Side Weld and Bend Method of Manufacturing Compliant Plate Seals

2013 ◽  
Vol 136 (2) ◽  
Author(s):  
William E. Adis ◽  
Michael Mack ◽  
Hrishikesh V. Deo
Keyword(s):  
Gas Turbines ◽  
Oil And Gas ◽  
Tip Clearance ◽  
Outer Diameter ◽  
Steam Turbines ◽  
Manufacturing Method ◽  
Low Leakage ◽  
Straight Line ◽  
Differential Shrinkage ◽  
Large Rotor

Compliant plate seals are being developed for various turbomachinery sealing applications including gas turbines, steam turbines, aircraft engines, and oil and gas compressors. These seals consist of compliant plates attached to a stator in a circumferential fashion around a rotor. The compliant plates have a slot that extends radially inward from the seal outer diameter and an intermediate plate extends inward into this slot from the stator. This design is capable of providing passive hydrostatic feedback forces acting on the compliant plates that balance at a small tip clearance. Due to this self-correcting behavior, this seal is capable of providing high differential pressure capability and low leakage within a limited axial span, and robust noncontact operation even in the presence of large rotor transients. Manufacturing of compliant plate seals is a challenging problem and in this paper we describe the development of a novel manufacturing technique called side weld and bend (SWAB). The compliant plates are tightly packed with alternating spacer shims in a straight line fixture and welded to a top plate from the side along a straight line. After removal of the spacer shims, the welded assembly is bent to form an arcuate seal of a desired diameter. The side weld and bend (SWAB) manufacturing method reduces distortion, deformity, differential shrinkage, and other associated problems with welding across gaps between adjacent compliant plate seals as is typical in current manufacturing processes.

Side Weld and Bend Method of Manufacturing Compliant Plate Seals

2013 ◽  
Author(s):  
William E. Adis ◽  
Michael Mack ◽  
Hrishikesh V. Deo
Keyword(s):  
Gas Turbines ◽  
Tip Clearance ◽  
Outer Diameter ◽  
Aircraft Engines ◽  
Steam Turbines ◽  
Manufacturing Method ◽  
Low Leakage ◽  
Straight Line ◽  
Differential Shrinkage ◽  
Large Rotor

Compliant Plate Seals are being developed for various turbomachinery sealing applications including gas turbines, steam turbines, aircraft engines and oil & gas compressors. These seals consist of compliant plates attached to a stator in a circumferential fashion around a rotor. The compliant plates have a slot that extends radially inwards from the seal outer diameter and an intermediate plate extends inwards into this slot from the stator. This design is capable of providing passive hydrostatic feedback forces acting on the compliant plates that balance at a small tip-clearance. Due to this self-correcting behavior, this seal is capable of providing high differential pressure capability and low leakage within a limited axial span, and robust non-contact operation even in the presence of large rotor transients. Manufacturing of Compliant Plate Seals is a challenging problem and in this paper, we describe the development of a novel manufacturing technique called Side Weld And Bend (SWAB). The compliant plates are tightly packed with alternating spacer shims in a straight line fixture and welded to a top-plate from the side along a straight line. After removal of the spacer shims, the welded assembly is bent to form an arcuate seal of a desired diameter. The Side Weld And Bend (SWAB) manufacturing method reduces distortion, deformity, differential shrinkage and other associated problems with welding across gaps between adjacent compliant plate seals as is typical in current manufacturing processes.

Compliant Plate Seals: Design and Performance Simulations

2012 ◽  
Author(s):  
Hrishikesh V. Deo ◽  
Ajay Rao ◽  
Hemant Gedam
Keyword(s):  
Gas Turbines ◽  
Tip Clearance ◽  
Outer Diameter ◽  
Aircraft Engines ◽  
Steam Turbines ◽  
Flow Rates ◽  
Cfd Models ◽  
Low Leakage ◽  
And Performance ◽  
Large Rotor

Compliant Plate Seals are being developed for various turbomachinery sealing applications including gas turbines, steam turbines, aircraft engines and oil & gas compressors. These seals consist of compliant plates attached to a stator in a circumferential fashion around a rotor. The compliant plates have a slot that extends radially inwards from the seal outer diameter, and an intermediate plate extends inwards into this slot from stator. This design is capable of providing passive hydrostatic feedback forces acting on the compliant plates that balance at a small tip–clearance. Due to this self–correcting behavior, this seal is capable of providing high differential pressure capability and low leakage within a limited axial span, and non–contact operation even in the presence of large rotor transients. CFD models have been developed to predict the leakage flow rates and hydrostatic lift and blowdown forces, and a design philosophy is proposed to predict the feedback phenomenon from the CFD results.

Compliant Plate Seals: Testing and Validation

2012 ◽  
Author(s):  
Hrishikesh V. Deo
Keyword(s):  
High Frequency ◽  
Gas Turbines ◽  
Tip Clearance ◽  
Outer Diameter ◽  
Aircraft Engines ◽  
Test Results ◽  
Steam Turbines ◽  
Leakage Test ◽  
Low Leakage ◽  
Large Rotor

Compliant Plate Seals are being developed for various turbomachinery sealing applications including gas turbines, steam turbines, aircraft engines and oil & gas compressors. These seals consist of compliant plates attached to a stator in a circumferential fashion around the rotor. The compliant plates have a slot that extends radially inwards from the seal outer diameter, and an intermediate plate extends inwards into this slot from stator. This design is capable of providing passive hydrostatic feedback forces acting on the compliant plates that balance at a small tip–clearance. Due to this self–correcting behavior, this seal is capable of providing high differential pressure capability and low leakage within a limited axial span, and non-contact operation even in the presence of large rotor transients. In this paper, we have reported leakage test results for Compliant Plate Seals and visually demonstrated robust non-contact operation for different assembly clearances and interferences, stator deflections, high frequency rotor transients, different pressure conditions and rotational speeds.

Static Testing of Compliant Plate Seals

2012 ◽  
Author(s):  
Hrishikesh V. Deo ◽  
Deepak Trivedi
Keyword(s):  
Gas Turbines ◽  
High Speed ◽  
Pressure Ratio ◽  
Differential Pressure ◽  
Tip Clearance ◽  
Design Parameters ◽  
Outer Diameter ◽  
Steam Turbines ◽  
Low Leakage ◽  
The Impact

Self–correcting Compliant Plate Seals are being developed for various turbomachinery sealing applications including gas turbines, steam turbines, aircraft engines and oil & gas compressors. These seals consist of compliant plates attached to a stator in a circumferential fashion around the rotor. The compliant plates have a slot that extends radially inwards from the seal outer diameter, and an intermediate plate extends inwards into this slot from stator. This design is capable of providing passive hydrostatic feedback forces acting on the compliant plates that balance at a small tip–clearance. Due to this self–correcting behavior, this seal is capable of providing high differential pressure capability and low leakage within a limited axial span, and robust non–contact operation even in the presence of large rotor transients. In this paper we have described the testing of Compliant Plate Seals in a static leakage test rig (“shoebox” rig) to study the impact of different design parameters on leakage and vibration. A novel high–speed visualization set–up is described and the high–speed videos demonstrate robust non–contact operation for different assembly clearances, bridge–gaps and bridge–heights, for various differential pressure and pressure ratio conditions. The reported leakage results indicate that the leakage is relatively insensitive to assembly clearances due to the self–correcting behavior.

Compliant Plate Seals for Turbomachinery Applications

2011 ◽  
Author(s):  
Hrishikesh V. Deo
Keyword(s):  
Experimental Testing ◽  
Differential Pressure ◽  
Tip Clearance ◽  
Outer Diameter ◽  
Leakage Flow ◽  
Blow Down ◽  
Flow Rates ◽  
Cfd Models ◽  
Low Leakage ◽  
Large Rotor

In this paper, a novel GE Compliant Plate Seal is proposed that consists of compliant plates attached to a stator in a circumferential fashion around a rotor. The compliant plates have a slot that extends radially inwards from the seal outer diameter, and an intermediate plate extends inwards into this slot from stator. This design is capable of providing passive hydrostatic feedback forces acting on the compliant plates that balance at a small tip-clearance. When the tip-clearance reduces below the equilibrium clearance, the hydrostatic lift forces cause the compliant plates to lift away from the rotor. Conversely when the tip-clearance increases above the equilibrium clearance, the hydrostatic blowdown forces cause the compliant plates to blow down towards the rotor. Due to this self-correcting behavior, this seal is capable of providing high differential pressure capability and low leakage within a limited axial span, and non-contact operation even in the presence of large rotor transients. Simplified CFD models have been developed to predict the leakage flow rates and hydrostatic lift and blowdown forces, and a design philosophy is proposed to predict the feedback phenomenon from the CFD models. The proposed models are validated and self-correcting behavior is demonstrated through experimental testing.

Progressive Clearance Labyrinth Seal for Turbo-Machinery Applications

2011 ◽  
Author(s):  
Binayak Roy ◽  
Hrishikesh V. Deo ◽  
Xiaoqing Zheng
Keyword(s):  
Theoretical Models ◽  
Labyrinth Seal ◽  
Tip Clearance ◽  
Labyrinth Seals ◽  
Lower Efficiency ◽  
Thermal Transients ◽  
Low Leakage ◽  
Packing Ring ◽  
Lift Off ◽  
Large Rotor

Turbomachinery sealing is a challenging problem due to the varying clearances caused by thermal transients, vibrations, bearing lift-off etc. Leakage reduction has significant benefits in improving engine efficiency and reducing emissions. Conventional labyrinth seals have to be assembled with large clearances to avoid rubbing during large rotor transients. This results in large leakage and lower efficiency. In this paper, we propose a novel Progressive Clearance Labyrinth Seal that is capable of providing passive fluidic feedback forces that balance at a small tip-clearance. A modified packing ring is supported on flexures and employs progressively tighter teeth from the upstream to the downstream direction. When the tip-clearance reduces below the equilibrium clearance, fluidic feedback forces cause the packing ring to open. Conversely, when the tip-clearance increases above the equilibrium clearance, the fluidic feedback forces cause the packing ring to close. Due to this self-correcting behavior, the seal provides high differential pressure capability, low leakage and non-contact operation even in the presence of large rotor transients. Theoretical models for the feedback phenomenon have been developed and validated by experimental results.

Duplex Spread Blade Method for Cutting Hypoid Gears with Modified Tooth Surface

1998 ◽  
Vol 120 (3) ◽  
pp. 441-447 ◽  
Author(s):  
K. Kawasaki ◽  
H. Tamura
Keyword(s):  
Cutting Edge ◽  
Tooth Surface ◽  
Radius Of Curvature ◽  
Large Radius ◽  
Ring Gear ◽  
Circular Arc ◽  
Hypoid Gears ◽  
Manufacturing Method ◽  
Straight Line

In this paper, a duplex spread blade method for cutting hypoid gears with modified tooth surface is proposed. The duplex spread blade method provides a rapid and economical manufacturing method because both the ring gear and pinion are cut by a spread blade method. In the proposed method, the nongenerated ring gear is manufactured with cutting edge that is altered from the usual straight line to a circular arc with a large radius of curvature and the circular arc cutting edge produces a modified tooth surface. The pinion is generated by a cutter with straight cutting edges as usual. The main procedure of this method is the determination of the cutter specifications and machine settings. The proposed method was validated by gear manufacture.

Using CFD to Enhance the Preliminary Design of High-Pressure Steam Turbines

2013 ◽  
Author(s):  
Juri Bellucci ◽  
Federica Sazzini ◽  
Filippo Rubechini ◽  
Andrea Arnone ◽  
Lorenzo Arcangeli ◽  
...  
Keyword(s):  
High Pressure ◽  
Steam Turbine ◽  
Design Tool ◽  
Tip Clearance ◽  
Large Set ◽  
Preliminary Design ◽  
Steam Turbines ◽  
High Pressure Steam ◽  
Wide Range ◽  
Pressure Steam

This paper focuses on the use of the CFD for improving a steam turbine preliminary design tool. Three-dimensional RANS analyses were carried out in order to independently investigate the effects of profile, secondary flow and tip clearance losses, on the efficiency of two high-pressure steam turbine stages. The parametric study included geometrical features such as stagger angle, aspect ratio and radius ratio, and was conducted for a wide range of flow coefficients to cover the whole operating envelope. The results are reported in terms of stage performance curves, enthalpy loss coefficients and span-wise distribution of the blade-to-blade exit angles. A detailed discussion of these results is provided in order to highlight the different aerodynamic behavior of the two geometries. Once the analysis was concluded, the tuning of a preliminary steam turbine design tool was carried out, based on a correlative approach. Due to the lack of a large set of experimental data, the information obtained from the post-processing of the CFD computations were applied to update the current correlations, in order to improve the accuracy of the efficiency evaluation for both stages. Finally, the predictions of the tuned preliminary design tool were compared with the results of the CFD computations, in terms of stage efficiency, in a broad range of flow coefficients and in different real machine layouts.

A Comparison Between ORC and Supercritical CO2 Bottoming Cycles For Energy Recovery From Industrial Gas Turbines Exhaust Gas

2021 ◽  
Author(s):  
M. A. Ancona ◽  
M. Bianchi ◽  
L. Branchini ◽  
A. De Pascale ◽  
F. Melino ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Thermal Efficiency ◽  
Gas Turbines ◽  
Supercritical Co2 ◽  
Energy Demand ◽  
Oil And Gas ◽  
Gas Production ◽  
Medium Size ◽  
Oil And Gas Production ◽  
Industrial Gas Turbines

Abstract Gas turbines are often employed in the industrial field, especially for remote generation, typically required by oil and gas production and transport facilities. The huge amount of discharged heat could be profitably recovered in bottoming cycles, producing electric power to help satisfying the onerous on-site energy demand. The present work aims at systematically evaluating thermodynamic performance of ORC and supercritical CO2 energy systems as bottomer cycles of different small/medium size industrial gas turbine models, with different power rating. The Thermoflex software, providing the GT PRO gas turbine library, has been used to model the machines performance. ORC and CO2 systems specifics have been chosen in line with industrial products, experience and technological limits. In the case of pure electric production, the results highlight that the ORC configuration shows the highest plant net electric efficiency. The average increment in the overall net electric efficiency is promising for both the configurations (7 and 11 percentage points, respectively if considering supercritical CO2 or ORC as bottoming solution). Concerning the cogenerative performance, the CO2 system exhibits at the same time higher electric efficiency and thermal efficiency, if compared to ORC system, being equal the installed topper gas turbine model. The ORC scarce performance is due to the high condensing pressure, imposed by the temperature required by the thermal user. CO2 configuration presents instead very good cogenerative performance with thermal efficiency comprehended between 35 % and 46 % and the PES value range between 10 % and 22 %. Finally, analyzing the relationship between capital cost and components size, it is estimated that the ORC configuration could introduce an economical saving with respect to the CO2 configuration.

An Optimization Design Platform for Fir-Tree Root and Groove for Steam Turbine

2018 ◽  
Author(s):  
Deqi Yu ◽  
Xiaojun Zhang ◽  
Jiandao Yang ◽  
Kai Cheng ◽  
Weilin Shu ◽  
...  
Keyword(s):  
Stress Concentration ◽  
Steam Turbine ◽  
Gas Turbines ◽  
High Speed ◽  
Optimization Design ◽  
Turbine Blades ◽  
Local Stress ◽  
Optimization Method ◽  
Steam Turbines ◽  
Geometry Configuration

Fir-tree root and groove profiles are widely used in gas turbine and steam turbine. Normally, the fir-tree root and groove are characterized with straight line, arc or even elliptic fillet and splines, then the parameters of these features were defined as design variables to perform root profile optimization. In ultra-long blades of CCPP and nuclear steam turbines and high-speed blades of industrial steam turbine blades, both the root and groove strength are the key challenges during the design process. Especially, in industrial steam turbines, the geometry of blade is very small but the operation velocity is very high and the blade suffers stress concentration severely. In this paper, two methods for geometry configuration and relevant optimization programs are described. The first one is feature-based using straight lines and arcs to configure the fir-tree root and groove geometry and genetic algorithm for optimization. This method is quite fit for wholly new root and groove design. And the second local optimization method is based on B-splines to configure the geometry where the local stress concentration occurs and the relevant optimization algorithm is used for optimization. Also, several cases are studied as comparison by using the optimization design platform. It can be used not only in steam turbines but also in gas turbines.

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