Chapter 01

Seals & Packings for Rotating Shafts
CHAPTER 1
SEALS AND PACKINGS FOR

ROTATING SHAFTS
Chapter # 1 Page. 1 of 45
INTRODUCTION
The purpose of this chapter is to introduce and describe seals and

packings which are widely used to perform sealing for rotating shafts in
fluid movers like pumps and rotary compressors (centrifugal compressors,
axial flow compressors and screw compressor)
We will discuss where and why seals are required, common types of seals,
their variations and how each type perform sealing?
Why do we Need to Perform Sealing?
As a natural phenomena, fluids (liquids and gases) move freely from places
where the pressure is higher to places of low pressure. This movement
could be from places where they are wanted to places where they are not
wanted. This movement of the fluids may be undesired for several
reasons:
• A pressure may be needed which cannot be maintained if the fluid

involved is allowed to move in certain direction.
• The presence of the fluid outside its container may involve waste,
expense, danger, contamination or other undesirable consequences.
This undesired motion is termed leakage, and our aim is to stop this
leakage or minimizing it to the lowest possible level.
The kind of leakage that may occur and the technique used to prevent it,
depends on the container construction. The container which may be a
tank, a pipe, a valve, a pump, a boiler, or any of several other things-may
be made of material which itself does not permit leakage. The leakage
may happen through joints or holes.
Joints are necessary in many structures and must be sealed. Gaskets,
pipe and thread compounds are used for sealing. The joining surfaces
may be so perfectly mated that leakage is restrained.
The structure to be made leak-proof may have a hole with a shaft

extending through it and the shaft may rotate or move in an axial direction.
Categorization of Seals
There are two basic kinds of seals:
• Static seals
• Dynamic seals
A- Static Seals
1. Static seals are used to perform sealing between two stationary

items, i.e., where no movement occurs at the juncture to be sealed.
Gaskets and O-rings are typical static seals.
2. Another category of static seals are sealant, which are similar to

gaskets except that they are applied as a liquid or past.
3. This gasket is any device maintains a barrier against the transfer of

fluids across mating surfaces of a mechanical assembly when the
surfaces do not move relative to each other. Gaskets seal by being
squeezed between the joint faces tightly enough so that they exert
more pressure against the faces than does the fluid pressure tending
to leak past them.
4. Joint and gasket design must be considered together. A joint is only

as good as its gasket, and the gasket may succeed or fail according
to whether the joint makes the best use of the gasket material.
Therefore, joint components must be thought of as a unit, or system,
for effecting a seal. Otherwise, the end result may be a leaky joint.
5. A prime factor in any seal or gasket is minimum sealing stress. This

is the minimum stress necessary to make the seal material conform
to the imperfections on the flange face (Figure 1.1) and, where
necessary, to close the material's porous structure so leakage does
not occur.
Figure 1.1 Conformation of gasket to flange Figure 1.2 Static Seals
Gaskets would not be necessary if the flanges-or the two meeting surfaces
were machined to mate perfectly and lapped to a good surface finish and if,
in addition, the piping was in perfect alignment. Under such conditions, we
might achieve a leak-proof joint but such procedures are obviously
impractical and very expensive. Figure 1.2 shows another example of
static seals (O-Ring).
B- Dynamic Seals
1. Dynamic seals are employed where surfaces move relative to one
another. Dynamic seals are used, for example, where a
reciprocating or rotating shaft transmits power or movement through
the wall of a tank (Figure 1.3), through the casing of a pump (Figure
1.4), or through the housing of other rotating equipment, such as a
filter or a screen.
Figure 1.3 Cross section of Figure 1.4 Typical centrifugal pump

tank and mixer.
In general, dynamic seals can not stop the leakage 100% like static seals,
but it is able to cut it (minimize it) to certain acceptable limits.
The Various Methods Of Sealing Rotating Equipment
There are several sealing devices which can be used to perform sealing
around rotating shafts. In the case of centrifugal pumps, sealing devices
limit liquid escape at the point where the pump shaft leaves the pump
housing (See Figure 1.4).
These sealing devices are:
1. Stuffing box packing.

2. Condensate injection sealing.
3. Floating seal rings.
4. Labyrinth seal.
5. Windback scroll or windback seal.
6. Segmented Carbon ring seals.
7. Lip seals.
8. Mechanical seals.
This chapter is divided into eight sections, each section covering one of the
sealing devices.
Section 1.1 Stuffing Boxes.

Section 1.2 Condensate Injection Sealing.
Section 1.3 Floating Seal Rings.
Section 1.4 Labyrinth Seal.
Section 1.5 Windback Scroll or Windback Seal.
Section 1.6 Segmented Carbon Ring.
Section 1.7 Lip Seals.
Section 1.8 Mechanical Seals.
SECTION 1.1
STUFFING BOXES
To understand how such a seal functions, a quick review of pump

fundamental is in order.
Any pump converts the energy of a prime mover, such as an electric motor,
into velocity or pressure energy of the liquid or gas being pumped.
In a centrifugal pump, the product enters the suction of the pump at the
center of the rotating impeller. (Figure 1.5).
Figure 1.5 Fluid flow in a centrifugal pump

As the impeller vanes rotate, they transmit motion to the incoming product,
which then leaves the impeller, collects in the pump casing, and leaves the
pump under the pressure through the pump discharge. Discharge pressure
will force some product down behind the impeller to the drive shaft, where it
attempts to escape along the rotating shaft. Pump manufacturers use
various design techniques to reduce the pressure of the product trying to
escape. Such techniques include:
1. The addition of balance holes through the impeller to permit most of the
pressure which acting behind the impeller to escape into the suction
side of the impeller. (Figure 1.6).
2. The addition of small pumping vanes on the back side of the impeller.
(Figure 1.7).
However, as there is no way to eliminate this pressure completely, sealing

devices are necessary to limit the escape of the product to the atmosphere.
Such sealing devices are typically either compression packing or
mechanical seal.
Figure 1.6 Back wear ring and Figure 1.7 Back vanes
balancing holes
1.1.1 Packed Stuffing Box
Stuffing boxes have the primary function of protecting the pump against
leakage at the point where the shaft passes out through the pump casing.
If the pump handles a suction lift and the pressure interior stuffing box end
is below atmospheric, the stuffing box function is to prevent air leakage into
the pump. If this pressure is above atmospheric, the function is to prevent
liquid leakage out the pump.
1.1.2 How it works?
Early attempts to control the leakage of the product around reciprocating or

rotating shafts consisted of merely restricting the clearance between the
shaft and the wall of the vessel or pump casing by packing a soft, resilient
material around the shaft within an extension of the tank wall or pump back
head called a stuffing box.
Figure 1.8 Shows a typical stuffing box sealed with square rings of
compression packing.
The compression packing rings, which must be carefully installed in a clean

stuffing box, are held in place by a gland. As the gland bolt nuts are
tightened, pressure applied to the gland is transmitted to the compression
packing, forcing it against the shaft or shaft sleeve and effecting a seal.
Because this pressure is not evenly distributed throughout the packing,
most of the sealing and consequently most the wear occurs in the first few
rings adjacent to the gland. (Figure 1.9).
Frictional heat, which develops where the compression packing contacts

the rotating shaft or shaft sleeve, is reduced by permitting the product to
leak to the atmosphere at a controlled rate. This leakage is essential to
carry away the frictional heat and as lubricant between the shaft (or shaft
sleeve) as rotating element and the packing rings as stationary element.
Figure 1.8 Stuffing box with Figure 1.9 Pressure distribution

compression packing
Figure 1. 10 Lantern ring Figure 1.11 Stuffing box with lantern ring
1.1.3 Lantern ring
The lantern ring (Figure 1.10) is a device made from a rigid material such
as bronze, stainless steel, nylon or TFE, and is of open construction to
allow free passage of sealing liquid (or lubricant). Normally, the sealing
liquid (or lubricant) enters the outside of the ring, and flows to fill the space
between the packing rings and the shaft ( or shaft sleeve). The lantern ring
usually has packing rings on either side (Figure 1.11)
1.1.3.1 Arrangements of the lantern ring to meet specific services
The following figure (figure 1.12) shows three different arrangements.

These arrangements are:
Figure 1.12 a
When a pump operates with negative suction head, the inner end of the
stuffing box (product side) is under vacuum, and air tends to leak into the
pump. For this type of service, packing is usually separated into two
sections by a lantern ring (seal cage).
Sealing fluid is introduced under pressure into the space, causing flow of
sealing fluid in both axial directions. This construction is useful to assure
liquid for cooling and lubrication between the packing rings and the shaft
(or shaft sleeve).
Figure 1.12 Arrangement of lantern ring to meet specific services
Figure 1.12.b
This construction is useful for pumps handling flammable or chemically

active and dangerous liquids since it prevents outflow of the pumped liquid.
Figure 1.12.c
If the product being pumped is too contaminated with abrasives, clean

liquid flush injected to lantern ring to prevent dirty liquid to enter the stuffing
box area. If the abrasives lodged between the packing rings and the shaft
(or shaft sleeve) it will act completely like a cutting tool against the shaft or
shaft sleeve.
1.1.4 Coopey packing design
There is another design for packed stuffing box to overcome the problem of
uneven distribution of the pressure throughout the packing, this is coopey
packing design. (Figure 1.13).
The designer added a helical spring between two washers where the
lantern ring normally is used. External lubrication ( or sealing liquid) is
introduced into the spring area and it is stated that "instead of the highest
friction point being next to the gland (Figure 1.9), there are now two points
at each end of the spring”. However, these are exposed directly to the
lubricant. If its pressure is the same as the fluid pressure, the inner
packing has just a slight differential across it and the packing acts very
much as a diaphragm. There is almost balanced pressure. The outer
packing is required only to retain the lubricant ( or sealing liquid) pressure.
This is relatively easy to do because the lubricant is in direct contact with
the point of highest pressure and friction. The spring compensates for any
slight wear or compression of the packing.
Figure 1.13 Coopey packing design

This arrangement removes the human factor from the equation because
when the packing is installed, the gland is pulled up to the face of the
stuffing box and no further adjustment is required. The spring takes care of
any thermal expansion or swelling of the packing.
1.1.5 Packing selection
Factors that must be considered in selecting a packing involve:
• All of the fluid's conditions, such as temperature, lubricity and pressure.
• All equipment parameters, such as speed, equipment condition,

material of shaft (or shaft sleeve); and miscellaneous factors, such as
dimensions of the stuffing box area and the shaft O.D. in the stuffing
box area, space available, continuous or intermittent service, and any
combination of these conditions.
1.1.6 Conventional packing drawbacks
The drawbacks of conventional packing are:
• Packing operates on the principle of controlled leakage in dynamic

applications. They never attempt to totally prevent fluid from leaking
from the equipment. This leakage will cause:
a. Waste of product. b. Pollution.
• It requires regular adjustment of the gland.
• Pressure limits: Packing not suitable selection for high pressure

working conditions like water injection pumps.
• Power consumption: The conventional packing consume more power.

Packing rubbing on a shaft (or shaft sleeve) similar to driving an
automobile with the hand brake engaged. This relatively high power
consumption will increase the running cost.
• Maintenance cost: Most of the time, the shaft ( or shaft sleeve) should
be changed due to damage. The rubbing between the packing rings
and the shaft will cause score marks and rough surface on the shaft in
the stuffing box area. That means extra maintenance cost and more
downtime. Beside this, most bearing failure is caused by
contamination rather than overloading. The easiest way to contaminate
a bearing is from the leakage coming through the packing. Stop this
leakage and you will stop most of your bearing failures.
• Speed limits: Packing have limited speed, if you try to use it in

peripheral speeds higher than its limits, the failure will happen. Most of
big pumps ( like water injection pumps and boiler feed water pumps)
the rubbing speed is too high due to high R.P.M. and big shaft
diameters.
The argument for packing usually centers around four statements:
1. You don't have to take the pump apart to change packing.

2 In an emergency, you can always add a ring of packing.
3. Packing is cheaper.
4. Packing is less complicated.
Let's look at each of these statements if it is true:
Statement 1:
You do have to take the pump apart to change sleeves and bearings. Shaft
sleeve replacement is a normal part of repacking a pump. The fact of the
matter is that you will have to dismantle a packed pump more than a
sealed pump.
Statement 2:
If you need reliability, use a mechanical seal with an auxiliary packing
gland.
Statement 3:
Packing is cheaper if you consider the packing alone. Bicycles are also
cheaper than automobiles.
Statement 4:
Packing is less complicated only to an inexperienced man. If you have ever
tried to teach an apprentice how to inspect a stuffing box and shaft, cut
packing, install it so as to align the lantern ring, tamp it in place, and adjust
it properly so as to keep leakage to a minimum and not generate excessive
heat (you have to do it by feel), then you know just how complicated
packing really is.
SECTION 1.2
CONDENSATE INJECTION SEALING
Condensate injection sealing (sometimes called packless stuffing box) has

been a very successful solution of the stuffing box problem for high-speed
boiler feed water pumps (about 5000 RPM) where neither conventional
packing nor mechanical seals provide a satisfactory answer.
1.2.1 How does it work?
The construction of a pump with condensate injection sealing (Figure 1.14)

involves the substitution of a serrated breakdown bushing for the
conventional packing. This serrated breakdown bushing is stationary part
and fixed to the machine casing. The pump shaft sleeve runs within this
bushing with a reasonably small radial clearance. Cold condensate, at a
pressure in excess of the boiler feed water pump suction pressure, is
introduced centrally in this breakdown bushing. A small portion of the
injection water flows inwardly into the pump proper; the remainder flows out
into a collecting chamber that is vented to the atmosphere. From this
chamber the leakage is piped back to the condenser.
Fig. 1.14 Condensate injection sealing (packless stuffing box)
Cold condensate at temperature from 80 to 100°F (26.7 to 37°C) is

available at pressures in excess of the boiler feed pump suction pressure in
closed cycles as well as open cycles in which the condensate pump
discharge into a derating heater from which the pump takes its suction. The
water for the injection in both should be taken immediately from the
condensate pump or condensate booster pump discharge before it has
gone through any closed heaters.
1.2.2 Factors affecting the water quantity
The injection water quantity will depend upon:
1. The diameter of the running joint between the shaft sleeve and the
pressure breakdown bushing (serrated bushing).
2. The clearance at that running joint.
3. The injection pressure.
To give some general idea of the values in question, if sleeve diameter is 5

inches (127 m.m.)and the diametral clearance 0.009 in (0.2286 m.m.), the
amount measured in a 3,600 RPM pump will be approximately as follows:
1. Total injection per box, 8 to 10 GPM(30 to 37.85 liters per min.).
2. Leakage into the pump interior per box, 2 to 4 GPM(7.57 to 15.14

liters per min.).
3. Return to condenser per box, 6 to 8 GPM(22.7 to 30.28 liters per

min.).
The injection supply must be absolutely clear and free of foreign matter. It
is therefore necessary to install filters or strainers in the injection line to
avoid the entrance of fine mill scale or oxide particles into the close
clearances between the stationary bushings and the sleeves. Pressure
gages should be installed upstream and downstream of these filters to
permit the operator to follow the rate at which foreign matters clogs up the
filters and to clean these when the pressure drop across them becomes
excessive.
1.2.3 Control of the injection flow rate
The variation in supply pressure to the condensate injection compared to

the internal pressures at both ends of the pump makes it necessary to use
a control for satisfactory seal operation. Three possible types of flow
control are:
• Manual,
• Pressure differential, and
• Temperature.
1.2.3.1 Manual flow control
A manual flow control requires hand-setting and re-adjusting a valve for

each seal. This necessitates the availability of a man to recheck the setting,
which varies with the load. While it is possible to use such a control it is not
normally recommended.
1.2.3.2 Pressure – differential control
The pressure-differential control senses the differences between injection

pressure and boiler feed water pump internal pressure and, by sending a
signal to an automatic valve in the injection line to each seal, maintains the
differential at some predetermined setting, usually 10 psi. This system
tends to be unstable because a change in pressure affects valve position
which changes pressure, and so on.
1.2.3.3 Temperature control
The temperature-sensitive control (Figure 1.15) operates on signals

received from a temperature-sensing probe in each seal drain line. A
controller transmits an air signal to a pneumatic control valve in the
injection line. In addition to providing rapid response to variations in
operating conditions, this type of control will use the least amount of
injection water. It will always supply just enough injection water to keep the
drains at the recommended temperature range of 140-150 °F. The injection
valves are equipped with limit stops so that they cannot close fully
regardless of the air signal.
Figure 1.15 Temperature control of condensate injection

1.2.4 Drains from condensate injection sealing
Two different systems are used to dispose of the drains coming from the
collecting chambers:
1. The first system utilizes traps that drain directly to the condenser.
2. The second system collects the drains in a condensate storage tank

into which various other drains are also returned. As this tank is
under atmospheric pressure, it must be set at a reasonable elevation
below the pump centerline so that the static elevation difference will
overcome friction losses in the drain piping. A pump then transfers
the condensate drains from the storage tank into the condenser.
1.2.5 The effect of the clearances between the sleeves and the
breakdown bushing
The clearances between the sleeves and the breakdown bushings will
double in a time approximately equal to the life of the pump internal
wearing parts. With double clearances, the leakage will double. This factor
should be considered when sizing the return-drain piping back to the
condenser or to the collecting tank if friction losses are to be kept to a
minimum in this piping.
The collecting chamber at the pump stuffing box is vented to the

atmosphere; the only head available to evacuate it is the static head
between the pump and the point of return. This head must always be well
in excess of the frictional losses (even after the leakage doubles),
otherwise the drains will back up and run off at the collecting chamber.
1.2.6 Drawbacks of condensate injection sealing
1. The injection of condensate requires a lot of piping and auxiliary

equipment. There is also an amount of energy required to keep it
going.
2. Pressure monitoring is also of great importance as the differential

pressure of the pump pressure must at all times remain equal.
3. Also of great importance is the radial clearance of the breakdown

bushing as increasing clearance through wear will require more and
more injection flow thus reducing the effectiveness of the system.
The modern mechanical seal for boiler duties required only a cooler
and a magnetic separators (or magnetic filters). As flow is induced by
rotating part of the mechanical seal no further auxiliary equipment is
required. (See Chapter 6)
SECTION 1.3
FLOATING SEAL RINGS
The floating seal ring type of seal is a variation found made by some pump
manufactures on the previous described sealing method.
The serrated breakdown bushing shown in figure 1.14 is replaced by a

number of individual solid rings. Each ring is mounted in a specially
constructed holder and is spring loaded to produce a stationary seal face in
an axial direction, and locked against rotation by a pin -and-slot
arrangement. (Figure 1.16).
A small radial clearance is provided between the rings and the shaft
sleeve. The length of each individual ring varies with the diameter of the
condensate injection seal, but is generally about 1/2 in. The individual seal
rings are "floating" to a certain degree and can find their own position
relative to the shaft. Their short length reduces the effect of angular
displacement between the stationary and rotating components, whether
this displacement arises from errors in original assembly or from distortions
caused by temperature changes.
Figure 1.16 Floating seal ring design
The further principle of operations is much the same as with the serrated
breakdown bushing, i.e., condensate injection, part of which enters the
pump, the remainder of which enter an atmospheric collecting chamber. No
direct contact between the floating rings (item #23-B figure #1-16) as a
stationary part and the shaft sleeve as a rotating part because the
condensate will provide a liquid film between them.
The efficiency of this system as a sealing device depends upon the running
clearance between the floating rings (item #23-B) and the shaft sleeve,
surface finish of all meeting parts and the purity of the injection
condensate.
SECTION 1.4
LABYRINTH SEAL
Labyrinth seals are the oldest type seals, simple to build and relatively
trouble free. They are used universally at interstage seal point in centrifugal
gas compressors, at the shaft ends of air blowers and compressors, and in
other applications when a small loss of process gas or seal gas (air,
nitrogen, etc.) may be tolerated.
1. The labyrinth seal is a set of metal rings or teeth that encircle the
shaft. The teeth do not contact, or touch the shaft. (Figure 1.17).
2. The spaces between the teeth form a labyrinthian passage. The gas
enters the space between the teeth, it slows down and changes
direction (Figure 1.17). The resulting turbulence resists the flow of
gas.
Figure 1.17 Straight labyrinth seal Figure 1.18 Fluid flow and the
resulting turbulence
3. If the gas velocity is high, some of the gas does not change direction
in the seal, but skips between the teeth and the shaft in a straight line
(figure 1.17), such skipping increases leakage.
Figure 1.19 Interlocking labyrinth
4. When the gas velocity through a straight labyrinth seal is high, it

becomes less effective in stopping leakage. To overcome this
problem there is another design (Figure 1.19). The interlocking
labyrinth seal is more efficient because the gas is forced to change
direction, it encounters resistance to flow.
1.4.2 The leakage across a labyrinth seal
Leakage rates are relatively high (1-2 percent of compressor flow on small
units). Leakage across a labyrinth seal depends on the following factors:
1. Number of teeth, more teeth less leakage.
2. Diameter of the packing ring; big diameters more leakage.
3. Running clearance; the leakage rate increases with big running

clearances.
4. Pressure to be sealed; the leakage rate increases in high pressure

applications.
There is always leakage and care must be taken that this leakage creates
no hazards. The normal operating limits are about 200 psi maximum or 20
psi per inch of axial length for a straight pass labyrinth seal. This works out
to be above 5 psi per tooth.
1.4.3 Labyrinth Seal Clearance
The clearance usually provided for turbomachinery shaft seals, using

labyrinth blading is maximum bearing clearance plus one mil per inch of
diameter of labyrinth.
Clearance is consider excessive when it exceeds two mil per inch of

diameter plus the bearing clearance. Labyrinth seals on casing operating at
pressures in excess of 50 psi have 8-20 blades. Lower pressure casings
contain three to six blades.
In general, the machine manufacturer will give the minimum and maximum
clearances. The minimum value to avoid any direct rubbing between the
rotating element and the labyrinth seal. The maximum limit to eliminate
excess leakage or in other words to keep the leakage rate within the
acceptable limits.
Note: 1 mil = 0.001 inch.
1.4.4 Influence of labyrinth seal clearance on the compressor's

efficiency
It is easy to improve compressor efficiency by minimizing interstage

labyrinth clearances. The new compressor will operate with minimum
internal leakage, but when the rotor become slightly unbalanced or
vibrations occur from another source, the labyrinth seals will wear rapidly,
opening the clearance and allowing greater leakage with a commensurate
decrease in efficiency. To prevent this situation, the minimum clearance
should be equal to the bearing clearance plus rotor run-out at the seal due
to its weight plus a given amount of mass unbalance.
1.4.5 Materials of labyrinth seals
Labyrinth seal's materials should have the following properties:
1. Must be softer than the rotor material. If the rubbing happen between
the rotor and the labyrinth seal, it is cheaper and easier to replace
the seal than replacing the rotor.
2. Should be able to resist chemical attack of the fluid to be sealed.
3. Should be able (up to certain degree) to withstand the erosion effect

of contaminated gasses. If some moisture condensate during
operation and this liquid droplets flows with the gasses, it could
cause under certain conditions erosion in the machine parts
including the labyrinth seals.
The common materials are: Aluminum, bronze, babbitt or steel.
1.4.6 Labyrinth Seal Designs
Many successful design variations are in use. In this section we will cover
different designs and applications:
1.4.6.1 The Straight labyrinth seal (Figure 1.20.a)
This seal consist of a series of thin strips or fins which are normally
mounted in a stationary ring which maintains a close clearance between
the shaft and the tip of the fins. Since the labyrinth seal resembles a series
of orifices minimizing the size of the openings is the most effective way of
reducing the flow. The diameteral clearance is thus normally limited to 1
1/2 to 2 mils per inch of diameter
c - Rotating.
Figure 1.20 Labyrinth seal designs
1.4.6.2 Stepped labyrinth seal (figure 1.20.b)

This seal increases the resistance to flow by destroying the line of sight
flow of the gas. A stepped tooth or staggered labyrinth design reduce
leakage by over 40% compared to the straight pass type.
One drawback to this type of seal is that the seal must be horizontally-split
to facilitate removal. This usually means lifting the compressor top-half to
replace the shaft seal.
The second drawback of this design is that rotor axial movement would
cause damage in the labyrinth seal teeth. For this reason, this design is
very sensitive for rotor axial movement.
1.4.6.3 Rotating labyrinth seal (figure 1.20.c)

Sometimes is called interference labyrinth seal. In this design, the fins are
machined into a rotating shaft sleeve (hard material like steel) and allowed
to cut their own clearance into the soft stationary ring (sleeve). This soft
stationary sleeve materials is usually lead, which is inert to most gasses,
and very ductile. The soft lead rubbing surface is normally bonded to steel
ring for support, In some cases, the soft stationary sleeve may be bronze,
aluminum, a lead-tin alloy, soft cast iron, carbon-graphite or (for high
temperature) stainless steel.
1.4.6.4 Honeycomb labyrinth seal (figure 1.21)
The use of honeycomb labyrinths offers better control of leakage rates (up
to 60 percent reduction of a straight pass type). Honeycomb seals operate
at approximately one-half the radial clearance of conventional labyrinth
seals. The honeycomb structure is composed of stainless steel foil about
10 mils thick. Hexagonal-shaped cells make a reinforced structure that
provides a large number of effective throttling points (figure 1.21). In
addition, stainless steel honeycomb retain its strength at temperature and
pressure levels which cause weakening of an aluminum labyrinth.
Figure 1.21Schematic of honeycomb labyrinth seal
1.4.6.5 Ported labyrinth seal arrangement

It is possible to alter the labyrinth seal for many gas applications. The
packing can be expose to full discharge pressure and a port or lantern to
bleed off leakage through the first section is connected to intake. Another
sectionalizing port may be used to inject another gas at slight higher than
intake pressure. This prevents process gas leaking out, but permits
injection gas leakage both to atmosphere and to intake. The operation may
be reversed and the port connected to an ejector, maintaining a pressure
below atmospheric. In this case, the process gas and atmospheric air
would leak to the port and removed.
Figures 1.22 through 1.24 show in schematic fashion in several types of
ported labyrinth seal arrangements. Such seal system are often used on
sour gas compressors, feed gas compressors, etc.
1. In the simple injection arrangement (Figure 1.22), a cool
(approximately 100°F/40°C) clean sweet gas, which is not
objectionable in small amounts in the compressed gas stream, is
injected at 3-5 psi (0.2-0.35 bar) above gas pressure or at
atmospheric pressure, whichever is higher. Naturally the gas will flow
in both directions from the inject point, thus the sweet gas must also
be non-toxic as well as relatively inexpensive.
Figure 1.22 Simple Sweet Gas Injection Figure 1.23 Simple Ejector
Seal
2. In the simple ejector seal arrangement (Figure 1.23), the seal port
pressure is maintained approximately 0.5-1.0 psi (35-70 m. bar)
below either gas stream pressure or atmospheric pressure,
whichever is lower. In this case, compressed gas plus atmospheric
air are pulled out through the seal ejector. The ejector motive gas can
be steam, discharge, or some other readily available gas.
These improvements are not attractive in these days of higher energy costs
because even under the best of conditions the leakage rate is too high and
the energy costs to operate the improvement are also costly.
3. While the above two mentioned arrangements have been used, the
combination injection and ejector seal arrangement combines the
good points of each and is thus used in the majority of labyrinth seal
applications. With this arrangement (figure 1-24), the sweet gas or
injection media is maintained 3-5 psi (0.2-0.35 bar) above the gas
reference pressure and flows into the gas stream as well as toward
the ejection point. At the ejection point, the sweet gas, as well as
some air from the atmosphere or bearing housing, is pulled off
through an ejector. In this way no product or compressed gas is lost,
while at the same time the sweet gas is not allowed to contaminate
the area outside the compressor.
Figure 1.24 Injection and ejector type seal
1.4.7 Labyrinth seal drawbacks
1. Labyrinth seal is never a positive seal, as all labyrinth seals are

designed only to restrict the flow of fluid
2. As mentioned before, the efficiency of this seal to perform the

required job depends on the running clearance beside some other
factors. Other problem also occur when using this type of seal.
Thermal growth of the mating surfaces must be carefully controlled
to maintain correct clearances under all operating conditions.
1.4.8 Areas of application
The labyrinth seals suitable for rotating shafts. It is widely used in the
following application:
1. Turbo compressors.
2. Gas and steam turbines.
3. In gear boxes, to seal around the input and output shafts in order to
stop oil leakage.
4. In some mechanical seals, where it is used as seal flange bushing

either for safety or for quenching.
5. In some designs of centrifugal pumps as inter-stage seal to minimize

the internal leakage from one stage to another.
SECTION 1.5
WINDBACK SCROLL OR WINDBACK SEAL
Figure 1.25 Windback seal
These seals are also called pumping screws. Windback seal in its simplest
form (figure 1.25) it is a sleeve with a helical (screw type) groove or
grooves (multiple entry). These helical grooves are machined on the
external surface of the sleeve. This sleeve is mounted over the pump shaft
in the stuffing box area and rotates with it. Windback seals are dependent
on the direction of rotation and the running speed (RPM).
When the pump is in operation, this sleeve acts completely like a rotating
element (rotor) of a screw pump. By suitable selection of the direction of
the helical groove as (right hand) or (left hand) groove it provides a
pumping action in reverse direction of the fluid leakage. This reverse
pumping action slowing down the flow of the product to atmosphere. At
certain R.P.M., the leakage rate will be zero. Variations can be found with
a helical groove in both rotary and stationary members.
Figure 1.26 Multistage Centrifugal pump with pumping screw
When a double bearing pump is sealed by this method, a right and a left
hand thread is required. Figure 1.26.
1.5.2 Disadvantages of windback seal
1. The main disadvantage of this sealing method is that it is less

effective at lower rotation speed when for example used on boiler
feed water pumps running at partial load conditions. The reason of
this is that this small screw pump (the sleeve with its helical grooves)
is able to pump a fluid in reverse direction at specific speed. If it runs
with speed lower than this specific value, its performance will
completely changed.
2. Under stationary conditions (when the pump on standby, fully primed

and ready to run) the windback seal has practically zero
effectiveness and then only acts as a regular throttle bushing.
1.5.3 Advantages of windback seal
1. No direct rubbing between moving and stationary parts i.e. no wear

due to rubbing.
2. Sophisticated arrangements can be found (when sealing gasses)

when the scroll fed with oil provides a back pumping action to
provide sufficient differential sealing pressure. Theoretically this type
of arrangement has zero leakage as far as the gas is concerned, but
as it is, once again, dependent on rotational speed it is sometimes
backed-up by a mechanical seal to provide sealing at low R.P.M.
Windback seals can be used in conjunction with mechanical seal to boost

the circulation of coolant for single and double seals. (This point will be
covered in details later on - Chapter #6)
SECTION 1.6
SEGMENTED CARBON RING SEALS
These seals are also called restrictive carbon ring seals. Figure 1.27
shows a restrictive carbon ring. In this seal the labyrinths are replaced by
carbon rings, which provide a more tortuous path to the passage of gas
along the shaft. As the carbon ring clearance is held to a minimum, the
leakage is less than for a comparable labyrinth seal. But this close
clearance increases the wear, and dry carbon seals thus normally require
more frequent replacement than labyrinth seals.
The rings are made out of low friction material such as carbon. It could be
one piece, reinforced by a steel band (Figure 1.27.A) or segmented (Figure
1.27.B). If the rings are segmented, they are usually held together with a
garter spring.
A- One piece, reinforced by steel band. B- Segmented ring with

garter spring.
Fig. 1.27 Restrictive Carbon Ring
1. Refer to figure 1.28. The rings are held in position around the
rotating shaft by stationary ring cups, these rings cups do not contact
the shaft.
Figure 1.28 Restrictive carbon ring seals
2. The leakage over the ring is prevented by the vertical contact

between the ring and the ring cup (in radial direction).
3. In this type of seal, the carbon rings actually do not contact the shaft,
so that some leakage will occur. The restrictive carbon ring seal can
be ported for scavenging or inert gas sealing.
4. Restrictive carbon seals is also used in conjunction with labyrinth

type seals to further reduce leakage.
If the sealed gas contains some humidity to lubricate the carbon rings,
radial clearances between the ring and shaft or sleeve may be very close
and leakage rates substantially lower than those of labyrinth seals of
similar space requirements may be achieved. The seal may be operated
dry (as in the labyrinth seal), with a sealing liquid (as in the mechanical
type) or with a buffer gas. An exception is where lube-oil is applied to
carbon-ring seals by drop-feed lubricators. This is done to reduce the
frictional heat of the higher pressure seal contacts and where the lube oil is
not a nuisance.
General operating limits are about 200 psi maximum or 35 psi per active
ring. The basic restrictions and problems cited for the labyrinth seal also
apply to this type. In addition, the carbon ring can shatter easily.
Its basic advantage lies in reduced leakage if proper clearances are

maintained (about two mils total at operating pressures and temperatures).
1. This seal can only be used in a relatively clean gas service.
2. In steam turbines to prevent steam from leaking to outside the

machine casing.
SECTION 1.7
LIP SEALS
Radial lip seals are used primarily for keeping lubricants in systems which
have moving shaft. These seals are also called oil seals or shaft seals.
A typical lip seal is shown in figure 1.29. All major elements are named
(SAE Nomenclature). The basic parts are the outer metal case and inner
flexible sealing element (soft lip).
Figure 1.29 Radial lip seal nomenclature
1.7.1 How it works ?
Figure 1.30 The lip seal working principle
Sealing of a lip-type seal is normally the result of an interference fit

between the inner soft lip (flexible sealing element) and the shaft. Usually
spring pressure behind the lip is also added keeping the fluid in depends
upon a precise amount of lip contact pressure. Figure 1.30 illustrates the
working principle of lip-seal.
The seal lip should ride on a thin film of lubricant. The film does the sealing
so it must be controlled precisely by the mechanical pressure of the sealing
element and the shaft finish. If the liquid film gets too thick, liquids leaks; if
too thin, the lip wears and friction, heat, and lip oscillations can result.
Normally, if contact pressure increases the film gets thinner. Heat build-up
can also reduce the liquid film. Never run lip seals without lubrication
unless necessary-and then only for short periods. Unless defective or
installed wrong, lip seals should leak only the thin lubricant film we
discussed before.
1.7.2 Advantages
Basic advantages of radial lip seals are:
1. Fit into small space.
2. Fairly low cost.
3. Easy to install.
4. Handle many variables while sealing. Variables include most oils and
hydraulic fluids over wide temperature ranges, moderate fluid
pressures, some misalignment, some shaft run-out and variations in
shaft speed.
1.7.3 Types of lip seals
Radial lip seals are classified by lip types as follows:
a. Single lip (figure 1-31-A). Lip not spring - loaded. For containing
viscous liquids like grease, at slow shaft speeds.
b. Single lip spring-loaded (figure 1-31-B). For retaining lower-

viscosity lubricant at higher shaft speeds in clean environment
(atmospheres).
c. Double lip (figure 1-31-C). Lips face opposite, one spring-loaded,

one not. For retaining lubricant on spring-loaded side, while
keeping out dirt on the other side.
d. Dual lip (figure 1-31-D). Lips face opposite, both are spring-loaded.
For containing lubricant on one side and excluding liquid on the
other.
a. b c d
Figure 1.31 Basic types of radial lip seals
Other special lip seals include:
1. Split Seals: for difficult installations in the plant and marine situs
applications (figure 1.32). Split seals allow a seal to be assembled in
situs around the shaft.
2. External Seals: for a fixed shaft and rotating bore (outer part of the
seal is the sealing surface).
3. Hydrodynamic Seals (Figure 1.33): Which have grooves or ribs

molded into the seal lip to direct oil flow back into the sealing area,
reducing heat and wear. This seal can operate at less lip pressure
than standard lip seals. Care must be taken when using these lip
seals as they are “uni-directional” and is used for the wrong direction
of rotation can actually encourage leakage.
SECTION 1.8
MECHANICAL SEALS
1.8.1 Mechanical Seals Overview
The mechanical seals was developed to overcome the disadvantages of
compression packing. Leakage can be reduced to a level meeting the
environmental standards.
Mechanical Seal Construction
All mechanical seals are constructed of four basic sets of parts. As shown
in figure 1.34, these are:
1. A set of seal faces which are called sometimes primary sealing
device. One that rotates (rotating face) and one that is stationary
(stationary face).
2. A set of secondary seals known as secondary sealing device or
gaskets such as 0-rings, wedges, U-cups and V-rings.
3. Spring (s).
4. Mechanical seal hardware including seal flange (gland ring), shaft
sleeve. etc.
Figure 1.32 A simple mechanical seal
1.8.2 Sealing Points for Mechanical Seal

There are four main sealing points, (see figure 1.32)
1. The primary seal is at the seal face, point A.
The primary seal is achieved by two very flat, lapped faces which
create a difficult leakage path perpendicular to the shaft. Rubbing
contact between these two flat mating surfaces minimizes leakage.
As in all mechanical seals, one face is held stationary in a housing
(stationary face), and the other face is fixed to, and rotates with the
shaft (rotating face). These two faces are made from two dissimilar
materials, one of them is usually a non-galling material such as
carbon-graphite. The other is usually a relatively hard material. The
seal faces are made from two different materials in order to help
prevent adhesion of the two faces.
2. The leakage path at point B (between the floating seal face and the
shaft or shaft sleeve) is blocked by floating seal face gasket (either 0-
ring, U-cup, a V-ring, or a wedge).
3. Leakage paths at point C (between the seal flange and stuffing box
face) is blocked by seal flange gasket which could be 0-ring or any
other shape of static gaskets.
4. Leakage paths at point D (between the seal flange and the stationary
face) is blocked by stationary face gasket or seat gasket.
1.8.3 How Does it Work?
1. The two flat seal faces are pushed together by axial force from the
closing mechanism (spring or metal bellows) and by product pressure
in the ^stuffing box cavity (seal chamber).
2. When the seal is in operation, the two seal faces are lubricated by the
same product inside the stuffing box. It is known that, for the seal to
work efficiently, it is necessary for a stable fluid film to exist between
the seal faces. In the majority of cases this film is a liquid, although in
certain applications a gas film may be induced between the faces.
The function of this liquid film between the seal faces is for cooling
(carry away the frictional heat) and lubrication. If this film stability is
destroyed, excessive wear takes place leading to rapid seal failure.
3. Improperly positioned seals could allow a wide gap between the

faces, causing a leak path. The faces could also be squeezed so
tightly together that no lubrication is present, causing rapid seal
failure.
1.8.4 Advantages of Mechanical Seals
Mechanical seals replace conventional packing in stuffing boxes where the

fluid must be contained inspite of a substantial pressure head. These seals
offer:
1. Reduced friction power loss.
2. Virtual elimination of wear on the shaft or shaft sleeve in the stuffing

box area.
3. Invisible or minimum leakage.
4. Ability to function in relative extremes of shaft deflection and end

play.
5. Suitable for high working pressures and high rubbing speeds.
6. Relative freedom from maintenance.
1.8.5 Comparison Between Conventional Packing and Mechanical

Seals
Conventional Packing Mechanical Seal

1. How does it work? 1. How does it work?
Conventional packing forced Mechanical seal has two rings (seal

into a stuffing box around a faces) at right angles to the shaft. One
revolving shaft seals by ring (seal face) is fastened to the shaft
throttling the casing fluid trying and revolves with it, while the other is
to leak between the packing stationary and is held against the
and shaft. The more packing machine casing. The wearing faces that
forced into the stuffing box seal have a small area compared to the
and the tighter it's jammed by area conventional packing seals
gland, the less leakage. But against. Because of this small area, and
packing wears the shaft and the preloaded spring(s) forcing the two
increases the power needed faces together at a few pounds per
to rotate the shaft. square inch of pressure, there's less
friction at the seal faces. And of course
there is no wear on the shaft because
seal faces take it all, they can relapped
or replaced when needed.
2. Shaft run-out 2. Shaft run-out
Shaft run-out is one costly Mechanical seals can take more shaft
enemy of conventional run-out without leaking. Reason is that
packing. It beats out packing, sealing faces are at right angles to
making sealing problem tough. shaft. The elastomeric gaskets and the
If the shaft run-out is over spring(s) allow for some misalignment
0.003, it's impossible to seal between the seal faces which could
properly, especially at high happen due to shaft run-out.
speeds.
At extremely high speeds, shaft run-out

may give trouble because of centrifugal
force.
3. Shaft axial float 3. Shaft axial float
End play is common with most Shaft end play does not affect the
shafts especially when starting mechanical seal if this end play within
up or shutting down. Such certain limits (about 0.003" for rolling
shaft movement does not element bearings as a thrust bearing
affect the conventional and about 0.015" for slide surface
packing if shaft has no bearing as a thrust bearing). The
grooves in packing area. But spring(s) will keep the seal faces close.
usually shafts or sleeves do The big values of shaft end play
groove after a short while. disturbs the mechanical seal.
Then shaft end play disturbs
packing, open it up and
causes leakage.
4. Power consumption 4. Power consumption
It is relatively high (about three It is relatively smaller. The seal faces
times the power consumption running with a lubricating liquid film
in the mechanical seal for the between them.
same shaft size and speed).
5. The required time for 5. The required time for installation
replacing
Can be packed in place. It Installed over shaft end. It needs more

needs adjusting several times time for installation. It does not need
after start up until it reach the any additional adjustment after the
normal running conditions. installation
6. Pollution 6. Pollution
Is relatively high because the In normal running conditions, less

packing must leak for cooling leakage i.e. less pollution. Double seals
and lubrication. are able to stop product leakage 100%.
7. Cost of Product 7. Cost of Product
High- due to high leakage Low- due to very small leakage rates.
rates.
8. High pressures and big 8. High pressures and big shaft

shaft diameter services diameter services
Not suitable sealing device for Mechanical seals can handle both
big shaft diameter or high vacuum and high pressures. Also it is
pressures. suitable sealing device for big
diameters.
On the next chapters you will find more details about mechanical seals.

Chapter 01

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Chapter 01

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Seals & Packings for Rotating Shafts

SEALS AND PACKINGS FOR

The purpose of this chapter is to introduce and describe seals and

Why do we Need to Perform Sealing?

• A pressure may be needed which cannot be maintained if the fluid

The structure to be made leak-proof may have a hole with a shaft

There are two basic kinds of seals:

1. Static seals are used to perform sealing between two stationary

2. Another category of static seals are sealant, which are similar to

3. This gasket is any device maintains a barrier against the transfer of

4. Joint and gasket design must be considered together. A joint is only

5. A prime factor in any seal or gasket is minimum sealing stress. This

Figure 1.1 Conformation of gasket to flange Figure 1.2 Static Seals

Figure 1.3 Cross section of Figure 1.4 Typical centrifugal pump

The Various Methods Of Sealing Rotating Equipment

These sealing devices are:

1. Stuffing box packing.

Section 1.1 Stuffing Boxes.

To understand how such a seal functions, a quick review of pump

Figure 1.5 Fluid flow in a centrifugal pump

However, as there is no way to eliminate this pressure completely, sealing

1.1.1 Packed Stuffing Box

1.1.2 How it works?

Early attempts to control the leakage of the product around reciprocating or

The compression packing rings, which must be carefully installed in a clean

Frictional heat, which develops where the compression packing contacts

Figure 1.8 Stuffing box with Figure 1.9 Pressure distribution

1.1.3 Lantern ring

1.1.3.1 Arrangements of the lantern ring to meet specific services

The following figure (figure 1.12) shows three different arrangements.

Figure 1.12 Arrangement of lantern ring to meet specific services

This construction is useful for pumps handling flammable or chemically

If the product being pumped is too contaminated with abrasives, clean

1.1.4 Coopey packing design

Figure 1.13 Coopey packing design

1.1.5 Packing selection

Factors that must be considered in selecting a packing involve:

• All of the fluid's conditions, such as temperature, lubricity and pressure.

• All equipment parameters, such as speed, equipment condition,

1.1.6 Conventional packing drawbacks

The drawbacks of conventional packing are:

• Packing operates on the principle of controlled leakage in dynamic

• It requires regular adjustment of the gland.

• Pressure limits: Packing not suitable selection for high pressure

• Power consumption: The conventional packing consume more power.

• Speed limits: Packing have limited speed, if you try to use it in

The argument for packing usually centers around four statements:

1. You don't have to take the pump apart to change packing.

Let's look at each of these statements if it is true:

CONDENSATE INJECTION SEALING

Condensate injection sealing (sometimes called packless stuffing box) has

1.2.1 How does it work?

The construction of a pump with condensate injection sealing (Figure 1.14)

Fig. 1.14 Condensate injection sealing (packless stuffing box)

Cold condensate at temperature from 80 to 100°F (26.7 to 37°C) is

1.2.2 Factors affecting the water quantity

The injection water quantity will depend upon:

2. The clearance at that running joint.

3. The injection pressure.

To give some general idea of the values in question, if sleeve diameter is 5

1. Total injection per box, 8 to 10 GPM(30 to 37.85 liters per min.).

2. Leakage into the pump interior per box, 2 to 4 GPM(7.57 to 15.14

3. Return to condenser per box, 6 to 8 GPM(22.7 to 30.28 liters per