HydroSele total sealing systems for

Water Turbine Shafts

Innovative rotary sealing cartridge systems that offer

Greatly reduced turbine downtime

Minimal leakage

Major cost savings

Full system compatibility

High Performance Sealing Technology

Issue
Issue 23

What is HydroSele ?

Extended family

HydroSele is James Walker's family of

Field trials, backed by commercial

We are constantly developing our

innovative cartridge seals for the shafts

operations since 2006, show that our

HydroSele family to provide a total shaft-

of water turbines. It is the result of over

HydroSele systems offer the best long-

sealing service to OEMs and operators of

12 years of design, development and

term value for money of any shaft sealing

water turbines. Current family includes:

operational experience on Francis and

arrangement for many Francis and Kaplan

HydroSele S the innovative rotary

Kaplan equipment working under a

turbines.

cartridge seal for turbine shafts (p3-7).

HydroSele MS S type plus

wide variety of conditions.

Our HydroSele offer
Our sole objective has been to produce

We will:

cartridge seals of superior reliability that

! Custom-manufacture the seal from

greatly improve a turbine's

modular components to suit your

! Cost efficiency, and

specific application.

! Operational performance.

! Install the seal on site for you.

! Fully support your HydroSele system

with worldwide technical advice and

refurbishment services.

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.

2.2

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

The innovative
innovative HydroSele
HydroSele S

HydroSele S offers many unique financial and

operational benefits over other sealing systems
used on Francis and Kaplan turbines

Why fit HydroSele S?

Simple to install & adjustment-free

Low power consumption

Our innovative HydroSele S offers

HydroSele S is one of the easiest sealing

HydroSele S has an exceptionally low

significant cost savings by being

arrangements to fit on a turbine shaft.

torque requirement compared to

retrofitted and fully operational in half the

With our technical expertise, your

traditional mechanical seals.

time of a traditional mechanical seal.

downtime is cut to a minimum and the

Swift payback on investment

cartridge sealing unit is totally adjustment-

Worldwide technical support

free once installed.

Every HydroSele installation is fully

costs, turbine downtime and power

Economical refurbishment

network of specialists in high performance

absorption.

It takes just hours rather than days to

sealing technology.

In less than two years, it should have

paid for itself in terms of maintenance

supported by James Walker's global

refurbish our innovative HydroSele. You

At four years, your total investment in

no longer need to hold expensive standby

cash and downtime could be just one-

sealing units in stock.

quarter of that for an equivalent

mechanical seal.

High efficiency sealing

HydroSele's unique method of operation

Long & reliable service

gives a very low and controlled level of

HydroSele S prototypes are still running

leakage. This greatly reduces the risk of

trouble-free after 12 years of operation.

flood damage to plant caused by

This outstanding reliability enables you to

uncontrolled leakage past sealing faces.

schedule your maintenance with absolute

confidence.

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

33.

HydroSele S is a fully split cartridge assembly, containing two

sealing elements working back-to-back with flush water
introduced between them

HydroSele S in operation
HydroSele S operating capabilities

Shaft diameter
Surface finish:
Surface hardness:

0.4 to 0.8m Ra (CLA 16 to 32in)

33 HRC minimum

Diameter tolerance:

ISO 286-2/BS EN 20286-2 h8

Maximum permissible shaft runout:

Please consult James Walker.

Inlet flush requirements

Shaft diameters:

250 - 1000mm
(9.84 - 39.37in)

Please consult James Walker if your shaft

diameter exceeds 1000mm (39.37in).

Maximum pressure at gland:

1MPa* gauge
(10bar)* gauge)

Pressure:

To be maintained at a minimum of 0.2MPa

(2bar) above maximum system pressure.
A through-flow flush system is generally
recommended.

Filtration:

100m (0.004in) or better

Maximum temperature: 50C (122F)

at seal/flush water
interface

0.4 to 0.8m Ra (CLA 16 to 32in)

Flush water pressure:

Maximum shaft speed: 20m/s*

(3937fpm*)

Equipment surface or adapter plate

Surface finish:
Flatness:
Cartridge outside diameter

4.4

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;
H9/f8 on cartridge outside diameter

0.2MPa (2bar)
above system
pressure.

(*These values will be size dependent and may

not necessarily be applied simultaneously)

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

HydroSele S
HydroSele

Standard sizes for HydroSele S

Metric sizes in mm (apart from G in inches)
Shaft (A)
Equal to
Below
or above

250
500
700

500
700
1000

Bolting details
Flush pipe fitting (G)
Overall Location
depth diameter Number Bolting
DIN ISO 228 Parallel
Thread
(C)
(B)
of bolts PCD (E) depth (F)

88.0
120.5
123.0

A+140
A+160
A+180

8
12
16

30
40

A+97

in operation, HydroSele S

G3/8

relies on engineering

G3/4

excellence for its outstanding

Tolerances 0.1 except where shown

sealing performance

Inch sizes
Shaft (A)
Equal to
Below
or above

Bolting details
Flush pipe fitting (G)
Overall Location
depth diameter Number Bolting
DIN ISO 228 Parallel
Thread
(C)
(B)
of bolts PCD (E) depth (F)

9.843
19.685
27.559

3.465 A+5.512
4.744 A+6.299
4.843 A+7.097

19.685
27.559
39.370

Simple in concept yet ingenious

8
12
16

A+3.819

1.181
1.575

G3/8
G3/4

Tolerances 0.004 except where shown

Compact cartridge

M16 bolts equi-spaced on E PCD

Compact cartridge

Aunit
Tol:thats
h9 can readily be installed
HydroSele S is a compact bolt-on sealing
HydroSele S is a compact boltwhere housing space is limited.
on sealing unit that can readily

be installed where housing

space is limited.

Dynamic sealing elements

Adapter plate

Shaft sleeve

C (location position) Tol: H9

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

55.

1.
2.

5.
4.

How HydroSele S works

OD pressure

HydroSele S relaxed

If the sleeve were rigid, the pressure

The ported pressure face (A) allows fluid

would drop almost linearly along this

to the outside diameter of the housing.

route, and leakage would be high. Instead

The un-ported atmosphere face (B),

the pressure distributions on the outside

however, forms a static seal that prevents

and inside of the seal produce a turning

the fluid from continuing around the back

of the seal to atmosphere.

B
M

moment (M) that tilts the seal to bring the

'atmosphere' edge of the seal sleeve into
close proximity to the shaft, stemming the
leakage.

Because the sealing element is

manufactured to have a small clearance
on the shaft, the fluid can also pass

The under-sleeve pressure then backs-up

between the shaft and the running sleeve

to produce a distribution approximating to

of the sealing element.

ID pressure

that shown with most of the pressure

drop occurring near the atmosphere edge
of the seal sleeve.

6.6

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

HydroSele S
S construction
construction
HydroSele

Modular concept

HydroSele S is modular in
concept, with each component
3.

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-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

HydroSele S energised

OD pressure

Loaded contact between the sealing

metal rings.
All modules of the fully assembled

element and shaft is prevented by the

HydroSele are held accurately and firmly

hydrodynamic pressure generated in the

in position by the bolts that fasten the

thin fluid film that is created by shaft

cartridge to the adapter plate or

rotation. Equilibrium is therefore set up

equipment surface beneath.

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

ID pressure

capability), with a low level of controlled

leakage.

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

77.

HydroSele MS

HydroSele RS

This enhanced version of HydroSele S

This is designed for situations where a

allows maintenance of the primary sealing

water-lubricated bearing is located

elements to be carried out safely and

immediately inboard of the HydroSele.

swiftly with the cartridge in situ.

The inner dynamic sealing element is
The inner housing ring is adapted to

fitted in the reverse direction, and

incorporate an externally energised

energised by pressurised clean water

maintenance seal that sits well clear of the

within the bearing. The same water as

shaft sleeve while the turbine is running.

supplied to the bearing is also fed to the

During turbine shut-down the

HydroSele flush ring at lower pressure to

maintenance seal is energised to make

lubricate and cool the seal assembly.

intimate contact with the shaft sleeve and

provide high-efficiency static sealing.

The result is an exceptionally stable

sealing system with very low leakage and

The maintenance seal is energised either

minimal additional pipework.

by automatic diversion of the cartridge

flush water, or by separate pressurised
water or air supplies.

8.
8

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

HydroSele variants
variants
HydroSele

HydroSele W

HydroSele WT

Our HydroSele W range comprises split

This version comprises a fully split

HydroSele WB
Our HydroSele WB is particularly suitable

cartridges that house James Walker's

cartridge unit containing two Walkersele

for protecting bearings in submerged

renowned Walkersele D7 rotary shaft lip

D7 On-Site Joining lip seals working in

applications such as bulb turbines.

seals. This standard version has a single

tandem. Both Walkerseles face the

sealing element in the cartridge.

pressurised water to provide increased

It uses the same cartridge design as

sealing integrity.

HydroSele WT, but the outer Walkersele

Moulded in tough, water resistant

is reversed.

elastomers, Walkersele D7 is ideal for

The space between the two lip seals is

lower pressure Kaplan turbine duties.

normally packed with grease during

In operation, the outer seal acts as a

assembly. A port is incorporated to allow

protective barrier to prevent the ingress of

Although HydroSele W is recommended

additional greasing to improve the

water and external contaminants.

for smaller turbines, it can be supplied in

lubrication of the seal lips and to extend

diameters up to 2000mm (78.74in) if

seal life.

required.
The Walkersele is supplied in spilt form for
ease of installation. It is then joined to
form an endless ring using our patented
OSJ (On-Site Joining) technique.

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

9.
9

HydroSele Service

We offer a full service package to support

HydroSele
Condition Monitoring

HydroSele
Shaft Sleeve

all HydroSele installations. Our

All HydroSele units are designed to give

We can provide precision manufactured

a long trouble-free working life, with their

split sleeves that protect the turbine shaft

elastomeric sealing elements performing

from wear, and present the optimum

perfectly for several years before on-site

running surface for HydroSele elements.

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.

replacement is needed.
These are manufactured in corrosion
To gauge the operational efficiency of an

resistant steel, and will be supplied with

installation, we can supply our

hard surface layers, if required. A taper-

HydroSele Condition Monitoring system.

wedge location/locking system ensures

perfect alignment of the split halves.

HydroSele Adapter

This monitors major parameters, such as

An adapter plate enables the HydroSele

gives prior warning of changes that affect

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.
10.
10

temperature, pressure and flow rates. It

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.

HydroSele FlushPak
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.

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

Case studies
studies
Case

Here are a few examples of the many successes achieved

with HydroSele S during development, testing

and commercial operations.

HydroSele case studies

Case study 1

Case study 2

Case study 3

Application: Two Francis vertical turbines

Application: Kaplan vertical turbine with

Application: Two Francis vertical turbines

with 410mm (16.14in) diameter shafts

380mm (14.96in) diameter shaft running

with 480mm (18.9in) diameter shafts,

running at 750rpm and 0.3MPa (3bar)

at 428rpm and 0.3MPa (3bar) operating

running at 375rpm and 0.25MPa (2.5bar)

operating pressure.

pressure.

operating pressure.

Previous seal type: Both turbines were

Previous seal type: The turbine was

Previous seal type: Both these turbines

fitted with spring-retained carbon rings.

originally fitted with a famous brand of

were formerly fitted with conventional

mechanical seal that lasted about two

mechanical face seals that leaked heavily.

HydroSele success: In December 1996

years, but suffered performance

the turbine shafts were fitted with

problems.

HydroSele success: In June 2001 each

turbine was fitted with a HydroSele S, with

prototypes of the HydroSele S cartridge

HydroSele success: In February 1998, a

immediate dramatic reductions in leakage

prototype HydroSele S was installed.

rates.

working precisely to the customers

In July 2007, the total leakage from the

In 2008, the leakage rate was measured

requirements, with the original

HydroSele S was measured at 2 litre/min

at 2 to 4 litre/min (0.53 to 1.06USgal/min),

elastomeric sealing elements in place.

(0.53USgal/min). The original elastomeric

which was fully acceptable to the

sealing elements were still in operation,

customer.

unit.
In March 2008 both units were still

and the unit was continuing to meet the

customers specifications.

To order or for further details, call your local contact shown on rear cover or listed at www.jameswalker.biz

11.
11

James Walker worldwide support and distribution

James Walker & Co
Tel: +44(0)1270 536000
Fax: +44(0)1270 536100
Email: [email protected]

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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.
To ensure you are working with the very latest product specifications, please consult the relevant section of the James Walker website: www.jameswalker.biz.

James Walker & Co Ltd

Power Generation Industry Support Team
1 Millennium Gate, Westmere Drive
Crewe, Cheshire CW1 6AY, UK
Tel: +44 (0)1270 536000
Fax: +44 (0)1270 536100
Email: [email protected]
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