| Basic seal construction | Balanced pusher seal with a dynamic elastomer secondary seal. | Balanced pusher seal with a dynamic polymeric secondary seal, commonly selected when elastomer compatibility is inadequate. | Metal bellows seal in which the bellows provides secondary sealing and spring force without a dynamic O-ring or polymeric pusher seal. |
| Secondary sealing element | Elastomer O-ring or equivalent elastomeric secondary seal. | Polymeric secondary seal, such as a PTFE-based or other engineered polymer element, depending on the design. | Welded or formed metal bellows; no dynamic secondary-seal sliding movement. |
| Pusher mechanism | Yes. The secondary seal moves axially with the rotating or stationary seal ring. | Yes. The polymeric secondary seal moves with the pusher component. | No conventional pusher O-ring; bellows flexibility provides face loading and axial movement. |
| Typical material-selection focus | Elastomer chemical compatibility, temperature capability, swelling resistance, and compression-set performance. | Polymer chemical resistance, extrusion resistance, temperature capability, and friction behavior during movement. | Bellows alloy compatibility, weld integrity, corrosion resistance, fatigue life, and face-material selection. |
| Common process-fluid considerations | Clean or moderately contaminated fluids where a compatible elastomer is available. | Fluids that attack common elastomers or applications requiring a wider chemical-resistance range from the secondary seal. | High-temperature, corrosive, toxic, or difficult-to-seal fluids where eliminating dynamic secondary-seal movement is beneficial. |
| Temperature capability | Usually limited by the selected elastomer and process-fluid compatibility. | Usually limited by the selected polymer, face materials, and extrusion-control design. | Often suitable for higher-temperature service than elastomeric designs, subject to bellows alloy, weld, face, and cooling limits. |
| Pressure and speed limits | Must be established from the qualified seal design, pressure-velocity limits, balance ratio, and equipment operating envelope. | Must be established from the qualified polymeric secondary seal, extrusion control, pressure-velocity limits, and equipment operating envelope. | Must be established from bellows stress, fatigue life, pressure rating, face loading, and rotational-speed limits. |
| Main advantages | Broad availability, comparatively simple construction, cost-effective maintenance, and a large range of elastomer options. | Improved chemical resistance compared with many elastomeric designs and reduced dependence on elastomer compatibility. | No dynamic O-ring wear, strong high-temperature potential, and good suitability for demanding or hazardous services. |
| Main limitations | Elastomer swelling, hardening, chemical attack, extrusion, and compression set may affect service life. | Polymer creep, extrusion, friction, thermal limitations, and installation sensitivity must be evaluated. | Higher design complexity, strict bellows and weld-quality requirements, and sensitivity to fatigue, corrosion, and incorrect operating conditions. |
| Typical selection priority | Best when the process fluid is compatible with an elastomer and operating conditions are within the qualified pusher-seal range. | Best when elastomer compatibility is a concern but a pusher configuration remains preferred. | Best when high temperature, hazardous-fluid containment, corrosion resistance, or elimination of dynamic secondary sealing is important. |
| API 682 design verification | Selection should be supported by API 682 qualification testing, correct materials documentation, and application-specific operating limits. | Selection should be supported by API 682 qualification testing, polymer compatibility data, and application-specific operating limits. | Selection should be supported by API 682 qualification testing, bellows design verification, weld inspection, and application-specific operating limits. |
| Important procurement checks | Seal type, API 682 edition, arrangement, piping plan, elastomer grade, face combination, pressure, temperature, speed, and emissions requirements. | Seal type, API 682 edition, polymer grade, extrusion-control design, piping plan, face combination, pressure, temperature, speed, and emissions requirements. | Bellows alloy, bellows configuration, weld quality, fatigue rating, piping plan, face combination, pressure, temperature, speed, and emissions requirements. |