No. 1, 2009 Trelleborg Sealing Solutions in the groove The world of seals and service
Automotive Sealing for a sustainable future The optimum sealing materials for biofuels proven in tests
Oil & Gas Controlled explosion
Exploring the options to reduce explosive decompression risk and extend seal life
Product Feature Extreme rotation
Mechanical Face Seals specifically engineered for difficult rotating environments contents
26 Automotive Sealing for a sustainable future
When engineers specify seals, biofuels present some significant challenges, as their chemical make-up can affect the sealing integrity of elastomers. Standard laboratory tests indicate that typical FKM and FVMQ compounds are compatible with biofuels. However, when sealing materials are tested in conditions reproducing those seen in service, it becomes evident that specialized formulations are required to ensure integrity and long service life.
6 Product Feature Extreme rotation
The new range of Mechanical Face Seals from Trelleborg Sealing Solutions is specifically engineered for rotating applications in extremely arduous environments. There they withstand severe wear and prevent ingress of harsh and abrasive external media.
16 Oil & Gas Controlled explosion
Explosive Decompression (ED) is a major concern to the oil & gas industry as well as other sectors utilizing gas at high pressure. ED occurs when applied system pressure is released, causing absorbed gas to expand, damaging elastomer seals. We explore this phenomenon and discuss some of the principles to reduce ED risk and extend seal life in applications where ED may occur.
Trelleborg Sealing Solutions in the groove No. 01/09 News Innovation
4 Pumped and ready to go 32 Low energy movement Sealing solutions for WEH hydrogen fuelling Trelleborg Sealing Solutions launches Turcon® systems Varilip® PDR. The optimum solution for high-speed rotating applications, it has exceptional low-friction On your bike characteristics, reducing torque. That cuts power Applications for seals on cycles are numerous consumption, contributing to lower equipment running costs and in the end, decreased energy 5 Semicon on the web bills. New industry section on the website specific to semiconductor sealing solutions
Two Compounds Achieve NSF Listing Processing Turcon® MF5 and MF6 conform to NSF/ANSI Standard 36 A fair exchange As energy conservation becomes a focus for 5S Success in Shanghai us all, the demand for Plate Heat Exchangers is Trelleborg Sealing Solutions Shanghai successfully booming. They are a fundamental part of many starts its lean manufacturing program production processes and Trelleborg Sealing Solutions is one of the leading suppliers for gaskets fitted to these systems. Off-road
10 One application – Many solutions Hydropower Tractor operators throughout the world rely on Trelleborg more than they can imagine. Our 40 The power of water solutions seal vital components and ensure On the Cowlitz River in the state of Washington reliability, enhance driver comfort through sits the Mossyrock Dam, the Pacific Northwest sophisticated damping and protect the soil. United States’ tallest. Owned and operated by Tacoma Power, the dam is being overhauled to 12 Plowing ahead improve efficiency. Hydraulics are used extensively on today‘s tractors. Each hydraulic device requires its own processor. In the search for a robust yet compact electronic Service control unit, manufacturers turn to one of the world’s leading specialists in the field of drive and 44 Matchmaking online control technologies: Rexroth. Always trying to make the lives of engineers easier when they are specifying seals, we have developed some new additions online - a material Rotary sealing search and chemical compatibility check. Both of these help match the optimum seal material to the 22 Compact performance requirements of specific applications. The new Turcon® Roto VL Seal® is a high-pressure compact seal that is ideal for rotary applications where there is limited space or for installation into standard O-Ring grooves.
Trelleborg Sealing Solutions in the groove No. 01/09 news +++ news +++ news +++ news +++ news +++ news
Automotive Pumped and ready to go Trelleborg Sealing Solutions supplies Whether refueling vehicles with natural gas or seals for the new innovative TK17 fuel hydrogen, “nothing works without WEH.” The latest in a long line of patented systems from nozzle from WEH. WEH is the single-handed TK17. It looks like a conventional gasoline nozzle but is completely innovative. The pressure-tight connection to the vehicle ensures that none of the gas, which is highly reactive, can reach the atmosphere. To meet stringent operating requirements, the engineers at WEH worked closely with Trelleborg Sealing Solutions to choose a group of suitable seals, including O-Rings, Turcon® Stepseal® and Turcon® Glyd Ring®. These seals use standard materials as well as ones specially developed for this application, including some capable of withstanding temperatures as low as -40°C/ - 40°F. For a longer version of this article go to the News section on: www.tss.trelleborg.com.
Cycles On your bike Ever been to Shanghai, China? If you have, then you’ll know what it’s like to face an onslaught of bikes at rush hour. The same is true of Delhi, India or Taipei, Taiwan and many other cities in Asia, where the bike is a major form of transport. You may not think so, but surprisingly, all of those two-wheeled vehicles need seals, and the applications are numerous. Seals from Trelleborg Sealing Solutions are found on front and rear shock absorbers, seat posts, as well as on brake levers and disks. To support their participation in this market, the Trelleborg Sealing Solutions marketing company in Taiwan recently participated at the Taipei Cycle exhibition.
Sealing solution for rear shock absorbers
Trelleborg Sealing Solutions in the groove No. 01/09 +++ news +++ news +++ news +++ news +++ news
Quality Food and Beverage 5S success in Two compounds achieve NSF Shanghai Trelleborg Sealing Solutions Shanghai, listing China successfully started its lean manufacturing program with 5S Trelleborg Sealing Solutions now and beverage production. Based on implementation (Sort, Straighten, has two compounds listed by NSF ultra-clean technology, these proprietary Shine, Standardize, Sustain) as the pilot International as conforming to the compounds are manufactured from project. requirements of NSF/ANSI Standard high-purity PTFE grades and additives. 51 - Food Equipment Materials. Turcon® Their smooth finish, with high gloss MF5 compound has recently achieved and low porosity, avoids the risk of this status, joining Turcon® MF6 in the contamination buildup and reduces listing. particle shedding. Each batch of MF material is manufactured using high- Turcon® MF5 and MF6 are part of purity material only and can be issued the Turcon® MF range of materials with a certificate of conformity. specifically engineered for demanding processing environments, including food www.nsf.org/international/
“All our efforts are driven by a desire to accomplish lean manufacturing. We want to achieve a safe and efficient operation to manufacture our products to the required standards of quality,” says Jim Wang, Production & Continuous Semiconductor Improvement Manager. “5S brings improvement in many aspects. Everyone feels more comfortable and efficient Semicon on the web in a better working environment. The A new and improved section on sealing energized Turcon® Variseal®, Turcon® customers who visit our plant are in semiconductor applications can now Varilip® PDR for rotary applications, V- impressed with our neat and well be found on the Trelleborg Sealing Ring® for external media exclusion and organized production areas.” Solutions website. The section outlines FlexiMold™ giant seals. our capabilities in this challenging The 5S discipline will be followed by other www.tss.trelleborg.com lean manufacturing tool implementation industry. In particular, we look at wet such as Total Productive Maintenance process applications, plasma systems, (TPM), Standardized Work and Kanban. high-temperature situations, vacuum conditions and working with demanding Trelleborg Sealing Solutions chemicals. You will find details on In the groove, No. 1, 2009 recommended materials and products, 99GBK9011EE0509 © 2009 Trelleborg Group. All rights reserved along with a number of application ® All trademarks are the property of the Trelleborg Group. examples. The turquoise color is a registered trademark of the Trelleborg Group. Come explore our materials and ® At time of publication the information contained in this products. Learn about our line of Isolast literature is believed to be correct and accurate. Fab Range™ FFKM materials, which offer Editorial team: the ultimate in elastomer sealing. These Mercedes Benjumeda, Donna Guinivan, Whitney Killip, Wendy Sack, Tobias Schmid, Sherry Sheng, high-performance materials demonstrate Sandro Silverio, Robert Zahiri almost universal chemical compatibility, Responsible under German Press Law: while operating in continuous Robert Zahiri temperatures up to +325°C/+617°F. Graphic Arts: Discover our wide range of products: the dialogart gmbh, Stuttgart, Germany inflatable Airseal, bonded-to-metal seals, Printing: O-Rings, Wills Rings® metal seals, spring- W. Kohlhammer, Stuttgart, Germany QUAD-RING® seal trademark of Quadion Corporation
Trelleborg Sealing Solutions in the groove No. 01/09 Product Feature Extreme rotation
The new range of Mechanical Face Seals from Trelleborg Sealing Solutions is specifically engineered for rotating applications in extremely arduous environments. There they withstand severe wear and prevent ingress of harsh and abrasive external media.
What are Mechanical Face Seals?
The Mechanical Face Seal consists of two identical metal sealing rings mounted in two separate housings face-to-face on a lapped seal face. The metal rings are centered within their housings most commonly by O-Rings or otherwise by elastomers with a diamond-shaped cross section. One-half of the Mechanical Face Seal remains static in the housing, while In short... the other half rotates with its counter face. Launching Mechanical Face Seals The elasticity of the O-Rings or elastomer rings generates a uniform axial face loading for the metal rings and these O-Rings Engineered for extremely arduous act as static seals on the inner and outer diameter. They also rotating environments prevent any contrarotation of the metal seal rings within their housings and ensure that all the relative rotary motion occurs Cost-effective steel bearing at the dynamic interface between the seal rings. option gives flexibility in design Manufactured at Trelleborg Sealing Solutions Modena in Italy The Mechanical Face Seal catalog is available for download from www.tss.trelleborg.com
Trelleborg Sealing Solutions in the groove No. 01/09 Selecting the right Mechanical Face Seal Mechanical Face Seals Face Mechanical Cast iron or roller bearing steel?
The metal part of the Mechanical Face Seal is available in a choice of two different types of material, a special heat treated high-alloy corrosion-resistant mold cast iron or a forged roller bearing steel. Selection of material depends on operating conditions. Cast iron will operate in speeds up to 3 m/s/ 10 ft/s with oil lubrication, while for rotational speeds up to 2.2 m/s/ 7.2 ft/s, bearing steel is adequate.
Bearing steel provides cost savings and flexibility
Up to 2.2 m/s /7.2ft/s the bearing steel option, due to lower process and material costs, can offer significant savings, especially for medium to large size Mechanical Face Seals. In addition, there is more flexibility in design, allowing the seals to be custom-engineered for specific housings.
Elastomers to suit the application
Temperature resistance depends on the type of elastomer used within the seal. A choice of Acrylonitrile Butadiene Rubber (NBR), Hydrogenated Nitrile Butadiene Rubber (HNBR), Fluoroelastomer (FKM) or Silicone (VMQ), provides an operating range between -40°C to +200°C/ -40°F to +392°F. These compounds also give chemical compatibility to virtually all media encountered in applications where Mechanical Face Seals are used.
Trelleborg Sealing Solutions in the groove No. 01/09 Product Feature
Italian fashion
An agricultural economy Food, drink and style Trelleborg has a strong became industrial presence in Italy
The economy of Italy has changed Food is still an important product for There are numerous Trelleborg dramatically since the end of World Italy. It is the third largest producer of Group manufacturing facilities in Italy. War II. From an agricultural base, it wine in the world, the most famous ones Automotive parts are produced in Turin, has become an industrial country, the of which are probably the Tuscan Chianti while Milan is the home of printing world’s seventh largest economy in USD and Piemontese Pinot Grigio. Italy is blankets, used on presses that produce exchange-rate terms and tenth largest in also known for its style and fashion our newspapers and books the world terms of purchasing power parity (PPP)*. houses including such famous names over. Alongside them is the related Italy’s major exports are precision as Versace, Valentino, Fendi, Gucci, technology of coated engineered machinery, motor vehicles, including the Prada, Dolce & Gabbana, Benetton and fabrics. They supply everything from iconic scooter, chemicals and electrical Armani. chemical and heat-resistant materials goods. Source: Wikipedia for protective clothing to the fabric for escape slides on aircraft. Trelleborg Wheel Systems is headquartered at its main production facility, just outside Rome, near Tivoli. Trelleborg Sealing Solutions has three plants in Italy: Livorno, near Pisa, Modena and Turin.
Mechanical Face Seals expertise in Modena
Mechanical Face Seals are manufactured at the Trelleborg Sealing Solutions plant in Modena, Italy. Originally known as GNL, the company was acquired by Trelleborg Group in 2008. Combining the expertise in this type of product from the original Modena site and that of Spilamberto close by, manufacturing has been consolidated within a state-of-the- art facility employing 60 people.
* World Bank, IMF and the CIA World Fact book
Trelleborg Sealing Solutions in the groove No. 01/09 Where are Mechanical Face Seals used? Mechanical Face Seals Face Mechanical
● Heavy duty rotating applications such as rollers, front idlers and final drives of tracked vehicles ● Graders, shovels, plows and scrapers on tractors ● Off-highway trucks, drilling machines ● Hydraulic excavators ● Conveyors ● Concrete mixers For further information ● Asphalt plants on Mechanical Face ● Mining and crushing equipment Seals check out our comprehensive catalog. ● Mowers You can download it from ● Hay balers the services area at ● Wind turbines tss.trelleborg.com ● Axles, gearboxes, mixers and stirrers
Trelleborg Sealing Solutions in the groove No. 01/09 Off-road
Tractor operators throughout the world rely on Trelleborg more than they can imagine. Our solutions seal vital components and ensure reliability, enhance driver comfort through sophisticated damping and protect the soil. One application many solutions
Protection and power
Tractors are becoming more powerful all the time. Traveling increased distances both on road and in the field, where they now use heavy multifunctional tools, demands are high on both the vehicle and its tires. Trelleborg supplies Original Equipment Manufacturers (OEMs) with a wide range of tires, including the advanced TM900, one of the largest available. Its longer footprint effectively transmits traction to respect and protect the soil, while providing driver comfort.
A central role
Trelleborg Wheel Systems not only supplies the tires, but is also a provider of rims. The company is experiencing increased demand for its wheel and tire combinations.
10 Trelleborg Sealing Solutions in the groove No. 01/09 Damping vibration Electronic controls
The Multi Directional Snubbing (MDS) mount To maximize their effectiveness, tractors are from Trelleborg Industrial AVS, part of Trelleborg increasingly utilizing high-tech controls. Electronic Engineered Systems, is designed to provide a control units on hydraulic systems ensure a high degree of isolation, while controlling the constant plowing depth, compensate for load motions from large shock inputs experienced in differences and even position the vehicle as it severe off-road applications. It has become the works its way up and down the field. These highly solution of choice for tractor-cab mounting sensitive devices require specialized sealing that applications. can only be offered by a custom-engineered molded product. One application Hydraulic sealing
A typical tractor has a minimum of five different pumps and motors that control the hydraulic many solutions systems. For these, Trelleborg Sealing Solutions provides an extensive range of seals. Each of these pumps and motors is fitted with some form of oil seal, with mineral oil being the most common fluid that requires sealing. Other applications include static seals in the tank, couplings, pumps and motors. There are also dynamic seals in the cylinders that work the hydraulic actuators.
Customer success
Trelleborg is the supplier of choice for agricultural radial tires to large tractor Original Equipment Manufacturers (OEMs), such as Massey Ferguson, Claas and Fendt.
Trelleborg Sealing Solutions in the groove No. 01/09 11 Off-road Plowing ahead
Seals are integral to the Rexroth EHS2 electro-hydraulic control unit for tractors.
12 Trelleborg Sealing Solutions in the groove No. 01/09 Modern-day tractors rely heavily on hydraulics. These are used to ensure a constant plowing depth, compensating for load differences, bundling hay bales and even positioning the vehicle as it works its way up and down the field. Each hydraulic device requires its own processor. In the search for a robust yet compact electronic control unit, manufacturers turn to one of the world’s leading specialists in the field of drive and control technologies: Rexroth. ahead Developed by Rexroth at its plant in Schwieberdingen, supplied with compressed oil from a central pump. Each Germany, the EHS2 fulfills the need to integrate a number of these slices is responsible for a certain task, whether of functions in one central, space-saving electro-hydraulic rotating, tilting, lifting or compressing. While this is now a control unit. Depending on the amount of hydraulic best-selling product for Rexroth, the team of developers equipment to be installed in a tractor, each EHS2 is first had to overcome several hurdles – especially in composed of three to seven SB33 hydraulic valve slices terms of sealing.
In short... German manufacturer Rexroth developed a The combined expertise of the two partners compact electro-hydraulic unit for controlling resulted in the smooth and economical the hydraulics in tractors. production of an extremely reliable electro- hydraulic control unit for modern farm The company involved Trelleborg Sealing machinery. Solutions from product concept in meeting their stringent sealing requirements.
Trelleborg Sealing Solutions in the groove No. 01/09 13 Off-road
Early involvement
Christoph Jochum, Manager Engineering Mobile Electronics – Sensors, Hydraulics at Rexroth, confirms, “The partnership showed me how important it is to integrate the seal manufacturer at an initial stage of development. This is especially the case as Trelleborg Sealing Solutions is not only an expert in seals and related materials, but also has wide-ranging experience with surface finishes at mechanical interfaces. This was extremely useful in terms of the different thermal properties involved here.” Thanks to the use of computer simulation and the combined talents of Rexroth and Trelleborg Sealing Solutions, the team was able to reach its target without undue trial and error. This was evident, for example, in the small number of immersion No easy task tests that needed repeating, as well as the minimum amount of time spent experimenting on the elastomer formulations. To begin with, agricultural machinery is exposed to extreme As a result, clients in the agricultural machinery industry now conditions 365 days a year and often around the clock. The have a new generation of modular electro-hydraulic control control unit has to withstand operating temperatures of up to units available, which remain compact while allowing for +120°C/ +250°F, as well as possibly an ice-cold soaking when increasingly complex systems. In turn, farmers benefit from a the tractor drives through water. In addition, the unit has to perfect control system that is virtually maintenance-free and remain watertight despite the partial vacuum inside. All this unrivaled in its resistance to internal and external influences. makes heavy demands on seals. After all, the crops will not wait for the tractor to be repaired. The task is further complicated by the need for the seals to protect the control unit against oil, detergents, manure, high- pressure steam jets and even acidic lubricants. At the same time, the aluminum EHS2 control unit has to be perfectly sealed off from the SB33 hydraulics housing made of cast iron. A simple solution to sealing two metals with different thermal expansion coefficients is the use of a larger sealing cross section. However, this was not possible in this case, since the unit was specifically designed to be slim line. Fortunately, the team had expert partners on hand at Trelleborg Sealing Solutions. Norbert Gläser, Key Account Manager, explains, “As the long-term partner for Rexroth we already knew their high demands regarding quality and tolerance levels by heart. Otherwise we might have underestimated the requirements a little bit.”
Tailored to requirements
The initial talks between the two partners made it clear that a special sealing solution would be necessary, designed to meet the demands of the application. Hermann Zöllner, Manager Engineered Products at Trelleborg Sealing Solutions, recalls that it was not easy to find the optimal mixture for the molded seal that fulfilled the requirements in terms of chemical and thermal resistance, while keeping the manufacturing process technically and economically viable. This obstacle was overcome thanks to both partners displaying a willingness to collaborate beyond the factory gates. Dr. Ulrich Müller, who heads Engineering Mobile Electronics Hydraulics at Rexroth, explains, “The interaction between our developers and Electro-hydraulic control units Trelleborg Sealing Solutions was perfect. Everyone worked over from Rexroth are proving to be extremely reliable in today‘s farm and above corporate restrictions. This joint expertise led, for machinery. example, to the optimum design of the aluminum casing for the control unit.”
14 Trelleborg Sealing Solutions in the groove No. 01/09 Trelleborg Sealing Solutions in the groove No. 01/09 15 Oil & Gas
Bill Allan Oil & Gas Segment Manager, Trelleborg Sealing Solutions Europe
Controlled 80 100 explosion60 6 120 4 40 8 2 20
0 140
BAR 160
16 Trelleborg Sealing Solutions in the groove No. 01/09 Explosive Decompression (ED) is a major concern to the oil & gas industry as well as other sectors utilizing gas at high pressure. It occurs when applied system pressure is released, causing absorbed gas to expand, damaging elastomer seals. Here we explore this phenomenon and discuss some of the principles to reduce ED risk and extend seal life in applications where ED may occur.
80 100 explosion60 6 120 4 40 8 2 20
140 “As a seal developer and manufacturer with a significant 0 proportion of our business in the oil & gas sector, Explosive Decompression (ED) has been a key area of focus for us,” says Bill Allan, Oil & Gas Segment Sales Manager for Europe.
Concentrating on engineering seals that give BAR 160 optimum performance
“We have invested considerable amounts of development time and money on the quest to find Explosive Decompression Resistant (EDR) materials,” continues Bill. “However, it is somewhat misleading to describe a particular elastomer as ED-resistant. It’s more about relative resistance. All elastomers are liable to absorb gases when placed under pressure. When the pressure is released the gas expands and this can cause internal cracks within the elastomer, leading to mechanical breakdown in severe cases. So our aim is to concentrate on engineering seals that give optimum performance based on operating conditions.”
Trelleborg Sealing Solutions in the groove No. 01/09 17 Oil & Gas
Trelleborg Sealing Solutions works with engineers to design their applications to minimize the risk and effect of ED. This is a complex matter. Numerous factors have to be taken into account. These include the elastomer, the housing, the contact fluids and gases as well as their solubility, any swelling of the seal due to absorption of fluid and the morphology of bubble formation.
Speed, cycles and level of decompression are significant factors affecting ED
“Explosive decompression is also a bit of a misnomer, as decompression does not have to be rapid to cause significant damage in elastomer seals,” Bill points out. “In fact it has been shown that a 30-minute decompression can cause as much damage as an instantaneous one. In general, though, the longer the decompression, the less likely damage is to occur. “Another factor is that in operation, seals tend not to be subject to a single decompression but cycles. There may be no apparent damage to a seal after a single decompression, but after several more cycles you can see the damage. The level of pressure in cycling tends not to be as important as the size of the pressure differential. A drop from 15 MPa/ 2,200 psi to 5 MPa/ 725 psi would probably be more damaging than, from say, 20 MPa/ 2,900 psi to 15 MPa/ 2,200psi.”
Work with the experts to maximize seal life
“Overall I’d always recommend talking to the experts,” says Bill. “A company like Trelleborg Sealing Solutions has the experience to help come up with the optimum seal groove design, configuration and material to ensure maximum seal life.”
For more information about Oil & Gas Sealing Solutions please contact your local marketing company or take a look at the XploR™ flyers in the services area on: tss.trelleborg.com
18 Trelleborg Sealing Solutions in the groove No. 01/09 When is there a higher risk Explosive Decompression – Facts of Explosive Decompression? How it occurs
In dry gas applications where system media is Gas or gas mixtures in contact with elastomer surfaces mostly gas can be absorbed under pressure. At high pressure absorbed gas is in a compressed state. When external When service pressures are 3,5 MPa/ 510 psi pressure is reduced, either rapidly or over a relatively or higher short period of time, the compressed gas rapidly Where system pressure is not constant expands within the elastomer. This can lead to crack If the differential between varying pressures is high When pressure variations are rapid At elevated or sub-zero temperatures
Factors to consider when designing equipment to minimize ED risk and effect initiation within the body of the elastomer. These cracks Application parameters propagate internally and this can cause void formation or · Gas pressure cracks to appear on the elastomer surface. · Type of gas · Number of decompressions · Rate of decompression events Seal and housing design · Pressure differential between cycles · Operating temperatures tips to improve Explosive Seal material Decompression Resistance · Chemical resistance (EDR) · Thermal capabilities · Modulus Keep seal section diameter as small as possible · Tear strength at 5.33 mm/ 0.2 inch or lower Seal design Make initial squeeze as low as possible around · Seal section 10-15 percent · Groove fill Ensure tear strength of the elastomer is as high as possible Design the seal groove combination to give close to 90 percent groove fill; this limits the potential area into which voids can expand Use rigid anti-extrusion rings on both sides
Trelleborg Sealing Solutions in the groove No. 01/09 19 Oil & Gas
80 100 60 6 120 4 40 8 2 20
0 140
BAR 160
XploR™: Features & benefits Facts
Each material demonstrates unrivalled Isolast® XploR™ J9513 gives almost Explosive Decompression Resistance (EDR) universal chemical compatibility within its material type Long life in aggressive media, including Temperature resistance over a broad range hydrocarbon and aqueous media, common within oil & gas applications Exceptional mechanical performance High modulus, high strength Low long-term compression set Materials compliant to NORSOK M-710 Very good chemical compatibility
20 Trelleborg Sealing Solutions in the groove No. 01/09 XploR™: Best-in-class elastomers specially engineered for optimized EDR
The XploR™ range from Trelleborg Sealing Solutions is a The first FFKM on the market to meet suite of advanced elastomers especially developed for Norsok M-710 RGD test conditions oil & gas applications. The portfolio includes compounds ® in HNBR, FKM and Isolast Perfluoroelastomer (FFKM), In independent tests, materials within the XploR™ range each of which demonstrates best-in-class Explosive were able to satisfy both the Norsok M-710 sour service Decompression Resistance (EDR) for its material type. and Rapid Gas Decompression (RGD) test conditions. XploR™ J9513 is the first perfluoroelastomer on the market to meet the requirements of this stringent RGD test. 80 100 Compound Number 60 XploR™ XploR™ XploR™ 6 120 H9T20 V9T20 J9513 4 Elastomer Base DIN ISO 1629 HNBR FKM FFKM DIN 53 505 90 +/- 5 90 +/- 5 95 +/- 5 40 Hardness 8 Shore A Shore A Shore A Color Black Black Black 2 Specific Gravity DIN EN ISO g/cm2 1.25 +/1 1.84 +/- 1.92 +/- 20 1183-1 0.03 0.03 0.03 Tensile Strength DIN 53 504 MPa N/mm2 34.8 25.5 18.6 140 0 psi 5,000 3,700 2,700 Elongation at Break DIN 53 504 % 204 186 68 Modulus 100% DIN 53 504 MPa N/mm2 16.6 13.2 N/A BAR 160 psi 2,400 1,915 Compression Set DIN ISO 815 Type B % 35 (72h/ 200°C/ 392°F) TR10 Point ASTM D 1329 °C -23 -15 -3 °F -9 +5 +27 Service Temperature °C -30 to +175 -20 to +230 -10 to +260 °F -22 to +350 -4 to +440 +14 to +500
Turcon® and PEEK™
In addition to the elastomers presented in this article, our proprietary range of PTFE based compounds, and Trelleborg Sealing Solutions also offers a number of PEEK™ materials. Turcon® demonstrates excellent EDR thermoplastic sealing materials with certificates of inherently due to the high crystallinity, low gas solubility compliance to NORSOK M-710. These include Turcon®, and granular morphology of PTFE based materials. Material Range
Trelleborg Sealing Solutions in the groove No. 01/09 21 Rotary sealing
Compact performance
The new Turcon® Roto VL Seal® is a high- pressure compact seal that is ideal for rotary applications where there is limited space or for installation into standard O-Ring grooves. Turcon® Roto VL Seal® is developed from the proven Turcon® VL Seal®, and like this consists of an L-shaped Turcon® seal that is energized by a static O-Ring. Its non-symmetric single- acting seal design optimizes sealing performance under various pressure and surface velocity conditions. “A unique feature of the new Turcon® Roto VL Seal® is that, due to its compact design, it can be fit into much smaller spaces than traditional rotary seals,” says Thomas Sandholdt, Product Manager for Trelleborg Sealing Solutions Helsingør, Denmark, where the product is manufactured. “It is also an excellent choice where standard O-Ring housing grooves are preferred.”
Turcon® Roto VL® Seal is ideal for a wide variety of applications. These include tractors, forestry equipment and injection molding machines.
22 Trelleborg Sealing Solutions in the groove No. 01/09 Features and benefits of Turcon® Roto VL Seal®: Turcon Elastomer O-Ring • High flexibility to satisfy hardware tolerances • High static sealing function eliminates fluid flow in the groove • Elastomer materials available to meet a wide variety of service conditions ® Roto VL Seal VL Roto Stabilizing Wing • Keeps the O-Ring in the correct position when not pressurized • Assists pressure transfer from O-Ring to seal lip • Stabilizes the seal profile Circumferential Lubricating Groove • Increases lubrication of dynamic contact area • Reduces contact area to lower friction
Rear Chamfer ® • Prevents extrusion of seal material into the radial clearance Pressure Relieved Sealing Lip • Optimized sealing lip position for high sealing efficiency • Short dynamic contact area for low friction and torque Contoured O-Ring Contact Zone • Stabilizes the O-Ring position in the seal groove • Secures optimal pressure transfer to dynamic sealing lip • Prevents O-Ring nibbling Stabilized Groove Contact • Strong seal profile with full groove wall contact for stable seal position • Prevents premature extrusion of seal material into the radial clearance
Trelleborg Sealing Solutions in the groove No. 01/09 23 Rotary sealing
Turcon® Roto VL® Seal is available in a broad range of sizes.
A multitude of applications Method of operation
Turcon® Roto VL® Seal is primarily intended for constant service As with other O-Ring based Slipper Seals, the initial in demanding situations where there are rotary, swiveling or squeeze of the O-Ring in Turcon® Roto VL® Seal helical movements at medium to high system pressure. ensures sufficient contact pressure between seal surface and mating surface to provide tightness at Some applications where the new Turcon® Roto VL Seal® would low pressure. With increasing system pressure, the be found are: O-Ring and the seal body direct pressure down on the sealing surface to ensure sealing efficiency at all • rolling mills Turcon pressures. At very high pressure, the contact area • machine tools with the mating surface is increased so excessive • hydraulic swivels stress in the seal and mating surface is avoided. • injection molding machines • valve spindles ®
• food processing (blenders and mixers) Seal VL Roto • hydraulic steering units • forestry machines and cranes • rotators for handling devices • vane actuators/motors • hydraulic motors • hydraulic pumps • propeller thrusters • ROVs (remotely operated vehicles) ®
Operating conditions Movement: Rotary, intermittent or oscillating service
Velocity to 2 m/s/ 6.5 ft/s Technical Data Pressure: Up to 30MPa / 4,350psi 40 MPa / 5,800 psi for short durations or when static Temperature: Turcon® materials: -40°C to +120°C/ -40°F to +248°F +200°C / +392°F static according to O-Ring material Zurcon® Z52: -40°C to +80°C/ -40°F to +176°F +100°C / +212°F short durations or static according to O-Ring material Zurcon® Z80: -40°C to +60°C/ -40°F to +140°F +80°C / +176°F short durations or static according to O-Ring material Media: Hydraulic fluids, water-based fluids, air and gases depending on seal material
24 Trelleborg Sealing Solutions in the groove No. 01/09 Some call you talented. We call you Trelleborg potential.
At Trelleborg, we aim high. Not only with our high-performance polymer solutions, but also with our people. Our world is challenging and Trelleborg is a global engineering demanding, which often results in pioneering developments. To stay group creating high-performance solutions that seal, damp and world leading, we need talented people. Are you Trelleborg potential? protect in demanding industrial environments, all over the world. Trelleborg. Where talents grow. Find out more about our world at www.trelleborg.com.
Solutions Securing Values™
080909_Studentannons_T-time.indd 1 08-10-28 17.08.29 Automotive
Sealing for a sustainable future
In short... Fulfilling all our energy needs from oil while Sealing in biofuels, especially the next generation
reducing our CO2 emissions will become ones developed to have less environmental increasingly difficult. impact, is challenging. Biofuels present a short-term sustainable option, Trelleborg Sealing Solutions has undertaken but much controversy has focused on the real substantial research, which means that we can environmental benefits of first generation fuels. recommend the optimum sealing solution for biofuel applications.
26 Trelleborg Sealing Solutions in the groove No. 01/09 When engineers specify seals, biofuels present some significant challenges as their chemical make-up can affect the sealing integrity of elastomers. Standard laboratory tests indicate that typical FKM and FVMQ compounds are compatible with biofuels. However, when sealing materials are tested in conditions reproducing those seen in service, it becomes evident that specialized formulations are required to ensure integrity and long service life.
It seems more and more likely that the use of fossil fuels is to play an increasingly important role as an energy source for heading down a dead-end street. Global warming, yo-yoing oil transportation in the near future. These biofuels are made from prices and an overwhelming dependency on oil make these non-edible feedstock and have increased yields.” fuels a less than viable option for the future. Biofuels can deteriorate the properties of As an energy source for transportation, biofuels elastomer seals will play a future role However, these biofuels present new challenges in many areas, Car manufacturers consider sustainable biofuels an essential from production, to the service station, to the vehicle. part of an integrated approach to reducing CO emissions. 2 “O-Rings are the most commonly used seal in fuel systems and They have invested in engine modifications to accommodate the effect biofuels have on the elastomers they are made of is current biofuel blends and future fuel mixes with higher biofuel critical in ensuring sealing integrity. For instance, a blend ratio content. of 25 percent alcohol in gasoline can cause major deterioration “The second generation of biofuels,” says Gordon Micallef, in the properties of elastomers.” Technical Director, Trelleborg Sealing Solutions Malta, “is likely
Trelleborg Sealing Solutions in the groove No. 01/09 27 Automotive
Testing and compound development for the with commonly used biofuels. However, going one step further, optimum sealing solution testing was conducted to reproduce service conditions. “This presented a different picture,” Micallef says. “Water Trelleborg Sealing Solutions is working on safe alternatives contamination in biodiesel is highly probable and can lead to for all types of combustion engines, collaborating with fuel nonreversible degenerative effects on certain FKMs.” producers and dealers – as well as with customers and original equipment manufacturers. Through testing and compound development, the company is comparing the effects of biofuels It is crucial to select the right compound on various elastomeric sealing compounds in search of optimal formulations. “In high-pressure gasoline applications,” he continues, “the risk “Recently,” Micallef says, “we evaluated the compatibility of of rapid decompression failure, where gas captured within the typical automotive fuels for both diesel and gasoline engines seal can cause the seal to split, is increased by the addition of with various fuel system compounds focusing on hardness, ethanol. In our tests, non-optimized compounds cracked sub- stress-strain and volume swelling. As newer gasoline engines surface. This dramatically reduces the integrity of the seal, while operate at high pressures, the combined effects of high being difficult to detect.” pressures and biofuels were also studied.” Tests by Trelleborg Sealing Solutions have proven it crucial to select the right compound for the various seals used in fuel applications. “Research and development is essential,” says Standard seal formulations may not give Micallef. “It is the only way we can ensure we have the optimum required integrity seal for the job.”
Standard laboratory tests suggested that typical elastomers of Fluorocarbon (FKM) and Fluorosilicone (FVMQ) were compatible
Fuel for thought Facts
By 2050, the world needs to double that is widely blamed for the For example, most biomass fuel its supply of energy while cutting destruction of the Malaysian rainforest production will have a protein by-
CO2 emissions in half. As the global and the orangutans that live there product, which can be used for animal population heads for nine billion, is used for food and cosmetics, feed. There may also be residue supplies of conventional oil and gas not biofuels. These experts argue of the biomass itself, which can be will not keep up. that biofuels, as the only short- used for power. Cellulosic ethanol term renewable alternative to oil in has by-product chemicals such as transport fuels, have an important role xylitol, which is used in a range of food Biofuels are the only short- to play now – subject of course to products. term alternative environmental safeguards on how they Another concern is whether biofuels are produced. take more energy to create than they The introduction of biofuels such give back. It is believed that in almost as ethanol and biodiesel, with their all situations this is not the case. inherent potential to reduce CO New sources of biofuel focus 2 Corn-based ethanol, for example, emissions significantly, appeared on sustainability emits around 10 to 30 percent less to be the sustainable solution. But CO than gasoline on a well-to-wheels eco-euphoria gave way to alarming Since widespread criticism of 2 basis. Ethanol made from Brazilian reports about the side effects of first generation fuels, research is sugar cane emits up to 90 percent biofuel production. They have been focusing on utilizing sources that less. blamed for everything from destroying do not compete with food, threaten the environment to starvation in the rainforests or undermine communities And biofuels are getting better all the developing world. creating biofuels. These include time, more energy efficient, lower cellulosic ethanol from straw, synthetic in CO and more sustainable. Algae, However, some experts supporting 2 biodiesel from woodchips and gasoline another future source, is expected the technology say that criticism made directly from sugars. Producers someday to absorb more CO than against biofuels is exaggerated 2 are also looking at maximizing use is later emitted during the production or just plain wrong. For example, of by-products, minimizing waste. and combustion processes combined. 98 percent of the palm oil production
28 Trelleborg Sealing Solutions in the groove No. 01/09 Helping bring in the crop
Trelleborg Sealing Solutions is not the only part of Trelleborg Group helping make biofuels a reality. Trelleborg Wheel Systems is doing so as well. Approximately 50 percent of the cars currently on Brazilian roads are fueled by ethanol produced from sugar cane, and the country is now the world’s second largest producer of ethanol and its number one exporter. Brazil’s seven million-plus hectares/ seventeen million-plus acres already under sugar cane are projected to double by 2020.
Sugar cane harvesting is the core business of Trelleborg Wheel Systems in South America. Extra-wide tires it developed for the forestry industry in the 1960s are ideally suited to sugar cane. Their extended width means less compaction of the soil, which in turn leads to improved nutrient absorption and a reduction in the need for fertilizers.
Trelleborg Sealing Solutions in the groove No. 01/09 29 Automotive
What are biofuels? Facts Biofuels are liquid fuels made from organic matter, 1st Generation Biofuels typically crops. Bioethanol begins with the fermentation of plants containing sugar, such as sugar cane, sugar beet Fermentation Esterification or corn. A series of reactions caused by yeast or bacteria convert this sugar to ethanol. Biodiesel is produced via Fruit / Seed base-catalyzed transesterification from oilseeds such as rapeseed, oil palm or others. Triglycerides (fat/oil) react with alcohol to form mono-alkyl ester (biodiesel) and glycerol. Ethanol Bio Ester These can be blended in relatively small quantities with existing fossil fuels for use in unmodified internal Diesel
combustion engines, making them an immediately viable Gasoline option for the transportation industry. Cellulose Ethanol BTL First generation biofuels are being superseded by second generation ones. Derived from the whole plant, they Biomass, include biomass to liquid (BTL) and cellulosic ethanol. organic residues Both contain a higher CO avoidance potential than the Enzymatic Gasification 2 decomposition first generation methods and increased yields, plus there FT-Synthesis are no direct interferences in the food chain. 2nd Generation Biofuels
Under pressure Fueling research
A practical example of sealing in biofuel applications is Trelleborg Sealing Solutions has been working
this high-pressure pump. In this application, there was Application with automotive manufacturers since biofuel engine oil on the drive side and fuel on the pump side. A technology was in its infancy. Recognizing the three-part seal in between them prevents the two from issues in finding the right seals for biofueling mixing. The seal has sealing lips in both directions made systems, we conducted in-depth research of Turcon® PTFE based material along with two O-Rings in on the suitability of sealing formulations in a specially formulated elastomer that act as pre-stressing biofuel mixtures. From this research, we can elements. This solution provides a good wiping effect, high recommend the optimum material for biofuel resistance to wear, the ability to function at temperatures sealing applications including diesel and gasoline down to -40°C/ -40°F and stability in the presence of fuel connectors and injectors, either high or low biofuels. pressure, as well as diesel pumps.
For full details of our biofuel research read “The optimum sealing compounds for biofuels” in the news area on tss.trelleborg.com
30 Trelleborg Sealing Solutions in the groove No. 01/09 The Turcon® alternative
Resistant to virtually all media, Turcon®, the Trelleborg Sealing Solutions proprietary PTFE based For more details, please sealing material, is an ideal option for dynamic and rotary biofuel contact your local Trelleborg applications. The material, is Sealing Solutions marketing available in a variety of geometries, company. For contacts go to energized either with an elastomer element or with a spring. tss.trelleborg.com
Read the article? Now see the movie!
Why not take a look at the Trelleborg Sealing Solutions movie on sealing in biofuels? You can order it from your local marketing company now.
Trelleborg Sealing Solutions in the groove No. 01/09 31 Innovation Low energy
movement Trelleborg Sealing Solutions launches Turcon® Varilip® PDR. The optimum solution for high-speed rotating applications, it has exceptional low- friction characteristics, reducing “Currently there is a big push by industry in general to reduce power consumption and our carbon footprint,” says Stuart torque. That cuts power consumption, Moares, Product Manager for Trelleborg Sealing Solutions contributing to lower equipment running Bridgwater, UK, one location where Turcon® Varilip® PDR is manufactured. “Apart from showing responsibility for the costs and in the end, decreased energy environment, it has the benefit of lowering ever-increasing energy bills.” bills.
“lowering ever-increasing energy bills”
Taking a specific example from the semiconductor sector, tests show that Turcon® Varilip® PDR requires only around 50 percent of the torque of a radial oil seal when running in Fomblin® oil, commonly used in vacuum pumps. This meets designers’ objectives for lower power consumption, a critical success factor in this type of equipment.
A cost-effective option for virtually any rotating application
Based on the substantial experience of Trelleborg Sealing Solutions in supply of custom-designed metal-bodied rotary shaft seals, the new range offers customers a wide choice of standard parts in various corrosion-resistant materials and lip geometries. These will meet the requirements of virtually any rotating application in numerous industries including chemical processing, oil & gas, semiconductor, automotive, motor sport, marine, machine tools and power transmission. As no specific tooling is needed in manufacturing, they prove a very cost- effective option.
Turcon® Varilip® PDR is ideal not just for processing systems. It has been successful in motor sport applications too.
32 Trelleborg Sealing Solutions in the groove No. 01/09 Benefits of Turcon® Varilip® PDR include: Turcon Turcon® PTFE based sealing lip • Low-friction to facilitate reduced power loss and friction- induced heat • Unique self-lubricating hydrodynamic feature further reduces friction ®
• Advanced geometries engineered to give excellent Varilip performance in almost every high-speed rotary situation • Multiple lip configurations to address most sealing needs • Material compatible with virtually all media • Available in FDA-compliant grades ®
Metal body PDR • Durability in harsh environments • Effective sealing on static outer diameter • Resistance to thermal cycling • Choice of high-quality metals including Stainless Steel, aluminum and other specialized metals such as Hastelloy® or Titanium • High corrosion-resistance • Superior precision-machined finish for improved sealing on the static interface
Overall Turcon® Varilip® PDR seal • Contributes to a reduction in power consumption of equipment • High speed capability up to 100 m/s / 19,680 ft/m • Wide operating temperature range from -60°C to +200°C/ -76°F to +392°F • Options available for dry-running applications and for soft shafts • Retrofits in radial oil seal grooves • Unlimited shelf life with no special storage requirements
Trelleborg Sealing Solutions in the groove No. 01/09 33 Innovation
Long service life in rotary applications
Turcon® Varilip® PDR (Performance, Durability, Reliability) rotary shaft seals are constructed from one or multiple Turcon® PTFE based sealing elements which are mechanically retained in a Product information precision-machined metal body. The metal body Download the gives a robust static seal against the housing, ® ® preventing thermal cycling, while the Turcon® Turcon Varilip PDR sealing element provides positive dynamic sealing catalog from on the shaft, leading to excellent performance at high rotary speeds. Characterized by low friction tss.trelleborg.com and stick-slip-free running, the seal reduces temperature generation, permits higher peripheral services area. speeds and lowers power consumption. This results in a long-service life, with maximized mean time between planned maintenance and greater productivity. High speed performance
Turcon® Varilip® PDR gives superior surface speed capability compared to elastomeric shaft seals.
8000 80 / 265 RPM
7000 70 / 230 Turcon® Varilip® PDR
60 / 200 6000 Surface Speed m/s / ft/s
50 / 165 5000
40 / 130 Fluoroelastomer 4000
30 / 100 3000
Polyacrylic
20 / 65 2000
Nitrile
10 / 35 1000
0 40 / 80 / 120 / 160 / 200 / 1.60 3.15 4.50 6.30 7.90
Shaft Diameter mm/in
34 Trelleborg Sealing Solutions in the groove No. 01/09 Turcon® Varilip® PDR has been successfully tested in 20 percent fluorine gas, used in semiconductor fabrication applications, at temperatures in excess of +250°C/ +482°F. Turcon ®
Wide temperature range Varilip
Turcon® Varilip® PDR provides outstanding high and low operating temperature performance. ®
+300°C / +572°F PDR
+250°C / +482°F
+200°C / +392°F
+150°C / +302°F
+100°C / +212°F
+50° / +122°F
0°C / +32°F
-50°C / -58°F
-100°C / -148°F
Turcon® Fluoroelastomer Nitrile Silicone Polyacrylic Leather
Trelleborg Sealing Solutions in the groove No. 01/09 35 Processing
As energy conservation becomes a focus for us all, the demand for Plate Heat Exchangers is booming. Not only are they a fundamental part of many production processes, they also facilitate the use of what otherwise would be wasted heat. Trelleborg Sealing Solutions is one of the leading suppliers for gaskets fitted to these systems. A fair exchange “It’s hard to tell you all the applications for Sealing Solutions Material Development Plate Heat Exchangers or PHEs, as they Manager for PHE gaskets. “In richer and are affectionately known,” says Jonas less environmentally aware times heat Jerleus, Trelleborg Sealing Solutions was just pumped out of the processing Global PHE Coordinator. “Originally system and wasted. That wasn’t good for they were used in the sterilization and energy conservation or the atmosphere. pasteurization of dairy products, mainly milk. Now though you’ll find them on ships, feeding heating systems for “PHEs ensure efficient energy buildings and in almost every processing use by recycling heat” plant.” “Think of a power station. Why get rid of all the steam used for energy production The demand for Plate Heat when it can be diverted into heating Exchangers has doubled offices and homes? On a ship, just like the function a car’s radiator performs, PHEs for liquid beverages used to take but on a larger scale, PHEs mean heat the lion’s share of the market. This sector from combustion engines is used for has diminished as the other sectors have air-conditioning and heating. While in expanded. In the early days, the number processing plants, PHEs ensure efficient of PHEs sold was relatively small. Then energy use by recycling heat. When they demand started growing, and driven by are employed within a system the overall a desire to manage energy better, in the heat loss can be extremely low.” last ten years the market has doubled. “Wander around a processing plant and “Heat is generated in all types of you’ll see PHE up to five meters/ 16 feet processing,” says Jon Cutler, Trelleborg in height,” adds Jonas. “The largest plate
36 Trelleborg Sealing Solutions in the groove No. 01/09 exchange
In short... Plate Heat Exchangers are used for heating and cooling. Depending on the process, heat is recycled in various ways to conserve energy. Applications are numerous, from liquid beverage production to district heating systems. Trelleborg Sealing Solutions produces the critical gaskets that allow PHEs to function successfully.
Trelleborg Sealing Solutions in the groove No. 01/09 37 Processing
width is one and a half meters/ five feet, and “we are able to guarantee meeting length is four meters/ 13 feet. This is restricted the OEMs’ tight tolerances” by the maximum size to which strip steel can be produced. They will range from this size down to “We’re taking gasket compounds to the limits of about 280 millimeters/ 11 inches long and 100 their performance,” says Jon. “Great efforts have millimeters/ four inches wide.” been made to ensure gasket material longevity at high temperatures and pressures. An advantage Gaskets preventing liquids mixing or we have is that applications are static. Materials can also be engineered with both high modulus leaking are critical in PHEs and excellent deformation resistance.” The plates are sealed with a rubber gasket that Trelleborg Sealing Solutions works very closely with prevents the two liquids within the PHE leaking its customers, and quality is key. “If there is one out or mixing. “Gaskets are critical elements thing we pride ourselves on more than any other,” within a PHE and potentially their weakest link,” Jon points out, “it is the initial fit of our gaskets. continues Jon. “We’ve been making them for Probably better than any other manufacturer we more than 25 years and customers rely on our are able to guarantee meeting the OEMs’ tight material expertise.” tolerances in gasket length control.” Sealing in PHEs is not easy. Temperatures are Heat exchanger plate at extremes from –45°C to +200°C/ –49°F to As OEMs expand production and gasket +392°F, while chemicals are some of the most worldwide, a supplier’s global reach aggressive processed. As the liquids are pushed through a large PHE with maybe 200 plates, is important pressures are also high. These are generally between 0,5 and 1.5 MPa/ 72 and 218 psi but Jonas emphasizes that service is also important. sometimes even up to 3.5 MPa/ 508 psi. “Timing can be critical, especially when a ship is being fitted out. We may be given one specific day that the gaskets can be delivered, and there can be no excuse if they are not ready on time.” An emerging trend is that the PHE original equipment manufacturers, who have predominantly manufactured in Europe up until Plate heat exchangers now, are expanding production globally. “That’s are used in a wide where our global reach is important,” says variety of sizes. Jonas. “In Europe we manufacture in Poland and demand from the Americas is fulfilled from our facility in Tijuana, Mexico. With manufacturing in Asia increasing, we have now transferred gasket technology to our plant in Shanghai, China.”
How a Plate Heat Exchanger works Facts
The design concept for all PHEs is the same. Between two metal end plates there is a series of thin metal plates close to each other. The liquid to be processed is pumped into one side of the plates while the liquid facilitating heating and cooling is pumped into the other. The key to the process is that both liquids come into contact with the maximum plate surface area to rapidly exchange heat from one liquid to the other.
Plates are produced in a variety of metals, primarily strip Stainless Steel and for contact with seawater, in titanium. The main gasket materials for plate heat exchangers are Nitrile Butadiene Rubber (NBR), Ethylene Propylene Diene Rubber (EPDM), Fluoroelastomer (FKM), Chloroprene Rubber (CR) and Hydrogenated Acrylonitrile- Butadiene Rubber (HNBR) with other compound types being used for specific applications.
38 Trelleborg Sealing Solutions in the groove No. 01/09 Plate heat exchanger applications:
Food and beverage processing Power industry PHEs were originally developed for the pasteurization Numerous PHEs are utilized for cooling, pre-heating Applications and sterilization of dairy products. Their use has and waste heat recovery in all types of power extended to all types of liquids in food and beverage stations. processing. Marine Chemical processing Below deck a variety of PHEs might utilize heat Large PHEs are used in many chemical generated from engines for various functions, manufacturing processes for controlled heating and including heating and air-conditioning, as well as cooling. cooling the engines themselves. Pulp and paper mills Biofuel production Waste heat is effectively recycled in pulp handling PHEs are an integral part of the extraction and and paper production. processing of ethanol from vegetable matter. Industrial refrigeration Building Heating Ventilating and Air-Conditioning For ice and snow production, PHEs often have (HVAC) refrigerants on one side of the exchanger and District heating systems where PHEs allow the use coolant on the other. of steam from power stations to heat or air-condition apartment buildings, factories and public buildings
Plate Heat Exchanger construction Facts
PHE gaskets range in length from 280 millimeters/ 11 inches up to four meters/ 13 feet at a maximum of one and a half meters/ five feet wide. The 3 smallest thickness is two millimeters/ 0.08 inches up to 20 millimeters/ 0.8 inches for gaskets used in evaporation and condensation processes, such as 2 ethanol production.
1 6 5 1 Fixed cover/end plate 2 Movable cover/end plate 3 Carrying bar 4 Guiding bar 7 5 End support 6 Plates/ gaskets 7 Tightening bolt 4 8 Connection port 8
Trelleborg Sealing Solutions in the groove No. 01/09 39 Hydropower
On the Cowlitz River in the state of Washington sits the Mossyrock Dam, the Pacific Northwest United States’ tallest. Owned and operated by Tacoma Power, the dam is being overhauled to improve efficiency. When completed, Riffe Lake reservoir, formed by Mossyrock, will power 78,000 homes with electricity. That’s 30,000 more than it powers currently. The power of water
40 Trelleborg Sealing Solutions in the groove No. 01/09 After over forty years of service, hydroelectric turbine units to calculate and design the bearings for proper installed on the Mossyrock Dam were not as efficient as they once clearances and interferences,” says Tom Carew, Hydro Segment were, with repairs and maintenance becoming more and Manager for Trelleborg Sealing Solutions Americas, who worked more expensive. Eventually, without replacement, failure due closely with ANDRITZ through the whole project. to mechanical fatigue would take place, meaning very costly The wicket gate bearings, vertical and horizontal liners, repairs. To avoid this, Tacoma Power decided to upgrade the operating rings and all linkage bearings on the turbines were two largest 150 megawatt units and install one additional unit all fitted out with Orkot® TXMM bearing materials. In addition, before any problems could occur. Variseal® VR seals, using an elastomeric energizer and Zurcon® ANDRITZ HYDRO Canada, a worldwide manufacturer of Z80 jacket, were incorporated into all intermediate and lower hydroelectric turbines, was awarded the contract to upgrade wicket gate bearing designs. These seals are specially designed the Mossyrock Dam hydroelectric turbine units. The two 150 by Trelleborg Sealing Solutions Broomfield for hydro bearing megawatt propeller units were originally built in 1968 and applications. have had an extended service life of almost 40 billion kilowatt hours. Partnership Formed
Complete Overhaul Trelleborg Sealing Solutions Canada is now a preferred supplier for ANDRITZ HYDRO, with Orkot® TXMM hydro bearings being Trelleborg Sealing Solutions Canada, working with ANDRITZ the recommended product for specification on all future HYDRO Canada engineers, specified machined Orkot® TXMM projects, where required. hydro bearing materials for the upgrades. “We worked together The new, upgraded turbines will be fabricated and installed in water 2009. In addition to also replacing the wicket gate seals and bearings with Trelleborg Sealing Solutions product, ANDRITZ will complete the project by replacing the exciters and generator stator, refurbishing the rotors and modernizing the governor with a new digital control system.
Orkot® bearings are used on numerous hydropower applications.
In short... Two hydroelectric turbines are being replaced and an additional one fitted as part of an upgrade to Mossyrock Dam after forty years of service. ANDRITZ HYDRO Canada will be undertaking this work. Once completed, the dam will power 30,000 extra homes with electricity. Trelleborg Sealing Solutions will supply hydro bearings and a variety of seals for the turbines.
Trelleborg Sealing Solutions in the groove No. 01/09 41 Hydropower Facts: The dam
Mossyrock Dam is the Pacific Northwest United States’ tallest at 185 meters/ 606 feet. Owned and operated by Tacoma Power, the dam is being overhauled to improve efficiency. After this has been done, Riffe Lake, the 34 kilometers/ 23 mile long reservoir formed by Mossyrock, will power 78,000 homes with electricity.
The reservoir serves multiple purposes besides power generation. It is a popular recreation destination, particularly in the summer and fall. During winter and spring the level of the reservoir is lowered to provide space to help manage down-river flooding. During the summer months water is gradually released to provide supplemental river flows for the benefit of the fish habitat.
42 Trelleborg Sealing Solutions in the groove No. 01/09 Mossyrock Dam: Hydroelectric Speak
Generating power since History Gross Head – the true vertical distance from 1968 intake to turbine and the resulting pressure at the Definitions bottom On October 13, 1968, Tacoma City Light’s Mossyrock the pressure at the bottom of a Dam on the Cowlitz River in eastern Lewis County Net Head – pipeline when water is flowing to the turbine generated electricity for the first time. The two generators within its powerhouse with net head of controls the magnetic field in the 105 meters/ 345 feet, each generate 150,000 Exciter – generator system and controls the output voltage kilowatts of electricity for Tacoma. and/or current
Generator Stator – stationary part of the rotor system, as is in an electric generator
Governor – electronic system that controls the speed on the turbine
Pictured are the tops of the generators. Each of these generators is powered by its own turbine unit, located below the generator floor.
Trelleborg Sealing Solutions in the groove No. 01/09 43 Service
Trelleborg Sealing Solutions prides itself on the best-in-class tools it has on the web. Always trying to make the lives of engineers easier when they are specifying seals, we have developed some new additions online - a material search and chemical compatibility check. Both of these help match the optimum seal material to the requirements of specific applications. Matchmaking online
44 Trelleborg Sealing Solutions in the groove No. 01/09 Chemical compatibility check
Quick and user-friendly way of finding the level of resistance of elastomer material groups to a broad range of media, both fluids and gases Simple symbols indicate resistance One or multiple media can be selected in a single search
Simple to use
It’s really easy to find the optimum material type for your application! 1. Select the media seals will come into contact with in your application from an A to Z list covering all common process and cleaning fluids and gases. You can select more than one at a time. 2. Click ‘Show compatibility.’ 3. The result is a table with symbols indicating if sealing material types have very good, good or limited suitability, or if the material type is unsuitable. 4. From the table the optimum material type can be selected. As the results are only a guide, then it’s time to email or pick up the phone to contact your local marketing company to select the best compound for the job. 5. Or go to Material Search to find out more information on specific materials
Trelleborg Sealing Solutions in the groove No. 01/09 45 Service
Material search
Find material properties searching by elastomer material type or trade names quickly and easily Identify compounds that meet specific property requirements such as operating temperatures or hardness Identify formulations that comply to specific approvals or standards
Detailed data at the click of a mouse
Use this tool to identify the optimum sealing compound from the hundreds of elastomers listed.
1. If you select ‘Search by Material Name and Properties’ on the first screen you have the choice of searching for compounds by material group, common trade names, the Trelleborg Sealing Solutions name, temperature in Celsius or Fahrenheit, hardness and approvals.
46 Trelleborg Sealing Solutions in the groove No. 01/09 Trelleborg Sealing Solutions believes that it now provides more widely available online services than any other sealing supplier. The new material search and chemical compatibility check join the already well-established O-Ring calculator, electronic catalog and CAD service. All are available in the Members Area free-of-charge. Go to tss.trelleborg.com
to access all our online services.
2. A good starting point is to add the lower and upper 4. The alternative of searching by product type allows you temperature range of your application. The result will to narrow your criteria down to recommended materials give you all the compounds that can theoretically for O-Rings, QUAD-RING® and V-Ring®. operate within those limits. 5. Again, the suitability of materials resulting from the 3. You can then more closely match your requirements tool is only a guide. So make sure you contact your by selecting hardness, a specific material type or an local marketing company to complete the specification approval that needs to be met. process.
Trelleborg Sealing Solutions in the groove No. 01/09 47 A completecomplete selection of the finest nest seals...
available from Trelleborg Sealing Solutions – your one-stop-shop. Trelleborg Sealing Solutions offers an outstandingly comprehensive sealing portfolio – a one-stop-shop providing the best in elastomer, thermoplastic, PTFE and composite technologies; our solutions are featured in virtually every application conceivable within the aerospace, automotive and industrial industries.
Your Partner for Sealing Technology Trelleborg Sealing Solutions www.tss.trelleborg.com
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