John Crane GmbH

Gleitringdichtungssysteme

GB

Instruction Manual
Mechanical Seal
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ORIG.

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Netzsch, Waldkraiburg
463484+468962
4000478446
GA-136052
89452030
5180217

John Crane
Engineered Sealing Systems

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

Gleitringdichtungssysteme

Werner-von-Siemens-Strae 6
D-36041 Fulda

Postfach 2528
D-36015 Fulda

Telefon (0661) 281-0

Telefax (0661) 71056

08/2012 AB
BA GLRD_Edition_7.6_GB.doc

Instruction Manual

Page: 2
of: 16
Edition 7.6

Contents
1

General ..............................................................................................3
1.1Introduction.........................................................................................3
1.2Range of Application ..........................................................................3

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

Transportation and Storage ............................................................5

Description of the Mechanical Seal ................................................5

4.1Construction .......................................................................................5
4.2Function .............................................................................................6
4.3Operating Conditions..........................................................................6

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

Commissioning and Decommissioning .......................................11

Maintenance/Repair .......................................................................14
7.1Maintenance.....................................................................................14
7.2Reconditioning..................................................................................15
7.3Spare Parts ......................................................................................16

Malfunction, Causes and Correction ............................................16

Accompanying Documents ...........................................................16

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Instruction Manual

Edition 7.6

1
1.1

General

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

Danger

Introduction

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).
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.

Mandatory instructions
designed to prevent
personal injury or extensive
damage.
ATTENTION Special instructions or

information to avoid
damage to the seal or its
surroundings.

Note:

Information for easy

installation and efficient
operation.

Environmental Note

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.

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:

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
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Instruction Manual

Edition 7.6

ATTENTION
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.
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.
Maintenance with steel tools must be avoided in
the presence of substances classed as explosive
group IIc according to EN50014.
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.

John Crane adopts the Design For the

Environment (DFE) principle in making this
product. Using this product will benefit the
environment directly by:

Reducing waste of precious resources

through decreasing the risk of leakage &
minimising energy consumption

Preventing pollution through controlling

harmful emissions to the atmosphere

Preserving valuable materials

resources through the re-use of these
high quality durable seals due to their
ability to be refurbished.

2.3.2 Recycling
Product refurbishment
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 reconditioning & 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.

Page: 5
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Instruction Manual

Edition 7.6

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

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:
x dry and dust-free
x ventilated at room temperature
x protected from direct effects of heat and
ultraviolet light

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.

ATTENTION

Ensure preservatives and

cleaning agents do not affect
the elastomers.

Once the seal is fitted on the

ATTENTION machine and the position is
set using setting devices do
not re-engage them for transportation and
storage.

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).

x elastomers require replacement after 60

months except Butyl rubber elastomers
that require replacement after 24 months
x 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.
x 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.

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

Page: 6
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Instruction Manual

Edition 7.6

4.3

Fig. 2:

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

Cranes published Product Data Sheet
specific to the seal type used (see
www.johncrane.com), or consult John
Crane direct.

Typical Metal Bellows Mechanical Seal

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 sealingpressure rating of the seal cartridge.

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

4.2

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 noncontacting. 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.
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.

Installation and Removal

5.1

Preparation for Fitting

x Check whether the seal is complete, clean

and undamaged.
x Clean all machinery abutments, sealing
and fitting surfaces (use only absorbent
and fluff-free polishing cloth for cleaning).
x Remove any protective coatings.
x 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

Fig. 3

ATTENTION

In the case of O-rings

chamfer
dimensions
are
related to the O-ring section.
The dimensions in Fig 3
apply only for O-rings up to
3.53 mm (0.139 in).

Instruction Manual

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Edition 7.6

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

Tolerance

Type

Shaft to
Housing

Squareness

Shaft to
Housing

Concentricity

static

1m/mm
chamber
bore FIM*
0.13 mm

0.25 mm

_______________________________

Shaft End Float Axial

dynamic

Carry out fitting according to the

installation drawing (section 9 and front
page) and with the following procedure:
x 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.
x Where appropriate fully engage the
specified eyebolt or eyebolts into the
tapped hole and connect to safe lifting
equipment.

0.065 mm

Shaft or Sleeve

Ovality

0.05 mm

Housing to
Shaft

Runout

0.05 mm

Installation tolerance figures stated on general

arrangement drawing (Section 9) take precedence
* API 682 and ISO 21049 requires <0.5 m/mm of
chamber bore, FIM.

Eyebolts must meet the appropriate

National Standards and their availability
and use should be part of a local QA
programme.
Dynamo eyebolts must only be used
with axial loading (straight pull). For all
other loading collared eyebolts must
be used.

5.2.2 Surface Finish

Seal Type

Value

static O-ring

0.3/0.8 m Ra
(ground or polished)
<1.6 m Ra (turned)

elastomer bellows

0.8/1.2 m Ra (turned)

PTFE bellows

0.8/1.2 m Ra (turned)

dynamic and static

wedge

0.1/0.25 m Ra
(polished)

dynamic O-ring

Packing ring (static) 0.8/1.6 m Ra (turned)

5.3 Installation
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.

ATTENTION

The seal eyebolt(s) must never be

used for lifting the machine.
x Maintain cleanliness during fitting.
x Lubricate shaft with a suitable fluid in the
installation area.
x 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.

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Instruction Manual

Edition 7.6

ATTENTION

ATTENTION

ATTENTION

Silicone-elastomer
O-rings
are not resistant to silicone oil
or grease.
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.

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.

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.
x

Tighten fasteners evenly to the torque

levels indicated in the installation drawing.

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.
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
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

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.
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

Edition 7.6

If possible check for freedom

movement by hand turning the shaft.

of

Check on all pipework, hoses and

fittings:

5.3.1 Tightening Torques

Thread
Size

x Remove and discard any plastic plugs

used during transit.

Tightening Torques [Nm] (u 0.125 lubricated)

Legacy
Socket
Socket
Socket
Size

Setscrew

Setscrew

Setscrew

Code

(ASTM A453Gr 660 C)

GMC 0649

(316)
GMC 0550

(High Tensile
Steel (14.9)
GMC 0225

- lubricated

- lubricated

- lubricated

Legacy

Legacy

Legacy

Part Code

Part Code

Part Code

x Ensure correct location, alignment and

support
x 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.
x Ensure correct size pipework and
specification.
x 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.
x 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.
x Ensure all pipework on liquid barrier/buffer
systems and cooling circuits are orientated
to ensure effective venting.

Size/305/712 Size/305/001 Size/305/050

M4

77**

N/A

1.5

M5

78**

N/A

2.5
4.5

M6

79**

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**

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
Size

Legacy
Size
Code

Stainless Steel
Steel
Cap or Hexagon Cap or Hexagon
Head Screws
Head Screws
(Class 12.9)

x Visually check for any damage and leaks.

(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

Instruction Manual

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Edition 7.6

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.

5.5

Installation and Removal of

Shrink Discs (John Crane
supply*)

Outer

Locking Screw
Inner Ring
Sleeve

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 Apply with

or nickel based brush or by
anti-seize
hand
compound

All fasteners for food,

pharmaceutical and related
applications

Consult
machine
manufacturer

Chloride free
All elastomer bellows on shaft
except for food, pharmaceutical and potable water
or glycerine
related applications
All elastomer bellows on shaft for
food, pharmaceutical and related
applications

5.4

Apply with
sprayer

Consult
machine
manufacturer

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.
Removal is essentially the reverse procedure
to installation.

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.

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.
x Degrease sleeve bore and shaft!
x Slide seal assembly over the shaft. Low
viscosity lubricants can be used. See
section 5.3.2.
x 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)
x Refer to the machine manufacturers
instructions if not of John Crane supply.
Do not tighten the locking
ATTENTION screws until the shaft is in its
correctly set operating
position
x 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
x Remove rust, which may have formed on
the shaft in front of the sleeve.

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Instruction Manual

Edition 7.6

x Loosen all locking screws uniformly, in a

clockwise sequence; initially about a
quarter turn per revolution only. Do not
remove screws from the threads.
x If the outer and inner rings have not
separated, remove some screws and
insert them in the neighbouring extraction
screw threads.
x The shrink disc may have to be cleaned
and re-greased before re-assembly (use a
grease containing MoS2 on the shrink disc
cones and locking screws).

Commissioning and
Decommissioning

Note before start-up:

x

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.
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.

Regular venting may be

ATTENTION needed during commissioning
on Plan 23, particularly on
vertical machinery.
x

If the seal is unidirectional, check that the

seals rotation direction matches the
machines 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).
Ensure that if a bearing is
ATTENTION 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.
It is advisable to pressurise
ATTENTION the machine and check for
static leaks before starting it
dynamically.
For hot duties (above 150C)
ATTENTION 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
ATTENTION connected to a flare header
ensure the connection is kept
isolated until the pump is
primed.
If a water test has been
ATTENTION 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 oC

Check the correct setting and

operation of electrical warning
systems associated with seal
operation.

Page: 12
of: 16

Instruction Manual

Edition 7.6

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.
To minimise any ignition hazard it is
important to ensure seal flush rates,
temperatures, and cooling water
flow rates are to specification.

In case of pressurised or
unpressurised dual seals note:
x

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 seals 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, anticorrosion etc) as these may damage the
rubbing seal face. The liquid should have
good lubricating properties, a viscosity <
15cSt @ 40C 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 (3rd
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 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.

x 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.
x

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.
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.

x 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.
x 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

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.

ATTENTION

The machine should not be

pressurised suddenly.

ATTENTION

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
of: 16

Instruction Manual

Edition 7.6

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.
Care should be exercised to ensure
the
barrier
systems
Maximum
Allowable Working Pressure (MAWP)
is not exceeded during filling and
pressurization.
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.

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
when commissioning the
accumulator in a Plan 53B.
Consult
the
System
Instruction Manual.

The cooling water outlet temperature

should be < 50oC. 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 < 80oC (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
of: 16

Instruction Manual

Edition 7.6

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.
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.
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.
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 nonhazardous
clean
fluid
is
recommended. Ensure drained buffer
and barrier liquids are disposed of in a
safe and environmental manner.
For removal instructions refer to Section
5.4

7
7.1

Maintenance/Repair
Maintenance

Carry out the following procedures for

trouble free operation:
Check daily:
x that the connections are leak free

x seal leakage rate and any change

from normal leakage rates.
x barrier gas flow for gas lubricated
seals
x Condition of alarm signals
x Possible blockage of any strainers,
magnetic filters, cyclones,
coalescers or any other filters used.
x Vibration levels in the machine.
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.

x in addition for dual seals check;

x barrier/buffer liquid level
x barrier/buffer liquid temperature
x barrier/buffer pressure
x 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.

x in addition for dry containment seals

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

Page: 15
of: 16

Instruction Manual

Edition 7.6

check monthly buffer gas flow when

applied,
x Wear parts for dry contacting
containment seals require
replacement after 24000 hrs
dynamic operation.
Check monthly, where appropriate, flow
rates for Plans 32, 54, and 62 are at the
required values.
x

Coalescing filters on gas barrier systems

require either replacement or regular
maintenance with the machine out of
service. Consult the system Instruction
Manual.
Check and adjust torque on external drive
collar socket set screws annually.

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 >150oC (300oF). 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.

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.
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.
In some regions where conformance
with TA Luft is required, gas and
steam may only be discharged in
small, controlled amounts.

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.

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.

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).

Page: 16
of: 16

Instruction Manual

Edition 7.6

Rebuilding seals to as-new specifications

must be carried out by qualified personnel.

Note:

7.3

It is recommended that a low

pressure integrity test is
carried out after repair and
before installation on the
machine.

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.

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.

Accompanying Documents

Seal Installation Drawing. See front sheet

for specific drawing reference number.

Seal Data Sheet (if applicable)

The following data is necessary for spare part

orders:
seal assembly code
part description
component code
quantity

John Crane International - Major Regional Centres

North America
6400 West Oakton Street
Suite 164,
Morton Grove IL. 60053, USA
USA
Telefon +1 847 967 2400
Fax
+1 847 967 3915

Europe, Asia and Africa

Buckingham House

Asia Pacific
15 Tuas View Place

Latin America
Sawgrass Lake Center,

361-366 Buckingham Avenue

Slough, Berkshire SL1 4LU, U.K.
Telefon +44 1753 224.000
Fax
+44 1753 224 224

Singapore 637432

Sunrise, Florida 33323,

Telefon +65 6518 1800

Fax
+65 6518 1803

Telefon +1 954 839 2700

Fax
+1 954 838 9985

Technische Beratung und Service Bundesrepublik Deutschland, Schweiz und sterreich

John Crane GmbH
Werner-von-Siemens-Str. 6
36041 Fulda
Postfach 25 28
36015 Fulda
Telefon 0661 2 81-0
Fax
0661 7 10 56
e-mail: mail@johncrane.de
Internet: www.johncrane.com

D-41468 Neuss
Service Center
Blindeisenweg 41
Telefone 02131 6 65 01-0
Fax
02131 6 65 01-11
scnordwest@johncrane.de

D-92353 Postbauer-Heng
Rosenstrae 10b
Telefone 09188 90 30 60
Fax
09188 90 30 61
JNagelstrasser@johncrane.de

A-4061 Pasching
Service Center
Industriestrae 1
Telefone +43 72 29 7 67 06
Fax
+43 72 29 7 67 07
sclinz@johncrane.de

D-21149 Hamburg
Service Center
Cuxhavener Str. 36
Telefon 040 796127-17
Fax
040 796127-64
schamburg@johncrane.de

D-69469 Weinheim
Service Center
Mierendorffstrae 21
Telefon 06201 25 90 97-0
Fax
06201 25 90 97-11
scweinheim@johncrane.de

D-06258 Schkopau
Service Center
Hallesche Strae 39a
Telefon 03461 72 34 33
Fax
03461 72 37 55
scschkopau@johncrane.de

CH-4103 Bottmingen
Service Center/Vertrieb
Wuhrmattstr. 13A
Telefone +41 61 4 26 92 92
Telefax +41 61 4 26 92 80
johncrane@johncrane.ch

'5$:,1*1R

GA-136052

02',),&$7,216

Zeichnungsnummer/
Drawing Number

Teil/
Ref

,668( A ORIGINAL ISSUE

'B' ECN #24418 PU/JH

Mat'l
Code

Header Code

Benennung/Description

0400/588/01/GA136052
SP-BB-Gegenring

105
G 1/8 "IN" / "OUT"
Eintritt / Austritt verschlossen
(Inlet / Outlet plugged)
Nach Montage entfernen
(Move out after assembly)

103.5
27.5

83

25.5

39

18.5

X
29

28

17

16

22

23

24

 105

 40 G7/h6

 110 e9

 85.5

19

18

21

20 15

10 9 11 12 13 14

25

X
Abdichtung Kundenbeistellung
(Sealing customer supply)

31
45

67

Anzugsmoment 18 Nm
Tightening torque 18 Nm

20

'V'

2340/123/134

9549

2260/123/134

9549

2330/123/134

9549

D/46594/1/218

9048

D/46595/1/001

0550

5409/317/001

0550

4963/092/033

0690

0412/F02/277

9221

10 0320/123/134

9549

12 1360/123/134

9549

13 0412/F20/033

0690

14 H-0400M-2295

0594

15 0412/F08/001

0550

0412/F08/001

0550

0001/F19/001

0550

16 0400/D60/001

0550

17 0310/123/134

9549

18 2230/123/134

9549

19 5304/317/001

0550

20 H-0400M-2297

0594

21 D/46598/1/001

0550

22 H-0400M-2296

0550

23 H-0400M-2298

0550

24 0400/D60/001

0550

25 61081250018

0225

26 7708/301/001

0550

27 0001/F18/001

0550

28 2340/123/134

9549

29 D/90430/C/475

0523

30 D/90083/C/475

0523

31 71061000035

0550

6($/$66
<12
DIN-Code: In: A2.Q1.V.M2.G1./G.
Out: A2.Q1.V.M2.G

G 1/8 "V"
Entlftung verschlossen
(Vent plugged)

22.5
15

,1 55mm T.588 / A.U.X1./1.X2.H.

X1=355; X2=277
287 55mm T.5610V / A.U.1.X2.H.

45

2(0

O-Ring
O-Ring
O-Ring
O-Ring
O-Ring
O-Ring
Gleitring
Face
Druckring
Thrust ring
Stift
Pin
Feder
Spring
Gegenring
Seat
O-Ring
O-Ring
Gleitring
Face
O-Ring
O-Ring
Feder
Spring
Wellenschutzhlse
Sleeve
Gegenringaufnahme kpl.
Seat carrier asm.
bestehend aus:
consisting of:
Gegenringaufnahme
Seat carrier
Stift
Pin
Sprengring
Snap ring
O-Ring
O-Ring
O-Ring
O-Ring
Stift
Pin
Gehuse
Housing
Einsatzhlse
Guide sleeve
Deckel
Cover
Mitnahmering
Drive collar
Sprengring
Snap ring
Gewindestift
Grubscrew
Senkkopfschraube
Socket head cap screw
Distanzblech
Spacer
O-Ring
O-Ring
Flachdichtung
Gasket
Verschlussschraube
Plug screw
Senkkopfschraube
Socket head cap screw

(48,30(175()(5(1&(

90

M12 -durchgehend / through hole

0
40

+100

Diese Daten sind maximale Werte und werden in der Regel durch die tatschlich anliegenden
Betriebsdaten zustzlich eingeschrnkt. Die angegebenen maximalen Einsatzgrenzen beeinflussen
sich gegenseitig und knnen nicht gleichzeitig in Anspruch genommen werden. Bei Unklarheiten
bitten wir um Rckfrage 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.

$OOLQWHOOHFWXDOSURSHUW\ULJKWVLQFOXGLQJEXWQRWOLPLWHGWRFRS\ULJKWDQGGHVLJQULJKWVZKHWKHUUHJLVWHUHGRUXQUHJLVWHUHGLQUHODWLRQWRWKLVGUDZLQJWRJHWKHUZLWKWKHLQIRUPDWLRQFRQWDLQHGLQWKLVGUDZLQJLQFOXGLQJEXWQRWOLPLWHGWRNQRZKRZDQGFRQILGHQWLDOLQIRUPDWLRQLV

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&86720(5,1)250$7,21

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Auslegung
(Design)

CrNiMo-Stahl
Stainless steel
CrNiMo-Stahl
Stainless steel
CrNiMo-Stahl
Stainless steel
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
CrNiMo-Stahl
Stainless steel
1.4462
1.4462
CrNiMo-Stahl
Stainless steel
CrNiMo-Stahl
Stainless steel
CrNiMo-Stahl
Stainless steel
CrNiMo-Stahl
Stainless steel
Hochlegierter Edelstahl
High tensile steel
CrNiMo-Stahl
Stainless steel
CrNiMo-Stahl
Stainless steel
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
1.4571
1.4571
1.4571
1.4571
CrNiMo-Stahl
Stainless steel

$66(0%/<

PUMP

'IN / OUT'

%,//2)0$7(5,$/6180%(5

(48,30(177<3(

'IN / OUT'

SiC
SiC
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
Hartkohle, antimonimprgniert
Antimony impregnated carbon
CrNiMo-Stahl
Stainless steel
CrNiMo-Stahl
Stainless steel
Hastelloy C-276
Hastelloy C-276
SiC
SiC
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
Hartkohle, antimonimprgniert
Antimony impregnated carbon
Fluorcarbon-Kautschuk
Fluorocarbon-rubber
Hastelloy C-276
Hastelloy C-276
1.4462
1.4462
CrNiMo-Stahl
Stainless steel

9221 SP-BB-Seat

D/46592/1/277

11 C-56-1625-1004-9048 9048

27 26

+0,2

 110.2

 134 0,2

 117 H8/f7

 235

 200 0,2

30

Stck./ Ersatz/
Qty Spare

Werkstoff/Material

'$7(

29.10.2012

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CV

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'5$:,1*1R

,668(

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$33529('

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$