WELCOME

TO
PRESENTATION
ON
MECHANICAL SEALS
EDR Industrial Estate N. Gujarat
MANUFACTURING FACILITY
Corporate Office (Mumbai)
Administration (Mfg. Unit)
Engineering and R&D. (Mfg. Unit)
CNC Machines
Metal Bellow Welding
TIG Welding
Lapping Department (up to 1000mm)
CMM (Tesa Switzerland)
Surface Roughness Measurement Hardness Tester

Spring Load Testing Machine

Profile Projector
Pneumatic & Hydrostatic Testing
Dynamic Seal Testing
API 682 Seal Qualification Tests for Propane Gas, Hot
Oil, Caustic & Water.
BASICS OF SEALS
 MECHANICAL SEAL

It is a device that prevents / restricts undesirable

flow of fluid in the rotating equipment from high
chamber pressure to lower side.
Mechanical Seal Components

Mechanical
Seal Parts
 Essential Elements of a Mechanical Seal

These are the three essential elements of a mechanical seal:

• Seal faces:
One rotating with the shaft and one stationary in the pump casing,
cover or flange.

• Secondary seals:
One to seal the rotating face to the shaft and one to seal the
stationary face to the pump cover or flange.

• Metal parts:
To transmit torque and to provide an axial mechanical force to load
the faces.
 WORKING PRINCIPLE

BASIC SEAL WORKS ON THE PRINCIPLE OF:

• Thin liquid film between a rotary and stationary face.

• One soft face rotating against stationary hard face.

• No interruption in liquid film.

• No gas phase to ensure prevention of face contact.

• No solid particles to damage seal faces.

 Forces on Seal Faces

FORCES ON
SEAL FACES

HYRAULIC FORCE PLUS SPRING FORCE PROVIDE CLOSING FORCE

 ESSENTIAL REQUIREMENTS

• Seal faces must be flat and polished.

• Seal faces must be installed perpendicular to the

shaft.

• Spring force must be sufficient to maintain contact of

the faces.
 SEAL FACES

• Flatness

Up to 3 light bands maximum

•Surface Roughness (Ra)

(Depends on the Face Material)

Tungsten Carbide : 0.01 Micron

Silicon Carbide / Ceramic : 0.04 Micron
Carbon : 0.10 Micron
CLASSIFICATION OF
SEALS
 PUSHER AND NON-PUSHER SEALS

• The seals where dynamic elastomer rubs with

the shaft / sleeve surface by pushing action
from spring and causes fretting action are
known as PUSHER type seals.

• The seals where elastomer does not get

pushing action from spring are known as NON
PUSHER type seals.
 PUSHER SEAL

As the seal springs and other pressures in the stuffing box are exerted
on the seal, closure of the faces is achieved.
Rotating face and
dynamic O-ring.
Hard Stationary Face

Closing forces exerted

on the seal faces
 Pusher Seals

As the softer carbon face wears down, the rotating

face must move to maintain face closure.
 Pusher Seals

Minute particles of carbon and solids from the process liquid

that migrate across the seal faces build up on the shaft.
 Pusher Seals

This build up will ultimately cause the seal to “hang up” and in
most cases, failure will occur well before the seal is actually “worn
out”.
Pusher Seals
 Non Pusher Seal Seals
Non-Pusher

Carbon rotating face Hard stationary face

Metal bellows
Non Pusher SealsSeals
Non-Pusher
 Non PusherNon-Pusher
Seals Seals
The bellows core expands to
compensate for face wear.
Non Pusher Seals
Non-Pusher Seals
 Non-Pusher Seals
Non Pusher Seals
Debris can build up without causing hang up. This feature is
probably the most notable selling point when comparing a
bellows seal to a pusher type seal.
Pusher vs Non-Pusher Seals

PUSHER VS
NON PUSHER
 Unbalanced Seal

Stuffing Box pressure Ps Ps

Pa

Closing Area = π/4((d2)2 - (d1)2)

Opening Area= π/4((d2)2 – (d3)2)
Average pressure between seal faces (Ps +Pa)/2
Closing Area>Opening Area
Pressure Distribution on Seal Faces

Pressure
Distribution in
seal face
 Balanced Seal

Closing Force

Stuffing Box Pressure Ps

Ps

Pa

Closing Area = π/4((d2)2 - (d1)2)

Opening Area= π/4((d2)2 – (d3)2)
Average pressure between seal faces (Ps +Pa)/2 i.e. Ps/2
Closing Area < Opening Area
Metal bellows seals
Inherently are self balanced
Balanced seal. Seals
Metal Bellows

Face OD Line
Balance Line

Face ID Line
 STANDARD AND
ENGINEERED SEALS
80U/85U
 Single Acting
 Unbalanced
 Inside Mounted
 Independent of Direction of Rotation

Pressure: 10 bar (max)

Temperature: -60…+200° C
Velocity: 20m/sec

 Petrochemicals
 Petroleum Refinery
 General Chemicals
 Light Hydrocarbons
80B & 85B
 Single Acting
 Balanced
 Inside Mounted
 Independent of Direction of Rotation

Pressure: 35 bar (max)

Temperature: -60…+200° C
Velocity: 20m/sec

 Petrochemicals
 Petroleum Refinery
 General Chemicals
 Light Hydrocarbons
82
 Single Acting
 Balanced
 Independent of Direction of Rotation
 Springs Are Outside Media
 Stable Drive- Pins / Lugs
 No Shaft Fretting

Pressure: 25 bar (max)

Temperature: -20 to +180° C
Velocity: 20m/sec

 Food Industry
 Chemical Industry
 Mining Industry
 Water Treatment
Media Contaning Slurry
LPM 500/CG
 Single Acting
 Balanced
 Independent of Direction of Rotation
 Springs Are Outside Media
 Stable Drive- Pins / Lugs
 No Shaft Fretting

Pressure: 20 bar (max)

Temperature: -20 to +180° C
Velocity: 20m/sec

 Food Industry
 Chemical Industry
 Mining Industry
 Water Treatment
Media Contaning Slurry
LPS150/LPS155
 Single Acting
 Unbalanced
 Inside Mounted
 Independent of Direction of Rotation
 Universal Chemical Compatibility
Due to PTFE Elastomer

Pressure: 14 bar (max)

Temperature: -23 to +200° C
Velocity: 20m/sec

 Crystallizing Slurry
 Suspended Solid Slurry
 Saturated Chemical Slurry
 General Chemical Slurry
70U/75U
 Single Acting
 Unbalanced
 Inside Mounted
 Independent of Direction of Rotation

Pressure: 10 bar (max)

Temperature: -60 to +200° C
Velocity: 20m/sec

 Petrochemicals
 Petroleum Refinery
 General Chemicals
 Light Hydrocarbons
70B/75B
 Single Acting
 Balanced
 Inside Mounted
 Independent of Direction of Rotation

Pressure: 35 bar (max)

Temperature: -60…+200° C
Velocity: 20m/sec

 Petrochemicals
 Petroleum Refinery
 General Chemicals
 Light Hydrocarbons
900B/CG
 Single Acting
 Balanced
 Inside Mounted
 Independent of Direction of Rotation
 Multiple Springs Design
 Study Drive Mechanism

Pressure: 25 to 150 bar

Temperature: -40 to +180° C
Velocity: 20m/sec

 Oil Pipeline Pumps

 Boiler Feed Water Pumps
800HB2/CG Boiler Feed Water Seal

 Single Acting
 Balanced
 Inside Mounted
 Independent of Direction of Rotation

Pressure: 50 to 140 bar (max)

Temp.: -20 to +250° C (API Plan 23)
Velocity: <50m/sec
 Boiler Feed Water Pumps
 HSD Pumps
 Booster Pumps
 Drip Pumps
 Condensate Pumps
Fuel Oil Pumps
High RPM Seal
850B & 855B

Pressure: 20 bar (max)

Temperature: -45 to +180° C
Speed: 25,000 RPM

 Sundyne Pumps  Single Acting

 Sunflow Pumps  Balanced
 Refineries  Inside Mounted
 Independent of Direction of Rotation
 High Speed
20M
 Single Acting
 Outside Mounted
 Independent of Direction of Rotation

Pressure: 6 bar (max)

Temperature: -45 to +120° C
Velocity: 20m/sec

 Extremely Corrosive Services

20RL
 Single Acting
 Outside Mounted
 Independent of Direction of Rotation

Pressure: 6 bar (max)

Temperature: -45 to +120° C
Velocity: 20m/sec

 Extremely Corrosive Services

88B2
 Single Acting
 Reversed Balanced
 Outside Mounted
 Independent of Direction of Rotation

Pressure: 25 bar (max)

Temperature: -45 to +180° C
Velocity: 20m/sec

 Corrosive Chemicals
 Hydro Carbons
 General & Light Chemicals
40 & 45
 Single Acting
 Inside Mounted
 Independent of Direction of Rotation
 Inherently Balanced
 Welded Metal Bellows

Pressure: 18 bar (max)

Temperature: -20 to +200° C
Velocity: 20m/sec

 Chemicals
 Petrochemicals
 Refinery
 Corrosive Chemicals
60L
 Single Acting
 Inside Mounted
 Independent of Direction of Rotation
 Inherently Balanced
 Welded Metal Bellows

Pressure: 20 bar (max)

Temperature: -20 to +350° C
Velocity: 20m/sec

 Chemicals
 Petrochemicals
 Refinery
LPM 900/CG
 Single Acting
 Balanced
 Inside Mounted
 Independent of Direction of Rotation
 Cartridge Unit

Pressure: 25 bar (max)

Temperature: -20 to +180° C
Velocity: 20m/sec

 Ash Slurry Pumps

 Clinker Grinders
 Pulp Pumps
 Sludge Pumps
 Syrup Pumps
LPM 935
 Single Acting
 Balanced
 Inside Mounted
 Independent of Direction of Rotation
 Compact Cartridge Unit

Pressure: 35 bar (max)

Temperature: -20…+180° C
Velocity: 20m/sec

 Food Industry
 Chemical industry
 Mining Industry
 Water Treatment
 Media Containing Slurry
LPH 5050  Fully Split Components
 Ease of Installation
 Balanced Seal Faces

Pressure: 15 bar (max)

Temperature: Amb to +140° C
Shaft Speed: 3600 rpm (max)

 Utility Pumps
 Transfer Pumps
 Agitator & Vessels (As Drive Running Seal)
88B2A/DG  Single Acting
 Reversed Balanced
 Outside Mounted
 Dry Running
 Independent Direction of Rotation

Pressure: Vacuum to 8 bar (max)

Temperature: Amb to +120° C
Speed: 320 rpm

 Food Products
 Pharmaceutical Products
88B2A/WCG & 88B2A/WCK
 Single Acting
 Reversed Balanced
 Outside Mounted
 Without Bearing
 Independent Direction of Rotation

Pressure: Vacuum to 8 bar (max)

Temperature: Amb to +180° C
Speed: 320 rpm

 Corrosive Chemicals
 Hydro Carbons
 General & Light Chemicals
Pressure: Vacuum to 35 bar
(max)
Temperature: Amb. to +200° C
Speed: 600 rpm (max)
800BB/CK & 850BB/CK Bottom Entry Seal for Cheminer
Polyreactor, Size: 7.5”

Pressure: Vacuum to 27 bar (max)

Temperature: -20…+200° C
Velocity: 10m/sec
Double Dry running Fermentor Seal
Single Dry running Seal without Bearing for Glass Lined Reactor
Single Seal with Bearing for Glass Lined Reactor
Concrete Volute Pump Seal
CONCRETE VOLUTE PUMP SEAL (320 mm)
CONCRETE VOLUTE PUMP SEAL (254 mm)
MATERIALS OF
CONSTURCTION
 MATERIALS OF CONSTRUCTION OF
MECHANICAL SEALS

FACE MATERIALS SPRING MATERIALS

Carbon graphite-resin impregnated AISI 304
Carbon graphite-antimony impregnated AISI 316
PTFE-glass fibre filled Alloy-20
PTFE-carbon filled Hastelloy-C
Bronze Monel
Stellite
Cast Iron HARDWARE MATERIALS
Cast Chorme steel Steel
Ceramic AISI 304
Tungsten Carbide-cobalt binder AISI 316
Silicon Carbide-reaction bonded Alloy-20
Silicon Carbide-sintered Hastelloy-B
Graphite Loaded Silicon Carbide Hastelloy-C
SECONDARY SEAL MATERIALS Monel
Nitrile Bronze
Butyle AM-350
Neoprene
EPDM
Silicone
Viton
Hypalon
Fluorosilicone
Kalrez
Chemraz
PTFE
GFT
Flexible Graphite
 TEMPERATURE LIMITS FOR SECONDARY SEAL MATERIALS

Material DIN 24 960 Temp. Range Comments

Code 0C

Nitrile (Buna-N) P - 40 to + 120

Neoprene N - 20 to + 90
Butyl B - 55 to + 110
Silicone S - 50 to + 210
EPDM E - 40 to + 150 Not resistant to mineral fats and oils.

VitonR V - 18 to + 200 For hot water, up to a maximum of

1200C only.
Hypalon X1 - 40 to + 120

Fluorosilicone X2 - 70 to + 205 With basic fuels and oils, has good low
& high temperature properties,
particularly dry heat resistance.

KalrezR X3 - 20 to + 270 Fluorine containing solvents may result

in swelling.
Chemraz - 20 to + 240
PTFE T1 - 75 to + 230
Glass filled PTFE T2 - 212 to + 250
Flexible Graphite Y - 270 to + 480 Very good resistance to high and low
Temperatures.

Notes: The temperature limits listed are for guidance only.

The values may vary depending upon the nature of surrounding liquids.
VitonR & KalrezR are registered trade marks of Dupont, USA.
 SEAL FACE MATERIALS
Material Compressive Density Modulus of Coef. Of Thermal Hardness
Strength Elastisity Thermal Conduc-
Expansion tivity
(N/mm2) (g/cm3) (kN/mm2) (x10-6/0C) (W/m0C)

Carbon 250 1.83 234 2.88 6 100*

(Resin impregnated)

Carbon (Antimony 350 2.15 262 3.96 8 115*

Impregnated)

Tungsten Carbide 4750 15 635 5.0 100 1500**

(6% Co.)

Silicon Carbide 2750 3.1 365 4.5 145 2400**

Alumina Oxide 2650 3.9 385 4.32 35 1800**

(99.5%)

* Brinnel hardness
** Vickers hardness
 TYPES OF FLUIDS

• CLEAN FLUIDS

• FLUIDS WITH DISSOLVED / LIQUIFIED GASSES

Ambient / moderate temperatures
Sub-zero temperatures

• HIGH TEMPERATURE FLUIDS

Thermic fluids
Hydrocarbons
Petroleum products

• THERMO SENSITIVE FLUIDS

Wax, Bitumen, Tar, etc.

• FLUIDS WITH SUSPENDED SLURRIES

Non-abrasive slurry
Abrasive slurry
EQUIPMENT CONDITIONS
SHAFT RUNOUT : 0.08mm TIR (Max.)
SHAFT AXIAL PLAY : 0.08 mm TIR (Max.)
STUFFING BOX SQUARENESS: 0.08 mm TIR (Max.)
ST. BOX BORE CONCENTRICITY : 0.15 mm TIR (Max.)
SHAFT WHIP : 0.08 mm TIR (Max.)
 RUN-OUT

Maximum allowable limit 0.2 mm TIR

 SQUARENESS

Maximum allowable limit 0.2 mm TIR

 CONCENTRICITY

Maximum allowable limit 0.2 mm TIR

 SHAFT END PLAY (AXIAL FLOAT)

Maximum allowable limit 0.2 mm TIR

Trouble Shooting
 Trouble Shooting
The operating life of a mechanical seal is complete when
either face has worn entirely. Whenever a mechanical seal
has failed, no matter what the length of service, a through
inspection should be made to determine the cause of failure. If
either face has completely worn, the cause of failure is evident
and no further inspection is required unless this occurs in a
very short time. If both faces are intact, then inspection should
continue using trouble shooting procedures and inspection of
the entire mechanical assembly.

Troubleshooting can be carried out as depicted in the

following slides.
 CHECK LIST FOR IDENTIFYING CAUSES OF SEAL LEAKAGE
Symptoms Possible Causes Corrective Procedures

Seal spits and sputters Seal fluid vaporizing at

1. Increase cooling of seal faces.
(face popping) in operation. seal interfaces. 2. Check for proper seal balance
3. Bypass flush line will be
needed if not in use.
4. Enlarge bypass flush line
and/or orifice in gland plate.
5. Check for seal cooling.
___________________________________________________________________________

Seal drips steadily.
1. Faces not flat.
2. Blistered carbon graphite
seal faces.
3. Thermal distortion of seal
faces.
1. Check for incorrect installation.
2. Check for improper materials or
seals used for application.
3. Check for gland plate distortion
due to over tightening of bolts.
4. Check gland gasket for
compression.
5. Clean out foreign particles
between seal faces.
6. Check for cracks & chips at
seal faces during installation.
Replace seal and mating faces.
7. Improve cooling flush lines.
 CHECK LIST FOR IDENTIFYING CAUSES OF SEAL LEAKAGE
Symptoms Possible Causes Corrective Procedures

Seal drips steadily. 1. Secondary seals nicked 1. Replace secondary seals.

or scratched during 2. Check for proper seals.
installation. 3. Check for proper lead in
2. Over aged ‘O’ rings. Chamfers, burrs, etc.
3. Compression set of 4. Check for alternate materials.
4. Chemical attack (soft or
sticky).
___________________________________________________
1. Spring failure. 1. Replace parts.
2. Erosion damage of 2. Check with seal manufacturer
3. Corrosion of drive for other materials.
mechanism.
___________________________________________________________________________

Seal squeals during 1. Inadequate amount of 1. Bypass of flush line may be

operation. liquid to lubricate seal needed if not in use.
faces. 2. Enlarge bypass flush line and /
or orifice in gland plate.
 CHECK LIST FOR IDENTIFYING CAUSES OF SEAL LEAKAGE
Symptoms Possible Causes Corrective Procedures

Carbon dust accumulating 1. Inadequate amount of

1. Bypass flush line may be
on outside of gland ring liquid to lubricate seal
needed if not in use.
(atmospheric side of the faces. 2. Enlarge bypass flush line and /
Seal). 2. Liquid film evaporating
or orifice in gland plate.
between seal faces.3. Check for proper seal design
with Leak-Proof if pressure
in stuffing box is excessively
high.
___________________________________________________________________________

Seal leaks. 1. Nothing appears to be

1. Refer list under “seal drips
wrong. Steadily”.
2. Check for stuffing box face
squareness with shaft axis.
3. Check alignment of coupling,
foundation bolts etc., to prevent
vibration to avoid distortion of
gland plate or mating ring.
___________________________________________________________________________
 CHECK LIST FOR IDENTIFYING CAUSES OF SEAL LEAKAGE
Symptoms Possible Causes Corrective Procedures

Short seal life. 1. Abrasive fluid. 1. Prevent abrasives from

accumulating at seal faces.
2. Bypass flush line will bee
needed if not in use.
3. Check for obstructed flow in
cooling lines.
___________________________________________________

2. Seal running too hot.1. Increase cooling of seal faces.

2. Increase bypass flush line flow.
3. Check for obstructed flow
in cooling lines.
___________________________________________________

3. Equipment mechanically 1. Align the equipment.

out of line or alignment. 2. Check for rubbing of seal on
shaft / shaft sleeve.
Trouble Shooting
Illustrations
 FULL CONTACT PATTERN
OBSERVATION

Typical contact pattern for a non-leaking seal. Full contact on the mating ring surface
through 3600. Little or no measurable wear on either seal ring. If Leakage is present
with this type face pattern, the secondary seals must be examined.
SYMPTOMS CAUSES CORRECTIONS

Seal drips steadily. Shaft 1. Secondary seals nicked or 1. Replace secondary

rotating or stationary. scratched on installation. Seals.
2. Damaged or porous secondary 2. Check secondary
seal surfaces. sealing surfaces.
3. Compression set of O-rings. 3. Check for proper
materials.
4. Check for proper
lead in chamfers,
burrs, etc.
CONING (Negative Rotation)
OBSERVATION

Heavy contact on the mating ring pattern at the outside diameter of the sealing
plane. Fades away to no visible contact at the inside diameter of contact pattern.
Possible edge chipping on the outside diameter of seal ring.
SYMPTOMS CAUSES CORRECTIONS

Little or no leakage at 1. Faces not flat due to pressure. 1. Check for over pre-
high pressure. ssurization of seal.
2. Faces not flat. Incorrect 2. Check flatness of
Leaks steadily at low lapping. lapped faces.
pressure. 3. Compression set of O-rings.
THERMAL DISTORTION (Positive Rotation)
OBSERVATION

Heavy contact on the mating ring pattern at the inside diameter of the sealing plane.
Fades away to no visible contact at the outside diameter of contact pattern. Possible
edge chipping on the inside diameter of the seal ring.
SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when 1. Thermal distortion of seal 1. Improve cooling to

shaft is rotating. Usually faces. Seal faces.
no leakage when shaft is 2. Faces not flat. Incorrect lapping. 2. Consult Leak-Proof
stationary. for proper materials.
3. Check for proper
materials.
4. Check flatness of
lapped faces.
 MECHANICAL DISTORTION
OBSERVATION

Mating ring is distorted mechanically, creating two large contact spots. Pattern fades
away between contact areas.
SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when Faces not flat. 1. Check for gland
shaft is rotating or distortion due to over
stationary. tightening of bolts.
2. Check squareness of
parts used to clamp
mating ring in place.
3. Check stuffing box
face flatness of split
case pumps.
4. Check the gland
surface in contact
with the mating ring.
Must be free of nicks
and burrs. Surface
must show full
pattern.
 MECHANICAL DISTORTION
OBSERVATION

Mating ring being distorted mechanically, creating contact through approximately

2700. Contact pattern fades away at low spot.

SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when Faces not flat 1. Check for gland distortion due
shaft is rotating or to over tightening of bolts.
Stationary. 2. Check for high stuffing box
pressure.
3. Check squareness of parts
used to clamp mating ring in
place.
4. Check for stuffing box
flatness.
5. Check the gland surface in
contact with the mating ring.
Must be free of burrs and high
spots.
 MECHANICAL DISTORTION
OBSERVATION

Mating ring being distorted mechanically creating contact at bolts. High spots at each
bolt location.

SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when Faces not flat 1. Check for gland distortion due
shaft is rotating or to over tightening of bolts.
Stationary. 2. Change to softer gasket
materials between stuffing
box and gland plate.
3. Provide full face gasket
contact or contact above PCD
of bolts to prevent distortion
or bending of gland plate.
 HIGH WEAR OR THERMALLY DISTRESSEDD SURFACE
OBSERVATION

High wear or thermally distressed surface of mating faces (heat checking) through
3600. High seal ring wear with carbon deposits on atmosphere side of seal. Possible
edge chipping of seal ring due to opening and closing of seal faces.
SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when Sealed liquid 1. Check suction pressure to be

shaft is rotating or vaporizing at seal sure that liquid pumped is
Stationary. Sound from interface. above flash point.
flashing or face popping. 2. For multi-stage pumps check
to be sure that stuffing
pressure is high enough to
prevent flashing.
3. Check if seal is set at working
length (not solid length).
4. Check for proper running
clearance between shaft and
seal ring at operating temp.
5. Increase cooling to seal
faces.
 PARTIALLY DISTRESSED (THERMAL) SURFACE
OBSERVATION

Thermally distressed area approximately 1/3 of the contact pattern. Distressed area
1800 from inlet of seal flush. High seal ring wear with possible carbon deposits on
atmospheric side of seal.
SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when Sealed liquid 1. Check suction pressure to be

shaft is rotating or vaporizing at 1800 from sure that liquid pumped is
Stationary. Sound from seal flush. above flash point.
flashing or face popping. 2. Check for proper bushing
clearances at the bottom
of the stuffing box.
3. Increase cooling to seal
faces.
4. Check gland plate for
circumferential flush grooves.
 PATCHES OF THERMALLY DISTRESSED SURFACE
OBSERVATION
Patches of thermally distressed surface (heat checking). Few hot spots can be
observed. High seal ring wear with possible carbon deposits on the atmospheric
side of seal. atmospheric side of seal. Failure due to high spots is likely to occur on
light specific gravity liquids at high speeds and pressures.
SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when Sealed liquid 1. Increase cooling of seal

shaft is rotating or vaporizing at seal faces.
Stationary. Sound from interface. 2. Check for mating ring
Flashing or face popping distortion.
3. Check for seal interface
cooling.
 HIGH FACE WEAR AND GROOVING
OBSERVATION

High wear of mating ring. Seal ring grooved in to the mating ring evenly through
3600.
SYMPTOMS CAUSES CORRECTIONS

Seal leaks steadily when 1. Poor lubrication from 1. Increase cooling of seal
shaft is rotating or liquid being sealed. faces.
Stationary. Common when both 2. Check for abrasive particles
seal faces are made in the pumpage.
from hard materials. 3. Check for dead ended
2. Abrasives imbedded stuffing box.
in faces.
 OUT OF SQUARE MATING RING
OBSERVATION

Contact pattern through 3600, slightly larger than seal ring face width. High spot may
be present on the mating ring opposite an anti-rotation pin location. Mating ring
without static seals will rock or move in gland plate.
SYMPTOMS CAUSES CORRECTIONS

Seal may not leak when Mating ring face 1. Check the gland surface in
shaft is stationary but not square to the shaft. Contact with the mating ring.
leaks steadily when Must be free of nicks and
shaft is rotating. burrs. Contact surface must
show full pattern.
2. Check for proper anti-rotation
pin extension from gland.
3. Check shaft for proper
alignment to be sure that it is
not passing through
stuffing box at an angle.
4. Check for piping strain on
pump casing.
WIDE CONTACT PATTERN
OBSERVATION

Contact pattern considerably wider on the mating ring than the face width of the seal
ring.

SYMPTOMS CAUSES CORRECTIONS

Seal does not leak when 1. Equipment bearing 1. Check and/or replace
shaft is stationary. Leaks failure. bearing.
steadily when rotating. 2. High shaft deflection. 2. Check and determine if
equipment is being
operated within
specification.
3. Check and determine if
shaft is bent.
4. Check and determine if
coupling has been
properly aligned.
5. Check for piping strain on
pump casing.
ECCENTRIC CONTACT PATTERN
OBSERVATION

Eccentric contact pattern on mating ring. Width of contact equal to seal ring through
3600. No leakage if shaft has not contacted inside diameter of the mating ring.

SYMPTOMS CAUSES CORRECTIONS

If mating ring is damaged, Misalignment of mating 1. Check for proper

leakage will occur when rings. clearances between gland
shaft is stationary or plate and stuffing box.
rotating. 2. Check for proper mating
ring design and
clearances.
3. Check for proper
concentricity between
outside diameter of shaft
and inside diameter of
stuffing box.
Seal Failure Analysis
 WHILE REMOVING THE SEAL…….

• Store seal faces carefully

• Check mounting dimensions on the equipment

• Examine parts for debris and deposits

• Check rotary head compression

• Do not clean parts till the analysis is completed

• Pack damaged parts carefully

 SURVEY OF SEAL FAILURES

• Unstable operating conditions 59%

• Faulty installations 24%

• Improper seal selection 9%

• Miscellaneous other causes 8%

FAILURE OF MECHANICAL SEALS
GENERAL CHECKS REQUIRED:

SEAL SURFACES

DIMENSIONS:
WORKING LENGTH
SQUARENESS
CONCENTRICITY
SHAFT END-PLAY
RADIAL RUN-OUT

POSSIBLE LEAKAGE PATHS

DEPOSITS & DEBRIS:

CONTAMINANTS
WEAR DEBRIS
CHIPS / BROKEN PIECES
CORROSION PRODUCT
MISC. DEBRIS
FAILURE OF MECHANICAL SEALS
GENERAL CHECKS REQUIRED:

SEAL HANG-UP

SUB-ASSEMBLY CLEANING:
AVOID

PACKAGING:
PACK DAMAGED SEALS / PARTS AS NEW FOR
TRANSPORT TO MANUFACTURER
SEAL FAILURES

PREMATURE FAILURE

MID-TERM FAILURE
 SEAL FAILURES

PRE-MATURE FAILURE
• IMPROPER INSTALLATION

• INITIAL DAMAGE

• INADEQUATE COOLING
(WRONG ENVIRONMENTAL CONTROL SELECTED)

• IMPROPER SEAL SELECTION

PRE-MATURE FAILURE
SEAL FACES:
NICKS, SCRATCHES, FRACTURES
CONTACT PATTERN OF THE SEAL
FACES
THERMAL DISTRESS OF SEAL FACES

SECONDARY SEALS:
OMMITED SEALS
MIS-ASSEMBLED SEALS
DAMAGE TO SECONDARY SEALS
SURFACE FINISH
VOLUME CHANGE OR SWELLING
FRETTING OF SEAL SURFACES

DRIVE MECHANISM:
MIS-ASSEMBLY
OMISSION

FACE LOADING HARDWARE:

INCORRECT TYPE
MIS-ASSEMBLY
OMISSION
 SEAL FAILURES

MID-TERM FAILURE
• CORROSION, LEACHING-OUT

• INSUFFICIENT COOLING

• PRESENCE OF SOLIDS

• DUTY CYCLES:
REPEATED START/STOP OPERATION
MID-TERM FAILURE
SEAL FACES:
OVERALL CORROSION
LEACHING
ABNORMAL GROOVING
EROSION DAMAGE
PITTING, SCALING, GALLING
THERMAL DAMAGE
DEPOSITION OF SOLID MATERIAL
DISCOLOURATION

SECONDARY SEALS:
EXTURSION
CHEMICAL ATTACK
VOLUME CHANGE/SWELLING
COMPRESSION SET
HARDENING & CRACKING

DRIVE MECHANISM:
FAILURE
EXCESSIVE WEAR
 IMPORTANT POINTS FOR MECHANICAL SEAL ASSEMBLY

1. Visual inspection of each part.

2. Inspection of small components: grub screws, springs snap rings if

required.

3. Check entry chamfers of all components where ‘O’ rings enter or fit.

4. Carry out debarring / smoothening operation (wherever needed).

5. Check whether tapping is properly done.

6. Carry out dummy assembly to ensure all components fit properly.

7. Important components like Bearings, Seal faces, etc. must be assembled

with care.
 IMPORTANT POINTS FOR MECHANICAL SEAL ASSEMBLY

8. Carry out seal assembly in proper sequence.

9. Do self inspection at every stage of inspection.

10. Special care must be taken when installing ‘TCV’ ‘O’ rings.

11. No mineral oil is applied to component surfaces when installing ‘EPDM’

‘O’ rings.
 10 POINTS FOR SUCCESSFUL SEAL
INSTALLATION

•THROUGH READING AND FULL UNDERSTANDING OF SEAL INSTALLATION

DRAWINGS IS THE KEY TO PROPER SEAL INSTALLATION.

• KNOW THE MATERIALS YOU ARE WORKING WITH. CRITICAL SEAL

COMPONENTS ARE OFTEN MADE OF NON-DUCTILE MATERIALS THAT WILL CHIP,
CRACK OR OTHERWISE BREAK, IF CARELESSLY HANDLED.

• RESPECT THE PRIMARY AND SECONDARY AREAS. A LOT OF TIME HAS BEEN
SPENT IN MAKING THE PRIMARY SEALING AREA FLAT AND SMOOTH. DON’T
SCRACH, NICK, MISHANDLE AND GET THOSE AREAS DIRTY. SOMETIMES EVEN A
FINDERPRINT CAN CAUSE A SEAL TO LEAK. REMEMBER, TOO, THAT RUBBER.
PTFE AND GASKETS CAN EASILY BECOME CUT AND TORN WITHOUT TOO MUCH
ATTENTION TO THEIR WELL BEING.

• MAKE SURE THAT THE SHAFT SLEEVE IS FREE OF BURRS AND SHARP EDGES.
IT MUST BE FINISHED TO THE APPROPRIATE SMOOTHNESS. IN CERTAIN CASES,
SPECIFICATIONS WILL BE CALLED OUT ON THE INSTALLATION DRAWING.
 10 POINTS FOR SUCCESSFUL SEAL
INSTALLATION (CONT’ED)

• ESTABLISH YOUR SEAL INSTALLATION REFERENCE POINTS AND MARK THEM

CLEARLY AND PERMANENTLY ON THE EQUIPMENT. ALL SEAL INSTALLATION
DRAWINGS GIVE THE REFERENCE DIMENSIONS.

• USE SOUND JUDGEMENT DURING THE INSTALLATION. DON’T OVER TIGHTEN

BOLTS, ALIGN OR INSTALL WITH A HAMMER OR, IN ANY OTHER WAY, APPLY
ANYTHING EXCEPT PROFESSIONAL WORKMANSHIP TO THE JOB.

• PIPING IS IMPORTANT TOO. INCORRECT CONNECTIONS, REVERSED FLOWS,

DEAD ENDED LINKS, ETC. WILL CAUSE PREMATURE SEAL FAILURE. DON’T MIX
UP THE WATER JACKET PORTS WITH THE SEAL CIRCULATION PORTS. TIME
SPENT IN CAREFUL PIPING WILL BE TIME SAVED.

• BLEED ALL THE GASEOUS ENTRAPMENT FROM THE SEAL CAVITY BEFORE
START UP. IF YOU DON’T, THE SEAL CAVITY MAY VAPOUR LOCK AND THE SEAL
WILL BURN UP.

• MAKE SURE ALL VALVES ARE OPEN SO THAT THE SEAL IS ENSURED OF A
POSITIVE FLOW OF LIQUID AT ALL TIMES. IN THOSE CASES WHERE THE SEALS
REQUIRE AUXILIARY LINES, FLOWS - HEATING OR COOLING – BE SURE THAT
THE SEAL IS PREPARED FOR OPERATION BEFORE THE PRIMARY EQUIPMENT
GOES ON STREAM.

•TURN THE EQUIPMENT ON, AND ENJOY MAINTENANCE FREE OPERATION.

Thank You
From EDR Group