Dynamic Response Analysis of Balance Drum Labyrinth Seal Groove Geometries Optimized for Minimum Leakage1

2017 ◽  
Vol 139 (2) ◽  
Author(s):  
Alexandrina Untaroiu ◽  
Neal Morgan ◽  
Vahe Hayrapetian ◽  
Bruno Schiavello
Keyword(s):  
Dynamic Response ◽  
Dynamic Properties ◽  
Labyrinth Seal ◽  
Leakage Rate ◽  
Response Analysis ◽  
Test Cases ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Computational Fluid Dynamics Cfd ◽  
Optimization Loop

Annular labyrinth seals often have a destabilizing effect on pump rotordynamics due to the large cross-coupled forces generated when the fluid is squeezed by an oscillating rotor. In this study, several novel groove geometries are investigated for their effect on the rotordynamic coefficients of the labyrinth seal. The groove cavity geometry of a baseline 267 mm balance drum labyrinth seal with a clearance of 0.305 mm and 20 equally spaced groove cavities was optimized for minimum leakage. From the pool of possible groove designs analyzed, nine test cases were selected for maximum or minimum leakage and for a variety of groove cavity shapes. The rotordynamic coefficients were calculated for these cases using a hybrid computational fluid dynamics (CFD) bulk-flow method. The rotordynamic coefficients obtained by this method were then used with a rotordynamic model of the entire pump to determine the overall stability. Results show that labyrinth seal’s groove shape can be optimized to generate lower leakage rates, while the effects on dynamic properties are only minimally changed. If the seal dynamic response needs to be modified in addition to targeting a lower leakage rate, for instance, to exhibit increased damping values, then the leakage rate and the damping coefficient need to be set as objective functions in the optimization loop.

Dynamic Response Analysis of Balance Drum Labyrinth Seal Groove Geometries Optimized for Minimum Leakage

2015 ◽  
Author(s):  
Alexandrina Untaroiu ◽  
Neal Morgan ◽  
Vahe Hayrapetian ◽  
Bruno Schiavello
Keyword(s):  
Dynamic Response ◽  
Dynamic Properties ◽  
Labyrinth Seal ◽  
Leakage Rate ◽  
Response Analysis ◽  
Test Cases ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Overall Stability ◽  
Optimization Loop

Annular labyrinth seals often have a destabilizing effect on pump rotordynamics due to the large cross-coupled forces generated when the fluid is squeezed by an oscillating rotor. In this study several novel groove geometries are investigated for their effect on the rotordynamic coefficients of the labyrinth seal. The groove cavity geometry of a baseline 267 mm balance drum labyrinth seal with a clearance of 0.305 mm and 20 equally spaced groove cavities were optimized for minimum leakage. From the pool of possible groove designs analyzed, nine test cases were selected for maximum or minimum leakage and for a variety of groove cavity shapes. The rotordynamic coefficients were calculated for these cases using a hybrid CFD-bulk flow method. The rotordynamic coefficients obtained by this method were then used with a rotordynamic model of the entire pump to determine the overall stability. Results show that labyrinth seal’s groove shape can be optimized to generate lower leakage rates, while the effects on dynamic properties are only minimally changed. If the seal dynamic response needs to be modified in addition to targeting a lower leakage rate, for instance to exhibit increased damping values, then the leakage rate and the damping coefficient need to be set as objective functions in the optimization loop.

Numerical Investigations of Leakage Performance Degradations in Labyrinth and Flexible Seals Due to Wear

2020 ◽  
Author(s):  
Xinbo Dai ◽  
Xin Yan ◽  
Kun He ◽  
Jun Li ◽  
Zhenping Feng
Keyword(s):  
Labyrinth Seal ◽  
Leakage Rate ◽  
Labyrinth Seals ◽  
Element Analysis ◽  
Numerical Investigations ◽  
Forward Bending ◽  
The Finite Element Analysis ◽  
Before And After ◽  
Computational Fluid Dynamics Cfd ◽  
Wear Damage

Abstract The Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) methods are utilized to investigate the leakage performance degradations in two kinds of flexible seals (i.e. forward bending and backward bending) and two kinds of shroud labyrinth seals (i.e. with straight fins and chamfered fins) in rubbing events. With the existing experimental data, FEA methods for contacting simulations and CFD methods for leakage rate and flow pattern predictions are carefully examined. The wear characteristic and leakage performance between labyrinth seals and flexible seals are compared before and after rub. The results show that, in rubbing process, the labyrinth seal with straight (symmetrical) fins is likely to undergo the mushrooming damage, whereas the labyrinth seal with chamfered (asymmetrical) fins is likely to undergo the tooth-bending damage. In rubbing process, compared with the labyrinth seal, the flexible seal has a superior characteristic in resisting the wear damage due to increased flexibility of fin. For a labyrinth seal with 0.3mm design clearance and a flexible seal with 0.15mm design clearance, the 0.5mm radial displacement of rotor will result in 110% increase of leakage rate for labyrinth seal, and 7% increase of leakage rate for flexible seal after wear. Under the same conditions, the forward bending flexible seal has a lower leakage rate than the backward bending flexible seal before and after rub.

Rotordynamic Performance of a Negative-Swirl Brake for a Tooth-on-Stator Labyrinth Seal

2015 ◽  
Vol 138 (6) ◽  
Author(s):  
Dara W. Childs ◽  
James E. Mclean ◽  
Min Zhang ◽  
Stephen P. Arthur
Keyword(s):  
Labyrinth Seal ◽  
Test Results ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Stiffness Coefficients ◽  
Shaft Rotation ◽  
Computational Fluid Dynamics Cfd ◽  
The Cross ◽  
Inlet Conditions ◽  
The Stability

In the late 1970s, Benckert and Wachter (Technical University Stuttgart) tested labyrinth seals using air as the test media and measured direct and cross-coupled stiffness coefficients. They reported the following results: (1) fluid preswirl in the direction of shaft rotation creates destabilizing cross-coupled stiffness coefficients and (2) effective swirl brakes at the inlet to the seal can markedly reduce the cross-coupled stiffness coefficients, in many cases reducing them to zero. In recent years, “negative-swirl” swirl brakes have been employed, which attempt to reverse the circumferential direction of inlet flow, changing the sign of the cross-coupled stiffness coefficients and creating stabilizing stiffness forces. This study presents test results for a 16-tooth labyrinth seal with positive inlet preswirl (in the direction of shaft rotation) for the following inlet conditions: (1) no swirl brakes, (2) straight, conventional swirl brakes, and (3) negative-swirl swirl brakes. The negative-swirl swirl-brake designs were developed based on computational fluid dynamics (CFD) predictions. Tests were conducted at 10.2, 15.35, and 20.2 krpm with 70 bar of inlet pressure for pressure ratios of 0.3, 0.4, and 0.5. Test results include leakage and rotordynamic coefficients. In terms of leakage, the negative-swirl brake configuration leaked the least, followed by the conventional brake, followed by the no-brake design. Normalized to the negative-swirl brake configuration, the conventional-brake and no-brake configurations mass flow rate was greater, respectively, by factors of 1.04 and 1.09. The direct-stiffness coefficients are negative but small, consistent with past experience. The conventional swirl brake drops the destabilizing cross-coupled stiffness coefficients k by a factor of about 0.8 as compared to the no-brake results. The negative-swirl brake produces a change in sign of k with an appreciable magnitude; hence, the stability of forward precessing modes would be enhanced. In descending order, the direct-damping coefficients C are: no-swirl, negative-swirl, and conventional-swirl. Normalized in terms of the no-swirl case, C for the negative and conventional brake designs is, respectively, 0.7 and 0.6 smaller. The effective damping Ceff combines the effect of k and C. Ceff is large and positive for the negative-swirl configuration and near zero for the no-brake and conventional-brake designs. The present results for a negative-brake design are very encouraging for both eye-packing seals (where conventional swirl brakes have been previously employed) and division-wall and balance-piston seals, where negative shunt injection has been employed.

Influence of Hole-Pattern Stator on Leakage Performance of Labyrinth Seals

2018 ◽  
Author(s):  
Xin Yan ◽  
Xinbo Dai ◽  
Kang Zhang ◽  
Jun Li ◽  
Kun He
Keyword(s):  
Experimental Tests ◽  
Labyrinth Seal ◽  
Leakage Rate ◽  
Control Performance ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Honeycomb Seal ◽  
Leakage Control ◽  
Stability Enhancement ◽  
The Cost

The honeycomb seal shows promising characteristics in many turbine machines for the leakage control and rotor stability enhancement. However, the cost of honeycomb seal is relative high due to its complexities in manufacture and installation process. The hole-pattern seal has a very close leakage and rotordynamic performance with honeycomb seal, and also the manufacture and installation of hole-pattern seal are easier than the honeycomb seal, which attract the researchers and designers in recent years. In the published literature, there have been many papers dealt with the rotordynamic coefficients measurements, but very few researchers concentrated on the leakage control performance for the labyrinth seal with hole-pattern land. In this paper, the experimental tests were carried out to obtain the leakage rates versus pressure ratios at four clearances for the straight-through labyrinth seal with smooth stator, straight-through labyrinth seal with hole-pattern stator, stepped labyrinth seal with smooth stator and the stepped labyrinth seal with hole-pattern stator. The flow fields in the seal chambers were also visualized at different clearances and pressure ratios. Moreover, the CFD tool was also implemented to predict the leakage performance in labyrinth seals, and the numerical results were compared with the measurements. The results show that, the stepped labyrinth seal with hole-pattern land performs better leakage control characteristic than the straight-through labyrinth seal with hole-pattern land, and the stepped labyrinth seal with smooth land performs better leakage control than the straight through labyrinth seal with smooth land. For the stepped labyrinth seal, holes in the stator increase the effective clearance thus increase the leakage rate in seal. However, the straight-through labyrinth seal with hole-pattern land almost has the identical leakage performance with the smooth configuration.

Impact of Frequency Dependence of Gas Labyrinth Seal Rotordynamic Coefficients on Centrifugal Compressor Stability

2010 ◽  
Author(s):  
Giuseppe Vannini ◽  
Manish R. Thorat ◽  
Dara W. Childs ◽  
Mirko Libraschi
Keyword(s):  
Molecular Weight ◽  
Numerical Model ◽  
Control Volume ◽  
Labyrinth Seal ◽  
Labyrinth Seals ◽  
Frequency Dependent ◽  
Rotordynamic Coefficients ◽  
Frequency Independent ◽  
Rotor Surface ◽  
Independent Model

A numerical model developed by Thorat & Childs [1] has indicated that the conventional frequency independent model for labyrinth seals is invalid for rotor surface velocities reaching a significant fraction of Mach 1. A theoretical one-control-volume (1CV) model based on a leakage equation that yields a reasonably good comparison with experimental results is considered in the present analysis. The numerical model yields frequency-dependent rotordynamic coefficients for the seal. Three real centrifugal compressors are analyzed to compare stability predictions with and without frequency-dependent labyrinth seal model. Three different compressor services are selected to have a comprehensive scenario in terms of pressure and molecular weight (MW). The molecular weight is very important for Mach number calculation and consequently for the frequency dependent nature of the coefficients. A hydrogen recycle application with MW around 8, a natural gas application with MW around 18, and finally a propane application with molecular weight around 44 are selected for this comparison. Useful indications on the applicability range of frequency dependent coefficients are given.

Numerical Comparison of Leakage Flow and Rotordynamic Characteristics for Two Types of Labyrinth Seals With Baffles

2020 ◽  
Vol 142 (9) ◽  
Author(s):  
Yuanqiao Zhang ◽  
Jun Li ◽  
Zhigang Li ◽  
Xin Yan
Keyword(s):  
Rotational Speed ◽  
Flow Resistance ◽  
Labyrinth Seal ◽  
Leakage Flow ◽  
Numerical Comparison ◽  
Vibration Frequencies ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Brush Seal ◽  
Swirl Intensity

Abstract Cavity separation baffles can decrease the circumferential swirl intensity of labyrinth seals and increase the seals' rotordynamic characteristics. Compared with conventional baffles, the bristle packs of brush seal baffles can contact the rotor directly, thereby further reducing the swirl intensity of the seal cavity. This paper, using the numerical model combining a multifrequency elliptical whirling orbit model, a porous medium model, and transient Reynolds-averaged Navier–Stokes (RANS) solutions, compares the leakage flow and rotordynamic characteristics of a labyrinth seal with brush-seal baffles (LSBSB) and a labyrinth seal with conventional baffles (LSCB). Ideal air flows into the seal at an inlet preswirl velocity of 0 m/s (or 60 m/s or 100 m/s), total pressure of 690 kPa, and temperature of 14 °C. The outlet static pressure is 100 kPa and the rotational speed is 7500 r/min (surface speed of 66.8 m/s) or 15,000 r/min (surface speed of 133.5 m/s). Numerical results show that the LSBSB possesses the slightly less leakage flow rate than the LSCB due to the flow resistance of the bristle pack to the fluid. Compared with the LSCB, the LSBSB shows a higher positive effective stiffness (Keff) at all considered vibration frequencies and a higher effective damping (Ceff) for most vibration frequencies. What is more, the crossover frequency (fc0) of the LSBSB is significantly lower than that of the LSCB, which means that the LSBSB has a wider frequency range offering positive effective damping. The increasing inlet preswirl velocity and rotational speed only slightly affect the Keff for both seals. The Ceff of two seals decreases as the inlet preswirl velocity rises, especially for the LSCB. The Ceff of the LSCB slightly decreases because of the increasing rotational speed. In contrast, the Ceff of the LSBSB is not sensitive to the changes in rotational speed. In a word, the LSBSB possesses superior rotordynamic performance to the LSCB. Note that this work also investigates the leakage flow and rotordynamic characteristics a labyrinth seal with inclined baffles (LSIB) under the condition of u0 = 60 m/s and n = 15,000 r/min. The inclined baffles of the LSIB are same as the backing plates of LSBSB baffles. The LSIB has rotordynamic coefficients almost equal to the LSCB. Hence, the reason why the LSBSB possesses better rotordynamic performance than that of the LSCB is the flow resistance of bristle packs of brush seal baffles, not the inclination direction variation of baffles.

scholarly journals Rotordynamic Coefficient and Leakage Test Results for Interlock and Tooth-on-Stator Labyrinth Seals

1988 ◽  
Author(s):  
Dara W. Childs ◽  
David A. Elrod ◽  
Keith Hale
Keyword(s):  
Labyrinth Seal ◽  
Damping Coefficient ◽  
Test Results ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Damping Coefficients ◽  
Leakage Test ◽  
Stiffness And Damping ◽  
Rotordynamic Coefficient

Test results (leakage and rotordynamic coefficients) are presented for an interlock and tooth-on-stator labyrinth seals. Tests were carried out with air at speeds out to 16,000 cpm and supply pressures up to 7.5 bars. The rotordynamic coefficients consist of direct and cross-coupled stiffness and damping coefficients. Damping-coefficient data have not previously been presented for interlock seals. The test results support the following conclusions: (a) The interlock seal leaks substantially less than labyrinth seals. (b) Destabilizing forces are lower for the interlock seal. (c) The labyrinth seal has substantially greater direct damping values than the interlock seal. A complete rotordynamics analysis is needed to determine which type of seal would yield the best stability predictions for a given turbomachinery unit.

Numerical and Experimental Investigation on the Effect of Swirl Brakes on the Labyrinth Seals

2015 ◽  
Vol 138 (3) ◽  
Author(s):  
Dan Sun ◽  
Shuang Wang ◽  
Cheng-Wei Fei ◽  
Yan-Ting Ai ◽  
Ke-Ming Wang
Keyword(s):  
Pressure Ratio ◽  
Flow Characteristics ◽  
Labyrinth Seal ◽  
Impedance Method ◽  
Swirl Ratio ◽  
Labyrinth Seals ◽  
Rotating Speed ◽  
Simulation And Experiment ◽  
Computational Fluid Dynamics Cfd ◽  
Static Flow

Swirl brake influences the static and rotordynamic characteristics of labyrinth seal which are important in the prediction of turbomachine stability. To study the influence of the swirl brakes on improving seal stability, the effects of swirl brakes on the static and rotordynamic characteristics of labyrinth seals were investigated by the combination of numerical simulation and experiment. First, it was performed to the effects of swirl brake on the static flow characteristics of labyrinth seal with swirl ratio and pressure distribution based on computational fluid dynamics (CFD). And then a comparison between leakage predicted by the CFD model and measurement was presented to verify the accuracy of the simulation. Moreover, an experiment was implemented to analyze the rotordynamic characteristics of labyrinth seal using an improved impedance method based on an unbalanced synchronous excitation method on a rotor test rig. The influences of swirl brake density, length, inlet/outlet pressure ratio, and rotating speed were measured and discussed, respectively. The CFD numerical results show that the swirl brake effectively reduces the seal swirl ratio (∼60–75% less), circumferential pressure difference (∼25–85% less) so that the seal destabilizing forces decrease. With the increasing of the swirl vanes density and length, the seal leakage drops (∼8–20% less). The experimental rotordynamic characteristics results show that it is more obvious to reduce the cross-couple stiffness (∼50–300% less) and increase the direct damping (∼50–60% larger) with the increasing in the number and length of the swirl vanes, and thus the swirl brake improves the seal rotordynamic stability. The efforts of this paper provide a useful insight to clearly understand the effects of swirl brakes on the labyrinth seal static and rotordynamic characteristics, which is beneficial to improve the design of annular seals.

Leakage and Windage Heating in Stepped Labyrinth Seals

2019 ◽  
Author(s):  
Kali Charan Nayak ◽  
Nomesh P. Kandaswamy ◽  
Syed Faheemulla
Keyword(s):  
Pressure Ratio ◽  
Labyrinth Seal ◽  
Vital Role ◽  
Step Height ◽  
Axial Position ◽  
Radial Clearance ◽  
Labyrinth Seals ◽  
Geometric Factors ◽  
Pitch Ratio ◽  
Computational Fluid Dynamics Cfd

Abstract Stepped labyrinth seals are used in multiple locations in the gas turbine with the intent to reduced leakage compared to straight labyrinth seals. However the selection of geometric factors in stepped labyrinth seals is critical to allow lower leakage in its operating envelope. Particularly the step height and axial position during the running condition play a vital role. The influence of these factors on the leakage, swirl development and windage heating in stepped labyrinth seal has not been thoroughly investigated in the previously published work. This paper focuses to study above effects with numerical simulations in a smooth four-fin stepped labyrinth seal. Specifically, a 2D axi-symmetric computational fluid dynamics (CFD) model is developed utilizing commercial finite volume-based software incorporating the standard k-ε turbulence model. Using this model, a broad parametric study is conducted by varying step height, axial position of the knife from the step, radial clearance and pressure ratio for a four-teeth stepped labyrinth seal. It has been observed that the seal leakage reduces with increase in step height to pitch ratio up to 0.35 and with further increase it tails off. The axial position of the tooth has strong influence on the flow structure and swirl development in the seal pocket.

Measured Rotordynamic and Leakage Characteristics of a Tooth-on-Rotor Labyrinth Seal With Comparisons to a Tooth-on-Stator Labyrinth Seal and Predictions

2015 ◽  
Author(s):  
Stephen P. Arthur ◽  
Dara W. Childs
Keyword(s):  
Cavity Length ◽  
Labyrinth Seal ◽  
Diameter Ratio ◽  
Radial Clearance ◽  
Rotor Speed ◽  
Labyrinth Seals ◽  
Rotordynamic Coefficients ◽  
Leakage Characteristics ◽  
Identical Diameter ◽  
Length To Diameter Ratio

Rotordynamic and leakage data are presented for a see-through tooth-on-rotor (TOR) labyrinth seal with comparisons to a see-through tooth-on-stator (TOS) labyrinth seal. Measurements for both seals are also compared to predictions from XLLaby. Both seals have identical diameter and can be considered as relatively long labyrinth seals. The TOR seal has a length-to-diameter ratio of 0.62, whereas the TOS seal is longer and has a length-to-diameter ratio of 0.75. Both seals also differ by number of teeth, tooth height, and tooth cavity length. TOR labyrinth tests were carried out at an inlet pressure of 70 bar-a (1,015 psia), pressure ratios of 0.4, 0.5, and 0.6, rotor speeds up to 20,200 rpm, a radial clearance of 0.1 mm (4 mils), and three preswirl ratios. For comparison, TOS labyrinth tests were run at identical conditions as the TOR tests but for only one positive preswirl ratio. TOR labyrinth measurements show a pronounced dependence of rotordynamic coefficients on rotor speed, especially when compared to prior documented TOS labyrinth seal tests run at a radial clearance of 0.2 mm (8mils). The TOR labyrinth cross-coupled stiffness is higher in magnitude and increases at a higher rate than that of the TOS labyrinth across all test speeds. However, the TOR labyrinth effective damping was determined to be greater due to higher measurements of direct damping. Measured leakage rates for the TOR labyrinth were approximately 5–10% less than the TOS labyrinth. XLLaby underpredicted the rotordynamic coefficients for both seals. However, as with measurements, it predicted the TOR labyrinth to have higher effective damping than the TOS labyrinth.

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