Mechanical Seal Failure Analysis Date

Cause & Effect Worksheet

Fluid Sealed Speed

Sealed Pressure Size

Seal Make Seal Model & Materials

Temperature Piping Plan #

Use this page to Check for Obvious Failure Modes before complete dismantling
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Shaft O-Ring Hard / Brittle 1
Compression Set Add Cooling > See
Product Temperature Environmental Control
Guide
Exceeded Elastomer
Excessive Heat
Limits
Check Equipment
Rotational Speed Too High
Operating Conditions
14,18,19

Eliminate Dry Running

Dry Running Insufficient or no liquid film between faces Poor Lubrication > See Environmental
Control Guide
10, 13, 14

Review Process
Chemical Attack O-Ring Material Selection Chemical Degradation
Conditions
4, 8, 11
Extrusion 2 Clearances in o-ring groove too large Check clearances,
Excessive Clearances Quality/design install back-up ring

Use higher durometer

Excessive pressure material
9, 10, 15, 19
Exceeded limits
Use higher durometer
Too soft material material

O-ring damaged during assembly Review installation

Installation damage Misinstallation instructions

Explosive 3
Decompression
If possible, eliminate
sudden pressure
Trapped gas ruptures o-ring when
Sudden pressure drop Equipment operation drops/shutdowns or
pressure is suddenly relieved
other elastomer
(consult factory)

Swollen / Soft 4 Review Process

Conditions

Chemical attack Incompatibility of o-ring material Loss of O-ring Integrity

1, 8, 11
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Set Screws Flattened 5
Review installation
instructions and use
Set Screw Loosened / Not Adequately Installation Instructions
hardened set screws
Tightened not followed
on hard shaft
materials
Spinning
Check Equipment
Process Conditions.
Excessive Pressure or Pressure Surges Equipment Operation Use hardened set
screws at higher
pressures
7
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Drive Collar Scoring 6
Check Equipment
Excessive Pressure / Pressure Surges Equipment Operation
Process Conditions

Overhaul Equipment
Bearing Clearance / Bearing Failure Equipment Condition and Maintain Good
Axial Motion
Condition

Check Equipment
Thermal Shaft Extension / Retraction Mis Application
Operating Conditions
 Remove the Sleeve and Check for signs of Scoring and Corrosion
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Sleeve Scoring 7
Sleeve Contacting Gland / Stationary
Miscentering
Components Follow Correct 10, 16, 17
Incorrect Installation
Installation Procedure
Set Screw Not tightened / Loosened

Spinning Review Installation

Procedure / Use
Excessive Pressure / Pressure Surges
Hardened Set Screws
for High Pressures
5
Improve Shaft
Slenderness Ration
3 4
Off Best Efficiency Point (BEP) Operation L /D (Should be less
Equipment Operation the 60 imperial units
or 2 metric units)

Check Net Positive

Suction Head
Available (NPSHa)
Shaft Deflection Cavitation 16, 20
against Net Positive
Suction Head
Required (NPSHr)

Check and reduce

Pipe Strain
Pipe Strain
Balance Impeller-
Shaft- Bearing
Unbalanced Impeller
Assembly together if
possible

Excessive Bearing Clearances / Bearing

Equipment Condition Overhaul Bearings
Failure

Bent / Twisted Shaft Replace Shaft

Radial Runout Check Stuffing Box to
Stuffing box-to-Shaft Misalignment Shaft Squareness
and axial alignment
Carry Out Pump
Incorrect Pump Alignment
Alignment 14, 16, 17
Corrosion 8 Surface corrosion, pitting, tensile stress
corrosion, galvanic corrosion and crevice
corrosion
Incompatibility with Check Equipment
Chemical Attack
Excessive temperature Process Media Process Conditions

1, 4, 11

Remove the Faces and Inspect for the following Conditions

Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Seal Faces Uneven Wear 9 Misalignment Misalignment of Split Seal Rings
Conditions Normally Track Review Installation
Overtightening of Gland bolts Incorrect Installation
Viewable on Wide and Procedure
Uneven Tightening of Gland Bolts
Narrow Face
Check Equipment
Face Distortion Excessive Pressure Exceeded Limits
Operating Conditions
Improper Stress Relieving of Faces During
Manufacture Quality Replace Component
Faces not Flat 2, 10, 15, 19
Scoring / Erosion 10 Stationary cartridge seal Review Installation
Miscentering Misinstallation 1, 16, 17
Procedure
Liquid vaporizes between seal faces Ensure sufficient
vapor margin. Add
Flashing Cooling or Pressure >
See Environmental
Poor Lubrication Control Guide 12, 14, 18, 19
Insufficient or no liquid between faces
Eliminate Dry Running
Dry Running > See Environmental
Control Guide 1, 13, 14
Excessive pressure Check Equipment
Face Distortion Exceeded Limits
Excessive temperature Operating Conditions 2, 9, 15, 19
Dirty flush Install Clean Flush
Dirty discharge recirculation Install Cyclone
Separator > See
Environmental Control
Dirty Pumpage Abrasive Wear
Guide
High velocity of flush/recirculation Install Flowguardian
Minerals/very fine particles in pumpage Use Hard Faces.
Install SpiralTrac
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Seal Faces Corrosion & Pitting 11 Softening, Disintegration, Increased
Porosity (Carbon Faces)
Review Installation
Conditions Normally Chemical Attack Binder / Filler Leaching from Hard Faces Misapplication
Procedure
Viewable on Wide and (RSC/TC/DC)
Narrow Face Very Excessive Temperatures
Ground Stationary
Insufficient Shaft Seal Face
Electro Spark Erosion Stray Shaft Voltage from VSD Motors
Grounding (Component Seals)
Ground Motor Shaft 1, 4, 8
Blistering 12 Use Hard Faces in
Use of Carbons in Oil Misapplication
Oils
Excessive Temperature
High Speed, Above PV limit Check Process
Limits Exceeded
High Pressure, Above PV limit Operating Conditions 1, 12, 14, 19
Increase Vapor
Margin > See
Flashing Vaporizing Fluid Film at the faces Poor Lubrication
Environmental Control
Guide 10, 12, 14, 19
Grooving 13
Eliminate Dry Running
Dry Running Insufficient Fluid Film between faces Poor Lubrication > See Environmental
Control Guide

Check Environmental
Particles on Face Particles in Pumped Media Abrasive Wear Control Plan / Install
SpiralTrac 10, 14, 19
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Seal Faces Heat Checking 14
Eliminate Dry Running
Dry Running Insufficient or no Fluid Film between faces > See Environmental
Conditions Normally
Control Guide 1, 10, 13
Viewable on Wide and
Poor Lubrication
Narrow Face Ensure Sufficient
Vapor Margin > See
Flashing Fluid Film Vaporizing between faces
Environmental Control
Guide 10, 14, 18, 19
Product/Process Temperature Too High
Check Equipment
High Temperature High Pressure (Above PV Limits) Limits Exceeded
Operating Conditions
High Speed (Above PV Limits) 1, 12, 18, 19
Fracture / 15 Swollen ID O-Ring (ID pressurized seals, Install Compatible O-
Chemical Attack
Smashed High Pressure i.e. 155) Rings
High Barrier Fluid Pressure Check Equipment 2, 4
Limits Exceeded
High Pressure Operating Conditions
Install Double Seal
High Viscosity / High Density Media Poor Lubrication
and Tank System
High Torque Control Media
Characteristics local
Sticky / Hardening Media Media Characteristics to seal > Check
Environmental Control
Guide 2, 18, 20
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Seal Faces Wide Wear Track 16 Review Installation
Incorrect Seal Installation
Procedure
Conditions Normally Miscentering Incorrect Installation Measure and Correct 7, 10, 17
Viewable on Wide Face Poor Equipment Condition Equipment
Misalignment
Excessive Bearing Clearances / Bearing
Replace Bearings
Dynamic Runout Failure 8, 15, 18
Bent / Twisted Shaft Replace Shaft
Poor Equipment Check for Pipe Strain
Pipe Strain
Condition and Correct
Balance Impeller.
Shaft Deflection Unbalanced Impeller (Rotating Assembly) Balancing rotating 7, 17, 19, 20
Assembly is preferred

Off BEP Operation Check NPSHR vs

Equipment Operation
Cavitation NPSHA
Miscentered Wear 17
Track
Poor Equipment Condition

Static Misalignment

Incorrect Seal Installation

7, 16, 20
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Seal Faces Coking & 18
Review Environmental
Crystallization Product Temperature
Controls
Conditions Normally
Viewable on Wide Face
Check Cooling Jacket
Media Temperature Too Cooling Jacket Inefficient
Efficiency and Clean
High
Media Properties Increase Stuffing Box
Small Seal Chamber Clearance Bore to encourage
fluid circulation 1, 14, 18, 19
Add Quench / Use
Media Vaporizes when in contact with Double Seal > See
Flashing
Atmosphere Environmental Control
Guide 10, 14, 18, 19
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Seal Faces OD / ID Chipping 19
Review Environmental
Rotary Component Seal
Controls
Conditions Normally Poor Installation / Poor
Misalignment
Viewable on Narrow Face Equipment Condition
Check Cooling Jacket
Stationary Cartridge Seal
Efficiency and Clean
Excessive Bearing Clearance / Bearing
Replace Bearing
Failure
Bent / Twisted Shaft Replace Shaft
Poor Equipment Check NPSHr vs
Dynamic Runout Cavitation / Vibration Condition NPHSa
Balance Impeller /
Unbalanced Impeller Balance Rotating
Assembly 7, 16, 20
Ensure Sufficient
Flashing Liquid Vaporizes between seal faces Poor Lubrication
Vapor Margin
Check Process
Face Distortion High Pressure Limit Exceeded
Conditions
Review Environmental
Excessive Heat Coking / Crystalizing / Plucking Product Hardening
controls 1, 12, 14, 18
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Shaft O-Ring Hard / Brittle 1 Add Cooling > See
Compression Set Product Temperature Environmental Control
Exceeded Elastomer
Excessive Heat Guide
Limits
Check Equipment
Rotational Speed Too High 14, 18, 19
Operating Conditions
Eliminate Dry Running
Dry Running Insufficient or no liquid film between faces Poor Lubrication > See Environmental
Control Guide 10, 13, 14
Review Process
Chemical Attack O-Ring Material Selection Chemical Degradation 4, 8, 11
Conditions
Extrusion 2 Clearances in o-ring groove too large Check clearances,
Excessive Clearances Quality/design
install back-up ring
Use higher durometer
Excessive pressure 9, 10, 15, 19
material
Exceeded limits
Use higher durometer
Too soft material
material
O-ring damaged during assembly Review installation
Installation damage Misinstallation
instructions
Explosive 3
Decompression
If possible, eliminate
sudden pressure
Trapped gas ruptures o-ring when
Sudden pressure drop Equipment operation drops/shutdowns or
pressure is suddenly relieved
other elastomer
(consult factory)

Swollen / Soft 4 Review Process

Conditions

Chemical attack Incompatibility of o-ring material Loss of O-ring Integrity

1, 8, 11
Component Symptom ID Cause Subcause Failure Mode Solutions Also See
Drive pins Wear & Fretting 20 Excessive product pressure Check operating
Exceeded limits
conditions
Low product viscosity and/or density Poor lubrication Use a dual seal
Excessive Torque
Product hardening Use proper
Product hardening environmental
controls 15
Off-BEP operation 3
Improve shaft's L /D
4

Cavitation Equipment operation Check NPSHR vs.

Shaft Deflection NPSHA
Pipe strain Check for pipe strain
Unbalanced impeller Balance impeller
Bearing failure Equipment condition Install new bearings
Dynamic Runout Excessive bearing clearances Install new bearings
Pump misalignment Re-align pump 7, 16, 17