Brush seal application as replacement

of labyrinth seals

labyrinth seal brush seal

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Brush seal application as replacement
of labyrinth seals

Advantages

• flexible seal element

• reduced sealing gap - leakage flow
• insensitive against axial movements
• capability to compensate for radial movements
without immediate performance degradation or
wear
• easy replacement
• compact design - less space consumption
• high efficiency

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Different manufacturing techniques
for brush seals

• When wires are being welded over, it

cannot be reliably ensured that all of
the individual wires have been
incorporated into the weld, nor is
there any means of checking this
• It may happen that the melting-off
progresses so far that wires become
loose again
• Excitation during operation may
cause wires, or even entire wire
bundles, to become detached from
the seal and result in damage

welded design

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Different manufacturing techniques
for brush seals

• easy manufacturing
• metallic brush seal (HS 25)
• ceramic brush seal (SIC)
• high reproduceability
• smaller in height
• stable seal function
• unit built from single components
which enables easy variation of seal
parameters
• up to 300 bristles per millimeters
under angle of 45°

clamped version
(MTU Patent)

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 Fields of application

brush seal housing

• aero engines
clamping tube

• stationary gas turbines

bristle pack • industrial compressors
• mechanical engineering
applications in general
• steam turbines

Actual maximum operating conditions (per element)*:

• differential pressure up to 1200 kPa (12 bar)
• temperature up to 750°C
• sliding velocity up to 400 m/s
* by 1999

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Retrofitting of existing seals with
brush seals

compressor stage sealing insert shaft sleeve

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Retrofitting of existing seals with
brush seals

compressor stage sealing insert shaft sleeve

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Leakage values for labyrinth and
brush seals

labyrinth seals
leakage values for labyrinth seals
connection average clearance
1 51 kg/h
2 14 kg/h

leakage values for brush seals

connection average clearance
1 27 kg/h
2 3,2 kg/h

results
brush seals connection absolute saving saving in %
1 24 kg/h 53
L labyrinth design
A connection 2 10,8 kg/h 77
B brush seals

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Retrofitting of existing seals by brush
seals

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Retrofitting of existing seals by brush
seals

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Leakage gas chart using the example
of a HVK 16
vent
1 bar recycle
638 kg/h

3. stage 4. stage

labyrinth seal

1. stage 2. stage

5.86 bar
1150 kg/h

PC = 5943 KW

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Leakage gas chart using the example
of a HVK 16
vent
recycle
1 bar
124 kg/h recycle
21 bar
40 kg/h recycle

3. stage 4. stage

14 bar
71 kg/h
brush seal
1. stage 2. stage

5.86 bar
151 kg/h

PC = 5883 KW

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Cost savings using the example
of a HVK 16
leakage at labyrinth seals power
pressure level 5943 KW requirement
[bar]
recycle [KW]
saving
20 60 KW

5883 KW
brush seal
15 recycle

brush seal
10

recycle recycle
5
labyrinth seal
saving
vent vent

100 200 300 400 500 600 700 800 900 1000 1100 1200

leakage quantity [kg/h]

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Cost savings

Savings
P1 = 5 barg
regarding PC HVK ~
P2 = 32 barg
[Euro in thousand]

300
PC 14000 KW
250
ROI
200 PC 10000 KW

150

PC 6000 KW
100

50
PC 2000 KW

basis 0,05 Euro/kwh 1 2 2,5 3 4 5

years
8600 h / year
PC = 1%

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Advantages of new machine designs with
brush seals instead of labyrinth seals

• overhung arrangement
reduced
• rotor more rigid
• insensitive to fouling
• more compact
construction possible

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