Pump, Compressor & Rotating Equipment Assembly worked example

Seal Leak Rate at 68% first-pass seal target: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop first-pass seal target to 68%, then walk the calculation through step by step. Seal leak rate is the percentage of pumps or compressors that fail their mechanical-seal leak test during assembly certification — the single most common warranty and rework driver on rotating equipment.

The inputs for this scenario

  • Units failing seal leak test: 8 units (held at the documented default)
  • Units seal-tested: 250 units (held at the documented default)
  • First-pass seal target: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Seal Leak Rate rate = affected amount ÷ total amount.
  • Rate works out to 3.2 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target works out to 64.8 points at these inputs.
  • Affected count works out to 8 count at these inputs.
  • Total count works out to 250 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass seal target sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to first-pass seal target, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. A rate alone hides sample size and Pareto detail — 8 fails out of 250 tells you the percentage but not whether one seal lot, one operator, or one product family is driving it.

Results at a glance

  • Rate: 3.2 % (headline result)
  • Gap to target: 64.8 points
  • Affected count: 8 count
  • Total count: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Seal Leak Rate calculator, set first-pass seal target to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.