SXL Segmented Shaft

Seals for Hydro-Turbines

Introduction
Hydro turbines generate power from the flow of
moving water from the penstock through the runners
to drive the turbine. The main turbine shaft is
immersed in the water that drives the runners,
where the water power is being harnessed. The
water driving the turbine can be under significant
pressure, especially in a high head machine. It is
essential to keep this water in the runner area and
away from the other parts of the machine. A seal is
required between the rotating shaft and the body of
the turbine. This is the turbine shaft seal (see Figure
1 below). The seal must operate in a very difficult
environment due to the high peripheral velocity of
the shaft O.D. and may be exposed to abrasives in
the water. The seal is normally located above the
turbine runner and below the main guide bearing.
Figure 1. SXL Radial Segmented Shaft Seal
Hydro turbines are often very large machines with
typical shaft diameters of 1000mm (39) or larger. It
is expensive and very time consuming to
disassemble a turbine. For this reason, turbine shaft
seals, especially on large machines, are normally
designed in segments that can be installed without
removing the shaft, generator and other parts of the
machine. A typical Francis turbine as shown in
Figure 2. Location of SXL Segmented Shaft Seals
Figure 2 displays the location of the SXL segmented
shaft seals. Note how inaccessible the location is.
A seal for hydro turbine shafting is in general a
misnomer. The seal is really a controlled leakage
device. These devices may be applied with the
dynamic sealing face either parallel to the shaft
(radial) or perpendicular to the shaft (axial).
Limits for SXL Segmented Shaft Seal Systems
Based on current testing on our dedicated
segmented shaft seal test rig, Thordon Bearings has
established an interface pressure limit of 0.7 MPa
(101 psi). Thordon requires injection of clean
cooling water between the first and second rings of
seals. Minimum leakage with the current design of
SXL seal systems is approximately 40 litres per
minute (10 G.P.M.). Work is continuing on new
system designs which will facilitate significantly
lower leakage rates. Thordon segmented shaft
seals have been designed for shafts up to 2000mm
(80) diameter.
Thordon SXL vs. Carbon Graphite
Segmented shaft seals for turbines have
traditionally been made from carbon graphite.
These seals have low friction and can accept a
significant amount of heat. Carbon graphite is,
however, very fragile. It is not unusual to damage
several segments during installation. Carbon
graphite also does not resist abrasives very well
which can often be present in the water flowing
through the turbine. SXL offers the advantages of
being almost unbreakable and also of being much
more abrasion resistant. Thordon SXL seals can
normally replace existing carbon seals without any
significant changes to the system design.
Radial and Axial Seals
According to the arrangement relative to the shaft
centre line, mechanical seals for turbines fall into
two (2) sub-categories:
1. Radial Seals- Wear face parallel to turbine shaft
(see Figure 4)
2. Axial Seals Wear face perpendicular to
turbine shaft (see Figure 5)
SXL SEGMENTED SHAFT SEALS FOR HYDRO-TURBINES
Figure 4. Radial Seal
Figure 5. Axial Seal
Radial Seals Basic Features
Figure 6. Physical Elements of Radial Seal
Typical radial segmented shaft seals comprise three
stages (rings) of interlocking segments. Each ring
has both dynamic (against the shaft) and static
(against the housing) sealing sections. First stage
seals are normally reversed compared with the two
upper rings, to allow introduction of a higher-
pressure injection flow between the first and second
rings. (see figure 6) This higher pressure flow (1.10
to 1.15 times turbine pressure) functions as a seal
lubricant, coolant and a barrier preventing abrasives
from entering the seal faces. A garter spring
functions to hold the segments with a nominal light
force against the shaft during periods of shutdown
and low pressure and also to maintain the integrity of
the seal ring within the housing cavity. In normal
operation, the seal ring is pressed against the shaft
by the force of the water in the turbine.
Axial Seals Basic Features
Figure 7. SXL Axial Seal
Thordon design always uses injection cooling
water
Central groove for cooling water is off-set toward
outside of segment
Seal segments are always attached to stationary
part
Physical Elements
Segmented Seal Rings
Press Plates
Garter (tension) Springs
Sealing Water Inlet
Anti-rotation Pins
Drainage
Housing
SXLSegShaft.03.2008
3225 Mainway, Burlington, Ontario L7M 1A6 Canada
Tel: (905) 335-1440 Fax: (905) 335-4033 www.thordonbearings.com
Your Local Thordon Distributor
ISO 9001:2000
CGSB
Registration #93649
Application Information and Design Parameters
Any prospective application for Thordon SXL
Segmented Shaft Seals should be evaluated by
Thordon Bearings. When evaluating an installation
the information and design parameters listed below
are required.
Information required from Hydro-Turbine site:
Water pressure being sealed (water pressure
inside turbine)
Shaft diameter
Shaft rotating speed (rpm)
Water quality (clean or abrasive) over year (i.e. is
there spring run-off?)
Environmental (water) temperature
Maximum leakage flow allowed
Turbine arrangement (Vertical or Horizontal)
Existing seal design if application is retrofit
Pioneers in Advanced Oil and Greae-Free
Hydro-Trubine Bearings
With over 25 years experience supplying main shaft
guide, pump, wicket gate, operating mechanism
bearings and radial and axial shaft seals, Thordon is
the proven choice for performance and value in
rehabilitation and new turbine projects. Long wear
life, low friction, high abrasion resistance, grease/oil
free operation and application engineering technical
support provide customers with bearing solutions
that meet, or exceed, specifications. With worldwide
installations ranging from micro-turbines to units with
main shafts up to 2.4m (94"), Thordon provides a
proven alternative to grease and oil lubricated
bearings.