Workshop Manual, Seal handbook part Mechanical seals for Large C-Pumps, L-Pumps and P-Pumps equipped with 605-series, 705-series, 805-series, 905-series drive units 894483/01
2 Seal handbook part, Large Pumps Contents How to use the workshop manual... 3 Safety precautions... 4 Mechanical seal overveiw... 5 Operating description... 6 Mechanical seal, outer 337 79 11... 6 Mechanical seal, outer 370 66 02... 10 Mechanical seal, outer 578 58 01... 14 Mechanical seal, outer 585 26 01... 16 Mechanical seal cartridge, outer/inner 556 60 00... 18 Mechanical seal, inner 617 99 01... 20 Mechanical seal, inner 559 80 00... 24 Notes...30
Seal handbook part, Large Pumps 3 How to use the workshop manual This part of workshop manual describes how to dismantle and assemble the different mechanical shaft seals in the drive units/generators for large pumps/turbines in connection with repair and reconditioning work. To reach the seals there must have been some dismantling of the product, see resp. workshop manual's operative part depending on which drive unit/generator the product are equipped with. This part is a operative part and contains numbered illustrations of different work operations with description. In front of the operative part there is a list of which mechanical seals are described in this manual and in which products they are a part of. Every pump/turbine have an outer and an inner seal or a combined outer/inner seal cartridge. The seals in the product are dependent of the shaft diameter. Most of the operations apply to all drive unit/generator types. However, in some procedures the instructions may differ between the drive units/generators. Here we have pointed this out with a picture or explained this in the text. Details are also provided of the special tools which not only facilitate repair work, but which are sometimes necessary in order to carry out a particular operation. We would also point out that the practical work involved in compiling this manual has been performed under extremely favourable conditions. We have dismantled and assembled new products. A drive unit/generator which has been in use for a longer period of time has acquired a "patina" and other working methods besides those recommended here will sometimes have to be used. If the drive unit is specially approved, please read the chapter "Specially approved drive unit" in the end of the general part. Flygt disclaims all responsibility for work done by untrained, unauthorized personnel.
4 Seal handbook part, Large Pumps Safety precautions In order to minimize the risk of accidents in connection with service work, the following rules should be followed: 1. Before starting work on the drive unit/generator, make sure that it is isolated from the power supply and cannot be energized. 2. Bear in mind the risk of accidents. Make sure that the drive unit/generator or parts of the drive unit/generator can not fall over. 3. Make sure that the lifting equipment can handle the weight you want to lift and that it is in good condition. 4. Make continuously sure that in the course of the work the drive unit/generator and / or its components stand steadily and cannot fall down and cause damage. 5. Don't work under suspended load. 6. Bear in mind the danger of electrical accidents. 7. Bear in mind health hazards. Observe strict cleanliness. When carrying out repair work take care to avoid injury by cutting or pinching. 8. Make sure you have a first-aid box near at hand. 9. Check that tools and other equipment are in good condition. 10. Two sets of lifting equipment are required to handle the drive unit/generator for repair work. Follow all other health and safety regulations, local codes and ordinances. See also the Installation, Care and Maintenance manual, chapter "Installation and start-up, safety precautions". General rules Wash the outside of the drive unit/generator thoroughly and blow it dry. Clean all parts thoroughly - particularly O-ring grooves - before assembly. Always change all O-rings, other seals and gaskets and lock washers. Lubricate moving parts, O-rings and shaft seals.
Seal handbook part, Large Pumps 5 Mechanical shaft seals overview Seals and shaft end dimensions Drive unit 6x5, 8x5 8x5, 9x5 9x5, Gear box Gear box Inner seal 617 99 01 617 99 01 617 99 01 559 80 00 599 80 00 - - Page 20-23 Page 20-23 Page 20-23 Page 24-28 Page 24-28 Outer seal 337 79 11 370 66 02 578 58 01 585 26 01 370 66 02 556 60 00 433 74 01 Page 6-9 Page 10-13 Page 14-15 Page 16-17 Page 10-13 Page 18-19 Page 18-19 Shaft end Ø 70 Ø 75 Ø 75 Ø 90 Ø 90 Ø 110 Ø 140 Product C/R 3231 X C 3306 X C 3312 X X C 3351 X C/L 3356 X C/L 3400 X X C 3501 X X C 3531 X X X L 3531 X X C/L 3602 X X X C 3800 X P 7061 X P 7076 X P 7081 X P 7101 X X P 7115 X P 7121 X X E 7556 X E 7570 X X E 7585 X X E 7600 X X X E 7620 X X E 7650 X X
6 Seal handbook part, Large Pumps Operating description Mechanical seal, outer 3377911 WCCR Disassembly Hydraulic unit C/R3231 C3306 C/L3356 P7061 P7076 E7556 Drive unit 6x5 1. Remove the flat key and lift off the rubber seal ring. 2. Remove the circlip 3. Remove the rotating seal ring, the support ring and the O-ring by carefully bending with two crow bars. 4. Remove the stationary seal ring with the same method. 5. Remove the four screws (M8) for the seal holder. Note. P7076 have no seal holder. The oil housing act as a seal holder 6. Fit two break screws in the threaded holes in the seal holder (M6 for drive units 6x5 or M8 for drive units ). Remove the seal holder by carefully bending with two crow bars at the break screws. 6 1 2 3 4 5 1 2
Seal handbook part, Large Pumps 7 3 4 5 6 6 Seal holder
8 Seal handbook part, Large Pumps Mechanical seal, outer 3377911 WCCR Assembly Hydraulic unit C/R3231 C3306 C/L3356 P7061 P7076 E7556 Drive unit 6x5 1. Fit new greased O-rings to the seal holder and put it in place. For P7076: put the greased O-ring into the groove in the oil housing. 2. Fit the four M8-screws and washers. Tighten the screws crosswise to a torque of 17 Nm. 3. Mount the stationary seal ring by pushing and turning until it fits in its locked position. Clean the seal surface accurately and oil it. 4. Clean and oil the rotating seal ring and mount it in place. Check that the slot in the seal ring is placed in line with the drive pin in the motor shaft. 5. Fit new greased O-ring and fit the support ring. 6. Fit the circlip. Push down the circlip to its groove with a suitable sleeve. 7. Fit the rubber seal ring. 1 7 6 5 4 3 2 1 1 (P7076) 1 4 5,6 7 3 Seal holder
Seal handbook part, Large Pumps 9 1 2 3-4 5 6 7
10 Seal handbook part, Large Pumps Mechanical seal, outer 3706602 WCCR Disassembly Hydraulic unit C3312 C3501 C/L3531 C/L3602 P7115 E7570 E7585 E7600 Drive unit 8x5 9x5 After disassembly of the impeller from the shaft this mechanical seal will be devided into two parts. The rotating part (1-5) is left at the impeller and the stationary part (6-8) is at the drive unit. 1. Fit the seal tool 3994100 to the shaft hole of the impeller. Select the suitable nut (1) depending on the shaft diameter (75 or 90 mm). 2. Screw down the lower part of the tool by pushing it down so that the pin engages the keyway, then turn it a half turn and screw down. 3. Put on the upper part of the tool and press down the seal ring with the upper wing nut until the stop spring is accessible. Remove the stop spring (4). 4. Remove the spring housing and the seal ring from the impeller. 5. Remove the screws (5) for the stationary seal ring at the drive unit and remove the ring (6). 6. Remove the three screws for the seal ring housing. 7. Lift up the seal ring housing and the seal ring. 8. Push out the stationary seal ring by hand. 4 6-8 1-5 1 2 1
Seal handbook part, Large Pumps 11 3 4 5 6 5 6 7 8
12 Seal handbook part, Large Pumps Mechanical seal, outer 3706602 WCCR Assembly Hydraulic unit C3312 C3501 C/L3531 C/L3602 P7115 E7570 E7585 E7600 Drive unit 8x5 9x5 4 6-9 1. Clean the surfaces at the impeller where the rotating seal ring should be mounted and check that the spring housing's rotation stop in the impeller is intact. Fit the seal tool 3994100 to the shaft hole of the impeller. Select the suitable nut depending on the shaft diameter (75 or 90 mm). 2. Fit the spring housing, well greased, to the impeller and a new greased O-ring. 3. Fit the rotating seal ring with greased O-ring groove. 4. Put on the stop spring (4). 5. Mount the upper part of the tool and press down the stop spring into the groove. Remove the tool and oil the sealing surface. 6. Clean the seal ring housing and the O-ring grooves for the stationary seal ring in the drive unit. Fit a new greased O-ring to the seal ring housing. 7. Fit the seal ring housing and tighten the screws to 57 Nm. 8. Fit two new greased O-rings on the stationary seal ring and push it in place into the seal ring housing. 9. Put on the ring and tighten the screws crosswise to a torque of 17 Nm for M8-screws at drive units and 8x5 and 7 Nm for the M6-screws at drive unit 9x5. Clean and oil the sealing surfaces well before assembly. 1 1-5 2 3
Seal handbook part, Large Pumps 13 4 5 6 7 8 9
14 Seal handbook part, Large Pumps Mechanical seal, outer 5785801 WCCR Disassembly Hydraulic unit C3400 P7081 P7101 Drive unit 1. Remove the circlip 2. Remove the four M8-screws for the stationary seal ring holder. 3. Remove the seal and the seal ring holder by carefully bending with two crow bars. Rotating seal ring 2 1 3 Stationary seal ring
Mechanical seal, outer 5785801 WCCR Assembly Hydraulic unit C3400 P7081 P7101 Drive unit 1. Clean all O-ring grooves thoroughly. Make sure that the O-ring grooves and the shaft end are clean and free of burrs. If necessary, polish off any flaws with fine emery cloth. 2. Put a new greased O-ring (A) to the seal ring holder (B) and mount it in place so the threaded holes are visible. 3. Fit a new greased O-ring to the stationary seal ring and put it in place. 4. Put the lock washer (C) in place and make sure the three anti-rotation tabs will get into the slots in the seal ring. Turn the lock washer and the seal ring so the screw holes are entirely visible. 5. Fit the four M8-screws (D) and tighten them crosswise to a torque of 17 Nm. 6. Grease all O-rings in the rotating seal ring. Clean and oil the sealing surfaces well. 7. Fit the rotating seal ring. Check that the seal ring's driving pin correspond to the shaft's driving slot. 8. Fit the circlip. Check that the spring pressure in the seal ring is working properly by pushing the outer edge of the ring (E). NOTE! Following parts are NOT included in mechanical seal (part no. 578 58 01): A O-ring B Seal ring holder C Lock washer D Screw Seal handbook part, Large Pumps 3-4-5 D C 6-7-8 15 1-2 8 E E B A
16 Seal handbook part, Large Pumps Mechanical seal, outer 5852601 WCCR Disassembly Hydraulic unit C3400 P7101 P7121 Drive unit 8x5 1. Remove the circlip 2. Remove the rotating seal ring by carefully bending with two crow bars. 3. Remove the eight M8-screws for the stationary seal ring holder. Use the two screw holes for M6 break screws to facilitate the removal of the seal ring holder. 4. Turn the seal ring holder upside down and remove the eight M6-screws and the washer holding the stationary seal ring. Push out the seal ring by hand. Rotating seal ring Stationary seal ring 1-3 4 2 1 2 3 4
Mechanical seal, outer 5852601 WCCR Assembly Hydraulic unit C3400 P7101 P7121 Drive unit 8x5 1. Clean all O-ring grooves thoroughly. Make sure that the O-ring grooves and the shaft end are clean and free of burrs. If necessary, polish off any flaws with fine emery cloth. 2. Put on two new greased O-rings to the stationary seal ring and mount it into the seal ring holder (A) by hand. Fit the washer (B) and the eight M6-screws (C) and tighten them crosswise to a torque of 7 Nm. 3. Fit a new greased O-ring (D) to the seal ring holder and mount it with the eight M8-screws (E). Tighten the screws crosswise to a torque of 17 Nm. 4. Grease all O-rings in the rotating seal ring. Clean and oil the sealing surfaces well. 5. Fit the rotating seal ring. Check that the seal ring's driving pin correspond to the shaft's driving slot. 6. Fit the circlip. Check that the spring pressure in the seal ring is working properly by pushing the outer edge of the ring (F). NOTE! Following parts are NOT included in mechanical seal (part no. 585 26 01): A Seal ring holder B Washer C Screw D O-ring E Screw Seal handbook part, Large Pumps 3 4-5-6 E D 17 1-2 6 A B C F F
18 Seal handbook part, Large Pumps Mechanical seal cartridge, outer/inner 5566000 WCCR and 4337401 WCCR Disassembly Hydraulic unit Drive unit C3351 C3531 C3602 C3800 P7121 E7585 E7600 E7620 E7650 9x5 9x5/Gear box Gear box Gear box Gear box 1. Remove the three/six screws (M12) holding the seal cartridge. 2. Use two of the screws in the disassembly holes in the seal holder and pull out the seal cartridge untill it release from the bearing housing. 3. Replace the screws with two lifting eye bolts (M12) and lift out the seal cartridge by hand. 1 1 2 2 3 3
Mechanical seal cartridge, outer/inner 5566000 WCCR and 4337401 WCCR Assembly Hydraulic unit Drive unit Seal handbook part, Large Pumps 3 M12 19 C3351 C3531 C3602 C3800 P7121 E7585 E7600 E7620 E7650 9x5 9x5/Gear box Gear box Gear box Gear box Grease Before installation, inspect the shaft and the O-ring seats for excessive wear, burrs, or any other surface defect. Polish off any flaws with fine emery cloth. Clean all O-ring seats carefully. 1. Turn the shaft so the driving pin of the seal correspond to one of the mounting holes of the seal cartridge. 2. Turn the rotating part of the seal cartridge so its driving slot correspond to one of the mounting holes of the seal cartridge. 3. Grease all O-rings and the shaft end. Fit two lifting eye bolts (M12) into the disassembly holes in the seal holder and lift the cartridge in place. Check that the driving pin and driving slot are corresponding and the screw holes are entirely visible. 4. Push in the seal cartridge by hand. Fit the three/six screws (M12) and tighten them alternately until the seal cartridge is seated. Tighten the screws to 57 Nm. 5. Fit a new greased O-ring onto the impeller hub neck/ gear box hub neck. 4 57 Nm 1 Mounting holes Shaft Driving pin 5 5 2 Seal cartridge Mounting holes Driving slot
20 Seal handbook part, Large Pumps Mechanical seal, inner 6179901 WCCR Disassembly Hydraulic unit C/R3231 C3306 C3312 C/L3356 C/L3400 C3501 C/L3531 C/L3602 P7061 P7076 P7081 P7101 E7556 E7570 Drive unit 6x5, 6x5, 6x5, 6x5, 6x5, 1. Connect the clamp 582 67 01 to the shaft journal and press down the spring housing. 2. Remove the stop spring.disconnect the clamp. 3. Remove the spring housing. 4. Remove the lock ring (drive units 6x5) 5. For drive units : Remove the four screws (C) and remove the lock ring (B). 6. Remove the rotating seal ring by carefully bending with two screwdrivers. 7. Remove the stop washer (A). 8. Remove the stationary seal ring and the O-ring by carefully bending with two screwdrivers. Rotating seal ring Stationary seal ring 1 2
Seal handbook part, Large Pumps 21 3 4 5 6 B C A 7 8
22 Seal handbook part, Large Pumps Mechanical seal, inner 6179901 WCCR Assembly Hydraulic unit Drive unit C/R3231 6x5, C3306 6x5, C3312 C/L3356 6x5, C/L3400 C3501 C/L3531 C/L3602 P7061 6x5, P7076 6x5 P7081 P7101 E7556 E7570 1. Fit a new greased O-ring on the stationary seal ring and mount it in the bearing housing. Note for drive units 6x5: one of the slots in the seal ring should correspond with the hole in the bearing housing. 2. Fit the stop washer (A). For drive units 6x5: the pin on the stop washer should be placed in the hole in the bearing housing. 3. Fit the rotating seal ring with greased O-ring and place the lock ring (drive units 6x5). Oil the sealing surfaces. 4. For drive units : Fit the lock ring (B) with the four screws (C). 5. Fit the spring housing. 6. Put on the stop spring. Connect the clamp and press down the spring housing. 7. Push down the stop spring. Remove the clamp. 6,7 5 3 1 NOTE! Following parts are NOT included in mechanical seal (part no. 617 99 01): A Stop washer B Lock ring C Screw 1 2
Seal handbook part, Large Pumps 23 3 4 B C A 5 6 7
24 Seal handbook part, Large Pumps Mechanical seal, inner 5598000 WCCR Disassembly Hydraulic unit Drive unit C3312 8x5 C/L3400 8x5 C3501 8x5 C/L3531 8x5, 9x5 C/L3602 8x5, 9x5 P7101 8x5 P7115 8x5, 9x5 P7121 9x5 E7570 8x5, 9x5 E7585 8x5, 9x5 E7600 8x5, 9x5 1. Remove the circlip. 2. Remove the ring and the lock washer. 3. Connect the mounting clamp 582 67 00 and suitable screw to the shaft end. 4. Compress the seal by tightening the screw and pull out the stop spring with spring puller tool 332 91 00. Remove the clamp tool. 5. Remove the spring housing. 6. Remove the rotating seal ring by carefully bending with two screwdrivers. Note the O-ring. 7. Remove the six screws and lift off the seal ring housing and seal ring by carefully bending with two screwdrivers. 8. Push out the stationary seal ring and O-ring by hand. Rotating seal ring Stationary seal ring 1 2
Seal handbook part, Large Pumps 25 3 4 5 6 7 8
26 Seal handbook part, Large Pumps Mechanical seal, inner 5598000 WCCR Assembly Hydraulic unit C3312 C/L3400 C3501 C/L3531 C/L3602 P7101 P7115 P7121 E7570 E7585 E7600 Drive unit 8x5 8x5 8x5 8x5, 9x5 8x5, 9x5 8x5 8x5, 9x5 9x5 8x5, 9x5 8x5, 9x5 8x5, 9x5 1. Fit a new greased O-ring to the seal ring housing. 2. Put on the seal ring housing, push it down, fit the screws and tighten to 57 Nm. 3. Fit a new greased O-ring to the stationary seal ring. 4. Place the ring with one of the slots in line with the slot mark in the seal ring housing. 5. Fit the lock washer 566 40 00 with the tabs faced downwards. The slot should correspond with the slot mark in the seal ring housing. 6. Put on the ring. Note! Place the lock tab in the slot. 7. Fit the circlip. 11 10 8, 9 NOTE! Following parts are NOT included in mechanical seal (part no. 589 80 00): 1 Seal ring housing 2 Screw 5 Lock washer 6 Ring 7 Circlip 3, 4 7 10 8,9 6 3,4 11 7 5 2 1 1
Seal handbook part, Large Pumps 27 2 3 4 75 5 6 7
28 Seal handbook part, Large Pumps 8. Oil the sealing surface of the rotating seal ring. 9. Put on the rotating seal ring and fit a new well greased O-ring into the rotating seal ring. 10. Fit the spring housing. Check that the slot for the stop spring correspond with the hole in the shaft journal. Put on the stop spring. 11.Connect the mounting clamp 582 67 00 and suitable screw to the shaft end. Compress the seal by tightening the screw until the stop spring can be pushed in place. Remove the tool. 8 9 10 11
Seal handbook part, Large Pumps 29
30 Seal handbook part, Large Pumps Notes
Seal handbook part, Large Pumps 31 Notes
Mechanical seals for drive units 605-, 705-, 805-, 905-ser. 33.01 Eng. 0,1M. 01.03 ITT FLYGT AB Printed in Sweden 894483 www.flygt.com