Eng.

\ WAEL ZAHRAN
 Content
What is the Mechanical Seal ?
What are the functions of the Mechanical Seal?
THE FUNDAMENTALS of Mechanical Seal
THE CONFIGURATIONS
Types of Mechanical Seal
THE SELECTION& THE CONFIGURATIONS
Mechanical Seal Installation
Keys and Keyways
Failure of mechanical seals
Mechanical Seal Troubleshooting

Q U ESTI O N S
THE Mechanical Seal
The basics
Mechanical seals are leakage control devices, which are found
on rotating equipment such as pumps and mixers to prevent
the leakage of liquids and gases from escaping into the
environment.
Failure of mechanical seals

In the following, examples of common causes of failure of mechanical

shaft seals will be discussed.
THE FUNDAMENTALS
The mechanical seal
Mechanical seals have the purpose
of preventing leakage of a fluid
(liquid or gaseous) through the
clearance between a shaft and the
fluid container
THE FUNDAMENTALS
THE FUNDAMENTALS
THE FUNDAMENTALS
Seal Basics – Centrifugal Pump

Create an effective seal in the stuffing box to prevent the media (in blue)
escaping to atmosphere. Shaft is rotating, stuff box static.
THE FUNDAMENTALS
Gland Packing Basics
Basics of Mechanical Seal
THE FUNDAMENTALS
Gland Packing Basics
➢ Simply fills the space between the shaft and inner wall . Remains
static at all times.
➢ If packing starts to drip, tighten the gland follower to increase
compression pressure on the packing and reduce the drip.
➢ Defining features are cross-section, designed to fill space with only
one layer, and fiber material, different lubrication levels, strengths
& chemical/temperature compatibilities.
➢ Downside – Never makes a complete seal, allows vapors to leak.
Constant abrasive contact with rotating shaft generates heat and
wears shaft.
PACKING THROAT BUSH
LANTERN RING
WITHOUT
PACKING
SLEEVE
FOLLOWER
GLAND

Equipment

• Wear is
directly on shaft
12
PACKING THROAT BUSH
LANTERN RING
WITH
PACKING
SLEEVE
FOLLOWER
GLAND

SLEEEVE

Equipment

* Wear is on
the sleeve
13
 Horizontal Surface wear Shaft wear

Equipment

Now it is essential to find a solution to avoid shaft wear,

Such as finding another surface of another parts to be
worn but easy and cheap to be replaced, It is the
MECHANICAL SEAL
14
What is going on inside a packed
stuffing box?

HOW A STUFFING BOX SHOULD LOOK WHEN IT IS

COMPLETELY PACKED
•How much water is being
used?

•Can you reduce this water

usage?

•Is water getting into the

product?

•How do solids get into the

packing?
LANTERN RING MUST BE POSITIONED BELOW FLUSH INLET TO ALLOW
MAXIMUM RESULTS FROM FLUSH FLUID: FLUSH PRESSURE SHOULD BE
10 TO 15 PSI (0.8 TO 1 BAR) OVER MAXIMUM STUFFING BOX 15
PRESSURE.
 Packing needs to compress to work.
Due to the compressibility of the packing the gland force
is not effectively transferred through each packing ring.

16
The lack of compression transmitted to the bottom rings
Causes them to run “loose”.
This allows solids from the process fluid being pumped
to accumulate between the sleeve and packing.

Conventional flush arrangements are not effective at

keeping solids out of packing. This is a major source of
17
packing and sleeve wear.
Lantern Ring Position Bottom of
Stuffing Box
Sleeve damaged by stock trapped
under the bottom packing rings

Bottom of Stuffing Box

 80 PSI Flush Flush water must overcome
the product pressure to keep
Process the solids out of the packing.
30 PSI
Solids A pressure drop is occurring
between the flush water
source and atmosphere.

The pressure in the stuffing

box is less than 80 PSI.
0 PSI
It is easier for the flush water
to go to the atmosphere than
it is to remove the solids.

Solids are not effectively

removed from the packing
with this method.

Flush water goes to drain.

Open Valve
 80 PSI Flush The flush water must
overcome the product
pressure to keep the solids out
Process of the packing.
30 PSI
The pressure drop now occurs
Solids between the flush water
source, atmosphere and the
product.
The pressure in the stuffing
box is now 80 PSI.
0 PSI The packing must now seal the
full 80 PSI.
The packing must be “tight” to
control leakage, causing
frictional heat.
This method reduces water
use and eliminates some
solids.
Considerable product
dilution can occur.
Closed Valve
SpiralTrac: How Does It Work?

Flow meter

Check Ball valve

Valve
 40 Flow Meter
with Valve Spiral Trac Type P separator
20 uses centrifugal force to
80 PSI direct the flow of the flush
0
GPH Flush and effectively prevents
solids from entering the
Process packing.
30 PSI
Adjustable flow meter is used
to reduce flow rates 20 to 30
Solids
gallons per hour!
This arrangement will
operate at significantly
reduced flush pressures and
flows.
Reduced pressure allows
the packing to seal
SpiralTrac effectively with reduced
Version “P” gland force.
 40 Flow Meter
with Valve
20 Reduced Flush Flow
80 PSI and Pressure.
0
GPH Flush
Flush Pressure only
Process
30 PSI
needs to be slightly
above (10-15 psi)
process pressure for
Solids
flow to occur

Reduced Gland
Force
No Solids
Gland has improved
“adjustment feel”
because bolt force is
SpiralTrac Ver “P” transmitted through
just 3 packing rings.
Shaft Sealing
Shaft sealing is provided to minimize the gas
leakage along the shaft.

Shaft seal types:

•Labyrinth seal
•Fluid film seal
•Mechanical seal
•Dry gas seal
Labyrinth Seal
Consist of a series of a sharp edged
circular fins generating flow
resistance for rotating gas inside
the casing.
The labyrinth seal has a small
clearance along the rotating shaft
and therefore a minute amount of
gas does escape.
Labyrinth Seal
Labyrinth Seal
Labyrinth seals are installed
on the diaphragm assembly
to minimize internal leakage
along the shaft from the
progressively higher stage
pressures.
Inter-stage Seal
Inter-stage seal:
Due to the pressure rise across
successive compression stages, seals
are required at the impeller eye and
rotor shaft to prevent gas backflow
from the discharge to inlet end of the
casing
Oil Film Seal
The seal oil enters the seal between bushings,
flow around the shaft and forms an oil film. This
oil film prevents gas from escaping.
Mechanical Seal
THE FUNDAMENTALS
Mechanical Seal Basics
➢Normally two components, one sealed to and
rotating with the shaft, one sealed to and remaining
static in the housing.
➢Each part has a technically flat polished sealing face.
The polishing allows the rotary face to run against the
static face while generating the minimum of friction.
➢A small amount of media enters between the faces
and acts as a running film further reducing friction. This
film evaporates before it reaches the inside of the
running faces.
 2-Mechanical seal function and component
Rotary Elements Stationary Element
1- Carbon ring
2- Snap Ring Tungsten Carbide ring
3- “O” Rings Or
Silicon Carbide ring
4- Springs
5- Sleeve

Equipment

33
 1-Principle of operation
Scarifying
elements
Vertical surface wear

Equipment

34
THE FUNDAMENTALS
Mechanical Seal Basics
 LESSON NUMBER ONE
ALL
MECHANICAL SEALS
LEAK
.
THE FUNDAMENTALS
THE FUNDAMENTALS
The liquid film
In order to minimize the amount of friction between the seal
rings.

lubrication is required.
Seal faces can be lubricated by the process fluid or, with double
mechanical seals, by a proper auxiliary fluid
THE FUNDAMENTALS
The liquid film
THE FUNDAMENTALS
The liquid film
THE FUNDAMENTALS
The liquid film
In order to insure good lubrication and sufficient
cooling of the seal rings, the correct selection of a
mechanical seal shall take into consideration the
following parameters:

❖ Process fluid temperature

❖ Vaporization pressure at operating temperature
❖ Process fluid characteristics
❖ Shaft speed
THE FUNDAMENTALS
Leakage
All mechanical seals produce leakage.
The reason lies in the previously discussed theory of lubrication ; it is
obvious that a stable lubrication layer means a certain amount of
leakage. Leakage can be calculated and depends on several factors as
rotational speed, fluid pressure and characteristics, and balancing
ratio. But the equipment on which the mechanical seal is installed
can have some influence on it too.

Often leakage is so reduced that it cannot be detected.

THE FUNDAMENTALS
Leakage
 SEALING THE LIQUID
• Mechanical seals were originally designed to lend a greater sealing
capability than could be achieved using common packing.
• Before the advent of mechanical seals, pump users relied primarily
on “rope” or braided style packing to achieve a “seal” around the
shaft. A series of pieces or “rings” were installed into the pump
“stuffing box” and they were compressed tightly so that they created a
difficult leak path for the liquid to negotiate in order to leak to
atmosphere.
 SEALING THE LIQUID

• Early packing styles did not seal very well. In fact, until
recently, braided packing styles required varying amounts of
leakage for lubrication. If leakage was not permitted to occur,
the packing would literally “burn up” and often cause severe
damage to the pump shaft. Even with adequate leakage for
lubrication, pump shaft wear was a commonly expected
occurrence and as the shaft wore it would in turn, cause poor
shaft packing life.
• As leakage becomes more excessive, the gland is tightened
to reduce leakage.
 SEALING THE LIQUID

• With the introduction of mechanical seals, this leakage

could be controlled to a much greater degree.
• Let’s look at the same pump with a mechanical seal
installed. Note that the seal shown is an RS-1 with O-
Ring type stationary and a set screw collar.
 SEALING THE LIQUID
• You have probably taken notice of the illustration showing minor
leakage to atmosphere. It is appropriate to point out at this
time…
 SEALING THE LIQUID
• It is a fact, all mechanical seals leak. Like packing, the mechanical
seal “faces” must also be lubricated. With proper application and
design however, the leakage is so minute that actual droplets of
liquid are not detected. Instead, the lubricating liquid will vaporize as
it crosses the seal faces and the leakage is a gas or vapor.
• Since we are discussing the sealing of the liquid at the faces, let’s
take a look at the sealing points of a typical mechanical seal. Again,
viewing the same pump and seal, note that there are four sealing
points to consider.
 The seal gland to the
stuffing box

O.D. of the stationary

Sealing on the shaft

And finally, the seal faces

THE FUNDAMENTALS
CENTRIFUGAL PUMPS

• A centrifugal pump is simply a shaft, suspended on bearings

with an impeller attached to one end. The impeller is encased in
a housing that is filled with a liquid. As the shaft is rotated,
centrifugal force expels the liquid out through an orifice, where it
is typically piped into a process or another collection point. As
the expelled liquid exits the case, additional liquid is added to
the case so that a flow develops. That is basically how a
centrifugal pump works.
• The next slide shows a photograph of a typical “End Suction
Centrifugal Pump”.
 PUMP SHAFT

IMPELLER BEARINGS
 A LIQUID IS SUPPLIED TO THE PUMP
“SUCTION”

CENTRIFUGAL FORCE EXPELS THE LIQUID OUT

FROM THE IMPELLER

AS THE PUMP SHAFT ROTATES

THE FUNDAMENTALS
Mechanical seals have been used for many years to
seal any number of liquids at various speeds, pressures, and
temperatures. Today plant operators are benefiting from improved
seal technologies driven by the U.S. Clean Air Act of 1990, and the
American Petroleum Institute (API) Standard 682. These new seal
technologies are based on advanced computer programs used to
optimize seal designs, which are then verified through performance
testing at simulated refinery conditions required by the API. The
results to date indicate not only an improvement in emissions
control, but also a major increase in equipment reliability.
CLASSIFICATION OF SEALS BY ARRANGEMENT
THE FUNDAMENTALS

CLASSIFICATION OF SEALS BY ARRANGEMENT

CLASSES OF SEAL TECHNOLOGY
1. Contacting liquid lubricated seals:
• Normally, a single seal arrangement is cooled and lubricated by
the liquid being sealed. This is the most cost-effective seal
installation available to the industry.
• Dual seals are arranged to contain a pressurized or non-
pressurized barrier or buffer liquid. Normally, this arrangement
will be used on applications where the liquid being sealed is not a
good lubricating fluid for a seal and for emissions containment.
These arrangements require a lubrication system for the
circulation of barrier or buffer liquids.
THE FUNDAMENTALS
CLASSIFICATION OF SEALS BY ARRANGEMENT
CLASSES OF SEAL TECHNOLOGY
2. Non-contacting gas lubricated seals:
• Dual non-contacting, gas-lubricated seals are pressurized with an
inert gas such as nitrogen.
• Dual non-contacting, gas-lubricated seals are used in a tandem
arrangement and pressurized by the process liquid being sealed,
which is allowed to flash to a gas at the seal. A tandem seal
arrangement is used on those liquids that represent a danger
to the plant environment. For non-hazardous liquids, a single seal
can be used.
THE FUNDAMENTALS
CLASSIFICATION OF SEALS BY ARRANGEMENT
Sealing arrangements can be classified into two groups:
1. Single seal installations
a. Internally mounted
b. Externally mounted
2. Multiple seal installations
a. Double seals
b. Tandem seals
THE FUNDAMENTALS
Outside mounted Single seal installations
Single Mechanical Seal
MECHANICAL SEAL

HANGED BEAM
IMPELLER
69
THE FUNDAMENTALS
Inside mounted Single seal installations
THE FUNDAMENTALS
Opposed double mounted Single seal installations
THE FUNDAMENTALS
Tandem double mounted Single seal installations
Multi Mechanical Seal

MECHANICAL SEALS

DRIVE END NON-DRIVE END

IN-BETWEEN TWO
73 BEARINGS IMPELLER
 Mechanical seal and bearings arrangement

oil

Equipment

74
Dry Gas Seal
Basic dry gas seals consist of a stationary ring held against a
rotating ring with spring pressure. The rotating ring has special
grooves or tapered lands cut into the outer portion of the face .

Dry filtered process gas or inert gas is introduced into the

seal area. As the shaft rotates, the gas is between the seal faces
along the grooves towards the smooth section of the face. The
action of the rotating grooved ring creates a pumping or lifting
effect that forces the stationary ring back against the springs
and away from the rotating face. This small gap. which may be
as small as 0.0002'" effectively restricts leakage to a minimum.
This minute gas leakage helps remove heat that is produced by
the constant action of gas shearing at the seal faces.
Dry Gas seal
Dry Gas seal
Dry Gas seal
Tandem double seal
In an unpressurised configuration there is the advantage
of avoiding relatively costly pressurization systems
obtaining a performance equivalent to the one of the
back-to-back lay-out, which consists of:
-No leakage of the process fluid into the atmosphere
-Good lubrication and cooling of the seal rings
This configuration however is not suitable with toxic,
abrasive or highly viscous process fluids, prone to create
sticking of seal rings; in these cases the back-to back
configuration should be used.
Dry Gas seal
Dry Gas seal
This is a new configuration foreseen by API 682 standard
(American Petroleum Institute), where the two seals are
assembled in a tandem lay-out. A special design of the seal
rings gives the possibility to operate both in an
unpressurised system and in a pressurized system (as with
the back-to-back configuration), obtaining the advantages
of the two previous configurations. Only a cartridge
assembly is allowed by API 682 in this configuration.
Dry Gas seal Grooves on rotating seat
Dry Gas seal Grooves on rotating seat

Spiral groove pattern on a dry gas seal face.

Dry Gas seal Grooves on rotating seat

Dry gas seal groove pattern profiles to provide bidirectional rotation

capability.
Dry Gas seal Principle of Seat and Face
Dry Gas seal Principle of Seat and Face

The pressure generated by the grooves is throttled across the

sealing dam and the combination of lift and restoring force
establishes a seal fluid film which may be in the range of two to ten
microns depending on the seal desi n, gas and speed of rotation.
The design of the seal with respect to lift, face distort ons and
restoring force are crucial to maintaining the few microns of gas
film that provides non-contacting operation. The design of the seal
to provide a stiff gas film is important so that it can accommodate
transient conditions such as pressure changes, axial shaft
movements, etc. As the seal face gap closes the force that it will
absorb increases, to create an equilibrium
Dry Gas Seal Principle of Seat and Face
Dry Gas Seal Principle of Seat and Face
Dry Gas seal Grooves on rotating seat

Gas film support vs film thickness for a typical dry gas seal.
Dry Gas Seal
Clean gas Primary leak secondary leak Instrument
supply to flare to safe location air
Dry Gas seal Principle of Seat and Face
Dry Gas Seal
Clean gas Primary leak secondary leak Instrument
supply to flare to safe location air
 GAS SEAL
Cut away view of the
DCG shows the Stationary
Carbon Face

Rotating Face Gas inlet

port

Thumb not an integral

part of the seal assembly
To save location To flare
Flame arrestor
Flame arrestor is a piece of
equipment installed in an industrial
process to stop the propagation of a
deflagration traveling along a
pipeline by extinguishing the flame.
Flame arresters are used on storage
tank vents, fuel gas pipelines,
storage cabinets, the exhaust
system of internal combustion
engines, Davy lamps and over proof
rums.
PUSHER VS. NON-PUSHER
• Both pusher and non-pusher types can be either shaft mounted or
cartridge assemblies.
• The basic difference between pusher and non-pusher types have
to do with the dynamics of the shaft packing or O-ring and whether
or not it moves as the seal wears.
• As the seal faces wear down over time, they must be closed to
compensate for lost face material. If the shaft O-ring must move
when this compensation takes place, it is pushed forward by the
components of the seal and by stuffing box pressure. If the seal is
configured with a “dynamic” O-ring of this type the seal is called a
pusher type.
Illustrated here is a Type RS-81, a common pusher seal. As the seal
springs and other pressures in the stuffing box are exerted on the seal,
closure of the faces is achieved.

Rotating face and

dynamic O-ring.
Hard Stationary Face

Closing forces exerted

on the seal faces
As the softer carbon face wears down, the rotating face
must move to maintain face closure.
Minute particles of carbon and solids from the process liquid
that migrate across the seal faces build up on the shaft.
This build up will ultimately caused the seal to “hang up” and in most
cases, failure will occur well before the seal is actually “worn out”.
PUSHER VS. NON-PUSHER
• There are seal types that have no dynamic O-rings. All O-
rings are “static” and the seal components compensate for
face wear without “pushing” any sealing points.
• One of these types is called a “Bellows Seal”. The bellows
can be constructed of metal, rubber or PTFE. The RS-1 seen
earlier in this presentation is an “Elastomer (or Rubber)
Bellows Seal”.
• Let’s consider the metal variety.
Bellow Mechanical Seal

BELLOW

Rotary ring Stationary ring

102
 Double Mechanical seal Bellow type

BELLOW BELLOW

103
Bellows Bellows
–Uniform stress distribution

– 45° tilt for enhanced

fatigue strength

–Three sweep radius

104
Bellows Benefits
• For high temperature applications
>260°C/500°F

• For higher pressure

• Generally have light spring loads

–Less heat
–Low power consumption
–Longer seal life
• Pressure balanced by design
105
 Hard stationary face

Carbon rotating face

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

111
Cartridge
Split Seal

112
 Plant Operations
• Rotating equipment maintenance
costs can be about 20 % of the total
maintenance budget.

• Rotating equipment is taken out of

service 70% of the time due to a
leaking Mechanical seal.

113
Split Seals
• Benefits Over Mechanical Seals :
– No Dismantling of Equipment
– Fast maintenance / high equipment
availability
– Reduced man hours / improve productivity

– Reduced complexity

114
 Split Seals merits

Production

Manpower

Maintenance Budget
Time
115
Split Seals

• Target Applications
– Shaft size greater than 3” ( 76) mm
– Vertical pumps (vertical in line)

• Limitations of Split Seals

– Not recommended for applications where
emissions will be a dangerous to the
environment or humans
116
 BRIEF DISCUSSION
ABOUT MECHANICAL
SEAL FACE DYNAMICS
FACE FLATNESS
• The mechanical seal faces are obviously the most critical sealing point
of a mechanical seal assembly.
• Although the faces can be manufactured from a myriad of different
materials, one is typically carbon, while the other is usually a hard
material. (i.e. Alox (Aluminum Oxide Ceramic), Tungsten Carbide,
Silicon Carbide, etc.)
• In order for a “seal” to be achieved, the faces must be very flat. This is
achieved by machining the faces, then “lapping” them to a fine finish.
• Flatness is measured in “Light Bands”. After lapping, the faces are
placed on an “Optical Flat”, a clear glass surface where a
monochromatic light is shined on the face. This single wavelength light
will produce an image of rings or lines on the face. Each ring/line is
“One Light Band”. Each light band is equivalent to .000011” or eleven
millionths of an inch. This refers to the variations in the surface of the
face. On most face materials, one light band is Utex’s standard.
FACE FLATNESS

• This illustration shows a face

being inspected on an Optical
Flat.
• Take notice of the light bands
that are visible on the reflection
of the face.
• Laying a straight edge on a
tangent to the inside
circumference of the face, how
many light bands are crossed?
Optically Flat Faces
100 psi

Rotary Stationary
Face Face

0 psi
 FACE FLATNESS

• As was stated earlier, it is hoped that the application

and design of the mechanical seal is suited for the
service. If so, there is leakage of only vapor through
the seal faces.
Degree of freedom
The elastic components of a mechanical seal (spring or bellow,
gaskets) are of paramount importance for good performance. The
gasket mounted on the seal ring pushed by the spring or bellow
(usually the rotary ring) has to follow the movement of the ring
induced by
Degree of freedom
 Vertical
Inline
Centrifugal
Pumps

Driver

Coupling

Gearbox

Pump
Degree of freedom
Degree of freedom
Spring Force
• Single coil-springs
• Multiple coil-springs
• Single wave-springs
• Nested wave-springs
• Continuous coil wave-springs
• “Rat-trap” springs
• Metal diaphragms
• Edge-welded metal bellows
• Formed metal bellows
• Heavy-section elastomer bellows
Degree of freedom
Degree of freedom
Degree of freedom
Hydraulic Balance

BALANCED VS. NON-BALANCED

• When speaking of “Balance” in reference to mechanical seals, we are
not talking about Mechanical or Rotational Balance. Instead, we are
referring to Hydraulic Balance.
• Since mechanical seals are subject to stuffing box pressure, this
pressure is utilized to achieve and maintain seal face closure in a
non-balanced seal.
• If stuffing box pressure is very high, typically over 100psi., then the
closing force may be too great to allow the “Boundary Layer Liquid”
that lubricates the faces to be sufficient and the faces will wear
prematurely.
• A balanced seal compensates for higher pressures by locating the
seal faces such that stuffing box pressure has less effect on face
closure.
Hydraulic Balance
An stable and complete layer of lubrication greatly affects the
performance and the life of a mechanical seal.
Hydraulic Balance
Carbon ring Stationary
Balanced mechanical seal

Product +Springs Contact face pressure

Product +Springs Contact face pressure

132
PRESSURE P > STRESS S
Unbalanced mechanical seal
Carbon ring Stationary

Product + Springs Contact face pressure

Product + Springs Contact face pressure

133 PRESSURE P < STRESS S

 FACE AND SEAT AREA EQUAL 100% BALANCE

Carbon ring Stationary ring

A = Contacted P A
S
A
Surface area

S = Contacted
Surface stress

P = Product +
Spring pressure

F = Acting force
F = P*A F= S *A

S P*A = S*A
= 100 %
134
P P = S
Hydraulic Balance
HYDRAULIC BALANCE OF SEALS 50 % BALANCE

P P

P
A1 0.5 A S
A
A = Contacted
Surface area

A1 = Projected area
of P

S = Contacted
Surface stress

P = Product +
Spring pressure

F = Acting force
F = P * A1 F= S *A
P * A1 = S*A
S 50 %
P
= S
=
A1
136
P A
Hydraulic Balance
Hydraulic Balance
Hydraulic Balance
HYDRAULIC BALANCE OF SEALS 75 % BALANCE

P S
A1 0.75 A A
A = Contacted
Surface area

A1 = Projected area
of P

S = Contacted
Surface stress

P = Product +
Spring pressure

F = Acting force
F = P * A1 F= S *A
P * A1 = S * A
S 75 %
P140
= S
=
A1
P A
Hydraulic Balance
 OPTIMUM HYDRAULIC BALANCE

Balance percentage is a compromise :

Below 65 % ------------- LEAK

Above 85 % ------------- WEAR

142 Optimum Balance 75% for medium pressure seals.

Mechanical seal has the following data:
A = contacted surface area = 230 cm2
A1 = ( projected area of P) = 120 cm2
Calculate the hydraulic balance Percentage
SOLUTION

S (contacted surface stress) A 1 ( projected area of P) 120 cm2

= =
P (product + spring pressure) A ( contacted surface area) 230 cm2

= 0.52 *100 = 52 %

Hydraulic balance % is less than 65 %

143
This Mechanical is prone to leak
Mechanical seal has the following data:
A = contacted surface area = 200 cm2
A1 = ( projected area of P) = 180 cm2
Calculate the hydraulic balance Percentage
SOLUTION

S (contacted surface stress) A 1 ( projected area of P) 180 cm2

= =
P (product + spring pressure) A ( contacted surface area) 200 cm2

= 0.9 *100 = 90 %

Hydraulic balance % is more than 85 %

This Mechanical is prone to wear
144
Mechanical seal has the following data:
A = contacted surface area = 30 cm2
A1 = ( projected area of P) = 24 cm2
Calculate the hydraulic balance Percentage
SOLUTION

S (contacted surface stress) A 1 ( projected area of P) 24 cm2

= =
P (product + spring pressure) A ( contacted surface area) 30 cm2

= 0.80 *100 = 80 %

This Mechanical is hydraulic balanced

as it is in between 65 % and 85 %
145
Hydraulic Balance
Hydraulic Balance
Hydraulic Balance
A non-balanced seal has faces located
outside the “Balance Diameter” of the
seal. Stuffing box pressure is applied
to the faces virtually evenly.

Face OD Line

Face ID Line
Balance Line
The faces of a balanced seal are located so that
a portion of the face contact occurs inside the
balance diameter resulting in reduced closing
force due to stuffing box pressure. This seal is
a Type RS-8B1. (The “B” = balanced)

Face OD Line
Balance Line

Face ID Line
Most metal bellows seals are balanced.

Face OD Line
Balance Line

Face ID Line
Hydraulic Balance
 Buffer fluid warmed
by seal generated
heat returns to the
buffer supply tank

Inside or Primary seal

Outside or Secondary Seal

Cool buffer fluid

from the buffer
Immersed in process liquid supply tank enters
in the stuffing box via the inlet port
 Pressurized Non-Pressurized
Dual Seal Dual Seal
Artificial Environment Artificial Environment
“Barrier” System “Buffer” System
Cooling system and API planes

The great importance of efficient lubrication of the seal

rings for good importance has been previously
underlined. It follows that a suitable cooling system
should be implemented to limit the operating
temperature of the seal. Many different lay-outs can
be used, depending on the configuration
and the required service.
Cooling system and API planes
There are two sources of heat in a seal chamber

1-Heat soak from the product 2-Heat generated by the seal.

Cooling system and API planes
The factors involved in the creation of heat at the seal faces:

❖• Size of the seal

❖• Rotational speed (revolutions per minute)
❖• Temperature of the fluid
❖• Nature of the service fluid
❖• Materials of construction
❖• Surface finish of the seal running faces
❖• Surface area of the running faces
❖• Pressure acting on the seal faces
Pressure Drop & Vaporization

Liquid 100 psi

Liquid + Vapor 50 psi

Vapor + Liquid 25 psi

Vapor 0 psi
Cooling system and API planes
A good seal selection must include criteria for a safe
and durable installation. API standard has supplied
an exhaustive collection of flushing and
pressurization lay-outs, each intended for a specific
service. The various connection lay-outs are
identified by a specific number which gives the
possibility to simply define all possible
configurations (See API plans)
Cooling system and API planes
Cooling system and API planes
 NON-PRESSURIZED TO FLARE / RECOVERY
BUFFER FLUID SYSTEM
PLAN 52 / 7352

DISCHARGE
SUCTION
 PRESSURIZED GAS IN

PRESSURIZED BARRIER FLUID

PLAN 53 / 7353

DISCHARGE

SUCTION
THE SELECTION & API
Clean, not harmful, neutral, not flammable products

API Plan 11 or 01 is the

recommended lay-out, in
order to dissipate the heating
produced by the seal rings and
to carry out a proper venting
of the stuffing box.

In the case of a conical stuffing

box also API Plan 02 can be
used.

Clean, not harmful, neutral, not flammable products

THE SELECTION & API
Clean, not harmful, neutral, not flammable products
THE SELECTION & API
Acid products
THE SELECTION & API
Toxic, poisonous or highly viscous fluids
Example: Solvent based varnishes, inks, creams, glues, lattice The
back-to-back configuration is recommended with a pressurized
API Plan 53. The lubrication of the seal faces is provided by the
auxiliary fluid. Suitable instruments (i.e. level switch ) installed on
the pressurization system can detect an eventual leakage.
THE SELECTION & API
Abrasive fluids

Example: Water mixed with sand,

slurries A double configuration is
recommended with a pressurized
API Plan 54. The best lay-out is a
stationary seal with the product
outside the seal rings.
THE SELECTION & API
THE SELECTION & API
Clean, not harmful, neutral, not flammable products
Failure of mechanical seals

Failure of the mechanical shaft seal is the most common cause of

pump downtime. The shaft seal is exposed to widely varying
operating conditions. Sometimes operating conditions change to
become quite different from the specific conditions for which the
seal was intended.
Failure of mechanical seals

In the following, examples of common causes of failure of mechanical

shaft seals will be discussed.
Reasons For Seal Failure
Seals will fail to seal at some point, only a failure if this happens
prematurely.

No.1 – Dry Running – no lubrication to seal faces causes heat build

up and face wear. Faces no longer flat, seal leaks.

No.2 – Elastomer failure – chemical attack or heat. Elastomer no

longer makes universal contact with surfaces, leak starts.

No.3 – Running faces not flat or contaminated – Always a drip on

start-up when new. If faces are not flat or particles between faces,
face no longer flat and will leak.
Failure of mechanical seals
Lubrication failures
Proper functioning of mechanical shaft seals with hard/hard seal face
material pairings depends on lubrication by the pumped medium. Dry
running and poor lubrication can produce the results described below.
Failure of mechanical seals
Dry running
Failure of mechanical seals
Poor lubrication
Failure of mechanical seals
Contamination failures
Hang–up
Failure of mechanical seals
Corrosion
Failure of mechanical seals
Failure of mechanical seals
Failure of mechanical seals
Failure of mechanical seals
Failure of mechanical seals
Failure of mechanical seals
Failure of mechanical seals
Failure of mechanical seals
Mechanical Seal Troubleshooting
Failure Modes and Causes for Mechanical Seals
Mechanical Seal Troubleshooting
Failure Modes and Causes for Mechanical Seals
Mechanical Seal Troubleshooting
Failure Modes and Causes for Mechanical Seals
Mechanical Seal Troubleshooting
Failure Modes and Causes for Mechanical Seals
Failure of mechanical seals

In the following, examples of common causes of failure of mechanical

shaft seals will be discussed.
Mechanical Seal Troubleshooting

Causes of mechanical seal failure.

An example of this
technique is that used
for the seals on the
boiler circulating pumps
for nuclear power plant.
Those employed on
pressurized water
reactors operate at up
to 170 bar.49 A series
arrangement of three
seals is used
QUESTIONS

Eng.\ WAEL ZAHRAN

Email: [email protected]