Performance

Analysis of
Mechanical Seals
KRL 12/02
Performance Analysis
Mechanical Seal Life is
Affected by:
Design Installation
 Seal  Seal
 Pump  Pump
 Support System
 Bearing Operation
 Coupling  Pump
 Flush  Support System
 Flush System
Performance Analysis
A Definition of Seal Failure

Undesirable passage or leakage of fluid past

sealing components causing:

 Dilution of a process stream

 Poisoning of the environment
 An immediate safety hazard

The actual threshold for "failure" criteria is defined

by the user or a governmental agency.
Performance Analysis

Classification of Seal Failures

 Mechanical – 24%
 Operation – 40%
 Poor Fluid Circuit Design – 19%
 Incorrect Seal Selection – 9%
 Miscellaneous – 8%
Performance Analysis

Diagnostic Path
 Failure Mode: Criteria, volume, when
 System Status: Changes, modifications, damage
 History: Run length, symptoms, trends, system
influences
 System and Equipment Checks
 Disassembly and Visual Inspection
 Comprehensive Examination
Performance Analysis

Notable Indicators on Site

 Noise: Continuous or periodic
 Visual: Carbon dust, leak volume
 Temperature changes: Process, support,
environment
 Leakage: Continually, startup, static, during excursions
 When: Startup, seasonal,
 Changes: procedure, human, conditions, fluid
 Failure frequency: Immediate, variable, diminishing
Stylus

Surfanalyzer
 Perfectly Flat
Reference Line
Part is
High

Part is
Low
 John Crane Test Lab

Scanning Electron Microscope

Full Contact Pattern

Contact
Pattern
Mating Ring Primary Ring
Wide Contact Pattern

Drive Notch
Wear
Contact Wider Than Width
of Primary Ring Face
Drive Notch Wear
Off Center Wear Track
Mating Ring Damage from
Off Center Shaft
Sleeve Damaged by
Off Center Shaft
Sleeve Damaged by
Excessive Shaft Runnout
Sleeve Damage by
Excessive Shaft Runout
Heavy Outside Diameter Contact

Possible
Edge Chipping

Rotation Due to
Pressure

Heavy to Light Contact

Moderate Contact
Heavy Inside Diameter Contact

Possible
Chipping

Rotation Due to
High Temperature

Light Heavy to
Contact Moderate Contact
One High Spot on Mating Ring Face
Mating ring misaligned, due to a high drive pin,
or upset on support surface. Look for wear at
drive notches on the primary ring.
Wear Track Through 270°
Full contact through approximately 270° as seen on seal ring face.
Pattern fades away at low spot. The primary ring may show "wire
drawing" in a position over the mating ring low spot.

The seal ring is being

distorted mechanically
or is not flat
Wire Draw on Carbon Face
Two High Spots on Mating Ring
Two large contact spots are noted while the pattern fades
away between these areas.

The mating ring

is being distorted
mechanically.
Pump casing split
line misalignment
is often the
cause.
Gland Bolt Distortion
Contact spots noted at gland stud locations on mating ring.
Mating ring is being distorted mechanically by uneven gland surface.

Most often the gland nuts have been over tightened.

No Contact

Contact at
High Spots No Unusual Wear
Near Gland Bolts
Heat Checking of Entire Face
Many small radial surface cracks through the entire wear track,
normally visible to the eye. Squealing or popping sounds will often
be observed during operation.

Caused by inadequate
fluid film at the seal
interface. This usually
results from inadequate
vapor pressure margin
or flush rate.
Heat Checking and Pullouts
Heat Checking 180° From Flush Port
Thermally distressed area on seal face, located opposite of
the flush port location.

Insufficient flush rate is most likely cause.

Undamaged Surface
at Flush Inlet

Heat Checked Area

Patches of Heat Checked Surface
Patches of thermally distressed surface on face.

The sealed liquid, probably a light hydrocarbon, is

vaporizing at the seal interface.

Good Contact
Pattern

Distressed
Surface
or Hot Spot
Abrasive Wear
High wear of seal face through 360° showing a “phonograph
pattern” appearance.

Caused by
abrasive
particles in the
process fluid or
from seal face
breakdown
resulting from
inadequate flush
conditions.
Abrasive Wear on Carbon Face
Abrasive Wear; Dry Run of SiC Face
Abrasive Wear; Dry Run of SiC Face

200 X

100 X
Abrasive Wear on TC Mating Ring
Blistering
A seal face has one or more (several) uplifts or “Blisters”.
Some may have been pulled out leaving a shallow crater.
Normally associated with carbon materials.

Caused by high
stresses in the
interface which
exceed the rupture
strength of the face
material. Viscous
fluids, including lube
oils, are most often
the cause.
Blistering
Bond Failure of Coated Seal Ring
A blistered or peeled surface layer on faces which have been
coated with a hard material.

Coated parts
should be used
with caution.
Chemical activity
and mechanical
action can easily
disturb the
coating.
Fractured Seal Ring
One or more cracks extend all the way through the part.

Often caused by
mishandling or
improper assembly. Can
be caused by excessive
torque, thermal shock,
mechanical (contact)
loading, or uneven
loading of brittle face
materials.
Erosion of Seal Parts
Extensive erosion of a component at a location that is
exposed to process fluid.

An abrasive laden
seal flush which is
directed at the part(s)
in question is a
common cause.
Trapped abrasives in
a seal chamber can
damage both pump
and seal
components.
Erosion of Rotating Primary Ring
Erosion of Stationary Mating Ring
Leaching
Material exhibits a rough matted appearance on surface
areas that are exposed to the process fluid.

Caused by
chemical attack of
one or more
phases of a multi-
phase material.
Leaching of RBSiC Mating Ring
Corrosive Chemical Attack
Metallic materials exhibit a cracked, rough, or irregular
surfaces. Carbon materials may become soft.

Acids, caustics, chlorides, de-ionized water to name a few.

Look at weld zones, crevices, friction areas, springs, etc.
Chemical Attack
Chemical Attack
Hydrocarbon Coking
A formation of hard, brittle material between seal and shaft
sleeve that may impede free movement of the seal.
Caused by oxidation or stripping of hot hydrocarbon fluids
in the presence of seal face generated heat.

Application of a steam quench often cures this problem.

Solid Deposits “Coking”

Hydrocarbon Coking
Hydrocarbon Coking
Dissolved Solids Deposits
Grainy, often abrasive substance that may form on either side
of the seal; though typically on seal faces or the atmospheric
side. Abrasive wear on the seal faces or hang-up are the most
common observations.

Application of a liquid quench and possibly the use of hard

seal ring materials are typical remedies.

Face Grooving
Deposits
Caustic Deposits
Suspended Solids Fouling
Process borne polymers, solids, or contaminants that imbed
in or adhere to areas on either side of a seal. Polymers may
form in the presence of seal face or pump generated heat.

An exclusionary flush plan or slurry style seal design may be

required.

Deposits
Polymer Deposits (Reactor Application)
Iron Oxide Deposits (Pipeline Application)
Solids Fouling of Metal Bellows
Fouling of Seal Face
Cuts or Tears on Secondary Seal
Physical damage on O-rings, U-cups, V-rings or soft packing.

Normally caused by mishandling during assembly or a defect.

Always inspect parts

for visible defects and
inclusions before
installation. Mounting
surfaces should not
have sharp edges or
burrs that could cause
damage.
O-Ring Extrusion
A thin lip has formed on the entire ID or OD of the O-ring.
Some materials may exhibit a shredded appearance.

Normally caused by application of pressure beyond the

limits of the design. Elastomer swell or expansion in a
confined space will often result in the same damage.

Normal
Lip
Ring
Shredding
O-Ring Extrusion
Extrusion of Perfluoroelastomer
Extrusion of Perfluoroelastomer
O-ring Blowout (Reverse Pressure)
Worn Surface on O-Ring
One surface will be flat from material being abraded or
chaffed. The ring may adhere to, or discolor the adjoining
surface.

Caused by sliding contact at a point where static contact

was intended.

Flat
Normal
Ring
Worn ID Surface on Dynamic O-Ring
Worn ID Surface on Dynamic O-Ring
Hard, Cracked Elastomer
The part is hard and has several cracks, it is easily broken when
bent by hand. Damage may be on process side, atmospheric
side, or only in areas in contact with a specific part.

Temperature too high for material in use. Possible chemical

attack if the damage is evident only on its wetted side.
Hard, Cracked Elastomer
Elastomer Compression Set
The part is permanently deformed with flat sides on its
sealing surfaces. The most common cause of O-ring failure.
Caused by designs that over compress the material,
resulting in a permanent set. Some elastomers are more
susceptible than others to compression set.

Normal
Ring Flat
Surfaces
Chemical Attack on Elastomer
The part has become either softer or harder than normal. It may
have swelled, formed blisters, or portions have been severely
deteriorated.

When in doubt,
elastomers
should be
compared to an
experience
database or
subjected to an
immersion test.

Original
Size
Fluoroelastomer Swell in Methanol
Fluoroelastomer Decay in Ammonia
Process Side Attack from HF Acid
Atmospheric Side in HF Acid Service
Blistered and Ruptured Elastomer
Many small blisters and ruptures throughout the part caused
by explosive decompression.

A fluid which is a gas at atmospheric pressure, is being

sealed under high pressure and over time is absorbed into
the elastomeric material. When the pressure is released too
quickly the fluid which is trapped in the elastomer expands
rapidly resulting in damage to the part.

Blister Rupture
Fretting
Metal surface which has been in contact with the secondary
seal has a rough and worn appearance.

Fretting occurs
when continuous
small movements
inherent to a
dynamic
secondary seal
occur while in
contact with a
metal shaft sleeve
or shaft.
Worn or Distorted Drive Components
Drive mechanisms are damaged; worn, distorted, or chipped.

Caused by excessive loads or relative movement between

drive components and the driven part.

Drive Dent Wear Sheared Drive Pin

Broken or Distorted Coil Springs
Springs are distorted, cracked, broken, or corroded.
Stress corrosion cracking, general corrosion, fatigue,
excessive shaft speed, and over extension or compression of
the spring.
Metal Bellows Separation at One End
Excessive vibration of the metal bellows.

Torsional fatigue;
usually at 1st or 2nd ID
weld from either end.

Normally caused by
inadequate face film
(stick-slip)
Metal Bellows Fatigue (Magnified)
 Metal Bellows Over Pressurization
Applied pressure greater than rating for the metal bellows.

Caused by pressure excursions or expansion of contained fluid.

Metal Bellows Over Pressurization

Normal

From OD From ID
Cracks in Metal Bellows
The bellows has cracks in one or more locations at any point
on the bellows, normally at or near a weld. May only be
detectable in a leak testing device.

Stress corrosion cracking is a common cause.