SUNDYNE ®

FIELD ENGINEERING BULLETIN

Effective Date: January 1996 Document Number: 40.20.02
Supersedes: Revision Level
Title: HMP-3000 GEARBOX SEAL IMPROVEMENT Page 1 of 3

SUMMARY

The Sundyne HMP-3000 product was introduced in 1984 with a circumferential gearbox seal. While many
installations have performed satisfactorily, others have not, especially under adverse operating or process upset
conditions. To address this issue, an extensive design program to improve the Sundyne HMP-3000 gearbox seal
was initiated. We are pleased to announce that a superior gearbox seal has been developed that will significantly
decrease gearbox oil leakage, improve pump reliability, and can easily be converted in the field. The objective of
this bulletin is to describe the new improvements, testing, and necessary parts to upgrade the pump.

DESIGN IMPROVEMENTS

The current circumferential Sundyne HMP-3000 gearbox seal (Figure 1) utilizes a spring loaded close radial
clearance carbon stationary sliding against a hardened shaft sleeve to prevent gearbox oil leakage. During normal
operation, the drain port, which collects any gearbox oil leakage, process leakage from a single seal, or outboard
dual seal buffer leakage, is open to atmosphere. This drain area is sufficiently sized to accommodate
approximately 10 gpm (2.3 m³/hr) of leakage flow before any significant pressure can build up in the drain cavity.
Unfortunately, even with the large drain cavities, operational situations have occurred that created back pressure
on the gearbox seal, and exceeded the reverse pressure capability of the circumferential seal.

To take advantage of advancements in mechanical seal technology, a mechanical face seal with premium blister
resistant carbon and tungsten carbide hardface materials (Figure 2) has been incorporated into the Sundyne HMP-
3000 to replace the current circumferentail gearbox seal arrangement. Features and advantages of the new
mechanical seal are briefly described.

1) Radial shaft position does not affect the new style axial mechanical face seal. Position of the shaft will
change with process flow variations and degrade the performance of the circumferential seal.

2) Selecting an inside diameter pressurized seal configuration takes advantage

of the natural centrifugal forces between the stationary and rotating components
to “draw in” a small amount of gearbox oil for seal face cooling and
lubrication purposes. This results in a very controlled and predictable
seal face environment to provide long life.

3) During excessive process or buffer seal leakage situations, the pressure in the gearbox seal cavity
could increase above atmospheric conditions. This situation has been addressed by optimizing the
secondary o-ring balance location such that the seal faces will still remain closed in a reverse pressure
mode.

4) Controlling seal face loading is critical to maximize sealing integrity throughout the seal’s life. The new
Sundyne HMP-3000 gearbox seal incorporates a unique constant force spring to control seal face load
during all pump-operating conditions. Since the seal face loading remains constant, regardless of
shaft position or wear, seal life is maximized.

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Effective Date: January 1996 Document Number: 40.20.02
Supersedes: Revision Level
Title: HMP-3000 GEARBOX SEAL IMPROVEMENT Page 2 of 3

5) Elastomer material for the secondary o-ring can be selected to avoid process vapor damage.
Gearbox lubricant compatibility must of course be considered in selecting the o-ring.

6) The hard face material is a plasma spray tungsten carbide face integral with the shaft sleeve. Blister
resistance, excellent wear characteristics, and optimum face alignment are achieved.

QUALIFICATION TESTING

Reverse Pressure. If the pressure in the drain cavity increases above atmospheric pressure, the new gearbox
seal faces will remain closed. Testing confirmed successful reverse pressure capability up to 300 psi (2.07
kPa) on liquid and gas with no noticeable leakage into the gearbox. In the event of a reverse pressure situation,
leakage into the gearbox can be estimated from Figure 3. The gas leakage curve may be used for fluids that
vaporize at atmospheric conditions.

For example: If a process or outer buffer seal should develop a 30 gpm (6.8 m3/hr.) leak, the back
pressure on the gearbox seal would increase to almost 30 psi (4.4 kPa), resulting in only approximately
0.8 ml/hour leakage into the gearbox.

Though the quantity of leakage is very small, it is recommended each application be evaluated considering the
particular pump operating situation, process fluid, etc., to determine the appropriate level of condition
monitoring. For instance a pressure switch in the drain cavity, to provide orderly pump shut down may be
advisable for hazardous or toxic fluids.

Leakage and Life: Seal leakage and life were evaluated together requiring several endurance runs to properly
establish the seal nose wear and leakage over time. Careful face height measurements were taken at key
intervals to allow accurate extrapolation. Leakage will be less than 1 pint per week (.13 liter/week), and life is
expected to be in excess of 25,000 hours or 3 years, provided the gearbox oil remains free of contaminants.

Blister Resistance: Blistering of carbon seal faces can lead to excessive seal leakage and short life. Selection
of the optimum materials was confirmed via independent blister testing to insure blister free operations.

CONVERSION PARTS

New pumps will of course already include the new seal design. Conversion from the circumferential
configuration to the new style simply involves removing the old seal and shaft sleeve, and installing the new
seal and new shaft sleeve. No shaft, impeller, or other process seal parts are affected. The new seal offers
many important improvements; the circumferential design will no longer be available.

Seal: SE04FA18X (X=Secondary o-ring material code)

Sleeve: Due the many possible configurations (single double, tandem), contact the Hamilton
Sundyne Corporation Customer Service Department.

Note: Slinger (SL03FA02) used in the circumferential style design Must Be Removed.
Effective Date: January 1996 Document Number: 40.20.02
Supersedes: Revision Level
Title: HMP-3000 GEARBOX SEAL IMPROVEMENT Page 3 of 3

CONCLUSIONS

The new HMP-3000 mechanical face gearbox seal will:

♦ Withstand reverse pressure without opening.

♦ Minimize gearbox oil leakage.
♦ Greatly increase seal life.
♦ Avoid premature gearbox seal blistering.
♦ Easily convert from the old style design.