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SOLUTIONS
Does Packing Use More Energy Than Seals?
The Myth
Over the years, fast talking mechanical seal promoters have perpetrated a myth regarding packing versus mechanical seals.
As they begin their presentation the twinkle in their eye prompts many in the audience to reach for their wallets to make sure
their safely tucked away. The speaker describes the function of the braking system of an automobile and how the brake shoes or
pads rub against a metallic surface causing the vehicle to slow down. Then they ask the question “Isn’t this what mechanical
packing does to the shaft in a pump?”. The audience sits in stunned silence as the voodoo permeates the ether freezing their
brain cells and prompting smiles as the metaphor sinks in. Then the speaker lines up for the kill shot with a pause, and finally
the phase “So when you use packing in pumps, it’s like your driving your car with your foot on the brake!” Everyone laughs,
nods in agreement and vows to replace mechanical packing with mechanical seals once they get back to the plant.
Specialists in the audience make a mental note to use this metaphor during their next plant visit to make the argument for
mechanical seals more persuasive. The argument can be effective unless the customer has recently changed the brake pads on
their vehicle, because brake pads are not lubricated, but mechanical packing is! Lubrication reduces friction which reduces the
energy consumed by mechanical packing.
The Reality
Brake Pad Energy Consumption
We calculate the distance an 18 inch tire traveling 30 mph will travel in one minute as follows:
30 mile/hour x 5280 ft/mile x 1 hour/60 minute = Distance traveled in one minute = ~2640 feet
The tire travels (18 inches x Pi)x(1 foot/12 inches) = 4.71 feet per revolution
If a brake pad is located 6 inches from the shaft centerline, then surface speed (∫ (x) dx) is calculated as:
Calculated Energy Consumed = μB ∫ FB (x) dx = .45 x 8 inch2 x 300 lbs/inch2 x 880 feet/minute
Calculated Energy Consumed = 950400 ft-lb/minute – Since 1 ft-lb/minute = .000026 Kilowatts
Calculated Energy Consumed = 24,000 Watts per brake pad at 30 mph for one minute
Is not equal to
Some explanation for these results can be found in how the tests were conducted. 1730 mechanical packing is constructed
with a modern braid style and modern lubricants. It was installed by experts sealing a shaft which is pressurized, but does not
drive an impeller (no shaft deflection). Power consumption shown above was measured as the power was applied to the motor
on the test rig, it does not represent actual shaft power consumption.
Real world testing was conducted in a water pumping station using a 125 HP motor running at 880 RPM using a Chesterton
442 RSC/RSC FKM seal versus Chesterton 329 1.250 inch cross section packing (3 Rings) with a SpiralTrac P bushing. The
customer used 3 rings instead of 5 commonly used because they used a SpiralTrac P from Enviroseal. The customer measured
the flow generated versus energy consumed (comparing amperage used) when pumping large volumes of water at different
frequencies (speeds) . The results are shown below. The mechanical packing used about 6% more energy than the seal.
200 200
150 150
I (amps)
I (amps)
100 100
50 50
0 0
4 5 6 7 8 9 10 11 20 30 40 50 60
Q (m gd) Shaft Speed (Hz)
The financial benefit of split seals over mechanical packing can easily be quantified in avoiding equipment wear
and downtime, product leakage, and the labor costs of re-packing and adjustment over the life of the equipment.
These cost savings will often result in a 6 to 8 month payback for split seals versus mechanical packing.