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Technical Report
Plant
Maintenance
Support
Reduced
Cost
Equipment
Reliability
EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
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Copyright 2000 Electric Power Research Institute, Inc. All rights reserved.
CITATIONS
This report was produced by
Nuclear Maintenance Application Center
EPRI
1300 W.T. Harris Boulevard
Charlotte, NC 28262
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Mechanical Seal Maintenance and Application Guide, EPRI, Palo Alto, CA: 2000. 1000987.
iii
REPORT SUMMARY
This guide provides information to personnel involved with the maintenance of mechanical seals,
including good maintenance practices, planning, predictive and preventive techniques, and
troubleshooting guidance. It provides insight to experienced personnel as well as basic
information, guidance, and instructions to personnel assigned to maintain mechanical seals.
Background
A mechanical seal prevents leakage of pressurized fluid between a rotating shaft and a stationary
housing. They are widely used for numerous power plant equipment applications, particularly on
pumps of various sizes and pressure ratings. Even though they are capable of providing longterm service, mechanical seals sometimes exhibit unsatisfactory performance, unpredictable
failures, and a short life, which can directly affect plant reliability and performance, resulting in
costly downtime and outages. Mechanical seal issues rank high in surveys completed by power
plant maintenance personnel.
Objectives
x To help power plant personnel deal with the maintenance and reliability issues of this critical
power plant component
x
To provide maintenance recommendations for optimizing seal performance and operating life
Approach
A detailed review of industry literature, product information, and standards was conducted to
establish the state of technology for mechanical seals. Utility and industry personnel were
surveyed to determine specific problems and commonly encountered failure mechanisms. Based
on all of the information gathered, suitable recommendations were developed for the problems
encountered and presented in this report.
Results
This guide presents a thorough discussion of mechanical seals and provides an in-depth
understanding of their design and operation, including expected life and a discussion of proper
application and selection. It also provides proper installation methods and guidance on expected
failure mechanisms. This guide offers troubleshooting approaches to assist in determining the
causes of failure and discusses recommended predictive, preventive, and corrective maintenance
practices. The contents of this guide will assist plant personnel in reducing costs and equipment
unavailability and in improving equipment reliability and performance.
EPRI Perspective
Problems with mechanical seals represent a significant reliability impact on rotating equipment.
This guide provides power plant maintenance personnel with information to help improve seal
performance and component reliability through a better understanding of the operation of
mechanical seals and their critical components. It also provides guidelines on investigating and
troubleshooting problems that arise during inservice operation and normal planned maintenance
activities.
Keywords
Mechanical seals
Maintenance
Engineers
vi
ACKNOWLEDGMENTS
This guide was developed by the Nuclear Maintenance Application Center (NMAC) and the
following Technical Advisory Group (TAG):
Steve Lemberger
Bob Mundlapudi
Vic Varma
Hugh Nixon
Steve Rosenau
Larry Price
Rich Hansen
John Montgomery
AEP
Amergen
Consultant
Consumers Energy
Duke Energy
PG&E
UNICOM
UNICOM
vii
CONTENTS
1 INTRODUCTION.................................................................................................................. 1-1
1.1
Background............................................................................................................... 1-1
1.2
1.3
Approach................................................................................................................... 1-2
1.4
Operating Principles and Basic Components of a Mechanical Face Seal .................. 3-1
3.2
3.3
3.4
3.5
3.8
3.9
4.2
4.3
4.4
ix
5.2
5.3
5.4
6.2
6.3
6.4
7.2
8 MAINTENANCE................................................................................................................... 8-1
8.1
8.2
xi
B.2
C TRAINING COURSES.........................................................................................................C-1
D LISTING OF KEY INFORMATION ......................................................................................D-1
xii
LIST OF FIGURES
Figure 3-1 Essential Components of a Mechanical Face Seal................................................. 3-1
Figure 3-2 Multiple Coil Springs .............................................................................................. 3-4
Figure 3-3 Single Coil Springs................................................................................................. 3-4
Figure 3-4 Corrugated Bellows................................................................................................ 3-4
Figure 3-5 Welded Bellows ..................................................................................................... 3-4
Figure 3-6 Rubber Bellows...................................................................................................... 3-5
Figure 3-7 Belleville Washers.................................................................................................. 3-5
Figure 3-8 Rotating Primary Ring - Outside Pressure (or Inside Mounted) .............................. 3-9
Figure 3-9 Rotating Primary Ring - Inside Pressure (or Outside Mounted) .............................. 3-9
Figure 3-10 Stationary Primary Ring - Outside Pressure (or Inside Mounted) ......................... 3-9
Figure 3-11 Stationary Primary Ring - Inside Pressure (or Outside Mounted) ....................... 3-10
Figure 3-12 Back-to-Back Dual Seal ..................................................................................... 3-10
Figure 3-13 Face-to-Face Dual Seal ..................................................................................... 3-11
Figure 3-14 Pressure Stage Tandem Seal ............................................................................ 3-11
Figure 3-15 Single Seal Cartridge ......................................................................................... 3-12
Figure 3-16 Balanced Stator Design Multi-Seal Cartridge Supplied by a Manufacturer for
a Main Coolant Pump .................................................................................................... 3-13
Figure 3-17 Seal Stage Details of a Balanced Stator Design Multi-Seal Cartridge
Supplied by a Manufacturer for a Main Coolant Pump................................................... 3-14
Figure 3-18 Common Variations in Seal Chamber Design .................................................... 3-15
Figure 3-19 A Typical Flush Plan for a Cooling Seal Chamber .............................................. 3-16
Figure 3-20 Unbalanced, Balanced, and Partially Balanced Seal Designs ............................ 3-19
Figure 3-21 Face Pressure Distribution Due to Hydraulic Pressure and Spring Force........... 3-21
Figure 3-22 Rotating Seal Balance Designs.......................................................................... 3-22
Figure 3-23 Pressure/Temperature Operating Envelope Showing 'T Margin Required for
Seal Operation .............................................................................................................. 3-25
Figure 3-24 Seal Face with Thermal Hydrodynamic Grooves for Positive Hydrodynamic
Lubrication..................................................................................................................... 3-26
Figure 3-25 Design Options with Hydrodynamic Grooves on the Outer Periphery or Inner
Periphery of Seal Face .................................................................................................. 3-27
Figure 3-26 Other Variations in Seal Face Geometry to Enhance Lubrication of the
Faces ............................................................................................................................ 3-27
Figure 3-27 Hydrostatic Face Seal Design ............................................................................ 3-29
xiii
xiv
LIST OF TABLES
Table 2-1 Glossary of Terms................................................................................................... 2-1
Table 3-1 Secondary Seal Properties...................................................................................... 3-3
Table 3-2 Advantages and Disadvantages of Mechanical Face Seal Configurations............... 3-6
Table 3-3 Advantages and Disadvantages of Mechanical Face Seal Springs ......................... 3-8
Table 3-4 Approximate PV Limits psi-ft/min (Mpa-m/sec) for General Seals with Various
Combinations of Seal Face Materials and Fluids ........................................................... 3-23
Table 5-1 Seal Application and Selection Guidelines .............................................................. 5-2
Table 6-1 Seal System Log Sheet........................................................................................... 6-3
Table 7-1 External Symptoms of Seal Failure ......................................................................... 7-3
Table 7-2 Checklist of Actions Before Dismantling .................................................................. 7-7
Table 7-3 General Checks During Dismantling........................................................................ 7-9
Table 7-4 Premature Failure Checks During Dismantling ...................................................... 7-10
Table 7-5 Mid-Life Failure Checks During Dismantling.......................................................... 7-11
Table 7-6 Visual Examination: Failure Symptoms Based on Mechanical, Thermal, or
Chemical Damage......................................................................................................... 7-13
Table 7-7 Visual Examination: Symptoms, Characteristics, Causes and Remedies .............. 7-14
xv
1
INTRODUCTION
1.1
Background
In the past, the Nuclear Maintenance Application Center (NMAC) of EPRI has published a
number of application and maintenance guides to provide technical guidance to engineers and
other plant personnel on mechanical seal equipment and component operation. These have
included information on proper selection, installation, and failure mode analysis, and
maintenance recommendations designed to optimize equipment operating life. EPRI has
conducted and published the following documents relating to equipment seals:
x
Mechanical seals are widely used in many types of rotating power plant equipment, especially
pumps of various sizes and pressure ratings. Even though mechanical seals are capable of
providing reliable long-term service with proper consideration to design, application, installation,
and maintenance, they still exhibit unsatisfactory performance, short life, and unpredictable
(random) failures in some applications. As such, mechanical seals have a significant influence on
the reliability of plant equipment.
A mechanical seal is a complex assembly of precision-machined components. Design and
prediction of mechanical seal performance in a given application requires an in-depth knowledge
of all mechanical disciplines: stress/deflection analysis, vibration analysis, heat transfer, fluid
mechanics, lubrication, friction and wear, materials, and manufacturing processes.
Mechanical seal technology, as well as a fundamental understanding of how such seals work, has
evolved and improved significantly over the last two decades. This has been the result of
extensive industry-wide research, testing, plant experience, availability of sophisticated
analytical tools (for example, computational fluid dynamics analysis and finite element analysis),
and advances in manufacturing technology. This has enabled improvements in the performance
of mechanical seals in a number of critical applications in nuclear and fossil power plants,
petrochemical plants, and other industries.
1-1
1.2
Purpose
The objective of this NMAC Mechanical Seal Maintenance and Application Guide is to provide
personnel in nuclear and fossil power plants with:
x
This guide presents the latest developments in mechanical seal technology and materials. Some
of the new seal designs are already in use in industries other than power plants. Their viability in
power plant operation was researched and, based on this research, the guide includes
recommendations for achieving plant-wide improvements in nuclear and fossil power plants.
This NMAC Mechanical Seal Maintenance and Application Guide is a comprehensive, state-ofthe-art text for nuclear and fossil power utility engineers.
1.3
Approach
A detailed review of the available literature was conducted to establish the state of technology in
mechanical seals [1-65*]. The objective was to establish the present state of the art regarding:
x
Application problems
Statistical/failure data
Plant experiences
Emerging technologies
All relevant technical papers, reports, and publications were reviewed from:
x
*
1-2
Seal manufacturers
The review included both domestic and international mechanical seal manufacturers such as John
Crane Company, Chesterton, Borg-Warner, Durametallic, Sealol, AST, Burgmann Seals,
Flexibox, Latty International. Significant United States Nuclear Regulatory Commission Generic
Communications relating to shaft seal issues were also reviewed and evaluated to develop
suitable recommendations for inclusion in this guide.
Additionally, a questionnaire was developed as a survey distributed among the nuclear and fossil
power utilities to facilitate determination of specific problems and commonly encountered failure
modes. The results of the survey were analyzed to determine the root causes of seal failure, to
develop troubleshooting, failure diagnosis, installation and maintenance guidelines, and to
develop suitable recommendations for this guide. This guide also utilizes relevant data from
technical papers, as well as principal investigators experience with mechanical seals in the
petrochemical, chemical, drilling, and mining industries.
1.4
Throughout this guide, key information is summarized in Pop Outs. Pop outs are bold-lettered
boxes that succinctly restate information covered in detail in the surrounding text, making the
key point easier to locate.
The primary intent of a pop out is to emphasize information that will allow individuals to take
action for the benefit of the plant. The information included in these pop outs was selected by
NMAC personnel and the consultants and utility personnel who prepared and reviewed this
guide.
The pop outs are organized according to three categories: O&M Costs, Technical, and Human
Performance. Each category has an identifying icon, as shown below, to draw attention to it
when quickly reviewing the guide.
Key O&M Cost Point
Emphasizes information that will result in reduced purchase, operating, or
maintenance costs.
Key Technical Point
Targets information that will lead to improved equipment reliability.
1-3
1-4
2
GLOSSARY OF TERMS
The terminology used to describe the various design features, configurations, applications,
installation, and performance of mechanical face seals has evolved over the years. Seal
handbooks, manufacturer catalogs, technical papers, and the industry standards for both the
United States of America and European countries [3-9] were reviewed to reconcile the
differences in definitions and prepare the following comprehensive glossary (Table 2-1) of terms
in common use today and adopted in this guide.
Table 2-1
Glossary of Terms
Term
Definition
Abeyance seal
A non-contacting auxiliary seal that is activated by failure of the primary seal in the
case of a single seal, or the outer seal in the case of a double seal.
Abrasive wear
Adhesive wear
Wear arising from small-scale local welding at asperities; a common wear mode
associated with running in and mild steady state wear.
Anti-rotation pin
or device
A device, usually a pin, designed to prevent the stationary seal member from
rotating in its mounting.
API 610
API Standard: Centrifugal Pumps for General Refinery Services (8th Ed. in
preparation). A specification widely used for heavy duty centrifugal pumps.
API 682
API Standard: Shaft Sealing System for Centrifugal and Rotary Pumps (1st Ed.,
1994).
Asperity
Minute high spot on the seal face resulting from the manufacturing process.
Autobalancing
Auxiliary seal
Back-to-back seal
A seal configuration consisting of a double seal with the seal rings adjacent to each
other, that is, two mechanical seals facing in opposite directions.
Back-up seal
Balance diameter
2-1
Definition
Balance ratio
Balance ratio determines the proportion of the seal chamber pressure that is applied
to the faces of a mechanical seal. Mechanical seals are available as both balanced
and unbalanced designs. The balance ratio is a ratio of the area subjected to the
differential pressure of the fluid to the area between the seal ring faces. Seals are
often identified by their balance diameter. The balance diameter, Db, is located
between the inside diameter, Di, and outside diameter, Do, of the seal ring contact
area.
For seals pressurized on the outside diameter:
Balance Ratio
Do 2 D b 2
D o 2 Di 2
2-2
Balanced seal
A mechanical seal arrangement whereby the effect of the hydraulic pressure in the
seal chamber on the seal face closing forces has been reduced through seal
geometry. Balanced seals have a seal balance ratio of less than 1 (0.65 to 0.85 is
typical range).
Balanced sleeve/
secondary seal
sleeve
Stationary balance seal designs allow the stationary member to move axially. The
secondary seal slides on a sleeve, or insert, called the balance sleeve.
Barrier fluid
A fluid injected between dual mechanical seals to completely isolate the pump
process liquid from the environment. Pressure of the barrier fluid is always higher
than the process pressure being sealed. (For contrast, see buffer fluid definition.)
Bellows seal
Blistering
Boundary
lubrication
Condition of lubrication where the seal faces are in solid contact, though separated
by adsorbed surface films.
Definition
Bubble point
Mixtures of liquids do not have a clearly defined boiling point. The bubble point is
the temperature at which the first bubble is evolved on raising the temperature at
constant pressure. The term is most frequently used with mixtures of hydrocarbons.
Buffer fluid
A fluid used as a lubricant or buffer between dual mechanical seals. The fluid is
always at a pressure lower than the pump process pressure being sealed. (For
contrast, see barrier fluid definition.)
Cartridge seal
Clamp plate
Closing force
Combined hydraulic and spring load acting on the floating seal member in the
closing direction.
Coking
Compression set
Axisymmetric distortion of the seal faces, causing a rotation of the seal ring crosssection and creating a radial variation in seal film thickness.
Contact pattern
Staged seal designs use an orifice to bypass a small flow around each seal to reduce
pressure to subsequent stages. If the resistance of each orifice device is equal, and
the seals are not leaking, the differential pressure across each stage will be equal.
This distribution of pressure provides the optimum condition to obtain the
maximum seal life.
Controlled
leakage seal
Convergence/
divergence
It is necessary to have an adequate gap at the inner or the outer periphery of the
seal faces that is exposed to the pressurized fluid to allow fluid to enter and provide
lubrication and cooling. Coning of seal faces can cause the gap to decrease
(converging seal faces) or increase (diverging seal faces) in the direction of
leakage.
Coolant
Critical
dimensions
Each specific seal design has a unique geometry. In this geometry some dimensions
are very important to the successful operation of the seal. Other dimensions,
although important, might not have a significant effect as they vary within
reasonable values. Dimensions that are very important to the proper operation of
the seal are termed critical dimensions. These might be very precise dimensions,
such as seal face flatness, or they might have tolerances of 1/16" (.16 cm), such as a
spring gap. Generally, critical dimensions are verified and recorded to ensure they
are correct.
2-3
Definition
Crystallization
Cyclone separator
Dead-ended
Degree of balance
The proportion of the face area that is exposed to the low-pressure side of the
balance diameter ( = 1 balance ratio).
Delta T, 'T
The difference between the bulk temperature of the liquid in the seal chamber and
the boiling point (or bubble point in the case of mixtures) of this liquid at the
pressure in the seal chamber. Also known as the product temperature margin.
Destaging
When individual seal stages leak more than other stages, the differential pressure
across the stages that are not leaking increases, and the differential pressure across
stages that are leaking decreases. This shift in differential pressures is termed
destaging.
Diameter ratio
The ratio (>1) between the outer and inner diameters of the narrower of the seal
faces.
Double balancing
A mechanical seal design feature that changes the balance diameter to improve the
seal's resistance to operating under reverse pressure. This prevents opening of the
inside seal in a double seal upon loss of barrier fluid pressure. (Sometimes called
autobalancing.)
Double seal
2-4
Drain connection
A connection to the quench (or secondary containment) chamber for the collection
of liquid.
Drive collar
The part of a cartridge seal that mechanically connects the sleeve to the shaft to
transmit rotation and prevent axial movement of the sleeve relative to the shaft.
Drive pin
A device for transmitting torque from the shaft to the rotating seal member.
Dry running
Dual mechanical
seal
A seal arrangement using more than one seal in the same seal chamber in any
orientation that can utilize either a pressurized barrier fluid or a non-pressurized
buffer fluid. (It is also referred to as a double or tandem seal.)
Dynamic
secondary seal
A secondary seal in a pusher seal that prevents leakage between the shaft or
housing and the floating seal member of a mechanical seal.
Early-life failures
Elastomer
Definition
Erosion
Externally
mounted seal
(also called
outside mounted).
Face
This term is used in a strict sense to mean the surface of a seal ring at the sealing
interface, but is also commonly used for the whole ring, for example, hard face.
Face load
The combined spring and hydraulic load carried between the seal faces before
allowing for any fluid pressure in the sealing interface.
Face plate
The primary sealing surface in a hydrostatic seal is a ceramic piece called the
faceplate. Some faceplates are stainless steel coated with aluminum oxide and
others are silica nitride.
Face width
Half the difference between the outer and inner diameters of the narrower of the
seal faces.
Face-to-face seal
A seal configuration consisting of a double seal with the seats adjacent to each
other, that is, two mechanical seals facing in opposite directions.
Film thickness
Film transfer
A process by which a film of the material of the soft face is deposited on the hard
face.
Fitness testing
Cartridge seals are assembled outside the pump and can be tested to verify the
assembly. Normally, a test vessel (with adequate ports, nozzles, gauges, and a flow
meter) is used to measure staging pressures and controlled bleed-off flow.
Frequently, fitness testers are supplied as skid-mounted assemblies with the
required pumps, reservoirs, instrumentation, and connecting piping.
Flashing
A rapid change in fluid state, from liquid to gaseous. In a dynamic seal, this can
occur when frictional energy is added to the fluid as the latter passes between the
primary sealing faces, or when fluid pressure is reduced below the fluid's vapor
pressure because of a pressure drop across the sealing faces. In this publication, the
definition of flashing is that vapor pressure is greater than 1 bar (14.5 psia) at
pumping temperature.
Flashing
hydrocarbon
service
Flatness
Flexible graphite
A pure carbon graphite material used for static gaskets in mechanical seal design,
both for cryogenic and hot service.
Floating seal
member
(also called
primary ring)
The spring-loaded seal member of a mechanical seal that is allowed limited axial
movement to accommodate shaft end float and seal wear.
2-5
2-6
Term
Definition
Fluid film
Fluid film
lubrication
Fluoroelastomer
Flush
A small amount of fluid that is introduced into the seal chamber on the process
fluid side in close proximity to the sealing faces and usually used for cooling and
lubricating the seal faces and to prevent accumulation of solid particulates.
Flush connection
Free length
Fretting
A combination of corrosion and wear resulting from very small amplitude relative
motion. In a mechanical seal, a common example of fretting occurs when the
rubbing motion of a secondary seal continually wipes the oxide coating from a
shaft or sleeve. The increased surface roughness of fretted surfaces can adversely
affect the ability of the floating seal member to track its mating seal ring.
Friction
coefficient
Defined in a mechanical seal as the ratio of the friction force at the sealing interface
to the closing force.
Gland plate
(Alternative term for seal plate.) An end plate that connects the stationary assembly
of a mechanical seal to the seal chamber.
Hang-up
Failure of the secondary dynamic seal to move under the applied spring and
hydraulic forces.
Hard face
Header tank
An external vessel providing a pressurized barrier fluid to a double seal, either with
a static head or with a thermal siphon system.
Heat checking
The formation of fine radial cracks on a hard seal face caused by thermal stresses
set up by inadequately lubricated or dry running and quenching by the sealed fluid.
Heat exchanger
A device for cooling a fluid by heat transfer. Heat exchangers might be internal to
the pump, or externally mounted and connected with piping spools. Typically,
these heat exchangers also cool the water that passes through the pump water
bearing. Three types of construction are used for these heat exchangers: a tube-intube, a tube bundle, or a rotating baffle type. Cooling water might be provided from
the component cooling water system (CCW).
Hook sleeve
A cylindrical sleeve with a step or hook at the product end placed over the shaft to
protect it from wear and corrosion. This step is usually abutted against the impeller
to hold it in place with a gasket between the shaft and the step (hook).
Hydraulic balance
Hydraulic load
The load on the floating seal member resulting from differential pressure between
the seal chamber and the low-pressure side of the seal acting on the area of the
sealing ring above the balance diameter plus that caused by pressure on the lowpressure side acting on the area of the seal ring below the balance diameter.
Definition
Hydrodynamic
lubrication
Fluid-film lubrication in which the pressure in the fluid film is generated by the
relative velocity between the seal faces; this can be in either a circumferential or
an axial direction.
Hydrodynamic
seal
Hydrostatic
instability
Face separation occurring when hydraulic opening forces exceed the total closing
force.
Hydrostatic
lubrication
Fluid-film lubrication in which the pressure in the fluid film is generated externally
to the seal faces, and is used to maintain separation of the seal faces.
Hydrostatic
opening force
The separating force on the seal faces resulting from the hydrostatic pressure
between the faces.
Hydrostatic seal
A mechanical seal designed to operate with hydrostatic lubrication between the seal
faces. Some seals in use as main coolant pump seals are of hydrostatic film riding
taper face design. These seals use large converging gap geometry designed to
separate the seal faceplates by introducing pressurized fluid before the pump is
rotated.
Icing
Inside mounted
seal (or internally
mounted)
The common arrangement with the mechanical seal mounted inside the pump or
sealed vessel. No parts of the seal's flexible element or stationary faces are outside
the gland. In this arrangement the sealed liquid is in contact with the outer diameter
of the seal faces.
Internal
circulating device
A device located in the seal chamber to circulate seal chamber fluid through an
internal cooler area or an external cooler barrier/buffer fluid reservoir. Usually
referred to as a pumping ring.
L10 life
A statistic used to express the life of a population of mechanical seals; it is the time
when 10 percent of the seals have failed.
Lapping
Leakage
Sealed fluid loss from the system; it includes non-obvious vapor formed by
evaporation, as well as the more obvious liquid emission. Leakage might occur
through secondary as well as primary seals.
Leakage rate
Light band
Refers to the wavelength of helium light (= 11.6 micro-inches, or 0.29 Pm) used as
a measure of the flatness of the seal faces.
2-7
Definition
Mating ring
Maximum
allowable
working pressure
(MAWP)
The greatest discharge pressure at the specified pumping temperature for which the
pump casing is designed.
Maximum
dynamic sealing
pressure (MDSP)
The highest pressure expected at the seal (or seals) during any specified operating
condition and during start-up and shutdown. In determining this pressure,
consideration should be given to the maximum suction pressure, the flush pressure,
and the effect of clearance changes with the pump.
Maximum static
sealing pressure
(MSSP)
Main coolant
pump (MCP)
The term used to describe a group or family of reactor coolant pumps used in
pressurized water reactors, and reactor recirculation pumps used in boiling water
reactors, is main coolant pumps (MCP).
Mechanical seal
A device for sealing a rotating shaft whereby the sealing interface is located
between a pair of radial faces, one rotating, the other stationary.
Mixed lubrication
Condition of lubrication where the load between the seal faces is partly carried by
boundary lubrication and partly by fluid-film lubrication.
Mean time
between failures
(MTBF)
Mean time between failures. A statistic used to express the life of a population of
mechanical seals. It is given mathematically by the expression
MTBF
L1 L 2 . . . L n
n
2-8
Neck bush
Closed clearance bush at the inner end of seal chamber to restrict flow of dirty fluid
from pump into the seal chamber or to maintain pressure of recirculation flow in
seal chamber.
The difference between the total closing force and the hydrostatic opening force.
Non-flashing
A fluid state that does not change to a vapor phase at any operating condition or
operating temperature.
Non-flashing
hydrocarbon
service
This category includes all hydrocarbon services that are predominately all
hydrogen and carbon atoms; however, other non-hydrocarbon constituents might
be entrained in the stream. A product in this category does not require vapor
suppression to prevent transformation from a liquid phase to a vapor phase. For this
publication, the definition of non-flashing means that the vapor pressure is less than
1 bar (14.5 psia) at pumping temperature.
Non-hydrocarbon
service
This service category includes all services that cannot be defined as containing all
hydrogen and carbon molecules. However, some hydrocarbons might be entrained
in the fluids. Included in this category are boiler feed water (and other water
services), borated water, caustics, acids, amines, and other chemicals commonly
used in refinery services.
Definition
Non-pusher type
seal
A mechanical seal (usually metal bellows) in which the secondary seal is fixed to
the shaft. A bellows seal is an example of a non-pusher seal in which the dynamic
secondary seal is eliminated.
Operating length
Optical flat
An optical flat is a precision ground quartz or Pyrex plate. When light waves reflect
off the lapped surface through the flat, light bands are visible. The greater the gap
between the flat and the lapped surface, the larger the number of light bands. When
used with a monochromatic light (emits only one wavelength visible light), the
number of light bands can be used to measure the flatness of the lapped parts.
Orifice nipple
A pipe nipple made of solid bar stock with an orifice drilled through it to regulate
the flush flow commonly found on Plan 11 systems described in API 682. The
nipple should be welded to the discharge casing.
O-ring
Outside mounted
seal
Perfluoroelastomer
Popping
A term used to indicate intermittent leakage of vapor resulting from a rapid change
in fluid state from liquid to gaseous and characterized by a popping sound.
Pressure
breakdown cells/
staging coils
Staged seal designs in MCPs use an orifice to bypass a small flow around each seal
to reduce pressure to subsequent stages. This configuration allows pressure to be
evenly distributed at each seal stage. The orifice is usually either a series of small,
machined grooves or a coil of small diameter tubing. These breakdown devices are
referred to as pressure breakdown cells or staging coils.
Pressure casing
The composite of all stationary pressure-containing parts of the seal, including seal
chamber, seal gland, and barrier/buffer fluid chamber (container) and other
attached parts, but excluding the stationary and rotating members of the mechanical
seal.
Primary seal
Mechanical seals have a rotating seal ring and a stationary seal ring. Fluid sealing
occurs at the interface of the rotating ring and the stationary ring. The seal that
occurs at this interface is often referred to as the primary seal.
Primary ring
Product
Product
recirculation
Circulation of the product through the seal chamber to provide cooling (see
recirculation flow, reverse circulation).
Product
temperature
margin
Pumping ring
A device fitted inside the seal chamber to circulate the liquid in the seal chamber
through an external cooler and/or header tank.
2-9
2-10
Term
Definition
A mechanical seal in which the secondary seal (for example, an O-ring, U-cup,
plastic wedge ring) is mechanically pushed (and therefore can move) along the
shaft or sleeve to compensate for face wear. Bellows are not classified as pusher
type seals.
PV factor
Quench
A neutral fluid, usually water or steam, introduced on the atmospheric side of the
seal to retard formation of solids or crystallization of dissolved solids that might
interfere with seal movement.
Quench chamber
Enclosed space on the atmospheric side of a mechanical seal to which the quench is
introduced; normally fitted with an auxiliary seal to prevent excessive leakage to
the atmosphere.
RMS or Ra
Root mean square or roughness average terms used to define surface roughness.
Random failures
Failures occurring during operation, other than early-life failures and those caused
by normal wear-out of the seal faces.
Recirculation flow
Flow of the product from the pump discharge through the seal chamber to the back
of the pump impeller, or from the back of the pump impeller through the seal
chamber to the pump suction.
Recirculation
impeller
Many MCPs have external heat exchangers mounted to the pump motor stand.
These heat exchangers require the fluid to be pumped from the seal/bearing cavity
to the heat exchanger and back. The recirculation impeller is normally a shaftmounted, axial flow-type impeller. Flow rates are normally in the range of 30 to 50
gpm (113 to 189 lpm) for MCPs.
Reverse balancing
Selection of the balance diameter so that a mechanical seal can withstand pressure
on the inside diameter of its face rather than on the outside diameter, that is, the
reverse of normal outside diameter pressurization. This is of particular use for the
inboard seal of a double seal as it puts any solids on the outside diameter of the
inboard seal and minimizes clogging.
Reverse
circulation
Flow of the product from the back of the pump impeller through the seal chamber
to the pump suction to provide cooling of the seal and reduce access of solids to the
seal faces.
Rotating balance
A rotating balance seal has the balance diameter Db on the rotating member.
Rotating seal
Mechanical seal in which the floating seal member is mounted on the shaft.
Rotating seal
member
The seal member that is mounted on the shaft, either directly or on a sleeve that
rotates with the shaft.
Rotation (coning)
Rotation (or conical deformation) of the seal ring cross-section due to torsional
ring-type axisymmetrically-distributed load applied by the differential pressure or
thermal load.
Seal arrangement
The way in which a seal is mounted in the seal chamber and the method of
exercising control over the liquid in the seal chamber, viz, dead-ended, product
recirculation (see also API piping plan).
Definition
See balance ratio.
Seal cavity
The seal assembly fits inside the pump between the shaft and housing. The area
that the seal fits into is referred to as the seal cavity.
Seal chamber
The region between the shaft and the pump case (housing) into which the shaft seal
is installed.
Seal configuration
The design or style of the primary seal (for example, pusher seal, bellows seal,
double seal).
Seal envelope
Seal environment
The radial dimension of the sealing face measured from the inside edge to the
outside edge.
Seal face(s)
The surfaces of the seal ring and seat in contact with each other.
Seal head
Assembly consisting of primary ring, spring, retainer, set screw, and secondary seal
(see Figure 3-1).
Seal injection
Plant designs include MCPs both with and without seal injection. Many seal
designers prefer units with seal injection, believing these installations to be more
reliable. Seal injection is taken off the charging and volume control system on
PWRs and off the control rod drive system for BWRs. Seal injection provides a
source of cool filtered water entering the pump seal cavity. Filter sizes typically
range from 2 Pm to 20 Pm and the supply temperature is usually between 110F
(43C) and 120F (49C).
Seal plate
A plate that is bolted to the seal chamber and carries the stationary seal member.
Seal reference
dimension
A reference mark scribed on the shaft to ensure that a mechanical seal is fitted with
the correct operating length.
Seal ring
The floating seal member (sprung seal member) that contacts the mating ring. It
can be either the stationary or rotating seal member.
Seal setting
The proper relative position of the rotating portion of the seal to the stationary
portion of the seal is necessary to establish the proper seal spring force. The
process of establishing this position is termed setting the seal. Some designs do not
require any adjustments, only that certain dimensions be measured to confirm the
seal setting dimensions. Other designs rely on taking measurements on the
assembled seal prior to installation, then establishing the same reference dimension
once the seal is installed in the pump.
Seal size
The maximum diameter of the shaft that will pass through the seal, that is, the
diameter of the shaft (or shaft sleeve) to which the mechanical seal is fitted.
(Alternative definitions based on other dimensions, for example, balance diameter,
are also in current use).
Seal springs
Staged seals use coil springs to create closing force at low pressures. The force
from the springs must be great enough to overcome the frictional forces from the
secondary seal, but not to cause unacceptably high contact pressure when the seal
is operating at low pressures.
2-11
2-12
Term
Definition
Seal tooling
Some mechanical face seals require special tools for inspection, assembly,
installation, removal, and refurbishment. This collection of special tools is
generally referred to as seal tooling. Seal tooling should be carefully controlled to
ensure that the tools are not lost or discarded. Attempts to perform seal
maintenance with inadequate tooling can result in equipment failures.
Sealant
Sealed fluid
Sealed pressure
Sealing interface
Seat
The axially fixed (unsprung) sealing element. It can be either the stationary or
rotating seal member.
Secondary
containment
Secondary seal
Seal used to prevent leakage through paths alternative to that between the seal
faces. See dynamic and static secondary seals.
Secondary seal
land
That part of the shaft or seal sleeve in contact with the dynamic secondary seal.
Service condition
Shaft sleeve
A sleeve fitted between the shaft and a mechanical seal to provide a wear-resistant
and replaceable secondary seal land. The sleeve is sealed to the shaft with
elastomers.
Shelf life
Some mechanical face seal components have a specific shelf life. These parts are
usually elastomers that have a shelf life of 5 to 10 years when properly stored.
Additionally, lapped parts should always be verified prior to installation.
Occasionally, lapped parts will distort over time and need to be relapped prior to
installation.
Single seal
A seal arrangement with only one mechanical seal regardless of whether other seal
types (for example, throttle bush, lip seal) are included in the seal arrangement.
A gland plate with slots instead of holes for the mounting studs.
Soft face
Seal faces manufactured from a relatively softer material (for example, carbongraphite or PTFE) as compared to a harder mating seal face material (for example,
tungsten carbide).
Solid length
Specific load
Spring load
The load on the floating sealing element exerted by the seal spring(s).
Spring pressure
Definition
Stage
Many MCP seals use multiple mechanical seals in series, each seal having a
predetermined differential pressure created by the controlled bleed-off. Each
individual seal in this style design is termed a stage. Seals of this type of design are
termed staged seals.
Start-up torque
Static secondary
seal
Seal used to prevent leakage between assembled parts that are not subject to
relative motion in service, for example, between seal sleeve and shaft, between
stationary seal member and seal plate.
Stationary balance
A stationary balance seal has the balance diameter Db on the stationary member.
Stationary seal
Mechanical seal in which the floating seal member is mounted on the seal plate.
Stationary seal
member
Stationary seal
ring
The stationary seal ring is mounted in a supporting piece called a gland, carrier,
holder, or ring support. In staged seal designs, the seal ring is generally a soft
material, normally carbon graphite. In hydrostatic seals, the stationary member
consists of an aluminum oxide or silica nitride faceplate mounted on a ring support.
Stator
Stuffing box
Alternative name for seal chamber, carried over from soft-packing technology.
Tandem seal
Thermal stress
failure
Throat bushing
A device that forms a restrictive close clearance around the sleeve (or shaft)
between the seal and the impeller.
Throttle bush
A close-fitting bush around the shaft to restrict flow; can be used at the inner end of
the seal chamber (neck bush) or as an auxiliary seal.
Throttle bushing
A device that forms a restrictive close clearance around the sleeve (or shaft) at the
outboard end of a mechanical seal gland.
Total closing
force
The sum of the hydraulic load and spring load acting on the floating sealing
member to close the seal faces.
Total indicated
runout (TIR)
2-13
Definition
Toxicity rating
2-14
Unbalanced seal
U-ring
Vent connection
A connection to the seal chamber for eliminating gas or vapor from the seal
chamber. This is normally accomplished through a gland connection, such as the
flush connection.
Volatile
hazardous air
pollutants
(VHAP)
Any compound as defined by Title I, Part A, Section 112 of the National Emission
Standards for Hazardous Air Pollutants (Clean Air Act Amendment).
Volatile organic
compound (VOC)
V-ring
Waviness
Deviation of the seal faces from circumferential flatness. Waviness can be present
on the faces as manufactured or can develop after running.
Wear track
The wear mark of the narrower seal face on the wider one.
Wedge ring
Support surface
Most seal designs provide some type of support surface for the seal rings to control
seal ring deflection. Different terminology might be used for these surfaces, such as
seat or back seat. In this publication, surfaces controlled to limit seal ring
deflections will be referred to as support surfaces.
Thermal barrier
Most MCP designs are insulated from the high Reactor Coolant System (RCS)
temperatures by a thermal barrier. The thermal barrier reduces pump cover (or
main flange), pump water bearing, and shaft seal cavity temperatures.
Total outflow
The combined flow, consisting of seal leakage and controlled bleed-off, which
leaves the seal cavity is referred to as total outflow. This flow rate is the amount of
fluid that leaves the seal cavity and is made up with injection or RCS that has been
cooled through the seal heat exchanger.
Wear tracking
The mating surfaces of both hydrostatic and hydrodynamic seals operate in close
proximity. The faces might either contact or have particulates contact the seal ring
faces, resulting in a circular grooving or wear pattern referred to as wear tracking.
3
TECHNICAL DESCRIPTION
3.1
A mechanical face seal is a dynamic seal that prevents leakage of pressurized fluid between a
rotating shaft and a stationary housing. Mechanical face seals are available in a variety of
configurations, and their selection depends on the application. However, no matter what the
application is, all mechanical face seals operate on the same principle. Basically, the seal is
comprised of two rings, either of which rotates relative to the other. One of the rings is usually
mounted rigidly and the other is mounted so that it can flex and align axially and angularly with
the rigidly mounted ring. Dynamic sealing is achieved at the interface between the two rings, the
primary ring and the mating ring. The rings achieve a seal at the interface due to their very high
face flatness. Typically, the two rings are made of dissimilar materials.
The essential elements of a mechanical face seal are illustrated in Figure 3-1. These elements
serve the functions of sealing dynamically and statically, loading the faces, and transmitting
rotation to the ring. The essential elements are described below. Advantages and disadvantages
of various configurations of these elements are discussed in Table 3-2.
Figure 3-1
Essential Components of a Mechanical Face Seal
Primary Ring: The primary ring is also called a seal ring. The primary ring is the floating seal
element that is usually spring-mounted and permits axial and angular alignment in the assembly.
Depending on the application requirements, it can be either the rotating member as shown in
Figure 3-1 or the stationary member as shown in Figure 3-10. The method in which the primary
3-1
ring is mounted is dictated by the application requirements because each configuration offers
both advantages and disadvantages. The mechanical face seal design or style is defined by the
primary ring configuration, that is, rotating primary ring, stationary primary ring, double seal,
bellows seal, and so on.
Mating Ring: The mating ring is also called a seat or seal seat. The mating ring is the rigidly
mounted element and can be installed in the housing as shown in Figure 3-1 or on the shaft as
shown in Figure 3-10. Where the mating ring is installed is dependent upon the application
requirements and the preferred implementation of the primary ring.
Key Technical Point
Mechanical face seals come in a variety of configurations, materials, and
designs for primary sealing faces, secondary seals, springs, drive
mechanisms. Options also include unbalanced or balanced designs, whether
the primary seal or the mating seal is rotating, and whether the fluid
pressure is on the outside or the inside surface of the seal. Seal design for a
given application should be selected after a careful evaluation of trade-offs,
as discussed in this section, Section 3.
Secondary Seal: Seals used to prevent leakage through paths alternative to that between the seal
faces. The secondary seals can be static or dynamic. Static secondary seals prevent leakage
between assembled parts that are not subject to relative motion in service, for example, between
seal sleeve and shaft, between stationary seal member and housing. Dynamic secondary seals
prevent leakage between the shaft or housing and the floating seal member.
The type of secondary seal depends on the fluid type, service pressure, and service temperature.
Table 3-1 provides the operating temperature limits and properties of materials typically used for
secondary seals.
3-2
Nitrile
Temp
F
-22 to 248
-30 to 120
Air
Permeability
Properties
0.25-1.00
General purpose
Low cost
Oil resistant
Attacked by ozone
Ethylene
Propylene
-58 to 302
-50 to 150
9.6
Silicone
-67 to 392
-55 to 200
170-260
Neoprene
-31 to 248
-35 to 120
104
Weather resistant
Fair oil resistant
Fluoroelastomer
14 to 302
-10 to 150
0.32
PTFE
-67 to 446
-55 to 230
Polyacrylate
-22 to 347
30 to 175
1.5
Epichlorohydrin
-40 to 302
-40 to 150
.015-0.70
Oil resistant
Low permeability
Metal Bellows
High
Temperature
Fluoroelastomer
-328 to 1202
650
-200 to
12 to 545
-10 to 285
Positive seal
Chemical resistant
0.32
Spring
Springs are used to develop the contact load between the primary ring and the mating ring in the
absence of fluid pressure. The amount of face load generated can vary significantly depending on
the type of spring selected. The choice includes a single coil spring, multiple coil springs, metal
bellows, non-metal bellows, wave or Belleville washer, and magnets (see Figures 3-2 to 3-7). In
some cases, such as bellows, the spring can serve both the face-loading function and the
secondary sealing function. Advantages and disadvantages of each type of spring are
summarized in Table 3-3.
3-3
Figure 3-2
Multiple Coil Springs
Figure 3-3
Single Coil Springs
Figure 3-4
Corrugated Bellows
Figure 3-5
Welded Bellows
3-4
Figure 3-6
Rubber Bellows
Figure 3-7
Belleville Washers
Drive Mechanism: All mechanical face seals require some kind of device to position the
primary ring axially and to transmit the rotation of the shaft to the primary ring to ensure that
relative motion occurs only at the seal faces. The drive mechanism is designed such that it is not
rigidly attached to the primary ring so that it does not prevent self-alignment between the
primary ring and the mating ring. The drive mechanism is typically a setscrew, locking collar,
key, or wedge ring. In some designs, the secondary seal is used to transmit the torque to the
primary ring when sufficient friction can be developed at the secondary seal interface. The drive
mechanism is also used to provide torque restraint to the stationary seal if the static secondary
seal does not develop sufficient friction to prevent the stationary seal from turning.
Seal/Flushing Chamber: An area around the seal is provided to permit heat transfer through the
fluid and to allow flushing of contaminants such as abrasive particles or toxic media. In a singleseal configuration, flushing is accomplished by injecting a liquid into the seal chamber at a
higher pressure than the sealed product.
3-5
Externallymounted
primary seal
Rotating primary
seal
Stationary
primary seal
3-6
Balanced seal
Unbalanced
seal
Advantages
Better cooling - seal surrounded by
product
Pressure acts to close the seal faces
(pressure assisted)
Can therefore be used at high
pressure
Components in compression
(preferable to tension)
Rotating elements centrifuge
particles away from seal face
Lower leakage due to centrifugal
action
Most of the seal is inside machine
housing, less space required outside
housing
Seal leakage containment is simpler
Easier to install/replace
Easier to inspect
Minimizes components in contact
with pumped fluid (corrosives, etc.)
Centrifugal action keeps particles
away from flexible member
Generally requires less axial
envelope, particularly outside seal
chambers
Smaller radial section for a given
shaft size
Generally lower cost
Capable of higher speeds
Better able to cope with
misalignment (particularly angular)
Less prone to clogging if leaked
product is inside seal chamber
Will accept media with higher
viscosity
Less friction loss due to turbulence of
liquids
Capable of much higher pressures
and/or speeds (enhanced Pressure,
Velocity (PV) capability)
Smaller envelope, particularly radial
No step required on shaft or sleeve
Lower cost
Disadvantages
No access for visual inspection
Any repair/replacement is labor
intensive
Subject to environmental
contamination and external
damage from other environmental
factors
Dynamic pusher
seal
Metal bellows
Single spring
seal
Multi-spring seal
Wave/Belleville
Magnetic
coupling
Advantages
PTFE bellows used in very severe
corrosive duties
Rubber bellows seal low in cost
Eliminates sliding packing (hang-up
hysteresis, sleeve wear)
More robust
Higher pressure/temperature/speed
capability
Rubber bellows require specially
designed components in a variety of
materials to cope with different media
Less prone to fatigue failure
More tolerant to shock and vibration
Eliminates sliding packing (hang-up
hysteresis, sleeve wear)
Can be used at higher temperatures
Can be used at higher speeds
Inherently balanced without stepping
shaft/sleeve
More compact (particularly larger
sizes)
Can be used for a flexible drive
Larger section, more robust
Better protection against corrosion
Less prone to clogging
Smaller radial space
Low stiffness gives greater axial
tolerance on fitting
Shorter axial length
Rotating seal can tolerate higher
speeds
Independent of direction of rotation
(some single spring designs are also
independent)
More consistent loading onto face
Disadvantages
Rubber bellows require specially
designed components in a variety
of materials to cope with different
media
3-7
Advantages
Disadvantages
Uneven loading
Low cost
More costly
Wave/Belleville
washer
Saves space
Elastomer bellows
Relatively inexpensive
Expensive
Corrosion resistant
Corrugated/welded
metal bellows
High temperature
High controlled spring rate
3.2
Design variations of the basic mechanical face seal illustrated in Figure 3-1 permit extending the
application range and life of the seal. The configuration variation description is based on two
primary factors:
x
A combination of these two parameters results in the four configurations illustrated in Figures 38 through 3-11. Figures 3-8 and 3-9 show rotating primary rings where pressure is applied to the
outside diameter of the seal and the inside diameter of the seal, respectively. Conversely, Figures
3-10 and 3-11 show a stationary primary ring with pressure on the outside and inside of the seal,
respectively. A description of each configuration, with its advantages and disadvantages, is given
in Table 3-2.
Rotating Primary Ring - Outside Pressure: This configuration (Figure 3-8) is also referred to
as a rotating primary ring - inside mounted. In this configuration, the primary ring is mounted on
the shaft inside the stuffing box and pressure is applied on the outside diameter of the seal faces.
A major advantage of this setup is that the product surrounds the face seals to provide good
cooling.
3-8
Figure 3-8
Rotating Primary Ring - Outside Pressure (or Inside Mounted)
Rotating Primary Ring Inside Pressure: This configuration (Figure 3-9) is also referred to
as rotating primary ring - outside mounted. In this configuration, the primary ring is mounted
outside the stuffing box and pressure is applied to the inside diameter of the seal faces. These
designs are easier to install and inspect than the other configurations. Because the pressure works
to push apart the seal faces, this design is not suitable for high pressures.
Figure 3-9
Rotating Primary Ring - Inside Pressure (or Outside Mounted)
Stationary Primary Ring Outside Pressure: This configuration (Figure 3-10) is also
referred to as stationary primary ring - inside mounted. In this configuration, the primary ring is
mounted on the housing inside the stuffing box and pressure is applied on the outside diameter of
the seal faces. This design offers higher speed capability with ease of inspection. Because the
rotating ring does not have multiple parts, this configuration is less susceptible to imbalance.
Figure 3-10
Stationary Primary Ring - Outside Pressure (or Inside Mounted)
3-9
Stationary Primary Ring Inside Pressure: This configuration (Figure 3-11) is also referred
to as stationary primary ring - outside mounted. In this configuration, the primary ring is
mounted on the housing inside the stuffing box and pressure is applied on the outside diameter.
This design also offers high-speed capability and is less susceptible to imbalance due to a single
rotating ring.
Figure 3-11
Stationary Primary Ring - Inside Pressure (or Outside Mounted)
3.3
Multiple Seals
Some applications require the use of multiple seals to provide for flushing or barrier fluids, or
pressure staging to deal with higher pressures. Flushing is used to remove contaminants, to cool
the faces, or to provide for proper lubrication. This is achieved by installing the seals in a backto-back or face-to-face configuration, as illustrated in Figures 3-12 and 3-13. For cooling and
solids/abrasives removal, fluid can be re-circulated from the product side or provided by an
external source. In applications where the product has a relatively low vapor pressure, for
example, water or hydrocarbons, a barrier fluid with a higher vapor pressure is used to keep the
product from vaporizing at the seal interface and to prevent the inboard seal from running dry. If
the product is toxic or harmful, a clean barrier fluid is introduced at a higher pressure to
minimize toxin release. The outboard seal also provides a back-up in case of failure of the
product seal.
Figure 3-12
Back-to-Back Dual Seal
3-10
Figure 3-13
Face-to-Face Dual Seal
Figure 3-14
Pressure Stage Tandem Seal
3-11
3.4
Seal Cartridges
Seal cartridges are pre-assembled mechanical face seal assemblies that contain all of the essential
components. Cartridges are used to package mechanical face seals for ease of handling and
installation. An example of a single seal cartridge is shown in Figure 3-15. In this arrangement,
the primary ring and its associated devices are mounted on a sleeve temporarily attached to the
enclosure that holds the mating ring. The assembly provides for proper spring loading and axial
positioning of the primary ring and mating ring. After the cartridge is mounted on the housing
and the sleeve is secured to the shaft, the temporary attachment device holding the sleeve to the
mating ring enclosure is removed.
Figure 3-15
Single Seal Cartridge
Cartridges can be provided with either rotating primary rings or stationary primary rings and
with single or multiple mechanical face seals. The schemes for assembling cartridges vary from
design to design.
Figure 3-16 shows a multi-stage balanced stator design seal cartridge assembly and Figure 3-17
shows details of one of the stages. This seal design is one of the four alternative designs
commonly used in a critical application (Main Coolant Pump) in U.S. nuclear power plants [35].
Key O&M Cost Point
Seal cartridges are pre-assembled mechanical face seal assemblies that
contain all of the essential components. Cartridges are used to package
mechanical face seals for ease of handling and installation. Even though
material cost is higher, cartridges save money by simplifying maintenance
and eliminating installation related failures.
3-12
Figure 3-16
Balanced Stator Design Multi-Seal Cartridge Supplied by a Manufacturer for a Main
Coolant Pump [35]
3-13
Figure 3-17
Seal Stage Details of a Balanced Stator Design Multi-Seal Cartridge Supplied by a
Manufacturer for a Main Coolant Pump [35]
3-14
3.5
The seal chamber is sometimes referred to as the seal cavity or seal box. Figure 3-18 shows the
most common variations in the seal chamber designs in centrifugal pumps. The seal chamber is
the cavity where the mechanical face seal resides and is often the same stuffing box chamber that
was designed to house conventional soft packing. As such, the chamber provides only limited
volume for the fluid to circulate naturally. Lack of circulation leads to hot spots in the face seal,
and the stagnant cavity allows solids to settle. To overcome these space limitations, either an
alternative seal chamber design can be used or the seal chamber can be equipped with a means to
circulate fluid. Depending on the application, the circulated fluid can be the process fluid or an
external fluid selected to provide better conditions in which the seal can operate, or to control the
release of contaminants.
Figure 3-18
Common Variations in Seal Chamber Design
3-15
Based on research in seal chamber designs [7,48], it is now well established that enlarged seal
chambers, and the use of tapered bore chambers, can dramatically lower fluid temperature and
seal face temperatures. Wherever the envelope constraints in a given pump application permit,
the seal chamber should be enlarged to improve the seal performance/life due to lower
temperatures and increased fluid circulation around the seal. The seal chamber design also plays
a critical role in obtaining satisfactory performance from mechanical face seals handling abrasive
slurries.
Key Technical Point
Mechanical seals are often installed in the same cavity that is designed to
accept conventional packings. This limits the fluid circulation around the
seal, leading to high seal temperatures and accumulation of solids. An
enlarged seal chamber with tapered bore can dramatically improve fluid
circulation, lowering seal temperature and eliminating accumulation of
solids.
In addition to the chamber design, seal flushing is dictated by application requirements in many
cases to achieve satisfactory performance. API Standard 682 describes 17 plans to flush the seal
chamber [8]. Selection of the type of plan needed will depend on the process fluid and operating
temperature. Fluids having high vapor pressures (for example, hot water, light hydrocarbons,
etc.), high temperature, containing abrasives (for example, service water, slurries, etc.), or
containing dissolved solids (for example, borated water) are common mechanical seal
application problems that can benefit from flushing.
The most common API Standard 682 flush plans used with clean process fluids are Plan 11 and
Plan 21. Plan 11 is illustrated in Figure 3-19. To control the amount of fluid re-circulated, a
throttle bushing is incorporated inboard of the mechanical face seal and a control orifice is
installed in the flush line. Flow enters the seal chamber adjacent to the mechanical face seal,
flushes the faces, and flows across the seal back into the pump. Plan 21 is similar to Plan 11
except that a cooler is installed in the flush line in series with the control orifice. For
contaminated process fluids, strainers/filters can be added to clean the flush fluid.
Figure 3-19
A Typical Flush Plan for a Cooling Seal Chamber
3-16
3.6
Closing Force
In order for the face seal to function properly, a certain amount of face load is required. Face
loading is developed by the energizing springs and by the process of pressure acting on the
unbalanced area of the seal. The closing force is the sum of the spring load plus the fluid
pressure, multiplied by the unbalanced area, and is expressed as:
Fclosing
=
=
=
=
=
=
=
=
=
=
Where,
'P
Af
B
P1
P2
Fclosing
Fs
Fh
3-17
The total closing force, Fclosing, is supported primarily by the fluid film pressure (p) between the
seal faces, and the residual force is supported by mechanical asperity contact (pm) between the
faces:
Fclosing
k p Af + pm Af
In this equation, k is a factor that can vary between zero and 1.0, depending upon the actual
pressure distribution across the face.
k = 0.5 for linear pressure distribution
> 0.5 for convex pressure distribution,
< 0.5 for concave pressure distribution
The value of k depends upon whether the faces are parallel convergent or divergent (Figure 4-3)
as further discussed in Section 4.4.4.
3.6.1 Balance Ratio
Mechanical face seals can be of an unbalanced design, a fully balanced design, or partially
balanced design to reduce the face loading due to hydraulic pressure, as shown in Figure 3-20.
The term balanced refers to the case where B < 1.0, or where the average pressure load on the
face is less than the sealed pressure. Most mechanical face seals have a balance ratio between
0.65 to 0.85. This range provides reduced face loading while maintaining stability. The seal can
become hydraulically unstable or the seal faces can separate under pressure fluctuations if the
balance ratio becomes less than 0.65. Seals with a balance ratio greater than 1.0 are termed
unbalanced, that is, these seals have an average pressure load on the face that is greater than the
sealed pressure. While most seals that operate at high pressure are of the balanced type, many
low-pressure seals operate at B > 1.0 because of the convenience of design.
3-18
Figure 3-20
Unbalanced, Balanced, and Partially Balanced Seal Designs
3-19
Be
S/4 D 2o D 2b
S/4 D o2 D i2
2 D2
b
D o
D o
D i2
Bi
S/4 D 2b D i2
S/4 D o2 D i2
2 D2
b i
2
2
D o D
i
For bellows seals, the mean diameter can be used or, alternatively, diameter Dsb is substituted for
diameter Db:
D 2bo D 2bi
D sb
Where
B
Be
Bi
Do
Di
Db
Dsb
Dbo
Dbi
3-20
2
=
=
=
=
=
=
=
=
=
Figure 3-21
Face Pressure Distribution Due to Hydraulic Pressure and Spring Force
3-21
Figure 3-22
Rotating Seal Balance Designs
3-22
3.7
The measure of a seal to provide useful service is defined by its PV parameter that, like Journal
bearings, is the product of the pressure and the sliding velocity. Two ways are used to define the
PV parameter. The first method uses differential pressure multiplied by the average sliding
velocity, and the second method uses net face pressure multiplied by the average sliding velocity.
The more common method used by mechanical face seal manufacturers and users to rate the PV
parameter, is the differential pressure drop method because it can be easily related to seal
operating pressure and balance ratio does not need to be known.
Table 3-4 provides the PV values (based on differential pressure approach) for materials
commonly used in both unbalanced and balanced mechanical face seals.
In general, the unbalanced seal design is simpler and less costly, and is the preferred choice if it
satisfies the PV limits for a given application. The balanced seal design permits operation under
higher pressure and speed combinations but it requires a stepped shaft or stepped sleeve
arrangement, which is generally more expensive. If the fluid is clean (free of abrasives/solid
particles) and is compatible with the carbon material, the carbon versus the appropriate harder
material combination should be selected. For non-clean fluids, both seal faces need to be hard to
provide satisfactory wear life.
Table 3-4
Approximate PV Limits psi-ft/min (Mpa-m/sec) for General Seals with Various
Combinations of Seal Face Materials and Fluids
Water and Aqueous Liquids
Face Material
Combination
Unbalanced
Balanced
Other Liquids
Unbalanced
Balanced
Carbon vs.
4
1.45x 10 (3)
1.01 x 10 (3.5)
x Stainless steel
1.45 x 10 (0.5)
x Lead bronze
7.23 x 10 (2.5)
x Stellite
x Alumina
1.01 x 10 (3.5)
2.46 x 10 (8.6)
1.45 x 10 (5)
6.08 x 10 (21)
2.60 x 10 (9)
1.22 x 10 (43)
1.22 x 10 (43)
1.82 x 10 (64)
x Chrome oxide
2.03 x 10 (7)
x Tungsten carbide
2.03 x 10 (7)
x Silicon carbide
2.60 x 10 (9)
1.68 x 10 (59)
1.22 x 10 (43)
3.53 x 10 (124)
5.35 x 10 (188)
1.22 x 10 (43)
3.04 x 10 (106)
6
6
2.60 x 10 (9)
2.60 x 10 (9)
2.03 x 10 (7)
2.60 x 10 (9)
6
6
1.30E+10 (4.6)
5
1.74E+10 (6)
7.52 x 10 (26)
1.04 x 10 (36)
3-23
3.8
For a mechanical seal to function reliably, a fluid film needs to be maintained between the seal
faces. Operation of the seal results in frictional heat generation at the sealing interface, which
lowers the fluid viscosity and the load carrying capacity of the liquid film. The load bearing
capacity can decrease sufficiently and result in heavy contact between the seal face, causing
severe wear or face damage. The frictional heat can also raise the temperature of the liquid film
at the sealing interface to such an extent that fluid instantaneously changes its phase from liquid
to gaseous under the pressure that is present on the low-pressure side of the seal. This phase
change often causes an intermittent banging or popping sound and results in severe face damage
and excessive leakage.
During seal operation, it is necessary that a stable liquid film be maintained, considering the
anticipated increase in temperature ('T) due to the seal friction over the bulk fluid temperature.
Figure 3-23 shows how pressure and temperature affect the boiling point of a liquid, and the 'T
margin that needs to be maintained between the bulk fluid temperature and the boiling point
curve to accommodate the increase in fluid temperature at the sealing interface without causing
vaporization. This figure also shows the operating envelope for seal performance defined by the
pressure/temperature limits (including the 'T margin), as well as the PV limit.
Cooling of the seal chamber (for example, by using one of the flushing arrangements described
in Section 3.5) protects against boiling of the fluid, as does an increase in the chamber pressure
above the vapor pressure. The most suitable approach to suppress boiling and ensure adequate
'T margin below the limit depends upon the application. Technical performance data regarding
the 'T margin should be obtained from seal manufacturers to evaluate and ensure reliable
operation in a given application.
Key Technical Point
For satisfactory performance, the seal design and material selections should
satisfy the PV limit and the 'T limit under all operating conditions to ensure
that fluid film is maintained between the seal faces. Loss of film can lead to
immediate seizure and seal failure.
3-24
Figure 3-23
Pressure/Temperature Operating Envelope Showing 'T Margin Required for Seal
Operation
3.9
A fundamental requirement for a mechanical face seal to function reliably is that the faces be
separated by a thin fluid film during operation. In practice, a small amount of asperity contact
between the faces occurs in most applications, causing a small amount of wear that determines
seal life but does not affect seal performance. Under high pressure and high temperature
combinations, the film thickness decreases and the asperity contact between the faces increases,
which in turn increases seal friction and heat (see Section 4.4.1 for further discussion). This
limits the pressure, temperature, and speed performance envelope, as well as, reliability of the
conventional flat face mechanical seals. The problem becomes especially severe when sealing
hot water and other low lubricity fluids [21-34].
One approach that has proven to be successful for sealing hot water under high pressure and high
speeds, as well as for sealing other high-volatility, low-lubricity fluids, is the use of seal face
designs that have positive hydrodynamic lubrication features. Figure 3-24 is the first design that
became commercially successful and is widely used in critical hot water sealing applications
(including Main Coolant Pumps) in many European nuclear power plants and some U.S. nuclear
power plants [3]. In this design, the cooling notches or thermal hydrodynamic grooves introduce
circumferential waviness of the seal face due to variations in the temperature around the seal
circumference.
3-25
Figure 3-24
Seal Face with Thermal Hydrodynamic Grooves for Positive Hydrodynamic Lubrication [3]
The circumferential waviness in conjunction with the relative rotational velocity between the
faces introduces a strong hydrodynamic action, higher film pressures, and a thicker film. This is
the fundamental mechanism responsible for extending the performance envelope of the seals
with hydrodynamic grooves on the seal face. It should be noted that the higher pressure and
speed capabilities are achieved at the cost of increased leakage and vulnerability of the seal to
ingest debris and unfiltered solid particulates in the fluid. The manufacturer of the specific seal
design being considered should be consulted for their recommendations and their experience in
similar applications. Prototype qualification testing is strongly recommended for critical service
applications.
As shown in Figure 3-25, the hydrodynamic grooves can be incorporated on the seal face to pick
up fluid from either the outer or the inner periphery, depending upon the application
requirements. Figure 3-26 shows several other variations of this basic approach to enhance the
lubrication between the seal faces.
3-26
Figure 3-25
Design Options with Hydrodynamic Grooves on the Outer Periphery or Inner Periphery of
Seal Face
Figure 3-26
Other Variations in Seal Face Geometry to Enhance Lubrication of the Faces
3-27
Several alternative designs that also maintain a full hydrodynamic film lubrication under high
duty application conditions (including transients) have been reported over the years since the
successful commercial introduction of the design shown in Figure 3-24. These include eccentric
seals for nuclear pumps, optimized grooves face seals, Rayleigh-step floating-ring seals, movingwave mechanical face seals, and polymer seal rings sliding against silicone carbide [37-41, 47].
Research in recent years has shown that the newest technology, laser-textured surface designs,
are capable of providing the full film lubrication (and therefore long life) without the penalty of
excessive leakage associated with the earlier hydrodynamic film seal designs. These include
laser-faced entry and return-flow recesses, laser-textured faces with micro-pores that serve as
micro-hydrodynamic bearings [42-46]. One of these laser-textured surface designs that has
emerged as a promising and commercially viable design was recently introduced by a seal
manufacturer [46].
3-28
In some applications, conventional mechanical face seals contain the leakage past the hydrostatic
seal. In this tandem configuration, most of the pressure breakdown occurs as leakage crosses the
hydrostatic seal, and the remaining pressure drop is taken across the conventional mechanical
face seal. Under normal operation, the mechanical face seal is exposed to a significantly lower
pressure drop than the hydrostatic seal. It is typically designed as a backup to the hydrostatic seal
to permit a safe shutdown of the system under higher pressure drop, should the hydrostatic seal
fail.
Hydrostatic seals are available in either a rotating balance design or a stationary balance design.
A detailed description of these designs, used in conjunction with hydrodynamic seals, is
provided in NMAC TR-100855, Main Coolant Pump Seal Maintenance Guide [35].
Figure 3-27
Hydrostatic Face Seal Design
3-29
4
FAILURE MODES AND FUNDAMENTAL MECHANISMS
4.1
Introduction
The purpose of this section is to describe the failure modes of mechanical face seals and the
fundamental mechanisms that are responsible for the failures. A significant amount of research
by seal manufacturers, universities, independent research organizations, national laboratories,
and seal users has continued over the last four decades to improve fundamental understanding of
the mechanisms that cause seal failure, which in turn has led to improvements in design, the
selection of an appropriate design for each application, and guidance for installation and
maintenance [3, 7, 9, 34, 36].
Industry-specific data were gathered under this project by conducting a utility survey to
determine the most common failure modes in the nuclear and fossil power applications. Analyses
were then performed to determine all of the significant seal failure mechanisms that are
described in this section.
4.2
The eventual failure mode of all mechanical face seals is leakage that is considered unacceptable
for the seal design/configuration being used. Excessive leakage can cause unacceptable loss of
fluid, reduction of pressure, or contamination of the system fluid by the barrier fluid in doubleseal installations.
Seal leakage can occur for a variety of reasons and might result from failure at any of several
leak paths. The possible leak paths in a typical mechanical face seal are (see Figures 3-1 and 315 for reference):
x
At the secondary seal in the sleeve (in seal designs employing sleeves)
While mechanical seal faces require some small level of leakage to function properly, the extent
of leakage above this minimum requirement can be from a few drops to a continuous drip. Under
normal performance, typical leakage rates from mechanical face seals are in the range of a
fraction of ml/hr to a few ml/hr, depending upon seal size, fluid viscosity, pressure, temperature,
4-1
and speed. There are no general quantitative criteria for what constitutes seal failure due to
excessive leakage.
The level of permissible leakage is dependent upon the operating requirements, environmental
and safety considerations, and economic considerations. In most clean water systems, quite high
leakage rates are often tolerated as long as other functions of the operation are not affected. In
general, most premature leakage problems result from improper selection of the seal design and
materials, improper use of the seal, and improper installation.
Key Technical Point
The eventual failure mode of all mechanical face seals is leakage that is
considered unacceptable for the seal design/configuration being used.
Excessive leakage can cause unacceptable loss of fluid, reduction of pressure,
or contamination of the system fluid by the barrier fluid in double seal
installations. The level of acceptable leakage is dependent upon the
application.
4.3
Industry Survey
Under this EPRI project, an industry survey was conducted to determine the most common
failure modes for mechanical seals encountered in the nuclear and fossil power plant
applications. A survey questionnaire was sent to all EPRI NMAC and FMAC utility members,
both domestic and international. The nuclear utilities included both BWR and PWR plants.
Appendix A includes a complete copy of the questionnaire. In addition to the survey results,
technical information from many other industry sources was used to identify the most common
failure modes and mechanisms responsible for the failures. Based on the above, the following
appear to be the most problematical mechanical seal applications:
x
This list does not include the main coolant pump seals, which, due to their higher importance,
have already been addressed separately in NMAC TR-100855, Main Coolant Pump Seal
Maintenance Guide [35].
4-2
It should be noted that the only European nuclear power utility that responded reported no
problematical applications. It is conjectured that, like most other European utilities, they are
using mechanical seal designs with special features (for example, thermal hydrodynamic grooves
or notches on the seal faces as described in Section 3.9) to provide enhanced seal face
lubrication.
A common denominator in all of these applications is sealing of hot water, which is a lowlubricity/high-volatility liquid that is difficult to seal, especially when high fluid pressures are
encountered [21-25]. The problem applications also include operation off the Best Efficiency
Point (mini-flow operation, variable flow requirements) and dissolved solids that can crystallize
(boric acid application).
The most commonly cited reasons (not root causes) for mechanical seal problems encountered at
the plants surveyed were:
x
Improper installation
Excessive axial or radial movement caused by off Best Efficiency Point operation cavitation,
out of balance, bent shaft, misalignment, and bad bearings
Improper design and face seal material selected for the application
Lack of training
4.4
Successful operation of mechanical seals depends upon the development of a thin film of fluid
[typically less than 40 micro-inches (1 Pm)] that separates the seal faces during operation, thus
keeping the seal wear to a minimum and providing long life [1-6]. It is now well accepted that
the fundamental mechanism responsible for generating a fluid film during operation of
mechanical seals is hydrodynamic lubrication caused by unavoidable geometrical imperfections,
especially waviness of seal faces in the circumferential direction [5,7]. The amount of waviness
required to generate hydrodynamic film pressures and keep the faces apart is small, less than 40
micro-inches (1 Pm), and can be caused by manufacturing imperfections, local mechanical
distortions due to drive pins/anti-rotation mechanisms, thermal distortions due to non-uniform
contact pressure, and wear of the faces during operation.
4-3
To function properly, mechanical seals must maintain a fluid film to provide lubrication, prevent
direct rubbing contact, and provide cooling of the seal faces under all operating conditions. Seal
failures occur when the film thickness and the film pressure between the seal faces change and
become unacceptably low or unacceptably high. This either leads to excessive friction, wear, and
heat, causing damage to the seal faces and other seal hardware, or leads to parting of the seal
faces. The eventual seal failure mode in both cases is high leakage.
The fundamental mechanisms most commonly responsible for seal failures are described below.
4.4.1 PV Limits Exceeded
As discussed in Section 3.7, the face loading of the seal faces is dependent upon whether the seal
is a balanced or unbalanced design, the degree of balance, the spring force, and the fluid pressure
being sealed. For optimum life, the film thickness should be sufficient to completely eliminate
asperity contact between the seal faces. As the fluid pressure increases, the film thickness
between the seal faces decreases, transitioning from full film lubrication to mixed lubrication,
and in extreme cases, to boundary lubrication (Figure 4-1).
Under full film operation, all of the seal face load is carried by the fluid pressure generated by
hydrodynamic action. Under mixed lubrication, the fluid film pressure still carries a majority of
the seal face load; however, the solid contact between the asperities of the mating seal faces
carries part of the load. Under a boundary lubrication regime, practically the entire load is carried
by direct solid contact and the fluid film carries a negligible amount of the total load.
When the asperity contact does occur but is not extensive (as in mixed lubrication), seal life is
governed by the wear of the face materials. Seal life can vary from several months to over 3 to 4
years, depending upon the application conditions. When asperity contact becomes extensive, as
in boundary lubrication, the seal frictional heat leads to immediate failure. Adverse thermal
stress conditions can result from higher pressures as well as from inadequate heat dissipation,
and can cause heat checking of the seal faces.
4-4
Figure 4-1
Lubrication Regimes at Seal Interface Showing Asperity
Contact as Lubrication Changes from Full Film to Mixed to Boundary
For higher pressures, balanced seals provide the best performance because they reduce the face
loads and the asperity contact. However, as the balance ratio is decreased to handle higher
pressures, the vulnerability of the seal to parting of the seal faces under fluid pressure/
temperature transients increases. Balance ratios of 0.62 or less should be avoided to prevent face
parting. The PV limits for both balanced and unbalanced seals for all commonly used materials
are provided in Table 3-4.
Key Technical Point
For satisfactory performance, the seal design and material selections should
satisfy the PV limit and the 'T limit under all operating conditions to ensure
that fluid film is maintained between the seal faces. Loss of film can lead to
immediate seizure and seal failure.
4.4.2
This is one of the most common causes of seal failure in high pressure, hot water pumps. As
discussed in Sections 3.7 and 3.8, sealing of low-lubricity/high-volatility fluids (for example,
water, glycol, and light hydrocarbons) is difficult, particularly under higher pressure and speed
combinations. If under given operating conditions the liquid film at the seal interface vaporizes,
dry rubbing of the seal faces occurs, leading to excessive heat, seal popping, and failure.
4-5
Figure 3-23 in Section 3 shows the 'T margin that needs to be maintained between the bulk fluid
temperature and the boiling point curve of the fluid being sealed to accommodate the increase in
fluid temperature at the sealing interface without vaporization. Both the PV limits and the 'T
margins are frequently challenged and must be respected for successful operation of face seals in
high pressure, low-lubricity/high-volatility fluid applications. Increasing the chamber pressure
and/or cooling to suppress fluid vaporization can improve seal performance.
Approaches discussed in Section 3.9 to improve lubrication of the seal faces can be used to
extend the PV and 'T limits of mechanical seals in many applications.
4.4.3 Inadequate Cooling
Many mechanical seal chamber dimensions in pumps are based on interchangeability with
stuffing box packing arrangement. Often this imposes severe restrictions on the seal design, thus
limiting the structural strength of and heat transfer from the seal to the process fluid. The narrow
radial clearances between the seal boundary and the seal chamber limits flow of the hightemperature fluid surrounding the seal, resulting in unacceptable thermal distortions and coning
of the seal faces. In such cases, isolated pockets of hot fluid in the vicinity of the seal can reach
temperatures that are several hundred degrees higher than the process fluid. Excessive coning
due to high differential temperatures is often responsible for seal failure as described in Section
4.4.4.
As described in Section 3.5, increasing the radial clearance at the seal outside diameter, using
enlarged and/or tapered seal chamber designs, incorporating a seal flushing arrangement, or
increasing the flow rate of the flushing fluid can significantly reduce the seal temperature. This
can provide a dramatic improvement in the performance of the seal in such installations.
Key Technical Point
Mechanical seals are often installed in the same cavity that is designed to
accept conventional packings. This limits the fluid circulation around the
seal, leading to high seal temperatures and accumulation of solids. An
enlarged seal chamber with tapered bore can dramatically improve fluid
circulation, lowering seal temperature and eliminating accumulation of
solids.
4.4.4 Transients Causing Excessive Seal Face Coning
Thermal stresses and pressures cause deflections of the seal faces (coning) that change the
initially parallel fluid film gap between the seal faces to either a convergent or a divergent gap
(Figure 4-2). By design, the distortion of the seal faces caused by coning should be limited to
less than 40 micro-inches (1 Pm), which is the typical film thickness between the seal faces.
4-6
Figure 4-2
Extremes of Seal Face Distortion (Coning) Due to Thermal and Pressure Effects
A frequent cause of seal failure is coning of seal faces that results in heavy contact at the inside
diameter of seal faces during operation (positive coning). Positive coning is caused by thermal
distortions due to seal friction and inadequate cooling. Positive coning, if excessive, changes the
lubrication regime from full film to mixed or boundary lubrication. This, in turn, increases
friction and interfacial temperature and causes rapid wear of the seal faces. Positive coning
changes the interfacial film pressure distribution from linear in a parallel face situation to convex
or concave pressure distribution, depending upon whether the seal is pressurized on the inside or
the outside diameter. Figure 4-3 shows the changes in pressure distribution for an outside
pressurized seal.
Key Technical Point
Thermal distortions of seal faces due to operational transients can cause
positive coning (contact on ID) or negative coning (contact on OD) of the seal
faces. Coning in excess of film thickness can cause film rupture seizure or
face parting, resulting in a large increase in leakage.
In extreme cases of positive coning with inside pressurization, fluid leakage past the sealing
faces is completely cut off, thus leading to total collapse of the fluid film and immediate failure.
In the case of outside pressurization, the increase in film pressure can cause parting of the seal
faces.
4-7
Figure 4-3
Pressure Distribution Changes Caused by Coning of the Seal Faces (for Outside
Pressurized Seal)
Another cause of seal failure is coning of seal faces that results in contact at the outside diameter
of seal faces (negative coning). Negative coning is caused by seal distortion due to pressures,
including transients, exceeding acceptable limits. Negative coning causes the pressure
distribution between the seal faces to change sufficiently to either overcome the seal closing
force, thus causing parting of the seal faces and very high leakage, or to reduce the film
thickness, resulting in mixed/boundary lubrication.
Key Technical Point
Pressure distribution across the seal faces is affected by seal face coning due
to changes in pressure and speed as well as the wear-in process. Excessive
coning causes seal failure either due to seizure or face parting. Hard face
versus soft face material combinations are more tolerant of coning than if
both faces are hard.
4-8
In fact, the coning and the wear-in process have complex interactions on seal performance,
depending upon the sequence of events (Figures 4-4 and 4-5). The performance is also affected
by the ability of one of the faces to wear-in rapidly without causing immediate seal failure (for
example, in the case of a carbon face) or by whether both the seal faces are too hard to wear-in
rapidly (for example, silicone carbide, tungsten carbide).
Figure 4-4
Changes in Seal Contact Area Under Constant Operating Conditions During the Wear-In
Process for a Seal With a Hard Face and a Soft Face
Figure 4-5
Example of a Wear-In Sequence (Stages 1 through 4) for a Mechanical Seal with a Soft Seal
Face
4-9
In applications where fluid is present on only one side of the seal, eccentricity can cause high
external leakage. In applications where fluid is present on both sides of the seal (for example, in
a double seal arrangement with buffer fluid), a high rate of fluid transfer can occur either
outwardly (from high-pressure to low-pressure side) or inwardly (from low-pressure to highpressure side). The fluid flow by this mechanism from low-pressure to high-pressure side is
called inward pumping. Inward pumping can cause significant mixing of the fluids. When
abrasives are present in one of the fluids, inward pumping causes high abrasive wear of the seal
faces. These effects can be minimized by controlling the misalignments and eccentricities to an
acceptably low level.
4-10
Figure 4-6
Fluid Pumping Action Across the Seal Faces Due to Static Offset and Misalignment
4-11
Figure 4-7
Rotating Balance Seal Wobble Caused by Shaft Tilt
4-12
4-13
Figure 4-8
Shaft Tilt Accommodated by Stationary Ring Pivot
Problems caused by dynamic misalignment also occur when the rotating seal face axis is offset
from the rotation axis of the shaft. Under this condition, the rotating seal face radially sweeps the
stationary face once every revolution as shown in Figure 4-9. This condition exists to some
extent in all seals, however, leakage and wear become a problem only when the runout is
excessive and the rotating face is narrower than the stationary face. If the narrower rotating face
turns with an offset around the axis of revolution, a radial vector is generated that pumps fluid in
and out of the narrow face. The problem becomes severe when the product or environment
contains abrasives that can be forced between the sealing faces. Leakage due to runout is usually
present only during running conditions unless the sealing faces have been damaged.
4-14
Figure 4-9
Seal Pumping Caused by Dynamic Offset of Rotating Narrow Face
Problems associated with dynamic offset are more common when the primary face (which has
more components and more potential for imbalance) rotates rather than when the mating ring
rotates. Offset problems can also be caused by excessive clearances in the assembly or improper
installation. The problem can usually be eliminated by selecting a seal configuration with a
rotating mating ring, which can be manufactured to much tighter tolerances to minimize
clearances and imbalance.
4.4.7 Excessive Out-of-Flatness (Warpage) During Operation
Key Technical Point
Mechanical face seals are precision components, requiring the sealing faces
to be flat, typically within one light band (11.6 x 10-6 inches) across one-inch
width. Too much out-of-flatness can lead to excessive seal leakage.
For proper operation without excessive leakage, manufacturers control seal flatness to typically
within one light-band per lineal inch. In some cases, the flatness of the seal faces can change
considerably during operation due to wear, misalignment, and exposure to high temperatures that
continue to age the seal face material. In applications where both faces are made of hard
materials (for example, tungsten carbide and silicone carbide), distortions of the seal faces that
result in excessive waviness can generate a much higher hydrodynamic pressure than under
normal conditions, thus causing a dramatic increase in fluid film thickness and leakage. In such
cases, the seal faces typically show no sign of wear or abnormal contact and the problem is only
4-15
recognized by inspecting the seal flatness. Local warpage of several light-bands over a small
circumferential part of the seal was observed in a controlled test in which leakage was found to
increase by a factor of more than 100 during operation [52]. A more thorough heat treatment and
stress relief prior to the final grinding and lapping operation can minimize distortions due to
continued aging in operation.
4.4.8 Seal Faces Too Perfectly Flat to Generate a Film
As mentioned earlier, mechanical seals function well due to a small, unavoidable circumferential
waviness (introduced by manufacturing tolerances or mechanical/thermal loads) that generates
hydrodynamic lubricant film pressure at the sealing interface, which prevents direct asperity
contact between the faces. Under certain circumstances (fortunately rare), in which the seal faces
are lapped too perfectly flat and the seal construction is robust enough to prevent mechanical
distortion of the seal faces, the hydrodynamic film pressures are insufficient to separate the faces.
This results in direct rubbing and very high friction, causing the seal temperatures to increase
rapidly and immediate destruction of the seal. Evidence of high temperatures is also seen in
discoloration of the seal hardware. This type of failure was encountered in controlled laboratory
tests performed under identical conditions for which a number of tests had been successfully
conducted previously [52]. It should be noted that, even though a maximum out-of-flatness
criterion has been established by seal manufacturers, there is no minimum flatness requirement
to ensure proper operation.
In conclusion, this section has described in detail all of the significant failure mechanisms that
can cause seal failure, either singly or in combination. The insights provided here should be very
helpful in following the systematic approach to troubleshooting and diagnosing seal failures in
service as outlined in Section 7.
4-16
5
APPLICATION AND SELECTION RECOMMENDATIONS
5.1
Introduction
The mechanical face seal represents a complex design that consists of several single-design
components. In order to achieve optimum performance, each of the single design components
must be selected to cover the operational requirements. Factors that affect the performance of the
seal (and that should be considered when selecting a seal) include:
x
Liquid type
Rotational speed
Radiation exposure
5.2
Selection Specification
In most power plants, the system liquid is either water or some type of hydrocarbon. The water
might be clean or contain abrasives that can significantly affect seal life if proper flushing is not
provided to remove the abrasives from the seal faces. In general, the following recommendations
are made depending on the process liquid.
5-1
Typical Construction
Installation Considerations
Water and
fuel
Boiler feed
Mild
corrosives
Highly
corrosive
liquid
5-2
Typical Construction
Installation Considerations
Hot
hydrocarbons
Slurry/dirty
process
5.3
The proper selection of a mechanical face seal requires examination of different areas of the seal
installation and operating requirements. The following selection sheet provides guidance on
recognizing the critical area that must be identified. This data sheet was developed from the data
sheets in API Standard 682. The more detailed data sheet in API 682 can be used in lieu of this
abbreviated data sheet. It is expected that the seal manufacturer might need to be contacted to
assist in filling out the data sheet.
5-3
Company
Date
Plant item no.
Ref pump drwg
For proposal/purchase
Seal installation drwg required, Y/N?
2. Application Details
Liquid
Seal Size
Temperature range
Speed range, rpm
3. Supplement Process Data
Pump suction pressure
Static pressure, max/min
Boiling temp at sealed pressure
Abrasives Y/N
Abrasives concentration
Specific gravity of process
Auto-ignition temp
Corrosive/pH
Dry running, Y/N
Special operation comments
4. Process Hazard
Hazard (state)
Toxicity rating
5. Standards
Identify applicable compliance standards
API
ANSI
NACE
ISO
Shaft/sleeve size
Sealed pressure range
Rotation CW/CCW
Allowable leakage
DIN
Other
5-4
Tandem
PTFE O-ring
Single spring
Temperature
Temperature
Temperature
Temperature
5-5
5.4
Qualification Testing
In some critical service applications, where seal failure is unacceptable from a safety standpoint,
or where the economic impact of failure is unacceptable (for example, unscheduled plant
shutdowns), seal selection should be verified by appropriate qualification testing. This is
especially recommended where the manufacturers cannot provide reference experience for the
selected designs from other similar applications.
The extent of testing, the key factors to be simulated, and parameters monitored during testing
depends upon the criticality of the application and the cost of performing the qualification tests.
Guidance is provided in API Standard 682 [8] and in other publications related to mechanical
seals [7,56,57], which can be consulted to tailor the qualification testing for a specific
application.
5-6
6
CONDITION-BASED MONITORING GUIDELINES
6.1
Introduction
Seal monitoring programs vary greatly from utility to utility, and from site to site. Some of this is
the result of different equipment designs, operating philosophies, and different rates of forced
outages experienced. Based on survey results, the level of condition monitoring required to
develop reliable seal performance data is quite basic except for main coolant pump mechanical
face seals. For many plants, condition based monitoring is limited to visual observations with
little actual quantification.
This section of the guide provides information on how to evaluate seal performance and
suggestions for monitoring and data acquisition. The data acquired and tended can be used to
assess seal performance and to provide reasonable predictions of the remaining life or operability
of a mechanical face seal. The parameters to be trended will be identified, evaluation described,
and examples provided. Trouble-shooting problems require good data. Without a trending
program, determining the root cause of an operating problem is difficult, if not impossible.
Data logging of the various parameters associated with mechanical face seals can be performed
in many different ways. The simplest way is to use manual recording, however, sophisticated
data-logging systems can also be utilized. Hand logging of data and trending is time consuming,
but it is effective in trending most seal performance characteristics over the long term. Required
parameters that are routinely trended can be added to the daily or shift logs recorded by the
operators. These parameters can then be plotted using standard spreadsheet programs and trends
can be maintained and provided to plant personnel as part of the normal system status reports.
The major advantages of automated systems are that data can be routinely recorded and
downloaded to trending programs, and changes in the frequency of data-logging can be triggered
from performance changes. Generally, when analyzing seal performance changes, it is necessary
to have data recorded frequently or to have key parameters on continuous recorders. These
automated systems are reasonably expensive and, in a time where utilities are being challenged
to hold the line on costs, are only appropriate for systems with a relatively high frequency of seal
failures.
Key O&M Cost Point
Seal monitoring programs vary greatly from utility to utility and from site to
site due to different equipment designs, operating philosophies, and different
rates of forced outages experienced. For many plants, condition-based
monitoring is limited to visual observations with little actual quantification,
except for main coolant pump mechanical face seals.
6-1
6.2
Data that is typically available for logging includes pressures, temperatures, flows, vibration
levels, and, in some cases, speed. The amount of each type of data collected for each seal will
depend on the type of seal used and its installation. For example, single seals will require less
data collection than double or tandem seal arrangements. The frequency of data logging will vary
from system to system based on system conditions and seal operating experience and
characteristics. Manual recording might be required only once a day. Automated data-logging
systems can acquire data at any frequency, and the frequency can be dynamically adjusted
depending on seal performance. A typical log sheet for a multiple seal arrangement and its
support system is shown in Table 6-1.
An example of pressure being used to trend seal performance is illustrated in Figure 6-1 for a
staged seal arrangement. In this example, the lower seal stage differential pressure is plotted
against time and a best guess projection is made to predict when the failure limit has been
reached. Similar trends can be plotted of temperature in a barrier fluid or loss of barrier fluid in
the barrier fluid reservoir. Loss of barrier fluid can be very useful in characterizing seal
performance in a corrosive system seal arrangement.
6-2
Unit
System
Equip. No.
Date
Time
Recorded By:
Seal No. 1
Item
Normal
Minimum
Maximum
Startup
Flow
Temperature
Differential Pressure
Backpressure
Frame Vibration level
Shaft Vibration level
Speed
Leakage rate
Seal No. 2
Flow
Temperature
Differential Pressure
Backpressure
Seal No. 3
Flow
Temperature
Differential Pressure
Backpressure
Flush
API Plan No.
Fluid type
Flow rate
Temperature, inlet
Pressure
Filtration
Quench/Drain
API Plan No.
Fluid type
Flow rate
Temperature, inlet
Temperature, outlet
Pressure
Filtration
6-3
Figure 6-1
Seal Data Plot Showing Declining Performance (Courtesy of Southern California Edison)
6-4
6.3
Other than seal dynamic torque, seal face temperatures and seal face temperature changes are the
key measures of the performance of a seal because they characterize what is happening at the
seal interface. Seal dynamic torque is almost impossible to measure and is, therefore, not a viable
measurement. Temperature is the easiest parameter to measure and, depending on the seal
arrangement, temperature measurements can directly characterize seal performance. Usually
temperature data in the vicinity of the seal are a measure of the process fluid or support system,
especially in seal systems that are flushed or quenched. These temperature measurements tend to
mask the actual seal performance and many times fail to provide meaningful data. The more
obvious measure of seal performance is leakage, but this method is only viable for single seals or
outboard seals of multiple seal arrangements. In systems where only a small leak is acceptable,
leakage measurement fails to provide an indication of impending failure.
Even within these limitations and short falls, data taken to monitor seal performance can provide
a useful tool. These measurements become even more meaningful when tracked over an
extended period of time and correlated to seal failure. Parameters such as pressure and flow,
which do not directly characterize seal performance but do affect seal performance, become
extremely important when predicting when the seal might fail.
6.4
Instrumentation
Seal monitoring can be accomplished with simple and easy-to-implement manual instruments
such as temperature and pressure gauges, or with complex computer data-acquisition systems
that can initiate controls based on parameter limits. This section describes the manual sensors
and switches that are commonly available and used. When used, the sensors should comply with
a recognized standard such as API Standard 682. Electronic sensors, such as pressure
transducers, thermocouples, etc., should be subject to similar design requirements. The following
sections (6.4.1 through 6.4.8) that outline various sensors and switches are based on
recommendations contained in the API Standard 682. Deviations from the following
recommendations can be made, and other design requirements might be imposed, based on
specific needs of the plant.
6.4.1 Temperature Gauge
Temperature gauges provide a visual indication of the local temperature. The sensing element is
in contact with the liquid being measured.
6-5
Dial temperature gauges should be heavy-duty and corrosion resistant. They should be bimetallic or liquid-filled, with a rigid stem suitable for mounting as needed. Mercury-filled
thermometers are not acceptable. Black printing on a white background is standard.
Dial temperature gauges should be installed in pipe sections or in tubing runs. The sensing
element of temperature gauges should be in the flowing fluid to the depth specified by the gauge
manufacturer.
Temperature gauges installed in tubing should be a minimum of 1 1/2 inches (38 mm) in
diameter and the stem should be a minimum of 2 inches (50 mm) long. All other gauges should
be a minimum of 3 1/2 inches (90 mm) in diameter and the stem should be a minimum of 3
inches (75 mm) long.
6.4.2 Thermowells
Thermowells provide protection for the sensing element of temperature gauges.
Temperature gauges that are in contact with flammable or toxic fluids, or that are located in
pressurized or flooded lines, should be furnished with separable threaded solid-bar thermowells
made of AISI Standard Type 300 stainless steel or another material more compatible with the
liquid as defined by the manufacturer. Thermowells installed in piping should be 1/2 inch-NPT
minimum. Thermowell designs and installation should not restrict liquid flow.
6.4.3 Pressure Gauges
Pressure gauges provide a visual indication of the pressure and the sensing element is in contact
with the liquid being measured.
Pressure gauges should conform to ANSI/ASME Standard B.40.1 grade 2A. The gauges should
be furnished with AISI Standard Type 316 stainless steel bourdon tubes or other material
compatible with the liquid, stainless steel movements, and 1/2-inch NPT male alloy steel
connections with wrench flats. Gauges installed in tubing should have 2 1/2-inch (64 mm)
diameter dials. Gauges not installed in tubing should have 4 1/2-inch (114 mm) diameter dials.
Black printing on a white background is standard for gauges. Gauge range should be selected so
that the normal operating pressure is at the middle of the gauge's range. In no case, however,
should the maximum reading on the dial be less than the applicable relief valve setting plus 10
percent.
6.4.4 Alarm, Trip, and Control Switches
Alarm, trip, and control switches provide a visual or audible signal or control an electric circuit
when the preset limit of a sensor has been exceeded.
Each alarm switch, each shutdown switch, and each control switch should be furnished in a
separate housing located to facilitate inspection and maintenance. Hermetically-sealed, double
6-6
pole, double throw switches, with a minimum rating of 5 amperes at 120 volts AC and 1/2
ampere at 120 volts DC, should be used. Mercury switches should not be used.
Unless otherwise specified, electrical switches that open (de-energize) to alarm and close
(energize) to trip should be furnished.
Alarm and trip switch settings should not be adjustable from outside the housing. Alarm and trip
switches should be arranged to permit testing of the control circuit, including when possible, the
actuating element, without interfering with normal operation of the equipment. If a shutdown
system is being implemented, the need for bypass indication and testing features should be
considered.
Pressure-sensing elements should be of AISI Standard Type 300 stainless steel. Low-pressure
alarms, which are activated by falling pressure, should be equipped with a valved bleed or vent
connection to allow controlled depressurization so that the operator can note the alarm set
pressure on the associated pressure gauge. High-pressure alarms, which are activated by rising
pressure, should be equipped with a valved test connection so that a portable test pump can be
used to raise the pressure.
All switches sensing the same variable should have reset ranges, such that changing the variable
to reset one switch does not activate other switches.
6.4.5 Pressure Switches
Pressure switches trip when a pre-set pressure limit has been exceeded. Pressure switches can
have low and/or high limit settings.
Pressure switches should have over-range protection to the maximum pressure to which the
switch can be exposed. Switches exposed to vacuum should have under-range protection to full
vacuum.
The measuring element and all pressure-containing parts should be AISI Standard Type 316
stainless steel unless the pumped fluid requires the use of alternate materials, as determined by
the seal manufacturer. Unless otherwise specified, pressure switches should be bellows or
diaphragm. Connections for pressure input should be 1/2-inch NPT. Connection for the air
transmission signal should be 1/4-inch NPT.
6.4.6 Level Switches
Level switches trip when a pre-set liquid level has been exceeded. Level switches can have low
and/or high limit settings.
Unless otherwise specified, level switches should be hydrostatic, capacitance, or ultrasonic.
6-7
Be aware that level switches might have a dead band wide enough to activate other switches
during re-setting. This is especially true when dealing with the small volumes of barrier fluids
associated with dual-seal reservoirs.
6.4.7 Level Indicators
Level indicators provide a visual indication of the liquid level and are also used when dealing
with small volumes of barrier fluids associated with dual-seal reservoirs. The standard level
indicator should be the weld pad reflex design.
When specified, an externally mounted, removable, reflex indicator should be furnished instead
of the standard weld pad design.
6.4.8 Flow Indicators
A flow indicator provides a visual indication of flow rate and, when used, should be a steel body
non-restrictive bull's eye.
To facilitate viewing of flow through the line, each flow indicator should be installed with its
bull's-eye glass in a vertical plane. The diameter of the bull's eye should be at least one-half of
the inside diameter of the line in which it is installed and should clearly show the minimum flow.
6-8
7
TROUBLESHOOTING TO IDENTIFY CAUSE OF SEAL
FAILURE
7.1
Introduction
A discussion of the fundamental mechanisms responsible for seal failure was presented in
Section 4. To improve seal reliability and extend its life in a particular application, a thorough
analysis of the cause of failure of a mechanical seal often gives the best indication of action
required. This section provides a comprehensive step-by-step troubleshooting approach that can
be followed by engineers and operating and maintenance personnel to diagnose seal failures in
actual applications.
Several excellent sources, including seal manufacturers' published information and seal
handbooks, identify causes of seal failure and provide illustrations of failed parts to aid in
diagnosis [3,7,11-19]. The troubleshooting approach and tables in this section are based on
relevant information for nuclear and fossil power applications from these sources along with the
authors experience in root cause analysis of seal failures. A number of the illustrations and
technical notes included in the tables in this section were obtained from John Crane Mechanical
Seals and Mechanical Engineering Publications, Ltd., London [7,17]. They have been updated
and are used here with permission from these organizations.
7.2
Failure Diagnosis
Seal failure diagnosis is very similar to any other failure investigation and often the best
indication of the cause of failure is from visual examination of the seal itself. Once the likely
cause of the problem is decided, the available solutions are usually clear. It is very important to
keep in mind that evidence of seal failure is an essential element in determining the cause of seal
failure and if the evidence is lost there is no way to back track. Therefore, to reduce the risk of
losing evidence, it is suggested that a systematic step-by-step approach be followed during the
investigation process.
7-1
7-2
Possible Causes
Inadequate amount of liquid
to lubricate seal faces (Note
that not all dry seals squeal.)
Recommendations/Remarks
x If not in use, a bypass flush line might be
See above
Product vaporizing/flashing
across the seal faces
manufacturer
x Change to a seal design not requiring so
required
x If already in use, the bypass flush line or
manufacturer
x If increase in leakage is permissible, use
7-3
Possible Causes
Recommendations/Remarks
compression.
x Check for gland plate distortion because of
scratched during
installation
x Leakage of liquid under
7-4
manufacturer.
Pump/shaft vibration
Possible Causes
Recommendations/Remarks
Spring failure
Renew parts
Erosion damage of
hardware
Corrosion of drive
mechanisms
Misalignment
Impeller/shaft system
imbalance
Cavitation
Bearing problems
7-5
7-6
Possible Causes
Seal running too hot
Recommendations/Remarks
x
Checklist
Documentation
Toxic/hazardous product
Process change
Background information
required
Machine vibration
7-7
Checklist
Safety note: all necessary precautions must be observed during any
leakage checks, especially if the fluid is toxic or hazardous.
Amount and nature of abnormal leakage?
Leakage constant or variable?
Leaks when shaft is stationary?
Leaks when shaft is rotating?
Related to changes of speed, pressure, or temperature of operation?
Hydrostatic testing
Face leakage
7-8
General Checks
Table 7-3
General Checks During Dismantling
Topic
Seal surfaces
Checklist
Avoid disturbing the seal surfaces
Avoid wiping or cleaning the faces more than is necessary for safe
disassembly
Visual examination of seal faces is included in Section 7.3
Dimensional checks
Wear debris
Small fragments or chips from broken components
Corrosion products
Miscellaneous debris/deposits
Seal hang-up
Check for hang-up by flexing the seal slightly above and below its
installed working length
Packaging
7-9
7.2.3.2
Table 7-4
Premature Failure Checks During Dismantling
Topic
Seal faces
Checklist
Examination for nicks, scratches, and fractures:
x
Secondary seals
Drive mechanism
Examination for :
x
Omitted seals
Misassembled seals
Examination for:
x
Mis-assembly
Mis-indexing
Omission
Check for loss of secondary seal interference when used for drive
purposes, for example, static seals and bellows
Face loading hardware
7-10
Examination for:
x
Incorrect type
Mis-assembly
Mis-indexing
Omission
7.2.3.3
Table 7-5
Mid-Life Failure Checks During Dismantling
Topic
Seal faces
Checklist
Examination for nicks, scratches, and fractures:
x
Overall corrosion
Leaching
Abnormal grooving
Erosion damage
Secondary
seals
Drive
mechanism
Examination for:
x
Extrusion
Examination for:
x
Failure
Excessive wear
Check for loss of secondary seal interference when used for drive purposes, for
example, static seals and bellows
7-11
7.3
The symptoms experienced might not be the prime cause of failure. It is often necessary to
identify the root cause in order to avoid a recurrence. Once the likely cause of the problem is
decided, the available solutions are usually clear. There are cases, however, where further checks
are necessary to clarify diagnosis. There are also proven remedies for particular concerns.
Therefore, this section notes likely causes, further checks, and proven remedies, as appropriate,
for each symptom.
As there are a relatively large number of ways a mechanical seal can fail (this section lists 45), it
is helpful to group them alpha-numerically, as shown in Table 7-6 below. This split is somewhat
arbitrary and several failure modes are caused by a complex mixture of mechanical, thermal,
and/or chemical aspects. However, it does show a pattern, which can be helpful when using the
subsequent extensive table of common seal, failure modes. Table 7-7 is similarly divided into
three parts: seal faced, secondary seals, and seal hardware.
7-12
Secondary
seal
Seal
hardware
Mechanical
Thermal
Chemical
A11: Fracture
A12: Scratches and
chips
A13: Adhesive wear
A14: Abrasive wear
A15: Grooving and
severe wear
A16: Erosion of
carbon ring
A17: Thermal
distress, over
360q
A18: Thermal
distress over
120q - 180q
A19: Thermal
distress in
patches
A20: Coking
A21: Carbon
chemical attack
A22: Corrosion of
metal faces
A23: Corrosion of
hard faces
A24: Flaking and
peeling
A25: Crystallization
A26: Sludging
A27: Bonding
A28: Blistering
B1: Physical
damage
B2: Extrusion
B3: Excessive
torque
C1: Physical
damage
C2: Hardware
rubbing
C3: Erosion or
abrasive wear
C4: Drive failure
C5: Spring distortion
and breakage
C6: Seal hang-up
C7: Sleeve marking
and damage
B6: Elastomer
chemical attack
B7: Corrosion at
secondary seal
interfaces
C8: Overheated
metal
components
C9: Corrosion of
seal hardware
C10: Excessive
deposits
7-13
7-14
A1:
Symptom
Characteristics
Table 7-7
Visual Examination: Symptoms, Characteristics, Causes and Remedies
x
x
x
x
x
x
x
x
Pipework distortion.
Remedial Action
Causes
Causes/Checks/Remedies
No contact pattern
A2:
A3:
Symptom
Characteristics
x
x
x
x
x
x
7-15
Checks
Cause
Improper installation.
Causes
Causes/Checks/Remedies
A5:
7-16
A4:
Symptom
x
x
x
x
x
x
x
x
Cause
Remedial Actions
Checks
Cause
Causes/Checks/Remedies
Characteristics
A6:
A7:
Symptom
Characteristics
x
x
x
x
7-17
Checks
Cause
Checks
Cause
Causes/Checks/Remedies
A9:
7-18
A8:
Symptom
Characteristics
x
x
x
x
x
x
Cause
Checks
Cause
Causes/Checks/Remedies
Symptom
Characteristics
7-19
Remedial Actions
Check
Cause
Causes/Checks/Remedies
7-20
A11:
Fracture
Symptom
Characteristics
x
x
x
Poor lubrication.
Cause
Causes/Checks/Remedies
A12:
Symptom
Characteristics
x
x
x
x
7-21
Checks
x
x
Cause
Causes/Checks/Remedies
7-22
A13:
Adhesive wear
Symptom
Excessive adhesive wear leaves typical nonmetallic seal faces heavily worn with a relatively
smooth appearance and a minimum of
grooving. Severe adhesive wear of metallic
faces can lead to scuffing, grooving, and even
face seizure.
Characteristics
x
x
x
Remedial Actions
Inadequate lubrication.
Cause
Causes/Checks/Remedies
A14:
Abrasive wear
Symptom
Characteristics
x
x
x
x
7-23
Remedial Actions
Possibilities include:
Cause
Causes/Checks/Remedies
7-24
A15:
Symptom
Characteristics
x
x
x
4GOGFKCN #EVKQPU
Checks
Cause
Causes/Checks/Remedies
A16:
Symptom
Characteristics
x
x
x
7-25
Remedial Actions
Cause
Causes/Checks/Remedies
7-26
A17:
Thermal distress over 360
vaporization
Symptom
Characteristics
Checks/Remedial Actions
Cause
Causes/Checks/Remedies
A18:
A19:
Symptom
CURGTKVKGU
Characteristics
x
x
x
x
7-27
Remedial Actions
Cause
Remedial Actions
Checks
Cause
Causes/Checks/Remedies
7-28
A20:
Coking
Symptom
Characteristics
Cause
Causes/Checks/Remedies
A21:
Symptom
Characteristics
Overall corrosion.
7-29
Cause
Causes/Checks/Remedies
A23:
7-30
A22:
Symptom
Characteristics
Remedial Actions
Cause
Cause
Causes/Checks/Remedies
A25: Crystallization
A24:
Symptom
Characteristics
A defective coating
7-31
Cause
Possibilities are:
Causes
Causes/Checks/Remedies
7-32
A26:
Sludging
Symptom
Characteristics
Cause
Causes/Checks/Remedies
Bonding
Blistering
A27:
A28:
Symptom
Characteristics
7-33
Remedial Actions
Cause
Cause
Causes/Checks/Remedies
Extrusion
B2:
7-34
Physical damage
B1:
Symptom
Causes/Checks/Remedies
x
x
x
x
x
Possibilities include:
Cause
Mishandling.
Possibilities include:
Cause
Characteristics
B3:
Excessive torque
Symptom
Characteristics
7-35
Possibilities include:
Cause
Causes/Checks/Remedies
7-36
B4.
Symptom
Rubber O-ring hardened and cracked. PTFE Oring discolored blue/black. The portion of the
ring nearest the faces is usually the worst. Most
commonly a problem with nitrile rubber.
Comparative analysis of secondary seals from
all locations will reveal whether the thermal
condition was local to one secondary seal or an
overall excessive temperature.
Characteristics
x
x
x
x
Checks
Cause
Causes/Checks/Remedies
Compression
set of elastomer
B5:
B6:
Symptom
x
x
x
Characteristics
7-37
Checks
Cause
Cause
Causes/Checks/Remedies
7-38
B7:
Symptom
Characteristics
x
x
x
x
Cause
Causes/Checks/Remedies
C1:
Physical damage
Symptom
Characteristics
Excessive force.
Use of incorrect tools, and so on.
x
x
7-39
Insufficient cleanliness.
Cause
Causes/Checks/Remedies
7-40
C2:
Hardware rubbing
Symptom
Characteristics
x
x
x
x
x
x
x
x
x
x
Bearing failure.
Possibilities include:
Cause
Causes/Checks/Remedies
C3:
Symptom
Characteristics
Making it tangential.
Checking this inlet for protrusion into the seal
chamber.
Flushing with a cleaner fluid.
Selecting a smaller outside diameter seal.
Boring out the seal chamber.
x
x
x
x
x
7-41
Remedial Action
Cause
Causes/Checks/Remedies
7-42
C4:
Drive failure
Symptom
Characteristics
x
x
x
x
x
x
x
x
x
x
Equipment vibration.
Possibilities include:
Cause
Causes/Checks/Remedies
C5:
Symptom
Characteristics
7-43
Checks
Cause
Causes/Checks/Remedies
7-44
C6:
Seal hang-up
Symptom
Characteristics
Remedial Actions
Causes/Checks/Remedies
C7:
Symptom
Characteristics
x
x
x
7-45
Cause
Causes/Checks/Remedies
C9:
7-46
C8:
Symptom
900-1000F
(480-540C)
1100F (590C)
1200F (650C)
Brown
Blue
Black
700-800F
(370-430C)
Straw Yellow
Characteristics
x
x
A change of material.
Ground the pump effectively to earth if pitting
from electrolysis is suspected.
x
x
Remedial Actions
Cause
Checks
Cause
Causes/Checks/Remedies
C10:
Excessive deposits
Symptom
7-47
Remedial Actions
Causes/Checks/Remedies
8
MAINTENANCE
8.1
Introduction
Seal maintenance programs at most power plants fall within one or more of the following
categories: reactive maintenance, preventative maintenance, and predictive maintenance based
on condition monitoring. The most cost effective maintenance program should be based on
predicted seal performance and its expected life. The least cost effective maintenance program is
one based on reactions to failure. Reaction type programs result in unexpected plant shutdowns
and reduced plant availability.
Except for seals in safety-related and critical applications, most maintenance is performed under
the reactive category because of a lack of control of the various factors that lead to premature
seal failure and the effort required to perform condition monitoring on such a large population of
seals. To prevent reactive maintenance of seals in critical applications, most plants implement
some level of preventative or periodic maintenance programs based on experience and
manufacturer recommendations. In safety-related installations, seals are maintained periodically,
regardless of the condition of the seal to prevent unexpected plant shutdowns.
Maintenance in most power plants is performed by maintenance personnel at the plant with
assistance from the plant engineer and seal manufacturer on unique problems and specialized
processes. In all cases, plant maintenance personnel are responsible for seal removal and
installation. However, to maximize their effectiveness, plant engineers and maintenance
personnel should not be limited to removal and installation. They should be trained in the proper
diagnosis of seal failure and how to correctly address the root cause of a seal failure. It, therefore,
becomes particularly important to provide the proper level of training necessary to identify the
problem rather than to just maintain the seal. Appendix C lists organizations that provide training
classes, short courses, and seminars on the design, selection, operation, maintenance,
troubleshooting, and failure diagnosis of mechanical face seals.
Key O&M Cost Point
The most cost-effective maintenance program should be based on predicted
seal performance and its expected life. The least cost-effective maintenance
program is one based on reactions to failure. An effective preventative or
periodic maintenance program, based on plant experience and manufacturer
recommendations, should be implemented to improve plant reliability and
prevent unplanned shutdowns.
8-1
8.2
As discussed in Sections 4 and 5, mechanical face seals are relatively precise and complex
assemblies that are subject to a variety of failure modes. For reliable operation, mechanical seals
require the correct working environment, which demands good engineering, maintenance, and
operations practices, and well-written and detailed procedures. Written procedures should be
kept current so that, as new information is acquired, it is properly accounted for and
implemented into working practice.
The following discussion outlines methods that can be utilized by plant engineers and
maintenance personnel to improve the chances of obtaining longer life from the seals. The topics
covered address:
x
Seal installation
Packaging
Key Human Performance Point
Proper storage and handling of seal components is important to seal
longevity and performance. Manufacturers recommendations should be
followed at all times.
8-2
Seal assemblies and spare parts are typically wrapped and boxed. If the package is opened with a
knife for inspection, care should be taken to ensure that the faces and elastomeric seals are not
cut or scored. If not used, seals should be repackaged in the same manner and returned to their
original box, if practical, to ensure that proper labeling and identification is maintained. If the
box is unusable, then the replacement box should have proper labeling.
8.2.1.2
Storage
To protect the seals from damage, storage of the seal assemblies and spare parts should be in
accordance with the seal manufacturer's recommendations. The storage area should be clean, dry,
and adequately warm and ventilated.
8.2.1.3
Handling
Many mechanical seal faces are brittle and fragile and can easily break if dropped. The metal
components of a mechanical seal provide the proper restraints and alignment needed for
operation. Care should be taken that these components are not damaged.
Protect parts from damage wherever possible. Avoid placing a seal face down on any surface,
unless it is protected by a clean cloth or similar material.
Some parts are prone to attack by common liquids. For example, ethylene propylene rubber is
attacked by mineral oil and silicone rubber is attacked by silicone oil.
8.2.1.4
Obtain specific drawings from the manufacturer. The drawings provide assembly details and key
dimensions for fitting and installation. When sufficient information is not available, contact the
manufacturer for advice. Technical recommendations and technical information provided with
the mechanical seal should be transferred to maintenance procedures for future use. Care should
be taken to note any safety/toxicity/industrial hygiene issues.
8.2.1.5
Ensure drive pins and/or spring pins are free to move in the pin holes or slots
Check that set screws are free in the threads. Set screws should not be reused because
damage to the drive end might have occurred in previous use.
Check metal bellows for damage that might cause leakage or improper alignment of the
faces.
Check secondary seals for nicks or cuts. If the seals need to be replaced, make certain that the
replacement seals are of the same type to ensure fluid and temperature compatibility.
8-3
8.2.1.6
Seal Faces
Visually check for nicks or scratches. Face imperfections of any kind can lead to leakage and
premature failure of the seal. Detailed inspection of the seal faces for flatness is discussed in
Section 8.2.3.1, Seal Dimensional Checks.
8.2.1.7
Gaskets
Check thickness against the manufacturer's specifications. Incorrect gasket thickness can lead to
incorrect seal length settings and improper face loading.
8.2.1.8
Spring
Check rotation of spring coil when a single coil is used. The spring coil rotation should be such
that shaft rotation tends to tighten the coil. Springs are available in right-hand and left-hand coil
rotation. Some springs can be used bi-directionally.
8.2.2 Pre-Installation Equipment Checks
Proper equipment function is critical to seal performance and it is recognized that seal life is
adversely affected by equipment misalignment and vibration. The following checks can be easily
accomplished using good engineering practices and simple measuring instruments. Limits of
acceptability on runout provided in this section are general in nature. The seal manufacturer
should be contacted for limits applicable to their products.
Key Human Performance Point
Pre-installation checks are an important element in reliable seal
performance. Personnel should perform the steps outlined herein to prevent
unsatisfactory seal performance.
8.2.2.1
Shaft straightness is checked with the shaft removed from the equipment. It is mounted between
centers to check for runout between the bearing and the shaft or shaft sleeve at the location
where the mechanical face seal is installed.
Typical runout limits:
0.004 inches (0.1 mm) for speeds d 1,800 rpm
0.002 inches (0.05 mm) for speeds > 1,800 rpm
8-4
Figure 8-1
Shaft Straightness Check
8.2.2.2
Shaft runout is checked with the shaft installed in the equipment. Runout is checked at the
location where the mechanical face seal is located on the shaft or shaft sleeve, and is
accomplished by slowly rotating the shaft against a stationary dial indicator.
Figure 8-2
Shaft Runout Measurement
8.2.2.3
Squareness of the stuffing box is checked to ensure that angular misalignment does not occur
upon installation. Angular misalignment is checked with the equipment completely assembled
except for the seals. The measurement is made by mounting a dial indicator on the shaft and then
slowly rotating the shaft and dial indicator to measure the runout of the face that controls the
angular placement of mating ring.
Typical runout limits for wedges, O-rings, and metal bellows seals:
0.003 inches (0.08 mm) for speeds d 1,800 rpm
0.0015 inches (0.04 mm) for speeds > 1,800 rpm
Typical runout limits for elastomer and PTFE bellows seals:
0.007 inches (0.18 mm) for speeds d 1,800 rpm
0.0035 inches (0.09 mm) for speeds > 1,800 rpm
8-5
Figure 8-3
Stuffing Box Squareness Measurement
8.2.2.4
Rotational balance of the shaft should be checked with the impeller installed as well as other
components that normally rotate with the shaft. Excessive out-of-balance can cause premature
seal failure. The acceptable amount of out-of-balance is dependent upon the specific application
but, in general, the deflection caused by out-of-balance should not exceed the limits defined in
8.2.2.1 and 8.2.2.3 when the shaft is turning at normal operating conditions.
Figure 8-4
Shaft and Impeller Rotational Balance Check
8.2.2.5
Shaft-to-bearing clearance can allow both radial and axial movement of the shaft. These tests are
performed with the shaft installed in the equipment. Radial movement is checked by loading the
shaft laterally with a light force so that the shaft does not bend. Axial movement is checked by
pulling and pushing the shaft along its axis.
Radial movement should be limited to 0.003 inches (0.08 mm) for rolling element bearings. For
plain bearings, the movement should not exceed the maximum bearing clearance specified by the
manufacturer.
Axial movement of the shaft should be limited to 0.003 inches (0.08 mm). If this limit is
exceeded, then the face seal load generated by the springs should be checked to ensure that it
remains within the manufacturer's recommendation for normal operating conditions. Abnormal
operating conditions and stop/start conditions that cause excessive axial movement can lead to
reduced seal life.
8-6
Figure 8-5
Radial and Axial Bearing Clearance Checks
8.2.2.6
The shaft and shaft sleeve should be checked to ensure that the diameter at the seal locations
(including secondary seals) is within the seal manufacturer's recommendations.
The surface finish under the seal (especially at the secondary seal position) should be free of
machine marks, and should have a roughness of less than 25 micro-inches (600 Pm) for static
seals and less than 10 micro-inches (250 Pm) for dynamic O-rings and wedge rings.
For elastomeric/rubber bellows, the shaft/sleeve surface finish can have fine machined marks but
the surface roughness should be limited to 50 micro-inches (1200 Pm).
Figure 8-6
Measurement of Critical Shaft and Sleeve Diameters
8.2.2.7
Sleeves are sometimes hardfaced to prolong their useful life in abrasive service. However,
hardfacing should be limited to secondary seal areas and should not extend to the location where
the set screws lock the seal to the sleeve. If the set screw lands on the hardfaced surface, the
screw grip might be impaired and allow relative movement between the seal and sleeve.
8-7
Figure 8-7
Sleeve Hardfacing to Prolong Life
8.2.2.8
Sharp edges are not acceptable where a seal must pass with an interference fit. Sharp edges can
occur at shaft steps, keyways, splines, holes, and so on. Sharp edges can cut or nick a soft sealing
member and create a leak path. If possible, chamfer the leading edge of the shoulder to allow the
seal to slide over it.
Figure 8-8
Lead-In Chamfers to Prevent Secondary Seal Damage During Installation
The overall dimensions and critical interface dimensions should be checked against drawings to
ensure that the mechanical seal is correct to the drawing. Some check should be made to verify
that the seal is able to compress to the correct length. Caution should be taken when compressing
metal bellows seals because over-compression might result in yielding of the bellows. If the
bellows yield, they will not generate the required load at the installed length.
8-8
Seal faces should be inspected by an optical flat to ensure that they meet the flatness
requirements specified by the seal manufacturer. Appendix B describes the typical procedures
used to check the seal face flatness and typical examples of out-of-flat conditions.
8.2.3.2
Seal cavity dimensions should be checked to ensure that proper clearance and alignment will be
achieved and to prevent seal damage during installation. Check the seal cavity inside diameters
and depths. Visually check for damage of the cavity that might have occurred during previous
operation or during disassembly.
Figure 8-9
Seal Cavity Dimensional Checks Prior to Installation
8.2.3.3
Interrelated dimensions between the shaft and seal cavity should be checked to ensure proper
compression loading of the seal faces. It is important to correctly account for the gasket thickness
when calculating the compression of the seal.
Do not use previous set screw indention in the shaft/sleeve as a reference point because there can
be significant difference in the stacked height of seals, particularly between different
manufacturers. It is also important to install the seal so that the set screws do not align with
previous indentations that might guide the set screw away from the preferred installation
position.
8.2.3.4
Auxiliary Glands
Auxiliary glands should be checked to ensure that fittings do not protrude into the seal cavity and
come into contact or affect the performance of the seal. The glands should also be checked to
verify that they are clear of obstructions that could prevent proper circulation of the barrier or
flushing fluids.
8-9
Safety
Because of their tolerance to a variety of fluids, mechanical face seals are often used in toxic or
hazardous processes. To ensure safety of personnel during the removal and handling of the seal
and the fluid in the seal cavity, training and written instructions should be provided to clearly
identify the type of equipment needed and other safety devices to be utilized during disassembly,
handling, and storage.
Key Human Performance Point
Equipment contents and conditions should be fully known before
disassembly to preclude injury.
8.2.4.2
Failure Evidence
As identified in Section 7, the best guide to determining the cause of failure of a seal is often the
condition of the seal. It is, therefore, important to properly mark, photograph, and carefully store
the seal and other related components for later detailed examinations. It is also recommended
that some of the seal cavity fluid be retained because it might also be used to determine the cause
of failure.
8.2.4.3
It is strongly recommended that mechanical face seals not be re-used unless they have been
reconditioned to the manufacturer's specifications. The mating faces of mechanical seals develop
a wear pattern after an extended period of use and it is almost impossible to reestablish the same
relationship after their alignment has been disturbed. Even checking for damage by separating
the faces can upset their relationship. The faces should not be separated unless it is absolutely
necessary. Whenever possible, inspection of the seals should be limited to visual external
inspection only.
8.2.5 Startup
Mechanical face seals are precision pieces of equipment. If they are to provide good service, they
must be correctly commissioned and operated. The primary aim of a proper startup is to ensure
that the seal does not initially run dry.
8-10
8.2.5.1
If barrier or flushing fluids are used, ensure that the seal cavity is properly filled and that there
are no leaks. If the fluids in the seal cavity are circulated externally, verify that the equipment is
functioning properly and delivering the required flow.
Fluids with low vapor pressures should be properly pressurized to ensure that the fluid at the
faces does not vaporize when the faces heat up during normal running.
8.2.5.2
Filtration
Dirt and particulate can cause a seal to fail in a very short period of time. Ensure that the seal
cavity is completely clean and that the recirculated fluid has been properly filtered. When
installing mechanical seals in new piping systems, it might even be necessary to temporarily
replace the mechanical face seal with conventional soft packing until the system has been
thoroughly flushed of construction and installation debris.
8.2.5.3
The stuffing box should be properly vented to ensure that the seal chamber is completely filled.
Never start a mechanical face seal before venting the seal cavity of air and foreign fluids. Ideally,
the installation should allow the seal cavity to be vented automatically during pump priming, but,
in some installations, it might be possible to flood the pump suction without purging the air
trapped in the top portion of the seal cavity. Special attention should be paid to vertical
installations where the mechanical face seal is in the uppermost portion of the pressure boundary.
Key Human Performance Point
Proper venting of seal chamber prior to placing into service is critical to seal
performance and longevity.
8-11
9
REFERENCES AND BIBLIOGRAPHY
1. B. S. Nau, Hydrodynamic Lubrication in Face Seals. Paper No. E5, 3rd International
Conference on Fluid Sealing, BHRA, Cranfield, Bradford, UK (1967).
2. J. G. Pape, Fundamental Research on a Radial Face Seal, ASLE Transactions. Vol. 11,
No. 4, (October 1968).
3. E. Mayer. Mechanical Seals, 3rd Edition. J. W. Arrowsmith Ltd., Bristol 1969.
4. H. H. Buchter. Industrial Sealing Technology. John Wiley & Sons, Inc., New York 1979.
5. Alan O. Lebeck. Principles and Design of Mechanical Face Seals. John Wiley & Sons, Inc.,
New York 1991.
6. Handbook of Fluid Sealing, edited by Robert V. Brink, McGraw-Hill, Inc., New York 1993.
7. Mechanical Seal Practice for Improved Performance, edited by Summers-Smith, Mechanical
Engineering Publications, Ltd., for The Institution of Mechanical Engineers, London 1988.
8. API Standard 682: Shaft Sealing Systems for Centrifugal and Rotary Pumps, 1st Edition,
American Petroleum Institute, Washington, D.C. October 1994.
9. Robert L. Johnson and Karl Schoenherr. Seal Wear, Wear Control Handbook, pp. 727-754,
American Society of Mechanical Engineers, 1980.
10. Seals Flow Code Development 93, NASA Conference Publication 10136, Proceedings
of a workshop held at the NASA Lewis Research Center, Cleveland, OH (November 3-4,
1993).
11. F. A. Conner and M. T. Thew, Trends in Mechanical Seal Performance at Three Process
Plants in the Oil Industry, 14th International Conference on Fluid Sealing, Publication 9,
BHR Group, Mechanical Engineering Publications Limited, London (1994).
12. D. H. Ahlberg and E. C. Fitch, Leaking Seals: Causes and Cures, ASME Paper 79-DE-E-7,
1979.
13. O. von Bertele, Why Do Seals Fail Unpredictably, Paper L4, presented at the 10th
International Conference on Fluid Sealing, Innsbruck, Austria (April 3-5, 1984).
14. F. K. Orcutt, An Investigation of the Operation and Failure of Mechanical Face Seals,
presented at the 4th International Conference on Fluid Sealing held in conjunction with the
1969 ASLE Annual Meeting, Philadelphia, PA (1969).
9-1
15. John C. Hudelson, Dynamic Instability of Undamped Bellows Face Seals in Cryogenic
Liquid, pp. 381-390, ASLE Transactions 9. (1966).
16. J. W. Abar, Failures of Mechanical Face Seals, pp. 437-449, Metals Handbook, American
Society of Metals, 8th Ed., Vol. 10, (1975).
17. Anon. Identifying Causes of Seal Leakage, Crane Packing Company, Form No. S-2031
(1979).
18. Donald L. Berg, Dynamic Seal MaintenanceStuffingbox Sealing Considerations,
presented at NMAC 6th Annual Conference and Technical Workshop, Orlando, FL
(December 9-11, 1996).
19. Steven Lemberger, Mechanical Seal Maintenance, presented at the NMAC 6th Annual
Meeting and Workshop, Orlando, FL (December 9-11, 1996).
20. E. Mayer, High Duty Mechanical Seals for Nuclear Power Stations, Paper A5, presented at
the 5th International Conference on Fluid Sealing, Warwick, Coventry, UK, March 30-April
2, 1971, BHRA Group, Mechanical Engineering Publications Limited, London (1971).
21. H. Laumer and D. Florjancic, Mechanical Seals for High Pressures and High
Circumferential Speeds, Paper A4, presented at the 5th International Conference on Fluid
Sealing, Warwick, Coventry, UK, March 30-April 2, 1971, BHRA Group, Mechanical
Engineering Publications Limited, London (1971).
22. W. Schopplein. Mechanical Seals for Aqueous Media Subject to High Pressures, Paper E3,
presented at the 8th International Conference on Fluid Sealing, University of Durham, UK
(September 11-13, 1978).
23. William V. Adams and Peter Lytwyn. Retrofit of an Unspared Main Boiler Feed Pump to
End Face Mechanical Seals, Paper No. 86-JPGC-Pwr-52, presented at the joint ASME/IEEE
Power Generation Conference, Portland, OR (October 19-23, 1986).
24. H-J. Franke, R. Lachmayer, and J. Mosowicz. Long-Term Tests of Mechanical Seals for
Hot Water Application, 14th International Conference on Fluid Sealing, Publication 9,
BHRA Group, Mechanical Engineering Publications Limited, London (1994).
25. J. Nosowicz and A. Eiletz. Operating Performance of Mechanical Seals for Boiler Feed
Pumps, 15th International Conference on Fluid Sealing, Publication 26, BHR Group,
Mechanical Engineering Publications Limited, London (1997).
26. R. Metcalfe, N. E. Pothier, and B. H. Rod. Diametral Tilt and Leakage of End Face Seals
with Convergent Sealing Gaps, Paper A1, presented at the 8th International Conference on
Fluid Sealing, University of Durham, UK (September 11-13, 1978).
27. A. H-C. Marr, R. L. Phelps, and B. Katz. Loss of Component Cooling Water Capability of a
PWR Reactor Coolant Pump, Paper No. 80-C2/PVP-28, presented at the Century 2 Pressure
Vessels & Piping Conference, San Francisco, CA (August 12-15, 1980).
9-2
28. Thomas R. Morton. Seal Performance from the Manufacturers Viewpoint, Paper No. 84PVP-115, American Society of Mechanical Engineers, New York, NY, 1984.
29. M. S. Kalsi, T. Horst, H. L. Richter, and M. Hojati. O-Ring Static Seal Performance at
Elevated Temperatures Simulating A Loss of Component Cooling Water Accident, Paper
87-PVP-5, American Society of Mechanical Engineers, presented at the Pressure Vessel &
Piping Conference, San Diego, CA (July 1987).
30. David L. Cummings and Sherman W. Shaw. Increased Reliability of Reactor Coolant Pump
Seals through Retrofit of Proven Technology, paper presented at the American Nuclear
Society Topical Meeting, Myrtle Beach, SC (April 17-20, 1988).
31. Takuya Fujita, et al. Development of Rotary Shaft Seals for Primary Coolant Pumps for
Nuclear Reactors, Preprint No. 87-TC-3D-1, presented at the STLE/ASME Tribology
Conference, San Antonio, TX (October 5-8, 1987).
32. Joseph A. Marsi and Dr. S. Gopalakrishnan, Full-Scale Station Blackout Test Conducted on
Advanced RCP Mechanical Seal, Nuclear Plant Journal. P. 86 (September-October 1988).
33. Ray Metcalfe, Canadians Solve Seal Problems, Nuclear Engineering Internationa.
p. 46 (July 1989).
34. T. E. Greene and G. B. Inch. Evaluation of Shaft Seal Leakage under Station Blackout
Conditions for the ReactorCirculation pumps at Nine Mile Point, Unit One, presented at
Fifth International Workshop on Main Coolant Pumps, Orlando, FL (April 21-24, 1992).
35. Main Coolant Pump Seal Maintenance Guide. Prepared by Quadrex Energy Services for
Nuclear Maintenance Application Center: 1993. TR-100855.
36. A. Parmar. Thermal Distortion Control in Mechanical Seals, 12th International Conference
on Fluid Sealing, BHRA, Cranfield, Bedford, UK (1989).
37. Antonio Artiles, Wilbur Shapiro, and Henry F. Jones. Design Analysis of Rayleigh-Step
Floating-Ring Seals, Preprint No. 83-LC-38-2, presented at the ASLE/ASME Lubrication
Conference, Hartford, CT (October 18-20, 1983).
38. L. A. Young and A. O. Lebeck, The Design and Testing of Moving-Wave Mechanical Face
Seals Under Variable Operating Conditions in Water, Preprint No. 85-TC-1C-1, presented
at the ASLE/ASME Tribology Conference, Atlanta, GA (October 8-10, 1985).
39. J. G. Evans. New Developments in Bellow Seals for Improved Performance and
Reliability, 14th International Conference on Fluid Sealing, Publication 9, BHR Group,
Mechanical Engineering Publications Limited, London (1994).
40. R. Metcalf, T. A. Graham, and W. C. Wong. Eccentric Seals for Nuclear Pumps, 14th
International Conference on Fluid Sealing, Publication 9, BHR Group, Mechanical
Engineering Publications Limited, London (1994).
9-3
9-4
54. M. S. Kalsi. A Novel High Pressure (up to 5000 psi / 340 Bars) Polymeric Rotary Shaft
Seal, World Tribology Congress, Organized by the Tribology Group of the Institution of
Mechanical Engineers, London (September 8-12, 1997).
55. K. C. Wilson, G. R. Addie, A. Sellgren, and R. Clift. Slurry Transport Using Centrifugal
Pumps, 2nd Edition. Blackie Academic & Professional, London 1996.
56. R. K. Flitney and B. S. Nau. Performance Testing of Mechanical Seals, Fluid Sealing.
Kluwer Academic Publishers, pp. 441-466.
57. Denis Buchdahl, Roger Martin, and Jean-Michel Girault. Mechanical Seals Qualification
Procedure of the Main Pumps of Nuclear Power Plants in France, Fluid Sealing. Kluwer
Academic Publishers, pp. 429-439 (1992).
NRC Information Notices and Generic Communications
58. USNRC Information Notice 95-42: Commission Decision on the Resolution of Generic Issue
23, Reactor Coolant Pump Seal Failure, September 22, 1995.
59. USNRC Information Notice 87-51: Failure of Low Pressure Safety Injection Pump Due to
Seal Problems, October 13, 1987.
60. USNRC Information Notice 96-58: RCP Seal Replacement with Pump on Backseat, October
30, 1996.
61. USNRC GI23: Reactor Coolant Pump Seal Failures and its Possible Effect on Station
Blackout (Generic Letter 91-07).
62. USNRC Information Notice 93-61: Excessive Reactor Coolant Leakage Following a Seal
Failure in a Reactor Coolant Pump or Reactor Recirculation Pump, August 9, 1993.
63. USNRC Information Notice 93-84: Determination of Westinghouse Reactor Coolant Pump
Seal Failure, October 20, 1993.
64. USNRC Regulatory Issue Summary 2000-02: Closure of Generic Safety Issue 23, Reactor
Coolant Pump Seal Failure, February 15, 2000.
65. USNRC Draft Regulatory Guide DG-1008: Reactor Coolant Pump Seals, April 1991.
9-5
A
MECHANICAL SEALS APPLICATION AND
MAINTENANCE GUIDE SURVEY
This appendix contains the form used to conduct the survey of fossil and nuclear power utilities
to determine the most common failure modes, the root causes, and installation and maintenance
recommendations in support of the development of this guide.
A-1
At the direction of the NMAC Steering Committee, NMAC has begun the preparation of an Application
and Maintenance Guide for Mechanical Seals used in nuclear power plants. This survey is intended to
obtain the most common problems with mechanical seals in use today. Information obtained from this
survey will be used in developing a comprehensive and state-of-the-art Guide for the application, use,
maintenance, repair, and troubleshooting of problems with mechanical seal. Your participation in this
survey is vital to the accuracy and usefulness of this Guide. The Guide is intended to be a single source
for utility engineers and maintenance personnel to minimize problems with mechanical seals while
extending the number of cycles between seal inspections.
In order to evaluate the responses and to make comparisons between utilities to determine successful and
unsuccessful practices, besides the responses to the following questions (which can be done by e-mail on
this form), the following information is also requested:
1) A copy of your latest procedures for mechanical seal maintenance, repairs, and troubleshooting.
2) Itemization of each individual pump's mechanical seal history since 1/1/90 (Maintenance Rule data is
acceptable). This should include any mechanical seal failures and the root cause determination of
those failures, corrective actions taken, and the seal inspection reports, even if the maintenance was
solely of a routine nature. Please include any mechanical seal leakage trending data available. Please
contact us if there is a question about this request.
3) Special problems that the plant may have experienced, and the plant's approach to addressing them.
The outcome of each repair or corrective action will be a valuable addition to your response.
An important element of a typical NMAC Guide is to involve industry personnel in the review/ comment
stages of guide development. Would someone at your facility be willing to participate as a member of our
Technical Advisory Group (TAG) which typically involves review/comment of an initial draft and final
version of the planned maintenance guide?
No
Yes
Please mail, fax or e-mail responses to:
A-2
Mike Pugh
1300 W. T. Harris Blvd.
Charlotte, NC 28262
Fax: 704-547-6035
E-mail: mpugh@epri.com
Phone: 704-547-6004
Phone: (_____)
Utility:
Fax: (_____)
Plant:
E-Mail:
1
PWR
3
BWR
4
or Fossil
Leakage
Availability
Other (explain)
(3) BWIP
(4) AECL
(4) Chesterton
(7) Borg-Warner/BWIP
(2) Durametallic
(5) Sealol
(8) AST
(6) Flexibox
(10) Other
6c) Most common at your plant (select 3 numbers from list in Question 6b) .
A-3
Compressible
(6) Air/Nitrogen
(7) Steam
(8) Other (Specify)
8b) Most common at this location (select 2 numbers from each category in Question 8a)
9) Most common secondary seals (select 2)
Elastomeric O-Ring
Elastomeric U-Cup
Metal Bellows
Other (specify)
Elastomeric Chevron
Elastomeric Wedge
Elastomeric Bellows
10) Select the 3 most common face material combinations from the list below
Rotating
Face
Stationary
Face
Combination 1
Combination 2
Combination 3
(1) Carbon - Graphite
(2) Carbon - Babbit
(3) Ceramic
(4) Nickel - Resist
(5) Silicon Carbide
(6) Laminated Plastic
(7) Teflon
(8) Stainless Steel
(9) Stellite Hard-Facing on
Stainless Steel
A-4
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Aluminum - Bronze
Bronze
Monel
Tungsten Carbide
Phosphor - Bronze
Carbon-Filled Teflon (nonoxidizing acids)
Glass-Filled Teflon (oxidizing acids)
Hasteloy A, B, or C
Other (specify)
Most
Least
Never
Common Common Occurs
A-5
A-6
21) Please provide a copy of your data sheet used to specify mechanical seals (if available).
Data sheet attached
22) Shaft stiffness criterion used to determine the suitability of a mechanical seal for a given
application.
3
4
Shaft deflection at seal
L /D ratio Specify value:
Other
None
23) List 3 applications in which mechanical seal problems continue to be difficult to solve.
Application 1:
Application 2:
Application 3:
Provide details of the 3 applications in the following table:
A-7
Application
1
Stationary
Rotating
Seal design
-
Balanced or unbalanced
A-8
Every 3 years
Other
26) Does your plant require contractors to have formal mechanical seal training before commencing
repair or replacement work?
Yes
No
A-9
B
INSPECTION OF SEAL FACES FOR FLATNESS
B.1
Optical Principle
Lapped surfaces of seal parts are inspected for flatness using an optical flat and monochromatic
light. Light is passed through the optical flat, then reflected off the lapped surface, and back
through the optical flat. When a gap exists between the optical flat and lapped surface, the light
reflections off the lapped surface and the optical flat interfere with each other, preventing some
of the light from passing back through the optical flat. Between the dark bands, the reflections
reinforce each other and produce light bands. This phenomenon produces a series of dark and
light bands when the optical flat is viewed from above, as shown in Figure B-1. The parallel dark
bands form where the change in distance between the flat and lapped surface is one-half the
wave length of the light as shown in this figure.
An optical flat is made from transparent material, normally quartz or Pyrex, which is very flat.
Different size optical flats with different flatness tolerances are available. Typically, seal parts
are inspected with an optical flat that is flat within 2 to 5 micro-inches (one micro-inch or 1 P in.
is one-millionth (0.000001) of an inch). Optical flats can be flat within the specified tolerance on
one or both sides. Single-sided flats are normally adequate for seal inspection. Coating on the flat
increases its reflectivity and makes the light bands easier to see.
A monochromatic light source emits light of a known wavelength. The most common type is a
helium-filled tube that emits orange/yellow light with a wavelength of 23.2 P in. The light bands
visible through the optical flat are one-half the total wavelength. Consequently, each band
(consisting of one light and one dark band) that is visible represents a gap of 11.6 P in. The
actual width of the bands cannot be related to the flatness of the part. The total number of bands
seen during inspection is a function of the gap that is created between the flat and the lapped
surface, not the flatness. Manufacturers will specify flatness in light bands, normally without
regard to the size of the part. A seal part that is required to be flat within 2 light bands has a
flatness tolerance of 23.2 P in. over the specified surface.
B-1
Figure B-1
Using an Optical Flat to Determine Seal Face Flatness Light Bands
B.2
When measuring the flatness of seal parts, the following basic good practices should be used to
obtain accurate results.
x
The optical flat and lapped surface should be free of dirt or other particles. Parts can be
wiped with a lint-free cloth or brushed off with a fine bristle brush prior to setting the flat on
the lapped surface.
Avoid putting any unnecessary force on the parts being inspected. The tolerances for lapped
surfaces are extraordinarily small and exerting unnecessary force on the parts can distort the
flatness.
The size of the flat needs to be matched to the part. Do not use an optical flat that is much
larger and heavier than what is required.
B-2
When inspecting carbon seal parts, place the carbon seal ring on a flat surface, such as
another flat or a lapped surface, like a carbide seal ring.
Flatness measurements should only be taken when the part being inspected and the flat are
both at a uniform room temperature. For example, if the flat is at room temperature and the
part has just been brought in from an uncontrolled cold environment, the warm flat might
distort a cold surface.
View the optical flat from the correct angle. The flatness reading can be seriously distorted
by determining the flatness when viewing the part with too great of incidence angle. Light
bands should be determined when looking straight down on the part, as shown in Figure
B-2, at a viewing angle of close to 90q. If the flatness reading is taken with a viewing angle
of 60q, each light band represents 13.4 P in. instead of 11.6 P in.
Figure B-2
The Viewing Angle Typically Should be 80q to 90q While Checking Flatness Using a
Monochromatic Light Source
A procedure for measuring flatness on seal rings and other toroidally shaped lapped seal surfaces
is provided below. This method places an air wedge under one side of the flat to help determine
if the part is convex or concave, or if it has other out-of-flatness conditions.
1. Place the lapped part under the monochromatic light. If the part is a carbon ring, make sure it
is adequately supported.
2. Clean the lapped surface and the optical flat of dust with a lint-free cloth or fine bristle brush.
3. Place the flat on the lapped surface.
B-3
4. Use a piece of lint-free tissue to create an air wedge. Place the tissue between the left side of
the lapped surface and the optical flat. Slowly pull the tissue out until the edge of the tissue is
at the edge of the lapped surface. The tissue can be manipulated until a light band pattern
width that is easy to view is visible. If the tissue wedge is too thick or foreign particles are
between the flat and the lapped surface, the light band pattern will be too narrow to read. To
check to see if the air wedge is too thick, use light thumb pressure at the air wedge to vary
the appearance of the light bands.
5. The light bands are used to determine the degree of flatness. When interference bands are
straight, parallel, and equally spaced, the surface is assumed to be flat to within 11.6 P in.
6. Interpretation is carried out noting the number of bands intersected by a straight tangent line,
as in the examples shown in Figures B-3 through B-7. Out-of-flatness is measured by
multiplying this number by 11.6 P in. It is important to note that, if the bands are inconsistent
or missing, it is necessary to draw two imaginary centerlines 90q apart and perpendicular to
the axis of the part, and then draw line AB at 45q, connecting the two previous lines (see
examples in Figures B-6 and B-7).
The procedure used by different seal manufacturers to determine flatness might vary from the
procedure above. The relationship to successful performance and flatness measurements should
be kept in perspective. If the lapping and measurement techniques provide consistent successful
operation, the procedures should not be changed.
Figure B-3
Flat Within One Light Band (The distance x is dependent on the amount of air between the
optical flat and the face and does not indicate lack of flatness.)
B-4
Figure B-4
Bands Bend on One side and Line AB Intersects 3 Bands (The face is therefore out-of-flat
by 3 light bands or 35 P in.)
Figure B-5
This Indicates an Egg-Shaped Curvature of 2.5 Light Bands (That is, 29 P in. Line AB
intersects 2 bands and falls between another 2 at the center of the ring. Line A'B'
intersects 2 bands that curve in the opposite direction.)
B-5
Figure B-6
Bands Show a Saddle Shape Out-of-Flat Condition of 3 Light Bands,
35 P in.
Figure B-7
Bands Show a Cylindrical-Shaped Part with a 3-Light Band Reading Error
Figure B-8
Band Symmetrical Pattern Indicates a Conical Convex or Concave Part. (The out-offlatness is measured by the number of bands on the part, that is, 3 bands
or 35 P in.)
B-6
C
TRAINING COURSES
The following is a listing and description of training materials or courses that are presently
known to NMAC that are available for enhancing skills involved with mechanical seals. They
are broken down into two major categories. The first category of training, Category A, supports
a basic understanding of mechanical seal installation and maintenance practices as well as
personnel qualification materials. The second category, Category B, provides a higher level of
training that will improve craftsmanship and understanding of seal operation and technology, and
also gives a greater insight into performance, problem analysis, and plant implications. NMAC
has reviewed these course offerings in limited detail. Reference herein is not intended to be an
endorsement of the materials but simply a reference, should additional training information be
desired by the membership.
CATEGORY A
EPRI Maintenance Performance Evaluation Test Bank
The Maintenance Proficiency Evaluation Test Bank (MPETB) is a database of validated and
reliable task-specific written and performance tests developed by participating utilities following
the proven MPE methodology referenced in EPRI technical reports. The database, made
available exclusively to utility participants in this project, already contains a large population of
task-specific written and performance tests that can be administered to plant or contractor
personnel. Currently there are several tests for mechanical seals that are available to
participating members. If you would like to find out more about the Mechanical Seals MPEs
you can visit the EPRI webpage at http://www.epriweb.com/epriweb2.5/ecd/np/mpe/index.html
or contact Loran Maier at 704-547-6152.
Annual International Pump Users Symposium and Short Courses Program
Texas A&M Turbomachinery Laboratory
College Station, Texas 77843-3254
Phone: 979/845-7417
Website: http://turbolab.tamu.edu
Contact: Dr. Bailey, Marketing Director
Background:
The Turbomachinery Laboratory receives inquiries from fluid handling and rotating equipment
users who are looking for intensive training opportunities in addition to those currently offered at
their symposia. In response to these inquiries, they have initiated a cooperative effort with some
exhibiting companies to provide information on their professional development opportunities.
These technical training sessions are listed below, by company, with a brief description of each
course.
C-1
C-3
C-4
D
LISTING OF KEY INFORMATION
The following list provides the location of key Pop Out information in this report.
Key O&M Cost Point
Emphasizes information that will reduce purchase, operating, or
maintenance costs.
Section
Page
Key Point
3.4
3-12
6.1
6-1
Seal monitoring programs vary greatly from utility to utility, and from
site to site due to different equipment designs, operating philosophies,
and different rates of forced outages experienced. For many plants,
condition-based monitoring is limited to visual observations with little
actual quantification except for main coolant pump mechanical face
seals.
6.3
6-5
7-1
8.1
8-1
8.2.5
8-11
D-1
Section
Page
Key Point
3.1
3-2
3.3
3-11
3.5
3-16
Mechanical seals are often installed in the same cavity that is designed
to accept conventional packings. This limits the fluid circulation around
the seal, leading to high seal temperatures and accumulation of solids.
An enlarged seal chamber with tapered bore can dramatically improve
fluid circulation, lowering seal temperature and eliminating
accumulation of solids.
3.6.1
3-20
3.6.2
3-21
Pressure distribution across the seal face width can be linear, concave,
or convex and it can change with variations in pressure, temperature,
and seal wear. This can affect seal performance (leakage, torque,
temperature) during operation.
3.8
3-24
3.9
3-28
D-2
3-28
4.2
4-2
The eventual failure mode of all mechanical face seals is leakage that is
considered unacceptable for the seal design/configuration being used.
Excessive leakage can cause unacceptable loss of fluid, reduction of
pressure, or contamination of the system fluid by the barrier fluid in
double-seal installations. Level of acceptable leakage is dependent upon
the application.
4.4.1
4-5
4.4.3
4-6
Mechanical seals are often installed in the same cavity that is designed
to accept conventional packings. This limits the fluid circulation around
the seal, leading to high seal temperatures and accumulation of solids.
An enlarged seal chamber with tapered bore can dramatically improve
fluid circulation, lowering seal temperature and eliminating
accumulation of solids.
4.4.4
4-7
4.4.4
4-8
4.4.5
4-10
4.4.6
4-13
Static and dynamic misalignment between seal faces can cause strong
fluid pumping action across the faces causing either inward pumping or
outward pumping of the product fluid and/or buffer fluid. Leakages
under misaligned conditions can be several times the normal leak rate.
4.4.6
4-13
4.4.7
4-15
D-3
4.4.8
4-16
5.2
5-3
D-4
Section
Page
Key Point
7.2.2
7-7
7.3
7-12
8.2
8-2
8.2.1.1
8-2
8.2.2
8-4
8.2.4.1
8-10
8.2.5.3
8-11
D-5
Targets:
Nuclear Power
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