Mechanical seal failures are a common but often preventable challenge in industries reliant on pumps and rotating equipment. Misdiagnosed as "dry-run" or blamed on operational mishaps, these failures often mask deeper system issues, imbalances and process upsets. Reliabix Analytics specializes in uncovering the hidden causes behind these failures by leveraging data you already have but may not be utilizing effectively.
Beyond the Obvious: Hidden Causes of Seal Failures
At Reliabix Analytics, we’ve learned that traditional monitoring techniques often fail to catch subtle issues that lead to mechanical seal failures. For example, a pump experiencing consistent seal issues may not be dry-running due to lack of product but could instead be operating under conditions of system imbalance or low-flow scenarios.
In multipump systems, for instance, pumps may “fight” each other, leading to erratic flow rates and uneven loads. These imbalances stress the seals and bearings, resulting in premature failures. Left unchecked, such issues can cascade into costly unplanned downtime and excessive maintenance budgets.
Case Studies: Success Stories in Preventing Mechanical Seal Failures
1. Mining Operations: Resolving Multipump Imbalance
A mining company faced frequent seal failures in their three-pump system, incurring annual maintenance costs of over $350,000. Analysis by Reliabix identified system imbalance as the root cause. The pumps were competing for flow due to poorly calibrated controls, leading to uneven loading.
Solution:
Improved flow control algorithms.
Adjusted operational parameters to synchronize pump performance.
Result:
Over eight years with no seal failures.
Transitioned to scheduled repairs, reducing maintenance costs by over 90%
2. Petrochemical Plant: Daily Risk Mitigation
A petrochemical facility suffered 1-2 seal failures per year, each costing $50,000 per hour in lost production. While traditional condition monitoring methods identified no abnormalities, our deep-dive analysis revealed unexpected low-flow conditions as the primary risk factor.
Solution:
Identified the source of the low flow conditions.
Realigned operational settings to prevent low-flow-induced failures.
Result:
Over five years and counting of uninterrupted operation without any seal failures
The Power of Data: Turning Signals into Insights
At the heart of our success is the ability to transform underutilized data into actionable insights. By analyzing electrical signals and converting into flow rates, pressure compared to the calculated flow, and vibration trends, we provide a holistic view of your pump system. Our approach doesn’t just react to failures—it predicts them.
Key Insights We Provide:
Identifying seal overheating before it causes failure.
Detecting process upsets in multipump systems.
Proactive alerts for low-flow or high-flow scenarios prior to increases in vibration.
Why Reliabix Analytics?
Traditional monitoring systems often rely on static thresholds and isolated metrics. Reliabix Analytics takes it further by analyzing the nonlinear relationships between operational variables. We provide:
Tailored Solutions: Insights specific to your pump designs and operational contexts.
Actionable Recommendations: From vibration monitoring to flow optimization, our reports drive results.
Immediate ROI: Our systems pay for themselves by significantly reducing maintenance costs and operational downtime.
Ready to Prevent Failures Before They Happen?
Mechanical seal failures don’t have to be a recurring problem. By unlocking the potential of your existing data, you can ensure reliability, extend the lifespan of your equipment, and achieve measurable cost savings.
Don’t let hidden issues remain hidden. Let Reliabix Analytics help you reveal them and take control of your operations.
Contact us today to learn how we can help your plant achieve reliability like never before.
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