CONSTRUCTION MAINTENANCE

DEPARTMENT

MECHANICAL TECHNICIAN
QUALIFICATION MODULE

MECHANICAL SEAL TRAINING

COURSE

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 Introduction

 Mechanical Seals is a device which absolutely prevents the leakage

of pressurized fluid along a rotary shaft in equipments such as
pumps, compressors, agitators, etc. This device replaces the
conventional method of sealing, viz gland ropes.
 Main Menu
Definition Flash Cards
Primary Seal

Secondary Seal

Hands-on Exercise

Seal Arrangement

How A Seal Works ?

Basic Mechanical seal

Hydraulic Balance Seals

Types Of Mechanical Seals EXIT

 Definition

 Advantages of mechanical seals over conventional packing are as

follows:
 Zero or limited leakage of product (meet emission regulations.)
 Reduced friction and power loss.
 Elimination of shaft or sleeve wear.
 Reduced maintenance costs.
 Ability to seal higher pressures and more corrosive environments.
 The wide variety of designs allows use of mechanical seals in almost
all pump applications.

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 The Basic Mechanical Seal

 All mechanical seals are constructed of three basic sets of parts as

shown in Fig.

1. A set of primary seal faces: one rotary and one stationary…shown in

Fig. as seal ring and insert.

2. A set of secondary seals known as shaft pickings and insert mountings

such as 0-rings, wedges and V-rings.

3. Mechanical seal hardware including gland rings, collars, compression

rings, pins, springs and bellows.

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 Conventional “Wet” Mechanical Seals
Basic Mechanical Seal - 1

Loose ring set screwed to the shaft.

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Basic Mechanical Seal - 2 Wear here will create leakage.
Wear here will create leakage.

O-ring prevents leakage through the bore.

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Basic Mechanical Seal - 3
Leak path
Large component.
Heat generated here

Spring ensures automatic adjustment

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Basic Mechanical Seal - 4 Gasket or O-ring
Recirculation
for cooling

Secondary Seal Tertiary Seal.

Primary Seal
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Basic Mechanical Seal - 5
Spring or Spring Force. Seat or Mating Ring

Face or Primary Ring

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Spring Drive

Left hand or right hand spring?

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 How A Mechanical Seal Works

The primary sealing is achieved by two

very flat, lapped faces which create a
difficult leakage path perpendicular to
the shaft. Rubbing contact between
these two flat mating surfaces
minimizes leakage. As in all seals, one
face is held stationary in a housing and
the other face is fixed to, and rotates
with, the shaft. Dissimilar materials are
usually used for the stationary insert
and the rotating seal ring face in order
to prevent adhesion of the two faces.

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 How A Mechanical Seal Works

There are four main sealing points

within an end face mechanical seal.
The primary seal is at the seal face,
Point A. The leakage path at Point B
is blocked by either an 0-ring, a V-
ring or a wedge. Leakage paths at
Points C and D are blocked by
gaskets or 0-rings.

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 Mechanical Seal Types
 Mechanical seals can be classified into several types and
arrangements.

PUSHER:
pusher mechanical seal incorporates a
secondary o-ring; for example, that is
responsible for sealing the fluid path
between the pump shaft and the inside
diameter of the rotating seal face. As the
seal face wears and is hydraulically; by
stuffing box pressure, and mechanically;
by means of spring tension, compressed
against the stationary face the o-ring
moves along the pump shaft to
accommodate this wear and assist in the
absorption of shaft misalignment.
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 Mechanical Seal Types

UNBALANCED:
They are inexpensive, leak less, and
are more stable when subjected to
vibration, misalignment, and
cavitations. The disadvantage is
their relative low pressure limit. If
the closing force exerted on the
seal faces exceeds the pressure
limit, the lubricating film between
the faces is squeezed out and the
highly loaded dry running seal fails.

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 Mechanical Seal Types

CONVENTIONAL:
Examples are the Dura RO and Crane
Type 1 which require setting and
alignment of the seal (single, double,
tandem) on the shaft or sleeve of the
pump. Although setting a mechanical
seal is relatively simple, today's
emphasis on reducing maintenance
costs has increased preference for
cartridge seals.

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 Mechanical Seal Types

NON-PUSHER:
In a non-pusher seal the secondary
seal; o-ring for example, is in a static
state at all times, even when the
pump is in operation. The secondary
sealing member is not required to
make up the travel as the rotary and
stationary seal faces wear. Primary
seal face wear is typically
accommodated by welded or
elastomeric bellows which move;
expand, to assist in the compression
of the rotary to stationary seal face HOME
members.
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 Mechanical Seal Types

BALANCED:
Balancing a mechanical seal
involves a simple design change,
which reduces the hydraulic forces
acting to close the seal faces.
Balanced seals have higher-
pressure limits, lower seal face
loading, and generate less heat. This
makes them well suited to handle
liquids with poor lubricity and high
vapor pressures such as light
hydrocarbons.
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 Mechanical Seal Types

CARTRIDGE:
which have the mechanical seal pre-
mounted on a sleeve including the
gland and fit directly over the Model
3196 shaft or shaft sleeve (available
single, double, tandem). The major
benefit, of course is no requirement for
the usual seal setting measurements for
their installation. Cartridge seals lower
maintenance costs and reduce seal
setting errors

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 Summary

 Mechanical seals prevent leakage.

 Rubbing faces are lubricated by fluid film.

 Fluid film must be present, stable, clean,

reasonable temperature and viscosity.

 Seals must be fitted in clean conditions and

with accuracy.

 Two types of seal: pusher and non-pusher.

Each has its advantages.
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 Summary

 Seal life (MTBF) affected by:

 Condition of pump.

 State of pumped product in pump.

 State of pumped product through the faces

dry running.

 Excessive heat generation/inadequate cooling.

 Pressure peaks.

 Change in process fluid.

 Sudden temperature changes.

 Stop/Start. HOME

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 Summary

 Fit mechanical seals accurately and in clean

conditions and operate pumps with a little care and
understanding, and the seals will last for years.

 If a seal fails prematurely, carry out detailed failure

analysis before fitting a new one whenever possible.

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 Mechanical Seal Theory
Primary Seal

Face or Seat or
Primary Mating
Ring Ring

Springs

Higher pressure on outside diameter.

Higher pressure holds faces closed.
Fluid is forced between faces to lubricate.
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Springs keep faces closed when no pressure.
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 Primary Seal

 Fluid film thickness is very important.

 too thin - wear, causing early seal failure
 too thick - visible leakage

 Must be:
 present - beware dry running
 stable
 clean - beware abrasive wear symptoms
 reasonable viscosity
 temperature controlled
 acceptable pressure.

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Abrasive Wear

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Abrasives or no lubrication?

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Primary Seal - Abrasives

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 Cyclone Separator

To mechanical seal

From pump discharge

To pump suction

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Coning Out

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Coning In

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Primary Seal

 Excessive start / stop operation.

 Will drastically reduce seal life (MTBF - Mean Time

Between Failure).

 Wear occurs between faces at start-up.

• No lubricating fluid film present.

 Wear on drive mechanism.

• Can cause lock-up / bayoneting.

 Is start / stop operation necessary?

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Primary Seal

If faces is not flat, contact generates heat

Excessive wear - short life
1 light band = 0.0000116 inch or 0.0003 mm.

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Film thickness = leakage

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Primary Seal
 Face (Primary Ring-Narrow) Materials

 Carbon-graphite
• Resin impregnated
• Antimony impregnated

 Carbon converted to Silicon Carbide

• Resin impregnated

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Carbon converted to
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Silicon Carbide
Primary Seal

 Face (Primary Ring-Narrow) Materials

 Carbon-graphite
• Resin impregnated
• Antimony impregnated

 Carbon converted to Silicon Carbide

• Resin impregnated

 Solid Silicon Carbide

• Pure sintered
• Reaction bonded

 Tungsten Carbide HOME

• Nickel or cobalt bonded.
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Primary Seal

 Seat (Mating Ring) Materials

 Ni-resist
• High nickel cast iron; austenitic cast iron

 Ceramic
• 99.7% aluminium oxide

Mating Rings: Ceramic

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 Primary Seal - Summary

 A mechanical seal is self-adjusting for wear.

 Has three main parts :-

 Primary ring (narrower running face).
 Mating ring (wider running face - harder).
 Spring Force.

 Usually the mating ring is stationary & the primary ring rotates with
the shaft.

 The liquid film between the primary ring & mating ring is only 0.5 -
3.0 microns thick.

 There are three main sealing areas :-

 Primary Seal - Primary ring & Mating ring.
 Secondary Seal - Primary ring & Shaft.
 Tertiary Seal - Mating ring & Housing.
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 Mechanical Seal Theory
Secondary Seal

 Three basic forms  Two groups

 o-rings Pusher
 wedges  sliding o-rings
 bellows  wedges
 Elastomer
 non-pusher
 Metal

 Formed  bellows.

 Edge welded
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 PTFE
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Secondary Seal : PUSHER

As face moves forward to take up wear.

The o-ring moves forward with the face.

Pushed by the hydraulic and spring pressures.
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 Secondary Seal : PUSHER

Positive drive Optimised cooling flow

Compact

multiple
springs

Optimised
face design

A typical pusher seal design for low emission duties.

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 Secondary Seal : PUSHER
 Advantages
 Sudden failure very unlikely

 Higher pressure capability - face not stressed

 Wide choice of materials for all components

 Field repairable

 Disadvantages
 Hang-up (not likely where o-ring is well isolated)

 Permanent set / pressure problems (cause hang-up)

 Excellent shaft surface finish required

 Maximum temperature ~260°C.

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 Secondary Seal : PUSHER
Pusher Seal: Hang-up

An external quench will

prevent hang-up

Product leakage solidifies / crystallises / polymerises HOME

This prevents o-ring pushing forward - leakage increases
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 Secondary Seal : PUSHER
Pusher Seal: Hang-up

Excessive pressure and / or heat: HOME

permanent set or extrusion
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Secondary Seal: O-Ring

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Type R*OL/R
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 Secondary Seal: O-Ring

O-Ring
Type 8B1 HOME

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 Secondary Seal: O-rings

 Nitrile
 -40°C to 100°C (Hydrocarbons 120°C)

 Ethylene Propylene (avoid oil/hydrocarbons)

 -40°C to 135°C (Water 150°C)

 Fluorocarbon (e.g., Viton)

 -30°C to 200°C* (Water 115°C - Max. in Steam
135°C)

 Perfluoroeleastomer (e.g., Isolast, Kalrez)

 -20°C to 215 / 315°C*

 Chloroprene - ideal for refrigeration duties

 -40°C to 100°C
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 Secondary Seal: Wedge

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Wedge
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 Secondary Seal: Wedge

Wedge

Type 109B HOME

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 Secondary Seal: Bellows
No contact here.

Elastomer Bellows grips shaft tightly HOME

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 Secondary Seal: Non-Pusher

Bellows flexes to take up wear, misalignment and axial play

Fine machined shaft surface required
Do not use a “good” lubricant - never use silicon grease.
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 Elastomer Bellows Seals

Type 502

Type 2
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 Secondary Seal: Non-Pusher

No movement here. No contact

here. HOME
Bellows expands to
take up wear
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 Secondary Seal: Non-Pusher

 Advantages
 Temperatures to 430°C (or more)
 No hang-up
 Non-clogging
 Fine machined shaft surface
 Acceptable

 Disadvantages
 Sudden failure possible
 (“flashing” or misalignment)
 Limited material choice
 Maximum pressure 35 bar g (2-ply to 65 bar g).

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 Hands-on Exercise

Fit a Type 2 Elastomer Bellows Seal

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Hands-on Exercise

Fitting a Type 2
Elastomer Bellows Seal

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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

(1)

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1 Lightly scribe first datum line (1) on shaft.
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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

(1)

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2 Dismantle pump – remove seal chamber.
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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

‘X’

Gasket

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3. Fit Mating Ring into Gland Plate.
Measure dimension ‘X’. EXIT
 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

‘X’

(2)
(1)

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4 Scribe line (2) ‘X’ mm outboard of line (1).
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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal
Note this dimension from line (3) to
end of shaft or a shaft step.

‘Z’

‘X’

(2)
(3) (1)

L3
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5 Scribe line (3) L3 mm inboard of line (2),
L3 is the working length of the seal unit (See Fitting Instructions).
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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal
Lubricate shaft with suitable lubricant On single-ended pumps, first slide
gland plate onto shaft, taking care
not to damage the mating ring

Suitable pushing sleeve

(2)
(3) (1)

6 Pushing on the tail of the bellows, slide seal head into position, passed
line
(3). NB: Spring and Locating Ring removed.
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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

(2)
(3) (1)

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7 Replace spring and spring locating ring.
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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal
Check this dimension from line (3) to
end of shaft or a shaft step.

‘Z’

(2)
(3) (1)

8 Ensure setscrews are withdrawn sufficiently to clear shaft and slide abutment
ring into position abutting line (3).

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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

(2)
(3) (1)

9 Check ring is square. Tighten setscrews. Refit seal chamber. Ensure lapped
faces are perfectly clean & dry.

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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

(2)
(3) (1)

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10 Insert gland plate into seal chamber.
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 Hands-on Exercise
Fitting a Type 2 Elastomer Bellows Seal

(2)
(3) (1)

L3
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11 Insert and evenly tighten 4 bolts, gently compressing seal to
its working length (L3). EXIT
 Hands-on Exercise
Assemble and Fit a Type 109 PTFE Wedge Seal

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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

(1)

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1 Scribe first datum line (1) on shaft.
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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

(1)

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2 Remove shaft from seal chamber.
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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

‘X’

Gasket

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3 Measure dimension ‘X’.
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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

‘X’

(2) (1)

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4 Scribe line (2) ‘X’ mm inboard of line (1).
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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

‘X’

(3) (2) (1)

L3
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5 Scribe line (3) L3 mm inboard of line (2),
L3 is the working length of the seal unit (see Fitting Instructions). EXIT
 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

(3) (2) (1)

6 Ensure setscrews are withdrawn sufficiently to clear shaft and

slide seal into position abutting line (3). HOME

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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

(3) (2) (1)

7 Tighten setscrews and replace shaft / seal in seal chamber. HOME

Ensure running faces are perfectly clean and dry.
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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal
‘A’

(3) (2) (1)

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8 Insert gland plate into seal chamber. Check gap ‘A’.
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 Hands-on Exercise
Fitting a Type 109 PTFE Wedge Seal

(3) (2) (1)

L3
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9 Insert and evenly tighten 4 bolts, gently
compressing seal to its working length (L3). EXIT
Holding Clips - Wedge Seals

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 Heat / Temperature Control
Heat in Stuffing Box
 Two sources of heat.
 heat soak from the product
 heat generated by the seal

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 Heat generation: the problem

 Pressure drops to
atmospheric

 Temperature increases
(~20°C)

 Fluid film thickness reduces

or disappears

 Premature failure.

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 Heat generation - the causes

 Size
 Speed
 Temperature
 Cooling
 Product properties
 Flush or multiple
 Surface finish - faces
 Materials of faces
 Hydraulic pressure
Too much heat generated
• Dry-running
• Excessive wear
• Very short seal life
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Hydraulic Balance

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Hydraulic Balance

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Hydraulic Balance

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Hydraulic Balance

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Hydraulic Balance

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 Hydraulic Balance

Pressure = 10 kg/cm2
50%
125%
10

cm2
0.8
cm2
1
0

125% - 50% = 75% (7.5 bar)

75% 50%
10

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75% - 50% = 25% (2.5 bar)

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 Hydraulic Balance

Unbalanced Pusher Seal Balanced Pusher seal

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 Hydraulic Balance - Benefits
 Reduced heat generation
– Ideal for unstable and low SG fluids
– Less heat to be dissipated - less cooling required

 Reduced wear rate

– Longer life

 Reduced power required to drive the seal

– Lower running costs

 Increased pressure range for the seal

– This simple modification allows much higher pressures to be sealed.

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 Mechanical Seal Arrangements

 Mechanical seals are arranged in different ways as per the API Plan.
Single Seals can be mounted internally, externally or internally mounted
with rotating counter ring.. They can be either balanced, unbalanced, with
or without circulation or flushing of seal faces, with or without throttle
bushes.

 As for Double Mechanical seals, either one of the seals can be

unbalanced or balanced on its own or both together. It can be arranged in
back to back, face to face, or tandem arrangement.

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 Mechanical Seal Arrangements

• Use multiple seals if:

– fluid is toxic
– fluid is flammable
– environmental
– isolation required
– fluid changes state
– fluid is not a good lubricant
or is a gas
– fluid is unstable
– dry running likely
– expensive product
Single seals utilise process fluid to – critical pump
provide the lubricating interface film

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 Mechanical Seal Arrangements

• Two common arrangements

– Tandem
• low pressure buffer fluid
• high integrity secondary containment
• inboard seal lubricated by product

– Back-to-Back (Double)
• pressurised barrier fluid
• inboard seal lubricated by barrier fluid

• There are many other arrangements

– Dual; Series; Concentric; Face-to-Face; etc.
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 Mechanical Seal Arrangements
Multiple seals: Tandem
Outboard Seal

Clean buffer
fluid lubricates
this seal

Buffer fluid is at
low
(atmospheric)
pressure.

Use API Plan 52

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Basic tandem non-pressurised double seal
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 Mechanical Seal Arrangements
Multiple seals: Tandem
Inboard Seal
Product
lubricates
this seal

This seal is
under full
product
pressure
Note possible
contamination
of buffer fluid.
Use API Plan 52
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Basic tandem non-pressurised double seal
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 Mechanical Seal Arrangements
Multiple seals: Tandem
Inboard seal
most likely to fail
first

Buffer fluid
level/pressure
will rise

Outboard seal
acts as secondary
containment

Process can
continue until
Use API Plan 52 completed.

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Basic tandem non-pressurised double seal
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 Mechanical Seal Arrangements
Multiple seals: Tandem

Low pressure
fluid supply

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 Mechanical Seal Arrangements
Double seals: Back-to-back
If outboard seal
fails, barrier
pressure will
fail and pump
must be
switched off as
product will
leak out.

Use API Plan 53

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Basic back-to-back pressurised double seal
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 Mechanical Seal Arrangements
Double seals: Face-to-face

Rotating
Mating Stationary
Ring seals

Similar in operation to back-to-back double seal

Much shorter arrangement - only one seat
Simple rotating components. HOME

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 Mechanical Seal Arrangements
Double seals: Back-to-back
Pressurised
barrier fluid is
circulated
round the seals

This lubricates
both sets of
seal faces.

Use API Plan 53

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Basic back-to-back pressurised double seal
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 Flash Cards

1. Mechanical Seals is a device which absolutely ______ the leakage of

pressurized fluid along a rotary shaft in equipments such as pumps,
compressors, agitators, etc.

 Allows

 Reduces

 Prevents Right Answer

 Controls

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 Flash Cards
2. What will prevent leakage through the bore?

 Seal Faces
Leakage
 Shaft Sleeve

 ‘O’ Ring
Right Answer

 Lock Screw

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 Flash Cards
3. Identify the seal marked in the fig below?

 Secondary Seal.

 Primary Seal.
Right Answer

 Tertiary Seal.

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 Flash Cards
4. Excessive start / stop operation:

 will drastically reduce seal life (MTBF - Mean Time Between

Failure).

 wear occurs between faces at start-up.

 no lubricating fluid film present.

 wear on drive mechanism.

 can cause lock-up / bayoneting.

TRUE FALSE

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Answer Is True EXIT

 Flash Cards
5. If the seal faces are not flat, what will be the result?

 The contact will generate heat.

 There will be an excessive wear.
 The seal life becomes short.

TRUE FALSE

Answer Is True

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 Flash Cards
6. In a mechanical seal, usually the mating ring rotates and the primary
ring is stationary.

TRUE FALSE

In a mechanical seal, usually the

mating ring stationary and the
primary ring is rotates.
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 Flash Cards
7. The 3 basic forms of secondary seal are?

 ‘O’ Rings.

 Primary Ring

 Wedges Right Answers

 Mating Ring

 Bellows

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 Flash Cards
8. Identify which is the balanced seal shown in the picture below.

You Are Wrong You Are Right

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Right Answer EXIT

 Flash Cards
9. The two sources of heat generated in the stuffing box are:

a) Heat soak from the product.

b) Heat generated by the seals.

TRUE FALSE

Answer Is True

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 Flash Cards
10. The fig. below shows coning out of a face or primary ring.

TRUE FALSE

It shows coning inn of a seal.

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