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TOPICS TO BE COVERED

Why at all a Mechanical Seal?


How does a Mechanical Seal work?
Types / Classification of seals.
Materials of Construction.
Environmental conditions.
Equipment condition.
Trouble Shooting & Failure Analysis.

CENTRIFUGAL PUMPS HORIZANTAL


CETRIFUGAL PUMPS VERTICAL
AXIAL FLOW PUMPS
MIXED FLOW PUMPS. / JET PUMPS.
POSITIVE DISPLACEMENT PUMPS.
RECIPROCATING PUMPS / PISTON PUMPS
DIAGHPRAM PUMPS
SCREW PUMPS SINGLE / DOUBLE / TRIPLE. / VANE
VACUUM PUMPS
SUBMERSIBLE PUMPS

TYPICAL END SECTION PUMP

Front End view of Pump.

Typical Stuffing box with Compression Packing

Impeller

Compression Packing

Packing Pusher

(Gland Packing)

(Gland)

Stuffing Box

Fastner

DISADVANTAGE OF PACKING.
Power Consumption is high. The Ratio of
Power Consumption of Mechanical Seal to
Compression is 1: 8
Leakage is very high and unpredictable.
Varies with the compression on the packing.
The Ratio of Leakage of Mechanical seal to
compression Packing is 1 : 600
No automatic wear compensation.
Fretting on Sleeve or Shaft.

Typical Mechanical Seal & Leakage Path.


1. Gland to Pump face- Sealed with a
Gasket.

Rotary

4. Under the Seal Ring

2.Over the top


of the
seal-ORing

3. Along
the Shaft
Stationary

5. BETWEEN
THE SEAL
FACES

Stuffing Box Pressure


The pressure acting on the stuffing box which must be sealed.
IT IS A FUNCTION OF PUMP IMPELLER DESIGN
AND THE PRESENCE OR CONDITION OF WEAR
RINGS.

Impeller design and Stuffing box pressure


Back vanes - Open impeller
Suction + 25% of differential = Stuffing box pressure

Balance Holes - Closed impeller


Suction + 10% of differential = Stuffing box pressure

Double Suction
Suction pressure = stuffing box pressure

Viscosity
Generally the higher the viscosity, the better the
lubricating characteristics
A product with a viscosity of 20,000 SSU (5000 cp) can be
sealed with standard seals
Beyond 5000 cp, the drive unit has to be beefed up to
compensate for the increased shear occurring at the sealing
faces.
For high viscous applications:
Single seal with external flush
Double seal with external flush
The viscosity & lubricity of water decrease with increased
temperature. Above 82C (viscosity 0.35 cp) seal faces can
contact each other and wear rapidly, unless specially designed

Specific Gravity
Specific Gravity = Density of a substance
Density of Water at 4C
Specific gravity is used to estimate the lubricity of light
hydrocarbons
Specific gravity below 0.68 (Heptane), require one face
as carbon and special seal face design with higher
balance to contain fugitive emissions

Vapour Pressure
THE PRESSURE AT WHICH A LIQUID WILL FLASH
INTO VAPOR AT GIVEN TEMPERATURE
If seal generated heat causes the sealing liquid to boil
in seal chamber pressure, the liquid film between the
seal faces will vaporize.
Solution :
Increase seal chamber pressure with proper bypass
flush line and throat restriction device.
Cooling the seal chamber. Seal chamber should be kept
at least 15C below the boiling point of the product at
the seal chamber pressure

Cavitations
OPERATED UNDER CAVITATING CONDITIONS
FOR SUFFICIENT LENGTH OF TIME:
* Pitting of impeller vanes and pump volute
* Short bearing life and heavy loading
*Shaft breakage and other fatigue failures in the pump

Damages to mechanical seals can be :

Short seal life


Worn pins and pin slots
Broken springs
Shaft fretting
Chipping of carbon faces

High speed video shows that seal face temperature excursions


occurred when gases were drawn across the seal faces and by
the formation of gas bubbles in the seal chamber near the seal
faces during pump cavitation.
Seal Performance during cavitation :
Zones

Normal Pump
Operation

Pump Cavitation
Mode

Seal chamber
temperature (C)

65

65

Shaft sleeve
vibration, mils p-p

1.9

2 to 8.4

Seal face
vibration, mils p-p

<2.0

13 to 35

Seal face
temperature ( C )

67 to 74

166 to 427

Nomenclature of a Typical Seal


Drive Pins
Set Screw

Springs

Collar

Gland Ring
Insert
Mounting

Compression Ring
Spring Pins
Insert
Compression Unit
Seal Ring
Shaft Packing

Gland Gasket

TYPES OF SEALS
Outside seal
(Single seal

Based on mounting
Inside seal
Based on arrangement
Single seal

Double seal

Tandem seal Dry running seal


High pr seal

Based on design
Balanced

Pusher type
(spring design)

Single coil
spring

Multi
spring

Unbalanced

Gas seal

Special seal

Based on construction

Slurry seal

Custom built seal


Bellow design

Rotary
bellow

Teflon bellow
Metal bellow

Stationary
bellow

Elostamar
bellow

Single Out Side Seal

EFFECT OF PRESSURE ON SEAL

BALANCED SEAL DESIGN FOR HIGH PR.

TANDEM SEAL

METAL BELLOW SEAL

MATERIALS OF CONSTRUCTION
Seal Hardware Materials.
300 Series Stainless Steel like SS 316, SS 316L
400 Series Stainless Steel like SS 410
Duplex Stainless Steel
Alloy 20
Hastalloy B & C
Monel
Inconel
Nickel
Titanium

SEAL FACE MATERIALS

Other General Seal Face Materials

Stellite
Ni-Resist
Bronze

Secondary Packing Materials

Pure Graphite

-400 C

Environmental Control
Environmental control is a key factor for
the proper functioning of Mechanical seal.
(I.e) flushing / quenching / Cooling or
heating / Jacketing / etc.,

API Plan 02 (Jacket)

Flushing of Seal.

API Plan 12

API Plan 13
Re-circulation from Seal Chamber to Suction

API Plan 21
Bypass Flush through Heat Exchanger
Orifice (when specified)
Close
Clearance
Bushing

Heat Exchanger

API Plan 23 -- Heat Exchanger


Re-circulation through Heat Exchanger
Single Inside Seal
with Pumping Ring

Pumping Ring

Circulating Device

API Plan - 31

API Plan 32
External Flush
Single Inside Seal
Close

Flow
Meter

Pressure Gauge

Clearance
Throat
Restriction /
LIP SEAL

External
Flushing
Source

LIP Seal Assembly

API Plan - 51
Vent Connection

API Plan - 52

API Plan - 53

API Plan 54

API Plan - 61

API Plan - 62
Flush and Quench

EQUIPMENT CONDITION

Shaft Whip -- Best limit 0.004


Check Condition of Radial Bearing

New Shaft Thrust bearing location.


Best Limit 0.004

Care has to be taken while removing front casing.


Max. 0.003

Care has to be taken while removing


the sleeve

Max 0.004

Causes of Seal Failure

Failure Analysis

Failure due to Chemical Attack

Fretting Corrosion

Failure Due to Mechanical Action

High Spots

Seal Face Deflection

O-Ring Extrusion

Anti Extrusion Ring.(with GFT)

Erosion

Drive Pin Wear

Failure Due to Heat Build up

Heat Checking

Vaporization.

BLISTERING

SPALLING

Oxidation & Coking

2PM 41D

11PM 6A

11P 10A

11PM 3B

11PT 2B

12PM 1B

16PM 4A

16PM 4A

42PM 17A

42PM 17A

12PM 1B

16PM 4A

CASE STUDY
Unit:
MEROX
Pump Item No.
16 P 04 AAmine Sump Pump.
Pump make
KSB WKT 50 / 2
Fluid handled:
Acid Condensate / H2S / NH3& solvents.
Operating Temp.
70o C
Max. Discharge Pr.
8.0 Kg/ cm2
Seal Size & Type
1.750 RA Outside seal
Seal Faces
Tung.Car / Carbon
Packing
Viton.
Flushing Plan
11 & 13
Due to urgent need and since there was no pump was available for the service, HPCL
had a spare Hot Well pump, which met the operating parameters was installed.
After few days of running the seal has failed.
The pump was opened and the internals were checked. The main attack was to the
secondary packing. Due to damage of packing the Carbon face also damaged.
Remedial action was taken by modifying the seal and the packing were revised to
Kalrez. The revised seal was installed about a week back, and the performance is being
monitored.

MECHANICAL SEAL CHECKS


Check seal flushing, steam purging & stuffing box cooling for
high temperature services.
Ensure flushing oil flow in the seal flushing line by sensing
the temperature of the line. It should have the same
temperature as that of the pump casing (incase no cooler is
provided).
Ensure flushing line is insulated for hot services.
Incase seal is smoking, check for proper cooling water
circulation to stuffing box, flushing flow is adequate.

Ensure LP dry steam to seal chamber as quench steam. Flow


to be adjusted so that steam does not impinge on bearing
housing

Contd

Ensure proper insulation to quench steam


lines.
Incase of seal puffing, check for condensate
in purging steam, contamination in product,
inadequate flushing at seal, periodic vapor
locking of pump. If no problem detected,
inform rotating section for further check.

INTERACTIVE SESSION.
Use of Mech. Seal or Packing.
Can we convert packing to seal vis-a vis.
Carbon face to be Rotary or Stationery
Selection of seal type.

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