Parametric Studies on Gas Turbine Labyrinth Seal for the Secondary Air Flow Optimization at Static and Rotating Conditions

2019 ◽  
Author(s):  
Karthick Raja Kaliraj ◽  
Giridhara Babu Yepuri ◽  
Jayakumar Janardanan Sarasamma ◽  
Kishor Kumar ◽  
Felix Jesuraj
Keyword(s):  
Experimental Data ◽  
Numerical Data ◽  
Labyrinth Seal ◽  
Leakage Flow ◽  
Stationary Condition ◽  
Cfd Analysis ◽  
Labyrinth Seals ◽  
Sst Turbulence Model ◽  
Parametric Studies ◽  
Secondary Air

Abstract Various studies have been carried out related to the labyrinth seals and reported in the open literature using the different seal arrangements at the stator-rotor seal cavity region. In the present study, numerical analysis has been carried out for the static and rotational effects of labyrinth seals at various flow and geometrical, parametric conditions for the optimized leak flow using straight and steeped seal configurations. And, an experimental data has been generated for the straight through seals, and the numerical data of the same case is validated with the experimental data. The k-omega SST turbulence model is considered with 5% turbulence intensity for the CFD analysis. At a particular seal clearance, as the number of teeth increases the leakage flow is found to be decreased. The leak flow is found to be lower with the stepped labyrinth seals in comparison to the straight through seals. The leak flow amount is found to be lower at a rotational condition in comparison to the stationary condition. From the overall results, it is observed that the stepped seal with a lower clearance at a compressor bleed air temperature and rotational conditions have shown better performance with the lower leak air mass flow.

Effect of Air-Curtains on Labyrinth Seal Performance

2016 ◽  
Author(s):  
Aakash C. Rai ◽  
Deoras Prabhudharwadkar ◽  
Sunil Murthy ◽  
Andrew Giametta ◽  
David Johns
Keyword(s):  
Gas Turbines ◽  
Cross Flow ◽  
Labyrinth Seal ◽  
Labyrinth Seals ◽  
Air Curtain ◽  
Baseline Design ◽  
Leakage Flows ◽  
Seal Design ◽  
Parametric Studies ◽  
Secondary Air

Labyrinth seals are used in many key sealing locations in gas turbines to control various leakage flows, e.g., to control the secondary air-flow from the compressor (bypassing the combustor), the turbine inter-stage leakages and blade tip leakages. This study was performed to assess the improvement in the performance of a labyrinth seal by using an air-curtain (cross-flow jet(s)) from the stator. Detailed parametric studies were performed to study the effect of the air-curtain jet pressure, location, and the number of jets on the seal performance with respect to the leakage flow. The analysis was done using 2-dimensional axisymmetric CFD simulations. It was found that in the case of a labyrinth seal with a flat stator (without a honeycomb attached to the stator) the air-curtain design can reduce the seal leakage by about 30% over the baseline seal design without air-curtains. This reduction happened because the air-curtain jet deflected the main seal jet away from the seal clearance. A similar conclusion was also obtained in case of a labyrinth seal with a honeycombed stator. Furthermore, our parametric studies with different air-curtain designs parameters implemented over a honeycombed labyrinth seal showed that the air-curtain jet pressure, location, and the number of jets were crucial factors governing the seal leakage. Amongst the air-curtain designs studied, it was found that implementing three air-curtains in the 1st pocket gave the maximum leakage reduction (by about 50%) over the baseline design.

Comparison Between a CFD Code and a Three-Control-Volume Model for Labyrinth Seal Flutter Predictions

2011 ◽  
Author(s):  
R. Phibel ◽  
L. di Mare
Keyword(s):  
Flow Model ◽  
Control Volume ◽  
Large Diameter ◽  
Labyrinth Seal ◽  
Control Flow ◽  
Cfd Analysis ◽  
Aeroelastic Stability ◽  
Labyrinth Seals ◽  
Aero Engine ◽  
Secondary Air

Labyrinth seals are extensively used in turbomachinery to control flow leakage in secondary air systems. While a large number a studies have been performed to investigate the leakage and rotordynamics characteristics of these seals, the studies on their aeroelastic stability remain scarce. Little is known about this phenomenon and the design methods are limited to a stability criterion which does not take into account many of the parameters which are known to influence labyrinth seal aeroelastic stability. As a consequence the criterion can be unreliable or overly pessimistic. The alternative to this criterion is the use of CFD methods which, although reliable, are computationally expensive. This paper presents a three-control-volume (3CV) bulk-flow model specifically developed for flutter calculations in labyrinth seals. The model is applied to a turbine labyrinth seal of a large diameter aero-engine and the results are compared to those of a CFD analysis. Conclusions are drawn on the potential of this 3CV model for design purposes.

Influence of Honeycomb Rubbing on the Labyrinth Seal Performance

2016 ◽  
Vol 139 (1) ◽  
Author(s):  
Daniel Frączek ◽  
Włodzimierz Wróblewski ◽  
Krzysztof Bochon
Keyword(s):  
Aircraft Engine ◽  
Labyrinth Seal ◽  
Turbine Rotor ◽  
Geometrical Model ◽  
Computational Effort ◽  
Radial Clearance ◽  
Leakage Flow ◽  
Leakage Flows ◽  
Full Structure ◽  
Sst Turbulence Model

The aircraft engine operates in various conditions. In consequence, the design of seals must take account of the seal clearance changes and the risk of rubbing. A small radial clearance of the rotor tip seal leads to the honeycomb rubbing in take-off conditions, and the leakage flow may increase in cruise conditions. The aim of this study is to compare two honeycomb seal configurations of the low-pressure gas turbine rotor. In the first configuration, the clearance is small and rubbing occurs. In the second,—the fins of the seal are shorter to eliminate rubbing. It is assumed that the real clearance in both configurations is the same. A study of the honeycomb geometrical model is performed to reduce the computational effort. The problem is investigated numerically using the RANS equations and the two-equation k–ω SST turbulence model. The honeycomb full structure is taken into consideration to show details of the fluid flow. Main parameters of the clearance and leakage flows are compared and discussed for the rotor different axial positions. An assessment of the leakage flow through the seal variants could support the design process.

Rounded Fin Edge and Step Position Effects on Discharge Coefficient in Rotating Labyrinth Seals

2015 ◽  
Vol 138 (1) ◽  
Author(s):  
Andrea Rapisarda ◽  
Alessio Desando ◽  
Elena Campagnoli ◽  
Roberto Taurino
Keyword(s):  
Experimental Data ◽  
Numerical Simulations ◽  
Leading Edge ◽  
Experimental Tests ◽  
Velocity Profiles ◽  
Pollutant Emission ◽  
Leakage Flow ◽  
Labyrinth Seals ◽  
Position Effects ◽  
Impact Reduction

The design of modern aircrafts propulsion systems is strongly influenced by the important objective of environmental impact reduction. Through a great number of researches carried out in the last decades, significant improvements have been obtained in terms of lower fuel consumption and pollutant emission. Experimental tests are a necessary step to achieve new solutions that are more efficient than the current designs, even if during the preliminary design phase, a valid alternative to expensive experimental tests is the implementation of numerical models. The processing power of modern computers allows indeed the simulation of more complex and detailed phenomena than the past years. The present work focuses on the implementation of a numerical model for rotating stepped labyrinth seals installed in low-pressure turbines. These components are widely employed in sealing turbomachinery to reduce the leakage flow between rotating components. The numerical simulations were performed by using computational fluid dynamics (CFD) methodology, focusing on the leakage performances at different rotating speeds and inlet preswirl ratios. Investigations on velocity profiles into seal cavities were also carried out. To begin with, a smooth labyrinth seal model was validated by using the experimental data found in the literature. The numerical simulations were extended to the honeycomb labyrinth seals, with the validation performed on the velocity profiles. Then, the effects of two geometrical parameters, the rounded fin tip leading edge, and the step position were numerically investigated for both smooth and honeycomb labyrinth seals. The obtained results are generally in good agreement with the experimental data. The main effect found when the fin tip leading edge was rounded was a large increase in leakage flow, while the step position contribution to the flow path behavior is nonmonotone.

A CFD Study on the Dynamic Coefficients of Labyrinth Seals

2012 ◽  
Author(s):  
Donghui Zhang ◽  
Chester Lee ◽  
Michael Cave
Keyword(s):  
High Speed ◽  
Fluid Dynamic ◽  
Labyrinth Seal ◽  
Leakage Flow ◽  
Labyrinth Seals ◽  
Dynamic Coefficients ◽  
Rotating Impeller ◽  
Coupling Stiffness ◽  
Direct Stiffness ◽  
Compressor Efficiency

Labyrinth seals are widely used in gas compressors to reduce internal leakage and increase the compressor efficiency. Due to the eccentricity between the rotating impeller and the stationary part as *well as the shaft whirling motion, forces are generated when the leakage flow passing through the cavities and the seals. For a lot of applications with high speed and pressure, these forces can drive the system unstable. Thus, predicting the forces accurately become a very important for compressor rotordynamic designs. A lot of research and studies has been done to the seals itself, including bulk flow method, computational fluid dynamic (CFD) and test measurement. The seal and leakage flow interaction forces can be predicted relatively accurate. But very few research treat the seal and cavities as one component interacting with the leakage flow and produce the forces. This paper presents results of CFD investigations on the dynamic coefficients of one typical impeller eye seal and front cavity. The CFD results show that large forces are generated in the front cavity due to circumferential uniform pressure distribution, which caused by the downstream labyrinth seal. The forces generated in the front cavity are more than in the front seal. It was found that the inertia, damping, and stiffness are proportional to average pressure. The cross-coupling stiffness increases with speed with power of 2 while the direct stiffness increases with speed with power of about 1.7.

Simulation of the Interaction of Labyrinth Seal Leakage Flow and Main Flow in an Axial Turbine

2002 ◽  
Author(s):  
Jan E. Anker ◽  
Ju¨rgen F. Mayer
Keyword(s):  
Experimental Data ◽  
Labyrinth Seal ◽  
Main Flow ◽  
Rotor Blades ◽  
Navier Stokes ◽  
Test Case ◽  
Leakage Flow ◽  
Computational Results ◽  
Axial Turbine ◽  
The Impact

This paper presents the simulation of the flow in a 1.5 stage low-speed axial turbine with shrouded rotor blades and focuses on the interaction of the labyrinth seal leakage flow with the main flow. The presented results were obtained using the Navier-Stokes code ITSM3D developed at University of Stuttgart. A comparison of the computational results with experimental data of this test case gained at Ruhr-Universita¨t Bochum verifies that the flow solver is capable of reproducing the leakage flow effects to a sufficient extent. The computational results are used to examine the influence of the leakage flow on the flow field of the turbine. By varying the clearance height of the labyrinth in the simulations, the impact of the re-entering leakage flow on the main flow is studied. As demonstrated in this paper, leakage flow not only introduces mixing losses but can also dominate the secondary flow and induce severe losses. In agreement with the experimental data the computational results show that at realistic clearance heights the leakage flow gives rise to negative incidence over a considerable part of the downstream stator which causes the flow to separate.

Numerical Comparison of Leakage Flow and Rotordynamic Characteristics for Two Types of Labyrinth Seals With Baffles

2020 ◽  
Vol 142 (9) ◽  
Author(s):  
Yuanqiao Zhang ◽  
Jun Li ◽  
Zhigang Li ◽  
Xin Yan
Keyword(s):  
Rotational Speed ◽  
Flow Resistance ◽  
Labyrinth Seal ◽  
Leakage Flow ◽  
Numerical Comparison ◽  
Vibration Frequencies ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Brush Seal ◽  
Swirl Intensity

Abstract Cavity separation baffles can decrease the circumferential swirl intensity of labyrinth seals and increase the seals' rotordynamic characteristics. Compared with conventional baffles, the bristle packs of brush seal baffles can contact the rotor directly, thereby further reducing the swirl intensity of the seal cavity. This paper, using the numerical model combining a multifrequency elliptical whirling orbit model, a porous medium model, and transient Reynolds-averaged Navier–Stokes (RANS) solutions, compares the leakage flow and rotordynamic characteristics of a labyrinth seal with brush-seal baffles (LSBSB) and a labyrinth seal with conventional baffles (LSCB). Ideal air flows into the seal at an inlet preswirl velocity of 0 m/s (or 60 m/s or 100 m/s), total pressure of 690 kPa, and temperature of 14 °C. The outlet static pressure is 100 kPa and the rotational speed is 7500 r/min (surface speed of 66.8 m/s) or 15,000 r/min (surface speed of 133.5 m/s). Numerical results show that the LSBSB possesses the slightly less leakage flow rate than the LSCB due to the flow resistance of the bristle pack to the fluid. Compared with the LSCB, the LSBSB shows a higher positive effective stiffness (Keff) at all considered vibration frequencies and a higher effective damping (Ceff) for most vibration frequencies. What is more, the crossover frequency (fc0) of the LSBSB is significantly lower than that of the LSCB, which means that the LSBSB has a wider frequency range offering positive effective damping. The increasing inlet preswirl velocity and rotational speed only slightly affect the Keff for both seals. The Ceff of two seals decreases as the inlet preswirl velocity rises, especially for the LSCB. The Ceff of the LSCB slightly decreases because of the increasing rotational speed. In contrast, the Ceff of the LSBSB is not sensitive to the changes in rotational speed. In a word, the LSBSB possesses superior rotordynamic performance to the LSCB. Note that this work also investigates the leakage flow and rotordynamic characteristics a labyrinth seal with inclined baffles (LSIB) under the condition of u0 = 60 m/s and n = 15,000 r/min. The inclined baffles of the LSIB are same as the backing plates of LSBSB baffles. The LSIB has rotordynamic coefficients almost equal to the LSCB. Hence, the reason why the LSBSB possesses better rotordynamic performance than that of the LSCB is the flow resistance of bristle packs of brush seal baffles, not the inclination direction variation of baffles.

Unsteady Interaction of Labyrinth Seal Leakage Flow and Downstream Stator Flow in a Shrouded 1.5 Stage Axial Turbine

2005 ◽  
Author(s):  
P. Peters ◽  
J. R. Menter ◽  
H. Pfost ◽  
A. Giboni ◽  
K. Wolter
Keyword(s):  
Flow Field ◽  
Three Dimensional ◽  
Numerical Data ◽  
Labyrinth Seal ◽  
Rotor Blades ◽  
Navier Stokes ◽  
Experimental Program ◽  
Leakage Flow ◽  
Axial Turbine ◽  
Flow Phenomena

This paper presents the results of experimental and numerical investigations into the flow in a 1.5-stage low-speed axial turbine with shrouded rotor blades and a straight through labyrinth seal. The paper focuses on the time dependent influence of the leakage flow on the downstream stator flow field. The experimental program consists of time accurate measurements of the three-dimensional properties of the flow through ten different measurement planes in the stator passage. The measurements were carried out using pneumatic five-hole probes and three dimensional hot-wire probes at the design operating point of the turbine. The measurement planes extend from the shroud to the casing. The complex three-dimensional flow field is mapped in great detail by 4,800 measurement points and 20 time steps per blade passing period. The time-accurate experimental data of the ten measurement planes was compared with the results of unsteady, numerical simulations of the turbine flow. The 3D-Navier-Stokes Solver CFX-TASCflow was used. The experimental and numerical results correspond well and allow detailed analysis of the flow phenomena. Additionally numerical data behind the rotor is used to connect the entry of the leakage flow with the flow phenomena in the downstream stator passage and behind it. The leakage flow causes strong fluctuations of the flow in the downstream stator. Above all, the high number of measurement points reveals both the secondary flow phenomena and the vortex structures within the blade passage. The time-dependence of both the position and the intensity of the vortices influenced by the leakage flow is shown. The paper shows that even at realistic clearance heights the leakage flow influences considerable parts of the downstream stator and gives rise to negative incidence and flow separation. Thus, labyrinth seal leakage flow should be taken properly into account in the design or optimization process of turbines.

Effects of Labyrinth Fin Wear on Aerodynamic Performance of Turbine Stages: Part I — Bending Damages

2019 ◽  
Author(s):  
Xin Yan ◽  
Xinbo Dai
Keyword(s):  
Labyrinth Seal ◽  
Flow Fields ◽  
Aerodynamic Performance ◽  
Leakage Flow ◽  
Original Design ◽  
Labyrinth Seals ◽  
Sealing Performance ◽  
Forward Bending ◽  
Design Case ◽  
Isentropic Efficiency

Abstract Labyrinth seals are widely applied in turbo machines because of their geometrical simplicity, convenient installation, reliable operation and excellent sealing performance. However, in realistic operation process, they usually encounter transient conditions (starting-up, shutting down, etc.) and unavoidable vibrations, which may cause wear in the labyrinth fins. After rubbing, the sealing performance of labyrinth seal will be varied in contrast to the original design. Correspondingly, the aerodynamic efficiency of the turbine stage will be affected by the variation of leakage flow in rubbing process. However, in published literature with respect to the labyrinth seal wear, most of the attention has been paid on revealing sealing performance degradation of labyrinth seal itself. Few studies have been concentrated on the influence of labyrinth seal wear on aerodynamic performance of turbine stages. In such background, the present paper utilizes the numerical methods to investigate the effects of labyrinth seal bending damages on aerodynamic performance of turbine stages. Firstly, under several assumptions, the bending geometrical model was established to describe different degrees of bending damages. Secondly, using three-dimensional RANS simulations, the effects of effective clearance variation due to bending on leakage flow and flow fields in turbine stages were investigated. The overall performance of the turbine stages with teeth-bending damages was also compared with the original design case. The influence of the forward bending and backward bending of labyrinth seals were analyzed and compared with each other. The total-total isentropic efficiency of turbine stages, leakage rates, outlet flow angles, reaction degrees and profile static pressure distributions, entropic distributions and flow fields in seals were obtained and compared to the original design case. The results indicate that the leakage rates in the worn labyrinth seal are quite relevant to the effective clearance, especially for the backward bending damages. As the effective clearances in backward bending cases are increased by 0.2–0.6mm, the isentropic efficiency of turbine stages is decreased by about 1–2%. However, for the forward bending damages, the aerodynamic performance and leakage rates in turbine stages are not sensitive to the effective clearance.

Effects of Pressure Ratio and Rotational Speed on Leakage Flow and Cavity Pressure in the Staggered Labyrinth Seal

2011 ◽  
Vol 133 (11) ◽  
Author(s):  
Zhigang Li ◽  
Jun Li ◽  
Xin Yan ◽  
Zhenping Feng
Keyword(s):  
Experimental Data ◽  
Numerical Simulations ◽  
Rotational Speed ◽  
Stokes Equations ◽  
Pressure Ratio ◽  
Labyrinth Seal ◽  
Flow Coefficient ◽  
Leakage Flow ◽  
Cavity Pressure ◽  
Cavity Structure

Effects of pressure ratio and rotational speed on the leakage flow and cavity pressure characteristics of the rotating staggered labyrinth seal were investigated by means of experimental measurements and numerical simulations. The rotating seal test rig with turbine flowmeter and pressure measuring instruments was utilized to investigate the leakage flow of the staggered labyrinth seal at eight pressure ratios and five rotational speeds. The repeatability of the experimental data was demonstrated by three times measurements at different pressure ratios and fixed rotational speed. The three-dimensional Reynolds-averaged Navier–Stokes equations and standard k-ε turbulent model were also applied to study the leakage flow characteristics of the staggered labyrinth seal at the experimental conditions. The validation of the numerical approach was verified through comparison of the experimental data. The detailed flow field in the staggered labyrinth seal was illustrated according to the numerical simulations. The experimental and numerical results show that the leakage flow coefficient increases with increasing pressure ratio at the fixed rotational speed and is more sensitive to the smaller pressure ratio. The influence of rotational speed on the leakage flow coefficient is not obvious in the present rotational speed limitations. The cavity pressure coefficient in the staggered labyrinth seal decreases and is significantly influenced by the cavity structure along the flow direction.

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