations

Module 11: Operation and Maintenance

• Operating envelope and limits

• Monitoring parameters (temperature, pressure, leakage)

• Normal vs. abnormal operation indicators

• Planned maintenance activities

• Seal life expectancy factors

• Spare parts management

• Documentation and record keeping

• Mean Time Between Failures (MTBF) tracking

Workshop 2: Installation Procedure Development

• Create installation procedure for specific seal

• Identify critical measurements

• Develop checklist

Day 4: Troubleshooting and Failure Analysis

Morning Session (0900-1230)

Module 12: Seal Failure Modes and Root Cause Analysis

• Common failure modes:

  • Face wear (excessive, uneven)

  • Thermal cracking and heat checking

  • Face chipping and fracture

  • Secondary seal extrusion

  • Elastomer deterioration

  • Corrosion and erosion

  • Coking and product buildup

  • Crystallization

• Root cause analysis methodology:

  • Data collection and documentation

  • Visual inspection techniques

  • Face pattern analysis

  • Measurement and dimensional checks

  • Process condition review

  • Operating history analysis

Module 13: Troubleshooting Guide

• Excessive leakage:

  • Causes: face damage, improper installation, process upsets

  • Diagnostic approach

  • Corrective actions

• High seal temperatures:

  • Inadequate cooling/lubrication

  • Support system failures

  • Solutions and preventive measures

• Short seal life:

  • Process-related causes

  • Design inadequacies

  • Installation errors

• Vibration and noise:

  • Seal hang-up

  • Cavitation effects

  • Pump/driver issues

• Premature wear:

  • Abrasive particles

  • Dry running

  • Chemical attack

Afternoon Session (1330-1700)

Module 14: Advanced Troubleshooting

• Process condition impacts:

  • Temperature excursions

  • Pressure fluctuations

  • Cavitation and flashing

  • Solids content and particle size

  • Polymerization and product fouling

  • Deadheading and low flow

• Support system problems:

  • Heat exchanger fouling

  • Reservoir contamination

  • Blocked piping plans

  • Instrumentation failures

  • Barrier fluid degradation

• Pump-related issues affecting seals:

  • Excessive shaft deflection

  • Bearing problems

  • Impeller imbalance

  • Cavitation

Module 15: Case Studies - Seal Failures

• Refinery case studies

• Chemical plant incidents

• Offshore platform experiences

• Root cause analysis examples

• Lessons learned and best practices

• Cost of failures vs. prevention

Workshop 3: Failure Analysis Exercise

• Analyze actual seal failure photographs

• Determine root causes

• Recommend corrective actions

• Group presentations

Day 5: Special Applications and Performance Optimization

Morning Session (0900-1230)

Module 16: Special Service Applications

• High temperature services (>300°C/570°F):

  • Design considerations

  • Cooling requirements

  • Material selection

• Cryogenic services (<-40°C/-40°F):

  • Low temperature materials

  • Thermal management

• High pressure services (>150 bar/2200 psi):

  • Seal face loading

  • Balance ratio optimization

• Slurry and solids handling:

  • Flush plans for particle removal

  • Wear-resistant materials

  • Seal face designs

• Polymer and crystallizing services:

  • Prevention of product buildup

  • Heating and quench systems

• Hydrocarbon and light ends:

  • Vapor pressure considerations

  • Cooling requirements

• Corrosive chemicals:

  • Material compatibility

  • Special alloys

Module 17: Gas Seals and Dry Running Seals

• Dry gas seals:

  • Operating principles

  • Applications in compressors and pumps

  • Support systems

• Non-contacting seals:

  • Lift-off mechanisms

  • Groove patterns

• Comparison with conventional mechanical seals

• Selection criteria

Afternoon Session (1330-1700)

Module 18: Performance Optimization and Reliability

• Reliability engineering approach:

  • Failure rate analysis

  • Weibull analysis for seal life

  • Reliability centered maintenance (RCM)

  • Condition-based monitoring

• Seal testing and qualification:

  • API 682 qualification testing requirements

  • Performance testing procedures

  • Acceptance criteria

• Upgrading existing installations:

  • Evaluation criteria

  • Retrofit considerations

  • Cost justification

• Emerging technologies:

  • Magnetic drive pumps (seal-less)

  • Canned motor pumps

  • Advanced seal face coatings

  • Smart seals with sensors

  • Digital twins and predictive analytics

Module 19: Specifications and Procurement

• Writing seal specifications

• API 682 data sheet preparation

• Vendor selection criteria

• Technical bid evaluation

• Quality assurance requirements

• Factory acceptance testing (FAT)

• Spare parts recommendations

Module 20: Course Review and Assessment

• Key learning points summary

• API 682 quick reference guide

• Best practices checklist

• Interactive Q&A session

• Final Examination: 60 questions, 2 hours, 70% passing score

• Course evaluation

• Certificate presentation

• Post-course support information

Learning Outcomes

Upon completion, participants will be able to:

✅ Understand API 682 standard requirements and applications
✅ Select appropriate seal arrangements for various services
✅ Design and specify piping plans for seal support systems
✅ Specify materials based on process conditions
✅ Install mechanical seals correctly per API standards
✅ Troubleshoot seal failures and identify root causes
✅ Optimize seal performance and extend seal life
✅ Develop maintenance strategies for sealing systems
✅ Evaluate and specify seal systems for new applications
✅ Improve pump reliability through proper seal management