Gas Seal Course Customer 112003 01a
Gas Seal Course Customer 112003 01a
Gas Seal Course Customer 112003 01a
■ Your name?
John Blaber
3
Tuesday Evening
5
Programme
■ Smiths & John Crane ■ Installation, Operation
■ Wet Seal Design & and Maintenance
Principles Manual
■ Dry Gas Principles ■ Fitting Procedure
■ Control and Monitoring ■ Commissioning
■ Seal Operation
■ Installing the Seal
■ Seal Configurations
■ Assembly / Dismantling
■ Transportation and
Storage ■ Assessment / Test
■ Seal Refurbishment Paper
■ Remedial work 6
Smiths Group
plc
£998 M £486 M
Over 12,000 employees Over 2,500 employees
26,000+ Employees
Speciality Detection
Engineering Systems
£872 M £273 M
Over 10,000 employees Over 1,500 employees
John Crane International
Mechanical Seals
£445 M
Sealant Supply
Over 6,000 employees
Systems
Flexible Couplings
Bearing Protectors
3D Modelling
John Crane International
■ 9000 employees
■ Operating in 47 countries
Engineers
■ Manufacturing in 17 countries
■ 30 manufacturing sites
12
History
John Crane founded in 1917 – Chicago, Illinois, USA
13
Major Historical Events
■ 1917 - John Crane founded in USA
16
Sales and Service Sites
17
Mechanical Seals Market
*BW/IP 6%
Eagle/NOK 9%
18
Centrifugal Gas Compressor
19
Centrifugal Pumps
20
Typical Pump
21
Typical Pump - Sectioned
22
Typical Pump - Sectioned
23
Shaft Turning
equipment
24
Wringing
25
Basic Operation
Conventional “Wet”
Mechanical Seals
API Plan 2
31
Basic Mechanical Seal
API Plan 2
32
Basic Mechanical Seal
API Plan 2
33
Basic Mechanical Seal
Recirculation
for cooling
API Plan 11
34
Seal Failure Analysis
35
Seal Failure Analysis
36
Basic Mechanical Seal
39
Mechanical Seal
Theory
Primary Seal
Primary Mating
Ring Ring
Springs
■ Must be:
➤ present - beware dry running
➤ stable
➤ reasonable viscosity
➤ temperature controlled
➤ acceptable pressure.
43
Abrasive Wear
44
Is this abrasive wear?
45
Primary Seal - Abrasives
46
Primary Seal - Abrasives
47
Cyclone Separator
To mechanical seal
To pump suction
48
Stable Fluid Film
49
Coning Out – Positive Rotation
50
Coning Out – Positive Rotation
51
Coning In – Negative Rotation
52
Positive & Negative Rotation
CStedy
Click here
to run… Type48.aas
54
Type 48 Primary Rings
Type 48MP
48LP
55
Type 48 / Type 28 Primary
Rings
56
Primary Seal
58
Lapping
59
Lapping
60
Flatness Checking - Tools
61
Flatness Checking
62
Flatness Checking
63
Flatness Checking
64
Flatness Checking
65
Flatness Checking
66
Flatness Checking
67
Flatness Checking
68
Primary Seal – Wet Seals
■ Primary Ring (Narrow - Softer) Materials
➤ Carbon-graphite
◆ resin impregnated
◆ antimony impregnated
69
Primary Seal – Wet Seals
Carbon converted to
Silicon Carbide
70
Primary Seal – Wet Seals
■ Primary Ring (Narrow - Softer) Materials
➤ Carbon-graphite
◆ resin impregnated
◆ antimony impregnated
◆ reaction bonded
➤ Tungsten Carbide
◆ nickel or cobalt
bonded 71
Primary Seal – Wet Seals
■ Mating Ring (Wide - Harder) Materials
➤ Ceramic
◆ 99.5% aluminium oxide
72
Mating Rings: Ceramic
73
Mating Rings: Ceramic
74
Primary Seal – Wet Seals
■ Mating Ring (Wide - Harder) Materials
➤ Ceramic
◆ 99.5% aluminium oxide
➤ Silicon Carbide
◆ pure sintered or reaction bonded
➤ Tungsten Carbide
◆ cobalt or nickel bonded
75
Primary Seal - Dry Gas Seals
■ Primary Ring Materials
➤ Carbon-graphite
◆ antimony impregnated
76
Primary Seal - Dry Gas Seals
■ Mating Ring Materials (Rotating in Type 28)
➤ Tungsten Carbide
◆ Cobalt bonded
◆ Nickel bonded (Optional)
➤ Silicon Carbide
◆ Pure sintered
◆ Liquid phase sintered - high pressure (XP/EXP)
➤ “Ductile” Mating Ring
◆ Tungsten carbide plating on stainless steel
77
Mating Ring Material Selection
■ Tungsten Carbide (Cobalt bonded)
➤ Tough
➤ High strength
➤ Best slow roll performance
➤ Cobalt binder can be chemically attacked
➤ Nickel bonded is available - better
resistance
■ Silicon Carbide
➤ Highly corrosion resistance
➤ Good slow roll performance
➤ Very brittle – easily chipped 78
Mating Rings
Chloride attack on
Tungsten Carbide
79
Mating Ring Material Selection
➤ Lower cost
80
Materials
JC Vickers Thermal Expansion Thermal Density
Material Code Hardness Conductivity Coefficient Shock 000’s kg/m3
-6
W/m°C@20°C X 10 /°C 000’s W/m
Silicon Carbide
277 2500 125 4.0 24 3.1
Pure Alpha Sintered
Silicon Carbide +10% 2500
088 150 4.6 35 3.1
Si. Reaction Bonded + softer Silicon
Converted Silicon 2500
121 50 4.0 30 2.0
Carbide/ Carbon + softer carbon
Tungsten Carbide
025 1500-1600 100 5.2 48 14.7
+6% Cobalt
Tungsten Carbide
005 1300-1500 80 5.6 43 14.7
+6% Nickel
Aluminium Oxide
059 1500+ 26 6.9 6 3.9
99.5% Alumina
Austenitic Cast I ron
007 200 40 19.3 - 7.3
13% Ni, 6% Cu
Carbon-Graphite 90
171 12 3.7 10 1.8
Resin I mpregnated (estimated)
81
Mechanical Seal
Theory
Secondary Seal
83
Secondary Seal
■ Three basic forms ■ Two groups
➤ O-rings ➤ Pusher
➤ PTFE sealing rings ◆ Sliding o-rings
◆ Wedges ◆ PTFE sealing rings
◆ Chevrons
➤ Non-pusher
◆ ‘C’ rings
◆ Sleeved o-rings
◆ Bellows
➤ Bellows
◆ Elastomer
◆ Metal
❖ formed
❖ edge welded
◆ PTFE
84
Secondary Seal: Pusher
■ Disadvantages
➤ hang-up (not likely where o-ring is well isolated)
➤ permanent set / pressure problems (cause hang-
up)
➤ excellent shaft surface finish required
86
Pusher Seal: Hang-up
An
external
quench
will
prevent
hang-up
Or, ensure
minimum
clearance here
89
Secondary Seal: O-rings
Fluorocarbon
90
Secondary Seal: O-rings
Perfluoroelastomer
91
Stainless Steel Colour Chart
■ Blue 600°C
■ Black 650°C
92
Heat /
Temperature
Control
Maintaining a stable
fluid film
94
Heat generation - the causes
■ size
■ speed
■ temperature
➤ cooling
■ product properties
➤ flush or multiple
Too much heat
generated
■ surface finish -
• dry-running faces
• excessive wear
• very short seal life
■ materials of faces
■ hydraulic pressure 95
Hydraulic Balance
96
Hydraulic Balance
97
Hydraulic Balance
98
Hydraulic Balance
99
Hydraulic Balance - Actual
100
Hydraulic Balance - Actual
Hydraulic Balance - Actual
102
Hydraulic Balance - Benefits
■ Reduced heat generation
➤ Less thermal distortion of the running faces
➤ less heat to be dissipated - less cooling
required
■ Reduced wear rate
➤ longer life
■ Reduced power required to drive the seal
➤ lower running costs
■ Increased pressure range for pusher seals
➤ this simple modification allows much higher
pressures to be sealed. 103
Environment of a
Mechanical Seal
Multiple Seals
Clean buffer
fluid
lubricates
this seal
Buffer fluid
is at low
(atmospheri
c) pressure
Low
pressure
fluid supply
111
Multiple Seals: Tandem
112
Double Seals: Back-to-Back
Pressurised
barrier fluid
is circulated
round the
seals
This
lubricates
both sets of
seal faces
Rotating
Mating Stationar
Ring y seals
116
Cartridge Seals
Advantages
119
Conventional Seals
Fitting Conventional Mechanical Seals
Mark position of face of stuffing box on shaft
Dismantle
Common questions:
■ pump
Lubricate tertiary seal
Fit seat in end cover - ensure fully home and square
Check seat➤ was it clean?
is correctly located on anti-rotation pin
Measure distance from front of end cover gasket to seat ('X') taking care not to scratch lapped face
Look up seal did I look up the correct seal?
➤working length in fitting instructions (L3)
Add 'X' to L3 (or subtract depending on pump design) and note dimension ('Y')
Measure 'Y'➤
did I look up the correct size?
from mark on shaft towards impeller
Mark shaft in this position
Measure from this mark to end of shaft, or nearest step towards impeller and note dimension ('Z')
Carefully wipe is the seat square?
➤ lapped face of seat perfectly clean
Place end cover on shaft taking care not to damage seat
did I measure accurately and correctly?
➤ shaft and secondary seal
Lightly lubricate
Slide seal unit on to shaft, ensuring it is the right way round
➤will it work?
Wipe lapped face of seal perfectly clean, taking care not to damage the surface
Fit seal 'Z' from end of shaft or shaft step, ensuring it is perfectly square to axis of shaft
Evenly tighten grubscrews
Assemble pump for how long?
➤ taking care not to damage rotating seal unit .
Offer end cover to face of stuffing box. Check gap before compressing seal with 'A' dimension in fitting instructions
If incorrect, dismantle pump and start again
If correct, tighten nuts on gland studs
Cross fingers
120
Cartridge Seals
Fitting Conventional Mechanical Seals
Mark position of face of stuffing box on shaft
Dismantle pump
Lubricate tertiary seal
Fit seat in end cover - ensure fully home and square
Check seat is correctly located on anti-rotation pin
121
Cartridge Seals
Fitting Conventional Mechanical Seals
Common knowledge:
Mark position of face of stuffing box on shaft
■
Dismantle pump
Lubricate tertiary seal
Fit seat in end cover - ensure fully home and square
Check seat is correctly located on anti-rotation pin
Measure distance from front of end cover gasket to seat ('X') taking care not to scratch lapped face
Fitting
the faces Cartridge
are perfectly Seals
clean
Look up seal working length in fitting instructions (L3)
➤
Add 'X' to L3 (or subtract depending on pump design) and note dimension ('Y')
Measure 'Y' from mark on shaft towards impeller
Mark shaft in this position
Measure from this mark to end of shaft, or nearest step towards impeller and note dimension ('Z')