Aessealpump and Seals Training

Italian Customers
TRAINING COURSE
Presented by: daniel de lorenzi

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
TOPICS of the Training

Mechanical Seals principles and evolution
Mechanical Seal typologies
Centrifugal Pumps Principles
How to install and run correctly mechanical seals
Systems for Double Seals
Failure Trouble Shooting
How to avoid premature seal failures
STATISTICS
AMONG THE MAJORITY OF INDUSTRIAL PROCESS 60 to
80% of the WORKING ORDERS ARE DIRECT LINKED WITH
SOME TYPE OF LEAKAGE.
ALSO IN AVERAGE 20% OF THE EQUIPMENTS ARE
RESPONSABILE OF 80% OF THE MAINTENANCE COST PER
UNIT PRODUCED (PARETO LAW)
THE INCIDENCE OF SEALING FAILURE AND BEARING
FAILURE ON THE CENTRIFUGAL PUMPS OUT OF SERVICE IS
OVER 90%
PUMP DEFINITION
WHAT IS A PUMP?
A PUMP IS DEFINED AS A MECHANICAL DEVICES THAT
ROTATES OR RECIPROCATES TO MOVE FLUID FROM ONE
PLACE TO ANOTHER
WHAT IS A PUMP PURPOSE?
To move fluid
against gravity
require a pump to
add energy to it
PUMPS CLASIFICATION
Will pump fluid up to a

designed level, when
this level is reached
the fluid no longer
moves and the kinetic
energy is converted in
heat
(Split case)
Separately-coupled
Single or Multi Stage
Vertically (radially) or
Horizontally (axially)
Split
Close-coupled
Separately-coupled
Seal-less
CENTRIFUGAL PUMPS CLASIFICATION

Driver
Wet End
Base Plate
Coupling/Spacer
Power End
ANSI / ASME B73 1991

ANSI / API 610 -10th Edition
ISO 13709:2003
Casing
Wet End
Power End
Impeller
Inboard Bearing
Trust Bearing
Back Cover
Adapter
Pump shaft
Seal Chamber Cover
WHAT is the Function of the WET END and

the IMPELLER?
Impeller
The Impeller is the bladed member attached to the pump shaft and
imparts the principle force to the fluid being pumped.
The rotation of the impeller is what adds velocity energy and is later
transformed in pressure energy inside the casing near the outlet or
discharge side.
Impellers shape can be classified as Radial Flow, Francis vane, Mixed flow or Axial flow
These shapes are defined by the hydraulic geometry of the fluids as it flows through the
impeller; also could be classified by the mechanical design as Open, Semi-open or Closed
WHAT is the function of the STUFFING BOX?

The Stuffing Box is a cylindrical opening in the pump casing where the shaft passes
through to the impeller. It has the primary function of containing a sealing device that
will minimize or eliminate leakage at this point. Mechanical Packing or Mechanical Seal
can be installed however in case of M.S. we will use Seal Chambers rather than Stuffing Box
STUFFING BOX
SEAL CHAMBER
WHAT is the POWER END?

The Power End is:
A- Bearing Housing (provide a body
which the bearings are mounted)
B- Frame Adapter (machined component

used to assembly the Power End to the
Wet End. Can be separated bolted part
or cast as part of the Bearing housing)
C- Shaft ( is part of the rotating

assembly, used to transmit the power
from the driver [motor]
D- Bearings (provide shaft support)
E- Bearing protection (should keep out
all the oil contaminants it could be Lip
seals, Labyrinth Seals and Face Seals)
F- Oil sump area (contain the oil)
G- Oil sight glass (to control the correct
oil level)
H- Breather (acts as small vent allowing

the expanded air in the oil sump to
escape, however it could bring air inside
when the system cool down)
I- Oil Flinger (distribute the oil and filter

it from heavy contaminants)
WHAT is the function of the COUPLING?
A coupling is a power transmission device that is used to connect the Motor shaft to the Power End shaft of
the pump, its primary purpose is transmit rotary motion and torque from the motor to the pump, also have
to recuperate misalignment between shafts, transmitting axial thrust loads, permitting adjustments of shafts
to compensate for wear and keep precise alignment between connected shafts.
WHY PUMPS FAIL?

Internal Forces
External Forces
Environment
INTERNAL FORCES
- RADIAL FORCES
- Performance Point
- Operating Point
- Radial Force and Shaft Deflection
- Operating Window
- BALANCING
- CAVITATION
RADIAL FORCE
BEP
Performance Curve
HEAD-CAPACITY
PERFORMANCE CURVE
& its BEST EFFICIENCY
POINT [BEP]
RADIAL FORCE
Performance Curve
BEST EFFICIENCY POINT
[BEP] for XYZ pump size
1,5x3-13 rpm 3,000
Max efficiency 60% @
Head= 44Mt [132] &
Capacity= 76m/hr [290
gpm]
BEP
RADIAL FORCE
Performance Curve
OPERATING POINT
Pump operation away from
the BEP causes the
hydraulic forces within the
casing become unbalanced,
which can cause the pump
shaft to bend or deflect.
This conditions, if severe
enough, could impact the
pump and seal reliability
BEP
RADIAL FORCE
K= Radial Factor [.37]
H= Head
S= Density
D= Impeller
B= Impeller width
F=K.KQ.H.S.D.B/2.31
KQ= 1-(Q/QBEP)
Q= Capacity at Operating Point
QBEP= Capacity at BEP
RADIAL FORCE
OPERATING
WINDOW
RADIAL FORCE
A- Small Shaft Diameter

& Long Overhung
E- Big Shaft Diameter
and Short Overhung
RADIAL FORCE
40
80
120
160
High Flow Cavit.
Discharge Recirc.
25
Suction Recirc.
50
Reduced Impeller life
75
Low Flow Cavitation
100
High Temperat. Rise
Mtrs
(400 ft)125
Low Brg. and Seal li fe
80 x 100 x 330 @ 3000 R/Min.(3x4x13)

BEP
200
3
240 M Hr
(1056 USGPM)
1USG=3,785L
RADIAL FORCE at BPE right hand side
BEP
RADIAL FORCE at BPE left hand side
BEP
RADIAL FORCE Slender Ratio L/D

Shaft Deflection Formula
=FL/3EI
I=D/64
Y= FL/3E x D/64
F= Force
E= Module of Elasticity
I= Moment of Inertia
L= Overhung
D= Diameter

SHAFT DEFLECTION
A Long shaft with a
small diameter has a
low resistance to
shaft deflection and
high level of
vibrations.
L=220mm
L
D= 32mm
L/D = 11

SHAFT DEFLECTION
A shortest and solid
shaft offer a great
resistance to shaft
deflection and a
lower level of
vibrations.
L=200mm
L
D= 40mm
L/D = 3.55

SHAFT DEFLECTION
A shortest and solid
shaft offer a great
resistance to shaft
deflection and a
lower level of
vibrations.
L=160mm
D= 48mm
L/D = 0.80

SLEEVE
OEM HIGH L/D
SOLID SHAFT
API POMPE LOWER L/D
API PUMPS *
EXXOM rule since

years: any new
pump MUST have
Shaft Stiffness
Ratio <3 or less
BALANCING
SURFACE CONDITIONS
MECHANICAL BALANCING
IMPELLER EYE CENTERED
CAVITATION
Insufficient Net Positive
Suction Pressure Required
NPSHD < NPSHR
Vapor pressure of the medium
Trapped Air in the fluid
System Sucks air
CAVITATION
CAVITATION
>10,000 bar
Bubbles of
Vapor
implode in a
form of
toroidal
shape this
shape create
pressures in
excess of
10,000 bar.
No known
material can
withstand
this type of
punishment.
EXTERNAL FORCES
MISSALIGNMENT PUMP/ELECTRIC MOTOR
PIPING LOADING
THERMAL DILATATION
MISSALIGNMENT
BEARING OVERLOAD
VIBRATIONS
Coupling Alignment Basics

Pump shaft and drive shaft must rotate on
common axis.
Aligning 4 bearings
Alignment check should be a final function
before start-up
Should take into account changes in
temperature
Motor direction should be checked before
coupling installed
Motor & Shaft Alignment
Motor low (pump high)
Divergent pump/motor (vertical)
Motor to one side of pump
Divergent pump/motor
(horizontal)
ALIGNMENT MOTOR/PUMP
METHODOLOGY
PRECISION SQUARE
DIAL GAUGE or COMPARATOR
LASER
MOTOR [DRIVER] ADAPTER is a machined
component used to assemble the motor to the power
end section of the pump. Allow easier pump and
motor alignment and compensate thermal growth.
This adapter is already required for most of vertical
pump applications
Motor & Shaft Alignment

Countless studies from all over the world
have come to the same conclusion.
The Better the Alignment the Better the

Savings, Safety and Environment.
ALIGNMENT PUMP/MOTOR
ADAPTER TYPE C-FRAME SUITABLE FOR VERTICAL
AND HORIZONTAL PUMP APPLICATIONS.
Piping Systems
Suction pipe work more important than the
discharge.
Correct installation critical.
Problems on the suction side:

Cause on-going problems
Usually expensive
Not normally traced
Piping Systems
When running, the fluid in a pump must:
Arrive at impeller eye with sufficient pressure
Have an even and straight flow (laminar).
Dependant on suction pipe work design
Piping Systems
Suction reducers - which is
correct?
Piping Systems
Suction pipe work
should be one size
larger than pump
suction nozzle and an
eccentric reducer is
used.
Piping Systems
The concentric
increaser is used on
the discharge side of
the pump and is
normally bolted straight
to the discharge flange
of the pump.
Piping Systems
The pump suction piping must
also be free of air pockets.
Piping Systems
Q:Piping Elbows:
How far should they
be from the suction
port?
The length of the straight inlet line = 5 to 10 times the

pipe diameter.
Piping Systems
Pipe stress reduces pump life and
performance
Pipe work must be properly aligned
Piping, valves etc should be

independently supported
Pump installed before pipe work
Pipe work should rise to pump
Maintenance
alignment tools?
PIPING LOADING
TENSION ON THE SUCTION AND DISCHARGE
FLANGES
Lost perpendicularity between the shaft and
the stuffing box face
Flanges deformation
THERMAL DILATATION
- ALLOW TO
MANTAIN THE
IMPELLER CENTER
LINE DURING THE
THERMAL
EXPANSIONS WITH
TEMPERATURE OVER
100 C
- ADJUSTABLE FOOTS
TO MATCH THE
PIPING CENTER LINE
Pump Installations Rules of Thumb

Use centreline design over 100o C
(200o F )
Dowel pump and motor after
alignment
Foundation mass min. 5 times

pump
Foundation 75mm / 3 bigger than
bedplate < 370kW / 500 Hp
Lines 30o from centre should pass
through plinth base not sides.
Where a seal perform

better?
With a STUFFING BOX
or
a MECHANICAL SEAL
CHAMBER ?
MECHANICAL SEAL ROOM
Stuffing Boxes are generally designed for Mechanical

Packing not for Mechanical Seals.
MECHANICAL SEAL ROOM
Above we have the same stuffing box designed for Mechanical

Packing sealed with Packing [left] and with a Mechanical Seal
[right]
MECHANICAL SEAL CHAMBER
A Stuffing Box designed for Packing hasnt ENOUGH volume

available for the correct operation of Mechanical Seals.
MECHANICAL SEAL CHAMBER
A real seal chamber has 10 to

20 times more volume than a
Packing stuffing box
A CORRECT
BEARING PROTECTION
INCREASE
EQUIPMENT LIFE
AND
SEALS PERFORMANCE
BEARING PROTECTION
1 Generation - FELT
BEARING PROTECTION
2 Generation LIP SEALS
BEARING PROTECTION
2 1/2 Generation
POSITIVE LIP SEAL
PTFE/Polyimide
BEARING PROTECTION
3 Generation LABTecta
BEARING PROTECTION
4 Generation MAGTecta
Bearing Study
60%
50%
CONTAMINATION
50%
Cause of Bearing Failure
40%
30%
20%
LOL*
14%
10%
FITS
9%
EQUIPT
VIB
5%
INSTAL
DEFECT
4%
2%
0%
*LOL: Loss Of Lubricant
OTHER
16%
AGE
34% Fatigue [>60,000 hr.]

36% Poor Lubrication
14% Contamination
16% Fitting
OIL
DIRT
FITTING
SKF Study Causes of Bearing Failure
IN OTHER WORDS
% REDUCTION IN FATIGUE LIFE
WATER CONTAMINATION REDUCES BEARING LIFE

SIGNIFICANTLY
% WATER IN OIL
80
70
60
50
40
30
78%
83%
3.0
6.0
48%
20
10
0.002
Mobil Oil evaluation on bearing fatigue life
0.002% water reduces fatigue life 48%

6.0% water reduces fatigue life 83%
0.002% water is approximately one drop of water in a liter of oil !
95% of All Rotary Shaft Bearings are protected with

Elastomeric Lip Seals !
Elastomeric Lip Seals protect for a short period of time

1.300/3.000 hrs and damage the shaft
REPRINT FROM A CR INDUSTRIES REPORT
MEDIAN RANK CR WAVESEAL .
Hours to Failure
( % Failure)
182
6.7
144
188
16.32
576
275
25.94
1343
300
35.57
1736
556
45.19
1763
648
54.81
1973
772
64.43
1979
902
74.06
2946
1264
83.68
2982
1366
93.30
3003
100
Hours to Failure
90
80
% FAILURE
NATIONAL
SHAFT DIAMETER ......................................... 3.000 INCH ( 76.2 MM )

SHAFT SPEED ................................................. 2550 RPM
SHAFT TO BORE
MISALIGNMENT .......................................... 0.005 INCH ( 0.13 MM )
DYNAMIC RUNOUT .......................................... 0.010 INCH ( 0.25 MM )
SUMP TEMPERATURE .................................... 200 F ( 0.13 MM )
FLUID (CENTERLINE) ..................................... TRANSMISSION
70
60
DUAL
LIP SEAL
50
SINGLE
LIP SEAL
40
30
20
10
3,000 hours is longest life for CR
500
1000
Fig. 11- Life Test Results
NATIONAL ( 645 hours )
SOCIETY OF AUTOMOTIVE ENGINEERS, INC.
Chicago Rawhide ( 1844 hours )
WARRENDALE, PENNSYLVANIA 15096
400 COMMONWEALTH DRIVE
(HOURS)
1500
2000
WATER CONTAMINATION REDUCED

DRAMATICALLY THE BEARING LIFE
When shaft scoring occurs,

a newly installed Lip Seal
riding in same location
on shaft will soon leak.
CR SPEEDY SLEEVE
IS A QUICK REPAIR DEVICE
GOOD FOR EMERGENCIES.
NEVERTHELESS AS IT WILL
INCREASE THE WHERE THE
STANDARD LIP SEAL WILL
WORK SO MORE FRICTION =
MORE HEAT = LESS
PROTECTION LIFE
BEARING
PROTECTION
RECAP
Install them correctly with the proper installation

procedure and tools.
Use the appropriate protection system specially if
you are in production.
Lip Seal of new Generation should be the
minimum, much longer life than standard rubber
lip seals, less shaft damage in a longer time,
better protection [5 to 10 times better bearing
life]
Labyrinth seals or GBS seals will be the best

solutions: No shaft damages, longer life an
positive protection.
WHAT TO DO TO
HAVE A RELIABLE
PUMPS - RECAP
Slender Ratio L/D must be lower than 3

Operational point have to be as closer as possible to
the BEP
Never go over the Operational Window
Protect the bearings with the appropriate protection
Increase the volume of the stuffing box as much as
possible.
Avoid misalignment between motor and pump
Preview a standard maintenance procedure to
control the oil conditions and levels
MECHANICAL SEALS
Introduction
How they work
Evolution of their technology
Mechanical seals types and classification
Centrifugal Pumps
has been
designed over 100
years ago and the
stuffing box was
sealed with
mechanical
packing.
Do you remember this ?
The same 100 years

old pump with the
same stuffing box
but sealed with a
Mechanical Seal
FACTS
- 80% of the Mechanicals Seal fail prematurely.
- A huge number of Component Mechanical Seals
damage the shaft or the sleeve.
- 80% Maintenance cost of a pump is due
Mechanical Seals which have to be repaired or
replaced within 12 months of service.
MECHANICAL SEALS
- DESCRIPTION
- PRINCIPLE OF WORKING
- CONCEPTS
* Face Planarity
* Roughness
* Face Parallelism
- SEAL LIFE
THE PURPOSE OF A MECHANICAL SEALS

Mechanical Seals were developed to address
the disadvantages of and problems with
compression packing.
The purpose of a Mechanical Seal is to reduce
or, in most cases, eliminate leakage of product
or other fluids to the environment.
MECHANICAL SEALS CONFIGURATIONS
INTERNAL
EXTERNAL
ROTARY
STATIONARY
COMPONENT
CARTRIDGE
SINGLE
COMPONENT
DOUBLE
COMPONENT
SINGLE
CARTRIDGE
DOUBLE
CARTRIDGE
SEMI-SPLIT
FULLY SPLIT
PUMP GAS
SEAL
COMPRESSOR
GAS SEAL
A MECHANICAL SEALS CONSISTS OF:

Two extremely flat surfaces, called faces
(Rotary and Stationary) which are held
together by product pressure and spring force
to prevent product from escaping to the
environment
MECHANICAL SEAL - CONSTRUCTION
SPRING
ROTATING
PART
STATIONARY
PART
SECONDARY
SEAL
PRIMARY
SEAL RINGS

PRIMARY SEAL RINGS are a set of
2 extremely lapped or polished flat
surfaces [<2 helium
monochromatic light band] held
together by process and spring
pressure. One ring must rotate
with the shaft while the other ring
must be static, commonly referred
as Rotary Seal Ring and
Stationary Seal Ring. Dissimilar
materials are commonly used for
the Rotary and the Stationary ring
seal.
Most of the seals fail, why we could

say that?
Seal Life

SECONDARY SEAL all
mechanical seal will use some
type of secondary sealing element
to eliminate the leakage at other
areas outside the primary seal
rings. Main places where
secondary seal are used is
between the mechanical seal and
the shaft or sleeve and between
seal gland and Stuffing Box face
O-rings, Gaskets, U-cups, V-rings,
PTFE wedges, Rubber Boots,
Chevrons, Square packing

METAL PARTS
Mechanical Seal have
plenty of metal hardware.
Typical hardware may
include the following:
Shaft Sleeves, Gland
Rings, Collars,
Compression Rings, Pins,
Springs. Bellows, Drive
lugs, Snap Rings, Seal
Ring Holders, etc.
MECHANICAL SEAL HOW IT WORKS?

The principle is simple:
The mechanical seal is
sealing as long the 2 Flat
faces will keep their
planarity and will run in
contact all the time.
Doing so the Sacrificial

narrow softer face will
worn down completely at
this point the Mechanical
Seal life has expired
MECHANICAL SEAL HOW IT WORKS?

P=
Process pressure
Ps= Spring pressure
Pa= Atmospheric pressure

Pf= Film pressure
CLOSING
FORCES
OPEN
FORCES
P + Ps
Pa + Pf
MECHANICAL SEAL Why a Seal Fail?
- FRETTING
- CLOGGING
- PRESSURE AND TEMPERATURE EFFECT
- FACE INSTABILITY / FACES OPEN
MECHANICAL SEAL FRETTING

Shaft fretting is defined as the action of wearing
away the protective oxide layer formed on corrosion
resistant metals as Stainless Steel, Bronze,
Aluminum, Copper, Gold, Silver, etc.
This Oxide layer protects as long as is left alone. If
we remove it the layer instantaneously reforms in
the presence of Oxygen, consequently if this
removal is constant, metal loss will occur.
MECHANICAL SEAL Causes of Failures

FRETTING
$$$$$
MECHANICAL SEAL Causes of Failures

CLOGGING
Springs & Dynamic Seal
MECHANICAL SEAL Face distortion due

Pressure [J.Crane paper]
MECHANICAL SEAL Face distortion due

Temperature [J.Crane paper]
MECHANICAL SEAL LEAKS because of Face

Instability/ Open Face
Face can be open because of:
-Shaft deflection
-Poor perpendicularity
-Radial movements
-Axial movements
-Cavitations
-Vaporization
-Seal design
MECHANICAL SEAL EVOLUTION

Mechanical Seal has been introduced in the market on
1917 [IWW] since that the Mechanical Seals designs has
been change in order to match the Industry needs.
New Chemicals, Safety, new Regulations, Environmental

laws, more Reliability, etc. push Seal Manufacturer to
develop new technologies.
We could divide those eras in 3 main generations
-1st Generation Seals

-2nd Generation Seals
-3rd Generation Seals
MECHANICAL SEAL Evolution 1st Generation

Single Spring in the
fluid prompt to be
damage by Chlorine
Unbalance Face high
heat generation
Seal shorter life
Dynamic Secondary
Seal damage the
sleeve or shaft
Fretting

Multiple Spring in
the fluid prompt to
be clogging by
media
Unbalance Face high
heat generation
Seal shorter life
Dynamic Secondary
Seal damage the
sleeve or shaft
Fretting
B
U
Example of 1st
generation seal
with Balanced
face using a
special sleeve
MECHANICAL SEAL 1st Generation Issues

Old technology [1917]
Unbalanced Faces [generated a lot of heat]
Face suffer distortions by Temp and Pressure

High face instability
Cause shaft or sleeve Fretting
Spring or Springs on the medium
Very sensitive to installation
Perceived as inexpensive when you buy
Very expensive when you run it due a short MTBF
MECHANICAL SEAL Evolution 2nd Generation

Multi-springs out of the
medium and protected
Balanced faces, less

heat => longer life
No longer dynamic
secondary seal on the
shaft therefore no
longer Fretting

Component
Seal
Cartridge Seal

Medium technology [1960s]
Balanced faces
Face suffer distortions by Temperature only

Better face stability
No longer cause shaft or sleeve Fretting
Spring out the medium
Still sensitive to installation
Perceived as expensive when you buy
Inexpensive when you run it due a longer MTBF
MECHANICAL SEAL Balance discussion
Unbalanced seal face

Balanced seal face
Double Balanced seal face
MECHANICAL SEAL UNBALANCED FACES
Pressure= 10 Kg/cm
Area =
5 cm
Force = Pressure x Area
F closing = 10 x 5 = 50 Kg
F opening = 5 x 5 = 25 Kg
10Kg/cm
atmospheric
Fc twice Fo, this seal is unbalanced

So this seals have an operating limits
- Speed
- Fluid viscosity
- Temperature
- Pressure
- Shaft size
- Face Material
MECHANICAL SEAL Unbalance Face

Unbalanced Mechanical Seal are seal arrangements
where the Hydraulic pressure of the seal chamber
acts on the entire seal face area without any of the
force being reduced through the seal design.
Common problems with Unbalanced Seals are
the pressure acting on the seal often

compromised the seal face lubrication
due the excessive closing forces have higher
heat generation
More wears occur due the excessive closing
forces
Higher power consumption
MECHANICAL SEAL BALANCED FACES
The Closing Force Fc can be reduced

by reducing the Closing Area.
The easiest way to accomplish this is
to install a stepped sleeve on the shaft
70/30, this the balanced seal ratio that

most of the seals companies supply,
because 70% of the total area face
insures that the seal face can not
accidentally blow open.
This seal balance ratio can easily
handle some vacuum service, but
deep vacuum service can open the
faces
External Mechanical Seal Balanced

faces ratio 70/30
Bellows seals are hard to balance

properly due pressure changes alter the
bellow configuration and change the
balance line.
MECHANICAL SEAL Balance Face

Balanced Mechanical Seal are seal
arrangements reduces the Hydraulic forces
through a seal design.
As the seal faces rub together, the amount of
heat is determinate 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 allow a better lubrication
resulting in lower heat generation, face wear
and power consumption.
MECHANICAL SEAL DOUBLE-BALANCED FACES

For Double Seals is important to be
able to handle pressure in both
directions [positive and vacuum
i.e.]. For dangerous applications, a
higher pressure between the seals
is better but for a back-up seal a
lower pressure would prevent
product dilution when the inner seal
fails.
MECHANICAL SEAL DOUBLE-BALANCED FACES
Higher pressure
being pushed in
inside diameter,
of the groove in
at the seal outside diameter, the inboard o-rings are

their respective grooves Higher pressure at the seal
the inboard o-rings are being pushed in the opposite side
response to the higher pressure
MECHANICAL SEAL Evolution 3rd Generation
Multi-springs out of the

medium and protected
Balanced faces, less
heat => longer life
No Fretting
Monolithic Faces F.E.A.
Conventional Seal Ring Design - Unloaded
Conventional Seal Ring - Loaded
Cartridge Seal
Component Seal
Dynamic Stress Relieve Seal Ring - Loaded

Centroid of loading
Cartridge Seal
Component Seal
Dynamic Stress Relieve Seal Ring - Unloaded

Using Computer Fluid Dynamics Model that help
to understand the flow behavior in the
Mechanical Seals

Latest technology [1990]
Balanced Faces [lowest generation of heat]
Face does not suffer distortions by Temp and Press. [DSR]
High face stability [F.E.A. technology]
No longer Cause shaft or sleeve Fretting
Spring out the medium [Anti-Clogging]
Easy to install and field reparable
Competitive price when you buy
In-expensive when you run it due a long life MTBR
MECHANICAL SEAL Evolution CARTRIDGE

1st Generation
Cartridge has
been introduce to
facilitate the
installation in
fewer
applications
however its
technology has
the same
problems of all
1st Generation
seals

2nd Generation
Has been
introduce in the
market as
common solution
in the earlier 70s
Sleeve and
driven collar of
2nd generation
have some issues
as well
PEK
24

In the 90s
Has been
introduce in the
market the
technology of
Stationary
Cartridge Seal
even though still
use a seal of
25
second
generation
PEK
Introduction to
Mechanical Seal
Trouble Shooting
List of Symptoms
Seal Face Symptoms
Elastomers Symptoms
Metal Components Symptoms
1
2
3
4
5
6
7
8
9
10
11
Wide Wear Track

Miscentered Wear Track
Uneven Wear Track
Scoring/Erosion
Corrosion
Chipping
Coking/Crystallization
Blistering
Heat Checking
Fracture
Grooving
12
13
14
15
Hard/Compression Set
Extrusion
Explosive Decompression
Swollen/Soft
16
17
18
19
Scoring
Corrosion
Flattened Set Screws
Drive Pin Wear
Wide Wear Track
/2.54 mm
/3.55 mm
Narrow Face
Vibrations
Wide Face
Seal Face Symptoms

Wide Wear Track
Component
ID
Symptom
ID
Seal Faces
Cause
Subcause
Rotary component seal
Miscentering
Wide Wear Track

B
Radial runout
Shaft deflection
Stationary cartridge seal
Bearing failure
Excessive bearing
clearances
Bent shaft
Pump misalignment
Pipe strain
Unbalanced impeller
Off-BEP operation
Cavitation
Related causes
2, 4, 16
2, 16, 19
2, 6, 16, 19
Failure Mode
Misinstallation
Solutions
Review installation
instructions and reinstall
seal
Review installation
seal
Install new bearings
Equipment condition
Install new shaft

Re-align pump
Check for pipe strain
Balance impeller
Equipment operation Improve shaft's L 3/D4
Check NPSHR vs. NPSHA
The contact pattern is considerably wider than the width of the narrow
face. Wear at the drive notches may be present.
Seal does not leak when seal is stationary, but leaks steadily when shaft
is rotating.
Centered
Housing
Tolerances
Miscentered
Seal Face Symptoms

Seal Faces
Component
ID
Symptom
ID
Cause
Subcause
Stationary seat
Miscentering
Radial runout
Shaft deflection
Miscentered Wear
Track
Cartridge seal
Seal chamber misalignment

Off-BEP operation
Related causes
1, 4, 16
1, 16, 19
1, 16, 19
Failure Mode
Solutions
Review installation
seal
Misinstallation
Review installation
seal
Check stuffing box to shaft
Equipment condition perpendicularity
Improve shaft's L 3/D4
A miscentered or eccentric contact pattern of equal width of narrow face.

Component seals may show rubbing marks on the inside diameter from
contact with shaft.
Seal does generally not leak unless cracks or damage from shaft rubbing
is present.
Uneven Wear Track
Even
Flatness PV-Limits
Uneven
Seal Face Symptoms

Uneven Wear Track
Component
ID
Symptom
ID
Seal Faces
Cause
Misalignment
Subcause
Related causes
Misalignment of split seal
rings
Overtightening of gland bolts
Failure Mode
Misinstallation
3
Uneven Wear
Track
Face distrortion
Uneven tightening of gland

bolts
4, 6, 10, 13
Excessive pressure
Improper stress relieved
component
Seal faces out of flat
Exceeded limits
Solutions
Check faces and review
installation instructions
Review installation
instructions for proper
tightening procedure
Review installation
instructions for proper
tightening procedure
Check operating conditions
Exchange component
Quality
Exchange component
The narrow face is distorted mechanically. High spots at drive pins or

bolting locations. Wear at drive notches may be present as well as
scoring/erosion of the sealing interface.
Seal does leak steadily both stationary and rotating.
Scoring/Erosion
Scoring
Lubrication
Seal Face Symptoms

Scoring/Erosion
Seal Faces
Component
ID
Symptom
Scoring/Erosion
ID
Cause
Subcause
Stationary cartridge seal
Miscentering
Flashing
Dry-running
Face distortion
Dirty pumpage
Related causes
1, 2, 16
Liquid vaporizes between

seal faces
Insufficient or no liquid
between faces
Excessive pressure
Excessive temperature
Dirty flush
Dirty discharge recirculation
Failure Mode
Misinstallation
6, 7, 8, 9
Poor lubrication
9, 11, 12
3, 6, 10, 13
High velocity of
flush/recirculation
Minerals/very fine particles
in pumpage
Exceeded limits
Abrasive wear
Solutions
Review installation
seal
Insure sufficient vapor margin
Eliminate dry running and/or
use proper environmental
controls
Install a clean flush
Install a suction recirculation
to remove solids
Install a flow controller
Use hard faces and/or a
clean flush
Scoring or adhesive wear is usually associated with inadequate

lubrication, however mild adhesive wear is the normal way seals wear
out over a long service life. Abrasive wear leaves faces severely grooved
and scuffed. Wear pattern often leaves coarse tangential grooves on
carbons.
Seal does leak steadily rotating but may hold stationary.
Corrosion (Faces)
146
Return
Seal Face Symptoms

Corrosion
Component
Seal Faces
ID
Symptom
Corrosion
ID
Cause
Subcause
Carbons - softening,
disintegration, increased
porosity
Chemical attack Hard faces (RSC/TC/DC) leaching of binder or filler
materials
Excessive temperatures
Related causes
12, 15, 17
Failure Mode
Misapplication
Solutions
Select compatible materials
Corrosion of hard face materials results from leaching of binders an

fillers. Binders are present in TC, RSC and DC. Carbon is attacked by
strong oxidizers and often results in overall softening and desintegration.
Impregnated carbons may also show selective leaching resulting in
increased porosity.
Seal leaks steadily both stationary and rotating
Chipping(ID/OD)
Vaporization
Seal Face Symptoms

Chipping (OD/ID)
Seal Faces
Component
ID
Symptom
Chipping (OD/ID)
ID
Cause
Flashing
Face distortion
Excessive heat
Shaft deflection
Subcause
seal faces
Excessive pressure
Coking/crystalization
Pipe strain
Cavitation
Unbalanced impeller
Related causes
Failure Mode
4, 7, 8, 9
Poor lubrication
3, 4, 10, 13
Exceeded limits
7, 8, 9, 12
1, 16, 19
Solutions

Use proper environmental
Product hardening
controls (quench)
Equipment operation Check NPSHR vs. NPSHA
Balance impeller
Chipping on the outer diameter and/or inner diameter of the seal rings
often result from face distortion and flashing. Chips can easily be
produced at disassembly of the seal so it is important to verify if they
occurred in service or after. Chips produced in service typically alter the
wear pattern.
Seal leaks only when chips have extended radially over the seal face.
Return
Crystallization
Coking
Seal Face Symptoms

Seal Faces
Component
ID
Symptom
ID
H
7
Cause
Subcause
Product temperature
Excessive heat
Coking
Crystallization
F
Flashing
Related causes
Pump cooling jacket not

efficient
Small clearances in seal
chamber
Liquid vaporizes and dries
out on atmospheric side of
face
Failure Mode
6, 8, 9 , 12
Product hardening
4, 6, 8, 9
Solutions
controls (cooling)
Check for scaling
Open up stuffing box bore
controls (quench)
Coking will occur with all oils except 100% synthetic oils at elevated
temperature (>120C). Crystallization occurs with a wide variety of fluids
of which caustics are the most common. Leakage is caused by the
abrasion of the seal faces and/or hang-up.
Seal leaks steadily, leakage rate vary widely.
Blistering
Carbon blistering
Blistering
Silicon carbide blistering
Seal Face Symptoms

Blistering
Component
ID
Symptom
ID
H
Seal Faces
Cause
Excessive heat
Blistering
F
Flashing
Subcause
Carbon incompatibility with
oils
Excessive speed
Excessive pressure
seal faces
Related causes
Failure Mode
Misapplication
6, 7, 9, 12
Exceeded limits
4, 6, 7, 9
Poor lubrication
Solutions
Use SC/TC in oils
Carbon blistering occurs with in all oils and manifest itself initially as
shiny bruised spots in the surface and later as craters. Carbon blistering
relates to high viscosity and all oils over 15cP may cause blistering.
Recently, blistering has also been found to occur with silicon carbides and
here caused by high PVs during operation
Seal leaks steadily when shaft is stationary or rotating
Heat Checking
Heat
Checking
Heat
Checking
Thermal
System
Thermal
System
Seal Face Symptoms

Heat Checking
Seal Faces
Component
ID
Symptom
ID
K
Cause
Dry-running
Subcause
between faces
Related causes
Failure Mode
4, 11, 12
Solutions
install environmental controls
Poor lubrication
9
Heat checking
Flashing
Excessive heat

seal faces
Product temperature
Excessive pressure
Excessive speed
4, 6, 7, 8
6, 7, 8, 12
Exceeded limits

Heat checking is caused by thermal distress of the material resulting in

small radial cracks. Scoring may be present or uneven wear with the heat
checking on the high spots. Occurs typically with tungsten carbides and
silicon carbides
Seal drips both stationary and when the shaft is rotating. Seal may pop
from flashing during operation.
Fracture
Overpressurization
High Torque
Seal Face Symptoms

Fracture
Component
ID
Symptom
ID
Cause
Seal Faces
I
10
Excessive
pressure
Fracture
J
Excessive face
torque
Subcause
Related causes
Swollen ID O-ring
13, 15
Exceeded barrier fluid
pressure limit
Excessive pressure
Low product viscosity and/or
7, 13, 19
density
Product hardening
Failure Mode
Chemical attack
Solutions
Install compatible o-rings
Exceeded limits
Poor lubrication
Product hardening

Use a dual seal
controls
Fracture of seal rings during operation presents itself with local

discoloration of the fracture surface or presence of wear debris. Fractures
caused by excessive face torque start from the drive notches and show
wear at the drive notches and pins.
Seal leaks steadily both stationary and when shaft is rotating
Seal Face Symptoms

Grooving
Component
Seal Faces
ID
11
Symptom
Grooving
ID
K
Cause
Dry-running
Subcause
between faces
Related causes
4, 9 , 12
Failure Mode
Poor lubrication
Solutions
High wear, possibly cracks with high circumferential scoring discolorations

and overheating symptoms. Metal parts may be discolored from heat.
Seal leaks steadily both stationary and when shaft is rotating
Extrusion
Elastomer Symptoms
Elastomers
Component
ID
12
Symptom
ID
Cause
Subcause
Product temperature
Excessive heat
Dry-running
Chemical attack
Hard/Brittle
Compression set
Excessive speed (frictional

heat on rotary and/or
stationary o-rings
between faces
Incompatibility of o-ring
material
Related causes
Failure Mode
6, 7, 9
Exceeded limits
Solutions
controls (cooling)
4, 9, 11
Poor lubrication

5, 15, 17
Chemical attack
Thermal loading on the elastomer causes elastomer to become hard or

compression set. Some elastomers (Aflas, Kalrez 4079, Nitrile)
compression set easily. Light compression can occur below the
elastomers high-temperature limit and can cause dynamic o-rings to
hang-up.
Seal drips or leaks steadily both stationary and when shaft is rotating
Extrusion
Elastomer Symptoms
Extrusion
Component
ID
Symptom
ID
M
I
Elastomers
13
Extrusion
Cause
Excessive
clearances
Excessive
pressure
Too soft material
Installation
damage
Subcause
Clearances in o-ring groove
too large
Related causes
Failure Mode
Quality/design
3, 4, 6, 10
Exceeded limits
O-ring damaged during
assembly
Misinstallation
Solutions
Check clearances, install
back-up ring
Use higher durometer
material
Use higher durometer
material
Review installation
instructions
Extrusion occurs when part of the o-ring is forced through close

clearance gaps. Typically a lip is formed which is then cut and sometimes
peeled off.
Seal leaks steadily when shaft is rotating. Leakage may reduce when
shaft is stopped.
Explosive Decompression
Elastomer Symptoms
Explosive decompression
Component
Elastomers
ID
14
Symptom
Explosive
decompression
ID
P
Cause
Subcause
Trapped gas ruptures o-ring
Sudden pressure when pressure is suddenly
drop
relieved
Related causes
Failure Mode
Solutions
If possible, eliminate sudden
pressure drops/shutdowns or
Equipment operation
other elastomer (consult
factory)
Elastomers under high pressure can absorb large amounts of gas.

Sudden decompression ( shutdowns) can cause explosive degassing
causing rupture of the elastomer. Explosive decompression rarely occurs
by pressures below 25 barg. Carbon dioxide is know to cause explosive
decompression
Seal leaks steadily both stationary and when shaft is rotating.
Swollen/Soft
Elastomer Symptoms
Swollen/Soft
Component
Elastomers
ID
15
Symptom
Swollen/Soft
ID
L
Cause
Subcause
Incompatibility of o-ring
Chemical attack
material
Related causes
5, 12, 17
Failure Mode
Misapplication
Solutions
Chemical attack of o-rings gives excessive volume change, either swell or

shrinkage. Swell may lead to seal failure due to extrusion, hang-up or
seal face distortion. Shrinkage causes loss of interference and possible
loss of drive. Chemical attack may also cause the o-ring to be eaten away
causing a direct failure.
Seal leakage rates vary widely.
Scoring
ID Scoring
OD Scoring

Scoring
Component
ID
Symptom
ID
Cause
Subcause
Related causes
Rotary component seal - OD
scoring
Miscentering
1, 2, 4
Cartridge seal - sleeve

scoring
Metal components
Set screws loosened
Q
16
Spinning
18
Excessive
pressure/pressure surges
Scoring
C
Shaft deflection
Radial runout
Off-BEP operation
Cavitation
Pipe strain
Unbalanced impeller
Bearing failure
Excessive bearing
clearances
Bent shaft
Seal chamber misalignment
1, 19
1, 2, 19
Pump misalignment
Failure Mode
Solutions
Review installation
seal
Review installation
Misinstallation
seal
Review installation
instructions and use
hardenend set screws on
hardened set screws
and hard set screws at
Equipment operation higher pressures
Improve shaft's L 3/D4
Balance impeller
Equipment condition
Install new shaft
Check stuffing box to shaft
perpendicularity
Re-align pump
Corrosion (Metals)
169
Return
Pitting
Surface Corrosion
Crevice Corrosion
12
Corrosion

Corrosion
Metal
Components
Component
ID
17
Symptom
Corrosion
ID
Cause
Subcause
Surface corrosion, pitting,
tensile stress corrosion,
Chemical attack galvanic corrosion and
crevice corrosion
Related causes
5, 12, 15
Excessive temperature
Failure Mode
Solutions
Misapplication
Corrosion results in overall and local loss of material. The type of damage
indicates the corrosion mechanism. Corrosion is always aggravated by
(local) temperatures and often by swirling.
Seal leakage can be low and seal appears to be running fine until
advanced stages of corrosion.

Metal
Components
Component
ID
18
Symptom
Flattened set
screws
ID
Cause
Subcause
Set screws loosened
Related causes
Spinning
16
Excessive
pressure/pressure surges
Failure Mode
Solutions
Review installation
instructions and use
Misinstallation
hardenend set screws on
hardened set screws
Equipment operation and hard set screws at
higher pressures
Insufficient fixture of the set screws allows shaft to spin under rotary seal
parts. Severe vibrations or use of stainless set screws on hardened shafts
can cause shaft to spin as well. With clamping devices seal may slide
axially under high pressure.
Seal leaks steadily when shaft is rotating. Axial sliding may cause steady
leaks when seal is stationary.

Drive Pin Wear
Component
ID
Symptom
ID
Metal Components
19
Drive pin wear
Cause
Excessive face
torque
Subcause
Related causes
Excessive product pressure
Low product viscosity and/or
10
density
Product hardening
Off-BEP operation
Cavitation
Shaft deflection
Pipe strain
Unbalanced impeller
Bearing failure
Excessive bearing
Radial runout
clearances
Pump misalignment
1, 2, 16
1, 2, 16
Failure Mode
Exceeded limits
Poor lubrication
Solutions
Use a dual seal

controls
Improve shaft's L3/D4
Equipment operation
Balance impeller
Equipment condition
Product hardening
Re-align pump
Drive pin wear or wear at the drive notches result from vibrations or
excessive torque. Drive pin wear is usually not the cause of failure but an
indication of a related cause of failure
Introduction to
Dual Seal Systems
Pressurized Vessel Systems

Most common system
Self contained system
Contains between 10 & 28 litres
Can run as buffer or barrier
One seal per vessel
Pressurised with air, nitrogen or water

Can be used with water and most
compatible fluids caution viscoity
Manufactured from 304 / 316 St Steel
Water Pressure Supply

Arrangement
Three way valve
Auto vent valve

Connects to plant water supply / FDU
No manual fill
Water Pressure Systems Summary

Eliminates water consumption
Allows thermal expansion
Self monitoring
Reduces disposal costs
Low maintenance
Water Pressure Systems Summary

Increases reliability
Cools and lubricates seal faces
Prevents sediment getting to the seal

Maintains its own pressure
Failure indicator
Header Tanks
Ring Main Circ Pump
Recirculation
Quench to Drain
Control Valves and Pressure Gauges
Effluent Treatment
To river or city sewer
Drain
Header Tanks
Pressure Drops
Ring Main Circ Pump
Recirculation line
To drain
Check
Valve
CARGILL MECHANICAL SEALS

DOUBLE
SEALS
DISP
CDSA
DSMF
SINGLE
SEALS
CON II
CSM
CURC
COMPONENT
SEALS
DIN SAI
Le tolleranze dimensionali degli alberi devono essere,

per tutte le tenute meccaniche,
di +/-0,05 mm rispetto al diametro nominale
Movimento assiale max. consentito per tutte le tenute usate
in Cargill: fino a 0,13 mm
Movimento radiale max. consentito:
-CSM: fino a 0,5 mm (+/- 0,25 mm)
-tutte le altre tipologie: 0,1 mm (+/-0,05 mm)
I movimenti radiali e assiali in realt sono superiori ma a
catalogo AESSEAL indica questi limiti per prudenza
THANKS FOR YOUR ATTENTION

Aessealpump and Seals Training

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Aessealpump and Seals Training

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Italian Customers

Presented by: daniel de lorenzi

TOPICS of the Training

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

WHAT IS A PUMP PURPOSE?

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Will pump fluid up to a

CENTRIFUGAL PUMPS CLASIFICATION

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

ANSI / ASME B73 1991

Seal Chamber Cover

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

WHAT is the Function of the WET END and

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

WHAT is the function of the STUFFING BOX?

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

WHAT is the POWER END?

B- Frame Adapter (machined component

C- Shaft ( is part of the rotating

H- Breather (acts as small vent allowing

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

I- Oil Flinger (distribute the oil and filter

WHAT is the function of the COUPLING?

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

WHY PUMPS FAIL?

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

A- Small Shaft Diameter

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

High Flow Cavit.

Reduced Impeller life

Low Flow Cavitation

High Temperat. Rise

Low Brg. and Seal li fe

80 x 100 x 330 @ 3000 R/Min.(3x4x13)

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE at BPE right hand side

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE at BPE left hand side

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE Slender Ratio L/D

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE Slender Ratio L/D

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE Slender Ratio L/D

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE Slender Ratio L/D

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE Slender Ratio L/D

OEM HIGH L/D

API POMPE LOWER L/D

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

RADIAL FORCE Slender Ratio L/D

EXXOM rule since

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,

System Sucks air