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Modern process equipment with rotating shafts (such as pumps and compressors) are
process fluid into the atmosphere. Compression packing works on the principle of
controlled leakage whereas mechanical seal tend to seal with no visible leakage.
tightening the compression packing overweigh the initial cost of a mechanical seal,
which works unattended for a long time. Because of the absence of visible leakage,
environment is clean and hazard free when mechanical seals are used. In this blog,
start-up procedure and check list for identifying causes of seal leakage.
A basic mechanical seal is a simple device. It has two flat faces running against each
other. The rotating face is secured to the pump shaft while the stationary face is held
in the gland. This is the first and most important of the four possible leak paths
(Primary Seal). This leakage path is sealed by providing absolutely flat mating
surfaces perpendicular to rotating shaft centre line where they come in contact and
maintaining healthy lubrication film between the two mating faces. Since both the
surfaces are continuously moving with respect to each other, there is heat generation
which keeps on evaporating the liquid film and new liquid film is formed. These
vapours keep on escaping to the atmosphere. Thus mechanical seal is not a zero
leakage seal. There is always invisible leakage in vapour form between the faces.
(elastomeric, PTFE or metallic). Metallic bellows are used for high temperature
application.
The last two are jointly referred to as the Tertiary Seal, and both are fairly simple
seals as there is no relative motion between the two parts involved. These leakage
If shaft sleeve is used, one more static leakage path will be there between shaft and
Although the main closing force on primary seal faces is normally provided by the
pressure in the stuffing box, some force is required to keep them closed during
startup and shutdown and to take care of the shaft movement. This force is supplied
There are many types of seals each having definite advantage as under.
Inside Seals
When a seal is mounted inside the stuffing box of the pump, it is called an inside seal.
Inside seals are more difficult to install and maintain. However, main advantage is
that it is possible to control the seal environment inside the stuffing box.
Outside Seals
An outside seal is located outboard of the pump stuffing box. Where stuffing boxes
are shallow and it is not possible to install a seal inside the stuffing box, it is installed
outside. It is also easy to install and maintain. Due to lake of heat dissipation from
below the seal faces, outside seals are suitable for low temperature, low speed and
Balanced Seal
All seals are available in either unbalanced or balanced versions. A seal is unbalanced
when fluid force to close the seal faces (due to the area of rotating seal face exposed
to the pumped fluid in stuffing box) is greater than force acting on rotating seal face
at the area of contact (pressure gradient between rotating and stationary seal faces).
In simple terms, it has a seal closing force in excess of the actual pressure to be
sealed. In a balance seal as seal face is subject to low force, less heat is generated
and seal life is more. As a stepped shaft sleeve is required for balancing, coat of a
To balance a seal, area of rotating seal face exposed to stuffing box pressure is
Double Seals
abrasive fluids. In a double seal arrangement, there are two seals with a fluid
circulating between them. The fluid that circulates between the seals is called a
barrier fluid if its pressure is higher than stuffing box pressure and it is called a buffer
fluid if its pressure is lower than stuffing box pressure. The two seal faces are
arrangement an inner seal leak will cause a dilution of the product. In case of failure
of the barrier fluid system, the inner seal can blow open dumping the pump contents
to the environment.
In this configuration two glands are required to house both seals and this adds to the
cost as well as the axial space requirement. A low pressure buffer fluid is circulated
between the seals, eliminating the possibility of product dilution. In this arrangement
loss of buffer fluid will not cause the seal faces to open. This configuration is generally
Face to face configuration is a compromise between the "back to back" and the
tandem arrangements. Here half the seal is housed in the stuffing box and the other
half outside it. In this arrangement a lower pressure buffer fluid is supplied between
seal faces.
Catridge Seals
The catridge design changes none of the functional components of the basic seal
(conventional seal). In a catridge seal, all items are containerized and preset to
working dimensions. They eliminates need to scribe lines and make critical
measurements during seal assembly. Such seal installation requires only tightening of
The successful and reliable operation of a mechanical seal is dependant upon the
conditions that are imposed on the seal assembly during running. The fluid being
sealed fills the stuffing box in which the seal is mounted and thus the physical and
chemical nature of this liquid will have direct effect on seal operation and life. Slurries
and fluids carrying solid particles are especially dangerous as there is a tendency for
solid particles to collect in the vicinity of the mating faces and finally even entering
the fluid film gap between the mating faces. Hard particles entering this gap will
seal. The most commonly used methods for control are flushing and quenching.
Flushing
62) into the stuffing box such that it impinges or jets onto the mating faces. This fluid
may be the same fluid that is being sealed, tapped from a point at a higher pressure
than that existing in the stuffing box, or any other fluid, preferably at a lower
Flushing effectively aids cooling of the seal mating face area. In addition, the
introduction of a pressurized clear fluid ensures that solid particles present in the
Quenching
# 62) on the atmospheric or outer side of the seal mating faces that either helps in
cooling or in maintaining a require temperature at the mating faces. This also creates
a barrier between the atmosphere and seal faces as the atmospheric air creates
problem to seal faces in some cases. Few such applications are given below.
When pumping cool media (say at 40 deg. C), moisture in the atmosphere
condenses and ice is formed below seal face hindering its operation.
atmosphere, they come in contact with oxygen and burn. These carbon particles
Crystallizing media forms crystals when water in it gets evaporated because of the
atmospheric air present blow seal faces. These crystals create problems for seal faces.
The American Petroleum Institute (API) issues guide lines to help petroleum people
select and then pipe various types of controls for mechanical sealing applications.
Equipment Parameters
Radial movement of shaft (runout / deflection) shall be less than 0.08 mm.
Axial movement of shaft (end play) shall be less than 0.26 mm.
Stuffing box face squareness (face runout) shall be less than 0.05 mm.
Stuffing box bore concentricity (with respect to shaft) shall be less than 0.13 mm.
A conventional (component) seal is one where each part of the seal must be
Do not use hammer for assembly as seal faces are delicate and may crack /
break.
Check that seal parts, gland and stuffing box are free from burrs, sharp edged
recommendation.
Check that set screws on either the rotary unit or the drive collar of the seal
Confirm hardness of shaft / sleeve to be such that after tightening set screws,
rotating assembly does not get loose (if set screws are tightened against a hard
surface, they will fail to hold assembly in desired position during operation).
It is a good practice to check fitting of shaft sleeve, rotary assembly and gland
without O-Rings to ensure that are fitting freely before assembling them with O-Rings.
Never use "glued together" O-Ring for any "dynamic" application. A hard spot will
shaft / sleeve. Rubber bellow seals should be lubricated with Vaseline. Dont apply
silicon grease on them. EPR (Ethylene Propylene Rubber) elastomers should not be
lubricated with petroleum based oil. For EPR material use silicon grease.
Check that all O-Rings are protruding out of respective groove provided on mating
part.
After assembly of rotating head, check for free movement of seal ring by
compressing and releasing the rotary head.
Check direction of helix of coil for single spring seal. Helix should be R.H. for C.W.
rotation and L.H. for C.C.W. rotation when looking at seal face.
Gland bolts or nuts should be tightened only enough to effect a gasket seal at the
stuffing box face. This can be achieved by initial finger tightening and further
tightening with to turns. Over tightening could result in distortion of seal faces.
Cartridge type seal assemblies are provided with axial location plates that hold the
assembly together before installation in the equipment. Make sure that the axial
location plates are moved out of the grooves provided on the shaft sleeve after their
fitting.
When seal assembly is complete, connect all piping, check that all environmental
controls have been connected, and all unused holes in the stuffing box / gland are
plugged.
Start-up Procedure
Take care of following before starting equipment and during its operation for the first
recommendations.
Check the shaft for free movement. Manually rotate the shaft several turns. If
Activate all auxiliary systems like flush, quench, barrier lines and vent the stuffing
Pump should have adequate NPSH (for its running without cavitations).
Excessive heat generation should not be there. This may be due to stationary
parts contacting the rotating shaft or rotating seal parts contacting the housing of the
equipment.
Examine the seal. Slight leakage should stop when the faces wear in.
stuffing box pressure. The seal should be tested for at least 3 hours. Leakage should
acceptable.
The operating life of a seal is complete when either face has worn entirely. If either
face has completely worn, the cause of failure is evident and no further inspection is
required unless this occurred in a very short time. If both faces are intact, seal parts
shall be inspected. Major seal problems and possible causes are as under.
Seal spits and sputters Seal fluid vapourizing at seal interfaces. This can be due to inadequate
(face popping) in operation. seal faces or seal unbalance.
Seal drips steadily. This can happen if seal faces are not flat, distorted or damaged.
Distortion of gland plate due to over tightening.
Damage to secondary seal during installation.
Over aged O-Rings.
Spring failure.
Erosion / corrosion of seal parts.
Seal squeals (gives sound) during Inadequate liquid to lubricate seal faces.
operation
Note:
API 682 (Shaft sealing systems for centrifugal and rotary pumps) requires that the
sealing system supplied, have a high probability of meeting the objective of at least
under
www.johncrane.co.uk
www.burgmannindia.com
www.leakproofseals.com
Acknowledgement:
The ability of a mechanical seal to meet its performance objectives depends upon a
wide range of factors involving equipment design, operating conditions and selection
Shaft diameters of 5 To 500 mm, pressures from 10 torr (vacuum) to 250 bar,
temperatures from -200C to +450C and sliding velocities up to 150 m/s limit the
Double Seal
Double seal arrangement with additional seal supply systems or buffer fluid systems
Due to restriction on length of a blog, I have posted this blog in two parts.
Material of Construction
Seal components can be divided into three major categories seal faces, secondary
Seal Faces
The rotating and stationary sealing faces commonly referred to as primary seal
members are the most important components of a mechanical seal. They shall be
selected based on their compatibility with the fluid being pumped. Following materials
This is the normal rotary seal face material recommended in most general purpose
application involving corrosive fluids. This carbon exhibits good resistance to thermal
shock and good dimensional stability over a wide temperature range. It has also low
This is an antimony impregnated hard carbon that is specially suited for extreme
heavy duty application involving non-corrosive media. Boiler feed water and
hydrocarbon service seals with hard carbon as a mating face have a much longer
service life. Hard carbon exhibits better abrasive resistance and emergency dry
running characteristics.
Ceramic
This is a super fine grain high Alumina ceramic material (99.5 % Al2O3) that exhibits
excellent low wear characteristics. It is the best seal face material for highly corrosive
chemical services. 95.0 % purity material may be used for light duty application.
Tungsten Carbide
This is universally accepted hard seal face material. It is available in two forms
nickel bonded and cobalt bonded. Solid seal rings are offered as a standard as against
Silicon Carbide
Technologically this is the best seal face material available to date. It is available in
two varieties, reaction bonded and sintered. It is highly resistant to thermal stress
and corrosion in high temperature oxidizing atmospheres. It has low wear properties
and is an idle seal face material for most of sealing applications. Silicon carbide also
exhibits better dry run capabilities making it an ideal choice for critical duties in the
It is offered as a standard seal face material on outside mounted PTFE bellows type
Other Materials
Alternate face materials are available for custom seals and other special applications.
Seal faces of stainless steel with stelliting and Ni-resist are available. Cast iron faces
Note:
Carbon face is made in many grades and is priced from the cheap / mass-produced
carbon ring from local supplier, specify correct grade of carbon for your application.
Seal faces require cooling and lubrication to function properly. The hydraulic pressure
acting on the seal faces and the rotating speed of the rotary seal will generate heat.
This heat limits seal design and material. The PV (face pressure x velocity)
capability of two opposing material is indicative of an ability to sustain a fluid film for
To maintain a healthy lubricating fluid film between seal faces they are lapped to
make them flat and smooth. If faces are not flat, waviness will generate
liquid trapped between the lapped faces. Seal surfaces shall be smooth also to reduce
There is often confusion between the terms "Seal face flatness" and "Seal face surface
finish". Seal face surface finish addresses the subject of roughness, and is measured
in terms of "rms" (root mean square) or CLA (center line average). One of the ways
describe this condition when we refer to mechanical seal faces. It is this flatness that
is of the most concern. One can read the flatness by using an optical flat and a
Flatness is measured by using light characteristic that when two lights of the same
wave length interfere with each other, the light disappears and the reflecting piece
goes black. A monochromatic or single wave length light source (mono means one,
and chromatic means color).) is used for this. Most companies use a pink color that
comes off a helium gas light source. This color has a wave length of just about 0.6
and polished clear glass of optical quality) is placed on the piece to be measured. The
monochromatic light is aimed at the piece and this light reflects off of the piece back
through the optical flat causing interference light bands. If the distance between the
optical flat and the piece we are measuring is one half the wave length of helium, or
an even multiple of the number, the band will show black. This is referred to as a
helium light band and because it is one half the wave length of helium it measures 0.3
For high pressure application (> 40 bar), faces should be lapped within 1 light band.
Carbon graphite faces relax after lapping. Although lapped to less than one light band
by the seal manufacturer, you will see readings as high as three light bands if you
check the faces. These faces should return to flat once they are placed against a hard
Seals that are going to be used in cryogenic (cold) service should be lapped at the
cryogenic temperature.
Ceramic: 0.07 m
Hydrodynamic Grooves.
Sometimes hydrodynamic grooves are provided on hard face as shown below for
effective lubrication between faces.
Secondary seals perform the function of sealing between mechanical seal elements as
well as sealing the mechanical seal and the equipment. They are either static or
For information on gaskets used for sealing seal and the equipment, please refer blog
on gaskets. Bellows and wedges are made from PTFE. Bellows are also made from
Elastomers
have it return to 90% of its original shape in less than five seconds after the
compression force is removed. It is this elasticity that gives the compound its memory
and eliminates the need for external loading to seal. If the compound does not return
to 90% of its original shape in five seconds or less it is called a "plastic" material and
Butyl
Buna N
Neoprene
Ethylene propylene
number. Dupont E60 Viton , 3M Fluorel 2174, Parker 747-75 and Parker V884-85
used for high temperature and aggressive chemical applications. Their chemical
resistance is often compared with PTFE. They are very expensive compounds.
The O-ring selected must be chemically compatible with fluid to be handled. It is very
common to clean and flush process lines with a solvent or steam. The O-ring selected
must be chemically compatible with them also. Most of the chemicals can be handled
easily attacked by any petroleum product so be careful with the type of lubricant you
use to lubricate it. For all practical purposes silicone grease is probably the safest
Each of these elastomers has an upper and lower temperature limit. Although the
elastomer may be chemically compatible with the sealing fluid it could still fail if the
under.
Note:
Elastomers are poor conductors of heat. Cooling one side of the O-ring does not
on the shore A scale), but harder durometers are available for high pressure
applications.
One measures O-ring sizes by the inside diameter (D) and the cross section diameter
(d). O-rings are the most precision rubber part that one can purchase. They are
The maximum volume of the O-ring should never be more than the minimum volume
of the gland groove. The groove depth must be less than the O-ring cross-section and
To identify Viton, Burn Test may be carried out. When ignited, Neoprene and Ethylene
propylene burns with a flame where as Viton does not burn with a flame.
Metal Components
Metal is used for making mechanical seal hardware. This hardware, depending on seal
design can include sleeves, retaining rings, set screws, pins, springs, bellows and
glands. Although mechanical seal have some unique requirements, the material
selection generally does not differ much from material selection for the equipment. As
seal components are thinner than equipment components, materials offering best
corrosion resistance are selected for hardware. Many of the common names used for
material designation are actually trade marks of the material manufacturer. Following
AISI 316 (UNS S31600) is considered the base material for most seal designs. It
should not be used in service with high chlorides since it is susceptible to pitting
corrosion.
Alloy C-276
Alloy C-276 (UNS N10276) is one of the most widely used high alloy material used for
aggressive environments. It is used for all major seal components including sleeves,
(2004).
Alloy 20
developed for hot sulfuric acid application. It is used for applications that cause stress
corrosion cracking.
Alloy 400
Alloy 400 (UNS N04400) is a copper-nickel alloy that exhibit good corrosion resistance
against many chemicals. It is used for sea water, sulfuric acid, hydrochloric acid,
Alloy K 500
Monel alloy K 500 (UNS N05500) is used for components requiring high strength like
Alloy 350
Alloy 718
Alloy 718 (UNS N07718).is a nickel-chromium alloy that exhibits excellent corrosion
resistance and high temperature properties. The material is mainly used for making
welded metal bellows. This alloy has been adopted as the default material for Type C
Note:
For more information on mechanical seal material selection please refer API Standard
682, 2004 Pumps-Shaft Sealing Systems for Centrifugal and Rotary Pumps.
Acknowledgment:
Information about metal components in this article is briefly reproduced from a paper