Brush SealsGeneral Product Introduction

Issue No. 1 – 21 Aug 2013

WBC - Confidential

What is a brush seal?

• A brush seal is an “engineered” product.

• Brush seals utilize a “bristle pack” comprised of thousands of small diameter wires which follow shaft movement.

• Product Definition:– Defined as a compliant contacting seal

– Provides controlled leakage

– Classified as a circumferential seal

• Configuration:– Front and back plates

– Bristle Pack

– Circular and Linear geometries

– Solid, split and multi-segment

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Shaft

Front Plate

Bristle Pack

Back Plate

Flow

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Theory of Operation

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Labyrinth_Animation.wmv Brush_Animation.wmv

Rolled Over TeethCompliant

Bristle Pack

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Compliant bristles reduce the leakage gap resulting from traditional labyrinth seals

Rubs can be caused thermally or from rotor dynamics (critical speeds)

Ideal Applications for:

High excursions (rotor/stator interference)

Air, gas, and steam sealing

Pressure reduction

Equipment Types:

Gas Turbines

Steam Turbines

Centrifugal Compressors

Turboexpanders

Brush Seal Fundamentals

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Brush seals can reduce leakage up to 80% or more in certain

applications

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80’s – Aerospace Initiates Development

Early 90’s – R&D Contracts (US Gov’t, NASA, DOE)

Mid 90’s – Aerospace Acceptance with Jet Engines

Late 90’s – Industrial Gas Turbines and Large Steam Turbines Begin to Adopt Technology

Early 2000’s – Other Turbomachinery applications begin to develop (eg. compressors, expanders, etc.)

2008 – Eaton Aerospace extends exclusive license to Waukesha Bearings

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Brush Seals - History

US Patents 6,231,047 B1 and 7,461,847

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Brush Seal Characteristics

Operating Parameters

Pressures: Up to 300 psid (20 bars) per brush seal

Temperatures: Up to 1,200 F (650 C)

Surface Speeds: up to 1,100 ft/sec (335 m/s)

Environments: Gas Path (Air, Steam); Bearing (Air Management)

Materials of Construction

Housing: Stainless, Inconel, Bronze

Bristles: Haynes 25

Sizes and Configuration

Diameters up to 120” (3000 mm)

Low Profile (3/16” axial x 5/8” radial)

Solid, Split, and Multi-segmented Rings

Bristle Strip

Radial Height

Rotor

Fence Height

Flow

Back PlateFront Plate

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US Patent 6,231,047 B1

WBC - Confidential

Benefits of Waukesha’s Brush Seal

US Patent 6,231,047 B1

Lower Cost of Ownership

– Replaceable Bristle Pack

– Up to 30% Reduction in Replacement Costs

– 3 to 5 week Turn-time to Repair

Readily Available

– Flexible Strip and Rings cover ¾” diameters and up

– 6 to 8 week leadtimes on Modular Designs*

– 3 to 5 weeks on Augmented Labys **customer supplied labyrinth

Easy to Retrofit Existing Hardware

– < ¼” Axial Requirement (hook)

Proven Technology

– Aerospace qualified

Before After

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Competition – “Not Refurbishable”

Bristles welded between plates

Waukesha’s – “Refurbishable”

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Custom Engineered Solutions - Examples

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Modular Assemblies

Augmented Labyrinths

W501 GT

Steam Turbine

Steam Turbine (J-Strips)GE Frame GTGE Frame GT

Steam TurbineSteam Turbine Steam Turbine (Baffle)

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Typical Applications and Benefits

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Modular Assemblies

Augmented Labyrinths

Floating Brush Seals

Industrial Gas Turbines

Steam Turbines&

Compressors

Process Steam Turbines

Efficiency Gains (1-3%)Refurbishable (30% less)Quick Turns• New: 6 – 8 wks (GT)• Refurb: 3 -5 wks (GT)

Efficiency Gains (>2%)Replaceable (30% less)3 -5 wk Turn-around*

*customer supplied laby

Drop-in Replacement+3X life improvement• 3 yr vs 6-12 months

Applications Benefits/Differentiators

US Patents 6,231,047 B1 and 7,461,847

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Compressor Discharge (HPP) Bearing Sump Sealing Interstage Sealing

Common MachinesGas Turbine Applications – Brush Seals

Size range: 25MW and Up

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Industrial and Utility Steam Turbines

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Brush Seal vs Labyrinth – 5 Year Maintenance Cycle (Steam Turbine)

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2% Efficiency Improvement

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Monetarizing the Benefits of Increased Electricity Sales

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2% Efficiency Improvement

Assumptions

‒ 500MW Steam Turbine

‒ 24/7/365 Duty Cycle

‒ Brush Seals applied to End Packing Labys

‒ 2% Efficiency Gain

‒ 5 year maintenance cycle

‒ Electricity Rate: 0.06 USD/kw-hr

‒ $200K purchased in brush seals

REWARD TO END USER

• 10 additional MW per year to sell to grid• Additional Revenues:

• 1 day: $14.4K/day• 1 year: $5.3 M/yr • 5 years: $26.5M

• Brush Seal Payback : < 2 weeks

• Technology Risk: Low

Brush Seals can provide:

• An Immediate Payback

• A Low Risk Upgrade

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Centrifugal Compressors – Closed Impeller

Impeller Eye

Impeller Hub

(Shaft)

Balance Piston

Closed Type Impeller

Why consider WB’s brush seal?

Laby wear (Al)

Efficiency Gains

Tight Real Estate

Compliancy in AMBs

Equipment Types:

Pipeline compressors

Barrel compressors

Waste treatment blowers

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Centrifugal Compressors – Open Impeller

Why consider WB’s brush seal?

Laby wear (Al)

Efficiency Gains

Tight Real Estate

Compliancy in AMBs

Equipment Types:

Heat Recovery Systems

Turbo Expanders

Air compression (geared)

Open Type Impeller

brush seal locations

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Floating Brush Seals for Elliott YR TurbinesAvailable for AYR, BYR, CYR and DYR models

Up to 3x lifevs

carbon rings

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• Plug-n-Play Replacement split design provides direct replacement of carbon rings

• 3X Life Improvement demonstrated 3 yr life over 6 to 12 months with carbon rings

• Predictable leakage (low and stable) over an extended operating life compared to carbon rings

• Self – centering and lightweight utilizing carbon element which also provides effective cavity sealing

• Compliant brush seal allows “wear-in” to optimum fit and eliminates incorrect bore sizing problems

• Protects downstream carbon rings from contamination and high pressure

• Prevents secondary damage to bearings and leakage to atmosphere

• Highly resistant to corrosion and high temperatures

• Reduces maintenance, downtime and steam losses

steam

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Detailed Definition – Floating Brush Seals

Split assembly eliminates rotor removal for a plug-n-play replacement.

Retainer for Carbon

Carbon(centering & cavity sealing)

Retainer for Brush Seal

Brush Seal (radial sealing)

Spring(holds assembly

together)

Anti-Rotation Clip (not shown)

Split halves

Complete assembly

US Patent 7,461,847

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Steam Flow

WBC - Confidential

Sentinel™ FBS - Characteristics

Operating Parameters

Pressures: Up to 150 psid (10 bar)

Temperatures: Up to 850 F (450 C)

Surface Speeds: up to 160 ft/sec (50 m/s)

Environment: Steam

Configuration and Materials

Split ring assembly (two-halves)

Aerospace qualified bristle ring

Specialty grade carbon ring

Stainless steel components

Available Designs

Elliott AYR/BYR: 2.25” (57.15mm) shaft

Elliott CYR/DYR: 3” (76.20mm) shaft

Other designs available upon request

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Operating Parameters are limited to the performance of the carbon element.

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Our Capabilities – Brush Seals

Engineering and Test

‒ Proprietary design code to model seal leakage and rotor-dynamics effects

‒ Custom seal designs

‒ Reverse engineered seals

• Frame Gas Turbines

• Steam Turbines

‒ Static test capability

‒ Dynamic test under-development

Manufacturing and Assembly

‒ (2) locations (25,000 sq ft ea)

• Houston, Texas (Bearings Plus)

• Rhode Island (Waukesha Bearings)

‒ 2014 Expansion (180,000sq. ft facility)

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Application Check List (for Custom Seal Designs)

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General Information

Turbine Make/Model

Brush seal location

No. Seals Required

Date Hardware Required

Operating Conditions

Rotor speed

Sealed fluid

Upstream pressure

Downstream pressure

Temperature upstream

Temperature downstream

Application Details

Provide drawing of area where seal would be located

Labyrinth material, if used

Diameter and tolerance of rotor

Rotor material

Provide details on rotor coating or sleeve, if applicable

Centrifugal growth

Thermal growth

Max. radial excursions

Bearing clearance

Axial movement of rotor

Max. housing/rotor closure

Dynamic radial movement

Housing concentricity to rotor

Describe any unique operating conditions that should be considered in designing the seal (e.g. fast start, reverse pressurization, reverse rotation, pressure/flow slugs, etc.)

Data inquiry form available on WB and BPI websites

Bristle Strip

Radial Height

Rotor

Fence Height

Flow

Back PlateFront Plate

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General Information

Turbine Make/Model

Brush seal location

OEM Part Number

No. Seals Required

Date Hardware Required

Application Details

Preferred - Provide sample of new or used brush seal, (if used how many hours were logged?)

Alternative – Provide drawing of seal inclusive of all features to ensure proper fit-up

Provide pictures of hardware

Provide any applicable performance data on existing seal (before/after) and/or description of any unique operating conditions

Application Check List (for Reversed Engineered Seals)

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Why Choose Brush Seals and Waukesha?

• Replaceable Bristle Pack

• Low Risk Upgrade

• Favorable Payback

• Demonstrated Experience

• Technical Know-how

• Solutions Oriented

• Global Reach and Support

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