Mechanical

shaft seals
for pumps
Mechanical
shaft seals
for pumps

Copyright 2009 GRUNDFOS Management A/S. All rights reserved.

Copyright law and international treaties protect this material. No part of this
material may be reproduced in any form or by any means without prior written
permission from GRUNDFOS Management A/S.

Disclaimer
All reasonable care has been taken to ensure the accuracy of the contents of
this material, however GRUNDFOS Management A/S shall not be liable for any
loss whether direct, indirect, incidental or consequential arising out of the use
of or reliance upon any of the content of the material.

First edition
Compositor: Gills Illustrations Services
Print: Scanprint A/S
Contents

Preface 5

Chapter 1. Introduction 7
1. Types of shaft seals 8
2. Mechanical shaft seals 10
3. Operating principle 12
4. Historical development 22

Chapter 2. Mechanical shaft seal types and sealing systems 25

1. Mechanical shaft seal types 26
2. Sealing systems 31
3. Selecting a mechanical shaft seal 42

Chapter 3. Materials 45
1. Seal face materials 46
2. Seal face material pairings 51
3. Testing of shaft seals 55
4. Secondary seals 59
5. Materials of other shaft seal parts 61

Chapter 4. Tribology 63
1. Lubrication 65
2. Wear 72

Chapter 5. Failure of mechanical shaft seals 75

1. Introduction to failures 76
2. Lubrication failures 77
3. Contamination failures 78
4. Chemical, physical degrading and wear 80
5. Installation failures 84
6. System failures 86
7. Shaft seal failure analysis 88

Chapter 6. Standards and approvals 93
1. European Standard EN 12756 94
2. Approvals 97

Index 102
Preface
Technology and using technology in our products is the very core of Grundfos’
success. It has been like that since the start of Grundfos, and this is also how it is
going to continue in future.

But this position doesn’t just come to us, and many of our colleagues in the pump
business would be happy to take over this position. However, this is not going
to happen – as we at Grundfos want to continue our tradition for long-range
technology and material development.

For most pumps a decisive element for the quality of the pump during its lifetime
is a good and robust shaft seal. Grundfos has many years of experience with the
development, production and use of mechanical shaft seals in pumps, and our
solutions in this field are contributing significantly to our leading position within
pump technology.

I am pleased to introduce this book which I encourage you to use in our organisation.
Looking ahead and working together, it is important that we systematically apply the
knowledge which we have gained, and which has now been set down in writing in
this book.

Enjoy the reading !

Carsten Bjerg
Group President
Chapter 1

Introduction

1. Types of shaft seals

2. Mechanical shaft seals
3. Operating principle
4. Historical development
 Introduction

Fig. 1.1: Position of shaft seal in pump

1. Types of shaft seals

Almost everywhere where pumps with rotating shafts are used, a shaft seal is involved.
The shaft seal forms a barrier between what is inside the pump and the atmosphere.

A pump with a through-shaft is not completely sealed. It is a challenge to the entire pump
industry to minimise leakage.

There are countless variants of shaft seals, reflecting the diversity of the pump industry, and
the need for specific solutions for individual situations. In its most basic form, a shaft seal
combines a rotating part with a stationary part. When properly designed and installed, the
rotating part rides on a lubricating film, only 0.00025 mm in thickness. Should the film
become too thick, the pumped medium will leak. If the film becomes too thin, the friction
loss increases and the contact surfaces overheat, triggering seal failure.

Seal performance greatly influences pump performance. When functioning correctly, the seal
remains unnoticed. As soon as it starts to leak, however, significant problems can arise, either
with the pump or the surrounding environment. The importance of the shaft seal must never
be underestimated during pump design, operation, or maintenance.

8
 Stuffing box
Stuffing A braided stuffing box packing is the simplest type of shaft seal.
box housing The packing is placed between the shaft and the pump housing.
See fig. 1.2.
Soft packing
In the stuffing box housing used in fig. 1.2, a soft packing ring is
axially compressed until it makes contact with the shaft. After
Shaft the soft packing has been exposed to wear, the stuffing box must
be further compressed to prevent excessive leakage.

Vibrations and misalignment will cause this seal type to leak.

Fig. 1.2: Braided stuffing box

packing with housing

Lip seal
A universal lip seal type is a rubber ring sliding against the shaft.
Lip seal
See fig. 1.3. This type of seal is primarily used in connection
with a low differential pressure and low operating speed.

Fig. 1.3: Lip seal

Mechanical shaft seal

A mechanical shaft seal consists of two main components:
a rotating part and a stationary part. See fig. 1.4. The rotating
part is axially pressed against the stationary part.
In the following, we shall focus on the mechanical shaft seal and
its many construction possibilities and applications.

Fig. 1.4: Mechanical shaft seal

Stationary Rotating
part part

9
 Introduction

2. Mechanical shaft seals

This section briefly describes the design and elements of the mechanical shaft seal.

As previously stated, a pump with a through-shaft is not leakproof. The mechanical shaft seal
is essentially a throttle arranged around the shaft. It reduces leakage between the pump and
the surroundings to an absolute minimum. The clearance between the stationary and rotating
part of the seal must be small in order to reduce leakage.

Atmosphere

Pump housing Mechanical shaft seal with two axial seal faces
Seal faces
The best possible way of making a seal with a minimum of
clearance and thus a minimum amount of leakage is by pressing
Stepped shaft two axial surfaces against each other. These axial surfaces can be
obtained with a stepped shaft, running against a flat surface on
the pump housing. See fig. 1.5.

The shaft and pump housing must be highly wear resistant and
well aligned.

Pumped medium

Fig. 1.5: Two axial surfaces

acting as a shaft seal

Stationary seat
Mechanical shaft seal with rotating seal ring and stationary seat
Seal gap
A more practical solution is obtained by fitting a rotating seal
ring on the shaft and a stationary seal ring (seat) in the pump
Rotating seal
ring housing. The tiny space between the seal faces is called the seal
gap. See fig. 1.6.

This design allows the use of a wide selection of materials for the
rotating seal ring and stationary seat.

Fig. 1.6: Mechanical shaft seal

with rotating seal ring
and stationary seat

10
 O-ring,
stationary

Secondary seals
Secondary seals consist of rubber parts such as O-rings or bellows,
O-ring,
rotating
used to avoid leakage between the shaft and the rotating seal ring as
well as between the stationary seat and the pump housing.

To minimise leakage, the rotating seal ring must be pressed against

the seat. Therefore the rotating seal ring must be able to move axially
on the shaft. To obtain axial flexibility, the secondary seal must either
be a bellows or an O-ring sliding on the shaft.

The secondary seal that seals between the rotating seal ring and the
Fig. 1.7: The secondary seals shaft rotates together with the shaft. The secondary seal that seals
confine leakage to the between seat and pump housing is static. See fig. 1.7.
atmosphere

Spring
The rotating spring presses the rotating seal ring against the seat
and the rotating O-ring along the shaft. See fig. 1.8.
Spring

Fig. 1.8: A spring presses the

rotating seal ring against
the stationary seat

Torque transmission element

A torque transmission element ensures that the rotating
Torque seal ring rotates together with the shaft. See fig. 1.9.
transmission
element

All compoments of a complete mechanical shaft seal have now

been introduced.

Fig. 1.9:The torque transmission

element completes the
mechanical shaft seal

11
 Introduction

3. Operating principle
This section describes how the lubricating film is generated in the sealing gap in a liquid-
lubricated mechanical bellows shaft seal. The design differs slightly from the O-ring seal
shown in fig. 1.9.

In its simplest form, the mechanical shaft seal consists of two main parts:
The rotating part and the stationary part. See fig. 1.10.

1. Pump housing

2. Stationary secon-
dary rubber seal

3. Stationary seat

Lubricating film
in sealing gap

4. Rotating seal ring

Stationary
5. Torque transmission
ring part
Sealing gap
Rotating
6. Spring part

7. Torque transmission
ring

8. Rubber bellows
(rotating secondary
seal)

9. Shaft

Fig: 1.10: Mechanical bellows shaft seal

12
The rotating part
The rotating part of the seal is fixed on the pump shaft and rotates in the liquid during pump operation.

The compression of the rubber bellows (8) between the shaft (9) and one of the two torque
transmission rings (7) fixes the rotating part to the shaft. See fig. 1.10.

The spring (6) transfers the torque between the torque transmission rings (7 and 5). The rotating seal
ring (4) is mounted together with the rubber bellows (8). The torque transmission ring (5) compresses
the rubber bellows (8) to the rotating seal ring (4). The rubber bellows prevents leakage between the
shaft (9) and rotating seal ring (4) and ensures axial flexibility despite contamination and deposits.

In a rubber bellows seal, as shown in fig. 1.10, axial flexibility is obtained by elastic deformation of the
bellows. However in an O-ring seal, as shown in fig. 1.9, the O-ring slides along the shaft.

The compression force from the spring keeps the two seal faces together during pump standstill and
operation thanks to the flexibility of the bellows or the O-ring. This flexibility also keeps the seal faces
together, despite axial movements of the shaft, surface wear, and shaft run-out.

The stationary part

The stationary part of the seal is fixed in the pump housing (1). It consists of a stationary seat (3) and a
stationary secondary rubber seal (2).
The secondary seal prevents leakage between the stationary seat (3) and the pump housing (1). It also
prevents the seat from rotating in the pump housing . See fig. 1.10.

The pumped medium to be sealed (A) is generally in contact with the outer edge of the rotating seal
ring (B). See fig. 1.11 . When the shaft starts to rotate, the pressure difference between the pumped
medium (A) in the pump housing and the atmosphere (D) forces the medium to penetrate the sealing
gap (from B to C) between the two flat rotating surfaces. The lubricating film is generated.

The pressure in the sealing gap is reduced from B to C, reaching

the pressure at D. Leakage from the seal will appear at C.

The pressure at B is equal to the pressure at A. The pressure drop

in the sealing gap during pump standstill is shown in fig. 1.12a.
D The closing force is only supported by direct contact between
A
the seal faces.
B C
A: Pumped medium The opening forces from the pressure in the lubricating film are
B: Rotating seal ring, shown by the red arrows in fig. 1.13b and 1.14b.
pumped medium side

C: Rotating seal ring,

The parts of the seal inside the pump are subjected to a force
atmospheric side emanating from the pressure within the pump. The axial
D: Atmosphere component of this force, together with the spring force, creates the
closing force (Fc) of the seal.

During pump standstill, the pressure at the outer edge of the

Fig. 1.11: Indication of sealing
gap positions ring (B) is equal to the system pressure (A). See fig. 1.12a.

13
 Introduction

System
pressure

System
Atmospheric
pressure
pressure

AtmosphericA B C D
System
pressure
pressure

A B C D
Atmospheric
pressure

A B C D
Fig. 1.12a: Pressure at standstill is either Fig. 1.12b: At standstill, there is
Pump system pressure or only direct contact

pressure atmospheric pressure between the seal faces

Pump
pressure

Atmospheric
Pump
pressure
pressure

AtmosphericA B C D
pressure

A B C D
Atmospheric
Fig. 1.13a: Hydrostatic
pressure pressure Fig. 1.13b: Opening forces from
distribution for seal with hydrostatic pressure
A parallel
B seal faces C D distribution

Pump
pressure

Pump
pressure

Pump
Atmospheric
pressure

A B C D
Atmospheric
Fig. 1.14a: Pressure distribution in the
pressure Fig. 1.14b: Opening forces from
sealing gap when the combined hydrostatic
A B C D

Atmospheric
hydrostatic and hydrodynamic and hydrodynamic

pressure pressures are added pressure distribution
A B C D

When the shaft starts to rotate, the seal rings will separate and the pumped medium will
enter the sealing
Pump
gap. The pressure decreases linearly from pump pressure B, to atmospheric
pressure C.pressure
See fig. 1.13a.
Note: In this book, pump pressure means pressure in the seal chamber.
Pump
The linearly decreasing pressure is known as the hydrostatic pressure in the sealing gap. The
pressure

opening force is shown with red arrows in fig. 1.13b.

Pump
Atmosphere
pressure
When the pump runs, see fig. 1.14a, a pressure builds up in the lubricating film. This is similar to
A B C D
a car hydroplaning on a wet road. This pressure is known as the hydrodynamic pressure in the
Atmosphere
sealing gap.
A B C D
The hydrostatic pressure combined with the hydrodynamic pressure
12 produces the pressure
pressure [bar]

Pump
distribution in the sealing gap. The opening force is shown with
pressure
Atmosphere 10 red arrows in fig. 1.14b.
Water
A B C D 8
12
pressure [bar]

Pump
Full-fluid-film lubrication can be obtained if the pressure in Pumped medium pressure
pressure 6 the sealing gap is sufficiently high
10
Vapour
Absolute

Water
to balance the closing force of the seal. 48 pressure
12 Vapour
ressure [bar]

Pump 26 Pumped medium pressure

pressure 10 Normal atmospheric pressure
Vapour
Absolute

Atmosphere
04 Water pressure
8 80 90 100 110 120 130 140 150 160 170 180
Vapour
14 A B C D
2 Pumped medium pressure Temperature [˚C]
 Fc = Ah x P + Fs = 179 mm2 x 1 MPa + 45 N = 224 N

Closing force
Ah = π (Do2— Ds2) = π (222 — 17.12) = 150 mm2
The parts of the seal inside the pump are subjected to an axial force from the pressure in the
pumped medium. Together with 4the spring force,
4 the axial force creates the closing force on the
seal faces.

If the differential pressure between the pumped medium and the atmosphere is above
As = π (Do2— Di2) = π (222 — 172) = 153 mm2
approximately 20 bar, the closing force becomes so strong that it prevents the formation of an
adequate hydrodynamic lubricating 4 film. The seal4 faces begin to wear. Wear can be avoided
by reducing the area where the hydraulic pressure affects the axial force on the shaft seal. The
hydraulic force of the primary seal faces as well as the closing force of the seal are reduced.

Unbalanced and balancedFcmechanical

= Ah x P + Fs shaft
= 150seals
mm2 x 1 MPa + 45 N = 195 N
The balancing ratio, k, is the ratio between the hydraulically loaded area, Ah, and the sliding face
area, As.

As As As As

Ah 150
k= = = 0.98
As 153

Formula 1:

Hydraulically loaded area A

k= = h
Sliding face area As

Ah Ah Ah Ah

Fig. 1.15a: An unbalanced shaft seal, k>1 Fig. 1.15b: A balanced shaft seal, k<1

The pump pressure acting on the area, Ah causes a closing force to be exerted on the seal. The area, Ah,
of an unbalanced mechanical shaft seal is larger than the area, As, and the balancing ratio, k, is larger
than 1. The contact pressure in the sliding face area exceeds the pumped medium pressure.
The spring force further increases the contact pressure. The balancing ratio is often chosen to be
around 1.2.
In the low pressure range of the pumped medium, unbalanced mechanical shaft seals are sufficient.
See fig. 1.15a.
The area, Ah, of a balanced mechanical shaft seal is smaller than the area, As, and the balancing ratio,
k, is smaller than 1. The area, Ah, can be decreased by reducing the diameter of the shaft on the
atmospheric side. See fig. 1.15b.
In the high pressure range of the pumped medium or at high speed, the balanced mechanical shaft
seal is used. The contact pressure in the sliding face area can be smaller than the pumped medium
pressure. The balancing ratio is often chosen to be around 0.8.

Balancing a mechanical shaft seal gives a thicker lubricating film in the sealing gap.
A low k value can cause a higher leakage rate or can even cause the seal faces to open up.

15
 Introduction

A = π (Do2— Ds2) = π (222 — 162) = 179 mm2

Calculation example, unbalanced and balanced shaft seal
4 closing force of
In this example, we shall look ath the 4 a liquid-lubricated mechanical shaft seal.
The data below apply to an unbalanced Grundfos type A shaft seal. For more details on this
shaft seal type, see Chapter 2, type A, page 27.
π D 2— D 2 = ππ 222 — 162 = 179 mm2
(D o2— Dis2D))s== 16
Ahs == π4diameter,
A (222 — 172))= 153 mm2
Shaft 4( o 44(mm
Do Sliding seal face, inner diameter, Di = 17 mm
Di Sliding seal face, outside diameter, Do = 22 mm
Ah =Aπ (Do2— Ds2) = π (222 — 162) = 179 mm2
Spring 4h force,
179Fs = 45 N4
k = π = 2 = 1.17
As = Aπs (Do153 — Di22) = ππ (2222— 172)2 = 153 mm2 2
This 4π (Dothe
Ah = gives 2
Ds2) = 4π (22
— following — 162) = 179 mm2
results:
AAh == π 4π (DDo22— D 2) = 4π(22 2
2— 16 2) = 179 mm 2
( 2 — Dss2 ) = π ( 22 2 — 162 ) = 179 mm2
44( o
A = 4
Hydraulically
h D o loadeds )area: 4(
— D = 4 22 — 16 ) = 179 mm
Ds h
4
π π
A ==Aπ (D
A 2— D 2) = π (22 2— 17 )
— Dis ) = 4 (22 — 162)==153 179mm
2 2 2 2 2
D179 mm2
k sh= 44h = oo = 1.17 4
AAhs 179 153
kAs== π
Sliding
π (
face
=Darea:
2
— =D1.17 i2)
2
= πππ(22
2
— 1722) = 153 mm22
AAs ==A4 π π (( D
D
153
o 2
— D
o2 — Di2 ) = 4
2 )
2 = 4π (2222
2
2— 17 2) = 153 mm 2
o — D i ) = 4 (22 — 172))= 153 mm2
( — 17 = 153 mm
k s= 4h4 (= o = 1.17
s
A s= A 4 D179 2
i 4
A 153
As =Aπs (D Di2) = πto
4 ( formula 1,)page 15:
Balancing
2
—according 222 — 172 = 153 mm2
4h ratio,179
o
Fig. 1.16: Unbalanced k = AAhh = 179 =
179= 1.17 1.17
Grundfos type k = AA h = 179 153
Fkkc ==
= AAhss x==P +
A 153
153Fs ==1.17 1.17mm2 x 1 MPa + 45 N = 224 N
179
A shaft seal hs
A s 153
Ahs 179
k = closing
The A = 179 = 1.17
force, F , at a 10-bar pressure
k = Ahs = 153 = 1.17c
(P = 1AMPa) s
153 is calculated as follows:
Fkc == A A 179
AAhh =P 179 + Fs = = 179 mm 1 MPa + 45 N = 224 N
h x 2 x

kk== AA π h = 153 179= 1.17 1.17

hs = 179
= π (222 — 17.12) = 150 mm2
4ss ( 153 s )
kAh==aAA =D153 2
—= 1.17
D1.17
o153=Grundfos
2
For Abalanced 4 type H shaft seal for a Ø16 shaft, the
Di Ah 179
s
calculation
k = = is as
= follows:
1.17
Fc = Ah P + Fs 179 mm2 x 1 MPa + 45 N = 224 N
x
As 153
Do Sleeve diameter, Ds = 17.1 mm
Fc = Aπh xseal
Sliding P +2 Fface, = 179 mm
2inner π diameter,
2 x
21 MPa D+ 45 N mm
==17 = 224 2N
FAF ==A4h x(xPD
ch = A P +o+— FFss =D
= 179 )
s179
=mm
mm ( 222
2 xx1— 17.1+2)i45
MPa 45N
150
==mm
224 NN
FAcc==Aπhhx(seal π4 x2 11MPa
MPa +D N22224
s Di ) = (22 — 17 ) = 153
Sliding PD +2— Fface,
s= 1792 outside
mm 2 diameter,2 + 45 =
N mm
= 224
o mm
2 N
Ds s 4 force, F = 45 N4
o
Spring
Fc = Ah x P + Fs =s 179 mm2 x 1 MPa + 45 N = 224 N
Ah = π (Do2— Ds2) = π (222 — 17.12) = 150 mm2
4
Hydraulically loaded area:4
π 22222 — 17.1
FA = π x(PDo+o222—Fs =D is2)) mm
22
== ππ ((22 172)+22=)45
—MPa = 150
153Nmm= mm
2 2
AAchsh===A4π 150 x 21 195 N
4hπ (DDo 2— D 2) = 4 4π(22 2— 17.1 2) = 150 mm 2
2
Ahh= 4face
Sliding
π
4 ((Darea:
o2— D s2))= 4 ((222 — 17.12))= 150 mm2
— D s = π
4
22 — 17.1 = 150 mm
Fig. 1.17: Balanced Grundfos 4 o s
4
π D 2— D 2 = ππ 222 — 17.12 = 150 mm2
Ahs = 4 (Doo — Dis ) = 4((222 — 172) =) 153 mm2
π ( )
type H shaft seal A = 2 2
4 4
Balancing
Fc = Aπh x Pratio: + Fs = 150 mm 2 x
1 MPa + 45 N = 195 N
As = π (Do22— Di22) = π π ( 22 2
— 1722) = 153 mm22
AAs == πh (DD150
A4 π 2— Di 2) = π (22 2— 17 2) = 153 mm 2
4π 2
kAs=s= 44 (=(Doo2— 2i ) = 4 (222 — 172 ) = 153 mm2
—=DD0.98
A4s 153 i ) 44(
o
= 22 — 17 ) = 153 mm
Aπh x PD +2—
FAc ==closing Fforce,
= 150=,mm π 2 1 MPa
)+=45153Nmm =(P
195
=2 1NMPa)
2 x

4( o
s D 2) F
4(
The s i c
at a2210-bar
— 172pressure
is calculated as follows:
Fc = A Ahh xx P + Fs = 150 mm22 x 1 MPa + 45 N = 195 N
150
FkFc ===A Ahx=PP+ P +FFFss=
==0.98
150150mm mm22 xx111MPa
x
MPa+ 45
45N = 195
195N
++45 NN==195 NN
h x
Fcc= AA h
+
153 s
= 150 mm MPa
s

Fc = Ah x P + Fs = 150 mm2 x 1 MPa + 45 N = 195 N

AHydraulically
150 loaded area A
k= h = = 0.98 = h
As 153 Sliding face area As
Ah 150
k = AAh = 150 150= 0.98
16 kk== AAhsh == 150
153 = 0.98
k = As = 153 ==0.98 0.98
In the examples above, where the areas of the sliding faces and the spring force are equal, the
closing force is reduced from 224 N to 195 N by reducing the balancing ratio from k = 1.17 to k = 0.98.
A smaller closing force gives less wear on the sliding faces because improved lubrication is
obtained. The result is also a higher leakage rate.

Leakage
The lubricating film formed in the sealing gap during pump operation results in the escape of
some of the pumped medium to the atmospheric side. If the mechanical seal works well and
no liquid appears, the lubricating film has evaporated due to heat and pressure decrease in
the sealing gap. Therefore, no liquid seeps out of the seal.

Fig. 1.18: Seal with excessive leakage

Note that evaporation of water can take place at temperatures below 100 °C, unless the
surrounding atmosphere is saturated with vapour. Think of how you can dry your clothes
outside on a clothes line.

The leakage rate of a mechanical shaft seal depends of a number of factors such as:

• surface roughness of seal faces

• flatness of seal faces
• vibration and stability of pump
• speed of rotation
• shaft diameter
• temperature, viscosity and type of pumped medium
• pump pressure
• seal and pump assembly.

17
 Introduction

Calculation of leakage rate

The leakage rate of a liquid-lubricated mechanical shaft seal with parallel seal faces through
the sealing gap can be calculated by means of this approximate formula:

π x Rm x h3 x ∆p
Formula 2: Q=
6xηxb
Where
Q = leakage rate per unit of time
Rm = average(22radius
+ 17) of the sliding face
R = = 9.75 mm
h = gapmheight4between the sliding faces (thickness of the lubricating film)
Δp = differential pressure to be sealed
h = dynamic viscosity of the pumped medium
b = radial (22
extension
– 17) = of the sealing gap (sliding face width).
b= 2.5 mm
2
The leakage rate, Q, is then linear to the radius, Rm, sliding face width, b, and pressure difference, Δp.
The gap height, h, however, is extremely important. Note that twice the height causes eight
times as much leakage, with all other conditions remaining the same.

(22 – 17)decreases
b = leakage
It seems as if the = 2.5 mm when viscosity, h, increases. But when viscosity increases, the
2
lubricating film and thus the sealing gap increases, which may result in an increase in the leakage
rate. The increase in sealing gap height with an increase in viscosity is not linear. This makes it
difficult to predict whether or not an increase in viscosity results in a higher or lower leakage rate.
Q = π 9.75 10 m (0.2 10 m) 1 10 N/m = 1.63 x 10-11 m3/s = 0.06 ml/h
x x -3 x x -6 3x x 6 2

The roughness and flatness of the

6 x 0.001 N two
x s/m sliding
2 x 2.5 x faces
10 maffect the height of the sealing gap and
-3
π x RmThe
thus theQleakage. x h3 x ∆p
hydrodynamic pressure increases with the speed. This can cause an
=
increase of the gap6 x ηheight
xb
and thus the leakage rate.

A gap height between the sliding faces of 0.2 micron is typical for a mechanical shaft seal
running in water. Consequently, the seal faces have to be very smooth and flat.
Rm = (22 + 17) = 9.75 mm
4
π x Rm x h
The calculation example below applies to a Grundfos 3x
type ∆p
H seal running in water at 20 °C at a
Q=
pressure of 10 bar. A sealing gap of 0.2 mm is assumed.
6 η b
x x

(22 – 17) 2.5 mm

Δpb == 10 bar = 1=MPa = 1 x 106 N/m2
2x 3x
π
Do = 22 mm
x R h ∆p
Q= m
Di = 17 mm 6xηxb Rm = (22 + 17) = 9.75 mm
4
Viscosity = 1 cst = 0.001 N x s/m2
h = 0.0002 mm = 0.2 x 10-6 m
b = (22 – 17) = 2.5 mm
Thus, m = (22 2+ 17) = 9.75 mm and b = (22 – 17) = 2.5 mm
R
4 2
Using formula 2, the leakage rate, Q, is as follows:

Q = π 9.75 10 m (0.2 10 m) 1 10 N/m = 1.63 x 10-11 m3/s = 0.06 ml/h

x x -3 x x -6 3x x 6 2

b = (22 – 17)6 =x 0.001

2.5 mmN s/m 2.5 10 m
x 2x x -3
2
b = (22 – 17) = 2.5 mm
If the roughness of the seal faces is higher, resulting2 in a sealing gap of 0.3 micron, the leakage
rate is 0.2 ml/h.

b = (22 – 17) = 2.5 mm

Q = π 9.75 10 m (0.2 10 m) 1 10 N/m = 1.63 x 10-11 m3/s
x x -3 x x -6 3x x 6 2
18 2
6 x 0.001 N x s/m x 2.5 x 10 m
2 -3
 Atmospheric
pressure

A B C D

Non-parallel seal faces

System
In practice,
pressure the seal faces become distorted due to temperature and pressure gradients. The
most typical deformation is a tapered seal face.
Pump
Atmospheric pressure
pressure

A B C D

Atmospheric
pressure

A B C D

Pump
pressure

Pump
pressure
Atmospheric
pressure
Fig. 1.19: Converging sealing gap Fig. 1.20: Diverging sealing gap
A B C D

Atmospheric
For non-parallel seal faces, the hydrostatic pressure
pressure no longer decreases linearly from the
pump side to the atmospheric side. In this situation A formula
B 2 is no longer
C Dvalid for calculating

the leakage rate.

Converging
Pump
pressure
sealing gap
When the sealing gap opens towards the pumped medium, as shown in fig. 1.19, the hydrostatic
pressure increases. This is called a converging sealing gap. It appears as the blue curve in fig. 1.21.

Diverging sealing gap Pump

Atmospheric pressure
When the sealing gap opens towards the atmospheric side, as shown in fig. 1.20, the hydrostatic
pressure

pressureAdecreases.
B This is a called
C aDdiverging sealing gap. It appears as the orange curve in fig. 1.21.

The pressure distribution in the sealing gap is obtained by adding the hydrostatic pressure and
the hydrodynamic pressure. This is shownAtmosphere
in fig. 1.22. Note the similarity with fig. 1.14 a, page 14.
A B C D

12
Absolute pressure [bar]

Pump Pump
pressure pressure 10
Water
Parallel 8
Pumped medi
6

Converging
4

2
Atmosphere Atmosphere
Diverging0
A B C D A B C D 80 90 100 110 120

Fig. 1.21: Hydrostatic pressure distribution Fig. 1.22: Hydrostatic and hydrodynamic
for different sealing gap pressure distribution for different
12
ute pressure [bar]

Pump geometries sealing gap geometries

pressure 10
Water
8
Pumped medium pressure
6
Vapour 19
 Introduction

Pump medium pressure

Stationary Evaporation
seat The absence or inadequate formation of
lubricating film frequently causes damage to the
seal faces. Evaporation of the pumped medium in
A B C D
the sealing gap occurs where the pressure is below
the vapour pressure of the pumped medium.
Rotating
seal ring
The frictional heat in the seal faces increases
the temperature of the medium resulting in an
increase of the vapour pressure. This moves the
start of evaporation point to the pumped medium
Pressure
side. See fig. 1.23.
Liquid
pressure For seals in cold water, the lubricating film
extends through the entire sealing gap. For a well-
functioning seal, the only leakage escaping on the
Vapour
atmospheric side is vapour. The evaporation will
pressure occur even in cold water due to leakages through
the very narrow sealing gap, i.e. 0.0002 mm.

A partial lack of lubricating film often occurs in the

sliding seal faces towards the atmospheric side
Atmospheric when pumping water above 100 °C. This is due to
pressure evaporation of the lubricating film.
Distance
g o

e
p
in t

er
io
al in

ap of
ga

m o
at

ph
se ntry

at it t
ev tart
or

os
Ex
S
E

Fig. 1.23: Pressure distribution in a sealing

gap with hot water

Stationary seat

Deposits and wear tracks

When the lubricating film in the sealing gap
evaporates, dissolved solids are left deposited on
the seal faces. Rotating seal ring

Fig. 1.24a: Development of wear tracks

If the thickness of deposits exceeds the necessary
due to hard deposits
thickness of the lubricating film, the seal starts
to leak.
Stationary seat

In case of hard deposits, wear tracks can develop in

one of the seal rings, see fig. 1.24a. In case of soft and
sticky deposits, a build-up can cause the seal faces to
separate, see fig. 1.24b.
Rotating seal ring

Fig. 1.24b: Deposits build-up on seal faces

20
 Atmosphere

A B C D

12

Absolute pressure [bar]

Vapour pressure Pumpcurve
pressure 10
In order to secure a proper liquid lubrication in the Water
8
major part of the seal gap, it is recommended to Pumped medium pressure
6
Vapour
keep the temperature around the seal at 10 to 15 °C 4 pressure
from the vapour pressure curve. The curve for 2
Vapour
Normal atmospheric pressure
water canAtmosphere
be seen in fig. 1.25. 0
A B C D 80 90 100 110 120 130 140 150 160 170 180
Temperature [˚C]
Fig. 1.25: Vapour pressure curve for water

Frictional heat
A mechanical shaft seal generates frictional heat. If the lubrication is poor, the heat generated
can be as high as 100 watts/cm2. Compared to this, a cooking plate generates around
10 watts/cm2 at maximum power. To minimise the temperature increase in the sealing gap, it
is important to remove the heat. The amount of heat removed is determined by these factors:

· liquid flow in the seal chamber

· thermal conductivity of the machine parts
· convection to the atmosphere.

Sometimes the influence of these factors is not sufficient, causing the lubricating film in the
sealing gap to evaporate. This results in dry running of the seal.

The power loss, P, due to friction can be calculated by means of the following formula:

P = Fc x f x v
Where:
Fc = Closing force
f = Coefficient of friction
v = Sliding speed

The coefficient of friction (COF) depends on the lubrication and the pairing of the seal face
materials. For well-lubricated seal faces, the factor is between 0.03 and 0.08.

In case of poorly lubricated seal faces, the COF depends on the seal face materials. Thus if the
two seal faces are made of hard materials such as tungsten carbide, a COF up to 0.4 is possible
in hot water.

For a balanced Grundfos type H shaft seal for a Ø16 shaft at 2900 min-1 and 10 bar, assuming
f = 0.04, the situation is as follows. See page 16:

Fc = 195 N, f = 0.04, v = 3.0 m/s

P = Fc x f x v = 195 [N] x 0.04 x 3.0 [m/s] = 23.4 [W]

Turbulence loss in the seal chamber generates small amounts of heat when the sliding speed
is below 25-30 m/s.
Sometimes a narrow seal chamber requires additional precautions to remove the heat, for
example increased circulation of the pumped medium around the seal. See Chapter 2, page 31.

21
 Introduction

1952
Grundfos CP pump 1971
with unbalanced Grundfos CR pump 1991
O-ring seal with rubber 1982 Grundfos CH
bellows seal Grundfos CH 4 pump pump with
with unbalanced unbalanced
O-ring seal O-ring seal with 1992
spring as torque Grundfos CHI
transmission pump with rub-
element ber bellows seal

Fig. 1.26: Grundfos shaft seal development

4. Historical development
At the beginning of the nineteenth century, many endeavours were made to develop a
replacement for the conventional, braided packing used for piston pumps and rotating shafts.
A more reliable system for different kinds of liquid-conveying rotating machinery was desired.

By the 1930’s, the James Walker Group came up with a mechanical shaft seal for refrigeration
compressors. At the same time, the John Crane company invented the first automotive
mechanical shaft seal. In the early 1940’s, the company developed and introduced the patented
elastomer bellows axial shaft seal, today known as “Type 1”.

After this breakthrough in sealing technology, other types of mechanical shaft seals were
developed. With several types of mechanical shaft seals, the John Crane company adopted the
tagline, “The right seal for the right application”.

Today, John Crane is still a leading seal manufacturer along

with Grundfos, Burgmann, Flowserve, etc.

The first Grundfos mechanical shaft seal

The first Grundfos mechanical shaft seal was launched
in 1952. The seal was introduced in the CP, the
first vertical multistage pump in the world.
It consisted of an O-ring seal type
with tungsten carbide seal faces.

Fig. 1.27: Original illustration of CP pump shaft seal from the

“Grundfos pump magazine”, 1956

22
1993
Rubber bellows
seal introduced
in Grundfos 1998
CR pumps Unbalanced 2000
O-ring seal in car- Balanced O-ring seal
tridge design for in cartridge design for 2004
large CR pumps CR pumps Silicon carbide introduced as
common seal ring material in
CR pumps

The Grundfos unbalanced O-ring seal with tungsten carbide seal faces was used with success in
abrasive liquids. It soon led to the development of seals for other Grundfos pumps, including the
BP deep-well pumps, CR multi-stage pumps, UPT single-stage pumps, LM and LP inline pumps.

The tungsten carbide/tungsten carbide seal faces proved to be a very successful material
pairing for cold-water applications. This pairing did not turn out to be as successful in hot-
water applications on account of very noisy operation.

Tungsten carbide against carbon graphite

In the early 1990’s, Grundfos developed a rubber bellows seal with tungsten carbide against
carbon graphite seal faces. This soon became the common material choice. The rubber bellows
is ideally suited for seals with a carbon seat. This bellows seal was developed for CR pumps and
also introduced in LM/LP single-stage pumps, CHI, AP and UMT/UPT single-stage pumps.

Later on a generation of cartridge seals facilitating mounting and service was developed.

SiC against SiC becomes the common material pairing

Since 2004, silicon carbide against silicon carbide (SiC/SiC) became the common material
pairing for Grundfos cartridge shaft seals. This pairing has an excellent abrasive resistance and
good performance in hot water.

Summary
This section has described the design and composition of a mechanical shaft seal.
We have learned that a lubricating film is very important in order to obtain good
performance. Balancing the seal can increase the thickness of the lubricating film.
However, to prevent excessive leakage, the lubricating film must remain thin.

23