Plan 54 Seal Support Systems – Reliable Pump Protection
Plan 54 Seal Support Systems – Reliable Pump Protection
Overview
HydroMax Seal STAN100-FCS | 26.42 US gallons Forced Circulation Oil System for API Plan 54 Applications
The STAN100-FCS is a 26.42 US gallons forced circulation system designed to meet the demanding requirements of API Plan 54 mechanical seal support. Built from 316 stainless steel, the unit is typically floor- or skid-mounted and provides reliable oil circulation via a positive displacement pump, ensuring effective cooling and lubrication of the double mechanical seals.
The system features a plate heat exchanger for thermal management, a back-pressure control valve to maintain unpressurized tank conditions, and a 60-micron stainless steel mesh suction filter to reduce contamination.
Product Description
Design Features
Ideal for API Plan 54 seal support
Positive displacement pump delivers oil at up to 1.06 (GPM)
Back pressure valve regulates system pressure, keeping the tank unpressurized
Integrated plate heat exchanger for efficient oil cooling
60-micron stainless steel suction filter to trap contaminants
Filler breather cap for safe and clean top-up
316 stainless steel tank construction for superior corrosion resistance
Supplied fully assembled and tested
Technical Specifications
| System Vessel Size | 26.42 U.S. gallons |
| Pressures | Up to 40 Barg (580 psig) |
| Instrumentation | Oil-Filled Pressure Gauge Flow Gauge IP66 Variable Speed Motor |
| Pipework & Fittings | Hard-piped assembly with all fittings included Flexible stainless steel hose kit to seal (length based on installation) |
| Temperatures | Up to 200°C (392°F) |
Optional Extras
ATEX Certification
Integral Cooling Coil (internal vessel)
Air Blast Cooler
Fully Instrumented Package with high/low pressure switches
The HydroMax STAN100-FCS offers a complete and reliable forced circulation system, engineered for critical sealing environments requiring dependable thermal and pressure management.
Typical Applications & Industry Use Cases
The STAN100-FCS Plan 54 System is a dedicated external circulation module engineered to provide clean, pressurised barrier fluid to dual-seal arrangements where standard flush plans are insufficient. It supplies filtered, cooled fluid at a pressure above the process side to protect the seals, eliminate leakage to the atmosphere, and deliver high reliability in demanding conditions.
Industries Served
Petrochemical & refining
dual‐seal installations handling aggressive, hot, or toxic media where zero atmospheric leakage is required.
Chemical processing
reactors, mixers, agitators, and dryers where the process media offer poor lubrication or generate significant heat between seal faces.
Power generation & utility
high-duty pumps and compressors where seal reliability and sealing integrity are critical for uptime.
Mining, bulk solids & slurry systems
applications where abrasive or polymerising fluids require robust seal support and continuous barrier fluid circulation.
Equipment & Use-Case Scenarios
- Dual‐seal pump setups, where the seal chamber pressure and temperature exceed the limits of simpler flush plans and demand an external forced circulation system.
- Systems handling volatile, toxic, or environmentally sensitive fluids where any leakage to the atmosphere must be avoided.
- Installations where multiple dual seals can be served by a single circulation unit, reducing cost and footprint compared to individual flush systems.
- Processes that generate excessive heat at the seal faces or require high flow and cooling of barrier fluid to maintain reliable sealing performance.
Why It Fits These Applications
- The external circulation system delivers barrier fluid at a pressure higher than the seal chamber pressure, preventing process fluid from entering the barrier loop.
- High-flow and controlled cooling keep seal faces lubricated, reduce thermal stress, and extend seal life even under extreme temperature or load conditions.
- The modular unit can serve multiple seals, making it more efficient for plant-wide reliability strategies than one-pump, one-system designs.
- Designed for critical, high-risk, or zero-leakage services—ideal where failure is not an option and operational integrity is paramount.
Installation Guidelines
Position the circulation system on a solid floor or skid, ensuring the pump, piping, filter, heat exchanger, and tank are correctly aligned as per the layout.
- Ensure the barrier fluid tank is filled with compatible fluid, properly vented, and that the breather or inert-gas blanket is functioning, if required.
- Connect the supply line from the circulation unit to the seal barrier port and ensure the return line flows through the heat exchanger/filter back into the tank.
Adjust the back-pressure control valve to maintain barrier pressure slightly above the seal chamber pressure (typically 1-2 bar above).
Commission the system by starting the circulation pump and verifying flow, pressure, cleanliness (filter status), and temperature of the barrier fluid prior to pump operation.
Maintenance & Inspection Best Practices
- Monitor barrier fluid pressure, flow, and temperature continuously; any drop in pressure or flow may indicate contamination, blockages, or pump issues.
- Inspect the suction strainer and filter element regularly (for example,e 60 µm mesh if specified) and replace or clean the filter to avoid barrier loop restriction.
- Periodically inspect the heat exchanger for fouling and verify that cooling performance remains within specification.
- Maintain the tank level, check for ingress of process fluid or contamination, and replace barrier fluid or undertake fluid quality checks at recommended intervals.
- Log system performance and seal support data (pressure, flow, temp, maintenance events) as part of your preventive maintenance program.
Service & Support Options
- HydroMax Seal offers pre-installation guidance to ensure the correct Plan 54 system configuration (tank size, pump flow, materials of construction) is selected for your specific dual-seal application.
- Field or remote commissioning support is available to validate barrier fluid circulation, instrumentation set-up, and dynamic testing of the barrier loop.
- Spare parts kits (filter elements, valves, gauges, seals) are available to streamline maintenance and minimize downtime.
- Lifecycle upgrade and audit services are provided: as process conditions change (higher temp, new media, additional seals), the system can be re-engineered or expanded to maintain optimal performance.
- Scheduled maintenance programmes or service contracts help you maximise uptime, control cost, and document performance for reliability assurance.
With a correctly configured and maintained circulation system, the STAN100-FCS Plan 54 unit becomes a cornerstone of your dual-seal reliability strategy—delivering high performance, zero-leakage risks, and extended service life in the most critical applications.
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Contact HydroMax Seal
Contact HydroMax Seal today for innovative solutions, expert guidance, and over a century of engineering excellence. Your journey to mechanical sealing excellence starts with HydroMax Seal!
E-Mail: sales@hydromaxseal.com
Address: 18511 Beaumont Hwy Building D
Houston, TX
77049
