CHAPTER 1

MECHANICAL
SEAL
Purpose
and Parts

Chapter 1
Mechanical Seal
Purpose and Parts
Introduction
Mechanical seals continue to evolve
using todays technological advances.
However, the purpose and the basic
parts of a mechanical seal have
not changed since its inception.
This chapter will explain the purpose
of mechanical seals along with their
basic parts and respective functions.

Objective
Upon completion of this chapter
you will be able to describe
the purpose of a mechanical seal,
the various mechanical seal parts
and their function.

Introduction
Objective

The Mechanical Seal Purpose

Mechanical seals are a very common
sealing device used extensively
throughout industry today.
This lesson will define a mechanical
seal and describe its purpose.

They may leak flush water or they

may leak product, but they still leak.
This fact is the number one reason
why mechanical packings are being
replaced by mechanical seals.

The packed stuffing box

Before mechanical seals, the
attempts to control leakage of
product around reciprocating or
rotating shafts meant restricting
the shaft and stuffing box wall
clearance. This was accomplished
by packing a soft, resilient material
around the shaft in what is typically
referred to as a stuffing box.
Compression packings, referred to
as mechanical packings, are still
used in many applications because
of their low initial cost, availability,
familiarity, and ease of installation.

Another problem with mechanical

packings is that they will cause shaft
or sleeve damage given enough time.
Even the newer materials will
eventually fret the shaft or sleeve.

However, there are issues with

mechanical packings. They can
be expensive to maintain and in
some cases result in excessive
product losses to the environment.
This high potential expense is
often the result of improper packing
installation or poor equipment
condition. But the fact still remains
with few exceptions, All packings
must leak to work properly.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts

The
Mechanical
Seal
Purpose
The
packed
stuffing box

5
Figure 1
The packed stuffing box

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
The
Mechanical
Seal
Purpose
The
purpose
of a
mechanical
seal

The purpose
of a mechanical seal
Mechanical seals were developed
to address the disadvantages of and
problems with compression packings.
The purpose of a mechanical seal
is to reduce or, in most cases,
eliminate leakage of product or
other fluids to the environment.
A mechanical seal consists of
two extremely flat surfaces, called
faces, held together by product
pressure and spring force to prevent
product from escaping to the
environment. Visible leakage that
comes from compression packing
is usually eliminated. Non-visible
leakage ( i.e., fugitive emissions ) is
often reduced by mechanical seals
in order to meet the environmental
laws of local, state, and federal
regulatory agencies. Compression
packings just cannot be used to
comply with these environmental laws.

Mechanical seals that are applied

correctly can reduce the operating
and maintenance costs of most plants.
However, a higher level of training
is required for engineering and
maintenance personnel in order to
ensure mechanical seal reliability.
It is important to note that
initial installation costs for seals
may be higher than compression
packings. It is also important to
realize increasing system reliability
means that mechanical seals
must be applied correctly and
the seal may require custom
designing for a certain application.

Mechanical Seal

6
Figure 2
The purpose of a mechanical seal

The Sections of a Mechanical Seal

All mechanical seals are constructed
similarly. They all can be distilled
down to three basic sets of parts:
the primary seal rings, the secondary
seals, and the metal parts.
This lesson will define these parts
and explain their function.
Mechanical seal construction
Almost every mechanical seal is
constructed of the same three basic
sets of parts. In no particular order,
the parts are as follows:
Primary seal rings
Secondary seals
The metal hardware

The primary seal rings

The primary seal rings are a set
of two extremely flat surfaces
held together by process and spring
pressure to prevent product from
escaping. In a mechanical seal,
one ring must rotate with the shaft
while the other ring does not rotate.
These rings are commonly referred
to as the rotary seal ring and the
stationary seal ring or seat, respectively.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
The
Sections
of a
Mechanical
Seal
Mechanical
seal
construction

Of course, each of the above is

comprised of many parts which are
discussed in the following sections.

The
primary
seal rings

Primary Seal Rings

7
Figure 3
The primary seal rings

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
The
Sections
of a
Mechanical
Seal
The
secondary
seals
The
metal parts

The secondary seals

All mechanical seals will
use some type of secondary
sealing device to eliminate
leakage at all other areas
outside the primary seal rings.
The two main places secondary
seals are used is between
the mechanical seal and the
equipment shaft or sleeve;
and between the seal gland
and pump stuffing box face.
These sealing devices can
take many forms. They can
be any one of the following:
O-rings
Gaskets
U-cups
V-rings
Teflon* wedges
Molded rubber boots
Chevrons
Square packing

The metal parts

Mechanical seals also have
plenty of metal hardware.
Typical hardware may include
the following, just to name a few:
Shaft sleeves
Gland rings
Collars
Compression rings
Pins
Springs
Bellows
Drive lugs
Snap rings
Seal ring holders

*Teflon is a registered trademark of DuPont Dow

Metal Parts

Secondary Seals

8
Figure 4
The secondary seals

Figure 5
The metal parts

Primary Seal Rings

Understanding the function of
the primary seal rings is the basis
for all mechanical seal discussions.
This lesson will define seal face
flatness, describe how an optical
flat works and try to explain what
takes place between these rings.
The primary seal rings
The primary seal rings consist of
two extremely flat surfaces held
together by process and spring
pressure to prevent product from
escaping. In a mechanical seal,
one ring must rotate with the shaft.
This ring is commonly called the
rotary seal ring. The second ring
does not rotate and is commonly
called the stationary seal ring.
Dissimilar materials are commonly
used for the rotary and stationary
seal rings. One of the seal rings
is usually a softer ring relative to
the other. Because the ring is softer,
it will wear as the mechanical seal
rotates. The softer seal ring contact
surface or face is always more
narrow than the harder seal ring
face material. As the narrow,
softer face wears on the seal ring,
it maintains contact with the harder
face throughout the life of the
mechanical seal. The narrow soft
face can be on either the rotary
or stationary seal ring. Its location
depends only on seal design and type.
When the sacrificial, narrow, softer
face has worn down completely,
the mechanical seal life has expired.
One can see a similarity between
mechanical seal face wear and
tread wear on an automobile tire.
When the seal face wears down,
leakage is likely, and its time for a
new seal. Illustrations showing a
new soft face made of carbon and
a worn soft face are shown in
Figures 8 and 9.

Primary Seal Rings

Primary
Seal Rings

Figure 6
The primary seal rings

Harder, Wider
Seal Ring

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts

The
primary
seal rings

Narrow, Softer
Seal Ring

Figure 7
Typical mechanical seal showing the narrow
soft face and the hard wide face

New Carbon
Figure 8
New soft face made of carbon.
Note: the long nose

Worn Carbon
Figure 9
Worn soft face. Note: the shorter nose

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Primary
Seal Rings
Seal face
flatness
Flatness
defined

Seal face flatness

A mechanical seal consists of two
seal rings whose faces have to be
extremely flat. There are numerous
factors that determine rate of
fluid flow between the seal faces,
however, the distance between
the two face surfaces is the factor
that has the greatest influence.
This means that it is vital that
the distance between these two
faces be minimized.
To achieve optimum seal face flatness,
the seal faces must be lapped and
polished. The first step is to lap or
create a flat surface. This surface is
then polished to achieve a reflective
finish. To ensure that a seal ring has
the proper face flatness, specialized
equipment is necessary to measure it.

Figure 10
Primary seal rings

10

Flatness defined
Flatness is a term that describes
a level surface that has no elevations
or depressions. We use terms like
waviness, or concave and convex
surfaces to describe the condition
when we refer to the mechanical
seal faces. It is this flatness that
is of the most concern to us.
Testing has shown that if the
faces are separated by a space
of about two microns or more,
the seal faces will show visible
leakage and, depending upon
the separation, let solids penetrate
that might score or in some way
injure these lapped faces.
We just said that the seal faces
should be separated by two
microns or less to seal properly.
Considering that the human eye
can, at best, see items that are
forty microns or greater, it stands
to reason that we cannot
detect the proper face flatness
by ourselves without help.
Some understanding of the
proper terminology is required
to discuss how we measure
distances this small.

What is a Helium Light Band?

To understand how we measure
such small distances we have
to know that it is a characteristic
of light to travel in waves.
These light waves can interfere
with each other, causing the
light to disappear. This appears
as a black band on the surface
of the measured surface.
It results from the interference
of the wavelength going and
coming from the reflective surface
of the piece being measured.
When you discuss visible light, color
and wavelength mean the same
thing, so to make the measurement
we use a monochromatic or single
wavelength light source ( mono means
one, and chromatic means color ).
Any color ( wavelength ) could
be used, but most companies use
a pink color that comes off a
helium gas light source. This color
has a wavelength of just about
0.6 microns ( 0.000023 inches ).
This monochromatic light operates
using a very simple law of physics.
This law is that if two lights with
identical wavelengths interfere with
each other the result is blackness,
not light. Please review the two
illustrations Figures 11 and 12.

1 Helium
wavelength

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts

0.0000232 inches
(0.00059 mm )

Primary
Seal Rings

Figure 11
Helium wavelength

What is
a Helium
Light Band?

Helium Light Source

Reflected Light
Cancel Points
1/2 Helium Wavelength =
1 Helium Lightband =
0.0000116 inches (0.000295 mm )
Figure 12
Helium light reflecting off a surface
causing light waves to cancel and
black lightbands to form

11

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Primary
Seal Rings
What is
an
Optical Flat?

What is an Optical Flat?

To measure seal face flatness
a precision ground and polished
clear glass of optical quality is
required. This type glass is called
an optical flat. Optical flat glass
is lapped flat on at least one side
to a certain accuracy standard.
This working standard is a
maximum of 0.000004 inches
(4 mK ) or 0.1 microns
The optical flat 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 wavelength of helium,
or an even multiple of the
number, a dark band is formed.
This is referred to as a helium
light band and because it is
one half the wavelength of
helium it measures 0.3 microns,
or 0.0000116 inches.
To understand this measurement
we might mention that the
smallest object that can be seen
with the human eye is 40 microns
or 0.0015 inches. Another way to
understand this measurement is
to know that the average coffee
filter is in the range of 10 to 15
microns or 0.0004 - 0.0006 inches.
Experienced seal people know
that this means that solids
cannot penetrate between the
seal faces unless they open.

Figure 13
Monochromatic light and optical flat

Figure 14
Optical flat under a monochromatic light showing
helium light bands on a mechanical seal ring

We check flatness of our seal face

by comparing the pattern we see
to a chart that is supplied by the
measuring equipment manufacturer.
A sample of this chart is shown in
Figure 15.

12

Figure 15
Typical flatness interpretation chart
showing light wave band pattern guide

Reading Light Bands

When using an optical flat
there are two methods that can
be used to determine face flatness.
The two methods are the
wedge and contact methods.
Wedge Method
This method is usually used when
the surfaces of the work and the
flat are nearly parallel. The flat will
contact the work at one point.
Use a tissue at this point between
the flat and the work. Read the
bands in two directions by changing
the pressure point by 90 degrees.
The amount of the curve indicates
flatness. If the band curves across
two adjacent bands then the
piece is flat within 23.2 mK.
Contact Method
This is the best method for Ring
Shaped Work. The optical flat
rests on the highest points of the
work. Establish an imaginary line
parallel to the bands in the center
of the piece. Count the bands
between one side of the line,
then on the other side of the line.
Divide the largest number by
the smallest number. The result
indicates the flatness in light
bands. Localized distortions are
measured by taking an imaginary
line across the light bands.

Contact
Point

Count the number of light bands

the line crosses. This indicates
the flatness in light bands.
Silicon carbide, tungsten carbide
and ceramic seal faces are less
likely to be out of flat than carbon.
Flatness is a good indicator of
wear on the wide face of the seal.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Primary
Seal Rings
Reading
Light
Bands

Contact Method
1 Light Band
0.0000116 inches
0.3 microns

Contact Method
2 Light Band
0.000023 inches
0.6 microns

Figure 17
Flatness interpretation chart
showing the contact method for various rings

Contact
Point

Contact
Point

Contact
Point

Optical Fla
t

Optical
Flat

Optica
l Flat

Optical
Flat

Work

Work

Work

Work

Wedge Method

Wedge Method

Wedge Method

Wedge Method

Figure 16
Flatness interpretation chart
showing the wedge method for various symmetric pieces of work

13

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Primary
Seal Rings
Flatness
Readings
Rules
of Thumb
Seal face
lubrication
The
asperity
theory

Flatness Readings Rules of Thumb

Hard seal faces should read less than
three light bands for seal faces with
a mean diameter up to four inches.
There should be no visible leakage.
Leakage is always subject to definition,
but three light bands of flatness
will allow a mechanical seal to seal
a vacuum down to a measurement of
one torr (one millimeter of mercury ).
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 face that is flat.
Most large seal manufacturers use
finite element analysis techniques
to design these faces. Some repair
and smaller seal facilities supply,
replace or repair these faces with
no provision for keeping them flat
during temperature and pressure
transients.
Carbon is a flexible material.
It can go out of flat easily.
It should go back flat again when
it presses against the hard face.
Some seal companies lap faces
concave or convex on purpose.
That is why three helium light
bands is often the specification.
Tests done with two hard faces
(they do not relap easily ) show that
visible leakage starts to occur at
about five helium light bands.

14

It is not a good idea to relap carbon

graphite faces. Imbedded solids
are pushed even further in, causing
scoring and wearing of the hard face.
Remember carbon cannot wear
a hard face, only foreign material
stuck in the carbon can do that,
and relapping cannot remove it.

Seal face lubrication

Mechanical seals typically require
a layer of gas or liquid lubrication
between the rotary and stationary
seal faces. Seal face lubrication
is crucial in maintaining seal life
and reducing energy consumption.
Even though mechanical seals have
been in operation since the early
1900s in one fashion or another,
it is still not known what actually
happens between seal faces.
There are at least five common
theories of what may be happening
between the faces. These are
explained in more detail as follows.
The asperity theory
This theory was proposed by
the Battell Memorial Institute back
in 1963. They were commissioned
by the U.S. Air Force to find
out once and for all what was
happening between seal faces.
Battell made one of the faces out
of glass and photographed the
result. The test was run on a carbon
graphite face running against this
glass face. The sealing medium was
MIL7808 oil, a high grade turbine oil.
Battell observed that the faces
were separated by vapors coming
from the asperities in the seal faces.
Figure 18-A describes the seal
face lapped flat. Being a mixture
of carbon and graphite, the graphite
transfers Figure 18-C to the
hard face, leaving asperities
(roughness of surface). Unlike
other materials that tend to wear
smooth, these asperities continue
to appear as the faces wear
( graphite is a natural lubricant ).
Battell observed vapors coming
from the asperities Figure 18-B.
The British picked up on this idea
and came out with vapor phase
seals in which the seal faces
were heated to vaporize the fluid.

Figure 18
Asperity theory

The pressure drop theory

This theory has some similarities
to the asperity theory. It assumes,
that as asperities develop, the fluid
goes through a series of pressure
drops across the face until all
pressure is lost at the atmospheric
side of the seal faces. In addition,
a meniscus of fluid forms on the
inside diameter of the face and
is held there by centrifugal force.

The
pressure
drop
theory
The
pressure
wedge
theory

Process Pressure Side

D
ro
p

Primary
Seal Rings

Pr
es
su
re

Carbon
Graphite

The pressure drop across this

wedge is assumed to be linear
for most applications. This means
that as the fluid travels from
the process pressure side ( high
pressure ) to the atmospheric side
( low pressure ) the pressure drops
by the same amount for every
0.0001 inches or 0.01mm we move
across the seal face. However, the
drop may not be linear across the
wedge and seal manufacturers
need to be aware of this to
properly design mechanical seals.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts

Li
ne
ar

Carbon
Graphite

The pressure wedge theory

This theory is the one we use when
discussing mechanical seal balance.
It claims that the faces are running
on a film of liquid that produces
hydrodynamic forces, keeping
the faces apart. The liquid is forced
between the faces by a combination
of pressure and capillary action.

Seal Face

The one problem with this theory

is it does not explain how we are able
to run ceramic against ceramic or
tungsten carbide against tungsten
carbide. These materials do not have
asperities on the seal face.

Pressure

Rotating
Face

Stationary
Face

Miniscus held by centrifugal force

Non-Linear
Pressure Drop
Atmosphere Pressure Side
Figure 20
Pressure drop across the pressure wedge
from the process pressure side
to the atmospheric pressure side

Figure 19
Pressure drop theory

15

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Primary
Seal Rings
The
dry running
theory
The
three band
theory

The dry running theory

This theory proposes that no
lubricant is necessary because the
seal is running on a combination
of carbon versus graphite.
The hard face is there to provide
a surface for the graphite to stick to.
While there is evidence that seals
run well in solvents and hot
water that provide no lubrication,
this theory does not explain
how hard faces can be run in
these non-lubricating applications.

The three band theory

This theory uses the observation
of three distinct areas, or bands,
between some seal faces as its basis.
A band of liquid forms on the outside
area, a vapor band in the middle and
a dry band on the inside diameter.
All of the conditions noted previously
have been observed when using
mechanical seals. The observation
of a certain phenomenon or theory
may be a function of the face
material and the fluid being sealed.
Tribological researchers really do not
know. The only thing we know for
sure is that something is happening.
Whenever we install seals we try to
keep the faces immersed in liquid.
Seals immersed in lubricating fluid
seem to last longer, as the faces
do not wear as quickly. One day we
will be able to explain what happens
between the faces and design seals
with extremely long lives.

Liquid
Vapor
Dry

Figure 21
Three band theory

16

Secondary Seals
CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts

In a mechanical seal there are

numerous secondary seals that
function to keep the liquid from
leaking to the atmosphere. This
lesson will describe the types and
functions of various secondary seals.
It is very important to understand
the limitations of each type of seal
so that it will be used properly.
The gland seal
The gland seal is a static seal.
A static seal is a seal between
two surfaces that have no relative
motion to each other. It functions to
provide sealing between the gland
and the face of the stuffing box.
The gland seal is usually a gasket
or an o-ring and can be made of
many different materials. As with all
secondary seals, this seal needs to be
compatible with the fluid being sealed.

Secondary
Seals

Dynamic Shaft Seal

The
gland seal

Figure 23
Typical dynamic shaft seal

The
shaft seal

Soft Seal Face Wears

Gland Seal

Shaft Seal is Moved by Springs

Figure 24
Dynamic shaft seal being moved by the springs
to the right as the soft seal face wears

Figure 22
The gland seal

The shaft seal

The shaft seal is the part between
the mechanical seal and the shaft
( or sleeve ) that prevents fluid from
leaking along the shaft out to the
atmosphere. The shaft seal can come
in various types and configurations.
Some common ones are o-rings,
V-rings (chevrons ), U-cups, wedges,
and boot-type seals.

Dynamic
Seal

Static Shaft Seal

Figure 25
Static shaft seal plus another secondary seal
that is dynamic and moves to the right
as the soft seal face wears

17

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Secondary
Seals
O-ring
seals

O-ring seals
An o-ring is a sealing ring with
a circular shaped cross section.
O-rings come in many different
sizes and cross sections depending
on the application. They are very
common in mechanical seals
and have two distinct advantages
over most other secondary seals.
It is impossible to install
an o-ring the wrong way.
Think about it. You cant do it.
An o-ring can seal both
positive pressure and vacuum.
This is important if the pressure
in the stuffing box can fluctuate
between these two extremes.

V-ring
(Chevron)
seals

O-ring Seal

V-ring (Chevron) seals

The V-ring, or Chevron, is a sealing
device that requires constant
loading in order to seal properly.
The V-ring must be oriented so the
V opens toward the fluid pressure.
If the V-ring is installed backwards,
the pressure in the stuffing box
could force the fluid underneath
the ring and leak to atmosphere.
Unlike o-rings, Chevrons can only
seal in one direction. In other words,
they can seal either positive pressure
( when installed as illustrated below )
or vacuum ( when installed backwards ),
but not both. Most V-rings are loaded
by the springs and the process pressure
and are usually dynamic shaft seals.

V-ring Seal

Figure 26
O- ring seal
Figure 27
V-ring ( Chevron ) seal with V open
to process pressure

18

U-cup seals
The U-cup seal is another sealing
device that requires constant
loading in order to seal properly.
The cup must be oriented so the
U opens toward the fluid pressure.
If the U-cup is installed backwards,
the pressure in the stuffing box
could force the fluid underneath
the ring and leak to atmosphere.

Wedge seals
This type of secondary seal
is a wedge, usually made of Teflon,
that is spring-loaded and mates
behind the rotating primary seal ring.
The spring and process pressures
keep the wedge in contact with the
shaft. The wedge must be oriented so
that it provides a leak-free seal when
exposed to this process pressure.

Like Chevrons, U-cups can only seal

in one direction. That is, they can seal
either positive pressure or vacuum,
but not both. Most U-cups are loaded
by the springs and the process pressure
and are usually dynamic shaft seals.

Like Chevrons and U- cups, wedges

can only seal in one direction.
Again, this means they can seal
either positive pressure or vacuum,
but not both. Because of the
tendency for Teflon to cold-flow,
almost all wedges need to be
loaded by one or more springs
along with the process pressure.
And in almost all mechanical seals
that use the wedge, they are
usually dynamic shaft seals.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Secondary
Seals
U-cup
seals
Wedge
seals

U-cup Seal

Wedge Seal

Figure 28
U-cup seal

Figure 29
Wedge seal

19

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Secondary
Seals
Boot-type
seals
Additional
secondary
seals

Boot-type seals
This type of secondary seal usually
consists of a rubber boot and
a large single-coil spring that loads
the boot against the back of the
rotating primary seal ring.
The boot is made of any number
of rubber materials and provides
two things for the mechanical seal.
The boot is the shaft seal
and prevents leakage
along the shaft or sleeve.
The boot, along with the spring,
provides the drive mechanism
that attaches to the shaft and
rotates one of the primary seal
rings. Drive mechanisms will be
discussed later in this chapter.

Additional secondary seals

Additional o-rings or secondary
seals may be located throughout
a mechanical seal design.
Typically, these seals will allow
for radial or axial movement
of the primary seal rings while still
eliminating leakage. These seals
can be dynamic or static in nature.
As we said earlier, all secondary
seals must be compatible
with the product and operating
temperature so it will not
deteriorate and produce leakage.

Because boot-type seals are loaded

by the spring and do not move
in relation to the shaft, they are
considered to be static shaft seals.
Also, because the boot has to adhere
to the shaft to work, almost all
mechanical seals that use this type
of secondary seal and need to be
replaced require a completely new seal,
as they cannot be rebuilt very easily.

Figure 31
Mechanical seal with numerous secondary seals,
including the shaft and gland seals

Boot-type Seal
Figure 30
Boot-type seal

20

Mechanical Seal Hardware

As mentioned earlier,
mechanical seals also contain
a multitude of other parts and
hardware, mostly made of metal.
Understanding the type and
function of this hardware
is important to ensure proper
mechanical seal operation.
This lesson will describe the
various pieces of hardware
found in most mechanical seals
and define the function of each.

The gland
The gland holds the non-rotating
parts of the mechanical seal,
including the stationary seal ring.
The gland is also called the
stationary holder, gland plate,
end plate, or flange. The gland
is mounted to the seal chamber,
by means of various types of bolts,
to prevent the stationary parts
from moving. It also provides
an opposing surface to mount
the static seal to the seal chamber
as previously discussed.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Mechanical
Seal
Hardware
The
gland

Gland

21
Figure 32
The gland

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Mechanical
Seal
Hardware
The
spring
mechanism
Large
single coil
springs
Multiple
small
springs

22

The spring mechanism

The spring mechanism is a machined
component that stores energy and,
when required, releases that energy.
The spring provides the force to hold
the rotary and stationary rings together
when the seal is not pressurized.
The fluid pressure in the seal chamber
provides the majority of the closing
force holding the seal rings together.
The spring mechanism may be
located on the rotary, stationary,
or both depending on mechanical
seal design. There are basically
five types of spring mechanisms.
All, except one, are metal parts.
The one that is made of an
elastomer must be compatible
with the product and operating
temperature so it will not
deteriorate and produce leakage.
Large single coil springs
Large single coil springs were
one of the first spring mechanisms
used in early mechanical seal
designs and are still used in a
wide range of applications today.
They are found in older seal designs,
but they work very well when
used properly. However, there are
several limitations to this spring.
They have a tendency to
distort at high surface speeds.
This means that large seals
at high rotational speed can
be affected by this problem.
There is a large axial
and radial space required.
Because there is just one
spring, it has to be of
sufficient mass to provide
the proper spring load.
There is a need to stock
a different size spring
for each seal size.
The large coil springs,
by design, cannot provide
even closing pressure for the
entire seal ring. This could
cause uneven seal face wear
and premature failure.

Large Single Coil Springs

Figure 33
Large single coil spring

Multiple small springs

Many of the newer mechanical
seal designs incorporate multiple
small springs as the spring
mechanism. These small springs
operate better in high speed
mechanical seal applications
as well as low speed applications.
Because of their quantity,
these small springs are not prone
to distortion. Consequently,
they exert an even closing force
on the seal ring at all times.
Unlike the large single coil spring,
the multiple small springs may
be used with a wide range of shaft
sizes. Also, because of their size,
they do not require as much axial
and radial space as large coil springs.

Multiple Small Springs

Figure 34
Multiple small springs

Metal bellows
Metal bellows are another
form of spring mechanism used
in mechanical seals. The welded
metal bellows is formed by welding
separate thin (~0.005 inches or
0.13 mm ) plates of metal together
to form the bellows assembly.
This one-piece unit provides the
spring loading required to maintain
face contact. Because metal bellows
mechanical seals are often designed
without elastomers ( i.e., no o-rings ),
they are typically used in high
temperature applications.

Thin (0.005 inches or 0.13 mm )

Welded Metal Plates
that Form the Bellows

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts

Vibration Damper

Figure 35
Typical welded metal bellows mechanical seal
with vibration damper

Mechanical
Seal
Hardware
Metal
bellows

Metal Bellows

23
Figure 36
Metal bellows. Note: this seal uses no elastomer

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Mechanical
Seal
Hardware
Some
common
problems
with
welded
metal
bellows
seals
Finger
springs

24

Some common problems with

welded metal bellows seals
Welded metal bellows seals work
well when applied properly. However,
there are some inherent problems
with them that are listed below.
Welded metal bellows are very
sensitive to vibration ( either
harmonic or slip-stick ). Vibration
problems can be recognized by
a cracking of the bellows near
the end-fittings. Vibration damping
is a serious problem at extreme
temperatures because the shaft
and the vibration damper ( notches
on the inside diameter of the
bellows ) are growing at different
rates. The shaft is usually growing
faster. If the vibration damper
causes the seal to fail by sticking
to the shaft, rub marks will be
present on the shaft.
Some bellows materials are
not very corrosion resistant. This
can cause problems if the seal is
cleaned with an acid or a solvent
because the bellows is very thin.
Recirculation lines can act
as a sand blaster and rupture
the thin bellows.
If the product that is being sealed
has a tendency to harden or
set-up between the seal faces,
the bellows can twist and rupture
because the faces have stuck
together. Remember the bellows
is only 0.005 inches ( 0.013mm ) thick.
When using welded metal bellows
in high temperature petroleum
products ( or other organics ),
the proper environmental controls
must be used or coking will cause
the seal to fail. Coking is the
build-up of a hard black organic
residue caused by over-heating.
This coke builds up on the
inside diameter of the seal and
can fill the spaces between the
metal bellows plates to stop the
bellows from acting like a spring.
* Hastelloy C is a registered trademark of
Haynes International Incorporated
** Inconel is a registered trademark of
International Nickel Company

Stainless steel should not

be used as a metal bellows
material because of the
possibility of chloride stress
corrosion ( to be discussed later).
Better materials like AM350,
Hastelloy* C or Inconel** 718
should be used instead.
Welded metal bellows seals have
limited use in slurry applications.
The seal can fail from bellows
rupture due to wear or corrosion.
It can also fail when the slurry
clogs the bellows.
Because the most common failure
for these seals is bellows breakage,
metal bellows seals are very costly
to repair. If this occurs, the whole
bellows requires replacement.
Finger springs
Finger springs ( sometimes called
leaf springs ) are spring mechanisms
that are typically located on the
outside of the mechanical seal gland.
These springs are a new design
that provide the force required
to hold the stationary and rotary
seal rings together. Because these
springs are outside the mechanical
seal, they are much less prone
to clogging from the product.

Figure 37
Finger springs.
Note: springs are external to the seal

Rubber bellows
The rubber bellows, although
not made of metal, also acts as
a spring mechanism when used
with a single coil spring. Because it
is a bellows, it has speed limitations.
Like all elastomer parts, it must be
compatible with the product and
operating temperature so it will not
deteriorate and produce leakage.
The rubber bellows is required to
bond to the shaft to work properly.
Silicone grease should never be
used to install this bellows. Rubber
bellows seal designs were one
of the first mechanical seal designs
available to industry over 50 years
ago. Due to its longevity, and low
cost, this is a popular seal choice for
original equipment manufacturer
( O.E.M.) pump companies.

Spring

Stationary Seal Ring

Rubber Bellows

Shaft Surface
Adhered to Bellows

Rotating
Seal Ring

Figure 38
Rubber bellows with single coil spring
bonded to a shaft to perform its shaft seal
and spring mechanism duties

Some common problems

with rubber bellows seals
Some of the more common problems
with rubber bellows are listed below:
Many of the existing rubber
bellows are made of Buna-N
rubber. This rubber has a finite
shelf-life and is easily attacked
by sunlight and ozone.
Mechanical seals using a
rubber bellows often fail due
to bellows breakage. This failure
is usually catastrophic in nature.
This is different from o-ring seal
failure because o-ring problems
usually begin slowly and
gradually deteriorate, allowing
for time to schedule repairs.
The rubber bellows suffers from
repair problems because the
elastomer bellows bonds to the
shaft in order to obtain a proper
seal and drive mechanism.
During a repair the bellows usually
must be scraped clean from the
shaft after the mechanical seal
has been removed.
Installation of this seal type is
often difficult. The rubber bellows
location is critical and there is no
way to set it. The only recourse
to this issue is to relocate the
spring, however, this does not
always solve the problem.
The rubber bellows must be
lubricated to slip it over the shaft,
however, once installed the
rubber bellows must bond to
the shaft. Most other mechanical
seals use silicon grease to lubricate
the elastomer. Silicon grease
should never be used with
a rubber bellows seal because
it will not allow the bellows to
bond to the shaft. The shaft
will spin through the bellows,
thereby causing premature failure.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Mechanical
Seal
Hardware
Rubber
bellows
Some
common
problems
with
rubber
bellows
seals

25

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Mechanical
Seal
Hardware
The
shaft
sleeve

The shaft sleeve

The shaft sleeve is a cylindricalshaped piece of metal or composite
material placed over the shaft,
usually inside the stuffing box.
Some common reasons for using
a shaft sleeve are listed below:
Probably the most common
is to provide protection
from wear to the shaft
due to mechanical packing.
The second most common
is to provide protection
from wear to the shaft
due to mechanical seals.
Shaft sleeves are often
used to provide the proper
spacing for the impeller.
They also can be used to
provide a step in the shaft
to achieve hydraulic balance
for the mechanical seal
( to be discussed later ).
Some sleeves are installed
because the fluid is extremely
corrosive and it would be
costly to make a shaft
from the sleeve material.
Lastly, cartridge mechanical
seal designs use a sleeve as
an integral part of the seal.

Hook Shaft Sleeve

Figure 39
Common shaft sleeve used to protect the shaft
and provide impeller spacing

Shaft Sleeve

26
Figure 40
Shaft sleeve used to provide hydraulic balance in a mechanical seal and protect the shaft

The drive mechanism

The drive mechanism is the part
of the mechanical seal that provides
positive contact to the rotating shaft.
This mechanism, once secured to
the shaft, allows the rotating parts
of the seal to rotate with the shaft.

Probably the most common drive

mechanism is a group of set screws.
However, other mechanisms
such as a clamp, rubber boot
( vulcanized or bonded to the shaft )
or o-ring drive are also used.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Mechanical
Seal
Hardware
The
drive
mechanism

Clamp

Vulcanized Rubber Boot

Figure 41
Clamp drive mechanism

Figure 43
Vulcanized rubber boot drive mechanism

Set Screw

O-ring Drive

27
Figure 42
Set screw drive mechanism

Figure 44
O-ring drive mechanism

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Review
Questions
1 through 10

Review Questions
1. For the most part,
all packings must leak to work.
a. True.
b. False.
c. It depends.

6. Typical mechanical seal

metal hardware includes
all of the following:
Shaft sleeves, Gland rings,
Teflon wedges, Pins,
Springs, Bellows.
a. True.
b. False.

2. The purpose of a mechanical seal

is to reduce or eliminate visible
leakage to the environment.
a. True.
b. False.

7. Which statement is not correct?

a. Dissimilar materials
are commonly used
for the rotary and
stationary seal rings.
b. One of the seal rings
is usually a softer ring
relative to the other.
c. The softer seal ring
is always wider
than the harder
seal ring material.
d. Because the ring is
softer, it will wear as the
mechanical seal rotates.

3. Mechanical seals are

constructed of:
a. Primary seal rings.
b. Secondary seals.
c. Metal hardware.
d. All of the above.
4. Which statement is correct?
a. In a mechanical seal,
all the seal rings
rotate with the shaft.
b. The ring that rotates
is commonly referred
to as the stationary
seal ring.
c. The seal ring that rotates
is commonly referred to
as the rotary seal ring.
d. The seal ring that does
not rotate with the
shaft is called the
rotary seal ring.

8. To achieve seal face

flatness, the seal faces must
be lapped and polished.
a. True.
b. False.
9. Surface finish is a term
that describes a level
surface that has no
elevations or depressions.
a. True.
b. False.

5. Mechanical seal secondary seals

can be
a. O-rings.
b. U-cups.
c. Rubber boots.
d. All of the above.

28

.
10. What gas is usually used
in a monochromatic light
to measure seal face flatness?
a. Helium.
b. Hydrogen.
c. Argon
d. Nitrogen.

11.
is used to measure mechanical
seal face flatness.
a. Only the human eye.
b. An optical flat.
c. A very accurate straight-edge.
d. A micrometer.
12. The methods used
to measure light bands
with an optical flat are the

a.
b.
c.
d.

methods.
contact and triangle.
wedge and interference.
interference and triangle.
contact and wedge.

15. The asperity theory assumes

that small holes appear
on the soft face as the face
wears providing places for
lubricant to reside.
a. True.
b. False.
16. The pressure drop theory
assumes that the asperities
formed on the seal face
act as an infinite number
of pressure reducers to
bring the process pressure
to atmospheric pressure.
a. True.
b. False.

13. When does visible leakage

start between two mechanical
seal faces?
a. 2 lightbands.
b. 5 lightbands.
c. 10 lightbands.
d. 20 lightbands.

17. The pressure wedge theory

assumes a film of liquid
exists between the seal faces
causing them to be pushed
apart.
a. True.
b. False.

14. Which statement is correct?

a. Mechanical seals
typically require a layer
of gas or liquid lubrication
between the rotary
and stationary seal faces.
b. Seal face lubrication
is crucial in maintaining
seal life and reducing
energy consumption.
c. We really dont know
what happens between
seal faces.
d. All of the above.

18. What theory proposes

that mechanical seal faces
run without the fluid
to act as a lubricant
between them?
a. The pressure wedge theory.
b. The dry running theory.
c. The pressure drop theory.
d. The three band theory.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Review
Questions
11 through 19

19.
proposes the separation
of the lubricated fluid
into a liquid, vapor and dry
are between the seal faces.
a. The dry running theory.
b. The pressure wedge theory.
c. The pressure drop theory.
d. The three band theory.

29

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts

20. Which of the following

is a static seal?
a. The primary seal rings.
b. The wedge seal.
c. The gland seal.
d. None of the above.

a.
b.
c.
d.

a primary seal.
a secondary seal.
a tertiary seal.
None of the above.

26. Boot-type secondary seals

are dynamic seals.
a. True.
b. False.

Review
Questions
20 through 30

27. The gland holds the rotating

parts of a mechanical seal.
a. True.
b. False.

21. Is the o-ring shown

in the above illustration,
static or dynamic?
a. Static.
b. Dynamic.
22. O-rings can be installed
backwards and still work.
a. True.
b. False.
23. Can a V-ring seal
be installed backwards
and still work properly.
a. Yes.
b. No.
24. U-cup secondary seals
can seal vacuum and high
pressure.
a. True.
b. False.

30

25. A wedge seal is

28. Which of the following

stores energy and releases
it as required?
a. The gland.
b. The drive mechanism.
c. The spring mechanism.
d. The o-ring.
29. What spring mechanism
is limited in its ability
to provide even face load.
a. The bellows.
b. The large coil spring.
c. The set of multiple springs.
d. The set of finger springs.
30. Multiple small springs
are recommended for high
surface speed applications
versus a single coil spring.
a. True.
b. False.

31. What spring mechanism

is constructed of thin metal
plates welded together?
a. Single coil spring.
b. Multiple coil springs.
c. Metal bellows.
d. Rubber bellows.
32. What is the most common
failure of bellows mechanical
seals?
a. O-ring failure.
b. Bellows breakage.
c. Bellows hang-up
due to coking.
d. Bellows corrosion.
33. What spring mechanism
is usually mounted outside
the gland?
a. The large coil spring.
b. The set of finger springs.
c. The metal bellows.
d. The set of multiple small
coil springs.

36. Which of the following

is a cylindrical-shaped piece
of metal or composite material
placed over the shaft to
provide protection to the shaft?
a. Metal bellows.
b. The spring mechanism.
c. The gland.
d. The sleeve.
37. Which of the following
is the part of the mechanical
seal that enables the rotary
seal ring to rotate?
a. The spring mechanism.
b. The gland.
c. The drive mechanism.
d. The shaft seal.

CHAPTER 1
MECHANICAL
SEAL
Purpose
and Parts
Review
Questions
31 through 37

34. Rubber bellows seals

are required to bond to
the shaft in order to
perform their functions.
a. True.
b. False.
35. If a rubber bellows
is lubricated with silicone
grease for installation,
what usually happens?
a. The shaft will spin
inside the bellows.
b. The bellows will not
seal properly.
c. The seal will fail
prematurely.
d. All of the above.

31
Answers Located on the Inside Back Cover