Special Edition: Wind Energy

groove
Trelleborg Sealing Solutions

in the
The world of seals and service

Tomorrow’s solutions

Investing in the
future
We are constantly looking for new challenges
in the renewable energy sector

Innovation Award

Rewarding new ideas

Trelleborg launches the Trelleborg Sealing
Solutions Innovation Award
contents

4 News Research & Development

16 Constantly tackling new challenges

Wind power
R&D is a vital ingredient in making sure we keep
up with our customers requirements.
06 Gone Global
With 22 manufacturing units worldwide, we can always
supply locally, providing close support to the customer.
Materials
08 One-Stop-Shop
20 Turcon® M12
Trelleborg Sealing Solutions offers an outstandingly
comprehensive sealing portfolio. The material of choice for a wide variety of
hydraulic applications.
10 A solid foundation
Trelleborg has become the world market leader in
offshore grout seals.

Service

24 Our innovative apps for engineers

Hydropower
Trelleborg Sealing Solutions offers an innovative
range of tools and services for mobile applications.
12 Green Electric
The hydropower sector offers a wide range of
opportunities to produce ‘green energy’.
Products
Tomorrow’s solutions 26 Trelleborg Sealing Solutions
14 Investing in the future Products for Renewable Energy
Trelleborg Sealing Solutions is constantly looking for A spotlight on products most frequently used
new challenges and opportunities in the renewable in wind energy applications.
energy sector.

Innovation Award

30 Rewarding new ideas

Trelleborg launches the Trelleborg Sealing
Solutions Innovation Award.

2 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

editorial
Seals for Renewable Energy
The global potential for renewable energy is enormous,
and events like the 2011 nuclear catastrophe in
Fukushima have again encouraged discussions about
the generation of power. “Green energy”, a buzzword
for power generated by clean and ethical means, is
still the focus of much debate in the energy sector,
and renewable sources – the only obvious solution
– are being viewed as increasingly more important
for the future. However, generating clean energy is
not without its difficulties, and requirements for the
sector are demanding.
Let’s take the example of an offshore wind park.
The expected life span of a turbine is more than
25 years, the operating environment is harsh and
variable, and when repairs are very complex and
costly, using the correct materials and developing the
ideal component is essential. The kind of knowledge
required to design a seal for this type of application
isn’t just about choosing the seal, it requires the
expertise that can only be obtained through practical
insights and a close relationship with industry leaders.
Many companies in this sector are global players.
Reliability, proximity to global customers, innovation
and competence are some of the attributes that
are necessary for a beneficial collaboration and a
small number of suppliers can provide these. But
few can boast dependable solutions already proven
successful for this sector and demonstrate the ability
editorial
to design parts from scratch that outperform the
application.
Trelleborg Sealing Solutions has worked in the wind
power sector from the very beginning, and through
our experience, expertise and competence, we will
find or develop the optimum solution for every
application. Reliability is our top priority.
We are continuously developing new products
and materials for the renewable energy sector,
from concept to installation, in one of our seven
development centers worldwide.
One of these is our new Turcon® M12 material – a
breakthrough PTFE based compound. It is capable
of unrivalled performance in key hydraulic sealing
characteristics, such as friction, wear and high
pressure operation, while being resistant to virtually
all media. Offering a wide window of operating
conditions, it extends seal life, regardless of
application.
With more than 5,100 employees, 49 marketing
companies, seven development centers, four logistic
centers and 22 manufacturing sites, we are close
to you on every continent and perfectly prepared for
upcoming challenges.
Take a few minutes to read this special edition of our
in the groove magazine. It will give you great insights
on the latest projects and the variety of sealing
solutions available for wind power and renewable
energies in general.
Jürgen Bosch, General Manager, Trelleborg
Sealing Solutions, Germany
Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 3
 news +++ news +++ news

Test bed

Trelleborg Sealing Systems tests rod sealing

systems in the world’s most powerful test bed...

Sinusoidal, trapezoidal or freely configurable movement and

pressure patterns can be run at speeds of up to one meter per
second. In endurance tests, information is additionally acquired
on the long-term behavior of seals, for example, through the
simulation of 25,000 aircraft landings or millions of strokes of a
press. With up to 225 kN, it can act on the rod continuously or
dynamically depending on the stroke.
The test bed was designed and developed within Trelleborg
Sealing Solutions and is based on 35 years of experience
building test equipment. The entire system sits in a specially
poured concrete pit that is isolated from the vibrations of the
rest of the building. The powerful drive is located in a separate
room, with the outlet air used to heat the building in an energy-
efficient and eco-friendly way.
... and puts them through their paces before they face an A further special feature of
application’s demanding tasks. the system is its ability to
model different temperature
Trelleborg Sealing Solutions has developed and installed a
scenarios. This allows media to
260kW, floating suspension test bed at its R&D facility in
be tested between 25° C and
Stuttgart, Germany. It is believed to be the most powerful in
the application limit, as well as
the world and will support the effective engineering of seals
at ambient temperatures of
for aircraft landing gear, mining equipment and other industrial
between -60° C and 90° C. In
applications.
this way, operating conditions
The state-of-the-art, high-tech 18-ton seal test bed can can be simulated for seals in a
simulate the toughest operating conditions as well as mine excavator for use in the
unexpected events that deviate from the norm. Movement cold temperatures of northern
and pressure patterns are run for rod seals of 100 to 400 Canada just as well as the
millimeters in diameter under the toughest and most realistic extreme heat of the Australian
conditions, that are as similar as possible to actual applications. desert.

Trelleborg Sealing Solutions Editorial team: Source information:

Trelleborg Sealing Solutions – in the groove –
Special Edition Wind Energy
99GBW5MAGEE0912
© 2012 Trelleborg Group. All rights reserved
® All trademarks are the property of Trelleborg AB.
The turquoise color is a registered trademark of
Trelleborg AB.
At time of publication the information contained in this
literature is believed to be correct and accurate.
p. 12: 2jenn © www.fotolia.de
Jan Winther, Ferdinand Krauss, Ruud Bokhout, Cees Wien, p. 16-19: © www.iStockphoto.com/TommL
Claudius Göller, Holger Jordan, Wolfgang Heinrich, Donna p. 17: Beboy © www.fotolia.de
Guinivan, Jan Sklucki p. 24: © www.iStockphoto.com/Elenathewise
Responsible under German Press Law:
Robert Zahiri
Graphic Arts:
dialogart gmbh, Stuttgart, Germany
Printing:
W. Kohlhammer, Stuttgart, Germany

4 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

+++ news +++ news +++ news

Award

In the top 100

TOP 100 is the most important award for small- and medium-
sized companies in Germany when it comes to innovation
management. For almost 20 years, the best companies have
competed for the TOP 100 seal of quality – because TOP 100
honors companies for structures that ensure that they will be
innovative over and over again.
Examination of the innovation management of Trelleborg
Sealing Solutions, Germany, produced excellent results and it is
now officially one of the TOP innovators in Germany.
At the awards ceremony on 22 June 2012 at the Dornier
Museum in Friedrichshafen, Germany, the award was presented
by Ranga Yogeshwar to directors Jürgen Bosch and Jochen
Sanguinette.

Trelleborg Sealing Solutions Innovation Force

Trelleborg Sealing Solutions Innovation Days

In July 2012, Trelleborg Sealing Solutions held its first
Innovation Days in the company’s history, which were a
great success. Over 150 invited customers were shown the
“Trelleborg Sealing Solutions Innovation Force” in numerous
technical presentations and company tours.
Our customers experienced exciting presentations about
solutions for tomorrow’s challenges. Each person was able
to individually put together his or her own program from many
current topics such as materials expertise, the PTFE innovation,
Turcon® M12, or the increasing requirements for the technical
cleanliness of seals.
The event was rounded off by a keynote speaker, Bernhard
Wolf, who talked about the emergence and development of
innovations, a social gathering with good music, and the latest
in molecular gastronomy.

Solutions for tomorrow’s engineering

Innovation days

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 5

Wind power
Gone
Global
The wind energy sector is very demanding. It has changed from a local
to a “glocal” business. Today, corporations in this sector are spread over
several countries or even continents. This calls for an internationally
set up, professional business partner. With the right contact on every
continent, Trelleborg Sealing Solutions meets those requirements.
Design and manufacturing;
Where it’s required
Trelleborg Sealing Solutions is a global company.
With our worldwide representation, we can support
our customers no matter where their operations are
situated.
At our research and development centers, Trelleborg
Sealing Solutions works closely with customers to
define and decide on the optimum sealing configuration
for specific hydraulic cylinders used in wind turbines.
Tests are carried out to verify a robust solution before
moving on to the next step.
Trelleborg Sealing Solutions uses its global internal
network to ensure all specifications of seals and
materials are transferred from the original country of
design to anywhere where the product is manufactured.
Production of the seals can take place locally,
minimizing transport and lead times.
6 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy
Designing and manufacturing hydraulics for wind turbines
is now an international business. In the past, development,
prototyping, testing and manufacturing all would have taken
place at the same location. Nowadays, these functions may be
spread over several countries, even over several continents.
This calls for a business partner that is capable of supporting
the customer and their needs, wherever they may be and
Trelleborg Sealing Solutions meets those requirements.
As Denmark did not have its own natural energy source, the
country was instrumental in the foundation of wind power.
Several companies key to the industry were founded there,
including a number specializing in development of hydraulics.
Sealing is key
Important in any hydraulic system is its sealing configuration.
Designing and specifying the right combination of sealing
solutions is crucial for a reliable and long service life. To
facilitate this, a close collaboration between the hydraulic
equipment manufacturer and sealing supplier is a necessity.
To ensure the optimum solution, all parameters have to be taken
into account – hardware design and material, surface roughness
and texture, operating conditions such as temperature, pressure,
and speed, and the nature of any media in the system – among
many others. Without taking everything into consideration, the
reliability and service life will be compromised.
Relationship for effective design
Global but Local

“Glocal”
“Only when working in close collaboration with our customers
can we reach the best solution for each application,” says Jan
With 22 manufacturing units worldwide, we
Winther, General Manager and Director of Fluid Power. “Such
a close relationship is what results in successful hydraulic can supply locally, providing close support to
equipment with outstanding performance specifications.” the customer.
Having concluded the design phase and started the Every location brings the same advantages
manufacturing and supply of parts, it is also important that the to you:
customer can be supported around the globe. Be it a customer
with manufacturing units in Brazil, China or India, we will be
close, not only with technical support, but also with local supply Technical support to the customer
services. ensuring the optimum solution
Liaison with local technical support
The “Glocal” approach
Local manufacturing
The wind power business is a truly international business
and calls for suppliers with a developed network, providing Minimized transportation, lowering both
technical support and delivery services all around the world. cost and impact on the environment,
Trelleborg Sealing Solutions, as an international, global supplier, reducing lead times and stockholding for
has years of experience in serving customers in the aerospace, customers
automotive and industrial markets. A global approach is
necessary, but always combined with a focus on how to locally
optimize the supply and support.

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 7

Wind power

One-Stop-
Worldwide, wind power is the most developed alternative
energy source. Growth has been stimulated by rising oil prices,
a greater concern for the environment and a growing need for
Shop
energy.
Trelleborg Sealing Solutions offers an outstandingly Seals for Main Seals for
comprehensive sealing portfolio – a one-stop-shop providing Brake Main Gear
the best in elastomer, thermoplastic, PTFE and composite
technologies. Assists the turbine in Converts the rotation
stopping at critical rotor of the blades into a
For wind turbines, Trelleborg has been supplying parts since speed or for maintenance. speed suitable for the
generator.
the technology began. Numerous advanced seals from Trelleborg products:
Trelleborg Sealing Solutions contribute to effective operation of scrapers, rod seals, wear Trelleborg products:
hydraulics, withstanding rigors on land and the tough conditions rings rotary seals
of offshore installations.

Seals for accumulators High Performance Mounts Flexible hoses for

Act as hydraulic
power batteries for
safety and energy
saving.
Trelleborg products:
piston seals, wear
rings, static seals
RA/RAEM and XK mounts have
become the preferred solution
of the major players in the wind
power industry. They are designed
to have a high-degree of isolation, to be easy to
install and to demonstrate extreme durability and
service life.
cooling and Filter
Systems
Large diameter, flexible hoses are
used in oil cooling and filter system
for turbine gear­boxes.

8 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 Seals for Lock
Cylinder
Locks the rotor blades in order to
avoid rotation in strong winds or for
maintenance.
Trelleborg products: piston seals,
wear rings, static seals
Seals for Yaw Brake
Keeps the nacelle in a steady
position towards the wind.
Trelleborg products: rod seals,
wear rings, scrapers
Sandwich Mounts
Designed to provide a high
compressive strength and low
shear stiffness, SAW sandwich
mounts have become a versatile
high-performance solution. They
are used mainly under gearboxes.
Damping Bearings
Designed to accomodate
torsional movements and
axial and radial loads, Teater
Bearings and UD bushes
enable structures to be silent
and vibration free. These mountings are mainly
used in the main turbine shaft and blades.
Seals for Main
Bearing
Holds the main shaft in position.
Trelleborg products: rotary
seals
Seals for Pitch
Cylinder
Control the angle at which the
rotor blades face the wind.
Trelleborg products: piston seals,
rod seals, wear rings, scrapers,
static seals
Want to find out more? Check
out our wind power movie
tss.trelleborg.com/films
Trelleborg as a whole serves the wind power industry
Other parts of the Trelleborg Group supply advanced polymer
solutions for wind power and some are featured in this breakout.
For more information on these products:
www.trelleborg.com/IndustrialAVS
www.trelleborg.com/IndustrialHose
www.trelleborg.com/Infrastructure
Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 9
Wind power

A solid foun
One of the most important requirements for offshore
wind turbines is a solid foundation. The expected
life span of a wind turbine is more than 25 years;
the operating environment is harsh and variable.
Trelleborg’s Grout Seals make sure that you have the
perfect seal for a solid and long lasting foundation.

In short...
Trelleborg has become the world market leader
in offshore grout seals, designing and producing
them at its manufacturing and development facility
in Ridderkerk in the Netherlands.

Grout

Seal

10 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

dation
The wind energy market offers oceans
of opportunity for Trelleborg’s grout seals.
A wind turbine normally consists of a foundation in the seabed,
a transition piece and the mast with turbine section and blades
on top. For the foundation there are different options. At the
moment monopile foundations are most common. In this, the
monopile is hammered into the seabed and a transition piece
slides over the pile. The function of the transition piece is to
correct the misalignment of the pile on the seabed and create
a stable and rigid base for positioning the mast and turbines.
It needs to withstand forces acting on the end of the windmill’s
turbine blades for the entire life of the wind turbine, which is at
least 25 years.
Making the connection
“The transition piece is usually around 25 meters high, will be
clearing the water by around 10 to 15 meters and is pushed
about 15 meters over the steel pile in the seabed. The steel
pile itself can be 40 to 50 meters long and will generally be
around five meters below the water table,” says Cees Wien,
Sales Manager, Trelleborg Infrastructure.
At the bottom of the transition piece a flexible grout seal is
mounted. During installation of the transition piece, the
seal slides over the monopile. It seals the annulus between
monopile and transition piece, takes the tolerances in the thick
steel bended surface and corrects for a small misalignment up
to 0.5 degree.
The transition piece is leveled with hydraulic jacks and to create
the stable foundation with the pile on the seabed, the annulus
is filled with grout . The grout is injected under the water level,
just above the seal up to a height of eight to 10 meters. The
seal is designed to close a large gap and simultaneously carry
a substantial weight of the grout during hardening. After the
grout has hardened and become solid, the seal will continue to
function for the life of the wind turbine, preventing loss of grout
and ensuring a solid foundation.
Flexibility is key
“The reason for choosing a rubber seal for this specific issue
is related to the flexibility of the material,” continues Cees. “A
rubber seal is able to handle varying gap sizes with minimum
and maximum tolerances.”
The self activating seal is a full rubber lip seal that initially seals
with a tight fit. The sealing properties increase as the pressure
becomes higher. The design and choice of material are the key
factors in the function and life expectancy of the seal.
Transition piece
Facts
Gwynt y Môr
Gwynt y Môr is one of the largest offshore wind
farms in construction in the world and is expected
to provide a major boost to the Welsh economy.
It is to be built with an installed capacity of 576
megawatts in Liverpool Bay, around 18 kilometers off
North Wales, UK, coast in the Irish Sea. Consisting
of 160 Siemens 3.6MW turbines, it will be capable
of generating enough energy to meet the average
annual energy needs of around 400,000 homes.
Onshore construction is already well underway and
the wind farm is due to be fully operational by the end
of 2014.
Bladt Industries and EEW SPC have successfully
completed the load-out of the first two foundations.
Special to this project is the choice of a combination
of a fully operational self-activating lip seal and an
inflatable spare seal. Trelleborg has been awarded
the contract to supply 160 inflatable grout seals and
self-activating lip seals for this prestigious project.
Wind farm specific
For each wind farm, there are specific design criteria. Based on
these criteria, Trelleborg develops a dedicated seal using finite
element analysis. Finally, the seals are tested at a scale of
one-to-one, normally in the presence of the client, consultants,
certifying bodies and the contractor.
“Our grout seals are successfully operating on wind farms
globally,” says Cees. “We’re proud of our work on many
installations offshore and how we have helped develop the
technology to bring sustainable technology to the world.”
Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 11
Hydropower

Green
Electric
The hydropower sector offers a wide range of opportunities to produce ‘green
energy’. One single turbine can generate as much electricity as a nuclear power
station and some countries cover 100 percent of their energy requirements
through hydropower.
For more information, go to

tss.trelleborg.com

In short...
Orkot® is the world renowned material
from Trelleborg Sealing Solutions that for
over 20 years has been used to produce
self-lubricating bearings in hydropower
applications.

12 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 Orkot® bearings are used on
numerous hydropower applications.
Hydroelectricity, typically, is electricity generated by the use
of the gravitational force of water taken from a reservoir or
barrier in a river. It is currently the most widely used form of
alternative energy. Hydropower provides 20 percent of the
world’s electricity and is a clean, renewable energy source that
does not contribute to global warming.
Environmentally-friendly alternative
Orkot® self-lubricating polymer bearings, from Trelleborg Sealing
Solutions, are replacing classic greased bronze bearings
on new and refurbished Francis, Kaplan and Bulb turbines,
allowing for a cleaner downstream environment. Trelleborg
Sealing Solutions also supplies bearings and seals for the
equipment surrounding the actual turbine including penstock
valve bearings, spilgate hinge bearings, gate roller bearings
and bearings for fish screens and fish ladders.
La Muela Pump, an example of a pump
storage station in Iberdrola, Spain
Next to conventional hydropower stations, there are a growing
number of so-called pump storage stations in operation
and new ones under construction. Water has a high energy
density and pump storage is applied to temporarily store
energy generated by wind or other sources, thereby making
the combined installation economically and environmentally
effective.
Advantages over metallic bearings
Orkot® Material is a proven solution in all these applications.
It is safe for the environment, extending the service life and
reliability of installations without using any grease or oil.
Compared to metallic bearings, Orkot® has specific advantages,
such as low friction in particular operating conditions, for
example when the movements are small or when there are
long stationary periods. Orkot® caters for an even transfer of
bearing forces thereby reducing stress concentrations in shafts
and surrounding steel components, extending service life and
time between overhaul.
Trelleborg also contributes to the development of new forms of
energy generation such as sea current, tidal motions or wave
energy. Orkot® material has a proven track record in the marine
industry, being fitted to safety critical items such as steering
and propulsion. Its low friction and ability to operate directly
in sea water offer major advantages for this up and coming
industry.
Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 13
Tomorrow’s solutions

Investing in the
future
Trelleborg Sealing Solutions is constantly looking for new challenges and
opportunities in the renewable energy sector. One way of doing that is to support
research and development projects. In the case of the “Wave Power Project –
Lysekil”, Trelleborg Sealing Solutions works in close cooperation with Seabased
AB and researchers at the Division for Electricity, Department of Engineering
Sciences, at Uppsala University (UU), Sweden. We are not only providing seals and
bearings but also technical advice and knowhow.

14 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 For more information,
go to
el.angstrom.uu.se
A linear generator
and floating buoys
In a small research area on the west coast of Sweden, a group of
Seabased AB workers and researchers from Uppsala University
are testing a whole new concept to generate green electricity
from the motion of waves. Initiated by Uppsala University, the
project was launched in 2006 and is expected to remain in
operation until 2014.
Smart system with simple setup
With a very simple setup, the wave energy converter (WEC)
consists of a linear generator that is placed on the seabed and
a floating buoy. Buoy and generator are connected through a
15-150 meter long rope, depending on water depth at the site.
Through the motion of waves, the buoy is driving a directly linked
translator with permanent magnets inside the encapsulated
generator. The motion induces an alternating current (AC) in the
generator. In a wave power park the individual ACs from several
WECs are transferred to an underwater substation where they
are converted into direct current (DC) and interconnected.
Diagram of a linear generator
The combined DC voltage from several WECs may then be
inverted back to a common AC voltage at power grid frequency
and transformed to high voltage before being transferred to an
onshore power grid connection point. The power rating of a WEC
varies between 10kW and 100kW, basically depending on the
size of waves in certain areas and stroke length of the generator.
Many advantages
“This new technology offers many advantages”, states Erland
Strömstedt, PhD candidate and Project Manager at UU. “Wave
power provides a higher degree of utilization with a higher energy
density compared to most other renewables. Due to a scalable
unique generator design, electrical energy can even be utilized
in wave climates with relatively low wave amplitudes and directly
connected to the main grid through a standard transmission.
“Furthermore, the generator, located on the seabed, is protected
from harsh weather. Should a buoy break adrift, it is easily
replaced a minor cost. In addition, the technology is expected
to have little or limited effect on the environment. Wave energy
converters do not produce any emissions, will not be visible from
land and may protect the marine environment. Also, the material
used for construction of the equipment has been used before
and is well known.”
Trelleborg Sealing Solutions provides hardware
and expertise
In close cooperation, Trelleborg Sealing Solutions has not only
provided hardware for the pilot project, but is also constantly
delivering technical expertise and support.
Holger Hagen, Technical Manager at Trelleborg Sealing
Solutions, Sweden says: “We are proud to be involved in such
research projects. This is one part of our contribution to push
the development of ‘green energy’ in general and wave power in
particular. We see a great opportunity in the production of wave
energy. Our cooperation with UU so far has been great and we
are very positive that we will have a good result in this project!”
Evidence of the cooperation is that Trelleborg Group, represented
by Trelleborg Sealing Solutions and Trelleborg Engineered
Systems, was invited to the eighth European Wave and Tidal
Energy Conference 2009 in Uppsala as one of the few suppliers
to this unique industry.
The new technology is expected to have a substantial commercial
potential with the possibility of 3,000 jobs being created.
Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 15
 Research & Development

Constantly tackling new

challenges
R&D is a vital ingredient in making
sure we keep up with our customers
requirements. Development Engineer
Ferdinand Krauss and Holger Jordan,
START
Manager Fluid Power Technology, give
us an insight into how the department
works in Stuttgart, Germany.

Ferdinand Krauss Holger Jordan

Product Development Engineer Manager Fluid Power Technology

Demands made on seals are changing constantly. Modifying
products or varying operating conditions often requires more
efficient seal designs. In addition, novel sealing concepts are
sometimes necessary for new applications. In all cases, a
creative and structured research and development environment
at Trelleborg Sealing Solutions ensures efficient and reliable,
standard and customized solutions.
“Customers all over the world utilize our expertise and the
close working relationships developed with Trelleborg Sealing
Solutions to regularly present us with new challenges,” says
Ferdinand Krauss.
Such requests for new sealing solutions from existing or
potential customers are welcomed by our product developers
at Trelleborg Sealing Solutions. In fact, they are a great
opportunity to demonstrate the efficiency of the globally
positioned and optimally networked research & development
environment of the Group.
As an effective seal manufacturer, Trelleborg Sealing Solutions
supervises the changing requirements of industries by means
of its own R&D departments with in-house testing facilities and
laboratories.
Seals are often optimized or new sealing solutions are
developed for existing applications when operating conditions
change. This might become necessary because, for example,
requirements have become more demanding, immobilization
periods are extended or higher pressures are required.

16 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 Requirements
Through close customer
collaboration and discussions,
our product developers find out
important details and insights
that cannot be determined by
any questionnaire.

Request Development
At Trelleborg Sealing Solutions,
efficient and reliable standard or
customized solutions are developed
in a creative and well-structured
R&D environment.

“The choice of the most suitable materials, as well as a
design tailored to the application, is of prime importance for
the success of a seal,” explains Krauss. “At Trelleborg Sealing
Solutions we work continuously on the development of new
materials which are then used in existing and new applications.”
Structured and efficient procedures worldwide
In all cases, the procedures at the R&D centers of Trelleborg
Sealing Solutions located in America, Asia and Europe are
structured in a similar way.
In the first step, a list of requirements is created including all
parameters of the application and all underlying conditions of
the operating environment. This is first done by means of a
standardized questionnaire, which upon evaluation, is followed
by discussions between the customer and Trelleborg engineers.
The appropriate solution can only be developed by those who
understand the applications and requirements.
“We learn important details and insights by talking to the
customer, that could never be determined by any questionnaire,
no matter how sophisticated,” emphasizes Krauss.
Here, the important factors and variables of use are determined
and the application is analyzed for the seal-specific requirements.
The earlier the R&D experts from Trelleborg Sealing Solutions are
involved, the more efficiently a solution can be developed.
In addition to freedom from leakage, seals must always display
good properties in terms of robustness during operation
and immobilization periods as well as a diverse range of
requirements depending on what is important in the application.
This can be the ability to withstand high or low temperatures,
as well as large temperature ranges or fluctuations.
As an example, high pressures or the use of steam and
liquids require a high mechanical or chemical resistance. This
applies equally to various types of seals such as hydraulic
and pneumatic seals, rotary and shaft seals or O-Rings. This
particularly concerns the requirements for safe functionality,
long maintenance cycles and long service life. Energy-efficient
operation is also becoming an increasingly important factor.
Solving challenging tasks
In wind turbines, seals are needed that work for long periods of
time without leaks and display low-friction to work in an energy-
efficient manner. In addition, they should demonstrate low stick-
slip and good sealing effect to ensure that components work
consistently.

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 17

Research & Development

FEA
In virtual FEAs (Finite Element
Analysis), concepts are tested
rotational-symmetrically or three-
dimensionally for resilience. Product

Prototype
As an efficient seal manufacturer,
Trelleborg Sealing Solutions examines
changing requirements by means of its
own R&D departments with in-house
testing facilities and laboratories.

The example of a bearing seal, such as the type installed at the
base of a rotor blade, demonstrates the particular requirements
that can be met.
The seal - with a diameter of up to four meters / 13 feet - must
always keep the grease in the bearing, withstand pressure and
cope with a local lack of lubrication. It should also keep dirt,
dust, salt crystals and water away from the bearing and must
be easy to replace when servicing.
However, since gravitational and centrifugal force cause the
size of the sealing gap to constantly change its shape during
the rotation of the rotor, a solution must be found where the
seal geometry and material adapts to this movement and the
bearing remains perfectly tight. In addition, the seal must keep
secure contact tightly when the gap increases in size. And
when it decreases in size, the frictional force must not become
too great to ensure energy efficiency and minimize abrasive
forces to extend seal life.
Holger Jordan, the Manager of Fluid Power Technology,
summarizes an important aspect: “Innovations initially start
in the mind of each individual. Creativity and good teamwork,
understanding of the applications and visions for further
improvements enable these innovations to become marketable
solutions.”
Trelleborg Sealing Solutions cultivates an environment in
which this principle is fundamental in development and offers
sufficient freedom for its realization.
Afterwards, the collected ideas are assessed. Our R&D centers
use a special rating system for this, which is adjusted to suit
the application. Individual criteria are defined and rated in a
matrix, creating a ranked list of ideas. This can vary depending
on the focus.
In one case, the main focus may be placed on the costs, in
another case, it could be ease of replacement of the seal when
servicing.

Developing initial ideas in a good working
environment
Once the application and underlying conditions have been
determined, the brainstorming and concept phase begins. In
the course of this, an appropriate material is selected, initial
designs are collected and functional diagrams are prepared.
Ferdinand Krauss explains the advantages: “This rating system
based upon what are known as “hard factors” has proved to
be effective because different concepts can be compared
systematically and decisions can be better understood.” But
equally as important are the so-called “soft factors”.
“In each new task, we apply our many years of experience in
R&D and insights gained from similar applications. By sharing

18 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 Helsingør, Denmark

Stuttgart, Germany

Fort Wayne, U.S.

Tokyo, Japan
Shanghai, China

Bridgwater, U.K.

Malta

Research & Development Facilities

In all cases, the procedures at the R&D centers of Trelleborg Sealing
Solutions located in America, Asia and Europe are structured in a similar way.

ideas with colleagues as well as with the other R&D centers,
the entire expertise of the Group is always involved.”
As a result, from one to three concepts can emerge from the
assessment stage that will then be presented to the customer.
An atmosphere of cooperation and transparency
that involves customers
Customers and users are closely involved in the decision-
making process aided by an atmosphere of cooperation and
openness. The concept for further development is selected
and then worked out in detail. This results in 2D technical
drawings and a 3D model.
simulations and tests beforehand can later meet the high
demands of modern assembly lines and satisfy even the most
demanding customers.
Efficient in-house laboratories and test rigs
One potential option is that material behavior is examined
with regard to strength, permanent elasticity and resistance to
media. Test rigs for endurance determine the behavior of the
seals under the influence of temperature and pressure, as well
as deflection properties and gas permeability.
“If no suitable test rig is available in the R&D centers, we build
a special structure with the necessary units,” explains Krauss.

The next stage involves the seal – though virtually – the
concepts are tested rotational-symmetrically or three-
dimensionally for resilience by means of FEA (Finite Element
Analysis). In this way, the limit ranges for the material and
geometry of the seals are determined. The behavior of the
product is examined when exposed to stress with regard to
contact forces, deformations and internal stresses.
This demonstrates how serious Trelleborg Sealing Solutions
considers the achievement of meaningful results to be. Hence,
for instance, the latest rod test rig in the company with its
400mm/16 inch rod diameter is the most effective in the world.
Field tests at the customer’s site then round off the verification
process. After that, the newly developed sealing solution can
become operational.

Prototypes are then produced from the chosen solution and

extensively tested in verification processes under real operating
conditions. Our in-house laboratories and test rigs achieve
excellent results here. Only prototypes that successfully pass

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 19

Materials

Turcon M12 – ®

Unrivaled performance in
hydraulic sealing
Turcon® M12 from Trelleborg Sealing Solutions is a polytetrafluoroethylene (PTFE)
based sealing material whose performance is unrivaled in key hydraulic sealing
characteristics, such as friction, wear and high pressure operation.

No other material can give such universally

exceptional performance
Extensive testing shows that Turcon® M12 is resistant to virtually
all media, including a broad range of lubricants, and has
outstanding wear resistance and friction characteristics. This
cost-effective material provides customers with extended seal
life, as well as a wide operating window in terms of temperature,
pressure and velocity. Comprehensive testing has shown that
no other PTFE material can give such universally exceptional
performance, and Turcon ® M12 is now recommended by
Trelleborg Sealing Solutions as the material of choice for a wide
variety of hydraulic applications.

Want to find out more?

Check out our Turcon M12 movie

tss.trelleborg.com/films

Turcon® M12
Features and benefits of Turcon® M12

Resistant to virtually all media including Robust for harsh environments

a broad range of lubricants
Good resistance to extrusion
Outstanding wear resistance and friction
Reduced environmental impact as it does not
characteristics
include bronze fillers
Provides extended seal life
Sealing material for universal use in hydraulic
Operates in wide temperature, pressure applications
and velocity ranges
Lower stock holding and fewer items to handle
Minimal abrasion of hardware, preventing
Cost-effective solution
damage to counter surfaces

20 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

Key applications
Turcon® M12 is the material of choice for a wide variety of hydraulic applications.

Segment Application Turcon® M12 advantages

Fluid power Hydraulic cylinders and actuators Compatible with all types of hydraulic
fluid, including fluids with low lubrication
Giant cylinders
performance
Hydraulic jacks
Low abrasion
Clamping cylinders
Low friction for frequent movement
Avoids hardware damage on counter surface

Hydraulic machinery
Machine tools and machining Low friction and suited to short stroke
centers linear movement
Injection molding machines Compatible with all types of hydraulic fluid,
especially those fluids with low lubrication
Hydraulic presses
performance
Press brake and punching
Withstands constant activation
machines
High wear resistance
Steel and rolling mills
Operates under high pressure
Heavy duty

Wind power
Hydraulic pitch cylinders Extended seal life reduces maintenance
Turbine piston accumulators 24-7 operation

Automotive
Cylinders for convertibles Avoids damage to counter surfaces
Shock absorbers Low friction gives smooth movement
Active body control Withstands high system pressure

Mobile hydraulics
Lifting and telescopic cylinders Withstands harsh environments
Active suspension and stabilizer High sealing efficiency
cylinders
Improved absorption of abrasive
contaminants

Rail
Shock absorbers Robust for difficult environments
Superior for short stroke and high
frequencies

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 21

Solutions for Tomorrow’s Engineering
Turcon® M12 a new Generation
of Hydraulic Seals

Innovations in hydraulic sealing are perfectly matched by the

Turcon® M12 material from Trelleborg Sealing Solutions. It’s
engineered to set the standard for improved performance in
hydraulic equipment, today and in the future.
Find more information at www.tss.trelleborg.com
or check out www.seals-innovation.com
Service

Our innovative
apps
for engineers
Trelleborg Sealing Solutions offers an innovative
range of tools and services for mobile applications
to make your life easier. We are continually working
to improve those mobile applications. Have a look
and download the Apps free-of-charge by simply
scanning the QR-Code or visiting the App store or
Google play.

Aerospace Groove This app covers two of the most important

SAE aerospace groove standards for
Selector App hydraulic systems, AS4716 Rev B and
AS5857 Rev A. It makes it really easy to
find the size of grooves and hardware and
it indicates if the groove is suitable for a
dynamic seal and/or a static seal. It also
provides an instant conversion between
inch and mm sizes.

24 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 ISO Fits & Tolerances
“ISO Fits & Tolerances” is intuitive and very
easy to use. Upon entering the nominal
diameter needed, users simply select the
tolerance classes for bore and shaft. The
app then provides the complete ISO fits
definition with all relevant values including
the type of fit. Tolerances are shown for
the most commonly used ISO tolerance
classes, and convenient graphs illustrate
these classes by bore and shaft. The app
provides results based on the ISO 286
System of Limits and Fits.

Unit and Hardness

Converter
The “Unit and Hardness Converter” is
intuitive and very easy to use. By simply
selecting the dimension and entering the
value for conversion, the app offers a
wide range of engineering and scientific
units for each dimension. For the hardness
conversion, the user selects the appropriate
material type table and upon entering a
value, the input can be converted to other
hardness scales.

O-Ring Selector App Based on our online O-Ring calculator,

renowned as the leading application of its
type, the new smartphone app calculates
O-Ring dimension tolerances according
to ISO 3601 and recommends the
appropriate Trelleborg Sealing Solutions
part numbers. You can search for O-Ring
and housing dimensions according to ISO
3601 recommendations by simply entering
bore or rod diameters and pre-selecting
the desired O-Ring cross sections. The app
also incorporates an O-Ring quick search
facility that allows you to search for O-Ring
dimensions according to various national
and international standards. A nice feature
is that the “Chemical Compatibility Check,”
a separate tool on the web, is integrated
into the mobile app. That means you can
quickly find out which material types are
compatible with the media used in your
application.

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 25

Products

Trelleborg Sealing
for Renewable
Rotary Seals
Rotary seals are used in components with oscillating or
rotating parts, and keep lubrication fluids in place while
preventing the ingress of contaminants.
Trelleborg Sealing Solutions components are proven
V-Ring®

to improve the life and long-term performance of your

application, demonstrating superior low-friction properties
and excellent resistance to wear.
Trelleborg offers one of the most extensive ranges of rotary
seals on the market including Radial Oil Seals, the rubber
V-Ring®, Mechanical Face Seals and the Turcon® Varilip® PDR.
Highlighted here are two of the most important seals for wind
power applications. Full details of the rotary seal range can
be found in the rotary seals catalog.
Radial Oil Seals

Want to find out more? Check out our

Rotary Shaft Seals and Oil Seals movies

tss.trelleborg.com/films

26 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 Solutions Products
e Energy
A unique all-rubber seal for rotary shafts that The V-Ring® is the perfect seal to prevent the ingress of dirt,
is suitable for a wide range of bearing types. dust, water or combinations of these media while positively
retaining grease. It can also be used as a secondary seal
• Frictional losses and heat kept to a minimum to protect primary seals that do not perform well in hostile
environments.
• Low contact pressure allows dry running in many applications
• Excellent wear characteristics
• Extended seal life
Pressure:
• Can perform even with certain amounts of run out,
Not applicable
eccentricity and shaft misalignment
• Easy to install Speed:
Up to 12 m/s / 40 ft/s
• Can be installed over various other components without
need for dismantling Temperature:
-54°C to +170°C / -65°F to +338°F

Radial Oils Seals are available with metal For more information on Radial Oil Seals see the Radial Oil
or fiber-reinforcement. Seals catalog.

• Excellent chemical resistance

• Outstanding resistance to heat and low temperature
• Good resistance to ozone and weathering
Pressure:
• High resistance to wear Up to 0.5 MPa /72 psi
• Low friction and compression set Speed:
• Highly elastic Up to 30 m/s / 90 ft/s
• To ease the mounting or in case of repair, a split version Temperature:
Radial Oil Seal is available -54°C to +170°C / -65°F to +338°F

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 27

Products

Hydraulic Seals
It is challenging to ensure seal life and performance in hydraulic
applications. Not only must leak-free operation be achieved,
but high pressures, temperatures and transverse forces must
be sustained. Trelleborg offers one of the most extensive
ranges of hydraulic seals on the market. Highlighted here are
a few of the most important seals for wind power applications.
Full details of the hydraulic seal range can be found in the
hydraulic seals catalog. Contact your local Trelleborg Sealing
Solution marketing company for a printed version or download
a digital copy from
www.tss.trelleborg.com.

Zurcon® U-Cup RU9 Boasting long service life, high wear and extrusion
resistance with low friction operation, the Zurcon®
U-Cup RU9 is the preferred U-Cup seal for wind
power applications. Pressure:
Up to 40 MPa /5,800 psi
• Lower friction and heat generation than standard
U-Cups Speed:
Up to 0.5 m/s / 20 in/s
• High extrusion resistance and seal stability within
the groove Temperature:
• Back-pumping ability over the entire pressure -45°C to +110°C /
range achieved by grooved profile -49°F to +230°F
• Suitable for use with the Zurcon® Buffer Seal as
secondary seal in tandem design

Slydring® Slydring® eliminates local stress concentrations

and dampen mechanical vibrations. This
simple non-metallic guide ring has decades of
engineering behind it, offering major benefits Load:
compared to its traditional metal counterpart. Up to 100 N /mm2

• Simple closed groove, easy installation Speed:

Up to 15 m/s / 50 ft/s
• High load bearing capacity
Temperature:
• Wear-resistant, long service life -60°C to 200°C /
• Favorable friction behaviour -75°F to +392°F

Turcon® Stepseal® 2K The result of years of research into providing an

all purpose fluid seal, revolutionizing fluid sealing
in cylinder applications. The seal demonstrates
Pressure:
high extrusion resistance and supports dynamic,
Up to 80 MPa / 11,600 psi
high frequency operation.
Speed:
• Low-friction, increasing performance and working life
Up to 15 m/s / 50 ft/s
• Stick-slip-free starting, no sticking even after
extended periods of rest Temperature:
-45°C to +200°C /
• High abrasion resistance
-49°F to +392°F
• Compatible with virtually all media

• Simple installation without seal edge deformation

28 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 Engineered to meet continuously increasing Turcon® Stepseal® V
demands. Offers a uniform, low friction
characteristic, throughout its whole life with
Pressure: its distinctive hydrostatic ventilation function.
Up to 80 MPa / 11,600 psi
• Check valve function eliminating potential build
Speed: up of disruptive intermediate pressure between
Up to 15 m/s / 50 ft/s seals
Temperature: • Hydrodynamic back-pumping
-45°C to +200°C / • Available for ISO 7425/2 groove
-49°F to +392°F
• Prolonged seal life
• Increased leakage control

Grout

Seal

The ‘grout capturing’ seal

Trelleborg seals give lifetime certainty
New technologies come with new challenges.
Trelleborg seals are robust, durable and secure your investment for decades to come.

Trelleborg Ridderkerk BV, PO Box 4007, 2980 GA Ridderkerk, The Netherlands

Tel: +31 180 49 55 55 ridderkerk@ trelleborg.com www.trelleborg.com/infrastructure

Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 29

Innovation Award Further details on the Trelleborg Sealing
Solutions Innovation Award and how to
submit ideas can be found by going to

seals-innovation.com

Rewarding
new ideas
Trelleborg launches the Trelleborg
Sealing Solutions Innovation Award

Aiming to continue to pioneer new sealing developments, ideas
are being sought that can provide engineering solutions for
today and tomorrow. The competition is open to anyone, with
prizes for the best submissions.
The philosophy behind the award is that everything around us
started with somebody having an idea. That idea then needs
to be taken and made into reality, to form it into something
tangible. The scope of the award is broad so that innovation
suggestions are not limited.
Why not visit our innovation site? Not only will you
find information on the award but also details of
some of our latest innovations.
www.seals-innovation.com
Innovation: A core value
Director Global Marketing and Communications, Trelleborg
Sealing Solutions, Robert Zahiri, says: “Open Innovation is one
of Trelleborg’s core values and we know that there are lots
of ideas out there that can add value to existing applications
today and those in the future. We’re not just interested in
suggestions for products and materials but anything that
relates to improving our business or the way we do business,
for instance, novel suggestions for online tools, manufacturing
processes or logistic related services.”
As well as receiving a 5,000 EUR prize, the winning idea will
be converted into a tangible project, if feasible. iPads will be
awarded to the ideas in second and third places.

30 Trelleborg Sealing Solutions in the groove Special Edition Wind Energy

 Innovation Award – Questions and Answers
Q: I am always struggling with certain issues connected
to sealing when I am designing applications. If I
submit them, does that count as an idea?
A:
Yes, certainly. These type of issues fuel our
research and development and can be the
foundation for new e-tools to make your
engineering job easier.
Q:
Our latest design project is a little bit different and
has presented some new challenges. Would you
like to consider that in the innovation award?
A:
Of course. At Trelleborg most of our new
materials are developed to meet new
requirements that are specific to applications.
Q:
For me, sustainability is a key issue. I have some
ideas of how you could cut waste in the sealing
production process.
A:
Please tell us! Sustainability is another one
of Trelleborg’s core values and we are always
looking for ways to improve sustainability,
whatever they are.
Q:
I don’t buy seals but am involved in equipment to
produce seals. I’ve some thoughts on how sealing
technology could be improved. Is that outside the
scope of the award?
A:
Certainly not. The award is broad so that we can
capture ideas such as yours.
Q: Are you interested in suggestions to improve
logistics and the way that you supply your product
to customers? I’m thinking of different packaging
and delivery methods, for instance.
A:
Definitely these are of interest. We’re looking
for anything that improves our service to our
customers.
Q:
You have some really excellent e-tools on your
website already but I’ve some thoughts on other
ones. Can I submit those as ideas?
A:
We’d love to know about those. We devote a
lot of resources to our e-tools as we know the
internet is so important to engineers when
developing applications.
Q:
I am often designing applications that use seals and
I have views on where the industry may go in the
future. Would that be in the scope of the award too?
A:
We’re looking for ideas for today and tomorrow,
so these future visions are totally in the scope
of the award. Don’t be afraid to submit ideas
that are different. Those could be the most
interesting!
Trelleborg Sealing Solutions in the groove Special Edition Wind Energy 31
Solutions for Tomorrow’s Engineering
Seal Matching at
your fingertips

Years of experience allows Trelleborg Sealing Solutions to offer the Sealing

Solutions Configurator, making future applications easier to specify. Innovation in
online services means that engineers have access to proven seal configurations
at the click of a mouse or touch of a button.
Find more information at www.tss.trelleborg.com
or check out www.seals-innovation.com