Failure Analysis of Mechanical

Seals Components

Cliff Smith
Jim Monnot, Ebby Moin, Bill Smith, Mike Huebner
Failure Analysis and Troubleshooting
Purpose:
– Provide participants with a structure for troubleshooting and seal failure analysis.
Learning objectives:
– Participants will be able to identify, gather, review and analyze seal failure data
and recommend a corrective action plan to promote good seal performance.
Organization:
– Seal damage on sliding faces, secondary sealing elements (O-rings) and other
seal components are classified into the following sections:
Mechanically caused
Corrosion caused
Thermally caused
Additional sections are:
– Heat Exchanger checks
– Mechanical soundness of:
Pump, seal chamber
Specialty equipment
Seal component parts
– Bellows seal data & checks
– Data gathering
– Analysis & corrective actions
– Case Histories, Bearing data & Intro. to lubrication theory
Structure of section topics:
– Wherever possible, each seal parts damage topic includes:
Description, symptoms, causes, image(s) of damage, corrective actions &
other data.
– Most sections include and conclude with a “Hands-On” portion:
Small groups of participants examine, check, measure, record, observe,
analyze various seal & pump parts to provide improved seal pump
performance.

Basic Steps in Completing a Seal Failure Analysis

Application Engineer trouble job reporting: Know / obtain these factors and data before
contacting Technical service group…

All operating conditions must be reviewed.

– Review the seal assembly drawing & title block operating data
– Review all actual application operating conditions & operating ranges
Provide clear description of failure symptoms
Provide clear description of operating history
Provide duration of unacceptable performance
Provide what customer expectations are
Provide what, if any, commitments have been made to our customer
Provide description / appearance of the mating seal faces
Provide any other relevant observations
– With respect to failed seal observations
– With respect to pump / mixer / compressor
– With respect to system characteristics
Provide what has been accomplished to improve seal performance, to date
Complete the S.A.R. (seal analysis request) form. (SAR 027 / 8/98)
Complete / review “Field Service Request Data” form.
Mechanically Caused Damage
Description:
– Mechanically caused damage originates from either non-conforming parts, part
size, shape or location of key functional features.
– This type damage is also caused by cavitation, abrasion and erosion changing
the balance, size and shape, characterized by material loss of material of a part,
let’s say, shaft OD, bearing damage or impeller wear ring(s), mating seal face
damage or other component seal parts damage that has resulted in a loss of
material

The usual mode of mechanical damage of seal parts are:

– Mating seal face flatness (2 - 3 light bands) that is affected by stresses which
cause face flatness to either pinch-off lubricating fluid by O.D. contact or produce
an uncontrolled face flatness pattern, waves and / or skewing.
– Radial clearance between parts that can contact from radial shaft movement.
– Damaged bearings (shaft support) can cause radial and / or axial seal damage.
– Non-conforming parts that contact, causing damage.
– Failure / damage degree can vary from hardly perceptible to severe.
Erosion
Description:
– Damage to a component by contact with a high velocity fluid that usually contains
solids. This is often characterized by a loss of material with smooth surfaces. In
some cases, there may be sharp edges due to the turbulent nature of the fluid
flow.
– Seal face or part exhibits a “washed-out” or “Jetting” appearance, sometimes in
one radial area. Softer materials, metals, and bellows most susceptible.

Symptoms:
– Increased static / dynamic seal leakage. Possible severe wear to the pump/seal

Causes:
– Excessive flush flow rate, plan 11, 54 or external quench 62
Orifice location distance from seal gland
Orifice size
– Process fluid and/or seal flush contains abrasive particles
– Seal chamber geometry: product velocity & 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
– Check multi port design to dissipate flush flow
– Increase size of through port in gland for seal flush
– Relocate seal flush point
– Check seal chamber geometry for anti erosive shape

Injection causing erosion on soft carbon stator Erosion on stator

Abrasion
Description:
– Excessive seal face / parts wear and material removal due to relative hard
particle velocity contact damage

Symptoms:
– Excessive static / dynamic seal / pump leakage

Causes:
– Abrasive particles in product or external flush carried into the seal chamber

Corrective Actions:
Review seal application and seal selection:
– Utilize slurry type seal, suited for the environment
– Utilize rotating metal bellows type seal, if bellows does not abrade
– Utilize hard ( SL / YO / Peramic ) seal faces
– Utilize tapered, 15 - 20º from seal face axial location, seal chamber to control
abrasive particle velocity / damage
– Utilize external flush / isolation bushing, plan 54
Rubbing: Contact Between Rotating & Stationary Seal / Pump Parts
Description:
– Appears as heavy score marks on stationary / rotating parts. Materials may
transfer. May leave heat discoloration marks and wear debris, contaminating
other seal / pump parts.

Symptoms:
– May seal statically
– Excessive dynamic leakage
– Vibration
– Safety hazard, fire

Causes:
– Pump bearing problems
– Rotor assembly unbalanced, wear rings & impeller wear
– Poor / no gland pilot / seal chamber eccentric
– Shaft misalignment

Corrective Actions:
Check seal parts for:
– Proper size, shape and location of features versus component part print
– Shaft OD. for size versus seal sleeve ID pilot(s) size / clearance
– Throttle and disaster bushing installed clearance / material
– Manufacturing defects / changed parts
Check pump for:
– Pump and bearing manufacturer recommended type, size and materials for this
service
– Mechanical soundness – concentricity, perpendicularity, shaft whip, bearing
clearances
– Pipe strain (at temperature)
– Alignment (at temperature)
– Wetted parts condition: Impeller, wear rings and bushings, etc…
– Manufacturing defects / changed parts
– Pump case thermal growth / shrinkage design and materials
Face Distortion

Description:
– A condition where the sealing surfaces of a seal faces are not flat within the
required tolerances. The forces or stresses that create this condition may be
mechanical, hydraulic, or thermal.

Symptoms:
Rotating / stationary face distortion can appear as:
– Non-uniform wear patterns after operation
– Light lapping of the mating face will produce clearer high spots, located at two or
more places
– Curved or unevenly spaced lines when viewed on an optical flat
– Static / dynamic mating face leakage

Causes:
– Improper seal design / assembly, clamped face & gland fasteners
– Improper cooling may induce thermal stresses and distortions
– Improper finishing of the seal faces
– Debris / deposits underneath seal faces
– 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 versus Shaft
Check the clamping areas ( sleeve ) of a rotating face, plus…
– Check the front to back dimension / I.D. of the rotating face

Seal face with two point contact

No Face Wear
Description:
– No wear on either the rotating or stationary face due to excessive fluid film
thickness

Symptoms:
– Static / dynamic seal face leakage
– May not pass static test

Causes:
– Improper seal setting, stack-up
– Improper seal balance for application
– Wavy or non-flat seal faces
– Set screws, torque transmission device, not tightened / loose
– Anti rotation mechanism ( pins, drive lugs, keys… )
– Viscosity of product / barrier / flush media
– Hang-up of stationary face assembly, debris, o-ring squeeze & type, improper
face

Corrective Actions:
Check / examine seal setting:
– Physical stack-up versus seal assembly drawing
Need seal component drawings and component seal parts to complete an
axial / radial stack up
Check / examine pump / seal maintenance history
– Frequency of repairs / nature of service
– Successful operation of pump / seal
Check physical seal parts for:
– Spring pusher:
Hang-up of stationary face assembly
Dynamic balance shoulder location, o-ring, surface finish, size, types
– Bellows:
Axial setting of bellows assembly & other rotating face designs
Load test check
– Axial location of component parts
– Contamination of any seal component
Check product for:
– All physical properties / constituents
– Viscosity @ operation temperature
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 dynamic packing, types of lip seals, dynamic
balance shoulder, dynamic secondary seal ( o-ring )
– Removes passive oxide metal surface coating that normally protects sleeve

Examine / reduce / eliminate causes of excessive vibration:

– Review mechanical soundness:
shaft run out
shaft whip
axial end play
deflection / lift
perpendicularity
– Protective coatings of hard facing alloys, aluminum oxide & chrome oxide apply
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 the 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
Mating Face Tracking – Excessive Wear Track Width
Description:
– Mating seal face wear track of the smaller width part, but track appears to be
wider, on the wider part, than the smaller width part.

Symptoms:
– Possible rubbing / contact at the I.D. / O.D.surfaces
– Seals may not exhibit leakage statically
– Seals will leak dynamically

Causes: Anything that causes mating seal face orbiting:

– Check equipment condition
Shaft deflection / perpendicularity
Bent shaft
Excessive dynamic run out
Bearing damage
Coupling misalignment
– Pressure deformation of mating seal faces

Corrective Actions:
Check / examine / re-establish concentricity:
– seal stationary / rotating face versus seal chamber bore
Review maintenance history:
– Condition of equipment: Check:
Shaft perpendicularity
Bent shaft / run out
Bearings
Review application and seal selection:
– Check gland pilot for damage, perpendicularity
– Check for proper clearance between sleeve O.D. versus mating face I.D.
– Check all close clearances for contact
Check equipment operating history record:
– Check pump BEP operation
Nonconcentric Mating Face Tracking
Description:
– Eccentric wear pattern located on the stationary mating face

Symptoms:
– Severe eccentricity can cause excessive leakage, contact between rotating /
stationary parts.
– Can also contribute to pump wear ring damage.

Causes:
– Seal assembly damage: misalignment of stationary face
– Shaft eccentric in relation to seal chamber

Corrective Actions:
– Review maintenance history:
Check / correct shaft eccentricity to seal chamber bore
Check / correct cartridge type seal that is shaft centered using centering type
setting clips

– Check / recheck concentricity between shaft versus seal chamber bore

– Check shaft run out

– Check hydraulic shaft defection

Check pump operation with respect to the O.E.M. pump curve:
% off of B.E.P. ?
How often ?

– Check seal design for proper flange pilot clearances

O-Ring Extrusion
Description:
– Ring extrudes into gap due to pressure resulting in 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
Check back-up ( pressure extrusion device * ) ring radial clearances
– Excessive temperature
– Chemical attack
– Insufficient space in O-ring groove to allow for expansion and swell

* back-up ring radial clearances, located at dynamic balance shoulder, can cause
stationary face assembly hang-up

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
Vibration
Description:
– Rapid cyclic motion resulting in wear and fatigue
– Axial vibration caused by pressure fluctuations, the transfer of vibrations to the
mating seal faces via rotor & shaft or housing
– Radial vibration caused by shaft deflection / unbalance, the transfer vibrations to
the mating seal faces via rotor & shaft / housing
– Torsional vibration caused by changes to the conditions of friction at the mating
seal faces

Symptoms:
– Pump / bearings / seal: wear and damage
Excessive vibration damage can cause static leakage, most likely to have
dynamic leakage
Wear on drive pins or contacting surfaces
Fatigue failures on stressed components

Causes:
– Pump cavitation
– Pump operating clearances / tolerances
– Pipe strain
– Transmitted vibration from adjacent running equipment
– Equipment condition / alignment / bearings

Corrective actions:
– Review maintenance history:
Review / check coupling alignment data
Check / examine internal pump clearances
Review bearing selection / support
Review suction / discharge nozzle loading / pipe supports
Review shaft / rotor assembly balance
Review pump base / support
– Review seal application and seal design
If pump cavitation cannot be avoided, check for hard over-lay coating located
at dynamic balance shoulder area, under balance shoulder o-ring
Review any pump capacity change, i.e. pump de-rate % data
Review pump operating procedures / suction & discharge valve operation /
sequence
O-ring cuts, tears, nicks, explosive decompression and manufacturing
defects
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
General carelessness
Cleanliness, identification, inspection
– Installation / equipment damage
– Explosive decompression

Corrective Action
Review application and seal selection:
Examine actual groove dimension versus 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:
– Surface finish and areas that could cause potential o-ring
damage
– Shaft 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
– Maintain static / dynamic seal pressure to help eliminate
explosive decompression
– Check maintenance history:
Installation procedures
General handling
Corrosion Caused Damage
Descriptions of Corrosion:
General data:
– This section is not meant to be a detailed review of corrosion principles, but will
provide common corrosion terms in relation to mechanical seal performance.
– Corrosion is a chemical/electrochemical process that results in the degradation of
a metal or alloy. It is a coupled reaction between an anode and at least one
cathode. Corrosion ( oxidation ) occurs at the anode while reduction occurs at the
cathode. Corrosion can manifests itself in numerous ways (forms) but its varieties
can generally be grouped in several basic categories.
– Often descriptive names chosen for corrosion types can come from minor
variations in the way corrosion is manifested. This can add a degree of
complexity to the subject and may require extensive analytical work for better
understanding of corrosion behavior.
– Although the following forms of corrosion are presented in the context of aqueous
corrosion, many of them also can occur at high temperatures. High temperature
corrosion by oxidation and sulfidation can result in an uniform attack, pitting or
alloying element depletion, to name a few.
– Failure / damage can vary from hardly perceptible to severe.

– Important: Recognize the difference between high temperature

corrosion ( oxidation ) and aqueous corrosion. The mechanisms
are different and therefore, the correct alloy choice for resistance
to one environment often is incorrect if applied to another.

– Use MSDS ( Material Safety Data Sheets ) to indicate all

corrosive / safety / application data.

Stainless Steel Corrosion – General Concepts

Stainless steels are iron-based alloys containing at least 12% chromium. Maximum corrosion
protection occurs, generally, with the highest chromium content, which may range about
30%. As examples we can mention 316ss, 304ss, 17-4ss.

Corrosion resistance of stainless steels is a function not only of chemical composition, but
also of heat treatment, surface condition and fabrication procedures.

Stainless steels are generally inert to “aqueous” corrosive environments by virtue of the
passivity due to solid solution of chromium in iron. They are also very resistant to “dry”
corrosion in oxidizing conditions.
– Many factors enter into the successful use of stainless steel in demanding
corrosive service conditions. Some of these factors are as follows:
Water, velocity, aeration, water purity and temperature.
– Stress-corrosion cracking, pitting and crevice corrosion of stainless steels may
be especially temperature sensitive.
– Organic acids are generally less aggressive than mineral acids, but they can be
corrosive to stainless, especially when impurities are present.
Presence of oxidizing agents, in the absence of chlorides, can reduce
corrosion rates.
– Stainless steels are also highly resistant to most neutral or alkaline non-halide
salts.
Halogen salts are more corrosive to stainless, because of tendency to cause
local film failure and pitting.
Pitting is promoted in aerated or mildly acidic oxidizing solutions.
 Chlorides generally are more aggressive than the other oxidizing halides in
causing pitting.
– At lower temperatures, most austenitic stainless steels resist chlorine or fluorine
gas if the gas is completely dry.
In the presence of even small amounts of moisture results in accelerated
attack, especially pitting or, possibly, stress corrosion cracking.
– At higher temperatures, in air or in a strong oxidizing environments, stainless is
highly resistant to oxidation.
However, increased attack can occur if sulfur vapor or sulfur compounds are
present in the gas.
– At higher temperatures, in gaseous oxidation, stainless steels are protected
principally by the chrome oxide film produced by interaction of oxygen with
chromium in the substrate.
Corrosion – General or Uniform Corrosion
Description:
– A form of attack that produced overall wastage of the metal. Often associated
with atmospheric corrosion and some high temperature oxidation or sulfidation
attack. Surfaces appear matted, dull, honeycombed, flaky, with loss of hardness.
O-rings may show damage.

Symptoms:
– Excessive seal leakage, static and dynamic.

Causes:
– Improper material(s) of construction (such as Invar).
– Fluid contamination or change (H2S, Chlorine etc…)
– Excessive temperature.

Corrective Action:
Review corrosion rating of all materials of construction
Review selection of material based of other components successfully operating in the
process
Laboratory study:
– Chemical analysis of product, physical properties ( temperature, pressure, &
speed )
– Material identification
– Metallurgical analysis of material to determine exact / extent of corrosion damage
Review application and seal selection:
– Material selection
– Increase seal chamber cooling
– Neutralize corrosive environment
Review all operating conditions. Look at:
– Upset conditions
– Start / shut down conditions
– Cleaning and sterilization conditions
Corrosion – Leaching
Description:
– Selective corrosion of elements or compounds within a material resulting in
surfaces that appear matted, dull, honeycombed, flaky, or suffer a loss of
hardness

Symptom:
– Leaching normally causes minor increase in seal leakage and major increase in
wear of carbon seal rings. Tungsten carbide and ceramic may appear dull /
matted. Hardness readings (Rockwell “A”) will indicate a decrease in hardness of
5 points of more

Causes:
– Chemical attack in the binder that hold the base material together in carbon,
metal and ceramic materials
– Damage can range from few thousands of an inch to scrap parts
– Example: Sodium hydroxide and hydrofluoric acid solutions can leach out free
silica in ceramic (silicon carbide: SL) seal rings and result in excessive rate of
wear on the carbon seal ring

Corrective Action:
Up-grade base materials of the:
– Rotating / stationary seal rings
Consider “YO” grade silicon carbide
Consider “Peramic” grade ( 99.5% pure ) ceramic
Consider “RI” to replace “LV” when using tungsten carbide
– Sleeve, flange, spring holder, pins, bellows

Use seal arrangement that will provide a clean buffer fluid:

– Plan 54

Use dual seal arrangement that will provide a barrier fluid:

– Double seal with plan 52 or 53
Pitting Corrosion
Description:
– A high localized attack of the metal creating pits of varying depth, width and
number.
– Pitting may lead to complete perforation of the metal with little or no general
corrosion of the surface.

Symptoms:
– Excessive seal leakage, static and dynamic.

Causes:
– Improper material(s) of construction.
– Fluid contamination or change.
– Excessive temperature.

Corrective Action:
Reduce the aggressiveness of the environment such as:
– chloride ion concentration
– temperature
– acidity
– oxidizing agents
– apply proper API plans.

Upgrade the materials of construction.

– Based on recommendation provided in the engineering failure analysis report,
and
– Site specific customer material / pitting corrosion data and / or
– Additional data source: 3rd party, laboratory study

Modify design of the system or the seal components.

Use different type of seal for a better suited for the service environment.
Crevice Corrosion
Description:
– Localized corrosion of a metal surface at, to immediately adjacent to, an area
that is shielded from full exposure to the environment because of close proximity
between the metal and the surface of another material.4
– Similar to pitting corrosion in its localized nature but associated with crevices.
– Stainless steels and some nickel-based alloys with little or no molybdenum are
particularly susceptible to this form of corrosion.

Symptoms:
– Excessive localized seal leakage, static and dynamic.

Causes:
– Interaction of trapped corrosive medium with metal in crevices (areas that are
shielded from full exposure to the environment because of close proximity
between surfaces).

Corrective Action:
Minimized gaps between joining / touching parts where contacting an aggressive
environment.

Reduce the degree of aggressiveness of the service environment.

Review and upgrade materials of seal components.

Modify the design of the seal or its components.

Intergranular Corrosion
Description:
– The preferential corrosion of grain boundaries in an alloy.
– Can cause separation or cracking at the grain boundaries, intergranular cracking.
– Can cause slight or negligible attack on adjacent grains.4
– Also called inter-crystalline corrosion.4

Symptoms:
– Excessive seal leakage, static and dynamic.

Causes:
– Occurs when the corrosion rate is higher at the grain boundaries than the interior
of grains due to differences in their compositions.

Corrective Action:
Laboratory study to determine if a corroded part failed due to intergranular corrosion
cracking, it is necessary to examine the following parameters:

– Microstructure examination of failed parts: Methodology:

Microscopically viewing a cut section through the crack.
The crack pattern can be clearly followed by adequate etching of the
prepared sample.
The crack path will follow grain boundaries.

– Analysis of service environment for chloride and sulfide ions concentration.

De-alloying Corrosion
Description:
– The selective removal of one element, usually the least noble, from an alloy by
the corrosive environment.
■ Also referred to as selective leaching or de-zincification, de-
nickelification, etc. designating the element removed1.

Symptoms:
– Gradual or sudden leakage/ seal failure.

Causes:
– Selective leaching will cause the corroded part become porous losing its
strength, ductility and hardness.
– Failure may be sudden or expected based on nature of the dimensional changes
in seal components.

Corrective Action:
Laboratory study to confirm the failure mechanism of failure components. Review the
following:

– Use a material more suitable for the service environment.

Example: The immediate alloy to substitute 304 type stainless steel is 316ss
with 2-3% molybdenum. Depending on the service environment, you may
have to select C-276 with much higher molybdenum content.

– Confirm / Review all product constituents, along with:

Temperature
Pressure
R.P.M.
Other internal / external system source of corrosive materials
Corrosion Fatigue
Description:
– The initiation and extension of cracks by the combined action of an alternating
stress and a corrosive environment. The introduction of a corrosive environment
often eliminates the fatigue limit of a ferrous alloy creating a premature failure
regardless of stress level.

Note: This cracking mechanism is often mistaken with the Stress Corrosion
Cracking ( SCC ).
We explain some differences between determining SCC and Corrosion Fatigue,
in the SCC section, ahead.

Symptoms:
– Gradually increasing seal leakage

Causes:
– Improper material selection
– Cyclic movement in addition to corrosive chemical environment such as shaft
play or vibration.

Corrective Action:
Load/stress correction

Environmental adjustment

Review and correction of mechanical operation

– minimize vibration to a recommended level
– Eliminate shaft play to a minimum level
– Control cyclic/dynamic motions

Replacement of materials
Galvanic Corrosion
Description:
– Accelerated corrosion of the least noble metal when electrically coupled to one or
more other metals. The more noble metals are protected from corrosion by this
action1.

Symptoms:
– Seal leakage

Causes:
– The potential difference between two alloys in seal structure
– The nature of chemical environment
– The polarization behavior / characteristic of alloys used in manufacturing the
component seal / pump parts
– The geometric relationship of the seal components

Corrective Action:
Material selection:
– Use materials with low polarization not widely separated in galvanic series
– Metallic coatings may be used to reduce separation in the galvanic series

Control electrolytic effect of the environment by:

– additives
– corrosion inhibitors

Electrical isolation (coating) and catholic protection:

– Cathodic protection is an electrochemical means of corrosion control in which the
oxidation reaction in a galvanic cell is concentrated at the anode and suppresses
corrosion of the cathode in the same cell.

Design consideration:
– Minimize unfavorable area ratios
Erosion Corrosion

Description:
– Many forms of flow assisted corrosion are often included in this term such as
cavitation, impingement and corrosion-erosion. All of these types are the result of
accelerated corrosion due to the flow of solids, liquids or gases1.
– A conjoint action involving corrosion and erosion in the presence of a moving
corrosive fluid, leading to the accelerated loss of material.4

Symptoms:
– Low to excessive, dynamic / static, seal leakage
■ Metal seal parts exhibit light to heavy material loss
– packing / lock-up can occur in dead areas of seal assembly
■ Mating seal faces, generally, exhibit:
– hard face: three plate erosion / jetting / material loss
– soft face: light, but out of flatness requirements, to severe, total
loss of mating seal face nose
Causes:
– Impact of moving abrasive particles in high speeds with seal parts in a corrosive
environment and over a period of time can cause material loss.

Corrective Action:
Determine amount, characteristics and type of erosive particles, measured by:
– % of solids, by weight, is most common, versus, by volume
– Do erosive particles:
■ settle-out ?
■ remain suspended ?
– Other chemical ( corrosive ) constituents ?

Review / change:
– seal chamber geometry, 15 - 20° taper
– inlet port location, size, flow rate
– impeller, pump-out vanes removed, resulting in high % solids, to boost seal
chamber pressure ?
– shut down / start up / volute cleaning procedures
– hard face mating seal face combinations
– Reduce dead areas in all seal designs, to reduce / eliminate packing
Stress Corrosion Cracking
Description:
– The initiation and propagation of cracks by the combined / simultaneous action of
a corrodent and a sustained tensile stress.
■ Generally, susceptibility to cracking increases with increasing
temperature.
■ May occur in combination with hydrogen embrittlement.

Symptoms:
– Gradual to heavy leakage of seal
– Long and multi-branched surface cracking
– Cracks could be either:
■ Inter-granular: Between crystals or grains. Also called inter-crystalline.
■ Trans-granular: Through or across crystals or grains.

Causes:
– Corrosive environment with chlorides, ammonia or sulfide (sour condition)
– Material operating under stress
– Material operating in a corrosive environment

Corrective Action:
Identification of failure mode by means of optical and electron microscopy

Control of service environment

Material substitution

Special surface treatment of components

Difference between Stress Corrosion Cracking and Corrosion Fatigue

Stress Corrosion Cracking ( SCC ) often is mistaken with Corrosion Fatigue failure. Some
differences between the two are:
All metals that are susceptible to corrosion are susceptible to Corrosion Fatigue in any
corrosive environment.
SCC occurs only in alloys subjected to a very specific environment.
SCC happens under static tensile stresses rather than dynamic stresses.
Cracking is in a repeated pattern for Corrosion Fatigue whereas it is in a branching river
pattern for SCC.
Fracture surface is jagged in Corrosion Fatigue. Flat and dull in SCC.
Hydrogen Damage
Description:
– These are numerous forms of damage associated with hydrogen which are
contained under the collective term “Hydrogen Damage”.
■ A general term for the embrittlement, cracking, blistering and hydride
formation that can occur when hydrogen is present in some metals.4
– For hydrogen embrittlement and hydrogen stress cracking, a tensile stress and
hydrogen atoms are necessary to cause failure. However, contrary to stress
corrosion cracking, susceptibility is greatest near room temperature.
– Other terms and forms are: hydrogen induced (assisted) cracking, sulfide stress
cracking, hydrogen stress corrosion cracking and hydrogen attack.

Symptoms:
– Gradual leakage or catastrophic seal failure depending on the strength level of
the material, operating stresses and degree of material damage.

Causes:
– Improper material production and incorrect heat treating.
– Chemical milling or pickling not followed by proper baking of the parts.
– Service environment.

Corrective Action:
Review production method.
– Production process for highly clean steel can induce hydrogen.

Review foundry practices such as baking sand core to remove moisture.

Review and correct baking process ( original manufacturing process ) for any parts with
chemical milling or pickling requirements.
– Pickling: Removing surface oxides from metals by chemical or electro-chemical
reaction.

Control hydrogen producing service environment.

Chemical Compatibility – O-Rings and Elastomers
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 prevent axial “lock-up” of stationary face assembly of spring pusher type
seals

Symptoms:
– Excessive static / dynamic seal leakage

Causes:
– Incorrect material selection
– loss or contamination of seal barrier / buffer fluid

Corrective Action:
Laboratory study:
– Chemical analysis of product fluid, physical properties ( temp. press. & speed )
– Material identification

Re-evaluate o-ring material

– Previously over looked product constituents
– New product constituents

Other areas of evaluation:

– Create an artificial environment by using a flush ( plan 54 )
– Consider using bellows type seal, with static secondary seal gaskets
Chemical Compatibility Swelling – O-Rings and Elastomers
Description:
– Elastomer exhibits increase in cross section size, usually caused by incompatible
fluid contact.

Symptoms:
– Excessive static / dynamic seal leakage

Causes:
– Chemical / corrosion attack:
The concentration of the fluid, in one percentage can be aggressive, while in
other concentrations it is not
Same applies to temperature
– Improper material selection
– Fluid contamination
– Improper lubricant used on installation
– Location of gasket:
Gasket confined: usual less swelling problem

Corrective Action:
Corrective actions: may be difficult to determine:

– Review seal selection and application:

Check material compatibility
Check product concentration
Check product temperature
Use alternative gasket material
Check external source of flush media
Check installation procedure:
– O-ring lubricant type

– Laboratory study:
Check material identification
Physical properties of product
Thermally Caused Damage
General Description:

– Usual thermal damage can be caused by heat generated at the mating seal
faces in addition to heat transferred into the seal from the pump case and shaft.

– Thermal tension cracks indicate a material is thermally overloaded. The most

obvious would be heat checking of a tungsten carbide seal ring.

– Elastomer gasket thermal damage usually appears as embrittlement which is

characterized by partial or complete loss of elasticity along with severe
secondary gasket leakage.

– Failure / damage degree can vary from hardly perceptible to severe.

Mating Seal Face Thermal Deflection
Description:
– Can appear as either I.D or O.D. / full face contact / high & low areas - stress
riser:
Pressure: carbon is most susceptible to face deflection, usually produces a
concave mating face condition, based upon geometric shape. Drive slots /
holes can change geometry = distortion
Temperature: distortion created from the force of pressure, pinches-off the
fluid film, flashes, heat rises, gas is created, moves mating faces apart, and
possible rotation

Symptoms:
– Full face contact pattern, with heavier I.D. / O.D. contact
– Can also exhibit shiny areas adjacent to drive slots
– Convex seal operation usually exhibits high leakage
– Concave seal operation usually exhibits high torque / heat

Causes:
Seal design:
– Improper dynamic balance shoulder o-ring size/ type / groove / force
– Inaccurate F.E.A. analysis / Inadequate balancing of hydraulic & mechanical
forces / face geometry / material
– Improper axial / radial mating face support
– Improper surface finish

Chemical attack of dynamic balance shoulder o-ring:

– Swelling creates mating seal face stress

Operation above the pressure limits of the seal

– Back-up ring can create hang-up of stationary face assembly

Corrective Action:
Engineering: Complete F.E.A. analysis / provide all operating temperature conditions /
redesign:
– Can we employ calibrated gages & data acquisition equipment to track, confirm
and compare operating conditions ?
■ pressure
■ temperature
■ flow meter or s.c.f.h. meter

QA / Lab: Confirm deflection damage magnitude:

– Use surface measuring equipment

Review application versus seal selection

Check / examine dynamic balance shoulder, o-ring condition / % squeeze, location,

surface finish, size

Check / examine bellows convolutions for deformation / damage

Mating Seal Face Thermal Deflection (continued)
Heat Checking
Description:
– A pattern of parallel, fine to large, surface cracks, that appear to have a common
origin location, the center of the seal ring.

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 Action:
Check / examine, in & out, barrier cooling temperatures for plans 11, 23, 52, 53, & 54.
Check barrier system for:
– Cooling water: flow, temperature & venting
– Reservoir: in & out temperatures, pressure, flow and level, physical properties of
barrier media

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 type seal faces
– Check face material combination and PV data

Check / examine:
– Pump shaft / seal axial movement to produce high face loads
– Upset conditions that could produce temporary dry running, check:
start up / shut down procedures
suction / discharge valve sequencing
seal flush
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.
■ Advanced stage: pieces of the carbon face break and create three plate
erosion, spalling 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 petroleum products.
– Mechanical process caused by high shear forces ( viscosity / temp.) acting on the
carbon seal ring, during start-up, that can produce micro fractures.
– Most likely to occur with equipment that has high number of starts & stops

Corrective Action:
Operating conditions:
– Review viscosity at pumping temperature:
Replace fluid
– Check compatibility with product
Increase temperature
– Reduce frequent starts & stops
– Reduce dry running

Review seal selection:

– Blister resistant materials
– Review mating seal face cooling / circulation
– Lower total unit loading at mating seal faces
– Review possibility of using lube-groove face geometry
Coking, Oxidation,, and Solids Build-up
Description:
– Coking is a result of oxidation or chemical breakdown the product
( hydrocarbon ) to form solidified / semi solidified product, under the mating seal
faces on the atmospheric side of the seal.
– Salting ( build up ) is a result of a dissolved mineral, transported in a liquid, after
the liquid evaporates / dries
– Suspended solids / abrasives: build up

Symptoms:
– Excessive product build up can:
Hang up spring pusher type seal
Severe wear to mating faces, especially soft material
Clogs bellows convolutions with sludge

Causes:
Thermal sensitive fluids / products solidify at lower, atmospheric temperatures.
Oxygen acts as catalyst to certain fluids.

Product solidification / abrasives when solid can result in excessive seal heat and
wear.

Corrective Action:
Review application and seal selection:
– Utilize clean / cool external seal flush
– Utilize clean external quench:
Dry steam: 1 - 2 psi max., for mobilizing build-up & cooling
– wet steam can upset bellows seal as water flashes
use water traps, heat trace, re heat steam, up-slop quench
piping, etc.
Water: 1 - 2 psi max., for cooling & some fluid formation
Methanol drip: for heating / dissolving of icing
Nitrogen: for cooling & elimination of oxygen
– Caution: Nitrogen can displace breathing air
– Utilize dual seal design
– Utilize metal bellows type seal
– Utilize hard mating seal face combinations
– Increase seal chamber cooling
– Check / examine physical properties of fluid for:
Coking / oxidation break down temperature limits
Vaporization and Flashing
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 does not usually cause catastrophic seal failure
– Creates fugitive emissions problem

Causes:
– Operating seal near or at vapor pressure of product
– Excessive pressure acting on mating seal faces
– Excessive mating seal face deflection
– Inadequate cooling and lubrication of mating seal faces

Corrective Action:
– Mechanical contact between pump / seal rotating / stationary components
Check shaft versus 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
– Product 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:
Heat exchanger
– Check seal design:
Consider using high balance
Consider using lube groove / hydro pads / wavy face
Thermal Damage – O-Rings and Elastomers
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 Action:
– 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
Compression Set – O-Rings and Elastomers
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 election

Corrective Action:
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 seal flush rates / orifice size / cleanliness
Check for other thermal / chemical damage
Review / examine all cooling water systems
Examine pump / seal cooling jacket condition
Examine operating history for upsets
Examine suction / discharge valve operation / sequence
Icing
Description:
– Freezing atmospheric moisture condenses as ice on surfaces on the atmospheric
side of pumps whose operating and standby temperatures are below 32°F ( 0°C )
and below ambient temperatures.
– Standby conditions can cause icing at mating seal faces causing freezing or
sticking mating face damage

Symptoms:
– Seal damage: Bent drive pins, mating seal face break / damage
– Excessive static / dynamic seal leakage

Causes:
– No atmospheric side quench media
– Excessive mating seal face leakage

Corrective Action:
– Review seal application and seal design
Obtain current / accurate seal operating / product data
Check if customer can install atmospheric side seal quench, use:
– Gas, nitrogen
– Methanol
– Dry air
Check / examine existing quench system
Review operating history:
– Frequent stops / starts
– Commissioning procedure may include pre start-up, pump case
drying which can dislodge inboard stationary seal face via
reverse pressure