MILLWRIGHT MANUAL: CHAPTER 14 Seals Static seals 14:1 Gaskets 14:1 oma las Sealants. 14:10 Dynamic seals... 14:11 Contact seals. 14:12 Clearance seals 14:37,Static seals iiktwaigiT—seAls CHAPTER 14 Seals Seals may be used between two stationary parts (static seals), or between a ‘moving and a stationary part (dynamic seals). They prevent or control leakage of a fluid (liquid or gas). They also prevent contaminants from entering Seals which prevent any fluid from leaking from one side of a system to the other are called positive seals. Seals which control the amount of such eakage are called non-positive seals. Static seals seal two surfaces which have little or no movement. All static seals are positive seals because they prevent any fluid movement between areas. A tapered fit and an interference (shrink) fit are ways to seal two ‘mating surfaces without the use of additional material. These methods use accurately machined surfaces to ensure correct sealing. In most cases an additional material, such as a gasket, an O-ring, or sealant is used to assist the sealing. Gaskets Gaskets are installed at a joint between stationary surfaces to : + seal against a pressure load—in hydraulic or pneumatic systems, gas or diesel engines, etc. + seal against leakage—in a reduction unit where no pressure is involved + control position—by means of shim pack gaskets (See Chapter 12: Gear Drives) In pressure sealing, the gasket is subject to the force of compression exerted by the bolts. This compression force must be greater than: + the internal pressure, which tends to move the gasket sideways + the hydrostatic end force due to the internal pressure, which tends to push the joint apart (see Figure 1), 1-414-2 = inernal Y pressure ALA Figure 1 Forces acting on the gasket Using gaskets to seal housings When using gaskets to seal housings, itis critical that the original gasket thickness be known and the same thickness of gasket replaced. This avoids increasing or decreasing any intemal clearance. For example, if the gasket ‘between the top and bottom casings of a reduction unit is 0.006" thick but is replaced by a gasket 0.015" thick, little or no pressure will be exerted against the outside bearing rings, allowing them to turn in the housing. Always ‘consider gasket thickness when replacing gaskets in an axially split pump with wearing rings. Gasket and flange arrangements | tA) BS Fiat (full) faco Raised face Tongue and groove Spigot and recess Figure 2 Common flange arrangements MILLWAIGHT—SEALSWicLWRiGHT SEALS Gasket joints may be flat-face (full face), or raised-face (ring), tongue and ‘groove, spigot and recess, or a combination of these. See Figure 2. The surfaces must be parallel and regular in finish, whether they are smooth or grooved. Gasket compression Free Compressed Figure 3 Conformation of the gasket to the flange ‘The gasket material is designed to conform to the machined surfaces or to flow slightly to fill small irregularities (see Figure 3). The compression of, the gasket is greatest atthe bolt locations and is least halfway between the bolts. The closer the bolts, the more even this compression becomes. The thickness of the material of the joint also determines the number of bolts required. Thin flanges require more bolts to hold an even pressure than heavy flanges of the same configuration. Figure 4 shows how a thin flange hhas a tendency to distort under bolting forces while a heavy flange does not. Heavy flange Gasket Thin flange Figure 4 A thin flange bolted to a heavy flange Gasket materials Gaskets may be made from metals or non-metals. Gasket material comes in sheets for on-the-job cutting or in special forms for specific applications. Gasket material should: ‘+ withstand the bolt load without being crushed ‘+ withstand the necessary temperature and pressure extremes + be compatible with the product being contained. 14-3tana Non-metallic gaskets Non-metallic gaskets are made of paper, cork, natural or synthetic rubber, or plastics. These are soft and used in relatively low-pressure applications compared with metallic gaskets. + Paper is inexpensive. It is often impregnated with fillers such as wax and seals well against water, oil, and petroleum fuel. Its upper temperature limit is 120°C (230°F) + Corkis used in low-load applications. It can be impregnated with an elastomer such as neoprene or nitrile rubber and seals well against water, oil, and solvent. Its usable temperature range is from ~30°C (-22°F) to 150°C (30°F) depending on its composition. Refer to manufacturers’ specifications. + Natural rubber has excellent mechanical properties and resists water and air. Its upper temperature limit is 121°C (250°F). + Synthetic rubber includes a variety of materials such as buna-S, buna-N, butyl, neoprene, nitrile, Viton, and silicone. All have specific characteristics and temperature limits. Refer to manufacturers’ specifications. + Asbestos is used today only for special applications such as in high temperatures and steam turbines. Caution! Because it is a health hazard, take extreme care when working with asbestos. For example, when gasket surfaces using asbestos are cleaned, scrape them; do not grind them. Handle and dispose of materials containing asbestos in accordance with the procedures specified in the Workers’ Compensation Board's Industrial Health and Safety Regulations. + Plastics such as acrylic and Teflon (PTFE) are commonly used. Acrylic resists heat, oil, and oxidation but does not perform well at low ‘temperatures. Its upper temperature limit is 232°C (450°F). Teflon is nearly chemically inert and performs well in extremely low temperatures. Its usable temperature range is from —190°C (-310°F) to 250°C (480°F) These gaskets are often coloured to show the thickness of the stock. A colour-thickness chart is used to determine their thicknesses. Metallic gaskets Metallic gaskets come in a variety of different materials and configurations. They are harder than non-metallic gaskets and are normally used in high- pressure and high-temperature applications. A few of the various materials are lead, brass, and stainless steel (of various alloys such as Inconel™ and Hastelloy™), Their temperature limit ranges from 100°C (212°F) for lead to 1094°C (2000°F) for Inconel™. See suppliers’ charts for specifications, MILLWRIGHT—SEALSMetallic gaskets can be solid or a composite of several materials. Some of the possible cross sections are shown in Figure 5: flat \V- or U-shaped (light section) rectangular, triangular, or octagonal (heavy section) round or oval spiral-wound corrugated or embossed jacketed with a filler material core (jacket may be corrugated) e f 8 a flexi-metallic has a metallic inner ring and non-metallic outer ring. KE SSS Figure 5 Designs of metallic gaskets Metallic gaskets seal by the flow or malleability of the gasket when the bolts ‘compress the two surfaces together. The surface finish of the gasket and the sealing surface is very important. The smoother the surface finish the better the seal. MiLLWaigHT SEALSGasket styles A circular gasket can have two styles. A ring style covers only the area inside the bolt circle. A full-face style covers the total flange area. See Figure 6. Ring gasket Figure 6 Full-face and ring gaskets The ring gasket is preferred over the full-face gasket for two reasons. It takes less time to make and it is easily installed because all the bolts do not have to bbe removed to allow the gasket to enter. An extension or handle left on the gasket allows even easier handling and positioning during installation. See Figure 6. we enemas “ iii REALSMILLWRIGHT™SEAIS Making gaskets Metallic gaskets are normally supplied pre-stamped and formed for a particular application. Making gaskets from non-metallic material is reasonably simple: ‘+ Either draw the gasket from measurements: 1. Get the OD, ID, bolt circle diameter, and any other needed information from drawings or actual equipment. 2. Draw the gasket shape onto the gasket material. + Ormark the material directly from the mating parts using one of the following methods: 1, Smear the part with a marking ink or graphite. 2. Lay the gasket stock on the material to get an impression, Or 1, Hold the gasket stock against the face. 2. Draw the outline and bolt holes. Most of the cutting is done with a pair of scissors or tin snips, depending on the gasket material. The holes are normally made by using a gasket hole punch of the required size. Always use a gasket hole punch against the end grain of a block of wood to protect its cutting edge. Installing new gaskets Before installing a new gasket: 1. Remove all old gasket stock. 2. Check the metal faces for iregularities. 3. Smooth the faces where necessary. 4 Smear a light film of lubricant on the contact surfaces. This helps the ‘gasket material to flow between the rigid mating parts and makes it easier to remove. Bolt tightening procedures The bolt tightening procedure is important for the successful installation and sealing of a gasket. Regardless of the shape of the mating parts or the gasket material, the bolts are first pulled snug around the casing, then tightened gradually, working across the body. It is more efficient to take two or more passes around the bolt sequence than to try to reach full tension the first time around, Figure 7 shows the tightening sequence for various configurations. a7Figure 7 Bolting pattern O-rings ‘An O-ring is circular with a round cross section like a doughnut. It is usually made from synthetic rubber. It can be used as a dynamic or a static seal (see Figure 8). Pynamic goal ‘Static seal Dynamic seal ‘outside packed \ Piston rod! Figure 8 O-rings used as dynamic and static seals 14-8 See \LLWAIGHTSEALSMiL{WRIGHT SEALS An O-ring used for a static seal has standard dimensions. The groove which holds the O-ring in place has the correct allowance for | compression, See Figure 9. eee The O-ring does not usually make a difference to the relative position of the machine parts. The joint is designed so that the correct compression of the O-ring is accomplished when the two machine | surfaces are in contact with each other. See Figure 10. eS Figure 9 Correct O-ring groove design Figure 10 O-ring groove designs O-ring materials ‘The material used for an O-ring is chosen to resist chemicals and suit the temperature. O-rings made of materials other then synthetic rubber have manufacturer's markings on them. Refer to manufacturers’ information sheets to ensure that the markings comply with the type of O-ring needed, Incorrect application of an O-ring may prevent it operating properly. Metallic O-rings are commonly used where extreme conditions of temperature, pressure, or corrosion exist. These O-rings are formed to the required shape, butt welded, and ground smooth. They may be open (see Figure 11) or closed. They compress slightly when installed, forming an effective seal “4-9Figure 11. Metallic O-ring O-rings in hydraulic equipment Multi-lobed, square, or rectangular section rings are often used as gaskets in hydraulic equipment. See Figure 12. The material is the same as that used in standard O-rings. a » e Figure 12 Four-lobed (quad) ring, square ring, and rectangular ring Sealants ‘A sealant is a gasket-forming or sealing compound often used in zero- or low-pressure applications. They are found in tape, paste or liquid form. ‘These sealants are frequently used with a flat gasket to fill up minor depressions in surfaces that are slightly corroded or pitted. They are classified as non-hardening, hardening-flexible, hardening-rigid, or tape. Flange Flange Figure 13 Sealants filing depressions in surfaces a= 40 MiLLWaIGHT—SEALSNon-i Non-hardening sealants are mastic (resin) materials which are soft and adhesive. They contain plasticizer which allows them to remain soft. They are usually brushed, extruded, or thumbed into place. ardening sealants Hardening sealants Flexible Hardening-flexible sealants are available in a variety of materials such as butyl, acrylic, silicone and polyurethane. These compounds contain curing or setting agents which also allow them to remain flexible. Some of these are true rubbers and others are adhesive. They are all resistant to various environments. Rigid Hardening-rigid sealants are based on epoxies, polyesters, acrylics, polyamides, or polyvinyl acetates (PVA). Because these cure to a rigid state, they tend to crack and result in joints that are difficult to remove. Some of these sealants can be used to join as well as seal. Tapes ‘Tapes are available in different shapes for a variety of different applications such as edge, sandwich, and lap sealing. Teflon packing in string form is frequently used to replace flat gaskets. The ends are twisted together three or four times to form a ring gasket. Tapes have various adhering methods such as pressure sensitive, solvent activated, and self-sticking, Teflon tape is commonly used to seal pipe-threaded connections. Dynamic seals z aries 5 Ht ae - Dynamic seals are grouped into two main categories: contact and clearance: + Contact seals make contact with the two surfaces to be sealed. Examples of contact seals are packing, and lip, diaphragm, and mechanical seals (piston rings). + Clearance seals seal without touching each other. Examples of clearance seals are bushings, and annulus, slinger, and labyrinth seals. Dynamic seals may be positive or non-positive. MiLLWRIGHT—SEALS 14-11Contact seals Packing Packing used as a non-positive seal, controls leakage between stationary and moving parts. The action of the moving part may be reciprocating, rotary, helical, or swinging-rotary. See Figure 14. One or more of these actions are found in equipment such as pumps, compressors, presses, and blowers. 1 9 Reciprocating Rotary Helical Swinging rotary Figure 14 Various motions Packing used as a positive seal prevents any leakage between the stationary and moving parts. These are found in situations such as gate valve stems. Packing is divided into three categories: compression, automatic and floating. These categories are described on the next few pages. Inside- and outside-packed Packing installed in the moving unit is called inside-packed. Examples are cylinder pistons and air valve spools. Packing installed in the stationary unit is called outside-packed. A stuffing box falls into this category. 14-12 MILLWAIGHT—SEALSMiLLWrIGHT™ SEALS / \ Outside packed Figure 15 inside packed, outside packed Hardness of packing Packing must withstand temperature, pressure, various fluids, and shaft misalignment and movement. The hardiness of packing or a scal helps to determine its action under pressure and movement. Hard packing withstands extrusion bette than soft packing, but it also creates more friction. Where clearances are excessive, hard packing, special packing, or packing aids should be used, ‘Compression packing Compression packing is so named because it relies on its compression to develop a seal. The amount of sealing or leakage is controlled by the amount the packing is compressed. Compression packing is commonly found in centrifugal pumps and reciprocating water pumps. (See Chapter 15: Pumps.) Compression packing is made of three classes of material: fabric, metallic and plastic. + Fabric packing is made of strong, pliable materials such as braided asbestos, metal, graphite, cotton, flax, wool, aramid, carbon, or polytetrafluoroethylene (PTFE) filament. PTFE is better known as Teflon. (Note: Asbestos is used less now due to its association with health problems and the difficulty of disposal.) + Metallic packing is made from materials such as lead, copper, or aluminum. It is either machined or pressed into rings to fit specific stuffing boxes and shafts. * Plastic packing is moulded to fit specific needs. Compression packing’s cross section may be round, square or rectangular, The choice of packing shape and material depends on the stuffing box design, temperature, pressure, and the type of fluid it is in contact with. 14-13ata ‘Some packing is impregnated with lubricant, such as graphite or Teflon, so that it is self-lubricating at start-up. It is supplied in continuous coils of the desired cross-section or in pre-formed, die-moulded rings. Lantern rings A lantern ring (seal cage) is often used with compression packing. It is a ring with channels in its inner and outer perimeters. Figure 16 shows that its cross section is H-shaped. The channels are connected by radial holes. ren = water i Packing vane | pag Ca jure 16 Lantern ring ‘The lantem ring distributes sealing liquid under pressure to the packing. This prevents air infiltration and provides lubrication, cooling and cleaning to the area. The sealing liquid is commonly delivered from the high-pressure section of the pump (internally supplied). When semi-fluids such as slurry are pumped, an external source of sealing liquid is used (externally supplied). Compression packing installation ‘Compression packing is replaced periodically because it deteriorates from. ‘wear and also dries out. How often itis replaced depends on operating conditions, quality of the packing, and quality of the packing’ installation. ‘The procedure for replacing packing is as follows: Prepare the pump for the replacement work. Remove the old packing and identify its sequence, amount, and size. (Check the conditions of the lantem ring and stuffing box. Cut the new packing. Install the new packing. mm oA w > Adjust the gland and check the leakage. The details are as follows: MILLWRIGHT—SEALS‘A, PREPARE THE PUMP FOR THE REPLACEMENT WORK 1, Ensure that the pump is locked out and drained to relieve any pressure behind the packing. 2. Ifextemally supplied sealing liquid is used, shut off the supply and rain the line B, REMOVE THE OLD PACKING AND IDENTIFY ITS ‘SEQUENCE, AMOUNT, AND S12 1. Remove the gland. 2, Remove all the old packing using a packing puller as, shown in Figure 17. 3. Remove the lantern ring if used. Figure 17 Using a packing puller 4. Count the number of rings removed and record the position of the lantem ring, if used, 5. Confirm this information with its stuffing box code. For example “2-L-3-G" indicates that the packing sequence is: 2 rings of packing, a lantem ring (L), 3 rings of packing, then the gland (G), If the stuffing box code is unavailable, determine the correct amount of packing by measuring the depth of the stuffing box, then: —Subtract the width of the lantern ring if used. —Divide it by the width of the new packing. 6, Determine the correct size and type of packing to be used by referring to equipment manuals: —The correct type is determined by matching the categories of the pumped product with the manufacturers’ recommendations. —If manuals are not available, find the correct size by subtracting the diameter (ID) of the shaft or sleeve from the bore (OD) of the stuffing box. See Figure 18. Divide the difference by two. (C._ Citeck THe CONDITIONS OF THE LANTERN RING AND STUFFING BOX 1, Ifa lantern ring is used, ensure that the sealing water inlet to the stuffing box is clear. 2. Check the condition and cleanliness of the stuffing box and shaft or shaft sleeve, MILLWRIGHT—SEALS” aepstutting box, f> i Figure 18 Determining the correct cross section D. Cur tie New packine 1, Cut the new packing to size. This is best done on a wooden mandrel with the same diameter as the pump shaft or shaft sleeve. Wrap the packing around it in the same direction as it comes off the roll. + Cutrings straight with the axis of the mandrel (butt cut) as shown in Figure 19. This reduces the chance of fraying and sloppy joints. LG Mande! Packing Figure 19 Square end cut on a mandrel + You may also cut the rings on a diagonal. To do this, draw two lines, the width of the packing apart, Then, cut each ring of packing diagonally between the lines as shown in Figure 20. Drawn ines, St Mandrel ey | Packing Figure 20 Cutting diagonally on a mandrel 2. Ifit is necessary to cut rigid (rolled, pressed or die formed) packing, make a diagonal cut (a skived cut). 14-16E, _ INSTALL THE NEW PACKING 1, Install packing onto the shaft or shaft sleeve. + Wrap mandrel-cut packing around the shaft. *+ For rigid packing, use an S twist to place it over the shaft. See Figure 21. Do not pull it open. Figure 21 Sliding rings sideways over the shaft 2. Where compatible, lightly lubricate the ID and the OD of the packing. 3. Install one ring into the stuffing box at a time. If stuffing is slightly bulged, it may be difficult to install. If this is the case, the packing ‘may be slightly flattened with a roller. Ensure that this is done on a clean surface. 4. Use a split bushing or tamping tool to place each ring in position. Ensure that the ends of the packing line up to each other. Then, work it in around the circumference in both directions. Ensure that each ring of packing is seated at the bottom. 5. Ensure the ring joints are staggered approximately 90° from each other as shown in Figure 22. Figure 22 Staggered ring joints 6. Ifa lantem ring is used, ensure that it lines up with the seal water inlet. See Figure 23. MILLWRIGHT—SEALS 14-1714-18 ‘Seal water | inter f Hs G Lanter ring Figure 23 Proper positioning of the lantern ring F, ADJUST THE GLAND AND CHECK THE LEAKAGE 1. After the last ring is installed, allow the gland to enter the stuffing box by Ye" to 3/16" 2. Tighten the gland nuts with a wrench to seat and form the packing to the stuffing box and the shaft. Ensure that the gland enters the stuffing box square with the shaft. . Undo the nuts and allow the packing to expand. 5. Finger-tighten the nuts again. . Start the pump allowing the packing to leak freely. . Gradually tighten the nuts equally (a sixth of a turn or one flat) until leakage is reduced to the recommended lubrication level. ‘Note that the packing in stuffing boxes should not be compressed too tightly. A slight leakage is allowed to provide lubrication between packing and shaft. If leakage is completely stopped the resulting friction causes excessive heat to build up. This bums the packing and damages the shaft. MiLLWRIGHT—SEALSMILLWRIGHT—-SEALS Note also that inside the stuffing box, the individual rings of packing do not compress equally. The rings closest to the gland compress the most. See Figure 24, Figure 24 Unequal compression of packing Automatic packing Automatic packing is so called because it uses system pressure to improve its sealing action. It does this by forcing the flexible lips of the packing onto its contact surfaces. These consist of V-ring and U-ring packing, O-rings, and cup packing. + Vering and U-ring packing and O-rings are considered balanced packing as they seal on both the ID and OD. Pressure is balanced at both diameters. *+ Cup packing is considered unbalanced packing as it seals on one diameter only. Vering packing (chevron packing) V-ring packing (also known as chevron packing) is a circular, one-piece ‘moulded ring with a V-shaped cross section. Its used in sets of three or ‘more rings, depending on the working pressure. 1449V-ring packing is used as an inside or outside packed seal. V-ring packing must be used with shaped internal and external adapter rings (see Figure 25). Internal adapter ring V-ting packing Extemal adapter ring Figure 25 V-ring packing with internal and external adapter rings ‘The internal adapter ring should be hard enough to prevent extrusion, yet soft enough to compress slightly under pressure. The external adapter ring merely shapes the V-ring and is not subject to wear. Where possible, V-ring packing sets should be installed as endless rings. When V-ting packing must be cut for installation, stagger the joints about 90° on successive packing. \V-ring packing requires both diameters to contact mating surfaces to obtain inital sealing. An adjustable gland is a common means of ensuring this and to maintain this seal due to wear. At the initial installation, the rings are tightened just enough to prevent leakage. This can be done in two ways: * by operating the unit and tightening the gland until any leaks cease * or, ifthe packing is frequently replaced, a spacer can be made the thickness of the necessary gap between the gland and the housing. Tightening the gland to the spacer ensures correct loading. As leaks develop, the gland can be tightened further. Excessive tightening during first installation causes friction and rapid wearing of the packing. MiLLWRiGHT SEALSoe 7 legal fing } Se adapter fing Figure 26 Even spacing used to ensure consistent loading > " Series of individual springs (One coil spring Figure 27 Methods of adjusting V-ring packing MILLWRIGHT™ SEALS 14-2114-22 Some applications use spring-loaded external adapter rings to maintain constant pressure, In this case, the gland is tightened down to the housing. This leaves no chance of overloading the packing set (provided it has the correct number of rings and has been properly installed). Figure 27a shows ‘one continuous spring supporting the external adapter ring. Figure 27b shows a series of small springs supporting the external adapter ring. \V-ring packing sets used on double-acting pistons should face away from each other. See Figure 28. The internal adapter ring should be supported by a solid backing, not by the opposing series of V-rings. In this case the adapter ring is often a non-metallic material and acts as a bearing to guide the piston. Figure 28 V-ring packing set for double-acting pistons ‘Materials in the V-ring packing sets can all be the same or be dissimilar. Dissinilar materials consist of hard and soft rings arranged in a specific sequence. The soft rings do most of the sealing while the hard rings act ‘mainly as spacers and bearing rings. When installing a set of mixed rings (for a special order), always keep the rings in the same sequence as they were supplied. MILLWRIGHT—SEALSMILLWRIGHT—SEALS U-ring packing A U-ring (U-cup) packing is a circular, one-piece moulded ring with a U-cross section usually made from one of the synthetic elastomers. This endless design is meant to be used singly per seat, unlike compression or \V-ring packing. Using packing can be used as an inside- or outside-packed seal. See Figures 29 and 30. Due to its low friction, itis primarily used in systems with pressures of less then 10 340 kPa (1500 psi). Pressures above that require the addition of an anti-extrusion washer (support ring). sting packing » Support ring cman14-24 For a double-acting piston, two separate seats must be used, Two U-rings should not be placed against each other in the same groove. Figure 31 shows {wo different options for mounting U-ring packing for double acting pistons. Figure 31. U-rings used in a double-acting piston Cup packing ‘Cup packing has only one lip and is considered an unbalanced packing. At low pressures, the cup may seal atthe lip, but it normally does not seal until the heel diameter has been expanded to the diameter of the cylinder wall. ‘The assembly must be tight enough to prevent leakage along the piston shaft. Itis standard to fasten the cup against the piston by means of a tightly clamped plate. U-ring packing often replaces cup packing because it requires less maintenance time. Cup packing with double-acting pistons requires a rigid separator between the two cups. In some assemblies the separator is made of synthetic or laminated bearing material and acts as a guide as well as a separator, When installing new cups, there should be a gap between the follower and the back-up plate (see Figure 32). ‘Cup material can be leather, synthetic rubber or elastomers, or impregnated fabric, depending on air or oil used and the maximum pressure.MiLLWAIGHT SEALS Hee! Figure 32 Cup packing configurations (single- and double-acting pistons) O-rings O-rings are used as dynamic seals on slow turning shafts or reciprocating parts such as valve spools. An O-ring sits in a groove whose width is generally 135% to 150% of the O-ring’s cross section. This allows for deformation due to squeeze, swelling due to fluid contact, and slight rolling of the O-ring. The rolling provides some surface lubrication during reciprocating motion. Diametral squeeze is necessary to maintain a seal. If there is no squeeze, leaks start at low pressure. Too much squeeze rapidly wears out the rings. Generally, the squeeze is equal to 10% of ring diameter, but the exact amount of squeeze is shown on suppliers tables. ‘The clearance between the carrier and the mating part should be held to a ‘minimum to prevent extrusion into this gap. Standard O-rings are rated to 10 340 kPa (1500 psi) with properly designed grooves, and up to 20 680 kPa (3000 psi) using anti-extrusion rings or back-up washers. ta 2814-26 Zero pressure Figure 33 O-rings under pressure Figure 33a shows the action of an O-ring under pressure up to and over the rated maximum, Figure 33b shows the action of the same O-ring with back- up washers under pressures up to 20 680 kPa (3000 psi) Back-up washers are often made of leather, Teflon or moulded nylon. Their purpose is to: ‘+ eliminate extrusion of the O-ring ‘+ permit wider clearance between moving parts + forma seal across a clearance gap + act as a dirt wiper Note: When back-up washers are used with O-rings, the grooves are required to be wider. Do not use a back-up washer and O-ring in a groove designed for O-rings only. To install O-rings: 1. Lubricate the O-ring with a light oil before seating. 2. Roll the O-ring into its seat. Stretch it only as much as needed for installation. 3. Do mot cut back-up washers. Teflon washers are supplied as spiral- ‘wound split washers to permit stretching. Leather back-up washers ean be stretched by soaking them in hot water for a prescribed time before installing. Air-dry the washers at about 200°F (93°C) to shrink the leather. Put the flesh side next to the O-ring. 4. Protect the O-ring from cuts and from nicks from sharp metal comers MILLWRIGHT—SEALS:MILLWRIGHT—SEALS Floating packing Floating packing is a seal that is retained in a groove but not held in a static position. Split rings and piston rings are examples of these seals. They are able to float within the groove and seal by means of spring tension. See Figure 34 Force (pressure) a Sealing position Figure 34 Piston rings Automotive or steam piston rings are often used when rapid travel and frequent cycling are needed. Material in rings can be cast iron or steel, either plain finished or chrome plated. Piston rings are not a positive seal because they leak slightly. ‘Some advantages for using floating packing rather than synthetic seals are that floating packing: + creates less friction * can take high pressure *+ is less affected by temperature extremes Some disadvantages are that floating packing: * conforms less to the mating surfaces + has a longer run-in period Handle cast iron rings with care. Due to their brittleness, they often break when they expand too much as they are slipped onto a piston, Lip seals Lip seals are used in low-pressure areas (2 to 10 psi). They are primarily used on rotating shafts which are partially or totally immersed in lubricant. A hydrodynamic film of lubricant is formed at the point of contact to prevent friction and wear. This film of lubricant should be about 0.025 mm (0.001") thick, If it is any thicker, leakage may occur. If it is much thinner, friction and heat occur, rapidly wearing the seal down. 14-27ya 28 ‘To maintain this hydrodynamic film, the shaft’s surface must be controlled. For speeds up to 8 m/s (26 fils), the shaft should have a ground finish (16 micro-inches = 0.4 microns). For speeds above this, the shaft should be hardened and ground (4 micro-inches = 0.1 microns) Note: | micro-inch (yin) = 0.0254 micron Materials used for lip seals are felt, leather or synthetic rubber. A simple lip seal consists of a lightweight pressed metal housing with felt or leather secured into it or synthetic rubber bonded onto it (see Figure 35). For the lip to maintain contact with the mating surface, it relies on the elasticity of the ‘material used or on a garter spring behind this material. Housing — ( Pressed metal 1 housing Garec| spring Synthetic tp LI rubber +— Rotating shat Figure 35 Single synthetic lip seal Single lip seals ‘A single lip seal consists of one sealing edge. It is usually installed with the lip inward to include or contain the lubricant in the housing (inclusion seal or seal in), assuring that the atmospheric side is relatively clean, When the atmospheric side is dirty, it can be installed with the lip facing out, to exclude foreign material (exclusion seal or seal out). The small amount of lubricant that leaks out acts as a flushing medium to keep the contact, surfaces clean. See Figure 36. Double lip seals ‘A double lip seal consists of two sealing edges. They can have their lips back to back or facing the same direction. See Figure 37. These are used where additional sealing is required. Examples are where there is higher housing, pressure or as inclusion and exclusion seals in dirty environments, ‘WiLLWAIGHTSEALSInclusion Exclusion Figure 36 Lip seal facing inward (inclusion) and outward (exclusion) me Rr Back to back b Facing same directions © Seal with lips fn front and rear Figure 37 Double lip seal configuration MILLWRIGHT— SEALS 14-29Installation The seals are manufactured with the required press fit, providing the housing is machined to standard dimensions, + Sean nto House 1. Lubricate the shaft, the housing, and the sealing edges. Leather seals should have the leather saturated with oil before they are installed, 2. Determine whether the seal is to be used as an inclusion or exclusion seal. 3, Remove any sharp edges around the bore of the housing. 4, Align the seal with the bore. 5, Press the seal into the housing squarely and smoothly. Ensure that the pressing device contacts the seal on its outer rim only, not to the unsupported inner section. 6. Ifthe seal isto rest below the machine face, ensure that the pressing device is slightly smaller then the bore of the housing. See Figure 38. Pressing device Figure 38 The method of installing lip seals + Suarranto seat 1, Ensure that the sealing edge does not slide over sharp edges such as, key-seats or threads, 2. Use plastic, shim stock, or even paper to cover any sharp edges over which the seal must pass. See Figure 39. 14-30 *MILLWAIGHT SEALSMiLLWRIGHT—SEALS 3. Unless the shaft has a chamfer with a long taper, use a proper leader or light-gauge shim stock. When using shim stock, make sure the seal twists away from the sharp edge of the shim stock. Caution! Do not use a screwdriver to pry the seal onto the shaft because this can damage the sealing edge. Mounting sleeve U ae Figure 39 Installing lip seal onto shaft Emergency repairs ‘A shaft wears under the seal contact point when fine abrasives or dirt are held by the seal. When the amount of wear interferes with proper sealing, the shaft should either be refurbished or replaced. These repairs are time- consuming and short-term solutions may be needed. The following are common short-term solutions: Change the seal to a wider seal to move the location of the lips. Reverse the seal ifthe lip has a pronounced offset. Install a spacer behind the new seal of original size to move the lip Contact to « new area (see Figure 40a). Install a thin sleeve over the wom spot. In some cases these sleeves can be purchased (see Figure 40b). 14-31Figure 40 Short-term repair methods Ring seals ‘A ring seal is a non-positive seal which is mounted into a groove in the housing. They are made of cork, felt, leather, or synthetic rubber. Figure 41 shows a felt ring seal. Figure 41 Felt ring seal Cork, felt and leather ring seals are precision-cut washers with a sealing edge broader than that of the lip seals. Over an extended period, they tend to polish the shaft. Synthetic rubber ring seals are moulded into shapes required for the job. 14-32 — MILLWRIGHT—SEALSMILLWRIGHT—SEALS Ring seals are used as follows: * Cork ring seals are used in slow speed, light duty applications where its operating temperature does not exceed 65°C (150°F). * Felt and leather ring seals are also used in slow speed, light duty applications but where their operating temperatures won't exceed 105°C (20°F), These seals absorb the lubricant and redistributes it as a film between the seal and the shaft. + Synthetic ring seals are used in high speed applications and can withstand temperatures as high as 250°C (480°F). Synthetic seals can retain lubricant without absorbing it and resist acids and alkalis Even though these seals are simple and inexpensive, they are being replaced by other types of seals Wipers A wiper (scraper) is a non-positive seal mounted on the stationary housing. It flexes against axially moving parts (see Figure 42). Wipers expel foreign ‘material away from the seals, packing or bearings. They are commonly found on hydraulic and pneumatic cylinders in dusty or dirty locations. They are also used on guides and slides on which equipment rides. ‘Moving part ‘Stationary part Figure 42 Wiper used around a shaft * Synthetic rubber or plastic wipers protect against dust and fine materials. + Metallic wipers protect against solid abrasive materials Their lip shape allows lubricant from the equipment to remain on the rod or guide but restricts any entry from the atmospheric side. Boots and bellows Boots and bellows are positive seals which have one end secured to the housing and the other to the moving part. Boots are used for short movements (strokes) and bellows for long ones. They are made of rubber or some other flexible material, See Figure 43. They replace wipers when it is vital that no atmospheric contaminants reach the working parts (for example, ‘on shock absorbers). 14-33Boot os Figure 43 A boot around a reciprocating shaft Diaphragm seals A diaphragm seal is a positive seal which has a flexible membrane which spans between the stationary and moving parts. It is clamped between the two stationary housing halves and is clamped to the moving part with plates. This seal does not allow any fluid to transfer from one chamber to another. ‘There are two styles of diaphragm seals: + A flat diaphragm seal is designed for a small amount of movement. Itis, ccut from a flat membrane and the elasticity in the material is enough to handle the movement. See Figure 44a, * A rolling diaphragm seal is a moulded membrane and rolls on the two mating surfaces as it moves. See Figure 44b, Figure 44 Flat and rolling diaphragm seals MILLWRIGHT—SEALSMILLWRIGHT—SEALS Mechanical seals ‘A mechanical seal is an extremely efficient axial seal. It is much more effective than any other dynamic seals in preventing leakage. The leakage is so minimal that the naked eye cannot detect it. Any fluid that leaks past tends to evaporate immediately. ‘A mechanical seal has primary and secondary sealing: * The primary seal is dynamic and is composed of two lapped (polished) faces in contact. One face is stationary and the other rotates. The mating faces are at right angles to the shaft (see Figure 45). A spring loaded device keeps these faces together. The contact faces are made of various combinations of materials such as carbon-graphite, ceramic, tungsten carbide, stellite, and stainless stee! * The secondary seal is static and is between the contact face and the shaft, ‘and between the contact face and the housing. The seal between these parts can be done in a variety of different ways, but the most common is by means of O-rings. Mating face (erimary sean os \\(tationary seat \ a | Washer | a [ — Housing Sering (ang sealing), Retainer > 7 \ Shatt VU. (‘otating) o-ings {Secondary seals) Figure 45 Mechanical seal components Flushing ‘The mechanical seal must always run in fluid. The flushing ports feed the fluid into the product side of the seal. The fluid can be used directly from the product discharge or from an external source. If the product discharge is used, this fluid may have to go through a cyclone strainer (separator) to remove any solids. Orit may pass through a heat exchanger to remove any excess heat. 14-3514-36 ‘The advantages of flushing are to: ‘+ maintain a consistent operating temperature ‘+ prohibit any vaporization of volatile fluids around the contact faces + prevent crystallization of fluids near the contact faces ‘+ prevent solids from accumulating around the seal ‘+ prevent the product from entering the stuffing box (if the flushing fluid is ata higher pressure then the system). Quenching Quenching is done through quenching ports on the atmospheric side of the seal. The fluid comes from an external source and must be compatible with the seal faces, the product being sealed, and the atmosphere. Steam is commonly used. A throttling bushing is used to keep the fluid at the contact face. The advantages of quenching are to: ‘+ prevent leakage of corrosive or toxic fluids into the atmosphere + prevent crystallization around the contact face ‘+ maintain a constant operating temperature and minimize any heat transfer along the shaft. Mechanical seal maintenance If either face is damaged it is best to replace the complete seal than to try and adjust a seal face or mix seal parts. Seals may be sent to the manufacturer for factory overhaul. If the proper equipment is available, the seal can be hand lapped in the following procedure: 1. Charge the lapping (polishing) plate with a diamond lapping paste 2. Lightly press the seal face against the lapping plate and move it in a figure eight motion. Continue this until the surface appears fat. ‘Wash the face with solvent. Check the surface with a monochromatic light and optical flats. anae Repeat the procedure if necessary. Caution! Mechanical seals are precision products. Handle them carefully. Do not touch their mating faces. WiLLWRIGHT SEALSMILLWRIGHT—SEALS Clearance seals Bushings ‘A bushing seal is a non-positive seal which is mounted in the stationary housing. The minimal clearance between it and the rotating shaft restricts the amount of leakage from the high to low pressure sides. It is considered the simplest of seals. See Figure 46. Figure 46 Bushing used to seal a shaft Annulus seals ‘An annulus seal is a non-positive seal with a series of concentric or helical grooves in the housing bore (sce Figure 47). A drain hole is placed at the bottom of the seal to make the seal effective, In a concentrically grooved seal, lubricant fills the grooves to prevent the entry of contaminants, When helical grooves are used, the oil is returned to the bearings by this action. Helical Concentric grooves grooves Figure 47 Annulus seals with concentric and helical grooves Slinger (finger) seals A Slinger scal is a non-positive seal which has a ‘cupped washer-like flange mounted to the rotating shaft. It is Placed just outside the seal housing to assist the sealing ofa ring seal. See Figure 48. As any lubricant passes the ‘ing seal, the lubricant is flung out by centrifugal force. This prevents contaminants from entering the seal. 14-3714-38 Fling seal Figure 48 Slinger seal used with a ring seal Labyrinth seals A labyrinth seal is a non-positive seal which has a tongue and groove design. ‘A series of internal and extemal passages form a maze-like path for foreign ‘material to follow. A labyrinth seal can be made to seal axially or radially, depending on application. Sec Figures 49 and 50. Radial labyrinth seals require split housings. SL. Figure 49 Radial labyrinth seal Because their surfaces are not in contact, labyrinth seals are used in high speed applications. They are also very effective where the environment includes abrasive contaminants or semi-solid liquids. This seal is usually lubricated and the lubricant fills the passages and forms a seal to trap contaminants. As the seal is re-lubricated, the lubricant forces trapped contaminants out. MLL WRIGHT —SEALS9 (stationary) Figure 50 Axial labyrinth seal MiLLWRIGHT—SEALS1440 WILLWRIGHT—SEALS