EC Declaration of Conformity

Manufacturer; John Crane UK

Buckingham House,
361-366, Buckingham Ave.,
Slough, Berks,
SL1 4LU, United Kingdom
Certifies that
its Product;

John Crane single mechanical seal systems, liquid lubricated (ISO 21049 code 1CW)

Types 88S, 88SRS; 611Q; 613; 1100; 1102; 3710; 4610; 5610; 5610L; 5610Q;
5611; 5611Q; 5615; 5615Q; 5860; 8610; EZ1; FFET; FFXP; SB1; SB1A.
And assemblies that include Types 1, 1A, 1AB, 1B, 1M, 1S, 2, 2B, 2M, 4, 5, 5A, 6A,
6D, 6J, 8-1, 8-1T, 8-1D, 8-1-0, 8-1TS, 8-1V, 8-1VO, 8A, 8AB, 8B, 8B1, 8BID, 8B1O,
8B1RP, 8B1RS, 8B1S, 8B1TS, 8B1V, 8B1VO, 8B2, 8B3, 8B5, 8BO, 8BV, 8BVS, 8D,
8RTD, 8TD, 9, 9-0, 9A, 9AB, 9B, 9BT, 9T, 9TS, 9V, 10; 10R; 10T; 10TC; 11, 11A,
13, 16, 17, 19, 20; 20R; 21, 23A, 29, 30, 34, 35, 36, 37FS, 37FSB, 38, 38B, 39, 43,
48HP, 48LP, 48MP, 48RP, 48S, 48XP, 48XPVL, 50, 51B, 51BMS, 52B, 52BMS,
55B, 55U, 56B, 56U, 57B, 58B, 58U, 59B, 59U, 75FS, 80, 80L, 80S, 85B1, 85B1RS,
87, 88SF, 99, 106, 108B, 109, 109B, 118B, 208B, 209, 209B, 270F, 285; 502, 515E,
515H, 521, 583B, 583U, 586, 587, 588, 599, 604, 604DP, 605, 605DP, 606, 606DP,
609, 609DP, 670, 676, 680, 800, 909, 909B, 1503, 1604; 1648; 1670; 2100, APSM,
AP1M, B2FN, B2EK, B2EM, B2SM, BF7, B*OL/R, B*SL/R, CLOS, DD, Diplo, DR,
EPR, FFGD, FFEL/R, FFOL/R, FFSL/R, FFSP, FFST, FFZL/R, FFZT, GF7, GL1B,
GL1H, GLSB, GLSH, GT1B, GTSB, IFH, KFJN, MK150, MK270, MLE, NAP; NAR;
NBP; NBR; R1, R2, R6, R10, R20, R32, R33, R36, R*OL/R, R*EL/R, R*SL/R,
RC718, RC719, RL1B, RLSB, RPAC, RRAL/R, RREL/R, RREM, RRGL/R, RRGM,
RROL/R, RROM, RRSL/R, RRSM, RREP, RRSP, PRR, RT1B, RTSB, S8B1, SAS;
SAW, SB1B; SB1S; SBOP; SE1; SE1C, SE1F; SEW; SEWC; ST1B, STSB,
SYMDBL, SYMSGL, U2EK, U2EM, U2SK, U2SM, UF8, U*OL/R, U*SL/R
are in accordance with EU Directive 94/9/EC and are to be considered as components (Article 4,
clause 2). They have been designed and supplied for use in equipment that itself meets the
specification Group II, category 2 and are in accordance with the following explosion protection class.

II 2 GD c TX 1)
It is assumed that the assembly into the equipment and the operation of the product will always be in
accordance with its original purpose. It must be operated within its safe operational limits together
with the recommended auxiliary services. Clarification of information and data is contained in the
Product Instruction Manual.
The following EU Standards have been used in the design and specification of the products listed
above;
EN 292, EN 1127-1, EN13643-1, prEN 13643-5 (08.02), prEN 13643-6 (08.02)
A Technical File, including an Ignition Hazard Analysis conforming to the above Standards, has been
filed with, TV Product Service GmbH, Ridlerstrasse 65, D-80339 Mnchen, Germany. Identification
number 0123. EC-Certificate No. EX9 03 08 49393 001
This EC Declaration of Conformity will be invalid if the product is built into equipment that does not
have an equivalent level of conformity assessment according to EU Directive 94/9/EC or 98/37/EC
(The Machinery Directive).

Signature

N Wallace, Technical Director John Crane EAA

1)

For potentially explosive gas/air mixtures, Class T1 to T6, depending on the maximum temperature in the seal chamber. For
specific information and maximum surface temperature with potentially explosive dust/air mixtures consult the Product
Instruction Manual.

Issue: H

Date: 25.03.04
404_1CW EGD-nass_UK.doc

John Crane GmbH

Gleitringdichtungssysteme

Instruction Manual Addendum

(IMA) Issue D
Standard Mechanical Seals
ATEX 94/9/EC Group II,
Category 2GD and 3GD

page 1 of 5

Customers Address:

Order no

Order date

Project

Order no. pos.

Item no.

Pump no.

John Crane job no.

John Crane order no.

Plant owner / plant / unit

Seal type & mating ring

Drawing no.
Seal chamber temperature (max.) in C
Max. surface temperature at
seal surface (MSTS) in C

<T

Checked:
Date

Name

Signature

This Instruction Manual is intended to be completed by the equipment supplier or user once the
application details are known. Where compliance with a specific Tx value is required then the
application should be referred to John Crane.
This IM Addendum should only be used in conjunction with the Standard Instruction Manual intended
for the seal type and mating ring listed. It covers Installation, Operation and Service information
specific to ATEX 94/9/EC and should be available on site together with the primary Instruction Manual.
If actual operating conditions were not provided with the order or if John Crane have only supplied the
mechanical seal and mating ring, responsibility for ATEX conformance also becomes that of the
organisation building the parts into a complete seal assembly, system or cartridge.

John Crane GmbH

Gleitringdichtungssysteme

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

Postfach 2528
D-36015 Fulda

Telefon +49 661 281-0

Telefax +49 661 71056

Issue D - Pe/AB
IMS 394/000

Instruction Manual Addendum

(IMA) Issue D
Standard Mechanical Seals
ATEX 94/9/EC Group II,
Category 2GD and 3GD

John Crane GmbH

Gleitringdichtungssysteme

page 2 of 5

The Declaration of Conformity cannot be wholly supported if absence of operational data has prevented
calculation of the maximum surface temperature MSTs (refer below Declaration of Conformity Requirements). If
actual process conditions are not provided at the time of order, John Crane cannot advise the supplier of ATEX
Equipment a specific value for Tx.
In order to assist the Equipment supplier meet his ATEX commitments the Max. Surface Temperature (MSTs) in
C can be calculated using the section Maximum Surface Temperature calculation and allowable Temperature
Class in this Addendum. Alternatively if the full operational data and description of the seal is retrospectively sent
to John Crane a new Instruction Manual Addendum will be issued specifying the appropriate Max. Surface
Temperature (MSTs) in C.
Range of Application
Mechanical sealing systems are used for the sealing of rotating shafts: they must be operated within their
performance limits (see Instruction Manual or Product Data Sheet).
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.

General
Maintenance with steel tools should not occur if there is the presence of substances classed as
explosive group IIc according to EN50014.
If the equipment is being used in ATEX zone 21 or 22 regular cleaning of dust from exterior surfaces is
required.
Function
Mechanical sealing systems are designed to operate with a very thin lubricating film between the rubbing faces.
Lubrication is provided by the sealed fluid; in the case of gases, the mechanism is usually enhanced by spiral
grooves. Light contact gas seals can be used without lubrication in specialised services.
Without the intended lubrication the seal face temperatures will increase and may provide an ignition
source in a potentially explosive atmosphere. Equipment operation must ensure seal face lubrication is
always available.

Installation
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.

Commissioning
To meet ATEX equipment specification it is important to ensure seal flush rates and temperatures are
to specification.

Maintenance
If 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.

Repair
Note:

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

John Crane GmbH

Gleitringdichtungssysteme

Instruction Manual Addendum

(IMA) Issue D
Standard Mechanical Seals
ATEX 94/9/EC Group II,
Category 2GD and 3GD

page 3 of 5

Maximum Surface Temperature calculation and Allowable Temperature Class

The values quoted below for temperature rise at the seal faces are generalised and conservatively rated values
only. They may be reduced by specific calculations at the actual seal size and operating conditions.
The seal description codes and piping Plans are those referenced in ISO 21049 and API 682.
Single mechanical seal, liquid lubricated (ISO 21049 & API 682 code 1CW)
The expected maximum surface temperature at the mechanical seal (MSTs) can be calculated by adding the
temperature rise at the seal faces (see Table) to the maximum process temperature*.

speed (1/min)
max 3600

water / flashing
hydrocarbons
20

Temperature rise (K)

Non-flashing
hydrocarbons
30

Mineral Oil
70

If a cooled seal chamber is included (Plan 21 or 23) the MSTs will be the maximum process temperature.
If a quench (Plan 62), sealed by a lip seal, is included the MSTs of the seal arrangement will be the quench fluid
o
o
temperature plus 50 K (water and PTFE lip material) or 25 K (mineral oil and elastomeric lip) or the maximum
process temperature*, whichever is greater.
If a non-removable PTFE setting ring is used to position the cartridge seal (Type 4610 or EZ1) the minimum
o
MSTs is the maximum ambient temperature plus 50 K but may be higher as a result of the calculations above.
Single mechanical seal, non-contact gas lubricated
The expected maximum surface temperature at the mechanical seal (MSTs) can be calculated by adding the
o
temperature rise at the seal faces of 5 K to the maximum process temperature*.
Single mechanical seal, dry contact lubricated (Agitator design, <2 m/s)
The expected maximum surface temperature at the mechanical seal (MSTs) can be calculated by adding the
o
temperature rise at the seal faces of 60 K to the maximum process temperature*.
If a quench (API Plan 62), sealed by a lip seal, is included the MSTs of the seal arrangement will be the quench
o
o
fluid temperature plus 50 K (water and PTFE lip material) or 25 K (mineral oil and elastomeric lip) or the
maximum process temperature*, whichever is greater.
Dual Unpressurised Seal with a dry contact, mechanical containment seal
(ISO 21049 & API 682 codes 2CW-CS and 2NC-CS, dry contact technology)
The maximum surface temperature in contact with the plant zoned area is ordinarily the outer seal. The expected
maximum surface temperature at the mechanical seal (MSTs) can be calculated by adding the temperature rise
o
at the seal faces of 60 K to the maximum process temperature*.
If a cooled flush is included (Plan 21 or 23) the MSTs will be the uncooled, maximum process temperature.(static
condition)
If a gas buffer flush is applied to the outer seal (Plan 72) the MSTs can be calculated by adding the temperature
o
rise at the seal faces of 60 K to the buffer gas temperature, comparing this with the maximum process
temperature*, and choosing whichever is the greater value.

Instruction Manual Addendum

(IMA) Issue D
Standard Mechanical Seals
ATEX 94/9/EC Group II,
Category 2GD and 3GD

John Crane GmbH

Gleitringdichtungssysteme

page 4 of 5

Dual Unpressurised Seal with a dry non-contact, mechanical containment seal

(ISO 21049 & API 682 codes 2CW-CS and 2NC-CS, dry non-contact technology)
The maximum surface temperature in contact with the plant zoned area is ordinarily the outer seal. The expected
maximum surface temperature at the mechanical seal (MSTs) can be calculated by adding the temperature rise
o
at the seal faces of 5 K to the maximum process temperature*.
If a cooled seal chamber is included (Plan 21 or 23) the MSTs will be the maximum process temperature.
If a gas buffer flush is applied to the outer seal (Plan 72) the MSTs can be calculated by adding the temperature
o
rise at the seal faces of 5 K to the buffer gas temperature, comparing this with the maximum process
temperature*, and choosing whichever is the greater value.
Dual Unpressurised Seal with a liquid buffer or quench fluid (ISO 21049 & API 682 code 2CW-CW)
The maximum surface temperature in contact with the plant zoned area is ordinarily the outer seal. The expected
dynamic maximum surface temperature at this mechanical seal (MSTs) can be calculated by adding the
o
o
temperature rise at the seal faces of (50 K for mineral oil and 20 K for aqueous buffers) to the maximum
o
o
temperature of the buffer liquid. Ordinarily this will be <80 C providing maximum surface values of 130 C for
o
mineral oil and 100 C for aqueous buffers. This must be compared with the static maximum surface temperature
which can be assumed to be the maximum process temperature*. The seal MSTs is the maximum of the two
values.
If this arrangement is used with a continuous quench (Plan 62) between the seals instead of a buffer fluid, in the
same way as the dynamic maximum surface temperature was calculated above, the outer seal MSTs can be
o
o
calculated by adding the temperature rise at the seal faces of (50 K for mineral oil and 20 K for aqueous buffers)
to the maximum temperature of the quench fluid. This must be compared with the maximum surface temperature
of other parts which can be assumed to be the maximum process temperature*. The complete seal MSTs is the
maximum of the two values.
If a non-removable PTFE setting ring is used to position the cartridge seal (Type 4620P or 611Q) the minimum
o
MSTs is the maximum ambient temperature plus 50 K but may be higher as a result of the calculations above.
Dual pressurised Seal with a liquid barrier fluid (ISO 21049 & API 682 code 3CW)
The maximum surface temperature in contact with the plant zoned area is ordinarily the outer seal. The expected
dynamic maximum surface temperature at this mechanical seal can be calculated by adding the temperature rise
o
o
at the seal faces of (70 K for mineral oil and 20 K for aqueous buffers) to the maximum temperature of the barrier
o
o
o
liquid. Ordinarily this will be <80 C providing maximum surface values of 150 C for mineral oil and 100 C for
aqueous buffers. This must be compared with the static maximum surface temperature which can be assumed to
be the maximum process temperature*. The seal MSTs is the maximum of the two values.
If a non-removable PTFE setting ring is used to position the cartridge seal (Type 4620P) the minimum MSTs is
o
the maximum ambient temperature plus 50 K but may be higher as a result of the calculations above..
Dual pressurised dry non-contact Seal with a gas barrier fluid
(ISO 21049 & API 682 code 3NC, dry non-contact technology)
The maximum surface temperature in contact with the plant zoned area is ordinarily the outer seal. The expected
dynamic maximum surface temperature at the mechanical seal can be calculated by adding the temperature rise
o
at the seal faces of 5 K to the maximum process temperature* of the process fluid in the seal chamber.

* If a Plan 32 is utilised in all operational conditions the maximum process temperature may assume to be the
Plan 32 maximum supply condition. Ordinarily, however, other parts of the equipment will then control the
maximum surface temperature.

John Crane GmbH

Gleitringdichtungssysteme

Instruction Manual Addendum

(IMA) Issue D
Standard Mechanical Seals
ATEX 94/9/EC Group II,
Category 2GD and 3GD

page 5 of 5

Calculation of Temperature Class

For assessment of the Group IIG temperature class carry out the above calculation of MSTs.
for Class T3 to T6, the MSTs must be 5K less than the max. allowable temperature of the relevant
T-class
for Class T1 and T2 it must be 10K less.
Temperature Class
T1
T2
T3
T4
T5
T6

Maximum Surface Temperature ( C)

450
300
200
135
100
85

Note; applicable to all seal configurations

The maximum operating performance boundary and recommended materials are specified in the relevant
product data sheet

It is assumed recommended product flush rates on single and dual unpressurised seals are applied and the
seal assembly is part of a cartridge supplied by John Crane.

Declaration of Conformity requirements

European Directive 94/9/EC (ATEX) requires that an equipment or component manufacturer confirm the
conformity of their equipment/ component and states
A certificate shall be issued by the manufacturer declaring the conformity of the components with the
provision of this Directive which apply to them and stating their characteristics and how they must be
incorporated into equipment ..
To comply with the above requirement the Declaration of Conformity for mechanical seals must contain
description of the seal
equipment group, category and Gas/ Dust e.g. II 2 D
advice to the equipment manufacturer that helps define the maximum surface temperature.
Mechanical seals are used across a wide variety of industries and applications and it is therefore impossible to
issue a Declaration of Conformity specific to any product and process fluid. In consequence a generic
Declaration is normally supplied with the typical marking

II 2 GD Tx

where Tx means that the maximum surface temperature is specific to the service and is clarified by the supplier
in his documentation. This maximum surface temperature is fundamental to the duty conditions that the seal will
operate under and in particular, the sealed fluid and the temperature of the process fluid temperature in the seal
chamber.
If John Crane are not given the seals intended operational conditions it cannot specifically define the maximum
surface temperature in its documentation and thus fully satisfy its responsibilities inferred by the Declaration of
Conformity. This Addendum endeavours to meet John Cranes ATEX commitments as far as is possible in this
regard and clarify where there becomes a joint responsibility with the purchaser.

John Crane GmbH

Gleitringdichtungssysteme

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 reserve the right to alter designs and specifications
without prior notice.

John Crane GmbH

Gleitringdichtungssysteme

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

Postfach 2528
D-36015 Fulda

Telefon (0661) 281-0

Telefax (0661) 71056

03/2004 Bo - Pe/AB

BA GLRD Edition 6_GB.doc

Instruction Manual
Mechanical Seal

Page: 2
of: 13
Edition 6

Contents
1

General ........................................................................................................3
1.1 Introduction...................................................................................................3
1.2 Range of Application ....................................................................................3
1.3 Declaration of Incorporation (98/37/EC) .......................................................3

Safety & Environment ................................................................................4

2.1 Symbols........................................................................................................4
2.2 Safety Instructions ........................................................................................4
2.3 Environmental Aspects.................................................................................5
2.3.1 Company policy extract ...................................................................5
2.3.2 Recycling .........................................................................................5

Transportation and Storage ......................................................................6

Description of the Mechanical Seal ..........................................................6

4.1 Construction .................................................................................................6
4.2 Function........................................................................................................7
4.3 Operating Conditions....................................................................................7

Installation and Removal ...........................................................................7

5.1 Preparation for Fitting ...................................................................................7
5.2 Installation Tolerances..................................................................................7
5.2.1 Shape and Positional Tolerances ....................................................7
5.2.2 Surface Finish..................................................................................7
5.3 Installation ....................................................................................................8
5.3.1 Tightening Torques..........................................................................9
5.3.2 Lubricants ........................................................................................9
5.4 Seal Removal ...............................................................................................9
5.5 Installation and Removal of Shrink Discs (John Crane supply*).................10

Commissioning and Decommissioning .................................................10

Maintenance/Repair..................................................................................12
7.1 Maintenance ...............................................................................................12
7.2 Reconditioning............................................................................................12
7.3 Spare Parts.................................................................................................12

Malfunction, Causes and Correction ......................................................13

Accompanying Documents .....................................................................13

Instruction Manual
Mechanical Seal
1

1.1 Introduction

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.

Edition 6

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.

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.

Page: 3
of: 13

1.3 Declaration of Incorporation

(98/37/EC)
Only relevant to equipment operating in EEC
countries, see below.

1.2 Range of Application

Mechanical sealing systems are used for the
sealing of rotating shafts; they must be
operated within their performance limits (see
4.3 Operating Conditions).
John Crane GmbH
Gleitringdichtungssysteme
Werner-von-Siemens-Strae 6
D-36041 Fulda
Phone +49 661 281-0
Fax

+49 661 71056

Declaration of Incorporation
E.C. Machinery Directive 98/37/EC, Annex II B
Section 1.0 - Machinery Description:
John Crane part no. according to drawing
Section 2.0 - Applicable Harmonised Standards:
EN 292
Section 3.0 - Declaration:
We John Crane, declare that the seal assembly described in Section 1.0 above is
intended to be incorporated into other machinery or assembled with other machinery
to constitute machinery as covered by this Directive.
The seal assembly, covered by this declaration must not be put into service until the
machinery into which it is to be incorporated has been declared in conformity with the
provisions of the Directive.

ppa. Bernhard Borngrber

Technische Leitung

Instruction Manual
Mechanical Seal
2

Page: 4
of: 13
Edition 6

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:

Danger
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.
In order to avoid unforeseen hazards do not make
unauthorised changes to the fluid to be sealed,
the specified duty, or the seal parts.

ATTENTION

Some mechanical seals are used in conjunction

with an ancillary 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 equipment
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 ancillary
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 equipment is being used in 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.

Instruction Manual
Mechanical Seal

Page: 5
of: 13
Edition 6

2.3 Environmental Aspects

Disposal

2.3.1 Company policy extract

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.

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.
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.

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

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.

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

When in doubt or for further information and

advice on this subject, please consult
John Crane.

Instruction Manual
Mechanical Seal
3

Transportation and Storage

Transport and store the seal in its original

packaging.
To ensure seals remain in good condition
they should be stored in the following
environment:
dry and dust-free

Page: 6
of: 13
Edition 6

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).

ventilated at room temperature

protected from direct effects of heat and
ultraviolet light
elastomers require replacement after 24
months except fluoro- and perfluoroelastomers that require replacement after
60 months
for further information
storage refer to ISO 2230

on

elastomer

If used seal parts are to be transported to the

manufacturer or a third party they have to be
cleaned, decontaminated and require safe
handling instructions externally attached.
For additional information on transportation
and storage refer to John Crane document
I-Storage-E.
The sealing system does not require any
preservatives, it is resistant against all normal
environmental conditions.

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

If any machine, with an installed seal, has

been stored with preservatives before putting
it back into operation then seal must be
removed, cleaned and dried. Particular
attention must be applied to the cleanliness
of the faces and condition of the elastomers.
Ensure preservatives and
ATTENTION cleaning agents do not affect
the elastomers.
Once the seal is fitted on the
ATTENTION equipment and the position is
set using setting devices do
not re-engage them for transportation and
storage.

Fig. 2:

Typical Metal Bellows Mechanical Seal

Primary seal components

a) primary ring
b) mating ring
Secondary seal component
c) static seal
d) static seal
Spring component
e) metal bellows
Drive and retaining components
f) compression collar

Instruction Manual
Mechanical Seal

Page: 7
of: 13
Edition 6

4.2 Function
The hydraulic pressure and the spring force
press the rotating and axially flexible primary
ring against the stationary mating ring. Wear
at the primary seal is minimised by a very thin
lubricating film. The sealed fluid provides
lubrication; in the case of gas, the
mechanism is usually enhanced by spiral
grooves in order that the faces run noncontacting. With very low contact loads
special seals can be operated without
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 equipment and
adherence to the recommendations in this
Instruction Manual and associated manuals
will prevent this occuring.

1,5 mm

20
1 mm
Radius

Fig. 3

5.2 Installation Tolerances

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

5.2.1 Shape and Positional

Tolerances
Component

Type

Tolerance

Shaft to Housing

Squareness

0.08 mm*

4.3 Operating Conditions

Shaft to Housing

Concentricity

0.13 mm

Refer to drawing and (if applicable) to

order related data sheet in Section 9.

Shaft End Float

static
Axial

0.25 mm**

_______________________________

dynamic 0.04 mm

If no data available refer to John Cranes

published Data Sheet specific to the seal
type used, or consult John Crane direct.

Shaft or Sleeve

Ovality

0.05 mm

Runout

0.05 mm

Maximum static seal chamber pressure is

equal to the maximum dynamic pressure
rating see published data sheet.

Housing to Shaft

* API requires <0.5 m/mm of chamber bore, FIM.

**Figure stated on general arrangement drawing
(Section 9) should take precedence

5.2.2 Surface Finish

5 Installation and Removal

Seal Type

Value

5.1 Preparation for Fitting

dynamic O-ring

Check whether the seal is complete, clean

and undamaged.

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)

Clean all machinery abutments, sealing

and fitting surfaces (use only absorbent
and fluff-free polishing cloth for cleaning).

PTFE bellows

0.8/1.2 m Ra (turned)

Remove any protective coatings.

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

dynamic
wedge

and

static 0.1/0.25 m Ra

Packing ring (static)

(polished)
0.8/1.6 m Ra (turned)

Instruction Manual
Mechanical Seal
5.3 Installation
ATTENTION Carefully protect the lapped
sealing surfaces of primary
and mating rings during fitting. Minor
damages to sensitive surfaces, such as
scratches and chips, reduce the sealing
effectiveness of the mechanical seal.

Carry out fitting according to the

installation drawing (section 9) and with
the following procedure:
Maintain cleanliness during fitting.
Lubricate shaft with a suitable fluid in the
installation area.
Lubricate the shaft and housing sealing
components with a suitable fluid (see
Section 5.3.2), also ensuring they maintain
their correct position during fitting.
EP-elastomer O-rings and
ATTENTION bellows are not resistant to
mineral oil or grease.
Silicone-elastomer O-rings are
ATTENTION not resistant to silicone oil or
grease.
When the sleeve is fixed to
ATTENTION 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
ATTENTION this may prevent introduction
of the sealed fluid in
operation,
leading
to
overheating and failures.

Page: 8
of: 13
Edition 6

Tighten bolts, nuts and 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 equipment
manual.
For high temperature metal
ATTENTION bellows seals eg, 1604, 2609,
3609 etc the pump shaft must
be dimpled to ensure adaquate drive. Bolt the
seal assembly to the pump back plate and
finish assembling 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 set screws and
using a drill of clearance size, 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,
dimple the shaft to the full diameter. Carefully
remove all burrs to avoid damaging the seal
sleeve.
If setting devices are used,
they must be removed after
the seal is fixed securely in
ATTENTION place in its final position.
They can then be disengaged
and fixed or appropriately
stored.

On
double-ended
pumps
ensure
the
drive-end
and
nonATTENTION
drive-end
seals
are
appropriately selected

On double ended pumps the

drive collar set-screws or
sleeve drive component must
ATTENTION 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.

Slide the seal assembly over the shaft and

into position.

If possible check for freedom of movement

by hand turning the shaft.

If a flexible graphite seal is

used as the shaft/sleeve seal
remove this before sliding the
ATTENTION seal assembly into position.
Follow-up by inserting the
flexible graphite seals and the
follower.

Check on all pipework, hoses and fittings:

Ensure the seal arrangement is orientated

correctly, according to the housing,
pipework, and shaft connections (e.g.
studs, keyways, pins and drive holes).

Correct location, alignment and support

Correct connections. Refer to installation
drawing (see Section 9) and relevant
rotating equipment manual.

Instruction Manual
Mechanical Seal

Page: 9
of: 13
Edition 6

Correct specification
All unused connections must be plugged
with the as supplied metal pipe plugs.
Check whether drain connection should be
open or piped to a collection area.
All pipework on liquid barrier/buffer
systems and cooling circuits are orientated
to ensure effective venting.
Lack of damage and leaks

5.3.1 Tightening Torques

Tightening Torques [Nm] (u 0.125 lubricated)
Socket

Socket

Socket

Thread

Size

Setscrew

Setscrew

Setscrew

Size

Code

(ASTM A453Gr
660 C)

(316)

(High Tensile
Steel (14.9)

Part Code

Part Code

Part Code

Size/305/712

Size/305/001

Size/305/050

M4

77**

1.5

2.3

M5

78**

4.5

M6

79**

7.5

M8

80**

11

18

M10

81**

30

16

36

M12

82**

50

40

60

M14

83**

M16

84**

M20

86**

1/4 - 20

35**

4.5

8.8

5/16 - 18

36**

10

17.5

3/8 - 16

37**

13.5

30

7/16 - 14

38**

32

48

1/2 - 13

39**

45

69

Thread

Size

Steel Screw

Steel Screw

Size

Code

(Class 12.9)

(316 A4-70)

Part Code

Part Code

Size/301/050

Size/310/001
2

M4

77**

4.5

M5

78**

9.4

M6

79**

16

6,5

M8

80**

38

16

M10

81**

77

32

M12

82**

135

55

M14

83**

215

90

M16

84**

340

140

M20

86**

663

275

5.3.2 Lubricants
The following lubricants are recommended by
John Crane
Lubricant
elastomeric Orings except
silicon rubber
O-rings of
silicone rubber
Bolts, screws,
nuts and
fasteners
Elastomer
bellows on
shaft

Silicone grease,
(Chloride Free)
potable water or
glycerine
PTFE paste

Note
Apply very thinly by
hand

Apply very thinly by

hand
Molybdenum or nickel Apply with brush or
based anti-seize
by hand
compound
Potable water or
Apply with sprayer
glycerine

5.4 Seal Removal

Removal is essentially the reverse procedure
to installation.

ATTENTION

Refit seal setting devices prior

to removal.

Work on the seal must only be

carried out when the machine is
stationary, and secured against any
unforeseen start-up.

Before the seal is removed the seal

chamber or machinery must be
depressurised and drained.

If the equipment has 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 equipment manual
should be consulted to check for any special
precautions.

Note:

Some seals are supplied with

threaded extraction holes in the gland plate.
Insert suitable extraction bolt.

Instruction Manual
Mechanical Seal
5.5 Installation and Removal of
Shrink Discs (John Crane
supply*)
Outer Ring
Locking Screw
Inner Ring

Shaft

grease-free

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).

Ensure transit plugs are removed and

seal drain connections are correctly piped
or open.

Ensure valves controlling circulation, flush

and quench are correctly positioned.
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.

Degrease sleeve bore and shaft!

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

*Refer

to the machine manufacturers

instructions if not of John Crane supply.
Do not tighten the locking
screws until the shaft is in its
ATTENTION
correctly
set
operating
position.

Make sure that outer and inner ring are

aligned. This is a visual check on the
effectiveness of the shrink disc. If not,
loosen and repeat above installation
procedure
Removal
Remove rust, which may have formed on
the shaft in front of the sleeve.
Loosen all locking screws uniformly, in a
clockwise sequence; initially about a
quarter turn per revolution only. Do not
remove screws from the threads.

Commissioning and
Decommissioning

Note before start-up:

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

Edition 6

If the outer and inner rings have not

separated, remove some screws and
insert them in the neighboring extraction
screw threads.

Sleeve

Page: 10
of: 13

Ensure the seal chamber and/or barrier,

buffer and cooling circuits are fully
vented. (Not necessary on 2800 range of
seals).

With liquid lubricated seals

avoid dry running under any
ATTENTION circumstances, as it will
damage the seal. (Not
relevant to 2800 range of
seals and dry containment
seals).
For hot duties (above 150C)
ensure pump has been
brought up to operating
ATTENTION temperature prior to start-up.
Rapid
axial
differential
thermal growth between shaft
and pump casing could result
in seal malfunction.
If the seal is unidirectional, check the
correct rotation direction.
Check the correct setting and
operation of electrical warning
systems associated with seal
operation.

Instruction Manual
Mechanical Seal

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.

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 barrier pressure should be set at

least 10% or 1 bar above the
maximum seal chamber pressure,
whichever is the greater value. If a
low-pressure switch is fitted to the
system ensure it is set above the
maximum seal chamber pressure and
below the barrier pressure; it must
have an adequate pressure difference
between its set point and the barrier
pressure to allow the switch to reset.

In case of pressurised double seals note:

Auxiliary barrier systems are designed to

service mechanical seals by cooling,
lubricating and pressurising; they must be
operated within their performance limits. If
the barrier system is not supplied by John
Crane check the system and specification
supplied meet the seals requirements for
reliable operation. Refer to the system
Instruction Manual.
The barrier 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.
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 (2nd Edition) also
offer advice on the selection barrier
liquids. It is advised John Crane is
contacted for more detailed advice on
barrier 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.

During the start-up of the machine in cold

ambient conditions the barrier viscosity
should not exceed 150 cSt. If this cannot
be ensured the barrier is to be preheated.

Edition 6

The seal barrier auxiliary system must be

pressurised before priming the machine.

To minimise any ignition hazard it

is important to ensure seal flush
rates, temperatures, and cooling
water
flow
rates
are
to
specification.

Page: 11
of: 13

For gas seals the barrier pressure

must be (2 bar for 2800ER, 3 bar for
2800BD and 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.
Care should be exercised to ensure
the Maximum Allowable Working
Pressure (MAWP) is not exceeded
during filling and pressurisation.

The cooling water outlet temperature

should be < 50oC. If not, check that the
cooling water inlet temperature is low and
that the flowrate 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 protection must then be applied.

When using thermosyphon systems,

ensure that the circuit minimises flow
restrictions and can be effectively vented.
Contact John Crane for more information.

Instruction Manual
Mechanical Seal

ATTENTION

ATTENTION

If a water test has been

applied when flexible graphite
seat/mating ring seals are
used, they must be replaced
or thoroughly dried before
use on a hydrocarbon service
above 100oC.

Maintenance/Repair

7.1 Maintenance
Carry out the following procedures for
trouble free operation:

Edition 6

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

When
the
machine
is
stopped, the seal system
pressure
should
be
maintained until the machine
itself is unpressurised.

Notes on decommissioning see Removal,

Section 5.4.

Page: 12
of: 13

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
equipment user to ensure that any
parts being sent to a third party
have appropriate safe handling
instructions or decontamination
certification externally attached to the
package. Without this information there may
be a refusal to handle the goods.

Check daily:
that the connections are leak free
seal leakage
barrier gas flow for 2800 range of
seals
condition of alarm signals
in addition for double seals
barrier/buffer liquid level
barrier/buffer liquid temperature
barrier/buffer pressure
in addition for dry containment seals
for dry contacting containment seals
(S48SC, 48SC, SBOP & ECS) a
monthly check with a 1.0 bar gas
test is recommended.
buffer gas flow when applied, check
monthly
wear parts for dry contacting
containment
seals
require
replacement after 24000 hrs
dynamic operation.
If 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.

Rebuilding seals to as-new specifications

must be carried out by qualified personnel.

Note:

It is recommended that a low

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

7.3 Spare Parts

Only John Crane spare parts should be used
to recondition seals.
It is advised to stock on site a spare seal
cartridge or the minimum replacement parts
shown on the installation drawing (Section 9).
The order codes for spare parts can be found
in the parts list on the installation drawing.
(Section 9). In the case of the 2800 range of
seals only complete cartridges should be
stored.
The following data is necessary for spare part
orders:
seal assembly code
part description
component code
quantity.

Instruction Manual
Mechanical Seal

Malfunction,
Correction

Causes

Page: 13
of: 13
Edition 6

and

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.

Accompanying Documents

Drawing
Data Sheet
(if applicable)

John Crane International - Major Regional Centres

North America
6400 West Oakton Street
Morton Grove IL. 60053
USA
Phone +1 847 967 2400
Fax +1 847 967 3915

Europe, Asia, and Africa

Buckingham House
361-366 Buckingham Avenue
Slough, Berkshire SL1 4LU
U.K.
Phone +44 1753 224 000
Fax +44 1753 224 224

Asia Pacific
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# 03-05/06 Mannesmann Centre
Singapore 609929
Phone +65 222 91 61
Fax +65 223 50 35

Latin America
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04532-001 Sao Paulo SP
Brazil
Phone +55 11 3049 99 79
Fax +55 11 3049 45 11

Technical Support and Service Germany, Austria and Switzerland

John Crane GmbH
Werner-von-Siemens-Str. 6
D-36041 Fulda
Postfach 25 28
D-36015 Fulda
Telefon +49 661 2 81-0
Telefax +49 661 7 10 56
e-mail: mail@johncrane.de
Internet: www.johncrane.com

D-41468 Neuss
Service Center
Blindeisenweg 45
Telefon +49 2131 6 65 01-0
Telefax +49 2131 6 65 01-11
scnordwest@johncrane.de

D-92353 Postbauer-Heng
Rosenstrae 10b
Telefon +49 9188 90 30 60
Telefax +49 9188 90 30 61
JNagelstrasser@johncrane.de

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

D-69469 Weinheim
Service Center
Mierendorffstrae 21
Telefon +49 6201 25 90 97-0
Telefax +49 6201 25 90 97-11
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Service Center
Hallesche Strae 39a
Telefon +49 3461 72 34 33
Telefax +49 3461 72 37 55
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CH-4103 Bottmingen
Service Center/Vertrieb
Wuhrmattstr. 13A
Telefon +41 61 4 26 92 92
Telefax +41 61 4 26 92 80
johncrane@johncrane.ch

D-86899 Landsberg a. Lech

Albert-Einstein-Strae 16
Telefon +49 8191 6 57 26-0
Telefax +49 8191 6 57 26 40
info@safematic.de