Flowserve Cartridge Seal Troubleshooting Guide: Common Seal Problems and Solutions

Introduction:

Cartridge seals are critical components used in various industrial applications to prevent leaks and maintain the efficiency of rotating equipment. However, like any mechanical system, cartridge seals can experience problems that may lead to decreased performance or even failure. In this troubleshooting guide, we will explore some common seal problems encountered with Flowserve cartridge seals and provide practical solutions to address these issues. Whether you are an operator, maintenance technician, or engineer, this guide aims to equip you with the knowledge and tools to effectively troubleshoot and resolve seal-related problems.

Symptom: Leakage

Leakage is a common issue experienced with cartridge seals, which can lead to product loss, environmental pollution, and potential safety hazards. Understanding the causes of leakage and implementing appropriate corrective measures is crucial for maintaining system integrity. One possible cause of leakage is improper installation or assembly of the cartridge seal. If the seal faces are not correctly aligned, or if the springs or drive pins are not securely fastened, leakage may occur. In such cases, disassembling the seal and carefully reinstalling it according to the manufacturer's instructions can resolve the issue. Additionally, inspecting the seal housing for any damage or defects and replacing it if necessary can also eliminate leakage problems.

Another cause of leakage is excessive pressure on the seal faces. High pressures can lead to seal face distortions, resulting in uneven contact and leakage paths. In these cases, it is essential to ensure that the seal is correctly sized for the operating conditions, including pressure limits. If the pressure exceeds the recommended limits, upgrading to a more robust seal design or employing a pressure relief system can help mitigate leakage issues.

Symptom: Excessive Heat

Excessive heat generation within the seal assembly can significantly impact its performance and lifespan. Some common causes of excessive heat include inadequate lubrication and insufficient cooling. Lack of lubrication can lead to increased friction between the seal faces, resulting in elevated temperatures and accelerated wear. Regularly monitoring and maintaining the lubrication system, including checking oil levels, replacing worn-out components, and using recommended lubricants, can help prevent excessive heat generation.

Insufficient cooling can also contribute to elevated temperatures in the cartridge seal. In cases where the seal operates in a high-temperature environment or handles hot fluids, ensuring proper cooling is crucial. Installing additional cooling systems such as heat exchangers or employing cooling jackets can effectively dissipate the heat and prevent seal overheating.

Symptom: Seal Face Wear

Seal face wear is another common problem encountered with cartridge seals, and it can occur due to various factors, including abrasive particles, inadequate lubrication, or improper material selection. Abrasive particles present in the process fluid can cause significant damage to the seal faces, leading to excessive wear and compromised sealing performance. Implementing effective filtration systems to remove contaminants from the fluid, as well as ensuring regular maintenance of the filtration system, can minimize the presence of abrasive particles and extend seal life.

Inadequate lubrication, as mentioned earlier, can also contribute to seal face wear. Proper lubrication is vital to reduce friction and wear between the seal faces. Regularly monitoring lubrication system performance, including oil quality, flow rates, and temperature, can help identify and address any lubrication-related issues promptly.

Moreover, selecting the appropriate seal face material plays a crucial role in preventing premature wear. Factors such as fluid compatibility, temperature, and operating conditions should be considered when selecting the seal face material. Consulting with seal manufacturers or suppliers for expert advice can aid in choosing the most suitable material for specific applications.

Symptom: Vibrations and Noises

Excessive vibrations and noises in cartridge seals can be indicative of underlying problems that require attention. Vibrations can result from misalignment, unbalanced rotating equipment, or improper installation. Ensuring proper alignment and balance of the rotating equipment, as well as performing regular maintenance and inspection routines, can help mitigate vibration-related issues.

Noises, such as squealing or rattling sounds, may be due to dry running of the seal faces or damaged components within the seal assembly. Insufficient lubrication or a lack of cooling can cause the seal faces to run dry, leading to increased friction and noise. Adequate lubrication, as mentioned earlier, is crucial to maintaining optimal performance and reducing noise levels. Additionally, inspecting the seal assembly for any damaged or worn-out parts and replacing them when necessary can eliminate noise problems.

Symptom: Seal Failure

Seal failure is a severe issue that can result in costly equipment downtime, increased maintenance requirements, and potential safety risks. Some common causes of seal failure include improper installation, excessive pressure or temperature, and chemical incompatibility. Correctly installing the cartridge seal, following the manufacturer's guidelines, and ensuring proper alignment and assembly are essential to prevent seal failure.

As discussed earlier, excessive pressure or temperature can significantly impact seal performance and lead to failure. Operating within the recommended pressure and temperature limits, as specified by the manufacturer, is crucial for maintaining seal integrity. If the system operates near or beyond the recommended limits, implementing appropriate mitigation measures, such as pressure relief valves or cooling systems, is necessary to prevent seal failure.

Chemical incompatibility between the process fluid and the seal materials can also contribute to seal failure. Understanding the chemical properties of the fluid and selecting compatible seal materials is essential to ensure long-term seal performance. Consulting with experts or referring to manufacturer recommendations can aid in selecting suitable materials for specific applications.

Conclusion:

Flowserve cartridge seals are reliable and efficient solutions for preventing leaks and maintaining the integrity of rotating equipment. However, addressing common seal problems promptly is essential to ensure optimal performance and longevity. By taking a proactive approach and implementing the troubleshooting solutions discussed in this guide, operators, maintenance technicians, and engineers can effectively mitigate issues such as leakage, excessive heat, seal face wear, vibrations and noises, and seal failure. Regular inspections, proper installation, adequate lubrication, and appropriate material selection are key factors in maximizing the reliability and lifespan of Flowserve cartridge seals. Remember, addressing seal problems early on can save time, money, and valuable resources in the long run.