original hydrosele usa issue 3
TRANSCRIPT
®
High Performance Sealing Technology
Innovative rotary sealing cartridge systems that offer
! Greatly reduced turbine downtime
! Minimal leakage
! Major cost savings
®HydroSele total sealing systems for Water Turbine Shafts
®
Registered Office: Lion House, Oriental Road, Woking, Surrey GU22 8AP, UK. Reg No. 2432592 © James Walker 2008
England
CERTIFICATE No. FM 01269BS EN ISO 9001:2000
BP 4302 508/2mCPN000083831
Health warning: If PTFE or fluoroelastomer (eg, FKM, FFKM, FEPM) products are heated to elevated temperatures, fumes will be produced which may give unpleasant effects, if inhaled. Whilst some fumes are emitted below 250°C from fluoroelastomers or below 300°C from PTFE, the effect at these temperatures is negligible. Care should be taken to avoid contaminating tobacco with particles of PTFE or fluoroelastomer, or with PTFE dispersion, which may remain on hands or clothing. Material Safety Data Sheets (MSDS) are available on request.
Information in this publication and otherwise supplied to users is based on our general experience and is given in good faith, but because of factors which are outside our knowledge and control and affect the use of products, no warranty is given or is to be implied with respect to such information. Specifications are subject to change without notice. Statements of operating limits quoted in this publication are not an indication that these values can be applied simultaneously.
James Walker & Co LtdPower Generation Industry Support Team1 Millennium Gate, Westmere DriveCrewe, Cheshire CW1 6AY, UKTel: +44 (0)1270 536000Fax: +44 (0)1270 536100Email: [email protected]
James Walker & CoTel: +44(0)1270 536000Fax: +44(0)1270 536100Email: [email protected]
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James Walker companies worldwide
High Performance Sealing Technology
Issue 3
Innovative rotary sealing cartridge systems that offer
● Greatly reduced turbine downtime
● Minimal leakage
● Major cost savings
● Full system compatibility
HydroSele® total sealing systems forWater Turbine Shafts
To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz2 To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz2
What is HydroSele ?®
® The innovative HydroSele S
®HydroSele is James Walker's family of
innovative cartridge seals for the shafts
of water turbines. It is the result of over
12 years of design, development and
operational experience on Francis and
Kaplan equipment working under a
wide variety of conditions.
Our sole objective has been to produce
cartridge seals of superior reliability that
greatly improve a turbine's
! Cost efficiency, and
! Operational performance.
Swift payback on investment®
Our innovative HydroSele S offers
significant cost savings by being
retrofitted and fully operational in half the
time of a traditional mechanical seal.
In less than two years, it should have
paid for itself in terms of maintenance
costs, turbine downtime and power
absorption.
At four years, your total investment in
cash and downtime could be just one-
quarter of that for an equivalent
mechanical seal.
Long & reliable service
HydroSele S prototypes are still running
trouble-free after 12 years of operation.
This outstanding reliability enables you to
schedule your maintenance with absolute
confidence.
Simple to install & adjustment-free
HydroSele S is one of the easiest sealing
arrangements to fit on a turbine shaft.
With our technical expertise, your
downtime is cut to a minimum — and the
cartridge sealing unit is totally adjustment-
free once installed.
Economical refurbishment
It takes just hours rather than days to
refurbish our innovative HydroSele. You
no longer need to hold expensive standby
sealing units in stock.
High efficiency sealing
HydroSele's unique method of operation
gives a very low and controlled level of
leakage. This greatly reduces the risk of
flood damage to plant caused by
uncontrolled leakage past sealing faces.
Low power consumption
HydroSele S has an exceptionally low
torque requirement compared to
traditional mechanical seals.
Worldwide technical support
Every HydroSele installation is fully
supported by James Walker's global
network of specialists in high performance
sealing technology.
Field trials, backed by commercial
operations since 2006, show that our
HydroSele systems offer the best long-
term value for money of any shaft sealing
arrangement for many Francis and Kaplan
turbines.
Our HydroSele offer
We will:
! Custom-manufacture the seal from
modular components to suit your
specific application.
! Install the seal on site for you.
! Fully support your HydroSele system
with worldwide technical advice and
refurbishment services.
® Why fit HydroSele S?
®HydroSele S offers many unique financial and
operational benefits over other sealing systems
used on Francis and Kaplan turbines
2. 3.
We are constantly developing our ®HydroSele family to provide a total shaft-
sealing service to OEMs and operators of
water turbines. Current family includes:®HydroSele S — the innovative rotary
cartridge seal for turbine shafts (p3-7).®HydroSele MS — S type plus
maintenance seal (p8).®HydroSele RS — S type with reversed
inner element (p8).®HydroSele W — cartridge containing a
®single Walkersele radial lip seal (p9).®HydroSele WT — cartridge with two
Walkersele lip seals in tandem (p9).®HydroSele WB — cartridge with two
Walkerseles back-to-back (p9). ®HydroSele Total Service — ancillary
equipment and services (p10).
Other variants and combinations of
HydroSele can be custom-designed,
including 'floating' versions to cater for
higher levels of shaft eccentricity.
Extended familyWhat is HydroSele® ? Extended familyHydroSele® is James Walker's family ofinnovative cartridge seals for the shaftsof water turbines. It is the result of over12 years of design, development andoperational experience on Francis andKaplan equipment working under awide variety of conditions.
Our sole objective has been to producecartridge seals of superior reliability thatgreatly improve a turbine's•Costefficiency,and•Operationalperformance.
We are constantly developing ourHydroSele® family to provide a total shaftsealing service to OEMs and operatorsofwaterturbines. Currentfamilyincludes:HydroSele® S — the innovative rotarycartridgesealforturbineshafts(p3-7).HydroSele® MS — S type plusmaintenanceseal(p8).HydroSele® RS — S type with reversedinnerelement(p8).HydroSele® W — cartridge containing asingle Walkersele®radiallipseal(p9).HydroSele® WT — cartridge with twoWalkerselelipsealsintandem(p9).HydroSele® WB — cartridge with twoWalkerselesback-to-back(p9).HydroSele® Total Service — ancillaryequipmentandservices(p10).
Other variants and combinations ofHydroSelecanbecustom-designed,including 'floating' versions to cater forhigherlevelsofshafteccentricity.
Fieldtrials,backedbycommercialoperationssince2006,showthatourHydroSele systems offer the best long-term value for money of any shaft sealing arrangement for many Francis and Kaplan turbines.
Our HydroSele offerWewill:•Custom-manufacturethesealfrom
modular components to suit your specificapplication.
•Supporttheinstallationofthesealonsitewithyou.
•FullysupportyourHydroSelesystemwith worldwide technical advice and refurbishmentservices.
3To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz 3
What is HydroSele ?®
® The innovative HydroSele S
®HydroSele is James Walker's family of
innovative cartridge seals for the shafts
of water turbines. It is the result of over
12 years of design, development and
operational experience on Francis and
Kaplan equipment working under a
wide variety of conditions.
Our sole objective has been to produce
cartridge seals of superior reliability that
greatly improve a turbine's
! Cost efficiency, and
! Operational performance.
Swift payback on investment®
Our innovative HydroSele S offers
significant cost savings by being
retrofitted and fully operational in half the
time of a traditional mechanical seal.
In less than two years, it should have
paid for itself in terms of maintenance
costs, turbine downtime and power
absorption.
At four years, your total investment in
cash and downtime could be just one-
quarter of that for an equivalent
mechanical seal.
Long & reliable service
HydroSele S prototypes are still running
trouble-free after 12 years of operation.
This outstanding reliability enables you to
schedule your maintenance with absolute
confidence.
Simple to install & adjustment-free
HydroSele S is one of the easiest sealing
arrangements to fit on a turbine shaft.
With our technical expertise, your
downtime is cut to a minimum — and the
cartridge sealing unit is totally adjustment-
free once installed.
Economical refurbishment
It takes just hours rather than days to
refurbish our innovative HydroSele. You
no longer need to hold expensive standby
sealing units in stock.
High efficiency sealing
HydroSele's unique method of operation
gives a very low and controlled level of
leakage. This greatly reduces the risk of
flood damage to plant caused by
uncontrolled leakage past sealing faces.
Low power consumption
HydroSele S has an exceptionally low
torque requirement compared to
traditional mechanical seals.
Worldwide technical support
Every HydroSele installation is fully
supported by James Walker's global
network of specialists in high performance
sealing technology.
Field trials, backed by commercial
operations since 2006, show that our
HydroSele systems offer the best long-
term value for money of any shaft sealing
arrangement for many Francis and Kaplan
turbines.
Our HydroSele offer
We will:
! Custom-manufacture the seal from
modular components to suit your
specific application.
! Install the seal on site for you.
! Fully support your HydroSele system
with worldwide technical advice and
refurbishment services.
® Why fit HydroSele S?
®HydroSele S offers many unique financial and
operational benefits over other sealing systems
used on Francis and Kaplan turbines
2. 3.
We are constantly developing our ®HydroSele family to provide a total shaft-
sealing service to OEMs and operators of
water turbines. Current family includes:®HydroSele S — the innovative rotary
cartridge seal for turbine shafts (p3-7).®HydroSele MS — S type plus
maintenance seal (p8).®HydroSele RS — S type with reversed
inner element (p8).®HydroSele W — cartridge containing a
®single Walkersele radial lip seal (p9).®HydroSele WT — cartridge with two
Walkersele lip seals in tandem (p9).®HydroSele WB — cartridge with two
Walkerseles back-to-back (p9). ®HydroSele Total Service — ancillary
equipment and services (p10).
Other variants and combinations of
HydroSele can be custom-designed,
including 'floating' versions to cater for
higher levels of shaft eccentricity.
Extended family Why fit HydroSele® S?Swift payback on investmentOur innovative HydroSele® S offerssignificantcostsavingsbybeingretrofittedandfullyoperationalinhalfthetimeofatraditionalmechanicalseal.
In less than two years, it should havepaid for itself in terms of maintenancecosts,turbinedowntimeandpowerabsorption.
At four years, your total investment incash and downtime could be just one-quarter of that for an equivalentmechanicalseal.
Long & reliable serviceHydroSele S prototypes are still runningtrouble-freeafter12yearsofoperation.This outstanding reliability enables you toschedule your maintenance with absoluteconfidence.
Low power consumptionHydroSele S has an exceptionally lowtorque requirement compared totraditionalmechanicalseals.
Worldwide technical supportEvery HydroSele installation is fullysupported by James Walker's globalnetwork of specialists in high performancesealingtechnology.
Simple to install & adjustment-freeHydroSele S is one of the easiest sealingarrangementstofitonaturbineshaft.Withourtechnicalexpertise,yourdowntime is cut to a minimum — and thecartridge sealing unit is totally adjustment-freeonceinstalled.
Economical refurbishmentIt takes just hours rather than days torefurbishourinnovativeHydroSele.Youno longer need to hold expensive standbysealingunitsinstock.
High efficiency sealingHydroSele's unique method of operationgives a very low and controlled level ofleakage.Thisgreatlyreducestheriskofflood damage to plant caused byuncontrolledleakagepastsealingfaces.
The innovative HydroSele® S
HydroSele® S offers many unique financial and
operational benefits over other sealing systems
used on Francis and Kaplan turbines
HydroSele® S in operationShaft diameter
Surface finish:
Surface hardness:
Diameter tolerance:
Maximum permissible shaft runout:
Inlet flush requirements
Pressure:
Filtration:
Equipment surface or adapter plate
Surface finish:
Flatness:
Cartridge outside diameter
0.4 to 0.8µm Ra (CLA 16 to 32µin)
33 HRC minimum
ISO 286-2/BS EN 20286-2 h8
Please consult James Walker.
To be maintained at a minimum of 2bar (29psi) above maximum system pressure.A through-flow flush system is generally recommended.
100µm (0.004in) or better
0.4 to 0.8µm Ra (CLA 16 to 32µin)
Within 0.05mm (0.002in)
Cartridge to be located in a counter-bored recess 5.00mm (0.197in) deep with a fit based on ISO 286-2/BS EN 20286-2;
®HydroSele S operating capabilities
Shaft diameters: 250 - 1000mm(9.84 - 39.37in)
Please consult James Walker if your shaft diameter exceeds 1000mm (39.37in).
Maximum pressure at gland: 10bar* gauge(145psi* gauge)
Maximum shaft speed: 20m/s*(3937fpm*)
Maximum temperature: 50°C (122°F) at seal/flush water interface
Flush water pressure: 2bar (29psi) above system pressure.
(*These values will be size dependent and may not necessarily be applied simultaneously)
®HydroSele S is a fully split cartridge assembly, containing two
sealing elements working back-to-back with flush water
introduced between them Simple in concept yet ingenious
®in operation, HydroSele S
relies on engineering
excellence for its outstanding
sealing performance
4.
Compact cartridge®HydroSele S is a compact bolt-
on sealing unit that can readily
be installed where housing
space is limited.
® Standard sizes for SHydroSele
5.
®HydroSele S
M16 bolts equi-spaced on E PCD
Dynamic sealing elements
Adapter plate
Shaft sleeve
ØC (location position) Tol: H9
ØA Tol: h9
Shaft (A)Equal toor above
Below Numberof bolts
BoltingPCD (E)
Threaddepth (F)
Locationdiameter
(C)
Overalldepth
(B)
Bolting details Flush pipe fitting (G)DIN ISO 228 Parallel
A+5.512A+6.299A+7.097
81216
A+3.819G3/8
G3/4
1.1811.575
3.4654.7444.843
19.68527.55939.370
9.84319.68527.559
Inch sizes
Tolerances ± 0.004 except where shown
A+140A+160A+180
Shaft (A)Equal toor above
Below Numberof bolts
BoltingPCD (E)
Threaddepth (F)
Locationdiameter
(C)
Overalldepth
(B)
Bolting details Flush pipe fitting (G)DIN ISO 228 Parallel
81216
A+97G3/8
G3/4
3040
88.0120.5123.0
500700
1000
250500700
Metric sizes in mm (apart from G in inches)
Tolerances ± 0.1 except where shown
To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz4
HydroSele® S in operationShaft diameter
Surfacefinish:
Surfacehardness:
Diametertolerance:
Maximumpermissibleshaftrunout:
Inlet flush requirements
Pressure:
Filtration:
Equipment surface or adapter plate
Surfacefinish:
Flatness:
Cartridge outside diameter
HydroSele® S operating capabilities
Shaftdiameters: 250-1000mm (9.84-39.37in)
Please consult James Walker if your shaftdiameterexceeds1000mm(39.37in).
Maximumpressureatgland:10bar*gauge (145psi*gauge)
Maximumshaftspeed: 20m/s* (3937fpm*)
Maximumtemperature: 50°C(122°F)at seal/flushwater interface
Flushwaterpressure: 2bar(29psi) above system pressure.
(*Thesevalueswillbesizedependentandmaynot necessarily be applied simultaneously)
0.4to0.8μmRa(CLA16to32μin)
33HRCminimum
ISO286-2/BSEN20286-2h8
PleaseconsultJamesWalker.
To be maintained at a minimum of 2bar(29psi)abovemaximumsystempressure.Athrough-flowflushsystemisgenerallyrecommended.
100μm(0.004in)orbetter
0.4to0.8μmRa(CLA16to32μin)
Within0.05mm(0.002in)
Cartridgetobelocatedinacounter-boredrecess5.00mm(0.197in)deepwithafitbasedonISO286-2/BSEN20286-2;H9/f8oncartridgeoutsidediameter
HydroSele® S
5To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz 5
Standard sizes for HydroSele® S
Simple in concept yet ingenious
in operation, HydroSele® S
relies on engineering
excellence for its outstanding
sealing performance
Compact cartridge
HydroSele® S is a compact bolt-on sealing unit that can readily be installed
where housing space is limited.
Metric sizes in mm (apart from G in inches)
Shaft (A) Overalldepth
(B)
Locationdiameter
(C)
Bolting detailsFlush pipe fitting (G)DIN ISO 228 ParallelEqual to
or aboveBelow Number
of boltsBoltingPCD (E)
Threaddepth (F)
250 500 88.0 A+140 8
A+97
30G3/8
500 700 120.5 A+160 1240
700 1000 123.0 A+180 16 G3/4
Tolerances±0.1exceptwhereshown
Inch sizes
Shaft (A) Overalldepth
(B)
Locationdiameter
(C)
Bolting detailsFlush pipe fitting (G)DIN ISO 228 ParallelEqual to or
aboveBelow Number
of boltsBoltingPCD (E)
Threaddepth (F)
9.843 19.685 3.465 A+5.512 8
A+3.819
1.181G3/8
19.685 27.559 4.744 A+6.299 121.575
27.559 39.370 4.843 A+7.097 16 G3/4
Tolerances±0.004exceptwhereshown
®HydroSele S is modular in
concept, with each component
designed and precision
manufactured to fit together
perfectly around the turbine
shaft without stripping down the
housing.
Modular concept
1. 3.
2.
4.
5.
6. 7.
® HydroSele relaxed
The ported pressure face (A) allows fluid
to the outside diameter of the housing.
The un-ported atmosphere face (B),
however, forms a static seal that prevents
the fluid from continuing around the back
of the seal to atmosphere.
Because the sealing element is
manufactured to have a small clearance
on the shaft, the fluid can also pass
between the shaft and the running sleeve
of the sealing element.
S If the sleeve were rigid, the pressure
would drop almost linearly along this
route, and leakage would be high. Instead
the pressure distributions on the outside
and inside of the seal produce a turning
moment (M) that tilts the seal to bring the
'atmosphere' edge of the seal sleeve into
close proximity to the shaft, stemming the
leakage.
The under-sleeve pressure then backs-up
to produce a distribution approximating to
that shown — with most of the pressure
drop occurring near the atmosphere edge
of the seal sleeve.
Each of the three metal rings is fully-split
and fitted with locator pins for accurate
realignment. The two sealing elements
and three 'O' rings have single splits.
The unit is installed simply by fitting each
component in sequence around the shaft,
with the bolt holes aligned through the
metal rings.
All modules of the fully assembled
HydroSele are held accurately and firmly
in position by the bolts that fasten the
cartridge to the adapter plate or
equipment surface beneath.
®HydroSele S construction
® How HydroSele S worksHydroSele energised
Loaded contact between the sealing
element and shaft is prevented by the
hydrodynamic pressure generated in the
thin fluid film that is created by shaft
rotation. Equilibrium is therefore set up
between the closing and opening forces
acting on the sealing element.
This results in a seal that is virtually
pressure balanced (providing high
pressure capability) and running on a
hydrodynamic film (providing high speed
capability), with a low level of controlled
leakage.
® S OD pressure
ID pressure
OD pressure
ID pressure
M
A B
To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz6
How HydroSele® S worksHydroSele® S relaxedTheportedpressureface(A)allowsfluidtotheoutsidediameterofthehousing.Theun-portedatmosphereface(B),however,formsastaticsealthatpreventsthe fluid from continuing around the backofthesealtoatmosphere.
Becausethesealingelementismanufactured to have a small clearanceontheshaft,thefluidcanalsopassbetween the shaft and the running sleeveofthesealingelement.
Ifthesleevewererigid,thepressurewould drop almost linearly along thisroute,andleakagewouldbehigh.Insteadthe pressure distributions on the outsideand inside of the seal produce a turningmoment (M) that tilts the seal to bring the'atmosphere' edge of the seal sleeve intocloseproximitytotheshaft,stemmingtheleakage.
The under-sleeve pressure then backs-upto produce a distribution approximating tothat shown — with most of the pressuredrop occurring near the atmosphere edgeofthesealsleeve.
®HydroSele S is modular in
concept, with each component
designed and precision
manufactured to fit together
perfectly around the turbine
shaft without stripping down the
housing.
Modular concept
1. 3.
2.
4.
5.
6. 7.
® HydroSele relaxed
The ported pressure face (A) allows fluid
to the outside diameter of the housing.
The un-ported atmosphere face (B),
however, forms a static seal that prevents
the fluid from continuing around the back
of the seal to atmosphere.
Because the sealing element is
manufactured to have a small clearance
on the shaft, the fluid can also pass
between the shaft and the running sleeve
of the sealing element.
S If the sleeve were rigid, the pressure
would drop almost linearly along this
route, and leakage would be high. Instead
the pressure distributions on the outside
and inside of the seal produce a turning
moment (M) that tilts the seal to bring the
'atmosphere' edge of the seal sleeve into
close proximity to the shaft, stemming the
leakage.
The under-sleeve pressure then backs-up
to produce a distribution approximating to
that shown — with most of the pressure
drop occurring near the atmosphere edge
of the seal sleeve.
Each of the three metal rings is fully-split
and fitted with locator pins for accurate
realignment. The two sealing elements
and three 'O' rings have single splits.
The unit is installed simply by fitting each
component in sequence around the shaft,
with the bolt holes aligned through the
metal rings.
All modules of the fully assembled
HydroSele are held accurately and firmly
in position by the bolts that fasten the
cartridge to the adapter plate or
equipment surface beneath.
®HydroSele S construction
® How HydroSele S worksHydroSele energised
Loaded contact between the sealing
element and shaft is prevented by the
hydrodynamic pressure generated in the
thin fluid film that is created by shaft
rotation. Equilibrium is therefore set up
between the closing and opening forces
acting on the sealing element.
This results in a seal that is virtually
pressure balanced (providing high
pressure capability) and running on a
hydrodynamic film (providing high speed
capability), with a low level of controlled
leakage.
® S OD pressure
ID pressure
OD pressure
ID pressure
M
A B
®HydroSele S is modular in
concept, with each component
designed and precision
manufactured to fit together
perfectly around the turbine
shaft without stripping down the
housing.
Modular concept
1. 3.
2.
4.
5.
6. 7.
® HydroSele relaxed
The ported pressure face (A) allows fluid
to the outside diameter of the housing.
The un-ported atmosphere face (B),
however, forms a static seal that prevents
the fluid from continuing around the back
of the seal to atmosphere.
Because the sealing element is
manufactured to have a small clearance
on the shaft, the fluid can also pass
between the shaft and the running sleeve
of the sealing element.
S If the sleeve were rigid, the pressure
would drop almost linearly along this
route, and leakage would be high. Instead
the pressure distributions on the outside
and inside of the seal produce a turning
moment (M) that tilts the seal to bring the
'atmosphere' edge of the seal sleeve into
close proximity to the shaft, stemming the
leakage.
The under-sleeve pressure then backs-up
to produce a distribution approximating to
that shown — with most of the pressure
drop occurring near the atmosphere edge
of the seal sleeve.
Each of the three metal rings is fully-split
and fitted with locator pins for accurate
realignment. The two sealing elements
and three 'O' rings have single splits.
The unit is installed simply by fitting each
component in sequence around the shaft,
with the bolt holes aligned through the
metal rings.
All modules of the fully assembled
HydroSele are held accurately and firmly
in position by the bolts that fasten the
cartridge to the adapter plate or
equipment surface beneath.
®HydroSele S construction
® How HydroSele S worksHydroSele energised
Loaded contact between the sealing
element and shaft is prevented by the
hydrodynamic pressure generated in the
thin fluid film that is created by shaft
rotation. Equilibrium is therefore set up
between the closing and opening forces
acting on the sealing element.
This results in a seal that is virtually
pressure balanced (providing high
pressure capability) and running on a
hydrodynamic film (providing high speed
capability), with a low level of controlled
leakage.
® S OD pressure
ID pressure
OD pressure
ID pressure
M
A B
7To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz 7
HydroSele® S energizedLoadedcontactbetweenthesealingelement and shaft is prevented by thehydrodynamic pressure generated in thethinfluidfilmthatiscreatedbyshaftrotation.Equilibriumisthereforesetupbetween the closing and opening forcesactingonthesealingelement.
This results in a seal that is virtuallypressure balanced (providing highpressure capability) and running on ahydrodynamicfilm(providinghighspeedcapability),withalowlevelofcontrolledleakage.
®HydroSele S is modular in
concept, with each component
designed and precision
manufactured to fit together
perfectly around the turbine
shaft without stripping down the
housing.
Modular concept
1. 3.
2.
4.
5.
6. 7.
® HydroSele relaxed
The ported pressure face (A) allows fluid
to the outside diameter of the housing.
The un-ported atmosphere face (B),
however, forms a static seal that prevents
the fluid from continuing around the back
of the seal to atmosphere.
Because the sealing element is
manufactured to have a small clearance
on the shaft, the fluid can also pass
between the shaft and the running sleeve
of the sealing element.
S If the sleeve were rigid, the pressure
would drop almost linearly along this
route, and leakage would be high. Instead
the pressure distributions on the outside
and inside of the seal produce a turning
moment (M) that tilts the seal to bring the
'atmosphere' edge of the seal sleeve into
close proximity to the shaft, stemming the
leakage.
The under-sleeve pressure then backs-up
to produce a distribution approximating to
that shown — with most of the pressure
drop occurring near the atmosphere edge
of the seal sleeve.
Each of the three metal rings is fully-split
and fitted with locator pins for accurate
realignment. The two sealing elements
and three 'O' rings have single splits.
The unit is installed simply by fitting each
component in sequence around the shaft,
with the bolt holes aligned through the
metal rings.
All modules of the fully assembled
HydroSele are held accurately and firmly
in position by the bolts that fasten the
cartridge to the adapter plate or
equipment surface beneath.
®HydroSele S construction
® How HydroSele S worksHydroSele energised
Loaded contact between the sealing
element and shaft is prevented by the
hydrodynamic pressure generated in the
thin fluid film that is created by shaft
rotation. Equilibrium is therefore set up
between the closing and opening forces
acting on the sealing element.
This results in a seal that is virtually
pressure balanced (providing high
pressure capability) and running on a
hydrodynamic film (providing high speed
capability), with a low level of controlled
leakage.
® S OD pressure
ID pressure
OD pressure
ID pressure
M
A B
Modular concept
HydroSele® S is modular in
concept, with each component
designed and precision
manufactured to fit together
perfectly around the turbine
shaft without stripping down the
housing.
Each of the three metal rings is fully-splitandfittedwithlocatorpinsforaccuraterealignment.Thetwosealingelementsandthree'O'ringshavesinglesplits.
Theunitisinstalledsimplybyfittingeachcomponentinsequencearoundtheshaft,with the bolt holes aligned through themetalrings.
AllmodulesofthefullyassembledHydroSeleareheldaccuratelyandfirmlyin position by the bolts that fasten thecartridge to the adapter plate orequipmentsurfacebeneath.
HydroSele® S construction
To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz8
HydroSele® MS HydroSele® RSThis enhanced version of HydroSele® Sallows maintenance of the primary sealingelements to be carried out safely andswiftlywiththecartridgeinsitu.
The inner housing ring is adapted toincorporateanexternallyenergizedmaintenance seal that sits well clear of theshaftsleevewhiletheturbineisrunning.During turbine shut-down themaintenancesealisenergizedtomakeintimate contact with the shaft sleeve andprovidehigh-efficiencystaticsealing.
Themaintenancesealisenergizedeitherby automatic diversion of the cartridgeflushwater,orbyseparatepressurizedwaterorairsupplies.
This is designed for situations where awater-lubricated bearing is locatedimmediately inboard of the HydroSele®.
The inner dynamic sealing element isfittedinthereversedirection,andenergizedbypressurizedcleanwaterwithinthebearing.Thesamewaterassupplied to the bearing is also fed to theHydroSele flush ring at lower pressure tolubricateandcoolthesealassembly.
The result is an exceptionally stablesealing system with very low leakage andminimaladditionalpipework.
HydroSele® variants
9To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz 9
HydroSele® W HydroSele® WT HydroSele® WBOur HydroSele® W range comprises splitcartridges that house James Walker'srenowned Walkersele® D7 rotary shaft lipseals.Thisstandardversionhasasinglesealingelementinthecartridge.
Moldedintough,waterresistantelastomers,WalkerseleD7isidealforlowerpressureKaplanturbineduties.
AlthoughHydroSeleWisrecommendedforsmallerturbines,itcanbesuppliedindiametersupto2000mm(78.74in)ifrequired.
The Walkersele is supplied in spilt form foreaseofinstallation.Itisthenjoinedtoform an endless ring using our patentedOSJ®(On-SiteJoining)technique.
This version comprises a fully splitcartridge unit containing two Walkersele®
D7 On-Site Joining lip seals working intandem.BothWalkerselesfacethepressurizedwatertoprovideincreasedsealingintegrity.
The space between the two lip seals isnormally packed with grease duringassembly.Aportisincorporatedtoallowadditional greasing to improve thelubrication of the seal lips and to extendseallife.
Our HydroSele®WBisparticularlysuitablefor protecting bearings in submergedapplicationssuchasbulbturbines.
It uses the same cartridge design asHydroSele®WT,buttheouterWalkersele®
isreversed.
Inoperation,theoutersealactsasaprotective barrier to prevent the ingress ofwaterandexternalcontaminants.
To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz10
®HydroSele case studies
Here are a few examples of the many successes achieved with
®HydroSele S during 12 years of development, testing and
commercial operations.
Case study 1
Application: Two Francis vertical turbines
with 410mm (16.14in) diameter shafts
running at 750rpm and 3bar (43.5psi)
operating pressure.
Previous seal type: Both turbines were
fitted with spring-retained carbon rings.
HydroSele success: In December 1996
the turbine shafts were fitted with
prototypes of the HydroSele S cartridge
unit.
In March 2008 both units were still
working precisely to the customer’s
requirements, with the original
elastomeric sealing elements in place.
Case study 2
Application: Kaplan vertical turbine with
380mm (14.96in) diameter shaft running
at 428rpm and 3bar (43.5psi) operating
pressure.
Previous seal type: The turbine was
originally fitted with a famous brand of
mechanical seal that lasted about two
years, but suffered performance
problems.
HydroSele success: In February 1998, a
prototype HydroSele S was installed.
In July 2007, the total leakage from the
HydroSele S was measured at 2 litre/min
(0.53USgal/min). The original elastomeric
sealing elements were still in operation,
and the unit was continuing to meet the
customer’s specifications.
Case study 3
Application: Two Francis vertical turbines
with 480mm (18.9in) diameter shafts,
running at 375rpm and 2.5bar (36.25psi)
operating pressure.
Previous seal type: Both these turbines
were formerly fitted with conventional
mechanical face seals that leaked heavily.
HydroSele success: In June 2001 each
turbine was fitted with a HydroSele S, with
immediate dramatic reductions in leakage
rates.
In 2008, the leakage rate was measured
at 2 to 4 litre/min (0.53 to 1.06USgal/min),
which was fully acceptable to the
customer.
Our compact skid-mounted FlushPaks are
custom designed to provide the clean,
cool and uninterrupted supply of flush ® water needed for efficient HydroSele
operation.
They contain all the fluid handling and
automatic control systems required to
ensure the minimum of operator
intervention and maintenance.
®An adapter plate enables the HydroSele
unit to be retro-fitted to a turbine casing,
usually via the bolt circle of the previous
sealing system. Sufficient detail is
provided on page 5 to enable a customer
to design and manufacture the plate.
Alternatively, we will custom-design and
supply a precision-machined adapter
plate that provides the perfect base for
optimum HydroSele performance.
®HydroSele FlushPak®HydroSele Adapter
®All HydroSele units are designed to give
a long trouble-free working life, with their
elastomeric sealing elements performing
perfectly for several years before on-site
replacement is needed.
To gauge the operational efficiency of an
installation, we can supply our ®HydroSele Condition Monitoring system.
This monitors major parameters, such as
temperature, pressure and flow rates. It
gives prior warning of changes that affect
the efficiency of a HydroSele unit, thus
enabling on-site maintenance to be
scheduled well in advance.
The system is particularly suitable for use
at plants that are not permanently
manned, and can submit its reports
automatically via email or text messaging,
if required.
®HydroSeleCondition Monitoring
® HydroSeleShaft SleeveWe can provide precision manufactured
split sleeves that protect the turbine shaft
from wear, and present the optimum ®running surface for HydroSele elements.
These are manufactured in corrosion
resistant steel, and will be supplied with
hard surface layers, if required. A taper-
wedge location/locking system ensures
perfect alignment of the split halves.
®HydroSele ServiceWe offer a full service package to support
®all HydroSele installations. Our
applications engineers will assist and
advise on all aspects of turbine sealing.
They are complemented by our site
personnel who are fully safety trained and
available to carry out pre-contract surveys
— plus all levels of on-site work, from
supervision and system installation, to
commissioning and customer training.
Case studies
10. 11.
®HydroSele case studies
Here are a few examples of the many successes achieved with
®HydroSele S during 12 years of development, testing and
commercial operations.
Case study 1
Application: Two Francis vertical turbines
with 410mm (16.14in) diameter shafts
running at 750rpm and 3bar (43.5psi)
operating pressure.
Previous seal type: Both turbines were
fitted with spring-retained carbon rings.
HydroSele success: In December 1996
the turbine shafts were fitted with
prototypes of the HydroSele S cartridge
unit.
In March 2008 both units were still
working precisely to the customer’s
requirements, with the original
elastomeric sealing elements in place.
Case study 2
Application: Kaplan vertical turbine with
380mm (14.96in) diameter shaft running
at 428rpm and 3bar (43.5psi) operating
pressure.
Previous seal type: The turbine was
originally fitted with a famous brand of
mechanical seal that lasted about two
years, but suffered performance
problems.
HydroSele success: In February 1998, a
prototype HydroSele S was installed.
In July 2007, the total leakage from the
HydroSele S was measured at 2 litre/min
(0.53USgal/min). The original elastomeric
sealing elements were still in operation,
and the unit was continuing to meet the
customer’s specifications.
Case study 3
Application: Two Francis vertical turbines
with 480mm (18.9in) diameter shafts,
running at 375rpm and 2.5bar (36.25psi)
operating pressure.
Previous seal type: Both these turbines
were formerly fitted with conventional
mechanical face seals that leaked heavily.
HydroSele success: In June 2001 each
turbine was fitted with a HydroSele S, with
immediate dramatic reductions in leakage
rates.
In 2008, the leakage rate was measured
at 2 to 4 litre/min (0.53 to 1.06USgal/min),
which was fully acceptable to the
customer.
Our compact skid-mounted FlushPaks are
custom designed to provide the clean,
cool and uninterrupted supply of flush ® water needed for efficient HydroSele
operation.
They contain all the fluid handling and
automatic control systems required to
ensure the minimum of operator
intervention and maintenance.
®An adapter plate enables the HydroSele
unit to be retro-fitted to a turbine casing,
usually via the bolt circle of the previous
sealing system. Sufficient detail is
provided on page 5 to enable a customer
to design and manufacture the plate.
Alternatively, we will custom-design and
supply a precision-machined adapter
plate that provides the perfect base for
optimum HydroSele performance.
®HydroSele FlushPak®HydroSele Adapter
®All HydroSele units are designed to give
a long trouble-free working life, with their
elastomeric sealing elements performing
perfectly for several years before on-site
replacement is needed.
To gauge the operational efficiency of an
installation, we can supply our ®HydroSele Condition Monitoring system.
This monitors major parameters, such as
temperature, pressure and flow rates. It
gives prior warning of changes that affect
the efficiency of a HydroSele unit, thus
enabling on-site maintenance to be
scheduled well in advance.
The system is particularly suitable for use
at plants that are not permanently
manned, and can submit its reports
automatically via email or text messaging,
if required.
®HydroSeleCondition Monitoring
® HydroSeleShaft SleeveWe can provide precision manufactured
split sleeves that protect the turbine shaft
from wear, and present the optimum ®running surface for HydroSele elements.
These are manufactured in corrosion
resistant steel, and will be supplied with
hard surface layers, if required. A taper-
wedge location/locking system ensures
perfect alignment of the split halves.
®HydroSele ServiceWe offer a full service package to support
®all HydroSele installations. Our
applications engineers will assist and
advise on all aspects of turbine sealing.
They are complemented by our site
personnel who are fully safety trained and
available to carry out pre-contract surveys
— plus all levels of on-site work, from
supervision and system installation, to
commissioning and customer training.
Case studies
10. 11.
®HydroSele case studies
Here are a few examples of the many successes achieved with
®HydroSele S during 12 years of development, testing and
commercial operations.
Case study 1
Application: Two Francis vertical turbines
with 410mm (16.14in) diameter shafts
running at 750rpm and 3bar (43.5psi)
operating pressure.
Previous seal type: Both turbines were
fitted with spring-retained carbon rings.
HydroSele success: In December 1996
the turbine shafts were fitted with
prototypes of the HydroSele S cartridge
unit.
In March 2008 both units were still
working precisely to the customer’s
requirements, with the original
elastomeric sealing elements in place.
Case study 2
Application: Kaplan vertical turbine with
380mm (14.96in) diameter shaft running
at 428rpm and 3bar (43.5psi) operating
pressure.
Previous seal type: The turbine was
originally fitted with a famous brand of
mechanical seal that lasted about two
years, but suffered performance
problems.
HydroSele success: In February 1998, a
prototype HydroSele S was installed.
In July 2007, the total leakage from the
HydroSele S was measured at 2 litre/min
(0.53USgal/min). The original elastomeric
sealing elements were still in operation,
and the unit was continuing to meet the
customer’s specifications.
Case study 3
Application: Two Francis vertical turbines
with 480mm (18.9in) diameter shafts,
running at 375rpm and 2.5bar (36.25psi)
operating pressure.
Previous seal type: Both these turbines
were formerly fitted with conventional
mechanical face seals that leaked heavily.
HydroSele success: In June 2001 each
turbine was fitted with a HydroSele S, with
immediate dramatic reductions in leakage
rates.
In 2008, the leakage rate was measured
at 2 to 4 litre/min (0.53 to 1.06USgal/min),
which was fully acceptable to the
customer.
Our compact skid-mounted FlushPaks are
custom designed to provide the clean,
cool and uninterrupted supply of flush ® water needed for efficient HydroSele
operation.
They contain all the fluid handling and
automatic control systems required to
ensure the minimum of operator
intervention and maintenance.
®An adapter plate enables the HydroSele
unit to be retro-fitted to a turbine casing,
usually via the bolt circle of the previous
sealing system. Sufficient detail is
provided on page 5 to enable a customer
to design and manufacture the plate.
Alternatively, we will custom-design and
supply a precision-machined adapter
plate that provides the perfect base for
optimum HydroSele performance.
®HydroSele FlushPak®HydroSele Adapter
®All HydroSele units are designed to give
a long trouble-free working life, with their
elastomeric sealing elements performing
perfectly for several years before on-site
replacement is needed.
To gauge the operational efficiency of an
installation, we can supply our ®HydroSele Condition Monitoring system.
This monitors major parameters, such as
temperature, pressure and flow rates. It
gives prior warning of changes that affect
the efficiency of a HydroSele unit, thus
enabling on-site maintenance to be
scheduled well in advance.
The system is particularly suitable for use
at plants that are not permanently
manned, and can submit its reports
automatically via email or text messaging,
if required.
®HydroSeleCondition Monitoring
® HydroSeleShaft SleeveWe can provide precision manufactured
split sleeves that protect the turbine shaft
from wear, and present the optimum ®running surface for HydroSele elements.
These are manufactured in corrosion
resistant steel, and will be supplied with
hard surface layers, if required. A taper-
wedge location/locking system ensures
perfect alignment of the split halves.
®HydroSele ServiceWe offer a full service package to support
®all HydroSele installations. Our
applications engineers will assist and
advise on all aspects of turbine sealing.
They are complemented by our site
personnel who are fully safety trained and
available to carry out pre-contract surveys
— plus all levels of on-site work, from
supervision and system installation, to
commissioning and customer training.
Case studies
10. 11.
HydroSele® Service
We offer a full service package to supportall HydroSele® installations.Ourapplications engineers will assist andadviseonallaspectsofturbinesealing.
They are complemented by our sitepersonnel who are fully safety trained andavailable to carry out pre-contract surveys—plusalllevelsofon-sitework,fromsupervisionandsysteminstallation,tocommissioningandcustomertraining.
HydroSele® Adapter
AnadapterplateenablestheHydroSele®
unittoberetro-fittedtoaturbinecasing,usually via the bolt circle of the previoussealingsystem.Sufficientdetailisprovidedonpage5toenableacustomertodesignandmanufacturetheplate.
Alternatively,wewillcustom-designandsupply a precision-machined adapterplate that provides the perfect base foroptimumHydroSeleperformance.
HydroSele®
Condition Monitoring
AllHydroSele® units are designed to givealongtrouble-freeworkinglife,withtheirelastomeric sealing elements performingperfectly for several years before on-sitereplacementisneeded.
Togaugetheoperationalefficiencyofaninstallation,wecansupplyourHydroSele®ConditionMonitoringsystem.
Thismonitorsmajorparameters,suchastemperature,pressureandflowrates.Itgives prior warning of changes that affecttheefficiencyofaHydroSeleunit,thusenabling on-site maintenance to bescheduledwellinadvance.
The system is particularly suitable for useat plants that are not permanentlymanned,andcansubmititsreportsautomaticallyviaemailortextmessaging,ifrequired.
HydroSele®
Shaft Sleeve
We can provide precision manufacturedsplit sleeves that protect the turbine shaftfromwear,andpresenttheoptimumrunning surface for HydroSele®elements.
These are manufactured in corrosionresistantsteel,andwillbesuppliedwithhardsurfacelayers,ifrequired.Ataper-wedgelocation/lockingsystemensuresperfectalignmentofthesplithalves.
HydroSele® FlushPak
Our compact skid-mounted FlushPaks arecustomdesignedtoprovidetheclean,cool and uninterrupted supply of flushwaterneededforefficientHydroSele®
operation.
They contain all the fluid handling andautomatic control systems required toensure the minimum of operatorinterventionandmaintenance.
Case studies
11To order or for further details, please call your local contact shown on back cover or listed at www.jameswalker.biz 11
®HydroSele case studies
Here are a few examples of the many successes achieved with
®HydroSele S during 12 years of development, testing and
commercial operations.
Case study 1
Application: Two Francis vertical turbines
with 410mm (16.14in) diameter shafts
running at 750rpm and 3bar (43.5psi)
operating pressure.
Previous seal type: Both turbines were
fitted with spring-retained carbon rings.
HydroSele success: In December 1996
the turbine shafts were fitted with
prototypes of the HydroSele S cartridge
unit.
In March 2008 both units were still
working precisely to the customer’s
requirements, with the original
elastomeric sealing elements in place.
Case study 2
Application: Kaplan vertical turbine with
380mm (14.96in) diameter shaft running
at 428rpm and 3bar (43.5psi) operating
pressure.
Previous seal type: The turbine was
originally fitted with a famous brand of
mechanical seal that lasted about two
years, but suffered performance
problems.
HydroSele success: In February 1998, a
prototype HydroSele S was installed.
In July 2007, the total leakage from the
HydroSele S was measured at 2 litre/min
(0.53USgal/min). The original elastomeric
sealing elements were still in operation,
and the unit was continuing to meet the
customer’s specifications.
Case study 3
Application: Two Francis vertical turbines
with 480mm (18.9in) diameter shafts,
running at 375rpm and 2.5bar (36.25psi)
operating pressure.
Previous seal type: Both these turbines
were formerly fitted with conventional
mechanical face seals that leaked heavily.
HydroSele success: In June 2001 each
turbine was fitted with a HydroSele S, with
immediate dramatic reductions in leakage
rates.
In 2008, the leakage rate was measured
at 2 to 4 litre/min (0.53 to 1.06USgal/min),
which was fully acceptable to the
customer.
Our compact skid-mounted FlushPaks are
custom designed to provide the clean,
cool and uninterrupted supply of flush ® water needed for efficient HydroSele
operation.
They contain all the fluid handling and
automatic control systems required to
ensure the minimum of operator
intervention and maintenance.
®An adapter plate enables the HydroSele
unit to be retro-fitted to a turbine casing,
usually via the bolt circle of the previous
sealing system. Sufficient detail is
provided on page 5 to enable a customer
to design and manufacture the plate.
Alternatively, we will custom-design and
supply a precision-machined adapter
plate that provides the perfect base for
optimum HydroSele performance.
®HydroSele FlushPak®HydroSele Adapter
®All HydroSele units are designed to give
a long trouble-free working life, with their
elastomeric sealing elements performing
perfectly for several years before on-site
replacement is needed.
To gauge the operational efficiency of an
installation, we can supply our ®HydroSele Condition Monitoring system.
This monitors major parameters, such as
temperature, pressure and flow rates. It
gives prior warning of changes that affect
the efficiency of a HydroSele unit, thus
enabling on-site maintenance to be
scheduled well in advance.
The system is particularly suitable for use
at plants that are not permanently
manned, and can submit its reports
automatically via email or text messaging,
if required.
®HydroSeleCondition Monitoring
® HydroSeleShaft SleeveWe can provide precision manufactured
split sleeves that protect the turbine shaft
from wear, and present the optimum ®running surface for HydroSele elements.
These are manufactured in corrosion
resistant steel, and will be supplied with
hard surface layers, if required. A taper-
wedge location/locking system ensures
perfect alignment of the split halves.
®HydroSele ServiceWe offer a full service package to support
®all HydroSele installations. Our
applications engineers will assist and
advise on all aspects of turbine sealing.
They are complemented by our site
personnel who are fully safety trained and
available to carry out pre-contract surveys
— plus all levels of on-site work, from
supervision and system installation, to
commissioning and customer training.
Case studies
10. 11.
®HydroSele case studies
Here are a few examples of the many successes achieved with
®HydroSele S during 12 years of development, testing and
commercial operations.
Case study 1
Application: Two Francis vertical turbines
with 410mm (16.14in) diameter shafts
running at 750rpm and 3bar (43.5psi)
operating pressure.
Previous seal type: Both turbines were
fitted with spring-retained carbon rings.
HydroSele success: In December 1996
the turbine shafts were fitted with
prototypes of the HydroSele S cartridge
unit.
In March 2008 both units were still
working precisely to the customer’s
requirements, with the original
elastomeric sealing elements in place.
Case study 2
Application: Kaplan vertical turbine with
380mm (14.96in) diameter shaft running
at 428rpm and 3bar (43.5psi) operating
pressure.
Previous seal type: The turbine was
originally fitted with a famous brand of
mechanical seal that lasted about two
years, but suffered performance
problems.
HydroSele success: In February 1998, a
prototype HydroSele S was installed.
In July 2007, the total leakage from the
HydroSele S was measured at 2 litre/min
(0.53USgal/min). The original elastomeric
sealing elements were still in operation,
and the unit was continuing to meet the
customer’s specifications.
Case study 3
Application: Two Francis vertical turbines
with 480mm (18.9in) diameter shafts,
running at 375rpm and 2.5bar (36.25psi)
operating pressure.
Previous seal type: Both these turbines
were formerly fitted with conventional
mechanical face seals that leaked heavily.
HydroSele success: In June 2001 each
turbine was fitted with a HydroSele S, with
immediate dramatic reductions in leakage
rates.
In 2008, the leakage rate was measured
at 2 to 4 litre/min (0.53 to 1.06USgal/min),
which was fully acceptable to the
customer.
Our compact skid-mounted FlushPaks are
custom designed to provide the clean,
cool and uninterrupted supply of flush ® water needed for efficient HydroSele
operation.
They contain all the fluid handling and
automatic control systems required to
ensure the minimum of operator
intervention and maintenance.
®An adapter plate enables the HydroSele
unit to be retro-fitted to a turbine casing,
usually via the bolt circle of the previous
sealing system. Sufficient detail is
provided on page 5 to enable a customer
to design and manufacture the plate.
Alternatively, we will custom-design and
supply a precision-machined adapter
plate that provides the perfect base for
optimum HydroSele performance.
®HydroSele FlushPak®HydroSele Adapter
®All HydroSele units are designed to give
a long trouble-free working life, with their
elastomeric sealing elements performing
perfectly for several years before on-site
replacement is needed.
To gauge the operational efficiency of an
installation, we can supply our ®HydroSele Condition Monitoring system.
This monitors major parameters, such as
temperature, pressure and flow rates. It
gives prior warning of changes that affect
the efficiency of a HydroSele unit, thus
enabling on-site maintenance to be
scheduled well in advance.
The system is particularly suitable for use
at plants that are not permanently
manned, and can submit its reports
automatically via email or text messaging,
if required.
®HydroSeleCondition Monitoring
® HydroSeleShaft SleeveWe can provide precision manufactured
split sleeves that protect the turbine shaft
from wear, and present the optimum ®running surface for HydroSele elements.
These are manufactured in corrosion
resistant steel, and will be supplied with
hard surface layers, if required. A taper-
wedge location/locking system ensures
perfect alignment of the split halves.
®HydroSele ServiceWe offer a full service package to support
®all HydroSele installations. Our
applications engineers will assist and
advise on all aspects of turbine sealing.
They are complemented by our site
personnel who are fully safety trained and
available to carry out pre-contract surveys
— plus all levels of on-site work, from
supervision and system installation, to
commissioning and customer training.
Case studies
10. 11.
®HydroSele case studies
Here are a few examples of the many successes achieved with
®HydroSele S during 12 years of development, testing and
commercial operations.
Case study 1
Application: Two Francis vertical turbines
with 410mm (16.14in) diameter shafts
running at 750rpm and 3bar (43.5psi)
operating pressure.
Previous seal type: Both turbines were
fitted with spring-retained carbon rings.
HydroSele success: In December 1996
the turbine shafts were fitted with
prototypes of the HydroSele S cartridge
unit.
In March 2008 both units were still
working precisely to the customer’s
requirements, with the original
elastomeric sealing elements in place.
Case study 2
Application: Kaplan vertical turbine with
380mm (14.96in) diameter shaft running
at 428rpm and 3bar (43.5psi) operating
pressure.
Previous seal type: The turbine was
originally fitted with a famous brand of
mechanical seal that lasted about two
years, but suffered performance
problems.
HydroSele success: In February 1998, a
prototype HydroSele S was installed.
In July 2007, the total leakage from the
HydroSele S was measured at 2 litre/min
(0.53USgal/min). The original elastomeric
sealing elements were still in operation,
and the unit was continuing to meet the
customer’s specifications.
Case study 3
Application: Two Francis vertical turbines
with 480mm (18.9in) diameter shafts,
running at 375rpm and 2.5bar (36.25psi)
operating pressure.
Previous seal type: Both these turbines
were formerly fitted with conventional
mechanical face seals that leaked heavily.
HydroSele success: In June 2001 each
turbine was fitted with a HydroSele S, with
immediate dramatic reductions in leakage
rates.
In 2008, the leakage rate was measured
at 2 to 4 litre/min (0.53 to 1.06USgal/min),
which was fully acceptable to the
customer.
Our compact skid-mounted FlushPaks are
custom designed to provide the clean,
cool and uninterrupted supply of flush ® water needed for efficient HydroSele
operation.
They contain all the fluid handling and
automatic control systems required to
ensure the minimum of operator
intervention and maintenance.
®An adapter plate enables the HydroSele
unit to be retro-fitted to a turbine casing,
usually via the bolt circle of the previous
sealing system. Sufficient detail is
provided on page 5 to enable a customer
to design and manufacture the plate.
Alternatively, we will custom-design and
supply a precision-machined adapter
plate that provides the perfect base for
optimum HydroSele performance.
®HydroSele FlushPak®HydroSele Adapter
®All HydroSele units are designed to give
a long trouble-free working life, with their
elastomeric sealing elements performing
perfectly for several years before on-site
replacement is needed.
To gauge the operational efficiency of an
installation, we can supply our ®HydroSele Condition Monitoring system.
This monitors major parameters, such as
temperature, pressure and flow rates. It
gives prior warning of changes that affect
the efficiency of a HydroSele unit, thus
enabling on-site maintenance to be
scheduled well in advance.
The system is particularly suitable for use
at plants that are not permanently
manned, and can submit its reports
automatically via email or text messaging,
if required.
®HydroSeleCondition Monitoring
® HydroSeleShaft SleeveWe can provide precision manufactured
split sleeves that protect the turbine shaft
from wear, and present the optimum ®running surface for HydroSele elements.
These are manufactured in corrosion
resistant steel, and will be supplied with
hard surface layers, if required. A taper-
wedge location/locking system ensures
perfect alignment of the split halves.
®HydroSele ServiceWe offer a full service package to support
®all HydroSele installations. Our
applications engineers will assist and
advise on all aspects of turbine sealing.
They are complemented by our site
personnel who are fully safety trained and
available to carry out pre-contract surveys
— plus all levels of on-site work, from
supervision and system installation, to
commissioning and customer training.
Case studies
10. 11.
Case study 1
Application: Two Francis vertical turbines
with410mm(16.14in)diametershafts
runningat750rpmand3bar(43.5psi)
operatingpressure.
Previous seal type:Bothturbineswere
fittedwithspring-retainedcarbonrings.
HydroSele success: In December 1996
theturbineshaftswerefittedwith
prototypes of the HydroSele S cartridge
unit.
In March 2008 both units were still
working precisely to the customer’s
requirements,withtheoriginal
elastomericsealingelementsinplace.
Case study 2
Application: Kaplan vertical turbine with
380mm(14.96in)diametershaftrunning
at428rpmand3bar(43.5psi)operating
pressure.
Previous seal type: The turbine was
originallyfittedwithafamousbrandof
mechanical seal that lasted about two
years,butsufferedperformance
problems.
HydroSele success: InFebruary1998,a
prototypeHydroSeleSwasinstalled.
InJuly2007,thetotalleakagefromthe
HydroSeleSwasmeasuredat2litre/min
(0.53USgal/min).Theoriginalelastomeric
sealingelementswerestillinoperation,
and the unit was continuing to meet the
customer’sspecifications.
Case study 3
Application: Two Francis vertical turbines
with480mm(18.9in)diametershafts,
runningat375rpmand2.5bar(36.25psi)
operatingpressure.
Previous seal type:Boththeseturbines
wereformerlyfittedwithconventional
mechanicalfacesealsthatleakedheavily.
HydroSele success: In June 2001 each
turbinewasfittedwithaHydroSeleS,with
immediate dramatic reductions in leakage
rates.
In2008,theleakageratewasmeasured
at2to4litre/min(0.53to1.06USgal/min),
which was fully acceptable to the
customer.
HydroSele® case studies
Here are a few examples of the many successes achieved
with HydroSele®Sduringdevelopment,testingand
commercialoperations.
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Information in this publication and otherwise supplied to users is based on our general experience and is given in good faith, but because of factors which are outside our knowledge and control and affect the use of products, no warranty is given or is to be implied with respect to such information. Unless governed by type approval or contract, specifications are subject to change without notice. Statements of operating limits quoted in this publication are not an indication that these values can be applied simultaneously.
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