Major savings follow change to AESSEAL FIDC™

With Murthy Budda

What was the main problem at this site and what was the cause? Why was the competitor’s seal so complicated?

The site was experiencing frequent failures of the competitor’s dual mechanical seal. The seal design was complex and non cartridge, relying on older component seals installed back to back to create a double seal arrangement rather than a true cartridge design. This configuration required precise assembly and handling, making installation difficult under site conditions. As a result, the risk of human error was high, leading to premature seal failures and reduced reliability.

How serious was it, and how much more serious could it have become if AESSEAL had not intervened? Why was it proving so costly?

The issue was extremely serious. Seal failures were occurring frequently -sometimes within weeks - leading to repeated unplanned shutdowns. Each failure caused loss of production, increased maintenance effort, and operational disruption, with downtime costing the site thousands of dollars per day. If AESSEAL had not intervened, these failures would have continued, leading to escalating costs, reduced equipment reliability, and ongoing production instability. The situation was proving so costly because the same seal was being repeatedly replaced without addressing the root cause, resulting in frequent downtime, high labour costs, and continued loss of output.

What was wrong with the fix the company was attempting before they contacted AESSEAL?

The company continued replacing the same complex, non cartridge dual seal. Because the design required precise assembly, repeated installation errors occurred, leading to premature failures. The approach treated the symptom rather than the root cause, so failures, downtime, and costs continued without improvement.

Was the solution obvious and why? What made the FIDC the go to solution?

Yes, once AESSEAL reviewed the application the solution was clear. The FIDC was the obvious choice because it is a true cartridge seal, fully assembled, preset, and factory tested. It eliminated installation complexity, improved barrier fluid circulation, and could be installed without modifying the pump or piping, delivering a reliable and long term solution.

How difficult was the application?

The application itself was not unusual, but it was critical to the customer’s process. Reliability was essential. The FIDC significantly simplified installation and improved robustness compared to the previous seal arrangement.

AESSEAL prides itself on reliability, stock availability, and preparation. How big a part did this play?

This played a very significant role. The FIDC uses modular components that were readily available in stock, allowing for quick delivery. In addition, being a true cartridge seal, it was easy to assemble and install, reducing site work, installation time, and the risk of errors. This ensured a fast turnaround and immediate improvement in reliability for the customer.

Was the customer an existing AESSEAL client and how pleased were they with the results?

Yes, the customer was an existing AESSEAL client. They were extremely pleased with the performance of the FIDC solution. The improvement in reliability and reduction in unplanned downtime were so significant that the customer upgraded 14 additional pumps with the same AESSEAL technology, clearly demonstrating their confidence and satisfaction with the results.

Did the cost savings quickly outweigh the outlay?

Yes. The improved reliability extended MTBF from nine months to approximately 60 months, significantly reducing downtime and maintenance. The solution delivered substantial annual savings, and the investment was quickly recovered. The customer continues to benefit from ongoing cost savings year after year.

How would you summarise the case?

This case clearly demonstrates how preparation, simplicity, and reliability make the difference. By removing complexity and reducing human error, AESSEAL delivered safer operation, improved uptime, and long term cost savings — a clear win for both the customer and AESSEAL.