Secondary Seal
Secondary Seal
TM-052
Delegate's Notes
Contents
Introduction 3
Pusher Seals 3
Advantages of Pusher Seals 4
Disadvantages of Pusher Seals 4
Elastomer 0-Ring Secondary Seals 3
Hang-Up 4
Common Materials 5
PTFE Secondary Seals 6
PTFE Wedge Rings 6
Other PTFE Secondary Seals 6
Common Materia ls 7
Non-Pusher Seals 7
Elastomer Bellows Seals 8
Materials 8
Formed Metal Bellows Seals 8
Two-Ply Bellows 8
Edge Welded Metal Bellows Seals 9
Rotating Seals 9
Stationary Seals 9
High Temperature Cartridge Seals 10
Double-Ply Bellows 10
Common Materials for Metal Bellows 10
Advantages of Non-Pusher Seals 10
Disadvantages of Non-Pusher Seals 10
PTFE Bellows Seals 11
2
Mechanical Seal Principles
The Secondary Seal
Introduction
1. 0 -Rings 3. Bellows
2. PTFE Sealing Rings • Elastomer
• Wedges • Metal
• Chevrons • Formed
• 'C' rings with internal spring energiser • Edge Welded
• PTFE sleeved a-rings • PTFE
It is a common practice to describe the seal by its Secondary Sealing device: e.g., Wedge Seals, Bellows
Seals, etc.
All secondary sealing devices clearly divide into two main groups, those that slide along the shaft to take
up wear and misalignment - Pusher Seals (e.g ., dynamic a-rings and wedges), and those that do not
slide along the shaft - Non-Pusher Seals (bellows secondary seals).
Pusher Seals
0 -rings are the most common components used as Secondary Seals in Pusher Seal designs. They are
readily available in a wide range of materials to suit most applications.
Hang-Up
Where a product can change state as it moves across the inter-
face film, e.g., solidify, crystallise or polymerise, the secondary
seal starts to 'hang up' on these deposits. As the primary ring
wears it is unable to follow-up to keep the faces together. Leak-
age will gradually increase, deposits build up, and eventually
leakage becomes prematurely unacceptable as the faces are
held in the open position. In many applications, this problem
can be overcome by the use of an external quench using API
Piping Plan 62 to immediately remove any small amounts of
leakage. (See Training Module TMOSO - Secondary Contain-
ment, for further details).
For example:
•
•
Sodium hydroxide solution (crystallisation) - use a cold water quench.
Hot oil (carbonisation/coking) - use a steam quench.
Urea melt
0-ring seals are very effective, but due to the small clearances required they may only have marginal
flexibility. The clearance between the seal and the shaft has to be such that when the shaft/sleeve is on
its maximum tolerance and the primary ring bore is on its minimum tolerance there is still adequate clear-
ance to allow for this flexibility.
To increase flexibility, clearances are often increased, but this can cause problems at higher pressures,
especially if the equipment maker's shaft/sleeve has been manufactured to its bottom limit, and the seal
maker's primary ring is on its top limit.
The o-ring is pushed into the corner of the groove by the hy-
draulic pressure, extruding it into the bore of the primary ring .
The o-ring can hang-up on the shaft and prevent the seal from
following up as the primary ring wears.
Note: It is possible for it to be inserted on the wrong side of the o-ring rendering it ineffective.
4
The anti-extrusion ring should be installed on the low
pressure side of the a-ring . Most PTFE anti-extrusion
rings have a small chamfer on the outside diameter.
This is to allow for the small radius in the corner of
the counterbore in the primary ring. It is important
to ensure that the anti-extrusion ring is fitted the
right way round.
The following chart lists some of the more common a-ring materials used in mechanical seals. Maximum
and minimum temperatures are given as a guide. These may vary with the many different grades avail-
able, and differences between various generic material manufacturers. Many other materials are available
for specialist applications. For chemical compatibility information, please consult John Crane.
* Caution
These elastomer materials may give off dangerous hydrogen fluoride vapours at elevated temperatures.
(Fluorocarbon above 275°(' Perfluoroelastomer above 400°C}. These can condense or mix with water to
form hydrofluoric aod. If you suspect that an a-ring has been subjected to excessive heat, please take
precautions_ including wearing suitable neoprene or PVC protective gloves and eye protection. Parts
should be neutralised with an alkali solution such as calcium hydroxide.
5
PTFE Secondary Seals- Pusher Seals
Where elastomers are not suitable, PTFE (Polytetrafluoroethylene) can often be used. However, PTFE has
an unfortunate property known as "cold-flow ". It tends to act like an extremely viscous fluid. In a pusher
type mechanical seal, the a-ring groove is designed to give a controlled compression of the section of the
a-ring, creating a sealing point on the outside and inside diameters of the a-ring. Too much compression
will cause hang-up, too little compression will allow leakage. PTFE is relatively hard, and when in the form
of an o-ring can be extremely difficult to fit as one tries to achieve the necessary compression. PTFE also
has a high rate of thermal expansion. All this means that it is difficult, if not impossible, to control the
compression of the section of the a-ring, so hang-up is more likely. Once a PTFE a-ring has been in-
stalled, the compressive forces will cause the a-ring to cold-flow and initial compression will be lost over
time. For these reasons, it is unusual to use PTFE dynamic a-rings in mechanical seals. PTFE secondary
seals must be designed to be constantly loaded to allow for any cold-flow, and they must be able to com-
pensate for any thermal expansion.
Wedge rings can also be manufactured from exfoliated graphite for high temperature applications.
This chart gives the usual temperature limits for dynamic PTFE and FEP Secondary Seals. The stability
and strength of pure PTFE at higher temperatures can be improved by the addition of glass filling, usually
about 25% glass/75% PTFE
IMaterial Minimum
temperature
Maximum
temperature
in seals in seals
Pure PTFE -40°C 230°C
Glass Filled PTFE -1oooc 280°C
Exfoliated Graphite -40°C 500°C
PTFE Sleeved Fluorocarbon -20°C 200°(
FEP Coated Fluorocarbon -20°C 150°C
Spring Energised Pure PTFE Envelope -20°C 2oooc
Spring Energised Glass Filled PTFE
-20°C 200°C
Envelope {Higher pressures)
Caution
At elevated temperatures PTFE can give off toxic fumes. Do not incinerate old or new PTFE components.
It is dangerous to smoke while handling products made from PTFE.
Non-Pusher Seals
With Non-Pusher seals, the Secondary Seal is formed by a flexible bellows. The actual sealing point be-
comes remote from the primary ring allowing a great deal more flexibility. The sealing point is fixed on
the shaft/sleeve and does not have to slide to accommodate wear of the primary ring, shaft end-play or
misalignment. There is no contact between the shaft/sleeve and the primary ring and movement is taken
up by the bellows flexing or extending. There is less likelihood, therefore, of hang-up caused by o-rings
sticking, or by deposits on the shaft/sleeve. There is also very little hysteresis as friction from a sliding
secondary seal component has been removed.
As nothing needs to be pushed along the shaft/sleeve to take up wear, shaft end-play or misalignment
this type of seal is described as a "Non-Pusher" seal.
The actual mechanism of sealing the mechanical seal unit to the shaft/sleeve varies dependent upon the
duty conditions, seal design and materials of construction.
7
Elastomer Bellows Seals
It can be seen here how the bellows flexes and expands, al-
lowing the primary ring to move freely, with nothing sliding
along the shaft surface.
Elastomer bellows seals are relatively low cost, and ideal for use where space is confined. They are ex-
tremely flexible and rugged, and are suitable for most general duties in pulp and paper, petrochemical,
waste water treatment and other demanding applications.
The bellows convolutions are formed either mechanically or hydraulically, or a combination of the two,
from a thin welded tube. In a few seal designs, the bellows is welded or press-fitted directly to the shaft/
sleeve, but it is more usual to incorporate a locking ring with grubscrews and an a-ring seal in the bore.
Al so, on some low duty designs, the primary ring is press-fitted directly into the end of the formed bel-
lows. In the design shown below, note that the primary ring carrier or shell is a machined component.
This is welded to the bellows core which means that it is possible to manufacture this shell from a differ-
ent material to the bellows, such as low expansion alloy. This enables higher temperatures to be sealed
without the possibility of the primary ring coming loose due to the higher thermal expansion coefficient of
the shell.
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The profile of this type of seal very smooth, and can be highly polished for use in hygienic and pharma-
ceutical applications. Seals are available using formed metal bellows that eliminate all possible "bug-traps"
and are designed specifically for use in the food and beverage industries.
Initially developed to solve critical and demanding applications for NASA, welded metal bellows seals are
now used in most industries. Bellows plates, which are about 0.15 mm thick (varies with seal type, size
and seal manufacturer) are welded together at the inside diameter. A number of welded pairs are then
welded together on the outside diameter to
form the required number of bellows convolu-
tions. A wide range of metallurgies can be used
in the manufacture of these bellows including
highly corrosion resistant materials such as
Hastelloy™ and Titanium. Edge welded metal
bellows can be designed to produce exception-
ally reliable, low stress welds. Many metal bel-
lows seal designs are apparently similar, but
performance can vary greatly depending on design features, materials and manufacturing quality. Note
the 45° tilt at the inside diameter of the plates (removes most of the bending stresses at the weld), the
three sweep shape (to prevent "oil-canning"), and the nesting ripple design (computer optimised to give
lower spring rate coupled with higher flexibility) .
Again, the primary ring carrier shell is a machined component welded to the bellows core so it can be
made of a different material such as low expansion alloy which will ensure that the primary ring remains
firmly held in position at elevated temperatures.
Where the temperature of the product is above the capability of conventional elastomers, exfoliated
graphite Grafoil™ packing rings can be used. These are fitted into a counterbore at the back of the seal
and small screws force the drive
ring/follower into the counterbore
to compress the packing, forming a
perfect seal on the shaft/sleeve.
There is no relative movement be-
tween the packing and the shaft/
sleeve so there will be no leakage
or wear at this point. Graphite
packing is also used as the tertiary
seal (see Training Module TM-053: Tertiary Seal) to seal the mating ring into its housing. An anti-rotation
pin is required due to the low coefficient of friction of graphite. A spiral-wound gasket seals the gland
plate to the face of the seal chamber. Seals of this design are able to withstand temperatures of up to
425°C.
For viscous or thermo-setting applications, welded metal bellows seal designs can incorporate drive lugs
under the bellows to provide additional rotational drive, thus reducing torsional stresses on the bellows.
At 2950 rpm, a misaligned stationary mating ring will cause a rotating seal to flex 8,496,000 time per day!
9
With high temperature hydrocarbons, a steam quench should be injected through the bore of the seal to
remove any small amounts of leakage that may occur as carbonised oil and coke deposits can build up on
the sleeve and seal compo-
nents. This picture shows a sta-
tionary cartridge seal which is
an idea l design for high tem-
perature refinery applications.
It is fitted with a bronze anti-
coking baffle which directs the
steam (shown in yellow) firstly
through the bore of the metal
bellows, and then past the run-
ning faces. Steam and any con-
taminants are then blown back through the bore of the baffle and out to a drain or safe area. Steam is
contained in the seal assembly by a Secondary Containment seal - in this case a floating segmented car-
bon bush . (See Training Module TM-050 : Secondary Containment). If a rotating seal had been used , the
steam laden with contaminants would be directed back through the bore of the bellows which would cre-
ate clogging.
Cartridge seals have many advantages over component seals, including simple, accurate, error-free instal-
lation .
• Edge welded metal bellows seals are capable of sealing pressures up to 20 bar g, de-
pending on seal size and service conditions. For pressures above this, double-ply bel-
lows are available, increasing the pressure rating to anything up to 65 bar g.
Common materials used for manufacturing the metal bellows used in mechanical seals:
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PTFE Bellows Secondary Seals
For highly corrosive duties including acids, salts and organic compounds, an externally mounted PTFE bel-
lows seal may be used. As these seals are externally mounted, clamped mating rings must be fitted . The
fluid only comes into contact with seal
components made from highly corro-
sion resistant PTFE and aluminium
oxide ceramic.
Most mechanical seals are replaced once they have started to leak unacceptably. As this seal is designed
for highly corrosive services, any leakage is unacceptable. For this reason, on the John Crane Type lOT
and Type lOR seals there are two setting lines, one green which tells the installer that it is fitted to its
correct working length and spring compression, and one red which indicates to the operators that plans
should be made to have the seal replaced as soon as possible as it is getting close to the point where it
might start to leak. A corrosion resistant clear plastic guard should always be fitted round the seal.
The running face of this type of seal is usually made from glass reinforced PTFE. Versions are available
with inserted carbon-graphite or silicon carbide primary rings for abrasive and other duties.
Please refer to manufacturer's literature regarding materials, maximum temperatures and pressures.
In many plants today, for Health & Safety reasons, double or tandem seals are preferred to a single seal
for highly corrosive applications.
This is critical, and can affect the life of a mechanical seal. This chart gives the recommended surface fin-
ish for all types of mechanical seal, but always check with the seal fitting instructions.
1.2 1-1m Ra or
ICartridge Seals ±0.05 mm 0.05 mm
better
Fine machined or better
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Shaft I Sleeve Lead-In
It is essential that the leading edge of the shaft/sleeve over which the Secondary Seal has to pass during
seal installation is chamfered to a suitable degree to prevent damage to the Secondary Seal, and to ease
fitting. Recommended dimensions for th1s lead-in will be found in the individual seal installation instruc-
tions, which should be supplied with each complete mechanical seal.
Seal Type
Seal Size Ymm
(Example Only)
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Self-Assessment Questions
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2. 0 -rings are often used as Secondary Seals. What, if any, are their drawbacks?
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3. Using a Bellows type Secondary Seal, describe how the component adjusts and com -
pensates for primary ring wear or movement:
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4 With a Wedge Ring design of Secondary Seal, the primary ring rocks on the nose of the
wedge ring to take up any misalignment.
True I False ?
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