Badr Petroleum Company – Obaiyed Field

OVERHAUL REPORT FOR

MECHANICAL SEAL OF P-2402
CONDENSATE EXPORT PUMP
26 Nov 2024

Prepared by: Eng. Hassan Kataya

 Corrective Maintenance Report

Equipment Specifications:

Tag No.: P-2402

Type: BB5 Pump
Service: Condensate Export Pump
Manufacturer: IDP
Model: 8WCC15 - 9 Stages
Serial no.: 7405009
Capacity: 473 mз/h
Suction Pressure: 5.34 bar
Discharge Pressure: 123 bar
Pumping Temperature: 39o C
Specific Gravity: 0.79
Line bearing: Sleeve
Thrust bearing: Tilting Pad
Motor Speed: 2970 RPM
Coupling: TSKS 1850
Seal Manufacturer: John Crane
Seal Size & type: 48RP/48LP Cartridge
Seal API Plan: PLAN 11/53/61

Action Taken:

• Fully dissemble the mechanical seal.

• Inspect the internal parts.
• Replaced the damaged parts
• Replace the Soft element
• Cleaning all parts.
• Re-assemble the mechanical seal.
• Test the mechanical seal using Static Air leak test
• Return the Mechanical Seal to Material warehouse.

Maintenance Team:

• E. Hassan Kataya
• E. Amr Tawfik

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Maintenance Activities:

Disassembly

• Start by loosening the set screws (POS 29) that holds the drive collar (POS 24) with
the sleeve (POS 24).
• Then remove the Drive Collar (POS 24)
• Then remove the 2x Transit Clip also known as spacers (POS 25)
• Then remove the set screws that holds the setting plate with the gland.
• Then remove the Setting Plate (POS 23)
• Gently remove Segmental Bush (POS 32), it consists of 3 pieces and garter spring.
• Gently remove the 3x Spring (POS 33) under the Segmental Bush.

24 23

25
25

29 24

33 33 32 29

23
32

33

33

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 Disassembly

• Loosening the set screws (POS 28) that holds the Cover Plate with Adaptor Plate.
• Gently lift the Adaptor Plate assembly along with Sleeve, Inboard seal assembly and
outboard rotating assembly (POS X).
• Remove the O-ring (POS 30) between Cover Plate and Adaptor Plate.
• Remove outboard stationary PG Seat (POS 17)
• Then remove the O-Ring (POS 11) under the PG Seat

28

X
28 30 11

30

17

11
17

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 Disassembly

• Loosening the set screws (POS 16) that holds the Outboard rotating assembly with
shaft sleeve.
• Gently lift the Outboard rotating assembly (POS X1).
• Gently lift the Adaptor Plate assembly (POS X2)

X1

16

X2 16 X1

X2

X2

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 Disassembly

• Start with the Adaptor Plate assembly, gently remove the ‘D’ Seat (POS 7)
• Then remove the O-ring (POS 1) under the ‘D’ Seat.
• Start loosening the set screws (POS 6) the holds the inboard rotating assembly with
the sleeve
• Gently lift the inboard rotating assembly (POS X3)
• Remove the O-ring (POS 30) which is between sleeve and the shaft.

7
7
1

6 X3

6
30

30

X3

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 Disassembly

• Now with the outboard rotating assembly, compress the springs with special tool to
allow easy removal of the snap ring.
• Then remove the snap ring (POS 15)
• Then remove the balanced face (POS 12) and the O-ring beneath it (POS 10)
• Then remove the thrust ring (POS 14) along with 18X springs beneath it (POS 18)
• Until the retainer along with pumping scroll are only left

15

14 15
18

12

12

10

18
5

10

14

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 Disassembly

• Now with the Inboard rotating assembly, compress the springs with special tool to
allow easy removal of the snap ring.
• Then remove the snap ring (POS 5)
• Then remove the balanced face (POS 2), the O-ring beneath it (POS 1) already slipped
when we removed the rotating assembly from sleeve.
• Then remove the thrust ring (POS 4) along with 14X springs beneath it (POS 8)
• Until the retainer is only left
• Now clean all metallic part by manual cleaning or with the Ultrasonic cleaning machine.
• Ensure that all flushing passage are clean for proper cooling and lubrication while in
service

5
2
4

5
8
4 2

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 Inspection

• The springs of the segmental bush is broken.

• There is a lot of contamination under the segmental bush.
• The inboard rotating face is completely broken.
• The outboard rotating face has damaged face.
• The inboard stationary seat has damaged face.
• The outboard stationary seat is at fair condition, has minor wear.
• The anti-rotation slots of the inboard retainer has wear.
• The anti-rotation slots of the outboard retainer has wear.

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 Assembly

• Prepare all the cleaned parts, new spare parts and the new O-rings.
• Place the 14X Springs (POS 8) of the inboard rotating assembly then place the thrust ring
(POS 4).
• Place the balanced face (POS 2), gently push it down to install the snap ring (POS 5).
• The O-ring (POS 1) will install while assembling with the sleeve.
• Then with the outboard rotating assembly, install the 18X springs (POS 18) then proceed
as the inboard and install O-ring (POS 10). Apply silicon grease to all O-rings to avoid
damage, twisting or come out of place for O-rings while assembling.

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 Assembly

• Install O-Ring (POS 1) on sleeve, then gently install the inboard rotating assembly.
• Tighten the set screw (POS 6) to hold the inboard rotating assembly with the Sleeve
• With the adaptor plate install O-Ring (POS 1) “Same O-ring as the rotating”.
• Then gently install the ‘D’ Seat (POS 7).
• Gently place the adaptor plate assembly over the inboard rotating assembly.
• Gently install the outboard rotating assembly and tighten the set screws of it.

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 Assembly

• Install O-ring (POS 11) in the Cover plate, then gently install the ‘PG’ Seat (POS 17).
• Install O-ring (POS 30) on the Cover plate assembly
• Gently install the cover plate assembly along with the sleeve, outboard and inboard
rotating assembly (POS X) over the cover plate assembly.
• Tighten set screws (POS 28) firmly. Rotate the mechanical seal to install the 3x springs
(POS 33) then gently install the segmental bush (POS 32).
• Install the retaining plate (POS 23) along with 2x Transit Clip (POS 25) and tighten the
set screws of it.
• Finally install the drive collar (POS 24). Compress the mechanical seal and place the
transit clip under drive collar to maintain the working compression of the mech seal.

X 28 30 11
23

29

24

17 33 32

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 Testing

• Install shaft sleeve Old O-ring “for test purpose only”.

• Place a dummy shaft in the sleeve.
• Install gland old O-ring “for test purpose only”.
• Place the mechanical seal on the test bench.
• For inboard seal test only, plug both ‘F1’ & ‘F2’, Apply air pressure 2 bar, check for any
leaks or pressure drop for about 10 mins
• For inboard & outboard seal test, connect air source to ‘BI’ and plug ‘BO’, Apply air
pressure 2 bar, check for any leaks or pressure drop for about 10 mins

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References:

:
Spare Used:

Description SAP No. Quantity

O-RING 2490/123/134 1000773349 2
BALANCED FACE A/A4822/1/530 1000773354 1
SEAT A/A4824/1/277 1000773359 1
O-RING 2470/123/134 1000773358 1
O-RING 2530/123/134 1000773357 1
BALANCED FACE A/A4646/1/530 1000773356 1
"PG" SEAT 1111/D99/277 1000773355 1
O-RING 2640/123/134 1000773325 2
O-RING 2430/123/134 1000773295 1
RETAINER ST/ST A/A4823/1/001 1000773300 1
RETAINER ASSY ST/ST W/21611/1/001 1000773299 1

Maintenance Team:

• E. Hassan Kataya
• E. Amr Tawfik

Comments:

This mechanical seal suffers from major damage of seal faces, the O-rings were in fair condition
no cuts nor extrusion.
Damage mainly occurred as a result of pump shaft failure were the shaft has broken at the thrust
collar section.

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