1- GENERAL

1- What is the maintenance classification ?

2- What is the function of filtered gas seal in dry gas seals ?

3- Define the hydraulic balanced mechanical seal.

4- What is the function of the hydraulic balance in mechanical seal.

5- When does centrifugal compressor surge? Why ?

6- If the balancing line is plugged what is the effect?

7- What are the total no of wearing rings in a 12 impellers (in row) in

a multi-stage compressor ?.

8- If the inlet pressure of 3 stages comp. = 0 barg and outlet

pressure = 63 barg . What is the intermediate stages pressures ?
(consider equal intermediate pressure ratio).

9- How to do 6 monthes power end clearances check ?

10- Draw a flow diagram for 2 stages reciprocating compressor starting

from suction to second stage discharge .
 Final assessment
Mechanical seals
1 What is the function of filtered gas seal in dry gas seals ?

2 What is the function of spiral grooves in D.G seals ?

3 Define the hydraulic balanced mechanical seal.

4 What is the function of the hydraulic balance in mechanical seal.

5 What is the difference between double and tandem seal ?

6 What is the function of Barrier fluid in double mechanical seals?

7 What is the difference between dry gas and wet seals ?

8 What is the function of barrier gas injected in :

a Primary seal room

b Separation zone

9 What is the acceptable consumption of seal oil in wet seals ?

10 On the starting sequence in compressors, Which one is first

operated ( barrier gas ) or ( lube oil ) ?. -----why

11 Mark the best hydraulic balanced mechanical seal.

a- 100% hydraulic balanced

b- 80 % hydraulic balanced
c- 120 % hydraulic balanced
d- 55 % hydraulic balanced

12 What is the advantage of dry gas seal over the wet seals ?
 Final assessment
Centrifugal compressors
1 What is the meaning of compressor surging?

2 When compressor surging ? Why ?

3 Draw the surge cycle on Q-H Curve.

4 Mention 3 methods to control Compressor Surge

5 If suction pressure pressure changes (As an example) from 0 barg

to 2 barg what will be the effect ?

6 Draw a flow diagram for 2 stages compressor staring from suction

to discharge .

7 If the inlet pressure of 2 stages comp. = 3 barg and intermediate

pressure = 11 barg . What is the final pressure ?
(consider equal intermediate pressure ratio).

8 If the balancing line is plugged what is the effect?

9 What are the total no of wearing rings in a 12 impellers (in row) in

a multi-stage compressor ?.

10 What is the acceptable consumption of seal oil in wet seals ?

11 On the starting sequence in compressors, Which one is first

operated ( barrier gas ) or ( lube oil ) ?. -----why

12 Mention two types of compressor anti-surge methods.

 Final assessment
Reciprocating compressors
1 What is the function of clearance volume ?

2 What are the function of Unloader ?

3 What are the types of packing rings in comp. Stuffing box ?

4 What is the function of each type of packing rings in comp. Stuffing box ?

5 Draw a Flow scheme for a 2 stages reciprocating compressor.

( Starting from inlet to final discharge )

6 What are the types of rings on comp. piston &what is the function of each ?

7 If the inlet pressure of 3 stages comp. = 0 barg and outlet

pressure = 63 barg . What is the intermediate stages pressures ?
(consider equal intermediate pressure ratio).

8 What is the pressure ratio for compressor dischare pressure = 116 psig
and suction pressure = 29 psig

9 If the clearance volume increases what will be affected ?

10 What is the maximum pressure ratio between the consecutive stages

in multi stages compressors?
 Final assessment
Centrifugal Pumps

1 A pump speed changes from N1 to N2 rpm, Find

a- New flow rate Q2
b- New Pressure P2
c- New horsepower

2 Draw a Q-H combined curve for two pumps in parallel

3 On Q-H curve plot two points have the same efficiency.

4 On that curve plot the iso-efficiency curves

5 Write the General equation of NPSHA in ft.

6 What is the NPSHA for a water pump has the following data:

a-Suction pressure = - 2.7 psig

b-Vapor pressure = 4 psia
c-Specific gravity = 1
Neglect the velocity energy

7 What is the function of balancing drum

8 If the inlet pressure increases, what is the effect on Q and motor Hp.

9 What is meant by centrifugal pumps Ns?

10 Two pumps A , B
Ns A = 600
Ns B = 2000
Which pump has (1) higher efficiency ( )
(2) high pressure Low flow ( )
(3) Low pressure high flow ( )
Explain

Final assessment
Reciprocating Pumps

1 What are the function of rider and pressure rings ?

2 What are the types of stuffing box packing rings ?
What is the function of each type ?
3 What is the function of
a- Lubricators
a- Lube oil pump .

4 Incase of reciprocating Pumps is there a NPSH critera or not.(why)

5 What is the NPSHA ( ft ) for a water pump has the following data:

a-Suction pressure = 5.3 psig

b-Vapor pressure = 10 psia
c-Specific gravity = 1
Neglect the velocity energy
 Final assessment
Gas Turbines

1 What is the effect of ambient temperature on the GT efficiency.

2 What is the reason of compressor blades fouling ?

3 What are the difference between

a- Compressor on wash
b- Compressor off wash
c- Compressor solid wash

4 Calculate the overall efficiency of a GT. If :

Compressor Inlet temp. = 20 C 0

Compressor outlet temp.. = 300 C 0
Exhaust temp. = 500 C 0
Cmbustion chamber temp. = 900 C 0

T4 - T1
1-
0 T3- T2

5 Mark (Y) or (N) and explain why ?

 a Pressure in combustion chamber b Velocity of air along comp. stages
1- incease 1- incease
2- constant 2- constant
3- decrease 3- decrease

c Velocity of air in comp stator blades d Compressor stator blades act as

1- incease 1- diffuser
2- constant 2- nozzle
3- decrease

6 Complete the following

a- GT. Bearings oil are sealed by---------------------------------

b- GT.Off wash is done while the GT is running at a speed of----
b- GT.Solid wash is done while the GT is -------------------------

7- Bleeding valve will open automatically at----,-----,--------

8- Inlet guide vanes will ------- automatically at -------,----------

9 How many oil pumps in GT.

10 What is the source of atomising air ?

 Final assessment
RCFA
1- What is the difference between RCA. And RCFA ?.

2- What are the types of maintenance ?

3- If the balancing line of a multi stage centrifugal equipment is blocked,

what will be the effect?

4- If the clearance volume in a reciprocating compressor increased,

what will happen to discharge pressure and flow rate (Mark)
INCREASED DECREASED NO EFFECT
Discharge pressure P
Flow rate Q

5- In dry gas mechanical seal, What is the function of buffer gas enters
to outboard seal ?

6-In a performance ( Q-H) curve of centrifugal pumps what is the meaning of

( ISO- EFFICIENCY CURVES ). ?
8- If a pump has the following data in a period of two months (1440 hrs) :
1- Stop for preventive maintenance = 144 hrs
2- Stop for breakdown maintenance = 144 hrs
3- Stop of standby = 144 hrs
What are the Performance Indicators.
AVAILABILITY = RELIABILITY = UTILIZATION =

9- FOR THE SAME FLOW RATE (Q)

THE PRESSURE DROP P1 = 32 PSI IN PIPE 2"

IF PIPE DIAMETER CHANGED FROM (2") TO ( 4" )
WHAT IS THE NEW PRESSURE DROP P2

Pre- assessment

Maintenance

1 What are the types of maintenance ?

2 In dry gas mechanical seal, What is the function of buffer gas enters
to outboard seal ?
3 In a 3 stages reciprocating compressor :
If ( r ) is the equal pressure ratio between stages,
and ( R) is the total pressure ratio, what is the relation between R & r
4 How can you check pipe strain?
5 What are the causes of seal failure during installation?
6 What are the function of rider and pressure rings ?
7 What are the types of stuffing box packing rings ?
8 What is the function of each type ?
9 What is the function of
a- Lubricators
b- Lube oil pump .
10 If a pump has the following data in a period of two months (1440 hrs) :
a- Stop for preventive maintenance = 72 hrs
b- Stop for breakdown maintenance = 144 hrs
c- Stop of standby = 216 hrs
What are the Performance Indicators.
 AVAILABILITY =
RELIABILITY =
UTILIZATION =

Modle Answer
1 1 PLANNED

a Preventive
A- Routine CMMS
B- Turnaround OVERHAUL MAINTENANCE
C- Conditional Monitoring

b Proactive
c Predictive

2 UNPLANNED

2 TO PRVENT FILTERED GAS LEAK

3
3
r = R

4 Dismantle each motor base stud(one by one) and measure the lift

5 Misalignment, Eccentricity, Thermal Growth and Pipe Strain

6 The function of rider rings ?

To carry the weight of piston & keep it in the centerline of the cylinder

The function of pressure rings

To prevent air or gas leak

7&8 T TANGENTIAL RINGS (Prevent INSIDE air or gas leak ( piston rod leak))
R RADIAL RINGS (Prevent OUTSIDE air or gas leak ( Casing leak))

9 a- Lubricators
b- Lube oil pump .

10 AVAILABILITY = 72/ 1440 = 95%

RELIABILITY = 72+144 / 1440 = 85%
UTILIZATION = 72+144+216 / 1440 = 70%
 comp. stages

blades act as
eaning of
 ASSESSMENT ON MECHANICAL SEAL

Lesson One Assessment( Part- A)

1- What is the function of the mechanical seal?

2- What is the function of the rotary seal ring packing (O-ring)?
3- How does the rotary seal ring packing (O-ring) maintain full-face contact between the rotary a
seal ring?the mechanical part which provides a cushion for the stationary seal ring to maintain its
4- Name
5- What is the function of the spring in the mechanical seal?
6- Define the hydraulic balance.
7- What is the relation between the face contact pressure and the fluid pressure in the unbalanced
seal?
8- Why is the seal face pressure is less than the pumped fluid pressure in a balanced mechanical
9- What is the effect of excessive heat on the liquid film stability in mechanical seals.
10- What will happen if a mechanical seal run dry.

Lesson One Assessment (Part- B)

11- What are the causes of circulation in the mechanical seals?

12- Why does the neck bush have a close clearance with the shaft?
13- What does thermo- syphon circulation means?
14- What is the difference between a double seal and a tandem seal.

Lesson One Assessment (Part- C)

15- What is the function of a throat bush in a pump?
16- Why is the safety bush (throttle bush) manufactured from non- ferrous metal?

17- What is the use of an auxiliary sealing device?

18- What is the main function of a quench feature?
19- How much pressure of the quench medium is entering the seal plate?
20- What is the function of the cyclone separator?
Lesson Two Assessment
1. What is the multi-spring unbalanced seal designed for?
2. What is the general purpose metal below the seal designed for?
3. What is the multi-spring balanced seal designed for?
4. What is the relation between barrier fluid pressure and product pressure in the double seals?
5. Which is higher in tandem seals, product pressure or barrier fluid pressure?
6. Explain why there is no contamination for the product in tandem seals.
7. Explain the double seal configuration.
8. Why does the barrier liquid have to compatible with the product in a double seal?

Lesson Three Assessment

1- What are the causes of seal failure during installation?
2- How can you check pipe strain?
3- How can you check the end float of the shaft?
4- What is the disadvantage of concentricity of the sleeve on the shaft?
5- What is maximum allowable run out of the seal sleeve?
6- What is maximum concentricity of a stuffing box?
7- How can you check the squareness of the stuffing box?
8- What is the maximum allowable limit for squareness?

Lesson Four Assessment

1. What is vaporization?
2. What are the symptoms of dry running seals?
3. What is the cause of carbon ring erosion?
4. What are the causes of O-ring failure?
5. What is the result when the gland ring bolt tightens excessively or unequally?
6. What is the effect when installing an improper seal gasket?
 Answers:
Lesson One (Part-A)
1-Prevent leakage between the rotating shaft and the housing.
2-Prevent leakage between the shaft (or shaft sleeve) and the rotary seal ring.
3- Because it allows sufficient freedom of movement to the rotary seal ring.
4-Stationary seal ring packing (O-ring)
5-Maintain the initial seal face contact.
6- The relationship between the pressure being sealed and the seal face contact pressu
7- The face contact pressure is greater than the fluid pressure.
8- To allow a thicker fluid film between the faces, thus reducing wear.
9- Excessive heat may destroy the liquid film stability and leads to vaporisation.
10-Excessive wear.

Lesson One (Part-B)

11- 1- Removal of heat from seal area.
2- Prevent sédiment deposits.
3- Control the flow temperature.
12-To increase the pressure in the stuffing box.
13-Circulation flow between the seal chamber and header by means of height
and deferential temperature.
14- For double seal:-
Barrier fluid pressure is greater than the product pressure.
For tandem seal:-
Buffer fluid pressure is smaller than the product pressure.

Lesson One (Part-C)

15. Protect against sudden seal failure.
16. To prevent sparking with the shaft in case of bearing failure.
17. Prevent leakage of the quenching medium from between the outer end of the seal
plate and the pump shaft.
18. To improve the function of the seal, by preventing a product build up on atmospheric side
of the seal. Also, to neutralise seal leakage for environmental control or safety reasons.
19. One bar.
20. The cyclone separator is a device used to remove solids continuously from the circuits,
using the centrifugal force.

Lesson Two
1- For application where seal length is critical and for dual rotation or when reverse
rotation is anticipated.
2- An excellent alignment capabilities.
Very low specific face loads.
3- For application where the reverse rotation is anticipated.
4- Barrier fluid pressure higher than product pressure.
5- Product pressure.
6- Because the leak-if occurs- form the product to the barrier fluid.
7- The double seal arranged back to back, to maintain a liquid barrier between the pumped
product a barrier fluid.
8- Because the leak-if occurs- will be from barrier liquid to the product.
Lesson Three
1. Misalignment, Eccentricity, Thermal Growth and Pipe Strain
2. Mount to dial indicators on the coupling at 12 & 3 o’clock as a preparation of for . If .
alignment. Zero dial indicators. Unbolt the pipe work and observe the movement of dial
more than 0.1 mm, you have to adjust pipe work
3. Using dial indicator at the shaft shoulder axially, push shaft as for as it will go and zero
dial indicator. Push to the other side again and record the reading should not
exceed 0.05mm.
4. It develops wash and tracking at he seal face which causes variation in fluid
film thickness.
5. 0.05 mm.
6. 0.1 mm.
7. Attach a clamp on shaft and dial indicator axially on stuffing box.
rotate shaft and record dial indicator reading.
8. 0.08 mm.

Lesson Four
1- Vaporization occurs when heat generated at the faces is not removed effectively.
The stable interface liquid film change into vapor condition.
2- Severe wear and grooving of stationary seal ring.
 Metal seal ring shows scoring.
O-ring hardened and cracking.
3- When differential pressure across mechanical seal is too great.
4- Extrusion and over heating.
5- Distortion which leads to seal face leakage.
6- It will affect the seal setting, and the spring load imposed on the seal, thus liquid film thickne

Final Assessment (Classroom)

Questions:
1. Identify the basic components of a single mechanical seal, and explain the function for each.
2. Define the hydraulic balance.
3. Define the unbalanced mechanical seal.
4. Define vaporization in mechanical seal.
5. List the types of pumping for circulating the sealant in Tandem seals.
6. Explain the Thermo- syphon circulation method in Tandem seals.
7. What is the difference in operation between double and Tandem seals.
8. Explain two of the safety features:-- Safety Bush – Quench – Impeller - Flushing
9. What is the function of cyclone separator in circulating system.
10. Explain how to correct pipe strain to avoid mechanical seal problems.
11. Explain the cause and remedy for the seal drips steadily.

Answers:
1. a. Stationary seal ring: The seal face of the Mechanical Seal.
b. Stationary Seal Ring Packing: Prevent leakage between stationary seal ring and gland housing.
c. Rotary Seal Ring: The seal face.
d. Rotary Seal Ring Packing: Prevent leakage between rotary seal ring and the shaft.
e. Spring: To maintain the initial seal face contact.
2. The relation ship between the pressure being sealed and the seal face contact pressure.
3. The unbalanced seal is the seal in which the seal face contact pressure is greater than the fluid pressure.
4. The case of loosing a liquid film between the seal faces. The vaporisation at the stuffing box destroy the f
stability.
5. a By using a pump and relief valve.
b. Thermo-syphon circulation method.
c. By using an impeller or pumping ring, fixed to the rotating sealing ring or pump shaft in side the seal hous
6. This Thermo-syphon circulation method depends on the height of the circulating header and the differentia
to make the circulating flow.
7. Double seal barrier liquid pressure is greater than the pressure of liquid being sealed.
 Tandem seal buffer fluid pressure is lower than the pressure of liquid being sealed.
8. Safety Bush: the close clearance of safety bush prevents severe leakage in the case of seal failure.
Quench: This type of cooling, is used to:
Prevent a product build up on the atmospheric side of rotary seal ring.
Prevent leakage to atmosphere due to safety reasons.

Impeller: A feature used to circulate the Buffer fluid in Tandem Seal. The impeller is mounted on the rota

Flushing: used to prevent settling of sediments, abrasives on the seal faces.

9. To remove solids continuously from the circulating system it uses a centrifugal force to extract the dense so
flushes it
away to the dirty outlet.

10. Attach two dial indicators on a fixed foundation, and anvils on the coupling hub of the pump at 3.00 and 12
Disconnect the suction and discharge piping of the pump.
If there is a reading more than .002 inch on the dial indicators, you have to correct the piping.
 Course contents
Mechanical seals
I- Technical aspects of mecanical seals

Principle of operation
Packing seals and its disadvantages
Mechanical seal types
Mechanical seal function and components
Hydraulic Balance

II- Optional features

Quenching
Flushing
Circulation
Barrier fluid
Ancillaries

III- Installation

Preparation
Precations
Checks
Measurements

IV- Cause of failure

V- Dry gas seals

Principle of operation
Design
Operating concept and precations
Self adjusing theory
 Auxiliaries

VI- Miscellaneous