ME140-IH-03-07 Mechanical Seals Vol-1 - R

QAF011 Rev. 04 Jan.
12, 06
Haward Technology Middle East
Mechanical Seals
Volume: 1
March 10-14, 2007

KJO Premises, KSA
Course Instructor
Mr. Gamal Attalla
This document is the property of the course instructor and/or Haward Technology Middle East. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording,
or otherwise, without the prior written permission of Haward Technology Middle East.
P.O.Box: 26608, Abu Dhabi, UAE Tel: +971-2-4488301 Fax: +971-2-4488302 Email: info@haward.org http://www.haward.org
To the Participant
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Fax: +971 2 4488302
Email: info@haward.org
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Table of Contents
Section 1
Gland Packing Brief
Overview
Pump Sealing Solutions
Section 2 Mechanical Seal Basics
Section 3 Heat Temperature Control
Section 4 Drive Methods
Section 5 Springs
Section 6 Balancing
Section 7 Fluid Film
Section 8 Multiple Seals
Section 9 Pumps
Section 10 The Environment of a

Mechanical Seal
Sealant Systems
Table of Contents
Section 11 Failure of Mechanical Seals
Section 12 Dry Seals
Section 13 API Flushing Plan
Section 14 API 682 Mechanical Seal

Standard
Section 1
Gland Packing Brief

Overview
PIONEERS IN TECHNOLOGY TRANSFER
Mr. Gamal Attalla Mechanical Seals
This document is the property of the course instructor and/or Haward Technology Middle East. No part of this publication may be reproduced,
stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of Haward Technology Middle East
Mechanical Seals
Section 1a
Gland Packing
Brief Overview
Section 1a Haward Technology Middle East 2

Mechanical Seals
Engineered Sealing
.
Mechanical Seals
Why do we need a seal?

Mechanical Seals
Old Style Sealing Using Packing
Mechanical Seals
WATER REDUCTION

Mechanical Seals
WATER REDUCTION
Mechanical Seals
WATER REDUCTION

Mechanical Seals
WATER REDUCTION
Mechanical Seals
WATER REDUCTION

Mechanical Seals
WATER REDUCTION
Mechanical Seals
WATER REDUCTION

Mechanical Seals
ALTERNATIVES
Mechanical Seals

Mechanical Seals
Mechanical Seals
Gland Packing

Mechanical Seals
Gland Packing
Product Gland nuts

pressure adjust the
forces liquid amount of
through bore leakage
Leakage
essential to
cool and
lubricate
Abrasives?.
Mechanical Seals
Gland Packing
Just a moment,
here they come . . .

Mechanical Seals
Gland Packing
Divide packing with a
lantern ring
Abrasives Inject clean fluid at 1

bar minimum above
Leak pump pressure
Flow keeps abrasives

away from packing bore
Leakage consists of
injected flush fluid
(ideal for corrosive
and toxic fluids)
Mechanical Seals
Summery – 1a
Disadvantages of GSP Advantages of GSP

• Leaks • No visible leakage
– Health and Safety – Zero emissions with
– Housekeeping Type 2800/2800E
– Environment seals
– Cost
• Wears Shaft/ Sleeve • No shaft / Sleeve wear
• Not Self-Adjusting • Self-adjusting
• Power Consumption • Lower power
• Open to tampering • Nothing to touch
• Rub-in time required • Work from day one
• Fitting errors • Cartridges

Mechanical Seals
Summary - 1b
Advantages of GP Disadvantages of GP
• Low initial cost • High running costs and

short life
• Fit without stripping • Until sleeve is worn -
consider a split seal
• Low skill level to fit • For long life, great skill /
art / time required.
Mechanical Seals
Gland Packing
Desirable properties for material
• pliable - conform to shaft and gland bore
• resist swelling and product attack
• elastic - absorb shaft gyrations
• self-lubricating - low heat generation
• good conductor or heat
• not wear shaft or sleeve
• slow volume loss - minimum adjustment
• withstand pressure
• not deteriorate with heat.

Mechanical Seals
Table of pH Values
4% NaOH Sodium Hydroxide = 14.0 14 Maximum Alkali
13
0.04% NaOH Sodium Hydroxide = 12 Severe Alkali
12.0
11
0.017% NH3 Ammonia Solution = 10.6
10
9 Mild Alkali
Sea Water = 8.3
8
Pure Water = 7.0 7 Neutral
Milk = 6.4 6
5 Mild Acid
Beer = 4.5
4
Vinegar = 3.1 3 Strong Acid
Lemon Juice = 2.3
2 .
0.49% H2SO4 Sulphuric Acid = 1.2 1 Maximum Acid
3.6% HCl Hydrochloric Acid = 0.1 0
Mechanical Seals
Gland Packing
pH Range
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Polyimide
Glassfibre
Flax
PTFE
Graphite
Aramid
pH ranges of some of the most common gland packing materials.

Mechanical Seals
Gland Packing
.
C1065 - GFO Fibre
Mechanical Seals
Gland Packing
K40 Tape .
K40 Pre-Formed Rings

Mechanical Seals
Gland Packing
Packing
extruding Excessive
through wear due to
neck bush incorrect
adjustment
of gland
nuts.
Problems with Gland Packing
Mechanical Seals
Gland Packing Installation
“Neville and the Problem Pump”

Mechanical Seals
Gland Packing
Disadvantages Advantages
• Leaks • Cheap
- Health & Safety • Fit without stripping
- Housekeeping • Simple to fit.
- Corrosion
- Environment
- Cost
• Wears shaft / sleeve
• Not self-adjusting
• Power consumption
• Open to tampering
• Run-in time required
Mechanical Seals
Advantages of Gland Packing
Inexpensive sealing medium

Many different types available
Established sealing medium (familiarity)
Ease of temporary repair
Considered easy to use / install

Mechanical Seals
Dis-Advantages of Gland Packing

Must leak to work effectively
Dilution of process from flush water
Runs on shaft/sleeve causing
• Wear
• Friction
• Parasitic power loss
Requires regular adjustment
With today’s emission regulations and productivity
goals, is this such a good solution?
Mechanical Seals
Packing vs. Mechanical Seals

Is not a seal but rather a restricting device. Requires
leakage or it will burn.
Will groove and wear shafts and sleeves.
High horsepower load to overcome friction.
Product loss.
auires large amounts of water.
Requires maintenance time and downtime for
installations and packing adjustments.
Equipment damaged and destroyed from leakage.

Mechanical Seals
Packing vs. Mechanical Seals (con’t.)
Will seal with invisible leakage. On difficult

applications the leakage ratio between seals and
packing is 1 to 100 or better.
Seals have been known to run 8 to 10 years without
failure.
Monetary savings from little to no product loss, water
savings and energy savings.
Little maintenance required after initial installation.
Seals offer better safety when sealing potentially
hazardous materials.
Mechanical Seals
End of This
Section

Mechanical Seals
Section 1b
Section 1b Haward Technology Middle East 1
Mechanical Seals
PUMP SEALING SOLUTIONS

GONE ARE THE DAYS OF CHEAP
AND NASTY PACKING

Mechanical Seals
How to Choose Packing

Take Out Your Catalogue, Anyone Will Do??
Most MEDIUM
Pumps PRESSURE
Take TEMPERATURE
Soft SPEED
Packing Ph
Mechanical Seals
IMPROVED PRODUCTS
LOW HEAT GENERATION

• HEAT IS FRICTION IS WEAR IS FAILURE
NO LIQUID LUBRICATION
• INTERNALLY LUBRICATED
FOR PUMPS AND VALVES
• PACKED DIFFERENTLY, LEAK Vs NO LEAK

Mechanical Seals
WATER REDUCTION
Mechanical Seals
WATER REDUCTION

Mechanical Seals
WATER REDUCTION
Mechanical Seals
WATER REDUCTION

Mechanical Seals
WATER REDUCTION
Mechanical Seals
WATER REDUCTION

Mechanical Seals
WATER REDUCTION
Mechanical Seals
ALTERNATIVES

Mechanical Seals
Mechanical Seals

Mechanical Seals
VALVE AND FLANGE

SEALING SOLUTIONS
Mechanical Seals
National Emission Standards for Equipment Leaks

(Fugitive Emission Sources)
This standard applies to equipment intended to operate in hazardous air pollutant (VHAP) service.
Fugitive emissions are unintentional emissions that do not occur as part of normal plant operations, but are the
result of the effects of :
Sources of Fugitive
Emissions
Valves
Pumps
Compressors
Fugitive VHAP Emissions
• Equipment malfunctions Flanges
• Age Heat Exchangers
Valves 60%
• Lack of proper maintenance Pressure Relief
• Improper equipment specifications Flange/Heatexchanger Devices
12%
• Use of inferior technology, or Relief Valve 3% Flow Meters
externally caused damage Threaded and

Drains 7%
Joined fittings
Compressors 8% Sight Gauges
Pumps 11% Drains

Sampling Ports
Agitator Seals
Control Devices
Misc....... others

Mechanical Seals
National Emission Standards for Equipment Leaks

(Fugitive Emission Sources)
VHAP service either contains or contacts a fluid (liquid or gas) that

is at least 5% by weight a VHAP. The 191 VHAP’s are shown in
Appendix A. These are also known as reactive organic gases.
A VHAP in “light liquid service” has a 20% or greater concentration
of pure components with a vapor pressure greater than 0.3 KPA
(0,044 psia) at 20 Deg. C (60 Deg.F) but is a liquid at operating
conditions.
A VHAP in “heavy liquid service” means that a VHAP is not a
gas/vapor or in light liquid service.
“In gas/vapor service” means that a piece of equipment in a VHAP
service contains a gas or vapor at operating conditions.
Mechanical Seals

Mechanical Seals
Mechanical Seals
NON- ASBESTOS VALVE SEALING SYSTEM

DESIGN PARAMETERS
SYSTEM APPROACH TO VALVE SEALING

LONG TERM RELIABILITY
SIMPLIFIED MATERIAL SELECTION
REDUCED PACKING INVENTORIES
GUARANTEED RESULTS
TOTALLY NON-ASBESTOS
INDUSTRY SPECIFIC
COMPLY WITH GOVERNMENT EMISSION REGULATIONS

Mechanical Seals

SEALING PHILOSOPHY
VALVES FALL INTO 2 DIFFERENT SERVICE CATEGORIES :

CRITICAL and GENERAL PURPOSE
CRITICAL VALVES GENERAL PURPOSE VALVES

• REGULATING VALVES • ISOLATION VALVES
• FLOW CONTROL VALVES • BLOCK VALVES
• MOV’s & AOV’s • STOP VALVES
• CRITICAL PROCESS VALVES • MANUAL VALVES ACTUATED LESS
• FREQUENTLY OPENED VALVES THAN ONCE PER MONTH
• HISTORICALLY PROBLEMATIC
VALVES
Mechanical Seals
CRITICAL VALVES: ARE APROX. 10 to 15% OF VALVES

SEALING SOLUTION: 5 RING LIVE LOADING PROGRAM
(EPS 1 or EPS 2)
GENERAL VALVES: REMAINING 85 to 90% OF VALVES

SEALING SOLUTION: SINGLE SPOOL PACKING OR
2 SPOOL PACKING

Mechanical Seals
EPRI
ELECTRIC POWER RESEARCH INSTITUTE
AN ORGANIZATION THAT PROVIDES TECHNICAL

SUPPORT TO POWER UTILITY MEMBERS
1984 - EPRI WAS ASSISTED BY AN ENGINEERING
COMPANY TO STUDY :
THE ROOT CAUSE OF VALVE STEM PACKING LEAKAGE
1988 - THE FINAL REPORT WAS TITLED :
VALVE STEM PACKING IMPROVEMENTS...
Mechanical Seals
9 CAUSES OF VALVE LEAKAGE

Valve Design
Packing Material
Pressure
Temperature
Temperature Cycling
Valve Actuation
Horizontally Mounted
Valve Condition
Maintenance Practices...

Mechanical Seals
VOLUME LOSS
STUFFINGBOX HAS
CHANGED
CORROSION
BOLTS LOOSE...
Mechanical Seals
VOLUME LOSS
AMOUNT OF PACKING
CHANGED
WEAR
CONSOLIDATION
EXTRUSION...

Mechanical Seals
1. VALVE DESIGN
OLD DESIGN
OLD DESIGN NEW DESIGN DEEP STUFFINGBOX - LOSS OF
COMPRESSION
1 RING SEALS, 10 RINGS MUST
SEAL BETTER
MORE RINGS = MORE
CONSOLIDATION (LUBE
MIGRATION)
NEW DESIGN
5 RING SET - MODIFY STUFFING
BOX...
DEEP STUFFINGBOX CARBON BUSHING
Mechanical Seals
2. PACKING MATERIAL
BRAIDED PACKING IS A SEAL
Flexible
YARN
SURFACE LUBRICANTS
BLOCKING AGENTS

Mechanical Seals
3. PRESSURE 4. TEMPERATURE
EVERY MATERIAL HAS IT’S LIMITATION

- P.T.F.E. & GRAPHITE
READ THE SMALL PRINT - NOT ALL MATERIAL CAN

PERFORM AS THE SUPPLIER SAYS IT WILL
RATHER SAFE THAN SORRY...
Mechanical Seals
5. TEMPERATURE CYCLING
COEFFICIENT OF THERMAL
EXPANSION
CHANGE IN TEMPERATURE
GIVES CHANGE OF VALVE
CONSTRUCTION
LONGER BOLTS MEAN LESS

SEALING PRESSURE
SAME AS VOLUME LOSS...

Mechanical Seals
6. VALVE ACTUATION
THE MORE MOVEMENT, THE MORE WEAR
WEAR = VOLUME LOSS...
Mechanical Seals
7. HORIZONTALLY MOUNTED VALVES
WEIGHT OF SPINDLE CAUSES UNEVEN

PACKING COMPRESSION...

Mechanical Seals
8. VALVE CONDITION
PITTED SPINDLE
CORRODED STUFFING
BOX
LARGE CLEARANCES...
Mechanical Seals
PITTING
TWO DISSIMILAR METALS IN THE PRESENCE
OF MOISTURE CAUSES PITTING CORROSION
ELECTROLYSIS
(GALVANIC ACTION)
GRAPHITE ACCELERATES VALVE STEM CORROSION DUE

TO ELECTROLYSIS
Passive Corrosion Inhibitor

Mechanical Seals
9. MAINTENANCE PRACTICES
PACKING A VALVE HAS BECOME AN ART
ANY TWO PEOPLE PACK VALVES DIFFERENTLY

TAKE OUT THE GUESS WORK
APPLY A PREDETERMINED TORQUE
COMPRESS PACKING TO PREDETERMINED STACK
HEIGHT
BUY A SOLUTION NOT A ROLL OF PACKING...
Mechanical Seals
SECOND SERVICE CATEGORY
CRITICAL VALVES
REGULATING VALVES
CONTROL VALVES
MOV’s AND AOV’s
CRITICAL PROCESS VALVES
FREQUENTLY ACTUATED VALVES
HISTORICALLY PROBLEMATIC VALVES...

Mechanical Seals
Liveload
What is Liveload Packing ?
• A liveloaded valve has springs added between gland
nut and gland to maintain a load/force on packing
during extended operation periods.
• The spring elastic energy maintains load on gland
follower to compensate for packing consolidation.
Why Liveload a Valve
• Key to successful performance of packing system is
maintaining the required load/force on gland/
packing.
Mechanical Seals
Liveload
When or Why is Liveloading Recommended
• Reduce maintenance or need to re-torque
• Services requiring controlled emission levels
• Frequently stroked/actuated valves
• Valves subject to high degree of thermal cycling
• Control Valves/Air or motor actuated valves
• Valves with difficult access
• Any valve actuated more than 10 cycles/month

Mechanical Seals
Liveload
Does Packing Design Impact Liveload performance ?
• Yes - The more resilient the packing set the greater
the effect of liveloading. A Liveloaded resilient
packing will provide longer service life.
Mechanical Seals
Liveload & Wave Form
Force/Load
Expands to form seal

Mechanical Seals
EPS 2 - Reverse Bevel Ring Set
G58I End
Rings
Crane-foil
Inner Rings
Mechanical Seals
LIVE LOADING
REDESIGN STUFFING
BOX
NON-POROUS RINGS
CORROSION INHIBITOR
Min. 97 % PURE
GRAPHITE
SPRING ASSEMBLY
PREDETERMINED
TORQUE
DEEP
STUFFINGBOX CARBON BUSHING
GUARANTEE

Mechanical Seals
LIVE LOADING SPRING ASSEMBLY

ALLOWS STORED ENERGY TO BE TRANSMITTED
THROUGH A CERTAIN DEGREE OF TRAVEL TO THE
GLAND.
FREE
HEIGHT
COMPRESSED
HEIGHT
Mechanical Seals

Mechanical Seals
Mechanical Seals

Mechanical Seals
LIVE LOADING
Mechanical Seals

Mechanical Seals
Mechanical Seals

Mechanical Seals
Mechanical Seals

Mechanical Seals
OTHER AREAS TO USE LIVE LOADING
FLANGES
HEAT EXCHANGERS
Mechanical Seals
FLANGES
DISK SPRING

Mechanical Seals
Mechanical Seals
Braided PTFE Packing

C1045 - Continuous filament PTFE yarn, permeated
with a PTFE dispersion.
C1050 - Continuous filament PTFE yarn that includes a

high temperature lubricant, permeated with a PTFE
dispersion.
C1056 - Continuous filament PTFE yarn that includes a

FDA compliant lubricant, permeated with a PTFE
dispersion.

Mechanical Seals
Operating Parameters
of PTFE Packing
Temperature limited to 500°F
High tensile strength of PTFE good for high pressure
applications (pumps - 300 psi, valves - 2500 psi)
PTFE will not contaminate process fluid or gas (as
opposed to carbon/graphite)
Excellent in corrosive services (pH operating range 0-14)
Moderate speed applications (C1045 - 1000 fpm, C1050,
C1056 - 2000 fpm)
Mechanical Seals
Equipment and Industries Served

1045 - non contaminating valve packing, slow speed
centrifugal pumps or positive displacement pumps
1050 - excellent valve packing, N/R for food & beverage or
pharmaceutical. Good centrifugal pump (clean) packing
1056 - FDA approved oil, recommended for food & beverage
or pharmaceutical. Good centrifugal pump packing
INDUSTRIES
Chemical Processing Industries
Food and Beverage
Pharmaceutical
Pulp and Paper
Mechanical Seals
Braided Graphited PTFE Packing
C1065 - Expanded PTFE filament yarn that

encapsulates graphite, with lubricant
C1070 - Continuous filament PTFE yarn that is

impregnated with graphite, with lubricant
Mechanical Seals
Operating Parameters of Graphited

PTFE Packing
High tensile strength of PTFE good for high pressure

Excellent in corrosive services (pH operating range 0-14).
Higher speed applications (3000 fpm, either style)

Mechanical Seals

Pumps, compressors, agitators, mixers – Highly recom-
mended for rotating equipment. Can significantly
reduce inventory costs by using as a standardized
packing. Graphite provides for good heat dissipation
and lubrication. 1065 considered a “clean” packing.
Not a popular valve packing.
INDUSTRIES
Chemical Processing Industries, Pulp and Paper Mining,
Steel, Power Utilities, Municipal
Mechanical Seals
Synthetic Braided Packing
1330 - Spun acrylic yarn with a PTFE dispersion applied

before and after braiding
1335 - Spun acrylic yarn with a PTFE dispersion applied

before and after braiding, with the addition of a
lubricant
1340 - Acrylic yarn, permeated with petroleum based

lubricant, with exterior coating of graphite

Mechanical Seals
of Synthetic Packing
Tensile strength of acrylic yarn good for medium
pressure applications (pumps - 300 psi, valves - 1000 psi)
Non-abrasive acrylic yarn reduces scoring on shaft or
sleeve
Good on corrosive services (pH operating range 3-11)
Moderate to higher speed applications (1330, 1335 -
2250 fpm, 1340 - 2750 fpm)
Mechanical Seals
1330,1335 - economical pump and valve packing.

Caution on rotating speeds, strong acid and alkali
solutions. 1340 better at heat dissipation and rotating
speeds.
INDUSTRIES
Agriculture, Commercial, Municipal (lower $’s), Pulp

and Paper, Steel/Metals

Mechanical Seals
Polyamide Packing
1345 - Continuous filament polyamide yarns, braided

integrally with PTFE continuous filament yarns. Both
yarns are permeated with a PTFE dispersion and a high
temperature lubricant.
Mechanical Seals
Operating Parameters of
Polyamide Packing
High tensile strength of polyamide good for high pressure

Polyamide will not contaminate process fluid or gas
Good speed applications (2500 fpm)

Mechanical Seals
Excellent in abrasive rotating equipment applications

(paper stock, phosphates, light slurries). Caution in
strong alkali solutions.
INDUSTRIES
Pulp and Paper (abrasion resistance and forgiveness on

shaft and sleeve wear)
Chemical Processing Industries, Marine, Petrochemical
Mechanical Seals
Corrosion Resistant High

Temperature Packing
1625G - High purity graphite yarn, with a PTFE

dispersion
1627 - Carbon yarn, with a graphite dispersion
1635G - Ultra high purity graphite yarn, no PTFE
added. MIL-Spec requirements

Mechanical Seals
of Corrosion Resistant Packing
Temperature limitations - 650°F (1625G, 1627) due to
PTFE. 850°F for 1635G (steam applications - 1200°F)
Pressure limitations - Pumps 500 psi, Valves 2500 psi
As end rings in valves - 1625G 4300 psi
• 1627 4000 psi
• 1635G 3000 psi
Excellent in corrosive services (pH operating range 0-
14, except in strong oxidizers)
Higher speed applications (1625G-3200 fpm, 1627-
4000fpm, 1635G-2500 fpm)
Mechanical Seals

excellent multipurpose packing, valve end rings (with
Crane-foil) or as pump packing (alone or as end rings
with flexible graphite). Low leakage, minimum flush.
1627 good for high rotating speeds. 1635 as nuclear
grade end rings.
INDUSTRIES SERVED
Petrochemical and Chemical Processing Industry
Pulp and Paper
Power Utilities
Mechanical Seals
Braided Flexible Graphite Packing
G58 - Flexible graphite yarn, reinforced with a high

strength, high temperature, non-scoring filament
G58I - Flexible graphite yarn, reinforced with a high
strength, high temperature, non-scoring filament. A
high strength, high temperature wire mesh encap-
sulates the yarn
Mechanical Seals
Operating Parameters of
Braided Flexible Graphite Packing
Temperature limitations - Oxidizing 850°F
• Nonoxidizing 4500°F
• Functional Steam 1200°F
Pressure limitations - Pumps 300 psi, Valves 4300 psi
Excellent in corrosive services (pH operating range 0-

14)
Very high speed applications (up to 4000 fpm)

Mechanical Seals

G58 - excellent valve end rings and rotating equipment
middle rings. Used when emission control is required
(valves). Extremely high rotational speed applications.
G58I - used as end rings on actuated and high cycle
valves. Wire mesh wipes valve stem clean. Used when
emission control is required.
INDUSTRIES
Power Utilities
Pulp and Paper (Primary and Recovery Boilers)
Steel and Metals
Mechanical Seals
Abrasion Resistant Aramid Packing
K1730 - Continuous filament aramid yarn, individually

lubricated with PTFE, with high temperature lubricant
applied
K1760 - Spun aramid yarn, with a PTFE dispersion and a

light lubricant

Mechanical Seals
of Aramid Packing
Pressure limitations - Valves 1000 psi

• Pumps 300 psi (K1730)
• 500 psi (K1760)
Non-contaminating to process fluid or gas
Excellent for abrasive services
Moderate speed applications (K1730 - 2500 fpm, K1760

- 2000 fpm)
Mechanical Seals
Recommended for severe slurry applications (mining,

coal preparation, sand and gravel). Hardened shaft of
sleeve recommended. K1760 used for higher pressure
applications.
INDUSTRIES
Mining, wastewater, steel, power utilities
Marine, pulp and paper

Mechanical Seals
Flexible Metallic Packing

100M - Crinkled and folded layers of babbit foil
(lubricated with oil), spirally wrapped around a
neoprene cord
100AL - Aluminum foil, spirally wrapped around a

fiberglass cord, permeated with oil and graphite.
124 - Aluminum foil, spirally wrapped and coated with

oil and graphite
1K - Extruded graphite and aramid fibers, with oil

based binder
Mechanical Seals
of Flexible Metallic Packing
Temperature limitations:
• 500°F (100M and 1K)
• 1000°F (100AL and 124)
Excellent high pressure packing (pump 1000 psi, valve

2500 psi)
Fair to excellent speed applications

• 100M and 1K - 3600 fpm
• 100AL and 124 - 1500 fpm
Moderate pH operating range of 4-10

Mechanical Seals
100M &1K - high pressure pump applications (lower

temperature). 100M end rings, 1K middle rings.
100AL & 124 - high temperature, high pressure pump
applications.
INDUSTRIES
Steel, mining, power utilities
Petrochemical and Refineries
Mechanical Seals
Automatic PTFE Packing Rings

CVU - Virgin, carbon or glass filled PTFE, U cup
design
CVH - Virgin, carbon or glass filled PTFE, V cup
design

Mechanical Seals
of Automatic PTFE Packing
Temperature limited to 450°F.
Low pressure CVU packing - 100 psi
High pressure CVH packing - 1000 psi
PTFE will not contaminate process fluid or gas
Excellent in corrosive services (pH operating

range 0-14)
Not for use on rotating equipment
Mechanical Seals
Reciprocating pumps
Most styles of valves
INDUSTRIES
Pharmaceutical, Food and Beverage
Municipal, Commercial

Mechanical Seals
Soot Blower Packing Sets
PTFE - Rings are filled with fiberglass and molydisulfide
Molydisulfide provides lubricity, fiberglass provides

strength
Graphite - High purity flexible graphite, die-formed to

standard sizes
Mechanical Seals
of Soot Blower Pacing Sets
Temperature limited to:
• PTFE - 450°F
• Graphite - 1000°F
Both packing styles will handle pressures up to 1000 psi
PTFE is designed for hot air service. Graphite is designed
for steam, or high temperature gases

Mechanical Seals
Boilers, Boilers, and Boilers

INDUSTRIES
Power Utilities
Mechanical Seals
LANTERN RINGS
PTFE - Virgin or glass filled, precision molded or

machined from extruded tubing
Available in split, two piece, or solid config-urations.
Also available in strip stock (can cut to size, reduce
inventory)

Mechanical Seals
Operating Parameters of PTFE Lantern

Rings

Pressures up to 1000 psi
Mechanical Seals
All styles of pumping equipment

Agitators, mixers, refiners, hydropulpers, any piece of
equipment that requires a flush for packing
INDUSTRIES
All!!

Section 2
Mechanical Seal Basics

Mechanical Seals
Section 2
Mechanical Seal Basics
Section 2 Haward Technology Middle East 1
Mechanical Seals
Sealing Fundamentals Part 1

Mechanical Seals
Why do we need a seal?
Mechanical Seals
The Basic Sealing Problem:

Preventing Leakage
Environment Vessel
Wall
Shaft
Process
Fluid
Leakage

Mechanical Seals
Packing
Environment Vessel
Wall
Shaft
Process
Fluid
Leakage
Mechanical Seals
The Concept of an End Face Mechanical

Seal
Environment Vessel
Wall
Shaft
Process
Fluid
Leakage

Mechanical Seals
Required Features
Small axial clearance
Shaft
Shaft
Movement
Mechanical Seals
Required Features
Small axial clearance
Self adjusting
Shaft
Movement

Mechanical Seals
Gland Packing
Mechanical Seals
Old Style Sealing Using Packing

Mechanical Seals
Typical Pump - Sectioned
Mechanical Seals
Typical Pump - Sectioned

Mechanical Seals
Advantages of Gland Packing
Inexpensive sealing medium

Many different types available
Established sealing medium (familiarity)
Ease of temporary repair
Considered easy to use / install
Mechanical Seals
Dis-advantages of Gland Packing

Must leak to work effectively
Dilution of process from flush water
Runs on shaft/sleeve causing
• Wear
• Friction
• Parasitic power loss
Requires regular adjustment
With today’s emission regulations and productivity
goals, is this such a good solution?

Mechanical Seals
Summary - 1b
• Low initial cost • High running costs
and short life
• Fit without stripping
• Until sleeve is worn -
• Low skill level to fit
• For long life, great
skill / art / time
required.
Mechanical Seals
Packing vs. Mechanical Seals
Is not a seal but rather a restricting device. Requires

leakage or it will burn.
Will groove and wear shafts and sleeves.
High horsepower load to overcome friction.
Product loss.
Requires large amounts of water.
Requires maintenance time and downtime for
installations and packing adjustments.
Equipment damaged and destroyed from leakage.

Mechanical Seals
Packing vs. Mechanical Seals (con’t.)
Will seal with invisible leakage. On difficult applications

the leakage ratio between seals and packing is 1 to 100 or
better.
Seals have been known to run 8 to 10 years without
failure.
Monetary savings from little to no product loss, water
savings and energy savings.
Little maintenance required after initial installation.
Seals offer better safety when sealing potentially
hazardous materials.
Mechanical Seals
Summary - 1a
Disadvantages of GP Advantages of M. Seals
- Health & Safety - Zero emissions with
- Housekeeping Type 2800/2800E seals
- Corrosion
- Environment
- Cost No shaft / sleeve wear
• Wears shaft / sleeve • Self-adjusting
• Not self-adjusting • Low power
• Power consumption • Nothing to touch
• Open to tampering • Work from day one
• Run-in time required • Cartridges.
• Fitting errors

Mechanical Seals
Desired Features of a Seal

Long Life
Low Leakage
Easy Maintenance
Low Cost
Mechanical Seals
Mechanical Seal Theory

Primary Seal

Mechanical Seals
TM 051-1
Basic Seal Principles

Part 1 : The Primary Seal
This Training Module describes the basic operating
principle of a Spring Loaded, Face Contact Mechanical
Seal.
It describes how the Faces are separated by a Fluid Film,

Spring Loading and the three main sealing points in the
design
Mechanical Seals
Basics of Mechanical Seals

A device for controlling leakage
Large variety of designs
Large selection of materials
Several arrangements
• Single seal
• Single seal with quench
• Tandem Seal
• Double seal
• Dual Seal
• Cartridge seals
Mechanical Seals
Basic Mechanical Seal

Spring or Spring Force Mating Ring or Seat
Primary Ring or Face
Mechanical Seals
Face, Seat and Springs

Mechanical Seals
Fig 2
Mechanical Seals
Fig 3

Mechanical Seals
The Optimum Sealing Interface

Fig 4
Mechanical Seals
Primary Seal
Face or Seat or
Primary Mating
Ring Ring
Springs
Higher pressure on outside diameter

Higher pressure holds faces closed
Fluid is forced between faces to lubricate
Springs keep faces closed when no pressure.
Mechanical Seals
Weak Spring Load
Result = Unacceptable Leakage
Mechanical Seals
Fig 6
Excessive Spring Load
Result = Unacceptable Seal Life

Mechanical Seals
Fig 7
Three Sealing Concerns
Mechanical Seals
Primary Seal
Primary Mating
Ring Ring
Springs
Higher pressure on outside diameter Rule 1

Higher pressure holds faces closed
Fluid is forced between faces to lubricate
Springs keep faces closed when no pressure

Mechanical Seals
Basics of Mechanical seals
Flexible member
Face (Primary Ring)
Metal Parts
Seat (Stationary Ring)
Springs
All mechanical seals have these 5 basic components
Mechanical Seals
Heat generated here Large component

Leak path
Spring ensures automatic adjustment

Mechanical Seals

Mechanical Seals

Recirculation
for cooling
API Plan 11

Mechanical Seals
Basic Mechanical Seal - 4

Recirculation Gasket or O-ring
for cooling
Secondary Seal Tertiary Seal.

Primary Seal
Mechanical Seals
A Flexible Seal
Hydrostatic Loading
Secondary Sealing Elements
Replaceable Parts
Mating
Ring
Primary Ring Secondary Sealing Element

Mechanical Seals
Basic Mechanical Seal - 6

Uneven spring pressure Face driven by spring
(Positive drive preferred)
Uni-directional Spring force unstable.

Excessive length
Mechanical Seals
An Example of a Complete Seal

Primary Ring
Snap Ring
Anti-X Ring
O-Ring
O-Ring
Disc
Springs
Retainer
Set Screw Mating Ring
Shaft

Mechanical Seals
Spring Drive
Mechanical Seals
Simply put, a mechanical seal is:
1. A wearable, stationary, primary sealing element

2. A wearable, rotating, primary sealing element
3. A secondary sealing element
4. A mechanical loading device to press primary sealing
elements 1 and 2 against one another, and
5. Auxiliary components to complete seal

Mechanical Seals
Fig 9
Summary-
A mechanical seal is self adjusting for wear.
Has three main parts :-
Primary ring
Mating ring
Spring
Normally the mating ring is stationary & the primary ring rotates with the
shaft.
The liquid film between the primary ring & mating ring is only 3 - 5
microns thick.
There are three main sealing areas :-
Primary ring & Mating ring.
Primary ring & Shaft.
Mating ring & Housing.
Mechanical Seals
Process Fluid Acts as

Lubricant Between Faces
Pump Housing
Gland
Process Fluid
Primary Ring Mating Ring
Invisible Leakage:
Fluid Evaporates Upon Reaching Atmosphere

Mechanical Seals
Film thickness = leakage
Mechanical Seals
Primary Seal
Fluid film thickness is very important
• too thin - wear, causing early seal failure
• too thick - visible leakage
Must be:
• present - beware dry running
• stable
• clean - beware abrasive wear symptoms
• reasonable viscosity
• temperature controlled
• acceptable pressure.
Mechanical Seals
Primary Seal
Fluid film thickness is very important
• too thin - wear, causing early seal failure
• too thick - visible leakage
Must be:
• present
• stable
• clean - beware abrasive wear symptoms
• reasonable viscosity
• temperature controlled
• acceptable pressure
Mechanical Seals
Primary Seal
Excessive start / stop operation
• will drastically reduce seal life (MTBF - Mean Time
Between Failure)
• wear occurs between face and seat at start-up
- no lubricating fluid film present
• wear on drive mechanism
- can cause lock-up / bayoneting
Is start / stop operation necessary?
.

Mechanical Seals
Primary Seal
If faces not flat, contact generates heat

Excessive wear - short life
1 light band = 0.0000116 inch or 0.0003 mm.
Mechanical Seals
Primary Seal
Materials

Mechanical Seals
Primary Seal
Seat (Mating Ring) Materials
• Ni-resist
- high nickel cast iron; austenitic cast iron
• Ceramic
- 99.7% aluminium oxide
• Silicon Carbide
- pure sintered
• Tungsten Carbide
- cobalt or nickel bonded.
Mechanical Seals
Materials – Wet Seals

JC Vickers Thermal Expansion Thermal Density
Material Code Hardness Conductivity Coefficient Shock 000’s kg/m3
-6
W/m°C@20°C X 10 /°C 000’s W/m
Silicon Carbide
277 2500 125 4.0 24 3.1
Pure Alpha Sintered
Silicon Carbide +10% 2500
088 150 4.6 35 3.1
Si. Reaction Bonded + softer Silicon
Converted Silicon 2500

121 50 4.0 30 2.0
Carbide/Carbon + softer carbon
Tungsten Carbide
025 1500-1600 100 5.2 48 14.7
+6% Cobalt
Tungsten Carbide
005 1300-1500 80 5.6 43 14.7
+6% Nickel
Aluminium Oxide
059 1500+ 26 6.9 6 3.9
99.5% Alumina
Austenitic Cast Iron
007 200 40 19.3 - 7.3
13% Ni, 6% Cu
Carbon-Graphite 90
171 12 3.7 10 1.8
Resin Impregnated (estimated)

Mechanical Seals
Primary Seal - Dry Gas Seals

Primary Ring Materials
• Carbon-graphite
- antimony impregnated
- resin impregnated (e.g., H2S > 1%)
- Cranite 2000 (e.g., high pressure – T28EXP)
« Carbon-graphite/silicon carbide composite
material
Note: In Type 28 Series Dry Gas Seals the Primary Ring is
always the stationary component
Mechanical Seals
Primary Seal - Dry Gas Seals

Mating Ring Materials (Rotating in Type 28)
- Cobalt bonded
- Nickel bonded (Optional)
• Silicon Carbide
- Pure sintered
- Liquid phase sintered - high pressure (XP/EXP)
• “Ductile” Mating Ring
- Tungsten carbide plating on stainless steel

Mechanical Seals
Mating Ring Material Selection

Tungsten Carbide (Cobalt bonded)
• Tough
• High strength
• Best slow roll performance
• Cobalt binder can be chemically attacked
• Nickel bonded is available - better resistance
Silicon Carbide
• Highly corrosion resistance
• Good slow roll performance
• Very brittle – easily chipped
Mechanical Seals
Mating Rings
Chloride attack on
Tungsten Carbide

Mechanical Seals
Mating Ring Material Selection

Ductile Mating Ring Material
• Ni/Cr tungsten carbide on stainless steel
- E.g., 410 SS; 17/4 PH; Duplex SS
• Ideal for outboard seal
• Virtually indestructible – will not shatter
• Lower cost
• Low thermal conductivity
• Maximum differential pressure 50 bar
• Higher leakage due to distortion
• Minimum ∆P of 1 bar required – note O/B
Mechanical Seals
Primary Seal
Face (Primary Ring) Materials
• Carbon
- resin impregnated
- antimony impregnated
• Carbon converted to Silicon Carbide
- resin impregnated
• Solid Silicon Carbide
– pure sintered
– nickel or cobalt bonded.
Mechanical Seals
Materials
Material
Material JC
JCCode
Code Vickers
Vickers Therm
ThermCond
Cond Expansion
Expansion
-6
Hardness
Hardness W/m°C@20°C
W/m°C@20°C Coeffx10
Coeffx10-6/°C
/°C
Tung
TungCarbide
Carbide 005
005 1300-1500
1300-1500 80
80 5.6
5.6
++6%6%Ni
Ni
Tung
TungCarbide
Carbide 025
025 1500-1600
1500-1600 100
100 5.2
5.2
++6%6%Co
Co
Sil
SilCarbide
Carbide 088
088 SiC 2500 150
150 4.6
4.6
++10%
10%free
freesil
sil + softer Si
Sil
SilCarbide
Carbide 277
277 2500
2500 125
125 4.0
4.0
Sintered
Sintered
Alumina
Alumina 059
059 1500
1500 26
26 6.9
6.9
99.7%
99.7%
Iron
Iron13%
13%Ni,
Ni, 007
007 200
200 40
40 19.3
19.3
6%
6%CuCu
Converted
Converted 121
121 SiC 2500 50
50 4.0
4.0
SiC/Carbon
SiC/Carbon + softer C
Carbon
Carbon 171
171 90
90 12
12 3.7
3.7
resin
resinbonded
bonded
Mechanical Seals
Mating Rings: Ceramic

Mechanical Seals
Mechanical Seal Theory
Secondary Seal
Mechanical Seals
TM 052
Part 2 : The Secondary Seal
This Training Module examines the purpose and method

of operation of the secondary seal

Mechanical Seals
Fig 1
Mechanical Seals
Fig 9
Summary-
A mechanical seal is self adjusting for wear.
Has three main parts :-
Primary ring
Mating ring
Spring
Normally the mating ring is stationary & the primary ring rotates with the
shaft.
The liquid film between the primary ring & mating ring is only 3 - 5 microns
thick.
There are three main sealing areas :-
Primary ring & Mating ring.
Primary ring & Shaft.
Mating ring & Housing.

Mechanical Seals
Secondary Seal
Mechanical Seals
Pusher Seal: Hang-up
Or, ensure
minimum
clearance here
Excessive pressure and / or heat:

permanent set or extrusion

Mechanical Seals
Excessive pressure and / or heat:

permanent set or extrusion
Mechanical Seals
Secondary Seal
Three basic forms Two groups
• O-rings • Pusher
• PTFE sealing rings - Sliding o-rings
- Wedges - PTFE sealing rings
- Chevrons
- ‘C’ rings
• Non-pusher
- Sleeved o-rings - Bellows
• Bellows
- Elastomer
- Metal
« formed
« edge welded
- PTFE

Mechanical Seals
Secondary Seal: Pusher
Primary ring moves forward to take up wear

O-ring moves forward with the primary ring
Pushed by the hydraulic and spring pressures
Mechanical Seals
An external quench
will prevent hang-up
Product leakage solidifies / crystallises / polymerises .

This prevents o-ring pushing forward - leakage increases

Mechanical Seals
An external quench
with a secondary
containment device
will prevent hang-up
Product leakage solidifies / crystallises / polymerises

Prevents o-ring pushing forward - leakage increases
Mechanical Seals
Secondary Seal: Pusher

Advantages
• sudden failure very unlikely
• higher pressure capability - face not stressed
• wide choice of materials for all components
• field repairable
Disadvantages
• hang-up (not likely where o-ring is well isolated)
• permanent set / pressure problems (cause hang-up)
• excellent shaft surface finish required
• maximum temperature ~260°C.

Mechanical Seals
Secondary Seal: O-Rings

Typical Trade/ Minimum Maximum
Material ISO/DIN/ temperature temperature Comments
Common names in seals in seals
NBR General purpose material.
Medium Nitrile -40°C 100°C
Buna N Up to 120°C in hydrocarbons
CR Ideal for refrigeration duties.
Chloroprene -40°C 100°C
Neoprene Some specialist applications.
EP; EPR; EPDM Ideal for water up to 150°C.
Ethylene Propylene -40°C 135°C
Nordel™ Avoid oil/hydrocarbons.
FPM Maximum 135°C in water.
Fluorocarbon* -30°C 200°C
Viton A™ Hardens in high temp steam.
Perfluoroelastomer* FFKM; Isolast™ Wide range of chemical
-20°C 215°C
(Low temp. grades) Kalrez™ compatibility.
Perfluoroelastomer* Isolast HT™ Wide range of chemical
-20°C 315°C
(High temp. grades) Kalrez™ compatibility.
* Note: Health and Safety warning!
Mechanical Seals
Secondary Seal: O-rings

Perfluoroelastomer
* > 400°
400°C - Hydrogen Fluoride gas is likely
Open system - Hydrogen Fluoride vapour
Closed system (e.g., o-
o-ring groove) condenses to
form liquid Hydrofluoric Acid
Wear Neoprene or PVC gloves

Protect eyes
Wash parts in Calcium Hydroxide solution

Mechanical Seals
Nitrile
• 100°C (Hydrocarbons 120°C)
Ethylene Propylene (avoid oil/hydrocarbons)
• 135°C (Water 150°C)
Fluorocarbon (e.g., Viton)
• 200°C* (Water 115°C - Max. in Steam 135°C)
Perfluoroeleastomer (e.g., Isolast, Kalrez)
• 215-315°C*
Mechanical Seals

Fluorocarbon
* > 275°
275°C - Hydrogen Fluoride gas is a possibility
> 316°
316°C - Hydrogen Fluoride gas is a certainty
Open system - Hydrogen Fluoride vapour
Closed system (e.g., o-
o-ring groove) condenses to
form liquid Hydrofluoric Acid
Wear Neoprene or PVC gloves

Protect eyes
Wash parts in Calcium Hydroxide solution

Mechanical Seals
Fig 5
Mechanical Seals
Fig 6

Mechanical Seals
Secondary Seal: Wedge
.
Type 109B
Mechanical Seals
PTFE Wedge Seal
Type 109 Seal

Mechanical Seals
Secondary Seal: Bellows

No contact here.
Elastomer Bellows grips shaft tightly
Mechanical Seals
Secondary Seal: Non-Pusher
Bellows flexes to take up wear, misalignment and axial play

Fine machined shaft surface required
Do not use a “good” lubricant - never use silicon grease.

Mechanical Seals
Fig 9
Mechanical Seals
Fig 10

Mechanical Seals
Fig 11
SURFACE FINISH AND HARDNESS REQUIREMENTS OF SECONDARY SEALING DEVICES
SECONDARY MATERIALS OF SLIDING STATIONARY SURFACE FINISH HARDNESS BRINELL

SEAL CONSTRUCTION Nanometers (nm) Minimum
‘O’ Rings Elastomer, PTFE 250 - 100 125
Wedge Pure PTFE 250 - 100 125
Wedge Glass / Carbon 250 - 100 500

Loaded PTFE
Bellows Elastomer 1200 - 800 125
Bellows PTFE 1200 - 800 125
Bellows and Metal 1200 - 800 125

‘O’ Rings
Bellows and Metal 600 - 400 125

Metal Wedge
Mechanical Seals
Formed Metal Bellows
.
Type 515E

Mechanical Seals
.
Type 515K Type 515E
Mechanical Seals
Edge Welded Metal Bellows

Mechanical Seals
Sealol 604 Head
Sealol 609
Sealol 670
Mechanical Seals

Low Temperature Seals
Type 680 - Alloy 20 Bellows

Type 670 - Hastelloy C-276 Bellows
Type 675 - Titanium Bellows
Type 676 - AM 350 Bellows

Mechanical Seals
Type 680
Alloy 20
Cast / Stamped Version3
Machined Version
Temperature: -75ºC to 200ºC
Pressure: vacuum to 20 bar
Speed: to 25 m/s
Mechanical Seals
Typical Welded Metal Bellows

Type 670
Alloy C-276
Temp: -75°C to 200°C

Pressure: Vac to 20 bar g
Speed: to 25 m/s

Mechanical Seals
Type 675
Titanium

Pressure: to 10 bar
No ID pressure
Speed: to 25 m/s
Sizes: Restricted ANSI
Mechanical Seals
Type 676
AM 350 Bellows
316SS Metal Parts
Pressure: Vacuum to 20 bar g

.
Speed: to 25 m/s

Mechanical Seals
High Temperature Seals
Type 604 - Stationary Seal

Type 606 - Rotating Seal with Drive Lugs
Type 609 - Rotating Narrow Cross Section
Mechanical Seals
High Temperature
Type 609

(up to 69 bar g with double-ply)
Speed: to 25 m/s

Mechanical Seals
Type 606
Mechanical Seals

Type 604
(up to 69 bar g with double-ply)
Speed: to 50 m/s
..

Mechanical Seals
Type 604 Cartridge
Mechanical Seals
No movement here No contact here.

Bellows expands to take up wear

Mechanical Seals

Advantages
• temperatures to 430°C (or more)
• no hang-up
• non-clogging
• fine machined shaft surface acceptable
Disadvantages
• sudden failure possible
- (“flashing” or mis-alignment)
• limited material choice
• maximum pressure 35 bar g (2-ply to <50 bar g).
Mechanical Seals
Secondary Seal: Metal Bellows

Bellows Materials
• Inconel X-750 and 718
• Alloy C-276 (e.g., Hastelloy C)
• AM350 Stainless Steel
• Alloy 20
• Titanium
Shaft Seal Materials
• O-rings - details as before
• Exfoliated Graphite
- 500°C.

Mechanical Seals
Secondary Seal: PTFE Bellows
Type 10T
Type 10R
Mechanical Seals
Stainless Steel Colour Chart
Straw yellow 370 – 425°C
Brown 480 – 540°C
Blue 600°C
Black 650°C
ALL of these are above the danger level for

Fluorocarbon and Perfluoroelastomer materials

Mechanical Seals
TM 053

Part 3 : The Tertiary Seal
This Training Module examines the purpose and method

of operation of the tertiary seal
Mechanical Seals
Fig 1

Mechanical Seals
Fig 2
The most common forms of tertiary sealing components

that are used with mechanical seals are :
• O - Rings
• Square Sectioned Rings
• Cup Mounted Rings
• Flat Joints or Gaskets
Mechanical Seals
Tertiary Seal
Prevents leakage round mating ring
Sometimes also prevents rotation
Three basic types
• o-rings
- elastomers
• seat rings
- PTFE
- graphite
• gaskets
- PTFE
- compressed fibre.

Mechanical Seals
Secondary and Tertiary Seals
Mechanical Seals
Fig 3

Mechanical Seals
Fig 4
Mechanical Seals
Fig 5

Mechanical Seals
Fig 6
Mechanical Seals
Fig 7

Mechanical Seals
Fig 8
Mechanical Seals
Fig 9

Mechanical Seals
Fig 10
Mechanical Seals
Fig 11
Summary :-
The purpose of the tertiary seal is to prevent leakage past the
mating ring.
Several methods are used :
• O-Rings.
• Square sectioned rings.
• Cup mounted rings.
• Flat joints or gaskets.
Distortion must be prevented in machined components.
Rectangular seat rings insulate the mating ring.
Floating mating rings do not transmit distortions.
Clamped mating rings provide good location.
Designed cover plates are heavy and rarely need replacing.

Mechanical Seals
Mating Rings
A / AG
P / PG / PP
Mechanical Seals
Mating Rings
BO
BP / 248X

Mechanical Seals
Mating Rings
N / NG
W / WG
WM
Mechanical Seals
Secondary Seal Tertiary Seal

Primary Seal

Mechanical Seals

Mechanical Seals
Classification of Mechanical Seals

Sealing System
Auxiliary Equipment Seal Assembly
Seals Adaptive Hardware
Design Arrangement/Type
balance ratio type

face pattern single
springs multiple
secondary seals
drive

Mechanical Seals
Classification of Seals
Mechanical Seals
Design Features Arrangements/Types

Arr angements
Mechanical Seals
Design Features
Balance Ratio
Face Pattern
Springs
Secondary Sealing Element Type
Drive Mechanism

Mechanical Seals
Design Features
Balance Ratio
Balance ratio is used to control the face load.
Closing Force Opening Force
Mechanical Seals
Design Features
Balance Ratio
Balance ratio is the ratio of the closing area

to the opening area.
A A
o
c
Closing Area
Balance Ratio =
Opening Area
Mechanical Seals
Design Features
Balance Ratio
Don’t say “Balance”

Say (and Think) “Balance Ratio!”
Mechanical Seals
Design Features
Balance Ratio
An Unbalanced Seal
A A
c Fc o

Mechanical Seals
Design Features
Balance Ratio
A Balanced Seal
Ac Ao
Mechanical Seals
Design Features
Balance Ratio
Metal bellows seals are “inherently” balanced at low
pressures. Balance ratio increases at higher pressures.
Balance Ratio < 1
Zero Pressure
Balance Line

Mechanical Seals
Design Features
Face Pattern
Most seals have faces that are plain (no pattern) and
are lapped flat.
Primary Ring
Mating
Ring
Cross Section Face View
Mechanical Seals
Design Features
Face Pattern
Plain, Flat Hydropads
Plain, Tapered Spiral Grooves

Mechanical Seals
Design Features
Springs
• Provide The Initial Closing Force

• Are Very Important At Low Pressures
• Are Not So Important At High Pressures
Mechanical Seals
Design Features
Springs
• Single
• Multiple
• Bellows
• Wave

Mechanical Seals
Design Features
Springs
• High Speed Seals Use Stationary Springs
(5000 ft/min Typical Break Point)
Mechanical Seals
Design Features
Secondary Sealing Element
• Static
• Dynamic

Mechanical Seals
Mating Ring / Seat Designs
L-Nonpinned
O-Ring
Square Cup Mounted

Section
Clamped-in
L-Pinned
Mechanical Seals
O-Ring Design
Covers greatest range of application requirements for
general services
A pin may be required to prevent rotation
Pressures up to 42 bar/600 psig
Temperature range is dependent on
the o-ring elastomer.

Mechanical Seals
Square Section Design

For use in higher pressure applications where an
elastomer o-ring is desired
Pressure range is 83 bar/1200 psig
• Using a glass-filled PTFE anti-extrusion ring and
optional pin drive, pressures can be increased over
83 bar/1200 psig
Temperature range is
dependent on the
o-ring elastomer
Mechanical Seals
L-Pinned Design
For applications requiring the excellent corrosion
resistance of PTFE and high temperature capabilities of
Crane-foil®
A pin is required to prevent rotation
Pressure range:
38 to 83 bar/
550 to 1200 psig.

Mechanical Seals
L-Nonpinned Design
Floating mating ring/seat design covering a wide range
of application requirements for general services.
Pressure range to 290 psig/20 bar.
Temperature range is
dependent on the
o-ring elastomer
Mechanical Seals
Cup Mounted Design

Low cost, high production mating ring/seat
For use in lower temperature applications
Pressure range to 14 bar/200 psig

Mechanical Seals
Clamped-in Design
Provides the widest temperature and pressure range
In general chemical application 1 PTFE and

1 reinforced fiber gasket should be used as sealing
elements -- if 2 PTFE gaskets are used, 1 gasket must
be glass-filled PTFE.
Pressure Ranges:
• PTFE Gasket:
to 52 bar/750 psig
• Spiral Wound Gasket:

to 83 bar/1200 psig
Mechanical Seals
Design Features
• Pusher Seal
O-ring must move axially

Mechanical Seals
Design Features
• Non-Pusher Seal
Static O-Ring
Mechanical Seals

Elastomeric Half Teflon Welded Metal
Bellows Convolution Bellows Bellows
V Rings U Cup Wedge Encapsulated O-Ring

O-Ring

Mechanical Seals
Pusher vs. Non-Pusher
Pusher vs. Non-Pusher
O-ring secondary seal Bellows secondary seal

must slide along shaft as expands to accommodate
seal face wears face wear. Bellows tail is
stationary against shaft
Mechanical Seals
Gasket Materials by Temperature Range

Virgin PTFE
• 17.7°C to 260°C / 0°F to 500°F
Spiral Wound
• -212°C to 399°C / -350°F to 750°F
Glass Filled PTFE
• -268°C to 260°C / -450°F to 500°F
Crane-foil®
• -17.7°C to 399°C / 0°F to 750°F
Reinforced Fiber
• to 399°C / 750°F

Mechanical Seals
Secondary Sealing Elements Temperature

Range
287°C / 287°C /
600°F 550°F 550°F 316°C
204°C / 204°C /
149°C 400°F 400°F
400°F 121°C / 204°C
/ 300°F
250°F
200°F 93°C
0 -18°C
-29°C -29°C / -
-54°C -45°C / - -40°C / -
/- 20°F
/ 50°F 40°F
-200°F -65°F
20°F -129°C
-400°F -212°C / - -240°C

350°F
Buna-N EPDM Viton® Kalrez® Aflas® PTFE
Viton & Kalrez are registered trademarks of DuPont. Aflas is a registered trademark of Asahi Glass Co. Ltd.
Mechanical Seals
Design Features
Drive Mechanism
• Must Transmit Torque
• Must Allow Axial Movement (Primary Ring)

Mechanical Seals
Types of Drive Mechanisms
Dent Drive Key Drive Set Screw Drive
Pin Drive Snap Ring Drive Slot and Ear
Elastomer Drive Spring Drive

Mechanical Seals
Type 1 Elastomer Bellows Seal
Set Screw
Collar Option
Temperature: -40°C to 205°C/-40°F to 400°F

Pressure: 29 bar g/425 psig

Mechanical Seals
Type 1 Design Features
Mechanical Drive
Self-Aligning
Special Balancing
Non-Clogging, Single Drive Spring
Low Drive Torque
Mechanical Seals
Set Screw
Collar Option

Speed: To 6000 rpm
Mechanical Seals
Full Convolution Elastomer Bellows

Positive Mechanical Drive
Inherently Pressure Balanced
Non-Clogging, Single Coil Spring
Self-Aligning Face
Mechanical Seals
Type 8 Elastomer O-Ring Seal

Pressure: 24 bar g /350 psig
Speed: 25 m/s / 5000 fpm
Mechanical Seals
Highly Versatile O-Ring Design

Mechanical Dent Drive Design
Compact Design
Easily Repaired on Site
Balanced Version Accommodates High Pressure
Mechanical Seals
Type 9 PTFE Wedge Seal


Mechanical Seals
Wedge Sealing Member for Corrosive Fluids

Compact Design
Mechanical Dent Drive Design
Precision Lapped Sealing Faces
Easily Repaired on Site
Balanced Design Accommodates High Pressures
Mechanical Seals
Type 20 PTFE Bellows Seal


Mechanical Seals
No Metallic Components in Contact with Process Fluid

Flexible PTFE Bellows Design for Extremely Corrosive
Fluids
Independent Spring Assembly
Replaceable Primary Ring
Multiple Spring Design Standard
Mechanical Seals
Alternate Methods


Mechanical Seals
Non-Clogging, Single Coil Spring

Positive Mechanical Drive
Lapped Sealing Faces
Stainless Steel Construction
Automatically Adjusts Seals Faces
Elastomer Bellows Convolution
Mechanical Seals
Classification of Seal Failures
Installation
Machinery Design and Operation
Seal Design and Operation

Mechanical Seals
Failures of Seal Components
Seal Faces
Loss of Flexibility
Material Compatibility
Mechanical Seals
Face Damage: Wearout
New
Worn

Mechanical Seals
Face Damage: Heat Checking
Mechanical Seals
Loss of Flexibility: Hangup
Leakage decomposes or
solidifies and locks primary
ring in place

Mechanical Seals

Problems
Cuts, overheated, or compatibility with fluid
Mechanical Seals
Material Compatibility of Faces and

Hardware
Corrosion
Wear

Mechanical Seals
Modern Mechanical Seals

Minimize or Prevent Leakage
• CMA/STLE Report
- better performance than older designs
- can meet local and federal requirements
Reliable
Economical
Evolving
• Materials
• Arrangements
• Testing
Mechanical Seals
Seal Selection Factors and

the Costs of Sealing

Mechanical Seals
Seal Selection
Based on the pump / duty data provided

Seal selected to suit the duty conditions
• Fluid and its properties
• Speed
• Temperature
• Size
• Pressures
• Pump type
• etc
Mechanical Seals
Factors in Seal Selection
Material compatibility
Hazardous nature of fluid
Handling contaminants or state changes
Customer preference
Available budget
Anticipated seal life
The balance of the above allows a seal selection to be

made based on the customers requirements

Mechanical Seals
A Change in Duty Conditions
If the duty conditions change ...

The seal selection should be checked as...
The seal may be operating outside of its performance
This will result in poor seal life
A change in duty may require a change in seal type or

arrangement or material or ...
Mechanical Seals
Facts about Mechanical Seals
Potentially the weakest part of the system

Potentially the highest maintenance spend
96% of premature seal failures are due to incorrect
installation (under one month)
The cost of a new seal is only 10% of the cost of the
failure
Approximately 48% of failures are caused by
operational or maintenance short falls
Are savings on seal purchases a good deal?
Are seal upgrades a good deal?

Mechanical Seals
Seal Costs - The Reality
The goal should be to increase seal life

• Reduce maintenance
• Improve plant uptime
• No lost product
• Reduced paperwork
This leads to increased profits for your company

A change from MTBF to MTBPM
Mechanical Seals
Mechanical Seal Types

Mechanical Seals
Different Seal Types
Elastomer Bellows
Elastomer O Ring
PTFE Bellows
PTFE Wedge
Welded Metal Bellows
Non Contacting - gas lubricated
Mechanical Seals
Elastomer Bellows Seals

Mechanical Seals
Elastomer Bellows Seals
Temperature -40oC to +205oC

Pressure up to 40 Bar
Speed up to 15 m/s
Elastomer bellows are usually the first choice due to

their easy construction and therefore lower price,
however they are limited in their duty capabilities.
Mechanical Seals
Elastomer Bellows Cartridge Seal

Mechanical Seals
Elastomer O-Ring Seal
Mechanical Seals
Elastomer O-Ring Seals

Speed up to 25 m/s
Elastomer O-ring seals are widely used in chemical

process plants. The effects of fretting are far less than
for wedge seals. Good temperature and pressure
range. O-rings available Worldwide.

Mechanical Seals
O-Ring Cartridge Seal
Mechanical Seals
PTFE Bellows Seal

Mechanical Seals
PTFE Bellows Seals

Speed up to 16 m/s
Excellent chemical resistance but limited duty

capabilities. Only inert PTFE comes into contact with
pumped fluid.
Mechanical Seals
Externally Mounted

Mechanical Seals
PTFE Wedge Seal
Mechanical Seals
PTFE Wedge Seals

Speed up to 25 m/s
Good chemical resistance and duty range but has its

problems. Now superseded by more modern seal
designs. Known for shaft fretting.

Mechanical Seals
Formed Metal Bellows Seal
Mechanical Seals
Formed Metal Bellows Seals

Speed up to 25 m/s
Non pusher design. Uses an asymetrical bellows shape

for enhanced stress resistance. Self cleaning and non-
clogging.

Mechanical Seals
Cut-away of Formed Bellows Seal
Bellows Assembly
Set Screw
O-Ring
O-Ring Mating Ring
Mechanical Seals
Formed Bellows Shape
High
Stress
Symmetric Low Asymmetric

Stress

Mechanical Seals
Welded Metal Bellows Seals

Speed up to 25 m/s
Non pusher design. Uses a welded bellows which makes

it expensive. Should only be used on clean services as
bellows clog easily. Excellent high temperature
operation.
Mechanical Seals
Welded Bellows Cartridge

Mechanical Seals
Typical Pump and Seal Problems
Mechanical Seals
Abrasives and Crystallisation

Mechanical Seals
Abrasives & Crystallisation
Hard or sharp particles as formed in crystallising fluids

will result in seal failure unless appropriate
precautions or materials are used.
Use hard seal faces (e.g. Silicon Carbide)
Use a quench
Use a cyclone separator
Controlling the seal environment allows for long seal
life
Mechanical Seals
Cavitation and Vibration

Mechanical Seals
Cavitation and Vibration
Shaking your pump either through overloading,

cavitation, mis-alignment or incorrect pipe supports
will lead to seal failure
Use seals that are more tolerant to these problems or
remove the proble
Mechanical Seals
Correct Alignment

Mechanical Seals
Correct Alignment
Alignment of the pump & motor should be conducted

after connection of the pipes, and at operating
temperature (hot or cold)
Un-necessary stresses in the system could cause a
pump breakage but a more likely effect is a seal
failure
Mechanical Seals
Changing the Duty

Mechanical Seals
Changing the Duty
Changing the duty of a pump may act the same as a

poison causing seal leakage through material
incompatibility or operating outside of the seals
performance rating
Check if the seal will accept the new conditions
Mechanical Seals
Flush, Quench and Lubrication
Oil !

Mechanical Seals
Flush, Quench & Lubrication
The life of the pump/seal is dependent upon “feeding”

it correctly. Bearings need oil and the seal requires the
flush and quench to be operated correctly. Unless the
pump is “fed” as stated then the result will be a seal
failure.
Ensure the flush / quench is operating
Lubricate the bearings as specified by the OEM
Consult the Technical Support Team for advice
Mechanical Seals
Don’t Choke your Pump

Mechanical Seals
Don’t Choke your Pump
Pumps need the correct NPSH at suction to operate.

Sump duties are hazardous as the NPSH changes as the
sump is emptied. The typical results are either
cavitation or seal dry running, both of which will cause
the seal to fail.
Use seals and systems that will tolerate this
Control sump emptying to avoid these problems
It’s not a difficult duty, if the correct selection is
made
Mechanical Seals
Don’t Cook your Pump

Mechanical Seals
Don’t Cook your Pump
Operating the pump at shut off will remove the cooling

effects needed by the seal. Heat is the enemy of seals
and unless it is removed, will cause excessive seal
wear.
Flush arrangements and coolers must be used as
specified
Don’t run the pump on shut off or with the bypass line
closed
Mechanical Seals
Some like it Hot!
Many Pumps in process plants operate at elevated

temperatures. Pre-heating and hot alignment must be
used to safeguard the seal. Thermal shocks can
fracture seal components. On coking services steam
quenches are used.
Before starting the pump ensure that it is at operating
temperature.
Ensure the steam quench is operating correctly

Mechanical Seals
Don’t Overload the Pump
Mechanical Seals
Don’t Overload the Pump
Forcing the pump to more than it was designed for will

lead to problems, this includes exceeding its operating
limits and stressing it with pipe loading. The result will
be seal failures.
Use the pump within its design limits
Don’t use the pump to carry pipe loading

Mechanical Seals
Prevention is Better than Cure
Mechanical Seals
Prevention is Better than Cure
The cost of a failure is far more than many people

think. By preventative maintenance methods and
ensuring correct operation, the cost of maintenance
and seal repairs can be significantly reduced.

Mechanical Seals
Increase Your Seal Life
Mechanical Seals
Increasing Seal Life
Ensure seal matches the duty conditions

Ensure safe handling of seal components
Ensure pump condition is OK
Ensure seal is installed correctly
Ensure pump is aligned to tolerance (hot or cold?)
Ensure pump can be rotated 360o
Ensure pump rotates in correct direction
Ensure pump is primed
Ensure seal chamber is vented

Mechanical Seals
Ensure pump is at operating temperature

Ensure all quench and flush lines are correctly
connected
Ensure quench and flush are working
Pressurize as required
Open valves according to procedures
Follow the fitting instructions for the seal
When all checks are completed - Start the pump
Mechanical Seals
Consider upgrading seal design

Consider upgrading the pump
Consider alternative materials
Consider a new arrangement
Consider a cartridge seal
Failure analysis can detect the causes of seal failure
and recommendations can be made to increase seal
life

Mechanical Seals
Single Cartridge Seal
Mechanical Seals
The Traditional View - A Component in

Isolation

Mechanical Seals
The Way Forward - Consider the Whole

System
Mechanical Seals
The Way Forward

Review the whole system
Understand and remove the problems
Upgrade as recommended
Remember upgrades save money
Get the process under control
Optimise seal life
Reduce seal related maintenance
Keep the plant running (MTBF to MTBPM)
Increase your company’s profitability and
international competitiveness

Mechanical Seals
Summary - 1a
Disadvantages of GP Advantages of M. Seals
- Health & Safety - Zero emissions with
- Housekeeping Type 2800/2800E seals
- Corrosion
- Environment
- Cost
• Wears shaft / sleeve • No shaft / sleeve wear
• Not self-adjusting • Self-adjusting
• Power consumption • Low power
• Open to tampering • Nothing to touch
• Run-in time required • Work from day one
• Fitting errors • Cartridges.
Mechanical Seals
Summary - 1b
• Low initial cost • High running costs and

short life
• Fit without stripping • Until sleeve is worn -
• Low skill level to fit • For long life, great skill
/ art / time required.

Mechanical Seals
Summary - 2
Mechanical seals prevent leakage

Rubbing faces are lubricated by fluid film
Fluid film must be present, stable, clean, reasonable
temperature and viscosity
Seals must be fitted in clean conditions and with
accuracy
Two types of seal: pusher and non-pusher. Each has its
advantages.
Mechanical Seals
Summary - 3
Seal life (MTBF) affected by:
• condition of pump
• state of pumped product in pump
• state of pumped product through the faces
• dry running
• excessive heat generation/inadequate cooling
• pressure peaks
• change in process fluid
• sudden temperature changes
• stop/start.

Mechanical Seals
No Seal Can Handle

All Applications
Mechanical Seals
Any Questions?

Section 3
Heat Temperature Control

Mechanical Seals
Section 3
Heat Temperature Control
Mechanical Seals
TM 066-2
Seal Cooling Part 2
This Training Module examines how cooling to face

contact mechanical seals can be enhanced by the use of
coolers and cooled mating rings. Also examines cooling of
sealant in double seal arrangements

Mechanical Seals
Heat / Temperature Control
Maintaining a stable fluid film
Mechanical Seals
Process Fluid Acts as Lubricant Between

Faces
Pump Housing
Gland
Process Fluid
Invisible Leakage:
Fluid Evaporates Upon Reaching
Atmosphere
Mechanical Seals
Without Lubrication, Faces Run Dry And

Overheat
Pump Housing
Gland
No Fluid Or Dry Running
Mechanical Seals
The Sealing Interface Separation

Magnified Surface B
Magnified Surface A
Lubrication Purpose:
• Separate surfaces
Lubricant
• Prevent contact of high

surface points
• Reduce friction/heat
generation
Heat
Mechanical Seals
Heat Generation
Rubbing
Viscous Shear
Mating Ring
Primary Ring
Mechanical Seals
The Sealing Interface
Shape:
Converging Parallel Diverging
Gap:
Face Separation
Fluid:
Non-flashing Flashing

Mechanical Seals
Heat Generation: The Problem
Pressure drops to
atmospheric
Temperature increases
(~20°)
Fluid film thickness
reduces or disappears
Premature failure.
Mechanical Seals
Heat in Stuffing Box

Two sources of heat
• heat soak from the product
• heat generated by the seal

Mechanical Seals
Heat Generation - the Causes

size
speed
temperature
• cooling
product properties
• flush or multiple
Too much heat generated surface finish - faces

dry-running materials of faces
excessive wear hydraulic pressure
very short seal life
Mechanical Seals
Heat Generation - Pressure
Reduce heat generation by reducing the

hydraulic pressure . . .

Mechanical Seals
Heat Transfer
Conduction
Convection
Mechanical Seals
Flushing
Removes Heat
Replenishes Cool Clean Lubricating Liquid
Injection

Mechanical Seals

Recirculation
for cooling
API Plan 11
Mechanical Seals
Primary Seal: Flush

Single Seal Flushing By - Pass from Discharge (API Plan 11)
Discharge
By- pass Line from
Pump Discharge
to Seal Gland
Flow
Suction

Mechanical Seals
Primary Seal: Flush

Single Seal Flushing from External Source (API Plan 32)
Discharge
Flow
A
Minimum
Pressure
0.3 bar / 5 psi
Above “A”
Suction
Restriction Device
(Bushing)
Mechanical Seals
Primary Seal: Quench

Single Seal Quench from External Source (API Plan 62)
Quench Source
Process Fluid
Restrictional Device (Packing)

Mechanical Seals
Quench and Flush

Quench
• low pressure (0.5 bar g)
• low flow (0.5 litres/minute)
• external to main seal
• no contamination
• no dilution
Flush
• high pressure (>1.0 bar above seal pressure)
• injected into seal chamber
• cools pumped product
• dilutes pumped product.
Mechanical Seals
Heat control / Removal
PTFE
Graphite

Mechanical Seals
Ensure flow at all

times:
constant and even
temperature
Removes heat
generated by the
seal
Do not use with

a cooling jacket.
Mechanical Seals

Mechanical Seals
Fig 1
Mechanical Seals

API Plan 11 Product recirculation line.

Mechanical Seals
API Plan 13
Reverse
circulation to
suction
Mechanical Seals
Fig 2

Mechanical Seals
API Plan 21
Mechanical Seals

Mechanical Seals
Fig 4
Mechanical Seals

API Plan 61 / 62

Mechanical Seals
Fig 6
Mechanical Seals
Fig 7

Mechanical Seals
Fig 8
Mechanical Seals
TM 041-2
Sealant Systems
This Training Module examines the equipment used to

maintain a barrier fluid when operating multiple
mechanical seal arrangements.

Mechanical Seals
Typical Sealant Systems
Mechanical Seals
Fig 2
USES OF SEALANT SYSTEMS
Reducing risk of product loss.

Flushing the seal interface.
Removing excess heat.
Isolating product from atmosphere.
Seal failure detection.
Lowering of inboard seal differential pressure.

Mechanical Seals
Fig 10
TANK SYSTEM ADVANTAGES VESSEL SYSTEM ADVANTAGES
Simple Maintenance Pressure Versatility
Long Life Positive Displacement
Multi-Server Material Traceability
Heat Removal Stainless Steel
Barrier Fluid Isolation
Mechanical Seals
Fig 12
OTHER SEALANT SYSTEMS
Fail Safe Sealant System

Gas Panel
Hand pump/Accumulator Set

Mechanical Seals
Boiler Feed Seals
Main and Booster
Mechanical Seals
API Plan 23

Mechanical Seals
Boiler Feed Seals - Type 270F
Mechanical Seals
Boiler Feed Seals
Type 85B1RS
Mechanical Seals
The Environment of a
Mechanical Seal
Secondary Containment
Mechanical Seals
To contain hazardous emissions
To contain product leakage when main mechanical seal
finally fails
To isolate product from the atmosphere
• coking
• crystallising
• freezing
• polymerising
To contain a quench for other reasons (e.g. cooling)
Non-contacting and contacting.

Mechanical Seals
Quench and Flush

Quench
• low pressure (0.5 bar g)
• low flow (0.5 litres/minute)
• external to main seal
• no contamination
• no dilution
Flush
• high pressure (>1.0 bar above seal pressure)
• injected into seal chamber
• cools pumped product
• dilutes pumped product.
Mechanical Seals
Non-contacting
Fixed non-sparking throttle
bush
Minimum requirement for API
610
Leakage reduction
Any shaft movement will
cause wear.
Use API Plan 61

Mechanical Seals
Non-contacting (close)
Floating carbon bush
Often segmented for ease of
replacement
Minimum requirement for API
682
Moves with the shaft
Leakage reduction
Steam quench
Less leakage
Longer life.
Use API Plan 61
Mechanical Seals
Contacting
Various lipseal type devices
Isolate product from
atmosphere and contain
any leakage
Must supply lubricant at all
times (quench)
Low pressures only.
Use API Plan 62 or 51

Mechanical Seals
Mechanical Seals

Mechanical Seals
QW Seal
Mechanical Seals
Leakage Containment
Type 28LD
Mechanical Seals
Leakage Containment
Dry Running Secondary Containment Seal
Type 28SC
Mechanical Seals
Type 28SC

Mechanical Seals
Leakage Containment
Typical Type 48MP / Type 28SC Tandem Installation
Mechanical Seals
Secondary Containment - ECS
Low temperature version shown

.
Mechanical Seals
Low Temperature ECS
Mechanical Seals
Low Temperature ESC

AM 350 Bellows or Hastelloy C-276
Backup / Safety Seal
• contain fugitive emissions
• enables Primary Seal recovery from upsets without
any emission leakage to atmosphere
• allows controlled pump shut-down when Primary
Seal failure occurs
No liquid lubrication required
• eliminates wet barrier systems
.
Cartridge Seal

Mechanical Seals
High Temperature ECS
Mechanical Seals
High Temperature ECS
Graphite or perfluoroelastomer Positive ball drive

Mechanical Seals
High Temperature
Mechanical Seals
High Temperature ESC

Inconel 718 Bellows & Alloy 42 Shell
Backup / Safety Seal
• contain fugitive emissions
• enables Primary Seal recovery from upsets without
any emission leakage to atmosphere
• allows controlled pump shut-down when Primary
Seal failure occurs
No liquid lubrication required
• eliminates wet barrier systems
.
Cartridge Seal with positive drive

Mechanical Seals
Mixer / Agitator / Reactor
Type 32 - Dry-Running Seal

..
Mechanical Seals
End of This
Section

Section 4
Drive Methods
Mechanical Seals
Section 4
Drive Methods
Mechanical Seals
TM 054-1
Basic Seal Principles Part 4 : Drive
Methods
This Training Module looks at commonly used drive

methods for mechanical seals.

Mechanical Seals
Fig 1
Mechanical Seals
Fig 2

Mechanical Seals
Fig 3
Mechanical Seals
Fig 4

Mechanical Seals
Fig 5
Mechanical Seals
Fig 6

Mechanical Seals
Fig 7
Mechanical Seals
Fig 8

Mechanical Seals
Fig 9
Mechanical Seals
Fig 10

Mechanical Seals
Fig 11
Mechanical Seals
Fig 12

Section 5
Springs
Mechanical Seals
Section 5
Springs
Mechanical Seals
TM 055-1

Part 5 : Springs
This Training Module examines the purpose and use of a

Spring in a Mechanical Seal.

Mechanical Seals
Fig 1
Mechanical Seals
Fig 2

Mechanical Seals
Fig 3
Mechanical Seals
Fig 4

Mechanical Seals
Fig 5
Mechanical Seals
Fig 6

Mechanical Seals
Fig 7
Mechanical Seals
Fig 8

Mechanical Seals
Fig 9
Mechanical Seals
Fig 10
Materials of Construction
Corrosion Levels
Shaft Diameter
Load Required
Space Available
Wear Allowance
Amount of Axial Movement Required
Speed and Direction of Rotation
The Nature of the Fluid being Handled
• Solids in Suspension
• Viscostiy
• Solidification
• Crystallisation
• Process Temperature
Mechanical Seals
Fig 11
SPRING TYPE ADVANTAGES DISADVANTAGES
Helical Large volume. Variable load circumference.

(single) Resistant to corrosion. Take up space.
Do not clog. Unwind at speed.
Create circulation of Create vibrations and out
product. of balance forces.
Helical Small and compact. High stress concentration.

(multiple) Uniform load by spacing. High spring rate.
Easy to install. Corrosion can be serious.
Can be lost. Tend to clog.
Wave Washer Compact. High spring rate.

Allows malalignment.
Metal Bellows No loose springs required. Limited range of

materials.
Mechanical Seals
End of This
Section

Section 6
Balancing
Mechanical Seals
Section 6
Balancing
Mechanical Seals
Hydraulic Balance
A brief explanation of
Hydraulic Balance follows

Mechanical Seals
Hydraulic Balance
FACE AND SEAT WIDTHS EQUAL
L = TOTAL LOAD P
S = COMPRESSIVE FACE STRESS
TOTAL LOAD L = HYDRAULIC HYDRAULIC

x
PRESSURE AREA
= PxA P A
COMPRESSIVE STRESS AT FACE = S
TOTAL LOAD PxA

S =
FACE AREA A
WHEN THE HYDRAULIC AREA AAND THE FACE AREA

ARE THE SAME S = P
Mechanical Seals
Hydraulic Balance
MACHINING FROM THE INSIDE DIALMETER
L = TOTAL LOAD
TOTAL L = P x A
P 0.2A
TOTAL LOAD L
S = =
FACE AREA 0.2A
∴ PxA P P A
S = = 5P
0.2A 0.2
THE FACE STRESS IS 5 TIMES THE

HYDRAULIC PRESSURE

Mechanical Seals
Hydraulic Balance
MACHINING FROM THE OUTSIDE DIAMETER
L = TOTAL LOAD
CLOSING LOAD = PxA

OPENING LOAD = P x 0.8A
RESULTANT LOAD = P X A – P 0.8A
= P X 0.2A
COMPRESSIVE STRESS “S” AT FACE =

TOTAL LOAD P x 0.2A
=
FACE AREA 0.2A
S = P
FACE STRESS = HYDRAULIC PRESSURE
Mechanical Seals
Hydraulic Balance
HYDRAULIC BALANCE OF SEALS
(50% BALANCED)
L = TOTAL LOAD
BALANCE DIA.
CLOSING LOAD = PxA
OPENING LOAD = PxA
2
RESULTANT LOAD = PxA–PxA=PxA

2 2
FACE STRESS S = TOTAL LOAD

FACE AREA
A
Px
S= 2 =P
A 2
FACE STRESS = HALF HYDRAULIC PRESSURE

Mechanical Seals
Hydraulic Balance
Balance diameter
BALANCE PERCENTAGE IS A COMPROMISE:
ABOVE 85% - WEAR

BELOW 65% - LEAKAGE
OPTIMUM BALANCE 75% FOR MEDIUM PRESSURE SEALS.
FORCE IS OFFLOADED WHILST FACE WIDTH IS MAINTAINED.
Mechanical Seals
Hydraulic Balance
Pressure = 10 kg/cm2 50%
125%
10
0.8 cm2
1 cm2
125% - 50% = 75% (7.5 bar)
75% 50%
10
75% - 50% = 25% (2.5 bar)

Mechanical Seals
Hydraulic Balance
Unbalanced Pusher Seal Balanced Pusher seal
Mechanical Seals
Hydraulic Balance
Metal bellows seals are INHERENTLY balanced.

Mechanical Seals
Hydraulic Balance - Benefits

Reduced heat generation
• ideal for unstable and low SG fluids
• less heat to be dissipated - less cooling required
Reduced wear rate
• longer life
Reduced power required to drive the seal
• lower running costs
Increased pressure range for the seal
• this simple modification allows much higher
pressures to be sealed.
Mechanical Seals
Type 8B1 Balanced Elastomer O-Ring Seal

'X'
Gasket
(3) (2) (1)
L65
L3
= Scribed datum lines
Section 7
Fluid Film
Mechanical Seals
Section 7
Fluid Film
Mechanical Seals
Fluid Film
This Training Module examines the limitations of the fluid

film with regard to pressure, seal life and temperature.

Mechanical Seals
Fig 1
Mechanical Seals
Fig 2

Mechanical Seals
Fig 3
Mechanical Seals
Fig 4

Mechanical Seals
Fig 5
Mechanical Seals
Fig 6

Mechanical Seals
Fig 7
Mechanical Seals
Fig 8

Mechanical Seals
Fig 9
Mechanical Seals
Fig 10

Mechanical Seals
Fig 11
Mechanical Seals
Fig 12

Mechanical Seals
Fig 13
Mechanical Seals
Fig 14

Mechanical Seals
Fig 15
OFF LOAD ON LOAD
+ HYDRODYNAMIC = HYDROSTATIC + FLUID SPRING

+ CONTACT
Mechanical Seals
Fig 16

Mechanical Seals
Fig 17
Mechanical Seals
Fig 18

Mechanical Seals
Fig 19
Mechanical Seals
Fig 20

Section 8
Multiple Seals
Mechanical Seals
Section 8
Multiple Seals
Mechanical Seals
TM 070-2
Multiple Seals
This Training Module examines the limitations of single

seals with regard to process, seal life and safety and
explains when and how multiple seals should be used.

Mechanical Seals
Single Seal
Process Atmosphere
Fluid
Leakage
around the
gland plate
Leakage along the

shaft
Mechanical Seals
Seal Arrangements
Single
• Inside Mounted
• Outside Mounted
Multiple
• Pressurized
• Non-Pressurized

Mechanical Seals
Seal Arrangements
Single
• Inside Mounted
Mechanical Seals
Arrangements
Single
• Outside Mounted

Mechanical Seals
Single Seal Arrangement

Gland
Inside Pump Housing

Mounted Atmosphere
Mating
Process Fluid Seal Head Ring
Shaft
Gland
Outside Pump Housing

Atmosphere
Mounted Mating
Process Fluid Ring Seal Head
Shaft
Mechanical Seals
Arrangements
Rotating Head and Rotating Seat
Rotating Seat
Rotating Head
Seal Head Seat Seat Seal Head

{
{
{
Rotating Stationary Rotating Stationary
Advantages Advantages
Less Radial & Axial Space Requirements Higher Speed Capability
Lower Cost Tolerates Misalignment Better
Better Cooling
Use Rotating Head Assemblies up to:
3500 fpm for Single Spring Designs
5000 fpm for Multiple Spring Designs

Mechanical Seals
Seal Arrangements
Multiple
• Non-Pressurized
• Pressurized
Mechanical Seals
Single Seal is not Enough

Use multiple seals if:
• product is toxic
• product is flammable
• environmental
• isolation required
• product changes state
• product is not a good
Single seals utilise process gas or lubricant or is abrasive
fluid to provide the lubricating • suction pressure is low
interface film • expensive product
• critical machine

Mechanical Seals
Single Seal is not Enough

Use multiple seals if:
• product is toxic
• product is flammable
• environmental
• isolation required
• product changes state
• product is not a good
lubricant or is abrasive
Single seals utilise process gas • suction pressure is low
or fluid to provide the
lubricating interface film • expensive product
• critical machine
Mechanical Seals
Multiple Seals
Tandem
Unpressurised

Mechanical Seals
Multiple Seal Arrangements

Classical “Tandem”
Process seal Backup seal
Classical “Double”
Process seal Barrier fluid seal
Mechanical Seals
Multiple Seals
Two common arrangements
• Tandem
- low pressure buffer fluid
- high integrity secondary containment
- inboard seal lubricated by product
• Pressurised Double (e.g., Back-to-Back)
- pressurised barrier fluid
- inboard seal lubricated by barrier fluid
There are many other arrangements
• Face-to-Face; Dual; Concentric; etc.

Mechanical Seals
Multiple Seals: Tandem

Inboard Seal
Product
lubricates
this seal
This seal is
under full
product
pressure
Note possible
contamination
Use API Plan 52 of buffer fluid
Basic tandem non-pressurised double
Mechanical Seals

Outboard Seal
Clean buffer
fluid lubricates
this seal
Buffer fluid is
at low
(atmospheric)
pressure
Use API Plan 52

Basic tandem non-pressurised double
Mechanical Seals

Inboard seal
most likely to
fail first
Buffer fluid
level/pressure
will rise
Outboard seal
acts as
secondary
containment
Process can
Use API Plan 52 continue until
Basic tandem non-pressurised double completed
Mechanical Seals

Mechanical Seals
Mechanical Seals
Multiple seals: Tandem

Inboard Seal
Product
lubricates
this seal
This seal is
under full
product
pressure
Note possible
contamination
Use API Plan 52 of barrier fluid.
Basic tandem non-pressurised double seal

Mechanical Seals

Outboard Seal
Clean barrier
fluid lubricates
this seal
Barrier fluid is
at low
(atmospheric)
pressure.
Use API Plan 52

Mechanical Seals

Inboard seal
most likely to
fail first
Barrier fluid
level/pressure
will rise
Outboard seal
acts as secondary
containment
Process can
continue until
completed.
Use API Plan 52

Mechanical Seals
Low pressure
fluid supply
Mechanical Seals

Mechanical Seals
Unpressurized
(Tandem)
Process
Pressure
Buffer Atmosphere
Mechanical Seals
Multiple Seals
Pressurised
Double

Mechanical Seals
Pressurized
(Double)
Barrier
Pressure
Process
Atmosphere
Mechanical Seals
Double Seals: Back-to-Back

Pressurised
barrier fluid
is circulated
round the
seals
This
lubricates
both sets of
seal faces
Use API Plan 53
Basic back-to-back pressurised double seal

Mechanical Seals
Double Seals: Back-to-Back

If outboard
seal fails,
barrier
pressure will
fail and pump
must be
switched off
as product
will leak out
Use API Plan 53

Mechanical Seals
Double seals: Back-to-back

Pressurised
barrier fluid is
circulated
round the
seals
This lubricates
both sets of
seal faces.
Use API Plan 53

Mechanical Seals

If outboard
seal fails,
barrier
pressure will
fail and pump
must be
switched off as
product will
leak out.
Use API Plan 53

Mechanical Seals

Mechanical Seals
Double Seals: Face-to-Face
Rotating
Mating Stationary
Ring seals
Similar in operation to back-to-back double seal

Much shorter - only one mating ring
Simple rotating components
Mechanical Seals
Double seals: Face-to-face
Rotating
Mating Stationary
Ring seals
Similar in operation to back-to-back double seal

Much shorter arrangement - only one seat
Simple rotating components.
Mechanical Seals
Double seals: Face-to-face
Type 7700 Dry-running Double Seals
Standard Installation Debris Well Installation
Mechanical Seals
Type 7700 Seal

Double seal for use where single seals are not acceptable
Gas barrier lubrication
Double, balanced design
Temperatures to 150 °C
Speeds to 300 rpm
Computer optimised face / primary ring profile
Solid, symmetrical tungsten carbide seat / mating ring
Handles more shaft movement than any other vessel seal
Major inboard and outboard components interchangeable
Field repairable
Cartridge seal
Debris well option
Liquid barrier lubrication can be used if preferred.
Mechanical Seals
Double Seals: Face-to-Face
Mechanical Seals
Dual Seal Arrangement
Pressurized
(Double)
Barrier
Pressure
Process Atmosphere

Mechanical Seals
Api 682 Definition of Terms (cont’d)
Dual Seals:
• Pressurized Double
• Un-Pressurized Tandem
Buffer Fluid (Gas)
• A fluid (gas) used to buffer the process liquid
from the environment. If the secondary seal leaks,
process fluid could leak into the environment.
Buffer fluid is always at a lower pressure than
the process pressure. (Used with dual
non-pressurized, tandem).
Mechanical Seals
Leak Paths for Seal Arrangements
Single
• From process into the atmosphere
Dual Non-Pressurized (Tandem)
• From process into the secondary seal
and possibly...
• From secondary seal to the atmosphere
Dual Pressurized (Double)
• From inboard seal into the process
• From outboard seal into the atmosphere

Mechanical Seals
Fig 8
ADVANTAGES AND DISADVANTAGES OF DOUBLE BACK
TO BACK AND TANDEM SEAL CONFIGURATIONS
Back to Back Tandem
Used to seal abrasive, very viscous Simple Sealant Systems - at atmospheric

or highly toxic media. The area pressure during normal operation.
between the seals is a minimum
of 1 bar or 10% above product As product recirculation is commonly used at
pressure ensuring no product the inboard seal, less heat is accumulated.
contamination of sealant.
The inboard seal will normally fail first as it is
Any leakage will be barrier fluid into
sealing full process pressure. The outboard seal
process since barrier fluid is at a higher
having operated in barrier fluid at atmospheric
pressure.
pressure’replaces’ the inboard seal.
The outboard seal will usually fail first
causing barrier fluid to leak, not the
process. The inboard seal operates at only
the differential of the process and barrier
pressures.
Mechanical Seals
Fig 8 (Continued)
ADVANTAGES AND DISADVANTAGES OF DOUBLE BACK

TO BACK AND TANDEM SEAL CONFIGURATIONS
Back to Back Tandem
Complex Sealant System. The sealant system, although simple,

must normally be vented to
atmosphere.
Seal failure results in a rapid loss of
barrier fluid. The system must be shut Can only be used if the product is
down on failure. suitable for lubricating the seals.

Mechanical Seals
Fig 12
TYPICAL BARRIER FLUIDS
Water Ethylene Glycol
Heat Transfer Oil Paraffin
Mineral Oil Ethyl Benzine
{
Vegetable Oil Paint Thinners
Milk Acetic Acid Customer

Preferred
Water Based Solutions Turpentine
Glycerine Toluene
Mechanical Seals
Double Seals: Concentric
Type 151 Seal for Top-Entry Vessels.

Mechanical Seals
Mechanical Seals
Type 157C Seal for Top Entry, Glass-Lined Mixers

Mechanical Seals
Double Seals: Top Entry
Mechanical Seals
Reverse Pressure
Type 8B1RP / Type 8B1 .

Mechanical Seals
Dual Seal
Type 5620
Mechanical Seals
End of This
Section

Section 9
Pumps
Mechanical Seals
Section 9
Pumps
Mechanical Seals
Engineered Sealing

Mechanical Seals
Centrifugal Pumps
Mechanical Seals
Centrifugal Pump Basics

Balancing
wear rings.
Minimum stuffing
box pressure Pseal
=
Psuct+Pdisch - Psuct
10

Mechanical Seals
Centrifugal Pump
Many varied designs
• vertical
• double ended
• horizontal split casing
• multi-stage
• close coupled
• bell housing
• axial flow
• etc . . .
Mechanical Seals
Vanes
Impeller
Vanes rotates at
impart high speed
centrifugal
force.

Mechanical Seals
Centrifugal Pump
Mechanical Seals
Centrifugal Pump
.
Mechanical Seals
Centrifugal Pump
Mechanical Seals
Centrifugal Pump

Mechanical Seals
Centrifugal Pump
Mechanical Seals

Impeller Discharge Stuffing Box
(Seal Chamber)
Vanes
Suction
Mechanical Seal Bearings Coupling.

or Gland Packing

Mechanical Seals

Wear rings “Balance” holes
Back vanes
Mechanical Seals
Positive Displacement Pump
Progressive Cavity Pump.

Mechanical Seals
Progressive Cavity Pump
Mechanical Seals
Positive Displacement Pump
Outlet Inlet
Rotary Lobe Pumps

.

Mechanical Seals
Pump Assembly Checks - 1

For extended MTBF pump must be in excellent
condition:
• shaft diameter ±0.05 mm
• shaft radial runout 0.05 mm FIM
• radial and axial movement 0.05 mm FIM
• shaft axis to stuffing box 0.05 mm FIM
• coupling alignment 0.05 mm FIM
• shaft ovality 0.05 mm FIM
All measurements taken at stuffing box.
Mechanical Seals
Pump Assembly Checks - 2
Shaft surface must be in good condition:

• no pits or scratches
• fine machined or better for non-pusher seals
• ground and polished with no machining marks for
pusher seals
No pipe strain.

Mechanical Seals
Hands-on Exercise
Assemble and Fit a Type 109 PTFE Wedge Seal
Mechanical Seals
Mixers / Agitators / Reactors
Three common arrangements

• Top Entry
• Bottom Entry
• Side Entry

Mechanical Seals
Mechanical Seals

Mechanical Seals
Mechanical Seals
Shaft Turning
Turn shafts of stored & standby equipment

• Bearings - false Brinnelling
• Shaft sag - permanent set
• Seal face wringing.

Mechanical Seals
Mechanical Seals

Mechanical Seals
Key Equipment
Other equipment includes
• air and gas compressors
• refrigeration compressors
• turbines (steam and water)
• dryers
• conveyors
• anywhere a rotating shaft passes through a
stationary housing where product has to be
contained
• valves.
Mechanical Seals
Centrifugal Gas Compressor

Mechanical Seals
Engineered Sealing
.
Mechanical Seals
End of This
Section

Section 10
The Environment of a Mechanical Seal
Sealant Systems
Mechanical Seals
Section 10
The Environment of a Mechanical Seal

Sealant Systems
Mechanical Seals
Sealant Systems
Sealant systems are required to

• supply low pressure sealant to tandem seals and
secondary containment seals
• supply pressurised sealant to back-to-back and
other pressurised seal arrangements
• cool the barrier fluid (sealant; buffer fluid)
• monitor seal condition / leakage.

Mechanical Seals
Sealant System
Cooling can be added to
the system
System must be above,
and within 3 metres of
pump
Fluid circulates by
thermosyphon
May need small pump or
pumping scroll to assist
flow.
Mechanical Seals
Sealant System
Large bore piping

Smooth bends
Constantly rising pipe runs
Lagged up-leg optional
Shortest route.

Mechanical Seals
Sealant System: Tandem
Fluid level must be Orifice plate.

monitored: Open to
increase = inboard atmospheric
seal failing pressure. Valve on
decrease = outboard this line should be
seal failing open until inboard
seal failure
Optional
temp/pressure
gauges
Optional circulating
pump
Pressure switch &
flow indicator are
also useful options. Use API Plan 52
Mechanical Seals
Sealant System: Pressurised
Nitrogen to Pressure
pressurise barrier relief valve
fluid:
1 bar above process Fluid level
pressure at the must be
seal, or 10% above checked
process pressure at regularly
the seal, whichever
is greater Hand pump to
manually
replace lost
barrier fluid
Pressure must be
while system
constantly
remains
monitored
API Plan 53 pressurised.

Mechanical Seals
Plan 53 System
.53M
Mechanical Seals
Plan 53 Modified
Can be used
above 30 bar g
Can be
installed away
from seal area
Simplified
instrumentation
Can refill
system under .
pressure
Mechanical Seals
Sealant System
Up-leg: temperature at the top
should be similar to (or slightly
lower than) the seal end
Down-leg: temperature at the
seal end should be similar to (or
slightly higher than) the top
Check the flow indicator
Actual temperatures and flows will

depend on the application. Consult
your seal supplier.
Mechanical Seals
Sealant Systems: Tandem

Sealant Sight Glass Level
Tandem Seal Arrangement
8
Indicates
7
deterioration of
6
inboard seal
4
Level
Slight rise due to Indicates

3
leakage of product deterioration
2
into sealant. Sealant of outboard
needs to be changed seal
1 regularly
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Time

Mechanical Seals
Sealant System: Pressurised

Sealant Sight Glass Level
Pressurised Double Seal Arrangement
8
7
Routine topping- Large drop indicates
up with hand deterioration of
6 pump inboard and/or
outboard seal
5
4
Level
3
Slight drop due
2
to leakage
through two
1 seals
0
.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Time
Mechanical Seals

Mechanical Seals
System 100 304 stainless

18 bar g max
7 litre nominal
5 litre sealant.
Mechanical Seals

System 200 System 300
• 321 stainless steel • as System 200 but
• 30 bar g maximum with internal cooler.
• 8 litre nominal
• 6 litre sealant
• level gauge reflex
glass

Mechanical Seals
Special Systems
Mechanical Seals

System 6SA
Oils or glycol
Up to 50 bar g
6.5 litres/minute
27 litres nom cap.
System 600
Section 11
Failure of Mechanical Seals
Mechanical Seals
Section 11
Failure of Mechanical Seals
Mechanical Seals
Seal Failure Analysis
A brief overview
What are the main causes of Seal Failure?

Mechanical Seals
What is a failed seal?
Mechanical Seals

I.Mech.E Pub’n. Global Chem. Co.
Seal selection & design
Design Pump selection, design 28% 15%

& suction circuitry.
Installation, alignment,
bearing & pump condition
Maintenance 24% 20%
Seal fitting & installation
tolerances
Process upsets, off-duty
operating, priming,
mal-operation.
Operation 48% 65%
Seal flushing, cooling,
quenching.
.
Mechanical Seals
Seal Failure Analysis - 1996

BP Chemicals, Hull - DF Plant
• Bearing Failure 25.6%
• Mechanical Damage 14.6%
• Operational Issues 4.6% (excl dry running)
• Dry Running 13.4%

• Excessive Face Wear 7.4%
• Seal Hang-Up 7.3%
• Incorrect Fitting 4.9%
• Chemical Attack 2.4%
.
• Normal Expected MTBF 9.8%
Mechanical Seals
Seal Failure - Data Collection

1) Warranty
- ALWAYS the first question to ask
if if
“YES” “No”
- Have they contacted OEM? - Then continue
- Insist that someone does.

- Get instructions from OEM.

Mechanical Seals

2) Fluid
- Write down all the basic fluid details.
- Get as much other relevant info as you can. . .
- % conc., effect on pump materials, etc - chemical
- Viscosity, SG, solids content, etc - slurry
- VP, SG, H2S content, etc - hydrocarbon
- Is there anything ‘odd’ when product is hot or cold?
- Is there another duty for this pump?
- Is there a cleaning cycle? (what & when)?
- Is the fluid treated in any way? (how & when)?
Mechanical Seals

3) Operation
- When was the equipment first run?
- When & how did the equipment fail?
- Is there anything odd about frequency of failures?
- Is it a stop/start, or continuous duty?
- What are the typical / common process upsets?
- Can system pressure losses / surges exist?
- How is flow controlled?, how started and stopped?
- How does the equipment ‘feel’, ‘sound’, and ‘look’?

Mechanical Seals

4) Installation
- Can you check working length?
- How about shaft condition? grubscrew marks?
- Have bearings been OK? always?
- Are all connections correctly piped up / unblocked?
- Is sealant pipework to our recommendations?
- How is the equipment vented?
- What is used as a fitting lubricant?
- Does the same person always fit this seal?
Mechanical Seals
Seal Failure - Procedure

DECISION TIME !!
- Me, or Someone Else ? ? . . . .
if “Someone else” . . .
- Have you got all the right information written down?
- Have you agreed with the customer the level of response?
- Have you been assured the seal is safe to handle?
- What are our disposal instructions?
- Have you warned the person doing the report?
- Is there an opportunity to SELL a report??
Mechanical Seals
DECISION TIME !!
- Me, or Someone Else ? ? . . . .
if “Me” . . .
- Have you got all the right information written down?
- Have you agreed with the customer the level of response?
- Have you been assured the seal is safe to handle?
Mechanical Seals
- What are our disposal instructions?
- Can you spot the common failure modes?
- Can you report them in a ‘commercially astute’ way?

Mechanical Seals
Seal Failure
Collect full details of ACTUAL operating conditions
Check dimensions (fitting/chemical/wear)
Were there any
• operational problems?
• unusual occurrences?
Note all visual evidence
• bad points
• good points.
Mechanical Seals
Information to Collect
Modus Operandi of Failure Initiated or
Equipment (Including Start Following Process Change.
/ Stop Sequences). Failure Related to
Maintenance Operational Change.
Arrangements. Start / Stop History and
Vibration Signature. Operation.
Prior to Start-Up Failure. DE / NDE Bias.
Cartridge Pressure Test. MTBF (Consistent or
Dynamic Failure. (< 1hr) Irregular).
Operating Hours? Comparable Duty with
Sudden Failure or Different History.
Progressive Leakage Anything Unusual?.
Increase.
Mechanical Seals
John Crane EMA SEAL FAILURE ANALYSIS GUIDE John A Blaber/FAILURE1.XLS
Engineered Sealing Systems Date of Issue: 20/08/97
POSSIBLE CAUSES OF FAILURE

VISUAL ABRASION POOR CONTAM- CORR- FLUID POOR THERMAL INCORRECT INSTALLATION MAL-ALIGNMENT MAL-OPERATION POOR SYSTEM FAULTS
EXAMINATION LUBRI- INATION OSION EROSION CONTROL Assembly Fitting Size Equipm'nt Pipework Flow Pressure Speed VENTING Cleaning/ Vibration
CATION Cooling Heating Treatment
Good Condition X1 X2 X3 X4 X5 X6
Burnt X8 X9 X9 X10 X11 X11 X12 X9
M Chipped X13 X14/X67 X31/46/67 X14 X15 X15/X67 X16/X67 X65 X67
A Decomposed X17 X17 X18 X17
T Eccentric Track X19 X4 X5 X20 X21 X65 X22
E Etched X17 X17 X17
R Flaked X23 X12
I Fretted X24/31/55 X25/X55 X25 X10/X31 X19 X4/X25 X5 X20 X12/X34 X65 X22 X55 X26
A Galled X27 X10 X28 X28
L Grooved X13/X63 X12/23/55 X55 X29 X34 X11/X41 X6/X16 X22 X55
Incomplete Track X44 X44 X44
Leached X30 X30 X30
L Matted X31 X30 X30 X32 X33 X33 X65 X7 X30 X26
O Pitted X55 X17/X55 X17 X22 X64/X14 X34/X43 X22 X17
S Polished X35 X29 X36 X34
S Scored/Scuffed X37 X27 X29 X40 X14 X12
Shredded X66
Wasted Away X17 X17 X17
Wide Track X38 X19 X4/X39 X4/X5 X65 X22
Bent X40 X11 X41 X11 X42 X42 X40
Blistered (Face) X43/X55 X43/X55 X43 X44 X45 X43 X43
Bruised X15 X15
N Changed Shape/Section X17 X17 X46/X61 X61/X67 X67 X42 X67
O Clogged X14 X47
Cracked X48 X49 X11 X11 X42 X20 X50 X65 X20
M Crazed (Full Track) X8/X55 X55 X51/X62 X62 X11 X11 X52 X12/X34 X22
A Crazed (Partial Track) X8 X69 X11 X11/X44 X44/X52 X34 X22
T Dented X11 X11 X50
E Dirty X53 X14 X54 X54 X53
R Discoloured X56 X56 X57 X56
I Distorted X40 X11 X38/X41 X11/X44 X42 X42 X40
A Extruded X49 X58 X59 X49
L Fractured X48 X49 X41 X11 X3 X52 X50 X65
Hardened X8/X55 X55 X46
L Jammed X60 X14 X38
O Ruptured X49 X11 X50
S Shrunk X17 X17 X61 X61 X17
S Softened X17 X17 X18 X17
Split/Torn X8 X38 X15 X50/X66
Swollen X17 X17 X24 X24 X17
Tacky/Waxy X17 X17 X14 X17
Mechanical Seals
'X' TYPICAL EXAMPLES OF 'X' 'X' TYPICAL EXAMPLES OF 'X'
X1 Differential expansion between static and rotating elements causing separation at seal interface. X43 RECOGNITION: Surface blisters on running track of carbon face
X2 Seal set at wrong working length with no contact between face and seat. 'Lumps' of carbon removed from running track, usually at ID.
X3 Shaft diameter tolerance >+0.05mm. Shaft ovality > 0.006mm with wedge seal.
X4 Bedplate distorting due to inadequate foundation support. Fabricated steel bedplate not filled with CORRECTIVE ACTION OPTIONS:
concrete. Vessel not aligned to vertical due to movement of foundations. Pipe strain - ensure flanges are 1. Use '218' or '539' face material.
correctly aligned. Check coupling alignment. 2. Reduce face width (e.g., 3mm).
X5 Leakage due to thermal expansion of pipework. NB: 100' length of stainless steel expands 3. Reduce spring load. If face width reduced, ensure face stress is at or below level before face
approx. 2" (50mm) per 100 deg C rise in temperature. Pipework inadequately supported. width reduced.
X6 Pressure too low to keep split faces together, e.g., T99/599 seals. 4. Use minimum hydraulic balance rate of 75%. Consider increasing up to 65%.
X7 Product recirc. from discharge on vertical pumps instead of reverse circulation back to suction. 5. Seat OD = Face OD to allow uninterrupted cooling flow.
X8 Seal faces dry-running resulting in overheating. T10T PTFE vs ceramic - PTFE will "burn". High 6. If seat is tungsten carbide or silicon carbide, matt lap the running track. If not TC or SC, consider
torque on hard face material combinations can generate heat that can be transmitted to an changing.
elastomeric secondary seal resulting in hardening and burning. Secondary seals may "spin". 7. Consider use of cast iron (006) extended surface seat
X9 Chemical reaction with an oxidizing agent, e.g., nitric acid. - this would negate the need for steps 6 above.
X10 Insufficient flow to heat exchanger or cooled hollow seat resulting in X8. 8. Eliminate any areas for face and/or seat distortion, e.g., hand-lap seat landings.
X11 Over-compression due to incorrect assembly or wrong working length resulting in X8. This will also 9. Improve venting and point of circulation entry. Consider multi-point injection or reverse
occur if no allowance is made for the reverse of X1. Balance step fouling shaft. circulation where appropriate.
X12 Seal chamber pressure too low, resulting in X8. No product in pump when running (not primed). 10. If sealing compressor oils, ensure that water content in oil is checked and that the oil is changed
X13 Shot blasting with solids due to position and entry angle of product recirculation. at least every 3000 hours. Ensure good flow, and that oil is not 'foaming'.
X14 Ineffective or inadequate heating leads to high viscosity and product solidifying across sealing X44 Check that the seat landing is flat and free from any burrs or debris.
faces. Alternatively, fluid film increases in viscosity due to viscous shear irrespective of heat applied, X45 Complete an equipment check including amount of total axial float of rotating element.
i.e., dilatant, rheopectic or thermosetting (paint). Also ID chipping of face when product solidifies on X46 W rong material selection, or environment is too hot. Refer to X24. (Chipping on face ID).
atmospheric side. (Oxidation?). X47 Clearance between rotating element and seal chamber too small, causing solids to precipitate out
X15 Physical damage due to mis-handling or over-compression. from pumped product, e.g., 'hard water'.
X16 Excessive pressure rotation. (Coning inwards - chipping on OD). X48 Liquid in pump freezes, e.g., pump not drained or dried after testing on water, and then stored at
X17 Seal material not chemically resistant to product or contaminant, e.g., HF in HCl or EPT in hydrocarbon sub-zero temperatures or put on cryogenic duty.
X18 Material decomposed due to temperatures beyond its limitations. Usually applies to an X49 Heating left on to pump whilst still full of liquid with both suction and discharge valves closed.
elastomer. NB: Danger of HF acid formation from Fluorocarbon or Perfluoroelastomer that has X50 Hydraulic shock due to too rapid valve closure.
been taken to >400°C. Virgin PTFE above 230°C gives off toxic gas (sublimates). X51 Poor heat transfer to cooling water due to fouling (scaling) on cooling surfaces.
X19 Poor alignment of rotating element. Seat not square to axis of rotating element. X52 Check axial float of rotating element. Also ensure seat cannot move axially due to X40 or X50.
X20 Product flow in pumped system restricted on discharge side by valve or blockage causing excessive X53 Pipescale formation - especially during commissioning.
shaft deflection. X54 W ill usually exhibit other symptoms of a seal failure, e.g., abrasive wear because seals have been
X21 High pressure jetting from recirculation line on to rotating seal causing eccentric running. handled in a dirty environment. See X63.
X22 Vortex formation in seal chamber due to trapped vapour/gas, i.e., no vent hole at TDC. Also X7. X55 Gas entrained in product/sealant expands as pressure drops across fluid film - dry running & popping.
X23 Product is poor lubricant for sealing faces, e.g., water on PTFE vs ceramic or carbon vs stellite. X56 Possible indication of corrosion, e.g., tungsten carbide can sometimes take on a 'blue' surface
X24 Pumping against closed discharge for long time - causes unstable fluid film. W orsens factor X8 & X20. colouring. This is not due to overheating. Check other product-wetted areas of seat.
X25 Continual removal of passive film (usually in chloride environment) due to relative movement. X57 Ni-resist (007) will appear 'straw' or 'blue' coloured. This is due to overheating. Also refer to X24,
X26 Can occur in pusher seal thrust rings due to slack clearances in ball bearings. This same fault can especially in tanker-loading pumps.
cause fretting under dynamic secondary seals. X58 Anti-extrusion ring not fitted. Anti-extrusion ring fitted the wrong way round. Flat side of
X27 Friction welding or pick-up between materials, e.g., polished tungsten vs polished tungsten. anti-extrusion ring must always be presented to the o-ring, on the non-pressure or low
X28 Material combination being operated above and beyond its PV limit, resulting in X27. pressure side of the o-ring.
X29 W ill arise when clearances are too small for fluid flow, e.g., high pressure recirculation from X59 Incorrect shaft diameter, or excessive clearance for the secondary seal to the shaft. Also, excessive
discharge feeding to low pressure suction via a seal chamber with small clearances around seal. clearance for any static seals.
X30 Chemical reaction with binders in component materials, e.g., '171' in nitric acid, '025' in Sea Water. X60 Seal chamber full of solids, e.g., boiler water treatment compound injected as a 'lump' into the
X31 Possible indication of phase change (liquid to gas/vapour) across fluid film. suction side of the pump instead of downstream of the discharge flange.
X32 Usually occurs at point of maximum distortion accompanied by high seal leakage. X61 Differential expansion, especially between PTFE components, resulting in change in diameter,
X33 Interface stress too low. Seal either under-compressed, overbalanced or springs hung-up/broken. length or shape/section.
X34 Seal chamber pressure too close to product Vapour Pressure at Pumping Temperature. Check neck bush. X62 Thermal shock on ceramic or carbide seats caused by sudden change in temperature. Check
X35 Seal interface running in permanent gas pocket. Also refer to X22. operating cycles and valve operation.
X36 Can occur as narrow band of contact on seal OD where protrusion into seal chamber is fouling the X63 Abrasives in fluid film - use cyclone separator, hard faces, back-to-back seal or UpStream Pumping
rotating element, e.g., cover plate gasket extrusion. X64 Fluid film viscosity too high. Use heated seat, heated stuffing box jacket, or change to double seals.
X37 Solids precipitating out of product across interface, e.g., sodium hydroxide crystals. X65 Changes in speed can aggravate the condition by increasing shaft deflection when running at or
X38 Component fitted wrong way round, e.g., carbon face on rubber bellows seal. through a critical shaft speed.
X39 Bent shaft. W orn bearings. High shaft deflection. X66 Explosive decompression caused elastomer material to burst due to sudden expansion of trapped gas.
X40 Cooling water pressure too high - will distort seat, i.e., 1 bar for L/K seats; 2 bar for SC/CE seats. X67 Excessive heat generation at seal faces will cause positive rotation, excessive wear on ID of face and
X41 Seal incorrectly assembled, e.g., T209 thrust ring wrong way round. Face fractures common. seat with possible chipping on the face ID
X42 Insufficient clearances between seat spigot and seat housing, resulting in distortion of metal seats X68 O-rings can take permanent set. PTFE can cold-flow.
and cracking of ceramic or silicon carbide seats. X69 Uneven cooling. Consider tangential flush, multi-point injection, or distributed flush.
JAB/FAILURE1.XLS John A Blaber. DATE OF ISSUE: 20/08/97

Mechanical Seals
Pump Operating Conditions

Loss of Suction
Dead Head Operation
Stability of Flow (Type of Control)
Vibration
Run Out Flow
Variable Products
Mechanical Seals
Support System Design

Appropriate for Type of Seal
Reliable
• Prevents Pressure Reversal
• Keeps Seal Clean
• Keeps Seal Cool
• Prevents Flashing
• Refillable Without Introducing Contaminates
or Reversing Pressure
• Acceptable Barrier Fluid

Mechanical Seals
Seal Performance Analysis

Definition of Seal Failure
Undesirable passage or leakage of fluid past sealing

components resulting in dilution of a process stream,
poisoning of the environment, or creation of an
immediate safety hazard. Actual threshold for "failure"
criteria is defined by the user or a governmental agency
at the local, state, or federal level.
Mechanical Seals
Acceptable Leakage Rates

Varies depending on application
• Environmental considerations/legislation
Increasing leakage.
• High hazard or pollution risk

• Process contamination
• Minimum levels of cleanliness
• Economic considerations
• Exceeding removal capacity
• Exceeding supply capacity

Mechanical Seals
Leakage - Newtonian Fluids

Diameter (mm)
100 Speed (rpm)
80
00
15
60
30 00
18
00
00
40
36
30
20
Pressure (bar g) L e a k a g e (m l/h ) .

0 2 4 6 8 10 12 14 16 18 20 0.01 0.1 1 10 100
Balanced Seal Unbalanced Seal
Mechanical Seals
Normal Operational Life of the Seal
First Few
Hours
Incidence of Failures
Time

Mechanical Seals
Mechanical Seal Reliability

Affected by:
Design Operation
Seal Pump
Pump Support System
Support System Flush System
Bearing
Coupling
Flush
Installation
Seal
Pump
Mechanical Seals
Seal Life - MTBF
Failure (%) Percentage of Seals
Survey of large UK refinery
40
Number of Seals = 3757
Period : 1988 - 1991
30
20
10
0
0 5000 10000 15000 20000 Over
Ref: P Connor - 1992
Installed Life (Hours) 24000
Mechanical Seals
Seal Design
Type of Seal Balance Ratio
Pusher/Bellows Heat
Leakage
Arrangement of Seal Life
Single/Dual
Inside/Outside Materials
Pressurized/Unpressurized Rotating Face
Flush Arrangement Stationary Face
Cooling/Cleaning/Isolating Adaptive Hardware
Seal Face Geometry
Flat Face
Spiral Groove
Hydropadded
Mechanical Seals
Pump Design
Type of Pump Brg Design
Overhung Anti friction
Between Brgs Sleeve
Tilt Shoe
Stuffing Box Design
Bore Process Parameters
Length Temperature
Flush Connections Differential Pressure
Actual Pressure
Shaft Design
Diameter Hydraulics
Deflection Close to BEP
Adequate NPSHA
Coupling Design
Mechanical Seals
Flush Design
Appropriate for Seal
• Single and Dual Unpressurized
Proper Flow
Proper Temperature
Proper Distribution
Clean
Mechanical Seals
Seal Installation
Free from Contaminates
Properly Set at Working

• Drop Both Seals for Dual
Seal Chamber Condition

• Face Perpendicular to Shaft
• Concentric Around Shaft
• Sealing Surface in Good Condition
• Flush Hole in Proper Location
Thermal Growth Offset

Mechanical Seals
Pump Installation
Alignment (Hot and Cold)
Soft Foot
Coupling Spacing (Axial Pull)
Piping
Mechanical Seals
Support System Operation

Flush System Operation
Proper Flow
Proper Pressure
Proper Temperature
Cleanliness
Free of Contaminants

Mechanical Seals
Seal Performance Analysis

Definition of Seal Failure
Undesirable passage or leakage of fluid past sealing
components resulting in dilution of a process stream,
poisoning of the environment, or creation of an
immediate safety hazard. Actual threshold for "failure"
criteria is defined by the user or a governmental agency
at the local, state, or federal level.
Mechanical Seals
Seal Failure Causes
Operation - 42%
Equipment - 26%
System Design - 24%
Incorrect Seal Selection - 8%

Mechanical Seals
Diagnostic Path
Failure Mode
• Criteria, volume, when
System Status
• Changes, modifications, damage
History
• Run length, symptoms, trends, system influences
System and Equipment Checks
Disassembly and Visual Inspection
Comprehensive Examination
Mechanical Seals
Failure Mode
Criteria for Failure
• VOC concentration, level or pressure alarm,
visible, blowout
Operating Status
• Static, dynamic, static and dynamic
Where
• Across seal components, under sleeve,
gaskets and fittings
When
• Operational mode, upsets, startups
Mechanical Seals
System Status
Equipment
• Modifications, vibration, pipe stress, shaft speed
Other Mechanical
• Piping, foundation, driver
Process
• Fluid, operating conditions, contaminants
Operation
• Cycling, procedures, lineup, control, upsets
Mechanical Seals
Life Cycle History

Noise (Chirps, Chatters, Pops)
• Continuous, periodic, carbon dust
Temperature of Seal Chamber Fluids
Leakage
• Continually, startup, excursions
Seal Life Change
• Gradual, step, erratic
When Does Failure Occur
• Startup, seasonal, human, conditions, fluid
Length of Run
• Immediate failure, < 1 month, < normal or desired
Mechanical Seals
System and Equipment Checks

Seal Flush Circuit
• Fouling, damage, lineup
Buffer or Barrier Fluid System
• Debris, pipe routing, damage, fouling
Barrier Fluid Pressure Control
Equipment Mechanical Condition
• Runout, fits, balance, wear
Process Circuit Condition
• Pipe stress, fouling, minimum flow
Mechanical Seals
Disassembly and Visual Inspection

General Practice
• Take notes, preserve evidence,
decontamination method
Removal and Disassembly
• Leak paths, setting, fouling, hang-up, wear,
missing parts
Face Inspection
• Contact pattern, location and type of damage
Secondary Seals
• Handling, Chemical attack, thermal,
wear, pressure
Adaptive Hardware
• Wear, breakage, cracks, fretting, corrosion
Mechanical Seals
Seal Component Visual Analysis

Seal Face
• Contact pattern, heat checking, wear, blistering
Seal Ring in General
• Fracture, erosion, fouling, chemical attack
Secondary Seals
• Handling, extrusion, wear, chemical
Adaptive Hardware
• Fretting, corrosion, drive
Metal Bellows
• Fatigue, stress corrosion cracking, distortion
Mechanical Seals
Comprehensive Examination
In House Methods
• 10X to 30X magnification
• Flatness check with optical flat
• Pressure test
• Dye penetrant
Surface Traces -
• Both Radial & Circumferential
Outside Lab Analysis
• Fracture analysis
• Corrosion mechanism
• Material analysis
• Change in physical properties
Mechanical Seals
1) Static Gaskets / O-Rings
2) Tertiary Seal
3) Secondary Seal
4) Primary Seal
Mechanical Seals
Static Gasket / O-Ring Leakage

EFFECT POSSIBLE CAUSE CORRECTIVE ACTION
Leaks immediately 1) Not Fitted!! Install new, check parts list.
Worsens with increase
in pressure. 2) Damaged on Installation Check Installation, assembly
(mechanical damage) procedure. Consider using a
temporary adhesive to hold in
position.
3) Incorrect / insufficient Check Installation, 2 point
loading (gasket) location, etc.
Check gasket areas and design
of location groove / bolting load.
Leakage initially zero, 1) Chemical Attack Check duty conditions.

but gradually worsens Select alternative material.
with time
2) Thermal Damage Check duty temperatures.
Increase cooling.
Select alternative material.
3) Over-aged o-rings Check supply date &
stock rotation.

Mechanical Seals
Tertiary Seal Leakage

Leaks immediately 1) Damaged on Installation Check Installation, assembly
Worsens with increase (mechanical damage) procedure. Check for correct
in pressure. lead-on/chamfer, surface quality.
Use adequate & correct lubricant.
2) Damaged on start-up due Check seat housing dimensions.
to seat rotation. Consider pinning/clamping seat.
(mechanical damage) Investigate cause of friction loss.
Leakage initially zero, 1) Chemical Attack Check duty & correct lubricant used
but gradually worsens Select alternative material (may
with time involve change of seat design).

Increase cooling to seal.
Ensure cooling on whilst pump is
stationary.
Check for obstructed cooling lines
Check for dry running.
Should balanced seal be used?
Consider alternative material.
Mechanical Seals
Secondary Seal Leakage

Leaks immediately 1) Damaged on Installation Check Installation, assembly
Worsens with increase (mechanical damage) procedure. Check for correct
in pressure. lead-on/chamfer, surface quality.
Use adequate & correct lubricant.
Leakage initially zero, 1) Chemical Attack Check duty & correct lubricant used
but gradually worsens Select alternative material (may
with time involve change of seat design).

Increase cooling to seal.
Ensure cooling on whilst pump is
stationary.
Check for obstructed cooling lines
Check for dry running.
Should balanced seal be used?
Consider alternative material.
3) Mechanical Damage Check shaft alignment & s/box face

(wear) squareness.
Ensure seal positively driven.

Mechanical Seals
Primary Seal Leakage

SYMPTOM POSSIBLE CAUSE
Seal spits and sputters Fluid film vaporising.
(Face Popping)
Seal drips steadily. Faces not flat

Carbon face blistered
Thermal distortion
Spring failure
Erosion / Corrosion of drive mechanism.
Stuffing box face and/or seat not square.
Seal squeals. Inadequate lubrication.
Carbon dust accumulation. Inadequate lubrication.

Fluid film evaporating.
Short seal life. Abrasive fluid.

Seal running too hot.
Incorrectly aligned equipment.
Mechanical Seals
Full Contact Pattern
Contact
Pattern
Mating Ring Primary Ring

Mechanical Seals
Wide Contact Pattern
Drive Notch
Wear
Contact Wider Than Width
of Primary Ring Face
Mechanical Seals
Eccentric Contact Pattern
Possible Damage from

Contact with Shaft

Mechanical Seals
Heavy Outside Diameter Contact
Possible
Edge Chipping
Rotation Due to
Pressure
Heavy to Light Contact

Moderate Contact
Mechanical Seals
Heavy Inside Diameter Contact

Possible
Chipping
Rotation Due to
High Temperature
Light Heavy to
Contact Moderate Contact

Mechanical Seals
One High Spot

Full contact through 360° with one visible high spot on
mating ring surface. Wear at drive notches on primary
ring may also be noted.
The mating ring misaligned, often due to a high

antirotation pin.
Mechanical Seals
Wear Pattern Through 270°

Full contact through approximately 270° as seen on mating ring surface.
Pattern fades away at low spot. The primary ring may show "wire drawing"
or "wire brushing" in a position where the ring lined
up with a low spot on the mating ring if the rotor was left idle while
under pressure.
The mating ring is being distorted mechanically.
No Contact
Possible Erosion From (Wire Possible Erosion

Drawing) if Allowed to Remain from Trapped Solids
Stationary Under Pressure (Wire Brushing)
Mechanical Seals
Two High Spots on Mating Ring

Two large contact spots are noted while the pattern fades away between contact
areas. The primary ring may show "wire drawing" or wire brushing" in a position
where the ring lined up with low spots on the mating ring if the rotor was left
idle while under pressure.
The mating ring is being distorted mechanically. The split line on axially split
pump casings is most suspect.
High Spots
Excellent
Condition
After Short Run
No Contact
Erosion (Wire Drawing) Possible Erosion from
Occurs While Stationary Trapped Solids
Mechanical Seals
Gland Bolt Distortion

Contact spots noted at gland stud locations on mating ring.
Mating ring is being distorted mechanically by uneven gland surface.
Clamping load provided by the gland bolting is distorting the gland.
Most often the gland nuts have been overtightened.
No Contact
Contact at
High Spots
Near Gland Bolts No Unusual Wear

Mechanical Seals
Heat Checking of Entire Face

Many small radial surface cracks through entire face contact area normally
visible to the eye. High wear of one face, typically the carbon face, is
likely as it will be ground down by the cracked surface.
Squealing, chirping, or popping will often be noted as well before the

seal starts to leak. Carbon dust may be visible on the atmospheric side
of the seal.
Caused by inadequate fluid

film at the seal interface.
This usually results from
inadequate vapor pressure
margin or flush rate on
a specific application. Small
Surface
Cracks
Mechanical Seals
Heat Checking 180° From Flush Port

Thermally distressed area through approximately 1/3 of the contact
pattern. Distressed area is 180° from the flush port.
The fluid film inadequate at the seal interface on the side opposite
the flush injection point. Vapor suppression of the liquid in the
seal chamber is not adequate to maintain an adequate film at the
seal interface.
Undamaged Surface
at Flush Inlet
Heat Checked Area

Mechanical Seals
Patches of Heat Checked Surface

Two to six patches of thermally distressed surface. High wear on one
face, typically a carbon face, is also likely.
The sealed liquid, probably a light hydrocarbon, is vaporizing at or near

the seal interface.
Good Contact
Pattern
Distressed
Surface
or Hot Spot
Mechanical Seals
Abrasive Wear
High wear of the mating ring through 360°. A groove will have some depth
and have a “phonograph” appearance.
Caused by abrasive particles which have become imbedded in the softer

primary ring. Grooving can also occur when both faces are metallic and
lubrication from the flush liquid is inadequate.

Mechanical Seals
Blistering
The surface of the carbon primary ring is covered with
small irregular holes where pieces of material have broken
away from the main body. Excessive wear of the drive
mechanism and heat checking of the hard face may also be
evident.
Caused by high stresses in the interface which exceed the

rupture strength of the carbon ring. High interface
temperatures, trapped gas, or highly viscous fluids can
result in this phenomenon.
Mechanical Seals
Bond Failure
A blistered or peeled surface layer on faces which have
been coated with a hard material. Some of the blistered
areas will probably have pulled away leaving a sharp
cutting edge which will damage the other seal face.
Coated parts should be used with extreme caution. Bond

strength is rarely as strong as the base material strength
and is usually very weak in comparison. Chemical attack of
the base material can occur as the sealed fluid passed
through a porous coating.

Mechanical Seals
Fractured Seal Ring

Cracks extend all the way through the part. The part may be in
multiple pieces.
Often caused by mishandling or improper assembly. Cracks which

originate from points of drive engagement probably signify excessive
torque. Thermal shock is also a likely cause. Uneven loading of brittle
face components which are in tight or shrink fit designs are definitely
suspect.
Mechanical Seals
Erosion of Seal Parts

Severe erosion of the part on its OD, a fairly clean hole
passing through the ring may be observed on stationary
parts.
Abrasive fines in the seal flush liquid which is being

directed at the part in question at a high enough velocity
to erode the part.

Mechanical Seals
Leaching
Seal ring material softer than normal with matted

appearance on surface which is exposed to the seal fluid.
Caused by chemical attack of the binder on carbide

and ceramic materials, or the filler on carbon graphite
seal rings.
Mechanical Seals
Chemical Attack
Carbon seal ring becomes very soft with irregular surface.

Metallic materials exhibit areas of attack.
Caused chemical attack of the seal ring and any binder or

filler if present. Highly oxidizing acids or concentrated
caustics will often cause this to happen.

Mechanical Seals
Coking
A hard brittle material between seal and shaft sleeve
which may “lock” the seal to the sleeve.
Caused by oxidation, cracking, or stripping of hot
hydrocarbon fluids resulting in a hard brittle residue which
impedes seal tracking ability.
Application of a steam quench often cures this problem.
Solid Deposits “Coking”

Mechanical Seals
Crystalline Deposits
Grainy, crystalline substance which has built up on either side of the
seal, on the faces, in the springs, or bellows convolutions. The seal
assembly may be frozen to the shaft sleeve by the deposits. Abrasive
wear of the faces will probably also be noted.
Caused by fluids which have abrasive qualities or which form crystals in

the presence of heat or air.
Deposits
Mechanical Seals
Polymer Deposits
Soft, sometimes gummy or rubber like substance which has built up
on the process side of the seal, on the faces, in the springs, or
bellows convolutions.
Polymer may be present in the process stream or can be formed in

normally clean process streams in the presence of heat.
Single spring seals or designs with isolated springs are often

recommended in polymer laden process.
Deposits
Mechanical Seals
Cuts or Tears on Secondary Seal

Cuts or tears across the width of secondary seal rings such as
O-rings, U-cups, V-rings and soft packing.
Normally caused by mishandling during assembly or product defect

present at time of procurement.
Always inspect parts for visible defects and inclusions before

installation. Mounting surfaces should not have sharp edges or burrs
which could damage these parts.
Cut
Mechanical Seals
Extrusion
A thin lip has formed on the entire ID or OD of the O-ring.
Some materials may exhibit a shredded appearance.
Often caused by an application where pressure is beyond the

design limitations for the material in use. Also, will result from
thermal expansion of the material if groove width is too narrow,
or from swell caused by chemical interaction with material.
Normal
Lip
Ring
Shredding
Mechanical Seals
Worn Surface on O-Ring

One surface will be flat from material being abraded or burned
away. Some of the ring may adhere to, or discolor the contacting
surface.
Caused by sliding contact at a point where static contact was

intended. Torque is too high for the contact friction between the
secondary seal and the mating component to resist.
Flat
Normal
Ring

Mechanical Seals
Hard or Cracked Elastomer

The part is hard and has several cracks, it is easily broken when
bent by hand. Damage may be on process side, atmospheric side,
or only in areas in contact with a specific part.
Temperature too high for material in use. Possible chemical attack

if the damage is evident only on the process side of
the part.
Flat Cracks
Normal
Surfaces
Ring
Mechanical Seals
Compression Set
The part is permanently deformed with flat sides on the sealing
surfaces.
Caused by improper design of parts which houses the O-ring
resulting in over compression of the material or by chemical attack
(swelling) of the material while in service.
Compression set is the most common cause of O-ring failure.

If it occurs on a dynamic O-ring the ability of a primary ring to
track will be impaired.
Normal
Ring Flat
Surfaces
Mechanical Seals
Chemical Attack on Elastomer

The part has become more soft or hard than normal, has swelled,
formed blisters, or portions have been totally deteriorated.
The elastomer being used is not chemically compatible with

the fluid being sealed in the temperature range in which it is
being used.
Surface Degradation
"Orange Peel"
Swelling
Mechanical Seals
Blistered and Ruptured Elastomer

Many small blisters and ruptures throughout the part caused by
explosive decompression.
A fluid which is a gas at atmospheric pressure, is being sealed

under high pressure and over time is absorbed into the elastomeric
material. When the pressure is released too quickly
the fluid which is trapped in the elastomer expands rapidly
resulting in damage to the part.
Blister Rupture

Mechanical Seals
Fretting
Metal surface (usually a sleeve) which has been in contact
with the secondary seal has a rough and worn appearance.
Fretting occurs when continuous small movements

inherent to a dynamic secondary seal occur while in
contact with a metal shaft sleeve or shaft. True fretting
involves adhesive wear in the area affected. A slight
amount of this wear probably occurs between the
secondary seal and metal part as asperities from the new
metal surface are broken off. The bulk of the wear
generally occurs as the worn particles from the metal for
abrasive fines from other sources embed in the secondary
seal and proceed to grind the component.
Mechanical Seals
Worn or Distorted Drive Components

Drive pins or lugs are damaged. Increase of contact
between drive and seal ring are worn, abraded, or
chipped.
Caused by excessive relative movement between drive

components and the driven part. High torque caused by
excessive face loading or lack of a sufficient lubricating
face film.
Drive Pin Wear Chipped Drive Slot or

Hole on Seal Ring

Mechanical Seals
Broken or Distorted Coil Springs

Springs are distorted, cracked, broken, corroded or missing.
Stress corrosion cracking, general corrosion, fatigue, excessive shaft
speed, and over extension or compression of the spring.
Single coil springs should be installed in the proper orientation if
they are of unidirectional design.
Mechanical Seals
Metal Bellows Separation

at One End
Caused by dry running condition do to inadequate face lubri-

cation which results in excessive deflection of the bellows.
Low cycle fatigue occurs at a high stress point in the bellows
unit.
Dry running for even short periods of time will often result in
low cycle fatigue of the bellows. Metal bellows seals should
be applied to services where face lubrication and pressure
are within published limits for the seal.

Mechanical Seals
Cracks in Metal Bellows

The bellows has cracks in one or more locations at any
point on the bellows, normally at or near a weld. May only
be detectable in a leak testing device.
AM-350 bellows are susceptible to stress corrosion cracking

in environments where chlorides are present. Alloy-718
will suffer from sulfide cracking. It is important to inform
the seal manufacturer of the presence of these conditions
at specification.
Mechanical Seals
ID or OD Contact of
Metal Bellows Seals
Caused by differential expansion of the material used for
the primary ring and the retainer in which it is housed with
an interference fit. This results in the primary ring face
not being
flat to varying degrees as the process temperature varies.
After Shrink Fit After Lapping After Heat Up

I.D. High O.D. High

Mechanical Seals
Information to Collect
• Modus Operandi of • Failure Initiated or Following
Equipment (Including Start / Process Change.
Stop Sequences). • Failure Related to
• Maintenance Arrangements. Operational Change.
• Vibration Signature. • Start / Stop History and
• Prior to Start-Up Failure. Operation.
• Cartridge Pressure Test. • DE / NDE Bias.
• Dynamic Failure. (< 1hr) • MTBF (Consistent or
• Operating Hours? Irregular).
• Sudden Failure or • Comparable Duty with
Progressive Leakage Different History.
Increase. • Anything Unusual?.
Mechanical Seals
Failed Seal New Seal

Mechanical Seals
Summary
Mechanical Seals
Summary - 2
Mechanical seals prevent leakage
Rubbing faces are lubricated by fluid film
Fluid film must be present, stable, clean, reasonable
temperature and viscosity
Seals must be fitted in clean conditions and with
accuracy
Two types of seal: pusher and non-pusher. Each has its
advantages.

Mechanical Seals
Summary - 3
Seal life (MTBF) affected by:
• condition of pump
• state of pumped product in pump
• state of pumped product through the faces
• dry running
• excessive heat generation/inadequate cooling
• pressure peaks
• change in process fluid
• sudden temperature changes
• stop/start
Mechanical Seals
Summary - 4
Fit mechanical seals accurately and in clean conditions
and operate pumps with a little care and
understanding, and the seals will last for years
If a seal fails prematurely, carry out detailed failure
analysis before fitting a new one.

ME140-IH-03-07 Mechanical Seals Vol-1 - R

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QAF011 Rev. 04 Jan.

Haward Technology Middle East

March 10-14, 2007

Haward Technology Middle East

The information contained in these course notes has been compiled

Haward Technology offers no warranty, guarantee or representation

Haward Technology has no responsibility in connection therewith;

Section 2 Mechanical Seal Basics

Section 3 Heat Temperature Control

Section 4 Drive Methods

Section 7 Fluid Film

Section 8 Multiple Seals

Section 10 The Environment of a

Section 11 Failure of Mechanical Seals

Section 12 Dry Seals

Section 13 API Flushing Plan

Section 14 API 682 Mechanical Seal

 Gland Packing Brief

PIONEERS IN TECHNOLOGY TRANSFER

Mr. Gamal Attalla Mechanical Seals

Section 1a Haward Technology Middle East 2

Section 1a Haward Technology Middle East 3

Why do we need a seal?

Section 1a Haward Technology Middle East 4

Old Style Sealing Using Packing

Section 1a Haward Technology Middle East 5

Section 1a Haward Technology Middle East 6

Section 1a Haward Technology Middle East 7

Section 1a Haward Technology Middle East 8

Section 1a Haward Technology Middle East 9

Section 1a Haward Technology Middle East 10

Section 1a Haward Technology Middle East 11

Section 1a Haward Technology Middle East 12

Section 1a Haward Technology Middle East 13

Section 1a Haward Technology Middle East 14

Section 1a Haward Technology Middle East 15

Section 1a Haward Technology Middle East 16

Product Gland nuts

Section 1a Haward Technology Middle East 17

Section 1a Haward Technology Middle East 18

Abrasives Inject clean fluid at 1

Flow keeps abrasives

Section 1a Haward Technology Middle East 19

 Disadvantages of GSP  Advantages of GSP

Section 1a Haward Technology Middle East 20

• Low initial cost • High running costs and

Section 1a Haward Technology Middle East 21

Section 1a Haward Technology Middle East 22

pH ranges of some of the most common gland packing materials.

K40 Pre-Formed Rings

Problems with Gland Packing

Section 1a Haward Technology Middle East 27

Gland Packing Installation

“Neville and the Problem Pump”

Section 1a Haward Technology Middle East 28

Section 1a Haward Technology Middle East 29

Advantages of Gland Packing

 Inexpensive sealing medium

Section 1a Haward Technology Middle East 30

Dis-Advantages of Gland Packing

Section 1a Haward Technology Middle East 31

Packing vs. Mechanical Seals

Section 1a Haward Technology Middle East 32

Gland Packing Brief

Disadvantages of GSP Advantages of GSP

Inexpensive sealing medium

Will seal with invisible leakage. On difficult

LOW HEAT GENERATION

AN ORGANIZATION THAT PROVIDES TECHNICAL

EVERY MATERIAL HAS IT’S LIMITATION

READ THE SMALL PRINT - NOT ALL MATERIAL CAN

RATHER SAFE THAN SORRY...

LONGER BOLTS MEAN LESS

THE MORE MOVEMENT, THE MORE WEAR

WEAR = VOLUME LOSS...

WEIGHT OF SPINDLE CAUSES UNEVEN

ANY TWO PEOPLE PACK VALVES DIFFERENTLY