JOB REPORT

MACHINERY MAINTENANCE (UREA I)

Tag # P-105 A Description Mechanical seal failure Date Apr 29, 2021

SAP Work Order 11128712 Area 01 (Urea) Job Duration 12 Hr.

Problem
Failure of P-105 A mechanical Seal.

Observations
P-105 A was handed over for maintenance. Pump was removed and shifted to workshop. Following
observations were made on failed mechanical seal,
 Foreign brownish particles were spread all over the impeller and also found inside mechanical
seal components.
 Impeller was tight on the shaft and hub nut was fully tightened with no thread damage.
 Shaft sleeve was found in good condition without any wear marks, fretting and damage to it.
 Shaft was found in good condition. No fretting and scratch marks were observed over it.
 No hang up of O-ring found.
 No O ring hang up was found so leakage was not contributed by them. And also, O rings were not
found brittle or hardened so their condition was satisfactory.
 No scratches, wear marks, pitting and roughness was fund on primary seal faces (carbon-graphite
and silicon carbide). They were in satisfactory condition.
 Pumping rings was in good condition without any wear and scratch marks.
 Process seal wedge (Pos. 4) was found damage and sludge deposited over it. Its sealing nose
was damaged and worn out. Brownish sludge was also found on the nose.
Note: Process seal wedge was the plausible reason to the failure of P-105 Mechanical seal.

Initial Checks
It is recommended to get certain initial checks before seal rectification. Following are the initial checks
recorded,

Sr. # Description Value

1 Impeller Run out 0.05 mm
2 Shaft run out 0.04
3 Shaft Axial float (Free) 0.12
4 Shaft Axial float (Forced) 0.18 mm
5 Suction wear ring clearance 0.80
6 Discharge wear ring clearance 0.75
7 Throat bush clearance 2.10
8 Suction Wear Ring run out 0.05
9 Shaft engagement length 16.15 mm
10 Distance between shaft face to sleeve face 86 mm
11 Inboard shaft radial clearance 0.05 mm

Work Done
Following activities were performed to rectify the seal leakage,
 JOB REPORT
MACHINERY MAINTENANCE (UREA I)
 After shifting the pump to workshop, its impeller was removed and cleaned to remove brownish
paste like material while taking the initial checks too.
 Sleeve was removed with Mechanical seal mounted to, and its disassembly was carried out. Each
of its components were inspected carefully to determine cause of failure.
 The process side wedge (Secondary seal) nose was found damage and sludge deposited over it.
 All the O rings were replaced with new O rings.
 New process seal balance face, mating face and wedge (Secondary element) were used.
 New buffer seal balance face, reclaimed mating rings and wedge were used.
 Seal tension was measured by ‘calculation method’ and adjusted accordingly.

Seal Nature Seal tension

Process seal 3.30
Buffer seal 4.10
 Mechanical seal was installed after assembly and final checks were recorded.
 That assembly was shifted to area where its radial and axial alignment was done.
 Impeller was installed to the casing tightened strongly.
 Bearings oil was replaced with new oil.

Final Checks
Sr. # Description Value (mm)
1 Process Seal tension 4.10
2 Buffer seal tension 3.30
3 Suction wear ring run out 0.07

Alignment
One of the critical factors for effective bearing performance and life is coincide centerline of shafts
(Alignment). Motor shaft in reference to impeller shaft was aligned axially and radially with following
measurements,
Radial alignment:
0

+ 0.01 + 0.01

Reference: See From MP-105 side

+ 0.02
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MACHINERY MAINTENANCE (UREA I)

Axial alignment:

-0.03 +0.05

Reference: See From MP-105 side

+ 0.02

Startup:
After installing the seal, it was pressurized with demineralized water to 8 kgcm -2. No leakage or seepage
was observed. Then it was pressurized with ammonia and kept on recycle in order to check its reliability.
No leakage was observed.
Vibrations were also found normal.

Team Members
M. Bilal Hassan (Ex. Mach MNT i)
Abdul Hameed Shakir (DO. Mach MNT)
Khalid Naseer (SSR MNT)
Nazar Hussain (SR MNT)
Abdul rehman (ST MNT)

Prepared By:
Reviewed By: Noor ul Hassan (DM MACH. I)
 JOB REPORT
MACHINERY MAINTENANCE (UREA I)

Brownish Paste on Impeller Failed Mechanical Seal Failed Wedges

Sludge in Retainer Pumping Ring Old Seal Assembly

 JOB REPORT
MACHINERY MAINTENANCE (UREA I)