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A centrifugal pump is one of the simplest pieces of equipment. Its purpose is to convert
energy of an electric motor or engine into velocity or kinetic energy and then into pressure of
a fluid that is being pumped. The energy changes occur into two main parts of the pump, the
impeller and the volute. The impeller is the rotating part that converts driver energy into the
kinetic energy. The volute is the stationary part that converts the kinetic energy into
pressure.
Centrifugal Force
Liquid enters the pump suction and then the eye of the impeller. When the impeller rotates, it
spins the liquid sitting in the cavities between the vanes outward and imparts centrifugal
acceleration. As the liquid leaves the eye of the impeller a low pressure area is created at the
eye allowing more liquid to enter the pump inlet.
CENTRIFUGAL PUMPS
Axial Flow - a centrifugal pump in which the pressure is developed by the propelling
or lifting action of the vanes of the impeller on the liquid.
Positive Displacement Pumps are classified into two general categories and then
subdivided into four/five categories each:
VANE
PISTON GEAR
FLEXIBLE MEMBER LOBE
SINGLE SCREW CIRCUMFERENTIAL PISTON
PROGRESSING CAVITY MULTIPLE SCREW
• SINGLE ROTOR
o VANE - The vane(s) may be blades, buckets, rollers or slippers which
cooperate with a dam to draw fluid into and out of the pump chamber.
o PISTON - Fluid is drawn in and out of the pump chamber by a
piston(s) reciprocating within a cylinder(s) and operating port valves.
o FLEXIBLE MEMBER - Pumping and sealing depends on the elasticity of
a flexible member(s) which may be a tube, vane or a liner.
o SINGLE SCREW - Fluid is carried between rotor screw threads as they
mesh with internal threads on the stator.
o Progressing Cavity - Fluid is carried between a rotor and flexible
stator.
• MULTIPLE ROTOR
o GEAR - Fluid is carried between gear teeth and is expelled by the
meshing of the gears which cooperate to provide continuous sealing
between the pump inlet and outlet.
o LOBE - Fluid is carried between rotor lobes which cooperate to provide
continuous sealing between the pump inlet and outlet.
o CIRCUMFERENTIAL PISTON - Fluid is carried in spaces between piston
surfaces not requiring contacts between rotor surfaces.
o MULTIPLE SCREW - Fluid is carried between rotor screw threads as
they mesh.
Soft packing stuffing boxes and pump glands appear so simple and are so
common-place that we continue to cope without taking a few moments to
understand why they fail or how to improve their performance.
Fillers, grease, graphite grease, tallow, and the other materials used serve
two functions in packing materials.
• The grease provides a lubricant at the shaft / packing interface.
• The material acts as a filler to prevent leakage occurring through the
interstices of the packing itself.
Now take the packing material and place it in the pump stuffing box.
Cut to size, the packing pieces are eased down the shaft to the neck ring.
The cut ends are staggered to prevent leakage through them, the lantern
ring is placed in position, the final three pieces of packing tamped in place
by the gland plate and the work is done.
The next stage is to adjust the gland to ensure that it leaks. The leakage
rate is controlled by the pressure exerted by the gland plate on the end of
the packing set and the leak is allowed to develop along the shaft /
packing interface to provide a cooling medium, removing the friction heat
generated by the rotation of the shaft in the packing set. Two further
things happen here. The grease in the packing melts slightly and is washed
away by the flow of liquid along the shaft, and wear at the surface of the
packing begins. A cycle is beginning which leads to the destruction of the
packed gland as an effective leakage control device. The packing volume
decreases as the lubricant is lost. Inevitably this causes the leakage rate
to increase. As the rate increases more material is lost until the gland is
tightened to reduce the leak to a minimum.
In very few cases can an engineer claim that the fluid passing through his
pumps is not contaminated by dirt particles. Iron oxides, chromium oxides,
grit, aluminum oxides, mica, and many other minute contaminants will
exist in all system fluids. These solids, being denser than the pumped
fluids, will be centrifuged and concentrated at the outer edge of the volute
casing at just the point where the lantern ring tapping is sited. This
contaminated fluid is then passed, at pressure, directly into the pump
gland. Whatever material is used to seal a stuffing box if it is cooled by
fluid contaminated by solids its surface will change producing an effective
grinding surface. To improve the life of the stuffing box gland,
contamination from the cooling water has to be avoided..
The gland packing has been wearing away. Through loss of lubricant it has
lost volume, and the packing surface is exposed. The fluid passing through
the gland, providing a cooling stream, is contaminated with various oxides
and grit. The flow is increasing. A passing engineer notices it and takes
appropriate action. The gland plate is tightened, pressure is exerted on the
packing material to make it deform to reduce the clearance between it and
the shaft. For a moment the flow of fluid is stemmed and the packing
clamps down on the shaft trapping any solids moving through the gland at
that moment. The interstices of the packing fill up with debris. The packing
surface is now beginning to be converted from its original state into one
consisting of oxides. The shaft sleeve itself may be contributing. Stainless
steel ss316 or ss304, continually polished by the action of the packing
replaces its surface of chrome oxide instantaneously, oxide which is taken
up into the packing material. The build up of oxides on the surface of the
packing changes the nature of the gland dramatically.
Our engineer has adjusted the gland plate and reduced the flow of fluid
leaking out of the pump gland. The packing set has deformed to reduce the
leak path. The deformation is not uniform. The action of the gland plate is
to provide a force directed along the shaft which has to be translated into
a radial force to effectively deform the packing. The friction at the outer
edge of the stuffing box possibly supplemented by vulcanization of the
packing material with the metal surface of the stuffing box, prevents the
packing from sliding easily. Consequently, the first two rings of packing,
experiencing the most force, are unable to transmit the axial force evenly
down the length of the stuffing box and invariably this results in an over-
tightening of this area of the gland in order to effect sufficient pressure
throughout the gland.
Combine the over-tightening of the front end of the gland with the oxide
impregnated gland packing and we are beginning to re-shape our shaft
sleeve. But there is more to come.
As the rest of the packing set is adjusted by the overtightened first two
rings the lantern ring is gradually pushed down the shaft. The packing
pieces between the neck ring and the lantern ring are squeezed allowing
the lantern ring to move further until in extreme cases it is cut off from its
fluid supply. The gland is failing fast. Cut off from its coolant the gland can
now overheat, causing rapid failure. Often before this occurs a partial
repacking of the gland has taken place. New packing pieces have been put
into the gland replacing the badly worn first three rings. But their life is
limited because the rings placed into a worn stuffing box need to be
deformed to accommodate the increased radial width of the stuffing box,
and the cycle continues until the shaft sleeve is destroyed. .
SP+ (DP-SP)/4
Where
SP = Suction pressure
DP = Discharge pressure.
Fluid is taken from a tapping in the volute casing and piped directly into
the lantern ring. This is a convenient pressure source readily to hand and
self contained within the pump unit but consider the action of the pump
impeller. Rotating at high speed the impeller acts as a very efficient
centrifuge. Any dirt particles entrained in the fluid will be flung to the
outer limits of the volute casing, leaving the less dense fluid clean until the
streams re-unite at the impeller throat on their way out of the pump. As all
the particles of dirt are at the periphery of the impeller clean fluid exists at
the impeller center.
The stuffing box pressure is greater than the suction pressure of the pump,
but less than the volute pressure. The state of the fluid within the volute
casing at the back of the impeller is relatively clean having been
centrifuged by the spinning action of the impeller. To prevent
contamination of the gland is therefore, a simple matter of reversing the
flow of fluid through the gland, using the volute casing pressure to
produce a flow back through the gland to the suction side of the pump.
Leakage will be controlled in the same way as before but the gland, being
supplied with clean fluid, will no longer be subject to contamination to the
same degree as before and a longer interval between adjustments and
replacements of the gland packing can be expected.
Mechanical Seals
Why use a mechanical seal? After all is said and done, its easy to stuff a few extra
bits of packing into a leaking stuffing box, and it doesn't require any skilled help to
achieve this, does it? In this section we take a look at some of the reasons why you
should be using seals. The Economic case and the Environmental case as well as
considering some of the seal types available for general use.
There are two basic cases to be made out for the use of rotary, fluid sealing
technologies.
Leak Chart
One drip a second is the standard rate for a properly adjusted packed gland : it leaks
water, chemicals, and heat. Leaks usually get worse so look at the chart and now tell
me if a leaking gland is inconsequential! Let's do another sum - how many leaking
glands are there in your plant? Not all packed glands hold back water ... there may
be more costly fluids leaking away. Each leaking gland is contributing to hard cash
overhead expense. Packing is cheap, to buy, to fit, but its running cost is hidden and
can be very expensive.
A mechanical seal appears expensive to buy when compared with a packing ring, but
properly installed a seal will run for many years. The optimum life of a seal is the
period between major overhauls of the pump unit. A seal that fails early by this
criteria is in need of investigation. The criteria for a failed seal is one in which the
running faces are not worn down to their designed minimum. However, an engineer
does not want to spend money on a super seal that will last virtually forever because
that will also not prove to be cost effective. When a seal fails it is possible, with
experience, or the aid of this web site, to determine the cause of failure and to
rectify that fault. This I promise!
I was asked to select a seal for a water pump working in a quarry. The engineer had
been plagued with seal failures for many years on this pump. His success criteria
was that the seal should run from tear down to tear down (12 months). I selected a
seal which was ten times more expensive than the one he had been using. It was
fitted over the Easter Holiday 1982. Over a year later actually the week after the
Easter holiday 1983 he rang me to say that the seal had failed. I reminded him of my
promise that the seal would run for 12 months trouble free. He calmed down and
started remembering, I told him that actually he had gotten an extra week over my
promised 12 months! The increased price of the seal was around $400 but the saving
in cost through not having to replace the seal several times in a year was over
$1,500. The whole plant soon became converted to seals because it is possible to
show a cost benefit analysis for every application.
It is often the thought that seals are expensive that prevents the engineer from
opting for them. The same applies to pump manufacturers. Ever wondered why your
plant is fitted with a particular pump make, each with a packing gland? In a word,
competition. In the enlightened 1990's whole life costing is becoming the way to
assess a particular project's initial cost, but in the real everyday world engineers are
facing the consequences of short sighted least cost solutions to immediate problems.
But now you do not have to continue living with these problems if you look at the
situation of your plant leakage in a business-like manner.
This web site does not represent any one company manufacturing seals. There are
good logistical and economic arguments for standardizing on one manufacturer so
long as they are major enough to run through all the applications you are likely to
need. Whilst working for one of these majors in Saudi Arabia I found that it was
common to find whole refineries using one manufacturers' seal. Long way from
home, gutsy job, $millions at stake in oil revenues every day, it made a lot of sense
for the engineers concerned. Only one company to deal with, lucky for some of them
it was mine and my expertise was part of the deal! But there are many designs of
seal and some I would think of as cheap and not so nice could give some of you
excellent service. So this is not about price, but very much concerns cost. Balancing
the cost of the seal installation against the outcome compared with the alternative.
There is a wide range of materials to choose from. The range encompasses small
variations in generic materials such as carbon, or o-rings and different metals used
to cope with the conditions that faces the seal. I am not encouraging you to
experiment blindly but to think the problem through and choose your materials
carefully.
We are not going to look at the materials in detail here. For that information
pop over to seal troubleshooting
I have not listed all seal types, the contact-less gas seals for instance are
not covered here, this is because they fall outside the general seal types I
aim to cover. For details on highly specialized seals of this and other types
contact your favored manufacturer for details. In the links section of this
site you will find hyper links to some manufacturers.
Now go look at the various seal types that are available to you for general
use. In these sections you will find explanations of seal types and some of
the problems associated with them.
Installation Checks
Face the facts, seals fail. They do not wear out. Most often something comes
along to disturb the smooth running of the pump and you are facing a
steady leak which has already destroyed your seal by damaging the seal
faces. But there is another case. The seal that leaks on startup after
maintenance. A seal that lasts a week without letting go is generally
thought to be OK. By the way that's a ROT (Rule of Thumb). Running
mechanical seals is an art form. There is a lot of science in it but either you
have the knack or you do not (in which case you need this web site bad).
A seal that leaks after maintenance has been badly installed. It is very
unwise to ignore the basic checks listed here because without these checks
there is no certainty that your seal will perform at all, let alone give a
reasonable running life. I hate having to go over a job again after having
fitted it all back together... don't you?
Pre-installation checks.
1. You have the correct seal and all the parts needed for the
replacement.
2. You have the pump drawing to hand with installation dimensions or
the seal manufacturer's drawing.
3. The pump stuffing box is clean
4. On split casing pumps the gasket does not extend into the stuffing
box.
5. The shaft is free of scratches and burrs, threads are taped, and
keyways are filled flush with the shaft surface to prevent seal
elastomers from being cut on the keyway edge (a dummy wooden key
insert is ideal).
6. All the seal parts are in their protective coatings at this stage.
Pump Checks
Shaft Run-out
Shafts get bent. The spinning impeller has unequal loading on in causing the
shaft to deflect away from the volute throat. Constant deflection causes
weakness and can lead to a permanent offset of the shaft leading to shaft
run out. Shaft run out is bad for seals. It causes them to flex twice on every
revolution of the shaft. At high enough speeds this can cause a vibration in
the seal which allows the seal faces to OPEN. BANG failed seal.
So, look into the dark recesses of your lockers and pull out the Dial Test
Indicator (DTI) or Clock Gauge that lurks there, unloved & unused and
check the shaft of your pump for any damaging shaft deflections.
Single stage overhung pumps should be checked near the seal running
position but multi stage pumps should be checked at suitable intervals
along the shaft as well as at the seal running position.
The run out should not exceed 0.002 inches or 0.05 m.metres.
A note about shaft sleeves. It is a false economy to omit to change the shaft
sleeve when replacing a mechanical seal.
I was called out to a cooling water pump supplying a 100Mw Power station.
The shaft size was 230mm and it took three men two days to strip and
rebuild the seal box. The shaft sleeve cost $4,000 and the seal cost $10,000.
The new seal had been fitted onto the old sleeve and leaked immediately on
startup. The seal faces were intact but having been run for 24 hours in that
condition another new seal assembly was required. On examination it was
found that the o-ring contacting the shaft sleeve surface had worn a groove
(Fretting damage) and the new o-ring was unable to seal against this
damaged surface. The extent of the damage was not immediately obvious to
the eye but by carefully measuring the surface the fault was found. Amount
saved on first installation $4,000, total cost of seal change $25,500, and it
should have cost $15,500. Believe me, skimping on the job is not the same
as saving hard cash.
Set up your DTI to measure the amount of axial movement of the shaft. The
amount will vary according to the type of pump, its bearing configuration,
and the type of thrust bearing in use.
The basic principle is that the shaft should be set to its running position
before attempting to fit the seal. In the case of cartridge seals, the seal
cover plate should be fixed to the pump casing, the shaft positioned, and
then the seal locking screws tightened to the shaft. Non cartridge types
need to have a datum mark scribed onto the shaft relative to the seal plate
position and then the fitting dimension marked from this point.
A note about fitting position. It is not good practice to fit a new seal by
looking at the old set-screw marks and then lining up on them. If you want
good seal performance then start out right ... measure the distance
required, don't take short cuts. The last seal could have been fitted
incorrectly, perhaps causing the rebuild that is now necessary. You are
storing up future trouble if you skimp.
The seal stationary must be fitted at 90 degrees to the axis of the shaft.
Failing to achieve this will cause the seal head to move to take up any mis-
alignment. This movement offers an opportunity for the seal faces to open
and for the ingress of dirt particles. If you are changing out packing and
up-grading your equipment to a mechanical seal you need to pay close
attention to setting the seal housing closing plate in the correct position.
The basic check is as shown in the diagram.
It is also wise to check the bore of the seal housing at this point for
concentricity with the shaft. Put the sensing tip of the Dial Indicator inside
the bore on the wall of the seal housing and rotate the shaft. A small
amount of misalignment is permitted but the important thing is to check
that the seal body cannot touch the seal housing wall at any point of its
rotation.
General Checks
While the pump unit is in the shop for maintenance take the opportunity to
ensure that the cooling water jacket is clear of debris, that any other
cooling water arrangement is cleared of any obstruction. Orifice plates
controlling the flow of water to a seal housing should be checked
dimensionally correct. A seal starved of its ration of cooling water will be
very unforgiving and cause you lots of grief in a short time. This kind of
fault is very difficult to diagnose for the average engineer. Even the best
have trouble with this one, too! So check it out now while the doing is easy.
Bearings need to be replaced if they have been running with any pump
leakage around. Moisture ingress into a bearing dramatically reduces a
bearing's useful life. If you are changing out soft packing for a mechanical
seal replace the bearings on the unit too. The leakage from the packing
gland is more than enough to damage the bearings.
Check the impeller for cavitation damage indicating a system problem that
might go un-noticed during normal running conditions. Cavitation can
cause vibration in the pump shaft which will affect the seal 's performance.
I know you will ensure that the impeller sealing rings are replaced or re-
bushed to keep the clearances within design limits. Allowing recirculation
within the pump volute is no way to keep the efficiency of your plant at the
highest level, and it can increase the pressure inside the seal housing which
will cause your seal to wear out faster!
W hy Se als Fa il
Seals fail for a number of reasons. Your job is to pinpoint the reason and fix
it.
Here you are in a situation in which the seal has run for a period well
beyond the installation period. Its leaking and now you have to make a
decision. Has the seal failed or simply worn out? What you decide now will
determine whether you fit a replacement seal or seek out an alternative
type. The basics are simple.
A worn out seal will leak when the seal face has worn away completely.
If we extend this criteria to all leaking seals it becomes sadly obvious that
the majority of seals, perhaps 85% of process seals, fail long before they
are worn out.
This section is devoted to the three main reasons why seals fail. Only three
you say? Three main reasons and lots of routes to them.
OK so there is another category ... the installation failure, but that's covered
in the installation section.
S e a l Fa c e s O p e n
The shaft moves for many reasons, those that affect the seal operation are:
Axial
• End play
• Thrust movement
• Temperature growth
• Impeller adjustment
Radial
• Bearing wear
• Bent shaft
• Shaft whip
• Shaft deflection (discharge closed)
Vibration
Other causes
All of the items described mean that the shaft and seal are in constant
relative movement. If anything interferes with the free movement of the
seal, the faces open.
When the faces open, dirt in the liquid penetrates the lapped surfaces,
embeds in the soft face which gradually changes to a grinding surface to
score and wear away the hard face of the stationary ring. Have you noticed
this effect? Do you look at your failed seals? You should, because on those
faces lie clues to help you find the faults opposing long seal life. Well when
we have gotten through this section and onto the tell tale signs I bet you
will take a bit more notice of your failed seal bodies.
• The elastomer sticks to the shaft. Spring loaded elastomers will stick
to the shaft, O-rings will flex by 0.005" (0.13mm) and then roll. O-
rings will fret a shaft but spring loaded elastomers (teflon wedges,
chevrons, etc.) can cause serious surface damage to your shaft or
sleeve leading to early seal failure. A leak under the seal head looks
very much like a face leak.
• The shaft is out on machining tolerance. Correct tolerance is +0.000"
to -0.002" from nominal. A packing sleeve is not machined to any
close tolerance, after all it is going to wear against the packing so its
external dimension is not too important. An oversize sleeve or shaft
will cause the seal to hang-up, an under size shaft or sleeve will
prejudice the ability of the elastomers to seal the head to the
shaft/sleeve.
• The surface finish on the shaft/sleeve is too rough. A lathe finish is
not good enough. The finish should be at least 32 RMS and for that a
ground finish is required.
• Have you got a hardened shaft on your pump unit? The seal set
screws will not "bite" into the shaft and could slip causing the setting
dimension of the seal to alter.
• The pumped fluid changes state. Sea water, brine pumps, sugary
solutions, cause crystallizing when the salts come out of solution or
the sugars become caramelized. Other coking substances, heat
transfer oil, tar, cause similar problems. You will see the build up of
material around the leak site.
• Solids can cause the seal head to stick to the shaft or restrict the o-
ring flexibility. Take a look at the double seal arrangement, back to
back version. Used on some services the O-ring could very quickly
become clogged preventing the seal head from moving to
accommodate wear of the faces.
• Incorrect setting length at installation. You may never figure this one
out. Just make sure that the fitting dimension is correct when
installing the seal. Otherwise sometime in the future the seal will let
go, usually after the pump is stopped, and the faces will look good but
only partly worn. What has happened is that the spring pressure has
reduced to the point where the seal leaks during idle periods. This can
be difficult to spot, unless you know what to look for ... and when.
• Fretting. Very small movements between components causes a
polishing action. The polishing action removes the surface molecules.
On pump shafts made of stainless materials the surface of the metal
consists of chromium oxide. Elastomers moving very slightly against
this surface wipe away the oxide which immediately reforms. The
oxide is carried into the wiping surface changing its character
completely. A rubber ring coated with chromium oxide becomes more
efficient as a polishing, grinding surface and removes material at a
faster rate. A "fret" ring is characterized by a polish mark on the shaft
surface at the point where the seal elastomer seals against the shaft.
If worn badly enough the fret ring can cause a new seal to fail on
installation because the elastomer cannot seal effectively due to the
damage on the surface.
• Distortion of the stationary face. This is not common but the
stationary could be badly fitted leading to over tightening, especially
the silicon carbide grades which are designed with a lip to be clamped
in the seal plate. Failure under these circumstances may be confused
with cracking due to heat checking of the component. S.C grades of
99.9% only heat check if they are tightened un-evenly, so check out
your grade and suspect poor fitting if its a high grade material failing
by cracking. With other materials such as tungsten carbide, or plated
surfaces, such as stellite, consider the distorting effect of poor
clamping if no other solution presents itself.
• Face Mis-centering or run-off. This is not common and is easy to
diagnose. The faces are not concentric and the rotating head comes
off the stationary track and picks up dirt. Scoring of the stationary
and an off center running track gives you all you need to know.
• Incorrect grade of O-ring material. Lots of things happen to
elastomers so check out the ones on your seal, are they swollen,
hard, squashed, shiny, cracking?
• The seal hits something, it is prevented from moving to accommodate
runout.
o Lots of possibilities here, so I list a few.
1. The shaft is bent and hitting the stationary face. You will notice
this pretty quick, but bear in mind that the running clearance of
the seal components and the shaft may be quite tight, so a
small shaft displacement may not be obvious, the seal will
show you what is happening.
2. Solids in the seal chamber hitting the seal.
3. Incorrectly fitted gasket extending into the seal chamber. Split
casing pumps can suffer this problem.
4. The shaft is not concentric with the seal chamber.
5. Insufficient clearance in the seal chamber. Check this out if you
are changing seal type or intend using different materials to
cope with other problems.
6. A seal box recirc line is directed at the seal faces. Most seal
chambers have a radial flow insert when most seal
manufacturer's will tell you that a tangential flow insert is
safer and causes less disturbance to the seal faces.
• Heat affects the elastomer. This the part most sensitive to extremes
of temperature.
• Heat can change the state of the fluid being pumped.
• Raising the temperature of corrosive liquids increases their potency.
A 16 deg F rise doubles the corrosion rate of most acids.
• Differential expansion rates can destroy plated seal surfaces. Low
grade silicon carbide will crack with sudden changes in temperature.
• Differential expansion of shaft and pump casing can change the face
loading by altering the fitting dimension.
We now have the over-view of heat related failures so let us look in more
detail at what is happening.
Elastomers.
A wide range of elastomers are in use and many of them are rubber
compounds. Teflon materials have a predetermined heat range of up to 226
deg C beyond which Teflon breaks down and burns making small amounts of
phosgene gas. Teflon should not be used in temperatures close to its
ultimate limit because it is a heat insulator and local heat production may
cause it to reach its ultimate temperature.
Heat is generated from the friction running at the seal faces. Depending
upon the type of face material and the seal box environment a rise of
around 25 deg C above the seal fluid temperature can occur. Look at your
seal types, where is the elastomer in relation to the seal faces. The nearer
the elastomer is placed to the running faces the greater the additional heat
it will experience. The use of low friction seal face combinations will reduce
this effect. The carbon / ceramic combination has the lowest friction rating
with hard faces such as tungsten / tungsten faces the highest.
Unbalanced seals, because the face weight is varying with the system
pressure, can experience greater rises in face generated heat creating
damage to the elastomer.
I was called to a split-casing boiler feed pump that was experiencing out-
board seal failure. Normally I would expect more problems with the in-
board (coupling end ) seal due to less opportunity to dissipate the heat soak
along the shaft. Examination of regular temperature recordings made of the
cooling water system and seal box temperatures revealed that the out-
board seal was being starved of cooling water flow. Dismantling the orifice
plate controlling the flow to the in-board seal showed excessive wear
enlarging the orifice and allowing through a larger proportion of the flow.
Replacing the orifice plate solved the problem. All can seem well with your
equipment but the seals will always let you know first when problems are
arising.
Liquid gases and other volatile fluids can vaporize and freeze water out of
the air on the outside of the seal restricting movement. Shortly before I
took up my post in Saudi Arabia a liquid propane pump blew its seal open
due to a build up of ice around the seal faces. Liquid released into the
atmosphere created a vast cloud of highly flammable gas. Fortunately no
one was hurt and no explosion occurred but it was a close thing. It was
thought appropriate to fit a double seal with a barrier fluid for future
installations.
Liquids changing state to a gas experience enormous volume increases.
Water increases in volume by 1700 times, so a small drop vaporizing across
a seal face will explosively blow apart the faces. Boiler feed pumps and
other hot water pumps can be heard "popping" or "puffing" if the seals are
not working correctly. As the water droplets expand and open the seal faces
more water rushes in to cool the area, collapsing the steam bubble and
causing the faces to snap shut. Another small droplet penetrating the faces
vaporizes and causes the faces to open again. Water treatment crystals,
entrained oxides, other dirt particles are trapped between the faces as they
close. Your seal is on its way to the scrap yard.
Some fluids crystallize with additional heat. Sea-water, brine, and similar
fluids leaking past your seal and drying out around the seal plate can build
up to affect the seal head and prevent it from moving. Crystals can also
score the running surfaces of the seal causing damage leading to failure.
Heat can cause impurities to come out of solution and plate onto seal
surfaces, building up hard films or lacquers.
I have mentioned some of these effects but I think a defined list will help
you.
The less expensive ceramic material (85%) will crack if cold shocked.
Sudden changes in temperature of 38 deg C or more will destroy the seal
face. The higher quality ceramic (99.9%) will cold shock if it is under
distorting stress, properly fitted and evenly clamped it will survive sudden
changes in temperature. Get to know which materials are being fitted into
your seal installations.
Carbon rings using fillers and fitted into high temperature pumps can have
the filler material melt out of the carbon causing them to become porous
Poor carbons with voids can blister and pit as the trapped air or gases
expand and blows pieces off the carbon surface.
Lapped seal faces can distort, going out of flat. The effect of touching the
lapped surface with a finger is to coat the surface with dirt and skin oils but
also to distort the surface away from flat by the application of heat from
your hand. Distorted seal faces leak.
• The carbon part of the seal will show signs of being attacked.
• O-ring grooves can be damaged limiting their ability to seal
effectively.
• O-rings can become hard or start to crack, or become swollen and
excessively soft.
• Metal surfaces can be attacked and appear pitted which will prejudice
the seals ability to work properly.
• Springs and other highly stressed parts can fail due to increased
corrosion.
All metals expand when heated. A stainless steel shaft 48" long by 4" dia
will grow 0.138" in length when heated through 300 deg F. The working
limit of most carbon seal faces is 0.125" . Seal compression is set at about
0.064" to produce the spring face weight. A seal mounted on a shaft moving
by 0.138" with other expansion effects happening to the pump casing is in
danger of opening. Apart from ensuring the accurate placing of the seal on
the pump shaft there is little to be done to compensate for such movement.
Tell-tale signs of inaccurate setting of the seal will be where you need to be
looking.
The shaft diameter will expand too, by about 0.010". The seal material will
expand also but under extreme circumstances this expansion can cause the
seal to hang-up on the shaft. Over-compression of the elastomers will limit
their effectiveness, as well as the other effects mentioned earlier.
M a t e r i a l Fa i l u r e .
This list is not exhaustive however comprehensive it may appear. You will
find some new problem and when you do I want to hear all about it. So do
all the other guys visiting this site. Look forward to hearing from you, I just
know I will in time!
General
Pump Problems can be either caused by:
or
Truth
The Great Majority of Pump Problems are with the Pump System
Mechanical Problem
To determine if this noise is a mechanical problem with the pump drain it, close
both suction and discharge valves and run the pump briefly.
2. Impeller Rubbing
3. Impeller out of Balance
5. Bad bearings
6. Coupling Misalignment
8. Pipe Stress
In any case the problem can be corrected by taking it apart and simply fixing it by
either replacing the damaged parts or correcting the installation.
Items Required:
4. Parts List
System Problem
However if the Noise goes away after draining the pump etc. then the noise is
caused by the Pumping System.
1. Cavitation
2. Vortexing
Tools Required
In order to troubleshoot a pump system problem the following tools are required:
5. Pump Performance Curve - To Check all Readings Against the Expected Pump
Performance
Cavitation
Suction Cavitation
Suction Cavitation occurs when the Net Positive Suction Head Available to the
pump is less than what is Required ------------ NPSHA < NPSHR.
Symptoms
Causes
Remedies
5. Install larger pump running slower which will decrease the Net Positive Suction
Head Required by the pump(NPSHR)
6. Increase discharge pressure
Discharge Cavitation
Discharge Cavitation occurs when the pump discharge head is too high where the
pump runs at or near shutoff.
Symptoms
3. Low flow
Causes
Remedies
5. Install larger pump which will maintain the required flow without discharge
cavitating
Symptoms
3. Loss of Flow
Causes
1. There is not enough liquid height above the suction line entrance
Remedy
Submergence can be increased by resetting the pump shutoff level higher in the
sump or tank.
Atmospheric
Atmospheric
Pressure/Elevation Chart
B
aro Eq E
Altit
metr uiv qui
ude
ic ale vale
Abov
nt nt
e
R
eadi H P
Sea
ng ead ress
Level
ure
Inch F
Feet
es of eet PSI
Mg
0 29.9 3 14.7
2 3.96
1000 28.86 32.76 14.18
2000 27.82 31.58 13.67
3000 26.81 30.43 13.17
4000 25.84 29.33 12.69
5000 24.89 28.25 12.22
6000 23.98 27.22 11.78
7000 23.09 26.21 11.34
8000 22.22 25.22 10.91
Va p o r C h a r t
Water Vapor Pressure Chart
Fitting Chart
Fitting Losses
Friction Chart
Friction Drop Chart
Vel Loss Vel Loss Vel Loss Vel Loss Vel Loss Vel Loss
GPM
10 3.72 11.7 1.02 0.50 0.45 0.07 - - - - - -
20 7.44 42.0 2.04 1.82 0.91 0.25 0.51 0.06 - - - -
30 11.15 89.0 3.06 3.84 1.36 0.54 0.77 0.13 0.49 0.04 - -
40 14.88 152 4.08 6.60 1.82 0.91 1.02 0.22 0.65 0.08 - -
50 - - 5.11 9.90 2.27 1.36 1.28 0.34 0.82 0.11 0.57 0.04
60 - - 6.13 13.9 2.72 1.92 1.53 0.47 0.98 0.16 0.68 0.06
70 - - 7.15 18.4 3.18 2.57 1.79 0.63 1.14 0.21 0.79 0.08
80 - - 8.17 23.7 3.65 3.28 2.04 0.81 1.31 0.27 0.91 0.11
90 - - 9.19 29.4 4.09 4.06 2.30 1.00 1.47 0.34 1.02 0.14
100 - - 10.2 35.8 4.54 4.96 2.55 1.22 1.63 0.41 1.13 0.17
110 - - 11.3 42.9 5.00 6.00 2.81 1.46 1.79 0.49 1.25 0.21
120 - - 12.3 50.0 5.45 7.00 3.06 1.72 1.96 0.58 1.36 0.24
130 - - 13.3 58.0 5.91 8.10 3.31 1.97 2.12 0.67 1.47 0.27
140 - - 14.3 67.0 6.35 9.20 3.57 2.28 2.29 0.76 1.59 0.32
150 - - 15.3 76.0 6.82 10.5 3.82 2.62 2.45 0.88 1.70 0.36