What causes overheating in industrial equipment and how to fix it

If you are working with pumps, you may have noticed this recurring issue of pump heating. Right? At first, the pump runs fine, then the temperature rises, and slowly vibrations, leaks, and surprises. There comes the real challenge, shut down! Sounds relatable, right? The pattern repeats, indicating that something needs to be fixed in the system. 

 

According to the Hydraulic Institute, overheating can be the result of:

·         Improper sealing

·         Poor lubrication

·         operating outside design conditions

This makes heat the most common contributor to failures. And, the most frustrating part is that this situation repeats. The maintenance team may fix the symptom, but are they addressing the reason behind the heat buildup? 

 

In this blog, we will break down what's really happening.


Friction

Friction = Heat

 

The mechanical seals are crafted in such a way that they keep friction and heat under control. But when the thin fluid film breaks down, even slightly, friction increases. When this happens, the team replaces the seal. Have you ever questioned why the lubrication film disappeared in the first place? 

 

This is why in high-speed applications, operators rely on dry gas seals. In a dry gas seal, a controlled gas film reduces direct contact and minimizes heat generation. 

 

Inadequate cooling

We know you have the best pump seal. But are you working on the heat? If not, the heat generation can affect the seal, and it won't last. It's essential. that the seal chamber is being cooled properly. When the fluid inside it becomes stagnant, heat is generated, and the seal faces start to degrade. 

 

Correct installation is not sufficient to help your system run effectively. This is where a thermosiphon system comes in. It allows natural circulation of cooling fluid, keeping the seal environment stable without needing complex systems. In this way, you can avoid overheating and help your pump perform well.

 

Misalignment

Are you facing recurring pump failures?

If so, you might end up blaming the seal. But, is it the seal or the way the equipment is running?

 

Let’s consider a shaft misalignment. Now this may cause:

·         Uneven pressure

·         Increased friction

·         Heat buildup.

Over time, this affects both the seal and the surrounding components. In systems using a Grundfos seal, maintaining alignment is essential because these seals are designed for specific operating conditions. When misaligned, the seal isn't operating as designed, resulting in overheating. 

 

Operating outside design conditions

We can say that this is the most overlooked cause of overheating. Pumps and compressors are often pushed beyond their operating conditions. That stress translates into an additional load on the seal, resulting in higher operating temperatures. This brings an imbalance in the system. When the system isn't operating the way it was designed to, heat is just its side effect. 

 

Selecting the right sealing solution

Seals are designed for different applications. Not every pump seal is built for every application. Operating conditions in industries vary, including different temperatures, fluids, and rotational speeds. These all require specific materials and designs. If you are still using a standard seal, it may work for a while, but over time, the seal faces wear faster, friction increases, and heat builds up. This is why it's essential to select the right sealing solution.

 

To conclude

Overheating can be caused by multiple issues, such as:

·         Friction

·         Poor cooling

·         Misalignment

·         Operating conditions

·         Seal selection

And all these problems develop slowly. By the time overheating becomes visible, the damage has already started. 

 

So, can cooling be the solution? No. 

Along with it, you need to understand what's causing the heat. And this is where you need expert advice. And guess what? Trisun helps industries with sealing solutions designed for real operating conditions. Whether it's improving pump seal performance, optimizing a mechanical seal, or recommending advanced solutions like dry gas seals for high-speed applications. 

 

Is overheating becoming a recurring issue in your equipment? Then it's time to take a closer look at your sealing system and operating conditions. Reach out to Trisun to build a system that runs cooler and lasts longer.

 

Frequently Asked Questions

Can misalignment cause overheating?

Absolutely. Misalignment increases friction at the seal faces, leading to overheating. 

 

How does a thermosiphon system help reduce heat?

A thermosiphon system is designed to circulate a fluid naturally, removing the heat from seal chambers.

 

What are the causes of overheating in pump seals?

Overheating can be caused by:

·         Friction

·         Poor lubrication

·         Misalignment

·         Inadequate cooling

 

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