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Dist.: Banaskantha PIN: 385210 Gujarat – India.

Case Study# CS/19-20/001

Case study on blistering issue in resin impregnated carbon

seal face during test in viscous oil
Mansi P. Joshi, Arafat I. Shaikh, Arbaz Z. Basar, Rizwan R. Shaikh
Research & Development Department
January, 2020

Problem & Observation

While testing a pusher type balanced
single mechanical seal on an oil test rig, seal
failed as leakage exceeds beyond acceptable
level.
Upon examination, blister marks
observed on carbon-graphite seal face. Other
than blister marks on carbon-graphite seal
face, no possible damage observed which can Image: Blister marks found on carbon-
lead to leakage. graphite seal face
Shiny spots, cracks with raised section and craters were present on a carbon-
graphite seal face. These marks can be distinguished as Level – I, II & III blister
marks.[1]
Blistering degrades the surface of the seal face causing irregularities in
topography, which leads to poor seal performance due to increased friction, higher
face temperature, and leakage.
Below are the operating parameters of the test setup:
Seal Type: Pusher type single seal (Balanced)
Face Materials: Resin Impregnated Carbon (Carbon – R) / Silicon Carbide (SiC)
Speed: 2900 rpm (VFD)
PV Value: 195 bar-m/sec
Test Loop Oil Pressure: 8 Bar
Test Loop Oil Temperature: 40 °C
Test Loop Oil Grade: SAE-30
Test Loop Oil Flow Rate: 6 – 8 lpm

CS/19-20/001 – Case study on blistering issue in resin impregnated carbon seal face during test in viscous oil
Root Cause
There are various causes which can lead to blistering effect in the carbon-
graphite seal face. But most probable root causes are identified and discussed below
with their possibility based on operating parameters.
1. Porosity of the carbon-graphite material: The mechanism of blister
formation appears to be a two-stage process. First, fluid diffuses into the
porous surface of the carbon-graphite during normal operation. Then any
transient increase of interface temperature causes thermal expansion of fluid
trapped in the surface layers of the carbon-graphite. As the trapped fluid is
unable to flow out fast enough to relieve the resulting pressurization of the
internal fluid, the surface of the carbon-graphite is deformed upwards,
fracturing local to form a blister.[2]
2. Thermal conductivity of carbon-graphite material: Since Carbon – R has
low thermal conductivity compared to SiC, Carbon – R will experience hot
spots on seal face which eventually will lead to blister formation as explained
in previous paragraph.
3. Viscosity of the oil: Viscous friction torque, especially under the start-up
conditions where fluid films are thin and viscosity is high, causes high traction
forces in the surface layers of the carbon-graphite, leading to micro-fracturing
at sites within the carbon-graphite.
4. Degradation of the oil: It has been observed that blisters were generated by
using oil being thickened as a result of exposure at high temperature for a
long time. There are chances that oil could get deteriorated due to a thermal
cause.[3]
Oil changes its properties while exposed to high temperature and pressure for
long period of time;
a. Build-up of contaminants/foreign particles in the oil, degrades the
chemical properties which thereby increases viscosity, making it unfit
for further use.
b. When oil molecules react with oxygen molecules, oxidation will take
place, which will lead to increase in viscosity and the formation of
varnish, sludge and sediment.
c. The small and light molecules in oil tends to evaporate as oil is heated,
leaving behind large and heavy molecules increases the oil’s viscosity.
5. Higher PV value: Higher PV value increases the friction which leads to
higher film temperature. PV value of a balanced seal with Carbon – R/SiC
interface operating in oil should be less than 1850 bar-m/sec. [4] In this case,
PV value is below 200 bar-m/sec which is very well within the limit. Thus,
PV value cannot be probable root cause here.
6. Inadequate Cooling: Since thermal conductivity of Carbon – R is very less;
it becomes very important to provide adequate cooling/circulation for heat

CS/19-20/001 – Case study on blistering issue in resin impregnated carbon seal face during test in viscous oil
 dissipation. As per calculations, this seal required 4-5 lpm flowrate to provide
adequate cooling. Since flowrate here is more than required, cooling cannot
be the probable root cause.

Solution
Below given solutions are based on the possibility of the causes discussed. All
solutions should be tried together or one after another to achieve the desired results.
1. Carbon – R is a porous material and should be avoided in light hydrocarbon
and viscous oil-based applications.[5] Replace the seal face material with
blister resistant carbon or harder face material (e.g. SiC).[6]
2. Oil with lower viscosity grade should be used. Oil below ISO VG 32 grade
should be used for testing to avoid blistering issue. [7]

References
[1] Lebeck, A.O., Principles and Design of Mechanical Face Seals. John Wiley &
Sons, Inc., New York, Page# 617, (1991).
[2] Heinz K. Muller, Bernard S. Nau, Fluid Sealing Technology, Page# 306,
(1998).
[3] Study of Mechanism and Controlling factors of carbon blister generation on
Mechanical Seals, Research and Development Division, Eagle industry
co.ltd.1500 Japan.
[4] JD Summers-Smith, Mechanical Seal Practice for Improved Performance,
Page# 24.
[5] Lebeck, A.O., Principles and Design of Mechanical Face Seals. John Wiley &
Sons, Inc., New York, Page# 623, (1991).
[6] The Evolution and Application of Mechanical Seal face materials,
Turbomachinery.
[7] Buffer and Barrier fluid, Fluid Sealing Association, (2013).

CS/19-20/001 – Case study on blistering issue in resin impregnated carbon seal face during test in viscous oil