Brush Seals Used in Steam Environments: Chronological Wear Development and the Impact of Different Seal Designs

2015 ◽  
Author(s):  
M. Raben ◽  
J. Friedrichs ◽  
J. Flegler ◽  
T. Helmis
Keyword(s):  
Abrasive Wear ◽  
Contact Force ◽  
Operating Conditions ◽  
Test Facility ◽  
Working Fluid ◽  
Two Stage ◽  
Blow Down ◽  
Frictional Contacts ◽  
Brush Seals ◽  
The Impact

During the last decades a large effort has been made to continuously improve turbomachine efficiency. Besides the optimization of the primary flow path, also the secondary flow losses have been reduced considerably, due to the use of more efficient seals. Brush seals, as a compliant contacting filament seal, have become an attractive alternative to conventional labyrinth seals in the field of aircraft engines as well as in stationary gas and steam turbines. The aim of today’s research related to brush seals is to understand the characteristics and their connections, in order to be able to make performance predictions, and to ensure the reliability over a defined operating period. It is known that inevitable frictional contacts lead to an abrasive wear on the rotor side as well as on the bristle side. The wear situation is essentially influenced by the resulting contact force at the seal-to-rotor interface during the operating time. This contact force depends on the seal’s blow down capability, which is mainly determined by the geometrical design of the bristle pack, e.g. the axial inclination of the investigated seal design, in combination with the design and material of the surrounding parts, as well as the thermal boundary conditions. For realistic investigations with representative circumferential velocities the TU Braunschweig operates a specially developed steam test rig which enables live steam investigations under varying operating conditions up to 50 bar and 450 °C. Wear measurements and the determination of seal performance characteristics, such as blow down and bristle stiffness, were enabled by an additional test facility using pressurized cold air up to 8 bar as working fluid. This paper presents the chronological wear development on both rotor and seal side, in a steam test lasting 25 days respectively 11 days. Interruptions after stationary and transient intervals were made in order to investigate the wear situation. Two different seal arrangements, a single tandem seal and a two-stage single seal arrangement, using different seal elements were considered. The results clearly show a continuous wear development and that the abrasive wear of the brush seal and rotor is mainly due to the transient test operation, particularly by enforced contacts during shaft excursions. Despite the increasing wear to the brushes, all seals have shown a functioning radial-adaptive behavior over the whole test duration with a sustained seal performance. Thereby, it could be shown that the two-stage arrangement displays a load shift during transients, leading to a balanced loading and unloading status for the two single brush seals. From load sharing and in comparison with the wear data of the tandem seal arrangement, it can be derived that the two-stage seal is less prone to wear. However, the tandem seal arrangement, bearing the higher pressure difference within one configuration, shows a superior sealing performance under constant load, i.e. under stationary conditions.

Brush Seals Used in Steam Environments—Chronological Wear Development and the Impact of Different Seal Designs

2015 ◽  
Vol 138 (5) ◽  
Author(s):  
Markus Raben ◽  
Jens Friedrichs ◽  
Thomas Helmis ◽  
Johan Flegler
Keyword(s):  
Wear Behavior ◽  
Test Facility ◽  
Working Fluid ◽  
Attractive Alternative ◽  
Test Duration ◽  
Steam Turbines ◽  
Two Stage ◽  
Frictional Contacts ◽  
Brush Seals ◽  
The Impact

During the last decades, turbo machine efficiency was considerably increased by using more efficient seals. Brush seals, as a compliant contacting filament seal, have become an attractive alternative to conventional labyrinth seals in the field of aircraft engines as well as in stationary gas and steam turbines. The aim of today's research related to brush seals is to understand the characteristics and their connections, in order to be able to make performance predictions, and to ensure the reliability over a defined operating period. The wear behavior is essentially influenced by frictional contacts at the seal-to-rotor interface during operation. For realistic investigations with representative circumferential velocities, the TU Braunschweig, Germany, operates a specially developed steam test rig which enables endurance investigations under varying operating steam conditions up to 50 bar and 450 °C. Wear measurements and the determination of seal performance characteristics, such as blow down and bristle stiffness, are enabled by an additional test facility, using pressurized cold air up to 8 bar as a working fluid. This work presents the chronological wear development on both rotor and seal sides in a steam test lasting 25 days or 11 days, respectively. Interruptions after stationary and transient intervals were made in order to investigate the degree of wear. Two different seal arrangements, a single tandem seal, and a two-stage single seal arrangement, using different seal elements were considered. Besides a continuous wear development, the results clearly show that the abrasive wear of the brush seal and rotor is mainly caused by transient test operations, particularly by enforced contacts during shaft excursions. Despite the increasing wear to the brushes, all seals have shown a functioning radial-adaptive behavior over the whole test duration with a sustained seal performance. Thereby, it could be shown that the two-stage arrangement displays a load shift during transients, leading to a balanced loading and unloading status for the two single brush seals. From load sharing, and in comparison with the wear data of the tandem seal arrangement, it can be derived that the two-stage seal is less prone to wear. However, the tandem seal arrangement, bearing the higher pressure difference within one configuration, shows a superior sealing performance under constant load, i.e., under stationary conditions.

The 2-Stage Axial Turbine Test Facility “LISA”

2001 ◽  
Author(s):  
M. Sell ◽  
J. Schlienger ◽  
A. Pfau ◽  
M. Treiber ◽  
R. S. Abhari
Keyword(s):  
Unsteady Flow ◽  
Mass Flow ◽  
Measurement Techniques ◽  
Operating Conditions ◽  
Test Facility ◽  
Two Stage ◽  
Axial Turbine ◽  
Aerodynamic Pressure ◽  
Second Stage ◽  
The Impact

This paper describes the design and construction of a new two stage axial turbine test facility, christened “Lisa”. The research objective of the rig is to study the impact (relevance) of unsteady flow phenomena upon the aerodynamic performance, this being achieved through the use of systematic studies of parametric changes in the stage geometry and operating point. Noteworthy in the design of the rig is the use of a twin shaft arrangement to decouple the stages. The inner shaft carries the load from the first stage whilst the outer is used with an integral torque-meter to measure the loading upon the second stage alone. This gives an accurate measurement of the loading upon the aerodynamically representative second stage, which possesses the correct stage inlet conditions in comparison to the full two stage machine which has an unrealistic axial inlet flow at the first stator. A calibrated Venturi nozzle measures the mass flow at an accuracy of below 1%, from which stage efficiencies can be derived. The rig is arranged in a closed loop system. The turbine has a vertical arrangement and is connected through a gear box to a generator system that works as a brake to maintain the desired operating speed. The turbine exit is open to ambient pressure. The rig runs at a low pressure ratio of 1.5. The maximum Mach number at stator exit is 0.3 at an inlet pressure of 1.5 bar. The maximum mass flow is 14 kg/sec. Nominal rotor design speed is 3000 RPM. The tip to hub blade ratio is 1.29, and the nominal axial chord is 50 mm. The rig is designed to accommodate a broad range of measurement techniques, but with a strong emphasis upon unsteady flow methods, for example fast response aerodynamic pressure probes for time-resolved flow measurements. The first section of this paper describes the overall test facility hardware. This is followed by a detailed focus on the torque measurement device including stage efficiency measurements at operating conditions in Lisa. Discussion of measurement techniques completes the paper.

Optimisation of CO Turndown for an Axially Staged Gas Turbine Combustor

2020 ◽  
Author(s):  
Jacob E. Rivera ◽  
Robert L. Gordon ◽  
Mohsen Talei ◽  
Gilles Bourque
Keyword(s):  
Residence Time ◽  
Parametric Study ◽  
Gas Turbines ◽  
Flow Reactor ◽  
Operating Conditions ◽  
Independent Effect ◽  
Inlet Temperature ◽  
Operating Characteristics ◽  
Two Stage ◽  
The Impact

Abstract This paper reports on an optimisation study of the CO turndown behaviour of an axially staged combustor, in the context of industrial gas turbines (GT). The aim of this work is to assess the optimally achievable CO turndown behaviour limit given system and operating characteristics, without considering flow-induced behaviours such as mixing quality and flame spatial characteristics. To that end, chemical reactor network modelling is used to investigate the impact of various system and operating conditions on the exhaust CO emissions of each combustion stage, as well as at the combustor exit. Different combustor residence time combinations are explored to determine their contribution to the exhaust CO emissions. The two-stage combustor modelled in this study consists of a primary (Py) and a secondary (Sy) combustion stage, followed by a discharge nozzle (DN), which distributes the exhaust to the turbines. The Py is modelled using a freely propagating flame (FPF), with the exhaust gas extracted downstream of the flame front at a specific location corresponding to a specified residence time (tr). These exhaust gases are then mixed and combusted with fresh gases in the Sy, modelled by a perfectly stirred reactor (PSR) operating within a set tr. These combined gases then flow into the DN, which is modelled by a plug flow reactor (PFR) that cools the gas to varying combustor exit temperatures within a constrained tr. Together, these form a simplified CRN model of a two-stage, dry-low emissions (DLE) combustion system. Using this CRN model, the impact of the tr distribution between the Py, Sy and DN is explored. A parametric study is conducted to determine how inlet pressure (Pin), inlet temperature (Tin), equivalence ratio (ϕ) and Py-Sy fuel split (FS), individually impact indicative CO turndown behaviour. Their coupling throughout engine load is then investigated using a model combustor, and its effect on CO turndown is explored. Thus, this aims to deduce the fundamental, chemically-driven parameters considered to be most important for identifying the optimal CO turndown of GT combustors. In this work, a parametric study and a model combustor study are presented. The parametric study consists of changing a single parameter at a time, to observe the independent effect of this change and determine its contribution to CO turndown behaviour. The model combustor study uses the same CRN, and varies the parameters simultaneously to mimic their change as an engine moves through its steady-state power curve. The latter study thus elucidates the difference in CO turndown behaviour when all operating conditions are coupled, as they are in practical engines. The results of this study aim to demonstrate the parameters that are key for optimising and improving CO turndown.

Springs® Design Optimized By Seawater Quality. Laboratory Pilot Tests

2021 ◽  
Author(s):  
Pierre Pedenaud ◽  
Marianna Rondon ◽  
Nicolas Lesage ◽  
Eric Tournis ◽  
Riccardo Giolo ◽  
...  
Keyword(s):  
Water Quality ◽  
Operating Conditions ◽  
Single Stage ◽  
Plant Performance ◽  
Future Application ◽  
Feed Water ◽  
Nanofiltration Membranes ◽  
Two Stage ◽  
Seawater Quality ◽  
The Impact

Abstract A new seawater laboratory pilot has been installed in order to evaluate the impact of the seawater quality on the performance of nanofiltration membranes and filters. The test program implemented was designed to produce the data required to optimize the design and operating parameters of a subsea sulfate removal plant, particularly with respect to the technology developed by Total, Saipem and Veolia, co-owners of the development. The equipment qualification plan is approaching completion with the development of subsea barrier-fluidless pumps, all-electric control systems, high-cycling valves operated by electric actuators and subsea water analyzers. This presented pilot laboratory study completes this plan. Nanofiltration membranes are commonly used to remove the sulfates found in seawater before the water is injected into wells. The principal advantages of relocating this equipment from topside to subsea are better reservoir sweep control, a substantial subsea water injection network reduction and savings on space and weight on the topsides deck. The move to subsea offers the opportunity to simplify the process due to improved deep water quality. This was previously demonstrated through a subsea test campaign. This new pilot study provides data both on the performance of a plant operating with different feed water quality and on the success of operating changes to further optimize the plant performance. The pilot has been installed at the Palavas-les-Flots site in France. Raw water collected from the basin was mixed with ultra-filtered water in order to calibrate the feed water quality. The pilot includes a two stage nanofiltration configuration and single stage nanofiltration unit. The two stage configuration was used to produce data for operation across an array of feed water quality and plant operating conditions. The single stage unit was used to produce data on membrane fouling over a long operating duration. Results from these tests and discussion on how this data relates to subsea plant performance shall be presented. This innovative approach enables a wide range of subsea water quality to be simulated and tested against different process configurations of the subsea unit. Indeed, for each industrial subsea application, the raw seawater quality is dependent on both the region and the depth of the seawater inlet. With this experimental data acquisition campaign and understanding of the seawater quality at inlet, the system design can be tailor-made for each future application case.

Breaking the Swirl With Brush Seals: Numerical Modeling and Experimental Evidence

2008 ◽  
Author(s):  
Peter Helm ◽  
Alexander Pugachev ◽  
Matthias Neef
Keyword(s):  
Experimental Evidence ◽  
Swirl Flow ◽  
Operating Conditions ◽  
Brush Seal ◽  
Stable Operating ◽  
Beneficial Impact ◽  
Rotor Surface ◽  
Brush Seals ◽  
Experimental Values ◽  
The Impact

Striving for smaller losses in turbomachinery has led to many advancements in the design of seals. Modern sealing concepts such as brush seals hold a great potential to increase the efficiency of both flight engines and stationary turbines. At the same time, in order to maintain stable operating conditions of the rotor, swirl-induced forces must be kept at a minimum in the sealing channels. Therefore, the influence of the permeable and flexible bristle pack of brush seals on the flow around the rotor surface must be known. In this paper the swirl flow in the cavities of two different seal geometries is studied experimentally and numerically. A conventional three-tooth labyrinth serves as a reference. A second seal arrangement with a bristle pack upstream of two teeth is compared with the reference labyrinth. The swirl is evaluated experimentally from total and static pressure measurements in various axial and circumferential positions. Additionally, the axial swirl distribution is calculated using computational fluid dynamics (CFD). Here, the numerical model of the brush seal is based on the porous medium approach and is calibrated using the experimental values of the leakage and the bristle clearance by adjusting the thickness of the bristle pack. The calibrated CFD model is then used to study the impact of the brush seal on the swirl component of the sealing flow. The observed significant decrease of the swirl by the brush seal shows good agreement with the experimental data. The impact of changes in bristle pack clearance on the swirl is also investigated and compared with experimental evidence. The aim is to show that the brush seals have a natural tendency to interrupt seal swirl. They can therefore be used for swirl control in order to create a beneficial impact on the dynamic stability of turbomachines.

Geothermal Power Cycle Analysis for Commercial Applicability Using Sequestered Supercritical CO2 as a Heat Transfer or Working Fluid

2011 ◽  
Author(s):  
Brian Janke ◽  
Thomas Kuehn
Keyword(s):  
Heat Transfer ◽  
Binary System ◽  
Power Plants ◽  
Power Production ◽  
Operating Conditions ◽  
Heat Transfer Fluid ◽  
Working Fluid ◽  
Direct System ◽  
Geothermal Power ◽  
The Impact

Thermodynamic analysis has been conducted for geothermal power cycles using a portion of deep ground sequestered CO2 as the working fluid. This allows energy production from much shallower depths and in geologic areas with much lower temperature gradients than those of current geothermal systems. Two different system designs were analyzed for power production with varying reservoir parameters, including reservoir depth, temperature, and CO2 mass flow rate. The first design is a direct single-loop system with the CO2 run directly through the turbine. This system was found to provide higher system efficiency and power production, however design complications such as the need for high pressure turbines, two-phase flow through the turbine and the potential for water-CO2 brine mixtures, could require the use of numerous custom components, driving up the cost. The second design is a binary system using CO2 as the heat transfer fluid to supply thermal energy to an Organic Rankine Cycle (ORC). While this system was found to have slightly less power production and efficiency than the direct system, it significantly reduces the impact of design complications associated with the direct system. This in turn reduces the necessity for certain custom components, thereby reducing system cost. While performance of these two systems is largely dependent on location and operating conditions, the binary system is likely applicable to a larger number of sites and will be more cost effective when used in combination with current off-the-shelf ORC power plants.

Effect of Trace Contaminants on PEM Fuel Cell Performance

2005 ◽  
Vol 885 ◽  
Author(s):  
Tony Thampan ◽  
Rick Rocheleau ◽  
Keith Bethune ◽  
Douglas Wheeler
Keyword(s):  
Carbon Monoxide ◽  
Fuel Cell ◽  
Strong Dependence ◽  
Pem Fuel Cells ◽  
Gas Analysis ◽  
Operating Conditions ◽  
Test Facility ◽  
Systematic Evaluation ◽  
Fuel Cell Performance ◽  
The Impact

ABSTRACTAt the Hawaii Fuel Cell Test Facility a systematic evaluation of the impact of impurities in hydrogen is underway to evaluate the effects on the performance of PEM fuel cells. Initial tests are being conducted using carbon monoxide and hydrocarbon contaminants. The effects of carbon monoxide poisons at atmospheric and pressurized operating conditions have shown a strong dependence on concentration of the impurity over the range 6.7 µmole/mole to 29.3 µmole/mole. Additionally, benzene and toluene were tested at 20 µmole/mole. Although both benzene and toluene showed no evidence of fuel cell degradation, on-line gas analysis of the exit anode stream showed that toluene hydrogenation occurs in the anode resulting in 90% conversion of the toluene to methyl-cyclohexane.

An Innovative Solution for Type Testing of Power Transformers

2019 ◽  
Vol 20 (1) ◽  
Author(s):  
Manohar Singh ◽  
Vishnuvarddhan Telukanta ◽  
K S Meera
Keyword(s):  
Power Transformer ◽  
Short Circuit ◽  
Operating Conditions ◽  
Power Transformers ◽  
Test Facility ◽  
Online Testing ◽  
Testing Laboratory ◽  
Power Testing ◽  
Grid Operation ◽  
The Impact

Abstract Type tests are essential to assess the short circuit withstand capabilities of transformer windings. The mechanical durability of power equipment are checked against the mechanical forces developed during making/breaking short circuit operations. These type tests are generally carried out in indoor transformer test laboratories. Testing of Power Transformer for size more than 200 MVA in 765/400 kV voltage class in an indoor laboratory is not economically feasible. Now a days, power transformer manufacturers are fabricating single phase auto- power transformers of size up to 630 megawatt volt ampere (MVA) rating. Type testing of these transformers in indoor laboratories is not feasible. In view of this, strong short circuit fault feeding capabilities of the national grids can be utilized for type testing of these power transformers in an online manner. However, this may affect the grid operation/control during weak grid operating conditions. Recently, National High Power Testing Laboratory is established for testing of power transformer upto of 630 MVA. This is a unique online transformer test facility for testing of 765/400/220/132 kV class power transformers. An offline simulation has been carried out in this article, to assess the impact of online type testing on the Indian National grid. In this article, an online testing scheme has been presented which enables the national grid operator to analysis the prevailing grid condition & subsequently to decide the safe rating of the power transformer for online testing. The simulated results are cross checked with field results and it is found that simulated results are close to actual field results. The concurrence of simulated and field results helped in successfully commissioning of the testing laboratory.

An Investigation of Heat Generation Characteristics of Brush Seals

2007 ◽  
Author(s):  
Mehmet Demiroglu ◽  
John A. Tichy
Keyword(s):  
Contact Force ◽  
Heat Generation ◽  
Operating Conditions ◽  
Frictional Heat ◽  
Design Parameters ◽  
Frictional Heat Generation ◽  
Operation Conditions ◽  
Seal Design ◽  
Wide Range ◽  
Brush Seals

Brush seals are considered as a category of compliant seals, which tolerate a great high level of interference between the seal and the rotor or shaft. Their superior leakage characteristics have opened many application fields in the turbo-machinery world, ranging from industrial steam turbines to jet engines. However, brush seal designers have to find a trade-off between the lower parasitic leakage but higher heat generation properties of brush seals for given operation conditions. As brush seals can maintain contact with the rotor for a wide range of operating conditions, the contact force/pressure generated at the seal-rotor interface becomes an important design parameter for sustained seal performance and longevity of its service life. Furthermore, due to this contact force at the interface, frictional heat generation is inevitable and must be evaluated for various design and operating conditions. In this paper, frictional heat generation at the sealrotor interface is studied. To capture temperature rise at the interface, a thermal image of the seal and rotor is taken with an infrared camera under various operating conditions. The temperature map of the rotor is compared to results from thermal finite element analysis of the rotor to back calculate the heat flux to the rotor. A closed form equation for frictional heat generation is suggested as a function of seal design parameters, material properties, friction coefficient and empirical factors from testing.

Assessment of Tesla Turbine Performance for Small Scale Rankine Combined Heat and Power Systems

2010 ◽  
Vol 132 (12) ◽  
Author(s):  
Van P. Carey
Keyword(s):  
Power Systems ◽  
Residential Buildings ◽  
Rankine Cycle ◽  
Combined Heat And Power ◽  
Operating Conditions ◽  
Working Fluid ◽  
Small Scale ◽  
Manufacturing Cost ◽  
Turbine Design ◽  
The Impact

For solar Rankine cycle combined heat and power systems for residential buildings and other small-scale applications (producing 1–10 kWe), a low manufacturing cost, robust, and durable expander is especially attractive. The Tesla-type turbine design has these desired features. This paper summarizes a theoretical exploration of the performance of a Tesla turbine as the expander in a small-scale Rankine cycle combined heat and power system. A one-dimensional idealized model of momentum transfer in the turbine rotor is presented, which can be used to predict the efficiency of the turbine for typical conditions in these systems. The model adopts a nondimensional formulation that identifies the dimensionless parameters that dictate performance features of the turbine. The model is shown to agree well with experimental performance data obtained in earlier tests of prototype Tesla turbine units. The model is used to explore the performance of this type of turbine for Rankine cycle applications using water as a working fluid. The model indicates that isentropic efficiencies above 0.75 can be achieved if the operating conditions are tailored in an optimal way. The scalability of the turbine design, and the impact of the theoretical model predictions on the development of solar combined heat and power systems are also discussed.

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