1. Safety & Pre-Installation Preparation
1.1 Safety Precautions
• Lockout/Tagout: Confirm the reactor/agitator is disconnected from power, fully depressurized, and all internal media is drained and cleaned.
• PPE: Wear chemical-resistant gloves, safety goggles, and clean work clothes to prevent contamination and injury.
• Environment: Maintain a clean, dry, dust-free workspace. Prevent any particles from entering seal faces.
1.2 Component & Dimension Inspection
• Verify Model: Ensure seal type, size, and material match equipment specifications (shaft diameter, seal chamber dimensions, pressure/temperature ratings).
• Check Parts: Inspect rotating ring, stationary ring, springs, O-rings, shaft sleeve, gland, and fasteners. Reject any parts with cracks, chips, scratches, deformation, or corrosion.
• Shaft & Chamber Tolerances:
◦ Shaft OD tolerance: ±0.05 mm (±0.002 in)
◦ Shaft radial runout: ≤ 0.1 mm T.I.R.
◦ Shaft axial end float: ≤ 0.13 mm (0.005 in)
◦ Seal chamber face squareness to shaft: ≤ 0.0005 in/in (0.5 μm/mm)
◦ Shaft surface roughness: ≤ 1.6 μm; shaft tolerance: h8
◦ Shaft sleeve end must have a 3×20° smooth chamfer
1.3 Thorough Cleaning
• Clean shaft, sleeve, seal chamber, flange faces, and gland with alcohol or acetone; remove all oil, grease, and debris.
• Wipe seal faces (rotating/stationary rings) with a lint-free soft cloth; never touch or scratch lapped faces.
• Clean all tools; avoid contamination.
1.4 Lubrication
• Apply a thin, compatible lubricant (food-grade silicone grease, clean machine oil, or manufacturer-recommended lubricant) to:
◦ Shaft/sleeve surface
◦ O-rings and secondary seals
◦ Mating faces of rotating and stationary rings
• Note: For EPDM, butyl, or FKM O-rings, avoid incompatible mineral oils.
2. Installation Procedure (Standard Single-Ended Seal)
2.1 Install Stationary Ring Assembly
1. Fit the stationary ring’s secondary seal (O-ring) onto the back of the stationary ring.
2. Insert the stationary ring into the seal chamber/gland. Align anti-rotation pins with anti-rotation slots (no hard contact).
3. Ensure the stationary ring face is perpendicular to the shaft centerline.
4. Install the gland onto the reactor flange. Tighten bolts crosswise and evenly in 2–3 stages to specified torque; avoid distortion.
2.2 Install Rotating Ring Assembly
1. Slide the shaft sleeve (if used) onto the shaft; align keyway and secure with set screws to manufacturer torque.
2. Assemble rotating ring, spring(s), and drive seat on the sleeve/shaft.
3. Use a guide sleeve to protect seal faces; slide assembly into position. Do not strike or force.
4. Verify springs are uniformly compressed, free of binding, and provide even pressure.
5. Tighten drive set screws evenly and crosswise to lock the assembly to the shaft.
2.3 Final Alignment & Check
1. Manual Rotation: Spin the shaft by hand. It must rotate smoothly, no binding, noise, or excessive friction.
2. Runout Check: Use a dial indicator to measure rotating ring face runout. Max allowed: ≤ 0.05 mm T.I.R.
3. Spring Function: Push the rotating ring axially; it should bounce back freely without sticking.
4. Remove any setting clips, lock pins, or transport locks before operation.
2.4 Cartridge Seal Installation (if applicable)
1. Align cartridge seal with shaft and chamber; ensure flange bolt holes match.
2. Slide cartridge into place; use centering guides if provided.
3. Hand-tighten flange bolts; align and check runout (≤ 0.05 mm).
4. Torque bolts to specs in a crosswise pattern.
5. Remove setting clips before startup.
3. Auxiliary System Connection (Double Seal / API Plans)
• For dual seals (Plan 52, 53, 54), connect flush, cooling, or barrier fluid lines.
• Ensure barrier fluid pressure is 0.05–0.1 MPa higher than kettle pressure per design.
• Check for leaks in piping; purge air from circuits.
4. Post-Installation Testing
1. Static Pressure Test: Pressurize to 1.25× design pressure; hold 10–30 minutes. No visible leakage.
2. Dry Run (Optional): Run idle for 15–30 minutes to check heat, noise, and seal performance.
3. Check for abnormal heat, vibration, or leakage during initial operation.
5. Critical Installation Rules
• Never use hard tools to strike seal components.
• Never touch or contaminate lapped seal faces.
• Even torque only — avoid over-tightening or uneven bolting.
• Maintain cleanliness at all stages.
• Follow manufacturer-specific dimensions (spring compression ±0.2 mm).
