Fluid Sealing Excellence Backed by Expertise and Innovation
To meet these demands, TESCO Engineering has Established a State-Of-The-Art Facility, equipped with advanced tools and supported by a team of Globally Experienced, Highly Skilled Specialists.
These experts are Fully Capable of Addressing Any Critical Challenge across industrial equipment, including rotating machinery and turbomachinery, regardless of the original equipment manufacturer (OEM).
Below is an overview of our Fluid Sealing Capabilities.
Fluid Mechanical Seal Dismantling
Our Mechanical Seal Dismantling Section is dedicated to the Careful Dismantling and Analysis of faulty Fluid Mechanical Seals. This process begins with a Comprehensive Inspection to assess the seal’s overall condition, followed by the meticulous Dismantling of Seals to evaluate wear and damage.
A thorough failure analysis is conducted to identify the root cause of seal performance issues. Each seal is Tagged For Traceability, and Detailed Documentation, including inspection reports and recommendations, is provided to customers for review and approval. These recommendations outline potential corrective actions for Seal Reliability and Performance optimization.
Ultrasonic Decontamination
At TESCO Engineering, we exemplify our Commitment To Precision Manufacturing through the application of cutting-edge Computer Integrated Manufacturing (CIM) processes.
Our CIM Framework seamlessly integrates Design Engineering, Advanced 3D Modeling, Computer-Aided Manufacturing (CAM) programming, and High-Precision Machining, ensuring exceptional Accuracy, Repeatability, and Efficiency throughout the entire production lifecycle. This integration not only Accelerates Time-To-Market but also Guarantees that every product Adheres to Stringent Tolerance and operational excellence. With a robust infrastructure of advanced CNC Machining Centers and Equipment, TESCO Engineering excels in Precision Manufacturing with unparalleled accuracy. Our skilled machinists Leverage CAM-Generated Instructions to perform a variety of machining operations, including milling, turning, grinding, and more, ensuring meticulous precision.
Microscopic Inspection
The Fluid Sealing Facility employs Advanced Microscopic Inspection to assess sealing components. Using optical and Scanning Electron Microscopy (SEM) with magnifications up to 1000x, the facility detects microfractures, surface defects, and particle contamination that could compromise sealing integrity.
SEM analysis provides High-Resolution Imaging at the nanometer scale, ensuring that surface roughness and tolerances are within 0.1 to 0.5 micrometers. This precise inspection ensures that components can withstand High-Pressure and High-Temperature Conditions.
Lapping
Our Lapping units ensure High-Precision Surface Finishes for Mechanical Seal Faces, which are crucial for minimizing leakage and extending service life of Mechanical Seals.
Using Advanced and Precise Lapping Machines, the seal faces achieve Flatness within 1-2 µm and surface roughness as low as Ra 0.1 µm. This results in a mirror-like finish that reduces wear and friction, ensuring Optimal Seal Performance in high-pressure, high-temperature applications across various pumps and compressors.
Laser Texturing
TESCO Engineering’s Laser Texturing machine is Designed for Seal Face Textures with outer diameters up to 400mm. It supports single-directional textures (unidirectional rotation), bi-directional textures (bidirectional rotation), and curvy, wavy profiles, all with consistent or variable depths and narrow profiles.
The system integrates directly with CAD, ensuring Precise Control over texture parameters. Quality control is achieved with a Digital Micro Height Gauge offering Less than 1-micron accuracy to measure groove depth. Surface roughness is quantified using a Specialized Tester, ensuring tight tolerance compliance. This combination of advanced machinery and strict QA processes Ensures High Precision and Surface Integrity for every component.
Assembly
Our state-of-the-art assembly facility is equipped with Advanced Assembly Tooling and Equipment, designed to optimize precision and efficiency.
A meticulously controlled, isolated, and dust-free assembly environment safeguards components from particulate contamination, ensuring Optimal Seal Performance. Our highly skilled technicians, Leveraging Advanced Quality Assurance and Integrity Testing Methodologies, are dedicated to delivering superior solutions that meet the stringent demands of our valued clients.
API 682 Integrity Testing
The in-house Assembly Section at TESCO Engineering is equipped with State-Of-The-Art Assembly and Testing Tools.
Upon completion of the assembly process, the mechanical seals are transferred to the Fully Automated Integrity Testing Section. Here, our technicians Simulate The Operational Conditions of The Seals, subjecting them to maximum pressure and monitoring pressure stability in accordance with API 682 standards. The Integrity Testing system Generates a Detailed Report, which is subsequently cross verified by our technicians and quality control team to ensure Compliance with Operational Requirements.
Manufacturing & Refurbishment of Fluid Mechanical Seals (API 682)
Application
- Pumps
- Compressors
- Steam Turbines
- Agitators
- Mixer Seals
- Blowers
Types
- Type A – Pusher seals
- Type B – Bellow with O ring
- Type C – Bellow with GRAFOIL packing
- Engineered seal
Categories
- Category 1
Temp = –40°C to 260°C
Pressure = 20 bar - Category 2
Temp = –40°C to 400°C
Pressure = 40 bar - Category 3
Temp = –40°C to 400°C
Pressure = 40 bar with seal
qualification test certificate - Engineered Seal
Temp = –40°C to 400°C
Pressure = 170 bar
Configuration
- Single seal
- Dual tandem arrangement
- Dual back-to-back arrangement
- Dual face-to-face arrangement
- Dual pusher containment seal
- Dual pusher non-contacting seal
- Dual bellow non-contacting seal
Scope of Work
- Inspection
- Failure Analysis or Root Cause Analysis
- Application Engineering
- 3D Scanning
- Fitment checking
- Seal selection
- System selection / calculation
- Heat load calculation
- Orifice sizing calculation
- Detail Product Engineering
- GA drawing
- Bill of material
- Manufacturing
- Soft parts (carbon, silicon)
- Adaptive parts
- Heat treatment
- Laser texturing non-contacting seal
- Lapping & Assembly
- Integrity testing as per API 682 standard
- Qualification testing as per API 682 standard – only Category 3 & Engineered seals
- Packing with protective box
Seal Support Systems
Seal Systems
- API Plan 21
- API Plan 23
- API Plan 31
- API Plan 32
- API Plan 52
- API Plan 53A
- API Plan 53B
- API Plan 53C
- API Plan 65
- API Plan 72
- API Plan 74
- API Plan 75
- API Plan 76
Scope of Work
- System selection
- System sizing & calculation
- System fabrication
- Inspection
- Hydro-Testing
- NDT testing
- Packing with protective box
- Site service
- Seal system installation & commissioning
- Troubleshooting
- Performance analysis
References
- API 682 / ASME
- TESCO Engineering guidelines for mechanical seals / systems
Partner with the Industry Leader
Need innovative engineering solutions? Reach out to TESCO Engineering for state-of-the-art products and expert support in the petrochemical and specialized industries.
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