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After the failure has occurred you will frequently get a chance to analyze the failed
components. You are going to be looking for several things:
• Evidence of corrosion.
• Wear patterns on those parts that should be rubbing.
• Evidence of rubbing or wear on those components that should not be in contact.
• Discoloration of any of the seal components, especially the metal parts.
• Parts that are missing. Springs, set screws and drive lugs as an example.
• Loose hardware. Either a seal component or a foreign object.
• Product attaching to a rotating component. Carefully inspect the impeller and
rotating part of the seal.
In the following paragraphs we will be inspecting the individual components and looking
for evidence of the above.
Pits in the carbon face. This problem is usually associated with poor grades of carbon/
graphite.
• Exploded carbon. Air trapped in the pores of the carbon expands and expels
pieces of the carbon when the seal faces get hot. Prior to ejection polished patches
will be visible, usually with small cracks visible in the center.
• If the product solidifies between the faces it will tear out pieces of the carbon at
start up. This is a common occurrence with ammonia compressor seals because
petroleum oil is mixed with the ammonia and it can coke at the elevated
temperature.
• Most petroleum products will "coke" because of the higher face temperature, and
pull out small pieces of the carbon as the faces rotate. You will see evidence of
these small pits if you inspect the carbon face under a magnifying glass.
• Solids, or a foreign object of some type from outside of the pump are getting
under the gland and are being thrown into the seal faces. This can occur if the seal
leaked at some time and the product solidified on the outboard side of the seal. It
can also occur if liquid, containing solids, is used in the quench connection of an
A.P.I. type gland.
• If the seal was installed outside of the stuffing box, as is the case with non
metallic seals, solid particles in the fluid can be centrifuged into the rotating
carbon face.
• If the stationary face is manufactured from carbon it can be chipped if it comes
into contact with the rotating shaft. This is a common problem at pump start up,
or if the pump is operating off of its B.E.P.
• A solid product was blown across the seal face. This happens in boiler feed water
applications.
• You are using the wrong carbon. Something in the product or the flush is
attacking the carbon filler. Switch to an unfilled carbon such as Pure grade 658
RC or C.T.I. grade CNFJ.
• You are trying to seal an oxidizing agent. Oxidizers attack all forms of carbon
including the unfilled type. The carbon combines with the oxygen to form either
carbon monoxide or carbon dioxide.
• Some forms of de ionized water will pit and corrode carbon faces
• The product is solidifying between the faces. Carbons are strong in compression
but weak in tension or shear. This problem is common with intermittent pumps
each time they start up.
• Excessive vibration can bang the carbon against a metal drive lug.
• A cryogenic fluid is freezing a lubricant that was put on the face.
• The elastomer is swelling up under a carbon or hard face.
• The shaft is hitting the stationary face or the rotating seal face is hitting a
stationary object.
• Mishandling.
• Poor packaging. The lapped seal faces should be able to survive a 39" (one meter)
drop.
• Ice is forming on the outboard side of the seal and preventing the seal from
moving to compensate for face wear.
Coking
• The carbon is not dense enough, causing the expanding gases trapped beneath the
surface of the carbon to explode through the face.
• Product is solidifying between the faces and pulling out pieces of the carbon as
the seal revolves.
Excessive carbon wear in a short period of time. Evidence of excessive heat is usually
present.
• Heat checking of the hard face. It shows up as a cracking of the hard face. This is
a problem with coated or plated hard faces. Cobalt base tungsten carbide is a
typical example.
• The shaft is moving in an axial direction because of thrust. This can cause an over
compression and heating of the seal faces
• The impeller is being adjusted towards the back plate. This is problem with seals
installed in Duriron pumps or any other pump that adjusts the open impeller
against the back plate.
• Any installation problem:
• The inner face of a "back to back" double seal application is not positively locked
in position. A snap ring must be installed to prevent the inboard stationary face
from moving towards the rotating face when the high pressure barrier fluid
pressure is lost or overcome by system pressure.
• The seal was installed at the wrong dimension.
• A cartridge double seal was installed by pushing on the gland. Friction, between
the shaft and the sleeve O-Ring is compressing the inner seal.
• A vertical pump was not vented.
• Solids have penetrated between the faces.
• The faces are not flat.
• The movable face is sluggish.
• The product is vaporizing between the faces because of either high temperature or
low stuffing box pressure .
• Non lubricants will cause rapid face wear. A non lubricant is any fluid with a film
thickness less than one micron at its load and operating temperature..
• Mishandling.
• Poor packaging.
• The hard face has been installed backwards and you are running on a non lapped
surface.
• The seal was shipped out of flat.
• The metal/ carbon composite has not been stress relieved and it is distorting the
carbon.
• When the carbon was lapped the lapping plate was too hot and as a result, not flat.
• The carbon was lapped at room temperature and the seal is running at cryogenic
temperatures.
• Solids are imbedded in the carbon. The faces have opened.
o The seal was set screwed to a hard shaft.
o The elastomer (rubber part) is spring loaded to the shaft causing the faces
to open as the shaft moves due to end play, vibration or carbon wear. The
shaft/ sleeve is over sized causing an excessive interference between the
elastomer and the shaft/ sleeve.
o The sleeve finish is too rough.
o The product has changed from a liquid to a solid.
o Dirt or solids are interfering with the seal movement.
o Some one put the wrong compression on the faces.
o Shaft fretting is hanging up the face.
o The face has been distorted for some reason allowing solid particles to
enter.
o The sliding elastomer has swollen up causing too much interference on the
shaft/ sleeve.
o Poor centering is causing the rotating face to run off the stationary face.
Keep in mind the gland bolts are not always concentric with the shaft.
o The single spring was wound in the wrong direction.
o An out of balance rotating assembly or bent shaft is causing the rotating
face to "run off" of the stationary face.
Chemical attack.
• Some ceramics and silicone carbides are attacked by caustic. Check to see if your
seal face contains silica. As an example: both reaction bonded silicone carbide
and 85% ceramic have this high silica content.
Cracked or broken.
• The product is solidifying between the faces. Most hard faces have poor tensile or
shear strength.
• Excessive vibration will cause cracking at the drive lug location..
• A cryogenic fluid is freezing a lubricant that was put on the face.
• The elastomer is swelling up under an outside seal face. This problem can also
occur if the seal design allows a spring to contact the I.D. of the hard face.
• The shaft is hitting the stationary face or the rotating seal face is hitting a
stationary object.
• Mishandling.
• Poor packaging.
• Caused by a high heat differential across the face. Most hard coating have only
one third the expansion rate of the stainless steel base material.
• The base material not compatible with the sealed product. These coating are very
porous so if the product attacks the base material the coating will come off in
sheets.
• The plating process was not applied correctly.
Deep grooves&emdash;excessive wear. Solids imbedded in the carbon are causing the
problem. The solids were trapped between the faces when the seal faces opened.
• Worn bearings.
• Bent shaft.
• Unbalanced impeller.
• Sleeve not concentric with the shaft.
• Seal not concentric with the sleeve.
• In a stationary seal, the stationary carbon is often not centered to the shaft,
causing a wiping action.
Non Concentric pattern. The wear track is not in the center of the hard face.
• The shaft is bending because the pump is running off of its best efficiency point.
• Poor bearing fit.
• Pipe strain.
• Temperature growth is distorting the stuffing box.
• The stationary face is not centered to the shaft.
• Misalignment between the pump[ and its driver.
• High pressure.
• Excessive temperature.
• Over tightening of the stationary face against the stuffing box.
• The clamping forces are not equal and opposite.
• The hard face is not wide enough.
• You are using a two bolt gland and the gland is too thin causing it to distort.
• You are using a pump seal in a motion seal application.
The product is sticking to the seal face. The product is changing state and becoming a
solid. Most products solidify for the following reasons:
• A change in temperature.
• A change in pressure.
• Dilatants will solidify with agitation. As an example: cream becomes butter.
• Some products solidify when two or more chemicals are mixed together.
• Mishandling.
• Poor packaging.
• The hard face has been installed backwards and you are running on a non lapped
surface.
• It was shipped out of flat.
THE ELASTOMER.
• … High heat is almost always the cause unless you are dealing with Kalrez,
Chemraz, or a similar material where a certain amount of compression set is
normal.
• High heat.
• The shelf life was exceeded. This is a big problem with "Buna N" that has a shelf
life of only twelve months.
• Cryogenics will freeze just about any elastomer.
• Chemical attack normally causes swelling, but in rare cases can harden an
elastomer.
• Oxidizing liquids can attack the carbon that is used to color most elastomers
black.
• Mishandling.
• Sliding over a rough surface.
• Forced out of the O-Ring groove by high pressure.
• The liquid has penetrated the elastomer, vaporizing inside and blowing out pieces.
This is a problem with Ethylene Oxide.
• Halogenated fluids can penetrate the Teflon coating on an elastomer and cause the
base material to swell up, splitting the Teflon jacket.
• Chemical attack.
• Be careful of the lubricant used to install the elastomer.
• Solvents or cleaners used in the system may not be compatible with the elastomer.
• Some compounds are sensitive to steam. Most Vitons are a good example of this
problem.
• The elastomer is not compatible with something in the fluid you are sealing.
• The bellows did not vulcanize to the shaft because you used the wrong lubricant.
• The shelf life was exceeded.
• The seal faces stuck together and the shaft spun inside the bellows.
• The pump discharge recirculation line was aimed at the rubber bellows. Solids
entrained in the high velocity liquid are abrading the bellows.
Corrosion.
• General or overall. This is the easiest to see and predict. The metal has a "sponge
like" appearance. It always increases with temperature.
• Concentrated cell or crevice corrosion. Caused by a difference in concentration of
ions, or oxygen in stagnant areas causing an electric current to flow. Common
around gaskets, set screws, threads, and small crevices.
• Pitting corrosion. Found in other than stagnant areas. Extremely localized.
Chlorides are a common cause. Can be recognized by pits and holes in the metal.
• Stress corrosion cracking. Threshold values are not known. A combination of
chloride, tensile stress, and heat are necessary. Chloride stress corrosion is a
serious problem with the 300 series of stainless steels used in industry. This is the
reason you should never use stainless steel springs or stainless metal bellows in
mechanical seals.
• Inter granular corrosion. Forms at the grain boundaries. Occurs in stainless steel at
800-1600 F. (412-825 C.), unless it has been stress relieved. A common problem
with welded pieces. Stabilizers such as columbium are added to the stainless steel
to prevent this. Rapid cooling of the welds, the use of 316L and stress relieving
after the welding are the common solutions.
• Galvanic corrosion. Occurs with dissimilar materials in contact with and
connected by an electrical current. Common in brine, caustic, and salt water
applications.
• Erosion / Corrosion. An accelerated attack caused by a combination of corrosion
and mechanical wear. Vaporization, liquid turbulence, vane passing syndrome,
and suction recirculation are special cases often called cavitation. Solids in the
liquid and high velocity increase the problem.
• Selective leaching. Involves the removal of one or more elements from an alloy.
Common with demineralized or de ionized water applications.
• Micro organisms, that will attack the carbon in active stainless steel.
• A gasket or fitting is protruding into the stuffing box and rubbing against the seal.
• The pump discharge recirculation line is aimed at the seal body.
• The shaft is bending due to the pump operating off of its best efficiency point.
• Pipe strain.
• Misalignment between the pump and its driver.
• A bolted on stuffing box has slipped.
• Bent shaft.
• An unbalanced impeller or rotating assembly.
• Excessively worn or damaged by corrosion or solids in the product.
• The product has attached its self to the impeller.
• The impeller never was balanced.
• The impeller was trimmed, and not re balanced.
• The seal is not concentric with the shaft, and is hitting the stuffing box I.D..
Discoloration. Caused by high heat. Stainless steel changes color at various temperatures.
NOTE: To tell the difference between discoloration caused high heat and product
attaching to the metal part, try to erase the color with a common pencil eraser.
Discoloration will not erase off.
The following applications cause a vacuum to be present in the pump stuffing box.
• Coatings are very porous. They do not provide corrosion resistance. The base
material is being attacked by the product.
Broken.
• Chemical attack.
• Excessive side load.
• The seal faces are glued together because the product has solidified.
• A cryogenic fluid is sticking the faces together.
• Vibration.
• Slipstick.
• The stationary is not perpendicular to the shaft.
• Corrosion.
• Improper fit.
• Bad part.
• Excessive vibration.
THE SPRINGS.
Broken or cracked.
• The stationary face is not perpendicular to the shaft causing excessive spring
flexing in the metal "plastic range". The spring material has "work hardened" and
fatigued.
• Chloride stress corrosion problems with 300 series stainless steel.
Corroded.
• Stressed material corrodes much faster than unstressed material. The springs are
always under severe stress.
Clogged.
• Be sure to distinguish between "cause and effect". If the springs are located
outside the liquid, it happened after the failure.
• If the product solidifies or crystallizes it can clog springs exposed to the pumped
fluid.
• Dirt or solids in the fluid can clog exposed springs.
Twisted.
• Almost always an assembly problem. The lugs were not engaged in the slots. This
is a problem with many seal designs. Check to see if your seals can come apart
easily or if the drive lugs can change position when the seal is not compressed.
• Excessive vibration.
• The single spring, rubber bellows seal, was not vulcanized to the shaft.
• The stationary is not perpendicular to the shaft, causing excessive spring
movement.
Because these seals do not have a dynamic elastomer to provide vibration damping some
other means must be provided or vibration will always be a problem.
• Fretting.
• Concentrated cell corrosion.
• The rubber bellows did not vulcanize to the shaft/ sleeve.
• The set screws slipped on a hardened shaft or were not tightened properly. The
seal faces stuck together causing the shaft to rotate inside the static elastomer.
• Salt water applications are particularly troublesome when a static elastomer or
clamp is attached to the shaft. Pitting caused by the chlorides and the low PH of
salt water are the main problems.
THE GLAND.
Rubbing at the I.D.
• Partial rubbing.
• The gland has slipped.
• Improper installation. It was not centered to the shaft.
• The shaft is bending.
• Pipe strain.
• Rubbing all around.
• The shaft is not concentric with the sleeve.
• The seal is not concentric with the sleeve.
• Bad bearings.
• Bent shaft.
• Unbalanced impeller or rotating assembly.
• Solids attached to the shaft, or caught between the shaft, and the gland.
• Cavitation.
Corrosion.
• A.P.I Gland.
o Hooked up wrong.
o Flushing connection clogged.
o Quench connection clogged.
BUSHINGS
Rubbing at the I. D.
• Partial rubbing.
• The A.P.I. gland has slipped.
• Improper installation. It was not centered to the shaft.
• The shaft is bending.
• The gland bolt holes are often not concentric with the shaft/ sleeve.
• Misalignment between the pump and its driver.
• Excessive pipe strain.
• Rubbing all around.
• The shaft is not concentric with the sleeve.
• The seal is not concentric with the sleeve.
• Bad bearings.
• Bent shaft.
• Unbalanced impeller.
• Cavitation
Erosion.
• Dirt and solids are present in the discharge or suction recirculating fluid.