Resolving Chronic Pump Failures with the PackRyt®Diverter System
Background
A major industrial facility faced persistent issues with a dilution pumpthat had become increasingly problematic over the past three years. Due toirregular maintenance intervals, the pump suffered from premature sleeve wearand persistent packing leaks. The degradation reached a point where bearingfailures became frequent, leading to repeated rebuilds and costly downtime. Intotal, losses related to this single pump exceeded $160,000.
The maintenance team had tried several standard solutions, butnothing provided long-term reliability. The underlying issue, they discovered,was not just the age or wear of components, but a deeper design flaw inherentin many traditional stuffing box configurations.
The Core Issue: Inadequate Flush Port Design
Most standard stuffing box designs include a flush port locatedtoo low within the box. As the pump wears over time, this positioning becomesmore problematic. A low flush port fails to direct flush water effectively tothe critical sealing zone, especially when concentricity between the shaft andthe stuffing box is lost. This contributes to increased leakage, excessivewater use, and packing degradation.
In this case, the pump’s flush port was positioned well belowthe ideal level, causing poor flushing, overconsumption of water, andineffective sealing—all contributing to the operational failures and rebuildcycle.
Introducing the PackRyt® Diverter System
SealRyt's PackRyt® Diverter was introduced as a retrofitsolution designed to address thesechallenges. Unlike traditional lantern ring setups that flood the stuffing boxwith flush water—often to the detriment of process efficiency—the PackRytDiverter integrates a flush channel relocation system directly within thecomposite bearing structure.
This innovation moves the flush port to the optimal locationinside the stuffing box without requiring any machining or structural changesto the pump. The Diverter’s internal design throttles excess flush water anddeposits it precisely where it is needed, eliminating waste while improvingsealing performance.
The system also brings the shaft into true concentricity andmaintains it, drastically reducing packing wear and increasing bearing andshaft longevity. The combined effects of better shaft alignment, optimal flush location, and controlledflush volume create a highly reliable seal environment.
Results
Since the installation of the PackRyt Diverter, the formerlytroublesome dilution pump has run continuously for over three months with justa slight, controlled drip—well within expected parameters. No bearing issues have been reported, and the packing has not needed adjustment or replacement.
In addition to the mechanical improvements, the Diverter hassignificantly reduced flush water consumption. By relocating the flushinternally and throttling it, the system no longer relies on high volumes ofwater to force lubrication into the seal area. This saves not only water butalso energy used to pump and treat it—adding to the cost savings over time.
Conclusion
This case illustrates how a thoughtful retrofit solution candeliver long-term reliability and savings without requiringcostly redesigns. The PackRyt Diverter not only fixedthe immediate issue of persistent leakage and rebuilds but also future-proofedthe pump against further failures due to wear-induced misalignment or flushinginefficiencies.
Many pump owners and operators accept chronic leakage andrebuilds as part of their maintenance routine. But as this case proves, thoseproblems are often symptoms of poor stuffing box and flush portdesign—especially as components wear. SealRyt’s PackRyt Diverter directly addresses these issueswith a unique internal architecture that adapts to existing equipment anddelivers lasting performance improvements.
For facilities looking to reduce maintenance costs, downtime,and water consumption, the PackRyt Diverter offers a proven path forward—onethat requires no costly structural changes and provides immediate, measurableresults.
