Welcome

4-Day Course on
Engineered Sealing
Systems
y
11-13 November 2003
11-
John Crane EAA Training Centre,Manchester, UK

© 2003 John Crane EAA 1

Introductions
„ Your name?

„ Where do you work?

„ How many years with your company?

„ What
Wh t do
d you do?
d ?

„ Knowledge of Mechanical Seals?

„ Anyy expectations
p or requirements?
q

2
International Customer Training Manager

John Blaber

3
Programme
„ Smiths & John Crane „ Hydraulic Balance
„ Pumps and Rotating „ Environment off Seals
Equipment „ Multiple Seals
„ Gl d Packing
Gland P ki „ Cartridge Seals
„ Mech. Seal Theory „ Spiral Groove Seals
„ Lapping „ Coding (Overview)
„ Pump Assembly Checks „ Seal Selection Basics
„ Hands-on Assembly and
Hands- Ê Apply new knowledge
Fitting „ Split Seals
„ Seal Failure Analysis
4
 Smiths Group plc

© 2003 John Crane EAA 5

„ Smiths Group established 4th December 2000
from merger of TI Group (1919) and Smiths
Industries (1851)

„ Over
O 26,000
26 000 employees
l world
world-
ld-wide
id

„ Over 450 manufacturing g and customer

facilities in 47 countries

„ Annual sales of £2.629

£2 629 billion

„ Market Capitalisation Approx. £4.3 billion

All quoted figures are from 2003 Financial Report
6
 - Core Businesses
Aerospace Medical

£998 M £ 86 M
£486
Over 12,000 employees Over 2,500 employees

26 000+ Employees
26,000+
Speciality Detection
Engineering Systems

£872 M £273 M
Over 10,000 employees Over 1,500 employees
John Crane International

M h i l Seals
Mechanical S l
£445 M
Sealant Supply Systems
Over 6,000 employees
Fl ibl Couplings
Flexible C li
Bearing Protectors
3D Modelling
M d lli
John Crane International

„ Over 6000 employees

„ Operating in 47 countries

„ Over 1400 Sales & Application Engineers

„ Manufacturing
f in 17 countries

„ 30 manufacturing sites

„ Over 200 Service Centres.

9
 John Crane: Product Size Range

Automotive Process Industries Marine Technology

3/8” - 5/8” : 9 - 16 mm 1” - 9” : 25 - 230 mm 8” - 56” / 200 - 1450 mm

10
 History
John Crane founded in 1917 – Chicago, Illinois, USA

Crane Packing Limited established in Slough, England, UK,

in 1923, by Frank Payne - the Company President.

Enlarged Berwick Avenue Works

Slough 1936
Frank Payne

11
Major Historical Events
„ 1917 - John Crane founded in USA

„ 1923
923 - John
h Crane
C UK subsidiary
b d established
bl h d

„ 1947 - John Crane UK acquired by TI Group, UK

„ 1987 - John Crane USA acquired by TI Group, UK

„ 1988 - Ropac join John Crane Group

„ 1998 - Safematic join John Crane Group

„ 1998 - Sealol join John Crane Group

„ 1998 - Flexibox join John Crane Group.

12
Manufacturing Sites

= Dry Gas Seal Manufacturing

and Reconditioning
13
Sales & Wet Seal Service Sites

14
Sales and Service Sites

= New & Planned Dry Gas Seal Repair Centres

15
 Mechanical Seals Market
*BW/IP 6%

Eagle/NOK 9%

John Crane 29% *Durametallic

ua ea c 8%

Burgmann6% 'Others' include:-

include:-
John Crane Asia M Exacta Seal Merkel
Beldam Freudenburg Metax
Other 14% Sealol 6% Bestobel Garlock Nash

Technologies Chesterton 4% Canning

BT George Angus
GPM
NDA
Safematic
John Crane Cartriseal Hecker Pac--seal
Pac
Other 14% Le Carbone Hoftland Petriseal
Flexibox 4% Chetra Huhnseal Roplan
Dae Sung James Walker Sepco
Dantec Klinger Simrax
Depac Korean Seal Sealtec
Dickow Latty Tekhniseal
*Flowserve Group = 14% Erving Lowener Vulcan
.
16
 Pumps & Rotating
Equipment
Where and Why is
Sealing Required?

© 2003 John Crane EAA 17

Engineered Sealing

18
Centrifugal Pumps

19
 Centrifugal Pump Basics

Vanes

Impeller
Vanes rotates at
impart high speed
centrifugal
force.

20
 Centrifugal Pump
Build--Up
Build

© 2003 John Crane EAA 21

Typical Pump

22
Centrifugal Pump

23
Centrifugal Pump

.
24
Pump Assembly Checks

25
Centrifugal Pump

26
Centrifugal Pump

27
Centrifugal Pump

28
Centrifugal Pump

29
 Centrifugal Pump Basics
Discharge Stuffing Box
Impeller
(Seal Chamber)

Vanes

Suction

Mechanical Seal
Bearings Coupling.
or Gland Packing
30
Many Types of Coupling

31
Membrane Design Coupling

32
 Centrifugal Pump Basics
Wear rings “Balance” holes
B k vanes
Back

33
Centrifugal Pump Basics
Balancing
wear rings.
g

Minimum stuffing
box pressure

Pseal =

Psuct + Pdisch - Psuct

10

Vertical Pumps:
stuffing box can
be at Discharge
Pressure

34
Centrifugal Pump
„ Many varied designs
Ê vertical
Ê double ended
Ê horizontal split casing
Ê multi--stage
multi g
Ê close coupled
Ê bell housing
Ê axial flow
Ê etc . . .
35
Centrifugal Pump - Close Coupled

36
Vortex Breaker

37
Centrifugal Pump - Multi
Multi--Stage

.
38
Between Bearing - Double Suction

39
Vertical - Rigid Coupling

40
Positive Displacement Pump

P
Progressive
i Cavity
C i Pump
P
41
Progressive Cavity Pump

42
 Positive Displacement Pump

Outlet Inlet

Rotary Lobe Pumps

43
Reciprocating Pumps

Stuffing box and gland packing.

May need harder/tougher rings at each end of the
stuffing box to prevent extrusion caused by drag.

44
Mixers / Agitators / Reactors

„ Three common arrangements

Ê T Entry
Top E t

Ê Bottom Entry

Ê Side Entry

45
Mixers / Agitators / Reactors

46
Mixers / Agitators / Reactors

47
Mixers / Agitators / Reactors

48
Key Equipment
„ Other equipment includes
Ê air and gas compressors
Ê refrigeration compressors
Ê t bi
turbines (steam
( t and
d water)
t )
Ê dryers
Ê conveyors
Ê anywhere a rotating shaft passes through a
stationary
t ti h
housing
i where
h product
d t has
h to
t be
b
contained
Ê agitato s / mi
agitators mixers
e s / reactors
eacto s
49
Centrifugal Gas Compressor

50
Shaft Turning

„ Turn shafts of stored & standby equipment

Ê Bearings - false Brinelling

Ê Shaft sag - permanent set

Ê Seal face wringing.

51
Wringing

52
 S lf Assessment
Self A

Questions / Answers

© 2003 John Crane EAA 53

Question 1

„ What is the heart of the „ The impeller

pump?

54
Question 2

„ What are the vanes „ Rotates the process

used for? fluid
„ Imparts centrifugal
force to the process
fluid
„ Secondary vanes may
be present on the rear
of the impeller to
reduce axial thrust

55
Question 3

„ If the area around the „ Corrosion resistant shaft

shaft is corrosive, what sleeve.
option is the best
solution?

56
Question 4

„ Why is the pump casing „ Withstand the effects of

( l t ) made
(volute) d so Ê Erosion
robust? Ê Corrosion
Ê Pressure
Ê Distortion
Ê Misaligned pipe work
„ Supports weight of
pump

57
Question 5

„ What types of bearings „ Thrust (axial) and radial

are used to support the bearings
shaft of the standard „ Rolling element
pump? Ê B ll
Ball
Ê Roller
„ Tilting pads
„ Magnetic
„ Others

58
Question 6

„ When can a bearing run „ Grease lubricated

hotter? „ Lack of lubrication
„ High load
„ Contaminated lubricant
„ Worn bearing

59
Question 7

„ Why use a flexible „ To connect the driver to

coupling? the pump and transmit
torque
„ To allow for
misalignment which
mayy occur after aligning
g g
the shafts
„ Back pull-
pull-out spacer
„ Start--up torque
Start
„ Fail--safe device
Fail

60
Question 8

„ Why is it necessary to „ False Brinelling on

rotate shafts of stored bearings
pumps? „ Shaft sag
„ S l faces
Seal f wringing
i i

61
Typical Pump

62
Typical Pump - Sectioned

63
Typical Pump - Sectioned

64
 Gland
Gl d Packing
P ki

Brief Overview

© 2003 John Crane EAA 65

Stuffing Box / Seal Chamber

66
Gland Packing

Product pressure forces Gland nuts adjust the

liquid through bore amount of leakage
67
Gland Packing

Leakage is essential to
cool and lubricate Abrasives?
68
Gland Packing

69
Gland Packing - Abrasives

Inject clean fluid at 1 bar

Divide p
packing
g with a
minimum above pump
lantern ring
pressure
70
Gland Packing

Flow keeps abrasives Leakage consists of injected

away from packing bore flush fluid (ideal for corrosive
and toxic fluids)
71
Gland Packing

72
 Amount of Fluid Lost Due to Small Leakage
1 Minute Loss = 0.004 litre 1 Minute Loss = 0.26 litre
1 Hour Loss = 0.35 litre 1 Hour Loss = 15.6 litres
1 Day Loss = 8.3 litres 1 Day Loss = 374.0 litres
1 Week Loss = 58.0 litres 1 Week Loss = 2,616.0 litres
One Drop Per Second 1 Month Loss = 255.0 litres ø1.6 mm Stream 1 Month Loss = 11,337.0 litres
1 Year Loss = 3,070.0 litres 1 Year Loss = 136,045.0 litres

1 Minute Loss = 0.01 litre 1 Minute Loss = 0.81 litre

1 Hour Loss = 0.71 litre 1 Hour Loss = 48.75 litres
1 Day Loss = 17.0 litres 1 Day Loss = 1,170.0 litres
1 Week Loss = 118.0 litres 1 Week Loss = 8,190.0 litres
Two Drops Per Second 1 Month Loss = 512.0 litres ø3.2 mm Stream 1 Month Loss = 35,490.0 litres
1 Year Loss = 6,144.0 litres 1 Year Loss = 425,880.0 litres

1 Minute Loss = 0.08 litre 1 Minute Loss = 1.35 litres

1 Hour Loss = 4.75 litres 1 Hour Loss = 81.25 litres
1 Day Loss = 114.0 litres 1 Day Loss = 1,950.0 litres
1 Week Loss = 796.0 litres 1 Week Loss = 13,650.0 litres
Drops Breaking to Stream 1 Month Loss = 3,450.0 litres ø4.8 mm Stream 1 Month Loss = 59,150.0 litres
1 Year Loss = 41 400 0 litres
41,400.0 1 Year Loss = 709
709,800.0
800 0 litres

1 Minute Loss = 2.93 litres

1 Hour Loss = 176.0 litres
1 Day Loss = 4,225.0 litres
1 Week Loss = 29,575.0 litres
ø6.4 mm Stream 1 Month Loss = 128,158.0 litres
1 Year Loss = 1,537,900.0 litres

73
Gland Packing
„ Desirable properties for material
Ê pliable
li bl - conform
f tto shaft
h ft and
d gland
l db bore
Ê resist swelling and product attack
Ê elastic
l i - absorb
b b shaft
h f gyrations
i
Ê self--lubricating - low heat generation
self
Ê good conductor or heat
Ê not wear shaft or sleeve
Ê slow volume loss - minimum adjustment
Ê withstand pressure
Ê not deteriorate with heat.
74
Table of pH Values
4% NaOH Sodium Hydroxide = 14.0 14 Maximum Alkali
13
0.04% NaOH Sodium Hydroxide = 12.0 12 Severe Alkali
0.017% NH3 Ammonia Solution = 10.6
11
10
9 Mild Alkali
Sea Water = 8.3
8
Pure Water = 7.0 7 Neutral
Milk = 6.4
6
Beer = 4.5
5 Mild Acid
4
Vinegar = 3.1
3
Lemon Juice = 2.3
2 Strong Acid
0.49% H2SO4 Sulphuric Acid = 1.2
1
3.6% HCl Hydrochloric Acid = 0.1 0 Maximum Acid
75
Gland Packing

pH Range
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Polyimide
Glassfibre
Flax
PTFE
Graphite
Aramid

pH ranges of some of the most common gland packing materials

76
Gland Packing

C1065 - GFO Fibre

77
PTFE / Graphite Packing

With acknowledgements to W L Gore Inc

78
Gland Packing

K40 Tape
.

K40 Pre
Pre--Formed Rings
79
 Gland Packing

Packing
extruding Excessive
through neck wear due to
bush incorrect
adjustment
of gland nuts.

Problems with Gland Packing

80
Gland Packing Installation

“Neville and the Problem Pump”

81
Gland Packing

„ Disadvantages „ Advantages
Ê Leaks Ê Cheap
‹ Health & Safety Ê Fit without stripping
‹ Housekeeping Ê Simple to fit
‹ Corrosion
‹ Environment
‹ Cost
Ê Wears shaft / sleeve
Ê Not self-
self-adjusting
Ê Power consumption
Ê Open to tampering
Ê R -in
Run-
Run i time
ti required
i d

82
Gland Packing – Cheap?
GLAND PACKING Year 1 Year 2 Year 3
Packing cost per gland £31.42 £47.12 £31.42
Labour cost to repack £144.00 £216.00 £144.00
Labour cost for adjus tm ents £40.80 £40.80 £40.80
Cost of s leeves (incl. labour to fit) £640.00 £640.00 £0.00
Cost of wasted packing (10%) £3.14 £4.71 £3.14
Cleaning costs £24.00 £24.00 £24.00
Power cost to overcom e packing friction £539.84 £539.84 £539.84
Cost of product los s £0.00 £0.00 £0.00
TOTAL COSTS FOR PACKING £1,423.19 £1,512.47 £783.19

MECHANICAL SEAL Year 1 Year 2 Year 3

Seal cost per gland (incl. reconditioning) £610.31 £0.00 £0.00
Labour cost to fit seal £120.00 £0.00 £0.00
Labour cost for adjus tm ents £0.00 £0.00 £0.00
Cost of s leeve (fitted with seal) £520.00 £0.00 £0.00
Cost of wastage £0.00 £0.00 £0.00
Cleaning costs £0.00 £0.00 £0.00
Power cost to over com e seal friction £107.97 £107.97 £107.97
Cost of product los s £0.00 £0.00 £0.00
TOTAL COSTS FOR SEALS £1,358.28 £107.97 £107.97

Time Gland Mechanical Savings

Packing Seal

Year One £1423.19 £1358.28 £64.91

Year Two £1512.47 £107.97 £1404.50

Year Three £783.19 £107.97 £675.22

Totals £3718.85 £1574.22 £2144.63

83
Gland Packing – No Stripping?
Is pum p rem otely located (15 m ins +) Y or N N
Gland Packing m anufacturer Jam es Runner
Gland Packing Type/Style Bonzo 630J
Gland Packing cros s section Inches or m m 3/8"
Num ber of turns per stuffing box 5
Packing cos t per m etre £/m etre £20.00
Average packing life Weeks 20.00
How often is packing adjusted/checked Num ber/m onth 1.00
Is pres ent s leeve in good condition Y or N N
Cost of new s leeve £'s £520.00
A
Average sleeve
l lif
life W k
Weeks 78
8
Average running tim e per day Hours /day 24.00
Num ber of tim es pum p cleaned externally Num ber/m onth 1
Tim e to clean pum p Hours 0.10
Product cos t per cubic m etre Pence/1000 litres 0.00
Labour cost per hour £/hour £20.00
Electricity cost per kWh Pence/KWh 8.50
Minim um Mechanical Seal life Years 3

Gland Packing
Have to strip the pump every 78 weeks or less to
fit new sleeve
Mechanical Seal
Have to strip the pump every 156 weeks or
longer to fit new mechanical seal

84