Dgs

John Crane
Engineered Sealing Systems
Installation, Operation &

Maintenance Instructions
for
Type 28 XP, XP-S & EXP
Gas Seal
Document No.: GS-IOM-0001
Issue: B
This document provides

instructions for the standard
Type 28 XP, XP-S & EXP Gas
John Crane EMEA
Seal ranges as supplied by John 361-366 Buckingham
Avenue,
Crane and installed within Slough, SL1 4LU,England,
UK
compressor applications
John Crane Inc.
6400 Oakton St.
Morton Grove, IL. 60053
USA
John Crane Japan

222 Kamitoyama
Ritto, Kurita-Gun
Shiga Prefecture
Japan
John Crane Type 28 Gas Seals 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.
GS-IOM-0001 issue B Installation, Operation & Maintenance
Page 2 of 16 Instructions
CONTENTS Page
1. INTRODUCTION TO THE JOHN CRANE TYPE 28 XP, XP-S & EXP GAS SEAL 3
2. SAFETY 3
2.1 SAFETY INSTRUCTIONS 3
3. SEAL INSTALLATION AND REMOVAL FROM THE COMPRESSOR 4
3.1 SEAL PREPARATION 4

3.2 COMPRESSOR PREPARATION 5
3.3 FITTING THE GAS SEALS 6
3.4 REMOVAL OF THE GAS SEALS 7
4. COMMISSIONING PROCEDURE 8
4.1 STATIC GAS SEAL TEST 8

4.2 DYNAMIC OPERATION 8
5. COMPRESSOR OPERATION & MAINTENANCE WITH DRY GAS SEALS 8
6. STORAGE, SERVICE LIFE AND TRANSPORTATION OF GAS SEALS 11
6.1 STORAGE 11
6.2 SERVICE LIFE 11
6.2 TRANSPORTATION 11
APPENDIX I PRINCIPLE OF OPERATION 12
APPENDIX II RETURNING SEALS TO JOHN CRANE 13
APPENDIX III REPLACING TOLERANCE RINGS 14
APPENDIX IV REPLACING EXTERNAL POLYMER SEALS 15

1. INTRODUCTION TO THE JOHN CRANE TYPE 28 XP, XP-S AND EXP GAS SEAL
This manual relates to matters affecting the operation of the Type 28 XP, XP-S and EXP dry gas seals within compressor machinery. It
covers areas directly associated with the installation and removal, operation and maintenance of the gas seal. For other related
subjects, such as the correct operation of associated systems or guidance when conducting hazard analysis (as may be required under
the European ATEX Directives) consult with the compressor equipment supplier and their documentation.
The gas seals are robust in operation. However, any incorrect handling or assembly fitting can easily lead to seal damage. Therefore
John Crane Type 28 Gas Seals may only be installed, commissioned and maintained by an authorised plant machinery specialist. This
person must pay close attention to these instructions, the John Crane Gas Seal Installation Drawing, compressor equipment suppliers
manuals and documentation and all relevant regulations. Failure to do this relieves the manufacturer John Crane from any liability or
warranties. It is strongly recommended that the seals are fitted by John Crane trained and approved Technicians.
Most often situated between the gas seal and the compressor bearing chamber is sited a further seal type. The function of this seal is to
prevent the ingress of bearing oil into the gas seal. This type of seal could be a labyrinth or some form of mechanical seal and can be
known by several generic names such as tertiary seal, barrier seal or separation seal. Throughout this document this seal will be
referred to as the separation seal.
If there are any gas seal problems that need an urgent response from John Crane please call one of the following numbers below:
For John Crane Europe, Middle East & Africa (John Crane EMEA) call:
Hotline Number + 44 (0)1753 224400 (answer phone out of hours).
Emergency line 24 hours + 44 (0) 7889 653846
For John Crane North America call: + 1 (0) 847 967 3533
For John Crane Japan call: + 81 (0) 77 558 3211
2. SAFETY
The safety notes refer to the gas seal arrangement supplied. They can never be exclusive, and must be used in conjunction
with the relevant safety regulations for the machine, auxiliary equipment, plant and sealed fluid.
WARNING SYMBOLS
The following symbols are used in this instruction manual to highlight information of particular importance:
Danger
Mandatory instructions designed to prevent injury or extensive damage.
ATTENTION Special instructions and / or information to avoid damage to the seal and / or its surroundings.
Note: Information for easy installation and efficient operation.
2.1 SAFETY INSTRUCTION
ANY WORKING PRACTICE THAT COMPROMISES SAFETY MUST BE AVOIDED. AT ALL STAGES IN WORK RELATING TO THE
GAS SEAL, REFERENCE MUST BE MADE TO THE JOHN CRANE INSTALLATION DRAWING, THIS DOCUMENT AND THE
COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND DOCUMENTATION AND ALL RELEVANT REGULATIONS.
GAS SEAL CARTRIDGE DISASSEMBLY IS NOT REQUIRED FOR NORMAL OPERATION AND MAINTENANCE AND MUST NEVER
BE UNDERTAKEN OTHER THAN BY A JOHN CRANE TRAINED TECHNICIAN APPROVED FOR THE SEAL TYPE BEING WORKED
ON. WHERE GAS SEALS REQUIRE INSPECTION AND REFURBISHMENT, PLEASE CONTACT JOHN CRANE.
IN THE EVENT OF AN OPERATING PROBLEM, THE MACHINERY MUST BE IMMEDIATELY SWITCHED OFF AND MADE SAFE.
PROBLEMS MUST BE SOLVED PROMPTLY.
A SMALL CONTROLLED LEAKAGE WILL OCCUR DURING NORMAL SEAL OPERATION. IN CASES OF A WORN OR DEFECTIVE
SEAL, THE LEAKAGE VOLUMES WILL INCREASE. THE LEAKAGE MAY BE HAZARDOUS OR TOXIC, AND A SAFE COLLECTION
SYSTEM IS REQUIRED.
IN THE RARE CASE OF CATASTROPHIC GAS SEAL FAILURE, A BULK ESCAPE OF PROCESS GAS AND OR BUFFER GAS
WITHIN THE COMPRESSOR CASING CAN OCCUR PAST THE GAS SEAL. IT IS THE RESPONSIBILITY OF THE COMPRESSOR /
MACHINE MANUFACTURES AND EQUIPMENT OPERATORS TO ENSURE THAT SYSTEMS AND PROCEDURES ARE IN PLACE
TO DEAL WITH THIS OCCURRENCE AND THAT THESE SYSTEMS PROVIDE ADEQUATE HEALTH AND SAFETY TO ALL
PEOPLE, AS WELL AS PROTECTION FOR THE ENVIRONMENT.
HOT SURFACES HAVE TO BE PROTECTED AGAINST ACCIDENTAL CONTACT.
AS A GENERAL SAFEGUARD, PROTECTIVE GLOVES SHOULD BE WORN IF HANDLING FAILED SEAL PARTS. COMPOUNDS
CONTAINING PTFE, FLUOROCARBONS AND PERFLUOROELASTOMERS SHOULD NEVER BE BURNED AS THE FUMES AND
RESIDUES ARE HIGHLY TOXIC. IF THIS OR GROSS OVER-HEATING OCCURS PROTECTIVE GLOVES MUST 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.
WHEN RETURNING SEALS TO JOHN CRANE, CUSTOMERS MUST CONFIRM IN WRITING THAT THE SPECIFIC SEALS BEING
RETURNED ARE SAFE TO HANDLE AND PROVIDE ANY ADDITIONAL SAFETY-CRITICAL INFORMATION ON REQUEST. THIS IS
FURTHER DISCUSSED IN APPENDIX II OF THIS DOCUMENT.
3. SEAL INSTALLATION AND REMOVAL FROM THE COMPRESSOR
3.1 SEAL PREPARATION
Note: Seal installation and extraction tools are not supplied by John Crane.
Prior to installation, the entire outer surface of the gas seal cartridge including the seal bore should be clean and dry.
DO NOT FIT THE GAS SEAL IF THE OUTSIDE OF THE SEAL CARTRIDGE IS SIGNIFICANTLY DIRTY, STAINED WITH
HYDROCARBON TAR DEPOSITS OR WETTED WITH FLUIDS AS THIS MAY INDICATE THE SEAL HAS BEEN INTERNALLY
CONTAMINATED. IN SUCH AN EVENT CONTACT JOHN CRANE.
NEVER CLEAN THE GAS SEAL WITH CLEANING FLUIDS OR SOLVENTS THAT COULD ENTER THE CARTRIDGE AND ATTACK
VULNERABLE COMPONENTS SUCH AS POLYMER SEALS AND O RINGS OR CAUSE CORROSION.
ATTENTION
IN THE CASE OF VERY MINOR DIRT OR FLUID PRESENT ON THE OUTSIDE OF THE SEAL CARTRIDGE THAT CAN BE EASILY
CLEANED AWAY AND THERE IS NO RISK OF INTERNAL SEAL CONTAMINATION, THEN IT IS POSSIBLE TO CONTINUE WITH
SEAL INSTALLATION. IF IN ANY DOUBT CONTACT JOHN CRANE.
All secondary seals (polymer seals or O rings) fitted to the outside diameter and in the bore of the cartridge should be carefully
examined for damage such as cuts or crushing. If damaged, they should be replaced (see appendix IV for polymer seal replacement)
with a correct part from the spares / installation kit, in accordance to the installation drawing.
On certain gas seal designs, tolerance rings are located within the seal sleeve bore of the gas seal (see figure 1). The function of these
tolerance rings is to centralise the seal rotor on the compressor shaft. If during service the tolerance rings have become damaged and
crushed then they can be replaced as per the instructions of appendix III.
ATTENTION
CAREFULLY CHECK ALL EXTERNAL SCREWS ON THE CARTRIDGE FOR ANY SIGNS OF LOOSENESS THAT MAY HAVE
OCCURRED. IF ANY HAVE BECOME LOOSE, RE-TIGHTEN USING AN APPROPRIATE ALLEN KEY. IF IN ANY DOUBT,
CONTACT JOHN CRANE BEFORE INSTALLING THE GAS SEAL.
3.2 COMPRESSOR PREPARATION
THE COMPRESSOR CAVITY INTO WHICH THE GAS SEAL IS FITTED MUST BE IN ACCORDANCE WITH THE GAS SEAL
INSTALLATION DRAWING.
PRIOR TO ANY WORK BEING CARRIED OUT ON THE COMPRESSOR, IT MUST BE IN A SAFE CONDITION. ALL PRESSURES
WITHIN THE COMPRESSOR CASING NEED TO BE ATMOSPHERIC PRESSURE WITH NO DIFFERENTIAL PRESSURES
PRESENT (INCLUDING PARTIAL VACUUM CONDITIONS). NO HAZARDOUS OR TOXIC GASES OR LIQUIDS MUST BE PRESENT
AND ANY REQUIRED DECONTAMINATION PROCEDURES MUST BE CARRIED OUT. FOR FURTHER INFORMATION, CONSULT
THE COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND DOCUMENTATION.
THE COMPRESSOR CASING AND SHAFT MUST BE ADEQUATELY EARTHED AND ELECTRICAL EARTH CONTINUITY MUST BE
MAINTAINED. SEE COMPRESSOR EQUIPMENT SUPPLIERS MANUAL AND DOCUMENTATION FOR DETAILS.
THE FOLLOWING TEXT ASSUMES THAT THE COMPRESSOR HAS BEEN MADE SAFE AND THAT THE REQUIRED
INSTALLATION AND EXTRACTION TOOLS ARE AVAILABLE.
To provide lubrication between the compressor shaft and the gas seal rotor during installation, John Crane recommends the use of
either:
Dow Corning MolKote(R) G-N Paste or MolKote(R) G-N Plus Paste
Jet-Lube InC White Knight anti-seize compound
The above individual substances should not be mixed and must be applied sparingly, and only at the seal bore / compressor shaft
interface.
For any O' ring situated on the outside diameter only of the seal cartridge (outside diameter of the retainers of the seal stator),
sparingly lubricate with a thin layer of silicon grease. No lubrication should be applied to the polymer seals.
ATTENTION
UNDER NO CIRCUMSTANCES MUST SILICONE GREASE BE USED FOR SHAFT / SEAL SLEEVE ASSEMBLY LUBRICATION
OTHERWISE SHAFT SLEEVE GALLING CAN RESULT.
ANY EXCESSIVE SILICON GREASE AND ANTI-SEIZE COMPOUND MUST BE REMOVED, AND CARE TAKEN TO PREVENT
INGRESS OF THESE LUBRICANTS INTO THE DRY GAS SEAL DURING CARTRIDGE INSTALLATION. EXTRA CARE SHOULD BE
TAKEN WHEN GAS VENT HOLES ARE PRESENT THROUGH THE RADIAL SECTION OF THE SEAL ROTOR AS THIS PROVIDES
A DIRECT PATH THROUGH TO THE INTERNALS OF THE SEAL (SEE FIGURE 1).
THE SUITABILITY OF ALTERNATIVE LUBRICANTS SHOULD BE CONFIRMED WITH JOHN CRANE.
FIGURE 1 Gas Seal with installation plates fitted
a) Clean the entire area within the compressor into which the gas seal fits. Ensure that it is free from defects and any rough or
sharp edges and burrs that could damage the seal on installation.
b) Ensure that the compressor shaft is positioned correctly to the compressor casing to allow fitting of the gas seal. Both the axial
and radial alignment needs to be considered. Ensure that the shaft is angularly aligned with the casing such that any pin
positions, keys, bolts or other features in the shaft and casing are aligned with the corresponding features within the gas seal
with the installation plates fitted (see seal installation drawing and figure 1). Consult the compressor equipment suppliers
manual and documentation for appropriate method for shaft and casing alignment.
IT MAY BE NECESSARY TO AXIALLY LOCK THE SHAFT TO PREVENT IT FROM MOVING WHILST FITTING THE GAS SEAL INTO
POSITION. FOR FURTHER INFORMATION, CONSULT THE COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND
DOCUMENTATION.
c) If the dry gas seals have not been previously fitted to the compressor or if there is a new rotor, check that the seal chamber is
in accordance with the installation drawings.
d) Apply a film of anti-seize compound to the compressor shaft.
e) Axial positioning shims or spacers may be provided. If supplied these need to be adjusted by appropriate machining to
achieve the correct rotor to stator working position. Once correctly adjusted, fit shims or spacers into the compressor or to
seal cartridge as shown on installation drawing or compressor equipment suppliers manuals and documentation.
3.3 FITTING THE GAS SEALS
ENSURE THAT THE GAS SEAL CARTRIDGE IS CORRECT FOR THE COMPRESSOR SHAFT END THAT IT IS BEING FITTED
TOO. CONSULT EQUIPMENT SUPPLIERS MANUALS AND DOCUMENTATION TO ASCERTAIN CORRECT PART NUMBERS
AND COMPARE THESE AGAINST THE SEAL CARTRIDGE PART NUMBERS AND THE SEAL INSTALLATION DRAWING.
ENSURE THE DIRECTION OF ROTATION OF THE GAS SEAL CARTRIDGE IS CORRECT FOR THE COMPRESSOR SHAFT END
THAT IT IS BEING FITTED TOO. THE ALLOWABLE DIRECTION OF ROTATION FOR A SEAL CARTRIDGE IS SHOWN ON THE
INSTALLATION DRAWING AND IS ALSO PRINTED/ETCHED ONTO THE SEAL CARTRIDGE ITSELF.
a) Loosen all the screws of both the inner and outer installation plate fitted to the gas seal by a turn each only (see figure
1). Do not loosen screws excessively.
b) Using appropriate lifting equipment carefully position the gas seal on to the shaft.
c) Align any key ways, pins, slots, holes or other features within the seal with corresponding features sited within the
compressor casing and shaft.
d) Using the fitting tools provided by the compressor manufacturer (or suitable studding and jacking bar), carefully and
evenly jack the gas seal assembly into position by applying jacking force to the seal stator.
WHILST FITTING THE GAS SEAL, IT IS IMPERATIVE THAT IT IS KEPT SQUARE TO THE SHAFT AXIS IN ORDER TO PREVENT
IT BINDING ONTO THE SHAFT.
e) When the gas seal is fully engaged home, remove all fitting tools.
f) Remove the seal installation plates and their screws as per the installation drawing.
g) Secure the seal stator into the compressor casing and the seal rotor to the shaft using the appropriate components as
shown on the installation drawing or if not shown as per the compressor equipment suppliers manual and
documentation.
ANY JOHN CRANE SUPPLIED SCREWS USED TO RETAIN SEAL COMPONENTS SHOULD BE TIGHTENED ADEQUATELY.
WHERE THESE SCREWS ARE SECURED INTO NON JOHN CRANE SUPPLIED PARTS, THEN CONSULT WITH THE
COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND DOCUMENTATION FOR ANY BOLT TORQUE REQUIREMENTS.
TABLE 1 LISTS THE RECOMMENDED TORQUE VALUES FOR JOHN CRANE SUPPLIED SCREWS FASTENED WITHIN JOHN
CRANE SUPPLIED PARTS.
ANY SEPARATION SEAL PARTS SHOULD BE FITTED IN ACCORDANCE WITH THE SEPARATION SEAL SUPPLIERS
DOCUMENTATION.
IT IS ESSENTIAL THAT BOTH THE GAS SEAL ROTOR AND STATOR ARE LOCATED IN THE CORRECT AXIAL POSITION AS
IDENTIFIED ON THE INSTALLATION DRAWING. ANY AXIAL MIS-ALIGNMENT OF THE SEAL ROTOR TO THE STATOR WILL
POTENTIALLY RESULT IN SEAL FAILURE.
IT IS ESSENTIAL THAT THE GAS SEAL ROTOR IS EFFECTIVELY LOCKED ONTO THE COMPRESSOR SHAFT AND THE SEAL
RETAINER EFFECTIVELY LOCKED WITHIN THE COMPRESSOR CHAMBER AND THAT ANY LOCKING DEVICES ARE FULLY
SECURED AND TIGHTENED. PLEASE CONSULT THE COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND
DOCUMENTATION.
PRIOR TO ANY ATTEMPT TO ROTATE THE SHAFT, THE SEAL INSTALLATION PLATES AND ASSOCIATED SCREWS MUST BE
REMOVED.
COMPLETE COMPRESSOR ASSEMBLY AS PER THE COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND
DOCUMENTATION.
IF COMPRESSOR SHAFT HAS BEEN LOCKED, ENSURE THIS HAS BEEN REMOVED PRIOR TO ANY COMPRESSOR
OPERATION. CONSULT COMPRESSOR EQUIPMENT SUPPLIERS MANUAL AND DOCUMENTATION FOR FURTHER
INFORMATION.
TABLE 1: Recommended Screw Torque Values for screws fitted to John Crane supplied parts.
John
Crane
Screw Screw Torque Value Screw Torque Value
Screw
Material Size Size
Material
Code (Nm) (lbf ft) (Nm) (lbf ft)
M4 5 4 #8 5 4
M5 10 8 #10 8 6
Alloy Steel GMC M6 18 13 1/4 19 14
Screws 0225 M8 43 31 5/16 39 29
M10 84 62 3/8 69 51
M12 147 109 1/2 169 124
M4 3 2 #8 3 2
Super
M5 5 4 #10 4 3
Duplex
GMC M6 9 7 1/4 10 7
Stainless
0581 M8 22 17 5/16 21 15
Steel
M10 44 33 3/8 36 27
Screws
M12 77 57 1/2 89 66
M4 1 1 #8 2 1
M5 3 2 #10 2 2
Hastelloy M6 5 4 1/4 5 4
GMC 0690
C-276 M8 12 9 5/16 11 8
M10 24 18 3/8 20 15
M12 43 31 1/2 49 36
Reference GS-ENG-001
For John Crane Screw Material Codes, consult the Installation Drawing.
3.4 REMOVAL OF THE GAS SEALS
BEFORE REMOVAL OF THE GAS SEAL, THE COMPRESSOR NEEDS TO BE IN A SAFE STATE. ALL PRESSURES WITHIN THE
COMPRESSOR CASING NEED TO BE ATMOSPHERIC PRESSURE WITH NO DIFFERENTIAL PRESSURES PRESENT
(INCLUDING PARTIAL VACUUM CONDITIONS). NO HAZARDOUS OR TOXIC GASES OR LIQUIDS MUST BE PRESENT AND ANY
REQUIRED DECONTAMINATION PROCEDURES MUST BE CARRIED OUT. FOR FURTHER INFORMATION, CONSULT THE
COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND DOCUMENTATION.
In accordance with the compressor equipment suppliers instructions, disassemble the compressor to the point where there is access to
the gas seal.
IT MAY BE NECESSARY TO AXIALLY LOCK THE SHAFT TO PREVENT IT FROM MOVING WHILST REMOVING THE GAS SEAL
FROM THE COMPRESSOR. FOR FURTHER INFORMATION, CONSULT THE COMPRESSOR EQUIPMENT SUPPLIERS
MANUALS AND DOCUMENTATION.
a) Carefully study the installation drawing. All devices that secure the gas seal stator or rotor to the compressor casing or shaft
must be removed.
b) Fit the seal installation plates as identified on the installation drawing. It is not necessary to fit the anti-rotation screw (see
figure 1).
c) Fit the removal tools as provided by the compressor manufacturer (or suitable studding and jacking bar) to facilitate gas seal
removal.
d) Fit any required lifting equipment.
e) Using these tools extract the gas seal cartridge from the compressor housing by applying a jacking force to the seal stator.
f) Using lifting equipment, remove the seal cartridge from the shaft
IT IS IMPERATIVE THAT WHILE EXTRACTING THE GAS SEAL CARTRIDGE, THAT THE CARTRIDGE IS KEPT SQUARE TO THE
SHAFT AXIS IN ORDER TO PREVENT IT BINDING ONTO THE SHAFT.
IF THE GAS SEAL IS REMOVED WITHOUT THE APPROPRIATE INSTALLATION PLATES, SEVERE DAMAGE MAY OCCUR TO
THE SEAL CARTRIDGE OR THE COMPRESSOR SHAFT AND CAVITY.
4. COMMISSIONING PROCEDURE
ONCE THE GAS SEALS HAVE BEEN INSTALLED INTO THE COMPRESSOR AND PRIOR TO COMMISSIONING OF THE GAS
SEALS, ALL COMMISSIONING PROCEDURES AS REQUIRED BY THE COMPRESSOR EQUIPMENT SUPPLIER MUST BE
CARRIED OUT AND THE COMPRESSOR MUST BE IN A SAFE CONDITION BEFORE ANY PRESSURE IS APPLIED TO THE
COMPRESSOR OR THE COMPRESSOR SHAFT IS ROTATED OR THE COMPRESSOR IS OPERATED. FOR FURTHER
INFORMATION, CONSULT THE COMPRESSOR EQUIPMENT SUPPLIERS MANUALS AND DOCUMENTATION.
THE FOLLOWING TEXT ASSUMES THAT THE COMPRESSOR IS IN A SAFE CONDITION IN ACCORDANCE WITH ABOVE AND
THAT ANY REQUIRED PROCEDURES HAVE BEEN CARRIED OUT.
4.1 STATIC GAS SEAL TEST
This task should be undertaken following gas seal cartridge installation and prior to starting the compressor.
a) It is recommended where possible that with the equipment drive coupling disconnected, rotate the compressor shaft to ensure
freedom of movement.
b) If a separation seal is installed, commission the separation seal gas system and ensure that it is functioning correctly. This
must be done prior to any bearing lubrication oil operation/circulation.
c) Pressurise the compressor casing incrementally up to line pressure. Record the gas seal primary stage leakage rate against
each pressure increment.
d) If leakage is observed that is close to or greater than alarm settings, the compressor must be depressurised and the cause of
the high leakage rectified.
4.2 DYNAMIC OPERATION
a) Commence normal start up procedure as defined by the compressor equipment suppliers manual and documentation.
Periodically record the gas seal primary stage seal leakage rate during the first 4 hours of operation or until full compressor
operating conditions are reached dependent on which is longer.
b) If excessive leakage is observed i.e. close to or greater than alarm settings, then the compressor must be shutdown and
depressurised and the cause of the high inboard leakage rectified.
5. COMPRESSOR OPERATION AND MAINTENANCE WITH DRY GAS SEALS
The gas seals are designed to cover the widest range of operating parameters and require virtually no maintenance. The gas seal
should be continuously monitored (especially gas consumption and leakage) and data recorded using the compressor logging system. A
trend of changing leakage, temperature or other parameters being monitored at or around the gas seal may give forewarning of a seal
problem.
OPERATING & ENVIRONMENTAL CONDITIONS.

THE GAS SEAL MUST NOT BE SUBJECTED TO OPERATING CONDITIONS, ENVIRONMENTAL CONDITIONS, SUBSTANCES
AND FLUIDS OUTSIDE THOSE DEFINED BY THE CONTRACT OF GAS SEAL SUPPLY, THE INSTALLATION DRAWING AND THIS
DOCUMENT.
REVERSE ROTATION.
THE DIRECTION OF ROTATION FOR THE GAS SEAL IS SHOWN ON THE INSTALLATION DRAWING. IT IS ALSO
PRINTED/ETCHED ON TO THE GAS SEAL CARTRIDGE. IT MUST BE ENSURE THAT GAS SEALS ARE FITTED FOR THE
CORRECT DIRECTION OF COMPRESSOR SHAFT ROTATION.
REVERSE ROTATION IS ONLY PERMISSIBLE ON BI-DIRECTIONAL DESIGNS OF GAS SEALS.
UNI-DIRECTIONAL GAS SEALS ARE NOT DESIGNED TO OPERATE WITH REVERSE ROTATION AND THIS MUST BE AVOIDED
AS DAMAGE WILL MOST LIKELY BE INCURRED THAT WILL LEAD TO FUTURE SEAL FAILURE. IF THE SEALS ARE
SUBJECTED TO ANY FORM OF REVERSE ROTATION NO MATTER HOW BRIEF THE DURATION, THEN CONTACT JOHN
CRANE. IN ALMOST ALL CIRCUMSTANCES, THE SEALS WILL REQUIRE INSPECTION BY A JOHN CRANE TRAINED AND
APPROVED TECHNICIAN AND REPLACEMENT BEFORE FURTHER OPERATION.
REVERSE PRESSURE.
REVERSE PRESSURE OCCURS WHEN DOWN STREAM PRESSURE IS GREATER THAN UPSTREAM PRESSURE ACTING ON
AN INDIVIDUAL GAS SEAL SEALING STAGE. THE SEALS ARE NOT DESIGNED TO OPERATE WITH REVERSE PRESSURE. IF
IT OCCURS UNDER STATIC CONDITIONS (IE. COMPRESSOR SHAFT IS NOT ROTATING AND IS AT STANDSTILL), REVERSE
PRESSURE WILL RESULT IN THAT SEALING STAGE OPENING AND NOT SEALING THE REVERSE PRESSURE.
FOR MANY COMPRESSOR SYSTEMS, FLARE GAS WILL BE UNCLEAN, HIGHLY CONTAMINATED AND CONTAIN LIQUIDS. IN
THESE INSTANCES, IF REVERSE PRESSURE WERE ENCOUNTERED WITH FLARE PRESSURE THEN THE GAS SEAL IT SELF
WOULD BE CONTAMINATED RESULTING IN LOSS OF PERFORMANCE AND THE RISK OF FAILURE. REVERSE PRESSURE
WITH CONTAMINATED FLARE GAS IS NOT ACCEPTABLE.
IF REVERSE PRESSURE OCCURS ON A SEALING STAGE UNDER STATIC CONDITIONS WITH VERY CLEAN FLARE GAS
(CLEANLINESS BEING WITHIN THE LIMITS FOR NORMAL GAS SEAL OPERATION) OR BUFFER GAS AT A PRESSURE OF NO
GREATER THAN 10BAR (145PSI), THEN IT IS EXPECTED THAT WHEN THE PRESSURE IS REMOVED THE SEALING STAGE
WILL RE-CLOSE. IF REVERSE PRESSURE OCCURS UNDER THESE CIRCUMSTANCES, IT IS REQUIRED THAT WITH THE
PRESSURE DIFFERENTIAL RESTORED TO THE CORRECT DIRECTION A STATIC PRESSURE TEST IS CARRIED OUT TO
ASSESS CORRECT SEAL PERFORMANCE. THIS MUST BE DONE BEFORE ANY DYNAMIC OPERATION OF EQUIPMENT.
UNDER DYNAMIC OPERATION, ANY REVERSE PRESSURE WILL RESULT IN DAMAGE THAT WILL IN ALMOST ALL
CIRCUMSTANCES LEAD TO CATASTROPHIC FAILURE AND THEREFORE MUST BE AVOIDED.
MINIMUM SEAL SPEED.

FOR ANY DYNAMIC OPERATION, THE ROTOR SPEED MUST EXCEED THE MINIMUM SPEED AS DEFINED WITHIN THE
CONTRACT OF GAS SEAL SUPPLY. THIS COVERS ALL TYPES OF COMPRESSOR OPERATION INCLUDING COMPRESSOR
TESTING, FIELD OPERATION AND ANY MAINTENANCE OPERATION. FAILURE TO COMPLY MAY LEAD TO DAMAGE THAT
COULD LEAD TO SEAL FAILURE. IT IS PARTICULARLY IMPORTANT THAT GAS SEALS ARE IN A CLEAN CONDITION AND
FREE FROM CONTAMINATION FOR SLOW SPEED OPERATION.
TRIP & ALARM VALUES.

SEALS MUST NOT BE OPERATED ABOVE ANY OF THE SET TRIP VALUES FOR COMPRESSOR PERFORMANCE.
IF DURING OPERATION AN ALARM VALUE IS ENCOUNTERED THEN THIS SHOULD BE INVESTIGATED AND THE CAUSE
RECTIFIED IMMEDIATELY. THE SEALS SHOULD NOT OPERATE CONTINUOUSLY ABOVE ALARM VALUES.
CONTAMINATION.
BY FAR THE LARGEST CAUSE OF SEAL FAILURE DURING SERVICE IS CONTAMINATION. WHILST VERY SMALL QUANTITIES
OF HYDROCARBON CONDENSATE AND / OR OIL ON THE SEALING SURFACES ARE GENERALLY NOT DETRIMENTAL TO
GAS SEAL OPERATION, THE GENERAL INGRESS OF THESE SUBSTANCES INTO THE SEAL MUST BE AVOIDED TO PERMIT
GOOD SEAL PERFORMANCE AND LONG LIFE. THE GREATER THE DEGREE OF CONTAMINATION THE GREATER THE RISK
OF SEAL FAILURE. THE TWO PRIMARY SOURCES FOR CONTAMINATION ARE DIRTY PROCESS GAS OR BEARING
LUBRICATION OIL ENTERING THE SEAL. IF IT IS SUSPECTED THAT QUANTITIES OF HYDROCARBON CONDENSATE, OIL OR
ANY FORM OF DEBRIS HAS CONTAMINATED THE SEAL, COMPRESSOR OPERATIONS NEEDS TO STOP, THE CAUSE
RECTIFIED AND THE GAS SEAL REPLACED. CONTAMINATED GAS SEALS SHOULD ONLY BE INSPECTED BY A JOHN CRANE
TRAINED AND APPROVED TECHNICIANS. CONTAMINATED GAS SEALS SHOULD BE RETURNED TO JOHN CRANE FOR
CLEANING AND REFURBISHMENT. CONTAMINATED GAS SEALS SHOULD NOT BE OPERATED.
TO HELP PREVENT CONTAMINATION, IT SHOULD BE INSURED THAT THE CLEAN GAS INJECTION THAT BUFFERS PROCESS
GAS FROM THE SEAL IS ALWAYS:
OF ADEQUATE QUANTITY AND QUALITY,
THE GAS TEMPERATURE IS ALWAYS AT LEAST 20C ABOVE THE DEW POINT. THIS INCLUDES GAS LEAKAGE
THAT PASSES ACROSS THE SEAL FACE THAT IS SUBJECT TO ADIABATIC EXPANSION AND THE JOULE
THOMPSON EFFECT.
CLEAN GAS INJECTION IS ALWAYS APPLIED BEFORE PROCESS GAS IS APPLIED AND IS PRESENT DURING ALL
FORMS OF OPERATION INCLUDING BOTH STATIC AND DYNAMIC OPERATION.
CLEAN GAS INJECTION IS ONLY TURNED OFF ONCE ALL PROCESS GAS HAS PASSED THROUGH THE
COMPRESSOR.
IN A SIMILAR MANNER, THE SEPARATION SEAL BUFFER GAS MUST ALWAYS BE APPLIED BEFORE THE BEARING
LUBRICATION OIL STARTS TO CIRCULATE AND ONLY BE TURNED OFF AFTER THE BEARING LUBRICATION SYSTEM IS
TURNED OFF.
IN GENERAL, THE LEVEL OF GAS FILTRATION FOR BOTH CLEAN GAS INJECTION AND BUFFER GAS SUPPLY SHOULD BE
3m(118inch). WHERE REQUIRED, GAS CONDITIONING SYSTEMS SHOULD BE EMPLOYED ALONG WITH COALESCING
FILTER TO ENSURE CLEAN GAS SUPPLY AND THE REMOVAL OF ANY LIQUIDS.
SEAL PERFORMANCE ISSUES RELATING TO CONTAMINATION OF ANY KIND WILL NOT BE COVERED BY THE SEAL
WARRANTY. JOHN CRANE CAN ADVISE FURTHER ON CONTAMINATION AS REQUIRED
SEAL LEAKAGE.
JOHN CRANE PROVIDES SEAL LEAKAGE VALUES UPON WHICH THE COMPRESSOR SUPPLIER WILL DEFINE THE ALARM
AND TRIP VALUES. THESE VALUES BEING SIGNIFICANTLY HIGHER THAN EXPECTED LEAKAGE VALUES QUOTED BY JOHN
CRANE. IF SEAL LEAKAGE APPROACHES AND OR REACHES THE ALARM VALUE, THEN INVESTIGATIONS NEED TO BE
CARRIED OUT INTO WHY LEAKAGE IS SO HIGH AND PREPARATIONS SHOULD BE MADE FOR SEAL REPLACEMENT AS
SOON AS POSSIBLE. SEALS SHOULD NOT OPERATE CONTINUOUSLY ABOVE ALARM VALUE. SEALS MUST NOT BE
OPERATED ABOVE THE TRIP LEAKAGE VALUE. IF THIS CONDITION IS REACHED THEN THE COMPRESSOR SHOULD BE
SHUT DOWN AND MADE SAFE IMMEDIATELY.
ATTENTION
HIGH STATIC PRESSURE HOLDS.
DEPENDENT ON THE PROCESS AND CLEAN BUFFER INJECTION GAS, THERE IS THE RISK OF THE FORMATION OF
CONDENSATION, LIQUID DROP OUT AND POSSIBLE FREEZING AT THE SEAL FACES UNDER HIGH PRESSURE STATIC
OPERATING CONDITIONS (I.E. NO SIGNIFICANT SHAFT ROTATION). THIS IS DUE TO THE COOLING THAT OCCURS WITH
ADIABATIC EXPANSION AND THE JOULE THOMPSON EFFECT WHEN GAS FLOWS FOR A LENGTH OF TIME FROM HIGH
PRESSURE TO LOW PRESSURE AT HIGH SPEED ACROSS THE SEAL FACES OR UNDER LABYRINTHS. THIS CAN LEAD TO
FURTHER SEAL PROBLEMS. ON APPLICATIONS WHERE THIS CAN OCCUR, PRECAUTIONS NEEDS TO BE TAKEN TO
PREVENT THIS EITHER BY ENSURING ADEQUATE GAS TEMPERATURE IS MAINTAINED UNDER ALL CONDITIONS OR BY
REDUCING THE STATIC PRESSURE SUCH THAT THE COOLING EFFECT IS INSIGNIFICANT. JOHN CRANE CAN ADVISE ON
THIS IF REQUIRED.
DECOMPRESSION RATE.
TYPE 28 XP, XP-S AND EXP GAS SEALS WILL SAFELY ACCOMMODATE A MAXIMUM PRESSURE DECOMPRESSION RATE OF
100BAR/MIN (1450PSI). HOWEVER COMPRESSOR DECOMPRESSION RATES NEED TO BE SUFFICIENTLY SLOW TO
PREVENT COOLING (BY ADIABATIC EXPANSION AND THE JOULE THOMPSON EFFECT) OF THE PROCESS / BUFFER GAS
SUCH THAT THE TEMPERATURE IS ALWAYS GREATER BY AT LEAST 20 ABOVE THE GAS DEW POINT. OTHERWISE THERE
IS THE RISK OF THE FORMATION OF CONDENSATION, LIQUID DROP OUT AND POSSIBLE FREEZING AT THE SEAL FACES.
WASHING / CLEANING OF COMPRESSORS.

IT IS THE PRACTICE OF SOME COMPRESSOR OPERATORS TO WASH OR CLEAN THEIR MACHINES INTERNALLY WHILST
IN SERVICE. JOHN CRANE CANNOT RECOMMEND THAT SUCH PRACTISES ARE APPLIED IN RELATION TO THE GAS SEAL
DUE TO THE DANGER OF LOOSENING CONTAMINANT WITHIN THE COMPRESSOR AND THEN THIS BECOMES LODGED IN
KEY AREAS OF THE GAS SEAL. WHERE COMPRESSOR WASHING IS PRACTICED, THEN THE SEAL SHOULD AT ALL TIMES
BE BUFFERED BY A SUITABLE CLEAN GAS SUPPLY FED INBOARD BETWEEN THE SEAL AND THE MACHINES LABYRINTH.
CORROSIVE OR REACTIVE CHEMICALS MUST NOT COME INTO CONTACT WITH THE GAS SEAL. ONLY GASES, LIQUIDS
AND CHEMICALS WHICH HAVE BEEN SPECIFIED IN THE CONTRACT OF GAS SEAL SUPPLY SHOULD BE ALLOWED TO
COME INTO CONTACT WITH THE GAS SEALS.
OIL IN ATMOSPHERIC VENT LINES

CHECK MONTHLY FOR OIL IN THE ATMOSPHERIC VENT LINES BETWEEN THE SEPARATION SEAL AND THE GAS SEAL.
DRAIN ANY OIL IN THESE LINES, AND RECTIFY THE CAUSE. IF THE LEVEL OF OIL IS SIGNIFICANT, THE GAS SEALS NEED
TO BE CHECKED FOR CONTAMINATION.
Note: For periods of shutdown or if the compressor is stored for a prolonged time, the seal cartridge should be isolated by
blanking off all connecting ports.
6. STORAGE, SERVICE LIFE AND TRANSPORTATION OF GAS SEALS
6.1 STORAGE
ATTENTION
JOHN CRANE GAS SEALS SHOULD ALWAYS BE STORED AS COMPLETE CARTRIDGE UNITS WITH THE INSTALLATION
PLATES PROPERLY FITTED AS SHOWN ON THE INSTALLATION DRAWING.
PRIOR TO DISPATCH EVERY GAS SEAL IS PACKED IN A PURPOSE BUILT CASE. THIS CASE IS SUITABLE FOR
SUBSEQUENT SHIPMENTS OF FULLY ASSEMBLED SEALS. SEALS AND/OR SPARE COMPONENTS SHOULD REMAIN IN
THEIR ORIGINAL PACKAGING AND TRANSPORTATION CASE UNTIL REQUIRED. THEY SHOULD BE STORED INDOORS IN A
CLEAN DRY ENVIRONMENT AT A TEMPERATURE BETWEEN 15 TO 25C.
IF THE GAS SEALS ARE TO BE STORED INSIDE THE COMPRESSOR FOR LONG PERIODS, IT IS NECESSARY TO ENSURE
THAT THEY DO NOT BECOME CONTAMINATED IN ANY WAY AND ADEQUATE PRECAUTIONS NEED TO BE TAKEN TO
PREVENT THIS.
IF THE COMPRESSOR IS SHIPPED WITH THE SEALS IN SITU, THE SHAFT SHOULD BE RESTRAINED TO PREVENT
MOVEMENT AND POTENTIAL SEAL DAMAGE. ALL COMPRESSOR CONNECTIONS SHOULD BE SEALED OFF, AFTER
ENSURING THAT THE ATMOSPHERE WITHIN THE MACHINE IS DRY. PRESERVING OIL SHOULD NOT BE ALLOWED TO
CONTACT THE SEAL.
6.2 SERVICE LIFE
ATTENTION
GAS SEAL CARTRIDGES NEED ROUTINE REFURBISHMENT AT REGULAR INTERVALS. AFTER THE AGREED PERIOD OF
OPERATION, THEY SHOULD BE RETURNED TO JOHN CRANE FOR INSPECTION AND REFURBISHMENT.
EXPECTED STORAGE AND INSTALLED SERVICE TIME COMBINED IS 10 YEARS. THE LENGTH OF THE SUCCESSFUL
INSTALLED SERVICE PERIOD WILL VARY DEPENDING ON THE SEAL ENVIRONMENT. CONSISTENTLY CLEAN SEAL GAS MAY
INCREASE SEAL LIFE BEYOND 10 YEARS. FOR APPLICATIONS WITH INTERMITTENT AND WET OR DIRTY PROCESSES, THE
SERVICE LIFE MAY BE REDUCED. SEAL CONDITION SHOULD BE ASSESSED IN OPERATION BY MONITORING LEAKAGE
LEVELS AND TRENDS. THE ABOVE IS FOR GUIDANCE. IT IS RECOMMENDED THAT SEALS ARE RETURNED TO JOHN
CRANE FOR REFURBISHMENT DURING REGULAR SCHEDULED SHUTDOWNS
6.3 TRANSPORTATION
ATTENTION
IT IS ESSENTIAL THAT THE GAS SEALS ARE SUITABLY PACKAGED AND ALWAYS TRANSPORTED IN THE PURPOSE BUILT
CASE SUPPLIED BY JOHN CRANE.
THE GAS SEALS SHOULD BE ASSEMBLED AS A CARTRIDGE UNIT WITH THE INSTALLATION PLATES FITTED (PREVENTING
MOVEMENT BETWEEN THE SEAL ROTOR AND STATOR).
ANY LOOSE ITEMS PLACED INSIDE THE TRANSPORTATION CASE MUST BE SECURELY WRAPPED TO PREVENT TRANSIT
DAMAGE.
FOR OTHER SHIPPING PROCEDURES SEE APPENDIX II

APPENDIX I PRINCIPLE OF OPERATION
Simply explained, the gas seal typically comprises of a secondary sealed Primary Ring, located in a static retainer, spring loaded against
a rotating Mating Ring mounted in the seal rotor and fixed to the compressor shaft, as shown in figure A below.
FIGURE A
Sealing of the fluid is achieved at the radial interface of the rotating and stationary rings by a unique and ingenious method. The sealing
surfaces are lapped to a high degree of flatness, but the rotating mating ring has a series of logarithmic spiral groove patterns printed
onto the running face (see figure B).
FIGURE B
Uni-Directional Spiral Groove Pattern Bi-Directional Spiral Groove Pattern
With shaft rotation, gas is drawn inwards towards the root of the groove, called the sealing dam. The sealing dam provides resistance to
flow, increasing the pressure. The generated pressure lifts the Primary Ring out of contact with the Mating Ring by a small amount
typically between 1m to 10m (39inch to 390inch). The gap between the radial faces is set when the closing forces, hydrostatic
pressure and spring load, equate to the opening forces generated within the fluid film. It is this very thin sealing gap that allows very high
speeds to be accommodated, yet provides sufficient restriction to limit gas flow to acceptable limits of leakage. The gas seal film
stiffness is very high providing robust performance and allowing very high pressures to be sealed.
Under equilibrium and normal operating gap, opening forces = closing forces as illustrated in figure C.
FIGURE C
If a disturbance occurs that results in a reduced sealing gap, then the pressure generated by the spiral grooves considerably increases
and exceeds the closing force. This will very quickly result in the sealing gap increasing until equilibrium ie, opening force = closing force
and the normal operating gap is restored.
Similarly if an upset causes the gap to increase, there is a reduction in the pressure generated by the spiral groove resulting in closing
force being greater than opening force. This will result in the sealing gap closing until equilibrium and a normal sealing gap is again
restored.
The result of this mechanism is a highly stable yet thin fluid interface between the static Primary Ring and the rotating Mating Ring that
keeps the two sealing surfaces apart under normal dynamic operating conditions. In turn this leads to a reliable seal with long life as
there is no wear at the interface.
To achieve this John Crane has invested heavily in advanced technology and has built up a considerable and unsurpassed fund of
knowledge and experience in rotary shaft gas sealing applications.
There are many principles governing the seals performance only a few of which are explained in the previous paragraphs. Further
information is available from John Crane.
APPENDIX II RETURNING SEALS TO JOHN CRANE
All gas seals should be returned to John Crane for any refurbishment. In order to maintain the required standards of health and
safety, prior to refurbishment customers must confirm in writing that the specific seals being returned are safe to handle and provide any
additional safety-critical information on request. John Crane can provide a suitable form for this purpose.
The following information must be made available on the Shipping Documentation.
1) Installation Drawing Numbers.

2) Cartridge Numbers.
3) Value (for insurance only).
4) Commodity Code 84842000000.
For refurbishment, gas seals should be returned to one of the following addresses:
FAO: Gas Seals Aftermarket

John Crane EMEA
361-366 Buckingham Avenue
Slough
SL1 4LU
United Kingdom.
Tel: + 44 (0)1753 224200
FAO: Gas Seals Aftermarket

John Crane Inc
6400 West Oakton Street
Morton Grove
Illinois
USA
Tel: + 1 (0) 847 967 3533
FAO: Gas Seals Service Centre

John Crane Japan Inc
222 Kamitovama
Ritto-City,
Shigan
520-3084
Japan
Tel: + 81 (0) 77 558 3231
APPENDIX III REPLACING TOLERANCE RINGS
On certain gas seal designs, tolerance rings are located within the sleeve bore of the gas seal (see figure 1 page 6). The function of
these tolerance rings is to centralise the seal rotor on the compressor shaft. The tolerance ring fits into a groove machined into the bores
of the sleeve and are glued in place. If during service the tolerance rings have become damaged and crushed then they can be replaced
as per the instructions below, though this may adversely affect the seal balance.
ATTENTION
IT IS ESSENTIAL THE TOLERANCE RING IS FULLY LOCATED IN THE APPROPRIATE GROOVE. IF EXCESSIVE
GLUE IS USED, SHAFT DAMAGE CAN RESULT.
EXERCISE EXTREME CARE WHEN HANDLING TOLERANCE RING AS THE EDGES CAN BE SHARP. WEAR APPROPRIATE
GLOVES THROUGHOUT THE FITTING PROCESS.
The method of installing a tolerance ring is as follows:
a) Spare tolerance ring will be supplied within the gas seal spares kit. This will be secured in place with a two part quick
acting adhesive such as Loctite Multi Bond (not supplied by John Crane).
b) For the tolerance ring all ready fitted to the seal, observe that the dimples of the tolerance ring are in the direction of the
compressor shaft. Also notice where the gap in the tolerance ring is. This gap will align with the T balance mark on the
outside of the sleeve rotor. Note, on certain designs where the seal rotor is fully obscured by the seal stator, the T
balance mark will not be visible. When replacing tolerance ring, it should all ways be installed with the dimples in the
correct direction and the gap in the same location as originally supplied. See figure A.
FIGURE A
c) For the damaged tolerance ring to be removed, mark the location of the tolerance ring gap with an appropriate pen.
d) Remove the old tolerance ring and all traces of adhesive or weld joint debris from the groove in the sleeve bore.
e) Using a small pair of tin-snips carefully cut a new tolerance ring between waves to slightly longer length than required.
f) With the dimples of the ring on the inside of curve (see b) above), curl the tolerance ring to the best possible fit to the
groove.
g) Trim tolerance ring length such that a 5mm (0.200) gap is established between the ends of the tolerance ring when fitted
to the groove. Cut the chamfered profile as shown in figure B on both ends
FIGURE B
h) Clean the tolerance ring and the sleeve bore grooves with a suitable solvent.
i) The tolerance ring is held in place by a two part quick acting adhesive such as Loctite Multi Bond. Apply adhesive
sparingly to 3 waves only of one end, of the replacement tolerance ring.
j) Ensuring the tolerance ring gap is in the correct position; apply hardener to the sleeve groove over a similar length.
k) Locate and hold tolerance ring in place with thumb pressure until set.
l) Repeat steps j) and k) for the other end of the replacement tolerance ring ensuring that the ring is pushed fully back
around the circumference of the groove.
m) When the adhesive is full set, remove any excess adhesive from the seal bore that interfere with seal fitting.
APPENDIX IV REPLACING EXTERNAL POLYMER SEALS
ATTENTION
EXTERNAL POLYMERS SEALS WITH PART NUMBERS TAB1815 XXXX 5251 & XXXX/H91/951 AS COMMONLY USED ON TYPE
28 EXP GAS SEALS CAN ONLY BE FITTED BY DISASSEMBLING THE SEAL. DISASSEMBLY AND REASSEMBLY OF THE GAS
SEAL MUST ONLY BE CARRIED OUT BY A JOHN CRANE TRAINED TECHNICIANS AND FOR THIS REASON THE FITTING OF
THESE TYPES OF POLYMERS SEALS IS NOT COVERED WITHIN THIS DOCUMENT. IF ANY OF THESE POLYMER SEALS
REQUIRE REPLACEMENT, PLEASE CONTACT JOHN CRANE. POLYMER SEAL PART NUMBERS CAN BE FOUND ON THE
INSTALLATION DRAWING. XXXX DENOTES THE 4 DIGIT POLYMER SEAL SIZE.
FOR ALL OTHER TYPES OF EXTERNAL POLYMER SEALS, IT IS NOT NECESSARY TO DISMANTLE THE GAS SEAL.
DO NOT REMOVE POLYMER SEALS FROM THEIR GROOVE UNLESS BOTH THE FOLLOWING CONDITIONS APPLY:
A) THE POLYMER SEAL HAS BECOME DAMAGED SO AS TO AFFECT ITS SEALING PERFORMANCE.
B) A SPARE POLYMER SEAL OF THE CORRECT TYPE AND SIZE IS AVAILABLE.
DURING THE FITTING PROCESS HOT TEMPERATURES ARE ENCOUNTERED AND THE APPROPRIATE PRECAUTIONS
SHOULD BE UNDERTAKEN. POLYMER SEALS SHOULD NEVER BE BURNED AS THE FUMES AND RESIDUES ARE HIGHLY
TOXIC. IF GROSS OVER-HEATING OCCURS THEN HYDROFLUORIC ACID MAY BE PRESENT. DURING THE FITTING
PROCESS DO NOT HEAT POLYMER SEALS TO A TEMPERATURE ABOVE 200C (392F). THROUGHOUT THE FITTING
PROCESS APPROPRIATE GLOVES MUST BE WORN.
Polymer seals offer high resistance to pressure, explosive decompression, temperature and chemical attack. Whilst being quite rugged,
they are made from relatively soft materials, in fine sections, and must be treated with care if they are to perform their function correctly.
Before fitting the seal cartridge the polymer seals should be inspected to ensure they are clean and free from damage.
INSTALLING POLYMER SEALS IN THE SEAL CARTRIDGE BORE

The following procedure should only be used for polymer seals fitted to the bore of the seal cartridge.
a) Referring to the installation drawing, note for the polymer seal being replaced the part number and the correct polymer
seal orientation within its groove and select the appropriate polymer seal from the spares kit.
b) Remove all traces of the old polymer seal from the groove, and ensure the groove is clean and free of burrs.
c) Using appropriate gloves throughout the fitting process, heat the polymer seal until it becomes soft to a maximum
temperature of 100C (212F). The best practice for this is to use an oven. Where an oven is not available, boiling water
or a heat gun can be used to soften the polymer.
WHEN HEATING AND INSTALLING POLYMER SEALS, EXERCISE EXTREME CARE AND ALWAYS TAKE ADEQUATE
PRECAUTIONS TO PROTECT AGAINST BURNS. APPROPRIATE PROTECTION / SAFETY EQUIPMENT SHOULD ALWAYS BE
WORN. PLEASE FOLLOW THE APPROPRIATE LOCAL SAFETY ADVICE.
d) On removing the polymer seal from the heat source, it is necessary to work fast as the seal will cool rapidly. Bend the
polymer seal in on itself at one point such that a heart shape is created. This will reduce its diameter enabling it to be
maneuvered into its groove in the bore of the gas seal cartridge. Position the polymer seal into its groove ensuring
correct orientation.
e) Carefully reform the polymer seal to its original (circular) shape. Be particularly careful to avoid the formation of any
kinks. Once fully cooled it should fit within its groove.
INSTALLING POLYMER SEALS ON THE SEAL CARTRIDGE OUTSIDE DIAMETER

The following procedure should only be used for polymer seals fitted to the outside diameter of the seal cartridge.
a) Referring to the installation drawing, note for the polymer seal being replaced the part number and the orientation within its
groove and select the appropriate polymer seal from the spares kit.
b) Remove all traces of the old polymer seal from the groove, and ensure the groove is clean and free of burrs.
c) Using appropriate gloves throughout the fitting process, heat the polymer seal to a maximum temperature of 200C (392F) to
allow it to soften and expanded. Note, the nearer the polymer seal temperature is to 200C (392F) then the easier it is to fit.
For this reason, heating the polymer in an oven is recommended. Where an oven is not available, boiling water or a heat gun
can be used to soften and expand the polymer seal. However a greater degree of stretch has to be employed to fit the
polymer seal increasing the difficulty and requiring greater care.
WHEN HEATING AND INSTALLING POLYMER SEALS, EXERCISE EXTREME CARE AND ALWAYS TAKE ADEQUATE
PRECAUTIONS TO PROTECT AGAINST BURNS. APPROPRIATE PROTECTION / SAFETY EQUIPMENT SHOULD ALWAYS BE
WORN. PLEASE FOLLOW THE APPROPRIATE LOCAL SAFETY ADVICE.
d) On removing the polymer seal from the heat source, it is necessary to work fast as the polymer seal will cool rapidly. Working
from the process side of the gas seal, stretch the polymers over the appropriate leading chamfer and following metal work and
feed the polymer seal into its groove ensuring correct orientation.
e) Carefully reform the polymer seal to its original (circular) shape. Be particularly careful to avoid the formation of any kinks.
Once fully cooled it should shrink down into its groove.
ATTENTION
ONCE A POLYMER SEAL IS FULLY FITTED, IT IS ESSENTIAL THAT IT DOES NOT PROTRUDE EXCESSIVELY FROM ITS
GROOVE. IF THIS WERE TO OCCUR, THEN THE POLYMER SEAL MAY SNAG ON THE COMPRESSOR SHAFT OR CASING
DURING INSTALLATION OF THE GAS SEAL CAUSING DAMAGE TO THE POLYMER SEAL.
DOCUMENT END
DRAWING No.
Rev. DATE DRWN CHEK'D APP'D
ISSUE MODIFICATIONS: DESCRIPTION COMPONENTMat'l
CODE
Drawing Number/ SPARES
DESCRIPTION MATERIAL
ITEM
Ref Part No. Description Material Qty Spare SP,L
B '13.06.07
A ORIGINAL ISSUE: OY OH AD MDT comments & JCJ amendments - Code Legacy Code
1 14
1 DRAWING3050
89148055 No. MAT'L
2514/F63/638 POLYMER SEAL GLASS TFM
/ ELGILOY 1 X QTY
G05
2 87098406 3048 2685/D25/570 POLYMER SEAL GLASS TFM / CO.CR 1
GA-143808-1 B 3
4
89148057
89148059
3048
3048
3015/F65/570
3017/D29/570
POLYMER SEAL
POLYMER SEAL
GLASS
GLASS
TFM
TFM
/
/
CO.CR
CO.CR
2
2
6 89009712 3048 3974/D25/570 POLYMER SEAL GLASS TFM / CO.CR 3 X G05
PORTING DETAILS 7 87098513 3048 4058/D25/570 POLYMER SEAL GLASS TFM / CO.CR 1 X G05
9
4 20 10 - 9028 28G-F3016-002 PRIMARY RING CARBON 2
A BUFFER GAS 111 - 1948
ITEM 10 I/M = 3016/G65/348
28A-F3016-002 MATING RING SILICON CARBIDE 1
112 - 1948 28A-F3016-002 MATING RING SILICON CARBIDE 1
263 ITEM 11 I/M = 3016/G59/
B SEAL GAS(N2 INJECTION) 12
13
89148069
87052554
3052
0690
3016/G66/664
S/88178/1/033
CARRIER
SPRING
ST. ST. 17-4PH/COATED
HASTELLOY
2
54
14 0635 PRG-F3016-012 RETAINER INNER ST. ST. 410 1
252.5 SEAL 15 0635 PRG-F3016-013 RETAINER OUTER ST. ST. 410 1
3
16 0635 PNG-F3016-009 SEAL SPACER ST. ST. 410 1
C MONITORING O/B SEAL(OPTION) 0
16.5 -0.05 45
17 0635 S/L3167/1/229 FACE RETAINER ST. ST. 410 1
'Y' +0.05
0.2 1 18
19
20
0635
1861
0635
PSG-F3016-017
PSG-F3016-018
S/L3170/1/229
LABYRINTH RETAINER
LABYRINTH
SLEEVE
ST. ST. 410
ALUMINIUM
ST. ST. 410
1
1
1
D SEAL & TERTIARY SEAL LEAKAGE 14.1 0 TOP DETAIL Y 2
13
21
22
23
0635
0635
0687
CLG-F3016-010
CLG-F3016-011
PSG-0000-246
LOCKING SLEEVE I/B
LOCKING SLEEVE O/B
SPECIAL CAP HEAD SCREW
ST. ST. 410
ST. ST. 410
HASTELLOY
1
1
6
35 30 22 63 22 16 15.9 8 27 10 PROCESS LABYRINTH 3
24 89147640 0635 S/L3173/1/229 SETTING PLATE INNER ST. ST. 410 1
E BEARING SEPERATION GAS 3 X 20 8 5 TEETH 25 89147643 0635 S/L3174/1/229 SETTING PLATE OUTER ST. ST. 410 1
TYP
47 40 SLOT 1 PIN 4 26
27
81733865
87000463
8401
8401
S/85022/1/951
S/85023/1/951
TOLERANCE STRIP
TOLERANCE STRIP
MONEL K500
MONEL K500
2
2
X G05
( N2 INJECTION ) 13
15 D 40 28 87099942 0825 S/98112/1/246 FINGER SPRING INCONEL - X750 2
A 17 B C E
PIN
29
SLOT
( 12.1 ) 13 45 0.1 4 30 0687 7105-0800-012 CAP HEAD SCREW HASTELLOY 6
SHEAR RING
4
MIN 3.9 5 31 0687 7108-1250-016 CAP HEAD SCREW HASTELLOY 16
& M4 FIXINGS
5
6 PIN 32 81673758 0225 7810/301/050 CAP HEAD SCREW HARDENED STEEL 3
14 32 6 33 16 33 41 33 81673920 0225 8022/301/050 CAP HEAD SCREW HARDENED STEEL 16
6 7 NOT JC SUPPLY 34 81673915 0225 8021/301/050 CAP HEAD SCREW HARDENED STEEL 6
35 81673849 0225 7921/301/050 CAP HEAD SCREW HARDENED STEEL 6
Z 44 36
37
81673837 0225 7916/301/050
100% SPARES AS MARKED "X"
CAP HEAD SCREW HARDENED STEEL 7
1
HOUSING
18
O 416 H7 HOUSING
O 415 H7 HOUSING
COMPLETE GAS SEAL - COMPRISES ITEMS 1 TO 36 - GPN.
O 413 H7 HOUSING
O 411 H7 HOUSING
O 409 H7 HOUSING
O 407 H7 HOUSING
40 81597692 9528 2820/123/387 BS O RING FLUOROCARBON 2 X G05

31 41 81045644 9528 2790/123/387 BS O RING FLUOROCARBON 1 X G05
8 X M4 ON 388 PCD
42 81064918 9528 2780/123/387 BS O RING FLUOROCARBON 3
RAD. CLEAR.
60
CUSTOMER SHEAR RING

43
30 44 0635 PSG-M2800-001 HOUSING - 93FR BD ST. ST. 410 1
+0.2
0.5 0.05
59 65 45 89147649 0635 S/L3176/1/229 CLAMP PLATE I/B - 93FR ST. ST. 410 1
0
46 89147650 0635 S/L3177/1/229 CLAMP PLATE O/B - 93FR ST. ST. 410 1
Y 'X' 47 89147652 0635 S/L3178/1/229 RETAINER - 93FR ST. ST. 410 1
O 417
8 42 48 3094 PLG-M2800-001 SLEEVE - 93FR ST. ST. 410 / COATED 1
49 89147667 0635 S/L3180/1/229 SETTING PLATE INNER - 93FR ST. ST. 410 1
6
19 46 50 89147668 0635 S/L3181/1/229 SETTING PLATE OUTER - 93FR ST. ST. 410 1
12 21 51 87000463 8401 S/85023/1/951 TOLERANCE STRIP MONEL K500 1 X G05
54 52
53 89079524 4191 2800/L34/4191 CARBON RING - 93FR CARBON 3
54 89084671 8401 2800/L35/8401 GARTER SPRING - 93FR ST. STEEL 3
23 55 89019447 8401 S/F2537/1/951 SPRING ST. ST. 9
O 280 H6 CARBON RING

O 279.76 u0.01 (TERTIARY SEAL )
O 285.2 0.05 SEAL RUNNING DIA
O 265 g6 SPLIT RING
+0.02
O 249 h6 SHAFT
3 4 10 28 5 53 62 81673658 0225 7616/301/050 CAP HEAD SCREW HARDENED STEEL 6
0
12 20 112 10 3 57 63 81673692 0225 7712/301/050 CAP HEAD SCREW HARDENED STEEL 1
51
O 380
O 241 CUSTOMER SPLIT RING
64 87104503 3061 2020/J16/714 BONDED WASHER ST. STL. 316/FLUOROCARBON 10
ATMOSPHERE
1 26 64 65 87104509 3061 2130/J16/714 BONDED WASHER ST. STL. 316/FLUOROCARBON 8
111 28 66 100% SPARES AS MARKED "X" 1
27 5 22 36 48 COMPLETE TERTIARY SEAL GPN. - COMPRISES ITEMS 40 TO 65 - GPN.
SHAFT
ADDITIONAL ITEMS DO NOT ADD TO BOM

SHAFT
2 O-RING 55 70 89147669 2811 SL3182/1/037 FITTING TOOL SLEEVE ALUMINIUM 1

0.3 62 71 89148070 2811 3016/J38/037 FITTING TOOL CARRIER ALUMINIUM 1
MIN NOT JC SUPPLY
12 72 87067202 9414 S/67543/1/199 ASM PARTS 1
SHAFT
PROCESS
61
SHAFT
O 250 h6 SHAFT
73 89147671 9414 S/L3183/1/199 SPARES KIT - DGS 1
74 89143858 9414 S/L3184/1/199 SPARES KIT - TERTIARY 1
-0.05
-0.032
27
0.1 64
0
MIN
O 257
-0.05
-0.15
26
-0.1
O-RING
0
O 252 h6
NOT JC SUPPLY
O 250
O 249
4 SPLIT RING BALANCE QUALITY G2.5 1940
ROTOR ASS'Y NO. MATING RING BLANK TEST PROCEDURE NO. US PATENT NOS. 4,212,475
& M3 FIXINGS AR28-F3016-007 S/98204.D AG3619 JAPAN PATENT NOS. 1-22509
MATERIALS TO NACE MR0103
14
NOT JC SUPPLY
10 GROOVE INFORMATION AS VIEWED FROM "X" TOTAL MASS OF SEAL = 129 kg 9
4.5
TOTAL MASS OF ROTOR = 39 kg 10
4.5 SHAFT ROTATION IS
9.5 TOTAL MOMENT OF INERTIA = 0.80kg/m2 11
7 BI-DIRECTIONAL
2 - M10 TAPPINGS FOR EYE 12.1 127.6 8
35 CENTER OF GRAVITY AS SHOWN
BOLTS. IMPORTANT NOTE, COG
ONLY USE EYE BOLT WITH SEAL AXIAL MOVEMENT = 4.0mm
THREAD LENGTH NOT +0.05 2 OFF HOLES SEAL RADIAL MOVEMENT = 1.0mm 13
EXCEEDING 17 mm. 31.1 4 18.3 84 6 43.9 12.1 0 TAPPED M4 x ONE HOLE M6 x 10 (EXCLUDING LABYRINTH)
80 9.5/6.0 DEEP AT TDC AS SHOWN
8 M4 SCREWS
0 0
TDC AS SHOWN ON DETAIL 'Z' Note:- Refer to John Crane Installation, Operation and Maintenance Instructions for recommended practice.
170 -0.2 SEAL 12 -0.05
ON A 388 PCD
W (SCREWS TO FIT 170.3 -0
+0.1
SHAFT
SHEAR RING
1 - M10 TAPPINGS FOR EYE
SEAL DATA
SPLIT RING-NOT SEAL SIZE: 11.875" ARRANGEMENT: DOUBLE TYPE: T28XP - T93FR
JC SUPPLY)
DGS SETTING 4 OFF HOLES TERTIARY SEAL BOLT. IMPORTANT NOTE,
M10 x 10 DEEP ONLY USE EYE BOLT WITH 10 DESIGN PRESSURE DESIGN TEMPERATURE
PLATES ON A 368 PCD SETTING PLATES THREAD LENGTH NOT
40 20
STATIC: 25 BARG -20C TO 230 C
@45v FROM TDC EXCEEDING 17 mm.
4 OFF HOLES M10 x 10 DEEP (THERMOCOUPLE) DYNAMIC: 25 BARG DESIGN SPEED: 5965 RPM
ON A 368 PCD @45v FROM TDC DETAIL W CUSTOMER DATA
193
SETTING PLATES
25 MUST BE REMOVED CUSTOMER: John Crane GmbH OEM: MAN Diesel & Turbo
BEFORE SHAFT NOTE: O-RINGS IN THE
22.5
25
OEM MODEL NO: A63-13 OEM PART NO:

IS ROTATED SHAFT NOT JC SUPPLY
34 ABUDHABI OIL REFINING COMPANY
58 END USER: (TAKREER) LOCATION:
NOTE:- ONLY ITEMISED
36 PARTS WILL BE SUPPLIED NORMAL SERVICE DATA
12.5
63 BY JOHN CRANE. PROCESS: 45.52% H2, 33.04% C3H8, 15.04% C3H6, 4.23% CH4 and others(M.W.=23.18)
45
22.5
24
50 SEAL GAS: NITROGEN SEPARATION GAS: NITROGEN
10
6 35 PROJECT RUWAISREC PRESSURE TEMPERATURE SHAFT SPEED
SETTING PLATES 49
2 CONTRACTOR SAMSUNG ENGINEERING Co., Ltd. 6 BARG 40 C 5965 RPM
+0.1

MUST BE REMOVED
5 0
4 OFF HOLES TO BEFORE SHAFT

ITEM NO. - REFERENCE DATA BILL OF MATERIALS NUMBER
SUIT M3 ON A 258 PCD 58 SERVICE -
IS ROTATED
(NOT JC SUPPLY) JCUK Drawing : S/L1610 COMPLETE
65 3 20 98.5 SHAFT/HOUSING/SHAFT DRG - MTZ, 10000594323 Rev.2 BUSHING

TH'D
M 6
FILE REFERENCE SEAL

ITEM 47 PORTING 4 OFF HOLES TO DSB304-26 KIT
12 OFF HOLES 6.0 SUIT M4 ON A 258 PCD 10 ITEMS NUMBER
ASS'Y
POSITIONED AS SHOWN (JC SUPPLY)
VIEW ON ARROW 'X' (THERMOCOUPLE HOLE DETAIL) CONTROLLING LOC. DRAWING No. ISSUE
3
WITH SETTING PLATES REMOVED DETAIL Z JP06 GA-143808-1 B

DRAWN DATE CHK'D APP'D SCALE
All intellectual property rights (including but not limited to copyright and design rights whether registered or unregistered) in relation to this drawing together with the information contained in this drawing (including but not limited to know-how and confidential information) is
proprietary to John Crane. Reproduction (whether in whole or in part) or use in any way whatsoever of this drawing or of any information contained therein is prohibited except with the prior written consent of John Crane. All rights in relation to this drawing are reserved. OY 2013.05.05 OH AD 1:1
DRAWING No.
Rev. DATE DRWN CHEK'D APP'D
ISSUE MODIFICATIONS: DESCRIPTION COMPONENTMat'l
CODE
Drawing Number/ SPARES
DESCRIPTION MATERIAL
ITEM
Ref Part No. Description Material Qty Spare SP'L
Code Legacy Code
B 2013.06.11
A ORIGINAL ISSUE:OY OH AD MDT comments & JCJ amendment 1 - 15
1 DRAWING 2264/F63/638MAT'L
3050No.
87104807 POLYMER SEAL GLASS TFM / ELGILOY 1 X QTYG05
GA-143809-1 B 3
4
89144770
89144220
3048
3048
2761/F65/570
2763/D29/570
POLYMER SEAL
POLYMER SEAL
GLASS
GLASS
TFM
TFM
/
/
CO.CR
CO.CR
2
2
6 89144224 3048 3671/D25/570 POLYMER SEAL GLASS TFM / CO.CR 3 X G05
PORTING DETAILS 263 7
8
89144225
87098422
3048
3048
3745/D25/570
2770/D25/570
POLYMER SEAL
POLYMER SEAL
GLASS
GLASS
TFM
TFM
/
/
CO.CR
CO.CR
1
1
X G05
0.45 u0.05 RADIAL

9
248.9 GAS SEAL - STATOR 10 - 9028 28G-F2762-003 PRIMARY RING CARBON 2
ITEM 10 I/M = 2762/G65/348
A BUFFER GAS +0 111 - 1948 28A-F2762-003 MATING RING SILICON CARBIDE 1
CLEARANCE
16.5 -0.05 45 4 TYP. 112 - 1948 28A-F2762-003 MATING RING SILICON CARBIDE 1
20 ITEM 11 I/M = 2762/G59/
12 89144237 3052 2762/G66/664 CARRIER ST. ST. 17-4PH/COATED 2
TYP. 13 87052554 0690 S/88178/1/033 SPRING HASTELLOY 50
+0.05
B SEAL GAS (N2 INJECTION) 170.3 -0
+0.1
SHAFT TO HOUSING
12
14.1 0
0.2 14 0635 PRG-F2762-041 RETAINER INNER ST. ST. 410 1
3
TYP. 15 0635 PRG-F2762-042 RETAINER OUTER ST. ST. 410 1
16 0635 PNG-F2762-024 SEAL SPACER ST. ST. 410 1
SHEAR RING 17 0635 S/J7983/1/229 FACE RETAINER ST. ST. 410 1
C MONITORING O/B SEAL (OPTION) 35 30 22 63 22 16 15.9 8 27 10 AND M4 FIXINGS 1 18 0635 PSG-F2762-029 LABYRINTH RETAINER ST. ST. 410 1
13 19 1861 PSG-F2762-030 LABYRINTH ALUMINIUM 1
NOT JC SUPPLY 20 0635 S/J7986/1/229 SLEEVE ST. ST. 410 1
2 21 0635 CLG-F2762-024 LOCKING SLEEVE I/B ST. ST. 410 1
28 22 0635 S/J7988/1/229 LOCKING SLEEVE O/B ST. ST. 410 1
O 260 u0.05 LABY

D SEAL & TERTIARY SEAL LEAKAGE 47 40 TOP 3 23
24 89143834
0687 PSG-0000-246
0635 S/J7989/1/229
SPECIAL CAP HEAD SCREW
SETTING PLATE INNER
HASTELLOY
ST. ST. 410
6
1
RUNNING DIA.
8 25 89143835 0635 S/J7990/1/229 SETTING PLATE OUTER ST. ST. 410 1
(PROCESS LABYRINTH 26
27
81733865
87000463
8401 S/85022/1/951
8401 S/85023/1/951
TOLERANCE STRIP
TOLERANCE STRIP
MONEL K500
MONEL K500
2
2
X G05
E BEARING SEPERATION GAS 13

A 32
B 13 C 45
D E 1 PIN 4 6 TEETH) 28
29
87099942 0825 S/98112/1/246 FINGER SPRING INCONEL - X750 2
15
(N2 INJECTION) 4 30 0687 7105-0800-012 CAP HEAD SCREW HASTELLOY 6
4 40 DETAIL Y 31
32 81673678
0687 7108-1250-016
0225 7708/301/050
CAP
CAP
HEAD SCREW
HEAD SCREW
HASTELLOY
HARDENED STEEL
15
3
4
18 6 7
14 6 17 33 16
Z 33 6 41
33
34
35
81673915
81673849
81673692
0225 8021/301/050
0225 7921/301/050
0225 7712/301/050
CAP
CAP
CAP
HEAD SCREW
HEAD SCREW
HEAD SCREW
HARDENED STEEL
HARDENED STEEL
HARDENED STEEL
12
12
1
37 100% SPARES AS MARKED "X" 1
COMPLETE GAS SEAL - COMPRISES ITEMS 1 TO 36 - GPN.
31
O 382 (H7) HOUSING
HOUSING
O 380 (H7) HOUSING
O 378 (H7) HOUSING
O 376 (H7) HOUSING
8 x M4 ON A O 370 PCD
44
O 385 (H7) HOUSING

SHEAR RING
42 81045631 9528 2760/123/387 BS O RING FLUOROCARBON 3
O 384 (H7) HOUSING

43
44 0635 PSG-M2500-001 HOUSING - 93FR BD ASM ST. ST. 410 1
30
ATMOSPHERE
45 89143839 0635 S/J7993/1/229 CLAMP PLATE I/B - 93FR ST. ST. 410 1
60 46 89143841 0635 S/J7994/1/229 CLAMP PLATE O/B - 93FR ST. ST. 410 1
'Y' 59 47 89143843 0635 S/J7995/1/229 RETAINER - 93FR ST. ST. 410 1
+0.2
8
'X' 48 3094 PLG-M2500-001 SLEEVE - 93FR ST. ST. 410 / COATED 1
-0
49 89143855 0635 S/J7997/1/229 SETTING PLATE INNER - 93FR ST. ST. 410 1
19 65 50 89143857 0635 S/J7998/1/229 SETTING PLATE OUTER - 93FR ST. ST. 410 1
42
O 386
51 87000463 8401 S/85023/1/951 TOLERANCE STRIP MONEL K500 1 X G05
12
+0.2
52
Y
-0
46 53 89079515 - 2500/L34/4191 CARBON RING - 93FR CARBON 3
PROCESS
54 54 89084668 - 2500/L35/8401 GARTER SPRING - 93FR ST. STEEL 3
O 362
5 23 55 89019447 8401 S/F2537/1/951 SPRING ST. ST. 9
O 250 H6 CARBON RING

O 249.79 u0.01 RUNNING DIAMETER (93FR)

53
O 240 (g6) SHEAR RING

SHAFT
O 233 SHEAR RING FIXINGS

O 227 (h6) SHAFT
21 20 3 4 64 87104503 3061 2020/J16/714 BONDED WASHER ST. STL. 316/FLUOROCARBON 10

10 28 5 112 10 26 4 3 57 65 87104509 3061 2130/J16/714 BONDED WASHER ST. STL. 316/FLUOROCARBON 8
58 51 66 100% SPARES AS MARKED "X" 1
61 COMPLETE TERTIARY SEAL - COMPRISES ITEMS 40 TO 66 - GPN.
1 26
-0.05
12 2 111 5 28 22 12 36 64
27 27 ADDITIONAL ITEMS DO NOT ADD TO BOM
+0
48 64 70 89143860 2811 S/J8000/1/037 FITTING TOOL SLEEVE ALUMINIUM 1

71 89144239 2811 2762/J38/037 FITTING TOOL CARRIER ALUMINIUM 1
O 232
8
55 72 89199504 9414 S/J8001/1/199 SEAT EXTRACTION TOOL - ASM 1
123.97 CENTRE OF GRAVITY O-RING 73 87067202 9414 S/67543/1/199 ASM PARTS 1
74 89143836 9414 S/J7991/1/199 SPARES KIT - DGS 1
(ROTATING PARTS) O-RING NOT JC SUPPLY 75 89143858 9414 S/J7999/1/199 SPARES KIT - TERTIARY 1
NOT JC SUPPLY SPLIT RING
+0 AND M3 FIXINGS
O 224 (h6) SHAFT

0.3 MIN 170 -0.2 ROTOR LENGTH
CLEARANCE NOT JC SUPPLY
O 225 (h6)
O 215 SHAFT
-0.1
-0.05
-0.15
+0
SHAFT
SHAFT
O 224
SHAFT
O 225
BALANCE QUALITY G2.5 1940

ROTOR ASS'Y NO. MATING RING BLANK TEST PROCEDURE NO. US PATENT NOS. 4,212,475
AR28-F2762-016 S/98204.D AG3620 JAPAN PATENT NOS. 1-22509
MATERIALS TO NACE MR0103
6
7
12 201.55 GAS SEAL - ROTOR 55.5 TERTIARY GROOVE INFORMATION AS VIEWED FROM "X"
SEAL - ROTOR TOTAL MASS OF SEAL = 110.7 kg 9
2 OFF HOLES TOTAL MASS OF ROTOR = 31.7 kg 10
1 - M10 TAPPINGS FOR EYE TAPPED M4 x SHAFT ROTATION IS

2 - M10 TAPPINGS FOR EYE TOTAL MOMENT OF INERTIA = 0.54kg/m2 11
31.2 4 18.3 84 6 43.9 4.5 35 BOLT. IMPORTANT NOTE, 9.5/6.0 DEEP BI-DIRECTIONAL
BOLTS. IMPORTANT NOTE, CENTER OF GRAVITY AS SHOWN
+0.05 ONLY USE EYE BOLT WITH TDC AS SHOWN
ONLY USE EYE BOLT WITH 30 12.1 10 SEAL AXIAL MOVEMENT = 4.0mm
4.5
14 0 THREAD LENGTH NOT
THREAD LENGTH NOT
EXCEEDING 15 mm. ONE HOLE
EXCEEDING 17 mm.
( 12.5 ) 9.5
TERTIARY SEAL TAPPED M6 x
SEAL RADIAL MOVEMENT = 0.9mm 15
(EXCLUDING LABYRINTH)
8 OFF HOLES TO
W SETTING PLATES 10 DEEP
SUIT M4 ON A 370 PCD 4 OFF HOLES M10 x 10 DEEP SETTING PLATES TDC AS SHOWN Note:- Refer to John Crane Installation, Operation and Maintenance Instructions for recommended practice.
14 11 4 OFF HOLES
(NOT JC SUPPLY) ON A 350 PCD @45v FROM TDC MUST BE REMOVED
BEFORE SHAFT M10 x 10 DEEP SEAL DATA
40
14 ON A 350 PCD

(
IS ROTATED SEAL SIZE: 10.875" ARRANGEMENT: DOUBLE TYPE: T28XP - T93FR

@45v FROM TDC
65

10 DESIGN PRESSURE DESIGN TEMPERATURE

)
34
25 50 20 STATIC: 25 BARG -20 C TO 230 C
62
(THERMOCOUPLE) DYNAMIC: 25 BARG DESIGN SPEED: 5965 RPM
175
35
CUSTOMER DATA
63 DETAIL W
25
24 CUSTOMER: John Crane GmbH OEM: MAN Diesel & Turbo

49 NOTE: O-RINGS IN THE OEM MODEL NO: RB90-5 OEM PART NO:
34 SHAFT NOT JC SUPPLY ABUDHABI OIL REFINING COMPANY
62 END USER: (TAKREER) LOCATION:
NOTE:- ONLY ITEMISED PARTS
22.5
4 OFF HOLES TO WILL BE SUPPLIED BY JOHN NORMAL SERVICE DATA

45
O 323.4 OUTER
SUIT M3 ON A 233 CRANE.

O 224.5 INNER
O 322.4 INNER
PROCESS: 45.52% H2, 33.04% C3H8, 15.04% C3H6, 4.23% CH4 and others(M.W.=23.18)
O 366 OUTER
PCD
O 323.4 OUTER
SETTING PL.
SETTING PL.
O 224.5 INNER
O 322.4 INNER
SETTING PL
SETTING PL
14
O 366 OUTER
9 (NOT JC SUPPLY) 14 SEAL GAS: NITROGEN SEPARATION GAS: NITROGEN
SETTING PL.
SETTING PL.
SETTING PL.
SETTING PL.
6 4 OFF HOLES TO SETTING PLATES PRESSURE TEMPERATURE SHAFT SPEED

3 SUIT M4 ON A 233 DGS SETTING MUST BE REMOVED
PCD BEFORE SHAFT 7.5 BARG 40 C 5965 RPM
(JC SUPPLY) PLATES IS ROTATED
REFERENCE DATA BILL OF MATERIALS NUMBER
COMPLETE
THREAD
JCUK Drawing : S/L1611

3 20 91.6 SHAFT/HOUSING/SHAFT DRG - MTZ, 10000543564 Rev.2 BUSHING
10
M 6
FILE REFERENCE SEAL

ITEM 47 PORTING
12 OFF HOLES 6.0 DSB304-27 KIT
POSITIONED AS SHOWN ASS'Y ITEMS NUMBER
PROJECT RUWAISREC
VIEW ON ARROW 'X'
CONTROLLING LOC. DRAWING No. ISSUE
+0.1
CONTRACTOR SAMSUNG ENGINEERING Co., Ltd.

O 3
WITH SETTING PLATES REMOVED (THERMOCOUPLE HOLE DETAIL)

-0
ITEM NO. -
GA-143809-1 B

O 5
DETAIL Z SERVICE -
JP06
DRAWN DATE CHK'D APP'D SCALE
All intellectual property rights (including but not limited to copyright and design rights whether registered or unregistered) in relation to this drawing together with the information contained in this drawing (including but not limited to know-how and confidential information) is
proprietary to John Crane. Reproduction (whether in whole or in part) or use in any way whatsoever of this drawing or of any information contained therein is prohibited except with the prior written consent of John Crane. All rights in relation to this drawing are reserved. OY 05/05/13 OH AD 1:1

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What are the main components of a John Crane Type 28 gas seal?

What are the main components of a John Crane Type 28 gas seal?

What are the steps involved in installing a John Crane Type 28 gas seal?

What are the steps involved in installing a John Crane Type 28 gas seal?

John Crane

Engineered Sealing Systems

Installation, Operation &

This document provides

John Crane Japan

2.1 SAFETY INSTRUCTIONS 3

3. SEAL INSTALLATION AND REMOVAL FROM THE COMPRESSOR 4

3.1 SEAL PREPARATION 4

4.1 STATIC GAS SEAL TEST 8

5. COMPRESSOR OPERATION & MAINTENANCE WITH DRY GAS SEALS 8

6. STORAGE, SERVICE LIFE AND TRANSPORTATION OF GAS SEALS 11

APPENDIX I PRINCIPLE OF OPERATION 12

APPENDIX II RETURNING SEALS TO JOHN CRANE 13

APPENDIX III REPLACING TOLERANCE RINGS 14

APPENDIX IV REPLACING EXTERNAL POLYMER SEALS 15

For John Crane Japan call: + 81 (0) 77 558 3211

Note: Information for easy installation and efficient operation.

2.1 SAFETY INSTRUCTION

HOT SURFACES HAVE TO BE PROTECTED AGAINST ACCIDENTAL CONTACT.

3. SEAL INSTALLATION AND REMOVAL FROM THE COMPRESSOR

3.1 SEAL PREPARATION

3.2 COMPRESSOR PREPARATION

THE SUITABILITY OF ALTERNATIVE LUBRICANTS SHOULD BE CONFIRMED WITH JOHN CRANE.

FIGURE 1 Gas Seal with installation plates fitted

3.3 FITTING THE GAS SEALS

3.4 REMOVAL OF THE GAS SEALS

4.1 STATIC GAS SEAL TEST

4.2 DYNAMIC OPERATION

5. COMPRESSOR OPERATION AND MAINTENANCE WITH DRY GAS SEALS

OPERATING & ENVIRONMENTAL CONDITIONS.

REVERSE ROTATION IS ONLY PERMISSIBLE ON BI-DIRECTIONAL DESIGNS OF GAS SEALS.

MINIMUM SEAL SPEED.

TRIP & ALARM VALUES.

WASHING / CLEANING OF COMPRESSORS.

OIL IN ATMOSPHERIC VENT LINES

6. STORAGE, SERVICE LIFE AND TRANSPORTATION OF GAS SEALS

6.2 SERVICE LIFE

FOR OTHER SHIPPING PROCEDURES SEE APPENDIX II

APPENDIX I PRINCIPLE OF OPERATION

Uni-Directional Spiral Groove Pattern Bi-Directional Spiral Groove Pattern

APPENDIX II RETURNING SEALS TO JOHN CRANE

The following information must be made available on the Shipping Documentation.

1) Installation Drawing Numbers.

FAO: Gas Seals Aftermarket

FAO: Gas Seals Aftermarket

FAO: Gas Seals Service Centre

APPENDIX III REPLACING TOLERANCE RINGS

The method of installing a tolerance ring is as follows:

APPENDIX IV REPLACING EXTERNAL POLYMER SEALS

INSTALLING POLYMER SEALS IN THE SEAL CARTRIDGE BORE

INSTALLING POLYMER SEALS ON THE SEAL CARTRIDGE OUTSIDE DIAMETER

40 81597692 9528 2820/123/387 BS O RING FLUOROCARBON 2 X G05

CUSTOMER SHEAR RING

Y 'X' 47 89147652 0635 S/L3178/1/229 RETAINER - 93FR ST. ST. 410 1

O 280 H6 CARBON RING

60 81673933 0225 8027/301/050 CAP HEAD SCREW HARDENED STEEL 8