Effects of Front Plate Geometry on Brush Seal in Highly Swirling Environments of Gas Turbine

Advanced brush seal technology has a significant impact on the performance and efficiency of gas turbine engines. However, in highly inlet swirling environments, the bristles of a brush seal tend to circumferentially slip, which may lead to aerodynamic instability and seal failure. In this paper, seven different front plate geometries were proposed to reduce the impact of high inlet swirl on the bristle pack, and a three-dimensional porous medium model was carried out to simulate the brush seal flow characteristics. Comparisons of a plane front plate with a relief cavity, plane front plate with axial drilled holes, anti-“L”-type plate and their relative improved configurations on the pressure and flow fields as well as the leakage behavior were conducted. The results show that the holed front plate can effectively regulate and control the upstream flow pattern of the bristle pack, inducing the swirl flow to move radially inward, which results in decreased circumferential velocity component. The anti-“L” plate with both axial holes and one radial hole was observed to have the best effect on reducing the swirl of those investigated. The swirl velocity upstream the bristle pack can decline 50% compared to the baseline model with plane front plate, and the circumferential aerodynamic forces on the bristles, which scale with the swirl dynamic head, are reduced by a factor of 4. This could increase the bristle stability dramatically. Moreover, the front plate geometry does not influence the leakage performance significantly, and the application of the axial hole on the front plate will increase the leakage slightly by around 3.5%.

Rotating Brush Seal Design and Performance Testing

Brush seals are widely used in various turbomachinery applications because they provide reduced leakage than labyrinth seals in a compact space. Brush seals are generally mounted on static components and their flexible bristle tips engage the rotor to form a dynamic seal. In this paper, development of a brush seal mounted on a rotor is discussed. Benefits of this enhancement to brush seal include avoiding localized rubs on the rotor, which reduces heating of a local spot and resulting rotor bow and instabilities. The bristles are angled circumferentially instead of axially and are supported by a conical backplate. Under rotation, the bristles are pushed towards the backplate by the centrifugal force. Seal configurations are designed to fit into interstage and inter-shaft locations. A modeling approach for predicting stiffness and operating stresses in these seals also is outlined. A test setup is developed to characterize the performance of rotating brush seals under engine-representative centrifugal force and pressure differentials. Presented results demonstrate that brush seal can achieve tight effective gaps and desired performance after undergoing initial wear.

Analysis of Heat Flux Distribution during Brush Seal Rubbing Using CFD with Porous Media Approach

This paper discusses the question of heat flux distribution between bristle package and rotor during a rubbing event. A three-dimensional Computational Fluid Dynamics (3D CFD) model of the brush seal test rig installed at the Institute of Thermal Turbomachinery (ITS) was created. The bristle package is modelled as a porous medium with local non-thermal equilibrium. The model is used to numerically recalculate experimentally conducted rub tests on the ITS test rig. The experimentally determined total frictional power loss serves as an input parameter to the numerical calculation. By means of statistical evaluation methods, the ma in influences on the heat flux distribution and the maximum temperature in the frictional contact are determined. The heat conductivity of the rotor material, the heat transfer coefficients at the bristles and the rubbing surface were identified as the dominant factors.

Numerical Investigations on the Leakage Flow Characteristics of Brush Seal Based on the Three-Dimensional Staggered Tube Bundle Model

To accurately predict the leakage flow and resistance characteristics of brush seals, the multiblock structured mesh and the mesh motion technique are applied to the three-dimensional (3D) staggered tube bundle model of brush seals. The multiblock structured mesh can easily add nodes and set boundary layers in the interbristle gap between adjacent bristles, which can ensure good mesh quality (orthogonal angle and expansion ratio). The mesh motion technique realizes the overall axial compactness of the bristle pack. The effects of pressure ratio Rp, sealing clearance c, and bristle pack compactness on the leakage flow and resistance characteristics are investigated. To analyze the aerodynamic resistance of the brush seals, Euler number (Eu) is applied in this study. The numerical results are in good agreement with the experimental data. Thus, the accuracy of the presented numerical method is validated. For the contacting brush seal, ΔSx, i has a significant effect on the leakage flow rate reduction. For the clearance brush seal, ΔSx, i has little effect on the leakage flow rate reduction. The leakage flow passing through the sealing clearance keeps almost constant. As for aerodynamic resistance, the presence of the sealing clearance can effectively convert the pressure energy of the leakage flow into the kinetic energy. As a result, the leakage flow velocity exiting the bristle pack of the clearance brush seal is 1.5 to 2.0 times larger than that of the contacting brush seal. Although the existence of the sealing clearance obviously increases the leakage flow rate, it effectively reduces the aerodynamic forces acting on the bristles. The developed numerical approach based on the three-dimensional staggered tube bundle model and multiblock structured mesh can serve as a technical method for analysis of the sealing mechanisms of brush seals.

Numerical Analysis of Flow across Brush Elements Based on a 2-D Staggered Tube Banks Model

In order to improve efficiency in turbomachinery, brush seal replaces labyrinth seals widely in the secondary air system. A 2-d staggered tube bank model is adopted to simulate the gas states and the pressure character in brush seal, and computational fluid dynamics (CFD) is used to solve the model in this paper. According to the simulation results, the corrected formula of the Euler number and dimensionless pressure are given. The results show that gas expands when flow through the bristle pack, and the gas expansion closes to an isotherm process. The dynamic pressure increases with decreasing static pressure. The Euler number can reflect the seal performance of brush seals in leakage characteristics. Compared with increasing the number of rows, the reduction of the gap is a higher-efficiency method to increase the Euler number. The Euler number continually increases as the gap decreases. However, with the differential pressure increasing, Euler number first increases and then decreases as the number of rows increases. Finally, the pressure distribution on the surface of end rows is asymmetric, and it may increase the friction between the bristles and the back plate.

Leakage Calculation Method of Carbon Fiber Brush Seal Based on Porous Medium

As a kind of flexible high-speed dynamic sealing device, brush seal has a good application prospect in high-speed dynamic sealing parts of major equipment, such as gas path of aircraft engines, rocket motors and gas turbines. However, the theoretical research and practical engineering application of brush seal are limited because there are some problems in the practical application. For example, the tip of bristle burned by friction heat under high speed, increased wear and the difficult calculation of leakage. To this end, the structure of the brush seal use the carbon fiber instead of the high-temperature alloy metal bristle. Then the carbon fiber brush volume equivalent diameter is used to establish the carbon fiber brush resistance calculation model based on the porous medium method, which construct the leakage calculation model of the carbon fiber brush seal. Finally, they are obtained by solution of the model in Fluent software that the leakage flow characteristics of the carbon fiber brush seal at work and the influence of different working conditions and structural parameters on the leakage performance. The results show that the carbon fiber calculation model has better adaptability, and the calculation results also show that the carbon fiber brush seal has a lower leakage than the metal bristle under the same working condition. Moreover, the linear factors affecting the leakage of the carbon fiber brush seal are the height of the back plate and the diameter of the bristle, and the height of the front baffles has little effect, while the nonlinear factors are the thickness of brush and the angle of the bristle arrangement. The study provide an significant reference for high performance design of brush seal and its engineering applications.