Advancements in Dynamic Sealing Technology

Oil Seals

Bearing Isolators

Mechanical Seals

David C. Roberts, P.E. Industrial Engineer

By the end of todays discussion we will be able to answer the following:

1. 2. 3. 4. 5. 6. 7. What are the 3 most common dynamic sealing technologies? What is the primary theory of operation behind radial lip seal technology? How have advancements in elastomer material science improved radial lip seals? What are the advantages to utilizing bearing isolator technology? What is the key limitation of both labyrinth seals & bearing isolators? What is the primary application for mechanical seals? What is one of the critical factors in successful mechanical seal applications?

Dynamic Sealing Applications

Differ from static sealing applications in that the equipment is i moving i Static sealing applications may have fluid movement, but the machine members do not move The most common dynamic sealing application is a rotary machine i.e. a shaft rotates as it is supported by bearings Reciprocating applications are less common i.e. a hydraulic application where a shaft strokes through a housing Our focus today will be on rotating applications

Dynamic Sealing Applications

Some dynamic sealing applications

There are many, many more !

Dynamic Sealing Applications

The basics

What are the 3 most common dynamic sealing technologies?

Radial Lip Seals

Bearing Isolators

Mechanical Seals

R di l Lip Seals a.k.a. oil seals; uses dynamic rubber lip to engage shaft Radial Li S l k il l d i bb li h f surface Bearing Isolators Hybrid labyrinth seal design, provides non-contact sealing solution Mechanical Seals Utilize hard mechanical faces (and other technologies) to provide a high pressure seal for severe sealing applications

Radial Lip Seal Theory of Operation

Hydrodynamic sealing Pumping action creates oil film between shaft & seal lip Oil film (meniscus) is actual seal lip interface Oil film reduces wear, friction, and power consumption Oil Film d Fil dependent on seal li d t l lip geometries & shaft surface conditions Wh film i not present, greater When fil is t t t seal wear (abrasion) occurs

Radial Lip Seal Theory of Operation

The shaft surface finish is
CRITICAL to lip seal performance p p Most lip seals require a 10-20 in Ra shaft surface finish (some designs require finer surfaces) Surface hardness must be no less than 30 Rockwell C (some designs require harder surfaces) The surface machining must be perpendicular to the axis of shaft rotation Many seal dams are created from the peaks-n-valleys of the finished surface

Seal Dam

Environment

Lubrication Meniscus (0.00018) (0.0046mm) Shaft Sh ft

Elastomer Material Science The Critical Factor for Lip Seal Performance
Commonly used lip seal materials are:
Nitrile Rubber (NBR, acrylonitrile butadiene) ( , y ) Hydrogenated Nitrile (HNBR) Silicone (VMQ) Fluoroelastomer (FKM, commonly called Viton)

Elastomers for Commodity Applications

Common formulations Easy to manufacture Large allowable tolerance

Engineered Elastomers
Specialized formulation More difficult to manufacture Small allowable tolerance Small Emphasis of performance

Elastomer Material Science The Critical Factor for Lip Seal Performance
Engineered Elastomers focus on improving overall seal performance Factors include: Chemical compatibility Temperature resistance T t i t Abrasion resistance Retention of physical properties over time

10

Improving Elastomer Abrasion Resistance

Taber Wear Test measures abrasion resistance:

A precisely measured disc is subjected to a grinding process for a specific number of cycles The amount of material lost is measured and compared to other samples The lower the taber wear number the better

11

Improving Elastomer Abrasion Resistance

Advances in elastomer formulations have lead to s g ca t p o e e ts abrasion es sta ce significant improvements in ab as o resistance Better abrasion resistance leads to longer seal life and thus longer equipment uptime (MTBF)

NBR elastomer improvements:

12

Improving Elastomer Abrasion Resistance

Improvements in HNBR & FKM elastomers:

13

Improvements in Retention of Mechanical Properties

Focus on retention of properties in service se ce Examines:
Hardness Tensile Strength % Elongation % Wear Width Abrasion Resistance
Taber Wear Factor* Hardness Change (points)

25 20 15 10 5 0 -5 -10 -15 -20 -25

Tensile Change (%)

How well are these properties p p maintained over time?

Wear Width (in (x100)) Elongation Change (%)

Mill-Right N (48713)
* ASTMD4060 Taber Wear Index Factor ASTM 903 Oil Immersion (70hrs @ 200F (93C)) KLOZURE 4-Hour Dry Run Volume Change (%)

Nitrile (49706) Perfection

14

Bearing Isolators Non-contact seals

Traditional Labyrinth Seal Uses complex pathway to separate fluids Rotor moves with shaft, while stator remains static in bore

Bearing Isolator Seal Uses basic labyrinth technology force, Incorporates centrifugal force pressure differential, and drain back designs to maximize sealing effect

15

Advantages of Bearing Isolator Seals

Can run on soft shaft materials Only require surface finish of 64 in or finer Can run dry P id b th oil retention and Provide both il t ti d contaminant exclusion Reduce power losses due to friction

16

Bearing Isolator provide significant power savings

Testing conducted at Garlock shows that radial lip seals consume 670 watts at start up and 285 watts in normal operation Similarly sized bearing isolators only consume 150 watts at start up and 120 watts during normal operation Other case study data shows that the service life of bearing isolators can be up to 65 times longer than that of traditional lip seals p

17

Advances in Bearing Isolator Technology

Bearing isolator incorporating internal air filter For use in very dirty, dusty environments Internal filter traps airborne contamination, preventing migration into bearing system

18

Advances in Bearing Isolator Technology

Split bearing isolators Allows for easy seal replacement without costly equipment tear down Drastically improves mean time to repair (MTTR)

19

Limitations to bearing isolator technology

Because bearing isolators are based in labyrinth technology technology, they are subject to a common limitation: BEARING ISOLATORS & LABYRINTH SEALS CAN ONLY BE USED IN NONFLOODED APPLICATIONS Oil level must be below lowest opening in labyrinth pathway

Shaft

Maximum Oil Level

Oil

Housing

20

Limitations to bearing isolator technology

Examples of flooded applications:

Shaft Flooded Oil Level

Shaft

Submerged Oil Level

Garlock is currently developing a flooded isolator design!

Housing

Housing

21

Mechanical Seals
The primary applications for mechanical seals are pump stuffing boxes Often replaces compression packing in challenging challenging applications Other applications includes mixers, mixers slurry applications applications, rotary fans, food processing equipment, and more

22

Mechanical Seals
Stuffing Box Discharge Impeller

Bearing Frame

Suction

Mechanical Seal

23

Mechanical Seals
Most mechanical seal designs use one or more sets of hard faces to form a dynamic seal Faces must be lapped very smooth (measured in helium light bands) Common materials used are carbon, carbon tungsten carbide and carbide, silicon carbide Elastomers form internal static seals Springs or metal bellows load the seal

Basic Mechanical Seal Design

24

Mechanical Seals
More specialized designs use advanced lip seal technology Hardened sleeve provides running surface for lips

Garlock PS-II Design

25

Critical factor for mechanical seal performance

One of the most critical factors affecting mechanical seal performance are the PROCESS CONTROLS used to regulate the seal Various types of process control include:
Barrier Fluids Buffer Fluids Controlled Flush Controlled Quench Convection Systems Quench & Drain Stand pipes

Example of Convection System

26

Review
1. 2. 2 3. What are the 3 most common dynamic sealing technologies? Radial Lip Seals, Bearing Isolators, Mechanical Seals What i the i Wh t is th primary theory of operation behind radial li seal th f ti b hi d di l lip l technology? Hydrodynamic Sealing How has improvement in elastomer material science improved radial lip seals? Improved Abrasion resistance and better retention of physical properties What are the advantages to utilizing bearing isolator technology? Non-contact seals, dry running, reduced power consumption What is the key limitation of both labyrinth seals & bearing isolators? Cannot be used under flooded conditions What is the primary application for mechanical seals? Pump stuffing boxes t ffi b What is one of the critical factors in successful mechanical seal applications? Process controls

4. 5. 6. 7.

27

For more information...

GARLOCK SEALING TECHNOLOGIES 1666 DIVISION ST PALMYRA, NY 14522 Ph: 1-877-427-5625 www.klozure.com www klozure com www.garlock.com

28