October 2006 - Component Seals

ORACLEOctober 2006-bOil & Gas Special EditionAESSEAL ® Voted BestManufacturer in the UKIn June 2006 AESSEAL ® won what is considered by many to be themost prestigious manufacturing prize in the UK: the Overall Awardfor Manufacturing Excellence from IMechE MX2006 Awards.Pipeline Seal InstallationsPlan 53b SystemsPreferreferred ed Supplierfor PipelinesNew Reliability FocusedWebsite is LaunchedSealing LNG in UAEUCAPIs Save e North SeaOffshore e PlatformExtended MTBT Successat PetrPetrobras2007 HydrocarbonProcessing ConferenceenceSuccess at PemexPContaining EmissionsSealing Gas PlantsAPI Seals installedin AsiaThis is a major endorsement ofAESSEAL’s strategy: effective andefficient operation. It is also arecognition of all its efforts gearedtowards providing exceptionalcustomer service. These servicevalues were put to the test on the firstweekend of August 2006, where acritical application on a North Sea oilplatform was left without a seal. Withinhours from Sunday morning to Sundayevening, AESSEAL ® produced a highlybespoke CAPI (Cartridge API) solutionfrom exotic materials and flew it to theplatform with an offshore engineer tohelp install the seal. See pages 4 and16 for further information.NEWSFLASHAESSEAL ® also IndependentlyNamed as the UK’s s BestEngineering Company See Page 6

Canadian Pipeline SealsIn May 2006 two 4.760" single EASASEALs(Ref: AZA10880SGS - 00201S) were fitted to aBingham HSB pump, in the pump house of apipeline station in Alberta, Canada.The seals were supported with API Piping Plans11 & 61 and operated on a 5°C (41°F) oil duty at99 bar (1435psi) at 1800 rpm.The conventional sealing technology, adoptedby previous seal suppliers (shown below left)leaked, resulting in coked oil around the seal.EASASEAL installed on Bingham HSB pump at Alberta pipeline station.Above left: Failed Competitor Pipeline Seal Before Removal.Above right: EASASEAL installed on Bingham HSB pump.2The revolutionary technology used in theEASASEAL product (as explained on page12), has to date provided outstandingperformance, showing no signs of seal leakage.Plan 53b System Installedon North Sea PlatformIn 2006 a clean-up package, comprising aframe mounted system and CAPI A1 dual seal,(Ref: AZA10060013P) was installed on theBuzzard North Sea platform.The system operates with a (50/50) ethyleneglycol/water mix at 24-27 barg (390 psi), usingnitrogen as its pressure source and plant watersupplied at 21°C (70ºF) and 10 barg (145 psi)pressure. Clearly, the electrical equipment ofthe system is Zone 1 IIB T3 rated.The clean-up package processes pressurisedbatches of solids and associated oily water,which are separated from the produced watertreatment package and de-sanding cyclones.Jet washed material from the processseparators, test separators, second stage oilseparator and degasser surge drum is alsorouted to the clean-up system.This self-contained package, installed on theprocess module level 1 deck in a Zone 1hazardous area, represents one of the manybespoke, turnkey solutions executedby AESSEAL ® .High pressure Bingham HSB pump.AESSEAL ® Plan 53b System

BAKU-TBILISI-CEYHAN(BTC) Pipeline ProjectThe Baku-Tbilisi-Ceyhan (BTC) project is a£1.83 (€2.71/$3.40) billion investment to unlocka vast store of energy from the Caspian Sea byproviding a new crude oil supply to Turkey foronward delivery to world markets.Traversing 1768km (1098 miles) of often remoteand challenging terrain, the BTC pipeline will beable to transport up to one million barrels ofcrude oil per day from a cluster of discoveries inthe Caspian Sea, known collectively as theAzeri, Chirag, and deepwater Gunashli(ACG) field.AESSEAL Turkiye won the mechanical sealcontract from BOTAS International Ltd (BIL)which runs the Turkish side of the BTC pipelineand has been selected as a preferred supplier.This contract covers the maintenance andtechnical support service for all mechanicalseals for the pipeline as well as the supply ofnew mechanical seals and additional manpowerservices on an “On Call” basis. The duration ofthe initial contract is for two years, with anoption to extend for an additional year with anannual review thereafter.The contract includes a site survey and adatabase set-up, technical advice, repair ofexisting seals and supply of new seals. Themain seals of choice are CAPI A1 single anddual seals.Above: Pipeline from Azerbaijan, through Georgia.By creating the first direct pipeline link betweenthe landlocked Caspian Sea and theMediterranean, the BTC project will bringpositive economic advantage to the region andavoid increasing oil traffic through thevulnerable Turkish Straits.New Reliability FocusedWebsite is LaunchedPeople rarely dedicate their working career and retirement to the pursuit ofBest Practice industrial solutions.Heinz P. Bloch P.E. is considered by many as the exception to thisstatement. For the last 40 years he has relentlessly pursued the research,use and promotion of Reliability Focused Solutions.Heinz Bloch’s professional career included long-term assignments asExxon Chemical’s Regional Machinery Specialist for the United States. Hehas also held machinery-oriented staff and line positions with Exxonaffiliates in the United States, Italy, Spain, England, Japan and TheNetherlands.Troubleshooting and reliability improvement missions have taken him to process plants andmanufacturing facilities in 30 or more countries on six continents. He has conducted hundreds ofpublic and in-plant courses internationally and is the author of 17 books and over 340 technicalpapers or similar publications.AESSEAL ® is proud to share synergistic views with those of Heinz and is delighted that he officiallyopened its new test house which bears his name. These views are summarised on this newwebsite: http://www.heinzbloch.com3

AESSEAL ® “The BestManufacturer in Britain”The Pump and Seal Industry was wellrepresented at the MX2006 Awards heldannually by the Institution of MechanicalEngineers (IMechE).The IMechE has been runningthese awards as a way ofacquiring benchmarkinginformation about UKmanufacturers and to encouragethe use of Best Practice.Sulzer Pumps (UK) Limitedreceived the Barclays Award forFinancial Performance.AESSEAL ® received TheKellysearch Award for CustomerFocus, The WarwickManufacturing Group Award forLogistics and ResourceEfficiency and TheManufacturing Advisory ServiceAward for ManufacturingExcellence – Overall Winner.Richard Cook, AESSEAL’s Production Directorcommented, “Rigorous benchmarking is centralin our pursuit of business excellence, includinga top-down commitment to the EFQMExcellence Model. The MX2006 assessmentprocess is thorough, taking a broad crosssection through all business disciplines. Theoutput from this and the associatedbenchmarking report is probably the singlegreatest benefit to those who participate.”According to John Ling, MX Manager: “In somepast years, the destination of the overall awardfor the best all-round performance in the MXcompetition has been the subject of debate,and even wrangling, among the final judges.“In MX2006, several entrants were short listedfor more than one award, but only one was astrong contender for every single categorywhere it filled in the self-assessment. In possiblyrecord time, and unanimously, AESSEAL ® wasdeclared the overall winner of MX2006.”4Leading Pumping RingTechnology Used Effectively“There is little point having the best tools in theworld, if they are not used correctly”.CAPI A1 Dual Seal Pumping RingTypical Position of Competitor API Pumping RingThe drawing, shown bottomleft, from API 682 clearlyrepresents typical Plan 53 or54 pumping arrangementsoffered by many of the mainincumbent mechanical sealsuppliers to the HydrocarbonProcessing Industry.Many engineers understandthat mechanical seal lifelongevity is a function of theseal environment, specificallyhow heat from the seal face isdissipated in the assembly.Plan 54 forced circulation systems, or Plan 53systems are only effective if the hot fluid at theseal faces is being adequately replaced orexchanged. An analogy for this is that you canpour water around a camp fire to cool thesurrounding grass, but it will not help to put outthe fire.The fact is that the mechanical seals of theincumbent suppliers to the HydrocarbonProcessing Industry have no room to provide adeflector inside the seal to direct the barrier fluidto where it is needed at the inboard seal faces.Their designs are based around the use ofcomponent seal technology screwed onto asleeve. Effectively, engineers must ask thequestion; why does one supplier provide, asstandard, a seal to a design which makeseffective use of a Plan 53 system, such as theCAPI seal shown, and another provide a sealwith near zero chance of an effective barrierfluid heat transfer to occur?

CAPIs Save North SeaOffshore PlatformSince October 2002, several 85mm CAPI A1 dualcartridge seals (Ref: AZA8796) and API 682 (AES28-SC) systems have been successfully runningon Warman 3/2 CCHH pumps, pumpingproduced water with methanol, oil and heavysand content.Two closed drains pumps are used to collect theslops from the drains system on the offshoreplatform and pump them back into the separationsystem so that nothing is wasted.Support SystemsPlan 53 CAPI Bi-Directional Pumping RingPlan 23 Bi-Directional Pumping RingInstalled CAPI SealsIf both of the pumps go out of service, given theircriticality, the asset is shut down until they arereinstated.As of June 2006 the AESSEAL ® CAPI seals werestill running and had never been out for repairsince their installation, despite the severity of theapplication.In August 2006 one of the seals was returned toAES for repair. The site engineers stated that,remarkably, the seal had not failed. The pump hadgone down because the pump casing hadgiven way.Due to the critical situation, AESSEAL ® produceda replacement seal over the weekend and flew itto the offshore platform with an offshore certifiedservice engineer. It wasn’t until the engineerviewed the application, that the full story wasrealized.45004000177157The seals operated in an API Plan 53 system witha seal chamber pressure at 13 barg (188 psi) anda shaft operating at 2100 rpm.The pipework connecting the seal and systemmeasured over 3 meters (10 feet) horizontally and2 meters (6.5 feet) vertically, with snakes andpipe bends everywhere. This is contrary to everyBest Practice text book guideline.Upon inspection of the application, the engineerrealized that part of the seal success was dueto the outstanding performance of the CAPIintegral pumping ring. This incredible bidirectionalpumping ring effectively circulated,against all the odds, the barrier fluid to thesystems.The innovative design of the CAPI pumping ring isclearly evident from the recently publishedgraphs, which show a 100mm (4.000") CAPIcirculates 6.2 litres/min (1.64 gals/hour) of barrieroil at 3,600 rpm.Head mm35003000250020001500100050000 2(0.53)2000 rpm1800 rpm1500 rpm46(1.06)(1.59)Flow L/Min (US Gal/Min)CAPI A1 Dual Seal Pumping Ring Performance on Diesel Oil.3600 rpm3000 rpm8(2.11)10(2.64)13711898785939200Head inchesIt is the world leading performance of thisAESSEAL ® innovation, especially when coupledwith an effective heat exchange configuration atthe inboard seal faces, which creates the fine linebetween application sealing success and failure inthe real world. See page 4.5

Success at PetroleumDevelopment Oman (PDO)As the world’s appetite for oil grows, highspeed, quiet running and low capital cost screwpumps become more popular, due to theirexcellent suction performance and pulse freeflow. Twin screw pumps for cargo handlingwere found to be most suitable for the oil andmarine industry, allowing a wide range ofviscosity of hydrocarbon liquids to be efficientlypumped at all temperatures.PDO employs many screw pumps installedthroughout the oil fields of Oman. In January2004 the MagTecta was presented to PDOFor the second time this year, AESSEAL plc hasbeen recognised for business excellence.On Friday 29th September, following on fromthe overall UK award at the ManufacturingExcellence Awards (MX2006) in June, theCompany won two further coveted honours atthis year's Best Factory Awards (BFA)ceremony, which was sponsored by CranfieldUniversity, School of Management.Having been shortlisted in a total of fiveand one particular engineer, Mr John Joyce, ex-Sulzer Pumps and Head of Maintenance forPDO South Fields, appreciated the addedbenefits of enhanced bearing isolation,particularly the fact that the MagTecta did notdamage expensive shafts.John no longer works with PDO and hasactually joined Shell in Nigeria, but with hisenthusiasm and drive along with assistancefrom the central workshop personnel AESSEAL ®has to date installed 28 MagTecta bearingisolators into PDO.AESSEAL ® Named the UK’sBest Engineering Businesscategories (plus the overall Best Factorycategory), AESSEAL ® was acknowledged as theBest Engineering Plant (in the UK) and BestFactory Regional Award (North and Scotland).The Company also received a judges 'HighlyCommended' award in the Health, Safety andEnvironment Award category.Benchmarking reports from the assessmentprocesses have since been received and willbe reviewed for improvement opportunities.6

Extended MTBF atPetrobras, ArgentinaAESSEAL ® has been extending rotating equipment MTBF at Petrobras Ricardo Elicaldein Argentina for a number of years. A few examples follow:The top photo shows a Byron Jackson SJA pump, which operates in a hot light gas oilapplication at 300ºC (572ºF). The pump was successfully sealed with a 1.750"AntCarb/SIC SAC BSFG in September 2002, extending the equipment MTBF to 1034days from less than 365 days, when the plant used other branded designs. This successis supported by a second BSFG which has operated for over 764 days and is stillrunning.The middle photo shows a Coppus RLH 19 steam turbine that suffered from prematurefailure every 6 to 12 months due to lubricant contamination and bearing damage. Clearly,this was not only a considerable inconvenience, which resulted in lost production, butalso the associated costs of reactive maintenance were high. In January 2003,AESSEAL ® installed a 2.250" TXS MagTecta to seal the bearing chamber of the turbineand this has been running problem-free ever since.In October 2004, AESSEAL ® installed a 2.125" TC/TC//TC/C/Viton DMSF andSSE25 support system on a Worthington 4HN 153 pump. The pump suffers fromvibration and cavitation, primarily a result of air pockets in the processed fluid, which istypical in this type of application. Given the intermittent duty, the pump operates withina pressure range of 2-12 bar (30–175 psi). After two years service, the DMSF seals arestill working leak free.Pablo Nogues of AESSEAL ® Argentina S.A, would like to thank Petrobras RicardoElicalde for their kind permission to publish these case histories.The API 682 Seal SupportSystem RangeIn 2002 AESSEAL ® launched a range of API seal support systems, AES-28, designed to operatein harmony with the AESSEAL ® API 682 mechanical seal range. The robust and adaptable AES-28 modular vessel can be supplied with a range of options to suit individual plant andpump specifications.Similar to API mechanical seal design, API specifications regulate thedesign of the pressure vessels used in the Refinery and PetrochemicalIndustries. The AES-28 systems are based around a 316 stainlesssteel, 28 litres/7.39 US galls vessel, which comprises a weld pad levelgauge and an integral cooling coil as standard. This vessel has a designrating of 45 barg at 38°C/652.7 psig at 100°F.The AES-28 vessels are designed and manufactured in accordancewith a wide range of international specifications including ASME III Div.11995 agenda 1997, AD Merkblatter 2000, API module H, ISO9001 andare certified by TÜV to cover PED requirements.The aggressively priced AES-28 is available in a choice of threeinventoried vessels: screwed connection, socket welded and buttwelded. A variety of component options are available to adapt thevessel to specific pump applications. These options include electricalequipment, which is intrinsically safe or explosion proof.7

Why AES and API?Pointers from the 682 SpecificationAESSEAL ® is believed to be the only majormechanical seal and system supplier to theglobal Hydrocarbon Processing Industry, whichhas applied 21st century best seal designpractice to create a range of API qualifiedproducts, in the literal and non-literal manner ofthe specification.3.10The clues, which help to illustrate this fact, aregiven in the API 682 specification. Clearsimilarities should be apparent between thesepoints and the designs of non-AESSEAL ® supply.6.1.6.46.1.5.16.1.1.116.1.1.5All AESSEAL ® API designs have multiplesprings, which are not in contact with theprocessed media. This standardisedapproach is clearly more suitable for allapplications, specifically those for sealingcorrosive media.6.1.6.4 - Unless otherwise specified, seals withmultiple coil-springs shall be Alloy C-276 …..6.1.5.1 - The single spring has advantagesand disadvantages. For corrosive services,the wire in single springs is significantlygreater in cross-section providing a greatercorrosion allowance……Multiple coil-springseals tend to be more axially compact thansingle coil-spring seals. Multiple springs alsotend to provide a more even loading.Standard AESSEAL ® API seal designs havepressure balanced seal faces which performexcellently in both positive and negativepressure applications. This feature preventsseal face distortion and damage that canresult with positive restraining means.6.1.1.11 - For vacuum services, all sealcomponents shall be designed with a positivemeans of retaining the sealing components toprevent them from being dislodged.AESSEAL ® Type A seal designs are, asstandard, a Stationary flexible element. Thisconfiguration is deemed to provide addeduser value, as described by thespecification, over a rotary configuration.Rotary designs are available on request.6.1.1.5 - a stationary flexible element should beprovided if…surface speed exceeds 23m/s…..ifpump case or gland plate distortion andmisalignment exist due to pipe loads, thermaldistortion, pressure distortion…ifperpendicularity of the seal chamber mountingsurface to the shaft is a problemStandard AESSEAL ® API682 Type A sealdesigns incorporate a one piece cartridgesleeve which carries the rotary seal faceindependently of a secondary drive collar.Drive collars are commonly found incomponent seal designs where setscrews areused to secure the seal to the equipmentshaft. Seal designs, which employ frictionaldrive setscrews, in contact with the processmedia, are viewed by many as not conformingto the spirit of a true cartridge seal design.3.10 – cartridge seal; completely self-containedunit which is pre-assembled and preset beforeinstallation.8The above API682 specification extracts, are just a few examples which help to illustrate thehidden depth and thought process behind the AESSEAL ® CAPI seal design.

Containing Emissions andFlashing Hydrocarbon SealingRefineries around the world operate underrestrictive emission levels for volatileorganic compounds (always = 10minutes > = 10minutesTest CriteriaAESSEAL ® Qualification Test CertificationTest Results9

Common Sense Sealingfor Electric MotorsAn alumina works in Ireland purchased twonew 900kW electric motors with variable speedpackages for over £27,000(€40,000/$50,000)each.After a presentation on LabTecta, the workswas curious as to what was protecting thebearings on their new motors. When theyremoved the cover, they found the only thingprotecting their £27,000(€40,000/$50,000)motor was a rubber v-ring, valued at around£6.70(€10/$12.50).It took around 0.3 of a second to realize thatafter a few hours the rubber v-ring would looksomething like the one that AESSEAL ® tested inthe laboratory, below.Given the LabTecta’s IP55 certification andconformance to IEEE 841-2001, the aluminaworks purchased 140mm standard LabTectasfor both the drive and fan end of the motor. Themotors have been running well ever since.LabTecta installed on Siemens Electric Motor.See Case History 3261 for further information.FACT: AESSEAL ® purchased anindustry standard IP55 electric motor andran it dynamically for 500 hours. When itwas re-tested it failed the IP55 test.Conventional v-ring after a few hours of dynamic equipment operation.R&D Test Facility ExpansionA major expansion program of the R&D testfacilities at AESSEAL’s headquarters will becomplete in November 2006.The development includes the construction of afirst floor as well as extensive ground floorlaboratory and workshop space, with stunningviews overlooking the company’s wetlandsenvironmental initiative.The expansion program has been fuelled by thecompany’s development of high-endtechnology; specifically dry gas compressorseals.10When complete, the extended facility should bethe most technologically advanced mechanicalseal test facility in the country, placing thecompany firmly on the Hydrocarbonsealing map.

Success at PetroquímicaPajaritos, MexicoRolando Toral Maintenance Manager at PEMEX PetroquimicaPetrochemical Pajaritos, Mexico reported that several 1.000" SMSSseals, installed in vertical multistage pumps, working with sour gasoline atambient temperature, have significantly reduced the incidences of failure inthese pumps, previously caused by mechanical seals.1.750" dual seal installation.2.750" DMSF installation.Rolando Toral further praised the exceptionalperformance of;- several 1.750" API 610 style dual seals,installed in pumps working with hydrochloricacid at ambient temperature, shown to the left.- 1.125" SMSS seals installed in the pumpsworking with heavy dichloroethane with solidsand very fine particles in suspension at 100ºC(212ºF)- a 0.962" CAPI A1 dual, installed in the verticalpump GA-401A, working with ethylene at -97ºC(-143ºF), shown to the right, and- further API 610 style dual seals including 2.750"DMSFs installed in pumps working with heavydichloroethane with very fine solids insuspension at 120ºC (248ºF), shown to the left.Vertical multistage pump.0.962" CAPI dual installation.Humberto Velásquez L, Mechanical Specialist Engineer of the Oxygen and Ethylene Oxide Plant atPemex Petroquimica Cangrejera complimented the performance of further API 610 style dual seals(2.875" DMSF) installed in pumps working with potassium carbonate at 107ºC (225ºF). JuanCebrero Castañeda, Mechanical Specialist Engineer at the Ethylene plant of the samepetrochemical facility also praised the 1.500" DMSFs installed in the pumps working with sour hotnaphtha at 120ºC (248ºF).Silverio Selvas would like to thank Petroquimica Pajaritos and Petroquimica Cangrejera for theirkind permission to publish these case histories.Oil Mist Bearing Seals -The Asian Market FutureHeinz P. Bloch P.E. is a strong advocate of the benefits of oil mist lubrication over traditional meansof lubrication. In 2004, AESSEAL ® introduced the MagTecta-OM to seal oil mist lubrication in thebearing chambers of rotating equipment. Since then, MagTecta-OM sales have grown at a rapidrate, with the Asia leading the way.Michael Hsu, head of AESSEAL ® VoLee Ltd, has with thehelp of Koh Choon Siew, head of AESSEAL MalaysiaSDN, BHD, installed hundreds of MagTecta-OM seals inboth pumps and motors supplied by Flowserve and DavidBrown in the Petrochemical Industry in Taiwan. Koh,however suggests that the Korean market is also veryeager for MagTecta-OM and he fully expects theproduct to lead the company’s sales for the entire Asianmarket in the next few years.Oil Mist(Inlet)Oil Mist(Inlet)The MagTecta-OM prevents the oil mist from leaking toatmosphere, ensuring a cleaner environment. 11API preferred oil mist lubrication arrangement.

Revolutionary PipelineSeal: Better by DesignLimitations of Conventional Sealing Technology at High Pressuresnot here pressure acts here not hereConventionalseal facesdeform underpressure,resulting in facecontact,damage andprematurefailure.The fundamental and important first stepin the EASASEAL development programwas understanding the limitations ofconventional mechanical seal faces.Seal faces deform as a result of forcesapplied to them relative to their centroid(centre of mass). These seal facedeformations can be predicted by finiteelement analysis (FEA) and verified bypost service seal face condition analysis.By analysing the forces applied to sealfaces in relation to their centroid,AESSEAL ® has produced a design thatdoes not deform under pressure. Thiseliminates failure modes associated withseal face deformation.EASASEAL - Innovation for Extreme Application SealingThis unconventional yetinnovative design employs arobust, uniformly shapedfloating face, which acts as aninterface between the rotaryand the stationary seal faces.100mm (4.000") EASASEAL faces after 500 hourstesting at 100 bar (1450 psi).In single seal format, process pressureacts on the outside circumference of thefloating face. This creates a force that isuniformly distributed through the centroid ofthe seal face. Unlike conventional seal facetechnology, the floating face is centroidallybalanced and will not twist or deform underpressure. This ensures the seal faces remain flat anddamage free.

Petrochem success inVietnam, Taiwan & ThailandAESSEAL ® installations are creating added end user value inAsia, with 3 - 5 fold increases in MTBF.CAPI TXS seals insalled on TaiwanesePetrochemical Plant.In a petrochemical plant in Bangkok, Burgmann seals have beenreplaced with 95mm CAPI A1 dual seals. The CAPIs areoperating successfully at 22 bar (320 psi), 28ºC (82.4ºF) onpolyethylene benzene duty. Further successes include 74mmCAPI A1 dual seals operating at 42/48 bar (700 psi), 201ºC(394ºF) on a benzene duty and 49.5mm CAPI-TXS sealsoperating at 3 bar (45 psi), 120ºC (248ºF) on styrene mono duties.In May 2005, AESSEAL ® supplied a large number of API sealsand systems as part of a seal improvement project for a largeTaiwanese Petrochemical plant. For example, several CAPI-TXSseals were installed on vertical pumps operating at 3.6 bar(52 psi), 38ºC (100ºF) on a Hydrocarbon duty. The seals havebeen installed for over 15 months which is a massiveimprovement over the previous seal life of three months. FurtherCAPI-TXS seals were also installed on horizontal pumpsoperating at 41ºC (106ºF) on propylene duty.CAPI -TXS seals.Flowserve Pump installation.In Vietnam, AESSEAL ® hasinstalled many API style sealsand systems, often upgradingexisting component seals inmature assets. For example arange of API Plan 11 pusherand bellows single seals wereinstalled on Flowserve pumpsin Petrochemical plants.Duties include dioctyl phthalateat 6 bar (87 psi) and 250ºC(480ºF).1.375" BQFD installation.In Refineries, succesful API 610 style seal installations includedesigns installed on Goulds 3700 (4x6-11N) in plan 11 and 62configurations and high temperature dual bellows designs onKSB (50-200/HPK-EMP) pumps with Graphite and Kalrez ® 7075.These operate at 350ºC (660ºF) at 3 bar (43 psi) with Theminoland in a API 11 and cooling jacket configuration.Goulds pump installation.For futher information on these and many more installationsin Asia contact Koh Choon Siew, Managing Director(AESSEAL Malaysia).BDFI installed on a KSB pump.Dual seals installeda on benzene duty.Dual seals installed on styrene mono duties.13

Success at PemexRefinacion MexicoAPI dual seals supported by API AES-15 systems.Since 2004, AESSEAL ® has supplied seals tothe Mexican State Oil Company, Pemex,helping to identify and solve issues withequipment and seals.In the pumping and storagearea of the Antonio DovalíJaime refinery, AESSEAL ® API682 style dual seals areinstalled on butane, propaneand isobutane at 32ºC (90ºF)in Plan 13 and 53Aarrangements. These aresupported by AESSEAL ® APIAES-15 systems.The API seals were installedon a variety of verticalmultistage pumps, includingGoulds, Worthington andByron Jackson.Jose Acosta, MaintenanceManager and Jorge Roman of BOYAL said,“The installation of AESSEAL ® seals hassignificantly reduced the incidences of failuresin mechanical seals.“The characteristics of the design, with theflexible stationary springs not in contact withthe product and the hydraulic and pressurebalance in both directions of the internal seal,allowed us to deal with the requirements thatthe process and pump demand.“It is important to mention the excellent serviceand advice received from the TechnicalDepartment in AESSEAL Mexico, identifying thecauses of the frequent failures of the currentseal as well as giving reasons why AESSEAL ®seals give more reliability.“Also we have to mention the excellent deliverytime of complete seals as well as the support ofthe prompt delivery of the spare parts, thesuperb support during the installation andsupervision in the start up”.Silverio Selvas, AESSEAL Mexico S. de R.L. deC.V., would like to thank Refineria AntonioDovali Jaime of Pemex Refinacion for their kindpermission to publish these case histories.LabTecta is a Hit atAchema 2006For the entire week of 15th-19th May, theAESSEAL ® exhibition stand at Achema,Germany (left) was bursting withexcitement and energy. One visitorcommented “The AESSEAL ® stand wasone of the best at the entire show forinnovative, reliability focused solutions.”Original Equipment Manufacturers, PlantEngineers and Reliability Focusedprofessionals even queued to review thepinnacle of the excitement, theLabTecta. A competitor of AESSEAL ®stated, “We have been trying for the last10 months to develop a product which wecan offer against the LabTecta, but wehave failed miserably... the LabTectaappears to be in a class of its own.”Throughout the week, international visitors tothe AESSEAL ® stand entered a dailyprize draw.A Spanish plant engineer from Clariant Frankfurtwas a “Real” winner, winning a Real Madridshirt. A French visitor, Christophe Mente, wassent home with a PSG shirt, but from thousandsof hopefuls Paul Wotton from Genzyme Ltd wonthe top prize of two World Cup tickets to seeEngland v Sweden.Barry Bamford, Managing Director of AESSEALDeutschland AG, concluded, “Achema hasbeen a great success for us in terms of allowingus to show our visitors what we have to offer.AESSEAL ® is a reliability focused business andour product innovation speaks volumes.”Visit www.labtecta.com or www.propack.netfor further information.14

A Successful UnionIn November 2002 a UK API pumpmanufacturer approached AESSEAL ® with anapplication for crude oil & produced water for arefinery in Nigeria. The seals had to be API 682suitable for 48 barg and fit a BB3 axially splitcase pump which pumped product containingsolids in suspension. The current seal supplierwas having difficulties with the duty and therewere 100 pumps, all with identical seals.AESSEAL ® agreed to trial four 67mm seals anddelivered them in June 2003.visited AESSEAL ® with the OEM and wasimpressed with the set-up. The project isongoing and both end user and OEM are keento work with AESSEAL ® because of the service,support and most importantly, the seals. Onlyanother 170 to go!The photo below shows the product settled outin the blank stages within the pump.The seals proved a success and were deemedto have passed the first test in November 2003.Orders followed in June 2004, November 2005,January and June 2006. Over three years laterthe original seals are still working andAESSEAL ® have installed 33 CAPI A1 single todate. An engineer from the Nigerian refinery2007 Hydrocarbon ProcessingBest Practice ConferenceFollowing the excellent two day API conference in Sheffield in 2005,where more than 70 people attended from eight countries,AESSEAL ® is delighted to announce a second HydrocarbonProcessing Best Practice Conference.The two day event will take place in early 2007 in England.Heinz P. Bloch P.E. introduces his theorieson reliability.Many guest specialist speakers, including Heinz P. Bloch P.E., willdeliver tips and techniques for Best Practice operations in the APIand associated industries and visitors will have the opportunity tosee some of England’s finest heritage. For futher details on thisevent please contact Liz Cooke: liz.cooke@aesseal.co.ukTo Russia With LoveIn September 2006, AESSEAL ® was awarded the GOST certificate tosupply a full range of AESSEAL ® mechanical seals, specifically the APIrange, to the Russian and former USSR markets.The AESSEAL Moscow office together with technical support personnelare now planning to support the penetration of these markets.Slava Erokin of Uniseal-Tech, with Silvio Striglia and Mark Williams ofAESSEAL ® are responsible for this achievement and the subsequentdrive to supply API products to end user customers and OEMs alike forall pumps being sold.AESSEAL ® GOST Certification.15

Over 500 API Web CaseReferences and Counting...For the last ten years, AESSEAL ®associated industry sectors.have supplied API seals to the Hydrocarbon Processing andOn-line detailed case references of installed seals, systems and bearing protectors are available inthe applications section of www.aesseal.com.24 hours, 365 days ofmanufacturing excellence16Shell U.K. Limited one of the of the biggest Oiland Gas companies in the global market place,which own and operates numerous oil productionplatforms in the North Sea, contacted AESSEAL ®one Sunday morning after encountering problemsthe night before with a pump and mechanicalseal.They had major problems with a piece of rotatingequipment which was furnished with an AESSEALfour years previously and as such did not haveany spare parts or mechanical seals due to thereliability of the existing installation.AESSEAL ® rose to the challenge and produced abespoke 85mm CAPI A1 dual seal in exoticmaterials during Sunday. The machinistscompleted all machining operations late into thenight going beyond the “call of duty”. The sealwas built and tested early Monday morning anddespatched on a same day courier service toreach Aberdeen for the afternoon. It was thentransferred to a “chopper” and sent offshoreready for an AESSEAL ® representative to carry outthe seal change on the offshore platform.Mark Gray (Tern – Reliability Engineer for ShellU.K. Limited) commented “We were delightedwith the service from AESSEAL, who came to ouraid at short notice with the right equipment.”Lee Gooch, Sales Engineer for Oil and Gas marketsaid “It’s reassuring that when AESSEAL winsbusiness in the North Sea, the seals first of allperform reliably as intended. Secondly it’s just asimportant that we can offer the back up andservice required by Oil and Gas Industry. Ouremergency manufacturing capabilities, which isonly limited by the suppliers of the materials, givesus the envious position of being the sealmanufacturer customers call when they are indesperate need of help.”Lee wishes to thank all involved on behalf ofhimself and Shell UK. In particular some of thestaff deserve a special mention for going beyondall expectations. The manufacturing team of SteveByrne, Bob Moore, Paul Beasley, Mick Dentonand Paul Baldwin. Of course we cannot forget theever-attentive Steve Haigh (AESSEAL ® StoresManager) who is the first port of call for allemergency breakdowns. Without your help noneof this would have happened and you are all acredit to the organisation for going “theextra mile”.

Sealing LNG Plantsin UAEA major Middle East LNG (liquid natural gas)processing plant located in the UAEapproached AESSEAL ® to propose a technicalsolution to resolve an ongoing issue with theirlean carbonate pumps. The pumps, located ontrain 1, had suffered from high failure rates formany years with seals lasting as little as a fewdays to a few months. The existing seal supplierhad done little to resolve the issue and hadenjoyed years of repeat business.When LNG enters the plant it is firstcompressed and then passed through apurification process to remove unwantedcontamination. The main constituent parts to beremoved are firstly carbon dioxide (CO2) andthen hydrogen sulphide (H2S). The CO2 isremoved to meet customer specification andalso to aid the process, as carbon dioxidewould freeze at certain parts of the cryogenicprocess at a later stage. The extracted H2S isfurther refined to produce sulphur. This specificplant currently produces approximately 1000tonnes of liquid sulphur per day.The CO2 and H2S are extracted by passing thegas through a series of absorbers. The first setuses potassium carbonate solution. Thisprocess would typically reduce CO2 contentfrom 45,000 to 60,000ppm down to 800 ppm.The gas is then passed through a secondabsorber where a Diethanolamine solution isused to bring the H2S level down to around3ppm and the CO2 to 30ppm. It is in this sectionof the plant that the lean carbonate pumps canbe found.A 3.250" AESSEAL ® CAPI A1 single seal withSiC/SiC seal faces and Kalrez ® elastomers wasinstalled on a David Brown D-10X19DVSLL at27 bar (391psi), 3000 rpm sealing leancarbonate at 121ºC (250ºF).The CAPI ran continuously for 12 months until itwas removed on the 7th July 2006 forexamination. The customer was delighted withthe dramatic up time increase over the existingseal and further roll out of this technologyis planned.Sealing Gas PlantsAESSEAL ® has been sealing gas plants in theUK for the last 15 years. Examples include:API682 style dual seals installed on GirdlestoneRe-Boiler pumps where a mono ethylene glycoland water mixture is directed to the glycolregenerator where water is flashed off at 125ºC(260ºF). This is then condensed and treated inan effluent treatment plant before beingdischarged to sea.Boiler PumpsGirdlestone gr2 2a BearingAPI682 style dual seals installed on Mk3 DurcoChemtech pumps on glycol recovery tocondenser and storage applications processing12.7 M/Hd. -90% MEG and 10% water at130ºC (266ºF).API682 style dual seals installed on hydrocarboncondensate transfer to storage duties,operating on Ingersoll Rand 3V1-10 pumps andtanker loading pumpsAPI682-dual SealsAPI682-dual SealsAPI682 style dual seals installed on 211ºC(411ºF), 10 bar (145 psi) condensate stabilisingcolumns, in a Plan 53 configuration with sealsupport systems which are air blast cooled.For further information contact Mike Carter,AESSEAL plc at: mike.carter@aesseal.co.uk.API682-dual SealsIngersoll Rand 3VI-1017

New API LiteratureThe latest AESSEAL ® Oil & Gas literature details the company’scomprehensive product range available for the API and associatedindustries sector.Clearly, as one would expect from the world’s fourth largestmechanical seal company, the AESSEAL ® brochure details CategoryII and III API 682 qualification tested mechanical seals for flashingand non-flashing hydrocarbon applications, in accordance withEdition three of the specification.Mature assets in refineries around the world, however, do not always conform to the latest design orspecification. Some have equipment more than 30 years old, clearly predating all 21st century BestPractice seal chamber concepts. The AESSEAL ® API literature now details the company’scomprehensive range of Category I designs for API 610 Edition 5 onwards. These thin-cross sectiondesigns, employed for the last 10 years in the API industry, are specifically engineered to fit inside0.500" and 0.750" radial seal chamber spaces. The designs employ modular seal face technology inaccordance with the company’s API 682 range thereby permitting 21st century qualified sealingtechnology to be applied to mature assets, without the need for equipment modification.The literature also provides an insight into the company’s API seal support system range, offeringcertified designs to ASME, AD-Merkblatt and API 610 standards as well as API 682.A glimpse of AESSEAL’s API bearing seal range is also shown, providing innovative solutions for alltypes of bearing chamber lubrication regimes from grease and oil splash to oil mist in accordance withAPI 610 (ISO13709).V.I.P. from AlaskaMr Aburto also observed a 100mm AESSEAL ®High Pressure Pipeline seal on test at 100 bar(1500 psi) at 3,600 rpm running on light oil. Thisseal was operating at twice the known PV of theface materials due to the unique three facedesign. One face is stationary, one rotates andone floats in between!18Pictured on the left, Lorenzo Aburto with Seth Short of Pro-Seal Service Group.Lorenzo Aburto, Mechanical MaintenanceTechnician of Conoco Phillips, Alaska, visitedAESSEAL’s Mill Close facilities on the 15th ofNovember 2005. Mr Aburto was accompanied bySeth Short of Pro-Seal Service Group, who is thelocal AESSEAL ® service provider for ConocoPhillips. During the visit Mr Aburto, picturedabove left, witnessed a 280 bar (4200 psi) Dry GasCompressor Seal test running at 12,000 rpm andoperating at a leakage rate of 30% less than theindustry standard for a 129mm balance diameterdual seal. The unique hydrostatic andhydrodynamic lift dry gas compressor seal designis one of the latest developments fromAESSEAL ® , focused on high duty sealingapplications.“Thanks to AESSEAL ® for the opportunity to visitthe UK facility. The program was well structuredand the experience was rewarding thanks to thewarmth and kindness of the wonderful folks of theAESSEAL ® organization” said Lorenzo Aburto.For further information contact Chris Carmody,Special Products Manager AESSEAL plc. atemail: Chris.Carmody@aesseal.co.ukHigh Pressure Cell-350 bar/5075 psi/45,000 rpm.

Other AES News...ideas2develop Ltd., part of the AES Engineering Group ofcompanies, is proud to announce a long term sponsorship dealfor the benefit of grass-roots football in the UK.The ideas2develop Junior Sunday League has nearly 650 teamscompeting across South Yorkshire and the North Midlands, in 55divisions and involves 10000 children, both boys and girls, betweenthe ages of seven and sixteen years old.Professional football originated in Sheffield in 1857 with SheffieldFC. As part of the company’s Social Responsibility Programme,ideas2develop Ltd. is highly committed to nurturing and developingnot only young talent, but the talents of passionate parents, coachesand people in the community.ideas2develop Ltd offers everything an inventor needs to protect, develop, finance and market anidea into a profitable venture. If you have an “idea to develop”, see www.ideas2develop.com forfurther information.Wetlands Gets Bigger & Wetter!In 2004, AESSEAL ® took the unprecedented step of creatinga wildlife sanctuary in the middle of an industrial region inRotherham, England.This environmental initiative not only provides a habitat forplants, birds, mammals, amphibians, fish and insectsindigenous to the area, it also serves to help control flashflooding and cleans water through a swale and reed bedsystem.In October 2006, the company completed a deal with thelocal authorities to double the size of the wetlands wildlifesanctuary.This will have a significant benefit to this environmentalinitiative and further demonstrates the company’s solidcommitment to its Corporate Social ResponsibilityProgramme.AESSEAL’s Wetlands Development.Technological Leaderby April 2008AESSEAL’s objective to become Technological Industry Leader by 2008 issupported through extensive R&D activity that is focused on seal designs tooperate in the most arduous applications. Current activities in this areainclude the further development of high pressure pipeline seals, high pressuremixer seals and API seals for the Hydrocarbon Processing Industry.19

The AESSEAL ® Group of CompaniesAESSEAL plc, Rotherham, U.K. Telephone: +44 (0) 1709 369966AESSEAL plc, Derby, U.K. Telephone: +44 (0) 1332 366738AESSEAL plc, Peterborough, U.K. Telephone: +44 (0) 1733 230787AESSEAL plc, Hamilton, U.K. Telephone: +44 (0) 1698 540422AESSEAL plc, Middlesbrough, U.K. Telephone: +44 (0) 1642 245744AESSEAL plc, Upminster, U.K. Telephone: +44 (0) 1708 256600AESSEAL plc, Pontypridd, U.K. Telephone: +44 (0) 1443 844330AESSEAL plc, Warrington, U.K. Telephone: +44 (0) 1925 812294AESSEAL plc, Grimsby, UK. Telephone: +44 (0) 1472 264285AESSEAL (MCK) Ltd., Lisburn, U.K. Telephone: +44 (0) 28 9266 9966AESSEAL (MCK) Ltd., Co. Cork, Eire. Telephone: +353 (0) 214 633477AESSEAL Inc., Knoxville, USA. Telephone: +1 865 531 0192AESSEAL Inc., Kingsport, USA. Telephone: +1 423 224 7573AESSEAL LLC, MW Division, Marion, USA. Telephone: +1 319 377 0170AESSEAL Inc., NE Division, Fairfield, USA. Telephone: +1 207 453 6915AESSEAL Inc., NW Division, Longview, USA. Telephone: +1 360 414 0118AESSEAL ALAA, Dammam, Saudi Arabia. Telephone: +966 3 847 0033AESSEAL Argentina S.A., Buenos Aires, Argentina. Telephone: +54 11 4744 0022AESSEAL Australia Pty Ltd., Seventeen Mile Rocks, Australia. Telephone: +61 7 32791144AESSEAL Benelux B.V., Breda, Holland. Telephone: +31 (0) 76 564 9292AESSEAL Brasil Ltda. São Paulo, Brazil. Telephone: +55 11 5891 5878AESSEAL Canada Inc., Vancouver, Canada. Telephone: +1 604 535 7512AESSEAL Chile SA., Providencia Santiago, Chile. Telephone: +56 2 2343022AESSEAL China Ltd., Ningbo, China. Telephone: +86 (0) 574 8823 2888AESSEAL Colombia S.A., Bogota, Colombia. Telephone: +57 (1) 634 9095AESSEAL Czech s.r.o., Brno, Czech Republic. Telephone: +420 543 212 489AESSEAL Danmark, A/S, Køge, Denmark. Telephone: +45 56 64 14 00AESSEAL Deutschland AG, Rödermark, Germany. Telephone: +49 (0) 6074 881293AESSEAL Deutschland GMBH, Kronau, Germany. Telephone: +49 7253 8090AESSEAL Finland OY, Muurame, Finland. Telephone: +358 1433 84500AESSEAL France S.A.R.L., Nieppe, France. Telephone: +33 320 172850AESSEAL India PVT. Ltd. Pune, India. Telephone: +91 20 24220868AESSEAL plc, Coldweld PVT Ltd., Mumbai, India. Telephone: +91 2255 029028AESSEAL Italia SRL., Gallarate, Italy. Telephone: +39 0331 799 952AESSEAL Malaysia SDN. BHD., Selangor, Malaysia. Telephone: +603 806 21233AESSEAL Malaysia, SDN. BHD., Gebeng, Malaysia. Telephone: +609 583 6133AESSEAL Malaysia, SDN. BHD., Johor, Malaysia. Telephone: +607 388 8323AESSEAL Mexico, S. de R.L. de C.V., Mexico City, Mexico. Telephone: +52 833 266 9551AESSEAL Polska SP. ZO.O., Bielsko Biala, Poland. Telephone: +48 33 818 4133AESSEAL Pty Ltd., Durban, South Africa. Telephone: +27 (0) 31 903 5438AESSEAL Pty Ltd., Johannesburg, South Africa. Telephone: +27 (0) 11 466 6500AESSEAL Ibérica S.L., Tarragona, Spain. Telephone: +34 977 55 43 30AESSEAL Sweden AB. Stockholm, Sweden. Telephone: +46 (0) 8 55602870AESSEAL Vo Lee Ltd., Kaohsiung City, Taiwan. Telephone: +886 7 310 0630AESSEAL Turkiye, Istanbul, Turkey. Telephone: +90 (0) 216 304 0237AESSEAL Uruguay, Montevideo, Uruguay. Telephone: +598 2 916 1040web: http://www.aesseal.com email: seals@aesseal.comDue to continuously fluctuating exchange rates this document assumes that UK £1 is equal to US $1.75 /€1.5AESSEAL ® is a Registered Trademark of AESSEAL plc Copyright © 2006 AESSEAL plc Ref: L-UK/US-ORACLESP-17 AES/DOC/IN 5085 10/06