INDEX

1. INTRODUCTION TO JOHN CRANE’S TYPE 28 GAS SEAL

2. PRINCIPLES OF OPERATION

3. SEAL SPECIFICATIONS

3.1. Application Data Sheet

3.2. Installation Drawing
3.3. Test & Commissioning Spares

4. SEAL INSTALLATION / REMOVAL

4.1. Exercising the Seal

4.2. Compressor Preparation
4.3. Fitting the Seals
4.4. Removal of Seals
4.5. Replacement of Tolerance Rings

5. COMMISSIONING THE COMPRESSOR

6. COMPRESSOR OPERATION AND MAINTENANCE

6.1. Operational Guideline

6.2. Cleaning
6.3. Storage of Seals
6.4. Shipping of the Seal Cartridge
6.5. Manufacturing & Repair Facilities

Gas Seals Group

John Crane International

4-33-3
1. INTORODUCTION

This manual was created to provide necessary information for seal operation, and the
preparation, fitting and removal of the Gas Seals. Seal assembly is not covered as the
complete cartridge should be returned to John Crane International if refurbishment is required.

Although the seals are robust in operation, they can easily be damaged by incorrect assembly
fitting or handling.

It is therefore recommended that the seals are fitted by a John Crane International trained
engineer or certified designee.

Gas Seals Group 1

John Crane International

4-33-4
2. PRINCIPLES OF OPERATION

Simply explained, the seal is typically comprised of an o-ring sealed carbon PRIMARY RING,
located in a stainless steel retainer, spring loaded against a rotating carbide MATING RING
fixed to the shaft, as seen in figure 2.1 below.

Primary Ring
Spring
(Hasteloy - C) (Carbon)

Mating Ring
Retainer
(Silicon Carbide)
(SUS410)

Polymer Seal
Tolerance Ring
(Filed TFE / CO-CR)
(Monel K - 500)
Carrier
(SUS630) Sleeve
(SUS410)
Collar
(SUS410)

Figure 2.1

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
with the rotating carbide ring having a series of spiral grooves. This is shown in figure 2.2
along with the nomenclature associated with the design of the mating ring.

Figure 2.2

Gas Seals Group 2

John Crane International

4-33-5
 With rotation, fluid is pumped 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 carbon ring surface out of contact with the carbide ring by a precise amount, typically 3
microns. The gap between the radial faces is set when the closing forces of hydrostatic
pressure and spring load equate to the opening forces generated within the fluid film.

Under dynamic equilibrium conditions, the forces acting upon the seals can be graphically
represented as shown in figure 2.3.
FC= FO
FC FO

CLOSING FORCE OPENING FORCE

S P

COM PRESSION

EX PA NSION

SPRING LOA D GA S FILM

+ HYDROSTATIC PRESSURE
DISTRIBUTION
NORA M L OPERATION

Figure 2.3

The closing force, FC, is a result of the system pressure plus a very small spring force. The
opening force, FO, is a result of the system pressure breakdown between the primary ring
mating ring, plus the pressure generated by the spiral grooves. At equilibrium, i.e. when FC=FO,
the operating clearance is, as previously mentioned, approximately 3 microns for most
commonly encountered fluids.

If a disturbance occurs which results in a reduced sealing gap, the pressure generated by the
spiral grooves is considerably increased, as illustrated in figure 2.4.
FC FO

CLOSING FORCE OPENING FORCE

S P

COM PRESSION

EX PA NSION

SPRING LOA D GA S FILM

+ HYDROSTATIC PRESSURE
DISTRIBUTION
REDUCED GA P

Figure 2.4

Gas Seals Group 3

John Crane International

4-33-6
 Similarly, if an upset causes the gap to increase, there is a reduction in the pressure generated
and the seal regains its equilibrium very quickly (figure 2.5).

FC FO

CLOSING FORCE OPENING FORCE

S P

EXPANSION

SPRING LOAD GAS FILM

+ HYDROSTATIC PRESSURE
DISTRIBUTION
INCREASED GAP

Figure 2.5

The result of this mechanism is a highly stable yet very thin fluid interface between the static
primary ring and the rotating mating ring. This results in the two surfaces being kept apart and
not touching under normal dynamic operating conditions. In turn this leads to a long life, reliable
seal with no wear at the interface.

To achieve this, John Crane International has invested heavily in advanced technology and
built up a considerable and unsurpassed fund of knowledge and experience in rotary shaft gas
sealing applications.

There are many principle governing the seal's performance only a few of which are explained in
the previous paragraphs.

Further information on this topic is available from John Crane International.

Gas Seals Group 4

John Crane International

4-33-7
3. SEAL SPECIFICATIONS

3.1. Application Date Sheet

DSA801-20

Gas Seals Group 5

John Crane International

4-33-8
4-33-9
 3.2. INSTALLTION DRAWINGS

MI-28-3002

Gas Seals Group 6

John Crane International

4-33-10
4-33-11
 3.3. RECOMMENDED COMMISSIONING SPARES

100% QTY
Item John Crane
per seal Description
No Component Code
cartridge

32 PSG-F2190-029-8401 1 POLYMER SEAL

33 0000-170-9549 1 O-RING

34 PSG-F2190-028-8401 1 POLYMER SEAL

35 0000-279-9549 1 O-RING

36 0000-279-9549 1 O-RING

52 0000-168-9528 1 O-RING

53 0000-279-9549 1 O-RING

54 0000-279-9549 1 O-RING

28 9208-2322-493-1825 2 TOLERANCE RING

Gas Seals Group 7

John Crane International

4-33-12
4. SEAL INSTALLATION / REMOVAL

When fitting seals, the compressor is ready to accept the dry gas seal, also that the required
fitting / extraction tools are available.

It should also be noted that only Dow CorningR No. 4 Silicone compound grease and MolykoteR
G-n paste must be used when fitting John Crane Gas Seals and this only sparingly, where
specified in these installation instructions. Excess amount of these agents on the seal may
adversely affect the seal performance.

An installation kit is supplied with each seal containing the required spare o-rings, lubricants,
LoctiteR No. 222, and items interfacing with the compressor that have the possibility for
damage the during installation process. Separate installation kits may be purchased from
John Crane Japan, Inc.

Caution and Warning Symbols

Caution : This alert sign appears with specific procedures which, if not observed,
could result in the malfunction of the seal.

Warning : This alert sign appears with specific procedures which, if not followed
correctly, could cause damage to the seal.

Gas Seals Group 8

John Crane International

4-33-13
 4.1. EXERCISING THE SEAL
Exercising the seal helps to eliminate possible "sticking" of the dynamic o-ring due to long
periods of storage. The seal should move freely during and after the exercise process.
If the seal does not move freely, contact John Crane for more specific instructions.
4.1.1. Place the seal cartridge on a table supported under the seal stator with
approximately a 5 mm clearance between the stator and the table. Refer to
figure 4.1.

4.1.2. Loosen the rotor socket head cap screws (item 41) two (2) complete turns.

4.1.3.Pull up on the installation plate until uniform contact is achieved with the socket
head cap screws.
4.1.4. Evenly push down on the installation plate and release and / or pull up.
Repeat five (5) or six (6) consecutive times.

4.1.5. Tighten the rotor socket head cap screws.

4.1.6. Loosen the stator socket head cap screws (item 39) two (2) complete turns.

4.1.7. Evenly push down on the stator assembly or loosened socket head cap screws
and pull up approximately five (5) or six (6) consecutive times.

4.1.8. Tighten the stator socket head cap screws and proceed with installation.


Figure 4.1

Gas Seals Group 9

John Crane International

4-33-14
 4.2. COMPRESSOR PREPARATION

4.2.1. Clean the entire area into which the seal fits. Check for burrs and scratches.
Rectify as necessary.
4.2.2. Ensure that all lead edges over which the seal passes have the required
chamfers. Rectify as necessary.
4.2.3. Inspect the lead edges connections into the seal chamber and shaft key (dress
as required to prevent o-ring damage).
4.2.4. Ensure compressor shaft is fixed axially in its running position.
4.2.5. If the dry gas seals have not been previously fitted to the compressor, check
that the seal envelopes are in accordance with the relevant John Crane
International Drawing MI-28-3002. Verify the installation dimension as shown
on the drawing.

4.2.6. It is recommended that the thrust end gas seal be installed first. After
installation of the seal, the thrust bearing can then be opposite end positioned
to secure the shaft and facilitate the installation of the as seal cartridge.

Gas Seals Group 10

John Crane International

4-33-15
 4.3. FITTING THE SEALS

IMPORTANT: Ensure that the direction of rotation shown on the seal

corresponds with actual shaft rotation for the end being
fitted.

4.3.1. Remove o-rings (items 33, 35, 36, 52, 53, and 54) and lightly grease using the
Silicon Grease supplied with the installation kit.
4.3.2. Replace o-rings in their respective grooves wiping off excessive grease.
4.3.3. Lightly coat the shaft and the bore of the sleeve with Dow Corning Molykote
"G-n" anti-seize paste.
4.3.4. Loosen the installation plate cap screws (items 39, 40 and 41) one half of a
turn to allow for slight misalignment between the shaft and the bore.

4.3.5. Position the shaft so that the pins are on the vertical top.

4.3.6. Ensure that the drive slots in the seal rotor are still in their correct position as at
top dead center for one of the slots. Also, check that the stator is in the correct
position relative to the rotor so that the stator pin is located to the rotor slots
orientation.
4.3.7. Lift the seal cartridge carefully onto the shaft.
4.3.8. Maneuver the seal onto the 181 mm diameter. Engage the sleeve by
approximately 15 mm using hand pressure alone. Check that the rotor and
stator are still in their correct positions.

4.3.9. Using suitable jacking equipment, fit the seal into the compressor housing by
supplying even pressure to prevent the cartridge becoming "locked up".
(4-1/2-13 taps are provided on a PCD 304.8 which are to used in conjunction
with threaded rods for jacking.) Jack the seal into the compressor until metal to
metal contact is reached between the seal housing and the compressor
housing.

4.3.10. With the seal in position, remove jacking equipment and installation plate
and screws (items 37, 38, 39, 40, and 41).

Gas Seals Group 11

John Crane International

4-33-16
 4.3.11. Install the split thrust ring (item 44) into the shaft groove and O-ring (item
52).
4.3.12. Ensure that Type 83 barrier seal (item 42) is assembled with the adapter
(item 43) and the sleeve (item 45) by fitting the setting plates for the barrier
seal assembly with screws, which are assembled prior to seal delivery from
John Crane.
4.3.13. Ensure that O-rings (items 53 and 54) are placed in their respective
grooves as stated above in 4.3.1. & 4.3.2..
4.3.14. Ensure that the sleeve (item 43) and the adapter (item 45) of Type 83
barrier seal assy are positioned properly.

4.3.17. Install carefully the Type 83 barrier seal assy (items 42, 43, and 45) by using
two of diametrically opposite 4-1/2-13 taps in the adapter (item 45).
4.3.18. Remove Installation Plates (items 55 and 56) and their screws (items 57 and
58) of the Type 83 barrier seal.
4.3.19. Tighten the screw (item 49) for the rotor.
4.3.20. Install the thrust ring (item 46) and tighten the screw (item 50) for the stator.
4.3.21. Continue building up the remainder of the sealed end.
4.3.22. Repeat steps (4.3.1.) to (4.3.21.) for the opposite end.

Gas Seals Group 12

John Crane International

4-33-17
 4.4. REMOVAL OF SEALS

It is assumed that compressor is in a state where the dry gas seal can be removed.

4.4.1. Remove screws (items 49 and 50) and the thrust ring (item 46).
4.4.2. And replace the Type 83 installation plates (items 55 and 56) and their screws
(items 57 and 58).
4.4.3. Remove the Type 83 barrier seal assy (items 42, 43 and 45) by using two of
diametrically opposite 4-1/2-13 taps in the adapter (item 45).
4.4.4. Remove the split thrust ring (item 44) and O-ring (item 20 & 52).
4.4.5. Replace installation plate and screws (items 37, 38, 39, 40, and 41).
4.4.6. Using two of the diametrically opposite 4-1/2-13 taps supplied in the
installation plate at PCD 304.8 and threaded rod, extract seal cartridge evenly
jacking against compressor housing shaft.
4.4.7. Remove the seal cartridge from the shaft.

Repeat steps 4.4.1 through 4.4.7. for the opposite end.

Gas Seals Group 13

John Crane International

4-33-18
 4.5. REPLACEMENT OF TOLERANCE RINGS

Type 28 seals are fitted with tolerance rings located in the bore of the seal shaft sleeve.

The tolerance rings fit into the grooves machined into the bores of the sleeve and are
glued in place. It is recommended that the tolerance rings are replaced whenever the seals
are refitted.

4.5.1. Remove the old tolerance ring and all traces of glue in and around the groove
of the sleeve bore.
4.5.2. Carefully cut the tolerance ring to the required length ensuring that the ends
meet in a close butt joint (0~5mm gap). Do not overlap the ends.
4.5.3. Clean the tolerance ring and the sleeve bore grooves with a suitable solvent.

4.5.4. The tolerance ring is held in place by a two part quick acting glue such as
Loctite Multi Bond.
4.5.5. The tolerance ring joint must line up with the balance match mark once fitted.
Using the small brush provided, with the activator half of the glue, paint the
sleeve with the activator 15 mm either side of the balance match mark in the
groove.
4.5.6. Take the tolerance ring and lightly coat one end on the surface, shown in
Figure 4.5, with adhesive half of the glue.
4.5.7. Fit the tolerance ring into the groove so that the wetted surfaces come into
contact. Make sure that the tolerance ring fits completely into the groove. The
glue will take three to four minutes to dry. Care should be taken when using
this type of glue to avoid contact with skin.
4.5.8. Repeat steps 4.5.5 through 4.5.7 for the other end of the ring.
4.5.9. Repeat steps 4.5.1 through 4.5.8 for the remaining tolerance rings.
4.5.10.The seal cartridge sleeves are now ready for installation as described in
section 4. 3.

Gas Seals Group 14

John Crane International

4-33-19
 ' T'

Activator
Adhesive on this in groove
surface only

Align joint w ith 0~5mm

' T' match mark

Tolerance Ring Figures

Figure 4.5

Gas Seals Group 15

John Crane International

4-33-20
5. COMMISSIONING THE COMPRESSOR

The following task should be completed prior and during the start of the compressor. This
should be carried out with all ancillary systems such as lubricating oil, cooling systems, buffer
gas supply etc. connected up and running and the drive unit uncoupled. Over speed trip testing
of the drive unit should also be carried out at this stage (if required).

5.1. Slowly increase the pressure of the compressor until the operating pressure is reached.
If necessary, clamp the shaft to prevent rotation (this will depend on the valve arrangement
used).
5.2. Slowly depressurize the machine taking care not to cause rotation of the shaft.
5.3. Confirm the drive unit direction of rotation and couple the drive unit to the compressor as
per manufacturers instructions, ensuring correct alignment.
5.4. Repressurize the compressor and commence the normal start-up procedure.
5.5. During the first 24 hours of operation, the Seal performance should be checked at hourly
intervals with the following information recorded for each Seal:
a. Seal pressure
b. Shaft speed
c. Dynamic leakage
d. Number of stop starts
5.6. Subsequent monitoring should take place with the normal monitoring of the plant. The
most important parameter to be measured as far as the seal is concerned is leakage, as
this has a direct relationship with seal performance. Seal leakage rates are given in
Section 3.2.

Gas Seals Group 16

John Crane International

4-33-21
6. COMPRESSOR OPERATION AND MAINTENANCE WITH DRY GAS SEALS

The seals are designed to cover the widest range of operating parameters and require virtually
no maintenance. Typically, a supply of filtered compressor discharge gas will be injected into
the cavity between the inboard gas seal and the inboard labyrinth. A mojority of this supply of
filtered gas will flow by the inboard labyrinth back into the compressor ensuring that the seal
cavity is free from liquids or particles which could damage the gas seal. A small portion of the
supply gas will leak pass the inboard gas seal into the cavity between the inboard and outboard
gas seals. This cavity is vented, in which case the seal leakage will go to either flare or an
approved vent. The outboard gas seal will be sealing on the gas leakage from the inboard
gas seal or a purge gas if so equipped. This in conjunction with a separation labyrinth for
bearing oil prevents the gas from entering the bearing area. The outboard gas seal, also,
functions as a safety seal in the event that the inboard gas seal begins to leak excessively.

Seal performance is monitored through leakage rates. Therefore, it is recommended that the
leakage is monitored and recorded on a daily basis.

6.1. Operational Guidelines

The following notes are intended for guidance only.

Please consult John Crane International in regards to specific applications.

6.1.1. GAS QUALITY: The gas quality feeding the seal should be clean and dry.
This will provide and environment for optimum performance and longevity. It
is generally recommended that a 2 micron (absolute) coalescing filter be
incorporated in the seal supply gas line. While the Type 28 Gas Seal is able
to cope with contamination from liquids, prolonged contamination with liquids,
such as bearing oil, is not recommended.
6.1.2. SEAL GAS SUPPLY FLOW: The seal gas supply flow must be sufficient
enough to ensure that the seal is supplied with filtered gas during operation
with the remainder going back into the compressor. This will provide an ideal
sealing environment to maintain the optimum performance of the seals.

Gas Seals Group 17

John Crane International

4-33-22
 6.1.3. LEAKAGE TRENDS: Seal performance is monitored through leakage trends.
Occasional spikes in the leakage are no cause for alarm. Such spikes be a
result of a process variation, shaft movement, pressure, temperature, and / or
speed changes. A trend of leakage, however, may give forewarning of a seal
problems. Please consult John Crane International if there are any concerns.
6.1.4. REVERSE ROTATION: Reverse rotation should be avoided. Short periods of
reverse rotation of speeds less 1000 RPM can be tolerated, however, the seal
may require refurbishment and should definitely be inspected after such a run.
6.1.5. REVERSE PRESSURE: Reverse pressure under static conditions will result
in an increase in static leakage. Under dynamic conditions, reverse pressure
can result in major damage to the seal components.
6.1.6. SLOW ROLL: It is recommended that continuous speeds below 1000 rpm
are avoided. This gives a wide safety margin over the speed at which a 3
micron running gap is achieved. It also provides an improved capability to cope
with fluctuations within the machine as a stiffer fluid film is generated.
6.1.7. TURNING GEAR: Short duration’s at a turning gear speed of 12 rpm with
pressure on the system has not been detrimental to the gas seal.
6.1.8. DECOMPRESSION: The gas seal decompression rate is typically
recommended at 8 bar / minute. Faster decompression rates may be
accommodated upon review of the specific application.
6.1.9. VIBRATION: The gas seal has a relatively high tolerance level for vibration.
It is capable of surviving vibration levels which exceed the machine's operating
limits. Experience has shown gas seals to survive vibration levels of 100
microns peak to peak.
6.1.10.INSTALLATION: Although the seals are robust in operation they can easily
be damaged by incorrect assembly, fitting or handling. It is therefore
recommended that the seals are fitted by a John Crane International trained
engineer.

Gas Seals Group 18

John Crane International

4-33-23
 6.2. CLEANING

If the Type 28 Gas Seal is exposed to oil or other contaminants. It is recommended that
they be cleaned.
It is recommended that the seals are returned to a John Crane repair facility or cleaned by
a qualified John Crane representative, if cleaning is required.

6.3. STORAGE OF SEALS

John Crane Type 28 Gas Seals should always be stored as complete cartridge units with
the installation plate properly fitted as shown on the installation drawing.

Prior to dispatch every seal is packaged in a purpose built wooden crate with a foam lining.
The crate is suitable for long term storage, provided that it remains in a warm, dry
atmosphere. The seal should be wrapped, if possible with a small bag of desiccant to
keep the cartridge components dry, in a suitable plastic film, such as polyethylene sheet
and then sealed in the crate. Grease or oil impregnated papers or waxed cotton must not
be used to wrap the seal.

If the seal are to be stored inside the compressor for long periods it is necessary to ensure
that the seal faces are not contaminated with oil. This will prevent the faces from
wringing together.

Gas seal cartridge need periodic refurbishment. They should be returned to John Crane
for o-ring replacement and general inspection. The exact timing of these refurbishment will
depend on the operating duty and/or environmental conditions, however the following
examples are an indication of the maximum permissible time between refurbishment:

Maximum storage and running time combined is 10 years. Maximum running time is 5
years.

As specific examples:
x Store for 5 years and run for 5 years giving a total of 10 years
x Store for 7 years and run for 3 years giving a total of 10 years.
x Store for 3 years and run for 5 years giving a total of 8 years.

Gas Seals Group 19

John Crane International

4-33-24
 6.4. SHIPPING OF THE SEAL CARTRIDGE

It is essential that the seals are suitably packaged.

The seals should be assembled as a cartridge unit with the installation plate, preventing
movement between the seal rotor and stator.

No "loose" items should be placed inside the box as this may result in damage to the seal
faces.

Gas Seals Group 20

John Crane International

4-33-25