Chapter 2 Mechanical Seal Classifications

Introduction Mechanical seals, just like automobiles, can be classified in a wide variety of ways. When describing a mechanical seal, it is essential that the correct description be used in order to discuss it properly. This chapter will identify and describe the various terms for classifying mechanical seals. Objective Upon completion of this chapter you will be able to describe the various mechanical seal classifications and define ways to discuss seals regardless of type.

Inside mechanical seal configurations

For inside seals, the configuration is for the mechanical seal to be inside the

Introduction Objective

Inside and Outside Mechanical Seal Configurations

Inside mechanical seal configurations

Inside and Outside Mechanical Seal Configurations

Learning the basic mechanical seal configuration terminology discussed in this chapter allows for a greater degree of understanding of how seals are used in industry, and to some extent, their engineering design history. This lesson will identify and describe the inside and outside mechanical seal classifications. fluid being sealed. These mechanical seals have the process fluid on the outside diameter of the seal rings. Most inside seals require a suitable stuffing box housing for installation.

Figure 1
Inside mechanical seal configuration. Note: mechanical seal is inside the fluid being sealed

Inside seals have several advantages over outside seals. They have the primary seal rings completely immersed in the product. This product provides cooling and lubrication to the seal. The rotating action of inside seals helps to keep it clean. Centrifugal force makes it difficult for suspended solids to migrate across the face of the seal. Inside seals usually are not susceptible to catastrophic leakage, because of the gland impeding the path of the product. Inside seals are better suited for higher pressure applications than outside seals because seal ring materials are strongest in compression. Lastly, environmental controls can also be applied and attached easily to most inside seals.

Outside mechanical seals are often used in extremely corrosive applications. An outside seal arrangement allows only the gasket, seal ring, and secondary seals to be exposed to the product. All of these components are non-metallic. No metallic parts come in contact with any corrosive media. Outside seals have several advantages over inside seals. They are typically easy to install and can be inexpensively made from corrosion resistant materials. Where stuffing boxes are shallow and inside seals cannot be used due to lack of radial or axial space, outside seals may be the seal of choice. One disadvantage is that outside seals should not be used where the fluid contains solids. Centrifugal force will constantly cause the solid particles to try to migrate across the seal faces. This action can cause premature seal failure. Outside seals are basically suited for lower pressure seal applications only. Higher pressures can fracture the seal faces causing leakage.

Inside and Outside Mechanical Seal Configurations

Outside mechanical seal configurations

Outside mechanical seal configurations

For outside seals, the configuration is for the mechanical seal to be outside the fluid being sealed. These mechanical seals have the process fluid on the inside diameter of the seal rings.

Seal is Outside the Fluid

Figure 2 Outside mechanical seal configuration. Note: mechanical seal is outside (surrounds) the fluid being sealed

Rotary and Stationary Mechanical Seal Configurati

Learning the basic mechanical seal configuration terminology discussed in this chapter allows for a greater degree of understanding of how seals are used in industry and, to some extent, their engineering design history. This lesson will identify and describe the rotary and stationary mechanical seal classifications.

Rotary and Stationary

Rotary mechanical seal configurations

A rotary mechanical seal has the spring mechanism in the rotating section of the mechanical seal. This rotating section is called the rotary. With all rotary seals, it is imperative that the stuffing box face be square (perpendicular) to the shaft. If this condition is not met, the seal faces will open during operation resulting in premature seal failure.

Stationary mechanical seal configurations

A stationary mechanical seal has the spring mechanism located in the section of the seal that does not rotate with the shaft. This non-rotating section is called the stationary. With any stationary seal, it is imperative that the rotary seal ring face is square (perpendicular) to the shaft. If these rings are not installed square to the shaft, the seal faces will open during operation resulting in premature seal failure. Stationary seals have to be designed with a clamp or a special lock ring in order to ensure face squareness.

Mechanical Seal Configurations

Rotary mechanical seal configurations Stationary mechanical seal configurations

Spring Mechanism Rotates

Spring Mechanism Does Not Rotate

Figure 3 Rotary mechanical seal configuration with the spring mechanism in the rotary

Figure 4
Stationary mechanical seal configuration with the spring mechanism in the stationary

Component and Cartridge Mechanical Seal Configurations

Learning the basic mechanical seal configuration terminology discussed in this chapter allows for a greater degree of understanding of how seals are used in industry and, to some extent, their engineering design history. This lesson will identify and describe the component and cartridge mechanical seal classifications.

Component mechanical seal configurations

A component mechanical seal is an assembly that includes all three sections of a mechanical seal; the primary seal, secondary seals, and all metal parts. The component seal requires assembly of the rotary and stationary parts on the equipment shaft or shaft sleeve.

Component and Cartridge Mechanical Seal Configurations

Component mechanical seal configurations

The seal faces must remain clean and intact during handling and installation. Component seals require many precise measurements to be taken on the equipment during installation. Due to the nature of seal assembly, incorrect installation can occur resulting in premature seal failure. The majority of seal failures for component seals come from misinstallation.

Figure 5
The rotary component of a component mechanical seal

Figure 7
The rotary and stationary components assembled on the shaft and bolted to the stuffing box

Figure 6
The stationary component of a component mechanical seal

Figure 8
Another example of a component mechanical seal

Cartridge mechanical seal configurations

A cartridge mechanical seal is a completely self-contained assembly that includes all three sections of a mechanical seal; the primary seal, secondary seals, and all metal parts. The cartridge seal is fully pre-assembled on a sleeve and enclosed in a gland. The seal faces remain in contact during handling and installation limiting damage and contamination. Measurements required for installing, while significant, are relatively easy to accomplish. Cartridge seals usually require no assembly prior to installation. There is one item that most distinguishes a cartridge seal from a component seal. It is the location of the drive mechanism (usually set screws). On most component seals, the drive mechanism is inside the stuffing box. This requires tightening before assembly of the equipment. On a cartridge seal, the drive mechanism is outside the stuffing box and seal. This allows for assembly of the equipment before tightening. If the cartridge seal is installed on a pump, the impeller can also be adjusted before the set screws are tightened.

CHAPTER I MECHANICAL

Component and Cartridge Mechanical Seal Configurations

Cartridge mechanical seal configurations

Figure 9
Cartridge mechanical seal configuration

Figure 11
Another cartridge mechanical seal configuration

Figure 10
Cutaway of cartridge mechanical seal shown above. Note: the set screws are outside the sea/

Figure 12
Cutaway of cartridge mechanical seal shown above. Note: the set screws are outside the seal

37

Metallic and Won-metallic Mechanical Seal Configurations

Learning the basic mechanical seal configuration terminology discussed in this chapter allows for a greater degree of understanding of how seals are used in industry and, to some extent, their engineering design history. This lesson will identify and describe the metallic and non-metallic mechanical seal classifications.

Metallic and Non-metallic Mechanical Seal Configurations

Metallic mechanical seal configurations Non-metallic mechanical seal configurations

Metallic mechanical seal configurations

A metallic mechanical seal is described as such not because it is made of metal. It is described this way because it has some metal parts in contact with the product being sealed. If any metal parts such as the springs, set screws, rotary holder, etc. are touched by the fluid, then it is called a metallic seal.

Won-metallie mechanical seal configurations

A non-metallic mechanical seal is described as such not because it is made of non-metallic parts. It is described this way because it has no metal parts in contact with the product being sealed. If all the metal parts such as the springs, set screws, rotary holder, etc. are not touched by the fluid, then it is called a non-metallic seal.

Figure 13
Metallic mechanical seal configuration. Note: metallic parts are in contact with the fluid

Metallic and Non-metallic Mechanical Seal Configurations

Metallic mechanical seal configurations Non-metallic mechanical seal configurations

Figure 14
Metallic mechanical seal configuration. Note: metallic parts are in contact with the fluid

Figure 15
Non-metallic mechanical seal configuration

Single and Multiple Seal Ring Mechanical Seal Configurations

Learning the basic mechanical seal configuration terminology discussed in this chapter allows for a greater degree of understanding of how seals are used in industry and, to some extent, their engineering design history. This lesson will identify and describe the single and multiple seal ring mechanical seal classifications.

Single seal ring mechanical seal configurations

A single seal ring mechanical seal is classified as such because it has one set of primary seal rings. This seal consists of one rotary seal ring and one stationary seal ring. This type of seal is often just called a single seal. Many different seals meet this criteria.

Single and Multiple Seal Ring Mechanical Seal Configurations

Multiple seal ring mechanical seal configurations

A multiple seal ring mechanical seal is classified as such because it has two or more sets of primary seal rings. This seal consists of two or more rotary seal rings and one or more stationary seal rings. This type of seal is often just called a double, triple or quadruple seal depending on if the seal contains two, three or four sets of seal rings, respectively. Many different seals meet this criteria.

Single
seal ring mechanical seal configurations Multiple seal ring mechanical seal configurations

Figure 16
Example of a single seal

Figure 17
Example of a double seal

Single and Multiple Seal Ring Mechanical Seal Configurations

Single seal ring mechanical seal configurations Multiple seal ring mechanical

Figure 18
Single seal ring mechanical seal configuration

seal configurations

Figure 19
Multiple seal ring mechanical seal configuration

Split and Non-split Mechanical Seal Configurations

Learning the basic mechanical seal configuration terminology discussed in this chapter allows for a greater degree of understanding of how seals are used in industry and, to some extent, their engineering design history. This lesson will identify and describe the split and non-split mechanical seal classifications.

Split mechanical seal configurations

A split mechanical seal is a seal with its components split into two equal halves. In most cases, split seals allow for installation without disassembly of the equipment. Some equipment modification may be required, depending on the type and physical dimensions of the equipment. Split seals are designed to work like non-split seals, but they are not a 100% leak-free mechanical seal. There may be certain applications where the seal will "weep" at start-up and eventually stop leaking over time. At the very least, the split seal works far better than mechanical packing for controlling leakage and usually does not damage the shaft or sleeve like packing. Splits seals usually have lower capabilities than a non-split seal. This means they handle lower pressures, temperatures, shaft speeds, etc. Also, in most instances the split seal is priced higher than a non-split seal of similar size and construction.

Split and Non-split Mechanical Seal Configurations

Split mechanical seal configurations Non-split mechanical seal configurations

lUon-split mechanical seal configurations

A non-split mechanical seal is a seal with its components in one piece such as the cartridge or component configuration previously discussed. Equipment disassembly is usually required for most installations of nonsplit seals. For discussions of mechanical seals, the non-split configuration is usually assumed unless otherwise specified.

CHAPTER 2

Spli t and Non-split Mechanical Seal Configurations

Split mechanical seal configurations Non-split mechanical seal

Figure 20
Split mechanical seal configuration

configurations

Figure 22
Non-split mechanical seal configuration component design

Figure 21
Non-split mechanical seal configuration cartridge design

Unbalanced, Balanced and Double Balanced Mechanical Seal Configurations

Unbalanced mechanical seal Learning the basic mechanical seal configuration terminology discussed in configurations this chapter allows for a greater degree Unbalanced mechanical seals are seal of understanding of how seals are used arrangements where the hydraulic pressure of in industry and, to some extent, their the seal chamber acts on the entire seal face engineering design history. This lesson area without any of the force being reduced will identify and describe the through the seal design. Unbalanced seals unbalanced, balanced and double usually have a lower pressure limitation than balanced mechanical seal classifications. balanced seals.
Most of the original mechanical seals from the early days were unbalanced designs. Some common problems with unbalanced seals are listed below. If the pressure acting on the seal face is high enough, seal face lubrication is often compromised. These seals have higher heat generation than balanced seals because there is excessive closing force trying to keep the seal faces together. More rapid face wear occurs because of the higher closing forces. Higher power consumption occurs because of the extra drag caused by the higher closing forces.

Unbalanced, Balanced and Double Balanced Mechanical Seal Configurations

Unbalanced mechanical seal configurations

Line Does Not Intersect the Seal Faces

Dynamic

H
Figure 23 Unbalanced mechanical seal configuration

Balanced mechanical seal configurations

A balanced mechanical seal arrangement reduces the hydraulic forces acting on the seal faces through mechanical seal design. As the seal faces rub together, the amount of heat generated is determined by the amount of pressure applied, the lubricating film between the faces, the rotational speed, and the seal ring materials. Balanced seals reduce the seal ring area on which the stuffing box pressure acts. By reducing the area, the closing force is diminished. This allows for better lubrication resulting in lower heat generation, face wear and power consumption. Balanced seals typically have higher pressure limitations than unbalanced seals. To identify a balanced seal from an unbalanced seal you first have to find the dynamic secondary seal. This seal could be an o-ring, wedge, etc. Once this is found, determine which surface will slide in relation to the secondary seal as the seal faces wear. Draw a straight line along that surface until it passes through the seal faces. If the line drawn intersects the faces somewhere, the seal is a balanced design. If the line does not intersect (usually this line is along the shaft or sleeve surface), the seal is an unbalanced design.

Unbalanced, Balanced and Double Balanced Mechanical Seal Configurations

Balanced mechanical seal configurations

Line Intersects the Seal Faces

Dynamic Secondary Seal Figure 24 Balanced mechanical seal configuration. Note: the step machined into the sleeve and the balance line as it passes through the seal faces

Line Does Not X Intersect the Seal Faces /

Dynamic Secondary Seal

fi

Figure 25 Unbalanced design. Note: the line along the surface of the sliding secondary seal does not intersect the seal faces

Seal Balance Discussion 1

Seal Balance Discussion 2

CHAPTER? MECHANICAL

The following illustration describes a typical unbalanced rotating seal with a pressure in the stuffing box of 100 psi and a face area of 2 square inches. Given:

Pressure = 100 Ib/in2 Area = 2 in2 Force = Pressure x Area

Unbalanced, Balanced and Double Balanced Mechanical Seal Configurations

The following illustration shows a pressure of 100 psig at the outside diameter of the seal faces and 0 psig (or atmospheric) at the inside diameter. If we assume a linear pressure drop, the average pressure between the faces, will be 50 psi. 50 psi x 2 square inches (area) = 100 Ibs. of force tending to open the faces. Face B cannot move because of the gland. The 100 psi pressure also acts on the back of face A and since there is no pressure drop behind the seal faces: 100 psi x 2 square inches = 200 Ibs. of force trying to close the face (in addition to the spring force). This seal is unbalanced because the closing force is 2 times the opening force. This greater closing force can cause excessive heating of the lapped faces and therefore, operating limits would have to be set on this seal. The factors that would contribute to these limits would be: Speed - The faster the shaft rotation, the more heat generated. Fluid Viscosity - Some fluids can support a greater load. Temperature - Can affect viscosity. Shaft Size - Force increases with area. Pressure - Force increases with pressure. Face Material - Some materials conduct heat better than others.

Seal Balance Discussion 1 Seal Balance Discussion 2

I
I

I I

)OOC
Figure 26

Typical unbalanced rotating seal

0 Ib/in* Figure 27
Force profiles for an unbalanced seal

Seal Balance Discussion 3 If the rotating face area were reduced, as shown in the illustration below, the closing force would now be 4 times the opening force (a common condition).

Seal Balance Discussion 5 This is a force diagram of the rotating face. The dotted lines describe the actual force as measured in laboratory conditions. As you can see from the illustration below, the opening force can vary because the pressure drop is not linear in all cases.

Unbalanced,

Pressure

Balanced and Double Balanced Mechanical Seal Configurations

Figure 28
Rotary face area being reduced while increasing the dosing force

Presure drop is not always linear; it could be concave or convex (dotted lines) Figure 30
Pressure drop across the rotating face

Seal Balance Discussion 3 Seal Balance Discussion 4

Seal Balance Discussion 4 The closing force can be reduced by reducing the closing area (force = pressure x area). The easiest way to accomplish this is to install a stepped sleeve on the shaft. Now only 1 square inch of seal face is exposed to the pressure. The illustration below shows how this is accomplished. 100 psi x 1 square inch (area) = 100 Ibs. of force closing the seal face (in addition to the spring force). Seal Balance Discussion 6 If the seal were perfectly balanced (i.e., closing force equals opening force) with only 50% of the face seeing the closing pressure, there would be a danger of the faces opening due to the opening force exceeding the closing force because of a non-linear pressure drop.

Seal Balance Discussion 5 Seal Balance Discussion 6

50%
. *

Sleeve

5 C

50% of the face area is exposed to closing pressure Stepped Sleeve Figure 31
Perfectly balanced rotating seal face

Figure 29
Reducing the dosing force by reducing the closing area on which the pressure can act

Seal Balance Discussion 7 This is the balanced seal that is supplied by the major seal companies. The slight over balance (70% of the total face area) insures that the seal faces are not accidentally blown open. The ratio of closing face area percentage to non-closing face area percentage is called the balance ratio. In the case shown below, the balance ratio is a 70/30 balance.
Unbalanced, Balanced and Double Balanced Mechanical Seal Configurations

Seal Balance Discussion 8 This illustration shows the balance of a typical outside seal. Since outside seals work backwards, no sleeve is needed for balance. You only need to place 30% of the face area above the sliding elastomer. Also, note that in this design the balance line is on the o-ring O.D. (outer diameter), because internal pressure holds the o-ring against the clamp. All sliding or flexing of the face occurs at the o-ring outside diameter.

Seal Balance Discussion 7 Seal Balance Discussion 8

In all of the above cases we have ignored the affect of spring force. Most balanced seals have a spring or springs designed to exert a closing force of 10 to 30 Ibs. to the face area. You can calculate the actual pressure by the formula: 20 Ibs. x Face area = Spring pressure applied to the seal faces. In many seal designs, the springs are also used to seal the elastomer to the shaft. These seals need larger and more powerful springs. 0-ring seals do not have this problem.

Figure 33
Typical outside seal balance design

Most balanced seals have about 70% of the face area exposed to pressure

Figure 32
Typical balanced ratio for many balanced seals

Seal Balance Discussion 9 This illustration shows the balance line in a typical metal bellows seal. This balance line is also called the effective area of a bellows seal. Bellows seals are hard to balance properly because pressure changes continually alter the bellows configuration and change the balance line.

Seal Balance Discussion 11 In this example, the 70/30 balance is designed for pressure at the O.D. of the face. Although balanced seals can easily handle some vacuum service, deep vacuum may cause the faces to separate.

Unbalanced,

Figure 36
Typical 70/30 balance ratio on a single seal

Balanced and Double Balanced Mechanical Seal Configurations

Balanced Line
Seal Balance Discussion 9

Effective area varies with changes in pressure

Seal Balance Discussion 10

Figure 34
Typical metal bellows seal balance ratio
Seal Balance Discussion 11

Seal Balance Discussion 10 This illustration shows a typical stationary seal. This type of seal does not require a sleeve, because the sliding elastomer is located high in the gland. As in the rotating seal, 30% of the face area is placed below the sliding elastomer.

Figure 35
Typical stationary seal balance ratio

CHAPTEB2

Double balanced mechanical seal configurations

In double seal applications, it is advantageous to be able to handle pressure in both directions (i.e., positive pressure and vacuum). For dangerous applications, a higher pressure between the seals is better, but for a back-up seal application, a lower pressure would prevent product dilution when the inner seal fails. With a slight alteration, in the basic single seal design, we can easily accomplish a two way balance. Compare the two illustrations Figures 37 and 38. Note that one half of the dynamic (outer) o-ring groove is in the inner barrel, and one half of the o-ring groove is in the outer barrel. You can also see that the seal face is wider than normal. If you measured this face, you would find that the width (thickness) of the o-ring represents 40% of the area of the seal face. This design allows the o-ring to slide or shift in response to an applied pressure. If the pressure is higher on the left, the o-ring will shift to the right and vice-versa. By designing seals in this manner, a two-way or double balance is achieved. Let's look at the two applications that can occur using this double balance, pressure at the inner diameter and outer diameter of the seal rings.

Unbalanced, Balanced

and Double
Balanced Mechanical Seal Configurations
Double balanced mechanical seal configurations

Figure 37
Single seal with a typical 70/30 balance ratio

\30% \ 40% I 30%

Figure 38
Single seal with o-ring groove modification for two-way balance

Higher pressure at the seal outside diameter The double seal illustrated in Figure 40 shows the inboard dynamic o-rings are pushed against the outer barrel and the balance diameter is at the I.D. (inner diameter) of the o-rings. This allows 70% of the face to see the pressure. This is very similar to the 70730 single seal shown in Figure 39.
Higher pressure at the seal outside diameter

Higher pressure at the seal inside diameter This double seal shows the higher pressure coming underneath the faces and pushing the o-rings against the inner barrel, shifting the balance line to the O.D. (outer diameter) of the orings. The 70% to 30% balance remains the same. We now have a seal balanced in both directions. This is very important in double seal applications to prevent the seal from accidentally being blown open due to a loss of barrier fluid or pressure surges in the system. Look again at the typical single seal with a 70/30 balance. You can see that if the pressure is at the seal I.D., the balance becomes 30% to 70%, causing the faces to open.
Higher pressure at the seal inside diameter will cause the faces to blow up Figure 41
Single seal with a typical 70/30 balance
Unbalanced, Balanced and Double Balanced Mechanical Seal Configurations
Higher pressure at the

Figure 39
Single seal showing typical 70/30 balance ratio

Figure 40
Double seal showing higher pressure at the seal outside diameter. Note: how the inboard o-rings are being pushed into their respective grooves in response to the higher pressure

seal
outside diameter Higher pressure at the seal inside diameter

if the higher pressure is on the seal I.D. Note: because the seal is not double balanced the higher I.D. pressure will force the seal faces open

Figure 42
Double seal showing higher pressure at the seal inside diameter.

51

Pusher and l\lon-pusher Mechanical Seal Configurations

Pusher mechanical seal Learning the basic mechanical seal configuration terminology discussed in configurations this chapter allows for a greater A pusher type mechanical seal configuration degree of understanding of how seals has a secondary seal that moves axially are used in industry and, to some along the shaft or sleeve as the seal face extent, their engineering design history. wears. The process pressure and the spring This lesson will identify and describe mechanism "push" this secondary seal as the pusher and non-pusher mechanical the soft face wears away. Most mechanical seal classifications. seals fall into this configuration. Newer
pusher-type mechanical seals have improved their designs by not allowing these dynamic secondary seals to contact the shaft or sleeve of the equipment.

Pusher and Non-pusher Mechanical Seal Configurations

Pusher mechanical seal configurations Non-pusher mechanical seal configurations

Non-pusher mechanical seal configurations

A non-pusher type mechanical seal configuration has no secondary seals moving axially along the shaft while the seal face wears. Metal and rubber (elastomer) bellows seals are examples of non-pusher mechanical seal configuration designs. These bellows mechanical seals may contain secondary seals, but they are not dynamic in nature.

Pusher and Non-pusher (Mechanical Seal Configurations

Pusher mechanical seal configurations Non-pusher mechanical seal configurations

Shaft Seal is "Pushed" by Springs

Figure 43
Pusher mechanical seal configuration

Nonpusher mechanic al seal configura tion

Figure 44

53

Gas and Non-gas

Mechanical Seal Configurations

Learning the basic mechanical seal configuration terminology discussed in this chapter allows for a greater degree of understanding of how seals are used in industry and, to some extent, their engineering design history. This lesson will identify and describe the gas and non-gas mechanical seal classifications.

Gas barrier mechanical seal configurations

Gas barrier mechanical seal configurations use an inert gas to penetrate between the seal faces. The seal faces are profiled to capture the gas and provide lift for seal face separation or light contact. With separation, or light contact minimal heat is generated. The inert gas provides the lubrication for the seal faces and acts as a barrier against the product. A continuous and uninterrupted supply of inert gas is required for proper operation. Gas seals are commonly a multiple seal ring configuration. The inboard seal rings seal the product using the inert gas. The outboard seal rings seal the inert gas from escaping into the atmosphere. Advanced designs combine this functionality from four seal rings into two or three. Gas mechanical seal configurations are typically used in pharmaceutical, chemical, petrochemical, and refinery applications.

Gas and Non-gas Mechanical Seal Configurations

Gas barrier mechanical seal configurations Non-gas mechanical seal configuration

Non-gas mechanical seal configuration Non-gas mechanical seal configurations use the process barrier or buffer fluid to penetrate between the seal faces. Fluid lubricated seals generally operate using the product being sealed as the lubricating film. In many instances these products do not have the fluid properties capable of lubricating the seal faces without unacceptable leakage rates. Environmental controls are often necessary.
Non-gas mechanical seals comprise the vast majority of mechanical seal designs. They are used very effectively in a wide variety of applications. Non-gas seals should always be the first choice, but the application may warrant an upgrade to a gas barrier seal.

Gas and Non-gas Mechanical Seal Configurations

Gas barrier mechanical seal configurations Non-gas mechanical seal configuration

Figure 45
Gas mechanical seal configurations

55
Figure 46
Non-gas mechanical seal configuration