Three-Dimensional CFD Rotordynamic Analysis of Gas Labyrinth Seals
Three-Dimensional CFD Rotordynamic Analysis of Gas Labyrinth Seals
Three-Dimensional CFD Rotordynamic Analysis of Gas Labyrinth Seals
Introduction
Labyrinth seals are widely used in turbomachinery to minimize
secondary leakage inside turbomachinery, including gas turbines
and compressors. Accurate leakage prediction is vital for reliable
performance prediction. The large gas pressure of high-pressure
centrifugal compressors develops forces inside the many labyrinth
seals that can affect the rotordynamic stability of the machine.
This research attempts to improve the prediction accuracy of these
forces by employing 3D, CFD techniques solving the general
Reynolds Averaged Navier-Stokes RANS equations along with
the energy equation, equation of state, and turbulence model. The
approach does not rely on empirical wall and interface constants
that may change for varying applications and geometry. Furthermore, the exact geometry of the seal may be modeled allowing
optimization of the profile of the teeth. The obvious drawback of
CFD compared to bulk-flow is increased computational requirement but is manageable with modern workstations.
Literature Review
Several authors have developed bulk-flow approaches to model
the dynamic forces of labyrinth seals including Iwatsubo 1,
Childs and Scharrer 2, Kirk 3, and Marquette, et al. 4. Use of
bulk-flow has been moderately successful for liquid labyrinth
seals but yields only fare predictions for gas labyrinths. Its primary advantage is efficient computational times.
Other approaches have utilized the rapidly maturing computational fluid dynamic analysis for modeling annular seals including
Dietzen and Nordman 5 and Arghir and Frene 6. These authors
employ a coordinate transformation from the 3D eccentric domain
into a 2D axisymmetric one. This technique requires a zeroth order solution and first order calculations at the different whirl frequency ratios. The procedure is efficient, but the coordinate transContributed by the Technical Committee on Vibration and Sound for publication
in the Jrgen Lund Special Issue of the JOURNAL OF VIBRATION AND ACOUSTICS.
Manuscript received June 2003. Guest Associate Editor: R. Gordon Kirk.
*Childs, D.W., 1993, Turbomachinery Rotordynamics, John Wiley & Sons, New
York, p. 345.
continuity
U j
0.0
t
x j
momentum
(1)
U i U iU j
p
Ui U j
eff
t
x j
xi x j
x j
xi
Ul
2
eff
k i j S iu
3
xl
2
Ul
eff
k ij
3
xl
T t h
x j
x j
Prt x j
Xr 2
V 2
2
2
(4)
(5)
The current work assumes the entire flow domain to be turbulent and implements the standard 2-equation model with wall
functions. The expression for turbulent kinetic energy (k) and the
dissipation rate , are given below along with the relation for
turbulent viscosity.
(k equation
P k t
t k
P k
k x j
Ui U j Ui 2
Uk Ul
k t
x j
xi x j 3
xk xl
equation
U i
t
xi
x j
Prt
.09
1.44
1.92
1.
1.3
0.9
u y
(6)
t
c 1 P k c 2
x j
k
(7)
c u k 2
for y 12
1
u ln Ey
K
where
for y 12
yU
,
and
(9)
u
U
(10)
(11)
(12)
k U ik
t
xi
x j
(3)
H U iH p
Ui U j
U i eff
t
xi
t x j
x j
xi
Ih
c 2
(2)
c 1
Law of the wall formulations model the sharp velocity gradients near the wall:
Note that the first term in Eqs. 1 and 2 vanishes for the current
work since only the steady terms are considered. The 2/3 i j k
term is a consequence of the eddy viscosity model of the Reynolds stress tensor. Also, eff represents the sum of the kinematic
viscosity and the turbulent viscosity ( t ). Equation 2 contains a source term accounting for the centripetal and Coriolis
effects.
X
Xr 2
XV
S iu
(8)
The flow field inside a whirling annular seal is inherently unsteady. However, for a centered seal the whirling, unsteady problem is transformed into a steady one by solving the threedimensional, eccentric flow field in the frame of reference
attached to the whirling rotor. In this rotating frame, the stator
wall moves in the opposite direction for positive whirl. The rotor
surface moves with, against, or not at all relative to the whirling
frame of reference, depending on the processional frequency ratio
PFR, defined as the ratio of rotor whirl to rotor spin. Quasisteady solutions are obtained at each PFR. A PFR equal to unity is
termed synchronous whirl, where the shroud is whirling at the
same frequency it rotates. A PFR of zero indicates a static displacement of the shroud, which then simply spins.
The choice of eccentricity is arbitrary but is typically kept near
10% of the shroud clearance to capture the linear, small motion
characteristics. This value was arrived at based on previous modeling of annular seals 12. Larger eccentricities are possible and
may be utilized to predict nonlinear characteristics.
A solution is obtained at multiple PFR values typically ranging
from 0.0 to 2.0. For gas annular seals, the impedance curves are
essentially linear no inertia coefficient, therefore a minimum of
two whirl frequencies are required to solve for the rotordynamic
coefficients. For this study, three precessional frequency ratios
PFR are used 0.0, 0.5, and 1.0 for better accuracy of the
curvefits.
After a converged solution is obtained at each PFR, a pressure
integration is performed on the rotor surface in the two orthogonal
directions yielding F t and F n , respectively. The shear stress contribution at the wall contributes less than 1% of the total impedance force and is ignored. These impedance forces may be normalized by yielding the impedance both normal and tangential
to the whirl orbit. A comparison of these impedance forces to a
linear, first order model is shown in Eqs. 13 and 14.
F n
Fn
Kc
(13)
F t
Ft
kC
(14)
Grid Generation
The 2D grid for the inlet and first seal cavity are created using
a commercial grid generator. A FORTRAN code was developed
which sweeps a 2D grid transforming it into an eccentric 3D grid.
The code was further refined to automatically create repeating
geometry like labyrinth teeth. Therefore, only the inlet region, the
first seal land, and the first cavity grid need to be defined as shown
in Fig. 1. The land and cavity grids are then repeated by N number
of times, where N is the number of labyrinth teeth minus one.
This code allows 3-D grids to be made quickly.
The grid is made eccentric to the height of the land by 10% of
the clearance. Starting with the one node away from the wall, the
grid points are redistributed linearly in the radial direction. The
near-wall grid points are not disturbed so as to maintain a nearly
constant y , resulting in improved wall shear stress prediction.
Figure 2 shows 2D view of the resulting 3D full seal model for an
18 tooth labyrinth seal showing the repeating seal geometry.
N
Shaft Radius
Radial Clearance
# Teeth
Tooth Pitch
Tooth Height
Tip Width
Inlet Tot. Pressure
Exit Tot. Pressure
IGV Swirl
An axisymmetric calculation is made including the upstream region to determine the actual conditions at the An inlet of the seal
used with the Seal-Only model. The mass-flow averaged values
are:
Seal
Seal
Seal
Seal
Seal
Inlet
Inlet
Inlet
Inlet
Inlet
Total Pressure
Swirl Ratio ( s )
Static Temp.
k
17.3 bars
0.12
297 K
477.4
1.55e8
Location
1
2
3
4, 6, . . .
5,7, . . .
Inlet
Inlet
Inlet
Land
Cavity
IJK
604051
124051
183151
141451
304351
Total 715,836 nodes
CFD Results Axisymmetric Seal. In addition to calculating simply forces with CFD, the entire flow field within the labyrinth seal may be viewed to give insight into the nature of the
flow. This section describes the flow field from the axisymmetric
seal model 3 nodes in circumferential direction, 1 pie slice.
Figure 6 shows the predicted velocity vectors inside one labyrinth
seal cavity. Notice the high through-flow jet, which diverges and
creates a stagnation point on the next tooth. The jet drives a large
vortex inside the cavity. Figure 7 shows the predicted pressure
breakdown across the seal. Most all of the pressure drop occurs
across the teeth. Initially, the seal clearance provided by Pelletti
Calculated
s Entering
Seal
Calc.
delta-P
Exper.
delta-P
0.35
0.00
0.35
0.11
0.20
0.24
610,500
611,200
600,900
640,000
621,000
Calculated
s Entering
Seal
Calc.
delta-P
Exper.
delta-P
0.00
0.35
0.12
0.22
993,600
833,700
1,097,000
1,088,000
rinth seal. Notice the spiraling nature of the flow. Figure 10 plots
the static pressure around the circumference variation about mean
pressure for the non-whirling case (WFR0). The plot starts at
the minimum clearance and travels around in the direction of rotation. The phase shift creates the tangential force Kxy and opposes whirl in this case negative Kxy.
Using the mesh independent grid and the inlet boundary conditions obtained from the axisymmetric calculations, the impedence forces were obtained for the two different inlet swirl values,
as plotted in Fig. 11 along with the experimental curves. This
model only contains the seal geometry and not the up or downstream regions. The predictions show the same trend as the ex-
periment where increasing swirl increases the tangential impedance. The cross-coupled stiffness (y-intercept is being
underpredicted as is the damping slope. Both prediction and
experiment show a linear impedance curve.
Figure 12 shows a similar plot but for a pressure ratio of 0.65
( s 0). The predictions show good agreement for cross-coupled
stiffness, but under-predicts the damping slightly.
In an effort to improve the predictions, the upstream region is
included as part of the seal model Up-Seal. Figure 13 shows an
improvement for the zero swirl, Pr0.403 case. Also plotted are
results using the bulk-flow code of Kirk 3 as well as the code of
Childs and Scharrer 2. Adding the upstream to the model improves the cross-coupled stiffness prediction. The Kirk code
shows reasonable agreement, but not as good as the CFD. The
Scharrer code shows the greatest deviation. It should be noted that
the same inlet boundary conditions are used in the bulk-flow cases
as in the CFD model. Table 4 summarizes these coefficients.
The addition of the upstream region Up-Seal improves the
Kxy prediction and the Kxx somewhat. Adding the downstream
block changes the Kxy only slightly but dramatically improves the
direct stiffness calculation. Both bulk-flow codes greatly underpredict in negative direction the direct stiffness though they provide slightly better damping prediction. Overall, the Up-SealDown CFD model provides the best results.
The effect of seal clearance is shown in Fig. 14. The Seal 1
clearance 0.118 mm shown previously was increased by 82% for
Seal 3 as reported by Pelletti resulting in a clearance of 0.216 mm
8.5 mils. These values were all corrected for centrifugal growth.
The experiment shows a reduction in cross-coupled stiffness and
damping as a result of the larger clearance. CFD shows a similar
trend of lower Kxy and Cxx, but the reduction in the experimental
data is more pronounced. Some of the difference may lie in the
uncertainty of the actual seal clearance tested.
Kxx
Kxy
Cxx
138,000
93,600
18,200
510,300
592,200
28,340
158,000
67,000
76,300
280,000
120,000
33,150
147
69
87
205
134
493
Mass flow
Inlet Temp.
Centrifugal Growth
s
Fluid
Shaft Radius
Radial Clearance
Pitch
Tooth Width
2.250
0.007
0.110
0.011
57.15 mm
0.178 mm
2.79 mm
0.279 mm
CFD is not only useful for prediction but is also a powerful tool
for design and troubleshooting. Using CFD a problem was discovered with the inlet guide vane arrangement in the experimental
test rig. The swirl generated all but vanished before reaching the
seal entrance. This result helps to explain the rather poor correlation to this data in the past.
Conclusion
This work benchmarked a CFD code used to model gas labyrinth seals. The CFD predictions show good correlation to experimental data for both rotordynamic force coefficients and leakage,
an improvement over bulk flow predictions. The addition of the up
and down stream regions in the CFD model further improves the
predictions, though in doing so increases the computational time
of the model somewhat. Leakage comparisons to in-house measurements show good agreement for both rotating and nonrotating cases.
s
K
t
eff
References
Fig. 18 Static pressure tap meas. vs. prediction for 18 tooth
DR Laby, 15 krpm
The drawback of CFD is computational time. The mesh independent grid for the 3D case contains over 700,000 nodes and
requires approximately 20 hours for one whirl frequency ratio
minimum of two required. Therefore, at the present time, CFD is
reserved for designing new seals and when the utmost in accuracy
is required. If only leakage is required ie. axisymmetric, the
model size is much smaller and solutions may be had in as little as
30 minutes. Solvers using advanced techniques such as multi-grid
reduces the computational time but with some memory penalty.
Bulk-flow continues to be used for day-to-day lateral rotordynamic stability analysis in industry. As computational power increases in the next few years, use of CFD techniques will become
a standard part of the design process for modeling gas forces in
turbomachinery.
Acknowledgments
The author would like to thank Dr. Lee Hill of Dresser-Rand
Co. for his assistance in the project. Thanks also goes to DresserRand Co. for funding this work.
Nomenclature
ij
E
Fn , Ft
Fn , Ft
K, C
k, c
k
N
P
PFR
Pr
Sij
u
ui
Ui
U
y