A General-Purpose Test Facility for Evaluating Gas Lubricated Thrust Bearings

2020 ◽  
Author(s):  
Keith Gary ◽  
Bugra Ertas ◽  
Adolfo Delgado
Keyword(s):  
Gas Turbines ◽  
High Performance ◽  
Load Capacity ◽  
General Purpose ◽  
Test Facility ◽  
Working Fluid ◽  
Test Rig ◽  
Auxiliary Equipment ◽  
Thrust Bearings ◽  
Low Viscosity

Abstract The design, construction, operational capabilities, and proof of concept results are presented for a test rig used to evaluate gas-lubricated thrust bearings. The following work is motivated by a desire to utilize the working fluid of high-performance turbomachinery, such as gas turbines, for bearing lubricant. Auxiliary equipment required to cool, pump, and clean oil for a typical thrust bearing is eliminated by taking advantage of the turbomachinery’s working fluid as bearing lubricant. The benefit of removing such auxiliary equipment is obvious when considering cost and weight of turbomachines, yet the working fluid of gas turbines typically has very low viscosity compared to oil which introduces load capacity and stability challenges. It is therefore necessary to build a facility capable of testing gas-lubricated thrust bearings to advance the technology. The test rig design in this work allows for 7 to 15 inch (180–380 mm) diameter thrust bearings, static loads up to 30,000 lbf (135 kN), and speeds up to 20 krpm. The test facility also provides up to 500 psig (3.45 MPa) static air pressure to enable testing of hydrostatic and hybrid (hydrodynamic combined with hydrostatic) bearings. This paper describes the test rig operating principle, details experimental procedures to obtain measurements, and provides test results necessary to prove the test rig concept by means of a hybrid gas bearing.

A General Purpose Test Facility for Evaluating Gas Lubricated Journal Bearings

2008 ◽  
Vol 131 (2) ◽  
Author(s):  
B. Ertas ◽  
M. Drexel ◽  
J. Van Dam ◽  
D. Hallman
Keyword(s):  
Load Capacity ◽  
Aircraft Engine ◽  
General Purpose ◽  
Journal Bearings ◽  
Test Facility ◽  
Test Rig ◽  
Component Level ◽  
Simultaneous Application ◽  
Design Elements ◽  
Lift Off

The present work describes the detailed design and operational capabilities of a general purpose test facility developed to evaluate the dynamics and performance of gas lubricated journal bearings. The component level test facility was developed to serve as an initial tollgate test platform for certifying gas lubricated journal bearings into aircraft engine applications. A rotating test rig was engineered to test 70–120 mm diameter bearings at 40,000–80,000 rpm and 1200°F. The test rig described in this paper possesses design elements that enable the simultaneous application of dynamic and static load profiles of up to 1000 lb while monitoring and measuring the bearing torque. This capability allows for the characterization of several critical metrics such as bearing lift off speed characteristics, load capacity, and frequency dependent rotordynamic force coefficients. This paper discusses the functionality of the test facility and presents sample test measurements from several experiments.

Identification of Dynamic Characteristics of Gas Foil Thrust Bearings Using Base Excitation

2016 ◽  
Author(s):  
Tae Ho Kim ◽  
Moon Sung Park ◽  
Jongsung Lee ◽  
Young Min Kim ◽  
Kyoung-Ku Ha ◽  
...  
Keyword(s):  
Dynamic Characteristics ◽  
Dynamic Load ◽  
Loss Factor ◽  
Load Capacity ◽  
Excitation Frequency ◽  
Vibrational Amplitude ◽  
Test Rig ◽  
Thrust Bearings ◽  
Bearing Plate ◽  
Bearing Stiffness

Gas foil bearings (GFBs) have clear advantages over oil-lubricated and rolling element bearings, by virtue of low power loss, oil-free operation in compact units, and rotordynamic stability at high speeds. However, because of the inherent low gas viscosity, GFBs have lower load capacity than the other bearings. In particular, accurate measurement of load capacity and dynamic characteristics of gas foil thrust bearings (GFTBs) is utmost important to widening their applications to high performance turbomachinery. In this study, a series of excitation tests were performed on a small oil-free turbomachinery with base excitations in the rotor axial direction to measure the dynamic load characteristics of a pair of six-pad, bump-type GFTBs, which support the thrust collar. An electromagnetic shaker provided dynamic sine sweep loads to the test bench (shaking table), which held rigidly the turbomachinery test rig for increasing excitation frequency from 10 Hz to 200 Hz. The magnitude of the shaker dynamic load, represented as an acceleration measured on the test rig, was increased up to 9 G (gravity). An eddy current sensor installed on the test rig housing measured the axial displacement (or vibrational amplitude) of the rotor thrust collar during the excitation tests. The axial acceleration of the rotor relative to the test rig was calculated using the measured displacement. A single degree-of-freedom base excitation model identified the frequency-dependent dynamic load capacity, stiffness, damping, and loss factor of the test GFTB for increasing shaker dynamic loads and increasing bearing clearances. The test results show that, for a constant shaker force and the test GFTB with a clearance of 155 μm, an increasing excitation frequency increases the dynamic load carried by the test GFTB, i.e., bearing reaction force, until a certain value of the frequency where it jumps down suddenly because of the influence from Duffing’s vibrations of the rotor. The bearing stiffness increases and the damping decreases dramatically as the excitation frequency increases. Generally, the bearing loss factor ranges from 0.5 to 1.5 independent of the frequency. As the shaker force increases, the bearing dynamic load, stiffness, damping, and loss factor increase depending on the excitation frequency. Interestingly, the agreements between the measured GFTB dynamic load versus the thrust runner displacement, the measured GFTB static load versus the structural deflection, and the predicted static load versus the thrust runner displacement are remarkable. Further tests with increasing GFTB clearances of 155, 180, 205, and 225 μm revealed that the vibrational amplitude increases and the jump-down frequency decreases with increasing clearances. The bearing load increases, but the bearing stiffness, damping, and loss factor decrease slightly as the clearance increases. The test results after a modification of the GFTB by rotating one side bearing plate by 30° relative to the other side bearing plate revealed insignificant changes in the dynamic characteristics. The present dynamic performance measurements provide a useful database of GFTBs for use in microturbomachinery.

Introduction and Commissioning of the New Darmstadt Transonic Compressor Test Facility

2019 ◽  
Author(s):  
Christian Kunkel ◽  
Jan Werner ◽  
Daniel Franke ◽  
Heinz-Peter Schiffer ◽  
Fabian Wartzek ◽  
...  
Keyword(s):  
Control Systems ◽  
Gas Turbines ◽  
State Of The Art ◽  
Test Facility ◽  
Test Results ◽  
Test Rig ◽  
Vast Number ◽  
Transonic Compressor ◽  
Profound Knowledge ◽  
And Control

Abstract With the well-known Transonic Compressor Darmstadt (TCD) in operation since 1994, profound knowledge in designing and operating a sophisticated test-rig is available at the Institute of Gas Turbines and Aerospace Propulsion of TU Darmstadt. During this period, TCD has been subject to a vast number of redesigns within different measurement campaigns (see [1], [2], [3], [4], [5], [6], [7], [8]). To expand the capabilities and ensure a sustainable process of compressor research, a new test facility was designed and built by the institute. The new test rig Transonic Compressor Darmstadt 2 (TCD2) features increased power for higher pressure ratios and higher mass-flow, a state of the art control system, increased flexibility towards different compressor geometries and modern data acquisition hardware and software. Following the successful commissioning of the test-rig in March 2018, a first measurement campaign has been conducted. Early test results regarding aerodynamic performance and aeroelastic effects of the test compressor are presented together with a detailed overview of test-rig infrastructure and control systems as well as the test compressor and the measurement hardware.

The Influence of Ambient Pressure on the Measured Load Capacity of Bump-Foil and Spiral-Groove Gas Thrust Bearings at Ambient Pressures up to 69 Bar on a Novel High-Pressure Gas Bearing Test Rig

2019 ◽  
Author(s):  
Jason Wilkes ◽  
Ryan Cater ◽  
Erik Swanson ◽  
Kevin Passmore ◽  
Jerry Brady
Keyword(s):  
Power Loss ◽  
Thrust Bearing ◽  
Load Capacity ◽  
Ambient Pressure ◽  
Spiral Groove ◽  
Test Rig ◽  
Thrust Bearings ◽  
Order Of Magnitude ◽  
Foil Thrust Bearing ◽  
Thrust Load

Abstract This paper will show the influence of ambient pressure on the thrust capacity of bump-foil and spiral-groove gas thrust bearings. The bearings were operating in nitrogen at various pressures up to 69 bar, and were tested to failure. Failure was detected at various pressures by incrementally increasing the thrust load applied to the thrust bearing until the bearing was no longer thermally stable, or until contact was observed by a temperature spike measured by thermocouples within the bearing. These tests were performed on a novel thrust bearing test rig that was developed to allow thrust testing at pressures up to 207 bar cavity pressure at 260°C while rotating at speeds up to 120,000 rpm. The test rig floats on hydrostatic air bearings to allow for the direct measurement of applied thrust load through linkages that connect the stationary thrust loader to the rotor housing. Test results on a 65 mm (2.56 in) bump-foil thrust bearing at 100 krpm show a marked increase in load capacity with gas density, which has not previously been shown experimentally. Results also show that the load capacity of a similarly sized spiral-groove thrust bearing are relatively insensitive to pressure, and supported an order-of-magnitude less load than that observed for the bump-foil thrust bearing. These results are compared with analytical predictions, which agree reasonably with the experimental results. Predicted power loss is also presented for the bump-foil bearing; however, measured power loss was substantially higher.

Thrust Bearings for Power Gas Turbines

1971 ◽  
Author(s):  
A. J. Leopard
Keyword(s):  
Gas Turbines ◽  
Load Capacity ◽  
Point Of View ◽  
Power Losses ◽  
Service Experience ◽  
Thrust Bearings ◽  
Tilting Pad ◽  
Bearing Assembly ◽  
Design Requirements ◽  
New System

The design requirements of thrust bearings for power gas turbines are discussed with reference to designs which have given satisfactory service. The shortcomings of these designs are analyzed both from the point of view of efficiency and that of service experience. The development of a new system of lubrication designed to overcome these shortcomings is outlined. It is shown that this system, when applied to tilting pad thrust bearings in power turbines, can result in a simpler bearing assembly with increased load capacity and substantially ower power losses.

Combustion System Development and Testing for MAN’s New Industrial Gas Turbines MGT 6100 and MGT 6200

2014 ◽  
Author(s):  
Frank Reiss ◽  
Sven-Hendrik Wiers ◽  
Ulrich Orth ◽  
Emil Aschenbruck ◽  
Martin Lauer ◽  
...  
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Test Facility ◽  
Combustion System ◽  
Test Rig ◽  
Low Emission ◽  
Pressure Test ◽  
Industrial Gas Turbines ◽  
And Performance

This paper describes the development and test results of the low emission combustion system for the new industrial gas turbines in the 6–7 MW class from MAN Diesel & Turbo. The design of a robust combustion system and the achievement of very low emission targets were the most important design goals of the combustor development. During the design phase, the analysis of the combustor (i.e. burner design, air distribution, liner cooling design) was supported with different CFD tools. This advanced Dry Low Emission can combustion system (ACC) consists of 6 cans mounted externally on the gas turbine. The behavior and performance of a single can sector was tested over a wide load range and with different boundary conditions; first on an atmospheric test rig and later on a high pressure test rig with extensive instrumentation to ensure an efficient test campaign and accurate data. The atmospheric tests showed a very good performance for all combustor parts and promising results. The high pressure tests demonstrated very stable behavior at all operation modes and very low emissions to satisfy stringent environmental requirements. The whole operation concept of the combustion system was tested first on the single-can high pressure test bed and later on twin and single shaft gas turbines at MAN’s gas turbine test facility. During the engine tests, the can combustors demonstrated the expected combustion performance under real operation conditions. All emissions and performance targets were fully achieved. On the single shaft engine, the combustors were running with single digit ppm NOx levels between 50% and 100% load. The validation phase and further optimization of the gas turbines and the engine components are ongoing. The highlights of the development process and results of the combustor and engine tests will be presented and discussed within this paper.

Design and Validation of a Compressor for a New Generation of Heavy-Duty Gas Turbines

2007 ◽  
Author(s):  
F. Eulitz ◽  
B. Kuesters ◽  
F. Mildner ◽  
M. Mittelbach ◽  
A. Peters ◽  
...  
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
High Performance ◽  
High Efficiency ◽  
Forced Response ◽  
Combined Cycle ◽  
Test Facility ◽  
Primary Driver ◽  
Compressor Technology

Siemens H-Class. Siemens has developed the world-largest H-class Gas Turbine (SGT™) that sets unparalleled standards for high efficiency, low life cycle costs and operating flexibility. With a power output of 340+ MW, the SGT5–8000H gas turbine will be the primary driver of the new Siemens Combined Cycle Power Plant (SCC™) for the 50 Hz market, the SCC5–8000H, with an output of 530+ MW at more than 60% efficiency. After extensive lab and component testing, the prototype has been shipped to the power plant for an 18-month validation phase. In this paper, the compressor technology, which was developed for the Siemens H-class, is presented through its development and validation phases. Reliability and Availability. The compressor has been extensively validated in the Siemens Berlin Test Facility during consecutive engine test programs. All key parameters, such as mass flow, operating range, efficiency and aero mechanical behavior meet or exceed expectations. Six-sigma methodology has been exploited throughout the development to implement the technologies into a robust design. Efficiency. The new compressor technology applies the Siemens advanced aerodynamics design methodology based on the high performance airfoil (HPA) systematic which leads to broader operation range and higher efficiency than a standard controlled diffusion airfoil (CDA) design. Operational Flexibility. The compressor features an IGV and three rows of variable guide vanes for improved turndown capability and improved part load efficiency. Serviceability. The design has been optimized for serviceability and less complexity. Following the Siemens tradition, all compressor rotating blades can be replaced without rotor lift or destacking. Evolutionary Design Innovation. The compressor design incorporates the best features and experience from the operating fleets and technology innovation prepared through detailed research, analysis and lab testing in the past decade. The design tools are based on best practices from former Siemens KWU and Westinghouse with enhancements allowing for routine front-to-back compressor 3D CFD multistage analysis, unsteady blade row interaction, forced response analyses and aero-elastic analysis.

Oxy-Fuel Gas Turbine, Gas Generator and Reheat Combustor Technology Development and Demonstration

2010 ◽  
Author(s):  
Roger Anderson ◽  
Fermin Viteri ◽  
Rebecca Hollis ◽  
Ashley Keating ◽  
Jonathan Shipper ◽  
...  
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Clean Energy ◽  
Test Facility ◽  
Working Fluid ◽  
Capital Costs ◽  
2Nd Generation ◽  
Wide Range ◽  
And Performance

Future fossil-fueled power generation systems will require carbon capture and sequestration to comply with government green house gas regulations. The three prime candidate technologies that capture carbon dioxide (CO2) are pre-combustion, post-combustion and oxy-fuel combustion techniques. Clean Energy Systems, Inc. (CES) has recently demonstrated oxy-fuel technology applicable to gas turbines, gas generators, and reheat combustors at their 50MWth research test facility located near Bakersfield, California. CES, in conjunction with Siemens Energy, Inc. and Florida Turbine Technologies, Inc. (FTT) have been working to develop and demonstrate turbomachinery systems that accommodate the inherent characteristics of oxy-fuel (O-F) working fluids. The team adopted an aggressive, but economical development approach to advance turbine technology towards early product realization; goals include incremental advances in power plant output and efficiency while minimizing capital costs and cost of electricity [1]. Proof-of-concept testing was completed via a 20MWth oxy-fuel combustor at CES’s Kimberlina prototype power plant. Operability and performance limits were explored by burning a variety of fuels, including natural gas and (simulated) synthesis gas, over a wide range of conditions to generate a steam/CO2 working fluid that was used to drive a turbo-generator. Successful demonstration led to the development of first generation zero-emission power plants (ZEPP). Fabrication and preliminary testing of 1st generation ZEPP equipment has been completed at Kimberlina power plant (KPP) including two main system components, a large combustor (170MWth) and a modified aeroderivative turbine (GE J79 turbine). Also, a reheat combustion system is being designed to improve plant efficiency. This will incorporate the combustion cans from the J79 engine, modified to accept the system’s steam/CO2 working fluid. A single-can reheat combustor has been designed and tested to verify the viability and performance of an O-F reheater can. After several successful tests of the 1st generation equipment, development started on 2nd generation power plant systems. In this program, a Siemens SGT-900 gas turbine engine will be modified and utilized in a 200MWe power plant. Like the 1st generation system, the expander section of the engine will be used as an advanced intermediate pressure turbine and the can-annular combustor will be modified into a O-F reheat combustor. Design studies are being performed to define the modifications necessary to adapt the hardware to the thermal and structural demands of a steam/CO2 drive gas including testing to characterize the materials behavior when exposed to the deleterious working environment. The results and challenges of 1st and 2nd generation oxy-fuel power plant system development are presented.

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