Overcoming Industrial Seal Failures in U.S. Automotive Manufacturing

At Professional Pump, we understand the critical role reliable equipment plays in keeping your industrial processes running smoothly. Here, we delve into a real-world case study where we diagnosed a faulty valve for an auto manufacturer and saved them $17,000 per year in valve maintenance costs. Learn how Professional Pump can help keep your operations running smoothly and efficiently by contacting a fluid handling expert today.

The Challenge:

Our client, a leading automotive manufacturer in the Midwestern U.S., was experiencing short seal life even after replacing the pump’s seals multiple times. One complication was the complex chemistry required in the pretreatment of equipment to prepare the product’s surface for painting, plating, or other industrial finishing. This was particularly challenging in the phosphate stage where parts are treated for corrosion protection, the process fluid builds up on surfaces which limits the axial flexibility of the seal and creates a gap between the seal faces.

These repeated valve failures resulted in costly downtime and production delays. They approached Professional Pump seeking a long-term solution to optimize their operations.

Our Approach:

Our team of experienced fluid sealing specialists assessed the client's application and by monitoring the flow rate, Professional Pump was able to identify the cause of the inboard seal failure. Phosphate sludge was building up on the seal causing the rotating seal face to freeze, or “hang up” which prevented the internal spring from exerting pressure on the seal and moving axially. This prevented flush water from passing through the seal and into the process solution which caused process water in the stage to rise, threatening a disastrous solution overflow.

The Solution:

The fluid process experts at Professional Pump recommended the client upgrade the seal with John Crane’s Type 5620USP fitted with the Upstream Pumping seal face technology. This applies a gas seal spiral groove technology to wet seals which directs barrier fluid towards the outside diameter (OD) and fills the void created by the polytetrafluoroethylene (PTFE) excluder.

For an added layer of protection, a PTFE excluder was added to encase and protect the process side of the seal to prevent deposits from accumulating.

The combination of the John Crane USP technology and the PTFE excluder prevented the fluids from binding on the seal and locking up the seal faces, keeping process fluid separate from the seal faces completely. This allowed for an unpressurized barrier system, eliminating the loss of barrier fluid pressure.

The Results:

The implementation of the new John Crane USP seals have lasted more than a year without issue, whereas the previous seals only lasted 3 to 4 months. The new seal has an excluder that acts as a check valve, regulating the flow of barrier fluids into the process. This controlled flow helps prevent phosphate buildup, ensuring optimal seal performance. The client also saved $4,500 to $7,500 in maintenance costs per pump per year (x2 pumps) with a total of $15,000 in savings per year. They also saved an additional $2,000 per year in maintenance hours troubleshooting failed valves, for a total cost savings of $17,000 per year.

• Reduced Downtime: Fewer seal failures resulted in minimized downtime and improved production efficiency.
• Enhanced Operational Costs: Lower maintenance costs due to extended seal life led to significant overall savings.
• Improved Productivity: Reliable equipment operation ensured uninterrupted production flow, boosting overall productivity.
• Increased Process Efficiency: The new seals minimized leakage and product contamination, leading to a more efficient process.

Professional Pump: Your Partner in Fluid Sealing Solutions

This case study demonstrates the value of partnering with a professional fluid sealing solutions provider like Professional Pump. Our expertise and access to a wide range of high-performance seals ensure we can identify the optimal solution for your specific application needs.

Contact Us Today!

If you're experiencing seal failures or looking to optimize your fluid handling processes, don't hesitate to contact Professional Pump. Our team of experts in Michigan and Ohio can assess your needs and recommend the best solution to keep your operations running smoothly and efficiently.