Reduced Leakage and Extended Pump Lifetime in the Chemical Industry
Our customer experienced recurring issues with both leakage and short seal lifetime in a process pump. By implementing the correct sealing solution from Fuglesangs, leakage was eliminated and operational reliability significantly improved.
Challenging Medium Caused Rapid Wear and Leakage
The pump handles a thick, sticky medium with high density and a temperature of around 40°C. This medium tended to adhere to the sealing faces, creating demanding operating conditions.
The original setup consisted of a double mechanical seal in a back-to-back configuration with a barrier fluid tank. However, the system lacked sufficient circulation, pressure control, and proper level monitoring.
As a result:
- The seal quickly started to leak
- The barrier fluid system lost functionality
- The process medium leaked into the atmosphere and into the bearing housing
This led to frequent maintenance interventions and an increased risk of serious operational issues.
Upgrade to a Modern Sealing Solution with Full System Control
To resolve the issue, the sealing solution was upgraded to a Chesterton 2810 combined with a PSSC seal support system (seal tank).
The new solution provides:
- Active circulation of the barrier fluid
- Stable and controlled seal pressure
- A design where springs are not exposed to the process medium
- Improved visibility with a clear level indicator and larger tank volume
This ensures that the medium does not build up on the sealing surfaces, while the seal operates under stable conditions.
Result: Stable Operation and Significantly Reduced Costs
Following the upgrade, the pump has operated without leakage, and the seal remains in service.
Previously, the seal lifetime was less than one year. The new solution has the potential to last several years without intervention.
For the customer, this results in:
- Reduced maintenance costs
- Eliminated leakage
- Increased operational reliability
- Lower risk of failure
With an estimated lifetime of five years, this corresponds to savings of approximately NOK 250,000 in maintenance costs alone.
Small Improvements Can Prevent Major Costs
During the work, poor bearing condition was also identified. A potential failure could have resulted in production losses of up to NOK 600,000 per day.
By upgrading the sealing solution, we not only eliminated leakage but also reduced the risk of major damage and unplanned downtime.
Looking for More Reliable Pump Operation?
Fuglesangs delivers and tailors sealing solutions for demanding applications in the process industry.
Contact us for a review of your facility and an assessment of how leakage, maintenance costs, and operational risk can be reduced.