Experimental Investigation on Fiber Thermocouples Used in Brush Seals for Temperature Measurements

Author(s):  
Shouqing Huang ◽  
Shuangfu Suo ◽  
Yongjian Li ◽  
Jun Ding ◽  
Yuming Wang

A type of fiber thermocouple is applied to a brush seal in order to obtain the temperature of the bristle-rotor friction zone. Using a brush seal test rig, the temperature measurements utilizing a fiber thermocouple, infrared thermometer, and common thermocouple are compared and studied. The fiber thermocouple is studied under various operational conditions consisting of different pressure and speed variations, rotor-bristle interferences, and eccentricities. Some interesting phenomena and characteristics of brush seals are revealed during these experiments. Some preliminary wear results of a fiber thermocouple are also presented. The results demonstrate the superiority of fiber thermocouples when used in narrow spaces, high temperature, and pressure environments within the heart of an aero-engine.

Author(s):  
Michael Flouros ◽  
Martin Stadlbauer ◽  
Francois Cottier ◽  
Stephan Proestler ◽  
Stefan Beichl

For the past 25 years brush seal technologies have evolved into the aero engine designs and, more generally, into the gas turbine world, not only for sealing gas areas at different pressure levels but also for sealing gas/liquid environments. This is the case in an aero engine where the bearing chambers are sealed. Aero engine bearing chambers enclose oil lubricated components such bearings and gears. In order to avoid contamination of the turbo machinery through oil loss, air blown seals are used to retain the oil into the bearing chamber. Oil loss may cause coking or ignition with the probability of an uncontained destruction of rotating parts such as disks or blades. It may also cause contamination of the air conditioning system with oil fumes thus causing health problems to the passengers and crew from such exposure. The most widely known seals for bearing chamber sealing are the labyrinth seals, however, in recent years brush seals and carbon seals have also been used. The latter are contact seals; that is, they may be installed having zero clearance to the rotating part and lift during operation when their air side is pressurized. During this survey an actual aero engine bearing chamber was modified to run with brush seals in a simulating rig. Two types of brush seals were used: (a) with bristles made of Kevlar, and (b) bristles made of a metallic material. Both types were installed with an overlap to the rotor. The targets set were twofold: (a) to measure the transient temperatures in the rotor and particularly in the contact zone between the bristles and the rotor, and (b) to measure the air leakage through the seals at different operating conditions. In order to obtain the transient temperature measurements with high fidelity, a new pyrometric technique was developed and was applied for the first time in brush seals. This technique has enabled placement of the pyrometer into the bristle's pack of the seal adjacent to the rotating surface and it could record the frictional temperature evolution in the bristles/rotor contact zone during acceleration or deceleration of the rotor. Additionally, the air consumption of the seals was measured and was compared to the air consumption through the labyrinth seals. For the metallic brush seal, up to 80% of the required sealing air can be saved, which can result, in turn, into a reduction in fuel burned by up to 1%. Furthermore, a design simplification of the bearing chamber architecture can be achieved by taking into account the reduced air flow. Even though the rotor was accelerated to high speeds up to 19,500 rpm, the produced temperature overshoots in the seal/rotor contact zone have caused no deterioration in either the materials or the oil.


Author(s):  
Michael Flouros ◽  
Martin Stadlbauer ◽  
Francois Cottier ◽  
Stephan Proestler ◽  
Stefan Beichl

For the past 25 years brush seal technologies evolved into the aero engine designs and more general into the gas turbine world not only for sealing gas areas at different pressure levels but also for sealing gas/liquid environments. This is the case in an aero engine where the bearing chambers are sealed. Aero engine bearing chambers enclose oil lubricated components such bearings and gears. In order to avoid contamination of the turbo machinery through oil loss, air blown seals are used to retain the oil into the bearing chamber. Oil loss may cause coking or ignition with the probability of an uncontained destruction of rotating parts like disks or blades. It may also cause contamination of the air conditioning system with oil fumes thus cause health problems to the passengers and crew from such exposure. The most widely known seals for bearing chamber sealing are the labyrinth seals but in the recent years also brush seals and carbon seals are used. The latter are contact seals, that is, they may be installed having zero clearance to the rotating part and lift during operation when their air side is pressurized. During this survey an actual aero engine bearing chamber was modified to run with brush seals in a simulating rig. Two types of brush seals were used: a) with bristles made of Kevlar and b) bristles made of metallic material. Both types were installed with an overlap to the rotor. The targets set were twofold: a) to measure the transient temperatures in the rotor and particularly in the contact zone between the bristles and the rotor and b) to measure the air leakage through the seals at different operating conditions. In order to obtain the transient temperature measurements with high fidelity, a new pyrometric technique was developed and was applied for the first time in brush seals. This technique has enabled placing the pyrometer into the bristle’s pack of the seal adjacent to the rotating surface and could record the frictional temperature evolution in the bristles/rotor contact zone during acceleration or deceleration of the rotor. Additionally, the air consumption of the seals was measured and was compared to the air consumption through the labyrinth seals. For the metallic brush seal, up to 80% of the required sealing air can be saved which can result in return into a reduction in fuel burned by up to 1%. Further, a design simplification of the bearing chamber architecture can be achieved by taking into account the reduced air flow. Even though the rotor was accelerated to high speeds up to 19500rpm, the produced temperature overshoots in the seal/rotor contact zone have caused no deterioration in either the materials or the oil. This work is part of the European Union funded research programme ELUBSYS (Engine LUBrication System TechnologieS) within the 7th EU Frame Programme for Aeronautics and Transport (AAT.2008.4.2.3).


Author(s):  
Michael Flouros ◽  
Patrick Hendrick ◽  
Bilal Outirba ◽  
Francois Cottier ◽  
Stephan Proestler

Due to the increasing fuel cost and environmental targets, the demand for more efficient gas turbines has risen considerably in the last decade. One of the most important systems in a gas turbine is the secondary air system, which provides cooling air to the disks and to the blades. It also provides air for sealing of the bearing chambers. The amount of secondary air that is extracted from the compressor is a performance penalty for the engine. In aero engines, bearing chambers are in most cases sealed by the most traditional type of seal, the labyrinth seal. Bearing chambers contain the oil lubricated components like bearings and gears. In order to avoid oil migration from the bearing chamber into the turbomachinery, the seals are pressurized by secondary air; thus, a pressure difference is setup across the seal, which retains the lubricant into the bearing chamber. Oil loss can lead to a number of problems like oil fire or coking with the probability of an uncontained destruction of the aero engine. Oil fumes can also cause contamination of the air conditioning system of the aircraft thus cause discomfort to the passengers. Beside labyrinth seals, other types of seals such as brush seals and carbon seals are used. Both the latter are contact type seals, that is, they may be installed with zero gap and lift during operation when they get pressurized. Brush seals particularly may be installed having an overlap with the rotating part. An original aero engine bearing chamber was modified by MTU Aero Engines to run with brush seals in a simulating rig in Munich. Two types of brush seals were used for testing: (a) a brush seal with bristles made of Kevlar fibers and (b) a brush seal with bristles made of steel. Both types were installed with an overlap to the rotor. The targets set were twofold: (a) to measure the transient temperatures in the rotor and particularly in the contact zone between the bristles and the rotor and (b) to calculate the heat generation by the seals which could enable predictions of the heat generation in future applications (i.e., scaling to bigger rotor diameters). For the heat transfer calculations, numerical models using ansys cfx were created. Additionally, a coupled computational fluid dynamics (CFD) and finite element analysis (FEA) approach was applied to simulate flow and bristle's behavior. In order to obtain the transient temperature measurements with high fidelity, a new pyrometric technique was developed and was applied for the first time in brush seals as reported by Flouros et al. (2013, “Transient Temperature Measurements in the Contact Zone Between Brush Seals of Kevlar and Metallic Type for Bearing Chamber Sealing Using a Pyrometric Technique,” ASME J. Gas Turbines Power, 135(8), p. 081603) and Flouros et al. (2012, “Transient Temperature Measurements in the Contact Zone Between Brush Seals of Kevlar and Metallic Type for Bearing Chamber Sealing Using a Pyrometric Technique,” ASME Turbo Expo 2012, Copenhagen, Paper No. GT2012-68354). This technique has enabled positioning of the pyrometer (SensorthermGmbH, www.sensortherm.com) into the bristles pack of the seal adjacent to the rotating surface. The pyrometer could record the frictional temperature evolution in the bristles/rotor contact zone during accelerations or decelerations of the rotor. The sealing air demand can be reduced up to 97% with brush seals compared to traditional three fin labyrinth. It has been estimated that this can result in a reduction in fuel burned up to 1%. Further, the reduction in air flow has additional potential benefits such as a possible simplification of the bearing chamber architecture (vent less chamber). Even though the rotor was accelerated up to 19,500 rpm, the temperature induced overshoots in the seal/rotor contact zone have caused no deterioration in either the materials or the oil.


Author(s):  
H. Schwarz ◽  
J. Friedrichs ◽  
J. Flegler

Brush seals, which were originally designed for gas turbine applications, have been successfully applied to large-scale steam turbines within the past decade. From gas turbine applications, the fundamental behavior and designing levers are known. However, the application of brush seals to a steam turbine is still a challenge. This challenge is mainly due to the extreme load on the brush seal while operating under steam. Furthermore, it is difficult to test brush seals under realistic conditions, i.e. under live steam conditions with high pressure drops. Due to these insufficiencies, 2 test rigs were developed at the University of Technology Braunschweig, Germany. The first test rig is operated under pressurized air and allows testing specific brush seal characteristics concerning their general behavior. The knowledge gained from these tests can be validated in the second test rig, which is operated under steam at pressure drops of 45 bar and temperatures up to 450 °C. Using both the air test rig and the steam test rig helps keep the testing effort comparably small. Design variants can be pre-tested with air, and promising brush seal designs can consequently be tested in the steam seal test rig. The paper focuses on a clamped brush seal design which, amongst others, is used in steam turbine blade paths and shaft seals of current Siemens turbines. The consequences of the brush assembly on the brush appearance and brush performance are shown. The clamped brush seal design reveals several particularities compared to welded brushes. It could be shown that the clamped bristle pack tends to gape when clamping forces rise. Gapping results in an axially expanding bristle pack, where the bristle density per unit area and the leakage flow vary. Furthermore, the brush elements are usually assembled with an axial lay angle, i.e. the bristles are reclined against the backing plate. Hence, the axial lay angle is also part of the investigation.


Author(s):  
Fakun Zhuang ◽  
Wen Sui ◽  
Guoshan Xie ◽  
Shanshan Shao ◽  
Zhiyuan Han ◽  
...  

Abstract The thread ring block heat exchangers, served at the high temperature and pressure, are the key equipment in the petrochemical industry. Due to the severe operational conditions and unsuitable assemble, internal leakage problem commonly occurs, especially for the seal gasket between the tube sheet and shell. Many failed gaskets are collected. Through a series of experiments including chemical composition, metallographic analysis, SEM and fracture analysis, the gasket damage and leakage causes are analyzed. For further interpretation, the gasket stress analysis is completed by the finite element method. It shows that the gasket stress is a main factor that affects the sealing performance for the thread ring block heat exchanger. Under long term operation at high temperature and pressure, the gasket stress between the tube sheet and shell becomes loose and creep. The gasket material also deteriorates with increasing time. Therefore, in order to prevent the internal leakage, the stress should be controlled in an appropriate range. And periodical inspection must be performed.


Author(s):  
D. Pfefferle ◽  
K. Dullenkopf ◽  
H.-J. Bauer

Brush seals play an increasing role in turbomachinery due to their improved behavior towards leakage and their capability to compensate for gap variations caused by thermal expansion and rotor excursions. The flexible bristles of brush seals are able to endure short-term reductions in gap width without severe damage. Consequently the necessary gap between the rotor and brush seal can virtually be reduced to zero, leading to a considerable reduction in air leakage of up to 80 percent. However the reduced gap height increases the probability of rubbing between the bristle package and the rotor surface. The friction forces generated can cause an unwanted heat load on the rotor, bristles and leakage air. In addition, the surfaces involved are exposed to abrasion effects. Especially in the thin and lightweight rotor structures of aircraft engines, the additional heat impact can lead to a problematic level of material stress. To study these effects and to give reliable quantitative design rules, a versatile test rig for brush seals was designed and built. The simulation of seal behavior under relevant engine conditions is the main emphasis of this rig, including high pressure drop, leakage flow and high surface speed. The key feature is the possibility to vary the axis symmetric radial gap width during the test rig operation by up to a 0.5 mm overlap. The so caused rubbing induces a transient rotor temperature rise which is measured via a set of 12 thermocouples embedded in the rotor. These temperature readings can be used to calculate the brush seal heat impact on the rotor structure. Preliminary results with moderate differential pressure and rotor speed proved the functionality of the test rig and confirmed the global approach of the project.


Author(s):  
Michael J. Pekris ◽  
Gervas Franceschini ◽  
David R. H. Gillespie

Compliant contacting filament seals such as brush seals are well known to give improved leakage performance and hence specific fuel consumption benefit compared to labyrinth seals. The design of the brush seal must be robust across a range of operating pressures, rotor speeds and radial build-offset tolerances. Importantly the wear characteristics of the seal must be well understood to allow a secondary air system suitable for operation over the entire engine life to be designed. A test rig at the University of Oxford is described which was developed for the testing of brush seals at engine-representative speeds, pressures and seal housing eccentricities. The test rig allows the leakage, torque and temperature rise in the rotor to be characterized as functions of the differential pressure(s) across the seal and the speed of rotation. Tests were run on two different geometries of bristle-pack with conventional, passive and active pressure-balanced backing ring configurations. Comparison of the experimental results indicates that the hysteresis inherent in conventional brush seal design could compromise performance (due to increased leakage) or life (due to exacerbated wear) as a result of reduced compliance. The inclusion of active pressure-balanced backing rings in the seal designs are shown to alleviate the problem of bristle-backing ring friction, but this is associated with increased blow-down forces which could result in a significant seal-life penalty. The best performing seal was concluded to be the passive pressure-balanced configuration, which achieves the best compromise between leakage and seal torque. Seals incorporating passive pressure-balanced backing rings are also shown to have improved heat transfer performance in comparison to other designs.


Author(s):  
M. Raben ◽  
J. Friedrichs ◽  
J. Flegler

Sealing technology is a key feature to improve efficiency of steam turbines for both new power stations and modernization projects. One of the most powerful sealing alternatives for reducing parasitic leakages in the blade path of a turbine as well as in shaft sealing areas is the use of brush seals, which are also widely used in gas turbines and turbo compressors. The advantage of brush seals over other sealing concepts is based on the narrow gap that is formed between the brush seal bristle tips and the mating rotor surface together with its radial adaptivity. While the narrow gap between the bristle tips and the rotor leads to a strongly decreased flow through the seal compared with conventional turbomachinery seals, it is important to be aware of the tight gap that can be bridged by relative motion between the rotor and the brush seal, leading to a contact of the bristles and the rotor surface. Besides abrasive wear occurrence, the friction between the bristles and the rotor leads to heat generation which can be detrimental to turbine operation due to thermal effects, leading to rotor bending connected to increasing shaft vibrations. In order to investigate the frictional heat generation of brush seals, different investigation concepts have been introduced through the past years. To broaden the knowledge about frictional heat generation and to make it applicable for steam turbine applications, a new testing setup was designed for the steam test rig of the Institute of Jet Propulsion and Turbomachinery - TU Braunschweig, Germany, enabling temperature measurements in the rotor body under stationary and transient operation in steam by using rotor-integrated thermocouples. Within this paper, the development of the instrumented new rotor design and all relevant parts of the new testing setup is shown along with the testing ability by means of the validation of the test rig concept and the achieved measurement accuracy. First results prove that the new system can be used to investigate frictional heat generation of brush seals under conditions relevant for steam turbine shaft seals.


Author(s):  
Bilal Outirba ◽  
Patrick Hendrick

This paper provides the first step in sizing carbon brush seals for aero-engine oil bearing chambers applications. Recent developments in the aeronautic domain focus strongly on the reduction of aero-engine specific oil consumption. For instance, optimizing the civil aircraft gas turbine engine lubrication oil system is considered as one of the main targets in this research. Specifically, brush seals have shown tremendous leakage performance in sealing secondary flows compared to classic labyrinth seals over the last few decades. Therefore, an attractive idea is to extent their utilization to oil bearing chamber applications. To perform the experimental part of the study, a test rig has recently been built at ULB. This test rig will be described in this paper. A parametrical study has been performed in stationary conditions, and at very low rotation speed. A particular attention was given to the air consumption and the torque friction losses. Finally, a test simulating the effects of a rotor excursion on the brush seal performance has been made.


Author(s):  
Marco Mantero ◽  
Alessandro Vinci ◽  
Luca Bozzi ◽  
Enrico D’Angelo

In order to achieve significant secondary air savings in heavy duty gas turbines, a remarkable item of improvement is the reduction of seal flows for turbine stator-rotor cavities. The optimization of such flows allows to avoid waste of air, obligatory with standard labyrinth seals, to ensure the minimum sealing flow rate in all operating conditions. Based on the experience gained in the design of sealing system of stator-rotor cavities with standard seals, the project of installation of inter-stage brush-seals was undertaken incorporating such devices into the vane seal rings of 2nd and 3rd turbine stages of a AE94.3A Gas Turbine (GT). The paper offers a detailed description of the installation project. The following describes in detail the design flow process and the calculation methodologies used, step by step, to define the geometry of brush-seals in order to ensure mechanical integrity and durability, needed in the commercial operation, without thereby affecting the performance. The first prototype of brush-seal devices has been installed on a AE94.3A4 unit of the Ansaldo fleet. In order to verify the behavior of stator-rotor sealing system, in particular in terms of temperature and pressure variations, vane seal rings have been equipped with special instrumentation. A series of tests to optimize the set points of bleed control valves was carried out.


Sign in / Sign up

Export Citation Format

Share Document