Upstream Pumping (USP): Supporting chemical plant processing

In our previous blog, we defined Upstream Pumping (USP) and examined the specific challenges it addresses for customers in the chemical industry.

Businesses involved in chemical processing know that meeting compliance and sustainability targets presents a distinct set of challenges for technology to address. Resolving them may be a different matter. Fortunately, in many cases, there is a significant overlap between today’s efficiency targets while working towards tomorrow’s sustainability goals. For example, the reduced friction of our spiral groove technology embedded in the Type 8628VL and the Type 285 non-contacting dry gas seals equates to lower power consumption. Additionally, USP seals often eliminate the need for cooling flush systems, thereby reducing water demand.

John Crane’s non-contacting USP seal face technology reduces water consumption by approximately 1 million gallons per pump per year compared to a traditional dual unpressurised seal. Most significantly, USP seals can achieve near-zero emissions, support corporate sustainability goals and help to meet regulatory compliance requirements.

Estimate your water savings

Reducing pump and mechanical seal water consumption is a primary strategic sustainability objective. Our user-friendly Water Savings Estimator tool compares our customers’ current sealing methods with proven technologies for reducing water consumption.

Meanwhile, our Lifecycle Cost Calculator tool can estimate the costs, energy requirements and greenhouse gas emissions associated with operating a rotary shaft seal on a centrifugal gas compressor. It evaluates five different sealing technologies.

John Crane’s Type 5620USP: Delivering real-world success

Nothing makes the case for John Crane’s Type 5620USP and other USP-enabled seals like a real-world customer success story. Our work to mitigate a high rate of pump seal MTBR in a proprietary process of a chemical plant in the Eastern U.S. is exactly that.

In brief: Our technicians determined that improper mixture levels in a recirculating processing tank and subsequent pump starvation triggered an excessive mechanical seal failure rate – specifically, 17 visits in one year. Replacing the non-John Crane seal with our Type 5620 improved MTBR to an impressive three years, saving nearly $25,000 in seal repair costs.

Similarly, a U.S. automotive company was experiencing reduced pump seal life and unacceptable MTBR. It resolved the issues by replacing existing seal infrastructure with the John Crane Type 5620 featuring upstream pumping seal face technology.

In brief: The process of corrosion protection pretreatment for painting or plating metal surfaces is both complex and intensive. The abrasiveness of chemicals frequently affects pump seal life, and a zinc phosphate sludge eventually limits the axial flexibility of the seal compromising MTBR. John Crane’s USP face technology and a PTFE excluder created a clean operating environment for the seal, contributing to a fourfold increase in MTBR.

Implementation tips

Achieving the benefits of USP doesn’t always require upgrading to new technology. Prohibitive infrastructure costs often create pressure to modify and reuse existing equipment.

Retrofitting USP seals into existing systems is an option and can maximise necessary planned downtime. That is usually possible as these seals are often interchangeable. USP seals have an identical installation process to traditional seals, fitting, like-for-like, into the same seal chamber dimensions.

Our video is a step-by-step installation walkthrough for the Type SB2USP seal.

However, standard support systems may not be directly compatible with USP seals, which have a slightly different setup from traditional pressurised dual seals. Operators may have to accept some reduction in benefits as a compromise.

Flush systems

For example, some might repurpose a flush system, such as the John Crane Safeunit™ and set pressure and flow rates at their minimum levels. While this reduces water consumption, the flow rate will still be too high. The consequence is an inability to detect some of the equipment failure modes unique to USP seals.

One mitigating measure would be to modify a reservoir system, such as the GR1/1C stainless-steel pressure vessel. This would enable automatic top-up and adjust the alarm settings to account for USP running modes, but the higher consumption rates of USP seals could necessitate frequent refill operations.

Indeed, deploying the correct, matching support system, such as the GS USP–R, the reservoir version of our standardised USP support system, and the GS USP–D (the direct connect version), can enable operators to extract full value from this technology and, by extension, add value to their operations by extending MTBR and increasing reliability.

We engineer these systems specifically to meet every need of USP seals. They account for every equipment failure mode that might compromise USP seal operation and provide operators with the correct alarms and containment.

John Crane upgrades and retrofits enable chemical operators to implement proactive enhancements that modernise rotating machinery and sealing systems. It’s just one service within the John Crane Performance Plus™ modular service framework.

Digital monitoring support

While these systems provide excellent analogue support, John Crane also offers proven remote digital monitoring through the Asset Condition Management Programme aspect of John Crane Performance Plus™.

John Crane Sense® Monitor provides wireless, remote vibration monitoring for pumps, motors, and fans. Our wireless condition monitoring solution provides near real-time insights into the health of the rotating equipment, including pumps, compressors, mixers, and agitators, that underpin chemical processing operations.

Wrapping up: The USP of Upstream Pumping

These two blogs have examined, in detail, the multiple benefits of USP technology above traditional options. We discovered why USP is the optimal choice for those in the chemical industry in terms of reliability, sustainability and performance – three key challenges in the chemical industry.

If you are interested in exploring how USP might benefit your chemical processing by transforming your sealing strategy, our case studies and blogs offer more research opportunities. If you’re ready to speak with a John Crane specialist, please contact us directly.