Dry Running Mechanical Seal Successfully Replaced Gland Packing in a Biogas Digester Application
How Ashish Seals eliminated repeated seal failures with a precision-engineered seal — delivering uninterrupted, zero-breakdown performance.
A pharmaceutical processing facility operating a test-scale biogas digester tank was facing continuous leakage issues from a vertically mounted agitator shaft. The existing sealing arrangement used conventional gland packing, which repeatedly failed under operating conditions.
The leakage was causing frequent maintenance intervention, product loss, operational inefficiencies, and increased downtime.
The client was experiencing persistent leakage from the agitator shaft assembly.
Key Issues Faced
- - Gland packing burning out within 2–3 days
- - Continuous leakage from the shaft area
- - Frequent maintenance shutdowns
- - Reduced operational reliability
- - Increased maintenance costs
The problem had persisted for approximately two months and was occurring every 2–3 days, making the existing sealing arrangement unsuitable for the application.
| Parameter | Details |
|---|---|
| Application | Vertically Mounted Agitator Shaft |
| Process | Test Scale Biogas Digester Tank |
| Gas Composition | CH4 – 60%, CO2 – 38%, H2S – Approx. 1000 ppm Max |
| Temperature | 55°C |
| Pressure | 0.02 Bar Max |
| Speed | 30 RPM Max |
| Operating Environment | Continuous Process |
| Service Condition | Vacuum Application |
After conducting a detailed application study, our engineering team identified the primary cause of failure:
Incorrect Sealing Technology Selection
The traditional gland packing arrangement was not suitable for:
To permanently eliminate the leakage problem, our team recommended replacing the gland packing arrangement with an engineered mechanical sealing solution.
Solution Supplied
- - Product: Dry Running Mechanical Seal
- - Model: DS71
- - Seal Type: Dry Running Mechanical Seal
- - Material of Construction: SS316L
Modifications Performed
Implementation Process
- - Site inspection and technical evaluation
- - Operating condition assessment
- - Mechanical seal selection
- - Assembly modification
- - Installation and commissioning
- - Performance validation
Total Project Duration: 1 Week
- Leakage every 2–3 days
- Frequent gland packing failure
- Continuous maintenance intervention
- Unstable operation
- Leakage eliminated
- Stable operation achieved
- Continuous performance for more than 8 months
- Significant reduction in maintenance requirements
| Parameter | Before | After DS71 Installation |
|---|---|---|
| Leakage | Frequent | Eliminated |
| Maintenance Frequency | Every 2–3 Days | Minimal |
| Seal Life | Very Short | 8+ Months Running |
| Reliability | Poor | Excellent |
| Operating Stability | Unstable | Stable |
The successful implementation delivered measurable benefits:
The DS71 was selected because it offers:
- - Reliable performance under vacuum conditions
- - Suitable operation in gas applications
- - Reduced maintenance requirements
- - Long service life
- - Improved process safety
- - Cost-effective lifecycle performance
One of the most common causes of repeated seal failures is selecting the wrong sealing technology for the application.
For vacuum and gas-handling systems, conventional gland packing often becomes a recurring maintenance problem. Application-specific mechanical seal selection is critical for achieving long-term reliability.
- - Leakage eliminated
- - Reduced maintenance cost
- - Increased equipment uptime
- - Improved operational reliability
- - Long-term sealing performance
- - Higher process efficiency
Ashish Seals specializes in:
- Dry Running Mechanical Seals
- Agitator Mechanical Seals
- Reactor Mechanical Seals
- Vacuum Pump Seals
- Mechanical Seal Repair & Upgradation
Our engineering team can evaluate your application and recommend the right sealing solution for long-term performance.
Request a Technical Consultation Today
Get a free application review and sealing recommendation from our experts.