German KALREZ seals KALREZ models KALREZ prices

KALREZ seals utilize the "container" concept from transportation to create cartridge seals. The rotating and stationary parts of this seal are pre-assembled into a single unit before installation. After passing inspection and pressure testing, the unit is mounted on the shaft within the seal chamber, fixed to the shaft with set screws, and the gland bolts are tightened. Once the cartridge positioning tabs are removed, the mechanical seal operates in a parallel face condition and is ready for service. This approach not only simplifies assembly but also ensures assembly quality. Welded metal bellows mechanical seals are all designed as cartridge seals, offering the aforementioned advantages. Cartridge seals are also a type of cartridge mechanical seal. In this design, the stationary ring, rotating ring, sleeve, gland, and auxiliary seals are all assembled together on a single sleeve before installation, facilitating inspection of assembly quality. After passing inspection, simply tighten the seal cover and secure the screws. This pre-assembled, inspected, and tested seal component makes it easier to ensure installation and assembly quality.

KALREZ seal operating principle

A mechanical seal is a shaft sealing device that prevents leakage by maintaining contact between one or more pairs of end faces perpendicular to the shaft, which slide relative to each other under the action of fluid pressure and the elastic force (or magnetic force) of a compensation mechanism, supplemented by auxiliary seals. A typical mechanical seal structure consists of a stationary ring (static ring), a rotating ring (dynamic ring), an elastic element spring seat, set screws, a rotating ring auxiliary O-ring, and a stationary ring auxiliary O-ring. An anti-rotation pin is fixed to the gland to prevent the stationary ring from rotating. The rotating ring and stationary ring may also be referred to as compensation rings or non-compensation rings, depending on whether they possess axial compensation capability.

KALREZ seal system composition

1) Seal chamber: In the past, seal chambers housing mechanical seals were designed as stuffing boxes for soft packing seals. They are unsuitable for housing mechanical seals, not only because they are too small and have narrow clearances, but also because their simple cylindrical shape is inappropriate. Standards for enlarged mechanical seal chambers have been established abroad. Furthermore, companies such as Durametallic in the United States and the Fluid Sealing Association in the United Kingdom are researching rational mechanical seal chamber designs. Their shapes should not only facilitate fluid flow and heat dissipation but also help remove solid particles, creating a favorable environment for the seal. 2) Fugitive emission control system: In the past, attention was focused only on eliminating visible fluid leaks, while ignoring the control of invisible fugitive emissions, resulting in environmental pollution and hazards to equipment and personnel. Organizations abroad, such as the Sealing Technology Committee of the Society of Tribologists and Lubrication Engineers (STLE) in the United States, have developed guidelines for controlling fugitive emissions from rotating machinery, compressors, and screw systems with mechanical seals, including SP-30 (1994), SP-32 (1990), and SP-33 (1991). SP-30 is implemented in three stages. It clearly defines barrier fluids and buffer fluids, clarifying erroneous and confusing concepts. A barrier fluid is introduced between dual seals to completely block process fluid from leaking into the surrounding environment. The pressure of the barrier fluid is always higher than the pressure of the sealed process fluid. A buffer fluid is used between dual seals as a lubricant or buffer, and its pressure is always lower than the pressure of the sealed process fluid. 3) Auxiliary system integration: Mechanical seal auxiliary systems require integration of cooling, heating, and flushing systems. Pump circulation needs optimization, and issues such as condition monitoring systems are being studied and resolved. Auxiliary system integration is specified in the API-682 standard. 4) Gas barrier seal system: In the past, liquid barriers were commonly used to seal liquids or gases in barrier seal systems. To simplify bulky barrier liquid systems, barrier gases are now used to seal liquids or gases. Gas barrier seal systems may employ spiral groove gas seals with barrier gas, floating bushings with barrier gas, etc., to seal gases and liquids.

KALREZ seal troubleshooting

1) Main factors causing oil seal leakage: Poor sealing of the oil seal is the primary factor causing leakage. When the shaft wears and forms grooves, even replacing it with a new oil seal may not achieve proper sealing. This is due to reduced contact pressure between the oil seal lip and the shaft, resulting in insufficient interference between the installed oil seal lip diameter and the shaft diameter. Taking the S195 diesel engine crankshaft oil seal as an example, the main reasons for poor sealing are analyzed as follows: (1) Poor manufacturing quality of the oil seal; (2) Poor quality of the shaft or bearing; (3) Improper use and maintenance; (4) Improper installation; (5) Improper storage, leading to adverse effects from environmental contamination. 2) Countermeasures for leakage due to poor oil seal sealing: Acquire basic knowledge to identify counterfeit and inferior products, and purchase high-quality, standard-compliant oil seals. During installation, if the outer surface of the shaft diameter has low roughness or defects such as rust spots, corrosion, or burrs, polish it smooth with fine sandpaper or an oil stone. Apply clean engine oil or lubricating grease to the oil seal lip or the corresponding position on the shaft diameter. Apply sealant to the outer ring of the oil seal. Wrap the keyway area on the shaft with hard paper to avoid scratching the oil seal lip. Use a special tool to rotate and press the oil seal inward. Never hammer or force it, to prevent deformation of the oil seal or breakage of the spring, which would cause failure. If the lip flips, the spring detaches, or the oil seal becomes skewed, it must be removed and reinstalled. Note: Do not arbitrarily tighten the inner spring when the shaft diameter is not worn and the oil seal spring tension is sufficient. Oil seals used in machinery generally operate under harsh conditions, with large ambient temperature differences, abundant dust, and frequent vibration causing constantly changing stress on components. Therefore, frequent inspection, maintenance, and upkeep are required. If the shaft diameter and bearing are severely worn, or if the oil seal rubber ages or the spring fails, repair and replace the corresponding parts promptly. Troubleshoot abnormal heating in components or assemblies immediately. Avoid overspeeding or overloading the machinery to prevent increased temperature at the oil seal lip, rubber aging, and premature lip wear. Regularly check the engine oil level. If the engine oil contains excessive impurities, such as alloy powder or metal filings, completely replace it with new oil. The brand and quality of the replacement oil must meet seasonal requirements. It is recommended to add Metraile Super Sealant & Lubricant to the engine oil. It is an excellent gearbox additive that forms an inert material film on components, which can reduce oil seal leakage, extend the service life of oil seal gears, and reduce gearbox noise. The use of this Metraile super sealant lubricant will not contaminate or degrade the oil.

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