Seal Failure Research Articles

Simulation Analysis of the Annular Liquid Disturbance Induced by Gas Leakage from String Seals During Annular Pressure Relief

Due to the failure of string seals, gas can leak and result in the abnormal annulus pressure in gas wells, so it is necessary to relieve the pressure in gas wells. In the process of pressure relief, the leaked gas enters the annulus, causes a the great disturbance to the annulus flow field, and thus reduces the protection performance of the annular protection fluid in the string. In order to investigate the influence of gas leakage on the annular flow field, a VOF finite element model of the gas-liquid two-phase flow disturbed by gas leakage in a casing was established to simulate the transient flow field in the annular flow disturbed by gas leakage, and the influences of leakage pressure differences, leakage direction, and leakage time on annular flow field disturbance and wall shear force were analyzed. The analysis results showed that the larger leakage pressure difference corresponded to the faster diffusion rate of the leaked gas in the annulus, the faster the flushing rate of the leaked gas against the casing wall, and a larger shear force on the tubing wall was detrimental to the formation of the corrosion inhibitor film on the tubing wall and casing wall. Under the same conditions, the shear action on the outer wall of tubing in the leakage direction of 90° was stronger than that in the leakage directions of 135° and 45° and the diffusion range was also larger. With the increase in leakage time, leaked gas further moved upward in the annulus and the shear effect on the outer wall of tubing was gradually strengthened. The leaked acid gas flushed the outer wall of casing, thus increasing the peeling-off risk of the corrosion inhibitor film. The study results show that the disturbance law of gas leakage to annular protection fluid is clear, and it was suggested to reduce unnecessary pressure relief time in the annulus to ensure the safety and integrity of gas wells.

Dynamic Models of Mechanical Seals for Turbomachinery Application

One of the primary causes of mechanical face seal failure is rotor vibration. Traditional dynamic seal models often cannot fully explain failure mechanisms. The dynamic models of seals proposed in this paper, including those developed by the authors, are valuable for predicting seal dynamics during operation in specific turbomachinery and for explaining the causes of seal failure. The single-mass dynamic model is suitable for analyzing the dynamics of contact mechanical face seals and simply designed dry gas seals. The two-mass dynamic model is used to investigate the operational dynamics processes of classical dry gas seals under complex loading conditions. The three-mass dynamic model is used to study various complex types of mechanical face seals. This model can determine the normal operating condition range and explain leakage mechanisms in the presence of excessive rotor vibrations.

Influence of separation, collision and friction of rotating ring in sleeve on vibration characteristics of gas face seals

Purpose This study aims to understand how the assembly of rotating ring affects the axial forced vibration of gas face seals. Design/methodology/approach A three-mass kinematic model is established to investigate the axial movement of the rotating ring with bilateral constraints. The separation, collision and frictional sliding of the rotating ring in sleeve are discussed under rotor excitation. The effects of operating parameters and O-ring dynamic characteristics on the separation degree and film thickness disturbance are analyzed. A dimensionless axial characteristic force is defined to determine the critical conditions for the occurrence of separation. Several effective methods to eliminate the separation are proposed based on the adjustment of typical installation parameters. Findings Under rotor excitation, there may be two collisions between the rotating ring and the sleeve surfaces in one excitation period. This will cause self-excited vibration of the fluid film, increasing the risk of seal failure. The separation and collision can be prevented by increasing the equilibrium ratio, the installation radius of the O-ring on the outer surface of the rotating ring and the friction in the sleeve. Originality/value The results develop the modeling of multibody dynamics of gas face seals, enabling more accurate prediction of vibration characteristics.

A Hybrid Method for Identifying Critical Failure Modes in a Ball Mill

The reliability of a ball mill is crucial for the seamless operation of ore processing and other industrial plants, where unexpected equipment failure or downtime can result in significant financial losses and reduced production efficiency. Thus, this paper examined a hybrid method for identifying critical failure modes in a ball mill using the Failure Modes, Effects, and Criticality Analysis combined with the Complex Proportional Assessment with Grey Numbers (COPRAS-G). The COPRAS-G method was employed to assess the criticality of various failure modes by determining the weights of significant failure modes in the bearing, gearbox, motor, and shaft components of a ball mill. It was observed that gear seal failure is the most critical failure with percentage contribution (Ni) of 100%, while bearing wear is the least critical failure with percentage contribution (Ni) of 62%. The result suggests that failure modes of gear seal failure, gear pitting, motor bearing fatigue, and shaft fracture are regarded as the main contributors to failure with percentage contribution (Ni) of 100%, 97%, 87% and 83% respectively. Current ball mill maintenance includes corrective, preventive and predictive maintenance. For failure modes with high criticality, predictive maintenance was advised, while for moderate and low criticality, corrective and preventive maintenance were advised.

Multi-Physical Field, Coupled, Mixed Lubrication Analysis of Hydraulic Reciprocating Vacuum Lip Seal

Engineering practice has demonstrated that seal failure can result in severe leakage and wear, reducing the efficiency of hydraulic systems and even leading to major safety risks. Currently, analyses of the thermal aspect of seal interfaces are relatively limited, with most studies focusing on mechanical analysis. However, in actual applications, temperature has a significant impact on sealing performance. In this paper, nonlinear elastomechanics, viscous fluid mechanics, micro-contact mechanics, micro-deformation theory, and thermodynamics are coupled to establish a mixed lubrication model considering the thermal effect. The reliability of the mixed lubrication model is verified through experiments, and the temperature distribution of the oil film in the sealing area and the temperature distribution of the seal ring are simulated. Finally, the effects of the reciprocating speed, root mean square roughness, fluid medium pressure, and seal pre-compression on seal friction force and leakage are investigated. The results show that the heat generated in the sealing area accumulates at the bottom of the V-ring. Under the same conditions, compared with the instroke, the temperature-rise area of the outstroke is biased to the left and the increase in temperature is greater. In addition, the piston rod speed and the preliminary compression of the seal ring have a greater impact on the overall seal friction force and leakage. Under a lower seal pre-compression, the RMS roughness has a great influence on the leakage and friction in the outstroke, while the impact of the internal stroke is limited.

Analysis of Friction and Wear Properties of Friction Ring Materials for Friction Rings under Mixed Lubrication

Aiming at the problem of mechanical seal failure due to serious wear and tear in operation, the numerical model of the thermal–solid coupling wear of the seal ring is established by taking the friction sub-material as the research object, and the hardness, wear coefficient, and friction coefficient of different soft-ring materials are obtained by a test to verify the accuracy of the numerical model of wear. Additionally, the temperature field and deformation field of the seal ring of different materials are calculated, and the effects of the material parameters, such as elasticity modulus and thermal conductivity, on the temperature, relative deformation, and axial deformation trend are reported. The wear relation of the mechanical seal was optimized, and the correction coefficients of several materials were calculated. The results show the following: the main wear of the seal ring is due to adhesive wear leading to particle shedding and extrusion, adhesive wear causes material transfer, which alters the composition of the worn surface.in turn leading to cratering, which also causes the wear of the seal ring; the friction performance is better when the soft-ring material is graphite (C); the temperature, as well as the deformation, is smaller when the soft-ring material is silicon carbide (SIC); the correction coefficients for the life of SIC are calculated to be 0.23, for C, to be 0.14, and for stainless steel (Ss), to be 0.31, and the corrected equations can more accurately predict the corresponding material. The corrected equation can more accurately predict the service life of the corresponding material.

Improving Marvel Hero Classification through Dataset Curation

lores the development of a computer vision model for classifying Marvel superheroes such as Black Widow, Hulk, Iron Man, and Spider-Man. Utilizing a curated dataset sourced from Kaggle, the research emphasizes the critical role of dataset quality in refining model accuracy. Insights gained include adjustments to neural network configurations and leveraging Edge Impulse for enhanced performance. The findings highlight effective strategies for optimizing classification accuracy in complex image recognition tasks.PART 2:This part explores the application of Bayesian logistic regression to model the relationship between temperature and the probability of O-ring failure. By leveraging Bayesian inference techniques, analyzing historical data to quantify the risk associated with temperature variations and emphasize the importance of probabilistic approaches in safety-critical decision-making.The Space Shuttle Challenger disaster on January 28, 1986, remains a poignant case study in aerospace engineering failure. The investigation concluded that the failure of O-ring seals in cold temperatures led to the tragic loss of the shuttle and its crew.

Knowledge and Practice in Cochlear Re-Implantation in the UK: A Survey for Audiologists.

Cochlear implantation (CI) has proven to be a highly effective method for rehabilitating individuals with severe to profound hearing loss. However, challenges persist, particularly in cases where CI failure necessitates re-implantation. This study aims to address the gap in understanding the knowledge and practices of audiologists in the UK regarding cochlear re-implantation through a comprehensive questionnaire survey. A bespoke questionnaire was distributed to audiologists working with CI across the UK. The survey, which included multiple-choice items, open-text responses, and visual analogue scales, was made accessible via an online link shared through professional bodies, email groups, and social media platforms. The survey received 27 responses, predominantly from female audiologists (71.4%), with significant representation from London (28.6%) and the East of England (21.4%). A majority of respondents had over 16 years of CI experience (35.7%) and held a master's degree (60.7%). Key reasons for CI re-implantation included electrode failure (82.1%) and hermetic seal failure (60.7%). While respondents showed strong confidence in counselling (88.8%) and managing re-implanted devices (84.6%), there was a noted variation in opinions regarding the need for additional training in intraoperative measures. This survey highlights the current practices and training needs of UK audiologists in CI re-implantation. This underscores the importance of targeted training to fill knowledge gaps and improve clinical care during CI re-implantation, ultimately enhancing outcomes for both audiologists and CI recipients.

Butterfly valve erosion prediction based on LSTM network

When valves and pipelines are used, erosion wear is a major concern. Erosion wear can lead to equipment downtime, material replacement, and other issues, as well as seal surface failure. The research delves into the phenomenon of erosion in butterfly valves, crucial components utilized across diverse industrial sectors. Erosion primarily affects the valve's disc and seat regions, leading to premature wear and compromised performance. To address this issue, the research employs computational fluid dynamics (CFD) and machine learning techniques, including long short-term memory (LSTM) and BP neural networks, to predict erosion rates under various conditions (different valve openings and particle diameters). Results indicate that erosion escalates with time and larger valve openings, highlighting the need for proactive maintenance strategies. The LSTM model demonstrates superior predictive capabilities compared to the BP neural network, offering valuable insights for improving butterfly valve design and operational efficiency in industrial settings. Furthermore, to seek a more efficient network configuration, the intelligent search capabilities of the particle swarm optimization (PSO) algorithm have been utilized to systematically explore the optimal network structure parameters. The prediction results highlight the advantages of LSTM in handling time series data, particularly in predicting erosion rates with complex dynamic characteristics.

Research on Thread Seal Failure Mechanism of Casing Hanger in Shale Gas Wells and Prevention Measures

The strength and sealing failure of the connecting thread of the casing head mandrel hanger causes huge economic losses. One of the major challenges is the thread seal failure mechanism of the casing hanger in the wellhead during pressure testing in shale gas wells. In order to analyze the failure causes of connecting threads and put forward improvement measures, a typical case of a well accompanied by a hanger seal failure is analyzed in this paper, and a series of material tests are carried out. The microstructure and mechanical properties of casing materials and hanger materials could meet the field requirements. It is concluded that both the hanger material and casing material are characterized with significant ductile fracture. A three-dimensional model of the hanger and casing system is established, and the mechanical behavior is calculated for the connecting thread under different working conditions. The results showed that the connection degree of the hanger–casing is insufficient at the torque recommended by the manufacturer because of the difference in wall thickness between the box thread of the hanger and the box thread of the joint according to the connection degree of the coupling casing. It is seen that the high contact pressure ring of zone three on the sealing surface plays an effective sealing role under the manufacturer’s recommended torque (20,465 N·m). Finally, when the torque is increased by 25%, the maximum contact pressure between the pin thread of the casing and the box thread of the hanger can fully meet the internal pressure from the wellbore pressure test and the internal pressure strength required for subsequent operations.

Fuzzy Rule Based System of Optimal Pavement Maintenance and Rehabilitation Strategies for Yangon-Mandalay Expressway

Purpose: Systematic pavement management plays a vital role in the better Road Asset Management system. The lifespan of pavement can be preserved and prolonged by adequate maintenance measures in proper time. By early detection and repair of defects at initial stages with predictive maintenance reduces the rapid deterioration of the pavement. Moreover, inaccuracy in pavement deterioration prediction leads to an improper maintenance with wastage of time, cost and labor strength. To overcome all of these obstacles, this paper attempts an approach on optimal pavement maintenance strategy by means of fuzzy rule-based system. Materials and Methods: In this research, four pavement indicators of PCI, IRI, PSR and PSI have been taken into account as antecedents and five different types of pavement maintenance as consequents. In this research, ASTM D-6433, Road Lab Pro software, AASHTO guidelines and Fuzzy Logic (Mamdani) model have been used to evaluate the current pavement condition and optimal pavement maintenance strategies. Findings: According to research area, 130 total pavement sample units were undertaken to study for the mean pavement condition of PCI value 54.93 (poor), IRI 7.01 (fair), PSR 3.33 (fair) and PSI 3.35 (fair). Due to 13 years-old life span of traffic volume, temperature and other external factors, this expressway is suffering from potholes, bleeding, longitudinal and transverse cracking, weathering, joint reflection cracking for Asphalt Concrete (AC) overlay and linear cracking, joint seal failure, scaling, faulting, depression, lane/shoulder drop off for existing concrete pavement. According to the fuzzy logic model results, 42 numbers of fuzzy If-Then maintenance rules were verified as the most relevant pavement maintenance and rehabilitation strategies for Yangon-Mandalay Expressway. Implications to Theory, Practice and Policy: This research provide implications to the study and contributions to theory, practice and policy. This research paper insights into effective infrastructure maintenance and investment, emphasizing the role of advanced computational techniques in transportation economics. The key advantage of this research paper is to be effective, supportive, easy and accessible decision-making tool for transportation and pavement engineers, expressway planners and highways department authorities especially from developing countries.

Research on dynamic sealing performance of sealer structure under the influence of temperature

Affected by the extreme environment of high temperature and high pressure downhole, the mechanical behavior of the sealer rubber sleeve undergoes significant changes during service, leading to a sharp decline in the mechanical properties of the rubber material within the high-temperature environment. To address the issue of seal failure in the sealer rubber barrel under high-temperature loads, experimental investigations were conducted to analyze the compression properties of rubber materials at various temperatures. The constitutive parameters of the rubber were then fitted using the Reduce-Polynomial model. Subsequently, a finite element model was employed to study the sealing performance and mechanical response of the three-compartment rubber-tube structure sealer at different temperatures. The findings demonstrate that temperature fluctuations have a substantial impact on the sealing performance and bearing strength of the sealer. Consequently, this research holds crucial guiding significance for the structural design of the sealer rubber cylinder under high-temperature conditions.

Failure and Damage of Reciprocating Lip Seals for Pneumatic Cylinders in Dry Conditions

Lip seals are components subjected to high mechanical stress and they are responsible for many out-of-service in pneumatic cylinders. The aim of this work is the development of an experimental methodology to evaluate lifetime duration and analyse failures and damages of rod lip seals for pneumatic cylinders. A dedicated test bench was designed and manufactured which reproduces actual working conditions of the seals i.e., compressed air action (seal pressurisation) and relative linear reciprocating motion. Three types of seals made of two elastomers (NBR and polyurethane) were tested; dry condition was considered to speed up the tests. The influence of geometric parameters like seal seat dimension and seal axis misalignment with respect to the rod axis, was analysed by multiple experimental tests. Results in terms of seal life duration and failure modes are presented which allow comparison of seals performance and provide a helpful tool to end-users in a proper selection of seals geometry, material and key working parameters.

Failure of protection against particle invasion in hard/soft dynamic seal: Modeling and observation

Particles invasion into sealing interface is difficult to avoid in downhole conditions, which directly induces the failure of FKM O-ring dynamic seals. To enhance the performance of hard/soft dynamic seals in particles environment, the work on particles invasion has been initiated. A displacement model for particles invasion was developed and tested. In-situ observations were used to investigate particles invasion process under different particles sizes and assembly compression forces. Theory and tests showed matching results that particles sizes and compression forces had significant effects on particles invasion. In addition, a particles sizes control strategy based on the model was tested. This work has clarified the invasion behavior of particles and provided recommendations for the elastomer dynamic seals assembly in particles environment.

Potential secondary seals within overburden: Observation from the CO2 storage sites Aurora and Smeaheia, northern North Sea

This study evaluates potential secondary seals within the overburden in two CO2 storage sites, Aurora and Smeaheia within the Horda Platform area, of the northern North Sea. Secondary sealing intervals provide for safe and reliable CO2 storage as they prevent injected fluids from migrating into the atmosphere in the case of primary seal failure. This study analyzes the possible fate of the CO2 plume in the case of primary seal failure for the Aurora and Smeaheia CO2 storage sites by evaluating the secondary caprock and sealing potential of polygonal fault systems within the overburden intervals using structural reliability methods. Our findings suggest that a ductile secondary caprock is present in the overburden intervals of the storage sites, which could act as a secondary seal in the case of primary seal failure. The trapped hydrocarbon leaked from the Troll field within this ductile unit indicating a good secondary sealing potential. The study also reveals the presence of polygonal fault systems in the entire study area, but their frequency and orientation vary between layers. However, polygonal fault systems are not structurally stable, posing a risk of fault-parallel flow within the overburden interval. Nonetheless, the ductile clay-rich secondary caprock provides a seal for the polygonal fault systems within the interval. Due to either erosion or non-deposition, the ductile rock interval is not present in the east of the study area. As such, the critical risk for the Alpha structure in the Smeaheia injection site is the Vette fault and the efficiency of the primary Draupne caprock. Moreover, the crucial factor in the western Aurora site is the connectivity between the depleted Troll reservoirs and the CO2-injected pressurized reservoirs underneath. Based on our qualitative assessment, it is concluded that the overburden interval in the Horda Platform has adequate secondary sealing potential to hold and accumulate CO2 in the case of primary seal failure. Still, further numerical simulations are recommended to quantify our findings for both the Aurora and Smeaheia sites.

Effective microseismic monitoring of the Quest CCS site, Alberta, Canada

Microseismic monitoring represents a key surveillance technology to verify the integrity of subsurface CO2 storage sites. The precise location of microseismic events is first and foremost a direct and immediate indication of caprock and seal behavior but could also provide insight into CO2 plume migration. Tiny precursor movements provide diagnostic information about injection-related reservoir and caprock dynamics long before potential seal failure occurs. We present a case study from the Quest CCS facility in Canada, where a variety of different monitoring technologies are employed. We present the different microseismic sensor technologies and array configurations currently installed at the site and compare them against each other with respect to their reliability and effectiveness in providing the required verification information.

Experiment and Simulation on the Ferrofluid Boundary Deformation and Fluctuation Characters of a High-Speed Rotary Seal

Abstract A ferrofluid seal is a rotary seal widely used in the chemical industry, shipbuilding, aerospace, aviation, and other fields, demonstrating various advantages, such as high reliability, low wear, and low leakage rate. The reason for sealing is that the ferrofluid ring isolates the sealed gas from the atmosphere. Hence, boundary deformation and fluctuation are two significant factors to consider for the design of a ferrofluid seal. However, the ferrofluid boundary is wrapped in the shell and pole shoe, which poses a challenge in direct observation. In this paper, an experimental ferrofluid rotary seal device is presented, which can be used to monitor the boundary changes at different rotational speeds and pressure differences. According to the simulation result, the boundary fluctuation affects the pressure transfer and causes the sealing performance to deteriorate. The ferrofluid boundary obtained through the experiment is essential for an in-depth investigation into the rotary seal failure mechanism for improving the design of the ferrofluid rotary seal.

Episodic fluid venting from sedimentary basins fueled by pressurized mudstones

Subsurface sandstone reservoirs sealed by overlying, low-permeability layers provide capacity for long-term sequestration of anthropogenic waste. Leakage can occur if reservoir pressures rise sufficiently to fracture the seal. Such pressures can be generated within the reservoir by vigorous injection of waste or, over thousands of years, by natural processes. In either case, the precise role of intercalated mudstones in the long-term evolution of reservoir pressure remains unclear; these layers have variously been viewed as seals, as pressure sinks, or as pressure sources. Here, we use the geological record of episodic fluid venting in the Levant Basin to provide striking evidence for the pressure-source hypothesis. We use a Bayesian framework to combine recently published venting data, which record critical subsurface pressures since ∼2 Ma, with a stochastic model of pressure evolution to infer a pressure-recharge rate of ∼30 MPa/Myr. To explain this large rate, we quantify and compare a range of candidate mechanisms. We find that poroelastic pressure diffusion from mudstones provides the most plausible explanation for these observations, amplifying the ∼3 MPa/Myr recharge caused primarily by tectonic compression. Since pressurized mudstones are ubiquitous in sedimentary basins, pressure diffusion from mudstones is likely to promote seal failure globally.

Measurement and assembly methods for bolted flange joints using three-dimensional digital image correlation

Bolted flange joints are extensively used in pressure vessels and piping equipment. The assembly coaxiality accuracy and bolt pre-tightening force are particularly important in causing the risk of seal and leakage failure. This paper proposed a novel non-contact measurement and assembly adjustment method to reduce the coaxiality angle deviation efficiently. The flange joint is first bolted according to standard flange joint assembly guidelines and then adjusted using the proposed method. In the proposed method, the surface deformation and the coaxiality of the flange are evaluated using a 3D-DIC (three-dimensional digital image correlation) technique; RMS (root mean square) of the surface deformation is used to drive the correction of the bolts to further reduce the coaxiality angle deviation. Compared with existing bolting patterns, the established measurement and assembly adjustment method, which combines 3D-DIC measurement and adjustment based on RMS, can effectively reduce the coaxiality angle deviation. The experiments using a correction strategy demonstrated that the coaxiality angle deviation is reduced by 48.9 % and 60.1 % on average compared with the well-known star bolting pattern and modified star bolting pattern provided by ASME PCC-1, respectively, and even by 30.6 % and 51.9 % compared with their rotational pass patterns. Further experiments with an iterative strategy showed that the coaxiality angle deviation could be reduced by around 70 % and 75 %, tending to be stable around 0.01°–0.035°, after only 5 iterative adjustments.

The use of mineral trioxide aggregate for treatment of children with complications of dental trauma

Jf the study was to assess the efficacy of mineral trioxide aggregate for treatment of children with complicated permanent teeth trauma. The study comprised 29 children aged 6-13 years (mean age 8.6±1.7 years) with 36 injured constant teeth, from which 30 had immature roots, 27 (75%) teeth had necrotic pulp at baseline examination, 12 (33.3%) teeth showed radiological signs of external imflammatory root resorbtion, 2 teeth were diagnosed with of the root fracture (5.6%). MTA was used for pulp regeneration procedure in 25 (69.5%) teeth, external closure of resorbtion site in 3 (8.3%) teeth, root canal filling in 4 (11.1%) teeth, apical plug creation in 4 teeth (11.1%). The patients were folowed up for 1 to 9 years. From 36 teeth only one was extracted 9 years after regenerative endodontic procedure because of cervical root fracture. In 2 teeth with external imflammatory resorbtion progession of replacement resorption took place, in 1 tooth necrosis of regenerated pulp tissue occurred 2 years after the procedure because of restoration marginal seal failure. In 25 teeth favorable outcome was registered with stabilisation of external root resorbtion, continous root growth in 24 teeth and radioluscent lesions healing in 6 teeht showing them at baseline examination. Change of external imflammator root resorbtion to replacement resorption was detected in 1 teeth from 3 with external closure of resorbtion site. Root calan filling with MTA was performed in 3 avulsed teeth with replantation delayed for more than 1 day and in 1 tooth with root fracture. All teeth were clinically asymptomatic during more than 5 years follow-up. Favorable outcome was received in all cases of apicl plug formation. MTA is highly effective for preservation of constant teeth in children with clinically complicated situations. In many cases with hopeless long-term prognosis for a teeth MTA allows stabilization of dental tissue level with the teeth being an object for guided tissue regeneration.