MECHANICAL SEALS FAILURE,CAUSES AND ITS

REMEDIES

Presented by:
YUMKHAIBAM FARUQUE KHAN
07109056
Mechanical Engineering
 Mechanical seals
Wear Nose

Springs Anti-Rotation
Pin

Semi-dynamic secondary seal

Stator
Rotor
Mechanical seal leakage points
1Gland to pump face -
sealed with a gasket
2 Over the top of the seal -
O-ring
3 Under the seal - O-ring
2
4 Between the faces
 On-Site Failure Analysis
Conduct Physical Equipment Inspection
• Inspect equipment for excessive shaft movement
– Axial deflection
– Radial deflection
– Run-out
• Inspect seal gland mounting surface to shaft Perpendicularity
• Confirm shaft to box bore Concentricity

Axial Shaft Movement

• Axial shaft movement ( end play ) is usually held within 0.001” to 0.004” T.I.R.
Exceptions: Machines with tilting pad type bearings can have axial thrust
bearing clearance of up 0.020”, machines with tapered roller bearings can
have axial thrust clearance of up to 0.008”
• Measurement usually requires the removal of the seal chamber. Install the dial
indicator support onto the power end portion of the pump, with the dial
indicator pointer against shaft shoulder, adjust to 0. Gently tap the shaft in the
axial axis from the coupled end, then readjust the dial indicator to 0, then
repeat the opposite direction, to obtain total axial end play. Warning:
excessive axial loading on most type of bearings can result in surface
deformation of the bearing races, and possible failure
 Excessive axial shaft movement can cause:
•Pitting, fretting, or damage to the shaft / seal / internal pump parts, at the point of
contact between various axial surfaces. Mechanical seals can be damaged by:
•Excessive spring overload / change in total face loading
•Axial contacting, rotating vs. stationary component parts
•Chipping of seal faces, from contacting seal component parts, silicon carbide and
carbon seal rings are relatively delicate and most susceptible
•Pump damage can include:
•Bearing failure
•Impeller contact with wear-rings / close internal fits
•Safety issues:

Radial shaft defection: Shaft lift

•Radial shaft defection, located at the face of the seal chamber must not exceed 0.002”
T.I.R. ( 0.05 mm )
•Measure: Install dial indicator base to seal chamber power end, place indicator pointer
onto the shaft O.D. at the 12 o’clock position, adjust to 0. Gently lift the shaft at the
impeller end
•If movement is excessive: Examine bearing cap / pre-load / shims/ bearing and internal
bearing clearances
 Excessive radial shaft defection can cause:
•Fretting of the shaft / packing & seal sleeve / internal pump parts, at the point of
contact between various radial surfaces. Mechanical seals can be damaged by:
•Close clearance between I.D. rotating / stationary components vs. sleeve O.D. can
contact
•Large amounts of mating face leakage
•Close clearance between O.D. rotating / stationary components vs. seal chamber /
gland I.D. can contact
•Disaster bushing contact
•Pump damage can include:
•Wear ring, throttle bushing and balance drum contact
•Safety issues:

Shaft run-out
•Shaft run-out must not exceed 0.002” T.I.R. ( 0.05 mm )
•Measure: Use two dial indicators. Install dial indicator base onto a convenient area of
the power end of the pump case. Place each pointer onto the shaft O.D. at coupling and
impeller ends then mark radial points, every 90º, adjust to 0.
•If run-out movement is excessive: Repair / re-balance / replace shaft
 Excessive shaft run-out can cause:
•Excessive dynamic mechanical seal leakage / vibration of pump shaft / bearing failure.
Mechanical seal can be damaged by:
•Broken / warn anti-rotation pins / drive pin wear
•Excessive mating face leakage from face tracking / vibration
•Springs may exhibit radial wear
•Dynamic balance shoulder fretting / wear
•Pump damage can include:
•Unscheduled shut down / loss of production
•Out-of-balance shaft will produce radial / axial vibration. Results range from limited
to total rotor/seal/ pump damage.
•Bearings usually sustain the most damage
•Safety issues:
Perpendicularity between seal chamber face and shaft
•Perpendicularity should not exceed 0.001” per inch of seal diameter, up to 0.005” ( 0.025
to 0.130 mm )
•Measure: Pre reading requirement: Install seal chamber / support rotor assembly in
bearings / install thrust bearing. Install dial indicator base to the O.D. of the shaft, the
pointer is placed onto the seal chamber face. For double ended machines use two, small
dial indicators, mounted at each end. Also need an inspection mirror. Mark the seal
chamber face, 12, 3, 6 & 9 o’clock, adjust to 0, begin sweep at the top. Repeat several times,
dial indicator should end at 0.
•If Perpendicularity is excessive: Repair to within acceptable specifications
 Poor perpendicularity can cause:
•Excessive dynamic / static mechanical seal leakage / loss of barrier fluids / damaged seal
parts. Seals can be damaged by:
•Fretting of the sleeve O.D. at the dynamic balance shoulder
•Damage / stress breaks to bellows convolution
•Damage to the mating seal faces due to uneven fluid film maintenance
•Damage to the dynamic balance shoulder o-ring
•Disaster bushing contact
•Pump damage can include:
•Unscheduled down time / process loss time
•Out of perpendicular condition must be corrected to within acceptable limits

Concentricity between seal chamber bore & shaft

•Concentricity should not exceed 0.005” T.I.R ( 0.13 mm )
•Measure: Pre reading requirement: Install seal chamber and support rotor assembly in
bearings. Install the dial indicator base onto a convenient location on the shaft O.D., place the
pointer onto the bore (diameter) of the seal chamber, where the seal gland pilot seats. For
double ended machines, use two small dial indicators, installed at each end, also will need an
inspection mirror. Mark seal chamber face, 12, 3, 6 & 9 o’clock positions, adjust to 0, record at
marked locations, repeat several times.
•If concentricity is excessive: Repair to within acceptable limits
 Poor concentricity can cause:
•Excessive seal damage / pump wear ring clearances / pump throttle bushing contact.
Mechanical seals can be damaged by:
•Contact between shaft/sleeve vs. stationary/rotating face I.D.
•Contact between shaft/sleeve O.D. vs.. disaster bushing I.D.
•Contact between close clearance parts, pumping ring,
•Pump damage can include:
•Rotor assembly damage due to contact at wear ring areas
•Rotor assembly damage due to contact at throat bushing areas
•Poor concentricity condition must be corrected to within acceptable limits
 On-Site Failure Analysis
Conduct Physical Seal Inspection
• Loading members
– Springs
– Bellows
• Metal Components
• O-rings and gaskets
• Rotating and Stationary Faces
Conduct Physical Seal Inspection
 Loading Members (springs)
• Correct Free Length
• Correct Load at working length
• Expected materials
• Required Quantity
 Loading members(bellows)
• Correct Free Length
• Correct Load at working length
• Expected materials
• Leak free core
 Metals component
• Corrosion or Erosion
• Fretting
• Vibration
• Expected materials
 Corrosion or Erosion:
 Description:
•Corrosion, leaching & pitting: Surfaces appear matted, dull, honeycombed, flaky, loss of
hardness.
•Erosion: Surfaces appear matted, dull.
Symptoms:
•Excessive seal static / dynamic leakage
Causes:
•Improper material of construction
•Fluid contamination
•Excessive temperature increases

Corrective actions:
Laboratory study:
Chemical analysis of product, physical properties ( temp. press. & speed )
Material identification
Review application and seal selection:
Material selection
Increase seal chamber cooling
Neutralize corrosive environment
Remove contaminates
Review service conditions. Look at:
Upset conditions
Start / shut down conditions
 Fretting corrosion:
Description:
•Damage to dynamic o-ring and seal sleeve, dynamic balance shoulder. Area appears pitted /
dull or bright / shiny
Symptoms:
•Excessive static / dynamic seal leakage
Causes:
•Results from constant back & fourth motion of secondary
seal(s) in contact with part in motion. Can occur with packing, lip
seal, dynamic balance shoulder, secondary seal ( o-ring )
•Removes passive oxide metal surface coating that normally
protects sleeve.
Corrective actions:
Examine / reduce / eliminate causes of excessive vibration:
•Review mechanical soundness: Shaft run out, whip, axial end play & deflection
•Apply protective coatings of hard facing alloys, aluminum oxide & chrome oxide to
areas directly under secondary seal
•Upgrade base material of shaft / sleeve to a material that does not depend upon
passive or protective coatings for corrosion resistance
•Elastomer o-ring used for secondary seals are less susceptible to fretting corrosion
because they can absorb minor internal axial shaft movement. Examine the possible
changing of PTFE, non elastomer gaskets or other geometric shapes
•Replace spring pusher type seal with a non pusher type seal: bellows with static
secondary seal
 Conduct Physical Seal Inspection
O-rings and Gaskets
Chemical attack of O-rings
Description:
•Swollen o-rings, o-rings that have taken a permanent set or melted /
eaten away appearance. Other appearances include:
bubbled
broken
hardened
blistered
Can cause axial “lock-up” of stationary face assembly of pusher seals
symptoms
Excessive static / dynamic seal leakage
Causes:
•Incorrect material selection
•loss or contamination of seal barrier / buffer fluid
•Improper lubricant used on installation
Corrective actions:
Review seal selection and application:
Check material compatibility Laboratory study:
Check product concentration Check material
Check product temperature
identification
Use alternative gasket material
Check external source of flush media Physical properties of
Check installation procedure: product
O-ring lubricant type
 O-ring compression set:
Description:
•Elastomer exhibits permanent, cross-section deformation, usually forms to the shape of
the groove / cavity, usually caused by temperature, excessive squeeze, etc…
Symptom:
•Excessive dynamic / static pump & seal leakage
Causes:
•Excessive temperature
•Excessive % of elastomer squeeze
•Chemical attack
•Improper material selection
Corrective actions:
Review application and seal selection:
•Check / examine % elastomer squeeze
•Check / examine axial stack-up of parts
•Check / examine actual o-ring groove dimensions / finish
•Obtain current / complete physical properties breakdown
•Check / examine elastomer material compatibility vs. product constituents
•Verify damaged o-ring material
•Check for other thermal / chemical damage
•Review / examine cooling water system
•Examine pump /seal cooling jacket condition
•Examine operating history for upsets
•Examine suction/ discharge valve operation / sequence
 O-ring Extrusion:
Description:
•Elastomer Exhibits a cut, peeled or nibbled appearance
Symptoms:
•Can exhibit static and/or dynamic seal leakage
Causes:
•Excessive pressure / water hammer effect
•Excessive elastomer clearances ( too large or too small )
•Incorrect elastomer application / shore hardness
•Excessive temperature
•Chemical attack

Corrective actions:
Review seal application and operating conditions:
•Check / examine elastomer % squeeze
•Check / examine surface finish / size
•Check anti-extrusion ring dimensions / clearance
•Check elastomer Shore hardness / material identification
•Check chemical analysis of product
•Check / examine mating seal faces for thermal damage
•Check / examine cooling to seal chamber
•Check / examine cooling water system / circuit
 O-ring: Thermal damage:
Description:
•Elastomer exhibits radial cracks, increase in hardness, brittle, charred or flaky
appearance. Teflon exhibits hardness and discolored black / blue
Symptoms:
•Static / dynamic seal leakage
Causes:
•Localized overheating of the elastomer
•Misapplication above elastomer temperature limit
•System upsets / temperature
•Cooling water upsets / temperature
•Suction / discharge valve operation / sequence
Corrective actions:
Review application and seal selection:
•Examine / increase cooling to seal chamber
•Confirm elastomer selection
•Replace elastomer with suitable alternative
•Check / examine for blocked / obstructed flush piping
•Check / examine heat exchanger / cooling water
•Check for signs of seal face localized heat build-up: dry running / flashing
 O-ring cuts, tears, nicks & explosive decompression
Description:
•Elastomer exhibits any physical damage marks or physical manufacturing defects, i.e. twisted, cuts,
nicks, tears, splits, caused by handling, manufacturing, damage from misapplication or explosive
decompression
Symptom:
•Static / dynamic seal leakage
Causes:
•Manufacturing defects
Handling
oGeneral carelessness
oCleanliness, identification, inspection
•Installation / equipment damage
•Explosive decompression
Corrective actions:
Review application and seal selection:
•Examine actual groove dimension vs. o-ring size / assembly drawing part number
•Check type & amount of o-ring lubricant
•Check / examine shaft o.d. / seal chamber bore / face / horizontal split pump gasket areas for:
oSurface finish and areas that could cause potential o-ring damage
oShaft features: Steps, keyways, threads, grooves, etc...
•Proper lead-in chamfer / blend & condition of any contacting areas that could
cause damage
•Utilize elastomer material better suited for use in explosive decompression applications
oMaintain static / dynamic seal pressure to help eliminate explosive decompression
 Conduct Physical Seal Inspection Rotating and Stationary Faces

•Correct Materials
•Face Distortion and Flatness
•Erosion or Radial Grooving
•Carbon Blistering
•Heat Checking and Dry Running
•Product Vaporization
Face Distortion
Description:
•Rotating / stationary face distortion can appear as:
•Non-uniform but concentric wear patterns
•Light lapping of the mating face will produce clearer high spots, located at two
or more places
Symptoms:
•static / dynamic mating face leakage
Causes:
•Improper cooling may induce thermal stresses and distortions
•Improper finishing of the seal faces
•Debris / deposits underneath seal faces
•Improper seal design / assembly, clamped face & gland fasteners
•Poor surface supporting surface finish ( corrosion / mechanical ) can produce face
distortion
 Corrective actions:
Recondition ( lapping ) seal face to remove all distortion.
•Check for conformity to print
Consider using flexibly mounted stationary face seals to compensate for any gland
distortion, plus...
•Check the gland fastener / stud tightening: use cross tightening method
•Check the stationary face support for debris / product build-up
•Check the stationary face support for surface finish / flatness
•Check the stationary face support for perpendicularity vs. shaft
Check the clamping areas ( sleeve ) of a rotating face, plus…
•Check the front to back dimension / I.D. of the rotating face

Description: Face Erosion:

•Seal face or part exhibits a “washed-out” or “Jetting” appearance, usually in one radial
area. Softer materials and bellows most susceptible.
Symptoms:
•Increased static / dynamic seal leakage. Possible severe wear to the pump / seal
Causes:
•Excessive flush flow rate, plan 11
•Orifice location distance from seal gland
•Orifice size
• Seal flush contains abrasive particles
•Gland flush port impinges directly on the mating seal faces
Corrective actions:
Review application / material selection
•Check product for abrasive particles
•Check suction / discharge / seal chamber pressure vs. orifice size
•Check orifice location, should not be located closer that 12” from gland
•Decide if application will show improved operation by applying “hard” mating face
materials
•Consider multi port design to dissipate flush flow
•Relocate seal flush point
•Install particle filters and/or magnetic separators

Carbon blistering
Description:
•Characterized by small circular sections that appear raised and highly polished, located on
the mating seal face. The raised areas promote mating seal face leakage by separation.
Primary stage: small raised areas appear on the mating faces. Intermittent stage: cracks
appear in the raised areas, and Advanced stage: pieces of the carbon face break and create
three body erosion, type wear and leave voids / pits.
Symptoms:
•May be leak free during static conditions
•Dynamic leakage can increase with time, until excessive leakage begins
 Causes:
•Occurs mainly in vaporizing products
•More common with equipment that has high number of starts & stops
Corrective actions:
Operating conditions:
•Review vapor pressure at pumping temperature:
•Increase box pressure
•Reduce pumpage temperature
•Reduce frequent starts & stops
Review seal selection:
•Blister resistant materials
•Review mating seal face cooling / circulation
•Lower total unit loading at mating seal faces
Heating Checking
Description:
A pattern of parallel, fine to large, surface cracks, that appear to have a common “center of the seal
face” origin.
Symptoms:
The cracks are the result of excessive heat build-up, due to loss of fluid film. Cracks have a grinding
effect on hard/soft, carbon most susceptible.
Static / dynamic seal leakage
High in / out cooling temperatures
Causes:
Rapid heating / cooling of local mating seal face surface(s) produce stresses that exceed the yield
strength of the material
Lack of adequate cooling
Lack of adequate mating seal face lubrication
Vaporization / flashing at the mating seal faces
Excessive pressure excursions or excessive speed excursions
Corrective actions:
Check / examine, in & out, barrier cooling temperatures for plans, 11,23, 52, 53, & 54.
•Check cooling water / venting / flow / in & out temperatures
Review operating conditions and seal selection
•Obtain accurate operating conditions: suction / discharge pressures, temperature, product,
speed, vapor pressure, viscosity, specific gravity & any other data
•Increase cooling at the mating seal faces
•Utilize lube groove or wave type seal faces
•Check face material combination and PV
Check / examine:
•Pump shaft / seal axial movement to produce high face loads
•Upset conditions that could produce temporary high face loads

Vaporization
Description:
•Seal exhibits dynamic puffing, popping or blowing of product vapors at the seal faces. Occurs
when generated heat is not adequately removed resulting in the product boiling / flashing.
Symptoms:
•Shortens seal life, but may not cause instant catastrophic seal failure
•Creates possible safety related problem (steam burns)
Causes:
•Operating seal near or at vapor pressure of pumpage
•Excessive pressure acting on mating seal faces
•Excessive mating seal face deflection
•Inadequate cooling and lubrication of mating seal faces
Corrective actions:
Eliminate mechanical contact between pump / seal rotating / stationary components
•Check shaft vs. seal chamber alignment
•Pump close clearance areas: wear rings / throttle bushings
Check for blocked / obstructed seal flush
Check for inadequate flush rate:Increase rate if necessary
Pumpage operating close to vapor pressure:
•Increase pressure by installing close clearance bushing in seal chamber to restrict seal
flush liquid from flowing back into the pump
Reduce seal chamber temperature:
•Cooling jacket, Seal cooler (heat exchanger)
Check seal design:
•Consider using high hydraulic balance faces
•Consider using lube groove / hydro pads / wavy type faces

Recommendation for improvement

Document and issue a report addressing:
•Modifications to seal materials
•Changes in Seal Design
•Corrections to seal support system or piping plans
•Repairs to Rotating Equipment
•Refinement to installation techniques
•Adjustment to start-up and/or operation
Monitor / track performance of changes
 SUMMARY
• Understand the “Root Cause” Failure Mode
• Look at the Condition of the Equipment
• Review Operating Procedures
• Review Seal Support System
• Inspect the Mechanical Seal Components
• Make Changes Based on Application
Requirements
• Document all Changes
 Root Cause of
Seal Failure
Oper at ing
Ot her Env ir onment
8% 40%

Seal Par t s
9%

Sy st em
Design
19% Equipment
24%
Thank you