BEARING & LUBRICATION

Knowledge (Contribute and Participate - Do but with Help)

Bearing
1. What is the function(s) of bearing?
(1) To carry / support weight / loads (radial, thrust and combination) subjected on rotor
(2) Maintain correct radial clearance between rotor and casing
(3) Permit smooth movement between surfaces – reduce friction that can induce heat and
wear rate

2. List different types of bearing

(1) Hydrodynamic bearings – plain bearings, journal bearings
(2) Anti-friction bearing

3. Describe how the following bearing works:

Journal Bearings (Plain Journal, Tilting Pad, elliptical,
lemon bore, etc)

Plain Bearing
The plain bearing is the simplest and most common design with a high load carrying capacity and
the lowest cost. This bearing is a simple cylinder with a clearance of about 1-2 mils per inch of
journal diameter. Due to its cylindrical configuration it is the most susceptible to oil whirl. It is a
fairly common practice during installation to provide a slight amount of "crush" to force the
bearing into a slightly elliptical configuration.

Tilting Pad
Tilting pad bearings is a partial arc design. This configuration has
individual bearing pads which are allowed to pivot or tilt to conform with
the dynamic loads from the lubricant and shaft. This type of bearing is a
unidirectional design and is available in several variations incorporating
differing numbers of pads with the generated load applied on a pad or
between the pads.

Lemon Bore
The lemon or elliptical bore bearing is a variation on the plain bearing where the bearing
clearance is reduced on one direction. During manufacture this bearing
has shims installed at the split line and then bored cylindrical. When the
shims are removed the lemon bore pattern is results. For horizontally
split bearings, this design creates an increased vertical pre-load onto
the shaft.

This bearing has a lower load carrying capacity that plain bearings, but
are still susceptible to oil whirl at high speeds. Manufacturing and
installation costs are considered low.
Thrust bearings (Flat face, tapered land, tilting pad, etc.)

Thrust bearing are used to support axial loads, such as vertical shafts. Spherical,
conical or cylindrical rollers are used; and non rolling element bearings such as
hydrostatic or magnetic bearings see some use where particularly heavy loads or low
friction is needed.

Ball Thrust Bearings

Ball thrust bearings provide optimum performance in high-speed applications,
particularly where loads are generally lighter. Timken offers standard axial (type
TVB) and angular contact (types TVL and DTVL) ball thrust designs

Spherical Roller Thrust Bearings

Spherical roller thrust bearings (type TSR) are ideal for applications where
conditions include heavy loads, difficulties in establishing or maintaining housing
alignment and problems with shaft deflection.

Cylindrical Roller Thrust Bearings

Cylindrical roller thrust bearings are designed to operate under heavy loads at
moderate speeds. Special design features are available for even higher rotational
speeds. Types include standard (type TP) and aligning washer (type TPS).

Tapered Thrust Bearings

Tapered thrust bearings include rollers that have conical sections. The
bearing design ensures a true rolling motion for maximum bearing life and load-
 carrying capacity. Available in both standard (heavy duty, v-flat, screw down,
oscillating and crossed roller) and custom designs.

Needle Thrust Bearings

Needle roller and cage thrust assemblies are designed to transmit a thrust
load between two relatively rotating objects while greatly reducing friction. Ideal
for automotive, agricultural and construction equipment.

Tilting Pad Thrust Bearing

Tilting pad bearings is a partial arc design. This configuration has individual bearing pads
which are allowed to pivot or tilt to conform with the dynamic loads from the lubricant and shaft.
This type of bearing is a unidirectional design and is available in several variations incorporating
differing numbers of pads with the generated load applied on a pad or between the pads.

Rolling Element or Anti-friction Bearings (Ball, roller,

deep groove, angular contact, etc)

A rolling-element bearing is a bearing which carries a load by placing round

elements between the two pieces. The relative motion of the pieces causes the round
elements to roll with very little rolling resistance and with little sliding. There are many
types of rolling-element bearings, each tuned for a specific kind of load and with specific
advantages and disadvantages. For example:
Ball bearings

Ball bearings use spheres instead of cylinders. Clever use of surface tension
allows balls of high accuracy to be made much more cheaply than comparable cylinders.
Ball bearings can support both radial (perpendicular to the shaft) and axial loads (parallel
to the shaft). For lightly-loaded bearings, balls offer lower friction than rollers. Ball
bearings can operate when the bearing races are misaligned.

Roller bearings

Common roller bearings use cylinders of slightly greater length than diameter.
Roller bearings typically have higher radial load capacity than ball bearings, but a low
axial capacity and higher friction under axial loads. If the inner and outer races are
misaligned, the bearing capacity often drops quickly compared to either a ball bearing or
a spherical roller bearing.

Roller bearings are the earliest known type of rolling-element-bearing, dating back to at
least 40 BC.

Needle bearing

Needle roller bearings use very long and thin cylinders. Since the rollers are thin,
the outside diameter of the bearing is only slightly larger than the hole in the middle.
However, the small-diameter rollers must bend sharply where they contact the races, and
thus the bearing fatigues relatively quickly.
Tapered roller bearing

Tapered roller bearings use conical rollers that run on conical races. Most roller
bearings only take radial loads, but tapered roller bearings support both radial and axial
loads, and generally can carry higher loads than ball bearings due to greater contact area.
Taper roller bearings are used, for example, as the wheel bearings of most cars, trucks,
buses, and so on. The downsides to this bearing is that due to manufacturing
complexities, tapered roller bearings are usually more expensive than ball bearings; and
additionally under heavy loads the tapered roller is like a wedge and bearing loads tend to
try to eject the roller; the force from the collar which keeps the roller in the bearing adds
to bearing friction compared to ball bearings.

Spherical roller bearings

Spherical roller bearings use rollers that are thicker in the middle and thinner at
the ends; the race is shaped to match. Spherical roller bearings can thus adjust to support
misaligned loads. However, spherical rollers are difficult to produce and thus expensive,
and the bearings have higher friction than a comparable ball bearing since different parts
of the spherical rollers run at different speeds on the rounded race and thus there are
opposing forces along the bearing/race contact.

Magnetic Bearing

A magnetic bearing is a bearing which supports a load using magnetic levitation.

(A high-speed rail technology by which a train can travel free of friction at speeds of 480
kilometers (300 miles) per hour or more. The train is suspended on a magnetic cushion
about half an inch above an elevated magnetic track, whose moving magnetic field
alternately attracts and repels magnets mounted on the train, which is pushed and pulled
along by this process). Magnetic bearings support moving machinery without physical
contact, for example, they can levitate a rotating shaft and permit relative motion without
friction or wear.
Servo Fluid Control (Pressurized) Bearing

Pressure Dam
A pressure dam bearing is basically a plain bearing which has been
modified to incorporate a central relief groove or scallop along the top half of
the bearing shell ending abruptly at a step. As the lubricant is carried
around the bearing it encounters the step that causes an increased
pressure at the top of the journal inducing a stabilizing force onto the journal
which forces the shaft into the bottom half of the bearing.

This bearing has a high load capacity and is a common correction for
machine designs susceptible to oil whirl. Pressure dam bearings are a
unidirectional configuration.

Another unidirectional bearing configuration is the offset bearing. It is similar to a plain bearing,
but the upper half has been shifted horizontally. Offset bearings have increasing load capacities
as the offset is increased.
Lubrication System

1. What is the function(s) of lubrication?

1) Create lift by forming a thin film of oil between shaft and bearings
2) Cooling effect keeping bearings at it at optimum temperature
3) Protection from corrosion
4) Flush away wear by product or debris

2. List different types of lubrication systems

1. Oil bath
2. Circulating System
3. Grease
4. Oil mist lubrication – spray

3. Describe the operating principle of the following lubrication:

Hydrodynamics (or Fluid Film)

Hydrodynamic lubrication is an excellent method of lubrication since it is

possible to achieve coefficients of friction as low as 0.001 (=0.001), and there is no
wear between the moving parts. Special attention must be paid to the heating of the
lubricant by the frictional force since viscosity is temperature dependent. One method of
accomplishing this is to cycle the lubricant through a cooling reservoir in order to
maintain the desired viscosity of the fluid. Another way of handling the heat dissipation
is to use commercially available additives to decrease the viscosity's temperature
dependence.

We also have to pay special attention to the extremes of motion, when using
hydrodynamic lubrication: starting and stopping. When the surfaces are at rest with
respect to each other, or at very low speeds, the distance of separation is theoretically
zero.
Elasto-hydrodynamic (or Boundary Layer)

In our earlier discussion of hydrodynamic lubrication we considered a rigid shaft

inside of a rigid bearing. We have to consider the more realistic case of non-rigid bodies
in contact. Consider a shaft of metal resting on a sheet of rubber as shown below.

With lubrication of some sort, lets use the generic case oil, the pressures of the
hydrodynamic film will complicate the picture. The pressure of the hydrodynamic film
will exert pressure on the deformable medium and the shaft, lifting it upward. The shape
of the rubber will be changed as suggested below. Actually however, the shaft will be
shifted to one side depending on its direction of spin.

Hydrostatic

Hydrostatic bearings

Hydrostatic films are created when a high-pressure lubricant is injected between

opposing (parallel) surfaces (pad and runner), thereby separating them and preventing
their coming into direct contact. Hydrostatic bearings require external pressurization. The
film is 5–50 micrometers thick, depending on application. Though hydrostatic lubrication
does not rely on relative motion of the surfaces, relative motion is permitted and can even
be discontinuous. Figure 1 is a schematic of a hydrostatic bearing pad. To handle
asymmetric loads, hydrostatic systems generally employ several evenly spaced pads.
Hydrostatic bearings find application where relative positioning is of extreme
importance. They are also applied where a low coefficient of friction at vanishing relative
velocity is required.
 Hydrostatic bearing pad

Forced-feed

Force Feed A somewhat more complete pressurization of lubrication is achieved in the

force-feed lubrication system (fig. 6-31). Oil is forced by the oil pump from the crankcase to the main
bearings and the camshaft bearings. Unlike the combination system the connecting-rod bearings are
also fed oil under pressure from the pump. Oil passages are drilled in the crankshaft to lead oil to the
connecting-rod bearings. The passages deliver oil from the main bearing journals to the rod bearing
journals. In some engines, these opening are holes that line up once for every crankshaft revolution. In
other engines, there are annular grooves in the main bearings through which oil can feed constantly into the
hole in the crankshaft. The pressurized oil that lubricates the connecting- rod bearings goes on to lubricate
the pistons and walls by squirting out through strategically drilled holes. This lubrication system is used in
virtually all engines that are equipped with semi floating piston pins.

Figure 6-31.—Force-feed lubrication system.

Oil Ring/Oil Bath

1) For low moderate speed

2) Oil level in housing should not be less than the lip of outer ring
3) Not higher than the center of lowest rolling element – verify during bearing not rotating
4) Oil ring can be used to splash oil to bearings

Splash (Crankcase and Gearbox Lubrication)

Figure 6-29.—Splash-type lubrication system.

Splash The splash system is no longer used in automotive engines. It is widely used in small four-
cycle engines for lawn mowers, outboard marine operation, and so on. In the splash lubricating system (fig.
6-29), oil is splashed up from the oil pan or oil trays in the lower part of the crankcase. The oil is thrown
upward as droplets or fine mist and provides adequate lubrication to valve mechanisms, piston pins,
cylinder walls, and piston rings. In the engine, dippers on the connecting-rod bearing caps enter the oil pan
with each crankshaft revolution to produce the oil splash. A passage is drilled in each connecting rod from
the dipper to the bearing to ensure lubrication. This system is too uncertain for automotive applications.
One reason is that the level of oil in the crankcase will vary greatly the amount of lubrication received by
the engine. A high level results in excess lubrication and oil consumption and a slightly low level results in
inadequate lubrication and failure of the engine.
Oil Mist

Air-oil mist: This method is very simple, inexpensive and reliable. A fog of oil
droplets is created in an air stream delivered to the bearing. It features adjustable
air pressure and oil delivery rate.

Grease

Grease lubrication in bearings is very common and simpler. It is a permanent

greasing solution and requires minimal maintenance and is inexpensive. The grease
is injected between the balls and races. Grease is actually oil mixed with a thickener.
Thickener is an inert substance added just to hold the oil like sponge.

4. What is the standard used for forced-feed lubrication

system?

5. Describe the general operation of the forced-feed lubrication

system based on the schematic (e.g. per API 614)
SEALING SYSTEM

1. What is the function of a Seal and Sealing system?

- Prevent leak of pumped product from leakage and escaping to atmosphere

PURPOSE OF ANY SEAL

Any mechanical assembly containing fluids must be designed so that these
substances flow only where intended and do not leak out of the assembly. Seals are
incorporated into mechanical designs to prevent such leakage at the points where
different parts of an assembly meet. These meeting points are known as mating
surfaces, and the space between them is called a clearance gap. The purpose of a
seal is to block the clearance gap so that nothing passes through it.

2. What are the common types of seal used on RE?

1) Face / mechanical seal

2) Non-contact seal

3. Describe the following and where/when it is used:

Shaft end seal

Interstage seal

Mechanical seal and sealing system (Single, Double, Tandem,

(1) Use for non-toxic and non-flammable application

(2) Can be installed inside or outside
Advantages of Inside Installation:
Better cooling, less space requirement and low leakage
Advantages of Outside Installation:
Ease in maintenance
Tandem Mechanical Seal:
(1) Use for toxic and flammable application
(2) Consist of two mechanical seals – primary and back-up
(3) Primary seal is flushed by any selected seal flush plan
(4) Back-up seal is provided with flush system incorporating a safe, low flash point
liquid
(5) A pressure alarm is provided to actuate on increase stuffing box pressure
between the primary and back-up seal indicating primary seal failure

Double Mechanical Seal:

(1) Use for toxic and flammable application – cannot be tolerated under any
circumstances such as H2S, Hydrofluoric Acid Alkylation or SulfuricAcid
(2) Leakage of the pumped fluid to the atmosphere is positively prevented by
providing a sealing system, whose liquid is compatible with pumped liquid, which
continuously provides a safe barrier liquid at a pressure higher that, the pumped
fluid
(3) Seals are usually identical in design with exception that one seal incorporates
pumping ring to provide continuous flow of liquid to cool the seals
(4) Can be installed Face-to-Face or Back-to-Back

API plans or flushing systems, etc)

Labyrinth type seal and system
(1) Simple configuration as compared to mechanical seal – more reliable
(2) Can be categorized to dynamic (as part of rotating part) and static (as part of
casing)
(3) A series of circumferential metal strip (4) Utilize when small loss in efficiency can
be tolerate
(5) Leakage can be kept at minimum by providing minimum clearance between seal
land and seal sleeve and sharp edges on the seal land
(6) High tolerance to dirt

Packing seals

Fillers, grease, graphite grease, tallow, and the other materials used serve
two functions in packing materials.

 The grease provides a lubricant at the shaft / packing interface.

 The material acts as a filler to prevent leakage occurring through the
interstices of the packing itself.

Now take the packing material and place it in the pump stuffing box.

PACKING SEAL

A high temperature braided packing good for most applications.

Great for high temp or chemical applications (non-oxidizing)
that can not leak. When you have to have the leak rate near that of a Mechanical
Seal this is the packing to use
 Carbon Packing Temp: 1200 F Steam, 0-14 pH ,

Ideal for use in combination with Thermabraid braided packing or alone. Impregnated
with graphite dispersion. For severe services in Pumps and Valves. Applications
include superheated steam, acids alkalis

PTFE Packing Temp: 500F Steam, 0-14 pH

Dense (154) soft (154S) and FDA (154FDA) braided packing styles are available. Ideal
for Chemical and food applications.

Fiber Temp: 550F Steam, 0-14 pH

The most common braided packing in industry. Very versatile and easy to work with.
For superior abrasive resistance try our style 3165.

Dry Gas Seal and system

An alternative to the traditional wet (oil) seal system is the mechanical dry seal system. This seal system
does not use any circulating seal oil. Dry seals operate mechanically under the opposing force created by
hydrodynamic grooves and static pressure. As shown in Exhibits 2a and 2b, hydrodynamic grooves are
etched into the surface of the rotating ring affixed to the compressor shaft. When the compressor is not
rotating, the stationary ring in the seal housing is pressed against the rotating ring by springs. When the
compressor shaft rotates at high speed, compressed gas has only one pathway to leak down the shaft, and
that is between the rotating and stationary rings. This gas is pumped between the rings by grooves in the
rotating ring.

The opposing force of high-pressure gas pumped between the rings and springs trying to push the rings
together creates a very thin gap between the rings through which little gas can leak. While the compressor
is operating, the rings are not in contact with each other, and therefore, do not wear or need lubrication. O-
rings seal the stationary rings in the seal case.
Wet or oil sealing system

Centrifugal compressors require seals around the rotating shaft to prevent gases from escaping where the
shaft exits the compressor casing. The more common “beam” type compressors have two seals, one on
each end of the compressor, while “over-hung” compressors have a seal on only the “inboard” (motor) side.
As shown in Exhibit 1, these seals use oil, which is circulated under high pressure between three rings
around the compressor shaft, forming a barrier against the compressed gas leakage. The center ring is
attached to the rotating shaft, while the two rings on each side are stationary in the seal housing, pressed
against a thin film of oil flowing between the rings to both lubricate and act as a leak barrier. “O-ring”
rubber seals pre-vent leakage around the stationary rings. Very little gas escapes through the oil barrier;
considerably more gas is absorbed by the oil under the high pressures at the “inboard” (compressor side)
seal oil/gas interface, thus contaminating the seal oil. Seal oil is purged of the absorbed gas (using heaters,
flash tanks, and degassing techniques) and recirculated. The recovered methane is commonly vented to the
atmosphere.
Bearing isolator (“Impro” seal)

Isolator Seal Advantage

Whether classified as an elastomer lip or isolator, a seal is essentially a bearing protection

device that eliminates cross-contamination between the lubricant and the external
environment as it protects the bearing by preventing lubricant leakage and contaminant
ingress.

While both seal types share a common purpose, the design and engineering behind the
isolator seal enables it to operate both more effectively and efficiently than the elastomer lip
seal in applications where the lubricant level resides below the seal. Elastomer lip seals are, of
course, essential in applications where lubricant levels come up to the bottom of the rotating
shaft.

Seal Design

The bearing isolator seal is a labyrinth seal that is made up of two non-contacting
components, and these two metal components -- a rotor and stator -- are separated by a
durable PTFE-ring. Together, these components create a torturous labyrinth path that
prevents contaminants from entering and lubricants from exiting the isolator seal in both
directions.

In comparison, a single lip seal is designed to seal in only one

direction and requires two opposing lips to seal in both directions.

Although considered one of the more superior bearing seals on the

market today, the first isolator seals had a very basic labyrinth
pathway made up of 90 degree turns that, in certain cases, still
allowed contaminants to work their way through to the bearing. To
build upon this innovation and improve its effectiveness, the isolator
was redesigned with a more torturous labyrinth path that included a
less direct route through the seal.
Today, the isolator is made up of both ingress and a retention labyrinth path. The ingress path
prevents contaminants from reaching the bearing by redirecting them to the expulsion port at
the bottom of the seal. Conversely, the retention path redirects the lubricant back to the
bearing through its separate bottom expulsion port.

This use of such a torturous labyrinth path removes the need for an elastomer lip seal, and
solves two common problems:

1. Increased torque and temperature from friction caused by the elastomer seal lip
contacting the shaft.
2. Contaminant entry allowed by elastomer lip wear.

With no rubbing parts to contend with, isolators do not wear away, and their design life is
extremely long. Plus, unlike elastomer lip seals, isolators do not require lubrication because
they do not have contacting components. Most importantly, isolator seals exert little to zero
torque, making them a contributor to electrical energy savings in many plants.

Other advantages in the newest isolator seals include an interference fit of the rotor
component to the shaft by using two fluoroelastomer o-rings that allow it to rotate with the
shaft. There are also two additional o-rings set into grooves on the stator; these grooves are
cut on an incline to securely trap the o-rings when they are forced to move in an opposite
direction.

4. Why use mechanical seal instead of shaft packing?

5. Name a few types of mechanical seal

Mechanical Seal Types

Mechanical seals can be classified into several types and arrangements:

PUSHER:
Incorporate secondary seals that move axially along a shaft or sleeve to maintain contact at the
seal faces. This feature compensates for seal face wear and wobble due to misalignment. The
pusher seals' advantage is that it's inexpensive and commercially available in a wide range of
sizes and configurations. Its disadvantage is that ft's prone to secondary seal hang-up and fretting
of the shaft or sleeve. Examples are Dura RO and Crane Type 9T.
UNBALANCED:
They are inexpensive, leak less, and are more stable when subjected to vibration, misalignment,
and cavitation. The disadvantage is their relative low pressure limit. If the closing force exerted on
the seal faces exceeds the pressure limit, the lubricating film between the faces is squeezed out
and the highly loaded dry running seal fails. Examples are the Dura RO and Crane 9T.

CONVENTIONAL:
Examples are the Dura RO and Crane Type 1 which require setting and alignment of the seal
(single, double, tandem) on the shaft or sleeve of the pump. Although setting a mechanical seal is
relatively simple, today's emphasis on reducing maintenance costs has increased preference for
cartridge seals.

NON-PUSHER:
The non-pusher or bellows seal does not have to move along the shaft or sleeve to maintain seal
face contact, The main advantages are its ability to handle high and low temperature applications,
and does not require a secondary seal (not prone to secondary seal hang-up). A disadvantage of
this style seal is that its thin bellows cross sections must be upgraded for use in corrosive
environments Examples are Dura CBR and Crane 215, and Sealol 680.
BALANCED:
Balancing a mechanical seal involves a simple design change, which reduces the hydraulic
forces acting to close the seal faces. Balanced seals have higher-pressure limits, lower seal face
loading, and generate less heat. This makes them well suited to handle liquids with poor lubricity
and high vapor pressures such as light hydrocarbons. Examples are Dura CBR and PBR and
Crane 98T and 215.

CARTRIDGE:
Examples are Dura P-SO and Crane 1100 which have the mechanical seal premounted on a
sleeve including the gland and fit directly over the Model 3196 shaft or shaft sleeve (available
single, double, tandem). The major benefit, of course is no requirement for the usual seal setting
measurements for their installation. Cartridge seals lower maintenance costs and reduce seal
setting errors

Mechanical Seal Arrangements

SINGLE INSIDE:
This is the most common type of mechanical seal. These seals are easily modified to
accommodate seal flush plans and can be balanced to withstand high seal environment
pressures. Recommended for relatively clear non-corrosive and corrosive liquids with
satisfactory' lubricating properties where cost of operation does not exceed that of a double
seal. Examples are Dura RO and CBR and Crane 9T and 215. Reference Conventional Seal.
SINGLE OUTSIDE:
If an extremely corrosive liquid has good lubricating properties, an outside seal offers an
economical alternative to the expensive metal required for an inside seal to resist corrosion.
The disadvantage is that it is exposed outside of the pump which makes it vulnerable to
damage from impact and hydraulic pressure works to open the seal faces so they have low
pressure limits (balanced or unbalanced).

DOUBLE (DUAL PRESSURIZED):

This arrangement is recommended for liquids that are not compatible with a single mechanical
seal (i.e. liquids that are toxic, hazardous [regulated by the EPA], have suspended abrasives, or
corrosives which require costly materials). The advantages of the double seal are that it can have
five times the life of a single seal in severe environments. Also, the metal inner seal parts are
never exposed to the liquid product being pumped, so viscous, abrasive, or thermosetting liquids
are easily sealed without a need for expensive metallurgy. In addition, recent testing has shown
that double seal life is virtually unaffected by process upset conditions during pump operation. A
significant advantage of using a double seal over a single seal.
The final decision between choosing a double or single seal comes down to the initial cost to
purchase the seal, cost of operation of the seal, and environmental and user plant emission
standards for leakage from seals. Examples are Dura double RO and X-200 and Crane double
811T.

DOUBLE GAS BARRIER (PRESSURIZED DUAL GAS):

Very similar to cartridge double seals ... sealing involves an inert gas, like nitrogen, to act as a
surface lubricant and coolant in place of a liquid barrier system or external flush required with
conventional or cartridge double seals. This concept was developed because many barrier fluids
commonly used with double seals can no longer be used due to new emission regulations. The
gas barrier seal uses nitrogen or air as a harmless and inexpensive barrier fluid that helps
prevent product emissions to the atmosphere and fully complies with emission regulations. The
double gas barrier seal should be considered for use on toxic or hazardous liquids that are
regulated or in situations where increased reliability is the required on an application. Examples
are Dura GB2OO, GF2OO, and Crane 2800.
TANDEM (DUAL UNPRESSURIZED): Due to health, safety, and environmental considerations,
tandem seals have been used for products such as vinyl chloride, carbon monoxide, light
hydrocarbons, and a wide range of other volatile, toxic, carcinogenic, or hazardous liquids.
Tandem seals eliminate icing and freezing of light hydrocarbons and other liquids which could fall
below the atmospheric freezing point of water in air (32? F or 0? C). {Typical buffer liquids in
these applications are ethylene glycol, methanol, and propanol.) A tandem also increases online
reliability. If the primary seal fails, the outboard seal can take over and function until maintenance
of the equipment can be scheduled. Examples are Dura TMB-73 and tandem PTO.

Mechanical Seal Selection

The proper selection of a mechanical seal can be made only if the full operating conditions are
known:
1. Liquid
2. Pressure
3. Temperature
4. Characteristics of Liquid
5. Reliability and Emission Concerns

1. Liquid: Identification of the exact liquid to be handled is the first step in seal selection.
The metal parts must be corrosion resistant, usually steel, bronze, stainless steel, or
Hastelloy. The mating faces must also resist corrosion and wear. Carbon, ceramic,
silicon carbide or tungsten carbide may be considered. Stationary sealing members of
Buna, EPR, Viton and Teflon are common.
2. Pressure: The proper type of seal, balanced or unbalanced, is based on the pressure on
the seal and on the seal size.
3. Temperature: In part, determines the use of the sealing members. Materials must be
selected to handle liquid temperature.
4. Characteristics of Liquid: Abrasive liquids create excessive wear and short seal life.
Double seals or clear liquid flushing from an external source allow the use of mechanical
seals on these difficult liquids. On light hydrocarbons balanced seals are often used for
longer seal life even though pressures are low.
5. Reliability and Emission Concerns: The seal type and arrangement selected must meet
the desired reliability and emission standards for the pump application. Double seals and
double gas barrier seals are becoming the seals of choice.
Seal Environment
The number one cause of pump downtime is failure of the shaft seal. These failures are normally
the result of an unfavorable seal environment such as improper heat dissipation (cooling), poor
lubrication of seal faces, or seals operating in liquids containing solids, air or vapors. To achieve
maximum reliability of a seal application, proper choices of seal housings (standard bore stuffing
box, large bore, or large tapered bore seal chamber) and seal environmental controls (CPI and
API seal flush plans) must be made.
STANDARD BORE STUFFING BOX COVER
Designed thirty years ago specifically for packing. Also accommodates mechanical seals
(clamped seat outside seals and conventional double seals.)

CONVENTIONAL LARGE BORE SEAL CHAMBER

Designed specifically for mechanical seals. Large bore provides increased life of seals
through improved lubrication and cooling of faces. Seal environment should be controlled
through use of CPI or API flush plans. Often available with internal bypass to provide
circulation of liquid to faces without using external flush. Ideal for conventional or cartridge
single mechanical seals in conjunction with a flush and throat bushing in bottom of chamber.
Also excellent for conventional or cartridge double or tandem seals.

LARGE BORE SEAL CHAMBERS

Introduced in the mid-8o's, enlarged bore seal chambers with increased radial clearance
between the mechanical seal and seal chamber wall, provide better circulation of liquid to and
from seal faces. Improved lubrication and heat removal (cooling) of seal faces extend seal life
and lower maintenance costs.
 BigBoreTM Seal Chamber

TaperBoreTM Seal Chamber

6. Describe main components of mechanical seal

7. Describe how a mechanical seal work

Mechanical Seals
A mechanical seal is a sealing device which forms a running seal between rotating and
stationary parts. They were developed to overcome the disadvantages of compression packing.
Leakage can be reduced to a level meeting environmental standards of government regulating
agencies and maintenance costs can be lower. Advantages of mechanical seals over
conventional packing are as follows:
1. Zero or limited leakage of product (meet emission regulations.)
2. Reduced friction and power loss.
3. Elimination of shaft or sleeve wear.
4. Reduced maintenance costs.
5. Ability to seal higher pressures and more corrosive environments.
6. The wide variety of designs allows use of mechanical seals in almost all pump
applications.

The Basic Mechanical Seal

All mechanical seals are constructed of three basic sets of parts as shown in Fig. 9:
1. A set of primary seal faces: one rotary and one stationary shown in Fig. 9 as seal ring
and insert.
2. A set of secondary seals known as shaft packing and insert mountings such as 0-rings,
wedges and V-rings.
3. Mechanical seal hardware including gland rings, collars, compression rings, pins, springs
and bellows.
 Fig. 9 A Simple Mechcanical Seal
How A Mechanical Seal Works
The primary seal is achieved by two very flat, lapped faces which create a difficult leakage
path perpendicular to the shaft. Rubbing contact between these two flat mating surfaces
minimizes leakage. As in all seals, one face is held stationary in a housing and the other face
is fixed to, and rotates with, the shaft. One of the faces is usually a non-galling material such
as carbon-graphite. The other is usually a relatively hard material like silicon-carbide.
Dissimilar materials are usually used for the stationary insert and the rotating seal ring face in
order to prevent adhesion of the two faces. The softer face usually has the smaller mating
surface and is commonly called the wear nose.
There are four main sealing points within an end face mechanical seal (Fig. 10). The primary
seal is at the seal face, Point A. The leakage path at Point B is blocked by either an 0-ring, a
V-ring or a wedge. Leakage paths at Points C and D are blocked by gaskets or 0-rings.

Fig. 10 Sealing Points for Mechanical Seal

 The faces in a typical mechanical seal are lubricated with a boundary layer of gas or liquid
between the faces. In designing seals for the desired leakage, seal life, and energy
consumption, the designer must consider how the faces are to be lubricated and select from a
number of modes of seal face lubrication.
To select the best seal design, it's necessary to know as much as possible about the
operating conditions and the product to be sealed. Complete information about the product
and environment will allow selection of the best seal for the application.

7. Why use mechanical seal flushing?

A clean liquid, from an outside source is brought into the stuffing box through a
regulating valve at one atmosphere (15 psi. /1 bar) higher than stuffing box pressure. The
liquid should be brought in at the bottom of the stuffing box to insure thorough cleaning.
All of this liquid will eventually go into your product.

If you're using balanced o-ring seals you'll only need enough liquid to remove solids that
might interfere with the seal movement. you'll not need additional liquid to provide
cooling because balanced seals do not generate enough heat to cause problems in most
applications.

Seal designs that have the springs out of the fluid require only one to two gallons per
hour (4 to 8 Ltrs./ hour) of flush. NOTE: this is per hour, not per minute. If you're using
designs with multiple springs in the fluid check with your manufacturer for his
recommendations. The clean flush can come from several sources:

 Clean water
 A compatible fluid
 A solvent
 One of the ingredients in the product
 Finished product will never hurt raw product. Finished product is almost always
clean.
 An additive that is going to be put into the product down stream and can be added
at the pump stuffing box instead.

If you're using shop water as the flush you must be careful or solids in the flushing water
will clog up the flow control valve. The shop water pressure also tends to vary through
out the day and in some instances it can fall below the pump stuffing box pressure. Most
states require an air gap in the line if you want to use shop or city water as a flushing
medium. A back flow presenter valve is used many times but it is illegal in most states.

 To introduce clean liquid into the stuffing box, to remove solids or any problem
fluid.
 Cool a hot liquid by flushing in a cold one.
 Remove a liquid that is sensitive to changes in either temperature and/ or pressure.
  You can use this connection to cross connect the stuffing boxes in a double ended
pump application, and thereby equalize the pressures in the stuffing boxes.

9. List some common types of flushing system per their API

plan
10. Describe the following API Flush Plans:
Plan 01 and 02
Plan 11, 12, 13 and 14
Plan 21, 23, 31 and 41
Plan 52, 53 and 54