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Turbine Case

Bearing Housing/Pedestal. Bearing. Steam Leakage In Small Steam Turbines. Turbine Case. Oil. Carbon Seals. Bearing Housing/Pedestal. Bearing. Turbine Case. Oil. Carbon Seals. Bearing Housing/Pedestal. Bearing. Turbine Case. Oil. Carbon Seals. 230 degrees f. 230 degrees f.

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Turbine Case

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  1. Bearing Housing/Pedestal Bearing Steam Leakage In Small Steam Turbines Turbine Case Oil Carbon Seals

  2. Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals

  3. Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals 230 degrees f. 230 degrees f. Temperature

  4. Bearing Housing/Pedestal Bearing Steam Turbine Case Oil Carbon Seals 230 degrees f. 230 degrees f. Temperature

  5. Condensate Magnet Bearing Housing/Pedestal Bearing Seal Failure Steam Turbine Case Oil Carbon Seals 230 degrees f. 230 degrees f. Temperature

  6. Bearing Housing/Pedestal Bearing Steam Path Turbine Case Oil Carbon Seals Steam moves out of the case, down the shaft and past the carbon seals to atmosphere.

  7. Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals Some steam dissipates into the atmosphere. In some instances (such as in cold climates), this could cause a visibility hazard.

  8. Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals It could also cause a slipping hazard as condensate collects on the ground, or can cause severe burns if contacted near the exhaust path.

  9. $$$$$$$$$$ Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals $$$$$$$$$$ Lost steam is also money thrown into the wind.

  10. Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals Yet another consideration – if water enters your bearing housing, the integrity of your oil (lubrication system) will be compromised.

  11. Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals This could lead to bearing failure and ultimately, equipment failure.

  12. Condensate Magnet Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals When shaft seals fail, your only barrier against oil contamination are your bearing case seals.

  13. Condensate Magnet Bearing Housing/Pedestal Bearing Turbine Case Oil Carbon Seals These seals can be standard OEM “H” seals, or “upgrades” such as modified “H” seals (Disrupter Seals) or aftermarket Barrier Seals.

  14. Solutions #1 Try to reduce or eliminate steam leakage at the source.

  15. Solutions #2 Protect your oil from contamination.

  16. Carbon Seals The standard shaft seals on most small steam turbines are carbon rings.

  17. Carbon Seals If installed correctly, they provide a good seal. However they do deteriorate rapidly.

  18. Effective Clearance Over Time

  19. Carbon Rings Advantages • Inexpensive • Easy to install • Perform well when properly sized and installed • Lightweight Disadvantages • Easily cracked/ chipped • If not properly sized, can either seize on shaft or leak too much • Short life, resulting in high leakage after short time

  20. Mechanical Seals

  21. Mechanical Seals Advantages • Best sealing performance • Longer life than standard carbon seals Disadvantages • Expensive initial investment • Difficult to install, requires entire rotor to be removed for installation/ maintenance • Can require permanent case modifications • Finite life-span before a costly overhaul is required.

  22. Brush Seals

  23. Brush Seals Advantages • Moderately priced • More durable than carbon seals • Extremely long life Disadvantages • Must be installed in shop • Not stocked for all size turbines • Relatively new technology for steam applications • Heavy “floating” seals can gravitate downward on turbines that cycle, thus decreasing efficiency

  24. Brush Seals Current Applications • Utility Turbines • Mechanical Drive Turbines • Gas Turbines – Aircraft & Industrial • Single Stage Turbines • Elliott – All YR sizes • Dresser Rand • General Electric • Westinghouse

  25. Rotation Shaft Brush Seals Brush Pack

  26. Holder Holder is SS Fence Flow Brush Pack Brushes are a Haynes 25 material

  27. Brush Seals • Little or no case modifications beyond original design specifications. • Lower sustained leakage than carbon rings. • Indefinite life span eliminating periodic replacement.

  28. Brush Seals Installation Considerations

  29. Sealing faces and ID of carbon box are machined to assure a good seal fit. Compressor & Turbine Services. LLC

  30. Internal Alignment is Important On Fixed (non-floating) Brush Seals Compressor & Turbine Services. LLC

  31. Suggested Shaft Coatings – None – Base Metal Chromium Carbide Tungsten Carbide (preferred) Compressor & Turbine Services. LLC

  32. Leakage Data Compressor & Turbine Services. LLC

  33. Leakage Data From SST Test • Test comparing brush seals with cold (new) carbon seals • Brush seals installed with “zero” clearance • Carbon seals installed with 2.5 mil radial clearance • Carbon seals exhibit equivalent clearance of 4.3 mils B = Brush Seal C = Carbon Seal

  34. Brush Seals vs. Carbon Rings Effective Clearance over Time Compressor & Turbine Services. LLC

  35. Effective Clearance over Time Carbon seals will degrade almost immediately. Brush seal performance will always stay the same. Compressor & Turbine Services. LLC

  36. Brush Seals Two Approaches * Stand Alone Application * Brush/Carbon Combo Compressor & Turbine Services. LLC

  37. Brush Seals for Steam Turbines May be used as a replacement for Carbon Rings Or May be used in conjunction with Carbon Rings

  38. Brush Seals Stand-Alone Application Compressor & Turbine Services. LLC

  39. Application: Brush Seals to Replace Carbon Rings Non Floating Seals COST: Around $10k Per SST Compressor & Turbine Services. LLC

  40. Application: Brush Seals to Replace Carbon Rings More Risky Than Brush/Carbon Combination Since Brush Seals DO NOT Have a History for this Application. Only recommended for turbines that are in continuous service. (floating seals) Compressor & Turbine Services. LLC

  41. Application Requirements:Brush Seals as Replacement for carbon rings Drain • Minimum radial space between shaft and packing box ID of 1.0 inch typically • Maximum pressure drop across one seal is 150 psid • Packing box must be reasonably aligned with bearings • Best used on turbines that are in continuous operation Brush Seals

  42. Split line Brushes Anti-rotation pin Sealing face Application: Brush Seals to Replace Carbon Rings Non Floating Seals Compressor & Turbine Services. LLC

  43. Elliott BYRHH Compressor & Turbine Services. LLC

  44. Flow No.1 Drain Pipe No.2 No.3 Compressor & Turbine Services. LLC

  45. Brush Seals - Used With Carbon Rings Compressor & Turbine Services. LLC

  46. A More Conservative Approach Estimated around 100 turbines in operation with Brush Seals in this configuration. Compressor & Turbine Services. LLC

  47. Brush Seals/Carbon Rings - A Winning Combination • No case modifications beyond original design specifications. • Lower sustained leakage than stand-alone carbon rings. • Indefinite life span eliminating periodic replacement. • Protects carbon rings from contamination • Reduces pressure on carbon rings Compressor & Turbine Services. LLC

  48. Leakage Data From SST Test • Test comparing brush seals with cold (new) carbon seals • Brush seals installed with “zero” clearance • Brush seals exhibit equivalent clearance of 3.4 mils radial • Carbon seals installed with 2.5 mil radial clearance • Carbon seals exhibit equivalent clearance of 4.3 mils B = Brush Seal C = Carbon Seal

  49. COST: Around $ 3k – 6k Solid Ring Design Compressor & Turbine Services. LLC

  50. Brush Seals Installation Considerations

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