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High Performance Sealing Technology Effective pump shaft sealing
High Performance Sealing Technology
Effective pump shaft sealing
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Since the earliest days of our company, innovative James Walker products have won respect for their excellent performance and value.
We set new benchmarks with our standard materials, and overcome the toughest application and operational challenges in the development of our special products, so our customers can trust the James Walker name every time.
Since 1882 our outstanding products have built a reputation for quality and reliability. From some of the earliest modern packing patents, through to the advanced materials used in today’s high performance products – a desire to deliver the very best performance, value and service has remained at the heart of the James Walker business.
Through our commitment to rigorous testing and continuous improvement we stay at the forefront of sealing technology. We ensure the highest levels of product performance and value for our customers through a proven portfolio that is one of the most extensive on the market today.
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Delivering the very best performance is at the heart of everything we do.
1882Established
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Efficiency and reliability
Sealing Success
“ In a challenging paper & pulp refiner application, KlickFix is operating without the need for frequent adjustment and emits no leakage. A significant productivity improvement on the previous sealing system.”Paper Mill Engineer
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The innovative alternative to compression packing and mechanical seals
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KlickFix® is a new alternative to mechanical seals and compression packings.
Removing the need for large volumes of flush water that can be required by mechanical seals and replacing the risk of sudden catastrophic failure with controlled, predictable performance.
The KlickFix system eliminates the need for the continual adjustment and tightening associated with compression packings, whilst the low friction seal lips also reduce potential shaft wear.
The multiple sealing lips, which are a feature of the KlickFix system, are safely stored until required and then can be rapidly deployed, preventing leakage and bringing pumps back into service with minimal process interruption.
KlickFix can be refurbished on-site in a matter of minutes and has the potential to significantly out-perform traditional mechanical seals and compression packings.
Offering simple, predictable maintenance, KlickFix also helps working towards the ISO 14001 environmental management standard by virtually eliminating leakage and minimising or eliminating flush water requirements.
Behind the brand
The KlickFix® name comes from the simple action required to deploy stored sealing lips to bring a pump back into service with minimal process interruption
What is ?
The colours of internal components in the above illustration have been chosen for illustrative purposes only and are not intended as an accurate representation of the actual materials used.
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Flush port.
Integral flush system (for use with abrasive applications) ensures sealing lip remains free from particulate contamination.
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• At the heart of KlickFix is a unique system - with International PCT Patent - for deploying individual lips in sequence.
• Multiple low friction PTFE lips are stored within the cartridge body and can be simply activated in a matter of seconds without any need for stripdown or equipment adjustment.
• Greatly reduced requirement for flush, (typically 0.1-0.15 l/min 0.026 - 0.040 US gal/min). Non-abrasive applications may not require flush at all.
• A KlickFix cartridge unit has no moving parts or brittle sealing faces to disturb. It can tolerate intermittent process faults and dry running conditions that would normally cause catastrophic failure within many traditional mechanical seals.
As the lip in use gradually wears, any leakage is stemmed in a matter of seconds by deploying the next stored lip. A simple ‘click’ to ‘fix’ operation with no specialist technical knowledge required. With a traditional mechanical seal the task of changing sealing elements or faces can cost many hours of expensive down time and skilled maintenance input.
When eventually all the lips are exhausted (and this could be a period many times longer than the service intervals required by mechanical seals or compression packings), the unit can be swiftly refurbished on-site using a simple Refurbishing Kit.
These kits are available to order from your local James Walker company.
Behind the brand
Extensive testing has shown that KlickFix® can significantly reduce water consumption when compared against other traditional pump shaft sealing options.
How does it work?
sequentially deployable sealing system
Rear centralising bush of bearing-grade PEEK ensures correct seating of sealing element.
Thin-walled deployment sleeve holds lips off therotating shaft until required.
Stored lips are simply engaged by removing the next positioning clip from the control pin and retracting the deployment sleeve.
O-rings retain lip profile during storage prior to deployment.
Sealing element is machined from single billet of PTFE.
Scraper lip functions as a non-return valve and provides protection against flush depletion in abrasive media applications
Separate front bush of bearing-grade PEEK.
The colours of internal components in the above illustration have been chosen for illustrative purposes only and are not intended as an accurate representation of the actual materials used.
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Case Study: Paper mill process pump shaft sealing
Application
Single mechanical seal
Paper and pulp mill in Poland, Scanpump BA 250/250-32.
• Shaft diameter: 65 mm (2½")
• Shaft speed: 5 m/s (984 ft/min)
• Discharge pressure: 3.7 bar (37 kPa / 54 psi)
• Media: black liquor
Short seal life cycle
A KlickFix® cartridge was installed in an effort to prolong the seal life cycle and reduce the costs associated with regular adjustment and replacement.
The KlickFix uses a sequentially deployable sealing lip system and contains five lips. When the stored lips need to be utilised, the process can be undertaken in a matter of minutes.
Hugelyextended
seal lifecycle
Reduced costs related to regular seal replacement
Improved operational efficiency due to less downtime
Significant reduction in maintenance
Results & Benefits
After 10 months, the KlickFix® cartridge is still in operation using the first lip. With a further four lips ready to be deployed when required, the cartridge is offering a massive improvement in seal life cycle. The customer has already reported cost savings through reduced downtime and maintenance.
Problem
The customer was experiencing a mean time between failure (MTBF) of mechanical seals of 3 - 6 months. This was resulting in excessive maintenance and downtime, in turn leading to rising costs.
Existing Solution
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Case Study: Pulp refiner shaft sealing
Application
Existing Solution
Problem
High costs and frequent unscheduled downtime due to the unreliability in service of the compression packing, which was resulting in heavy leakage and the need for regular adjustment.
Compression packing
Voith Twin-Flow Refiner at a tissue production plant in the UK.
• Shaft diameter: 90 mm / 3½"(shaft sleeve 105 mm / 4")
• Shaft speed: 4.7 m/s (925 ft/min)
• Media: abrasive paper stock 3% to 5% concentration
Heavy leakage leading to increased maintenance
Results & Benefits
After more than 9 months the KlickFix® is still operating on the first sealing lip with no visible leakage, massively outperforming the compression packing.
With a further five sealing lips in the cartridge ready to be deployed when required, the lengthy service life of the KlickFix cartridge is already allowing the customer to realise significant benefits in maintenance planning.
No visible leakage in operation
Simplified maintenance planning
Zero leakage in operation
Reduced servicing and associated costs
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Case Study: Paper mill process pump shaft sealing
Application
Existing Equipment
Problem
Massive cost implications from a typical seal life of 9-11 months before unpredictable catastrophic failure - leading to a great deal of time spent on maintenance and clean up.
Cartridge mechanical seal
Single stage centrifugal process pump within a paper and board mill
• Shaft diameter: 57.15 mm
• Shaft speed: 1780 rpm
• Stuffing box pressure: 0.9 bar (13 psi) Flush pressure: 1.12 bar (16 psi)
• Media: paper stock 3% to 5% concentration
Frequent catastrophic failure in operation
James WalkerSolution
Results & Benefits
The KlickFix® unit has performed for over 3 years and 5 months leak free - an exceptional improvement to the previous solution. Not only has the customer saved money on the seals, they have been able to realise savings in terms of maintenance, production downtime and clean-up as a result of failure in operation. In addition, the flush rate has been reduced using the KlickFix by 90% to less than 2 US gallons per hour.
No leakage, no adjustment in over 3 years
Cost savings on maintenance, as well as savings from process improvement
No adjustment required in over 3 years
Zero leakage in operation in over 3 years
90% reduction in flush water consumption
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Let’s talk about value and benefits
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The key benefits of using KlickFix®
• Easy and quick to install - no special tools or expertise required
• Multiple sealing lips offer extended operational life
• Stored sealing lips can be deployed in seconds - bringing pumps back into service with minimal process interruption
• Predictable performance allows accurate planning of maintenance
• Long, trouble-free life, predictable in operation
• Easy on-site refurbishment and return to service
• Simple seal element refurbishment kit reduces cost of spares stockholding
• Low flush flow rate/consumption in abrasive applications (typically 0.1-0.15 l/min 0.026 - 0.040 US gal/min)
• Tolerant of dry running - can periodically run without flush
• Operates with a wide range of media due to PTFE sealing elements
• No/low leakage
• No adjustment required
• Minimises environmental impact by reducing flush requirements
• Simple/robust design with no moving parts
From this... to this
Behind the brand
“ KlickFix® is one of the best innovations I’ve seen in the last 10 years.”Paper Mill Engineer
"Where can I use ?"• Centrifugal process pumps and other rotary machinery
• Shaft sizes 38 mm to 114 mm / 1¹/2" to 4¹/2" (For other sizes consult your local James Walker company)
• Shaft running surface is 0.1 to 0.4 μmRa surface finish and 60 HRC hardness
• Maximum run-out 0.10 mm / 0.004" TIR (total indicated run-out)
• Maximum shaft speed 12 m/s (2,360 ft/min)
• Maximum chamber pressure 0.70 MPa (100 psi)
James Walker Sealing Products & Services Ltd
Registered Office: Lion House, Oriental Road, Woking, Surrey GU22 8AP, United Kingdom.
Reg no: 00264191 England
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James Walker Worldwide
Health warning: If PTFE products are heated to elevated temperatures, fumes will be produced which may give unpleasant effects, if inhaled. Whilst some fumes are emitted below 300°C (572°F) from PTFE, the effect at these temperatures is negligible. Care should be taken to avoid contaminating tobacco with particles of PTFE or PTFE dispersion, which may remain on hands or clothing. Safety Data Sheets (SDS) are available on request.
Information given in this publication is given in good faith and represents the results of specific individual tests carried out by James Walker or third parties in accordance with the methodologies described in this publication, performed in a laboratory. No representation or warranty is given in relation to such information. Values and/or operating limits given in this publication are not an indication that these values and/or operating limits can be applied simultaneously. While such results may comprise useful additional information and are industry standard tests, they are no substitute for conducting (or procuring from James Walker) your own tests and engineering analysis and satisfying yourself as to the suitability of the product you select. Please also note that a product tested in accordance with the published methodology may not perform to such values in application and/or under different test conditions or methodologies for a variety of reasons, including but not limited to the environment in which it is used/tested or which passes through it or otherwise affects the product, or due to the handling, storage or installation, or due to the effect of housing or other parts. Our personnel will be happy to discuss any historical examples we have of a product having been previously used in a particular application.
To ensure you are working with the very latest product specifications, please consult the relevant section of the James Walker website: www.jameswalker.biz.
Issue number 2.2
BN4771 0220/PDF© James Walker 2020
