Understanding Friction Factor Behavior in Liquid Annular Seals With Deliberately Roughened Surfaces

2005 ◽  
Vol 127 (1) ◽  
pp. 213-222 ◽  
Author(s):  
Larry A. Villasmil ◽  
Dara W. Childs ◽  
Hamn-Ching Chen
Keyword(s):  
Friction Factor ◽  
Flow Behavior ◽  
Shear Stresses ◽  
Centrifugal Pumps ◽  
Typical Application ◽  
Number Range ◽  
Dynamic Coefficients ◽  
Seal Design ◽  
Pattern Size ◽  
Annular Seals

Multistage centrifugal pumps and compressors are among the most widely used pieces of rotating machinery in industry. A typical application demands the arrangement of several impellers or wheels mounted on a shaft that spins within a stationary case. Annular seals are the most common sealing devices used in this type of machinery. The annular seal design affects both (i) machinery performance in terms of energy conversion efficiency, and (ii) stability due to the interaction within the rotor and the stator through the fluid flow within the seals. Traditionally, the “bulk-flow” theory due to Hirs (ASME J. Lubrication Technol., pp. 137–146) has been used to estimate annular seals leakage and dynamic coefficients. To predict the flow behavior through the seal, this theory relies on empirical friction factor correlations. While leakage is well predicted, the dynamic coefficients are not. The discrepancy is attributed to the friction factor model. Several experiments have produced seal leakage data indicating that friction factor increases as the seal clearance is increased, contradicting predictions based on Moody’s pipe-friction model. A Computational Fluid Dynamics (CFD) commercial code was used to simulate flat-plate-channel-flow experimental tests of water flowing with deliberately roughened surfaces, showing an increase of friction factor with clearance increase. The higher friction factor characteristics of these deliberately roughened surfaces are governed by their ability to develop a high static pressure in the trailing face of each roughness cavity, while the wall shear stresses on the smooth land play a secondary role. In a certain Reynolds number range, the maximum friction factor observed on a specific roughness pattern size is independent of the actual clearance, which we have referred to as the friction-factor-to-clearance indifference behavior. This phenomenon is found to be related to the roughness cavity size and its length-to-clearance ratio.

Understanding Friction Factor Behavior in Liquid Annular Seals With Deliberately Roughened Surfaces: Roughness Geometric Characteristics Defining Flow Resistance

2006 ◽  
Author(s):  
L. A. Villasmil ◽  
D. W. Childs ◽  
H. C. Chen
Keyword(s):  
Friction Factor ◽  
Flow Behavior ◽  
Round Hole ◽  
Centrifugal Pumps ◽  
Typical Application ◽  
Geometric Characteristics ◽  
Seal Design ◽  
Annular Seal ◽  
Leakage Characteristics ◽  
Annular Seals

Multistage centrifugal pumps and compressors are among the most widely used pieces of rotating machinery in industry. A typical application demands the arrangement of several impellers mounted on a shaft that spin within a stationary case. Annular seals are the most common sealing devices used in this type of machinery. The annular seal design affects both (i) machinery performance in terms of energy conversion efficiency, and (ii) stability due to the interaction within the rotor and the stator through the fluid flow within the seals. Extensive numerical research of several liquid annular seal experiments is in progress, focusing on the patterns that experimentally and numerically provide larger resistance to flow, hexagonal cells (honeycomb) and equilateral triangular cells (isogrid), both constant depths. In the present paper, the geometric characteristics that define the leakage resistance of roughened seals are explored. First, the results of a parametric analysis are discussed, which include previous 2-D predictions and new simulations of multiple rectangular grooved seal geometries. The analysis is limited to the original clearance in the experiments, 0.175 mm. The results indicate that roughened surface to total area ratio, and the depth-to-length ratio are the primary parameters defining the leakage characteristics of these surfaces. Secondly, the effect of the roughness orientation on the friction factor characteristics of these surfaces is addressed. Previous numerical tests have shown that solving the flow up to the laminar sub-layer better captures the behavior of the friction-factor-to-clearance proportionality. Resolving this layer is demanding. Recent numerical studies show promise in reducing computational efforts by employing a simplified empirical model with extended wall functions, indeed avoiding including each roughness in the numerical domain. These studies evaluated the flow behavior in round-hole seals, a perfectly symmetric pattern. Contrary to round holes, nonsymmetric patterns; knurls, honeycombs, or isogrids, consistently provide larger friction factor values. The numerical evaluation of the leakage characteristics in the last two patterns indicates a non-negligible sensitivity to the pattern orientation in one of them.

Convergent-Tapered Annular Seals: Analysis and Testing for Rotordynamic Coefficients

1985 ◽  
Vol 107 (3) ◽  
pp. 307-316 ◽  
Author(s):  
D. W. Childs ◽  
J. B. Dressman
Keyword(s):  
Dynamic Pressure ◽  
Momentum Equation ◽  
Computational Method ◽  
Centrifugal Pumps ◽  
Zeroth Order ◽  
Taper Angle ◽  
First Order ◽  
Dynamic Coefficients ◽  
Direct Stiffness ◽  
Annular Seals

A combined analytical-computational method is developed to calculate the pressure field and dynamic coefficients for tapered high-pressure annular seals typical of neck-ring and interstage seals employed in multistage centrifugal pumps. Completely developed turbulent flow is assumed in both the circumferential and axial directions and is modeled by Hirs’ bulk-flow turbulent-lubrication equations. Linear zeroth- and first-order perturbation equations are developed for the momentum equations and continuity equations. The development of the circumferential velocity field is defined from the zeroth-order circumferential-momentum equation, and a leakage relationship is defined from the zeroth-order axial-momentum equation. A short-bearing approximation is used to derive an analytical expression for the first-order (dynamic) pressure gradient. This expression is integrated numerically to define dynamic coefficients for the seal. Numerical results are presented and compared to previous results for straight and tapered seals. The direct stiffness and leakage increase with increasing taper angle, while the remaining dynamic coefficients decrease. An optimal taper angle is shown to exist with respect to (a) the direct stiffness, and (b) the ratio of direct stiffness to leakage. Stiffness increases on the order of 40-50 percent are predicted. Experimental results are presented for seals with three taper angles which show generally good agreement between theory and prediction.

Computational Modeling and Experimental Investigation of Static Straight-Through Labyrinth Seals

2008 ◽  
Author(s):  
Alexandrina Untaroiu ◽  
Christopher P. Goyne ◽  
Costin D. Untaroiu ◽  
Houston G. Wood ◽  
Robert Rockwell ◽  
...  
Keyword(s):  
Experimental Data ◽  
Flow Behavior ◽  
Optimization Techniques ◽  
Bulk Flow ◽  
Numerical Code ◽  
Cfd Modeling ◽  
Leakage Flow ◽  
Dynamic Coefficients ◽  
Seal Design ◽  
Flow Parameters

To design highly efficient and stable turbomachines, engineers require accurate methods to model seal flows and calculate clearance-excitation forces generated by the eccentric position of the rotor. One of the most widely used methods to predict leakage flow and dynamic coefficients is the use of computer codes developed based on bulk flow theory. In recent years, computational fluid dynamics (CFD) modeling is increasingly being recognized as an accurate assessment tool for flow parameters and dynamic coefficients evaluation as compared to the bulk flow codes. This paper presents computational and experimental investigations that were carried out to calculate flow parameters in a stationary straight-through model labyrinth seal. The main objective of this study is to explore the capabilities of Ansys-CFX, a commercially available state of the art 3D numerical code, to accurately model compressible flow through the seals. The flow behavior is analyzed using CFD and the flow parameters calculated by CFD are validated against experimental data taken for the same seal configuration. The integrated values of leakage flow rates estimated from the computational results agree with the experimental data within 7.6%. This study serves as a benchmark case that supports further efforts in applying CFD analysis in conjunction with automatic design optimization techniques for seals used for compressible media. It was shown that optimization algorithms combined with CFD simulations have good potential for improving seal design.

Finite-Length Solutions for Rotordynamic Coefficients of Turbulent Annular Seals

1983 ◽  
Vol 105 (3) ◽  
pp. 437-444 ◽  
Author(s):  
D. W. Childs
Keyword(s):  
Pressure Distribution ◽  
Finite Length ◽  
Reaction Force ◽  
Centrifugal Pumps ◽  
First Order ◽  
Rotordynamic Coefficients ◽  
Dynamic Coefficients ◽  
Continuity Equations ◽  
Complex Differential Equations ◽  
Annular Seals

Expressions are derived which define dynamic coefficients for high-pressure annular seals typical of wear-ring and interstage seals employed in multistage centrifugal pumps. Completely developed turbulent flow is assumed in both the circumferential and axial directions, and is modeled by Hirs’ turbulent lubrication equations. Linear zeroth and first-order perturbation equations are developed by an expansion in the eccentricity ratio. The influence of inlet swirl is accounted for in the development of the circumferential flow. The zeroth-order momentum and continuity equations are solved exactly, while their first-order counterparts are reduced to three ordinary, complex, differential equations in the axial coordinate Z. The equations are integrated to satisfy the boundary conditions and define the pressure distribution due to seal motion. Integration of the pressure distribution defines the reaction force developed by the seal and the corresponding dynamic coefficients. Finite-length solutions for the coefficients are compared to two “short-seal” solutions.

Experimental Study on the Effect of Localized Blockages on the Friction Factor of a 61-Pin Wire-Wrapped Bundle

2020 ◽  
Vol 142 (11) ◽  
Author(s):  
Mason Childs ◽  
Robert Muyshondt ◽  
Rodolfo Vaghetto ◽  
Duy Thien Nguyen ◽  
Yassin Hassan
Keyword(s):  
Reynolds Number ◽  
Friction Factor ◽  
Flow Behavior ◽  
Fluid Pressure ◽  
Transition Flow ◽  
Flow Area ◽  
Number Range ◽  
Rod Bundle ◽  
Transition Flow Regime ◽  
Friction Factor Correlation

Abstract The thermal-hydraulic behavior of the flow in rod bundles has motivated numerous experimental and computational investigations. Previous studies have identified potential for accumulation of debris within the small subchannels of typical wire-wrapped assemblies with subsequent total or partial blockage of subchannel coolant flow. A test campaign was conducted to study the effects of localized blockages on the bundle averaged friction factor of a tightly packed wire-wrapped rod bundle. Blockages were installed within the bundle, and fluid pressure drop was measured across one wire pitch for a Reynolds number range of 500–17,200. The Darcy–Weisbach friction factor of the perturbed rod bundle geometry was compared with that of the unblocked bundle, as well as with the predictions of a well-established friction factor correlation. Differing effects based on blockage size and location for various flow regimes were studied. A number of conclusions can be made about the effects of the blockages on the friction factor, such as an increasing effect of the blockage on friction factor with an increase in Reynolds number, a change in flow behavior in the turbulent transition flow regime near Reynolds number 3000, differences in effect on friction factor for different types of subchannel blockage, and a nonlinear trend in friction factor variation with flow area impeded for edge subchannels. To this end, all data and quantified uncertainty produced in this study are made available for comparison and validation of advanced computational tools.

Heat Transfer for High Aspect Ratio Rectangular Channels in a Stationary Serpentine Passage With Turbulated and Smooth Surfaces

2013 ◽  
Author(s):  
Matthew A. Smith ◽  
Randall M. Mathison ◽  
Michael G. Dunn
Keyword(s):  
Heat Transfer ◽  
Reynolds Number ◽  
Aspect Ratio ◽  
Flow Behavior ◽  
Reynolds Numbers ◽  
Hydraulic Diameter ◽  
Internal Cooling ◽  
Number Range ◽  
Aspect Ratios ◽  
Parallel Configuration

Heat transfer distributions are presented for a stationary three passage serpentine internal cooling channel for a range of engine representative Reynolds numbers. The spacing between the sidewalls of the serpentine passage is fixed and the aspect ratio (AR) is adjusted to 1:1, 1:2, and 1:6 by changing the distance between the top and bottom walls. Data are presented for aspect ratios of 1:1 and 1:6 for smooth passage walls and for aspect ratios of 1:1, 1:2, and 1:6 for passages with two surfaces turbulated. For the turbulated cases, turbulators skewed 45° to the flow are installed on the top and bottom walls. The square turbulators are arranged in an offset parallel configuration with a fixed rib pitch-to-height ratio (P/e) of 10 and a rib height-to-hydraulic diameter ratio (e/Dh) range of 0.100 to 0.058 for AR 1:1 to 1:6, respectively. The experiments span a Reynolds number range of 4,000 to 130,000 based on the passage hydraulic diameter. While this experiment utilizes a basic layout similar to previous research, it is the first to run an aspect ratio as large as 1:6, and it also pushes the Reynolds number to higher values than were previously available for the 1:2 aspect ratio. The results demonstrate that while the normalized Nusselt number for the AR 1:2 configuration changes linearly with Reynolds number up to 130,000, there is a significant change in flow behavior between Re = 25,000 and Re = 50,000 for the aspect ratio 1:6 case. This suggests that while it may be possible to interpolate between points for different flow conditions, each geometric configuration must be investigated independently. The results show the highest heat transfer and the greatest heat transfer enhancement are obtained with the AR 1:6 configuration due to greater secondary flow development for both the smooth and turbulated cases. This enhancement was particularly notable for the AR 1:6 case for Reynolds numbers at or above 50,000.

An Experimental and Analytical Study of Single-Phase Liquid Flow in a Horizontal Well

1997 ◽  
Vol 119 (1) ◽  
pp. 20-25 ◽  
Author(s):  
H. Yuan ◽  
C. Sarica ◽  
S. Miska ◽  
J. P. Brill
Keyword(s):  
Experimental Data ◽  
Friction Factor ◽  
Horizontal Well ◽  
Flow Behavior ◽  
Reynolds Numbers ◽  
Test Facility ◽  
Phase Liquid ◽  
Rate Ratios ◽  
Friction Factor Correlation ◽  
Better Than

A new test facility was designed and constructed to simulate flow in a horizontal well with a single perforation. A total of 635 tests were conducted with Reynolds numbers ranging from 5000 to 60,000 with influx to main rate ratios ranging from 1/5 to 1/100, and also for the no-influx case. The flow behavior in a single-perforation new friction expression for a single-perforation horizontal well was developed. A new simple correlation for the horizontal well friction factor was developed by applying experimental data to the general friction factor expression. The new friction factor correlation and experimental data were compared with the Asheim et al. (1992) data and model, and showed that the new correlation performed better than the Asheim et al. (1992) model.

Heat Transfer And Pressure Drop Of An Angled Discrete Turbulator At Elevated Reynolds Numbers Up To 900,000

2021 ◽  
pp. 1-29
Author(s):  
Sam Ghazi-Hesami ◽  
Dylan Wise ◽  
Keith Taylor ◽  
Peter Ireland ◽  
Étienne Robert
Keyword(s):  
Heat Transfer ◽  
Reynolds Number ◽  
Pressure Drop ◽  
Friction Factor ◽  
Rectangular Channel ◽  
Reynolds Numbers ◽  
Enhance Heat Transfer ◽  
Near Surface ◽  
Number Range ◽  
Smooth Channel

Abstract Turbulators are a promising avenue to enhance heat transfer in a wide variety of applications. An experimental and numerical investigation of heat transfer and pressure drop of a broken V (chevron) turbulator is presented at Reynolds numbers ranging from approximately 300,000 to 900,000 in a rectangular channel with an aspect ratio (width/height) of 1.29. The rib height is 3% of the channel hydraulic diameter while the rib spacing to rib height ratio is fixed at 10. Heat transfer measurements are performed on the flat surface between ribs using transient liquid crystal thermography. The experimental results reveal a significant increase of the heat transfer and friction factor of the ribbed surface compared to a smooth channel. Both parameters increase with Reynolds number, with a heat transfer enhancement ratio of up to 2.15 (relative to a smooth channel) and a friction factor ratio of up to 6.32 over the investigated Reynolds number range. Complementary CFD RANS (Reynolds-Averaged Navier-Stokes) simulations are performed with the κ-ω SST turbulence model in ANSYS Fluent® 17.1, and the numerical estimates are compared against the experimental data. The results reveal that the discrepancy between the experimentally measured area averaged Nusselt number and the numerical estimates increases from approximately 3% to 13% with increasing Reynolds number from 339,000 to 917,000. The numerical estimates indicate turbulators enhance heat transfer by interrupting the boundary layer as well as increasing near surface turbulent kinetic energy and mixing.

A Comparison of Rotordynamic-Coefficient Predictions for Annular Honeycomb Gas Seals Using Three Different Friction-Factor Models

2002 ◽  
Vol 124 (3) ◽  
pp. 524-529 ◽  
Author(s):  
Rohan J. D’Souza ◽  
Dara W. Childs
Keyword(s):  
Friction Factor ◽  
Flow Model ◽  
Factor Model ◽  
Control Volume ◽  
Bulk Flow ◽  
Shear Stresses ◽  
Steam Turbines ◽  
Frequency Range ◽  
Rotordynamic Coefficients ◽  
Rotordynamic Coefficient

A two-control-volume bulk-flow model is used to predict rotordynamic coefficients for an annular, honeycomb-stator/smooth-rotor gas seal. The bulk-flow model uses Hirs’ turbulent-lubrication model, which requires a friction factor model to define the shear stresses at the rotor and stator wall. Rotordynamic coefficients predictions are compared for the following three variations of the Blasius pipe-friction model: (i) a basic model where the Reynolds number is a linear function of the local clearance, fs=ns Rems (ii) a model where the coefficient is a function of the local clearance, and (iii) a model where both the coefficient and exponent are functions of the local clearance. The latter models are based on data that shows the friction factor increasing with increasing clearances. Rotordynamic-coefficient predictions shows that the friction-factor-model choice is important in predicting the effective-damping coefficients at a lower frequency range (60∼70 Hz) where industrial centrifugal compressors and steam turbines tend to become unstable. At a higher frequency range, irrespective of the friction-factor model, the rotordynamic-coefficient predictions tend to coincide. Blasius-based Models which directly account for the observed increase in stator friction factors with increasing clearance predict significantly lower values for the destabilizing cross-coupled stiffness coefficients.

An Experimental Study of Mist/Air Film Cooling With Fan-Shaped Holes on an Extended Flat Plate—Part II: Two-Phase Flow Measurements and Droplet Dynamics

2017 ◽  
Vol 140 (4) ◽  
Author(s):  
Reda Ragab ◽  
Ting Wang
Keyword(s):  
Flow Behavior ◽  
Data Rate ◽  
Main Flow ◽  
Shear Stresses ◽  
Two Phase ◽  
Flow Measurements ◽  
Droplet Dynamics ◽  
Mist Flow ◽  
Film Layer ◽  
Upper Boundary

A phase Doppler particle analyzer (PDPA) system is employed to measure the two-phase mist flow behavior including flow velocity field, droplet size distribution, droplet dynamics, and turbulence characteristics. Based on the droplet measurements made through PDPA, a projected profile describing how the air–mist coolant jet flow spreads and eventually blends into the hot main flow is prescribed for both cylindrical and fan-shaped holes. The mist film layer consists of two layers: a typical coolant film layer (cooling air containing the majority of the droplets) and a wider droplet layer containing droplets outside the film layer. Thanks to the higher inertia possessed by larger droplets (>20 μm in diameter) at the injection hole, the larger droplets tend to shoot across the coolant film layer, resulting in a wider droplet layer than the coolant film layer. The wider droplet layer boundaries are detected by measuring the droplet data rate (droplet number per second) distribution, and it is identified by a wedge-shaped enclosure prescribed by the data rate distribution curve. The coolant film layer is prescribed by its core and its upper boundary. The apex of the data rate curve, depicted by the maximum data rate, roughly indicates the core region of the coolant film layer. The upper boundary of the coolant film layer, characterized by active mixing with the main flow, is found to be close to relatively high values of local Reynolds shear stresses. With the results of PDPA measurements and the prescribed coolant film and droplet layer profiles, the heat transfer results on the wall presented in Part I are re-examined, and the fundamental mist-flow physics are analyzed. The three-dimensional (3D) droplet measurements show that the droplets injected from the fan-shaped holes tend to spread wider in lateral direction than cylinder holes and accumulate at the location where the neighboring coolant film layers meet. This flow and droplet behavior explain the higher cooling performance as well as mist-enhancement occurs between the fan-shaped cooling holes, rather than along the hole's centerline as demonstrated in the case using the cylindrical holes.

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