Professional Documents
Culture Documents
TRAINING COURSE
STATISTICS
AMONG THE MAJORITY OF INDUSTRIAL PROCESS 60 to
80% of the WORKING ORDERS ARE DIRECT LINKED WITH
SOME TYPE OF LEAKAGE.
ALSO IN AVERAGE 20% OF THE EQUIPMENTS ARE
RESPONSABILE OF 80% OF THE MAINTENANCE COST PER
UNIT PRODUCED (PARETO LAW)
THE INCIDENCE OF SEALING FAILURE AND BEARING
FAILURE ON THE CENTRIFUGAL PUMPS OUT OF SERVICE IS
OVER 90%
PUMP DEFINITION
WHAT IS A PUMP?
A PUMP IS DEFINED AS A MECHANICAL DEVICES THAT
ROTATES OR RECIPROCATES TO MOVE FLUID FROM ONE
PLACE TO ANOTHER
To move fluid
against gravity
require a pump to
add energy to it
PUMPS CLASIFICATION
(Split case)
Separately-coupled
Single or Multi Stage
Vertically (radially) or
Horizontally (axially)
Split
Close-coupled
Separately-coupled
Seal-less
Driver
Wet End
Base Plate
Coupling/Spacer
Power End
Casing
Wet End
Power End
Impeller
Inboard Bearing
Trust Bearing
Back Cover
Adapter
Pump shaft
Impeller
The Impeller is the bladed member attached to the pump shaft and
imparts the principle force to the fluid being pumped.
The rotation of the impeller is what adds velocity energy and is later
transformed in pressure energy inside the casing near the outlet or
discharge side.
Impellers shape can be classified as Radial Flow, Francis vane, Mixed flow or Axial flow
These shapes are defined by the hydraulic geometry of the fluids as it flows through the
impeller; also could be classified by the mechanical design as Open, Semi-open or Closed
STUFFING BOX
SEAL CHAMBER
A coupling is a power transmission device that is used to connect the Motor shaft to the Power End shaft of
the pump, its primary purpose is transmit rotary motion and torque from the motor to the pump, also have
to recuperate misalignment between shafts, transmitting axial thrust loads, permitting adjustments of shafts
to compensate for wear and keep precise alignment between connected shafts.
INTERNAL FORCES
- RADIAL FORCES
- Performance Point
- Operating Point
- Radial Force and Shaft Deflection
- Operating Window
- BALANCING
- CAVITATION
RADIAL FORCE
BEP
Performance Curve
HEAD-CAPACITY
PERFORMANCE CURVE
& its BEST EFFICIENCY
POINT [BEP]
RADIAL FORCE
Performance Curve
BEST EFFICIENCY POINT
[BEP] for XYZ pump size
1,5x3-13 rpm 3,000
Max efficiency 60% @
Head= 44Mt [132] &
Capacity= 76m/hr [290
gpm]
BEP
RADIAL FORCE
Performance Curve
OPERATING POINT
Pump operation away from
the BEP causes the
hydraulic forces within the
casing become unbalanced,
which can cause the pump
shaft to bend or deflect.
This conditions, if severe
enough, could impact the
pump and seal reliability
BEP
RADIAL FORCE
K= Radial Factor [.37]
H= Head
S= Density
D= Impeller
B= Impeller width
F=K.KQ.H.S.D.B/2.31
KQ= 1-(Q/QBEP)
Q= Capacity at Operating Point
QBEP= Capacity at BEP
RADIAL FORCE
OPERATING
WINDOW
RADIAL FORCE
RADIAL FORCE
40
80
120
160
Discharge Recirc.
25
Suction Recirc.
50
75
100
Mtrs
(400 ft)125
200
3
240 M Hr
(1056 USGPM)
1USG=3,785L
BEP
BEP
F= Force
E= Module of Elasticity
I= Moment of Inertia
L= Overhung
D= Diameter
L=220mm
L
D= 32mm
L/D = 11
L=200mm
L
D= 40mm
L/D = 3.55
L=160mm
D= 48mm
L/D = 0.80
SOLID SHAFT
API PUMPS *
BALANCING
SURFACE CONDITIONS
MECHANICAL BALANCING
IMPELLER EYE CENTERED
CAVITATION
Insufficient Net Positive
Suction Pressure Required
NPSHD < NPSHR
Vapor pressure of the medium
Trapped Air in the fluid
CAVITATION
CAVITATION
>10,000 bar
Bubbles of
Vapor
implode in a
form of
toroidal
shape this
shape create
pressures in
excess of
10,000 bar.
No known
material can
withstand
this type of
punishment.
EXTERNAL FORCES
MISSALIGNMENT PUMP/ELECTRIC MOTOR
PIPING LOADING
THERMAL DILATATION
MISSALIGNMENT
BEARING OVERLOAD
VIBRATIONS
Divergent pump/motor
(horizontal)
ALIGNMENT MOTOR/PUMP
METHODOLOGY
PRECISION SQUARE
DIAL GAUGE or COMPARATOR
LASER
MOTOR [DRIVER] ADAPTER is a machined
component used to assemble the motor to the power
end section of the pump. Allow easier pump and
motor alignment and compensate thermal growth.
This adapter is already required for most of vertical
pump applications
ALIGNMENT PUMP/MOTOR
ADAPTER TYPE C-FRAME SUITABLE FOR VERTICAL
AND HORIZONTAL PUMP APPLICATIONS.
Piping Systems
Suction pipe work more important than the
discharge.
Correct installation critical.
Piping Systems
When running, the fluid in a pump must:
Piping Systems
Suction reducers - which is
correct?
Piping Systems
Suction pipe work
should be one size
larger than pump
suction nozzle and an
eccentric reducer is
used.
Piping Systems
The concentric
increaser is used on
the discharge side of
the pump and is
normally bolted straight
to the discharge flange
of the pump.
Piping Systems
The pump suction piping must
also be free of air pockets.
Piping Systems
Q:Piping Elbows:
How far should they
be from the suction
port?
Piping Systems
Pipe stress reduces pump life and
performance
Pipe work must be properly aligned
Maintenance
alignment tools?
PIPING LOADING
TENSION ON THE SUCTION AND DISCHARGE
FLANGES
Lost perpendicularity between the shaft and
the stuffing box face
Flanges deformation
THERMAL DILATATION
- ALLOW TO
MANTAIN THE
IMPELLER CENTER
LINE DURING THE
THERMAL
EXPANSIONS WITH
TEMPERATURE OVER
100 C
- ADJUSTABLE FOOTS
TO MATCH THE
PIPING CENTER LINE
A CORRECT
BEARING PROTECTION
INCREASE
EQUIPMENT LIFE
AND
SEALS PERFORMANCE
BEARING PROTECTION
1 Generation - FELT
BEARING PROTECTION
2 Generation LIP SEALS
BEARING PROTECTION
2 1/2 Generation
POSITIVE LIP SEAL
PTFE/Polyimide
BEARING PROTECTION
3 Generation LABTecta
BEARING PROTECTION
4 Generation MAGTecta
Bearing Study
60%
50%
CONTAMINATION
50%
40%
30%
20%
LOL*
14%
10%
FITS
9%
EQUIPT
VIB
5%
INSTAL
DEFECT
4%
2%
0%
*LOL: Loss Of Lubricant
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
OTHER
16%
AGE
16% Fitting
OIL
DIRT
FITTING
IN OTHER WORDS
78%
83%
3.0
6.0
48%
20
10
0.002
Hours to Failure
( % Failure)
182
6.7
144
188
16.32
576
275
25.94
1343
300
35.57
1736
556
45.19
1763
648
54.81
1973
772
64.43
1979
902
74.06
2946
1264
83.68
2982
1366
93.30
3003
100
Hours to Failure
90
80
% FAILURE
NATIONAL
70
60
DUAL
LIP SEAL
50
SINGLE
LIP SEAL
40
30
20
10
500
1000
(HOURS)
1500
2000
CR SPEEDY SLEEVE
IS A QUICK REPAIR DEVICE
GOOD FOR EMERGENCIES.
NEVERTHELESS AS IT WILL
INCREASE THE WHERE THE
STANDARD LIP SEAL WILL
WORK SO MORE FRICTION =
MORE HEAT = LESS
PROTECTION LIFE
BEARING
PROTECTION
RECAP
WHAT TO DO TO
HAVE A RELIABLE
PUMPS - RECAP
MECHANICAL SEALS
Introduction
How they work
Evolution of their technology
Mechanical seals types and classification
Centrifugal Pumps
has been
designed over 100
years ago and the
stuffing box was
sealed with
mechanical
packing.
FACTS
- 80% of the Mechanicals Seal fail prematurely.
- A huge number of Component Mechanical Seals
damage the shaft or the sleeve.
- 80% Maintenance cost of a pump is due
Mechanical Seals which have to be repaired or
replaced within 12 months of service.
MECHANICAL SEALS
- DESCRIPTION
- PRINCIPLE OF WORKING
- CONCEPTS
* Face Planarity
* Roughness
* Face Parallelism
- SEAL LIFE
INTERNAL
EXTERNAL
ROTARY
STATIONARY
COMPONENT
CARTRIDGE
SINGLE
COMPONENT
DOUBLE
COMPONENT
SINGLE
CARTRIDGE
DOUBLE
CARTRIDGE
SEMI-SPLIT
FULLY SPLIT
PUMP GAS
SEAL
COMPRESSOR
GAS SEAL
SPRING
ROTATING
PART
STATIONARY
PART
SECONDARY
SEAL
PRIMARY
SEAL RINGS
Seal Life
Process pressure
CLOSING
FORCES
OPEN
FORCES
P + Ps
Pa + Pf
- FRETTING
- CLOGGING
- PRESSURE AND TEMPERATURE EFFECT
- FACE INSTABILITY / FACES OPEN
-Seal design
Fretting
B
U
Example of 1st
generation seal
with Balanced
face using a
special sleeve
Cartridge Seal
Pressure= 10 Kg/cm
Area =
5 cm
Force = Pressure x Area
F closing = 10 x 5 = 50 Kg
F opening = 5 x 5 = 25 Kg
10Kg/cm
atmospheric
Higher pressure
being pushed in
inside diameter,
of the groove in
Cartridge Seal
Component Seal
Cartridge Seal
Component Seal
24
Has been
introduce in the
market the
technology of
Stationary
Cartridge Seal
even though still
use a seal of
25
second
generation
PEK
Introduction to
Mechanical Seal
Trouble Shooting
List of Symptoms
Elastomers Symptoms
Metal Components Symptoms
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Hard/Compression Set
Extrusion
Explosive Decompression
Swollen/Soft
16
17
18
19
Scoring
Corrosion
Flattened Set Screws
Drive Pin Wear
/2.54 mm
/3.55 mm
Narrow Face
Vibrations
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Wide Face
Component
ID
Symptom
ID
Seal Faces
Cause
Subcause
Rotary component seal
Miscentering
Radial runout
Shaft deflection
Bearing failure
Excessive bearing
clearances
Bent shaft
Pump misalignment
Pipe strain
Unbalanced impeller
Off-BEP operation
Cavitation
Related causes
2, 4, 16
2, 16, 19
2, 6, 16, 19
Failure Mode
Misinstallation
Solutions
Review installation
instructions and reinstall
seal
Review installation
instructions and reinstall
seal
Install new bearings
Install new bearings
Equipment condition
The contact pattern is considerably wider than the width of the narrow
face. Wear at the drive notches may be present.
Seal does not leak when seal is stationary, but leaks steadily when shaft
is rotating.
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Centered
Housing
Tolerances
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Miscentered
Seal Faces
Component
ID
Symptom
ID
Cause
Subcause
Stationary seat
Miscentering
Radial runout
Shaft deflection
Miscentered Wear
Track
Cartridge seal
Related causes
1, 4, 16
1, 16, 19
1, 16, 19
Failure Mode
Solutions
Review installation
instructions and reinstall
seal
Misinstallation
Review installation
instructions and reinstall
seal
Check stuffing box to shaft
Equipment condition perpendicularity
Improve shaft's L 3/D4
Even
Flatness PV-Limits
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Uneven
Component
ID
Symptom
ID
Seal Faces
Cause
Misalignment
Subcause
Related causes
Misalignment of split seal
rings
Overtightening of gland bolts
Failure Mode
Misinstallation
3
Uneven Wear
Track
Face distrortion
4, 6, 10, 13
Excessive pressure
Improper stress relieved
component
Seal faces out of flat
Exceeded limits
Solutions
Check faces and review
installation instructions
Review installation
instructions for proper
tightening procedure
Review installation
instructions for proper
tightening procedure
Check operating conditions
Exchange component
Quality
Exchange component
Scoring/Erosion
Scoring
Lubrication
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Seal Faces
Component
ID
Symptom
Scoring/Erosion
ID
Cause
Subcause
Stationary cartridge seal
Miscentering
Flashing
Dry-running
Face distortion
Dirty pumpage
Related causes
1, 2, 16
Failure Mode
Misinstallation
6, 7, 8, 9
Poor lubrication
9, 11, 12
3, 6, 10, 13
High velocity of
flush/recirculation
Minerals/very fine particles
in pumpage
Exceeded limits
Abrasive wear
Solutions
Review installation
instructions and reinstall
seal
Insure sufficient vapor margin
Eliminate dry running and/or
use proper environmental
controls
Check operating conditions
Check operating conditions
Install a clean flush
Install a suction recirculation
to remove solids
Install a flow controller
Use hard faces and/or a
clean flush
Corrosion (Faces)
146
Return
Component
Seal Faces
ID
Symptom
Corrosion
ID
Cause
Subcause
Carbons - softening,
disintegration, increased
porosity
Chemical attack Hard faces (RSC/TC/DC) leaching of binder or filler
materials
Excessive temperatures
Related causes
12, 15, 17
Failure Mode
Misapplication
Solutions
Select compatible materials
Chipping(ID/OD)
Vaporization
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Seal Faces
Component
ID
Symptom
Chipping (OD/ID)
ID
Cause
Flashing
Face distortion
Excessive heat
Shaft deflection
Subcause
Liquid vaporizes between
seal faces
Excessive pressure
Coking/crystalization
Pipe strain
Cavitation
Unbalanced impeller
Related causes
Failure Mode
4, 7, 8, 9
Poor lubrication
3, 4, 10, 13
Exceeded limits
7, 8, 9, 12
1, 16, 19
Solutions
Insure sufficient vapor margin
Chipping on the outer diameter and/or inner diameter of the seal rings
often result from face distortion and flashing. Chips can easily be
produced at disassembly of the seal so it is important to verify if they
occurred in service or after. Chips produced in service typically alter the
wear pattern.
Seal leaks only when chips have extended radially over the seal face.
Coking/Crystallization
Return
Crystallization
Coking
Seal Faces
Component
ID
Symptom
ID
H
7
Cause
Subcause
Product temperature
Excessive heat
Coking
Crystallization
F
Flashing
Related causes
Failure Mode
6, 8, 9 , 12
Product hardening
4, 6, 8, 9
Solutions
Use proper environmental
controls (cooling)
Check for scaling
Open up stuffing box bore
Use proper environmental
controls (quench)
Coking will occur with all oils except 100% synthetic oils at elevated
temperature (>120C). Crystallization occurs with a wide variety of fluids
of which caustics are the most common. Leakage is caused by the
abrasion of the seal faces and/or hang-up.
Seal leaks steadily, leakage rate vary widely.
Blistering
Carbon blistering
Blistering
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Component
ID
Symptom
ID
H
Seal Faces
Cause
Excessive heat
Blistering
F
Flashing
Subcause
Carbon incompatibility with
oils
Excessive speed
Excessive pressure
Liquid vaporizes between
seal faces
Related causes
Failure Mode
Misapplication
6, 7, 9, 12
Exceeded limits
4, 6, 7, 9
Poor lubrication
Solutions
Use SC/TC in oils
Check operating conditions
Check operating conditions
Insure sufficient vapor margin
Carbon blistering occurs with in all oils and manifest itself initially as
shiny bruised spots in the surface and later as craters. Carbon blistering
relates to high viscosity and all oils over 15cP may cause blistering.
Recently, blistering has also been found to occur with silicon carbides and
here caused by high PVs during operation
Heat Checking
Heat
Checking
Heat
Checking
Thermal
System
Thermal
System
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Seal Faces
Component
ID
Symptom
ID
K
Cause
Dry-running
Subcause
Insufficient or no liquid
between faces
Related causes
Failure Mode
4, 11, 12
Solutions
Eliminate dry running and/or
install environmental controls
Poor lubrication
9
Heat checking
Flashing
Excessive heat
4, 6, 7, 8
6, 7, 8, 12
Exceeded limits
Fracture
Overpressurization
High Torque
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Component
ID
Symptom
ID
Cause
Seal Faces
I
10
Excessive
pressure
Fracture
J
Excessive face
torque
Subcause
Related causes
Swollen ID O-ring
13, 15
Exceeded barrier fluid
pressure limit
Excessive pressure
Low product viscosity and/or
7, 13, 19
density
Product hardening
Failure Mode
Chemical attack
Solutions
Install compatible o-rings
Check operating conditions
Exceeded limits
Poor lubrication
Product hardening
Component
Seal Faces
ID
11
Symptom
Grooving
ID
K
Cause
Dry-running
Subcause
Insufficient or no liquid
between faces
Related causes
4, 9 , 12
Failure Mode
Poor lubrication
Solutions
Eliminate dry running and/or
install environmental controls
Hard/Compression Set
Extrusion
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Elastomer Symptoms
Hard/Compression Set
Elastomers
Component
ID
12
Symptom
ID
Cause
Subcause
Product temperature
Excessive heat
Dry-running
Chemical attack
Hard/Brittle
Compression set
Related causes
Failure Mode
6, 7, 9
Exceeded limits
Solutions
Use proper environmental
controls (cooling)
Check operating conditions
4, 9, 11
Poor lubrication
5, 15, 17
Chemical attack
Extrusion
Elastomer Symptoms
Extrusion
Component
ID
Symptom
ID
M
I
Elastomers
13
Extrusion
Cause
Excessive
clearances
Excessive
pressure
Installation
damage
Subcause
Clearances in o-ring groove
too large
Related causes
Failure Mode
Quality/design
3, 4, 6, 10
Exceeded limits
O-ring damaged during
assembly
Misinstallation
Solutions
Check clearances, install
back-up ring
Use higher durometer
material
Use higher durometer
material
Review installation
instructions
Explosive Decompression
Elastomer Symptoms
Explosive decompression
Component
Elastomers
ID
14
Symptom
Explosive
decompression
ID
P
Cause
Subcause
Trapped gas ruptures o-ring
Sudden pressure when pressure is suddenly
drop
relieved
Related causes
Failure Mode
Solutions
If possible, eliminate sudden
pressure drops/shutdowns or
Equipment operation
other elastomer (consult
factory)
Swollen/Soft
Elastomer Symptoms
Swollen/Soft
Component
Elastomers
ID
15
Symptom
Swollen/Soft
ID
L
Cause
Subcause
Incompatibility of o-ring
Chemical attack
material
Related causes
5, 12, 17
Failure Mode
Misapplication
Solutions
Install compatible o-rings
Scoring
ID Scoring
OD Scoring
Component
ID
Symptom
ID
Cause
Subcause
Related causes
Rotary component seal - OD
scoring
Miscentering
1, 2, 4
Metal components
Q
16
Spinning
18
Excessive
pressure/pressure surges
Scoring
C
Shaft deflection
Radial runout
Off-BEP operation
Cavitation
Pipe strain
Unbalanced impeller
Bearing failure
Excessive bearing
clearances
Bent shaft
Seal chamber misalignment
1, 19
1, 2, 19
Pump misalignment
Failure Mode
Solutions
Review installation
instructions and reinstall
seal
Review installation
instructions and reinstall
Misinstallation
seal
Review installation
instructions and use
hardenend set screws on
hardened set screws
Check operating conditions
and hard set screws at
Equipment operation higher pressures
Improve shaft's L 3/D4
Check NPSHR vs. NPSHA
Check for pipe strain
Balance impeller
Install new bearings
Install new bearings
Equipment condition
Install new shaft
Check stuffing box to shaft
perpendicularity
Re-align pump
Corrosion (Metals)
169
Return
Pitting
Surface Corrosion
Crevice Corrosion
12
Corrosion
Copyright 2010 AESSEAL plc Ref: DW IH -01 , October 14,
Metal
Components
Component
ID
17
Symptom
Corrosion
ID
Cause
Subcause
Surface corrosion, pitting,
tensile stress corrosion,
Chemical attack galvanic corrosion and
crevice corrosion
Related causes
5, 12, 15
Excessive temperature
Failure Mode
Solutions
Select compatible materials
Misapplication
Select compatible materials
Corrosion results in overall and local loss of material. The type of damage
indicates the corrosion mechanism. Corrosion is always aggravated by
(local) temperatures and often by swirling.
Seal leakage can be low and seal appears to be running fine until
advanced stages of corrosion.
Metal
Components
Component
ID
18
Symptom
Flattened set
screws
ID
Cause
Subcause
Set screws loosened
Related causes
Spinning
16
Excessive
pressure/pressure surges
Failure Mode
Solutions
Review installation
instructions and use
Misinstallation
hardenend set screws on
hardened set screws
Check operating conditions
Equipment operation and hard set screws at
higher pressures
Insufficient fixture of the set screws allows shaft to spin under rotary seal
parts. Severe vibrations or use of stainless set screws on hardened shafts
can cause shaft to spin as well. With clamping devices seal may slide
axially under high pressure.
Seal leaks steadily when shaft is rotating. Axial sliding may cause steady
leaks when seal is stationary.
Component
ID
Symptom
ID
Metal Components
19
Cause
Excessive face
torque
Subcause
Related causes
Excessive product pressure
Low product viscosity and/or
10
density
Product hardening
Off-BEP operation
Cavitation
Shaft deflection
Pipe strain
Unbalanced impeller
Bearing failure
Excessive bearing
Radial runout
clearances
Pump misalignment
1, 2, 16
1, 2, 16
Failure Mode
Exceeded limits
Poor lubrication
Solutions
Check operating conditions
Use a dual seal
Re-align pump
Drive pin wear or wear at the drive notches result from vibrations or
excessive torque. Drive pin wear is usually not the cause of failure but an
indication of a related cause of failure
Introduction to
Dual Seal Systems
Self monitoring
Reduces disposal costs
Low maintenance
Failure indicator
Header Tanks
Recirculation
Quench to Drain
Effluent Treatment
To river or city sewer
Drain
Header Tanks
Pressure Drops
Ring Main Circ Pump
Recirculation line
To drain
Check
Valve
DISP
CDSA
DSMF
SINGLE
SEALS
CON II
CSM
CURC
COMPONENT
SEALS
DIN SAI