Seal optimization

Case studies

• Cost savings on operation and maintenance of the NRA pump

  Replacing the packing cord with a mechanical seal

  Applications: NRA pump, 22 kW, continuous operation, water hoses.

  Existing condition

  • Sealing with a sealing cord
  • Frequent maintenance
  • Media leakage and polluted surroundings
  • Risk of injury to workers

  Proposed solution

  • Sealing with a mechanical seal

  Result

  • Longer seal life
  • Save time and money
  • Drip-free clean operation
  • Increased operational safety
  • Lower water consumption

  After optimizing the sealing with a mechanical seal, the following savings were made:

  • The first 4 years after the exchange: savings of CZK 42,200 / year.
  • Next 4 years: savings CZK 44,740 / year.

   

  • 

    Pump condition before replacement

  • 

    The course of the exchange

  • 

    Pump after replacement

  The customer has been using packing cords to seal the pumps for a long time. He was mainly bothered by frequent maintenance and leakage of the medium, which polluted the immediate surroundings of the pump. This condition significantly increased the risk of injury. The high water consumption required to operate the pump with a soft stuffing box was also not to be missed. The customer now operates the pump with a service life of 4 years. The renovation is being solved by replacing a set of spare parts at a price of CZK 15,246.

   

  Existing condition	CZK 48,553 / year
  Sealing cord: 1 kg = 10 m (1.6 g / cm 3 ) = approx. CZK 4,000. Cord 12x12 mm. Housing diameter 60 mm = approx. 200 mm per ring. 6 rings in the chamber = approx. 1200 mm, ie 480 CZK	480 CZK
  Housing: The housing is changed 1 to 2 times a year.	1500 CZK
  Continuous maintenance: at least 30 min per pump. weekly with proper operation, ie annually 26 hours. Total wage costs (including levies) CZK 200 / hour, ie CZK 5,200 / year	CZK 5,200
  Media leakage: A stream of drops means a loss of medium of min. 30 m 3 / year. Water price approx. 40 CZK / m 3 .	CZK 1,200
  Bearings: The water content in the bearing lubrication system in the amount of 0.002% reduces the bearing life by 48% (source: Mobil oil). At least once a year replacement of two bearings at a price of 1200 CZK	CZK 2,400
  Energy: The cord brakes the motor and to overcome this friction it takes min. 4-8% of engine power. If we take min. 4%, motor 22 kW, ie loss  approx. 7708 kW / year. At a price of CZK 4.9 per kW, the annual loss is CZK 37,773	CZK 37,773

  A suggested solution	CZK 10,164 / year
  POWERseal CX10-60-TC / TC-V mechanical seal	CZK 25,410 / 4 years
  Set of spare parts	CZK 15,246 / 4 years

• Sealing of inspection openings

  Inspection manholes on the operating steam boiler in the production of acrylic acid

  Existing condition

  • A small number of bolts on the flange joint
  • Gasket with small springback
  • Large sealing area

  Proposed solution

  • Changing the seal type
  • Calculation of tightening torque
  • Change of bolt material
  • Delivery of material
  • Professional installation

  Result

  • Joint tightness guarantee - tightening protocol
  • Longer seal life
  • Continuous trafic
  • Save time and money

  • 

    Tightening the manhole

  • 

    Tightened manhole

  • 

    Applying POWERgraf COR tape due to uneven surface of the flanges

  • 

    Detail of surface irregularities

  The connection of the manhole caused long-term problems for the customer, especially when "starting" and shutting down the boiler. The connection was problematic mainly due to the use of a small number of bolts and thus the development of insufficient specific pressure on the seal in some phases of operation.

  The implementation itself was preceded by a complete analysis of the joint, which included the calculation and design of a seal with respect to the new joint material treated with the supplied metal-free DEPAC paste. The dimension of the designed POWERgraf HP Premium seal has been adjusted to be subjected to a higher specific pressure in all operating conditions. Thanks to this, it was possible to achieve a higher tightness class.

  During the on-site implementation, damage to the flanges by pitting corrosion was found. POWERgraf COR tape was used to better compensate for unevenness . After solving the initial problems, the tightening of the manholes to the calculated tightening torque took place by means of hydraulic machines and a tightening protocol was handed over. Subsequently, a pressure test was performed, which was successful.

  The solution guaranteed the tightness and reliability of this connection from downtime to downtime. In previous years, the customer was forced to shut down part of the operation due to leaks on this connection. Thanks to our reliable solution, the customer promised us cooperation on resealing other problematic joints.

• Heater seal optimization

  Heater seal optimization

  Existing condition

  • Graphite seal leak
  • Demanding seal installation
  • Uncontrolled tightening

  Proposed solution

  • Changing the seal type
  • Calculation of tightening torque
  • Delivery of material
  • Professional installation

  Result

  • Joint tightness guarantee - tightening protocol
  • Longer seal life
  • Continuous trafic
  • Save time and money

  • 

    Heat exchanger

  • 

    Front part of the heat exchanger

  The customer solved the problem of frequent leaks on the large diameter heater. Originally, a graphite seal made of segments was used, which showed a leak due to the large size of the heater and the operating pressure used. The installation of the segment seal itself was also challenging.

  Due to the large dimensions of the heater, a seal was designed for DynaGraph heat exchangers (2270 x 2241.4 x 3.2 mm) with a baffle. The seal has been designed with operating pressure and temperature cycling in mind.

  During the application, the customer appreciated the significantly easier installation of the seal in 1 piece in the shape corresponding to the heat exchanger.

  The result of the implementation was the overall satisfaction of the customer, both with the simplicity of installation of the seal and with its parameters, thanks to which it is replaced after a much longer time. The customer has achieved time and money savings and has been removing seals for several years.

• Elimination of thread jamming problem

  Elimination of thread jamming problem

  Existing condition

  • Seizure of stainless steel plugs
  • Complicated device revisions

  Proposed solution

  • Treatment of plugs with POWERtorque LFkote 450 dry lubricant

  Result

  • There is no seizing
  • Save time and money

  • 

    Drawing of the stopper

  • 

    Treated stopper

  The customer struggled with stuck stainless steel plugs, which are used to seal the individual heat exchanger tubes. Despite the use of various lubricants, they seized. This subsequently complicated regular inspections of the equipment, especially in terms of time and money.

  To solve the problem, the treatment of the used plugs with dry lubricant POWERtorque LF kote 450 was proposed . Both the threaded part of the plugs and their bearing surface were treated. The bonding material treated with POWERtorque LF kote 450 proved to be effective and was applied to the device.

  Thanks to the treatment of the connecting material, it does not seize. The customer thus gained significant time and money during regular inspections of the equipment. We supply the treated connecting material to the customer regularly, which testifies to its quality and efficiency.

• Burner generator seal

  Burner generator seal

  Existing condition

  • Bent flanges
  • Extrusion of material from the sealing surface
  • Flanges fit on top of each other

  Proposed solution

  • Changing the seal type
  • Treatment of fasteners
  • Delivery of material

  Result

  • Reliable functional seal
  • Easy to tighten and loosen
  • Continuous trafic
  • Save time and money

  • 

    Diagram of the burner generator

  • 

    Burner generator

  The flange sheets were significantly deformed due to frequent uncontrolled tightening, and when a graphite seal was used, the material was pushed out of the sealing surface and the flanges abutted. This resulted in an uncontrolled specific pressure on the seal.

  The POWERgasket non-parallel seal has proven successful for problematic flange joints of larger dimensions, where a die-cut graphite seal was previously used. Due to the poor condition of the flange joint, the use of the POWERgasket for non-parallel surfaces has been proposed, which can compensate for strongly rotated and deformed flange leaves and thus prevent them from abutting on each other.

  During our implementation, the seal designed by us was tightened with a connecting material treated with POWERtorque LF kote 450 , which ensures better torque transmission to the seal and more even tightening of the flanges. The treatment also serves as a prevention for easier loosening and re-tightening of the connecting material.

  Thanks to the sealing and treatment of the connecting material designed by us, we were able to provide the customer with a reliable sealing of the burner generator as well as possible loosening / tightening of the connecting material.

• Resolving a leak in an ammonia bottling plant

  Resolving a leak in an ammonia bottling plant

  Existing condition

  • Unsuitable sealing material
  • The need for continuous tightening

  Proposed solution

  • Change of seal material
  • Delivery of material

  Result

  • Reliable functional seal
  • The flanges do not need to be tightened continuously
  • Continuous trafic
  • Save time and money

  • 

    Ammonia tanks

  During the investment project for the customer's ammonia bottling plant, a sintered PTFE seal was used in the flange joints . However, this material has the property that under load, ie after tightening the flange joint, it gradually begins to lose its thickness, ie. drains. Therefore, leaks occur and must be tightened continuously.

  A seal made of restructured PTFE with inert fillers POWERflon 20 PINK was designed for the customer's flange joints . Inert fillers prevent material flow under load. The seal was applied and properly tightened according to our recommendations.

  The result is high tightness and safety of the joint without the need for continuous tightening of the flanges. We have been supplying seals for several years.