Industry Solutions

I. Project Background and Current Situation Analysis

1.1 Project Background

Due to policy adjustment requirements, a large chemical enterprise in Hebei Province needs to renovate a batch of existing single-face mechanical seals into double-face ones. Entrusted by the enterprise, our company dispatched technical and after-sales personnel to conduct on-site investigations, aiming to formulate a scientific and efficient renovation plan to ensure the smooth implementation of the project.

1.2 On-site Current Situation Analysis

Continuous production demand: The project needs to be carried out without interrupting the enterprise's normal production, which places extremely high requirements on the construction time window and operation process planning, and the shutdown renovation time of a single piece of equipment must be shortened as much as possible.

Non-unified equipment manufacturers: On-site equipment is from different manufacturers with varying models and specifications, leading to inconsistent mechanical seal installation interfaces and adaptation standards, which increases the complexity and customization needs of the renovation.

Differences in frame height: The frame height of some equipment does not match the installation requirements of double-face mechanical seals. Frames that fail to meet the requirements need to be replaced or structurally adjusted to ensure the installation space and operational stability of the mechanical seals.

Problems with the connection position of the stirring shaft: The connection position of the stirring shaft and the mechanical seal has insufficient height and unqualified finish. Insufficient height will result in incorrect alignment and installation of the mechanical seal, while unqualified finish will affect the sealing performance and service life. This part needs to be renovated or the stirring shaft replaced as a whole.

II. Renovation Objectives

Compliance: Ensure that the renovated double-face mechanical seals meet the latest policy requirements and relevant industry standards, satisfying work safety and environmental protection regulations.

Minimal production impact: Minimize equipment downtime through scientific planning, reduce interference to the enterprise's continuous production, and ensure the on-time completion of production tasks.

Reliability: The renovated mechanical seal system shall have good sealing performance, stability and durability, reducing the later maintenance costs.

Adaptability: Provide customized solutions for equipment from different manufacturers, frame height issues and stirring shaft problems to ensure the coordinated and efficient operation of the renovated equipment.

III. Renovation Plan

3.1 Equipment Surveying and Mapping & Plan Design

Surveying and mapping schedule: Arrange 3-5 days for comprehensive on-site surveying and mapping. Technical personnel will use high-precision measuring tools (such as laser rangefinders, dial indicators, micrometers, etc.) to conduct detailed measurement and recording of key parameters of each equipment to be renovated, including frame height, stirring shaft diameter, length, connection position dimensions, equipment precision and installation space, and draw equipment layout plans and 3D models of key components.

Customized planning: Formulate differentiated renovation plans for different equipment based on surveying and mapping data and on-site actual conditions.

3.2 Recommendation of Equipment Manufacturers

Considering factors such as equipment quality, performance, price, delivery cycle and after-sales service comprehensively, the following well-reputed manufacturers in the industry are recommended:

Mechanical seal manufacturers: Zhejiang Lantian Mechanical Seal Co., Ltd. is recommended. Its double-face mechanical seal products feature mature technology and excellent sealing performance, and it can provide customized services to adapt to different working conditions.

Frame and stirring shaft manufacturers: Local or surrounding heavy machinery processing enterprises with good cooperative relations are recommended. They have strong processing capacity and rapid response capacity, can produce accurately according to our design drawings, and ensure the delivery cycle and product quality.

3.3 Production Arrangement

Procurement of materials and components: Immediately initiate the procurement and customized production process of key components such as mechanical seals, frames and stirring shafts after the completion of surveying and mapping and confirmation of the plan. Sign supply contracts with manufacturers, clarify quality standards, delivery time and liability for breach of contract to ensure the on-time arrival of components. The production cycle of mechanical seals and customized components is expected to be 5 weeks.

Production progress tracking: Assign a dedicated person to connect with equipment manufacturers, track the production progress regularly, and coordinate and solve problems arising in the production process in a timely manner to ensure the on-schedule completion of component production.

3.4 On-site Renovation Implementation and Guidance

Pre-construction preparation: Communicate with the customer in advance to determine the shutdown renovation time window for each piece of equipment, and formulate detailed construction plans and emergency plans. Prepare required tools, measuring instruments, hoisting equipment and safety protective articles, and conduct technical disclosure and safety training for construction personnel.

Phased renovation: Arrange the equipment renovation sequence reasonably according to the enterprise's production plan, and adopt the method of "small batches and multiple phases" to avoid major impacts on production caused by centralized shutdowns. The renovation of a single piece of equipment shall be completed within 8-12 hours as far as possible.

Installation and commissioning: Replace/adjust frames, replace/renovate stirring shafts and install double-face mechanical seals in strict accordance with the renovation plan and equipment installation instructions. Conduct static and dynamic commissioning after installation, and check whether the mechanical seal performance, equipment operation stability and various parameters meet the requirements.

Technical guidance and training: Our technical personnel provide on-site technical guidance throughout the renovation process to ensure construction quality. After the completion of the renovation, conduct training for the enterprise's operators and maintenance personnel on the use, daily maintenance and troubleshooting of mechanical seals.

3.5 Quality Control and Acceptance

Quality control: Strictly implement the quality inspection system in every link from component procurement and production to on-site installation and commissioning to ensure all components meet the design requirements and relevant standards.

Acceptance criteria: Conduct acceptance in accordance with national relevant standards and the technical indicators agreed by both parties, including the mechanical seal leakage rate, stable equipment operation, and vibration and temperature within normal ranges.

IV. Project Time Plan (Example)

V. Safeguard Measures

Organizational guarantee: Set up a special project team, with an experienced project manager responsible for overall coordination and technical backbones responsible for plan design and on-site guidance to ensure the efficient progress of the project.

Technical guarantee: Rely on the company's professional technical team and rich renovation experience to provide strong technical support for the project and solve technical problems in the renovation process in a timely manner.

Safety guarantee: Strictly abide by the enterprise's work safety regulations, implement various safety protection measures to ensure accident-free construction process.

After-sales guarantee: Provide a 12-month warranty period after the completion of the renovation, offer free technical support and maintenance services within the warranty period, and conduct regular follow-up visits to understand the equipment operation status.

Through the above comprehensive and detailed renovation planning, our company will high-quality complete the project of converting single-face mechanical seals to double-face ones on the premise of meeting the enterprise's continuous production needs, effectively solve on-site problems such as equipment differences and stirring shaft issues, and provide strong guarantee for the enterprise's work safety and compliant operation.