Split S l
655
Type 37 FS Split Seal
656
Type 37 FS Split Seal
657
Type 37 FS Split Seal
658
Type 37FS Split Seal
659
Type 37 FS Split Seal
Radial shaft movement
3.0 mm TIR
Shaft runout
0.5 mm TIR
Stuffing box waviness
0.7 mm TIR
Axial end play to
1.5 mm TIR
Squareness of stuffing
box face to shaft
2.5 mm TIR
660
Type 37FS Split Seal
661
Type 37FS Split Seal
662
Type 37FS Split Seal
663
Type 37FS Split Seal
664
Type 37FS Split Seal
665
Type 37FS Split Seal
667
Type 37FS Split Seal
668
Type 37FS Split Seal
669
Type 37 FS Split Seal
670
Type
yp 3710
External
finger
fi
springs
Hydraulically balanced
673
Performance Capabilities
p
Temperature: 121
121°°C max.
Pressure:
Carbon vs Sealide-
Sealide-C vacuum to 13.7 bar g
Sealide--C vs Sealide
Sealide Sealide--C vacuum to 6.9 bar g
‘vacuum’ = 635 mm (25”) Hg
(86% of full vacuum)
Sh ft S
Shaft Speed:
d 3600 RPM up to
t 2.5”
2 5” / 62 mm
1800 RPM above 2.5”/62 mm
to 5
5.25
25” / 130 mm
Radial Runout: 0.13 mm TIR
Axial Movement: 0.38 mm TIR
674
Materials of Construction
Metallurgy: 316 Stainless Steel
Finger
Fi Spring
S i is i 17-
17-7 pH
H SS
Elastomers: Viton
Ethylene Propylene
675
Seal Failure
Analysis
Observation
Here is a test
Ê There are no visual tricks
Ready?
y
677
Seal Failure - Observation
678
Seal Failure
Analysis
A brief overview
680
Leakage - Newtonian Fluids
Diameter (mm)
100 Speed (rpm)
80
60
40
30
20
.
Pressure (bar g) L e a k a g e ( m l/h )
Incrreasin
Ê High hazard or pollution risk
Ê Process contamination
ng leakkage
Ê Minimum levels of cleanliness
Ê Economic considerations
Ê Exceeding removal capacity
Ê Exceeding supply capacity
682
Seal Failure Analysis
Normal Operational Life of the Seal
First Few
Hours
Time
.
683
Seal Life - MTBF
Survey of large UK refinery
40
of Seals
30
e (%) Percentage o
10
Failure
0
0 5000 10000 15000 20000 >24000
I t ll d Lif
Installed Life (H
(Hours)) .
Ref: P Connor - 1992
684
Seal Failure Analysis
685
Seal Failure Analysis
Institute of Global
Mech. Eng. Chemical Co
Seal selection & design
Design Pump selection, design 28% 15%
& suction circuitry.
Installation, alignment,
bearing & pump condition
Maintenance 24% 20%
Seal fitting & installation
tolerances
Process upsets, off-duty
operating, priming,
Operation mal-operation. 48% 65%
Seall flushing,
S fl hi cooling,
li
quenching.
686
Seal Failure Analysis
Static Gaskets / O-
O-Rings
Tertiary
T ti Seal
S l
Secondary Seal
Primary Seal
687
Static Gasket / O-
O-Ring Leakage
EFFECT POSSIBLE CAUSE CORRECTIVE ACTION
Leaks immediately 1) Not Fitted!! Install new,
new check parts list
list.
Worsens with increase
in pressure. 2) Damaged on Installation Check Installation, assembly
(mechanical damage) procedure. Consider using a
temporary adhesive to hold in
position.
3) Incorrect / insufficient Check Installation, 2 point
loading (gasket) location, etc.
Check gasket areas and design
of location groove / bolting load.
Leakage initially zero, 1) Chemical Attack Check duty conditions.
but gradually worsens Select alternative material.
with time
2) Thermal Damage Check duty temperatures.
Increase cooling.
Select alternative material.
3) Over-aged
Over aged o-rings
o rings Check supply date &
stock rotation.
688
Tertiary Seal Leakage
EFFECT POSSIBLE CAUSE CORRECTIVE ACTION
Leaks immediately 1) Damaged on Installation Check Installation
Installation, assembly
Worsens with increase (mechanical damage) procedure. Check for correct
in pressure. lead-on/chamfer, surface quality.
Use adequate & correct lubricant.
2) Damaged on start-up
start up due Check seat housing dimensions.
dimensions
to seat rotation. Consider pinning/clamping seat.
(mechanical damage) Investigate cause of friction loss.
Leakage initially zero, 1) Chemical Attack Check duty & correct lubricant used
b tg
but gradually
ad all worsens
o sens S l
Select alternative
l i material
i l (may
(
with time involve change of seat design).
689
Secondary Seal Leakage
EFFECT POSSIBLE CAUSE CORRECTIVE ACTION
LLeaks
k immediately
i di t l 1) Damaged on Installation Check Installation
Installation, assembly
Worsens with increase (mechanical damage) procedure. Check for correct
in pressure. lead-on/chamfer, surface quality.
Use adequate & correct lubricant.
Leakage initially zero
zero, 1) Chemical Attack Check duty & correct lubricant used
but gradually worsens Select alternative material (may
with time involve change of seat design).
690
Primary Seal Leakage
692
Seal Failure Analysis
693
Seal Failure
Collect full details of ACTUAL operating
conditions
Check dimensions (fitting/chemical/wear)
Were there any
Ê operational problems?
Ê unusual occurrences?
Note all visual evidence
Ê bad points
Ê good
d points.
i t
694
Information to Collect
• Modus Operandi of • Failure Initiated or Following
Equipment (Including Start / Process Change.
Stop Sequences). • Failure Related to Operational
• Maintenance Arrangements. Change.
• Vibration
Vib ti Signature.
Si t • Start
St t / St
Stop Hi
History
t andd
• Prior to Start-
Start-Up Failure. Operation.
• Cartridge Pressure Test. • DE / NDE Bias.
• Dynamic Failure. (< 1hr) • MTBF (Consistent or
• Operating Hours? Irregular).
• Sudden Failure or Progressive • Comparable Duty with
Leakage Increase.
Increase Different History.
• Anything Unusual?.
695
Root Cause Failure Analysis
How Can This Happen?
How Can This Happen?
How Can This Happen?
How Can This Happen?
How Can This Happen?
How Can This Happen?
Experience Experience
User User
Operator Root Cause Maintenance
Failure Analysis
How Can This Happen?
Seal Vendor
Common
Information
Sources
Experience
697
Seal Failure Analysis
SEAL FAILURE ANALYSIS GUIDE J ohn A B l aber / FA I LURE 1 . X LS
EXAMINATION LUBRI- INATION OSION EROSION CONTROL Assembly Fitting Size Equipm'nt Pipework Flow Pressure Speed VENTING Cleaning/ Vibrat ion
.
698
Seal Failure Analysis
'X' TYPICAL EXAMPLES OF 'X' 'X' TYPICAL EXAMPLES OF 'X'
X1 Differential expansio n between static and ro tating elements causing separatio n at seal interface. X43 RECOGNITION: Surface blisters o n running track o f carbo n face
X2 Seal set at wro ng wo rking length with no co ntact between face and seat. 'Lumps' o f carbo n remo ved fro m running track, usually at ID.
X3 Shaft diameter to lerance >+0.05mm. Shaft o vality > 0.006mm with wedge seal.
X4 B edplate disto rting due to inadequate fo undatio n suppo rt. Fabricated steel bedplate no t filled with CORRECTIVE A CTION OP TIONS:
co ncrete. Vessel no t aligned to vertical due to mo vement o f fo undatio ns. P ipe strain - ensure flanges are 1. Use '218' o r '539' face material.
co rrectly aligned. Check co upling alignment. 2. Reduce face width (e.g., 3mm).
X5 Leakage g due to thermal expansio
p n of p
pipewo
p rk. NB : 100' length
g o f stainless steel expands
p 3. Reduce spring
p g lo ad. If face width reduced,, ensure face stress is at o r belo w level befo re face
appro x. 2" (50mm) per 100 deg C rise in temperature. P ipewo rk inadequately suppo rted. width reduced.
X6 P ressure to o lo w to keep split faces to gether, e.g., T99/599 seals. 4. Use minimum hydraulic balance rate o f 75%. Co nsider increasing up to 65%.
X7 P ro duct recirc. fro m discharge o n vertical pumps instead o f reverse circulatio n back to suctio n. 5. Seat OD = Face OD to allo w uninterrupted co o ling flo w.
X8 Seal faces dry-running resulting in o verheating. T10T P TFE vs ceramic - P TFE will "burn". High 6. If seat is tungsten carbide o r silico n carbide, matt lap the running track. If no t TC o r SC, co nsider
to rque o n hard face material co mbinatio ns can generate heat that can be transmitted to an changing.
elasto meric seco ndary seal resulting in hardening and burning. Seco ndary seals may "spin". 7. Co nsider use o f cast iro n (006) extended surface seat
X9 Chemical reactio n with an o xidizing agent, e.g., nitric acid. - this wo uld negate the need fo r steps 6 abo ve.
X10 Insufficient flo w to heat exchanger o r co o led ho llo w seat resulting in X8. 8. Eliminate any areas fo r face and/o r seat disto rtio n, e.g., hand-lap seat landings.
X11 Over-co mpressio n due to inco rrect assembly o r wro ng wo rking length resulting in X8. This will also 9. Impro ve venting and po int o f circulatio n entry. Co nsider multi-po int injectio n o r reverse
o ccur if no allo wance is made fo r the reverse o f X1. B alance step fo uling shaft. circulatio n where appro priate.
X12 Seal chamber pressure to o lo w, resulting in X8. No pro duct in pump when running (no t primed). 10. If sealing co mpresso r o ils, ensure that water co ntent in o il is checked and that the o il is changed
X13 Sho t blasting with so lids due to po sitio n and entry angle o f pro duct recirculatio n n. at least every 3000 ho ursurs. Ensure go o d flo w w, and that o il is no t 'fo
fo aming
aming'.
X14 Ineffective o r inadequate heating leads to high visco sity and pro duct so lidifying acro ss sealing X44 Check that the seat landing is flat and free fro m any burrs o r debris.
faces. A lternatively, fluid film increases in visco sity due to visco us shear irrespective o f heat applied, X45 Co mplete an equipment check including amo unt o f to tal axial flo at o f ro tating element.
i.e., dilatant, rheo pectic o r thermo setting (paint). A lso ID chipping o f face when pro duct so lidifies o n X46 Wro ng material selectio n, o r enviro nment is to o ho t. Refer to X24. (Chipping o n face ID).
atmo spheric side. (Oxidatio n?). X47 Clearance between ro tating element and seal chamber to o small, causing so lids to precipitate o ut
X15 P hysical damage due to mis-handling o r o ver-co mpressio n. fro m pumped pro duct, e.g., 'hard water'.
X16 Excessive pressure ro tatio n. (Co ning inwards - chipping o n OD). X48 Liquid in pump freezes, e.g., pump no t drained o r dried after testing o n water, and then sto red at
X17 Seal material no t chemically resistant to pro duct o r co ntaminant, e.g., HF in HCl o r EP T in hydro carbo n sub-zero temperatures o r put o n cryo genic duty.
X18 M aterial deco mpo sed due to temperatures beyo nd its limitatio ns. Usually applies to an X49 Heating left o n to pump whilst still full o f liquid with bo th suctio n and discharge valves clo sed.
elasto mer. NB : Danger o f HF acid fo rmatio n fro m Fluo ro carbo n o r P erfluo ro elasto mer that has X50 Hydraulic sho ck due to to o rapid valve clo sure.
been taken to >400°C. Virgin P TFE abo ve 230°C gives o ff to xic gas (sublimates). X51 P o o r heat transfer to co o ling water due to fo uling (scaling) o n co o ling surfaces.
X19 P o o r alignment o f ro tating element. Seat no t square to axis o f ro tating element. X52 Check axial flo at o f ro tating element. A lso ensure seat canno t mo ve axially due to X40 o r X50.
X20 P ro duct
d t flflo w in
i pumped d system
t restricted
t i t d o n di
discharge
h side
id b by valve
l o r bl
blo ckage
k causing
i excessive
i X53 P ipescale
i l ffo rmatio
ti n - especially
i ll d
during
i co mmissioi i ning.
i
shaft deflectio n. X54 Will usually exhibit o ther sympto ms o f a seal failure, e.g., abrasive wear because seals have been
X21 High pressure jetting fro m recirculatio n line o n to ro tating seal causing eccentric running. handled in a dirty enviro nment. See X63.
X22 Vo rtex fo rmatio n in seal chamber due to trapped vapo ur/gas, i.e., no vent ho le at TDC. A lso X7. X55 Gas entrained in pro duct/sealant expands as pressure dro ps acro ss fluid film - dry running & po pping.
X23 P ro duct is po o r lubricant fo r sealing faces, e.g., water o n P TFE vs ceramic o r carbo n vs stellite. X56 P o ssible indicatio n o f co rro sio n, e.g., tungsten carbide can so metimes take o n a 'blue' surface
X24 P umping against clo sed discharge fo r lo ng time - causes unstable fluid film. Wo rsens facto r X8 & X20. co lo uring. This is no t due to o verheating. Check o ther pro duct-wetted areas o f seat.
X25 Co ntinual remo val o f passive film (usually in chlo ride enviro nment) due to relative mo vement. X57 Ni-resist (007) will appear 'straw' o r 'blue' co lo ured. This is due to o verheating. A lso refer to X24,
X26 Can o ccur in pusher seal thrust rings due to slack clearances in ball bearings. This same fault can especially in tanker-lo ading pumps.
cause fretting under dynamic seco ndary seals. X58 A nti-extrusio n ring no t fitted. A nti-extrusio n ring fitted the wro ng way ro und. Flat side o f
X27 Frictio n welding o r pick-up between materials, e.g., po lished tungsten vs po lished tungsten. anti-extrusio n ring must always be presented to the o -ring, o n the no n-pressure o r lo w
X28 M aterial co mbinatio n being o perated abo ve and beyo nd its P V limit, resulting in X27. pressure side o f the o -ring.
X29 Will arise when clearances are to o small fo r fluid flo w, e.g., high pressure recirculatio n fro m X59 Inco rrect shaft diameter, o r excessive clearance fo r the seco ndary seal to the shaft. A lso , excessive
discharge feeding to lo w pressure suctio n via a seal chamber with small clearances aro und seal. clearance fo r any static seals.
X30 Chemical reactio n with binders in co mpo nent materials, e.g., '171' in nitric acid, '025' in Sea Water. X60 Seal chamber full o f so lids, e.g., bo iler water treatment co mpo und injected as a 'lump' into the
X31 P o ssible indicatio n o f phase change (liquid to gas/vapo ur) acro ss fluid film. suctio n side o f the pump instead o f do wnstream o f the discharge flange.
X32 Usually o ccurs at po int o f maximum disto rtio n acco mpanied by high seal leakage. X61 Differential expansio n, especially between P TFE co mpo nents, resulting in change in diameter,
X33 Interface stress to o lo w. Seal either under-co mpressed, o verbalanced o r springs hung-up/bro ken. length o r shape/sectio n.
X34 Seal chamber pressure to o clo se to pro duct Vapo ur P ressure at P umping Temperature. Check neck bush. X62 Thermal sho ck o n ceramic o r carbide seats caused by sudden change in temperature. Check
X35 Seal interface running in permanent gas po cket. A lso refer to X22. o perating cycles and valve o peratio n.
X36 Can o ccur as narro w band o f co ntact o n seal OD where pro trusio n into seal chamber is fo uling the X63 A brasives in fluid film - use cyclo ne separato r, hard faces, back-to -back seal o r UpStream P umping
ro tating element, e.g., co ver plate gasket extrusio n. X64 Fluid film visco sity to o high. Use heated seat, heated stuffing bo x jacket, o r change to do uble seals.
X37 So lids precipitating o ut o f pro duct acro ss interface, e.g., so dium hydro xide crystals. X65 Changes in speed can aggravate the co nditio n by increasing shaft deflectio n when running at o r
X38 Co mpo nent fitted wro ng way ro und, e.g., carbo n face o n rubber bello ws seal. thro ugh a critical shaft speed.
X39 B ent shaft. Wo rn bearings.g High g shaft deflectio n. X66 Explo
p sive deco mpressio
p n caused elasto mer material to burst due to sudden expansio p n o f trapped
pp g gas.
X40 Co o ling water pressure to o high - will disto rt seat, i.e., 1 bar fo r L/K seats; 2 bar fo r SC/CE seats. X67 Excessive heat generatio n at seal faces will cause po sitive ro tatio n, excessive wear o n ID o f face and
X41 Seal inco rrectly assembled, e.g., T209 thrust ring wro ng way ro und. Face fractures co mmo n. seat with po ssible chipping o n the face ID
X42 Insufficient clearances between seat spigo t and seat ho using, resulting in disto rtio n o f metal seats X68 O-rings can take permanent set. P TFE can co ld-flo w.
and cracking o f ceramic o r silico n carbide seats. X69 Uneven co o ling. Co nsider tangential flush, multi-po int injectio n, o r distributed flush.
.
J A B / FA I LURE 1 . X LS J ohn A B l aber . DA T E OF I SSUE : 20/ 08/ 97
699
Seal Failure Analysis
Complete
p Seals . . .
700
Seal Failure Analysis
701
Seal Failure Analysis
702
Seal Failure Analysis
703
Seal Failure Analysis
704
Seal Failure Analysis
.
Failed Seal New Seal
705
Seal Failure Analysis
706
Seal Failure Analysis
707
Seal Failure Analysis
708
Seal Failure Analysis
709
Seal Failure Analysis
710
Seal Failure Analysis
711
Seal Failure Analysis
712
Seal Failure Analysis
713
Seal Failure Analysis
714
715
Seal Failure Analysis
716
Seal Failure Analysis
717
Seal Failure Analysis
718
Seal Failure Analysis
719
Seal Failure Analysis
720
Seal Failure Analysis
721
Seal Failure Analysis
Rotating
g and Stationaryy Faces . . .
722
Seal Failure Analysis
723
Seal Failure Analysis
724
Seal Failure Analysis
725
Seal Failure Analysis
726
Seal Failure Analysis
727
Seal Failure Analysis
728
Seal Failure Analysis
Carbon Faces . . .
729
Seal Failure Analysis
730
Seal Failure Analysis
731
Seal Failure Analysis
732
Seal Failure Analysis
733
Seal Failure Analysis
734
Seal Failure Analysis
735
Seal Failure Analysis
736
Seal Failure Analysis
Ceramic Faces . . .
737
Seal Failure Analysis
738
Seal Failure Analysis
739
Seal Failure Analysis
740
Seal Failure Analysis
741
Seal Failure Analysis
742
Seal Failure Analysis
Metal Faces . . .
743
Seal Failure Analysis
744
Seal Failure Analysis
745
Seal Failure Analysis
746
Seal Failure Analysis
747
Seal Failure Analysis
Elastomers . . .
748
Seal Failure Analysis
749
Seal Failure Analysis
750
Seal Failure Analysis
751
Seal Failure Analysis
752
Seal Failure Analysis
753
Seal Failure Analysis
754
Seal Failure Analysis
755
Summary
Summary
757
Summary
Advantages of GP Disadvantages of GP
761
Mechanical Seals
C leanliness
A ccuracy
Time
762
Apply “CAT” and you can . . .
763
Produced by John Blaber