Development of a Computational Tool to Simulate Foil Bearings for Supercritical CO2 Cycles

2016 ◽  
Vol 138 (9) ◽  
Author(s):  
Kan Qin ◽  
Ingo Jahn ◽  
Rowan Gollan ◽  
Peter Jacobs
Keyword(s):  
Turbulent Flow ◽  
Supercritical Co2 ◽  
Three Dimensional ◽  
Structural Deformation ◽  
Working Fluid ◽  
Computational Tool ◽  
Element Analysis ◽  
Thrust Bearings ◽  
Foil Bearings ◽  
Foil Bearing

The foil bearing is an enabling technology for turbomachinery systems, which has the potential to enable cost efficient supercritical CO2 cycles. The direct use of the cycle's working fluid within the bearings results in an oil-free and compact turbomachinery system; however, these bearings will significantly influence the performance of the whole cycle and must be carefully studied. Moreover, using CO2 as the operating fluid for a foil bearing creates new modeling challenges. These include highly turbulent flow within the film, non-negligible inertia forces, high windage losses, and nonideal gas behavior. Since the flow phenomena within foil bearings is complex, involving coupled fluid flow and structural deformation, use of the conventional Reynolds equation to predict the performance of foil bearings might not be adequate. To address these modeling issues, a three-dimensional flow and structure simulation tool has been developed to better predict the performance of foil bearings for the supercritical CO2 cycle. In this study, the gas dynamics code, eilmer, has been extended for multiphysics simulation by implementing a moving grid framework, in order to study the elastohydrodynamic performance of foil bearings. The code was then validated for representative laminar and turbulent flow cases, and good agreement was found between the new code and analytical solutions or experiment results. A separate finite difference code based on the Kirchoff plate equation for the circular thin plate was developed in Python to solve the structural deformation within foil thrust bearings, and verified with the finite element analysis from ansys. The fluid-structure coupling algorithm was then proposed and validated against experimental results of a foil thrust bearing that used air as operating fluid. Finally, the new computational tool set is applied to the modeling of foil thrust bearings with CO2 as the operating fluid.

Effect of Operating Conditions on the Elasto-Hydrodynamic Performance of Foil Thrust Bearings for Supercritical CO2 Cycles

2016 ◽  
Author(s):  
Kan Qin ◽  
Ingo H. Jahn ◽  
Peter A. Jacobs
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Supercritical Co2 ◽  
Operating Conditions ◽  
Hydrodynamic Performance ◽  
Working Fluid ◽  
Inertia Force ◽  
Fluid Structure ◽  
Thrust Bearings ◽  
Foil Bearings

In order to efficiently utilize the abundant solar resources in Australia, the supercritical CO2 cycle is proposed as an alternative to conventional steam power cycles due to high thermal efficiency and compact system layout. To mature the technology readiness of the supercritical CO2 cycle, each part, including turbine, compressor, seals and bearings, needs to be evaluated and possibly re-designed under consideration of the high density working fluid. One key technology is the foil thrust bearing, which is an enabler for high speed operation and oil-free systems. Bearings are at the core of the turbomachinery system and have a significant influence on the performance of the whole system. In this paper, a quasi three-dimensional fluid-structure model, using computational fluid dynamics for the fluid phase is presented to study the elasto-hydrodynamic performance of foil thrust bearings. For the simulation of the gas flows within the thin gap, the computational fluid dynamics solver Eilmer is extended and a new solver is developed to simulate the bump and top foil within foil thrust bearings. These two solvers are linked using a coupling algorithm that maps pressure and deflection at the fluid structure interface. Results are presented for ambient CO2 conditions varying between 0.1 to 4.0MPa and 300 to 400K. It is found that the centrifugal inertia force can play a significant impact on the performance of foil thrust bearings with the highly dense CO2 and that the centrifugal inertia forces create unusual radial velocity profiles. In the ramp region of the foil thrust bearings, they generate an additional inflow close to the rotor inner edge, resulting in a higher peak pressure. Contrary in the flat region, the inertia force creates a rapid mass loss through the bearing outer edge, which reduces pressure in this region. This different flow field alters bearing performance compared to conventional air foil bearings. In addition, the effect of turbulence in load capacity and bearing torque is investigated. This study provides new insight into the flow physics within foil bearings operating with dense gases and for the selection of optimal operating condition to suit foil thrust bearings in supercritical CO2 cycles.

Theoretical Study on Static Performance of Double-Bump Foil Bearings

2021 ◽  
Author(s):  
Fangcheng Xu ◽  
Jianhua Chu ◽  
Wenlin Luan ◽  
Guang Zhao
Keyword(s):  
Finite Element ◽  
Film Thickness ◽  
Thrust Bearing ◽  
Load Capacity ◽  
Static Characteristics ◽  
Thrust Bearings ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Static Performance ◽  
Initial Clearance

Abstract In this paper, single-bump foil models with different thickness and double-bump foil models with different initial clearances are established. The structural stiffness and equivalent viscous damping of double-bump foil and single-bump foil are analyzed by finite element simulation. The results show that the double-layer bump foil has variable stiffness and the displacement of the upper bump is greater than the initial gap when the two-layer bumps contact. A model for obtaining static characteristics of aerodynamic compliant foil thrust bearing is established on the basis of the stiffness characteristics of the double-bump foil. This paper solves gas Reynolds equation, the gas film thickness equation and the foil stiffness characteristic equation via the finite element method and the finite difference method. The static characteristics of the thrust bearings including the bearing pressure distribution, the gas film thickness and the friction power consumption have been obtained. The static characteristics of two kinds of foils have been compared and analyzed, and the effect of initial clearance on the static performance of double-bump foil bearings is studied. The results show that the double-bump foil structure can effectively improve the load capacity of thrust bearing. In addition, the static performance of double-bump foil thrust bearings is between the performance of the single-bump foil bearing and the double-bump foil bearing whose foil’s clearance is zero. The smaller the initial clearance is, the easier it will be to form a stable double-bump foil supporting structure.

Successful Oil-Free Version of a Gas Compressor Through Integrated Design of Foil Bearings

2008 ◽  
Author(s):  
Jonathan L. Wade ◽  
Daniel R. Lubell ◽  
Dennis Weissert
Keyword(s):  
Integrated Design ◽  
Pass Rate ◽  
Working Fluid ◽  
Acceptance Test ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Higher Power ◽  
Bearing Design ◽  
Maintenance Requirements ◽  
Conventional Oil

In the pursuit of higher power density turbomachinery the rotor speeds and temperatures have been increased to the limits of conventional oil lubricated bearings. Additionally, with conventional oil lubricated bearings there is a risk of oil contaminating the working fluid; this is unacceptable for some applications. When properly designed and integrated the foil gas bearing is one option that can easily operate at higher temperatures and DN’s than conventional oil lubricated bearings systems. This is a case study of a small variable speed gas compressor that progressed through a variety of bearing configurations. The compressor was initially designed with ball bearings; the ball bearing design did not meet the compressor life targets for some operating regimes, requiring extra maintenance. The second iteration was to move to a foil bearing design; unfortunately because of design constraints an under-sized bearing was selected. The under-sized foil bearing provided only marginally better unit life, and was much more sensitive in the build process and the acceptance test pass rate fell dramatically. Unique field operation experience showed a variety of failures and successes from a marginal design. Finally, a properly sized foil bearing was integrated into the pump, capitalizing on the foil bearing strengths. With the properly sized foil bearings the pumps have seen a 100% acceptance test pass rate, no field failures, and the pumps are exceeding the desired life without any maintenance requirements.

scholarly journals Finite Element Analysis of Turbulent Flows Using LES and Dynamic Subgrid-Scale Models in Complex Geometries

2011 ◽  
Vol 2011 ◽  
pp. 1-20 ◽  
Author(s):  
Wang Wenquan ◽  
Zhang Lixiang ◽  
Yan Yan ◽  
Guo Yakun
Keyword(s):  
Finite Element ◽  
Turbulent Flow ◽  
Turbulent Flows ◽  
Stokes Equations ◽  
Three Dimensional ◽  
Turbulent Channel Flow ◽  
Francis Turbine ◽  
Complex Geometries ◽  
Subgrid Scale ◽  
Element Analysis

An innovative computational model is presented for the large eddy simulation (LES) of multidimensional unsteady turbulent flow problems in complex geometries. The main objectives of this research are to know more about the structure of turbulent flows, to identify their three-dimensional characteristic, and to study physical effects due to complex fluid flow. The filtered Navier-Stokes equations are used to simulate large scales; however, they are supplemented by dynamic subgrid-scale (DSGS) models to simulate the energy transfer from large scales toward subgrid-scales, where this energy will be dissipated by molecular viscosity. Based on the Taylor-Galerkin schemes for the convection-diffusion problems, this model is implemented in a three-dimensional finite element code using a three-step finite element method (FEM). Turbulent channel flow and flow over a backward-facing step are considered as a benchmark for validating the methodology by comparing with the direct numerical simulation (DNS) results or experimental data. Also, qualitative and quantitative aspects of three-dimensional complex turbulent flow in a strong 3D blade passage of a Francis turbine are analyzed.

scholarly journals A New Analysis Tool Assessment for Rotordynamic Modeling of Gas Foil Bearings

2010 ◽  
Author(s):  
Samuel A. Howard ◽  
Luis San Andre´s
Keyword(s):  
Power Loss ◽  
High Speed ◽  
Structural Deformation ◽  
Analysis Tool ◽  
Test Rig ◽  
Contributing Factors ◽  
Foil Bearings ◽  
Rotordynamic Coefficients ◽  
Foil Bearing ◽  
Analytical Tools

Gas foil bearings offer several advantages over traditional bearing types that make them attractive for use in high-speed turbomachinery. They can operate at very high temperatures, require no lubrication supply (oil pumps, seals, etc), exhibit very long life with no maintenance, and once operating airborne, have very low power loss. The use of gas foil bearings in high-speed turbomachinery has been accelerating in recent years, although the pace has been slow. One of the contributing factors to the slow growth has been a lack of analysis tools, benchmarked to measurements, to predict gas foil bearing behavior in rotating machinery. To address this shortcoming, NASA Glenn Research Center (GRC) has supported the development of analytical tools to predict gas foil bearing performance. One of the codes has the capability to predict rotordynamic coefficients, power loss, film thickness, structural deformation, and more. The current paper presents an assessment of the predictive capability of the code, named XLGFBTH©. A test rig at GRC is used as a simulated case study to compare rotordynamic analysis using output from the code to actual rotor response as measured in the test rig. The test rig rotor is supported on two gas foil journal bearings manufactured at GRC, with all pertinent geometry disclosed. The resulting comparison shows that the rotordynamic coefficients calculated using XLGFBTH© represent the dynamics of the system reasonably well, especially as they pertain to predicting critical speeds.

A Numerical Study of Turbulent Flow in Helical Static Mixers

2006 ◽  
Author(s):  
Ramin K. Rahmani ◽  
Anahita Ayasoufi ◽  
Theo G. Keith
Keyword(s):  
Turbulent Flow ◽  
Molecular Diffusion ◽  
Stokes Equations ◽  
Numerical Study ◽  
Critical Role ◽  
Three Dimensional ◽  
Turbulent Dispersion ◽  
Working Fluid ◽  
Static Mixer ◽  
Static Mixers

Many processing applications call for the addition of small quantities of chemicals to working fluid. Hence, fluid mixing plays a critical role in the success or failure of these processes. An optimal combination of turbulent dispersion down to eddies of the Kolmogoroff scale and molecular diffusion would yield fast mixing on a molecular scale which in turn favors the desired reactions. Helical static mixers can be used for those applications. The range of practical flow Reynolds numbers for these mixers in industry is usually from very small (Re ∼ 0) to moderate values (Re ∼ 5000). In this study, a helical static mixer is investigated numerically using Lagrangian methods to characterize mixer performance under turbulent flow regime conditions. A numerical simulation of turbulent flows in helical static mixers is employed. The model solves the three-dimensional, Reynolds-averaged Navier-Stokes equations, closed with the Spalart-Allmaras turbulence model, using a second-order-accurate finite-volume numerical method. Numerical simulations are carried out for a six-element mixer, and the computed results are analyzed to elucidate the complex, three-dimensional features of the flow. Using a variety of predictive tools, mixing results are obtained and the performance of static mixer under turbulent flow condition is studied.

Application of Materials on Foil Thrust Bearings for Micro Turbines

2011 ◽  
Vol 201-203 ◽  
pp. 2759-2762
Author(s):  
Quan Zhou ◽  
Yu Hou ◽  
Ru Gang Chen
Keyword(s):  
Thrust Bearing ◽  
Load Capacity ◽  
Bearing Surface ◽  
Thrust Bearings ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Soft Surface ◽  
Static Part ◽  
Micro Turbine ◽  
Foil Thrust Bearing

Foil bearing that has a soft surface is a kind of air bearing. The performances of foil bearings are greatly affected by the materials of bearing surface, which is called foil element. In order to estimate the performance of foil bearings, two kinds of foil thrust bearings that are made of different materials respectively were tested in a micro turbine system, which contains rotation part and static part. Load capacity and stability of these foil thrust bearings were investigated in experiments. The results show that bearing which contains rubber has higher load capacity and bearing which contains copper foil has higher stability. According to the work in this paper, applications with different requirements can adopt suitable foil thrust bearing.

scholarly journals Measurement of Flow Phenomena in a Lower Plenum Model of a Prismatic Gas-Cooled Reactor

2008 ◽  
Author(s):  
Hugh M. McIlroy ◽  
Donald M. McEligot ◽  
Robert J. Pink
Keyword(s):  
Turbulent Flow ◽  
National Laboratory ◽  
Three Dimensional ◽  
Index Of Refraction ◽  
Optical Measurements ◽  
Scale Model ◽  
Working Fluid ◽  
Mean Velocity ◽  
Standard Problem ◽  
Flow Phenomena

Mean-velocity-field and turbulence data are presented that measure turbulent flow phenomena in an approximately 1:7 scale model of a region of the lower plenum of a typical prismatic gas-cooled reactor (GCR) similar to a General Atomics Gas-Turbine-Modular Helium Reactor (GTMHR) design. The data were obtained in the Matched-Index-of-Refraction (MIR) facility at Idaho National Laboratory (INL) and are offered for assessing computational fluid dynamics (CFD) software. This experiment has been selected as the first Standard Problem endorsed by the Generation IV International Forum. Results concentrate on the region of the lower plenum near its far reflector wall (away from the outlet duct). The flow in the lower plenum consists of multiple jets injected into a confined cross flow — with obstructions. The model consists of a row of full circular posts along its centerline with half-posts on the two parallel walls to approximate geometry scaled to that expected from the staggered parallel rows of posts in the reactor design. The model is fabricated from clear, fused quartz to match the refractive-index of the working fluid so that optical techniques may be employed for the measurements. The benefit of the MIR technique is that it permits optical measurements to determine flow characteristics in complex passages in and around objects to be obtained without locating intrusive transducers that will disturb the flow field and without distortion of the optical paths. An advantage of the INL system is its large size, leading to improved spatial and temporal resolution compared to similar facilities at smaller scales. A three-dimensional (3-D) Particle Image Velocimetry (PIV) system was used to collect the data. Inlet jet Reynolds numbers (based on the jet diameter and the time-mean bulk velocity) are approximately 4,300 and 12,400. Uncertainty analyses and a discussion of the standard problem are included. The measurements reveal developing, non-uniform, turbulent flow in the inlet jets and complicated flow patterns in the model lower plenum. Data include three-dimensional vector plots, data displays along the coordinate planes (slices) and presentations that describe the component flows at specific regions in the model. Information on inlet conditions is also presented.

Three-Dimensional Modeling of Creep Damage in Airfoils for Advanced Turbine Systems

2008 ◽  
Author(s):  
Ventzislav G. Karaivanov ◽  
Danny W. Mazzotta ◽  
Minking K. Chyu ◽  
William S. Slaughter ◽  
Mary Anne Alvin
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Gas Turbines ◽  
Damage Mechanics ◽  
Thermal Loading ◽  
Three Dimensional ◽  
Creep Damage ◽  
Creep Model ◽  
Working Fluid ◽  
Element Analysis

Future oxy-fuel and hydrogen-fired turbines promise increased efficiency and low emissions. However, this comes at the expense of increased thermal load from higher inlet temperatures and a change in the working fluid in the gas path, leading to aero-thermal characteristics that are significantly different than those in traditional gas turbines. A computational methodology, based on three-dimensional finite element analysis (FEA) and damage mechanics is presented for predicting the evolution of creep in airfoils in these advanced turbine systems. Information revealed from three-dimensional computational fluid dynamics (CFD) simulations of external heat transfer and thermal loading over a generic airfoil provides detailed local distributions of pressure, surface temperature, and heat flux penetrating through the thermal barrier coated layer. There is an additional mechanical loading due to the centrifugal acceleration of the airfoil. Finite element analysis is then used to predict temperature and stress fields over the domain of the airfoil. The damage mechanics-based creep model uses a scalar damage parameter. This creep model is coupled with finite element analysis to predict the evolution of stress and creep damage over the entire airfoil. Visualization of the creep damage evolution over the airfoil shows the regions that are most susceptible to failure by creep.

Effect of Operating Conditions on the Elastohydrodynamic Performance of Foil Thrust Bearings for Supercritical CO2 Cycles

2016 ◽  
Vol 139 (4) ◽  
Author(s):  
Kan Qin ◽  
Ingo H. Jahn ◽  
Peter A. Jacobs
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Supercritical Co2 ◽  
Load Capacity ◽  
Fluid Phase ◽  
Operating Conditions ◽  
Inertia Force ◽  
Fluid Structure ◽  
Thrust Bearings ◽  
Foil Bearings

In this paper, a quasi-three-dimensional fluid–structure model using computational fluid dynamics for the fluid phase is presented to study the elastohydrodynamic performance of foil thrust bearings for supercritical CO2 cycles. For the simulation of the gas flows within the thin gap, the computational fluid dynamics solver Eilmer is extended, and a new solver is developed to simulate the bump and top foil within foil thrust bearings. These two solvers are linked using a coupling algorithm that maps pressure and deflection at the fluid structure interface. Results are presented for ambient CO2 conditions varying between 0.1 and 4.0 MPa and 300 and 400 K. It is found that the centrifugal inertia force can play a significant impact on the performance of foil thrust bearings with the highly dense CO2 and that the centrifugal inertia forces create unusual radial velocity profiles. In the ramp region of the foil thrust bearings, they generate an additional inflow close to the rotor inner edge, resulting in a higher peak pressure. Contrary to the flat region, the inertia force creates a rapid mass loss through the bearing outer edge, which reduces pressure in this region. This different flow fields alter bearing performance compared to conventional air foil bearings. In addition, the effect of turbulence in load capacity and torque is investigated. This study provides new insight into the flow physics within foil bearings operating with dense gases and for the selection of optimal operating condition to suit CO2 foil bearings.

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