SIX STEPS TO

INCREASE
PUMP PACKING
RELIABILITY
MINING and ORE PROCESSING

A.W. Chesterton Company

1
ABOUT THE AUTHOR

INTRODUCTION
In mining operations, small improvements in uptime can have
a major impact on profitability. The sealing of pumps used
throughout various mining applications can play a major role.

In mining/ore processing, where slurries and gritty fluid prevail,

Raman Hanjra
Raman Hanjra is Global Product
Line Manager of Packing and
Gaskets for A.W. Chesterton
Company. He holds a BS in
Mechanical Engineering and
an MBA in Product and Market
Development and Supply
Chain Management. He started
his career as a corporate
sales engineer for mechanical
seals and has held various
sales, marketing and product
leadership positions globally.
compression packing is the primary method of sealing pumps and
other rotating equipment. In this e-book, we’ll explore how a
thorough analysis of packing failures can help you make smart
decisions that lead to extended reliability and, consequently,
more uptime.
You’ll Learn
1 Why pump packing systems fail

2 The steps for thorough failure analysis

3 Which packing types are best for specific

applications
4 Installation/maintenance issues

to watch out for
5 How to start a continuous improvement

program to reduce packing failure

DISCLAIMER: This document is for informational and educational purposes only. It is intended to be a general guide. It should not
be considered advice or a replacement for addressing equipment concerns with a qualified professional. Chesterton assumes no
responsibility for any action or inaction you take based on or made in reliance on the information contained in this document.

2
FAILURE ANALYSIS: FACT FINDING
When pumps and mixers break down frequently or unexpectedly,
it’s time to start investigating. Determining why the equipment
failed and correcting the issue properly are keys to
improved reliability.
You’ll want to:
n S
 tep 1: Review the application and your packing
material selection
n S
 tep 2: Examine the equipment
n S
 tep 3: Conduct a flush audit
n S
 tep 4: Evaluate the condition of the packing
n S
 tep 5: Check for other common packing installation
and maintenance issues Four Common Reasons
Pump Packing Fails:
n S
 tep 6: Keep records of each pump failure and packing
performance to help identify and measure trends
to document success and increase uptime. 1 Poor Solids Removal
– Flush issues (clogged flush
line, dirty flush, low flush
Finding the Root Cause pressure)
– In flushless applications,
Finding the root cause of the failure sometimes means looking
loss of gland load
beyond the obvious to investigate numerous possibilities.
The answers are not always straight forward. For example, 2 P
 acking doesn’t meet
burnt packing could be caused by a flush issue, but it could also application ranges
be an issue with an inappropriate packing material selection. – Speed/Temperature/
In this instance, we would recommend you install flush tracking/ Pressure/pH
pressure monitoring to figure out if there is enough flow.
If the flush does not appear to be an issue, you’ll want to 3 Pump Condition
investigate the best packing material to avoid the burning – Poor surface finish of shaft
of packing. It may take more than one failure analysis round – Shaft misalignment
to figure out the real problem and the best solution.
– Gland or box throat inside
diameter clearances

4 P
 acking Installed Incorrectly

3
STEP 1: REVIEWING THE APPLICATION AND PACKING
MATERIAL SELECTION
For this step, you’ll want to have all the information on hand that you need to ensure
you have selected the optimal packing for the pump and the media being sealed.
Pump Application Data
n Shaft speed
n Shaft/Sleeve size
n Box size
n Depth
n Configuration (lantern ring)
n Process Temperature
Sealing Media
n What is the percentage of solids?
n Is there hardening/crystallization during cooling?
n What is the pH?
n What kind of cleaning media (if any) is used?

Packing Material
Choosing the best packing for maximum reliability is often a balancing act between the various
attributes and, of course, cost. But make sure the expense of the packing is weighed against the
time and money caused by frequent maintenance and unplanned shutdowns.
While natural fibers may be much less expensive, new synthetic packing formulations and braiding
technologies can solve many issues and greatly extend Mean Time Between Failures (MTBF). Synthetic
fibers such as Nomex® and Kevlar® are typically used in the mining industry because of their respective
glaze resistance and resilience. New braiding technology such as Chesterton’s
DualPac™ 2211, which uses a combination of two synthetic
fibers, offer the next level in packing reliability
for severe slurry packing as it combines the
resilience and sealabilty of those fibers.

Nomex® and Kevlar® are registered trademark of E.I. du Pont de Nemours and Company.
DualPac™ is a registered trademark of A.W. Chesterton Company

4
 STEP 2: E
 XAMINING THE EQUIPMENT
Operating Pump: If possible, you’ll want to look at the
pump/mixer while it is still in operation:
n Is there leakage from the gland ID or OD?
n G
 land OD leakage is a sign of an off-center
lantern ring
n E xcessive flush ID leakage is a sign of reduced
gland load
n  easure pressures with a gauge—both the stuffing box
M
and flush pressure. Flush pressure must be greater than
stuffing box pressure

Non-Operating Pump: When not in operation, you’ll want to check:

Gland Condition
n Look for excessive wear on the ID, which is the sign of a cocking gland or misaligned shaft.
n  easure the ID of the gland follower to determine the clearance with the shaft.
M
Large clearances can cause packing extrusion.
n Measure the OD of the gland follower and check clearance with the box diameter
n Check that the gland goes into the stuffing box easily and there is no interference

Gland

ID Clearance

Shaft

Gland ID Clearance

5
Lantern Ring
n Check that it is sized correctly.
n Is it evenly loaded?
n Is it aligned with the stuffing box flush port?
(Measure the flush port location and lantern ring configuration).
n Check if damaged/worn

Misaligned
Lantern Ring

Flush Line

Consolidated
Packing Rings

Misaligned Lantern Ring

A misaligned lantern ring will result in heavy flush fluid leakage along the outside diameter of the
packing. The use of a throat bushing with built-in flush ports can help eliminate the problems
associated with lantern rings installations and help use less packing. Alternatively, environmental
control technologies such as SpiralTrac™ eliminate the need for a lantern ring use. Since SpiralTrac
also reduces the flow of water, it is a good solution where there is less flush to work with. (However,
a relatively clean flush is still required).

Environmental
Controller (SpiralTrac) Stud, Nuts

Flush Port

Gland
Follower

Packing with the Environmental Controller

Inside Stuffing Box

Read our blog post on slurry pump maintenance to learn more.

SpiralTrac™ is a trademark of EnvrioSeal Engineeting Products Ltd.

6
Environmental Controller

If an environmental controller such as SpiralTrac is being used, and the packing is not meeting the
expected MTBF:
n Examine the SpiralTrac ring for wear—you may need to use a harder material due to heavy solids.
n  roper orientation (clockwise/counter-clockwise)—SpiralTrac is specific to the pump shaft
P
rotation. If it is set up incorrectly, there is a potential for clogging.

Worn Shafts/Sleeves

Shafts and sleeves that have been compromised can result in leak paths, excessive leakage, and early
packing failure.
n If a flush is available, there are new packing technologies that can help such as Chesterton’s
DualPac 2211 which combines PTFE and Aramid fibers. This fiber combination offers the low
friction and high sealability of PTFE without the consolidation and extrusion.
n If a flush is not available, consider injectable packing which conforms to worn surfaces
to provide more reliable sealing.

Condition of Fasteners

Threads need to be in good condition throughout the

bolt so that the gland nose can be fully inserted into
the stuffing box.

Damaged Shaft/Sleeve Due

to Packing Friction

7
STEP 3: A
 UDITING THE FLUSH
The flush condition plays another major role in packing success. You’ll want to review:
The cleanliness of the flush water


Excessive solids in the flush can lead to embedment of these solids in the packing which in turn
create leak paths and lead to premature failure. These solids may also lead to fretting of the shaft
or sleeve which further deteriorates the sealing and leads to a decrease in MTBF.

Solids in the Packing

Embedment of
.... .... Flush with
Solids

....
Flush with
Flush with

Solids
Solids

.....................................................
. .......
Embedment of
Solids in the Packing

Embedment of
 Solid Embedment Due to ExcessiveSolids
Solids in the
in the Fluid
Packing

A clean source of flush water can help extend the life of the packing. When a clean flush is not available,
environmental control technologies such as SpiralTrac can help remove the solids from the flush water
assuring a clean flush is available for the packing rings.
Flush water pressure


Low pressure/low flow is a common issue. Pressure must

be 1 bar (14.5 psi) above the application you are sealing
or it will not be strong enough to push solids away
from the first two packing rings on the bottom of the
stuffing box.

8
Issues in this area make a good case for injectable packing, such as Chesterton CMS 2000, as long as it
fits your other application parameters (injectable packing tends to have narrow pH parameters). Unlike
standard packing, the injectable form does not require a flush or process fluid to be kept cool. Injectable
packing is a hybrid between a solid and a liquid composed of chopped reinforced fiber mixed with
lubricants. It is injected through the lantern ring flush port into the stuffing box and can easily be
replenished overtime while the pump is in operation.

Injectable Packing Molds to Irregularities

and Reduces Sleeve Wear

Flush water header

Does the pump have pressure surges? Is there a drop downstream? Does the flush pressure remain
constant or does opening a water valve drop the flush pressure? Note that for pumping flush lines that
are in series, pressure may vary significantly from one end to the other.
System anomalies such as pressure surges in the process will lead to debris moving into the packing,
which causes premature packing failure. This can be an issue that arises in an instance causing close
to immediate flush failure. To avoid this situation, put a check valve in your flush line and a flow meter
to monitor flow conditions.

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STEP 4: EVALUATING THE PACKING
Assess the Condition of the Packing Rings
Try to keep the rings in order when you remove them
from the stuffing box to best determine failure mode.
Check for the following: Gland Lantern Ring Lantern Throat Side
Side Front Ring Back
n A
 re solids embedded?
If so, are they embedded in all the rings? This
may indicate that solids in the flush are getting
embedded in the packing which is leading
to leak paths. The rings need to be in intimate
contact to avoid the creation of leak paths.
n I s the packing burnt?
If so, is it the packing fiber or the sealed media?
If it is the fiber, the packing material may be
inadequate to handle the shaft speed limit. Tagged Pump Rings
n I s the packing ring soft or mushy?
If so, it could be impacted by chemical attack from the sealed media or by the cleaning
fluid used on the pump. Selection of a packing with the appropriate pH capability may
be recommended
n I s the packing brittle or weakened?
Incompatibility with process medium may cause packing embrittlement.
n A
 re there signs of packing extrusion?
Extrusion is typically caused by improper clearances between
the box, shaft and lantern ring.
n F or top ring ID extrusion, check for excessive clearance
in gland ID
n A top ring OD extrusion is indicative of a worn gland
n F or bottom ring ID extrusion, check for excessive shaft
runout, bad bearings or worn box throat
n F or extrusion around the lantern ring, check that the
lantern ring is properly sized

Extruded Packing

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Assess the Condition of the Packing Fibers:
n I s the fiber torn apart/badly worn, or fractured?
Check the ID and OD for fiber wear. This could
indicate that the wrong fiber has been used or the
shaft is damaged.
n I s there uneven compression in the used packing?
This could indicate a cocked gland. To determine
if the packing is unevenly compressed, measure the
cross-section in four locations of the ring 90 degrees
apart and compare the measurements.
n C
 heck the cutting of the rings: Was the cut “skive”
or “butt”? Does it appear to be a sharp cut and do
Checking Dimensional Accuracy
the ends match up? We recommend always purchas-
ing pre-cut and pre-formed rings.
Always follow the packing manufacturer’s instructions and
best practices to ensure the optimal fit for performance.
Watch our instructional video on cutting packing ring.

Checking Packing Rings for Cut Accuracy

11
STEP 5: CHECKING FOR OTHER PACKING INSTALLATION
OR MAINTENANCE ISSUES
There are many possibilities for packing failure in this area.
Below are some other common problems to watch out for and
recommended solutions:
n  vertightening of the packing gland: This can lead
O
to burnout/early failure of the packing. Depending on the
material, burnt packing may appear to be a solid mass,
lacking compressibility. For example, a packing using PTFE
fiber may glaze and harden due to heat generated on
overtightening. If using a PTFE fiber, during installation make
sure to make small tightening gland adjustments every
15 mins to avoid overtightening. Some advanced packing
products such as Chesterton 1730 are glaze resistant. Even
Glazed Packing
if someone happens to overtighten the packing gland,
the packing will resist glazing.
n F
 ailing to re-torque or improper re-torquing: Keeping up with re-torquing can be
an issue due to maintenance staff shortage or the remote location of a pump. Failing
to re-torque can impact packing load and cause more leakage. Loading on the packing
needs to be greater than the force of the media being sealed. Loss of load on the packing
will result in the ingress of media as well as shaft damage, and shorten packing life.
Some new packing technologies use a unique combination of materials and/or unique
construction to create packing that requires less re-torquing of gland bolts. Chesterton’s
DualPac 2211 is one such example; field tests for this product showed an 88% drop
in gland adjustments.
n N
 ot turning on the flush before turning on the pump: Turning on the pump first
can force solids into the packing and cause issues down the road.
n Tamping the packing rings improperly: If the rings are not tamped consistently, they
will expand before they hit the bottom of the box and will not be well seated. As a result,
they will move when you turn on the pump and have a poor response to gland load.

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STEP 6: USING A CONTINUOUS IMPROVEMENT PROCESS
APPROACH TO INCREASE PACKING LIFE
For the most effective use of packing, we recommend that our customers create
a Continuous Improvement Program for their pump/mixer sealing systems.
This effort can:
n Improve MTBF of pumps and other rotating equipment
n Save time and labor
n Reduce use of the wrong packing product
n Streamline inventory
Creating this type of program involves:
n Catching all pump failures as noted above in detail
n T raining all groups to save, bag, and log the packing
taken off pumps
n Analyzing the packing rings to find the failure root cause
n Focusing on the data
Consistent and thorough tracking of equipment and packing
failure pays off over time, allowing you to reduce issue and
focus on other challenges.

Want to Learn More?

n Read about Chesterton’s sealing solutions for the Mining and Ore Processing Industry
n Ask an Expert: Contact one of our Application Engineers
n Find a local Chesterton Sales/Service Office

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 © 2018 A.W. Chesterton Company.
® Rin egistered trademark owned by A.W. Chesterton Company
USA and other countries, unless otherwise noted.

A.W. Chesterton Company Telephone: 781-438-7000 Form No. EN36600

860 Salem Street Fax: 978-469-6528 Mining ans Ore eBook – English
Groveland, MA 01834 USA chesterton.com 6/18