M 604 Content

PDHonline Course M604 (4 PDH)
Centrifugal Pumps and Mechanical Seals
A. Bhatia, B.E.
2016
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www.PDHcenter.com PDHonline Course M604 www.PDHonline.org
Centrifugal Pumps and Mechanical Seals

A. Bhatia, B.E.
The process industry spends well over a billion dollars annually world over in maintenance of
rotating equipment’s and a substantial amount of this expenditure is towards to containing
leakage and hazardous emissions. For decades, the rotating equipment’s were sealed with
compression gland packing. This is no longer permitted in many industries by current
environmental standards, set forth by the federal regulations. With the development and
perfection of the mechanical seal, the leakage problem has been fixed to a large extent.
A mechanical seal is a sealing device that separates liquid from the atmosphere. It is widely
used in rotating equipment’s such as pumps, mixers, compressors, blenders, rotary towers,
centrifuges, drum filters and other process equipment to prevent leakage between a shaft and
the housing.
The performance of the seals is greatly influenced by factors such as fluid pressure, service
temperature, nature & characteristics of fluid, impurities, lubricating properties, rotating speed
and hazard control measures. There are multitudes of different styles of rotating equipment’s
and many dozens of sealing configurations. Seal design features that are considered are
balanced or unbalanced; rotating or stationary seal head; single spring or multiple
constructions; pusher or non-pusher secondary seal design; cartridge or non-cartridge; and
split or non-split. The standards of modern mechanical seals are widely defined by American
Petroleum Institute, API Standard 682 ‐ Shaft Sealing Systems for Centrifugal and Rotary
Pumps.
©2016 A.Bhatia Page 2 of 105

This course provides a comprehensive overview of different types of mechanical seals and
their applications. The course will assist design engineers in the specification and procurement
of mechanical seals.

CHAPTER - 1
SEALING DEVICES
Most pumps require a sealing device to prevent liquid escaping from where the drive shaft
enters the pump casing. There are three common sealing devices:
1. Gland Packing
2. Mechanical Seals
3. Magnetic drives (seal-less pumps)
Gland Packing
Gland packing is the simplest and still widely used shaft sealing mechanism on many pumps.
This packing consists of braided rings of compression material placed behind the impeller to
restrict the clearance between the shaft and the pump back head or the “stuffing box”. Most
standard packing is an abrasion resistant synthetic fiber material impregnated with PTFE for
additional strength and lubrication.
Gland packing is inexpensive but requires regular attention and maintenance. Periodic
adjustments must be made to tighten the gland as the packing wears overtime. A clean flush is
almost always recommended to assist with packing lubrication – especially when pumping
solids or abrasives.
Benefits
Low upfront cost.
Excellent for sealing thick, difficult to seal liquids such as chocolate, molasses, asphalt,
resins, tar, and some adhesives
Seldom catastrophically fails, allowing for replacement at scheduled shut down dates.
Drawbacks
Consume 6 times more energy than mechanical seals. (Packing a pump would be like
running your automobile with the emergency brake engaged).
Require some leakage for lubrication and cooling. It is not suitable for use in toxic,
flammable, hazardous or polluting fluids.
Packing should be periodically adjusted when excessive leakage from the stuffing box
is noticed.

Poor seal for thin liquids, especially at higher pressures.

Can damage the pump shaft if adjusted too tightly.
Need longer stuffing box, which in turn results in higher shaft deflection.
Vibrations and misalignment will cause this seal type to leak.
Short life and need frequent replacement over the life cycle of pump.
Mechanical Seals
Mechanical seal uses two highly polished surfaces (known as ring faces), pressed together
axially through a spring mechanism. One face rotates and the other is stationary. An elastomer
seals the primary ring to the shaft and an O-ring seals the mating ring in the housing.
Mechanical seals are available in a wide variety of designs and materials for nearly every
application. Axial mechanical seals are generally used where pressure and/or surface speeds

exceed the capabilities of radial shaft seals. These are used not only in pumps but also in
other rotating equipment’s such as mixers, agitators, compressors, rotary unions, submersible
motors, etc.
Other types of axial seals are “non-mechanical” ones, such as V-Rings.
Benefits
Near zero leakage is possible. Good for toxic and hazardous chemicals.
Provides longer life. It will not wear out itself or the shaft, or sleeve as fast as the
packing rings.
Lower frictional drag than traditional packing means improved pump efficiency.
Requires less periodic maintenance than packing.
Can be applied to higher pressures, temperatures and shaft speeds.
Drawbacks
Less tolerant to shaft deflection and misalignment.
Less tolerant to dirty or contaminated liquid. In some cases, will require auxiliary
equipment such as cyclone separator to clean the liquid.
Require expensive seal piping to flush and quench.
Costlier than packing rings. However, consume less power and require less
maintenance.
Sealing faces must be finished smooth (0.08 to 0.4 micrometer) and can
catastrophically fail.
Magnetic Drive Seal-less Pump
A Mag Drive pump is a seal-less pump that utilizes a magnetic coupling to create a static shaft
seal. Both packing and mechanical seals use dynamic sealing, whether it being a shaft
rotating in stationary packing or the seal faces rotating against a stationary face. Magnetically
driven (Mag Drive) pumps use no dynamic seals. They have zero leakage and provide the
most reliable seal for hazardous or difficult-to-contain liquids. Magnets mounted radially
around the pump drive set up a magnetic field. When the drive shaft rotates, the field compels
the pump shaft to rotate. The canister wall is not penetrated by either shaft and is statically
sealed at its interface with the pump housing.

Magnetic drive pump applications include corrosive liquids such as sodium hydroxide,
hazardous liquids such as sulfuric acid, difficult to seal liquids such as isocyanate, and critical
sealing applications such as pipeline sampling of oil. These certainly aren’t the only
applications however; seal-less pumps once made up just a small fraction of the total pump
market, but are now the fastest growing area across several markets.
Benefits
Mag Drive pumps are a truly seal-less design which ensures zero leakage of liquid or
emissions, making them ideal for hazardous, toxic, corrosive, flammable, or expensive
liquids.
Extremely reliable for maximum insurance against seal leakage and maximum seal life
Drawbacks
More expensive than most shaft seal options.
Typically limited to about 500°F / 260°C maximum temperature (heat can permanently
damage the magnets).
Comparison between Mechanical Seal and Gland Packing
Parameters Mechanical Seal Gland Packing

Leakage Extremely small or none Certain leakage is
necessary for lubrication

and to avoid seizure

Life Long with appropriate Comparatively short
design and material
Power consumption Negligible friction between High friction due to surface
seal component and shaft contact.
/ sleeve. Comparatively Packing generates
less power consumption. approximately six times as
much heat as a balanced
mechanical seal.
Applications Wide applications with Limited applications for
appropriate materials and critical hazardous fluids.
design. Not suitable for vacuum
applications.
Cost Initial cost is comparatively Initial cost is Low. But
high but running costs are running cost is high.
lower.
Spares Only line contact of As there is surface contact
secondary packing is of pacing with shaft /
there. Hence less chances sleeve with more
of wear, resulting less possibility of shaft / sleeve
spares consumption and damage, resulting higher
reduced maintenance spares consumption and
cost. increase in maintenance
cost.
Maintenance No routine maintenance Periodical tightening
required. Spring load required and must be
keeps faces in contact. replaced if wear of shaft or
Reduces equipment sleeve becomes
shutdown frequency. excessive. Require
frequent monitoring and
shutdown of equipment.
Meet API standards and Yes Can't be used where API
requirements standards are insisted.

CHAPTER - 2
MECHANICAL SEALS
Mechanical seals - also referred to as face seals or dynamic 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. Available in a wide variety of
types, arrangements and materials, mechanical seals create an extremely restrictive leak path
perpendicular to the axis of the shaft between two rubbing seal faces. The design,
arrangement and materials of construction are essentially determined by the pressure,
temperature, speed of rotation and product being sealed (the product media). When conditions
around the seal are too severe, additional support systems such as flushing, quenching or
cooling are applied to create an artificial environment for the seal.
Basic Seal Types
Static Seals
The function of static seals is to create barriers between relatively non-moving surfaces.
Typical “static” applications of seals are valve-cover gaskets, cylinder covers, packings of
many kinds, and O-rings used in stationary situations. The gasket lining a refrigerator door
used to seal the inside chilled air from the outside ambient temperature is a classic static seal
example.
Dynamic “Radial” Seals
A dynamic radial seal is accomplished by two surfaces making contact radially, one usually
stationary while the other rotates. Typical radial seal examples include gearboxes, drives,
motors, pumps and speed reducers.
Axial Seals
Axial seals are “face” type mechanical seals that create an axial interface between radially
mounted components. In operation, one face is usually stationary in the housing while the
other moves with the shaft. Sealing pressure is applied in the axial direction through a spring
mechanism which keeps the surfaces together.
Axial seals are generally used where pressure and/or surface speeds exceed the capabilities
of radial shaft seals. Common applications include the water pumps and the most types of

pumps used in chemical processing plants or refineries. Other types of axial seals are “non-
mechanical” ones, such as V-Rings.
We will focus on face type axial mechanical seals in this course.
Design Principles
A mechanical seal consists of primary and secondary sealing. The primary sealing consists of
two rings; one rotates with shaft and other mating ring is stationary in housing. Both rings are
pressed against each other by compression device such as a spring or bellows. The
secondary sealing (O-rings, V-rings etc.) provides a fluid barrier on the stationary and rotating
component(s) to the shaft.
How does seal hydraulic balance work?
There are two forces closing the seal faces.
1. A spring force caused by the springs or bellows pushing on the seal face.
2. A hydraulic force caused by the pressure of the fluid acting on the closing area of the
seal faces.
There are three forces opening the mechanical seal:
1. A hydraulic force caused by fluid or vapor trapped between the lapped faces.
2. Centrifugal force that is causing the rotating portion of the seal to try and become
perpendicular to the rotating shaft.
3. Hydrodynamic forces generated between the seal faces because for all practical
purposes liquids are not compressible.
The forces are balanced by reducing the closing area of the seal faces and thereby reduce the
closing force. This is usually done by a small sleeve inserted into the seal or as step machined
into the shaft. Metal bellows seals have an effective diameter measured through the bellows to
accomplish the same thing.
The faces in a typical mechanical seal are lubricated with a boundary layer of gas or liquid
between the faces. Lubrication can be provided from the pumped liquid itself or from an
external source, depending on system requirements. Successful operation of mechanical
seals depends on maintaining a thin lubricating film of fluid between the faces. The film is as
thin as 0.00001 inches – a hundred thousand of an inch. In metrics, that is 0.25 microns. The

fluid film prevents the rotary surface touching the stationary ring and prevents the dry running
of pump and thereby preventing the destruction of the mechanical seal due to frictional heat.
Sealing Systems for Pumps
Centrifugal pumps are the most common type of pump used in industry, agriculture, municipal
(water and wastewater plants), power generation plants, petroleum and many other industries.
All centrifugal pumps include a shaft-driven impeller that rotates (usually at 1750 or 3500
RPM) inside a casing (volute) that is filled with a liquid. The fluid being conveyed enters the
pump through the suction inlet and exits the volute through the discharge outlet at a greater
pressure and velocity. The liquid could leak out of the pump between the rotating shaft and the
stationary pump casing. Since the shaft rotates, preventing this leakage can be difficult.
A mechanical seal positioned just behind the spinning impeller on the motor shaft can prevent
the fluid from leaking. That part of the pump casing that contains the mechanical seal or
packing rings is called the stuffing box (or seal chamber). Horizontal end-suction pumps and
vertical pumps have only one stuffing box, whereas horizontal between-bearing pumps are
provided with two stuffing boxes on both sides of the pump casing.
The seal selection is influenced by many parameters such as fluid pressure and temperature,
fluid purity and lubrication properties are among them, as are such criteria as product quality
and failure avoidance. For critical oil, gas, chemical and hydrocarbon services, the American
Petroleum Institute (API) standards recommend the most appropriate selection.
The mechanical seals for pumps are available in diverse ranges:
Shaft diameters from about 5 to 630 mm
Shaft speeds up to 50,000 rpm
Pressures from about 0.01 to 300 bar

Temperatures from about – 200 to + 450°C
Sliding rates of up to about 150 m/s.
Why Mechanical Seals
Emissions control
The mechanical seals are mandatory to meet the safety and the environmental standards set
forth by the federal regulations.
The centrifugal pumps especially in the industrial applications handle variety of hazardous
chemicals, volatile organic compounds (VOC) and toxins. Any leakage of these corrosive or
hazardous fluids can be highly dangerous to humans and also to the external surroundings.
Federal law dictates that these emissions must be contained. There is currently a list of 189
substances regulated by the Environmental Protection Agency as toxins under Section 112 of
the Clean Air Act. Any product classified as a fugitive emission or any VOC that has a specific
gravity of 0.4 or less requires a double mechanical seal.
Product savings
One of the most important advantages of the mechanical seal is its low leakage rate. Reduced
leakage means savings in many forms; these are reduced product loss, less spillage, reduced
load on effluent treatment plants and less dilution of process fluids. The hazards of fire and
personal injury are also reduced when the pumps are handling inflammable or toxic products.
Energy costs
In mechanical seal, when two perfectly lapped surfaces rub against each other, there is
negligible friction. Hence, the load on motor is considerably reduced compared to the gland
packing. The more you tighten the gland packing, the more power is consumed.
Results of various trials have shown that power saving between 10 to 15% in centrifugal
pumps ranging between 2 HP to 10 HP.
Low payback
Mechanical seal cost is recovered roughly within 4 months considering the power saving
alone. Average life of a mechanical seal is 2-3 years in normal applications like water, oil, and
clear non-corrosive liquids. This means that recurring savings is a direct profit to the user,
once the seal cost is recovered.

Other benefits
Mechanical Seals also offer the following advantages: -
1. Plant down time losses eliminated
2. Cleaner environment
3. Protection from health hazard in chemical handling
4. Can sustain high pressures of the fluids and highly corrosive fluids.
5. Require very less maintenance. There is no wearing of the shaft or the sleeve on which
the mechanical seal is mounted.
6. Negligible replacement of spare parts
7. Better bearing life
Components of Face Seals
There are the four essential components of a mechanical seal:
1. Primary Sealing Surfaces: The primary sealing surfaces consists of two rings; one
rotates with the shaft, and the other is stationary fitted to the casing. In most cases the
stationary part of the primary ring is made of a hard material like silicon carbide or
tungsten carbide. The other, the rotating part of the primary seal is made of a soft
material like carbon.
2. Secondary Sealing Surfaces: The secondary seals are the static devices such as O-
rings, wedges and V-rings mounted under the rotating assembly and also behind the
stationary seat. These devices prevent leakage from occurring between the assembly
and the shaft.
3. Compression Devices: The compression devices are springs or bellows for force
closing the seal faces. The spring is installed around the shaft and rotates with the
rotating component. Contrary to popular belief, the primary function of the spring is to
keep the seal faces together when the pump is not operating (turned off). It is the
hydraulic pressure of the pumped fluid within the seal chamber that keeps the seal
faces together during operation.
4. Drive mechanism: The primary sealing surfaces are the only components of the seal
that are permitted to rotate relative to one another. These must not rotate relative to the

parts of the seal that hold them in place. To maintain this non-rotation, drive
mechanism comprising socket set screws, key, pin, drive band, etc. are used.
Materials
The stationary and rotating seal ring faces are usually made of dissimilar materials. A
distinction is made between hard-hard or hard-soft material pairings. A hard-soft material
pairing designates a combination of sliding components where one sliding face is significantly
softer than its sliding partner and therefore wears down more easily while offering better dry
run characteristics during unfavorable lubricating conditions.
A typical combination is usually a softer material such as carbon-graphite as rotating face and
relatively hard materials like nickel-iron (Ni-Resist), ceramic or tungsten carbide as a stationary
face. The softer face usually has the smaller mating surface and is commonly called the
sacrificial face. The non-galling, natural lubricating and low friction characteristics of
impregnated-fine grade carbon graphite materials are the main reason that these materials
have become standard in mechanical seals most applications. The seal should run leak free
until the carbon face is worn away. If the seal leaks for any other reason, we consider it a
premature failure and always correctable.
In hard-hard material pairings, both seal rings are made of hard and wear-resistant material,
e.g. silicon carbide (SIC). This combination is mainly used in abrasive service environments
because of its superior wear resistance, however at the expense of poor dry run capabilities.
Two hard faces are normally selected:

With any of the oxidizing agents.
When sealing any of the halogens.
If the product tends to stick the faces together.
If you are sealing hot oil and you have to pass a fugitive emission test.
Some de-ionized water will attack carbon in any form.
When you are not allowed anything black in the system because of the possibility of
color contamination.
Any time carbon/graphite will not work for some reason.
Sealing Points
Point A – Shaft /sleeve O - ring
Point B – Gland gasket
Point C – Rotary Face
Point D – Stationary O-ring
Point E – Primary O-ring
The component of a mechanical seal which prevents axial leakage is O-ring.
Leakage Control
Mechanical seals are NOT zero leakage devices.

Like packing, the mechanical seal faces must also be lubricated and there will always be some
leakage. The leakage however will be so minute that the actual droplets of liquid won’t get
detected. Instead, the leakage will vaporize as gas or vapor as it crosses the seal faces.
Leakage from seals is strongly influenced by:
1. The gap height, which is determinate by several factors, materials, manufacturing

quality, lubrication regime, face distortions.
2. Other pump related factors such as run outs and vibration levels.
Some of the essential requirements to limit leakage include:
1. The flatness of seal faces - The flatness of the seal ring faces is crucial for the
performance of a mechanical seal. The seal will not seal unless the seal faces are flat,
smooth, polished and perpendicular to the shaft and remain so during operation.
Flatness is measured in helium light bands; one light band is 0.0000116”
(0.000294mm). Seals lapped to less than three helium light bands (0.000034") inches
or 1 micron) should NOT show visible leakage. Visible leakage occurs at about 5 light
bands.
2. The spring load - The spring force must be sufficient to maintain continuous contact of
the faces when the pump is shut off. During operation, however, the dominant force
pressing the seal faces together and closing the seal is the pressure exerted from the
liquid.
A typical mechanical seal face load would be 30 psi when the carbon is new and 10 psi
when the carbon is fully worn away. You must never guess as to how much to
compress a mechanical seal. Either take the information from the seal print or calculate
the correct length from the above information.
3. The lubrication film - The thickness of the lubrication film between the seal faces is
an important factor determining the performance of a mechanical face seal.
A seal with a thick lubrication film suffers virtually no wear and would mean a
long life, but leakage would be high. This is referred to as Full film lubrication.
A seal with thin lubrication film would face low leakage but the expected life of
the seal would be short due to excessive wear. This is referred to as Boundary
lubrication.

A well-functioning mechanical face seal has what is known as mixed lubrication.

This means that the closing force from the spring and the hydraulic pressure is
borne by both the hydrodynamic lubrication film, and direct contact between the
seal faces.
With increasing load on the seal faces, the lubrication changes from “mixed lubrication”
to “boundary lubrication”. At some point, the load reaches a critical point where the
increased material contact pressure causes the seal to seize. This critical load point
depends on the seal face material, the balancing ratio and the ability of the seal’s
design to dissipate heat.
4. Critical applications - In critical applications (example toxic, explosive, carcinogenic,

corrosive or mutagenic fluids posing a health or environmental hazard or having other
critical properties) where it is absolutely necessary to avoid leakage, double
mechanical seals operated with buffer fluid are recommended. These seals consist of
two tandem-arranged mechanical seals. The clearance so created is flushed with a
buffer medium having a pressure above that of the product to be contained. Dual seal
systems with liquid or gas barriers can minimize detectable leakage at significant
increase in expense.
Beyond that solution, there are seal-less pumps such as canned or magnetically driven
designs which can also be quite expensive but totally leak free.
*******

CHAPTER - 3
BASIC SEAL DESIGNS
There is wide variety of seal designs and types due to the diversity of applications utilizing
different machinery, fluids and processes.
Selection of the best type is not always easy and straight forward as there is usually a
compromise between economical and technical factors.
Pusher Type Seals
Pusher-type seals are defined as seal assemblies in which the secondary seal is moved along
the shaft by the mechanical load of the seal and the hydraulic pressure in the seal chamber.
The designation applies to seals that use an O-ring, wedge, or V-ring. The surface underneath
the dynamic ‘O’ ring must therefore be very smooth (<32 RMS*) to allow for axial movement.
This feature helps compensate for the wearing that may occur at the seal face and wobbling
due to misalignment.

*RMS stands for “root mean square” and is a measure for comparing how rough things are.
Smaller the RMS, more polished or slippery the surface.
Benefits
These are inexpensive and commercially available in a wide range of sizes and
configurations.
Compensates for seal face wear or wobble due to misalignment.
Disadvantages
If solids are abundant in the sealing fluid, they can build up on the ‘O’ ring and prevent
this axial movement (hang up). Sometimes there is fretting (wear) of the shaft.
Non-Pusher Type Seals
Non-pusher seals are defined as seal assemblies in which the secondary seal is not forced
along the shaft by the mechanical load or hydraulic pressure in the seal chamber. It consists of
a bellows assembly that acts as both the load element (like a spring in a pusher type) and a
secondary sealing element (like an ‘O’ ring in a pusher type). It does not have to move along
the shaft or sleeve to maintain seal face contact. Because the bellows prevents any leakage to
the atmospheric side of the seal, and has a large clearance between itself and the shaft or
sleeve, it can move freely in the axial direction (no dynamic ‘O’ ring), reducing the potential for
hang up.

Benefits
Do not require a secondary seal, which means these are not prone to secondary seal
hang-up.
Disadvantages
The disadvantage is that it normally uses thin metal bellows cross sections that must
be upgraded for use in corrosive environments.
Applications
Non-pusher seals are preferred where one or more of the following conditions exist:
Axial shaft vibrations greater than 002" in amplitude and frequencies greater than 60
Hertz.
Deposition of foreign material, and/or corrosion products on the shaft is sufficient

magnitude to restrict the movement of pusher type secondary seals. This restriction
prevents the seal from following shaft dynamics or prevents the primary seal faces
from advancing to accommodate seal face wear. The end result is complete seal
failure.
Excess volumetric swell of secondary seal elastomers which may cause distortion of
the primary seal faces in case of pusher type seals.
Minimum balance is required and standard balance seals cannot be accommodated.

Unbalanced-non-pusher seals although classified as unbalanced can be designed to
have a balance less than 1.0 at low seal pressure without any geometry changes
normally required in changing from unbalanced to balanced seals. It should be noted
that seal balance on non-pusher seals will vary with seal pressure. The amount of
balance variance is a function of bellows design and material of construction.

Non-pusher seals normally employ elastomer bellows where temperatures and other
environmental conditions permit their use. Under extreme temperature conditions,
more expensive Teflon and metal bellows can be employed.
Balanced Seals
Balanced seals are geometrically designed to operate at considerably lower hydraulic forces
that will effectively close the seal faces and prevent leakage between the faces. These utilize
a stepped shaft sleeve, which allows the wear nose of stationary insert to be moved toward
the center of the seal. More of the seal face is thus exposed to the seal chamber pressure
which in-turn reduces the forces acting to close the seal faces. A standard 70 – 30 balanced
seal design used by most manufacturers operates with 70 % of rotating seal face area
exposed to stuffing box pressure.
Benefits
Balanced seals have higher-pressure limits, lower seal face loading, and higher seal
life. This makes them well suited to handle liquids with poor lubricity and high vapor
pressures such as light hydrocarbons. Always recommended for volatile liquids.
Hydraulically balanced seals generate very little heat between the faces.
Disadvantages
As a stepped shaft sleeve is used, the cost of a balanced seal is higher than
unbalanced seal.
Unbalanced Seals
A seal is unbalanced when seal closing forces are greater than the actual pressure to be
sealed. In unbalanced arrangement, all of the seal face contact area lies outside of the shaft

diameter. The amount of seal face leakage is inversely proportional to the amount of seal face
loading. Higher the loading, the lower is the leakage.
Benefits
Have higher face loading than balanced seals.
Leak less and are more stable when subjected to vibration, misalignment or cavitation.
Often less expensive compared to balanced seals and more adaptable to standard
stuffing boxes without need for modification of either the shaft sleeve or the stuffing
box.
Disadvantages
Unbalanced seals see a high pressure at the impeller side and therefore have a
reduced fluid film between the seal faces. This leads to overheating, rapid face wear
and seal fatigue at early stages.
Relatively low pressure limit. If the closing force exerted on the seal face exceeds that
limit, the lubricating film between the faces is squeezed out and soon the faces get
destroyed. This problem is overcome by balancing seals.
Recommendations
Balanced or unbalanced seal selection is determined by pressure in the seal chamber and the
type of liquid to be sealed.
1. When stuffing box pressure < 10 bar (142.2 psig), use unbalanced seals.
2. When stuffing box pressure > 10 bar (142.2 psig), use balanced seals.

Single and Multiple Spring Design
Selection of single or multi-spring construction is determined by the availability of space, shaft

size and the sealed liquid.
Single-spring construction is most often used with elastomeric bellows seals to load seal
faces. The advantage is that the openness of the design makes the spring and seal non-
clogging, suitable for handling fluids with a high percentage of abrasives. In addition, coils are
made of larger diameter spring wire and can withstand a greater degree of corrosion.
Multiple spring seals require a shorter axial space. Face loading is achieved by a combination
of springs placed about the circumference of the shaft. Most multiple-spring designs are used
with assemblies using O-rings or wedges as secondary seals.
Stationary and Rotating Spring Seals
A stationary seal is a design where the spring(s) do not rotate with the pump shaft, but remain
stationary. The advantage is that these are unaffected by the pump speed. The springs do not
correct or adjust for each rotation. They adjust for misalignment only once, when installed, and
are much less subject to fatigue or breaking.
Rotating seals (the springs rotate with the shaft) seldom can pass a fugitive emission tests
because of their sensitivity to misalignment. Stationary seals usually do not have this
limitation.
Recommendations
The selection of a rotating or stationary seal is determined by the speed of the pump shaft.
In most cases, stationary seal designs are employed up to 3,500 and 5,000 feet per minute
peripheral speed for single and multiple spring assemblies respectively. Above these speeds
rotating seats are employed to eliminate centrifugal force on springs, secondary seals and
other seal head components.
Stationary spring seals are more suitable for machinery with inherently larger tolerances such
a heavy duty slurry pumps and older pumps which have lesser tolerances. The use of
cartridge seal employing rotating seats can be very practical for high volume production.

Mechanical Seal Arrangements
Single Seals
Single seals are the most common sealing devices that contribute to 90% of the installations.
These are available in two configurations - inside and outside mounting configurations.

Inside seals
An inside seal is designed in such a way that the rotary portion of the seal is located inside the
pump seal chamber. The main components consist of a primary ring that rotates with the shaft
and the stationary mating ring affixed to the gland. A pusher mechanism (either springs or
bellows with associated O-rings) presses against the primary ring to ensure both faces are in
contact to avoid leakage.
The incoming flush fluid, typically supplied at a flow rate of approximately 1 gpm taken from
the process fluid, enters through the inlet port(s) and flows over the rings and in between the
faces to create a hydrodynamic pressure as an opening force that promotes separation of the
surfaces. Two other elements contribute to this opening force: hydrostatic lift resulting from a
fluid pressure difference in the container and ambient and centrifugal action caused by rotation
of the primary ring. As a result, there is net pressure acting on the surfaces. This is a delicate
design parameter. A large closing force tends to cause excessive wear, and a large opening
force causes the seal to be susceptible to more leakage.
Benefits
The fluid pressure acts on the outside diameter (OD) of the seal faces, which keeps the
seal faces free of clogging.
The seal is submerged in the liquid making it easier to flush and carry away heat.
Inside seals are easily modified to accommodate environmental controls and can be
balanced to withstand high stuffing box pressures.
Drawbacks
Inside seals require suitable stuffing box housing for installation and cannot be
adjusted without dismantling the equipment unless they are cartridge mounted.

Applications
Recommended for relatively clear fluids with satisfactory' lubricating properties.
Outside seals
An outside seal is designed in such a way that the rotary portion of the seal is located outside
the pump seal chamber. With some outside designs, the product pressure can overcome the
spring load. Centrifugal force acts to increase flow/migration of lubricating fluid across the seal
faces which, combined with pressure, limits the outside seal’s service pressure to 150 psi. Set
screw or clamp ring drives are options with some outside seals.
Figure below shows a typical outside seal arrangement in which only the insert seal ring and
secondary seals are exposed to the product. All these components can be non-metallic. The
metallic rotary unit parts are exposed to the atmosphere.
Benefits
The outside seals are easier to access for adjustment and trouble shooting.
Since the pumped fluid does not come in contact with the metal parts of the seal, it
eliminates the need for expensive and/or exotic metals for seal assembly.
Drawbacks
Because the fluid pressure is on the interior diameter (I.D.) of the seal faces, it can
cause clogging if the media contains solids.
The outside location of the seal makes it vulnerable to damage from impact.
The hydraulic pressure in an unbalance outside seal tends to open, rather than to close
the seal faces.
It is difficult to flush this seal.

Applications
All outside seals are limited to applications having moderate pressures.
Typically, outside seals are used for chemical service in non-metallic pumps, where set
screws do not work well.
The service must be free of solids which might collect under the seal.
Dual Seals
Dual seals mean arduous service, an application where leakage cannot be tolerated. In these
seals, two mechanical seals are arranged in series. The space in between is filled with a
natural fluid called barrier or buffer fluid. It is called a barrier fluid, if its pressure is higher than
the pumped medium and is called a buffer fluid, if its pressure is lower compared to the
pumped medium. The inboard or primary seal keeps the product in the pump housing and the
outboard or secondary seal prevents leakage of the flush fluid into the atmosphere.
This mechanical seal arrangement is used:
1. If a fluid product leakage needs to be avoided.
2. When aggressive media are used or at high pressures and temperatures.
3. For many polymerizing, sticky media and media which tends to sedimentation.
4. For vacuum applications.
The major advantage of the double seal is that the metal inner seal parts are never exposed to
the liquid product being pumped, so viscous, abrasive, or thermosetting liquids are easily
sealed without a need for expensive metallurgy. In addition, the double seals are virtually
unaffected by process upset conditions. These seals are very common in the petroleum
industry and other critical applications involving toxic, volatile, hazardous or abrasive fluids.

Important
Unlike single seal, dual seals utilize external fluid to lubricate both sets of faces, NOT
the liquid being pumped.
Dual seals should be hydraulically balanced in both directions so that they will stay
shut regardless of the direction of the fluid pressure.
Avoid oil as a barrier or buffer fluid between two mechanical seals. Most petroleum
base and other oils have a low specific heat (0.2 - 0.4) and combined with poor
conductivity (0.5 of water) makes them a poor choice compared to fresh water. If oil is
mandatory, a clean heat transfer oil would be your best choice.
Configurations
The dual seal faces are installed in three different configurations as under.

Back to back seals (or facing in opposite directions)
Two rotating seal rings are arranged facing away from each other “Back to Back”. The
lubricating film is generated by the barrier fluid. The barrier pressure should be up to 30 psi
above the product pressure in the seal area.
Both inboard and outboard seals can be either balanced or unbalance depending upon the
pressure encountered.
Benefits

The life of double back to back seal can be up to five times that of a single seal in
certain severe environments.
Disadvantages
Back to back seal does not tolerate the pressure reversals. Pressure upsets can result
in a seal failure.
It cannot be bench tested; hence seal performance cannot be verified until it is actually
assembled in the pump.
Tandem seals (or facing in the same direction)
Tandem dual seals are oriented in the same direction. It uses a buffer fluid between the seals
to act as a backup when the first seal wears out or fails. The buffer fluid will prevent unwanted
product dilution and simplify the installation because there is no need for a compatible high
pressure barrier fluid that is often hard to find.
The biggest advantage is that it provides a backup seal in the event of inner seal failure. The
cavity between inner and outer seal is flooded from a closed reservoir, which provides
lubrication to outer seal. The inner seal is lubricated by the product. If the inner seal fails, the
resulting pressure rise in the area between seals is sensed at the reservoir, where it can be
either registered on gauge or activate an alarm. In any event, failure of the inner seal can be
detected while the outer seal assumes the responsibility of sealing the shaft until pump is
taken for seal repair. Hence reliability of tandem is high compared to other seals. A typical
tandem seal is illustrated below.

The flushing fluid (buffer) between the two seals has lower pressure as compared to the
pumped medium and offers several advantages.
Benefits
Increased reliability.
No product dilution.
No evaporation in the sealing gap. This prevents the formation of deposits as well as
crystallization on the flushing fluid side.
The flushing fluid lubricates and cools even when the pump runs dry or runs with
vacuum.
Tandem seals eliminate icing and freezing of light hydrocarbons and other liquids
which could fall below the atmospheric freezing point of water in air (32°F). [Typical
buffer liquids in these applications are ethylene glycol, methanol, and propanol.]
Drawbacks
Tandem seals use two glands to house both seals and this adds to the cost as well as
the axial space requirement.
Applications
This configuration is generally found in oil refinery applications and other chemical
industries handling volatile, toxic, carcinogenic, or hazardous fluids.
Face to face seals (or facing towards each other)
Face to face configuration is a compromise between the "back to back" and the tandem
arrangements. The spring loaded rotary seal faces are arranged face to face and slide from
the opposite direction to one or two stationary seal part(s).
This arrangement is often used in the food industry in particular for products which tend to
stick and for vacuum applications. The buffer fluid pressures are very low (3 psi). In the case
of leakage the product penetrates the buffer fluid.

Benefits
This seal is compact and can be bench tested using air as a buffer fluid before assembly.
Pressure reversal will not cause it to blow up.
Disadvantages
The main limitation is in the exposure of inner seal to the product. Viscous, abrasive,
thermosetting or corrosive products can damage the inner seal and cause leakage.
Cartridge Seals
To simplify maintenance many seals are available in cartridges which are pre‐packed seal
assemblies. The rotating portion of the seal is mounted on a cartridge sleeve and this
assembly is connected to the stationary portion of the seal along with the seal gland to form a
cartridge assembly. Cartridge seals simplify the installation process and allow you to make
impeller adjustments without upsetting the seal face loading.

Benefits
Cartridge seals lower

maintenance costs and
reduce seal setting errors.
Easy to install.
No measurements during
installation.
Spring load is preset.
May be factory tested with

air, water or oil.
Drawbacks
Costlier as compared to
component seal.
Split Seals
Seat is axially split.
Does not require disassembly of

the pump to install.
Reduce down time.
Leaks more than a conventional

seal.
Costlier as compared to
conventional seal.
Applications
There are places where split seals are the only logical solution:
Double ended pumps. If one seal is leaking why take the pump apart and change both
- change only the one that is leaking.

Large vertical pumps. Sometimes you have to take the roof off the building to remove
the solid mechanical seal.
Large size shafts are a natural for split seals.
Changing a seal means doing a re-alignment.
If you have to remove a lot of pump insulation to get to the seal.
If the pump is in an awkward location, split seals make sense.
Many split seal designs can run with no visible leakage, but they seldom can pass a
fugitive emission test that calls for leak rates in the order of parts per million.
**********

CHAPTER - 4
SELECTION FACTORS
When selecting a seal for a specific application, it is important to know what the seal is
supposed to do and what operating conditions are present. If the incorrect seal is selected
there are chances that the fluid would start leaking and the very purpose of the expensive
mechanical seal will be defeated. In addition, there would be loss of time, manpower,
resources and also some safety hazards.
There are four steps that must be taken for every application.
1. Choose materials that are chemically compatible with the product and will handle the
temperature requirements and consistency (slurry, viscous, low specific gravity, etc.).
2. Choose the design/style, which is appropriate in size, to fit the equipment and
engineered to handle the product.
3. Install the seal properly into a piece of equipment that is in good mechanical condition.
4. Apply environmental controls that will provide the best possible environment for the
seal.
Common types of applications and seal designs recommended for them are covered below.
Factors Affecting Mechanical Seal Selection
1. Type of fluid
2. Pressure & speed (PV limit = Pressure x Velocity)
3. Temperature
4. Shaft speed
5. Reliability and Emission Concerns
Type of fluid
The fluid being sealed fills the stuffing box in which the seal is mounted and thus the physical
and chemical nature of this liquid will have direct effect on seal operation and life. The first and
the most important factor to consider is the fluid to be handled.
1. Corrosiveness of media decides the material of construction.

If the pump has to handle corrosive liquids like acids, it is very important to select
corrosion resistant materials for the mechanical seals. Some of these materials can be
stainless steel, bronze or HASTEALLOY. The mating faces must also resist corrosion
and wear. Carbon, ceramic, silicon or tungsten carbide may be considered. Stationary
sealing members of Buna, EPR, FKM (Viton) and PTFE (Teflon) are common. Material
shall also be checked to find the performance against the fluid. For example, FKM
(Viton) is not recommended for fluid containing H2S.
2. Density or viscosity decides the seal arrangement.
The viscosity of the pumped medium affects the lubrication and leakage of the seal.
The viscosity of most media depends on the temperature. A single shaft seal can be
used for a dynamic viscosity below 2500 cP (centipoise). For a higher viscosity, a
back-to-back seal arrangement should be used.
3. Abrasives in the media decide the type of flushing plan required.
If the media is abrasive, it can cause excessive wear and tear of the parts of the
mechanical seals and shorten the seal life. The seal must use an appropriate flushing
plan.
Pressure of the liquid
The pressure of the liquid decides whether one should opt for the balanced seal or the
unbalanced type of seal.
Recommendations
For high pressures, a balanced seal should be used.
Temperature of the liquid
The elastomeric parts of the seal must be able to withstand the temperature of the medium
around the seal. This might be different from the temperature of the pumped medium. If the
temperature is above the boiling point of the pumped medium, lubrication is poor. This must be
considered when selecting seal design and materials.
Shaft speed
Maximum speeds for effective seal operation depend on shaft finish, pressure, temperature,
eccentricity, lubricant or fluid being retained, seal type and other conditions.
Recommendations

If the speed of rotation is low, shaft seals with hard/hard material pairings might
produce noise because the lubricating film in the seal gap is extremely thin.
At surface speeds above 15 meters per second (3000 feet per minute), a balanced
seal with a rotating seat must be used to reduce seal unbalance.
The standard configuration for API single pusher and all dual mechanical seals is for
the flexible elements to rotate. For seals having a seal face surface speed greater than
25 meters per second (5000 feet per minute), the standard alternative of stationary
flexible elements shall be provided.
The shaft seal diameter must be selected to fit the pump shaft. If no seal with the
required diameter is available, the shaft diameter can be changed with a bushing.
With increase in speed, the chances of seal running dry increases. So proper flushing
plan has to be decided which can give positive flush between the faces.
For satisfactory seal performance, following standard guidelines apply:
Radial movement of shaft (run out / deflection) shall be less than 0.08 mm.
Axial movement of shaft (end play) shall be less than 0.26 mm.
Stuffing box face square-ness (face run out) shall be less than 0.05 mm.
Stuffing box bore concentricity (with respect to shaft) shall be less than 0.13 mm.
Stuffing box shall be free of burrs and sharp edges.
Shaft / sleeve shall be free of burrs and sharp edges.
Please refer to manufacturer’s drawing /instruction for above checks and further instructions.
Reliability and Emission concerns
The seal type and arrangement selected must meet the desired reliability and emission
standards for the pump application. To be on the safer side it is always better to used double
seals that work as the better sealants and are more reliable.
Selection Recommendations for various Product Categories
Products Recommendations
Oxidizing agents Don’t use ‘carbon” face material in

Following is a list of common oxidizing agents: the presence of strong oxidizing

agents.
Aqua Regia - nitric acid and
hydrochloric acid, used for dissolving
metals.
Calcium Chlorate - greater than 5%,

used in photography.
Chloric acid - at 200°F (93°C) and over

10% concentration will ignite organic
material.
Hydrofluoric Acid - over 200°F (93°C) at

40% concentration. Used in pickling,
etching, dissolving ore, fermentation,
cleaning bricks, stones and castings.
Iodine - 200°F (93°C) with 5% or more

concentration, used in soap, dyes, salt,
medicine and lubrication.
Nitric Acid - 250°F (121°C) and 20% or

more concentration, used in fertilizer,
dyeing, explosives, drugs and etching.
Oleum or fuming sulfuric acid - used to

manufacture detergents and explosives.
Sulfuric Acid - 75% at 250°F (121°C) or

more, most widely used chemical.
Sodium Chlorate - 5% or more

concentration, used as bleach in paper
processing, textiles, medicine and
tanning leather.
Sodium Peroxide - used in dyeing,

paper bleaching and oxygen generation.
Sodium Hypochlorite - 5% or more,

used in paper pulp bleaching process

and water purification.
Abrasive products Don’t use ‘carbon” face materials.
Some fluids cause abrasive wear to carbon

face material. Following is a list of common
chemicals that abrade carbon:
Chromic Acid, Chromic Oxide

(Aqueous), Chrome Plating Solutions,
Potassium Dichromate (Aqueous),
Sodium Chromate, Sodium Dichromate
etc.
Chlorides SS springs should NOT be used.
Chlorides in fluid cause cracks in stainless Hastealloy C is preferred choice

steel. The major concern is the spring and/or where chlorides are a concern.
metal bellows materials of mechanical seals.
Corrosive acids and bases Try to cool the seal by using a

double seal with cool barrier/buffer
Corrosion is aggravated at twice the rate with
fluid.
as little as a 15°F (9°C) increase in
temperature. Some of the most corrosive acids Quench and drain or flush with cool
and bases are sulphuric acid, hydrochloric acid, product.
nitric acid, caustic etc.
Use a seal designed for chemical
service.
Cryogenics Use a double seal with buffer fluid

between the product and
Liquid oxygen and nitrogen tend to freeze
atmosphere.
elastomers and moisture from atmosphere
outboard. Use a quench and drain to keep
atmosphere isolated from the faces
and prevent freezing.

Products that crystallize Use a quench and drain to control

temperature and clean the debris
Some products crystallize when the product
from the atmospheric side of the
passes across the faces and moisture
seal.
vaporizes on the atmospheric side of seals.
Over time the crystals will clog and restrict the Use a double seal with barrier fluid
seal’s ability to adjust for movement, stalling O- to control the temperature and
rings and clogging springs or bellows. Crystals insulate/isolate atmosphere from the
formed between seal faces are very abrasive product.
and can cause abrasion of the faces.
These products include sugar, syrups, caustics,

brine, etc.
Dangerous products Use a double seal as a tandem and

provide containment for liquids and
These products include carcinogens,
vapor recovery system (i.e.
explosives, radiation, toxins and other lethal
convection system).
products, which are hazardous to plant workers
and the environment, where leakage cannot be
tolerated.
Dry solids Use double seal approach.
Dry solids will clog seals and cause excessive

heat at elevated speed.
These products include cake mix, granulated

soap, powder, etc.,
Film producing Use double seals, with the barrier

fluid at least 15 psi (1 bar) greater
Film producing compounds such as plating
than seal chamber pressure.
solutions, hard water, hot oil, etc. form a layer
of film across seal faces and often sticks and Quench and drain.
tends to roll up, causing the faces to separate.

Hot products Use restriction bushing
Hot products such as hot oil, liquid sulphur, Use hi-temperature metal bellows
heat transfer products coke etc. become film
Flush with cool product
building, and also build up on the atmospheric
Double seal with cool barrier fluid 15
side of seals, much like crystallization residue,
psi (1 bar) greater than seal
only sticky.
chamber pressure).
In some cases, flush, quench and

drain, flush with cool fluid, quench
with steam.
Non - lubricants Cooling can be achieved by using a

pumping ring with double seals
Non lubricants should be cooled, in some
cases, to avoid flashing and abrasion. Use coolers (heat exchangers) for
cool barrier
Liquefied petroleum gas, solvents, products
with low specific gravity, boiler feed water etc. Quench and drain, depending on
the situation and availability, to
isolate product from atmosphere
and prevent freezing (liquefied
petroleum gas) and quench to drain.
NOTE: Always use carbon as one of

the face materials if compatibility is
not a problem (Carbon vs. Silicon
Carbide is the coolest running face
combination).
Slurries Use hard faces against product.
Slurries (raw product, lime slurry, dirty water, Use a double seal with the barrier
and sewage etc.) are the kinds of products that fluid at least 15psi greater than seal
clog seals, abrade metal parts and damage chamber pressure.
faces.
Use a quench and drain, with some
single seals, to avoid clogging on

atmospheric side by quenching

debris to drain.
Flush from an outside source and

use a restriction device in the
bottom of seal chamber to control
the flush volume required for cooling
while isolating the seal from the dirty
product.
Use a GPA seal, which is designed

for slurry applications.
Products that solidify Double seal with appropriate barrier

fluid can help and is historically the
Solidification will glue seal faces together
way most seal companies choose.
resulting in seal damage at start up. These
products also restrict the flexibility of Quench with steam or hot water can
mechanical seals. Some products include: often control solidification,
depending on the product.
Glue, polymers, asphalt, latex, paints, etc.
Steam jackets are often used.
Viscous products As above
Some products are thick and viscous and can

create problems much the same as
solidification.
Asphalt, cold oil, sugar, syrups etc.
Vaporizing products Use cool running faces
Vaporizing products such as hot water, Double seals are often used
propane, liquefied petroleum gas, Freon etc.
A cool flush may help prevent
can cause flashing between the faces, which
flashing
blows the faces apart, causing leakage and
Quench and drain to control
damage to the faces as they crash together
temperature on the atmospheric
(chips on face O.D. is most common sign).
side of the faces and prevent

freezing in the case of some light

gases.
Control the pressure with a

discharge return to seal chamber,
this raises pressure above the flash
point.
Pressure and Temperature Limits
Unbalanced
Non-pusher
Max. Pressure Temp. Range

Balanced
Seal Type
Pusher
(kPag/psig) (ºC / ºF)
Elastomeric 2070 / 300 -40 to 205 /

x x
bellows -40 to 400
Elastomeric 6900 / 1000 -40 to 205 /

x x
bellows -40 to 400
2070 / 300 -75 to 425 /

Metal bellows x x
-100 to 800
O-ring secondary 1380 / 200 -40 to 260 /

x x
seal -40 to 500
O-ring secondary 6900 / 1000 -40 to 260 /

x x
seal -40 to 500
Polymer 1380 / 200 -75 to 260 /

x x
secondary seal -100 to 500
Polymer x x 5070 / 500 -75 to 260 /

secondary seal -100 to 500
2670 / 400 -40 to 205 /

Stationary slurry x x
-40 to 400
1380 / 200 -40 to 205 /

Split seal x x
-40 to 400
2070 / 300 -40 to 260 /

Dual gas seal x x
-40 to 500
1725 / 250 -40 to 260 /

Dual gas seal x
-40 to 500
Pressure and Velocity (PV) Limits
Pressure velocity (PV) on mechanical seal is an indicator for the severity of an application. PV
factor is defined as the product of the pressure drop across the seal and the average rubbing
velocity.
As a general guide, seal capabilities can be classified as,
Low, if the PV value is 0.7 MPa m/s (about 20,000 psi ft./min)
Medium, if the PV value is between 0.7 and 10 MPa m/s (about 285,000 psi ft./min)
High, if the PV value ranges from 10 to 70 MPa m/s (about 2,000,000 psi ft. /min)
PV limits based on 16,000 hours’ wear life for common seals are given in Table below. For
lubricating fluids multiply number by 1.5.
Primary Ring Mating Ring PV Limit PV Limit

(MPa x m/s) (psi x ft./min)
Glass-Filled PTFE Ceramic / Silicon 6.13 25,000

Carbide
Carbon Cast Iron 24.52 100,000

Carbon Ceramic 24.52 100,000
Carbon Tungsten Carbide 122.59 500,000
Carbon Silicon Carbide 147.11 600,000
Tungsten Carbide Tungsten Carbide 24.92 120,000
Silicon Carbide Silicon Carbide 85.81 350,000
Selection of balanced vs. unbalanced is made on the basis of maximum PV factor and
subsequently maximum frictional power. Balanced seals reduce the pressure acting on the
seal faces; therefore, they have higher PV values than unbalanced seals.
Wear and Reliability
Some seals last indefinitely while others have only a short life span, therefore little life and
wear data is available.
When machinery operators encounter early cases of high leakage or other indication of wear,
consideration should be made to lower the PV factor at the seal face, use a more wear-
resistant material combination and eliminate contamination.
Wear rate generally varies with the PV factor at the seal face in a pattern similar to power loss:
the higher the face contact pressure P and surface velocity V, the higher the wear rate. With
higher hardness of the seal material, the wear rate is expected to be proportionately less.
*******

CHAPTER - 5
AUXILIARY EQUIPEMENT FOR ENVIRONMENT CONTROL
Friction heat and fluid impurities are the two major causes of seal failures.
Slurries and fluids carrying solid particles are especially dangerous as there is a tendency for
solid particles to collect in the vicinity of the mating faces and finally even entering the fluid film
gap between the mating faces. Hard particles entering this gap will cause premature seal face
failure.
Heat affects a seal several ways:
The faces can be attacked. Plated faces can have the hard coating crack off and filled
carbons can have the binder melted out in high heat.
The elastomer (rubber part) has a temperature limit determined by the compound
used.
The corrosion rate of all liquids increases with temperature.
Thermal expansion can cause seal face loads to alter and seal face flatness to change.
Many products will change from a liquid to a solid or gas at high temperature. If this
should occur between the seal faces, they can be blown open.
The full performance and benefits of mechanical seals can be achieved with the proper
combination of auxiliary equipment. Auxiliary equipment for mechanical seals is broadly
categorized for cooling (or warming), flushing, or quenching.
Cooling (Warming)
Cooling (warming) can be achieved by either of two methods: cooling/warming the periphery of
the seal face; or installing a jacket on the sealed box or seal cover. Cooling (warming) through
a cooling jacket may have to be performed when stopped depending to the fluid temperature
and the nature of the fluid.

A design for cooling should incorporate temperature adjustment of the sealed fluid within the
heat tolerance and cold tolerance of the packing and should have sufficient capacity to absorb
the heat generated at the seal face. When the purpose is cooling, design to reduce the
saturation temperature of the sealed fluid at ambient atmospheric pressure by 30 to 55°F. In
the case of normal water, cooling is used when the temperature inside the sealed box exceeds
175°F. Because some heat is conducted by the body of the equipment, the cooling capacity
must be designed to incorporate the above conditions.
Important
The best way to cool a seal is to use the jacketed stuffing box that came as a part of
the pump. This jacket will not only cool down the seal area, but will provide the
necessary cooling to the shaft so that it will not transmit stuffing box heat back to the
bearings.
Air or gas trapped inside the sealed box reduces thermal conductivity and significantly
reduces the cooling (warming) effect. This contributes to abnormal heating and
premature wear of the seal face. The sealed box must be completely purged of all air
and gas.
Flushing
Flushing is intended to cool the seal face by causing the sealed fluid to flow, thus preventing
the stagnation of foreign matter and intrusion to the seal face. The flushing fluid may be the
same fluid that is being sealed, tapped from a point at a higher pressure than that existing in
the stuffing box, or any other fluid, preferably at a lower temperature, that may be permitted to

mix with the sealed fluid. Injection pressure should be 14.2 to 30 psig higher than the pressure
in the sealed box.
Types of Flush
Bypass flush
This method consists of piping run from the pump discharge to the flush connection on the
seal gland, providing flow from the pump, past the seal, and back into the pump through the
seal chamber throat. It can also be piped from the flush connection on the seal gland back to
the pump suction, which would result in the flow going the opposite direction and can have the
added benefit of lowering the operating pressure at the seal. If warranted, accessories such as
a heat exchanger or pressure reducing orifice can be installed in the piping.
This method is used when the pumped fluid is clean, does not exceed the temperature limits of
the seal, and is compatible with the seal components.
It’s not recommended if the pumped fluid contains solids that could adversely affect the seal or
if the temperature of the pumped fluid exceeds the maximum temperature for the seal.
External flush
External flushing is a preferable method for fluids containing slurry. The external flushing liquid
flows past the seal and into the pump, mixing with the pumped fluid. Usually a flushing liquid
pressure of about 10-15 psi above the pump seal chamber pressure is sufficient. Flow rates of
about 0.25-0.50 gpm are typical. A control valve, gauge, and flow meter should be installed in
the flushing liquid supply line to provide the control functions necessary to set and monitor the
flushing liquid supply, with the flow meter being the most important so that a positive flow of
flushing liquid into the pump can be confirmed.
Thermo-syphon systems
A thermo-syphon is a closed loop system in which fluid flow is produced by gravity through the
effects of temperature on density. This natural circulation results from the differential head that
exists between the cold and hot sections of the system. The cold fluid has the greater density
and displaces the hot fluid. The saying “warm air rises” is better described as “cold air sinks.”
Thermo-syphon systems can provide cooling for liquid sealing systems; however, it may lead
to vapour locking (stopping of flow). To prevent vapour locking and maximize flow, large

diameter piping, connections, and drill-through should be used. The cooler or reservoir should
be 2 to 5 ft above the seal chamber.
Flush Sizing
The minimum flush rate is typically determined by an energy balance computation. The
assumption is that heat generated by the seal faces is absorbed by the flush through ideal
mixing. This raises the temperature of the flush. It is recommended the temperature increase
be kept below:
15°F for water and low vapour pressure hydrocarbons
30°F for lube oils
5°F for high vapour pressure hydrocarbons
In the absence of specific guidance, a simple rule of thumb is to use 1 gpm per inch of seal
size for water at 15°F temperature rise. The rule of thumb yields 2 gpm for a 2-inch seal.
Important!
Seal face temperature decides its material of construction so that the seal does not fail at
operating temperature and also the seal flushing plan. The following points are certain items to
be considered for lowering seal temperature:
Reduce face pressure: lower spring closing force to be closer to the hydraulic opening
forces.
Provide a high modulus of elasticity difference between the primary and mating rings
for the stiffer face to run into the softer face to provide a tighter seal.
Use a material combination with a lower friction coefficient.
Explore a more appropriate flush plan as specified by the American Petroleum Institute
in its standard (API 682) for pump sealing systems.
System control
The preferred method for controlling flush flow is with an orifice. The orifices should not be less
than 0.125 in, unless the product is very clean. Many small or low speed pumps have a low
differential pressure and no orifice would be required in the piping. On the other hand, when

the differential pressure is high, a single 0.125-in orifice would allow for more flow than
desired. In such cases, multiple orifices must be used to control flow.
The line/orifice size is calculated on the basis of differential pressure between the flushing
media header and the stuffing box. The flush should not impinge directly on the mating area; it
should enter toward the driven side and flow into the seal faces in a streamlined motion.
Important
In seal flushing, the parameter to control is the flow. When seal flushing is applied to pumps it
is highly advisable to control the flow with a flow regulator and not a pressure regulator.
For mixers, a pressure regulator is OK as the pressure outside the seal chamber, the
submergence depth, is constant. In pumps, however, the pressure outside the seal chamber
consists of both submergence depth and pump pressure. If a pressure regulator is used, the
seal chamber will be over‑pressurized when the pump is shut down and the flow restrictor
may be damaged.
Quenching
Quenching is used to wash out toxic or explosive fluids; volatile fluids such as LPG; and
leaked fluids that precipitate and harden when exposed to outside air. Clean water is typically
used as a quench medium when the fluid being sealed has solids in solution or will crystallize
upon exposure to atmosphere. It is essential that the injection fluid not react with the leaked
fluid; if there is no suitable fluid, steam, nitrogen gas or argon gas may be used.

Recommended quench rate
1. Minimum Rate based on Purging - If a quench is to be applied then the minimum

quench rate can be thought of as a purge. In that case, the minimum rate is a function
of the volume being purged and the leakage being diluted. For typical seal gland plates
and a contingency plan for high leakage rates, dilution of leakage usually governs.
2. Minimum Quench Rate Based on Washing - Another consideration is that the

quench should wash away the leakage. This is based upon the quench rate with a
certain velocity thru the quench area. The velocity should be in the range of 10 to 15
fps through the flow area to be effective. This consideration may call for more quench
than the consideration for purging.
3. Minimum Quench Rate Based on Cooling - Steam is usually readily available in

plants and the flow rates are typically not regulated very closely due to the availability.
This is also due, in part, to the cost versus other quench media.
Controlling the quench
The recommended quench rates are low enough that the flow rate may be somewhat difficult
to control with any accuracy. The flow rate for water does not have to be very large. In some
cases it can just be enough to keep a volume of fluid on the atmospheric side of the seal, while
in other cases a slight flow rate of 0.125-gpm to 0.250-gpm is sufficient to prevent build-up of
product underneath the seal faces. There is little need for precision, especially with steam.
***********

CHAPTER - 6
SEAL MATERIALS
The choice of material is important to seal performance. A basic rule is that the material must
be harder than the particles present in the pumped medium.
When choosing materials, the primary and mating rings are typically selected from dissimilar
materials to reduce friction and wear. The most common mechanical seal face material
combination is carbon against a nickel-iron (Ni-Resist).
Key Properties of Seal Materials
A good face material must also exhibit good sliding properties, high stiffness, high thermal
conductivity and low thermal expansion. On top of this, it must also be chemically compatible
with the medium. The primary and mating rings are often selected with materials that have a
high modulus of elasticity difference; therefore, the stiffer face can run into the softer one and
thereby provide a tighter seal.
The following characteristics are important:
Mechanical properties
High modulus of elasticity
High tensile strength
Low coefficient of friction between 0.02 and 0.08
Excellent wear characteristics and hardness
Self-lubricating
Thermal properties
Low coefficient of expansion
High thermal conductivity
Resistant to thermal shock
Thermal stability

Chemical properties
Corrosion resistant
Good wettability and adhesion characteristics
Additional
Dimensional stability
Good machinability and ease of manufacture
Economical and readily available
Surface finish – high flatness within two to three helium light bands with a surface finish
of four to five µin.
Face Materials
Tungsten carbide
Corrosion resistant Tungsten Carbide provides high strength, stiffness and toughness which
give the seal rings great shape stability and seal faces that stay flat. It is the best choice in
most media, except for strong acids and those media with high chloride content. It is an
excellent conductor.
The drawback is that is brittle and highly susceptible to heat checking (formation of surface
cracks) if allowed to run dry for even a few seconds.
Silicon carbide
Silicon carbide has hardness greater than tungsten carbide, outstanding chemical stability,
good anti-frictional properties and thermal conductivity but very brittle. It is primarily
recommended when the corrosive properties of the liquid demand it. It offers very good
resistance to acidic and chloride liquids.
Not recommended for alkaline liquids. It should not be applied where the liquid side of the seal
is exposed to lower pressure than its atmospheric (air) side, usually less than 1 atmosphere
(14.7 psia).
Aluminium oxide (Al2 O3)
Aluminium oxide is hard, chemically inert and comparatively inexpensive. It is economically

feasible to design aluminium oxide seal rings as one piece, which has advantages for leakage

and wear performance. The drawback of aluminium oxide is its inferior sliding properties
compared to cemented carbide and silicon carbide.
Usage limited to low speed and pressure applications.
Carbon
Although it’s not sufficiently hard for use in outer seals, carbon’s excellent sliding properties,
and its ability to conform to its harder counter face, makes it suitable for use in inner seals.
Apart from high temperature durability, its wear characteristics and dimensional stability are
superior.
One significant draw-back is its poor ability to withstand continuous operation for extended
periods of time. Especially large seal rings are prone to surface blistering after a couple of
thousand hours of running.
Steel
Seal head hardware items such as springs, retainers, drive bands, discs, and snap rings are
fabricated from stainless steel. The two predominant types are:
AISI 302/304: This is a chromium/nickel alloy that can withstand most of the liquids.
The higher carbon content of AISI 302 makes it suitable for springs and circlips, while
304 is preferable for sheet metal parts.
AISI 329: Apart from chromium and nickel, this alloy also contains molybdenum and
can therefore withstand chlorides and acids better.
The springs and bellows shall be Hastealloy C to avoid problems with Chloride stress
corrosion.
Use low expansion metal such as Carpenter 42 or Invar 36 for metal bellows seal face holder
if the product temperature can exceed 400° Fahrenheit (205°C). These low expansion steels
will prevent the carbon or hard seal faces from leaking between the face and the metal holder.
Temperature Limitations
Material Construction Max. Temperature
°F °C

Stellite Face Welded Stellite Face on Metal Ring 350 177
Chrome cast Solid Cast Ring 450 232
Tungsten Carbide Solid Tungsten Carbide Ring 750 400
Tungsten Carbide Solid Tungsten Carbide Element mounted 250 120

in 316 SS Body

in Hastealloy “C” Body

in 17-4PH SS Body
SS316 Solid Machined Stainless Steel Ring 600 316
Ni-Resist Solid Nickel-Cast Iron Ring 350 177
Bronze Solid Leaded Bronze Ring 350 177
Ceramic Solid Pure Ceramic Ring (99.9% Pure) 350* 177*
Chrome Oxide Chrome Oxide Facing on Metal Ring 350 177
Carbon Solid Carbon Graphite Ring (Resin 525 275

impregnated)
Carbon Solid Carbon Graphite Ring (Metal 585 310

impregnated)
Silicon Carbide Solid Silicon Carbide Ring (Sintered) 800 427
Silicon Carbide Solid Silicon Carbide Ring (Reaction 800 427

bonded)
Silicon Carbide Solid Silicon Carbide Element mounted in 250 120

316 SS Body


Hastealloy “C” Body

17-4PH SS Body
Secondary Seal Materials
The following elastomers are most commonly encountered as secondary seals. Many of the
names used for these materials are trade names that have been adopted as generic by the
mechanical seal industry.
Buna N
Buna N, referred to as Nitrile or NBR, is a copolymer of butadiene and acrylonitrile with

excellent resistance to petroleum products and wide acceptance for use in water applications.
Buna N has low resistance to ozone, sunlight, and weather, so spare Buna N O-rings should
be stored in a protected area where they will not be exposed to direct sunlight or ozone
generating electrical equipment.
Buna N can be used at temperature ranging from -40°F to +225°F (-40°C to 105°C).
Viton
Viton, also known as Fluorocarbon rubber (FPM) is usually the standard choice for the rubber
parts of the face seals.
Viton is used in a wide range of applications, including those involving petroleum oils, di-ester
base lubricants, silicon fluids, halogenated hydrocarbons and wide variety of acids, and
numerous other fluids.
Beware; most Viton® compounds are attacked by water. Be sure to check if you have the
recommended grade. Remember that steam is another name for water. The steam cleaning of
lines is very common in the process industry. Caustic is another common cleaner that contains
a high percentage of water. Viton will NOT tolerate ketones, anhydrous ammonia, amines, hot
hydrofluoric acid, chlorosulphonic acids, or strong caustics.

Viton has excellent tolerance for use at temperatures ranging from 0°F to +400°F (-18°C to
+204°C).
EPR
EPR, also known as ethylene propylene rubber or EPM, is a copolymer made from ethylene
and propylene monomers. EPT or EPDM, containing a third monomer, is an ethylene
propylene terpolymer.
Both EPR and EPT are widely used in the sealing industry. EPR has excellent corrosion
resistance to dilute acids and alkalis, ketones, alcohols, water, steam and phosphate ester
hydraulic fluids, but it is not recommended for use with petroleum oils or di-ester base
lubricants. EPT, with added resistance to oxidation and radiation, is recommended for nuclear
service. EPR and EPT materials are applicable for use at temperatures ranging from -40°F to
+350°F (-40°C to +177°C).
Perfluroelastomer (FFKM)
For extremely aggressive media, neither nitrile nor Viton™ may have sufficient chemical
resistance. A perfluoroelastomer (FFKM) has excellent corrosion resistance to solvents,
inorganic and organic acids and bases, strong oxidizing agents, metal halogen compounds,
hot mercury, chlorine, fuels, and heat transfer fluids. For amines special compounds are
available. FFKM is a costly material resistant to most chemicals and with a temperature limit of
240°C.
Neoprene
Neoprene was among the earliest of the synthetic rubbers to be made available for seal
manufacture. It continues to be used for sealing refrigerants, such as Freon and ammonia, and
for other mild services. Neoprene has a unique resistance to petroleum lubricants.
Like Buna N, Neoprene can be used at temperatures ranging from -40°F to +225°F (- 40°C to
+107°C).
Teflon
Teflon® offers the most universal resistance of all materials and for all practical purposes has
complete resistance '"with no restrictions or temperature limitations. It is often used for coating
the elastomers.

Important
Teflon® is not an elastomer. It doesn't have a memory and has to be spring-loaded to the
sleeve or shaft. This spring loading interferes with the flexibility of the seal and prevents the
elastomer part from flexing and rolling to compensate for minor shaft movements. Beware;
Teflon® is attacked by Halogens.
Temperature Limitations
The elastomers can be very sensitive to a temperature change in the stuffing box, or an
increase of temperature at the seal faces. The elastomers (rubber parts) are the parts you
have to watch.
Material Form Minimum Maximum

Temperature Limit Temperature Limit
°F °C °F °C
Buna N (Nitrile) O-Ring -40 -40 +225 +107
Neoprene O-Ring -40 -40 +225 +107
Viton O-Ring 0 -18 +400 +204
EPR/EPT (Ethylene O-Ring -40 -40 +350 +177

Propylene)
Karlez (Compound O-Ring 0 -18 +560 +280

4079)
Note – The minimum and maximum limits listed are general limits and will vary with the liquid
in contact with the Elastomer.
********

CHAPTER - 7
API SEALING REQUIREMENTS
The API (American Petroleum Institute) standard is the one universal standard being used by
oil refineries throughout the world. It provides minimum requirements for sealing systems for
centrifugal and rotary pumps supplied with:
Seal sizes from 1.5 to 4.5 inches (30mm to 120 mm)
Stuffing box temperatures from -40°F to 500°F (-40°C to 260°C)
Stuffing box pressures from 0 psia to 515 psia (0 bar to 34.5 bar).
The standard is designed to default to the equipment types most commonly supplied that have
a high probability of meeting the objective of at least three years of uninterrupted service while
complying with emission regulations.
Seal Selection Procedure
Below is the generic selection procedure for selecting a seal for a variety of refinery and
general services. Although chemical and petrochemical industries are covered b API 682, the
selection procedure did not attempt to cover every application due to myriad process fluids
involved in industries.

The information is used to select the seal category, type arrangement and piping plan.
Codification of Mechanical Seals based on API 682
Based on API 682, all mechanical seal shall be cartridge design. Sample codification/
specification shall be as follows:
C2 A1 C 11 62
C2: Category 2
A1: Arrangement 1
C : Type C
11: Flush Plan 11
62: Quench Plan 62
Seal Categories
The first step in selection of appropriate seal is to determine the seal category required for the
service. The category is a function of the pump design, operating conditions, the design
features of the seal, and the documentation required by the user. There are three
recommended seal categories:
Category # 1: ANSI/ASME B73.1, ANSI/ASME B73.2 and ISO 3069

Type C seal chamber (non-ISO 13709 seal chambers).
Category # 2: ISO 13709, API 610 seal chamber.
Category # 3: ISO 13709, API 610 seal chamber.
Duty
Category #1 Intended for chemical duty pumps.
Category #2 Intended for API, requiring fewer features than a 682

first edition seal.
Category #3 Intended for API 610 pumps.
Temperature Range

Category #1 40°C to 260°C (40°F to 500°F)
Pressure Limits
Category #1 22 bar (315 psia)
Face Materials
Category #1 Anti-blister carbon vs. self- sintered

silicon carbide
Category #2 Anti-blister carbon vs. reaction bonded

silicon carbide
Category #3 Anti-blister carbon vs. reaction bonded

silicon carbide
*For seals requiring two hard faces the default material for both faces is silicon carbide.
Recommended Metal Components
Category #1 Hastelloy C276 springs 316 stainless

steel metal components.
Category #2 Inconel 718 bellows 316 metal

components.
Category #3 Inconel 718 bellows 316 stainless steel

components.
Recommended Elastomers (Secondary seals)

Category #1 Fluro-elastomer (Viton) O-rings
Category #2 Fluro-elastomer (Viton) O-rings
Category #3 Flexible graphite
Operating temperatures and pressures beyond the API 682 standard may require
“engineered seal”, designed for specific requirement.
Seal arrangements
The selection of the seal arrangement is a function of regulations, hazard assessment and
process fluid properties. All applications start with Arrangement 1 (single seal). The user
follows a flow chart of “yes” and “no” questions and final (1, 2 or 3) is determined.
1. Arrangement 1: Single Seal

2. Arrangement 2: Dual un-pressurized seal (use buffer fluid)
3. Arrangement 3: Dual pressurized seal (use barrier fluid)
Seal Types
Seal applications are divided into three major services: non-flashing hydrocarbon, flashing
hydrocarbon and non-hydrocarbon.
Non-hydrocarbon services are further divided into water, sour, water, caustic, amines,
crystallizing services and acids. Each of the service groups is defined for a range of pressures
and temperatures. The applicable seal types are listed under each of the groups along with
any special design or material recommendations for the specific service.
1. Type A – Describes a pusher seal with a rotating flexible element, silicon carbide
versus carbon faces, alloy C-276 springs, fluoro-elastomer O-rings, and 316 SS metal
components.
2. Type B – Is a bellows seal with a rotating flexible element, silicon carbide versus
carbon faces, alloy C-276 bellows plats, fluoro-elastomer O-rings, and 316 SS metal
components.
3. Type C – Is a bellows seal with a stationary flexible element, silicon carbide versus
carbon faces, Inconel alloy 718 bellows plates, flexible graphite secondary seals, and
316 SS metal components.

4. Type CS – Describes a containment, or backup seal in a dual un-pressurized seal

arrangement. It’s designed to operate at less than 10-psi for the life of the inner seal.
When the inner seal fails, the containment seal is designed to run under full seal
chamber conditions for a minimum of eight hours and prevent or minimize process fluid
leakage to atmosphere.
5. Type NC – Is a non-contacting seal that is designed to intentionally create a

hydrodynamic lift and operate with a specific face separation. This design is used
primarily on dual pressurized gas seals. It may also be used on liquid or mixed phase
applications.
Seal Orientation
1. Face-to-back (tandem): one mating ring is between the two flexible elements and one
flexible element is between the two mating seal rings.
2. Back-to-back: both of the flexible elements are between the mating seal rings.
3. Face-to-face: both of the mating seal rings are between the flexible elements.
Seal Flush and Quench
The selection flowcharts for piping plans are divided into the same three services as the seal
type selection: non-flashing hydrocarbon, flashing hydrocarbon and non-hydrocarbon. Each of
these flowcharts has a starting point for each of the arrangements. The user answers a
number of questions about the process conditions, fluid properties and the presence of
contaminants. The user then follows the flowchart to arrive at the suggested piping plan for the
seal flush and quench.
Barrier & Buffer Fluid
The selection of a barrier or buffer fluid is critical to the success of liquid dual seals. Barrier
and buffer fluids must be compatible with the process fluid and seal materials of construction.
In addition, it must provide adequate lubrication for the seals and have suitable fluid properties
over the entire range of expected operating conditions.
Other Definitions of Sealing Methods
1. Contacting wet seals CW: mating faces are not designed to intentionally create
aerodynamic or hydrodynamic forces to sustain a specific separation gap.

2. Non-contacting seals (whether wet or dry) NC: mating faces are designed to
intentionally create aerodynamic or hydrodynamic separating forces to sustain a
specific separation gap.
3. Containment seals (whether contacting or non-contacting) CS: Seal design with

one flexible element, seal ring and mating ring mounted in the containment seal
chamber.
On dual pressurized seal, the lubricating film is generated by the barrier fluid which
should be up to 30 psi above the product pressure in the seal area. In case of a
leakage, the barrier liquid penetrates the product.
Mechanical Seal Codification based on API 610, 8 Edition
On the latest edition, this seal code does not specify any more in API 610 and seal
arrangement refers to API 682. But some vendor and end-user sometimes still use this
designation.
Sample: BSTFN
1. 1st letter: Balanced (B), Unbalanced (U)
2. 2nd letter: Single (S), dual un-pressurized (T) and Dual Pressurized (D)
3. 3rd letter: T – Seal gland type (P = plain, no throttle bushing; T = throttle bushing with
quench, leakage and/or drain connections; A = auxiliary sealing device, type to be
specified)
4. 4th letter: Gasket (refer table below)
Stationary Seal Ring Seal Ring to Sleeve

Letter
Gasket Gasket
E FKM FKM
F FKM FKM
G PTFE PTFE
H Nitrile Nitrile
I FFKM FFKM elastomer

R Graphite Foil Graphite Foil
X As specified As specified
Z Spiral wound Graphite foil
5. 5th Letter: Sealing Ring Face Material
Letter Ring 1 Ring 2
L Carbon Tungsten carbide 1
M Carbon Tungsten carbide 2
N Carbon Silicon carbide
O Tungsten carbide 2 Silicon carbide
P Silicon carbide Silicon carbide
X As specified As specified
Key Features of API (Extracts)
The API specification addresses just about everything about mechanical seals. The subjects
include:
1. All standard mechanical seals, regardless of type or arrangement, shall be of the

cartridge design. The standard single arrangement pusher seal shall be an inside
mounted balanced cartridge seal. The standard, un-pressurized dual mechanical seal
shall be an inside, balanced, cartridge mounted mechanical seal (with two rotating
flexible elements and two mating rings in series). Outer seals shall be designed to the
same operating pressure as the inner seal, but do not have to be balanced.
2. Cooling for the inboard seal is achieved by a seal flush. Cooling for the outside seal is
accomplished by a circulating device moving a buffer fluid through an external seal
flush system.

3. Seal chambers shall conform to the minimum dimensions so that the minimum radial
clearance between the rotating member of the seal and the stationary surfaces of the
seal chamber and gland shall be 3 mm (1/8 inch). O-ring grooves shall be sized to
accommodate perfluoro elastomer O-rings.
4. For horizontally split pumps, slotted glands shall be provided to make disassembly
easier.
5. Provisions shall be made for centering the seal gland and/or chamber with either an
inside-or outside diameter register fit. The register fit surface shall be concentric to the
shaft and shall have a total indicated run out of not more than 125 micrometers (0.005
inch). Shaft centering of mechanical seal components or the use of seal gland bolts is
not acceptable.
6. Seal chamber pressure for single seals, and for the inner un-pressurized dual seal,
shall be a minimum of 3.5 bar (50 psi) or 10 percent above the maximum fluid vapor
pressure at seal chamber fluid temperature. This margin shall be achieved by raising
the seal chamber pressure and/or lowering the seal chamber temperature. Lowering
the temperature is always preferable. Pumps which develop less than 3.5 bar (50 psi)
differential pressure may not meet this requirement and alternate requirements shall be
agreed upon by the purchaser and the seal manufacturer.
7. On vertical pumps the seal chamber or gland plates shall have a port no less than 3
mm, (1/8") above the seal faces to allow the removal of trapped gas. The port must
have orifice and valve.
8. For single seals and when specified for dual seals, a non-sparking, floating-throttle
bushing shall be installed in the seal gland or chamber and positively retained against
blowout to minimize leakage if the seal fails.
9. Unless otherwise specified a shaft sleeve of wear, corrosion, and erosion resistant
material shall be provided to protect the shaft. The sleeve shall be sealed at one end.
The shaft sleeve assembly shall extend beyond the outer face of the seal gland plate.
Shaft sleeves shall be supplied by the seal manufacturer.
10. Shaft sleeves shall have a shoulder or shoulders for positively locating the rotating
element or elements.
11. Shaft to sleeve sealing devices shall be elastomeric O-rings or flexible graphite rings.

12. Standard seal sizes shall be in even increments of ten millimetres. It is preferred that
alternate seals be sized in increments of 0.635 mm (0, 25 inches) starting with 38.0
mm (1.5 inches).
13. Sleeves shall have a minimum radial thickness of 2.5 mm (0.100 inches).
14. Sleeves shall be relieved along their bore leaving a locating fit at or near each end.
15. Shaft to sleeve diametric clearance shall be 25 micrometres to 75 micrometres (0.001

inch to 0.003 inch.
16. Drive collar set screws shall be of sufficient hardness to securely embed in the shaft.
17. Seal and mating rings shall be of one homogeneous material. Overlays and coatings
shall not be used as the sole source of wear resistant material. Materials such as
silicon or tungsten carbide may be enhanced by applying additional coating.
18. One of the seal face rings shall be premium grade, blister resistant carbon graphite
with suitable binders and impregnates to reduce wear and provide chemical resistance.
Several grades are available; therefore, the manufacturer shall state the type of carbon
offered for each service.
19. The mating ring should be reaction bonded silicon carbide (RBSiC). When specified,
self-sintered silicon carbide (SSSiC) shall be furnished.
20. Abrasive service may require two hard materials. Unless otherwise specified for this
service, the seal ring shall be reaction bonded silicon carbide and tungsten carbide
(WC) with nickel binder.
21. Unless otherwise specified, gland plate to seal chamber seal shall be fluoro-elastomer
O-ring for services below 150°C (300°F). For temperatures over 150°C (300°F) or
when specified, graphite-filled type 304 stainless steel spiral wound gaskets shall be
used.
22. If you are using dual mechanical seals, only mechanically forced seal flush and
barrier/buffer fluid systems shall be provided. Systems that rely upon a thermos-
syphon to maintain circulation during normal operation are not allowed.
23. Seal systems that utilize internal circulating devices, such as a pumping ring, that rely
upon the rotation of the mechanical seal to maintain circulation shall be designed to
thermo-syphon when the seal is not running.

24. If a dual seal buffer/barrier fluid reservoir is specified, a separate barrier/buffer fluid
reservoir shall be furnished for each mechanical seal.
The standard also covers:
1. Accessories such as:
Seal coolers, buffer/barrier fluid reservoirs, condensate collection reservoirs, and

buffer/barrier gas supply panels,
2. Seal qualification tests
During testing, the seals must maintain a leakage rate of less than 1000-ppm (as
measured by EPA Method 21) or 5.6-gr/hr. This leakage criterion does not apply to
testing of dual gas seals or containment seals under failure conditions. In addition,
the measured wear on the seal faces must be less than 1 percent of the available
wear.
3. Seal hydrostatic testing
Hydrostatic testing is required for the seal gland, all piping, reservoirs, and other
auxiliary equipment exposed to process fluids.
In the second and latter editions, there is an exemption for seal glands machined
from a single piece of wrought material or bar stock.
Cast seal glands still require testing.
4. There are many annexes that include references, calculation techniques, and tutorial
information. Here are two examples:
Annex F - Mechanical seal data sheets
One set of datasheets covers Category 1 and 2 seals. Another set covers
Category 3 seals.
These datasheets are provided in both SI and U.S. customary units.
Annex J - Mechanical Seal Coding (as discussed under item 7.2)
5. Recommended seal selection procedures that are broken down into three process
fluids:
Non-hydrocarbons

Non-flashing hydrocarbons
Flashing hydrocarbons.
6. Standard flush plans and auxiliary hardware. The following piping plans have been
altered in this new edition
14, 53, 53A, 53B, 53C, 65, 71, 72, 74, 75, and 76
Get a copy of these standards to learn more on the design, selection and application of seals
and how they’ll affect your project.
*******

CHAPTER - 8
API STANDARD SEAL FLUSH PLANS
This section discusses the basic flush plans. The American Petroleum Institute (API) in its
international seal standard API 682 3rd edition (ISO 21049) recognizes 26 piping plans; many
other variations are also used. It’s important for reliability engineers to become familiar with the
merits of one flush plan or another.
Grouping Information
The various flush plans can be grouped by a variety of categories. One method for grouping is
based on the internal and external recirculation and the other is single/dual/quench and gas
seal plans as follows:
API Plan Type Description
01, 02 Single seal Internal system for single seals
11, 12, 13, 14, 22 Single seal Simple recirculation system for
single seals
21, 23, 31, 41 Single seal plans Recirculation systems with

auxiliary equipment for single
seals
52, 53A, 53B, Dual seal plans External systems for dual seals
53C, 54
32, 62 Quench seal plans External injection systems
72, 74, 75, 76 Gas seal plans External control system for
containment seals.
These groups can have similarities in advantages/disadvantages, sizing of the system and
system controls.
You can notice that PLAN 01, 02, 11, 13, 14, 21, 23, 31, 32, and 41 are recirculation systems.
It has following advantages and disadvantages:

Advantages
The flush source comes from the pumpage and goes back to the pumpage, so no
product contamination occurs.
Unlike an external injection, these do not require any reprocessing of the product.
Disadvantages
If the product pumped is not a good face lubricant, then the seal can become
damaged.
For some of the plans, circulation from the pump discharge back to pump suction or
vice versa will decrease pump efficiency and increase power required for the
application.
Mechanical Seal Piping Plans
An appropriate match between piping and auxiliary equipment is required in order to maximize
the performance of mechanical seals. In the piping examples shown in the diagrams below, all
plans are numbered according to API standards (API682-3rd).
The most commonly used API Plans are: 11, 13, 21, 23, 52, 53 and 62.
Piping Symbols
Legends

PLAN 01
Plan 01 is an integral recirculation from the pump discharge to the seal chamber. This
is an internal version of Plan 11.
Features Uses Caution
Removes heat from the Custom seal chamber, most Ensure that the
seal chamber as well as likely an ANSI/ASME pump. recirculation is sufficient for
acting as a vent seal heat removal.
Clean, moderate
connection in horizontal
temperature fluids.
pumps.
Used with single seals,
No exposed plumbing
rarely with dual seals.
around pump. Reduces
Not recommended for
risk of freezing or
vertical pumps.
polymerization of
process.
PLAN 02
Plan 02 is a dead-ended seal chamber with no recirculation of flush fluid.

No fluid recirculation In cool clean fluids with high To avoid flashing, process
needed. specific heat, such as water, fluid temperature must be
in relatively low speed taken into consideration.
Process solids are not
pumps.
continuously introduced Avoid use without cooling /
into seal chamber. Use only when adequate heating jacket (for
vapour margin is present in cylindrical chambers).
the seal chamber.
Ensure top point vent in
Often used with a jacketed throat bush (for cylindrical
seal chamber to control chambers in horizontal
temperature in high pumps).
temperature processes.
PLAN 11
Plan 11 is recirculation from pump discharge to the seal through a 1/8” minimum flow
control orifice, when necessary, to the seal and flows back into the pump. The
recirculation line is connected to the flush port of the seal itself.
Prevents product from In general, applications with Calculation of recirculation

vaporizing by maintaining clean non-polymerizing fluids flow rate, heat removal and
positive pressure above with moderate temperatures. orifice size are required.
vapour pressure.
It is used to increase the Orifice size should be at

Becomes a self-venting pressure in the stuffing box least 1/8” (3.2mm).

plan for horizontal to avoid vaporization of the
Check the margin between
pumps. medium pumped and to
discharge pressure & seal
provide cooling to the seal
Default API Plan for chamber pressure to
faces.
most single seals. ensure proper flow of fluid.
Do not use with media

containing solids &
abrasives.
PLAN 12
Plan 12 is recirculation from pump discharge through a Y strainer and a flow control
orifice to seal chamber.
Becomes a self-venting Always ensure that orifice

plan for horizontal In general used in slightly is placed after the Y
pumps. dirty and non-polymerizing strainer.
fluids.
Can handle dirty liquids This plan is normally
to some extent. discouraged due to non-
reliability of Y strainer.
Calculation of recirculation.
PLAN 13

Plan 13 is recirculation from the seal chamber to the suction of the pump through a
1/8” minimum flow control orifice. The recirculation line shall be connected to the seal
as close as possible to the 6 o’clock position. In case the impeller of the pump features
balancing holes, Plan 13 cannot be used and a flushing arrangement (Plant 32) shall
be used instead.
It is used to evacuate Wherever Plan 11 is not Check margin between

solids from the seal usable due to low-pressure seal chamber pressure &
chamber and to prevent margin between discharge & suction pressure.
crystallization. seal chamber pressure.
Orifice size should be at
Provides continuous vent Used in vertical pumps. least 1/8” (3.2mm).
for vertical pumps.
Used in applications where
the seal chamber pressure is
greater than suction
pressure.
Can reduce the seal

chamber pressure when
used along with a close
fitting throat bushing.
Moderate temperature fluids

with moderate solids.

PLAN 14
Plan 14 is recirculation from pump discharge through a properly sized flow control
orifice, when necessary, to the seal chamber and from the seal chamber through a
properly sized flow control orifice, when necessary, to the pump suction. (A
combination of Plan 11 and Plan 13)
Ensures product Used in vertical pumps. Check for pressure margin

recirculation as well as between discharge to seal
Used in light hydrocarbon
venting. chamber pressure and
services.
seal chamber to suction
Reduces seal chamber
Clean, non-polymerizing
pressure.
pressure.
fluids at moderate
temperatures.
PLAN 21
Plan 21 is recirculation from pump discharge through a cooler to the seal.

Improves pressure For high temperature Always ensure that cooler

margin over vapour applications e.g. hot water is placed after the orifice.
pressure. application (temperature >
Check pressure difference
180ºF), hot hydrocarbons
Improves temperature between discharge and
etc.
margin to meet seal chamber.
secondary sealing In hot non-polymerizing
Cooler duty is high leading
element limits, to reduce fluids.
to fouling on waterside.
coking or polymerizing &
Recommended over the
Potential plugging on
to improve lubricity.
Plan 23 when used in
process side if fluid
Self-venting plan. viscous applications that
viscosity gets high quickly.
may clog seal flush cooler.
Provides sufficient
pressure difference to
allow proper flow rate.
PLAN 22
Plan 21 is recirculation from pump discharge through a Y strainer, a flow control orifice
and a heat exchanger to seal chamber.
Improves pressure For high temperature Always ensure that cooler

margin over vapour applications with slightly dirty is placed after the orifice.
pressure. liquid.
Check pressure difference
Improves temperature between discharge and
margin to meet seal chamber.
secondary sealing

element limits, to reduce to fouling on waterside.

This plan is normally
discouraged due to non-
Self-venting plan. reliability of Y strainer.
Provides sufficient
pressure difference to
allow proper flow rate.
PLAN 23
Plan 23 is recirculation of process fluid from the seal chamber, through a seal flush
cooler, back into the seal chamber utilizing a pumping ring.
Cool process, improving High temperature service, Maintain maximum 0.5m

lubricity and increasing hot hydrocarbons. horizontal distance from
the vapour margin in the seal chamber to heat
In hot and clean services
seal chamber. exchanger.
e.g. in boiler feed water and
Reduce coking. hot hydrocarbon services. Vent valve required at
highest point of piping
Has greater cooling
system.
efficiency than Plan 21
because it continuously Ensure that pump has a
recirculates the seal close clearance throat
chamber fluid through the bush.
seal flush cooler. It
Ensure that the seal outlet

decreases the duty, connection is in the top

reduces cooler fouling half of the gland.
and increases cooler life.
Ensure that the cooler is
mounted above the pump
centre line.
Vent the system fully

before start up.
PLAN 31
Plan 31 is recirculation from pump discharge through a cyclone separator, sending

clean flush into the seal chamber and heavy particles back to pump suction.
Remove solids from the Used in media with Pump throat bushing is
seal flush and seal suspended solids, dirty or recommended.
chamber. contaminated fluids, water
Ensure use for services
with sand or pipe slag.
Particles from cyclone containing solids with
separator are returned to Works best for solids with a specific gravity twice or
suction. specific gravity twice the more than that of process
process fluid. fluid.
PLAN 32
Plan 32 is injection of a cleaner or cooler fluid to the seal chamber from an external

source, mixing into the process stream.
Reduces flashing or air Dirty or contaminated fluids. External source should be

intrusion across seal continuous and reliable at
High temperature
faces by providing a all times, even during start-
applications.
positive flush. up & shut down.
Polymerizing and oxidizing
Maintains vapour Flush fluid must be
fluids.
pressure margin. compatible with process
Media with poor lubrication
fluid due to product
Always provided at a
properties.
contamination.
pressure greater than
seal chamber pressure. Product degradation can
occur.
Seal life can be extended
and vapour margin Ensure use with close
increased. clearance throat bushing to
maintain pressure in
stuffing box & control the
rate of contamination of
pumped media.
Careful selection of flush

fluid required to ensure
that it does not vaporize on
entering the seal chamber.

PLAN 41
Plan 41 is recirculation from pump discharge through a CYCLONE SEPARATOR,

sending clean flush through a seal flush cooler, then into the seal chamber and heavy
particles are sent back to pump suction.
Improves pressure High temperature service, Pump throat bushing is

margin to vapour typically less than 350°F. recommended.
pressure.
Dirty or contaminated fluids, Ensure use for services
Improves temperature water with sand or pipe slag. containing solids with
margin to meet specific gravity twice or
Non-polymerizing fluids.
secondary sealing more than that of process
element limits, to reduce fluid.
to fouling on waterside.
Removes entrained
solids from the process
fluid.
Particles from cyclone

separator are returned to
suction.
PLAN 51
Plan 51 uses external reservoir providing a dead-ended blanket for fluid to the quench

connection of the gland.
No direct process Preferred for clean, non- Keep pot vent continuously
leakage to atmosphere. polymerizing media with open, which is necessary
vapour pressure higher than to maintain buffer fluid
No need to maintain
buffer fluid pressure. pressure close to
pressure system as in
atmospheric pressure &
Plan 53A
vent the vapors to flare.
Should not be used in dirty

of polymerizing products.
Never run the system with

level in the sealant vessel
being at low level as
marked on the level gauge.
Vent the system properly

before start up.
PLAN 52
Plan 52 is an external reservoir, typically NONPRESSURIZED or maintained at a

pressure less than the pressure in the seal chamber. Provides BUFFER fluid for the
outer seal of a dual seal “arrangement 2”. Circulation provided for by an internal
pumping ring.

No process For media where product Keep the sealant vessel

contamination. dilution is not allowed but vent continuously open,
leakage to atmosphere in which is necessary to
No direct process
diluted form may be allowed. maintain buffer fluid
leakage to atmosphere.
pressure close to
Preferred for clean, non-
Enhanced cooling
atmospheric pressure &
polymerizing media with
available using cooling
vent the vapors to flare.
vapour pressure higher than
coils in the reservoir.
buffer fluid pressure (Is also Should not be used in dirty
Outboard seal acts as a
used for lower vapour or polymerizing products.
safety backup to the
pressure media).
A restriction orifice is
primary seal.
Best for hazardous fluids, necessary in vent line to
Zero to very low process
light hydrocarbons, heat maintain back pressure in
emissions. No process
transfer fluids and vapours pot and facilitate quick
contamination is allowed.
which are contained by a release of vapors to flare.
safety backup seal.
Pressure switch setting
Used with dual should be done above
unpressurized seals minimum flare back
(“tandem”). pressure in order to avoid
false alarms.
Never run the system with

level in the sealant vessel
being at low level as
marked on the level gauge.

Check for temperature

difference in inlet and
outlet lines to ensure that
circulation is on.

before start up.
PLAN 53A
Plan 53A is an external reservoir, PRESSURIZED greater than the seal chamber
pressure. Provides clean BARRIER fluid to a dual seal “arrangement 3”. Typically,
pressure is provided by nitrogen gas below 200 psig. Circulation is by an internal
pumping ring.
Isolate process fluid. Best for toxic, hazardous, There will always be some
polymerizing, abrasive fluids leakage of barrier fluid in to
Assure zero process
and light hydrocarbons. the product. Check
emissions.
compatibility of barrier fluid
Used for dirty, abrasive or
Clean fluid film formation
with product.
polymerizing products where
between the inboard seal
media is unsuitable as a Always ensure that the
faces gives better seal
lubricant for inboard seal pressure source maintains
life.
faces. higher pressure at the seal
Works as a Plan 52
support system so that
arrangement if barrier

fluid pressure is lost. process does not dilute the

barrier fluid.

before start up.
In certain cases, the inert

gas can dissolve in the
barrier media.
Product quality can

deteriorate due to barrier
fluid contamination.
PLAN 53B
Plan 53B utilizes a pre-pressurized BLADDER ACCUMULATOR isolating pressurized

gas from barrier fluid and providing a PRESSURIZED system greater than the process
pressure being sealed. Provides clean BARRIER fluid to a dual seal “arrangement 3”.
Circulation is by an internal pumping ring.
Keeps barrier fluid and Applications where no There will always be some
pressurized gas (inert leakage to atmosphere can leakage of barrier fluid in to
gas) separate by using a be tolerated e.g. hazardous, the product. Check
bladder. toxic, inflammable media. compatibility of barrier fluid
with product.
Heat is removed from the For dirty, abrasive or
circulation system by an polymerizing products where Low volume of barrier fluid

air-cooled or water- media is unsuitable as a in system, hence heat

cooled heat exchanger. lubricant for inboard seal dissipation is totally
faces. dependent on cooler
Being a stand-alone
efficiency.
system does not rely
upon a central pressure Always recharge bladder
source. Hence much to 0.9 times the working
more reliable than a Plan pressure.
53A.
Isolate process fluid. before start up.
Zero process emissions. Product quality can

faces gives better seal Cannot be used where
life. seal chamber pressure
varies. Use Plan 53C for
such applications.
PLAN 53C
Plan 53C utilizes a reference line from the process in the seal chamber as a pressure
source to a PISTON ACCUMULATOR. Provides a PRESSURIZED system greater
than the process pressure being sealed, providing clean BARRIER fluid to a dual seal
“arrangement 3”. Circulation is by an internal pumping ring.

There will always be Applications where no Always connect reference

some leakage of barrier leakage to atmosphere can pressure line from seal
fluid in to the product. be tolerated e.g. hazardous, chamber to accumulator
Check compatibility of toxic, inflammable media. and keep it open.
barrier fluid with product.
For dirty, abrasive or There will always be some
Vent system properly polymerizing products where leakage of barrier fluid in to
before start up. media is unsuitable as a the product. Check
lubricant for inboard seal compatibility of barrier fluid
Heat is removed from the
faces. with product.
circulation system by an
air-cooled or water- Where pump pressure varies Vent the system properly
cooled heat exchanger. during operation needing an before start up.
auto setting of barrier fluid
In no case media Product quality can
pressure, thus maintaining
leakage to atmosphere. deteriorate due to barrier
the same differential
throughout.
faces gives better seal
life.
PLAN 54
Plan 54 is an external system supplying clean BARRIER fluid to a dual seal

“arrangement 3” at greater pressure than the process pressure being sealed. Pressure
and circulation are provided for by an external pump or pressure system.

Advantages same as Applications where no Carefully consider the

Plan 53A but provides leakage to atmosphere can reliability of barrier fluid
excellent circulation and be tolerated e.g. hazardous, source, if a central source
cooling. toxic, inflammable. is used.
Ensures higher flow rate, For dirty, abrasives or Expensive system, proper
better heat dissipation & polymerizing products where engineering required.
positive circulation of media is unsuitable as a
Circulating system must be
barrier fluid. lubricant for inboard seal
pressurized at least 1.5 bar
faces.
If maintained properly, is greater that the pressure in
the most reliable For media with high pressure the seal chamber.
pressurized plan for dual and / or high temperature
Product contamination
seals as compared to and / or high heat generation
does occur. Barrier fluid
Plan 53 A/B/C. between faces.
selected should be
Can also be given as a Wherever Plan 53 A/B/C compatible with the
standalone unit per circulation is insufficient to process fluid.
pump. dissipate heat.
Always check filter /
strainer in the system for
any possible blockages.
Loss of pressure in system

can lead to entire barrier
liquid contamination.
Product quality can

PLAN 61
Plan 61 is plugged connections for future use for Plan 62 or Plan 65. Typically, this
plan is used when the purchaser is to provide fluid (such as steam, gas, or water) to
an external sealing device.

The drain connection can For future provision. Always keep ports
be piped in order to plugged.
collect leakage and use
as Plan 65.
Both quench & drain can

be piped and used as
quench in and out
connection as Plan 62.
PLAN 62
Plan 62 is an external source supplying quench (nitrogen, water, steam, etc.) on the
atmosphere side of the seal. Typically used with a throttle bushing or auxiliary sealing
device for containment.
The quench fluid acts as In caustic or crystallising Ensure availability of

barrier in between fluids. continuous supply of low-
atmosphere and process pressure quench fluid
In oxidising fluids or hot

fluid. hydrocarbons. limited to maximum 1 bar.
The quench fluid reduces Can be used to purge steam Use of throttle bushing on
oxidation and cocking of in hot applications especially atmosphere side is
product & also cools seal for stationary bellows to mandatory.
faces. avoid coking.
Use proper bearing
Flushes away Used with single seals. isolators to ensure that the
undesirable material quench fluid does not enter
build up under seal the bearings.
faces.
Can be used with water,

steam or an inert gas.
PLAN 65
Plan 65 is a liquid leakage detection system measured by a level switch, arranged to

set off an alarm when EXCESSIVE leakage occurs. Normally for single seals
“arrangement 1”. The orifice downstream of the level switch is typically 1/4” located in
a vertical piping leg. Includes a bypass around the orifice to prevent pressure build up.
Use with close clearance gland throttle bushing.
The quench fluid acts as In services where seal Vent connection should
barrier in between leakage is condensing. always be plugged.
atmosphere and process
Used for single seals. Orifice downstream of the
fluid.
level switch should be

The quench fluid reduces Used for remote locations located in vertical piping
oxidation and cocking of and critical processes. leg to avoid accumulation
product & also cools seal of fluid in drain piping.
May be used with Plan 62
faces.
quench to reduce Shut down the pump as
Flushes away oxidation/coking build-up. soon as high-level alarm is
undesirable material activated & attend the seal.
build up under seal
faces.
Can be used with water,

steam or an inert gas.
Safely control continuous

draining to liquid
collection system and
alarm or shut pump down
when excessive.
Safety indicator for

primary seal to detect
failure.
PLAN 72
Plan 72 is an external control system supplying a “whisper” of BUFFER gas (typically

Nitrogen) at less pressure than the process pressure being sealed, to a dual gas seal
“arrangement 2”, with a dry running containment seal. Used alone to dilute seal
leakage or in conjunction with Plan 75 or 76 to help sweep seal leakage into a closed
collection system.

Zero to very low process Used with dual Always keep the ports
emissions. unpressurized containment plugged.
seals (“tandem”).
Safety backup to primary
seal. High vapour pressure fluids,
light hydrocarbons.
Remove moisture, filter
the gas and regulate the Hazardous/toxic fluids.
pressure to the seal.
Clean, non-polymerizing,
non-oxidizing fluids.
Used in combination with

Plan 75 and/or Plan 76.
PLAN 74
Plan 74 is an external control system supplying BARRIER gas (typically Nitrogen) at

greater pressure than the process pressure being sealed, to a dual gas seal
“arrangement 3”.

Features Uses
Prevent process from Best for hazardous, non-

leaking to the polymerizing, non-oxidizing
atmosphere. fluids, light hydrocarbons
and vapours.
Remove moisture, filter
the gas and regulate the Lower cost and maintenance
pressure to the seal. than dual liquid systems.
Zero process emissions. Used with dual pressurized

gas seals (“double”).
PLAN 75
Plan 75 is a containment seal chamber which allows draining of condensing leakage

on dual seals “arrangement 2”. The collection system is located below the seal
chamber and uses an orifice and a pressure switch to detect high vapour leak rates.
Typically used with contacting secondary containment seals.

Can be used with Plan Best for processes that Ensure that collection
72 with buffer gas. condense at ambient system is located below
temperatures. Can be used the seal drain with sloping
Collection can be
with Plan 72 to sweep the pipelines.
redirected to process
leakage into the containment
fluid by using separate Drain port should be at
system.
pumping device. bottom of containment seal
Hazardous, toxic fluids. to allow the leakage to flow
Can be used in single
to the collection system.
containment seal also. May also be used for non-
condensing leakages. In Collection system should
Test connection is
such cases, the collector can always be vented releasing
provided to check the
help in collecting condensate vapours of process liquid
inner seal by closing the
from the vapour recovery to vapour recovery system.
block isolation valve
system.
while pump is in Valves that are installed
operation and noting the High vapour pressure fluids, should be accessible to
time / pressure build-up light hydrocarbons. operator relative to ground
relationship in the clearance and other
collector. obstructions.
A flow control orifice is

required to create back
pressure on collection
system and to have
effective condensation of

vapors.
Pressure switch should be

set at a gauge pressure of
0.7 bar.
PLAN 76
Plan 76 is a containment seal chamber which allows venting of noncondensing

leakage from a dual seal “arrangement 2”, to a flare or vapour recovery system.
Leakage collection for Best for processes that Do not use for condensing
zero to very low process vaporize at ambient media.
emissions. temperatures.
Ensure continuous vent to
Vent leakage to recovery Is used with contacting or low pressure vapor
while monitoring leak rate non-contacting containment recovery or flare system.
by sizing the orifice to seals.
Tubing shall be 13mm
allow maximum leakage.
Less expensive than dual (1/2”) minimum diameter
Pressure switch will shut seals using Plan 52. and shall rise continuously
down the pump if the from the CSV connection
High vapour pressure fluids,
leak rate is excessive. to the piping /
light hydrocarbons.
instrumentation harness.
Hazardous/toxic fluids.
A flow control orifice is
Clean, non-polymerizing,

non-oxidizing fluids. required to generate back

pressure.
Ensure proper support to

harness piping.
Ensure a low point drain in

the piping loop.
Recommended Guidelines for appropriate Seal Flush Plan Selection
Different seal flushing scenarios have considerations that are specific to each. In general,
following points may be noted:
1. For hydrocarbon service with no known solid particles and temperature under 300°F,
assuming satisfactory vapour margin (approximately 50 psi) above vapour pressure in
seal chamber
Plan 11 would be the optimal choice.
Plan 13 or 14 would be choice for vertical pumps that would require venting of
the seal chamber back to suction.
Plan 52, 53 or 54 would be recommended in low S.G. (<0.7) services.
2. For clean hydrocarbon service between 300 and 450°F:
Plan 23 is the most efficient in cooling, however proper installation and venting
is required.
Plan 21 will be sufficient in most cases and will be easier to operate (Note that
the orifice sizing is critical here as this determines the velocity of the fluid
through the heat exchanger.
3. For hot oil service above 450°F:
Plan 32 is the most reliable/cost effective single seal, if a reliable source is

available nearby (Note that if the source is a product that has to be reprocessed
it may not be cost effective.

Plan 53 or 54, if Plan 32 is deemed not feasible and a dual pressurized seal
would be desired.
4. For Acid Service:
Plan 32 (single seal option) can be used; however, it is very critical for it to be
operating at times when pump is installed in field (standby and start-up
situations).
Plan 53/54 (Dual Seal options) will give the optimal seal life with ease of
operation (Note that process side seal components will need to be constructed
for materials that are corrosion resistant to the particular acid) or Non -
contacting Plan 74 may be another alternative.
5. For Dirty Service (containing suspended solid particles):
Plan 31 with a cyclone separator can be effective; however, it must be sized correctly
and particle size must not fluctuate greatly. Plan 32 with clean external flush source is
an alternative.
Plan 54 for dual seals will isolate the seal faces from solids that can cause premature
failure due to abrasion.
Rules of Thumb
Summarizing, the most popular seal flush plans are….
1. API Plan 01: Recommended for clean fluids only.
2. API Plan 02: It is more common in the chemical industry in application with low seal
chamber pressures and process temperatures.
3. API Plan 11: The default seal flush plan for all single seals.
4. API Plan 13: The standard flush plan for vertical pumps that are not provided with a
bleed bushing below the seal chamber.
5. API Plan 23: This is a plan of choice for all hot water services, particularly boiler feed
water, and many hydrocarbon services.
6. API Plan 32: For a service containing solids or contaminants and where a suitable
cleaner or cooler external flush will improve the seal environment.

7. API Plan 52: It is used in a service where no leakage to atmosphere can be tolerated.
8. API Plan 53A, 53B and 53C: Pressurized dual seal systems are used in services where
no leakage to atmosphere can be tolerated.
9. API Plan 54: Pressurized dual seal system with inner seal leakage into the pumped
product.
10. API Plan 62: A quench stream is brought from an external source to the atmospheric
side of the seal faces.
11. API Plan 72: Unpressurized dual seals which also use a dry containment seal.
12. API Plan 75: Unpressurized dual seals, which also utilize a dry containment seal and
where the leakage from the inner seal may condense.
13. API Plan 76: Unpressurized dual seals which also utilize a dry containment seal and
where leakage from the inner seal will not condense.
********

CHAPTER - 9
INSTALLATION, START-UP and TROUBLE SHOOTING
Heat effects are the major cause of failure in mechanical face seals used in pumps, mixers,
agitators and wherever a rotating shaft passes through the housing of a machine. Improper
design, installation or maintenance of seals can lead to overheating and catastrophic failure of
a system, endangering the safety of plant operators and posing an environmental hazard as a
result of pollution associated with leakage from seals.
Installation Instructions
A component seal is one where each part of the seal must be assembled on the equipment
individually. This requires considerable skill and significant time as compared to installation of
a cartridge seal. During installation of a mechanical seal take care of following.
a. Assemble seal parts in a clean environment.
b. Do not use hammer for assembly as seal faces are delicate and may crack / break.
c. Check that seal parts, gland and stuffing box are free from burrs, sharp edged and
deep scratches / damage.
d. Check surface finish at elastomer area to be as per manufacturer’s recommendation.
e. Check that set screws on either the rotary unit or the drive collar of the seal assembly
are free in the threads.
f. Confirm hardness of shaft / sleeve to be such that after tightening set screws, rotating
assembly does not get loose (if set screws are tightened against a hard surface, they
will fail to hold assembly in desired position during operation). Alternatively, use
hardened set screws.
g. It is a good practice to check fitting of shaft sleeve, rotary assembly and gland without
O-Rings to ensure that are fitting freely before assembling them with O-Rings.
h. Use correct size O-Rings at all places.
i. Do not use used O-Rings and gaskets.
j. Never use "glued together" O-Ring for any "dynamic" application. A hard spot will be
created that will interfere with the movement of the O-Ring.

k. Lubricate shaft and secondary seal (O-Rings / bellows) as per manufacturer’s

recommendation. If assembling is difficult, apply water as lubrication. Rubber bellow
seals should be lubricated with Vaseline. Don’t apply silicon grease on them. EPR
(Ethylene Propylene Rubber) elastomers should not be lubricated with petroleum
based oil. For EPR material use silicon grease.
l. Install seal at its correct operating length as per manufacturer’s drawing.
m. Check direction of helix of coil for single spring seal. Helix should be R.H. for C.W.
rotation and L.H. for C.C.W. rotation when looking at seal face.
n. Gland bolts or nuts should be tightened only enough to affect a gasket seal at the
stuffing box face. This can be achieved by initial finger tightening and further tightening
with ½ to ¾ turns. Over tightening could result in distortion of seal faces.
o. Cartridge type seal assemblies are provided with axial location plates that hold the
assembly together before installation in the equipment. Make sure that the axial
location plates are moved out of the grooves provided on the shaft sleeve after their
fitting.
p. When seal assembly is complete, connect all piping, check that all environmental
controls have been connected, and all unused holes in the stuffing box / gland are
plugged.
Start-up Procedure
Startups can be particularly hard on mechanical seals. Always ensure that the pump seal
chamber is filled with appropriate liquid so the seal does not start dry. Otherwise, initial dry
start damage will progress to a severe leak. Dirt and other fines will also deteriorate the
surface finish of the mechanical seal faces resulting in premature leakage.
Take care of following before starting equipment and its operation for the first time after
installation of mechanical seal.
a. Equipment should be aligned with the drive as per manufacturer’s recommendations.
b. Check the shaft for free movement. Manually rotate the shaft several turns. If shaft
binds due to any reason, investigate and correct it.
c. Activate all auxiliary systems like flush, quench, barrier lines and vent the stuffing box
until all trapped air has been released.

d. Pump should have adequate NPSH and it should work without cavitation’s and
vibration.
e. No noise should come from stuffing box.
f. Excessive heat generation should not be there. This may be due to stationary parts
contacting the rotating shaft or rotating seal parts contacting the housing of the
equipment.
g. Examine the seal. Slight leakage should stop when the faces “wear in”.
Common Failures
If you have mechanical seals that have failed, it is important to look at them to determine what
caused the failure. There are many factors that cause failure:
1. Chemical Degradation: The mechanical seals may exhibit many signs of degradation
including blisters, cracks, voids or discoloration. It may be honey combed, flaky or
starting to crumble. In some cases, the degradation is observable only by
measurement of physical properties.
2. Extrusion or Nibbling: The mechanical seals develop ragged edges (generally on the
low-pressure side) which appear tattered.
3. Thermal Degradation: The seals may exhibit radial cracks located on the highest
temperature surfaces. In addition, certain elastomers may exhibit signs of softening - a
shiny surface as a result of excessive temperatures.
4. Fretting Corrosion: This causes leakage at the secondary seals and will cause
problems with the sleeve directly beneath the secondary seal area. This area will be
pitted and shiny.
5. Vaporization: You will see places on the seal faces where vapor was blown out. There
will be chipping on the inside and outside diameters and the whole area will be pitted.
6. Oxidation & Coking: The mechanical seals will have a film or sludge on the side that
is exposed to the atmosphere. This not only can lead to the seal faces wearing quicker
than usual, but it can cause the seals to want to hang up.
The operating life of a mechanical seal is complete when either face has worn entirely.
Whenever a mechanical seal has failed, no matter what the length of service, a thorough
inspection should be made to determine the cause of failure. If either face has completely

worn, the cause of failure is evident and no further inspection is required unless this occurred
in very storm time. If both faces are intact, then inspection should continue using standard
troubleshooting procedures.
Trouble Shooting
Possible cause Description Corrective action
Corrosion Is found exclusively on Check the Seal Selection

cemented carbide seal and Compatibility for a
faces and can be identified more corrosion resistant
by scratching the surface seal face material.
with a knife or needle. If
material comes loose, the
seal face is corroded.
Thermo cracks Are caused by thermal Check the mounting of the

overloads, resulting from, seal.
for example, extensive
Check its operating
dry‑running or excessive conditions.
seal face pressure.
If the faces are made of
Excessively high face
aluminum oxide upgrade
loads can, in turn, be
to cemented carbide or
caused by a spring that is
silicon carbide.
fully compressed because
of incorrect mounting (or Use level switches to
mounting dimensions), or eliminate dry‑running.

a media pressure in
excess of the seal’s
pressure limit.
Coupling Misalignment Improperly aligned Adjust the motor side only.

couplings frequently cause
Alignment Methods:
seal and bearing failures.
Dial Indicator Method
Vibration generated by

misalignment causes Straight Edge

chipped or broken faces,
Laser Equipment
as well as overheated and
damaged bearings.
Pitting or blistering Is encountered on carbon Change to cemented

faces and is most likely to carbide in both seal faces.
occur on pumps that run
continuously.
Slide marks Appear on the backside of Check mounting and

the seal ring and indicate torque locks.
that the seal ring has been
rotating relative to its
retaining structure (when it
should have been
stationary).
Chemical attack Appears in the form of Check the media and

cracks, discoloration or select compatible material.
volume increase. A
volume increase may
manifest itself by extrusion
distortions.
Irreversible set Failure of the O‑ring to Check for low oil volume if
adopt its original shape the inner seal is affected.
after being dismantled.
This is caused by
excessive temperature.
Tearing Usually originates from Replace O‑rings.

mounting without grease
Check for sharp edges in
and/ or sharp edges on
the O-ring chamfer.
the components

surrounding the O‑ring.

Always use plenty of
grease when mounting
seals and smooth all
surrounding surfaces with
an emery cloth before
assembly.
Mechanical wear Or a “burnt” appearance is Check mounting and

most often caused by torque locks.
incorrect rotation between
the seal ring and its
retaining structure.
Broken spring Usually the consequence Check the mounting.

of angular misalignment of
Check the corrosive
the stationary seal ring in
properties of the media
relation to the shaft. This
and select appropriate
forces the spring‑loaded materials.
ring to constantly alter its
Check that the shaft runs
position, which eventually
true according to the
leads to fatigue and
“Shaft Deviations”.
rupturing of the spring.
Another possible cause is
chemical attack.
Clogging Occurs when the spring Change to a more

loaded face fails to exert clog‑resistant design.
pressure against the
Consider seal flushing.
opposite face because its
spring, and/ or
semi‑dynamic static seal,
is clogged by debris.

Jammed spring action Caused by wear between Replace or polish worn

moving and stationary parts.
parts in the spring
Check that the shaft runs
arrangement. It’s
true according to “Shaft
particulary important to
Deviations”.
check for this when
replacing seals of Type S
design, because the
spring arrangement is not
included in the
replacement unit.
Shaft deviations Are harmful to the seal’s Gauge the shaft and the
performance and must be seal seat.
kept within narrow limits.
*********

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PDHonline Course M604 (4 PDH)

Centrifugal Pumps and Mechanical Seals

PDH Online | PDH Center

An Approved Continuing Education Provider

Centrifugal Pumps and Mechanical Seals

©2016 A.Bhatia Page 2 of 105

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3. Magnetic drives (seal-less pumps)

Low upfront cost.

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Poor seal for thin liquids, especially at higher pressures.

Vibrations and misalignment will cause this seal type to leak.

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Other types of axial seals are “non-mechanical” ones, such as V-Rings.

Requires less periodic maintenance than packing.

Can be applied to higher pressures, temperatures and shaft speeds.

Less tolerant to shaft deflection and misalignment.

Require expensive seal piping to flush and quench.

Magnetic Drive Seal-less Pump

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More expensive than most shaft seal options.

Comparison between Mechanical Seal and Gland Packing

Parameters Mechanical Seal Gland Packing

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and to avoid seizure

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Basic Seal Types

Dynamic “Radial” Seals

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We will focus on face type axial mechanical seals in this course.

How does seal hydraulic balance work?

There are two forces closing the seal faces.

There are three forces opening the mechanical seal:

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Sealing Systems for Pumps

The mechanical seals for pumps are available in diverse ranges:

Shaft diameters from about 5 to 630 mm

Shaft speeds up to 50,000 rpm

Pressures from about 0.01 to 300 bar

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Temperatures from about – 200 to + 450°C

Sliding rates of up to about 150 m/s.

Why Mechanical Seals

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Mechanical Seals also offer the following advantages: -

1. Plant down time losses eliminated

3. Protection from health hazard in chemical handling

6. Negligible replacement of spare parts

7. Better bearing life

Components of Face Seals

There are the four essential components of a mechanical seal:

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Two hard faces are normally selected:

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With any of the oxidizing agents.

When sealing any of the halogens.

If the product tends to stick the faces together.

Some de-ionized water will attack carbon in any form.

Any time carbon/graphite will not work for some reason.

Point A – Shaft /sleeve O - ring

Point B – Gland gasket

Point C – Rotary Face