3-day gen open 112003 1a [compatibility mode]

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Engineered SealingEngineered Sealing44--Day Course onDay Course on

Engineered Sealing Engineered Sealing SystemsSystemsyy1111--13 November 200313 November 2003

John Crane EAA Training Centre,Manchester, UKJohn Crane EAA Training Centre,Manchester, UK

© 2003 John Crane EAA 111

IntroductionsIntroductions

Your name?Your name?

Where do you work?Where do you work?

How many years with your company?How many years with your company?

Wh t d d ?Wh t d d ?What do you do?What do you do?

Knowledge of Mechanical Seals?Knowledge of Mechanical Seals?Knowledge of Mechanical Seals?Knowledge of Mechanical Seals?

Any expectations or requirements?Any expectations or requirements?

222

y p qy p q

International Customer Training ManagerInternational Customer Training Manager

John BlaberJohn Blaber

333

ProgrammeProgramme

Smiths & John CraneSmiths & John Crane Hydraulic BalanceHydraulic Balance

ffPumps and Rotating Pumps and Rotating EquipmentEquipment

Gl d P kiGl d P ki

Environment of SealsEnvironment of Seals

Multiple SealsMultiple SealsGland PackingGland Packing

Mech. Seal TheoryMech. Seal TheoryCartridge SealsCartridge Seals

Spiral Groove SealsSpiral Groove SealsLappingLapping

Pump Assembly ChecksPump Assembly ChecksCoding (Overview)Coding (Overview)

Seal Selection BasicsSeal Selection BasicsHandsHands--on Assembly and on Assembly and FittingFitting

Apply new knowledgeApply new knowledge

Split SealsSplit Seals

444

Seal Failure AnalysisSeal Failure Analysis

Smiths Group plcSmiths Group plcSmiths Group plcSmiths Group plc


Smiths GroupSmiths Group established 4established 4thth December 2000 December 2000 from merger offrom merger of TI Group (1919)TI Group (1919) andand SmithsSmithsfrom merger of from merger of TI Group (1919)TI Group (1919) and and Smiths Smiths Industries (1851)Industries (1851)

O 26 000 l ldO 26 000 l ld ididOver 26,000 employees worldOver 26,000 employees world--widewide

Over 450 manufacturing and customer Over 450 manufacturing and customer ggfacilities in 47 countriesfacilities in 47 countries

Annual sales of £2 629 billionAnnual sales of £2 629 billionAnnual sales of £2.629 billionAnnual sales of £2.629 billion

Market Capitalisation Approx. £4.3 billionMarket Capitalisation Approx. £4.3 billion

666

All quoted figures are from 2003 Financial ReportAll quoted figures are from 2003 Financial ReportAll quoted figures are from 2003 Financial Report

-- Core BusinessesCore BusinessesMedicalMedicalAerospace

£ 86£ 86Over 12,000 employeesOver 12,000 employees

£998 M£998 MOver 2,500 employeesOver 2,500 employees

£486 M£486 M

26 000+ Employees26 000+ Employees Detection Detection SystemsSystems

Speciality Speciality EngineeringEngineering

26,000+ Employees26,000+ Employees

Over 1,500 employeesOver 1,500 employees£273 M£273 M

Over 10,000 employeesOver 10,000 employees£872 M£872 M

John Crane InternationalJohn Crane International

M h i l S lM h i l S l

Over 6,000 employeesOver 6,000 employees

£445 M£445 MMechanical Seals

Sealant Supply Systems

Fl ibl C li

Mechanical Seals

Sealant Supply Systems

Fl ibl C liFlexible Couplings

Bearing Protectors

3D M d lli

Flexible Couplings

Bearing Protectors

3D M d lli3D Modelling3D Modelling

John Crane InternationalJohn Crane International

Over 6000 employeesOver 6000 employees

Operating in 47 countriesOperating in 47 countries

Over 1400 Sales & Application EngineersOver 1400 Sales & Application Engineers

ffManufacturing in 17 countriesManufacturing in 17 countries

30 manufacturing sites30 manufacturing sites30 manufacturing sites30 manufacturing sites

Over 200 Service Centres.Over 200 Service Centres.

999

John Crane: Product Size RangeJohn Crane: Product Size Range

Marine TechnologyMarine Technology8” 8” -- 56” / 200 56” / 200 -- 1450 mm1450 mm

AutomotiveAutomotive3/8” 3/8” -- 5/8” : 9 5/8” : 9 -- 16 mm16 mm

Process IndustriesProcess Industries1” 1” -- 9” : 25 9” : 25 -- 230 mm230 mm

101010

HistoryHistoryJohn 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 Enlarged Berwick Avenue Works Slough 1936Slough 1936

111111

Slough 1936Slough 1936Frank PayneFrank Payne

Major Historical EventsMajor Historical Events

1917 1917 -- John Crane founded in USAJohn Crane founded in USA

923923 h C b d bl h dh C b d bl h d1923 1923 -- John Crane UK subsidiary establishedJohn Crane UK subsidiary established

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

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

1988 1988 -- Ropac join John Crane GroupRopac join John Crane Group

1998 1998 -- Safematic join John Crane GroupSafematic join John Crane Group

1998 1998 -- Sealol join John Crane GroupSealol join John Crane Group

121212

1998 1998 -- Flexibox join John Crane Group.Flexibox join John Crane Group.

Manufacturing SitesManufacturing Sites

131313

= Dry Gas Seal Manufacturing= Dry Gas Seal Manufacturingand Reconditioningand Reconditioning

Sales & Wet Seal Service SitesSales & Wet Seal Service Sites

141414

Sales and Service SitesSales and Service Sites

151515

= New & Planned Dry Gas Seal Repair Centres= New & Planned Dry Gas Seal Repair Centres

Mechanical Seals MarketMechanical Seals Market

*BW/IP*BW/IP 6%6%

John CraneJohn Crane 29%29%

Eagle/NOKEagle/NOK 9%9%

*Durametallic *Durametallic 8%8%u a e a cu a e a c 8%8%

BurgmannBurgmann 6%6% 'Others' include:'Others' include:--

John CraneJohn Crane

Chesterton Chesterton 4%4%John CraneJohn Crane

OtherOtherTechnologiesTechnologies

14%14%Asia MAsia M Exacta SealExacta Seal MerkelMerkelBeldamBeldam FreudenburgFreudenburg MetaxMetaxBestobelBestobel GarlockGarlock NashNashBTBT George AngusGeorge Angus NDANDACanningCanning GPMGPM SafematicSafematicCartrisealCartriseal HeckerHecker PacPac--sealseal

John CraneJohn CraneSealol 6%Sealol 6%

John CraneJohn CraneFlexibox 4%Flexibox 4%

OtherOther 14%14%CartrisealCartriseal HeckerHecker PacPac sealsealLe CarboneLe Carbone HoftlandHoftland PetrisealPetrisealChetraChetra HuhnsealHuhnseal RoplanRoplanDae SungDae Sung James WalkerJames Walker SepcoSepcoDantecDantec KlingerKlinger SimraxSimraxDepacDepac Korean SealKorean Seal SealtecSealtec

161616

DickowDickow LattyLatty TekhnisealTekhnisealErvingErving LowenerLowener VulcanVulcan

..*Flowserve Group = 14%*Flowserve Group = 14%

Pumps & RotatingPumps & RotatingPumps & Rotating Pumps & Rotating EquipmentEquipment

Where and Why is Where and Why is Sealing Required?Sealing Required?


Engineered SealingEngineered Sealing

181818

Centrifugal PumpsCentrifugal Pumps

191919

Centrifugal Pump BasicsCentrifugal Pump Basics

VanesVanes

ImpellerImpellerrotates atrotates athigh speedhigh speed

VanesVanesimpartimpart high speedhigh speedimpartimpartcentrifugalcentrifugalforce.force.

202020

Centrifugal PumpCentrifugal PumpBuildBuild--UpUpBuildBuild--UpUp


Typical PumpTypical Pump

222222

Centrifugal PumpCentrifugal Pump

..

232323


242424

..

Pump Assembly ChecksPump Assembly Checks

..

252525


..

262626


..

272727


..

282828


..

292929


ImpellerImpeller DischargeDischarge Stuffing BoxStuffing Box(Seal Chamber)(Seal Chamber)

VanesVanes

SuctionSuction

303030

Mechanical SealMechanical Sealor Gland Packingor Gland Packing

BearingsBearings Coupling.Coupling.

Many Types of CouplingMany Types of Coupling

313131

Membrane Design CouplingMembrane Design Coupling

323232


Wear ringsWear rings “Balance” holes“Balance” holes

B kB kBack vanesBack vanes

333333


Balancing Balancing wear rings.wear rings.gg

MinimumMinimum stuffing stuffing box pressurebox pressure

PPsealseal ==

PP + P+ P PPPPsuct suct + P+ Pdisch disch -- PPsuctsuct

1010

Vertical Pumps:Vertical Pumps:Vertical Pumps:Vertical Pumps:stuffing box canstuffing box canbe at be at Discharge Discharge PressurePressure

343434

PressurePressure


Many varied designsMany varied designs

verticalvertical

double endeddouble ended

horizontal split casinghorizontal split casing

multimulti--stagestagegg

close coupledclose coupled

bell housingbell housingbell housingbell housing

axial flowaxial flow

353535

etc . . .etc . . .

Centrifugal Pump Centrifugal Pump -- Close CoupledClose Coupled

..

363636

Vortex BreakerVortex Breaker

373737

Centrifugal Pump Centrifugal Pump -- MultiMulti--StageStage

383838

..

Between Bearing Between Bearing -- Double SuctionDouble Suction

..

393939

Vertical Vertical -- Rigid CouplingRigid Coupling

..

404040

Positive Displacement PumpPositive Displacement Pump

P i C i PP i C i P

414141

Progressive Cavity PumpProgressive Cavity Pump

Progressive Cavity PumpProgressive Cavity Pump

..

424242

Positive Displacement PumpPositive Displacement Pump

OutletOutlet InletInlet

..

434343

Rotary Lobe PumpsRotary Lobe Pumps

Reciprocating PumpsReciprocating Pumps

Stuffing box and gland packing.Stuffing box and gland packing.May need harder/tougher rings at each end of theMay need harder/tougher rings at each end of the

444444

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

Mixers / Agitators / ReactorsMixers / Agitators / Reactors

Three common arrangementsThree common arrangementsThree common arrangementsThree common arrangements

T E tT E tTop EntryTop Entry

Bottom EntryBottom Entry

Side EntrySide Entry

454545


464646


474747


484848

Key EquipmentKey Equipment

Other equipment includesOther equipment includesair and gas compressorsair and gas compressorsair and gas compressorsair and gas compressors

refrigeration compressorsrefrigeration compressors

t bi ( t d t )t bi ( t d t )turbines (steam and water)turbines (steam and water)

dryersdryers

conveyorsconveyors

anywhere a rotating shaft passes through a anywhere a rotating shaft passes through a t ti h i h d t h t bt ti h i h d t h t bstationary housing where product has to be stationary housing where product has to be

containedcontained

agitato s / mi e s / eacto sagitato s / mi e s / eacto s

494949

agitators / mixers / reactorsagitators / mixers / reactors

Centrifugal Gas CompressorCentrifugal Gas Compressor

..

505050

Shaft TurningShaft Turning

Turn shafts of stored & standby equipmentTurn shafts of stored & standby equipment

Bearings Bearings -- false Brinellingfalse Brinelling

Shaft sag Shaft sag -- permanent setpermanent set

Seal face wringing.Seal face wringing.

515151

WringingWringing

..

525252

S lf AS lf ASelf AssessmentSelf Assessment

Questions / AnswersQuestions / Answers


Question 1Question 1

What is the heart of the What is the heart of the The impellerThe impellerpump?pump?

545454


What are the vanes What are the vanes Rotates the process Rotates the process used for?used for? fluidfluid

Imparts centrifugal Imparts centrifugal force to the processforce to the processforce to the process force to the process fluidfluid

Secondary vanes maySecondary vanes maySecondary vanes may Secondary vanes may be present on the rear be present on the rear of the impeller to of the impeller to reduce axial thrustreduce axial thrust

555555


If the area around the If the area around the Corrosion resistant shaft Corrosion resistant shaft shaft is corrosive, what shaft is corrosive, what option is the best option is the best solution?solution?

sleeve.sleeve.

solution?solution?

565656


Why is the pump casing Why is the pump casing ( l t ) d( l t ) d

Withstand the effects ofWithstand the effects of(volute) made so (volute) made so robust?robust?

ErosionErosionCorrosionCorrosionPressurePressurePressurePressureDistortionDistortionMisaligned pipe workMisaligned pipe work

Supports weight of Supports weight of pumppump

575757


What types of bearings What types of bearings Thrust (axial) and radial Thrust (axial) and radial are used to support the are used to support the shaft of the standard shaft of the standard pump?pump?

bearingsbearings

Rolling elementRolling elementB llB llpump?pump? BallBall

RollerRoller

Tilting padsTilting padsTilting padsTilting pads

MagneticMagnetic

OthersOthersOthersOthers

585858


When can a bearing run When can a bearing run Grease lubricatedGrease lubricatedhotter?hotter? Lack of lubricationLack of lubrication

High loadHigh load

Contaminated lubricantContaminated lubricant

Worn bearingWorn bearing

595959


Why use a flexible Why use a flexible To connect the driver to To connect the driver to coupling?coupling? the pump and transmit the pump and transmit

torquetorque

To allow forTo allow forTo allow for To allow for misalignment which misalignment which may occur after aligning may occur after aligning y g gy g gthe shaftsthe shafts

Back pullBack pull--out spacerout spacer

StartStart--up torqueup torque

FailFail--safe devicesafe device

606060


Why is it necessary to Why is it necessary to False Brinelling on False Brinelling on rotate shafts of stored rotate shafts of stored pumps?pumps?

bearingsbearings

Shaft sagShaft sag

S l f i iS l f i iSeal faces wringingSeal faces wringing

616161

Typical PumpTypical Pump

626262

Typical Pump Typical Pump -- SectionedSectioned

636363

Typical Pump Typical Pump -- SectionedSectioned

646464

Gl d P kiGl d P kiGland PackingGland Packing

Brief OverviewBrief Overview


Stuffing Box / Seal ChamberStuffing Box / Seal Chamber

666666

Gland PackingGland Packing

Product pressure forcesProduct pressure forces Gland nuts adjust theGland nuts adjust the

676767

Product pressure forces Product pressure forces liquid through boreliquid through bore

Gland nuts adjust the Gland nuts adjust the amount of leakageamount of leakage


Leakage is essential toLeakage is essential to

686868

Leakage is essential to Leakage is essential to cool and lubricatecool and lubricate Abrasives?Abrasives?


696969

Gland Packing Gland Packing -- AbrasivesAbrasives

Divide packing with a Divide packing with a Inject clean fluid at 1 bar Inject clean fluid at 1 bar minimum above pumpminimum above pump

707070

p gp glantern ringlantern ring minimum above pump minimum above pump

pressurepressure


Flow keeps abrasives Flow keeps abrasives away from packing boreaway from packing bore

Leakage consists of injected Leakage consists of injected flush fluid (ideal for corrosiveflush fluid (ideal for corrosive

717171

away from packing boreaway from packing bore flush fluid (ideal for corrosive flush fluid (ideal for corrosive and toxic fluids)and toxic fluids)


727272

Amount of Fluid Lost Due to Small LeakageAmount of Fluid Lost Due to Small Leakage

1 Minute Loss = 0.004 litre1 Hour Loss = 0.35 litre1 Day Loss = 8.3 litres1 Week Loss = 58.0 litres

1 Minute Loss = 0.26 litre1 Hour Loss = 15.6 litres1 Day Loss = 374.0 litres1 Week Loss = 2,616.0 litres

1 Minute Loss = 0.01 litre1 Hour Loss = 0.71 litre

One Drop Per Second 1 Month Loss = 255.0 litres1 Year Loss = 3,070.0 litres

ø1.6 mm Stream 1 Month Loss = 11,337.0 litres1 Year Loss = 136,045.0 litres

1 Minute Loss = 0.81 litre1 Hour Loss = 48.75 litres

1 Day Loss = 17.0 litres1 Week Loss = 118.0 litres

Two Drops Per Second 1 Month Loss = 512.0 litres1 Year Loss = 6,144.0 litres

1 Day Loss = 1,170.0 litres1 Week Loss = 8,190.0 litres

ø3.2 mm Stream 1 Month Loss = 35,490.0 litres1 Year Loss = 425,880.0 litres

1 Minute Loss = 0.08 litre1 Hour Loss = 4.75 litres1 Day Loss = 114.0 litres1 Week Loss = 796.0 litres

Drops Breaking to Stream 1 Month Loss = 3,450.0 litres1 Year Loss = 41 400 0 litres

1 Minute Loss = 1.35 litres1 Hour Loss = 81.25 litres1 Day Loss = 1,950.0 litres1 Week Loss = 13,650.0 litres

ø4.8 mm Stream 1 Month Loss = 59,150.0 litres1 Year Loss = 709 800 0 litres1 Year Loss = 41,400.0 litres

1 Minute Loss = 2.93 litres1 Hour Loss = 176.0 litres1 Day Loss = 4,225.0 litres

1 Year Loss = 709,800.0 litres

737373

1 Week Loss = 29,575.0 litresø6.4 mm Stream 1 Month Loss = 128,158.0 litres

1 Year Loss = 1,537,900.0 litres


DesirableDesirable properties for materialproperties for materialli blli bl f t h ft d l d bf t h ft d l d bpliable pliable -- conform to shaft and gland boreconform to shaft and gland bore

resist swelling and product attackresist swelling and product attack

l il i b b h f ib b h f ielastic elastic -- absorb shaft gyrationsabsorb shaft gyrations

selfself--lubricating lubricating -- low heat generationlow heat generation

good conductor or heatgood conductor or heat

not wear shaft or sleevenot wear shaft or sleeve

slow volume loss slow volume loss -- minimum adjustmentminimum adjustment

withstand pressurewithstand pressure

747474

not deteriorate with heat.not deteriorate with heat.

Table of pH ValuesTable of pH Values

14141313

Maximum AlkaliMaximum Alkali4% NaOH Sodium Hydroxide = 14.04% NaOH Sodium Hydroxide = 14.0

121211111010

Severe AlkaliSevere Alkali0.04% NaOH Sodium Hydroxide = 12.00.04% NaOH Sodium Hydroxide = 12.0

0.017% NH0.017% NH33 Ammonia Solution = 10.6Ammonia Solution = 10.6

998877

Mild AlkaliMild Alkali

NeutralNeutralPure Water = 7.0Pure Water = 7.0

Sea Water = 8.3Sea Water = 8.3

665544

Mild AcidMild AcidBeer = 4.5Beer = 4.5

Milk = 6.4Milk = 6.4

332211

Strong AcidStrong Acid0.49% H0.49% H22SOSO44 Sulphuric Acid = 1.2Sulphuric Acid = 1.2

Lemon Juice = 2.3Lemon Juice = 2.3

Vinegar = 3.1Vinegar = 3.1

757575

00 Maximum AcidMaximum Acid3.6% HCl Hydrochloric Acid = 0.13.6% HCl Hydrochloric Acid = 0.1


pH Range0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

PolyimideGlassfibre

FlaxPTFE

GraphiteAramid

767676

pH ranges of some of the most common gland packing materialspH ranges of some of the most common gland packing materials


..

777777C1065 C1065 -- GFO FibreGFO Fibre

PTFE / Graphite PackingPTFE / Graphite Packing

787878

With acknowledgements to W L Gore IncWith acknowledgements to W L Gore Inc


K40 TapeK40 Tape..

797979K40 PreK40 Pre--Formed RingsFormed Rings


PackingPackingPacking Packing extruding extruding through neck through neck bushbush

Excessive Excessive wear due to wear due to incorrectincorrectincorrect incorrect adjustment adjustment of gland nuts.of gland nuts.

808080Problems with Gland PackingProblems with Gland Packing

Gland Packing InstallationGland Packing Installation

“Neville and the Problem Pump”“Neville and the Problem Pump”

..

818181


DisadvantagesDisadvantages AdvantagesAdvantagesLeaksLeaks

Health & SafetyHealth & SafetyHousekeepingHousekeeping

CheapCheapFit without strippingFit without strippingSimple to fitSimple to fitHousekeepingHousekeeping

CorrosionCorrosionEnvironmentEnvironmentCostCost

Simple to fitSimple to fit

CostCost

Wears shaft / sleeveWears shaft / sleeveNot selfNot self--adjustingadjustingPower consumptionPower consumptionOpen to tamperingOpen to tamperingRR i ti i di ti i d

828282

RunRun--in time requiredin time required

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

MECHANICAL SEAL Year 1 Year 2 Year 3Seal cost per gland (incl. reconditioning) £610.31 £0.00 £0.00Labour cost to fit seal £120.00 £0.00 £0.00Labour cost for adjustments £0.00 £0.00 £0.00Cost of s leeve (fitted with seal) £520.00 £0.00 £0.00Cost of wastage £0.00 £0.00 £0.00Cleaning costs £0.00 £0.00 £0.00Power cost to over come seal friction £107.97 £107.97 £107.97Cost of product loss £0.00 £0.00 £0.00TOTAL COSTS FOR SEALS £1,358.28 £107.97 £107.97

Time Gland Packing

Mechanical Seal

Savings

Year One £1423.19 £1358.28 £64.91

Year Two £1512.47 £107.97 £1404.50

Year Three £783.19 £107.97 £675.22

838383

Totals £3718.85 £1574.22 £2144.63

Gland Packing Gland Packing –– No Stripping?No Stripping?Is pump remotely located (15 mins +) Y or N NGland Packing manufacturer James RunnerGland Packing Type/Style Bonzo 630JGland Packing cross section Inches or mm 3/8"Number of turns per stuffing box 5Number of turns per stuffing box 5Packing cost per metre £/metre £20.00Average packing life Weeks 20.00How often is packing adjusted/checked Number/month 1.00Is present s leeve in good condition Y or N NCost of new s leeve £'s £520.00A l lif W k 8Average s leeve life Weeks 78Average running time per day Hours/day 24.00Number of times pump cleaned externally Number/month 1Time to clean pump Hours 0.10Product cost per cubic metre Pence/1000 litres 0.00Labour cost per hour £/hour £20.00

Gland PackingGland PackingHave to strip the pump everyHave to strip the pump every 78 weeks or less78 weeks or less toto

Electricity cost per kWh Pence/KWh 8.50Minimum Mechanical Seal life Years 3

Have to strip the pump every Have to strip the pump every 78 weeks or less78 weeks or less to to fit new sleevefit new sleeveMechanical SealMechanical SealHave to strip the pump every Have to strip the pump every 156 weeks or 156 weeks or

848484

longerlonger to fit new mechanical sealto fit new mechanical seal

3-day gen open 112003 1a [compatibility mode]

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