MECHANICAL PACKING

Design and Theory of Operation

Mechanical Packing
Design and Theory of Operation
One of the vital parts of any machine in which gases are compressed or expanded is the seal around the reciprocating rod, through which
power is put into or taken from the cylinder. This seal is called packing. The word packing comes from the method of sealing in pressure where
the stuffing box around a pump or compressor shaft is “packed” with a soft material. The type of seal we will discuss is a mechanical seal, which
is often also called by the following names:

• Metallic Packing - from the earliest days when the parts were all metallic.
• Floating Packing - because the sealing rings are free to move.
• Segmental Packing - from the segmented construction of the rings.
• Mechanical Packing - since it is a precision machined part which functions on principles of mechanics.

Mechanical packing is made of many materials and sizes, depending dimensional limitations must be taken into account. A set of packing
upon the specific application involved, and may be utilized to seal may vary in cost from a few dollars to several thousand, depending
pressures ranging from a vacuum to pressures currently as high as on construction and material. It is one of the most critical parts
50,000 psi, with sealing rings of all the bearing metals and many involved in the operation of a compressor. Failure of the packing to
plastics. The variables of type of gas, suction and discharge pressures, operate satisfactorily can prove to be very expensive in terms of plant
temperature, speed and length of stroke, lubrication, rod material, and downtime and loss of output.

Purpose of Packing
The purpose of packing is to prevent leakage of a gas between a rod and bushing. Second, perfect alignment must be maintained so
cylinder and a piston rod. It is necessary to seal this clearance even that the rod and bushing do not come into contact and cause wear
when compressing a harmless or inexpensive gas. Take, for example, and frictional heat. Third, no compensation is made for the difference
an air compressor. As the clearance between the rod and the opening in fit of the rod and bushing at operating temperatures. Fourth,
increases or decreases, the amount of leakage will increase and running at extremely high speeds, in order to avoid extreme leakage,
decrease as well. The larger the passage for the gas to escape, the may be impossible because of speed limitations of other parts of
larger the leakage will be. If the machine is operating at a sufficiently the compressor. It is for these four reasons that packing as we know
high speed and the flow through the discharge valves is rapid, the it today is used as standard equipment as a seal on reciprocating
compressed gas will take the path of least resistance through the compressors. To be considered successful, it is necessary that this
valves rather than through the restricted opening between the rod packing prevent the leakage of gas through the clearance between
and the cylinder. Compressors have been built without conventional the cylinder head and the piston rod. The packing must operate over a
seals based on these principles. They have reduced clearance to a long period of time with little or no leakage, and a minimum of friction
minimum in a bushing around the piston rod and have run the engine and resultant wear while compensating for wear, lateral movement of
at high enough speeds that leakage past the bushing was insignificant the rod and changes in temperature.
in comparison to the flow through the discharge valves. However,
creating and maintaining such a seal is impractical for several reasons.
First, the high velocity of the escaping air would cause erosion of the

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 MECHANICAL PACKING | DESIGN AND THEORY OF OPERATION

Packing History
Sealing of the piston rod was originally accomplished on the first high-tech materials were sought. Operators then tried various forms
steam engines by cutting washers from ham rind to fit the piston rod of fabric packing, usually lubricated with flake graphite and oil. These
and placing them around the rod where it entered the cylinder in the performed with varying degrees of success but rapidly lost ground,
recess known as the stuffing box. Pressure was then applied to them and soon the early forms of metallic packing began to appear. These
through a bolted flange and follower, the follower having a tapered took the form of wedge-shaped pieces of some soft metal arranged
face which caused the washers to press on the rod and make the so that pressure from the flange caused them to press onto the piston
seal. The natural grease in the ham rind gave good lubrication as did rod. Like their predecessors, they required continual maintenance,
the packing, but required a maximum amount of maintenance and consumed much of the engine’s power and scored the piston rods
constant adjustment. As steam temperatures and pressures increased, rapidly.
greater demands were put on the packing. For this reason, more

Full Floating Principle

Around the close of the 19 th century, packings of the full floating metallic type were first marketed. The “floating” principle means sealing ele-
ments of the packing are free to move within the assembly as opposed to non-floating packings in which the sealing elements are held rigidly
in the stuffing box and require outside adjustment to compensate for wear or misalignment. The full floating metallic packing was designed to:

• Take advantage of the operating economies resulting from the operating at high pressures and elevated temperatures. But the
elimination of friction-producing materials such as hemp, duck, term “metallic” packing is, at least partially, a misnomer. Originally
rubber, metal foil, metal shreds and innumerable combinations it was termed metallic packing because all of the parts were
of these materials previously used as packing materials. made from metal, primarily cast iron. As pressure conditions and
temperatures increased, various grades of bronze were used
• To utilize a precision machined, anti-friction metal sealing ring
for the wearing parts and, as other gases were becoming more
that will withstand high temperatures and pressures.
common in the chemical industry, various plastics and non-
• To provide an effective seal on piston rods that rise and fall or metallics were added. The term then evolved into “mechanical”
have a lateral movement as they move through the packing due packing, which is the seal as we know it today. Its parts are rigid
to wear of the crosshead or cylinder, unequal expansion of the and interwork mechanically to reduce the clearance around the
parts, misalignment, or innumerable causes which can create piston rod to the point where leakage will not occur. Unlike soft
such a condition. packing which requires continual external adjustment, it is self-
These buiIt-in features made this type of packing desirable for all adjusting, and compensates for wear and temperature changes.
reciprocating engines and compressors and a must for machines

A. Packing Set
The packing unit is made up basically of two parts: the packing case to 200 psi to seven or eight for the highest pressures in the industrial
(See Fig. 1) and the packing rings (See Fig.2). The case is a series reciprocating compressors. Until a few years ago, packings with 12 to
of retainers gasketed on the surface of the contact of the cylinder, 15 sealing elements were not uncommon. However, as rotative speed
centered around the piston rod by a stuffing box and held in place by increased and the stroke of the compressor was reduced, it was found
a flange bolted to the end of the cylinder. The number of retainers and that much was to be gained by decreasing the length of the packing
consequently the number of sealing elements is determined by the necessitating a reduction in the number of sealing elements. This
operating conditions of the compressor, and by standards established was achieved through the ability of the manufacturer to obtain finer
by the individual packing manufacturers for the various conditions. finishes on all the sealing parts on a production basis.
These will vary in number from two or three retainers for pressures up

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B. Packing Cups
The packing retainers which are referred to as packing cups are depth which allows side clearance between the cups and the rings.
machined to provide a nominal amount of clearance around the The faces of the packing cups are ground, or ground and lapped,
piston rod so that the rod will not contact them should any lateral depending on the pressure, and the gas being sealed. Special care is
movement occur due to run-out, misalignment or wear. This clearance taken to ensure that the faces are both flat and parallel so that when
will vary with piston rod diameter, with the operating pressure, and assembled in the stuffing box, and bolted in place, they will present
is also influenced by the compressor design and the possibility and surfaces which are perpendicular to the piston rod. The pressure
magnitude of change in piston rod orientation. As an example: on necessary to ensure a seal between cups and to seat the gasket
non-lubricated compressors where the piston is supported on wear between the end of the packing and the bottom of the stuffing box
rings which may be subject to a high rate of wear causing both the is furnished by the flange. It can be seen from Fig.1 that the clearance
piston and the piston rod to drop from their initially aligned position, between the cups and the rings is unaffected by stud pressure, so
increased clearance is generally added between packing cups and the that the rings will be free to move axially within the cup. It should be
piston rod. Depending on these factors just described the clearance noted that the rings contact the case only on the sealing face.
between the packing case and the piston rod may vary from 1/32” They do not in any way support the rod through contact with the
to 3/16”. The recess which houses the packing rings is held to a fixed packing case.

Fig.1 | Mechanical packing nomenclature

Box depth Flange
stud and
Front or Joints Packing nut
pressure between Groove rings
end cups width (pair) Ring sealing face

Lubrication
connection

Rod diameter
Box diameter

diameter
Groove

Bore

Vent
connection

Back or
flange end

Gasket Gasket Oil cup Tie rod Packing cups Vent cup Flange (gland)
cup

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 MECHANICAL PACKING | DESIGN AND THEORY OF OPERATION

Fig.2 | The basic sealing element of a mechanical packing

The tangent ring will make a
Dowel pin in tangent ring
complete seal except at the gaps
Clearance hole prevents joints of radial and
which permit compensation for
in radial ring tangents from aligning
wear. These are covered by the
Seal made between segments of the radial ring.
Pressure Tangent and packing case

Piston rod

Pressure
Packing case

Gas tight joint

Radial ring Tangent ring Three radial cuts in radial ring

permit compensation for wear

Joints Between Cups

The joints between the packing cups may take one of several forms The Tongue and Groove Gasketed Joint has the disadvantage of
(See Fig.3). They may simply be ground or ground and lapped; they being relatively expensive to manufacture and makes holding of the
may have a tongue and groove gasketed joint, or they may have a side clearance on the packing rings more difficult since the crush
ground joint with an auxiliary “O” ring seal. In the latter type, the “O” of the gasket is difficult to predict and it is necessary to maintain
ring is in effect “insurance” since the ground joint properly loaded can three tolerances accurately — the width of the ring groove, the
form a satisfactory seal for all pressures. These various types have their depth of the gasket groove and the thickness of the gasket. Its most
advantages and disadvantages. serious disadvantage is that uneven tightening of the flange studs
can cause cocking of the packing cups, through uneven crushing
The Ground Joint is the least expensive to produce and probably is
of the gasket, not keeping them perpendicular to the piston rod.
in widest use. It has the disadvantage of being susceptible to damage
The advantage of this type of joint is that it is the least susceptible
by scratching or through foreign material getting between the two
to damage and even small scratches in the metallic part of the
surfaces. Generally this is a suitable joint for pressures up to the range
joint can be sealed through the soft gasket. The seal between the
of 3000 psi. For higher pressures, lapping of the surface is desirable
cups can be renewed simply by replacing the gasket without the
since it removes minute scratches left by grinding which could be
necessity of resurfacing the sealing faces.
a possible source of leakage at higher pressures and even at lower
pressures with certain gases, such as hydrogen. Both ground or lapped
joints have the advantage of accurate control of side clearance of the
packing rings, but each is vulnerable to foreign materials or scratching.

Fig.3 | Typical methods of sealing between cups

Confined gasket
Lapped surfaces of suitable material Ground surfaces

“O” ring groove

Lapped joint with “O” ring Gasket joint Ground or lapped joint

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Fig.4 | Methods of introducing lubricants
Oil tube
Oil tube

To connection Oil tube

on flange

Drilled passages Confined gasket connection Standard pipe thread 59˚- 60° high pressure connection Straight thread with
confined gasket

Ground Joint with “O” Ring Seal is one of the latest and relatively inexpensive developments in seals between packing retainers. The joint
itself may be ground or ground and lapped, dependent upon pressures and the gas being handled. It has the advantage of the tongue and
groove joint in that it will compensate for some minor injury to the joint, and the advantage of the ground joint, in that it is possible to control
accurately the side clearance of the packing rings.

Lubrication Connections
Lubrication connections to a packing case generally take one of three confined gaskets are used to make the seal between the packing cup
forms. These will vary with pressure and physical space limitations or and the end of the oil tube.
requirements. The 59°-60° Joint is used on very high pressure packings. With this
The Ordinary Pipe Thread Type of Connection is made on packings type of joint the seat in the packing cup is accurately made at 60° and
for lower pressures. It may take one of several forms. Where it is the end of the oil tube is accurately made at a 59° angle, so that contact
possible, the packing set is drilled with an oil passage to introduce between the two will give a line contact and make a very good seal.
lubrication at the desired point and the oil connection is made on Because this particular type of joint requires more maintenance than
the face of the packing flange. In some instances the pipe thread the others, it is generally used only on very high pressure packing
connection is made directly into the packing cup. The first of these where the sealing is critical. See Fig.4.
methods is shown in Fig.1. The latter is shown in Fig.4. Vent Connections
Gasketed Oil Tube Connections are desirable as pressures increase. The vent connections to the packing set may be made in much the
With these, the connection is made directly to the cup through which same manner as the oil connections. Generally, because they are low
oil is being fed (See Fig.4). The oil tube may be threaded directly into the pressure, they use ordinary pipe thread fittings. Example shown in Fig.1.
cup or may be “jacked” against the outside of the cup through a flange
arrangement on the outside of the cylinder. In either case, completely

Fig.5 | Geometry of the tangent joint packing ring

New ring New ring Ringgap

Ring worn to butt worn to butt gap

Gap Gap Gap worn Gap worn

to zero to zero

Direction of movement
Direction of movement Joints remain Joints remain on a true
on a true
of segment asof segment
bore is as bore is equilateral
equilateral triangle but triangle but
worn away worn away of a smaller size
of a smaller size

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 MECHANICAL PACKING | DESIGN AND THEORY OF OPERATION

Fig.6 | How a standard bore packing ring will fit an oversize and an undersize rod. Note: joints remain in contact

Rod oversize Rod undersize

Piston rod Piston rod

C. Packing Rings
The packing rings are the other component of the packing unit. These are actually the heart of the packing and the elements which make the
seal, compensate for wear, movement of the rod, and temperature change. There have been many patents obtained on various types of packing
rings; however, the most popular and widely used design is that patented by A. W. France, November 7, 1899.

Fig.7 | Surfaces on which leakage can occur are moving surfaces and require an oil film
to minimize wear. Arrows indicate possible paths of leakage.

Surfaces of rings and cup must be flat and smooth

Tangent joint must be light tight
and the corners must be square

Piston rod

These corners must be

square or leakage will occur
through joint in radial ring
around rod and through gap
of tangent ring, as shown on
the end view - left

These corners must be square or leakage will Clearance must be sufficient to allow rings to move
occur through joint in radial ring around rod freely with rod regardless of temperature change
and through gap of tangent ring, as shown here
on this end view

Segmental Packing Ring Operation

The principle of this packing (See Fig.5) is that the three cuts of the ring. Each segment overlaps and seals the gaps in the tangential ring
tangential ring lie on the sides of an equilateral triangle. This ring is so (See Fig.7). The radial ring can also compensate for wear on its bore
cut that the segments maintain contact at the joints with variations of simply by closing its radial joints as wear occurs. A dowel pin in the
the inside diameter of the ring (See Fig.6). As wear occurs on the bore tangential ring prevents rotation of one ring with respect to the other,
of the ring or on the rod, the ring will collapse, with the segments and prevents alignment of their joints. This combination of two rings
moving in the directions indicated by the arrows in Fig.5, and will doweled together is commonly referred to as a pair of rings but is a
continue to make a seal both on the bore and on the tangential single sealing element. These two rings together make a seal along
joints. Obviously this ring cannot by itself create a seal since the gaps the piston rod. To prevent gas from bypassing the rings, the tangential
provided to permit the ring to collapse as it wears leave a straight ring also seals along its back face against the sealing surface of the
path for leakage. To seal these gaps another ring is cut into three packing cup immediately behind the one in which it is housed.
segments with simple radial cuts and paired with the tangential

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The seal then is made by the combination of radial and tangential between the side of the retainer or packing cup and the face of the
rings on their bores along the piston rod, between the back of the radial ring. Through this clearance and through the end gaps of the
tangential ring and the sealing surface of the cup and through radial ring, pressure can build up on the outside of both the radial and
the tangential joints of the tangential ring. See Figs.8 and 9 for tangent rings and can also relieve itself toward the cylinder on the
the percentage breakdown of leakage past a pair of rings and the suction stroke of the compressor cycle, provided, of course, that the
pressure conditions at three locations on the rings. pressure existing around the rings exceeds the suction pressure of
the cylinder.
With the packing rings in place on the piston rod and the tangential
ring making contact with the sealing face of the cup, clearance exists

What Happens When Rings are Reversed?

If you visualize this pair of rings reversed in the grooves so that the pressure will fluctuate from one end of the packing to the other,
radial ring is against the sealing face of the cup, clearance will then double tangent pairs of rings must be used so that sealing can be
exist between the pressure side of the tangent ring and the cup, accomplished in either direction. Except as dictated by special sealing
permitting pressure to build up on the outside of the rings and to requirements as just described, generally it is not desirable to use
bypass the rings through the radial joint of the radial ring. Correctly double tangent pairs of rings since with their use it is possible to trap
positioned, the radial ring always faces the highest pressure. pressure within the packing case and cause more rapid wear than would
otherwise exist.
In some instances, where a packing may be subject to a fluctuating
pressure differential, such as a machine using a pressurized distance
piece or one used between two cylinders where the highest

Plastic Materials
The development of plastic materials, particularly the filled TFE transmitting any load from the gas pressure to the piston rod. The
materials for both lubricated and non-lubricated service, have anti-extrusion or back-up ring may be used with a conventional pair
brought about some alteration in packing ring configuration as of rings that is one radial and one tangent cut pair or with a single
just described. These materials under elevated temperatures and ring which is cut tangent to the piston rod. When a ring cut tangent to
pressures tend to creep and extrude into the clearance between the the rod is used without a radial ring it becomes a double acting unit
packing cups and the piston rod. To permit the necessary clearance similar to the double tangent pair as previously described. Unless the
between the packing cups and the piston rod to exist and at the same double acting feature is intended, slots are cut across the face of the
time prevent extrusion of the plastic sealing rings, the anti-extrusion ring toward the pressure to build up and to relieve pressure on the
or back-up ring was developed. outside of the ring as previously described.
These rings may be either segmental or uncut and they are bored
to have a small amount of clearance on the piston rod. They are
designed to “float” with the packing rings without themselves

Fig.8 | Typical test of leakage past a pair of rings Fig.9 | Pressure drop across a pair of packing rings
showing percentage of total leakage

Radial ring Tangent ring Radial ring Tangent ring Radial ring Tangent ring
P1 P1 P1
Face of radial Face of tangent
18% 27%
P2 P2 P2
Bore of radial
4½%
Bore of tangent
22½% P2 P2 P2
Tangent joint
P1 P1 P1
28%

Condition away from joint of both rings Condition at gap of radial ring Condition at gap of tangent ring

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 MECHANICAL PACKING | DESIGN AND THEORY OF OPERATION

Oil Control Rings

Most reciprocating compressors use oil control or wiper rings to It should be understood that it is virtually impossible to wipe the rod
prevent crankcase oil from passing into the cylinder and in some completely dry of oil by mechanical wiper rings. On compressors
instances to prevent condensate, cylinder and packing lubricant from where crankcase oil must be absolutely excluded from the cylinder
entering the crankcase. On crosshead type machines, this control and contact with the gas, the compressor must be designed to
is achieved through piston rod wiper rings. The desirability and prevent any part of the piston rod, which enters the crankcase from
necessity of this control is several fold. First, by containing crankcase entering the cylinder.
oil in the crankcase, the amount of oil entering the cylinder and
Segmental wiper rings may be either radially or tangentially cut.
consequently the gas stream is controlled. Second, the crankcase oil
They are garter spring actuated. The scraper edges in contact with
may not be compatible with the cylinder lubricant and may dilute or
the piston rod are proportioned to give a bearing load sufficient to
react with it. Third, oil may not be permissible in contact with the gas
break the surface tension of the oil film on the rod and wipe it away.
being handled — such gases as oxygen and chlorine are examples
While there are many variations and innovations of wipers, there are
of these. Fourth, it is desirable to avoid oil contamination of gases
basically two types. One is designed to turn back a large volume of oil
intended for “dry” use. Finally, cylinder lubricants and condensate may
along the rod. The other type has drainage passages through which
be detrimental to the bearings and other parts of the running gear if
oil wiped from the rod drains into an annular area around the outside
mixed with the crankcase oil.
of the rings and thence back into the crankcase. Normally two or three
wipers are used in an1oil2 seal and as previously indicated may be used
3 4 5 6 7 8
as a part of or in conjunction with a pressure packing.

Fig.10 | Pressure drop pattern through a packing discharge pressure

suction pressure
atmos
1 2 3 4 5 6 7 8
positions in packing 1st pair of rings seal
completely
discharge pressure
suction pressure
1 2 3 4 5 6 7 8 atmos
1 2 3 4 5 6 7 8
positions in packing 1st pair of rings seals
discharge, last pair seal suction pressure
discharge pressure
suction pressure
atmos
1 2 3 4 5 6 7 8
positions in packing 1st pair of rings seals
discharge pressure discharge and suction pressure breaks down
through packing
suction pressure
How a Packing Works
atmos
1 2 3 4 5 6 7 8
As previously described, a packing set consists
positions in of a series of1st
packing sealing sealing
pair of rings a minimum of the differential between suction pressure
seal
units. Mechanical packing is notcompletely
bottle tight but the amount of and atmospheric pressure for a short period of each stroke. These
leakage is an extremely small fraction of one percent of the capacity of conditions of time and pressure differential give three “normal”
discharge
the machine and pressure
usually within tolerable limits. If, due to the toxicity patterns of pressure breakdown across a set of packing.
suction pressure
of the gas or danger of explosion or corrosion, any leakage exists,
atmos Condition I - Both suction and discharge pressure are sealed by the
it may be vented to a safe place. The fact that the individual rings
1 2 3 4 5 6 7 8 first pair of rings.
will leak slightly is the reason for the series of rings. It is through the
series of rings that the pressure ispositions
broken down in from
packing 1st to
discharge pair of rings sealsII - The suction pressure is sealed by the last pair of rings
Condition
discharge, last pair seal
atmosphere. You will recall that the volume of leakage will increase suction pressure
and the discharge by the first. Such a condition is believed to be
discharge
with pressure
an increase in the differential pressure across the rings and will transitory between Condition I and Condition III.
also suction pressure
increase with the time that the differential pressure exists; in Condition III - This is a breakdown of suction pressure in increments
other words, the atmos
higher the differential pressure and the longer the across the rings with each increment reducing the differential
1 be2the volume
differential exists, the greater will 3 4 of 5 leakage.
6 7 In normal
8 and consequently the amount of leakage by any pair of rings. The
compressor operation the minimum pressure which will be existent
positions in packing 1st pair of rings in discharge
sealspressure is generally sealed by the first pair of rings. Should
the cylinder, and consequently to which the packing will be subject,
discharge and suction pressure breaks down pressure higher than suction exist beyond the first pair of rings, it
through
will be equal to the suction pressure. packingpressure across
The differential would on the first suction stroke leak back to the cylinder since the
the packing will fluctuate between suction and discharge pressure rings will seal in only one direction.
on each compression stroke, with the full discharge pressure existing Each of these conditions or patterns (See Fig.10) is considered to be
only instantaneously on each stroke. The problem then is one of “normal” and will exist alternately during normal operation.

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Mechanical Packing for Reciprocating Liquid Pumps
Until recent years the type of packing herein described has been applied only to compressors handling gases. It has been found, however,
that by adjusting sealing ring clearances and by making certain modifications to compensate primarily for the incompressibility of liquids that
mechanical packing can be successfully applied to reciprocating liquid pumps. The seal in this application requires no external adjustment,
produces virtually no plunger wear, and consumes considerably less of the pump’s power. Packing case and packing ring materials are the
same as those used in compressor packings and their selection is based on compatibility with the liquid being handled, mating material of the
plunger, temperature and pressure involved.

Packing Ring Materials

Packing rings have been made from a wide variety of materials, from wood (lignum vitae) to sterling silver, and for an equally wide range of
conditions. The more common ones, such as cast irons, bronzes, babbitts, laminated phenolics, plastics and carbon graphite materials should
be familiar to the maintenance mechanic. He should be familiar with their limitations and uses since much is to be gained by proper selection of
packing rings.

Plastics have come into wide use as a packing ring material due to self- more than water lubrication, making them a particularly good material
lubricating qualities, chemical resistance and a degree of conformability for use on gases which thin lubrication. The material itself is made up of
which virtually eliminates the necessity of a break-in or wear-in period. laminations of various woven fabrics impregnated with phenolic resin,
TFE, polyamides, and polyimides filled with a variety of materials to bonded by pressure and temperature. The temperature resistance of the
improve their dimensional stability, resistance to cold flow and heat material is generally determined by the base fabric. Cotton fabric base
conductivity have become standard materials for both non-lubricated materials are limited to 275°F, maximum. Other fabric base materials are
and lubricated service, and are rapidly replacing many materials limited to 400°F, maximum. For most satisfactory operation they should
previously used. be used, however, at temperatures less than their maximum limit.
Localized surface temperatures may exceed allowable limits and, since
Cast Iron packing rings have a wide range of application on low
the material is a relatively poor conductor of heat, it may be difficult for
pressure steam, air, and gases which do not tend to thin lubrication.
it to dissipate heat from its rubbing surface. In addition to the variations
Generally they are used up to pressures of 600 psi although some
in base materials, carbon or molybdenum disulfide may be added to the
manufacturers will surface treat them and recommend their use at
resin to improve the anti-friction properties of the material. Laminated
slightly higher pressures. They are all dependent on good and sufficient
phenolics are generally limited to compressors discharging at less than
lubrication. Bronze as used in packing rings covers a wide range of
1000 psi.
alloys.
Babbitt rings find most of their use on stainless steel rods where
Bronze rings are used in the highest pressure reciprocating compressor
corrosive conditions limit the use of other materials for either packing
packing made today. Because of their good heat conductivity they will
rings or piston rods. For satisfactory life they should be used only on
conduct heat away from the rubbing surface, helping to preserve the oil
clean gases, since Babbitt rings are very susceptible to damage and to
film. Generally, the leaded bronzes have been found most satisfactory
picking up foreign materials.
and will not scuff or seize on the rod.
Carbon Graphite materials possess self-lubricating qualities and
Laminated Phenolics also cover a wide variety of materials. They are
for many years were the only materials suitable for non-lubricated
used where chemical resistance and/or adverse conditions of lubrication
packing. They have high temperature and corrosion resistance to many
are anticipated. Their various grades are particularly recommended for
chemicals and are still used in non-lubricated applications requiring
“sour” gases and hydrocarbons in general. They will run with virtually no
materials with these attributes.

Packing Cup Materials

Packing cup materials are selected for wear resistance, strength, corrosion resistance and heat conductivity. They have been made from a wide
range of materials, the most common of which are cast iron, bronze and steel.
Cast Iron has excellent wear resistance and good strength, making it applications where either exceptional heat conductivity is required or
the best selection of materials up to pressures in the neighborhood of resistance to corrosion and chemical attack is needed.
2000 psi, although in some instances it has been used as high as 5000 Steel in several basic forms is used where the stresses induced in high
psi. Its limiting factor insofar as pressure is concerned is the strength of pressure packings require the strength obtainable in steel. Carbon,
the material. alloy or stainless steel in the form of either castings, bar or individual
Bronze, although stronger than ordinary cast iron, has poor wear forgings may be used. The steels are heat treated to obtain optimum
resistance but superior heat conductivity and in some instances, combinations of strength, fatigue resistance and wear resistance.
resistance to chemical attack. For these reasons it is used on many

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 MECHANICAL PACKING | DESIGN AND THEORY OF OPERATION

Lubrication of Mechanical Packing

Lubrication in metallic packing serves a four-fold purpose. It provides a low friction film between the rings, between the rings and the cups, and
between the rings and the rod. This film provides resistance to corrosion from moisture and in some cases chemical attack of the gas, it helps in
dissipating heat and helps to prevent leakage through minute passages which may exist due to minor damage to the part, such as scratching
or slight discrepancies in the fit of the parts due to non-uniform expansion. In these respects the lubrication requirements of metallic packing
are much more exacting than those of bearings or other lubricated parts.

The lubricating oil or media used with metallic packing must be able supplementary lubrication is obtained from connections in the
to form and maintain strong films between all of the components and suction valve chambers, allowing the lubricant to be carried by the
thereby reduce wear and friction since operation of the packing is gas. Some valve stem packings running on hardened steel rods on
dependent upon the ability of the parts to move freely under pressure. steam engines are operated solely with steam-carried lubrication.
The rings must be able to maintain sliding contact with the rod, at The same is true of some relatively low pressure compressor packings;
the same time being free to slide on the cups, compensating for axial however, force feed lubrication is desirable on all lubricated type
movement of the rod. mechanical packings and is, in fact, a necessity on high pressure
packings which use ordinary materials for rings and rod.
Generally, lubricant is fed directly to the packing at one or more
points from a multiple force feed lubricator. In some instances

Amount of Lubrication
The amount of lubrication fed to a packing will vary substantially should be pointed out that a lubrication film must be maintained for
with various operations and can be best determined by actual satisfactory operation. Intermittent lubrication will tend to misplace a
field experience. The use of plastic materials, specifically the filled film which will be built up on the piston rod surface during periods of
TFE resins, has made possible successful packing operation with dry operation. With any mechanical packing, excessive amounts of oil
substantially reduced amount of lubrication. In some cases, the use can be as detrimental as insufficient quantities. This is due to the fact
of plastic rings has permitted reduction of 80% in the amount of that increased amounts of oxidation products will be formed which
lubrication which had been fed to metallic rings. While substantial tend to be abrasive. In some instances, hydraulic pressure will build up
reductions in lubrication are possible with these plastic materials, it within the packing case and cause excessive wear of the packing rings.

Non-Lubricated Mechanical Packing

Non-lubricated packing, as its name implies, requires no external It is frequently asked why, if packing can be made to operate without
lubrication. It is made and functions essentially the same as lubrication, are not all packings non-lubricated. This is of course, the
lubricated ones except that the packing ring material is selected for ultimate goal of the packing manufacturer and the operator since
its self-lubricated qualities. These materials have previously been it would be substantially less expensive from the point of view of
described and include the carbon graphite and the filled TFE resins lubricant cost and even more of the cost of removing the lubricant
predominantly. Some materials, such as the phenolic laminates, will from the process gas. Until recent years the answer lay in the life of
run under most adverse conditions of lubrication, even on moisture the packing. Friction and consequently wear were high with the ring
in the gas, but cannot be considered to be a non-lubricated material materials available and replacement with its costly accompanying
in the strictest sense of the word. The most notable difference in downtime were frequent. Today, with the packing ring materials
lubricated and non-lubricated packings is that cooling of the packing which are available, many operations are converting to the use of
is at much lower pressures due to higher frictional heat and the minimum lubrication at pressures in excess of 10,000 psi and fully
generally inherent poor conductivity of the packing ring material. non-lubricated at pressures in excess of 5000 psi. Continuing work
As the pressure requirements are increased, it becomes increasingly in this field indicates that completely non-lubricated compressor
necessary to remove heat from the packing case, the rings and the packing operation is feasible at even higher pressures.
rod. With non-lubricated packing, it has been found that even at very
low pressures the ultimate life of the packing rings can be extended
beyond that normally expected with a non-cooled packing.

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Temperature Control
The problem of obtaining satisfactory results with packing insofar as temperature is concerned is one of preventing excessively high
temperature which would be detrimental to lubrication, either through reducing viscosity or forming of carbon; of limiting as much as possible
localized heating of the packing; of keeping the packing temperature as nearly as possible constant; of keeping a temperature from developing
in the packing which would be detrimental to the process or the packing ring material; and of maintaining a packing temperature which will
not cause moisture or the gas to condense in the cups.

This control is obtained in one or more of the following ways: air such that cooling the cup can be effective. With non metallic rings,
cooling, water jacketing the stuffing box, running coolant in direct such as laminated phenolics and plastics, because of their poor heat
contact with the packing cups, running coolant through a chamber or conductivity, the heat must be removed at its source by cooling. This is
series of chambers in the packing, running coolant through a hollow generally done by cooling by one of the last two methods mentioned.
piston rod or running coolant directly in contact with the rod. On high pressures (6000 psi upward) and on non-lubricated packing,
frequently both cup and rod cooling are used. Each of the methods
The first four of these are based on the assumption that the packing
mentioned has its advantages and disadvantages.
rings will transmit heat from their bore, where it is generated, to
the cup, where it is being removed. This assumption does not hold
true for all materials. With metallic rings the heat conductivity is

Air Cooling is the simplest and least expensive. It is done simply by Running Coolant Through the Cups is another method of bringing
allowing the packing to extend beyond the stuffing box and depends the coolant in more intimate contact with the source of heat and
on cooling through the transfer of heat to the air circulating around it. is generally used on non-lubricated packing where heat transfer
It is effective only on packings of low pressure where the requirement must be more rapid. Corrosion -resistant cup materials can be used,
of the heat removal is low since air will tend to stagnate in the distance permitting the use of water as a coolant, so that a separate circulating
piece around the packing, reducing heat transfer. and cooling system for the coolant may not be necessary.
Water Jacketed Stuffing Box cooling is provided by extending the Running Coolant Through a Hollow Piston Rod is effective but
cylinder jacket to include the entire stuffing box. This is effective expensive. It is effective in that it is cooling directly one of the rubbing
and in most common use. Its only drawback lies in the fact that an surfaces generating the heat. Generally, it is used in conjunction with
air space, although small, helps insulate the packing cups from the some method of cooling the packing cup.
stuffing box and requires that the heat be transferred through the cup, Running Coolant Directly on the Piston Rod is the most effective
the air space and the wall of the stuffing box, to be removed by the method of heat removal although it requires a coolant compatible
jacket coolant. It is because of the distance between the coolant and with the process and frequently requires a separate circulating and
the source of heat that this method does not give optimum cooling cooling system for the coolant.
although effective for all but very critical jobs.
Regardless of method of temperature control, it must be remembered
Running the Coolant in Contact with the Cups is more effective that the requirement is not to make a packing cold but to control
than the first two methods since it brings the coolant closer to the its temperature. Packing temperatures of several hundred degrees
source of the heat and eliminates the insulating effect of the air on lubricated packing are not unusual nor indicative of trouble.
space around the packing. It requires that passages be provided on Substantially higher temperatures can be anticipated on non-
the outside of the cup for flow and that a seal be made around the lubricated packings.
stuffing box to contain the coolant. Generally, because of corrosion
problems, a coolant such as light oil must be used. A system for
cooling and circulating the cooling medium is used and consequently,
because of the expense involved, this method is limited to critical jobs.

12
 MECHANICAL PACKING | DESIGN AND THEORY OF OPERATION

Major Sources of Packing Trouble

There are several indications of trouble with metallic packing that are frequently taken as “the problem” when in reality they are a by-product or
a manifestation of the actual source of trouble. Excessive or rapid wear is an example of this. Barring improper selection of mating materials or
of material and gas, excessive wear is an indication of one or more of several causes. To fully understand and diagnose abnormal wear, normal
wear should be understood.

A. Normal Wear
Wear of sliding parts appears to be inevitable and it is to some extent there is the difference of as much as one to two or more times the
desirable. It can be broken down into two classes: wearing in and coefficient of expansion between rod and rings. This means that
wearing out. We generally consider wearing in to be a burnishing even though the fit between the rod and the rings is perfect at
of the rubbing surfaces. With packing, the problem is somewhat room temperature, at operating temperature, due to the gradient
different. Packing rings must first undergo a period of wearing out, through the packing and the difference in expansion rates, each pair
followed by a period of wearing in, then followed by the normal of rings must wear to a running fit to make a satisfactory seal. Having
wearing out. This first wearing out period is caused by the fact that obtained this fit we should now expect the surfaces to burnish and
the rings must have a gas-tight fit with the piston rod and must the original high wear rate to be replaced by a much slower normal
obtain that fit by wearing out to the point of making that contact. wear pattern. What then will change this pattern of normal wear,
Temperatures may vary substantially from front to back of packing accelerating it to unacceptable limits?
and between rod and rings. In addition to the temperature difference,

B. Causes of Abnormal Wear

Temperature can put the packing back to the high wear rate of the Moisture, causing pitting, erosion and corrosion, can take place
initial wear out-wear in cycle. Radical changes in cylinder or packing on the rubbing surfaces during shutdown, giving unusual abrasive
temperature can be caused by failure of the cooling system, excessive conditions.
cylinder temperatures caused by recompression, lubrication failures Contamination of the gas with foreign material, such as welding
causing excessive frictional temperatures, and sticking of the rings beads, sand, pipe scale, catalyst, etc., will also cause rapid wear
causing excessive friction. through abrasion.
Lubrication, if thinned beyond the point of effectiveness by the Improper Break-In can be a source of rapid wear if the rings are
gas or by excessive temperatures, can permit metal contact, giving improperly worn in and a burnished rubbing surface is not obtained.
high frictional temperatures and excessive wear. Build-up of gummy If this condition exists, the rings may continue to wear without
or sticky carbon deposits, due to poor lubrication or reaction with
obtaining a burnished condition.
the gas, can cause restriction of free movement of the rings, further
contributing to excessive wear.
Blow-By, caused by improper break-in or erosion due to leakage past
the bore of the rings after a sudden temperature change, can cause
excessive wear or what can be classified as wear.

Causes of Abnormal Wear of Filled TFE Packing Rings once established will permit the packing rings to run on this film at
Because of the wide use of filled TFE plastic as a packing ring very low wear rates. When running with lubrication, this film is not
material certain peculiarities in its operating characteristics should established unless the lubricant is completely withdrawn. Once this
be understood. While the same conditions which cause abnormal film has been established, if oil is introduced it will mechanically
wear in metal packing rings just described apply also to the plastics, displace the TFE surface on the piston rod and the rings will operate
there are certain additional phenomena to be considered. To do so, as lubricated ones. If the lubricant is then withdrawn, the rings will
one must understand that because of self-lubricating properties the again establish this film on the mating piston rod surface. During
filled TFE materials will run completely without external lubrication this coating period, high wear rates of the packing rings will be
or they will run as any lubricated material except requiring a bare experienced. It can be seen that conditions which cause alternate
minimum of lubricant. When running without lubricant, the TFE periods of lubrication and non-lubrication to TFE packing rings will be
rings will lay down a coating on the mating piston rod surface and a source of very short ring life.

13
C. Leakage
It is apparent that wear in itself is not the problem but is a Improper Assembly is a readily detectable source of leakage. Rings
manifestation of one or a combination of problems. Leakage, on the installed improperly, that is, with the radial ring facing away from the
other hand, can be both a by-product and a problem in itself. pressure, will allow the packing to leak. If the set has been assembled
in such a way that the packing cups are not perpendicular to the rod,
Wear can be the most obvious cause of leakage. Complete wearing
the packing rings will not be perpendicular to the rod and can cause
out of the rings and failure to compensate for additional wear
leakage.
would, of course, permit clearances and leakage. Wear on the sealing
face of the cup can prevent proper sealing of the rings against the In these instances just mentioned, leakage is actually a by-product
cup, causing leakage. Wear or damage of the cup may be caused of other trouble; however, leakage can in itself be a problem. During
by inadequate or poor lubrication, corrosion, build-up of carbon break-in, where a discrepancy may exist between the rings and the
formations or abrasive material in the gas. rod due to expansion, blow-by can destroy the oil film and cause
excessive packing temperatures, causing further expansion and blow-
Damage to the Rod in the form of scuffing or scoring can be a source
by. In this case, leakage is the problem in itself.
of leakage, or, if excessive wear has occurred on the rod and rings of
the original diameter are used, leakage will occur.

Packing Care During Assembly

One of the large contributing factors to the ultimate life of a metallic packing is the break-in. As has been discussed, break-in consists of
wearing the rings to a suitable fit with the rod at operating temperature. The most expedient way to accomplish this is to run at the operating
temperature. It is difficult to predict with any degree of accuracy the exact temperature of each pair of rings in the set or of the piston rod
because of the variables which affect it; consequently, premachining to obtain the fit and operating conditions is in most cases impractical.
Proper break-in can be broken down into the following steps: assembly, wear-in and burnishing.

Assembly requires care in handling of the parts to prevent damage, will prevent cocking of the packing cups and ensure their being in a
observing a few simple precautions and following the assembly perpendicular plane with the piston rod.
drawing provided with the operator’s manual. The parts should all be Before making oil connections to the packing, the lubricators should
free of nicks, burrs, scratches, etc., and should be laid out in the order be hand operated to ensure that oil is reaching the point of the
in which they are to be assembled. connection. After making the connections, the lubricator should
As the rings are assembled on the rod, care should be taken that the continue to be hand operated to fill the oil holes in the case.
numbered side faces the pressure, and that dirt or foreign material During break-in, some operators have found that filling the lubricator
does not separate the joints of the rings or the rings of
with a heavier oil than will be used during operation is helpful since
a pair. On lubricated packing, the rings should be liberally the heavier, more viscous oil will help seal the rings during wear-in.
coated with oil. Extra oil can be put on the rod with a swab or an oil can at the face of
The cup joints should also be free of anything which would hold them the flange.
apart and interfere with their seal. Check the cooling system to ensure that it is functioning properly and
With the packing assembled and in the stuffing box, the flange studs that an unrestricted flow of coolant is obtained. Temperature control
should be tightened as any gasketed joint-applying pressure through is a most important factor during break-in.
opposite studs gradually to obtain even crushing of the gaskets. This

Wear-In of Metallic Rings

Wear-in begins with a no-load run for a short period to ensure that It should be kept in mind that generally the packing temperature is
a film of lubricant has been created between the wearing parts. The checked at the face of the flange, which is the most remote part of
load should be applied in increments, allowing a period of run-in at the packing from the point of highest generation of heat, so that in
each pressure level. The length of time at each level will depend on determining whether or not a stabilized temperature has been reached,
the particular job. If the packing temperature continues to rise without allowance must be made for the fact that the heat must travel through
stabilizing at any given pressure level, or if oil coming from the face of the packing case to the packing flange where it is being felt. Burnishing
the packing is darkened, showing signs of excessively rapid wear, or if of the rubbing surfaces begins when the packing rings have worn to
leakage occurs, the pressure should be dropped back to the previous a fit at the operating temperature. During this period, extra oil should
level for additional running. continue to be fed to the packing for several hours after reaching

14
 MECHANICAL PACKING | DESIGN AND THEORY OF OPERATION

operating conditions. It is during the first few hours of operation at will generally leave a smooth finish which can inhibit break-in and it
actual operating conditions that the rings achieve the burnished serves only to obtain a size which is not the actual size at operating
rubbing surface that contributes so greatly to their life. temperature.
Break-in practice of some operators is to lap the rings to the rod. In Break-in compounds have been used by some operators to speed
general, this is of little if any help. The bore of packing rings is, by “wearing out” of the ring to a fit on the rod. Unfortunately, they
comparison to their other surfaces, rough. This is an intentional finish frequently leave a residue which can cause the rings to stick or bind
and is so made to speed the wearing-in process. Lapping the surface in the grooves and are a problem more frequently than not.

Wear-In of Filled TFE Rings

One of the great advantages gained from the use of filled TFE packing rings has been the virtual elimination of the break-in or wear-in period.
Because the material has some degree of conformability it is possible, even desirable, to obtain operating conditions on the packing as quickly
as permitted by the process. If the TFE rings are being used in lubricated service and it is desired to operate with minimum lubrication, it is
generally desirable that the packing be started with higher feed rates than ultimately intended and that the rate be gradually reduced to the
desired level.

Conclusion
Mechanical packing is a precision seal accurately machined inside and out. It must be handled carefully, installed intelligently, and operated
with good judgment. It is not a frail part to be installed in your machine; it is built as ruggedly as any finely finished, accurately machined piece
of equipment can be, but a bump may burr or scratch it and disturb its seal. A chip or grain of dirt may hold the sealing surfaces apart, bind the
rings tight in the groove, or cause premature wear.
Treat your Mechanical Packing with Respect, Break it in Carefully, Keep it Clean, Lubricate it Properly and it Will Serve You
Economically, Faithfully and Well.

Venting and Purging of Packing

During normal dynamic operation of compressor packing, a certain inert nitrogen — to the packing assembly in addition to special
amount of process gas leakage will occur through the packing ring set, side loaded packing rings. To be effective, this must be supplied
and this can vary according to various operating parameters including gas at a pressure higher than the vent line pressure, and to a position
molecular weight, piston rod diameter, whether lubricated or oil-free, etc. between the vent and the final packing ring seal.
To prevent process gas emissions to atmosphere (or crankcase) it is Purge control panels are available which provide automatic control
necessary to divert any gas leakage, through a gas vent line piped to a safe of purge gas supply and ensure that the proper differential pressure
area. This vent line is taken from within the packing assembly, prior to the relative to vent pressure is maintained.
final packing ring seal, and via a pipe connected onto the packing flange.
For total control of the process gas with a guarantee of no emissions to
atmosphere it is necessary to supply a purge (or buffer) gas — usually

Static Sealing
Some users wish to hold pressurized gas inside the compressor cylinder while the compressor is stopped. This cannot be successfully achieved
with conventional compressor packings, which are designed to function dynamically. For such requirements, it is necessary to incorporate a static
sealing device within the packing assembly. This sealing device is pneumatically activated whenever the compressor is stopped, and de-activated
when the compressor re-starts

This booklet has been reprinted from the original write-up in 1968 by Ed Cummings, Chief Engineer, France Compressor Products. While there have been
improvements in design and materials since then, this still serves as a comprehensive study of the design and performance of rod packing. © 1968

15
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