Professional Certificate of Competency in Practical Mechanical Sealing

The course is composed of 12 modules, covering topics such as environmental considerations related to seals as per API 610 and 682, design, installation, and troubleshooting of seals, and how to maximize mechanical seal life. It will also demonstrate the classification of various seals, including special seal types, considerations related to the materials used in seal construction, and selection, operation, and maintenance strategies.

Module 1: Fundamentals and Principles

• Definition of zero leakage
• Mechanics of sealing
• Leakage
• Purpose of sealing
• Basics regarding speed and pressure
• Temperature considerations
• Basic seal requirements
• Seal friction
• Wear and seal life
• Texture

Module 2: General, Special Seal Types and Materials of Seal Construction

• Static and dynamic seals
• Special seal types
• Bushing, labyrinth and diaphragm seals
• Gas, motion, slurry seals
• Carbon seals
• Liquid ring and liquid barrier seals
• Inflatable, ferrofluidic seals
• Positive action type
• Self-adhesive compression seals
• Properties of elastomers
• Elastomeric materials
• Plastic polymers
• Cemented carbides
• Miscellaneous sealing materials

Module 3: Seals for Specific/Special Applications

• Hydraulic and pneumatic seals
• Seals for special applications
• Large diameter seals
• High-speed sealing applications and requirements
• Sources of excessive hydraulic pressure
• Overcoming problems associated with high-pressure
• Vacuum sealing applications

Module 4: Seal Selection, Application and Standards

• Seal selection guides
• Static and dynamic seal applications
• Standards-ISO, British, DIN, ASME

Module 5: Mechanical Seal Fundamentals, Seal Design and Classification

• Introduction and fundamentals
• Sealing mechanism
• Desirable features
• Identifying seal components and their function
• Primary sealing components – seal head, seal seat, springs for face loading, metal bellows
• Secondary sealing components-elastomeric O-rings, V-rings, U-cup rings, wedge rings
• Seal types and arrangements
• Sealing face conditions
• Seal pre-loading
• Seal balance and balance ratio
• Pressure distribution

Module 6: Mechanical Seal Materials, Environmental Considerations and Control

• Desirable properties
• General considerations
• Suitable mating combinations
• Abrasives, heat, dry operation
• Flushing, recirculation, quenching
• Convection, cooling, jacketing
• Buffer and barrier fluid
• Dead-end lubrication, grease packing, circulating face lubrication
• API 610 and 682 environmental control schemes

Module 7: Auxiliary Equipment

• Cyclone separators
• Pressurization units
• Air-coolers and heat exchangers
• Rotameters and flow controllers
• Leakage detectors
• Pressure-sensitive switches
• Filters and strainers

MODULE 8: Seal Storage, Handling and Installation

• Seal storage and handling
• Seal installation considerations
• Seat squareness

Module 9: Mechanical Seal Selection and Standards

• Selection considerations
• Process liquid characteristics
• Inboard vs. outboard mounting
• Rotating vs. stationary seal ring
• Face loading
• Primary seal ring design
• Secondary sealing devices
• Seal selection rules
• Mechanical seal standards

Module 10: Seal Failures

• Factors influencing seal life
• Factors affecting seal performance
• Categorization of failures
• Seal malfunction and probable causes
• Premature failure causes
• Seal face symptoms
• Friction and wear
• Adhesion, abrasion, corrosion and surface fatigue

Module 11: Troubleshooting Failed Seals

• At the pumping site
• At the equipment teardown
• Leakage types
• Discoloration, chipping, cracking, rubbing, elastomer swelling, stickiness, hardness – what do these mean?

Module 12: HOW TO MAXIMISE MECHANICAL SEAL LIFE

• Preparing the pump – mechanically, hydraulically
• Controlling temperature in the stuffing box
• Controlling pressure in the stuffing box
• What seal to choose?
• What face combination and elastomer?

To obtain a certificate of completion for EIT’s Professional Certificate of Competency course, students must achieve a 65% attendance rate at the live, online fortnightly webinars.  Detailed summaries or notes can be submitted in lieu of attendance.  In addition, students must obtain a mark of 60% in the set assignments which could take the form of written assignments and practical assignments. Students must also obtain a mark of 100% in quizzes.  If a student does not achieve the required score, they will be given an opportunity to resubmit the assignment to obtain the required score.

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You are expected to spend approximately 5-8 hours per week learning the course content. This includes attending fortnightly webinars that run for about 90 minutes to facilitate class discussion and allow you to ask questions. This professional development program is delivered online and has been designed to fit around full-time work. It will take three months to complete.