Identifying Causes of Seal Leakage
Mating Ring
Primary Ring
Illustration and analysis of seal
face damage patterns
Copyright © 2003 John Crane
Published by John Crane Inc.
6400 West Oakton St., Morton Grove, Illinois 60053 U.S.A.
All rights to illustrations and text reserved by John Crane. This work may not be copied, reproduced,
or translated in whole or in part without written permission of John Crane, except for brief excerpts in
connection with reviews or scholarly analysis. Use with any form of information storage and retrieval,
electronic adaptation, computer software, etc., or by similar or dissimilar methods now known or
developed in the future, is also strictly forbidden without written permission of John Crane.
Printed in the United States of America
Identifying Causes of Seal Leakage
The purpose of this book is to provide educational information about seal leakage to those involved in the application and
maintenance of mechanical seals. Identifying and correcting the cause of leakage will promote long, trouble-free operation.
Observations made about the seal parts and installation are compared to symptoms, possible causes and corrective procedures.
Pictures of common seal difficulties are given for easy identification. For purposes of illustration, these pictures, symptoms, caus-
es and corrective procedures are based on the assumption that the primary ring is rotating.
CAUTION: Seal repairs should be undertaken only by qualified personnel. If problems continue, contact your local
John Crane sales representative immediately.
Pictorial Description of a Seven Digit John Crane Material Code
1ST SYMBOL 2ND SYMBOL 3RD SYMBOL 4TH SYMBOL 5TH SYMBOL 6TH SYMBOL 7TH SYMBOL
Secondary Primary Hardware: Secondary Mating Loading Metallurgy
Seal for Ring Retainer, Seal for Ring Force 3rd/6th
Primary Ring Disc, Etc. Mating Ring
Bellows Types 1 & 2 Types 1, 2,& 21 Types 1, 2, & 21 Gaskets, O-Rings, Cups Pinned O-Ring Multiple-Coil Spring
O-Ring Types 8 & 48 Type 8 Types 8, 9, & 48 Rectangular Single-Coil Spring
O-Ring
Wedge Type 9 Type 48 Metal Bellows Floating L-Pinned Single-Wave Spring
Bellows Type 21 Type 9 Cup-Mounted Multiple-Wave Spring
Compression Ring 600 Series Clamped-In Metal Bellows
Type 37
PTFE Bellows Modified Clamped-In
Type 20
Metal Bellows
O-Ring Grafoil
Note: Seal adaptive hardware including glands, sleeves, collars,
pins, screws, etc. are not described by this code.
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Checklist for Identifying Causes of Seal Leakage
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal spits and sputters 1. Seal fluid vaporizing at seal interface. 1. Increase cooling of seal faces.
(“face popping”) in 2. Check with seal manufacturer for proper seal
operation. balance ratio.
3. Check design and operation of seal flush system.
4. Increase flush flow rate.
5. Check for seal interface cooling with
seal manufacturer.
Seal drips steadily. 1. Faces not flat. 1. Check for incorrect installation dimensions.
2. Blistered carbon graphite seal face. 2. Check for improper materials or seals used for
3. Thermal distortion of seal faces. application.
3. Check for gland plate distortion due to over-
torquing of gland bolts.
4. Check gland gasket for proper compression.
5. Clean out foreign particles between seal faces.
Re-lap faces if necessary.
6. Check for cracks and chips at seal faces during
installation. Replace primary and mating rings.
7. Improve cooling flush lines.
1. Secondary seals nicked or scratched 1. Replace secondary seals.
during installation. 2. Check with seal manufacturer for proper seals.
2. Over-aged o-rings. 3. Check for proper lead in chamfers, burrs, etc.
3. Compression set of secondary seals 4. Check seal manufacturer for other material.
(hard and brittle).
4. Chemical attack (soft and sticky).
1. Spring failure. 1. Replace parts.
2. Erosion damage of hardware. 2. Check seal manufacturer for other material.
3. Corrosion of drive.
Seal squeals during 1. Inadequate amount of liquid to lubricate 1. Check design and operation of seal flush system.
operation. seal faces. 2. Increase flush flow rate.
Carbon dust 1. Inadequate amount of liquid to lubricate 1. Check design and operation of seal flush system.
accumulating on outside seal faces. 2. Increase flush flow rate.
of gland plate. 2. Liquid film evaporating between 3. Check with seal manufacturer for proper seal
seal faces. design if pressure in seal chamber is
excessively high.
Seal leaks. 1. Nothing appears to be wrong. 1. Refer to list under “seal drips steadily.”
2. Check for squareness of seal chamber to shaft.
3. Align shaft, impeller, bearing, etc., to prevent
shaft vibration and/or distortion of gland plate
and/or mating ring.
Short seal life. 1. Abrasive fluid. 1. Prevent abrasives from accumulating at seal faces.
2. Check design and operation of seal flush system.
3. Use abrasive separator or filter.
2. Seal running too hot. 1. Increase cooling of seal faces.
2. Increase flush flow rate.
3. Check for obstructed flow in cooling lines.
3. Equipment mechanically out of alignment. 1. Align this equipment.
2. Check for rubbing of seal on shaft.
1. Full Contact Pattern
OBSERVATION:
Typical and desired contact pattern for a mechanical seal. Full contact on both mating ring and primary ring surface through
360°. Little or no measurable wear on either seal ring.
SYMPTOM POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal drips steadily 1. Secondary seals nicked or scratched 1. Replace secondary seals.
whether shaft is rotating on installation. 2. Check secondary sealing surfaces.
or stationary. 2. Damaged or porous secondary 3. Check with seal manufacturer for
seal surfaces. proper materials.
Fails allowable 3. Compression set of o-rings. 4. Check for proper lead in chamfers, burrs, etc.
emission limits. 4. Chemical attack of secondary seals. 5. Change seal to low emission design, materials
5. Not a low emission seal or arrangement. or arrangement.
6. Materials not conducive to low emissions.
Mating Ring Primary Ring
contact pattern
2. Coning (Negative Rotation)
OBSERVATION:
Heavy contact on the mating ring pattern at the outside diameter of the seal. Fades away to no visible contact at the inside
diameter of contact pattern. Possible edge chipping on the outside diameter of primary ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Little or no leakage at 1. Faces not flat due to pressure. 1. Check for over-pressurization of seal.
high pressure. 2. Faces not flat. Incorrect lapping. 2. Check flatness of lapped parts.
Leaks steadily at
low pressures.
possible edge chipping
deflection of primary ring due
to pressure
no contact similar pattern on primary ring
heavy to moderate contact
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3. Thermal Distortion (Positive Rotation)
OBSERVATION:
Heavy contact on the mating ring pattern at the inside diameter of the seal. Fades away to no visible contact at the outside
diameter of contact pattern. Possible edge chipping on the inside diameter of the primary ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal leaks steadily when 1. Thermal distortion of seal faces. 1. Improve cooling to seal.
shaft is rotating. Usually 2. Faces not flat. Incorrect lapping. 2. Consult seal manufacturer for proper materials.
no leakage when shaft 3. Check flatness of lapped parts.
is stationary.
possible edge chipping
deflection of mating or primary
ring due to temperature
similar pattern on primary ring
no contact heavy to moderate contact
4. Mechanical Distortion
OBSERVATION:
Two large contact spots on mating ring pattern fades away between contact areas. 360° contact on primary ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal leaks steadily 1. Mechanical distortion. 1. Check for gland plate distortion due to
when shaft is rotating 2. Faces not flat. over-torquing of bolts.
or stationary. 2. Check squareness of parts used to hold
mating ring in place.
3. Check seal chamber face flatness of split
case pumps.
4. Check the gland plate surface in contact
with the mating ring. Must be free of nicks
high spots
and burrs. Surface must show full pattern
when blued with mating ring.
Excellent condition after short
static and dynamic tests.
Possible erosion of the primary ring (wire
brushing) if allowed to rotate. Out-of-flat
mating surface will cause dirt to enter the
seal area.
no contact
Possible erosion of the primary ring (wire
drawing) if allowed to remain stationary.
5. Mechanical Distortion
OBSERVATION:
Uneven circumferential contact spots on mating ring, pattern fades away between contact areas. 360° contact on primary
ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal leaks steadily 1. Mechanical distortion. 1. Check for gland plate distortion due to over-
when shaft is rotating 2. Faces not flat. torquing of bolts.
or stationary. 2. Check for high seal chamber pressure.
3. Check squareness of parts used to hold
mating ring in place.
4. Check seal chamber face flatness.
5. Check the gland surface in contact with the
mating ring. Must be free of nicks and burrs.
no contact Surface must show full pattern when blued with
mating ring.
Excellent condition after short static
and dynamic tests.
Possible erosion of the primary ring (wire
brushing) if allowed to rotate. Out-of-flat
contact pattern mating ring will cause dirt to enter the seal area.
Possible erosion of the primary ring (wire drawing)
if allowed to remain stationary under pressure.
6. Mechanical Distortion
OBSERVATION:
Mating ring shows intermittent contacting and non-contacting areas. High spots are at each bolt location. 360° contact on
primary ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal leaks steadily 1. Mechanical distortion from bolt load. 1. Check for gland distortion due to over-torquing
when shaft is rotating 2. Faces not flat. of bolts.
or stationary. 2. Change to softer gasket materials between seal
chamber and gland plate.
3. Provide full face gasket contact or contact
above centerline of bolts to prevent bending of
gland plate.
no contact
Excellent condition as initial leakage will be
high, preventing any long-term service life.
contact only at high spots
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7. High Wear or Thermally Distressed Surface
OBSERVATION:
High wear of mating ring or thermally distressed surface (heat checking) through 360°. High primary ring wear with carbon
deposits on atmosphere side of seal. Possible edge chipping of primary ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal leaks steadily when 1. Sealed liquid vaporizing at seal interface. 1. Check seal chamber pressure for adequate vapor
shaft is rotating or 2. Overloaded seal faces. pressure margin.
stationary. Sound from 2. Check seal setting for proper working height.
flashing or face popping. 3. Check for proper running clearances between
shaft and primary ring at operating temperature.
4. Review flush system design; increase flush
flow rate.
5. Review details of seal selection.
surface cracks referred to as heat checking
possible wear at drive notches
possible edge
chipping on
OD and ID
8. Section of Thermally Distressed Surface
OBSERVATION:
Thermally distressed area approximately 1/3 of the contact pattern. Distressed area 180° from inlet of seal flush. High
primary ring wear with possible carbon deposits on atmosphere side of seal.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal drips steadily when 1. Sealed liquid vaporizing 180° from 1. Check seal chamber pressure for adequate vapor
shaft is rotating or seal flush. pressure margin.
stationary. Possible 2. Overloaded seal faces. 2. Check seal setting for proper working height.
sound from flashing or 3. Inadequate flush distributed around 3. Check for proper running clearances between
face popping. seal faces. shaft and primary ring at operating temperature.
4. Review flush system design; increase flush
flow rate.
5. Review details of seal selection.
6. Use distributed flush design instead of single
good contact pattern at flush inlet point flush.
possible wear at drive notches
distressed or heat
checked area
9. Patches of Thermally Distressed Surface
OBSERVATION:
One or more patches of thermally distressed surface (heat checking) on mating ring. High primary ring wear with possible
carbon deposits on atmosphere side of seal. Most likely to occur on low specific gravity liquids at high speeds and pressures.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal leaks steadily when 1. Sealed liquid vaporizing at seal interface. 1. Check seal chamber pressure for adequate vapor
shaft rotating or 2. Overloaded seal faces. pressure margin.
stationary. Leakage may 3. Inadequate flush distributed around 2. Check seal setting for proper working height.
be in the form of vapor. seal faces. 3. Check for proper running clearances between
Sound from flashing or shaft and primary ring at operating temperature.
face popping. 4. Review flush system design; increase flush
flow rate.
5. Review details of seal selection.
6. Use distributed flush design instead of single
point flush.
good contact pattern 7. Check for mating ring distortion.
distressed surface or hot spot possible wear at drive notches
10. High Wear and Grooving
OBSERVATION:
High wear of the mating ring. Primary ring has grooved the mating ring evenly through 360°.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal drips steadily 1. Poor lubrication from liquid being sealed. 1. Increase cooling of seal faces.
when shaft is rotating Common when both seal faces are made 2. Check procedures for lapping carbon primary
or stationary. of hard materials. ring. Do not use abrasives for lapping hard
2. Abrasives are embedded in softer primary mating ring.
ring material. 3. Check for abrasive particles in the pumpage.
4. Check for dead-ended seal chamber.
possible wear at drive notches
depth of
groove
Possible edge chipping of soft carbon
primary rings. Edges will be rounded
for hard material of construction like
full contact pattern tungsten carbide.
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11. Out-of-Square Mating Ring
OBSERVATION:
Contact pattern through 360° slightly larger than primary ring face width. High spot may be present on the mating ring
opposite a drive pin hole. Mating ring without static seals will rock or move in gland plate.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal does not leak when 1. Mating surface is not square to shaft. 1. Check the gland plate surface in contact with
shaft is stationary. Leaks the mating ring. Must be free of nicks and burrs.
steadily when rotating. Surface must show full pattern when blued with
mating ring.
2. Check for proper drive pin extension from
gland plate.
3. Check shaft for proper alignment to be sure that
highly polished area possible opposite it is not passing through stuffing box at an angle.
drive pin hole (only if pin has been used) 4. Check for piping strain on pump casing.
slightly wider
contact area on wear at drive notches
mating ring
12. Wide Contact Pattern
OBSERVATION:
Contact pattern considerably wider on the mating ring than the face width of the primary ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
Seal does not leak when 1. Equipment bearing failure. 1. Check and/or replace bearing.
shaft is stationary. Leaks 2. High shaft deflection whirl. 2. Check and determine if equipment is being
steadily when rotating. operated within specifications.
3. Check and determine if shaft is bent.
4. Check and determine if coupling has been
properly aligned.
5. Check for piping strain on pump casing.
possible wear at drive notches
wider than width of primary ring face
13. Eccentric Contact Pattern
OBSERVATION:
Eccentric contact pattern on mating ring. Width of contact equal to primary ring through 360°. No leakage if shaft has not
contacted inside diameter of mating ring.
SYMPTOMS POSSIBLE CAUSES CORRECTIVE PROCEDURES
If mating ring is 1. Misalignment of mating ring. 1. Check for proper clearances between
damaged, leakage gland plate and seal chamber.
will occur when shaft is 2. Check for proper mating ring design
stationary or rotating. and clearances.
3. Check for proper concentricity between
outside diameter of shaft and inside
diameter of seal chamber.
no abnormal wear if mating ring has
possible contact with shaft, not been damaged
which may crack mating ring.
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If the products featured will be used in a potentially dangerous and/or hazardous process, your John Crane representative should be consulted prior to their selection and use.
In the interest of continuous development, John Crane Companies reserve the right to alter designs and specifications without prior notice. It is dangerous to smoke while handling
products made from PTFE. Old and new PTFE products must not be incinerated.
©2003 John Crane Inc. Print 08/03 [Link] ISO 9001 and QS-9000 Certified B-SealLeak
