4 Ways to Prevent Seal Failure

The life expectancy of a mechanical seal is determined by a wide variety of

factors, most of which are independent from the seal design. Seal selection,
installation technique, equipment startup procedure, operation, seal storage
conditions, product variables and seal support systems all play a part in how long
a seal will last.
Even with so many variables, there are steps users can take to prevent seal failure
and increase seal life. Here are four proven methods to ensure any seal operates
in peak condition for as long as possible.

1. Choose the Correct Seal

Lack of knowledge and information is an obstacle in the seal selection process.
Before deciding on a seal, carefully consider the application and normal operating
conditions, as well as any potential off-design usage. For example, selecting a seal
to operate in hot water may seem easy because the medium is not particularly
difficult. However, if the application is boiler feed water, this assumption is
incorrect. Hot water at temperatures above 190 F is unable to appropriately
lubricate and cool the seal faces. The sealing process is then compromised by
elevated friction between the two mating faces and will culminate in premature
seal failure.
To solve this issue, the user must determine if the correct operating parameters
are being maintained, then talk with the seal supplier to verify the appropriate
American Petroleum Institute (API) flush plan and to choose the correct seal face
combination and elastomer materials. Every application has unique requirements,
and the proper seals are designed specifically to overcome application challenges.

2. Properly Install the Seal

Seal installation should be performed using the steps outlined by the
manufacturer and with great care to avoid damaging the delicate seal faces
and/or O-rings. Common issues that may occur when installing a seal include
forgetting to tighten set screws before removing setting clips, not tightening
gland bolts evenly, damaging O-rings, nicking seal faces or incorrectly using the
piping connections. Improper seal installation caused by a lack of knowledge is a
significant factor in most seal failures.
Component seal installation is inherently more prone to installation errors when
compared with cartridge seals because of the extra steps and measurements
needed. This is why, if possible, users should choose a cartridge seal over a
component design. There is already enough to be meticulous about when
installing a mechanical seal; why add additional opportunity for mistakes?
3. Prevent Excess Heat Generation
Excessive heat generation between seal faces will drastically reduce seal life. Dryrunning is the most common example of this issue. It typically occurs when a
pump is flooded and/or the seal chamber is incorrectly vented before pump
startup. Other situations can also lead to excessive heat generation and dryrunning.
For example, the seal chamber's pressure can exceed the seal's design
parameters during upset conditions. In this situation, contact the seal
manufacturer. The seal design may need to be altered if condition fluctuations are
an ongoing issue.

The use of API 682 flush plans and seal support systems is generally
recommended for all applications. Piping plans such as Plan 11 (flush line from
pump discharge), Plan 13 (recirculation to pump suction) or Plan 53A (pressurized
barrier fluid with a seal reservoir) can be simple or highly complex, but they all
have the same goal: to keep the seal faces clean, cool and well-lubricated.
The correct seal support system (based on API 682 flush plans) will have an
overwhelming impact on the overall success of production. For example, if
abrasives are present in the product, the seal manufacturer may recommend
changing a softer carbon face to either silicon carbide or a tungsten carbide face.
This hard face combination has proven to be successful in abrasive services.
However, if there are no abrasive solids or chemical issues with the process fluid,
the carbon versus silicon carbide face may be the best seal face combination to
achieve long seal life. In all cases, it is easy to remember: A cool-running seal is a
happy seal.

4. Maintain Proper Storage Conditions

Mechanical seals are composed of many unique parts formed from a variety of
materials. Because of the diverse properties and the precise, delicate nature of
these components, it is important to understand how long a seal can be stored
safely without compromising function.

If the following procedures are followed and the seal is stored in a clean,
temperature/humidity-controlled environment, a seal can be stored effectively
for five years.
To store a new seal for less than two years, store it in a clean, cool environment.
Prevent face lock and loss of face flatness by rotating the seal faces against each
other (by rotating the sleeve or shaft) two turns every three months if the seal is
not used in operation during that time.

To store a new seal on a shelf for more than two years or to store a seal that has
been in service already and will be stored for more than one year:
Disassemble the seal and store all parts as individual components. Ensure
that O-rings are in a relaxed state and meet the appropriate environmental
conditions. For a seal that has been in service, clean and dry all components
before storage.
Plug all openings in the seal's gland as well as the unused pump's seal
chamber.
Do not store seal faces (silicon/carbon/tungsten) together in the same
packaging. Faces are best separated into individual, protective, bubblewrapped package

To reassemble the seal after storage:

Check O-rings for cracks, cuts and wear, and lubricate O-rings for easier
assembly.
If O-rings are damaged or have experienced compression set, replace them.
Check mating ring/seal ring for cracks or chips, especially on the sealing
faces. If they are damaged, contact the vendor for a replacement.

These are just a few of the basic recommendations for storage, maintenance and
reintroduction to service for a mechanical seal. For more details, see international
standards such as Detaches Institute fr Normung (DIN) 7716 and International
Organization for Standardization (ISO) 2230, which detail fundamental
instructions on the storage and maintenance of elastomeric seal elements.