Why TST SEAL sealing modules offer a long service life and more stable performance

The service life and reliability of sealing modules go beyond simply “how long they last”; rather, it involves a systematic process integrating materials science, environmental engineering, failure analysis, and prognostic technologies. Accurately assessing sealing performance is particularly crucial in high-risk, high-cost industrial environments such as offshore oil platforms and hydropower plants. The following is a multi-dimensional assessment system commonly used in the sealing module industry:

1. Material Performance: The “Gene Code” of Lifespan
The sealing material is the fundamental determinant of its lifespan. This assessment requires in-depth laboratory analysis:

Chemical Compatibility Testing: Sealing materials (such as EPDM, FKM, and PTFE) are immersed in actual operating media (crude oil, seawater, acidic gases, hydraulic fluids, etc.) and regularly monitored for changes in hardness, volume expansion, and loss of tensile strength. Materials that swell by more than 10% or lose 30% in strength are considered unsuitable for use.

Aging Testing: Simulates long-term environmental impacts. Thermal Aging: Accelerated aging in a high-temperature oven (e.g., 150°C for 1000 hours) assesses material embrittlement and cracking tendencies.
Ozone and UV Aging: Tests material durability in highly oxidizing environments, particularly important for offshore platforms.
Compression Set: This is a core metric for evaluating the “rebound capacity” of elastomeric seals. After the seal is compressed at a specified temperature and pressure for 70 hours, its recovery is measured. The lower the compression set (e.g., <20%), the better the long-term seal fit and lifespan.

II. Operating Condition Simulation: “Stress Testing” in Real Environments
Laboratory data must be combined with actual operating conditions to verify reliability through simulation testing:
Dynamic Life Test Bench: Simulates equipment operating conditions. For example, a turbine main shaft seal is subjected to a combination of rotation, axial displacement, and high-pressure water loading for thousands of hours of continuous operation, with leakage changes recorded until failure.
Thermal Cycling Test: Pipe flange seals are subjected to repeated thermal shocks from -40°C to 150°C to assess material fatigue and changes in seal surface fit. Vibration and shock testing: TST SEAL seal components are mounted on a vibration table, simulating the vibration environment of offshore platforms or large machinery, to detect loosening or cracking.
IP rating verification: IPX7 (submersion) or IPX8 (continuous submersion) testing verifies the seal’s effectiveness in extreme water environments.

III. Failure Mode and Effects Analysis (FMEA): The “brain” for anticipating risks
This is a systematic risk assessment method used to identify potential seal failure modes and their consequences:
Identify failure modes: Examples include “O-ring extrusion,” “gasket creep relaxation,” “corrosion cracking,” and “installation damage.”
Analyze the cause: Is it excessive pressure? Excessive temperature? Incorrect material selection? Or improper installation?
Assess the consequences: The resulting leakage level (minor/major), whether it will cause downtime, fire, or environmental contamination.
Calculate the Risk Priority Number (RPN): A composite score of severity (S), frequency of occurrence (O), and detectability (D) is used to identify high-risk areas and prioritize improvements. Through FMEA, companies can develop targeted preventive measures, such as optimizing designs, strengthening quality inspections, and improving installation processes.

IV. Field Data and Intelligent Monitoring: From “Judgment Based on Experience” to “Data-Driven”
Historical Data Statistics: Collect the mean time between failures (MTBF) and failure rates of similar equipment and seals in actual operation. For example, the average lifespan of a certain type of mechanical seal on an offshore platform is 25 years, which can be used as a reference for selecting new projects.
Condition Monitoring Technologies:
Infrared Thermal Imaging: Detects abnormal temperature rise in the seal area (due to increased friction or cooling effects caused by leaks).
Ultrasonic Leak Detection: Captures ultrasonic signals generated by tiny leaks of high-pressure gas, providing early warning.
Intelligent Sealing Systems: Integrated pressure, temperature, and humidity sensors upload data in real time. If the seal chamber pressure drops abnormally or the internal humidity rises, the system automatically issues an alarm, enabling “predictive maintenance.”

5. Standards and Certifications: The “Passport” to Reliability
Internationally recognized standards are the “hard currency” for evaluating seal reliability:
ISO 15848: Fugitive Emissions Standard for Industrial Valves, strictly specifies leakage limits for valve packing and seals.
API 6A/17D: Sealing Performance Requirements for Oil and Gas Wellheads and Subsea Equipment.
ATEX/IECEx: Sealing and Protection Requirements for Equipment Used in Explosion-Proof Environments.
Classification Society Certifications such as RS, BV, CCS, and ABS: Mandatory requirements for the pressure resistance, corrosion resistance, and fire resistance of seals for offshore equipment.
Achieving these certifications means that TST SEAL products have undergone rigorous testing at third-party laboratories, providing authoritative assurance of their reliability.

Quality and reliability are not simply calculated, but also managed. The lifespan of TST SEAL sealing modules cannot be solely based on experience or supplier assurance. It requires material testing as a foundation, performance testing under simulated operating conditions, FMEA risk management, process monitoring, and standard certification to ensure a bottom line. Ultimately, a reliable seal lifespan assessment requires a deep integration of scientific data and engineering practice. Against the backdrop of the “dual carbon” goals and intelligent manufacturing, seal reliability management is becoming a core competitive advantage in high-end equipment operation and maintenance, evolving from “passive replacement” to “active prediction.”