As the most commonly used seals in almost every industry you can think of, from chemical processing, fluid power, and aerospace, to life sciences, pulp and paper, as well as energy oil and gas, O-rings are used vigorously every single day. Yet, more often than not, most users don’t even realize that one might be damaged until the O-ring actually starts to leak. One of the most common causes of leakage in O-rings is ozone cracking, or “ozonolysis,” which occurs mostly with O-rings made from nitrile rubber.
On the manufacturing floor, ozone cracking can be a mere source of aggravation, but when in the field, it can cause leaks that lead to serious incidents of death or injury. Fortunately, this phenomenon of crackage and leakage is highly preventable, just as long as you understand the causes of why it happens and how to take certain measures to combat it.
Why an O-Ring Fails
Within the service field, the failure of an O-ring can usually be attributed to a combination of causes. First and foremost, it is important to maximize sealing life and reliability by reducing the probability of seal failure at the onset by using good design practices, proper compound selection, pre-production testing, and continued education and training of assembly personnel.
As mentioned, Ozone cracking occurs mostly with O-rings made from nitrile rubber (or with material most recognized as nitrile, buna, or buna-N).
This material is called a polymer, which is Greek for “many units,” with each molecule consisting of individual units that are bonded together into a long chain. Sometimes, the links in a nitrite polymer chain can develop “weak spots” and become broken due to oxygen atoms contributed by the ozone. Hence, polymer chains can literally be cut, forming a tiny crack in the O-ring that continues getting bigger and bigger until the damage is large enough to be seen with the naked eye.
Preventing Ozone Cracking in O-Rings
Since oxygen is ever present in the air that we breathe and is necessary for life on Earth, its presence among O-rings is quite inevitable.
Oxygen atoms typically join up in pairs, forming dioxygen, which go on to make up the vast majority of oxygen in the atmosphere. When oxygen atoms join in groups of three, an ozone substance is created in the air we breathe, which can not only cause health problems, according to the EPA, but can also cause ozone cracking in nitrile O-rings even at the very tiniest of concentrations levels.
In general industrial applications, the primary drivers of ozone concentration are ultraviolet light, electrical arcing, and electromagnetic fields (which are the main reasons for higher ozone concentrations in the stratosphere), so in order to prevent further O-ring cracking or damage to occur, it is vital to:
• Keep O-rings away from ultraviolet light when storing, as the most common sources are direct sunlight, and fluorescent light bulbs.
• To not store O-rings within six feet of an electric motor (or other potential sources of electrical arcs).
• To not store O-rings in a stretched state because O-rings typically need to be stretched for ozone cracking to actually occur.
Further, when installing O-rings, remember to assemble nitrile O-rings wet with a grease to protect from ozone and to install them into the mating part within 24 hours of installing the O-ring on the fitting. If O-rings have no choice but to be stored in a stretched state, remember to store them in an airtight bag until ready to use.
In applications where long-term environmental exposure is inevitable, it is also recommended to make use of ozone-resistant material, such as HNBR, EPDM, or fluorocarbon.
For additional information and resources regarding the causes of O-rings cracking and how to combat it, contact Real Seal today.
Used as protective devices designed to isolate pressure gauges, pressure transmitters, and pressure switches from potentially damaging process media, diaphragm seals provide effective solutions to protecting pressure instruments when and if applied. They are typically used in refining, petrochemical, and chemical plants, dramatically extending the lifetime of various instruments by preventing contact between dangerous hot or corrosive media and the gauge itself.
Seals were especially designed to meet the safety demand requirements of the process industry to offer the utmost of protection against harsh temperatures, variable pressure ranges, pulsation, vibration, aggressive chemicals, and steam. The AWS design is strong enough to endure high vibration and thermal cycling applications, making it suitable for pump discharge applications.
Understanding How the Seal Actually Works
A diaphragm seal is usually connected to the measuring instrument using a direct connection or capillary. It is an elastomer or flexible metal diaphragm that keeps the process media from coming into contact with the workings of the gauge. The chamber between the diaphragm and the instrument contains system fill fluid, which transfers the pressure of the process media. When fluctuations in pressure of the process media occur, the change is transmitted across the flexible diaphragm through the system fill fluid, which is hydraulically transmitted to the measuring instrument.
Diaphragm seals are easily mounted onto gauges using threaded, flanged, in line, sanitary, or other types of connections, and in most cases, are made out of stainless steel. Others materials such as carbon steel and Hastelloy® C-276 can also be used for specific applications. There are also times that they are installed on pressure transmitters and switches that can be exposed to extreme conditions.
When to Use a Diaphragm Seal
Simply put, a diaphragm seal should be used whenever there is highly toxic or dangerous media present that could potentially harm an instrument. Most of the time, an all-welded process gauge and diaphragm seal system can provide protection to minimize the chance of any toxic media escaping. The usage of a diaphragm seal should also be considered under other conditions including:
• High-temperature media – Contains a cooling element that can protect the instrument, such as a diaphragm seal with an 8″ cooling tower that can tolerate temperatures of up to 750°F.
• Viscous or crystallizing media – Reduces the number of connections in a process by minimizing internal cavities where clogs usually form.
• Media with suspended solids – Minimizes clogging in process applications that include pharmaceutical, pulp and paper, food and beverage, chemical, and waste water.
• When overpressure protection is required – There are seals available with continuous-duty contoured diaphragm beds for robust overpressure protection.
• Corrosive media – Seals can be made using a variety of custom alloys, including PTFE, gold and silver, or carbon steel.
Recommended Remote Seals
These are the recommended remote seals for the refining, petrochemical, and chemical industries:
• Standard Flush Diaphragm Seal, Flanged
• Pancake Type Water Seal with Flush Diaphragm, Flanged
• Rotatable Flush Diaphragm Seal, Flanged
• Standard Version, Welded Diaphragm Seal, Threaded
• All Welded System (AWS), Threaded
Let Us Help
For more information on top quality diaphragm seals specifically designed to fit your wants and needs, contact REAL SEAL. Sometimes, a small investment in the right seals can definitely pay off over the long run by not only lengthening the lifetime of your pressure measurement instrumentation, but also leading to significant cost savings.
Processing equipment that come with pumps, compressors, and any type of rotating shaft also comes with mechanical seals. This is to reduce the emission of liquid outside the machine, preventing any visible leakage. With a mechanical seal, the environment is not only clean and hazard free but the integrity of the equipment is also protected so they last longer.
A mechanical seal is a very simple device and it comes with two flat faces that run against one another. While the rotating face is secured to the pump shaft, the stationary face is held properly in the gland. Since leaks are bound to happen in machines with pumps, the possible leakage path is sealed by a matted surface that is perpendicular to the shaft center. It is applied with a lubricating film for added protection against heat and friction. There are also other components to a mechanical seal that helps prevent leakage and these include an O-ring, metallic bellows, gaskets, and elastomers to name a few.
Mechanical seals rarely have problems and they do last longer than compression packing. But if they are failing too often, it is a good indicator that there is either a problem with the parts of the seal or in the process. Thus, monitoring and maintenance of the seal is a great way to solve problems and improve the efficiency of your machines.
The Importance of Maintenance
A failing mechanical seal often leads to wasting money. First, companies end up losing a lot of revenue because of the halt in the production and replacement of the damaged machines. Next, there is also a loss of revenue caused by the downtime of repairing the machine as well as replacing the seal. Moreover, leaking requires the pump to be changed because the internal surfaces may have been damaged due to the presence of moisture. This means that the pump needs to be rebuilt aside from the seal itself. There is a lot at stake when mechanical seals break down.
To prevent the seals from failing, it is extremely crucial for them to undergo proper maintenance on a regular basis. However, it is also crucial to take note that improper mechanical seal maintenance can also lead to failure of the seal. Mechanical seal maintenance often involves removing parts and improper re-installation of the parts can cause them to not be aligned properly thus leading to too much train during the shaft movement. Moreover, mishandling of the seal and using the wrong lubricant during the maintenance can also result to the seal failure. It is therefore important that proper maintenance should be observed so that further damage will not be inflicted upon the mechanical seals.
Proper Mechanical Seal Maintenance
Different mechanical seals require different maintenance steps and while it is best to leave the maintenance to professionals, it pays to know about proper maintenance tips so that you will be able to know if your mechanical seals need maintenance or not.
• Learn the different symptoms of seal failure: You need to know the different symptoms of a seal failure before you implement the maintenance. The tell-tale sign of a seal failure is the presence of some leakage. The leakage can occur as a small tight spray outside the seal or a continual drip to a full spray. Do not wait for the seal to produce a continual drip to undergo maintenance.
• Lock the mechanical seals: When performing a shaft axial displacement adjustment, make sure that the collar screws are locked to prevent the seal faces from getting damaged due to exposure to environmental factors.
• Keep the ports on the gland plant plugged: When the mechanical seal is installed on the shaft, make sure that the ports on the gland plate are plugged before you connect the ports to the external seal piping.
• Use a hydraulic cylinder: For faster detachment and attachment of parts, use a hydraulic cylinder so that you not only save on time in these processes but you also ensure that the parts are properly aligned and secure.
• Remove the shaft deflection: Eliminate shaft deflection as much as possible during maintenance as this can cause a lot of strain to the mechanical seals leading to eventual failure in the future. To remove shaft deflection, use a C or D frame adapter or a pump center line to lessen the strain problems.
• Reduce the vibrations: Too much vibration can also cause a lot of damage to mechanical seals. Make sure that you reduce them by balancing the rotating components.
• Keep the pressure of the stuffing box within the seal limits: The pressure of the stuffing box should be within the seal limits to avoid pressure build up that can damage the seals. To do this, you can do discharge or suction recirculation to balance the pressure within the stuffing box.
The integrity of your pump relies heavily on the health of your mechanical seals. Make sure that you conduct proper maintenance as this is a more cost-efficient option than replacing damaged ones.
For additional information and resources regarding the families of rubber and plastic sealants, machinery, and laboratory testing, contact Real Seal today.
Pumps are devices that move liquids or gasses by mechanical action. For the pump to work, it needs to be sealed completely tight to avoid leaks from occurring. In the past, pumps were sealed using rings, however rings were not effective in protecting the device from leaks. Today, most pumps are sealed by mechanical pump seals that are more competent in preventing leaks from happening.
Benefits of Seals
Leaking is the primary issue that is addressed by seals. The most obvious benefit of seals is that they allow pumps to function leak-free. So, if you are still using packing seals, then it is time that you switched to mechanical seals. Below are the benefits of mechanical pump seals.
• Having less fluid loss in a machine means better savings in terms of repair work due to pump failures. Moreover, they reduce the number of hazards that can put the lives of the pump operators in danger. Less leakage means fewer incidents of falling and slips due to the wet floor. It also reduces the potential of harmful emission, if the pump is housing toxic chemicals.
• Pumps do still have leaks, just not visible leaks. Experts approximate “healthy” and acceptable leaks to half of a teaspoon a day under normal operating procedures. Most machines will recapture the lost air and condense it.
• Seals can adjust to different faces of wear as they come with inboard springs. This reduces the necessary daily maintenance that needs to be done for the seal to work optimally.
Elements of A Seal
Seals allow the pumps to work by reducing downtime caused by leaks. They are commonly applied to contain any liquid or gas within a vessel where there are rotating shaft and a stationary housing. But how do seals protect the pump? Simple, they comprised of elements that would protect the machine against leaking. Below are the elements of mechanical seals.
• A set of primary sealing faces: A mechanical seal is made up of a set of lapped faces to minimize leaking. Different faces are made from different materials such as carbon-graphite and ceramic to prevent them from adhering to one another. Different materials are made so that they can perform different functions. For instance, one face of the housing is held stationary while the other one rotates along with the shaft.
• Static seals: Mechanical pump seals also come with a set of static seals like V-rings or O-rings to provide secondary protection against leaks.
• Spring: To create face contact, seals often come with a spring member which include either single or multiple springs.
• Other hardware: Seals are also made from other hardware which include gland rings, shaft sleeves, compression rings, pins, and collars.
Things to Consider When Looking for Seals
There are different mechanical pump seals out there on the market, but before you decide on which one to get, there are three important things that you need to remember when looking for mechanical seals.
• Seal faces need to stay together. If they open, leaks will occur thus allowing solids or contaminants to enter between the faces. Entry of contaminants will likely destroy the lapped surfaces not only of the seal but also the pump.
• The seal materials should be compatible with any fluids that are being pumped through the system. These include cleaners, solvent, and steam. Using fluids that are not compatible may destroy the seal by disintegrating its components and cause leaking in the pump.
• Mechanical seals have a good seal life. They expire once the carbon face is worn out which usually happens after a long time.
How Seals in Pumps Work?
Mechanical seals are watertight fittings that are located between the fixed part of a rotating device and a shaft thus they are commonly used in pumps. It is important to stress the water-tightness of the pump. This is achieved using a fine fluid or film that is located between two friction faces to prevent the remaining fluid from passing. The film also works as a lubricant thereby reducing the wear and tear between the two lapped faces. With a mechanical seal, the pump can work naturally without the fear of any leaks.
Seals provide damage-free and leak-free performance for almost any solution. Thus, understanding the science behind it will allow you to optimize the use of the seal based on its design.
For additional information and resources regarding the families of rubber and plastic sealants, machinery, and laboratory testing, contact Real Seal today.
Automotive seals, as the name implies, are used in vehicles. They are devices that are used to join systems together. It also prevents leakage, exclude contaminants, and contain pressure. There are different types of seals and they are used in induction sealing, heating, stuffing, and adhesion of parts. The efficacy of the seals is dependent on the adhesion of both the sealant and the gasket.
Functions of Automotive Seals
Unlike other seals used in different industries, automotive seals have excellent reliability, are long-lasting and extremely silent. They can survive heavy duty use and extreme vibrations attributed to a running engine. Without these seals, everything would fall apart. Seals allow the vehicle to function properly as well as to run. They are used in different applications not only in cars but also in motorcycles, ATVs, and off-road heavy machinery and equipment.
Seals are integral parts of the automotive industry. They are used in a variety of different applications. Seals may be small but they serve an even bigger and greater purpose in the integrity of the vehicle. Below are the functions of the seals in cars.
• They enclose the gas and liquid within the chamber. The gas tank contains seals that allow the vehicle to use up the fuel without wasting it. Hydraulic seals are also important for the movement of vehicle parts. Systems within the vehicle that uses hydraulic seals include suspensions and brakes.
• Stave off contaminants from crucial parts of the vehicle components. Seals keep away dust and other debris away from the engine and other important components of the vehicle.
• They keep liquids and gases separated from one another. There are many car parts that use liquids and gases to function properly. Examples include: the engine which keeps the coolant and engine oil, brakes for the brake fluid, and the reservoir to keep the power steering fluid to name a few.
• To protect bearings. Bearings are often filled with lubricants that protect the parts from corrosion, wear, and tear. The bearings need to be spotless, thus a contamination within it may cause the housing elements to experience premature failure. The seals protect the bearing by preventing dust and powder from entering the assembly.
Types of Automotive Seals
There are a lot of seals that the automotive industry use but there are two types of seals that are commonly used. These seals have also found their way into other industries. Below are the different types of automotive seals that also have mechanical applications.
O-rings seals
O-rings are made from elastomeric materials. They function by sealing two adjacent surfaces thus keeping the liquids contained from within a particular system. They are designed to take on extreme pressure and temperature as well as corrosive gases and liquids. They are designed to have a contact with the sealing face. It is very flexible. Thus, allowing it to accommodate any imperfections on the mounting surfaces.
It is considered as one of the most common type of seals used in machines as they are cheap and very easy to manufacture. They are also very reliable and have simple requirements, making the mounting process less complicated. Also called toric joint or packing, O-rings also have mechanical applications especially where relative motion between parts are involves. They are used to contain pressure and fluid. O-rings are used in vacuum applications to keep the pressure in check. They are also used to prevent leaks in pumps.
Lathe-cut seals
Lathe cut seals are used similarly with O-rings. They are made from a rubber tubing that has been inserted with a mandrel to cut the desired dimension. They provide more cost-performance benefits especially when static seal is needed. Unlike O-rings, lathe-cut seals provide wider surface for sealing thus making it more resistant against compression. They are also less expensive making them great for high volume gaskets.
Lip seals
This type of seal is used in rotating shafts. The lip provides a seal from a low-pressure chamber. It is installed in the pressure source and it balloons out to provide tight sealing. They are used in motors as well as reversible motors. They are also used in devices that need to maintain vacuum conditions to preclude dirt and contamination for entering.
Packing
Packing is a type of woven fiber that are packed between parts that needed to be sealed. This type of packing can be dynamic or static. It functions as a rotating shaft seal and gasket in different types of application. It is placed in a bore and compressed by a flange in automotive parts. It can also be used to seal a pump. In fact, industries like the paper manufacturing and milling use packing seals to prevent leaks.
Seals are created to prevent leaks. There are different types of leaks that are used in different industries but it is important to take note that even if they are designed to cater to the automotive industry, they have profound mechanical applications.
For more information on a variety of engineered rubber and plastic sealants, machinery devices, laboratory testing, and design engineering, contact Real Seal.
Our organization is geared to meet the more fragmenting aspects of industry today. Industrial manufacturers are being tasked with offering consumers more choice, a wider latitude of performance criterion, and greater economic restraints. As American industry continues to evolve to meet the demands of today’s consumers and the challenges of international competition, Real Seal continues to provide solutions and create value.
Mechanical seals are perhaps one of the most underrated and unappreciated parts of pumps or machines. They ensure that pumps, for instance, do not leak, causing damage to the rest of the machine.
In general, mechanical seals contain the fluid within machines, like pumps and mixers, where a rotating shaft passes through a stationary housing. It prevents visible leaks from leaking. The thing is that machines do leak about ½ teaspoon of liquid each day. But this is normal as the machine captures the moisture and is condensed within it. It also has lightly loaded faces that consume less power. Moreover, the machines suffer from less corrosion because the product or liquid is contained within the pump.
There are different types of seals that machines use and these include stationary seal, rotating seal, balanced seal, unbalanced seal, and mounted seal. The most common seal is the rotating seal and it is used as a component that holds rotating springs together.
The quality of seals is crucial. It is also important to apply the correct seal for the appropriate function. But even if you have chosen the right seal, there will be moments wherein your seals are failing fast. This is especially true if you are working in a plant containing different industries. You have to take note that the mechanical seal serves as the lifeline of the machine. Thus, letting you understand the health of your machine. When the seals are failing, it indicates that your machine might also be failing. There are so many reasons why seals fail and understanding these reasons is crucial to protecting the seal and making it last for a long time. Below are the common reasons why seals get broken.
Letting the Pump or Machine Run Dry
Letting the pump run dry can damage the mechanical seal. Because the seals should not run dry, they are usually designed to allow a thin film of liquid that migrates across the seal faces. If the seals run dry, the friction can cause heat to build up eventually cause damage and leaks. In most cases, the mechanical seal undergoes thermal shock and can disintegrate within 30 seconds after friction and heat have been introduced to it.
Too Much Vibration
Machines do vibrate over time and this is caused by many factors like improper alignment and pump imbalance. It can also be caused by operating the pump beyond its best efficiency point. This means that the machine is operating beyond its normal working point. Machines normally make vibrations as they contain different moving components that produce movements resulting in vibrations. Vibrations can hurt the machine thus resulting in damaged components including reduced seal life.
Hammering Couplings
Machines contain components such as pistons that take on a hammering action. While it is necessary to move the machine, hammering can be very destructive not only for the machine but also for the seals. In some machines, the hammering is so intense that it produces a lot of movement and vibrations. While hammering is inherent among machines that are driven by the piston, it can cause a lot of problems to the seal.
Human Error
Human error can also cause the seals to fail. An example of human error that can lead to damage of seals is skipping initial start-up procedures. If the machine does not start properly, this causes the motor to trip and the shaft to twist. In turn causing movement that results to internal parts coming into contact. It can also lead to failure of the seal and reduce the bearing life. On another note, improperly installing the seal can cause damage to components such as the O-rings. Failure to clean the surrounding of the seals can also lead to failure. Proper maintenance should be given to the seal. The thing is that seals are very sensitive and they can get damaged with even the presence of oil, dirt, and even fingerprints.
Using the Wrong Mechanical Seal
There are different types of mechanical seals out there and it is important that the appropriate seal should be used for a particular machine. Unfortunately, even seasoned engineers lack the necessary information on which type of mechanical seal they should use with their machines. Choosing an inappropriate mechanical seal leads to errors during the installation process. Remember that different machines or pumps handle different kinds of products. You cannot, for instance, choose a seal to handle an abrasive and caustic liquid and expect it to not leak eventually.
If you want to improve the lifespan of your machine, it is important to reduce the mechanical seal failure. You can do this by selecting the right seal and also engaging in good operating practices. While seals look small and disposable, they are very reliable and they can function effectively if they are used and cared for properly.
For more information on a variety of engineered rubber and plastic sealants, machinery devices, laboratory testing, and design engineering, contact Real Seal. Our organization is geared to meet the more fragmenting aspects of industry today. Industrial manufacturers are being tasked with offering consumers more choice, a wider latitude of performance criterion, and greater economic restraints. As American industry continues to evolve to meet the demands of today’s consumers and the challenges of international competition, Real Seal continues to provide solutions and create value.
Seals have a crucial impact on system performance. Life and reliability of what is often considered a simple component can make all the difference to your products and operations.
Here is a quick look at some of the different types of seals and the applications that rely on them.
Types of Industrial Engineering Seals
Heavy industries like metal, construction, wind energy, forestry, mining, and pulp and paper all rely on different types of seals that have to operate within a wide range of speeds, temperatures, and environmental conditions.
Some of the major types of seals that can be found in industrial engineering applications include:
Hydraulic seals—are use to seal the opening between various components in the hydraulic cylinder.
Pneumatic seals—operate in dynamic applications, often at high speeds, generally with rotary or reciprocating motions.
Piston seals—are used in hydraulic cylinders for fluid sealing. They are internal to the cylinder head and seal against the cylinder bore, preventing fluid from flowing across the cylinder head. This allows pressure to build up on one side of the piston, making the cylinder extend or retract.
LC profile seals—is used in applications where pressures fluctuate rapidly.
Fastener seals—are composite sealing washers, consisting of a metallic carrier and a vulcanised elastomer sealing lip. They provide a static function on flanges or threaded connections, and consistently assure ideal compression conditions between the housing components to prevent the destruction of the sealing lip.
Integral seals—eliminate the need for a machined groove in the mating sealing flanges. The seal is kept in place by mechanically and/or chemically bonding the elastomer to a frame edge that is separate from the flange.
Rotary shaft seals—are used in components with oscillating or rotating parts to keep lubrication fluids in, while preventing ingress of mud and water.
Types of Mechanical Seals
There are multiple designs available for the mechanical seal configuration including:
Conventional seals—are relatively simple mechanical seals that have to be properly set and aligned on the shaft or the sleeve of the pump.
Pusher seals—incorporate secondary seals that move axially along a shaft or sleeve to maintain contact at the seal faces, to accommodate wear and to assist in the absorption of shaft misalignment.
Non-pusher seals—also known as a bellows seal, has a secondary seal that is in a static state at all times, even when the pump is in operation. A secondary sealing member is not required to make up the travel as the rotary and stationary seal faces wear. Primary seal face wear is typically accommodated by welded metal or elastomeric bellows, which move to assist in the compression of the rotary to stationary seal faces.
Unbalanced seals—are used under drastic conditions where there are vibrations, misalignment of the shaft, and the problem of the cavitation of the fluid.
Balanced seals—have the ability to sustain higher pressures across the faces, and they generate less heat; therefore, they are suitable for handling liquids that have low lubricating capacity and hydrocarbons that have high vapor pressure.
Cartridge seals—have the mechanical seal pre-mounted on a sleeve (including the gland). They fit directly over the shaft or shaft sleeve, and are available in single, double, and tandem configurations.
Types of Automotive Seals
There is also a wide spectrum of advanced sealing solutions for cars, light vehicles, trucks, buses, motorcycles, and bikes, including:
Bearing seals—rolling resistance is a significant factor in the power losses of vehicles. Seals used in bearings can be a significant contributor due to the friction generated.
Body seals—gas springs are used to assist opening, closing, lifting, lowering, and damping movements.
Driveline seals—can deliver unparalleled performance over a wide range of operating conditions to reduce power losses and minimize fuel consumption and vehicle emissions. In addition, for automatic transmissions, the gear change performance affects the overall comfort of the vehicle.
Engine seals—a variety of outer diameter designs are available for optimal installation and retention of the seal, which provide optimized performance for automotive applications.
Steering seals—many power steering applications use high-pressure hydraulic systems where seals are critical components, playing an important role in preventing pressure loss.
Suspension seals—serve a duel purpose: contributing to the vehicles road holding and braking capacity, and keeping occupants comfortable and reasonably isolated from road noise, bumps, and vibrations.
Wheel end seals—are key to determining the life of the unit. If the seal allows external contaminants to enter the bearing or lubricant to escape from the bearing, then premature failure of the unit will result.
For more information on a variety of engineered rubber and plastic sealants, machinery devices, laboratory testing, and industrial engineering, contact Real Seal. Our organization is geared to meet the more fragmenting aspects of industry today. Industrial engineering manufacturers are being tasked with offering consumers more choice, a wider latitude of performance criterion, and greater economic restraints. As American industry continues to evolve to meet the demands of today’s consumers and the challenges of international competition, Real Seal continues to provide solutions and create value.
Taking care of the machinery utilized in various industries can be a time-consuming and occasionally hazardous task. To help alleviate these issues, many companies have opted for automated maintenance systems, be it in the form of automatic greasing systems or by ensuring they use the right type of seals to keep applications running efficiently without the need of much oversight or repeat maintenance.
But what are the pros and cons of automated machine maintenance versus manual machine maintenance. That’s what we’re going to answer today.
Health Factors
When it comes to health and safety, it’s hard to deny that automated systems can be incredibly beneficial. By removing the need for an individual to go in and clean or adjust different components, it reduces the risk of them potentially hurting themselves.
This point is particularly applicable when it comes to larger machinery that can have a wide range of potentially deadly parts that could cause serious harm if something was to go wrong. Imagine a crushingly heavy peripheral suddenly collapsing while an employee is performing maintenance. While such occurrences are rare, they’re still possible.
But when an automated or semi-automated system is used, it can ensure that employees are out of harm’s way should the unforeseen occur. In this event, the worst case scenario is the automated system being damaged or destroyed – a far smaller price to pay.
Efficiency
While some automated systems can be a little hit and miss, a large majority are very effective at their job. By having your machinery maintained by automated systems or products, it means less time is spent by individuals on keeping machinery in top condition. By extension, this means the machinery will experience less downtime and employees can better focus their time on other tasks, increasing overall operational efficiency.
By having the right seals on different applications and machinery, it means there will be less spills and potential malfunctions. Seals may not be an automated system, but they permit applications to run with greater autonomy without issues arising.
Longer Operational Life and Less Costs
With the right systems in place, machinery and applications will ultimately have longer operational lives. As a result, there will be less downtime and a decreased need to repair or replace machinery, thus resulting in less overall costs. As with anything, automated systems are an investment, but choosing the right ones will save you money in the long run.
When it comes to seals, it’s imperative to choose the right material. If your applications are dynamic (e.g. they move around), then you’ll need a dynamic-friendly sealing comprising the right materials. What material you opt for depends on, for example, factors such as the operating temperatures of the application and the types of chemicals the seals may come in contact with. By knowing these factors and having the seal designed to exact specifications, you’ll find they will last far longer than other seals.
To ensure you have the o-rings and seals for your machinery or application, contact Real Seal today.
When dealing with any manner of machinery or industrial applications, the important role o-rings play is undeniable. In our last article, we looked at when it can be time to buy a new seal and what factors can lead to premature deterioration. Continuing further with the aspect of preventing deterioration, we’re going to offer some quick tips on how to keep your o-rings, which typically play a big role in proper sealing, well-preserved for the longest operational life possible.
So let’s discuss what you can do.
Choose the Right O-Ring
Now, this may seem like an obvious and possibly patronizing statement, but it is actually a very important factor to take into consideration at all times. Depending on the machinery or application at hand, your o-ring material may differ.
We touched on this previously, but remember that factors such as moisture, temperature, how dynamic or static the application is, and others can all dictate the applicable materials. O-ring materials comprise several variations, including:
Silicone
Polyurethane
Viton / fluorocarbon
Ethylene-Propylene (EPDM)
Different materials work better for different applications, such as silicone seals often being a good choice for high-temperature applications. If an o-ring is being used on scuba gear, a material such as Buna-N (aka nitrile) could be a solid option. If an application expels hot water and/or steam, EPDM could be a good suit.
Cleaning and Maintenance
While all o-rings are respectively designed to last and endure when installed to the right application, typical cleaning and maintenance is always worthwhile. Of course, it’s possible that you may not be able to do this for certain o-rings – such as where removing them could lead to problems with the machinery or application they were installed on as they may need to operate constantly.
However, for those where you can stop the application and clean the o-ring, methods differ. Some may involve immersing the o-ring (dependent on its material) in an acidic solution that will eat away at hardened grit that has managed to calcify on its exterior. If the o-ring isn’t inflicted with calcium or hardened chemicals, then you may be able to simply remove slime or grime with a simpler cleaning solution or even water.
However, such efforts are on a case-by-case basis and entirely dependent on what the o-ring can or cannot withstand.
On the maintenance front, this involves regularly checking the o-rings for any signs of wear, tear, or general damage. So if you notice any cracks, warping, or thinning, consider your next step. Can the issue be resolved through some general repairs or would it be best to replace the affected o-ring(s) with a new one?
Regularly revising your o-rings will allow you to better maintain it and catch any damage before it could turn into a catastrophic problem.
To ensure you get the best o-rings for your applications, always hire a company that can provide custom made o-rings backed by decades of experience. Contact Real Seal today.
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When it comes to maintaining the life of an industrial seal, there’s only so much you can do until the seal simply reaches the end point of its operational life. Other times, using the wrong seal on a specific application means that the seal itself will deteriorate at a faster rate. Either way, there are certain signs you can look out for that may indicate it’s time to invest in a new seal.
Signs of Damage
Cracks
Signs of damage can differ between seals depending on their material and what they’re applied to, but many do share some similar signs of deterioration. One big sign is that of a crack forming in the seal. This may appear as a type of hairline fracture (one that may require you to even examine the seal at extremely close quarters) or a crack that is far more noticeable.
Often, cracks will appear along the height of the seal. This, of course, makes sense as the height is typically shorter than the seal’s length, and allows you to more easily spot where tension or age can have an initial impact. If you’re using the correct seal for your application (for example, you don’t need a seal capable of dealing with regular movement if your application is static), you hopefully should not see any signs of cracking for years. However, even if you use the right type of seal for its respective application, remember to keep in mind the material.
Say, for example, you have a seal that is perfect for dynamic applications – a rubber seal may perform better or worse than a thermoplastic one. It all depends on the nature of the application, the chemicals that may be involved, the temperature range of the application, etc. You can read more about the importance of choosing the right materials here.
Thinning
Another warning sign is if the seal is beginning to thin. When first having a seal installed, consider measuring its width. The width is usually relatively thin as it is (at least when compared to the height and length), but any thinning after installation is worth keeping track of. Friction could cause thinning, as well as damage caused by certain erosive chemicals. Chances are if your seals are becoming thinner and thinner at a rapid rate, you’re using the wrong material.
Melting/Deformation
If your seals become deformed or have shown clear signs of melting, you’ll undoubtedly need to change them. More importantly, it’s a sign that you’re using the wrong material. Different seals handle different temperature ranges (from subzero temperatures to those that can reach above 400 degrees Fahrenheit); so if your seal has deformed/melted, it means you likely need a new a more heat-resistant seal.
On the flipside, if your seal appears to crack or even outright shatter, it could also be a sign that the material of your elected seal is unable to handle extremely low temperatures. That’s why it is important to consider all facets of every application and which seal and material is appropriate.
To ensure you get the seal you need, talk to a professional seal manufacturer and provided such as Real Seal. We’ve been in the industry for decades, offering our wide range of clients custom-made seals perfect for any requested applications and operations. To find out how we can produce the right seal for you, contact us today.
Image: By U.S. Marine Corps photo by Lance Cpl. Sarah A. Beavers [Public domain], via Wikimedia Commons
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