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John Crane GmbH Gleitringdichtungssysteme GB Instruction Manual Mechanical Seal Item no. 10 Customer: Netzsch,

John Crane GmbH

Gleitringdichtungssysteme

GB
GB

Instruction Manual Mechanical Seal

Item no.

10

Customer:

Netzsch, Waldkraiburg

Customer order no.:

463484+468962

John Crane order no.:

4000478446

Seal drawing no.:

GA-136052

John Crane material no.:

89452030

Customer material no.:

5180217

John Crane Engineered Sealing Systems

GB
GB

Instruction Manual Mechanical Seal

This seal may only be installed, commissioned and maintained by an authorised plant machinery specialist, paying close attention to these instructions and all other relevant regulations. Failure to do this relieves the manufacturer from any liability or warranties.

In the interest of continuous development, John Crane reserves the right to alter designs and specifications without prior notice.

For your nearest John Crane facility, please contact one of the locations below

John Crane GmbH

Werner-von-Siemens-Straße 6

Postfach 2528

Telefon (0661) 281-0

08/2012 AB

Gleitringdichtungssysteme

D-36041 Fulda

D-36015 Fulda

Telefax (0661) 71056

BA GLRD_Edition_7.6_GB.doc

Page: 2

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Edition 7.6

16

Instruction Manual

Page: 2 of: Edition 7.6 16 Instruction Manual Contents 1 3 1.1Introduction 3 1.2Range of Application

Contents

1

3

1.1Introduction 3 1.2Range of Application

3

General

2 Safety & Environment

3

2.1Symbols

3

2.2Safety Instructions

3

2.3Environmental Aspects

4

2.3.1 Company policy extract

4

2.3.2 Recycling

4

3 Transportation and Storage

5

4 Description of the Mechanical Seal

5

4.1Construction

5

4.2Function

6

4.3Operating Conditions

6

5 Installation and Removal

6

5.1Preparation for Fitting

6

5.2Installation Tolerances

7

5.2.1 Shape and Positional Tolerances

7

5.2.2 Surface Finish

7

5.3Installation

7

5.3.1 Tightening Torques

9

5.3.2 Lubricants

10

5.4Seal Removal

10

5.5Installation and Removal of Shrink Discs (John Crane supply*)

10

6 Commissioning and Decommissioning

11

7 Maintenance/Repair

14

7.1Maintenance 14 7.2Reconditioning 15

7.3Spare Parts

16

8 Malfunction, Causes and Correction

16

9 Accompanying Documents

16

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Instruction Manual

Page: 3 of: Edition 7.6 16 Instruction Manual 1 General 1.1 Introduction This Instruction Manual is

1

General

1.1

Introduction

This Instruction Manual is provided to familiarise the user with the seal arrangement and its use. The Instructions must be read and applied whenever work is done on the seal, and must be available to the operating and maintenance personnel.

These instructions will help to avoid danger and increase reliability.

John Crane reserve the right to change the seal and specifications described in this manual where it is necessary for technical development and without prior notice. The latest issue supersedes all previous versions.

1.2 Range of Application

Mechanical sealing systems are used for the sealing of rotating shafts; they must be operated within their performance limits (see 4.3 Operating Conditions).

their performance limits (see 4.3 Operating Conditions). If the process or operating conditions are changed from

If the process or operating conditions are changed from those referenced in this Manual, John Crane must be consulted to ensure the sealing system is safe.

2 Safety & Environment

The safety notes refer to the arrangement supplied. They must be used in conjunction with the relevant safety regulations for the machine, auxiliary equipment, plant and sealed fluid.

2.1 Symbols

The following symbols are used in this Instruction Manual to highlight information of particular importance:

Manual to highlight information of particular importance: ATTENTION N o t e : Danger Mandatory instructions

ATTENTIONManual to highlight information of particular importance: N o t e : Danger Mandatory instructions designed

Note:

Danger

Mandatory instructions designed to prevent personal injury or extensive damage.

Special instructions or information to avoid damage to the seal or its surroundings.

Information for easy installation and efficient operation.

Environmental NoteInformation for easy installation and efficient operation. 2.2 Safety Instructions ATTENTION Every working practice

2.2 Safety Instructions ATTENTION Every working practice which compromises safety is to be avoided. In
2.2 Safety Instructions
ATTENTION
Every working practice which compromises safety
is
to be avoided.
In
the event of an operating problem the
machinery must be switched off immediately and
made safe! Problems must be solved promptly.
A slight leakage will occur during normal seal
operation. Depending on the duty, this leakage
can appear as a gas, a liquid or a solid. In case of
a worn or defective seal the leakage will increase.
The leakage may be hazardous or toxic, and a
safe collection system is required.
Hot surfaces have to be protected against
accidental contact.
In order to avoid unforeseen hazards do not make
unauthorised changes to the fluid to be sealed,
the specified duty, or the seal parts.
Page: 4 Instruction Manual of: 16 Edition 7.6 ATTENTION John Crane adopts the ‘Design For
Page: 4
Instruction Manual
of:
16
Edition 7.6
ATTENTION
John Crane adopts the ‘Design For the
Environment’ (DFE) principle in making this
product. Using this product will benefit the
environment directly by:
Some mechanical seals are used in conjunction
with an auxiliary support system; this is clarified
by the flush plan description described on the seal
arrangement drawing. It is important for the safe
function of the seal that the support system is
assembled and incorporated into the machine
before operation. This Instruction Manual should
be read in conjunction with the appropriate
documentation for auxiliary systems and rotating
equipment.
Reducing waste of precious resources
through decreasing the risk of leakage &
minimising energy consumption
Preventing pollution through controlling
harmful emissions to the atmosphere
Alarm systems are often included in the auxiliary
support system and the operator must ensure
appropriate action is taken promptly in the event
of an alarm.
Preserving valuable materials
resources through the re-use of these
high quality durable seals due to their
ability to be refurbished.
Maintenance with steel tools must be avoided in
the presence of substances classed as explosive
group IIc according to EN50014.
2.3.2 Recycling
Product refurbishment
If the machine is being used in a zone 21 or 22
regular cleaning of dust from exterior surfaces is
required.
It is dangerous to smoke while handling products
made from PTFE.
Compounds containing PTFE, fluorocarbons and
perfluoroelastomers should never be burnt as the
fumes and residues are highly toxic. If this
accidentally occurs protective equipment should
be worn as hydrofluoric acid may be present.
Follow the local relevant guidelines for the safe
and environmentally friendly disposal of assembly
lubricants, supplied fluids and scrapped
components.
This product has been designed for potential
reuse. Depending on its post operation
condition, the seal may be repaired or rebuilt
for further use. All metal components may be
reused. The Primary & Mating Rings may be
relapped and reused. Drive screws and
springs are replaced. O-Rings must be
replaced. Please consult John Crane for
assessment of seal condition and its potential
re-conditioning. Only qualified John Crane
Engineers at recognised John Crane
Customer Support Units should carry out re-
conditioning & repair of this product
Disposal

2.3 Environmental Aspects

2.3.1 Company policy extract

“It is the policy of John Crane to manage its business activities in an environmentally responsible manner, comply with all relevant laws and regulations, prevent pollution, and continually improve its environmental performance, certification to the latest issue of ISO 14001 ensures compliance.”

When the product is considered to be beyond economical repair and potential reuse, it should be disposed of by environmentally beneficial means. The product can be disassembled with ease.

Scrapped components

These should be handled with extra care due to possible contamination. They should be recycled through local industrial recycling plants.

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Instruction Manual

Page: 5 of: Edition 7.6 16 Instruction Manual Special materials Follow the local relevant guidelines for

Special materials

Follow the local relevant guidelines for the environmentally friendly disposal of assembly lubricants, supplied fluids and scrapped components. Compounds containing PTFE, fluorocarbons and perfluoroelastomers should never be burned as the fumes and residues are highly toxic. Please refer to Safety Instructions- Section 2.2.

Packaging

All packaging materials used are made from recyclable, environmentally friendly materials.

For additional information on transportation and storage refer to John Crane document I-Storage.

The sealing system does not require any preservatives; it is resistant against all normal environmental conditions.

If any machine, with an installed seal, has been stored with preservatives before putting it back into operation then the seal must be removed, cleaned and dried. Particular attention must be applied to the cleanliness of the faces and condition of the elastomers.

ATTENTIONcleanliness of the faces and condition of the elastomers. Ensure preservatives and cleaning agents do not

Ensure preservatives and cleaning agents do not affect the elastomers.

When in doubt or for further information and advice on this subject, please consult John Crane.

3 Transportation and Storage

Once the seal is fitted on the machine and the position is

ATTENTIONOnce the seal is fitted on the machine and the position is set using setting devices

set using setting devices do not re-engage them for transportation and storage.

Transport and store the seal in its original packaging.

To ensure seals remain in good condition they should be stored in the following environment:

dry and dust-free

ventilated at room temperature

protected from direct effects of heat and ultraviolet light

elastomers require replacement after 60 months except Butyl rubber elastomers that require replacement after 24 months

pusher seals (e.g. API 682/ISO 21049 Type A) installed in a machine that has not rotated for 1 year or more must be axially moved prior to starting the machine. Depending on the seal type it may require removal from the machine to carry this out. Consult John Crane for more information.

further information on elastomer storage can be found in ISO 2230 and US Aerospace Standard SAE ARP 5316

If used seal parts are to be transported to the manufacturer or a third party it is the responsibility of the sender to ensure that the parts are cleaned, decontaminated and have safe handling instructions externally attached.

4

Description of the Mechanical Seal

4.1

Construction

All mechanical seals are composed of the same basic elements (also refer to the installation drawing in Section 9).

(also refer to the installation drawing in Section 9). Fig. 1: Typical Pusher Mechanical Seal Primary

Fig. 1:

Typical Pusher Mechanical Seal

Primary seal components

a) primary ring

b) mating ring

Secondary seal component

c) dynamic seal

d) static seal

Spring component

e) multiple spring

Drive and retaining components

f) retainer

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Instruction Manual

Page: 6 of: Edition 7.6 16 Instruction Manual Fig. 2: Typical Metal Bellows Mechanical Seal Primary
Page: 6 of: Edition 7.6 16 Instruction Manual Fig. 2: Typical Metal Bellows Mechanical Seal Primary

Fig. 2:

Typical Metal Bellows Mechanical Seal

Primary seal components

a) primary ring

b) mating ring

Secondary seal component

c) static seal

d) static seal

Spring component

e) metal bellows

Drive and retaining components f) compression collar

4.3 Operating Conditions

Refer to data recorded on drawing and Seal Data Sheet (if applicable) in Section 9 and referenced on the front page.

If no data is available refer to John Crane’s published Product Data Sheet specific to the seal type used (see www.johncrane.com), or consult John Crane direct.

used (see www.johncrane.com), or consult John Crane direct. The seal cartridge has been selected to safely

The seal cartridge has been selected to safely contain the maximum static seal chamber pressure. Any change from the original, specified pump operating conditions, including casing and/or piping hydrotest may compromise this safe containment. Refer to the Seal Data Sheet specific to the plant item or consult John Crane for the maximum sealing- pressure rating of the seal cartridge.

5 Installation and Removal

4.2

Function

The hydraulic pressure and the spring force press the axially flexible primary ring against the stationary mating ring. Wear at the primary seal is minimised by a very thin lubricating film. Lubrication is provided by the sealed fluid; in the case of gas, the mechanism is usually enhanced by spiral grooves in order that the faces run non- contacting. Some liquid seals use macro features on the face to enhance lubrication such as shallow slots and grooves (spiral grooves in the case of Upstream Pumping). With very low contact loads special seals can be operated without a liquid lubricant. The leakage is minimised by flat lapping to a fine surface finish.

is minimised by flat lapping to a fine surface finish. Without the intended lubrication the seal

Without the intended lubrication the seal face temperatures will increase and may provide an ignition source in a potentially explosive atmosphere.

Proper operation of the machine and adherence to the recommendations in this Instruction Manual and associated manuals will prevent this occurring.

5.1 Preparation for Fitting

Check whether the seal is complete, clean and undamaged.

Clean all machinery abutments, sealing and fitting surfaces (use only absorbent and fluff-free polishing cloth for cleaning).

Remove any protective coatings.

Check all relevant machinery dimensions, and that correct chamfers (see fig. 3) exist on all leading edges. Refer to drawing in Section 9.

1,5 mm 20° 1 mm Radius
1,5 mm
20°
1 mm
Radius
Fig. 3 ATTENTION
Fig. 3
ATTENTION

In

chamfer dimensions are related to the O-ring section. The dimensions in Fig 3 apply only for O-rings up to

O-rings

the

case

of

3.53 mm (0.139 in).

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Instruction Manual

Page: 7 of: Edition 7.6 16 Instruction Manual 5.2 Installation Tolerances The performance and reliability of

5.2 Installation Tolerances

The performance and reliability of the sealing system is influenced by the installation tolerances. Ensure that the tolerances do not exceed the required limits.

5.2.1 Shape and Positional

Tolerances

Component

Type

Tolerance

Shaft to

Squareness

1µm/mm

Housing

chamber

bore FIM*

Shaft to

Concentricity

0.13

mm

Housing

 
   

static

± 0.25 mm

Shaft End Float

Axial

dynamic

± 0.065 mm

Shaft or Sleeve

Ovality

0.05

mm

Housing to

Runout

0.05

mm

Shaft

 

Installation tolerance figures stated on general arrangement drawing (Section 9) take precedence * API 682 and ISO 21049 requires <0.5 µm/mm of chamber bore, FIM.

5.2.2 Surface Finish

Seal Type

Value

dynamic O-ring

0.3/0.8 µm Ra (ground or polished)

static O-ring

<1.6 µm Ra (turned)

elastomer bellows

0.8/1.2 µm Ra (turned)

PTFE bellows

0.8/1.2 µm Ra (turned)

dynamic and static wedge

0.1/0.25 µm Ra (polished)

Packing ring (static)

0.8/1.6 µm Ra (turned)

5.3 Installation

ATTENTION

Carefully protect the lapped

sealing surfaces of primary and mating rings during fitting. Minor damages to sensitive surfaces, such as scratches and chips, reduce the sealing effectiveness of the mechanical seal.

Carry out fitting according to the installation drawing (section 9 and front page) and with the following procedure:

A tapped hole on the top of the gland plate is provided for those cartridges requiring additional mechanical lifting assistance. Refer to the Installation Drawing (see Section 9 and front page) for the recommended eyebolt type and size. On vertical shaft machines two linked collar eyebolts should be used. Eyebolts are not ordinarily a part of the scope of supply. Where appropriate fully engage the specified eyebolt or eyebolts into the tapped hole and connect to safe lifting equipment.

Eyebolts must meet the appropriate National Standards and their availability and use should be part of a local QA programme.into the tapped hole and connect to safe lifting equipment. “Dynamo” eyebolts must only be used

“Dynamo” eyebolts must only be used with axial loading (straight pull). For all other loading collared eyebolts must be used.availability and use should be part of a local QA programme. The seal eyebolt(s) must never

pull). For all other loading collared eyebolts must be used. The seal eyebolt(s) must never be

The seal eyebolt(s) must never be used for lifting the machine. Maintain cleanliness during fitting.

Lubricate shaft with a suitable fluid in the installation area.

Lubricate the shaft and housing sealing components with a suitable fluid (see Section 5.3.2), also ensuring they maintain their correct position during fitting.

ATTENTION

EP-elastomer O-rings and bellows are not resistant to mineral oil or grease.

Page: 8 Instruction Manual of: 16 Edition 7.6 ATTENTION Silicone-elastomer O-rings are not resistant to
Page: 8
Instruction Manual
of:
16
Edition 7.6
ATTENTION
Silicone-elastomer O-rings
are not resistant to silicone oil
or grease.
If not indicated refer to Section 5.3.1.
Torque levels for gland plate studs or
bolts must conform to those given in the
relevant rotating machinery manual.
ATTENTION
When the sleeve is fixed to
the shaft by shrink disc, the
area under the clamp must
be kept free of lubricant (see
Section 5.5).
The seal faces should not be
lubricated with oil or grease
as this may prevent
introduction of the sealed
fluid in operation, leading to
overheating and failures.
For cartridge seal designs that do not
have a metal-to-metal contact
between the gland plate and the seal
chamber face it is important they are
aligned and the axial gap between
them is equal around its
circumference. This can be checked
with a gap gauge.
ATTENTION
ATTENTION
Ensure the seal arrangement is orientated
correctly, according to the housing, pipework,
and shaft connections (e.g. studs, keyways,
pins and drive holes).
On double-ended pumps
ATTENTION
ensure the drive-end and
non-drive-end seals are
appropriately selected.
Slide the seal assembly over the shaft
and into position.
If a flexible graphite seal is
ATTENTION
used as the shaft/sleeve seal
remove this before sliding the
seal assembly into position.
Re-insert the flexible-graphite
seals and retain with the
follower. Set the seal to the
correct working length and
fully tighten the radial socket
set screws. Then fully tighten
the follower screws (see
warning below for high
temperature metal bellows
seals.
For high temperature metal bellows seals
e.g., 1604, 2609, 3609 etc the pump shaft
may need dimpling to ensure adequate drive.
Check on the drawing in Section 9. If required
bolt the seal assembly to the pump back
plate and finish assemble the pump so that
the shaft is in its final position relative to the
casing. In the case of hot pumps where
thermal growth is known to be a problem,
allowance can be made by offsetting the
shaft by the required amount. Remove the
collar socket set screws and using a
clearance drill, drill through to mark the
centre of each screw. The shank of the drill
should be protected by masking tape to avoid
damaging the threads. Remove the seal
assembly and using a drill 2mm larger than
the collar screw size, dimple the shaft to the
full diameter. Carefully remove all burrs to
avoid damaging the seal. Refit socket set
screws with a suitable thread-lock liquid,
located into the shaft dimples.
ATTENTION
If setting devices are used,
they must be disengaged
after the seal is fixed securely
in place in its final position.
They can then be disengaged
and locked securely or
appropriately stored.
be disengaged and locked securely or appropriately stored. If a pumping scroll is included and is

If a pumping scroll is included and is externally exposed, extreme care must be taken in handling due to the sharp edges that are required in this component. It is recommended that protective gloves are worn whenever these devices are handled, either during installation or removal.

Tighten fasteners evenly to the torque levels indicated in the installation drawing.

ATTENTION

On double ended pumps the drive collar socket set screws or sleeve drive component must be tightened after the bearing brackets have been fitted. When the seal is radially located from the shaft (no gland spigot) the gland nuts must also be tightened after the bearing brackets have been fitted.

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Instruction Manual

Page: 9 of: Edition 7.6 16 Instruction Manual If movement by hand turning the shaft. possible

If

movement by hand turning the shaft.

possible

check

for

freedom

of

Check on all pipework, hoses and fittings:

Remove and discard any plastic plugs used during transit.

Ensure correct location, alignment and support

Ensure all porting is correctly connected and the intended fluids flow at the correct flow rate. Refer to installation drawing (see Section 9) and relevant rotating machinery manual or P & ID.

Ensure correct size pipework and specification.

All unused connections must be safely plugged with the as-supplied metal pipe plugs. Check whether drain connection should be open or piped to a collection area.

During assembly to the machine all pipework and plug connections to seal gland plate or chamber ports must have the threads sealed with a sealant suitable for the service.

Ensure all pipework on liquid barrier/buffer systems and cooling circuits are orientated to ensure effective venting.

Visually check for any damage and leaks.

5.3.1 Tightening Torques

Tightening Torques [Nm] (u 0.125 lubricated)

Thread

Legacy

Socket

Socket

Socket

Size

Size

Setscrew

Setscrew

Setscrew

Code

(ASTM A453- Gr 660 C) GMC 0649

(316)

(High Tensile

Steel (14.9)

GMC 0550

GMC 0225

- lubricated

- lubricated

- lubricated

Legacy

Legacy

Legacy

Part Code

Part Code

Part Code

Size/305/712

Size/305/001

Size/305/050

M4

77**

N/A

1.5

2.5

M5

78**

N/A

3

4.5

M6

79**

6

4

7.5

M8

80**

15

11

18

M10

81**

30

16

36

M12

82**

50

40

60.5

M14

83**

N/A

N/A

N/A

M16

84**

N/A

N/A

N/A

M20

86**

N/A

N/A

N/A

1/4 - 20

35**

6

7.9

9.8

5/16 - 18

36**

N/A

14.7

18.6

3/8 - 16

37**

N/A

26

32.8

7/16 - 14

38**

N/A

31.6

48.6

1/2 - 13

39**

N/A

56.5

70.1

 

Tightening Torques [Nm] ( lubricated)

Thread

Legacy

Steel Cap or Hexagon Head Screws

Stainless Steel Cap or Hexagon Head Screws

Size

Size

Code

(Class 12.9)

(316 A4-70)

GMC 0225

GMC 0550

- lubricated

- lubricated

Legacy

Legacy

Part Code

Part Code

Size/301/050

Size/301/001

M4

77**

4.6

1.9

M5

78**

9.4

3.9

M6

79**

16

6.6

M8

80**

39

16

M10

81**

77

32

M12

82**

135

56

M14

83**

215

90

M16

84**

340

142

M20

86**

664

277

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Page: 10 16 of: Edition 7.6 Instruction Manual These torque values are important for the safe

These torque values are important for the safe operation of the seal assembly and sleeve retention. Retention calculations assume a maximum shaft hardness of 32HRC (301HB, 318HV). If the shaft surface has a higher hardness specification contact John Crane for advice.Page: 10 16 of: Edition 7.6 Instruction Manual 5.3.2 Lubricants The following lubricants are recommended by

5.3.2 Lubricants

The following lubricants are recommended by John Crane:

Application

Lubricant

Note

All o-rings except for food, pharmaceutical and related applications

Du Pont

Apply very

Krytox® FG24

thinly by

hand

All o-rings for food, pharmaceutical and related applications

Consult

 

machine

 

manufacturer

All fasteners except for food, pharmaceutical and related applications

Molybdenum or nickel based anti-seize compound

Apply with brush or by hand

All fasteners for food, pharmaceutical and related applications

Consult

 

machine

manufacturer

All elastomer bellows on shaft except for food, pharmaceutical and related applications

Chloride free

Apply with

potable water

sprayer

or glycerine

All elastomer bellows on shaft for food, pharmaceutical and related applications

Consult

 

machine

manufacturer

5.4 Seal Removal

Ensure that the decommissioning instructions as given in Section 6. have been carried out.

Work on the seal must only be carried out when the machine is stationary, and secured against any unforeseen start-up.instructions as given in Section 6. have been carried out. Removal is essentially the reverse procedure

Removal is essentially the reverse procedure to installation.

ATTENTION
ATTENTION

Refit seal setting devices prior to removal.

Note: Some seals are supplied with threaded extraction holes in the gland plate. Insert suitable extraction bolts.

5.5 Installation and Removal of Shrink Discs (John Crane supply*)

Outer Locking Screw Inner Ring Sleeve Shaft grease-free
Outer
Locking Screw
Inner Ring
Sleeve
Shaft
grease-free

Installation

The shrink disc is supplied ready to be installed on the sleeve, and should not be dismantled prior to the initial installation.

Degrease sleeve bore and shaft!

Slide seal assembly over the shaft. Low viscosity lubricants can be used. See section 5.3.2.

Tighten all locking screws uniformly in a clockwise sequence, over several revolutions. It is advisable to tap the outside surface of the outer ring occasionally to free any amount of misalignment or jamming that may occur. Check the correct full tightening torque of all screws!* (see installation drawing in Section 9)

Refer to the machine manufacturer’s instructions if not of John Crane supply. Do not tighten the locking

ATTENTION

screws until the shaft is in its correctly set operating position

Make sure that outer and inner rings are aligned. This is a visual check on the effectiveness of the shrink disc. If not, loosen and repeat above installation procedure

Removal

Remove rust, which may have formed on the shaft in front of the sleeve.

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Page: 11 of: 16 Edition 7.6 Instruction Manual Loosen all locking screws uniformly, in a clockwise

Loosen all locking screws uniformly, in a clockwise sequence; initially about a quarter turn per revolution only. Do not remove screws from the threads.

If the outer and inner rings have not separated, remove some screws and insert them in the neighbouring extraction screw threads.

The shrink disc may have to be cleaned and re-greased before re-assembly (use a grease containing MoS 2 on the shrink disc cones and locking screws).

6

Commissioning and Decommissioning

Note before start-up:

If the seal cartridge requires auxiliary systems for its reliable operation refer to the separate Instruction Manuals for advice on the installation, operation, function/alarm setting and maintenance of the system or systems.

Ensure transit plugs are removed and seal drain connections are correctly piped or open.

Ensure all connections are either correctly piped or safely plugged with a metal plug.

Ensure valves controlling circulation, flush, quench and buffer or barrier topping up systems are correctly positioned. Check, where appropriate, flow rates for Plans 32, 54, 62, and 72 are at the required values.

for Plans 32, 54, 62, and 72 are at the required values. If a heat exchanger

If a heat exchanger is included in the support system and isolating valves are used in the coolant supply, a pressure relief valve should be incorporated between the isolating valves.

Ensure the seal chamber and/or barrier, buffer and cooling circuits are fully vented. (Not necessary on gas lubricated seals). This is particularly important on Upstream Pumping designs if a localised closed-loop system is used; it is recommended the machine shaft is spun for a short time and static venting repeated to ensure all gas is removed from the circuit.

ATTENTION
ATTENTION

Regular venting may be needed during commissioning on Plan 23, particularly on vertical machinery.

If the seal is unidirectional, check that the seal’s rotation direction matches the machine’s rotation direction.

With liquid lubricated seals avoid dry running under any circumstances, as it will damage the seal and may result in a hazard. (Not relevant to gas lubricated seals and dry containment seals).direction matches the machine’s rotation direction. ATTENTION Ensure that if a bearing is fitted as part

ATTENTIONrelevant to gas lubricated seals and dry containment seals). Ensure that if a bearing is fitted

Ensure that if a bearing is fitted as part of the seal assembly the Instructions on the Installation drawing (see Section 9 and front page) are applied. Bearings must not be run without lubricant.

ATTENTION

It is advisable to pressurise the machine and check for static leaks before starting it dynamically.

ATTENTION

ATTENTION ATTENTION
ATTENTION
ATTENTION

For hot duties (above 150°C) ensure pump has been brought up to operating temperature prior to start-up. Rapid axial differential thermal growth between shaft and pump casing could result in seal malfunction.

If a Piping Plan 52, 75 or 76 is connected to a flare header ensure the connection is kept isolated until the pump is primed.

If a water test has been applied when flexible graphite seat/mating ring seals are used, they must be renewed or thoroughly dried before use on a hydrocarbon service above 100 o C

Check the correct setting and operation of electrical warning systems associated with seal operation.ring seals are used, they must be renewed or thoroughly dried before use on a hydrocarbon

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Instruction Manual

Page: 12 16 of: Edition 7.6 Instruction Manual Before start-up, ensure that all personnel and assembly

Before start-up, ensure that all personnel and assembly equipment have been moved to a safe distance, that guards are fitted and there is no contact with rotating parts.Page: 12 16 of: Edition 7.6 Instruction Manual To minimise any ignition hazard it is important

To minimise any ignition hazard it is important to ensure seal flush rates, temperatures, and cooling water flow rates are to specification.are fitted and there is no contact with rotating parts. In case of pressurised or unpressurised

In case of pressurised or unpressurised dual seals note:

Auxiliary barrier systems are designed to service mechanical seals by cooling, lubricating and pressurising; they must be operated within their performance limits. If the barrier system is not supplied by John Crane check the system and specification supplied meet the seal’s requirements for reliable operation. Refer to the system Instruction Manual.

The barrier or buffer liquid must be clean, with stable properties over the operating temperature and pressure conditions, and not constitute a hazard or introduce potential damage to the environment. If a mineral oil is to be used it is recommended it be free of any additives (e.g. anti-wear, anti-foaming, anti- corrosion etc) as these may damage the rubbing seal face. The liquid should have good lubricating properties, a viscosity < 15cSt @ 40°C and be compatible with the process fluid. The viscosity should ideally be between 1 and 10 cSt at the working temperature. ISO 21049 and API 682 (3 rd Edition) also offer advice on the selection of barrier liquids. It is recommended John Crane is contacted for more detailed advice on barrier or buffer liquids and a formal approval sought.

Properties of buffer or barrier liquids may be the source of flammable or explosive hazards. In Europe, Plan 53A barrier liquids classified as Group 1 in the Pressure Equipment . In Europe, Plan 53A barrier liquids classified as Group 1 in the Pressure Equipment Directive (97/23/EC) or described in 67/548/EEC, 96/56/EC, 96/54/EC, must not be used without formal approval from John Crane.

During the start-up of the machine in cold ambient conditions the barrier or buffer viscosity should not exceed 150 cSt. If this cannot be ensured the liquid is to be preheated.

Interconnecting pipework between the system and the gland plate must be the correct specification and its length, bend radii, numbers of bends must be as recommended in the system Manual. They must all be continuously rising to aid venting.

Manual. They must all be continuously rising to aid venting. Effective seal cooling is achieved by

Effective seal cooling is achieved by maintaining adequate buffer or barrier liquid flow rate. This is strongly influenced by the system pipework resistance and any trapped gas in it. Recommendations must be applied.

Where a liquid based seal buffer auxiliary system is fitted to non-pressurised dual seals, ensure that the liquid level is correct and that the system is correctly connected to the venting pipework before starting the machine.

Where a liquid based seal barrier auxiliary system is fitted to pressurised dual seals ensure that the liquid level is correct and that the system is correctly pressurised before starting the machine.

ATTENTION
ATTENTION
ATTENTION ATTENTION
ATTENTION
ATTENTION

Cleanliness of the buffer or barrier liquid and cleanliness of the supply pipework for gas barrier systems or liquid top-up systems will have a direct affect on seal reliability.

The machine should not be pressurised suddenly.

If the machine is to be pressure tested the auxiliary barrier system must first be pressurised. The test pressure must be within the seal and barrier system MAWP.

Page: 13

16

of:

Edition 7.6

Instruction Manual

Page: 13 16 of: Edition 7.6 Instruction Manual The barrier pressure for liquid lubricated seals should

The barrier pressure for liquid lubricated seals should be set at least 1 bar above the maximum seal chamber pressure. If a low-pressure switch or alarm is fitted to the system ensure it is set above the maximum seal chamber pressure and below the barrier pressure; there must be an adequate pressure difference between its set point and the barrier pressure to allow the switch to reset. For gas seals the minimum barrier pressure must be 2 bar for 2800E, 2800ER, 2874 and 2874NE, 3 bar for 2800BD, 2800XA & 2800XP 5 bar for 2800HP above the maximum seal chamber pressure, unless other values have been given. The maximum barrier pressure should be within the published seal operational limits. Consult the System Instruction Manual for pressure and alarm settings.Page: 13 16 of: Edition 7.6 Instruction Manual Care should be exercised to ensure the barrier

Care should be exercised to ensure the barrier system’s Maximum Allowable Working Pressure (MAWP) is not exceeded during filling and pressurization.System Instruction Manual for pressure and alarm settings. High ambient temperatures and solar radiation can increase

High ambient temperatures and solar radiation can increase the pressure on Plan 53A and 53B Barrier systems. When normal barrier pressures are close to the seal maximum dynamic sealing pressure or system MAWP measures must be taken to eliminate the risk. Fit a sun-shade and consult John Crane for alternative setting options.(MAWP) is not exceeded during filling and pressurization. Under some circumstances very low ambient temperatures can

and consult John Crane for alternative setting options. Under some circumstances very low ambient temperatures can

Under some circumstances very low ambient temperatures can result in the pressure in Plan 53A and 53B Barrier systems to reduce below the seal chamber pressure. With a Plan 53A ensure the pressurizing gas system isolation valve is never left closed. If a 53B system is operated with the ‘fill isolation valve’ closed (note, some auto-fill systems operate with this valve open) there is a risk of low ambient temperatures causing the barrier pressure to drop below the chamber pressure. An alternative gas charge pressure is then required; consult John Crane.

ATTENTION

Special

gas

pre-charge

precautions

are

advisable

the

accumulator in a Plan 53B.

Consult

the

when

commissioning

System

Instruction Manual.

The cooling water outlet temperature should be < 50 o C. If not, check that the cooling water inlet temperature is sufficiently low and that the flow rate is correct.

The buffer or barrier settlement temperature when in service should typically be < 80 o C (measured at the seal exit connection). Some systems sealing hot process liquids may need to operate above this temperature; suitable warnings and personal protection must then be applied.

When using thermosiphon systems, ensure that the circuit minimises flow restrictions and can be effectively vented. Contact John Crane for more information.

ATTENTION

When

the

machine

is

stopped,

the

seal

system

pressure

should

be

maintained until the machine itself is unpressurised.

Page: 14

16

of:

Edition 7.6

Instruction Manual

Page: 14 16 of: Edition 7.6 Instruction Manual Notes on decommissioning The seal chamber must be

Notes on decommissioning

The seal chamber must be safely completely depressurized and emptied of process fluid before the seal is removed. If the process vapour is hazardous the machine casing must be purged with an inert gas before working on the seal.of: Edition 7.6 Instruction Manual Notes on decommissioning If the machine and any auxiliary equipment have

If the machine and any auxiliary equipment have been used on toxic or hazardous fluids, ensure all precautions are taken to avoid personnel hazards, such as correct decontamination. Note, fluid is often trapped during draining and may exist outside the seal. The relevant rotating machinery manual should be consulted to check for any special precautions.must be purged with an inert gas before working on the seal. If a Plan 23

If a Plan 23 is used the cooling loop must be safely completely drained of process liquid before the seal is removed. If the heat exchanger does not naturally drain and the process liquid is hazardous a gas purge must be applied through the coil to displace the liquid to a suitable drain point.should be consulted to check for any special precautions. Buffer and barrier liquid may be contaminated

Buffer and barrier liquid may be contaminated with process fluid. When draining ensure all precautions are taken to avoid personnel hazards. In a buffer or barrier system it is important to remove all contamination; following draining flushing with a non- hazardous clean fluid is recommended. Ensure drained buffer and barrier liquids are disposed of in a safe and environmental manner.the coil to displace the liquid to a suitable drain point. For removal instructions refer to

For removal instructions refer to Section

5.4

7

Maintenance/Repair

7.1

Maintenance

Carry out the following procedures for trouble free operation:

Check daily:

that the connections are leak free

seal leakage rate and any change

from normal leakage rates. barrier gas flow for gas lubricated

seals Condition of alarm signals

Possible blockage of any strainers,

magnetic filters, cyclones, coalescers or any other filters used. Vibration levels in the machine.

or any other filters used. Vibration levels in the machine. Vibration levels are a good indicator

Vibration levels are a good indicator of the condition of the machine and high levels can have a direct affect on seal and bearing life e.g. - Operation of the machine beyond its Allowable Operating Range (AOR) will increase vibration unacceptably. - Sleeve retention socket set screws can be loosened by high vibration. - Worn bearings can develop into catastrophic seal and machine failure. Monitoring vibration levels and changes can minimise the risk of a hazard.

ATTENTION

If the seal leakage is a process gas this may be difficult to measure. If it is a hydrocarbon an Organic Vapour Analyser may be used and EPA Method 21 applied (contact John Crane for the detail). Alternatively it is advised the machine is regularly pressure tested every 9000 h of operation.

in addition for dual seals check;

 

barrier/buffer liquid level

barrier/buffer liquid temperature

barrier/buffer pressure

in addition for Upstream Pumping seals with a Plan 54 that includes an in-line filter check the differential pressure across the filter is within the design specification.

in addition for dry containment seals

For dry contacting containment seals (S48SC, 48SC, SBOP & ECS) a monthly check with a 1.0 barg gas test is recommended.

Page: 15

16

of:

Edition 7.6

Instruction Manual

Page: 15 16 of: Edition 7.6 Instruction Manual   check monthly buffer gas flow when applied,
 

check monthly buffer gas flow when

applied,

Coalescing filters on gas barrier systems

Wear parts for dry contacting containment seals require replacement after 24000 hrs dynamic operation.

require either replacement or regular maintenance with the machine out of service. Consult the system Instruction Manual.

Check monthly, where appropriate, flow rates for Plans 32, 54, and 62 are at the required values.

Check and adjust torque on external drive collar socket set screws annually.

Steadily increasing leakage rate normally indicates a seal failure condition and attention is required. If the fault cannot be remedied a repair will be required.torque on external drive collar socket set screws annually. If the buffer or barrier liquid systems

If the buffer or barrier liquid systems need replenishment this should only be done with fill systems that exclude air ingress and/or prevent gas leakage to the atmosphere. If the barrier system pressure cannot be maintained at the correct value during topping up then the machine must be stopped, depressurised and isolated first.If the fault cannot be remedied a repair will be required. In some regions where conformance

In some regions where conformance with TA Luft is required, gas and steam may only be discharged in small, controlled amounts.machine must be stopped, depressurised and isolated first. ATTENTION ATTENTION ATTENTION ATTENTION Be careful not to

ATTENTION
ATTENTION
ATTENTION ATTENTION
ATTENTION
ATTENTION

ATTENTION

Be careful not to overfill the reservoir of a Plan 52 with buffer liquid as it may damage the inner seal.

If an auto top-up system is used with a Plan 53A, B or C be careful not to over pressurise the barrier circuit.

If a bearing is included as part of the seal assembly ensure grease or oil is applied at the replenishment periods advised on the Installation drawing (see Section 9 and front page)

Where the seal is externally mounted and there is visibility of the condition of the seal face wear this should be checked monthly. Replacement is advised after 75% of the wear allowance has been used.

Shaft temperature fluctuations, over a period of time, may reduce the original socket set screw friction. This is a risk on all pumps with a process temperature >150 o C (300 o F). Refer to Section 5.3.1 Vibration from unplanned or poor machine o C (300 o F). Refer to Section 5.3.1 Vibration from unplanned or poor machine operation and high levels of start/stop can, over a period of time, loosen socket set screws and other fasteners.reduce the original socket set screw friction. This is a risk on all pumps with a

When repairing the rotating machine ensure all dimensions controlling the radial location of the seal in relation to the shaft are as specified by the machine manufacturer. Excessively damaged, corroded or

worn parts that control the radial location of the shaft to the casing may result in contact between rotating and stationary parts of the seal. This can result in a serious hazard.

parts of the seal. This can result in a serious hazard. 7.2 Reconditioning The mechanical seal

7.2

Reconditioning

The mechanical seal will always require reconditioning after operation. In order to maximise reliability, and minimise safety risks, it is strongly recommended that used seals are returned to John Crane for rebuilding to as-new specification (essential for 2800 range of seals). Alternatively ask for John Crane service personnel to visit site.

It is the responsibility of the sender to ensure that before shipping the parts are cleaned, decontaminated and have safe handling instructions externally attached. Without this information there will be a refusal to handle the goods. (A blank decontamination certificate is available from John Crane).specification (essential for 2800 range of seals). Alternatively ask for John Crane service personnel to visit

Page: 16

16

of:

Edition 7.6

Instruction Manual

Page: 16 16 of: Edition 7.6 Instruction Manual Rebuilding seals to as-new specifications must be carried

Rebuilding seals to as-new specifications must be carried out by qualified personnel.

Note:

It is recommended that a low pressure integrity test is carried out after repair and before installation on the machine.

7.3 Spare Parts

Only John Crane spare parts should be used to recondition seals.

It is advised to stock on site a spare seal cartridge or the minimum replacement parts shown on the installation drawing (Section 9). The order codes for spare parts can be found in the parts list on the installation drawing. (Section 9 and the front page). In the case of gas lubricated seals only complete cartridges should be stored.

The following data is necessary for spare part orders:

seal assembly code part description component code quantity

8 Malfunction, Causes and Correction

John Crane must be consulted in the event of any malfunction of the sealing installation or sealing system. Excessive leakage rate, premature failure, high relative temperatures are all considered examples of abnormal malfunction.

9

Accompanying Documents

Seal Installation Drawing. See front sheet for specific drawing reference number.

Seal Data Sheet (if applicable)

John Crane International - Major Regional Centres

North America

6400 West Oakton Street Suite 164,

Europe, Asia and Africa Buckingham House

Asia Pacific 15 Tuas View Place

Latin America Sawgrass Lake Center,

Morton Grove IL. 60053, USA

361-366 Buckingham Avenue

Singapore 637432

Sunrise, Florida 33323,

USA Telefon +1 847 967 2400

Slough, Berkshire SL1 4LU, U.K. Telefon +44 1753 224.000

Telefon +65 6518 1800

Telefon +1 954 839 2700

Fax

+1 847 967 3915

Fax

+44 1753 224 224

Fax

+65 6518 1803

Fax

+1 954 838 9985

Technische Beratung und Service Bundesrepublik Deutschland, Schweiz und Österreich

John Crane GmbH

Werner-von-Siemens-Str. 6

D-41468 Neuss

D-92353 Postbauer-Heng

A-4061 Pasching

36041 Fulda

Service Center

Rosenstraße 10b

Service Center

Postfach 25 28

Blindeisenweg 41

Industriestraße 1

36015 Fulda

Telefone 02131 6 65 01-0

Telefone 09188 90 30 60

Telefone +43 72 29 7 67 06

Telefon 0661 2 81-0

Fax

02131 6 65 01-11

Fax

09188 90 30 61

Fax

+43 72 29 7 67 07

0661 7 10 56

e-mail: mail@johncrane.de Internet: www.johncrane.com

Fax

scnordwest@johncrane.de

JNagelstrasser@johncrane.de

sclinz@johncrane.de

D-21149 Hamburg

D-69469 Weinheim

D-06258 Schkopau

CH-4103 Bottmingen

Service Center

Service Center

Service Center

Service Center/Vertrieb

Cuxhavener Str. 36

Mierendorffstraße 21

Hallesche Straße 39a

Wuhrmattstr. 13A

Telefon 040 796127-17

Telefon 06201 25 90 97-0

Telefon 03461 72 34 33

Telefone +41 61 4 26 92 92

Fax

schamburg@johncrane.de

040 796127-64

Fax

scweinheim@johncrane.de

06201 25 90 97-11

Fax

scschkopau@johncrane.de

03461 72 37 55

Telefax

johncrane@johncrane.ch

+41 61 4 26 92 80

Teil/ Zeichnungsnummer/ Mat'l Stck./ Ersatz/ Benennung/Description Werkstoff/Material A ORIGINAL ISSUE Ref
Teil/
Zeichnungsnummer/
Mat'l
Stck./
Ersatz/
Benennung/Description
Werkstoff/Material
A
ORIGINAL ISSUE
Ref
Drawing Number
Code
Qty
Spare
'B'
ECN #24418
PU/JH
GA-136052
B
Header Code
0400/588/01/GA136052
SP-BB-Gegenring
SiC
1 D/46592/1/277
9221
SP-BB-Seat
SiC
1
X
O-Ring
Fluorcarbon-Kautschuk
2 2340/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
105
O-Ring
Fluorcarbon-Kautschuk
3 2260/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
O-Ring
Fluorcarbon-Kautschuk
103.5
G 1/8 "IN" / "OUT"
Eintritt / Austritt verschlossen
4 2330/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
Gleitring
Hartkohle, antimonimprägniert
5 D/46594/1/218
9048
Face
Antimony impregnated carbon
1
X
27.5
83
(Inlet / Outlet plugged)
Nach Montage entfernen
Druckring
CrNiMo-Stahl
6 D/46595/1/001
0550
Thrust ring
Stainless steel
1
Stift
CrNiMo-Stahl
25.5
39
(Move out after assembly)
7 5409/317/001
0550
Pin
Stainless steel
2
Feder
Hastelloy C-276
18.5
6
8 4963/092/033
0690
Spring
Hastelloy C-276
10
X
Gegenring
SiC
9 0412/F02/277
9221
Seat
SiC
1
X
O-Ring
Fluorcarbon-Kautschuk
10 0320/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
X
Gleitring
Hartkohle, antimonimprägniert
11 C-56-1625-1004-9048
9048
Face
Antimony impregnated carbon
1
X
Fluorcarbon-Kautschuk
30
29
28
27
O-Ring
26
12 1360/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
Feder
Hastelloy C-276
13 0412/F20/033
0690
Spring
Hastelloy C-276
1
X
Wellenschutzhülse
1.4462
14 H-0400M-2295
0594
Sleeve
1.4462
1
Gegenringaufnahme kpl.
CrNiMo-Stahl
15 0412/F08/001
0550
Seat carrier asm.
Stainless steel
1
bestehend aus:
consisting of:
Gegenringaufnahme
CrNiMo-Stahl
0412/F08/001
0550
Seat carrier
Stainless steel
1
Stift
CrNiMo-Stahl
0001/F19/001
0550
Pin
Stainless steel
2
Sprengring
CrNiMo-Stahl
16 0400/D60/001
0550
Snap ring
Stainless steel
1
O-Ring
Fluorcarbon-Kautschuk
17 0310/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
19
2
3
1
5
4
6
7
17
16
22
23
24
O-Ring
Fluorcarbon-Kautschuk
18 2230/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
Stift
CrNiMo-Stahl
19 5304/317/001
0550
Pin
Stainless steel
3
Gehäuse
1.4462
20 H-0400M-2297
0594
Housing
1.4462
1
Einsatzhülse
CrNiMo-Stahl
18
21
8
20
15
10
9
11
12
13
14
25
21 D/46598/1/001
0550
Guide sleeve
Stainless steel
1
Deckel
CrNiMo-Stahl
X
22 H-0400M-2296
0550
Cover
Stainless steel
1
Mitnahmering
CrNiMo-Stahl
23 H-0400M-2298
0550
Drive collar
Stainless steel
1
Sprengring
CrNiMo-Stahl
24 0400/D60/001
0550
Snap ring
Stainless steel
1
Gewindestift
Hochlegierter Edelstahl
25 Grubscrew
61081250018
0225
High tensile steel
8
X
Abdichtung Kundenbeistellung
(Sealing customer supply)
Senkkopfschraube
CrNiMo-Stahl
26 7708/301/001
0550
Socket head cap screw
Stainless steel
4
Distanzblech
CrNiMo-Stahl
27 0001/F18/001
0550
Spacer
Stainless steel
4
45°
O-Ring
Fluorcarbon-Kautschuk
45°
28 2340/123/134
9549
O-Ring
Fluorocarbon-rubber
1
X
Flachdichtung
1.4571
29 D/90430/C/475
0523
Gasket
1.4571
3
20°
31
Verschlussschraube
1.4571
Anzugsmoment 18 Nm
30 D/90083/C/475
0523
Plug screw
1.4571
3
Tightening torque 18 Nm
Senkkopfschraube
CrNiMo-Stahl
22.5°
67
31 Socket head cap screw
71061000035
0550
Stainless steel
6
90°
15°
G 1/8 "V"
Entlüftung verschlossen
(Vent plugged)
DIN-Code: In: A2.Q1.V.M2.G1./G.
Out: A2.Q1.V.M2.G
1-31
89452030
'V'
55mm T.588 / A.U.X1./1.X2.H.
X1=355; X2=277
55mm T.5610V / A.U.1.X2.H.
53
BDPFN/N
PUMP
NM053S (P),
X
P147 1 X O58 H - INB
X
P147 1 X O58 H - OUT
'IN / OUT'
NM053S (P)
'IN / OUT'
NETZSCH
WALDKRAIBURG
Auslegung
Temperatur an der GLRD
(Product temperature at seal)
Druck an der GLRD
(Chamber pressure)
bar (g)
(Design)
stat.
dyn.
stat.
dyn.
Ø55,00 mm / Ø55,00 mm
min.
-7
0
0
0
M16 -durchgehend / through hole
max.
+120
588 / 5610V TANDEM CARTRIDGE
+100
40
8
M12 -durchgehend / through hole
Diese Daten sind maximale Werte und werden in der Regel durch die tatsächlich anliegenden
Betriebsdaten zusätzlich eingeschränkt. Die angegebenen maximalen Einsatzgrenzen beeinflussen
sich gegenseitig und können nicht gleichzeitig in Anspruch genommen werden. Bei Unklarheiten
bitten wir um Rückfrage bei John Crane.
These are max values and as a rule in addition reduced by real service conditions.
Stated max. application limits affect each other and must not be accepted at the same time.
In case of any doubt ask John Crane.
1:1,5
29.10.2012
PU
CV
DE01EN
GA-136052
B
235
200 ±0,2
134 ±0,2
117 H8/f7
110.2 +0,2
110 e9
85.5
40 G7/h6
105