Simulation and Flow Analysis of the Hole Diaphragm Labyrinth Seal at Several Whirl Frequencies

The seal is designed to reduce leakage and improve the efficiency of gas turbine machines, and is an important technology that needs to be studied in gas turbine design. A series of seals were proposed to try to achieve this goal. However, due to the complex fluid dynamic performance of the seal-rotor system, the seal structure can obtain both the best leakage performance and best rotordynamic performance. This paper presents a detailed flow analysis of the hole diaphragm labyrinth seal (HDLS) at several whirl frequencies and several rotation speeds. The pressure drop, velocity, turbulence kinetic energy and leakage performance of the HDLS were discussed by simulations. An interesting exponential–type relationship between rotation speeds and leakage flow at different whirl frequencies was observed by curve fitting technology. A reverse flow rate was proposed to describe such an unusual phenomenon. Such a relationship can be used to further establish the leakage model of the HDLS and other similar seals.

Influences of Randomly Uncertain Factors on Dynamic Coefficients of an Interlocking Labyrinth Seal-Rotor System

Many randomly uncertain factors inevitably arise when gas flows through a labyrinth seal, and the orbit of the rotor center will not rotate along a steady trajectory, as previously studied. Here, random uncertainty is considered in an interlocking labyrinth seal-rotor system to investigate the fluctuations of dynamic coefficients. The bounded noise excitation is introduced into the momentum equation of the gas flow, and as a result, the orbit of the rotor center is expressed as the combination of an elliptic trajectory with the bounded noise perturbation. Simulation results of the coefficients under randomly uncertain perturbations with various strengths are comparatively investigated with the traditional predictions under ideal conditions, from which the influences of random uncertain factors on dynamic coefficients are analyzed in terms of the rotor speed, pressure difference, and inlet whirl velocity. It is shown that the deviation levels of the dynamic coefficients are directly related to the random perturbations and routinely increase with such perturbation strengths, and the coefficients themselves may exhibit distinct variation patterns against the rotor speed, pressure difference, and inlet whirl velocity.

EFFECTIVE CLEARANCE AND DIFFERENTIAL GAPPING IMPACT ON SEAL FLUTTER MODELLING AND VALIDATION

This paper presents an update of the model derived by Corral and Vega (2018, “Conceptual Flutter Analysis of Labyrinth Seal Using Analytical Models. Part I - Theoretical Support”, ASME J. of Turbomach., 140 (12), pp. 121006) for labyrinth seal flutter stability, providing a method of accounting for the effect of dissimilar gaps. The original CV model was intended as a conceptual model for understanding the effect of different parameters on the seal stability comprehensively, providing qualitative trends for seal flutter stability. However, the quantitative evaluation of seal flutter, and the comparison of the CV model with detailed unsteady numerical simulations or experimental data, require including additional physics. The kinetic energy generated in the inlet gap is not dissipated entirely in the inter-fin cavity of straight-through labyrinth seals, and part is recovered in the downstream knife. This mechanism needs to be retained in the model. It is concluded that when the theoretical gaps are identical, the impact of the recovery factor on the seal stability can be high. The sensitivity of the seal stability to large changes in the outlet to inlet gap ratio is high as well. It is concluded that fin variations due to rubbing or wearing inducing inlet gaps more open than the exit gaps lead to an additional loss of stability concerning the case of identical gaps. The agreement between the updated model and 3D linearized Navier-Stokes simulations is excellent when the model is informed with data coming from steady RANS simulations of the seal.

Development of a New Loss Model for Turbomachinery Labyrinth Seals

The preliminary design of labyrinth seals requires a fast and accurate estimate of the leakage flow. While the conventional bulk flow models can quickly predict labyrinth seal discharge characteristics, they lack the accuracy and pragmatism of modern CFD technique and vice-a-versa. This paper presents a new 1D loss model for straight-through gas labyrinth seals that can provide quick seal leakage flow predictions with CFD-equivalent accuracy. The present seal loss model is developed using numerical experimentation technique. Multiple CFD computations are conducted on straight-through labyrinth seal geometries for a range of pressure ratios. A distinct post-processing methodology is developed to extract the through-flow stream tube in seal. Total pressure losses and flow area variations experienced by the flow in seal stream-tube are systematically accounted for based on the well-known knife-to-knife (K2K) methodology. Regression analyses are conducted on the trends of variations of loss and area coefficients to derive the independent pressure loss and flow area correlations. These novel correlations can predict the bulk leakage flow rate, windage flow rate and inter-knife static pressures over a wide range of variation of flow and geometry parameters. Validation study shows that the leakage mass flow rate predicted by this model is accurate within ±8% of measured test data. This fast and accurate model can be employed for various applications such as, in seal design-analysis workflows, for secondary air system (SAS) performance analysis and for the rotor-dynamic and aeroelastic assessments of seals.

Large Eddy Simulation of Leakage Flow in a Stepped Labyrinth Seal

Large eddy simulation (LES) and Reynolds averaged Navier-Stokes simulation (RANS) of leakage flow in straight-through and stepped labyrinth seals were performed in order to compare their performances in sealing the secondary flow passage of the gas turbine based on the respective discharge coefficients. The results indicate a 17.8% higher leakage prevention performance for the stepped seal relative to that of the straight seal. Further, while the LES predicts an ~7% reduction in the discharge coefficient due to shaft rotation, this effect is underestimated by the RANS. Moreover, the LES correctly predicts a laminarized flow pattern in the clearance, whereas the RANS overestimates the turbulence kinetic energy. In addition, a turbulence kinetic energy spectrum analysis was performed based on the vorticity at selected points in order to identify the flow structure that has a dominant influence on the oscillation of the discharge coefficient. This analysis also enabled identification of the changes in the flow structure due to shaft rotation.

Periodic Unsteady Kinematics of Hub Flows in a Shrouded Multistage Compressor

Periodic unsteady flow kinematics in a shrouded multistage low-speed axial compressor has been measured for the first time. Data have been acquired at the inlet and exit of a shrouded 3rd- stage stator with a particular focus on the hub flows. The newly found features of the hub flow in a shrouded multistage compressor are different from those at the midspan or in unshrouded (i.e., cantilevered) compressors. First, the merging of the 2nd-stage stator and 3rd-stage rotor wakes causes positive radial migration near the rotor wake pressure surface at the hub of the 3rd-stage stator inlet. Second, the low-momentum labyrinth seal leakage flow of the 3rd-stage stator merges with the 3rd-stage rotor wake to create streamwise vorticity at the 3rd-stage stator inlet hub. Third, contrary to unshrouded stators, suction side hub corner separation in the shrouded 3rd-stage stator reduces rotor wake stretching. Thus, velocity disturbances are attenuated less, and amplitudes of periodic fluctuations in flow angles are larger at the 3rd-stage stator exit hub than at midspan. The positive radial migration of the rotor wake hub flow and wake stretching reduction are expected to decrease efficiency, whereas streamwise vorticity generation is expected to increase efficiency.

Analysis on the escape phenomenon of oil mist from turbine lower guide bearing based on VOF model

To analyze the cause and mechanism of oil mist escaping from the lower guide bearing during the operation of a turbine, the oil-gas mixture in the lower guide bearing was numerically simulated by using the VOF two-phase flow model and the SST turbulence model. The influences of different sealing clearances and speeds on the flow field and the oil-gas distribution in the oil tank were studied, and the escaping characteristics of oil mist were analyzed. The results show that increasing the clearance of the labyrinth seal will reduce the pressure difference between the inside and outside of the oil tank and reduce the driving force for the escape of the oil mist. However, increasing the clearance will increase the turbulence of the flow field, the number and volume of bubbles in the lubricating oil, which will lead to the uneven distribution of oil and gas and reduce the motion stability of the lower guide bearing. The change of speed will affect the normal use of the shaft-collar pump. High speed will aggravate the generation of bubbles in the oil tank and increase the possibility of cavitation in the lower guide bearing structure. In engineering practices, it is necessary to comprehensively consider factors such as oil mist escape phenomenon, economic benefits, process manufacturing and assembly, and adopt the lower guide bearing structure with a suitable labyrinth seal clearance.

Nonlinear Dynamics of a Blade Rotor with Coupled Rubbing of Labyrinth Seal and Tip Seal

The dynamic response and its stability of a blade rotor with coupled rubbing in the labyrinth seal and tip seal are investigated. The dynamic equations are established based on the Hertz contact rubbing force at the labyrinth seal and the tip rubbing force considering both the contact deformation of the tip seal and the bending deformation of the blade. Numerical simulations show that the coupled rubbing response includes periodic motions, almost periodic motions, and chaotic motions. Compared with the single rubbing fault, coupled rubbing increases the range of rotation velocity of contact. A new continuation shooting method is used in the solution and stability analysis of the periodic response to give the bifurcation diagrams. The paths of the system for entering and exiting chaos are analyzed.

Unsteady flow phenomena in turbine shroud cavities

This paper presents those flow parameters at which coherent structures appear in the blade tip cavities of shrouded turbine blades. To the authors’ knowledge, this is reported for the first time in the open literature. The unsteady flow in a shroud cavity is analysed based on experimental data recorded in a labyrinth seal test rig. The unsteady static wall pressure in the shroud cavity inlet and outlet is measured using time-resolving pressure sensors. Sensors are located at staggered circumferential positions to allow cross-correlation between signals. The unsteady pressure signals are reduced using Fourier analysis and cross-correlation in combination with digital filters. Based on the data, a theory is formulated explaining the phenomena reflected in the measurements. The results suggest that pressure fluctuations with distinct numbers of nodes are rotating in the shroud cavity outlet. Moreover, modes with different node numbers appear to be superimposed, rotating at a common speed in circumferential direction. The pressure fluctuations are not found at all operating points. Further analysis indicates that the pressure fluctuations are present at operating points matching distinct parameters correlating with the cavity flow coefficient. Unsteady RANS simulations predict similar flow structures for the design operating point of the test rig.

Numerical validation of an analytical seal flutter model

An analytical model to describe the flutter onset of straight-through labyrinth seals has been numerically validated using a frequency domain linearized Navier-Stokes solver. A comprehensive set of simulations has been conducted to assess the stability criterion of the analytical model originally derived by Corral and Vega (2018), “Conceptual Flutter Analysis of Labyrinth Seals Using Analytical Models - Part I: Theoretical Support,” ASME J. Turbomach., 140 (12), pp. 121006. The accuracy of the model has been assessed by using a simplified geometry consisting of a two-fin straight-through labyrinth seal with identical gaps. The effective gaps and the kinetic energy carried over are retained and their effects on stability are evaluated. It turns out that is important to inform the model with the correct values of both parameters to allow a proper comparison with the numerical simulations. Moreover, the non-isentropic perturbations included in the formulations are observed in the simulations at relatively low frequencies whose characteristic time is of the same order as the discharge time of the seal. This effect is responsible for the bending of the stability limit in the <inline-formula><mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline" overflow="scroll"><mml:mn>0</mml:mn><mml:mi>t</mml:mi><mml:mi>h</mml:mi></mml:math></inline-formula> ND stability map obtained both in the model and the simulations. It turns out that the analytical model can predict accurately the stability of the seal in a wide range of pressure ratios, vibration mode-shapes, and frequencies provided that this is informed with the fluid dynamic gaps and the energy carried over to the downstream fin from a steady RANS simulation. The numerical calculations show for the first time that the model can be used to predict accurately not only the trends of the work-per-cycle of the seal but also quantitative results.