Seal Failure Analysis

Seal failure is the malfunction of sealing components, resulting in leakage or contamination, which can lead to system inefficiencies and equipment damage. Signs of seal failure include degradation or wear, cracking, blistering, pitting, voids or gaps, and swelling or discoloration. In industrial settings, factors like excessive pressure, temperature fluctuations, chemical exposure, or wear over time contribute to seal failure, commonly seen in pumps, valves, and compressors. This compromises operational efficiency, increasing maintenance costs, downtime, and potential machinery damage. Independence Seal Company offers seal failure analysis services. These services are designed to help businesses optimize the lifespan of their sealing solutions and extend equipment life, minimize downtime, and enhance operational efficiency and reduce the risks associated with seal failure.

Common Causes of Seal Failure

Seal failure is a critical issue that can lead to equipment malfunction, downtime, and costly repairs. Understanding the common causes of seal failure can help prevent breakdowns and extend the life of your machinery. Below are some of the primary reasons for seal failure

Changed Operational Parameters: Variations in pressure, temperature, or speed can cause the sealing material to exceed its design limits, leading to deformation, loss of sealing efficiency, or mechanical failure. These changes may alter the stress distribution on the seal, accelerating wear and compromising its performance.
Fluid changes: Switching to a different type of hydraulic or lubricating fluid without considering compatibility can cause chemical reactions with the seal material. This can lead to softening, swelling, cracking, or other forms of degradation, undermining the seal’s ability to contain fluids effectively.
Fluid breakdown: Over time, hydraulic fluids and lubricants can oxidize, degrade, or get contaminated with particles, which reduces their protective properties. As the fluid loses its viscosity or becomes chemically reactive, it can increase friction, accelerate seal wear, and cause failure.
Inadequate maintenance: Failing to monitor or replace fluids, or neglecting to clean the system, can result in contamination that damages the seals. Particles, water, or other debris may enter the sealing interface, leading to erosion or blocking the seal’s ability to function properly.
Incorrect seal material: Using a seal material not suited to the operating conditions, whether in terms of temperature, pressure, or chemical exposure, can result in rapid deterioration. The seal may fail to maintain its shape, leading to leaks or allowing contaminants to penetrate the system.
Poor lubrication: Inadequate or incorrect lubrication increases friction at the sealing interface, causing excessive wear and heat generation. This can lead to seal failure by promoting erosion, hardening of materials, or deformation of the sealing components.
Overheating: When the temperature exceeds the design limits of the seal material, it can cause it to lose its elasticity or become brittle. This results in the seal losing its ability to maintain a proper seal, leading to leakage, cracking, or complete failure.
Contaminants: External dirt, dust, or particles that enter the sealing area can abrade or damage the seal material. This contamination may create gaps, deform the seal, or lead to localized wear, significantly reducing its sealing performance.
Aging: Seals naturally degrade over time as they are subjected to heat, pressure, chemicals, and physical stress. Aging causes seals to lose their flexibility, leading to hardening, cracking, or shrinking, compromising their ability to maintain an effective seal.
Installation issues: Improper installation, such as misalignment, over-tightening, or incorrect seal positioning, can create uneven pressure on the seal, leading to premature wear or deformation. This can result in leakage or mechanical failure due to improper seal seating.
Surface imperfections: Scratches, grooves, or corrosion on the shaft or housing surface can disrupt the integrity of the seal by creating high-stress areas. These imperfections can lead to seal damage, leakage, or reduced lifespan due to concentrated wear at the affected points.
Excessive vibration: High-frequency vibrations from machinery or external forces can cause the seal to shift or deform, leading to misalignment or rupture.
Improper pressure differential: Seals depend on a stable pressure differential to maintain their sealing function. Fluctuating, excessive, or insufficient pressure can cause the seal to collapse, leak, or become displaced, leading to a loss of sealing performance and potential system failure.

The Process of Seal Failure Analysis at Independence Seal Company

Seal failure analysis is vital in identifying the root causes of seal malfunctions and preventing future issues. It helps enhance equipment performance, extend the life of seals, and reduce operational downtime. At Independence Seal Company, we proceed in the following ways:

Initial Assessment: The process begins with a visual inspection to identify any apparent signs of seal damage or wear.
Gathering Operating Data: Key operating conditions, such as pressure, temperature, and environment, are reviewed to understand the context in which the seal failure occurred.
Material Evaluation: A detailed examination of the seal material is performed to check for degradation, chemical incompatibility, or manufacturing defects.
Failure Mode Analysis: Our experts identify common failure modes such as extrusion, abrasion, or chemical attack through physical examination and failure patterns.
Root Cause Identification: Using the data collected, experts determine whether the failure is due to design issues, improper installation, or operational errors.
Reporting and Recommendations: A final report outlining the failure cause and offering corrective actions to prevent recurrence.

Partner with Experts to Prevent Seal Failures

If you are dealing with frequent seal failures or want to extend the lifespan of your seals, it’s time to request a seal failure analysis. Our experienced engineers will carefully assess the root cause of the failure using their technical expertise. Once identified, we will collaborate with you to develop a customized solution that often enhances seal life and performance beyond the original specifications.

Contact Independence Seal Company today to schedule your seal failure analysis and ensure your seals perform reliably long-term.