C05 Enhanced Lubrication Kalsi Seals

Kalsi Seals Handbook
ChapterC5
EnhancedLubricationKalsiSeals
Revision 8 May 8, 2015

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Document 3062
2015 Kalsi Engineering, Inc. All rights reserved.
Enhanced Lubrication Kalsi Seals
1.
Chapter C5 Page 1
Introduction to Enhanced Lubrication Seals
Enhanced Lubrication seals1 (Figure 1) are a family of rotary seals that use an
advanced hydrodynamic wave which reduces running torque and seal generated heat by
providing a more aggressive hydrodynamic pumping action. The Enhanced Lubrication
(EL) wave shape has several geometry attributes that can be tailored to influence
interfacial lubrication and related hydrodynamic pumping related leakage. Six wave
variations have been developed ranging from moderate to significant torque reduction.
Seals with the more aggressive EL wave types can seal against high differential
pressure even with low viscosity lubricants. They can seal against even higher differential
pressure with increased lubricant viscosity. They have moderate hydrodynamic pumping
related leakage with low viscosity lubricants. The most aggressive wave patterns can also
be used to lubricate very wide dynamic interfaces (Figure 1).
The less aggressive EL wave types were developed to provide increased seal
capacity and performance in applications having a limited lubricant supply. Although the
less aggressive wave types provide less torque reduction, compared to the more
aggressive types, they do provide significantly increased performance and capacity
compared to more conventional Kalsi Seals. For example, they can lubricate wider
dynamic lips in small radial cross-section seals used in high differential pressure
conditions.
Because of the wide range of performance that is achieved by the different wave
types, the EL Seal is applicable to a wide range of applications. Examples of relevant
oilfield applications include rotary control devices, rotary steerable tools, mud motors,
hydraulic swivels, coring swivels, and washpipe assemblies.
standard width
extra wide
Figure 1
Enhanced Lubrication Seals
The Enhanced Lubrication Seal uses advanced hydrodynamic wave geometry
to reduce seal torque and generated heat, even in high differential pressure
conditions. The seal performance can be designed for specific operating
conditions and application constraints.
1
Enhanced Lubrication Seals and Enhanced Lubrication Seal are trademarks of Kalsi Engineering, Inc.
Covered by issued and pending U.S. and foreign patents.
For available seal sizes, visit kalsiseals.com.
Chapter C5 Page 2
Figure 2
Used 568-24-106 Enhanced Lubrication Seals
These used 568-24-106 standard width, 2.75 I.D. (69.85 mm) seals are from a 43.2 ft/minute test
(0.22 m/s) with an ISO 32 VG lubricant at 162F. The condition of the seals is nearly new after
running 189 hours with low viscosity lubricant, slow speed, and pressures ranging from 20 to
2,000 psi (0.14 to 13.79 MPa). The combination of low viscosity lubricant and high differential
pressure would have destroyed sine wave based Kalsi Seals.
2.
Chapter C5 Page 3
Enhanced Lubrication Seal options and configurations
The EL Seal can be designed to provide the maximum lubrication and seal
performance for the allowable hydrodynamic pumping related leakage dictated by the
application. This is made possible by varying EL wave geometry attributes to provide
lubrication ranging from performance near that of conventional Kalsi Seals all the way up
to performance near the theoretical limits of full film hydrodynamic lubrication.
Wave Type
Six EL wave variations are available. The waves vary in pressure capacity and
hydrodynamic pumping related leak rate (higher pressure capacity and lower torque with
higher leakage). These EL wave types can be combined with more conventional waves to
make a Hybrid Seal. This reduces the hydrodynamic pumping related leak rate further
while still providing improved interfacial lubrication. The test results provided in this
chapter are for type A, B, and C waves. See Table 1 for the available EL wave types.
Wave
Type
Leak Rate
Order
Pressure
Capacity
Order
Seal
Friction
Order
Dynamic Lip Width

Limit
highest
highest
lowest
Extra Wide
Extra Wide
Extra Wide
Extra Wide
Extra Wide
lowest
lowest
highest
Wide Fooprint
Table 1
Available Enhanced Lubrication wave types and their relative hydrodynamic pumping
related leak rates
Identifying Wave Type
To ensure the correct EL/Hybrid Seal is installed in an apparatus, the seals are
marked with the EL wave type at one location on the ID of the seal, as shown in Figure 3.
Verification of the wave type marking should be performed, as there are several EL and
Hybrid Seals available for some shaft diameters.
Chapter C5 Page 4
Figure 3
EL wave types are indicated with the corresponding letter at one
location on the ID of the seal.
Dynamic Lip Width
As shown by Figure 1, the EL Kalsi Seals can be manufactured in different footprint

widths. The extra wide footprint variation (only tested with the Type A wave and 0.345
inch C.S.) that is shown has a dynamic lip that is 2.4 times wider at the minimum lip
width, compared to the minimum lip width of a Standard Kalsi Seal. Wave type A-F can
be manufactured with a dynamic lip that is 1.75 times wider in cross sections 0.305 inch
and larger, and 1.5 times wider2 in cross sections 0.27 inch and larger. Such wide lips not
only provide significantly more sacrificial material to accommodate various wear
mechanisms; they also experience less high pressure extrusion damage.
The list below is intended to provide guidance in using the rotary seal configuration
best suited for the application.
Standard Lip Width This configuration is intended for applications that require
minimal breakout torque or high speed, high pressure operation with thin viscosity
lubricants. For the highest pressure capacity, dual modulus construction is
recommended. For applications requiring sealing against an abrasive media (e.g.
drilling mud), single durometer construction is recommended.
Wide Footprint Lip Width This configuration is intended for general abrasive
service, high pressure applications. The increased seal width, compared to the standard
lip width, provides significantly more sacrificial material to accommodate abrasive
wear and extrusion damage, resulting in longer seal life.
Extra Wide Footprint Lip Width This configuration is recommended for applications
that have larger extrusion gaps and high pressure. It is also a robust barrier seal against
abrasive media. Moderate viscosity lubricants are required to lubricate conditions that
have high pressure combined with high speeds. This configuration has only been
tested with the Type A and F waves, but is also suitable for Types B, D, and E.
2
The1.5 wider type C is qualified for -11 material in a 0.27 inch cross section. More aggressive wave
types may be suitable with a -15 material, but no testing has been performed to confirm this.
Chapter C5 Page 5
Figure 4
Used extra-wide Enhanced Lubrication Seals
These 655-4-11 seals are from the un-cooled test 568 Evaluation #61. They
were tested at 34.56 ft/minute (.18 m/s) with an ISO 32 viscosity grade
lubricant at pressures from 16 to 1760 psi (0.11 to 12.1 MPa), for a total of
137.8 hours. Despite the thin lubricant and slow speed, seal lubrication was
excellent.
3.
Introduction to Kalsi Seal torque and rotary leakage test results
The rotary seal tests, reported in this section, were designed to capture the upper
bound hydrodynamic pumping related leakage (lower temperature testing) and seal
lubrication and pressure sealing capability (higher temperature, higher pressure testing)
of the EL seal. The range of test parameters such as temperature, pressure, speed, and
lubricant were selected to be applicable to a wide set of applications. However, we are
not able to test for every set of conditions. For applications that are not bracketed by the
testing presented, or for applications that require accurate hydrodynamic pumping related
leakage prediction, contact Kalsi Engineering for input or additional test data.
A list of the EL seals tested, and their basic dimensions, are given in Table 2. The
hydrodynamic pumping related leakage of the EL seal is sensitive to wave type and
number, seal material, temperature, surface speed, pressure, extrusion gap size, and
dynamic lip width. A 0.02 inch diametric extrusion gap was used in the tests reported in
this chapter unless otherwise noted. The number of EL waves increases with seal
diameter and is determined by dividing the seal ID in inches by 0.3125.
Chapter C5 Page 6
Seal Part No.
Radial Cross
Section (CS) inch
EL Wave
Type
Footprint
568-24-11 & 106
0.335
Standard width
568-39-11
0.335
Standard width
568-43-10, 11, 15
0.335
Standard width
655-4-11
0.335
Extra Wide
641-7-11
0.335
Wide Footprint
568-152-30
0.186
Standard width
568-156-30
0.145
Standard width
Table 2
This table shows the EL seal part numbers that were tested for the data
shown in this chapter.
4.
Standard width and Wide Footprint single durometer test results
Single durometer construction is recommended when the seal is running directly

against an abrasive media such as drilling mud.
Type A wave
Figures 5 through 9 show the hydrodynamic performance of the Type A EL Seal at

various operating conditions. From Figures 5 through 7 it is clear that the leakage is
sensitive to changes in temperature (lubricant viscosity) and velocity.
The leakage, per EL wave, between a 50% wider Wide Footprint Hybrid and
standard width Hybrid Seal, and between 0.335 inch (8.51 mm) and 0.305 inch (7.75
mm) radial CS seals does not vary significantly, therefore, the same leakage bound, used
for predicting EL leakage, is appropriate for EL/Hybrid seals of lip widths and radial
cross-sections within this range.
For 85 durometer HNBR seals (-11 material) one can see (Figure 8) that with an ISO
320 VG lubricant at low to moderate pressure, the hydrodynamic leakage varies
significantly. The hydrodynamic leakage tapers off dramatically at pressures above 1,000
psi (6.9 MPa).
Figure 9 shows the hydrodynamic pumping related leakage for the type A wave with
a -11 material tested at 345 ft/minute (1.75 m/s) at 162F (72.2C) using an ISO 32
viscosity grade lubricant.
Chapter C5 Page 7
Figure 5
Upper bound hydrodynamic leakage characteristics for a type A
wave with a -11 material tested at 346 ft/minute (1.76 m/s) using
an ISO 320 VG lubricant. The number of EL waves varies with seal
diameter.
Figure 6
wave with a -11 material tested at 200F (93.33C) using an ISO
320 VG lubricant. The number of EL waves varies with seal
diameter.
Chapter C5 Page 8
Figure 7
wave with a -11 material tested at 300F (149C) using an ISO
320 VG lubricant. The dip in leak rate at 173 ft/minute is due to
the test set up. The number of EL waves varies with seal
diameter.
Figure 8
Hydrodynamic torque and leakage characteristics for a pair of 2.75"
(69.85 mm) ID, PN 568-24-11 type A EL seals tested at 346 ft/minute
(1.76 m/s) using an ISO 320 VG lubricant at 162F (72.2C).
Chapter C5 Page 9
Figure 9
(69.85 mm) ID, PN 568-24-11 type A EL seals tested at 346 ft/minute
(1.76 m/s) using an ISO 32 VG lubricant at 162F (72.2C).
Type B wave
Figure 10 shows the leakage for the type B wave with a -11 material tested at 346
ft/minute (1.76 m/s) using an ISO 320 VG lubricant at various temperatures. For this
condition, the Type B hydrodynamic pumping related leakage is 3 times less than that of
the Type A wave.
Type F wave
In a 300 psi (2.07 MPa) 252 ft/minute (1.28 m/s) test of -11 Type F Wide Footprint
Enhanced Lubrication seals with an ISO 150 viscosity grade lubricant at 120F (48.9C),
leakage was 0.52 ml/hr per wave. This test was done to evaluate the use of such seals as
partitioning seals in lower operating temperature conditions.
Chapter C5 Page 10
Figure 10
Hydrodynamic leakage characteristics for a type B wave with a -11
material tested at 346 ft/minute (1.76 m/s) using an ISO 320 VG
lubricant. The number of EL waves varies with seal diameter.
Type C wave
The Type C wave has the lowest hydrodynamic pumping related leakage of the
various EL types, and lubricates significantly better than the sine wave and zigzag wave
patterns. This increase in lubrication allows the Type C EL Seal to operate in conditions
that a zigzag seal cannot. It was developed to have a leak rate that is compatible with
practical reservoir sizing in oilfield downhole drilling tools. For reservoir sizing
purposes, use the leakage data for the lowest anticipated long term operating temperature.
Figures 11 through 22 show the hydrodynamic performance of the EL Seal with a
Type C wave at various operating conditions.
Chapter C5 Page 11
Figure 11
Hydrodynamic leakage characteristics for a type C wave with a -11
lubricant. The number of EL waves varies with seal diameter.
Figure 12
material tested at 155F (68.3C) using an ISO 320 VG lubricant.
The number of EL waves varies with seal diameter.
Chapter C5 Page 12
Figure 13
material tested at 300F (149C) using an ISO 320 VG lubricant.
Figure 14
(69.85 mm) ID, PN 568-43-11 type C EL seals tested at 264 ft/minute
(1.34 m/s) with an ISO 32 VG lubricant at 250F (121C).
Chapter C5 Page 13
Figure 15
Figure 16
material tested at 155F (68.3C) using an ISO 32 VG lubricant. The
number of EL waves varies with seal diameter.
Chapter C5 Page 14
Figure 17
Figure 18
Chapter C5 Page 15
Figure 19
Figure 20
lubricant at 155F (68.3C). The number of EL waves varies with
seal diameter.
Chapter C5 Page 16
Figure 21
Hydrodynamic torque and leakage characteristics for a type C wave
with a -15 material tested at 346 ft/minute (1.76 m/s) using an ISO
320 VG lubricant at 155F (68.3C). The number of EL waves varies
with seal diameter.
Figure 22
Hydrodynamic torque and leakage characteristics for a type C wave
with a -30 material tested at 346 ft/minute (1.76 m/s) using an ISO
680 VG lubricant at 155F (68.3C). The number of EL waves varies
with seal diameter.
5.
Chapter C5 Page 17
Standard width dual durometer test results
Dual Durometer seal construction (Figure 23) provides lower interfacial contact
pressure, torque and heat, compared to single durometer seals having similar extrusion
resistance. The outer part of the seal, which defines the static sealing lip, is made from a
relatively soft compound to minimize interfacial contact pressure. The inner part of the
seal, which defines the dynamic sealing lip, is made from a harder, more extrusion
resistant compound to bridge higher pressure.
The as molded seal diameter depends on the molding shrinkage characteristics of the
selected material combination, and the shrinkage correction factor a specific mold has
been designed for. At present most EL tooling is designed for -10 and -11 materials.
Dedicated tooling for a specific diameter and material combination can be built.
Figure 23
Dual Durometer Seals
The Dual Durometer Kalsi Seal employs composite
construction. The outer material is softer than the
inner material, to reduce interfacial contact pressure.
This reduces torque and seal generated heat, and
improves extrusion resistance.
Chapter C5 Page 18
Type A wave
Figures 24 through 28 show the average running torque and leakage range for a pair
of 2.75" (69.85 mm) ID, 0.335" (8.51 mm) radial cross-section dual durometer Kalsi
Seals (-106 material) at various operating conditions.
The hydrodynamic leakage for dual durometer -106 seals, which have a higher
modulus inner material than a -11 seal, does not taper off for thicker viscosity lubricants
at pressures above 1,000 psi (6.9 MPa) as dramatically as with the -11 EL seals.
Figure 24
(69.85 mm) ID, PN 568-24-106 dual durometer type A EL seals tested
at 39 ft/minute (0.2 m/s) using an ISO 32 VG lubricant at 162F
(72.2C).
Chapter C5 Page 19
Figure 25
at 576 ft/minute (2.93 m/s) with an ISO 220 VG lubricant at 162F
(72.2C).
Figure 26
(72.2C).
Chapter C5 Page 20
Figure 27
(68.3C).
Figure 28
at 86.4 ft/minute (0.439 m/s) with an ISO 1000 VG lubricant at 145F
(62.8C).
6.
Chapter C5 Page 21
Extra wide single durometer test results
The extra wide footprint configuration provides better extrusion damage

resistance at high pressures or in applications where the extrusion gap is larger
than ordinarily recommended. In addition to improved resistance to extrusion
damage, there is 2.4 times more sacrificial material to tolerate other mechanisms
that lead to seal failure. Applications with higher speed combined with high
pressure require more cooling to dissipate the additional seal generated heat
associated with the wider dynamic interface.
Type A wave
Figures 29 through 32 show the average running torque and leakage range for
a pair of 2.75" (69.85 mm) ID, 0.335" (8.51 mm) radial cross-section extra wide
Type A EL seals at various operating conditions.
Leakage increases at lower temperatures. In a 300 psi (2.07 MPa) 252
ft/minute (1.28 m/s) test of -11 Type A extra wide seals with an ISO 150 viscosity
grade lubricant at 120F (48.9C), leakage was 3.67 ml/hr per wave. These results
suggest that lower viscosity lubricants should be considered for cooler operating
conditions, that wave types with lower leakage may be preferable for partitioning
seals, and that reservoir size should take startup leakage into consideration.
Chapter C5 Page 22
Figure 29
(69.85 mm) ID, PN 655-4-11 extra wide type A EL seals tested at 346
ft/minute (1.76 m/s) using an ISO 150 VG lubricant at 162F (72.2C).
Chapter C5 Page 23
SINGLE TEST
Figure 30
Figure 31
Chapter C5 Page 24
Figure 32
(69.85 mm) ID, PN 655-4-11 extra wide Type A EL seals tested at 46
ft/minute (.23 m/s) using an ISO 460 VG lubricant at 250F (121.1C).
Figure 33
(69.85 mm) ID, PN 655-4-11 extra wide Type A EL seals tested at 252
ft/minute (1.28 m/s) and 300 psi (2.07 MPa) using an ISO 32 VG
lubricant at various temperatures.
Chapter C5 Page 25
Type F wave
The Type F wave lubricates the 2.4 times wider dynamic interface of the
Extra Wide Seal sufficiently for many operating conditions. It has less seal
leakage than Type A EL seals.
Figures 34 and 35 show the average running torque and leakage range for
a pair of 2.75" (69.85 mm) ID, 0.335" (8.51 mm) radial cross-section extra wide
Type F EL seals at various operating conditions.
Figure 34
Hydrodynamic torque and leakage characteristics for a pair of 2.75" (69.85
mm) ID, PN 655-7-11 extra wide Type F EL seals tested at 252 ft/minute
(1.28 m/s) and 300 psi (2.07 MPa) using an ISO 150 VG lubricant at various
temperatures.
Chapter C5 Page 26
Figure 35
mm) ID, PN 655-7-11 extra wide Type F EL seals tested at 252 ft/minute
(1.28 m/s) and 300 psi (2.07 MPa) using an ISO 46 and 150 VG lubricant at
a bulk temperature of 190F (87.78C).
7.
660 Series 1.75 times wider single durometer test results
The Type C wave lubricates the 1.75 times wider dynamic interface of the 660 series
seal sufficiently for many operating conditions. It has less seal leakage than Type A or F
Extra Wide seals. Although it does not have as much sacrificial material as the Extra
Wide Seal it still has more than the standard width or Wide Footprint Seal.
Figure 36 shows the maximum recorded running torque and per wave leakage for a
pair of 2.75" (69.85 mm) ID, 0.345" (8.51 mm) radial cross-section 660-1-11 seals at
various operating conditions.
Chapter C5 Page 27
Figure 36
mm) ID, PN 660-1-11 Wide Footprint Type C EL seals tested at 346
ft/minute (1.76 m/s) using an ISO 320 VG lubricant at a bulk temperature of
162F (72.22C) and 300F (148.89C).
8.
Small cross-section high temperature test results
At elevated temperatures, lubricant viscosity decreases significantly. The EL

Kalsi Seal geometry constructed with high temperature materials enables
sufficient hydrodynamic lubrication in applications with thin viscosity due to high
temperature, even at low speeds. The FKM -30 (80 Shore A) material is rated to
higher than 400F (204C) service.
Type A wave
Figure 37 shows the average running torque and leakage range for a pair of
PN 568-152-30 (2.75" (69.85 mm) ID, 0.186" (4.72 mm) radial cross-section)
type A EL seals tested at 54 RPM and 15 psi pressure with AeroShell 560
lubricant up to 350F (177C) .
Figure 38 shows the running torque and leakage for a pair of PN 568-156-30
(2.75" (69.85 mm) ID, 0.145" (3.68 mm) radial cross-section) type A EL seals
tested at 125 RPM and 15 psi (0.10 MPa) pressure with AeroShell 560 lubricant
up to 350F (177C) .
Chapter C5 Page 28
SINGLE TEST
Figure 37
(69.85 mm) ID, 0.186 inch (4.72 mm) radial cross-section, PN 568-15230 type A EL seals tested at 39 ft/minute (0.20 m/s), 15 psi (0.10 MPa)
using AeroShell 560.
Figure 38
(69.85 mm) ID, 0.145 inch (3.68 mm) radial cross-section, PN 568-15630 type A EL seals tested at 90 ft/minute (0.46 m/s), 15 psi (0.10 MPa)
using AeroShell 560.

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Kalsi Seals Handbook

Revision 8 May 8, 2015

2015 Kalsi Engineering, Inc. All rights reserved.

Enhanced Lubrication Kalsi Seals

Introduction to Enhanced Lubrication Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

Enhanced Lubrication Seal options and configurations

Dynamic Lip Width

Identifying Wave Type

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

Dynamic Lip Width

As shown by Figure 1, the EL Kalsi Seals can be manufactured in different footprint

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

Introduction to Kalsi Seal torque and rotary leakage test results

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

Seal Part No.

568-24-11 & 106

Standard width and Wide Footprint single durometer test results

Single durometer construction is recommended when the seal is running directly

Figures 5 through 9 show the hydrodynamic performance of the Type A EL Seal at

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

Standard width dual durometer test results

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

Extra wide single durometer test results

The extra wide footprint configuration provides better extrusion damage

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.

Enhanced Lubrication Kalsi Seals

For available seal sizes, visit kalsiseals.com.