Avoiding

Seal Failure
Department Editor: Kate Torzewski

S
eals are assemblies of elements that prevent
the passage of a solid, liquid, gas or vapor
from one system to another. When a seal
allows leakage of material, failure has occurred.
This guide provides an overview of common seal
types and a discussion of seal failure to aid in
choosing the most effective seal and avoiding
future failure.
SEAL TYPES
Seals types can be classified within two broad
categories: static and dynamic. Static seals have
no relative motion between mating surfaces, while
dynamic seals do have relative motion between
a moving surface and a stationary surface. Seals
do not have to fit into one category or the other;
rather, seal types can fall anywhere on a spectrum
between static and dynamic, and few seals are
strictly one type or the other. Table 1 describes the
applications and requirements of several common
seal types.
SEAL FAILURE
Seal failure is caused by a wide variety of circumstances, including improper in-
stallation and environmental factors such as temperature, pressure, fluid incompat-
ibilities, time and human factors.
Most causes of failure can be described as mechanical difficulties or system
operations problems. Examples of mechanical difficulties include strain on the
seal face caused by improper installation and vibration caused by improper net
positive suction head. Meanwhile, system operating problems can include condi-
tions that are outside of a pump’s best performance envelope, such as upsets, dry
running, and pressure or temperature fluctuations. Changes in the fluid being pro-
cessed can cause problems as well, especially with fluids that flash or carbonize.
Common visual indicators of failure include short cuts, V-shaped notches in the
seal, skinned surface in localized areas, or thin, peeled-away area on the seal.
Table 2 describes causes of some of the most prevalent types of seal failure with
recommended methods of action.
In some cases, the cause of failure may be difficult to determine due to the com-
plexity of the seal construction. These unique failure modes can result in flaking or
peeling of the seal face, corrosion, flaking or pitting of the carbon faces, degrada-
tion of the elastomer energizer seals, and spring or bellows breakage. It is likely
that these rapid degradations are a result of contamination, which can be avoided
with careful installation or using pre-assembled, cartridge-type mechanical seals.

TABLE 1. COMPARISON OF COMMON SEAL TYPES 3FGFSFODFT

Type Applications Periodic Moving Tolerances Gland Space 1. Ashby, D. M. Diagnos-
Adjustment friction required (mov- adapters require- ing Common Causes of
Static Dynamic Required? ing seals) required? ments Sealing Failure, Chem.
O-ring X X No Medium Close No Small Eng. June 2005, pp.
41–45.
T-seal X X No Medium Fairly close No Small
U-packing — X No Low Close No Small 2. Netzel, J., Volden,
V-packing — X Yes Medium Fairly close Yes Small D., Crane, J. Suitable
Cup-type pack- — X No Medium Close Yes Medium Seals Lower the Cost
ing of Ownership, Chem.
Flat gasket X — Yes — — No Large Eng. December 1998,
Compression or X X Yes High Fairly close Yes Large pp. 92–96.
jam packing

TABLE 2. SOLUTIONS TO COMMON CAUSES OF SEAL FAILURE

Failure type Definition
Compression A lost of resiliency caused by the
set failure of a seal to rebound after it has
been deformed for some period of
time. The seal will exhibit a flattened
surface corresponding to the contours
of the mating hardware
Nibbling and A seal starts to appear to be torn
extrusion away in little pieces until it loses its
overall shape and flows into whatever
void area is available
Spiral failure A seal rolls within its gland, resulting Applications where a seal is
in cuts or marks that spiral around the used in a slow, reciprocating
circumference of the seal
Explosive Seal exhibits blisters, fissure, pock
decompres- marks or pits, both externally and
sion internally
Wear Smooth burnishing of a sealing
surface
Causes Solutions
Exposure to excessive tempera- Choose proper deflection for the seal
ture or incompatible fluids Choose appropriate elastomer mate-
Excessive deformation of the rial for the application in terms of
elastomer at installation thermal stability and compression set
An incompletely vulcanized seal resistance
Excessive clearance gaps Increase bulk hardness of the sealing
Improper seal material element
Excessive volume-to-void ratio Decrease clearance gaps
Inconsistent clearance gaps Redesign volume-to-void ratio
Add anti-extrusion devices
Use an elastomer with a higher bulk
hardness
fashion For male-type installation, increase the
Irregular surface over the mating installed stretch on the seal
parts causing the seal to grip to Specify a smoother, more uniform fin-
certain contact points ish on mating hardware
Change the type of seal to a lip-type
configuration
Gas entrapment within the Use an elastomer material that is more
elastomer during high-pres- resilient to explosive decompression
sure cycling, followed by rapid Use polymeric or metal seals if
depressurization 0possible
Relative motion of the seal Use a harder material
against the mating surface Use a polymeric solution