Whichever industry you are in, manufacturing poses potential hazards to both people and the quality of the goods you may be producing. Ensuring a long-lasting lifespan for this equipment guarantees a smooth-running operation with minimal error and maximum efficiency. The key to expanding this lifespan is thorough and attentive maintenance.

Rust

Corrosion due to rust is responsible for millions of dollars lost for different companies every year. Iron and steel are some of the most common materials used in industrial machinery, and when the structural integrity of this equipment is compromised by moisture and oxidation, it can drastically hinder its effectiveness.

When metal is exposed to moisture and oxygen, it forms an oxide that, over time, flakes away the surface of the metal. This eventually weakens the structure it’s on and, left untreated, will lead to failure. Aside from moisture, the presence of heat and salt also expedite the corrosion process. To avoid this harmful process, it is critical to keep your machinery as far away as possible from water and moisture to avoid oxidation.

Leaks

At first glance, leaking fluid can be a minor annoyance. Repeated monitoring can be easily dismissed and chalked up to routine wear and tear. However, over time these seemingly habitual maintenance needs can lead to much more significant problems down the road. You’ll first want to not only locate the site of the leak but identify the source. Next, the cause of the leak must be determined and recorded in the appropriate data bases for continued improvement.

It’s imperative that these leaks are completely repaired in a timely manner, to prevent further damage. Products such as O-rings offer easy-to-implement and cheap solutions, offering water-tight seals to leaks in certain machinery.

For more information on a variety of engineered rubber and plastic sealants, machinery devices, laboratory testing, and design engineering, contact Real Seal. Our organization is geared to meet the more fragmented aspects of industry today.

Industrial manufacturers are being tasked with offering consumers more choice, a wider latitude of performance criteria, and greater economic restraints. As American industry continues to evolve to meet the demands of today’s consumers and the challenges of international competition, Real Seal continues to provide solutions and create value.

Unless you’re dealing with water, the solutions that are being sealed within systems are either acidic or basic. Either one can wreak havoc on a seal made of the wrong material type. For acidic solutions, a weak seal can cause a dangerous situation that can damage property and harm employees, this is where acid-resistant o-rings come into play.

Knowing what types of seals are best for these operations is imperative to protecting your assets and your employees. Not only are acids dangerous when touched, the fumes can often be just as harmful to both people and materials. Avoid making the mistake of choosing a material that is weak to acid. Here is a list of materials that can be used in operations involving acidic solutions:

Fluorocarbon Rubber

Fluorocarbon Rubber, or FKM, is best for applications requiring both chemical and heat resistance up to 400 degrees Fahrenheit, in addition to the acid resistant quality. There are even FDA grades available for food and beverage applications. A lot of food products are acidic, such as sodas, juices, and other fruit products.

Specialty fluorocarbons allow for a large range of resistances to various forces and chemical properties. If your application includes extremely acidic solutions, then these may be your best option. Customization is often a key concern for applications in the current industry trends as each operation has such unique and specific needs for their operation to run at the highest possible efficiency. Specialty materials allow for the most flexibility and can be designed by experts to fit your application.

EPDM

Ethylene Propylene Diene Monomer, or EPDM, is resistant to weathering, ozone, water, and steam, as well as the acid resistance needed for these operations. Compounds cured with peroxide have excellent compression set resistance. So, if you are looking for a material that can retain its shape under high levels of pressure and is resistant to most acids, EPDM may be the way to go. Often it’s a combination of harsh factors that destroy a seal, so knowing if it is acid-resistant is merely the first step. High-pressure operations aren’t uncommon, and when you need a compound that resists acid and deformation, EPDM should be considered.

Materials to Avoid

A lot of materials are able to handle lower acidity fairly well. However, there are certain materials that are very bad at handling acids and will degrade quickly under this kind of stress. Knowing these materials is just as important as knowing ones that are good for acid-resistance.

Silicone is an extremely common material for o-rings and is not good at resisting acids. While you may want to use silicone because of its low cost and good set resistance, it is a poor choice if the solutions you are sealing are acidic. Urethane is another material that should be avoided in operations using acids. Certain rubbers have a mild resistance to acids in static applications, but high acidity is very corrosive to most rubbers.

Selecting the Right Seal for Your Operation

Acidity is merely one factor that should be considered when choosing the right seal for your operation. Other factors in combination with acid can make the process of finding the right seal complicated and potentially dangerous and expensive.

When you are choosing the o-rings for your systems, consulting with an expert in the industry, and buying seals from a reliable manufacturer are essential to your success. Real Seal has been in the industry for decades, creating and finding solutions for a massive range of applications. Contact Real Seal today to ensure your company’s success!

As a seal degrades and becomes defective, it becomes imperative that you inspect it to find out the reason for its failure. Sometimes, it’s reasonable for a seal to fail, as these are parts being exposed to extreme conditions and may suffer some kind of abnormal strain during an operational mechanical failure.

On the other hand, if a seal fails within its normal operating ranges and before expected, then you may have cause for concern. You may be using the wrong kind of seal or material and future failures can be avoided by replacing the seal with a better fit. Here are some signs to watch for:

Distorted Material

If the seal you are using feels or appears sticky, swollen, or is disintegrating you are probably using the wrong kind of material. The chemicals that the seal is interfacing with are degrading the material through a chemical reaction. Depending on whether you consulted an expert or chose the seal yourself, you may want to either consult an expert or switch to a more knowledgeable supplier. Knowing which material your seal should consist of is a major part in selecting the right seal for your operation.

Heat Related Issues

Heat can affect different materials in a wide range of ways; not just melting. The most obvious signs of heat being the cause of your defective seal are: charring, burning, or melting appearance. Hardening is another possible sign of excessive heat, the elastomer is essentially being baked. If the operation is outputting the expected amount of heat, then it is best to switch to a more heat tolerant material. Ensure that no additional friction is being generated, as this is a common source of excess heat. If all factors are accounted for, there are many materials with higher heat resistance than what you may be using.

Physical Damage

Pressure and friction are major factors when identifying defects in your seal. If a seal has become flattened, it’s very likely the pressure being exerted upon the seal is too great. Harder seals may crack when under too much pressure. In operations with extreme pressure, a material that is able to retain its shape while not cracking or fracturing is the ideal.

Decompression can cause an explosive outwards force, possibly tearing off the seal.

Friction will tear, rip, or shred the seal if it isn’t hard enough. Seal hardness can also damage machinery if it is too hard, causing damage to the surfaces they are sealing or putting additional strain on moving parts. The additional friction may also be caused by the coarseness of the fluid the seal is keeping in, which may cause physical damage to the seal.

Cutting and slicing can also occur when the mechanical parts the seal is touching are too sharp. A harder material may be required for these types of applications.

Manufacturing Defects

Perhaps the hardest to detect and most costly cause of seal failure and defects is improper manufacturing. Outsourced material and manufacturing can be less effective than more specialized companies. If the seals you are receiving have visible defects such as large seams, cracking, blistering, or other warping effects, then the seals are low quality.

Not all defects will be so obvious. If your operation is working within expected ranges and the material should hold up to these ranges, your manufacturer may be at fault. Seals are such an important aspect of any operation, ensuring safety and efficiency is paramount. When your seals break regularly, it can cause lost time, product, and money.

Using an expert in the field can ensure that you are using the correct seal for your operation. Real Seal is a veteran in the sealing industry with decades of experience. If your seals are defective, underperforming, or less economical than desired, contact Real Seal today for a consultation.