Case Studies
Sensor Identifies Cause of Costly Mechanical Seal Failure
Challenge
Background
A chemical plant was experiencing an unusually high failure rate for single cartridge mechanical seals on a 65% Nitric Acid Transfer Pump application. At the time, the Mean Time Between Repair (MTBR) was only 1.2 months.
Our seal analysis revealed square, hardened O-Rings and seal faces with a heavy wear track. These symptoms typically point to dry running of the pump. However, the customer checked the operation of the system. All controls were in good working condition so dry running was very questionable. A specialist observed the installation of the seal and found that the customer was doing it correctly. There were no noticeable issues with the operation of the pump.
The pump seal failure occurred nearly every month.
Solution
Product
The Chesterton sealing specialist recommended installation of a Chesterton Connect™ sensor, which safely and conveniently monitors operating conditions of many types of process equipment. Connect uses Bluetooth technology and offers a solid design that withstand harsh environments.
Chesterton Connect makes it easy to monitor:
- Equipment vibration
-
Surface temperature
-
Process temperature
- Process pressure
$ = USD
Chesterton Connect installed on the pump.
Results
Within a few days, the team gathered enough data from Connect to identify negative pressure in the seal chamber when the pump was running. In turn, this pressure caused the mechanical seal to show classic dry run symptoms…square, hardened O-Rings with heavy seal face wear tracks.
After conducting a system audit, the customer was able to throttle back a valve to ensure proper flow from the pump. The pump and mechanical seal are now running properly and the projected MTBR has improved to more than 24 months!
The potential cost savings for mechanical seals for this one pump is more than $30,000. The savings due to reduced maintenance and operational improvements are estimated to be even greater.
Chesterton Connect saved more than $30k/year.
About Us
Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service. Chesterton product range includes mechanical seals, packing and gaskets, industrial lubricants and coatings.
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APAC350989. Issued 02/2021
Technical data reflects results of laboratory tests and is intended to indicate general characteristics only. A.W. Chesterton Company disclaims all warranties expressed or implied, including warranties of merchantability and fitness for a particular purpose. Liability, if any, is limited to product replacement only. Any images contained herein are for general illustrative or aesthetic purposes only and are not intended to convey any instructional, safety, handling, or usage information or advice respecting any product or equipment. Please refer to relevant Safety Data Sheets, Product Data Sheets, and/or Product Labels for safe use, storage, handling, and disposal of products, or consult with your local Chesterton sales representative.