Even or uneven wear track Another common problem is that the wear track can become uneven.

Continuous, even wear on a seal face usually indicates good contact between mating seal rings. Uneven (usually not continuous) wear on a seal face is a problem that needs to be corrected. This uneven face wear can be caused by the following: Distortion of a seal ring due to over-tightening or clamping. Distortion due to insufficient seal gland support. Misaligned seal rings (usually in a split seal). An improperly stress-relieved component.
Possible solutions to this failure are to review installation techniques and instructions, check and sometimes reduce torque while evenly tightening the gland bolts or use a softer gasket with the properly torqued bolts.

Figure 6
Typical even wear track

Figure 7
Example of an uneven wear track. Note: how the track seems to fade out from left to right

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Scoring or erosion of the seal faces

Mechanical Seal Seal Face Symptoms

Another common cause of face scoring has nothing to do with the seal faces opening. It is the act of rebuilding the seal in a dirty environment. Be extra careful when rebuilding or assembling the seal to avoid dirt and other hard particles getting into the seal
Mechanical SealSeal Face Symptoms

A properly operating mechanical will show a smooth set of seal faces and no signs of attack. However, sometimes the seal faces can become scored or eroded. This leads to quick seal failure. In almost all cases face scoring and eras on occur because the seal faces are opening when they should be closed. This allows contaminants and particulates to infiltrate and cause problems. Common causes of seal face opening are as follows: The product is flashing near the seal faces. This often blows the faces open. Excessive pump vibration due to cavitation, bad bearings, misalignment, impeller imbalance or some other reason. Distortion of the seal faces due to temperature and pressure fluctuations. This often occurs when the seal faces are "pressed-into" a metal holder. Minerals that deposit or plate out on the seals faces and force the faces open. Shaft deflection caused by operating the pump far away from its BEP. Possible solutions to this type of failure are: Maintain seal face flatness (consider monolithic seal face designs). Eliminate seal dry running. Make sure you vent vertical pumps. Eliminate product flashing. Reduce pump vibration. Use a clean flush with restriction bushing where possible. Use suction recirculation control when applicable. Examine pump operation and L/D ratio and correct if necessary. Use harder seal face materials. Use non-conducting (electrical) seal face materials to eliminate mineral plating. SSC or ceramic are usually the only alternatives.

Scoring or erosion of the seal faces

Figure 8
Common seal face scoring, caused by the seal faces opening

Figure 9
Common seal face erosion, caused by product flashing

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Figure 10

Chipping on the outside or inside diameter of the seal face

A properly operating mechanical seal will show a smooth set of seal faces and no signs of degradation. Sometimes the seal faces can become chipped on the outside diameter, inside diameter or both. This leads to premature seal failure. This seal face chipping can be caused by the following: The faces were forced open and closed again many times in succession. Sometimes known as "chattering". The product was flashing at the seal faces. The pump had excessive vibration due to cavitation, bad bearings, misalignment, impeller imbalance or some other cause. The products hardened or "set-up" between the seal faces. The seal was overpressurized beyond its design limit. Possible solutions to this failure are to maintain proper seal environmental controls, check equipment operating conditions, ensure the product is not flashing between the seal faces, and verify the seal is operating within its design parameters.

Seal Face O.D. Chipping

Typical seal face chipping on the O.D.

Figure 11
Typical seal face chipping on the I.D.

Coking or crystallization of the seal face

A properly operating mechanical will show a smooth set of seal faces and no signs of degradation. Sometimes the seal faces can become coked or crystallized product. This of course, will cause premature seal failure. The causes of this coking or crystallization are as follows: Excessive temperature of the product (causes both). Dirty or contaminated product (causes coking). Operating outside of the temperature envelope of the fluid (causes both). Fluid evaporation occurred between the seal faces (causes crystallization). Small clearances in the seal chamber or stuffing box. Pump cooling jacket is inefficient. Possible solutions to this type of failure are to maintain the proper use of environmental controls, operate the seal within its temperature and pressure limits, or get a firm understanding of the temperature characteristics for the fluid being sealed. Other solutions that involve modifying the pump are to use a large bore seal chamber and make sure the pump jacket is clean for efficient heat transfer.

CHAPTER 7
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SEAL troubleshooting
Mechanical Seal Seal Face Symptoms
Coking or crystallization of the seal face

Figure 12
Coked product on the seal face

Figure 13
Crystallization of product on the seal face

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Heat cracking or checking of the seal face

A properly operating mechanical seal will show a smooth set of seal faces and no signs of degradation. Sometimes the seal faces can show thin radial cracks on the hard face. This phenomenon is known as heat checking. It commonly occurs on ceramic or TC seal faces because of the following: The Pressure/Velocity (PV) limit of the seal face material has been exceeded. The seal faces have been running dry. The seal face has been subjected to excessive heat from the product (i.e.,condensate) and then rapidly cooled. Possible solutions to this type of failure are to operate the seal within its design limits, eliminate dry running conditions, or properly use the available environmental controls.

Figure 14
Common heat checking on a TC seal face

Figure 15
Common heat checking on other TC seal face

Blistering of the seal face A properly operating mechanical seal will show a smooth set of seal faces and no signs of degradation. Some times the seal faces can show pockets or holes where parts of the seal face has been removed. This phenomenon is known as blistering Both the hard and soft seal faces can blister. Common causes of face blistering are the following: Using carbon seal faces in oil is by far the most common. Exceeding the limits of the material. Extremely light product flashing at or near the seal faces. Possible solutions to this failure are to eliminate carbon use in oil and use an SC/TC face combination instead, operate the seal within its limits, verify that the proper environmental controls are in use or ensure the seal face is properly lubricated with liquid product (no flashing).

Mechanical SealSeal Face Symptoms

Figure 16
Typical carbon seal face blistering

Figure 17
A not so typical silicon carbide seal face blistering

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Mechanical Seal - Elastomer Symptoms

Hard or compression set (squared) elastomers
Under normal conditions, o-rings should last for a very long time. However, various problems can result if they are not applied properly or are unknowingly attacked by incompatible chemicals. If an elastomer has become hard, brittle or compression set (squared edge), quick seal failure is usually the result. The most common causes of this failure are the following: The temperature limit of the material was matched or exceeded. Make sure the known product temperature, plus any increase from the mechanical seal itself, is taken into account when specifying an elastomer. The elastomer is incompatible with the fluid. Chemical attack will cause weakening and brittleness of material. Possible solutions to this failure are to use the proper o-ring material for the fluid being sealed and temperature conditions, avoid dry running situations, or the proper use of environmental controls to control temperature.
F i g u r e 1 9
S l i g h t compression set for o-ring that approached its temperature limit

Figure 18
Severe compression set and possible chemical attack. Note: cracks are often caused by exposure to incompatible fluids

Extrusion or nibbling

Under normal conditions o-rings should last for a very long time. However, o-rings can become extruded or show signs of nibbling under some severe circumstances. The following can cause this to occur: The o-ring clearances are too large. This excessive space allows the o-ring to extrude. The system pressure is too high. Excessive pressures will push even the strongest o-ring through any clearance. The o-ring material is not of the proper durometer (hardness). The material is too soft for the application. This usually means that a higher temperature than anticipated caused the o-ring to soften.

CHAPTER 7 MECHANICAL

SEAL Troubleshooting
Mechanical SealElastomer Symptoms
Extrusion or nibbling

Figure 20
Typical o-ring extrusion. Note: the extruded edge

Possible solutions to this failure are to use the proper o-ring material for the application, use a proper seal design, verify the actual seal chamber pressure, verify o-ring groove dimensions or have adequate cooling for the seal.

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Figure 21
Typical o-ring nibbling. Note: the "gash" as though it had been bitten

Explosive decompression
An uncommon, but disastrous, problem with elastomers is explosive decompression. Explosive decompression occurs when trapped gas or vapor from the process fluid is forced into the o-ring under high pressure and with an instantaneous decrease of process pressure the trapped gases rapidly expand causing ruptures of the material. This type of failure usually occurs when high vapor pressure liquids (hydrocarbons) are being sealed under high pressure and then the pressure suddenly drops. The hydrocarbon is absorbed by the oring and then explodes out. Possible solutions to this failure are to use the proper o-ring material (type and durometer) and verify the system operation (i.e., shut-downs).

Soft, mushy, swollen, or twisted elastomers A very common o-ring failure is that the elastomer has become soft (even mushy), swollen, or twisted. This is often due to chemical attack or excessive temperatures higher than the material limit. If the cause is chemical attack, the o-ring will often revert back to its original size and shape after it is removed from the chemical.
This swelling phenomenon is quite common for hydrocarbons. An ethylene-propylene rubber (EPR) oring dropped in a glass of gasoline is a classic example. In the gasoline the EPR o-ring can swell to twice its normal size. Once removed, however, it shrinks back to its original size. Of course, the o-ring should still be replaced if this occurs. The only solution to this failure is to use the proper o-ring material for the fluid and temperature requirements. Check the compatibility charts for the correct elastomer.

Area where trapped gas exploded out of the o-ring

Figure 22 Explosive decompression. Note: the large holes where trapped gas exploded from the o-ring

Typical twisted o-ring

Mechanical Seal - Parts Inspection

Scoring of inside or outside diameters of seal faces and metal parts
In a properly operating mechanical seal, neither the seal rings nor the metal parts should be worn or degraded. Problems can result when scoring or circular rub marks are found on the inside or outside diameters of the rings and/or metal parts. These rub marks can me caused by the following: Misscentering of the seal during installation. This is very common on component seals. Shaft runout (bent shaft). Shaft deflection. Build-up of product in the seal chamber that contacts the seal. Contact between the seal components such as the seal sleeve and stationary components. This is caused by miscentering of cartridge seals. Contact between the seal and the pump stuffing box. The seal was not properly at ached to the shaft and was spinning on the shaft. Possible solutions to this failure are to check for proper installation techniques, check equipment for racial runout and endplay, use proper environmental controls, or open up the seal chamber to increase clearances around the seal.

Mechanical SealParts Inspection

Figure 24
Scoring found on the I.D. of the seal ring

Figure 25
Scoring found on the O. D. of the seal sleeve

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Corroded or pitted parts

CHAFFEB 7

In a properly operating mechanical seal, neither the seal rings nor the metal parts should be pitted or degraded. Problems can result when the rings or metal parts become corroded or pitted. This can be caused by the following: The most common cause, by far, is chemical attack. Any "trace" of chemicals found in the process fluid should also be checked for compatibility. Increasing temperatures will increase the corrosiveness of most acids. Leaching of the binder material of a seal ring by the fluid being sealed. Shaft deflection. Possible solutions to this failure are to use the proper metal for the fluid being pumped, select the proper seal face material with a compatible binder, and be aware of temperature influence on corrosive properties of the fluid being pumped.

Flattened set screw cup points

Most mechanical seals are held on the shaft with set screws. The normal screw used is the cup point. When cup points are loosened they still should have some "cup" to them. Sometimes the set screw cup points become flattened. This can lead to quick seal failure. The causes for this are as follows: The most common cause of flat set screws is the use of stainless screws on a hardened shaft or sleeve. Sleeves are often hardened to reduce the wear from packing. The seal slid on the shaft because of excessive pressure (above holding power of screw) or steel screws were not tightened properly. An unexpected pressure spike or surge in the system. Possible solutions to this failure are to use hardened set screws, use a pressure gauge to determine the presence of pressure spikes, or identify pump shaft or sleeve material to see what type set screws are needed.

Figure 26
Corrosion of a metal seal sleeve

Figure 27
Typical flattened set screw alongside normal cup point

Discoloration of the metal

Metal changes color when it is heated. What color it turns depends on the metal and the temperature. Most seals use 316 stainless steel for many of their metal parts. Here are some guidelines on how temperature affects 316 stainless steel. 700F - 800F (370C - 425C) Straw Yellow 900F - 1000F (480C - 540C) Brown 1100F (600C) Blue 1200F (650c) Black

The issue with metal discoloration is usually not about the metal; it's usually about the elastomer that contacts the metal. In other words, if a seal sleeve appears blue it probably was exposed to temperatures near 1100F (600C). If the blue area on the sleeve contacted an o-ring, it too was exposed to that temperature. No known o-ring that is currently used in mechanical seals can withstand this temperature. Try to determine what caused the seal to become so hot. A very common cause is that the seal ran dry. A seal running dry will generate a tremendous amount of heat. Once you have determined the cause, make sure it does not happen again.

Mechanical SealParts Inspection

Discoloration of the metal

Exposed to 1100F (600C)

The metal shaft discoloring because it was exposed to a high temperature. Note: not all metal will change color

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Mechanical Seal - Bellows Symptoms

Crack at or near weld
One of the most common bellows seal failures is the cracking of the bellows at or near a weld. This, of course, leads to immediate seal leakage and failure. The causes for bellows rupture are many and are listed below: Excessive seal chamber pressure. High torque at start-up because the product has solidified between the seal faces. The seal was run dry or was sealing a non-lubricating volatile fluid. Quality or design related issue. Corrosion of bellows caused by incompatible fluid. Excessive vibration Figure 29 of equipment movement.
Rupture at the inner diameter of a bellows seal

Possible solutions to this failure are as follows: Use bellows seals in the proper application. Use quench and drain to remove product from seal when needed. This environmental control is the most useful for single bellows seals. Ensure lubricity of process fluid at the seal faces with environmental controls. Avoid running bellows seals dry. Vent all vertical pumps. Use bellows seal in clean, compatible fluids. Dirty fluids can fill bellows with dirt so it does not expand as the seal face wears. Minimize equipment vibration. Vibration is a big killer of bellows seals due to metal fatigue.

Coated or clogged with product

Another common failure of bellows seals is the coating or clogging of the bellows with product or coked product. This eventually will lead to failure as the seal faces wear. A bellows can become clogged for the following reasons: Product hardening within the bellows convolutions. Excessive heat, causing the fluid to coke. Dirty or contaminated process fluid filling the bellows convolutions. Insufficient clearances in the seal chamber to remove solids. Possible solutions to this failure are as follows: Increase the size of the seal chamber. Properly use steam quench and drain to remove coked fluid. Use a clean compatible flush fluid for dirty product. Verify process fluid characteristics to eliminate hardening in seal chamber.

Mechanical SealBellows Symptoms

Figure 30
Bellows heavily dogged with coked product on the inner diameter

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