Bell & Gossett Centrifugal Pumps

Mechanical Seal Failure

Troubleshooting Guide

Table of Contents

Section I – Mechanical Seal Failure Diagnostic Flow Chart

Section II - Mechanical Seal Failure Troubleshooting Check List

Section III - Mechanical Seal Failure - Typical Modes of Failure

September 8, 2003

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Premature Seal Failure? Normal Seal Service Life
Normal? Varies per application.
Identify seal service life

Abnormal?
Section I
Mechanical Seal Failure Diagnostic Flow Chart
1
Abnormally Short
Procedure
Term Seal Life.
Identify seal Seal life normal or abnormal? Identify how many operating hours the seal has run
installed in pump trouble free. Seal life can vary dramatically with operating conditions and
Via serial number
application. A major seal vendor has advised that normal seal life on elastomer
bellows seals can reach up to 26,000 operating hours under ideal conditions. Those
conditions require a properly installed seal operating consistently in fresh clean
water at ambient temperatures, and correct pressure / velocity limitations. Any
variance from these conditions will greatly reduce seal life.
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Identify full (1)
operating
conditions.
Identify the part number of the seal currently installed via pump serial number or
order number. Determine if the correct seal was supplied with the pump for the
application. Refer to B&G Sales Bulletin 4976 “Mechanical Seal Selection
Guidelines” published 11/2000.

(2)
Identify pump operating conditions, application type, fluid type, chemical
3 treatment, temperature, and pressures. Are there any other pumps in the system (in
Investigate pump
service/ parallel, other loops etc) that are also having problems? Gather information on the
maintenance application to check if the pump and seal are matched to the application. Use
history
Bulletin # 4976 dated 11/00 "Mechanical Seal Selection Guidelines" as a reference.
(3)
Investigate the pumps service/maintenance history. Is this the original seal supplied
with the pump? Were the seals installed correctly? What lubricant was used for
installation? Refer to the pumps IOM for correct installation instructions.
4
System water (4)
quality & test on
glycol
System water quality is often taken for granted. The quality of water mixed with
applications glycol concentrate can have an enormous impact on seal life. Marginal quality
water can lead to the development of scale, sediment, deposits or the creation of
sludge. Poor water quality can damage the system by depleting the corrosion
inhibitor. Refer to Service Bulletin 4941 update issued with" Mechanical Seal
Guidelines" as stated above for minimum water quality. A simple test used by Dow
Chemical Company to ensure water quality meets less than 100ppm of hardness can
Continued be conducted in the field. Use a small sample bottle with 50% glycol and 50%
Page 2 water from the same source used to fill the system. Let the solution stand for 8-12
hours shaking occasionally. If any whitish sediment forms, the water is to hard and
should not be used to fill the system.

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 Mechanical Seal Failure Diagnostic Flow Chart
Procedure Continued

Continued
From Page 1
(5)

5 Perform a through visual inspection of all seal components. Using simple

Request return of magnification (5x – 10x magnifying glass or jeweler’s loupe) and an adequate light
parts to B&G for
inspection
inspection
source, inspect all seal components. Use the attached checklist and typical seal failure
illustrations to locate and document any suspicious component damage.
Contact the B&G Service Department. Return suspected failed seal components for
inspection and analysis if instructed.

(6)
Request return of a system fluid sample to the B&G Service Department for analysis.
Occasionally, the B&G Service Department requests that a fluid sample be returned so
that it can be sent out for a lab analysis. This process is costly and not always accurate.
Problems include rapidly changing system fluid conditions that can lead to inaccurate
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results. Chemical injection/slug feeding methods may cause varying chemical
concentrations at the pump over time. Because of the inherent problems and costs of a
Request return of
system fluid sample lab fluid analysis, we avoid this process if at all possible. We consider the condition of
for analysis
the mechanical seal faces and other components to be the only accurate measure to
cause of failure.
If a system fluid sample is required, use the following procedure to obtain the sample:

1. Fluid Samples should be taken from a valve located in the lowest point in the
system piping.
2. The valve, the sample is taken from should be purged prior to collecting the
sample.
3. The system fluid should be in circulation at the time the sample is taken, so that
any solids within the system stay in suspension.
4. The sample should be placed in a lab-approved sample-bottle and always labeled.
7 (7)
Recommend
alternate seal
Recommend alternate seal type and or fluid conditions. The B&G Service Department
type and or Fluid typically writes a report where system fluid maintenance is recommended, and the
Conditions
condition of the seal components are reviewed for cause of failure. If the standard
(B&G) seal was first used, the Service Department may recommend the use of a
carbon Vs tungsten carbide or silicon Vs silicon carbide face seals.

(8)
Follow up with the B& G Service Department with the status of any changes made to
the system and how the pumps are performing.
8
Follow up
With Status

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 Section II
Mechanical Seal Failure Troubleshooting Check List

Date: Representative:
Report completed by: Contact Name:
Phone Number: Fax Number:
E-mail Address:__________________________________________

Basic Information
How many operating hours has the existing seal been in service?

(1) Pump and Seal Information

Pump Series Serial Number Pump Size
Bell & Gossett Order Number Config. Number
For Inline Pump installations, what is the pump orientation? Vertical Motor Horizontal Motor

(2) Operating Conditions

Pump Application
Fluid Description
Operating Temperature Maximum Working Pressure
Chemical Treatment Type
System pH*
% Concentration Abrasive particulate in fluid based on PPM

(3) Service/Maintenance History

Is the failed seal the factory installed original?

If the failed seal is not the original fitted from the factory, did a B&G representative install the replacement, if so what
representative?

Identify the lubricant used for installation of the replacement seal

(4) System Water Quality

If the system fluid contains water, what was the source? (I.e.: well, city, distilled, deionized)
Results of the Simple Water Quality Test as described in procedure notes

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(5) Inspection of Failed Seal
Complete a full visual inspection using 5-10x magnification and good illumination. Document the following:
Faces (I.E. Scoring, “Record Grooving” Heat Tracing)
Elastomers (I.E. Heat Degradation, Hardening, Chemical Attack)
Metallurgy (I.E. Pitting, Mechanical Failure)
Additional Remarks

* System pH should be checked using accurate instrumentation. It is suggested to use a Hanna Pocket pH
meter, Model HI 98107 pHep or equivalent. The meter should have a range of at least 0.0 to 14.0 pH.

(6) System Fluid Sample

Retain the system fluid lab report, with this file.

(7) Recommendation of Alternate Seal Type

What alternate seal type or materials of construction were recommended?

What system maintenance was recommended?

Retain a copy of the recommendation made to the Representative with this file.

(8) Follow Up
Date of Follow-up:
Status:

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 Section III
Mechanical Seal Failure Troubleshooting - Modes of Failure

Components of a Typical Mechanical Seal

Elastomeric Retainer
Bellows or O-Ring (Brass or Stainless Steel)
(EPR, Buna N, or Viton)

Rotating Primary Ring

Spring with Matte Finished
(Stainless Steel) Face
(Usually Carbon)

Spring Holder Stationary Seat Insert

(Brass or With Super Polished Face
Stainless Steel) Usually Ceramic, Tungsten
Carbide, or Silicon Carbide w/EPR,
Buna N or
Viton cup/o-ring

Possible Leak Paths of a Typical Mechanical Seal

Between Elastomeric
Bellows and back side
of Primary Ring

Between Stationary
Seat insert and cup
or O-Ring and Seat
Between Primary Ring and Bore
Between Bellows or O-Ring
Stationary Insert Faces
and Shaft or Sleeve

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 Mechanical Seal Failure Troubleshooting
Mode of Failure: Excessive Iron Oxide Deposits

Iron Oxide (Rust) Deposits

The above illustration is a water/glycol sample (red) in the bottom of a white pail. Note the sediment
on the bottom.

The above is iron oxide sediment circulating within a system. Iron oxide can be detrimental to seal life.
Use a magnet to determine if iron oxide is present within a fluid sample.

Iron oxide limitations for seals used in B&G pumps with carbon/ceramic seal faces should not exceed 6% @
1 micron particle diameter.

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 Mechanical Seal Failure Troubleshooting
Mode of Failure: Scored or “Record Grooved” Primary Ring
or Seat Inserts

Standard material Buna, or EPT/Carbon/Ceramic

seals are suitable for glycol type fluid applications
provided the quality of the water utilized as well
as maintaining a proper concentration level of
glycol to water. The carbon face to the right is
“record grooved” a sign of a dirty system which
caused seal failure.
An indication of heavy concentrations of abrasive
particulate within the system fluid, passed
between the seal faces. A scored face provides a
direct leak path across the seal faces.

Magnified Image

Possible Cause Corrective Action

(In order of recommendation)

• Solids or abrasive damage
(1) Eliminate solids or abrasives from process fluid
if possible.
(2) Install a Sediment Separator or Cuno Filter
Kit if the pump is stuffing box equipped
and operating conditions are met. (See B&G
Sales Bulletin 4976).
(3) Change seal selection to a hard face type.
(Consult factory for recommendation details)

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 Mechanical Seal Failure Troubleshooting
Mode of Failure: Face Failure - Carbon Blistering

A pitted or blistered carbon

face indicates the system fluid
had flashed to steam,
damaging the carbon face and
creating a direct leak path.

Magnified Image

Possible Cause Corrective Action

• Overheating of the seal face, either by lack of
flush fluid or dry running. Process fluid could
also be exceeding temperature limits of the seal.
Check the operating temperature of the
pump. Ensure temperature does not
exceed the maximum temperature rating
of the pump/seal. Refer to Bulletin 4976
(11/2000) for seal material temperature
limitations. Install Brazed Plate Heat
Exchanger Kit if required (-S
Configured pumps.)

Ensure flush tubing is not kinked, or

blocked HSC-S, HSCS,
-S or –D configured pumps.

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 Mechanical Seal Failure Troubleshooting
Mode of Failure: Face Failure -Dry Run

This silicon carbide seat insert has a deep wear track

worn into the super polished face. A wear track will
create a direct leak path. This seal was “Dry Run”
and failed after only a few operating hours.

Magnified Image

Possible Cause Corrective Action

• Solids or abrasive damage
(1) Eliminate solids or abrasives from process fluid
if possible.
(2) Install a Sediment Separator or Cuno Filter Kit if the
pump is stuffing box equipped and operating conditions are
met. (See B&G Sales Bulletin 4976).
(3) Change seal selection to a hard face type.
(Consult factory for recommendation details)

• Dry run damage. Ensure the system, and pump is bled of air on start-up and
(Air entrapment in seal chamber) air never enters the seal chamber during the operation of
the pump.

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 Mechanical Seal Failure Troubleshooting
Mode of Failure: Face Failure - Metal Fragments in System Fluid

This ceramic stationary insert’s face was destroyed when metal

fragments suspended in the system fluid attempted to pass between
the faces creating a direct leak path.

Magnified Image

Possible Cause Corrective Action

Metal fragments or filings circulating within
system fluid. The fragment attempted to escape
to the atmospheric side (Low-pressure, and inside diameter)
of the ceramic stationary insert.
In this case history, the fragments were copper.
Identify fragment material and locate source
of the stray material. If copper, check system
tube bundles, fittings and tubing.
Flush system & refill.

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 Mechanical Seal Failure Troubleshooting
Mode of Failure: Face Failures - Incorrect Installation

This silicon carbide seat insert was

installed backwards in the seat bore.
Note the rough, partially worn away
grind marks on the backside of the seat
face. The opposite, polished face is
always installed towards the primary
ring.

Magnified Image

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 Mechanical Seal Failure Troubleshooting

Mode of Failure: Face Failure - Cracked or Fractured Seat Inserts

Possible Cause Corrective Action

• Cracked during installation Install seat insert in accordance to the seal

installation instructions contained within the
appropriate IOM.

• Thermal Shock due to wet/dry running. Ensure the system, and pump is bled of air
on start-up, and air never enters the seal
chamber during the life of the pump.

• Thermal shock caused by extreme system fluid Upgrade seal to EPT/Tungsten Carbide materials.
temperature differentials during static or dynamic
pump operation.

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 Mechanical Seal Failure Troubleshooting
Mode of Failure: Face Failure - Chips on the I.D. of the Seal Faces

The I.D. of this carbon primary ring was

chipped after solids circulating in the
process fluid collected between the I.D. of
the ring and pump shaft. Broken chunks
of carbon were driven between the faces
causing catastrophic seal failure.

Magnified Image

Possible Causes Corrective Action

•A high concentration of solids collected
between the carbon I.D. and the pump shaft or sleeve.
(1) Eliminate solids or abrasives from process fluid if possible.
(2) Install a Sediment Separator or Cuno Filter Kit if the
pump is stuffing box equipped and operating conditions
are met. (See B&G Sales Bulletin 4976).

(3) Change seal selection to a hard face type

(Consult factory for recommendation details)

•Mechanical misalignment, either on

seal installation, or within the pump itself. Check alignment and correct if required.

•The pump is operating beyond the recommend- Resize pump & or impeller trim.
ed 25% of BEP range limitations causing
shaft defection.
.

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 Mechanical Seal Failure Troubleshooting

Mode of Failure: Dry Run Damage

The carbon drive notches have spun, and are
misaligned with the retainer notches. An Carbon Face is blistered
indication of abnormally high torque loads Indicating abnormal
between the carbon face and the seat insert. heat and friction.

Shredded Neoprene
Treat.

Magnified Image

Abnormal wear in the drive system

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 Mechanical Seal Failure Troubleshooting

Mode of Failure: Elastomer Heat Damage

Catastrophic failure of this seal’s elastomer bellows

occurred due to the temperature of the process fluid
exceeding the temperature limit of the seal.

Possible Cause Corrective Action

Process fluid temperature to high for the
rating of the pump/seal. (1) Upgrade the seal with a temperature limit
above the maximum application temperature.

(2) Install Brazed Plate Exchanger Kit if required

(-S configured pumps.)

(3) Ensure flush tubing is not kinked, blocked

HSC-S, HSCS, -S or –D configured pumps.

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 Mechanical Seal Failure Troubleshooting

Mode of Failure: Chemically Attacked Seal Elastomers

Normal Size

Swollen

Cause Corrective Action

• Locate and identify all chemicals that may
May have come in contact with the elastomer.
Include lubricants used for seal installation,
system fluid compatibility, and any chemicals
Used to flush the system.
(1) Check the pump’s IOM for recommended seal
Installation lubricants.
(2) Refer to Bulletin 4976 (11/2000), 4941 (3/24), and
4566 (attached) for chemical compatibility. If the
chemical is not listed, consult factory for an alternate
elastomer recommendation if available.

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References:
For further technical information regarding mechanical seals, see the following web sites and technical bulletins:
• B&G Bulletin 4976 “Mechanical Seal Selection Guidelines” published 11/17/2000
• McNally Institute See “Links” on the B&G web site at www.bellgossett.com
• The Burgmann Dictionary at www.burgmann.com

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