FIELD REPORT

Crude bottom pump 1G

Observation
Observations are as below and detailed explanation in the body of the report:
 Seal leakage was observed on 1G on Friday September 11, 2020 at around 15:15.
 After initial inspection seal leakage was observed coupling condition was satisfactory.
EQUIPMENT Crude bottom pump
TAG NO. 1G

Description of events
 At 15:30 9/11/2020, Plant 1 crude bottom standby pump (1G-8A) was observed with seal
leakage issue.
 After receiving the MWR the job was planned and spares including bearing 7313(qty 2), 3214
(qty 1) and seal repair kit (SAP code 3020585; qty 1) issued from warehouse.
 At Friday evening September 11, 2020. Pump shifted to workshop for disassembly.
 However, on it was found that the below assembly in the repair kit does not match with the rest
of its parts and is smaller in size.
 Due to which warehouse was reopened at night date: September 12, 2020, below assembly (SAP
code 3012303; qty 1), Bellow face gasket (sap code 3014383; qty 1) and bushing flange (SAP
code 3012656; qty 1) was issued from warehouse.
 After installation of new repair kit along with the above mentioned parts and replacement of
both I/B and O/B bearings, the pump was assembled and shifted to area.
 On Saturday evening September 12, 2020 pump test run performed, during static pressure the
seal performance was satisfactory and no leakage was found. While, after taking the pump on
load seal leakage was suspected after few minutes of startup. Operation shifted to 1G-3 (motor
driven pump) and 1G-8A dismantled and shifted to workshop for repair.
 On Sunday at around 02:00 September 13, 2020. The mechanical seal faces includes
BELLOW,ASSY,PART#3R10583,1G-8 (sap code 3012301; qty 1) and SEAL FACE
PART#3R11424LO,1G-8/8AX (sap code 3016227; qty 1) were issued again from the warehouse
and replaced with the existing seal faces.
 On Sunday September 13, 2020 at around 16:00, complete assembly the pump is installed and
alignment completed. After performing test run the seal again failed.
 After seal failure pump was kept as a bad standby and Hardcastle (seal vendor) was called at site
at Monday September 14, 2020 for solution.
 During Monday meeting it was decided that the possible seal failure is due to the missing
keyway in the sleeve, which was present in previously installed sleeve (sample provided by
byco).
 Vendor agreed to perform machining job on the sleeve and install the machined sleeve in his
supervision.
 On Tuesday September 14, 2020 at approx 18:00. Vendor along with the machined sleeve and
sample sleeve arrived at site and while pump was available in workshop however the seal flange
was intact and seal disassembly was witnessed by vendor.

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  Seal disassembling activity started at around 19:00 dimensions were recorded and pictures were
taken during this activity.
 Due to limitation of spares, following new parts are installed during assembly of seal, while the
below assembly screw was not opened during the process, hence to keep the integrity of bellow
gasket:
o Machined sleeve with keyway (from vendor)
o Flange gasket (
o Sleeve gasket (
o Rotary face gasket (
 On Wednesday September 15, 2020 at around 04:00. After installation pump shifted to site and
alignment completed.


Analysis:
 During the second assembling process only faces were replaced which might have caused the
seal to fail again.
 The seal face needs to be checked for any sign of thermal and mechanical distortion. Inspection
of O-rings should be conducted to check for swollen portion.
 The below assembly size found different from rest of the repair kit parts, which caused delay in
the seal replacement activity as the below assembly (of correct size) has to be reissued from
warehouse practicing all the off-duty protocols to open the warehouse.

Conclusion and corrective actions required

 Detail investigation report is awaited from vendor suggesting the root cause of failure and
future actions.
 Query to be raised to the vendor, asking the repair kit part numbers that are present in the
item# 3020585.
 A joint inspection need to be conducted between integrity and reliability department to find
root cause of seal failure.

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