Technical Skills Development:

Artisan Development Programme (ADP)

Pumps & Associated Equipment
CONTENTS

• INTRODUCTION - CENTRIFUGAL PUMPS

• TYPES OF IMPELLERS
• MECHANICAL SEALS
• GLAND PACKINGS
• SECONDARY SEALS
• FLUSHING LINES
• QUENCHING
• INSTALLATION OF SEALS
• TROUBLE SHOOTING

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Introduction

Mechanical seals are used in applications where a rotating

shaft enters a housing and where the media on either side
of the housing needs to be separated from each other, as
in the case of a pump or mixer.
Impeller Mechanic
al seal

Shaft

Couplin Motor
g

Bearing
Housing housing
Stuffing
box
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4
Impeller Types
Centrifugal pump impellers are selected with purpose and are dependent
upon the application. Some are better for solids handling, others are better
for high efficiency. Read on to find out which impeller will be best for your
next pumping application.

Open Impeller

An open impeller has vanes that are attached to a center hub and mounted
directly onto a shaft. There is no wall surrounding the vanes which makes
open impellers weaker than closed or semi-closed valves.
Open impellers are generally faster and easier to clean and repair. Open
impellers are usually used in smaller pumps and pumps that handle
suspended solids.

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Semi-Closed Impeller

Semi-Closed impellers have a back wall that adds strength to the

impeller. Semi-closed impellers are usually used with liquids or products
that have solids. Reduced efficiency is a common problem with semi-
closed impellers, but the ability to pass solids is an important trade-off.

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Closed Impellers

Closed impellers have a back and front wall around the vanes, to increase
strength. Closed impellers are used primarily in larger pumps and can be
used in applications that handle suspended-solid service.
These types of impellers are commonly found in clear liquid applications.
They don't do well with solids and are difficult to clean if they become
clogged.

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GLAND PACKINGS

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Introduction

In it’s most basic form the

mechanical seal comprises
the following:
1 5
• 1 Seal face

• 2 Stationary seat - or counter

face 3 4 2

• 3 Spring(s)

• 4 Secondary seal (rotating)

• 5 Secondary seal (stationary)

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MECHANICAL SEAL SOLUTION

Rotating

Stationary

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TYPES OF SEAL FACES

Solid face Shrink

fitted

Inserted Brazed
face

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TYPES OF STATIONARY SEALS

Single O- Seat with

ring, Single O-ring, With seat locking
with pin double O-ring
without pin

With gaskets,
With rubber cup With rubber cup
clamped
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SPRINGS

Only compression springs are used in mechanical seals, and are

found in a number of different forms, i.e. metal bellows, super-
sinus springs (wave springs) and helical springs.

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SECONDARY SEALS

• Seals which are used to

seal the rotating part onto
Static O-ring max. 20%
the shaft, and the
stationary part in the
housing.
• Must be partially dynamic
to accommodate shaft
movement
• Examples are o-rings,
bellows, v-rings etc.

Dynamic O-ring 7% - 8% Stationary O-ring 10% to 15%

(observe pin)
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SECONDARY SEALS

• 0-Ring

• Wrapped o-ring

• Cup rubber

• Statotherme

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SEAL FACE MATERIALS

• We define 5 main categories of materials

that are suitable for use as seal faces:

 Carbons

 Metals

 Carbides

 Ceramics

 Plastics

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SEAL FACE MATERIALS
Carbon:
 Soft material
 Runs on any hard face. Carbides, Metal, Ceramic
Stainless steel:
 Hard material
 Runs only on Carbon
Carbides:
 Hard material. Two types silicon and tungsten
 Runs on other soft and hard faces
Ceramics:
 Hard material
 Usually runs on soft face. Never ceramic on ceramic
can’t handle thermal shock
Plastic:
 Usually runs on hard face. Never ceramic or silicon
 Rare but used on aggressive mediums

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SECONDARY SEALS

Secondary seals will invariably come into contact with the

medium to be sealed, and thus the choice of material is just as
important as the choice of face materials.

The main types are:

 Viton
 Ethylene Propylene Rubber
 Nitrile Rubber
 Kalrez
 PTFE jacketed Viton
 PTFE jacketed EPDM
 Statotherm (99% pure graphite rings)

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SEALING POINTS

 There are 3 points of sealing common to

all mechanical seal installations:

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SEALING POINTS

 Between the rotating and stationary seal faces:

 The underlying principle of the operation of a seal, is the “sealing

gap”, sometimes called the “interface fluid film”. This principle states
that as the rotating seal face turns, a hydrodynamic fluid film is built
up between the rotating and stationary faces. The two faces
therefore, do not actually come into direct contact with each other, but
slide upon this invisible film of fluid.
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SEALING POINTS

Acceptable minimal leakage

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FORCES

Closing forces:
• Static closing force

• Hydraulic closing force

Spring Hydraulic

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LUBRICATION

Media as a lubricant and coolant

Lubrication

Cooling

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SEAL TYPES
Double Mechanical Seals
 Double seals are normally two seals, either in back to back
arrangement, or in tandem

They are used when:

 no leakage is allowed to emerge from the machine, (danger of

explosion, environmentally unfriendly)
 the medium contains dissolved gases
 the medium has unsatisfactory lubricating properties, i.e. cream
cheese
 aggressive media is pumped under high pressure and temperature
 the medium tends to polymerise or crystallise in contact with the
atmosphere, i.e. saturated sugar solution

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SEAL TYPES
Double mechanical seal arrangements:
• double mechanical seals may be arranged with
the seals in a back to back arrangements
• or with two rotating seal faces

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OPERATION 1 : FLUSH

 External medium used to flush the stuffing box

- Increase of pressure in the stuffingbox

- Temperature reduction

- Avoid build-up of deposits

- Reduction of solids content

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OPERATION 1 : FLUSH

 Product circulation from discharge

- Increase of pressure in the stuffingbox

- Temperature reduction

- Avoid build-up of deposits

- Reduction of solids content

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OPERATION : QUENCH
Operation with an external quench with different media:
 liquid
 steam
 gas

 Collection of leakage
 Prevent air contact
 Cooling / heating
 Additional lubrication
 Vacuum operation
 Leakage control

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OPERATION : QUENCHES

Packing

Throttlebusch

Lipseal

Mechanical seal

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Installation of Mechanical Seals
CAUTION: Never put hands on lapped seal faces or put lapped seal parts face down on the workbench. Keep the mechanical seal in
its original container until ready for installation.

PREPARE PUMP

• Clean and inspect pump parts.

• Replace shaft or shaft sleeve and gland if worn in secondary sealing areas under
O-rings, Teflon wedges or Teflon rings.
• Check for good starting bevel and remove all burrs that would cut secondary seal
O-rings or cause misalignment. Pay close attention to set screw marks.
• Check shaft run out (to be within .001” TIR per inch of shaft dia.), shaft end play
(not to exceed .005”), stuffing box face alignment (must be square to within .003”
• TIR and have a good sealing surface, 125 RMS min.) and condition of bearings.
• Replace if necessary.

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Installing the Seal
1. Bolt stuffing box back plate to the pump frame.
2. Install shaft sleeve.
3. Screw on impeller to hold shaft sleeve in proper position securely on shaft.
4. Scribe a line on the shaft sleeve at the face of the stuffing box.
5. Remove stuffing box plate.
6. Determine the operating length of a mechanical seal:
a) Place gland on clean area of workbench with the stuffing box face up.
b) Install stationary seal face with secondary sealing member in the gland
(make
sure gasket is in place if using a clamp type stationary).
c) Place gland gasket in proper position.
d) Place rotary unit, lapped face down, against the lapped stationary seal face.
e) With rotary unit at free height (not compressed by holding clips), measure
the distance from the gland gasket to the top of the seal.

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7. Determine the amount of compression on the seal:

• Mechanical seals with multiple springs that are less than 2” in diameter
require 1/8” compression.
• Mechanical seals with multiple springs that are larger than 2” in diameter
require 3/16” compression.
• Mechanical seals with single springs usually have fixed or predetermined
compression. Usually 1/2 of the free length of the single spring.
• Subtract the proper compression from the length of the seal determined in
step 6e. This will be the working height of the seal from the face of the stuffing
box.
• On the impeller end of the shaft sleeve, scribe a second line the exact
distance from the first line as determined in step 7d.

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8. On the impeller end of the shaft sleeve, scribe a second line the exact distance
from the first line as determined in step 7d.
9. Install the mechanical seal in the pump:
a) Place gland with stationary seal face and gasket on the pump shaft.
b) Slide rotary unit on shaft sleeve and set the back of the rotary unit on the
second scribe line as determined in step 8. Set screw the rotary unit to the
shaft sleeve (if seal is supplied with holding clips, remove at this time).
c) Bolt stuffing box back plate to the pump frame.
d) Install impeller using new impeller gasket.
e) Compress gland against stuffing box plate. Double check seal compression
by the gap between gland gasket and stuffing box plate. (Same as step 7.)
Tighten gland studs evenly. Rotate shaft to ensure that the seal is not in a
bind.

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Installation Damage

 Not Following Installation Instructions

Mechanical seals are easily damaged during installation. That’s why it’s
imperative to read the installation instructions carefully before attempting to install
the seal. See photo here. The installation instructions stated to remove the
spacers before starting the unit. The spacer became lodged in the seal,
damaging internal components
 Install on a Misaligned Pump

Pump misalignment is caused by pipe strain, deflection during a hard start, shaft
run out, or a myriad of other scenarios. Misalignment puts undue stress on
mechanical seal components, causing them to not function properly, wear
prematurely, and potentially fail.

Be sure to follow proper installation guidelines and use laser alignment tools to
ensure the pump (and ultimately the mechanical seal!) is set up for success.

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Shaft Alignment
A quick check revealed misalignment of the pump and motor, causing
excessive noise and premature bearing wear.

Up to 50% of damage to
rotating machinery is directly related to misalignment. Machine vibration,
bearing damage, premature seal wear, and coupling damage are all
examples of issues pumps experience if improperly aligned at installation.
Misaligned pumps can also draw up to 15% more energy than aligned
pumps.

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There are 3 common tools and methods used to align pumps. Here are the
pros and cons of each:
Straight Edge -This method requires placing a straight edge on the pump
and motor coupling, then making a visual check to see if the components
are aligned.

 Pros
o Quick and easy to perform
 Cons
o Highly inaccurate. Today's high performance machinery and
expectations for up time require more accurate measurement.

Reverse Dial Indicator - This method uses two indicators that check for
radial run-out and angularity. The readings are then plugged into
mathematical formulas to calculate shim requirements for proper alignment.

 Pros
o Very accurate, far more accurate than the straight edge method.

 Cons
o Time consuming, cumbersome
o Requires a high level of technical skill
o Reading errors

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Lack of or wrong Lubricant on Shaft

• Lubrication is necessary for proper mechanical seal installation. Lack

thereof can damage o-rings or rubber bellows on the seal, causing
them to tear, or roll. There are many options available, from petroleum
jelly, to silicon grease, to special lubricants. Always check the
installation instructions to ensure the lubrication you choose is
compatible with seal components and the product pumped.

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Dirty work surface/hands
 Dirt on the seal face, even oil from finger prints, can set a mechanical
seal up to fail. Tiny particles can create wear and destroy seal faces,
causing leakage.
 Ensure proper handling during installation by following these tips:
 Don’t unpack the seal until ready to install

 Wash hands

 Avoid touching or handling lapped seal faces

 Use clean tissue paper on workbench to prevent contamination

 Don’t set the seal down on its face

 Clean faces with soft tissue and approved solvent before putting them together
on the equipment

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Uneven or over tightening of fasteners
 This is probably one of the most common mistakes. Over-tightening
fasteners can cause seal components to become distorted and leak.
Oftentimes when a seal starts to leak, the natural reaction is to tighten
even further! Unfortunately this just exacerbates the problem. Instead,
try loosening a bit, the problem may correct itself, if the internals haven’t
broken already from mechanical shock.

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THE END
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