Rotordynamic Performance Research Articles

Stability analysis of electrorheological (ER) lubricant operated multilobe hydrodynamic journal bearing

PurposeAn electrorheological (ER) fluid consists of dielectric particles blended in a nonconducting oil. ER lubricants are often considered smart lubricants. This paper aims to examine the steady state and dynamic response of multilobe journal bearings using an ER lubricant.Design/methodology/approachReynold’s equation has been used to describe the lubricant flow in the journal-bearing clearance space. The Bingham model is used to characterize the nonlinear behavior of the lubricant. The solution of the Reynolds equation is obtained using the Newton–Raphson method, with gaseous cavitation in the fluid film numerically addressed by applying a mass-conserving algorithm. The effects of lobe geometry and the applied electric field are investigated on film pressure profile, fluid film thickness, direct stiffness and damping parameters. The equation of motion for journal center coordinates is solved using the fourth-order Runge–Kutta method, to predict journal center motion trajectories.FindingsUsing ER lubricant combined with two-lobe journal bearing significantly improved the minimum film thickness by 49.75%, the direct stiffness parameter by 132.18% and the damping parameter by 206.3%. However, the multilobe configuration was found to negatively impact the frictional powerloss of the bearing system. In the case of multilobe configurations of journal bearings using ER lubricant, linear motion journal trajectories are observed to be reduced and exhibit increased stability.Originality/valueThis study presents the effect of an ER lubricant and multilobe configuration on the rotor-dynamic performance and stability analysis of hydrodynamic journal bearings.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2024-0201/

A comparative study on rotordynamics characteristics of hole-pattern damping seals with different cavity shapes

PurposeThe purpose of this paper is to improve the seal performance by proper design of the cavity shape of the damping holes, especially the rotordynamics characteristics of the hole-pattern damped seal (HPDS).Design/methodology/approachA new damping seal structure that comprises a circle-shaped cavity and two directional leaf-shaped cavities with a dovetail-shaped diversion groove is proposed. The comparative study on the sealing characteristics of dovetail-shape, leaf-shape and classical circular HPDSs was carried out using ANSYS CFX.FindingsThe dovetail-shaped HPDS significantly outperformed two other damping seal designs in leakage and rotordynamic performance. At a rotating speed of 7,500 rpm, it showed a 25% reduction in leakage, a 23% increase in average effective damping and a 119% increase in average effective stiffness. The cross-coupled stiffness Kxy shifted from positive to negative, reducing circumferential flow. The dovetail's inclined leaf-shaped grooves create a double vortex that slows jet velocity in the seal clearance and alters spiral flow direction, resulting in a uniform pressure distribution and enhanced rotor stability at low frequencies.Originality/valueThis study proposes a novel HPDS with dovetail-shaped diversion grooves. The seal can realize the simultaneous improvement of rotordynamics and leakage characteristics compared to the current seal structure.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-04-2024-0127/

Nonlinear modeling and vibration response analysis of rod fastening rotor-bearing system with curvic coupling

Rod fastening combined rotor system (RFCR) are particularly popular in gas turbine rotor systems. The bolted connection introduces a discontinuity in this RFCR, which has a substantial influence on system performance.Traditional models of RFCR tend to neglect the influence of the connection structure, especially failing to fully consider the contribution of the curvic coupling to the rotor dynamics. To address this problem, this study proposes a new nonlinear analytical model of the rotor system, which focuses on the impact of the curvic coupling. This study provides a detailed analysis of the structural parameters and load forces of the curvic coupling. Based on this analysis, a mechanical model is created to assess how bolt preload and torque impact the stiffness of the curvic connection. The stiffness matrix of the curvic coupling is derived by the gear stiffness analysis method, and the accuracy of the model is confirmed using the finite element method. Furthermore, the model also considers the viscous and sliding state between the curvic coupling, which effectively describes the damping effect of the curvic coupling. On this basis, the motion control equations for the RFCR are formed, and a dynamic model considering the curvic connection in the RFCR system is introduced. The results show that the curvic coupling results in a decrease in stiffness and the occurrence of nonlinear damping phenomena in the RFCR.The RFCR exhibits a significant stiffness loss compared to the continuous rotor system, resulting in a decrease in the critical rotor speed. The nonlinear damping is mainly excited at high friction coefficient conditions and may lead to a self-excited vibration component in the rotor response at supercritical speeds. The negative impact of structural discontinuities on rotor dynamic performance can be reduced by increasing the bolt preload, decreasing the friction coefficient, and adjusting the amount of imbalance. This study offers a theoretical foundation for predicting curvic coupling-induced instability and serves as a reference for enhancing rotor system stability.

Dynamic Performance of Liquid Smooth Annular Seal Operating in the Transition Regime

Abstract This paper presents the experimental leakage and rotordynamic performance for a liquid smooth annular seal operating in the transition regime. The test conditions include pressure differentials up to 64 bars with 1∼2 bar increments for 6 rotor speeds (2.5, 3.8, 5, 7.5, 8.8, and 10 krpm), as well as nonrotating rotor case under zero preswirl condition. The rotordynamic coefficients for all the test conditions are obtained by pseudo-random excitation of the seal at multiple subsynchronous frequencies. By considering the transition Reynolds number (1000 < Re < 3000) and the Taylor Number (Ta) versus Axial Reynolds Number (Rez), the variations in the direct stiffness coefficients (K) can used as an indicator of the flow regime transition boundaries. The direct stiffness K resulting from the Lomakin and hydrodynamic effects significantly drops until Rez reaches ∼1500. For higher Rez, K increases mainly due to hydrodynamic effects. When K drops, the cross-coupled stiffness k, the direct damping C and the cross-coupled virtual mass m increase while the cross-coupled damping c and virtual mass M decrease. None of predictions based on either laminar or turbulent flow show the variations in rotordynamic coefficients obtained from experimental results. The leakage is not highly influenced by rotor speeds for low speed cases crossing laminar boundary as ΔP increases, however, results for higher speeds in the superlaminar region show reduced leakage rates as rotor speed increases.

Aerothermodynamic and rotordynamic performance evaluation to diagnose deposits accumulation in a gas lift centrifugal compressor

The paper presents a case study focusing on the assessment of the aerothermodynamic and rotordynamic performance to diagnose deposit accumulation on the internals of a centrifugal compressor. The case involves a four-stage gas lift centrifugal compressor powered by a 5.9 MW induction motor and utilizing a fluid coupling to regulate the compressor's rotational speed. The Huntington 4-point method was employed to evaluate the polytropic head and efficiency of the four compressor sections over a 20-month period, with pressure and temperature data sampled every 6 hours. The efficiency model was supported by the GERG-2008 equation of state, used to calculate the necessary thermodynamic properties at intermediate and endpoint states. The aerothermodynamic analysis identified a deterioration in polytropic efficiency in compressor section 3, accompanied by a pressure drop and an increase in discharge temperature. Simultaneously, the rotordynamic response was examined through various vibration plots. Although the increase in the vibration amplitudes was not significant, a notable phase shift was observed. This decline in polytropic efficiency and change in vibration patterns were attributed to severe fouling, which was confirmed during the overhaul of the HP compressor. Root cause investigations revealed the deposit as reactive, leading to the installation of an online washing system. Over a nine-month observation period post-maintenance, the compressor operation was stable with no degradation in its polytropic efficiency.

Leakage flow-induced excitation behavior and rotor instability in the high-speed supercritical CO2 scallop damper seals

As an innovative type of damper seal, the scallop damper seal (SDS) has shown greatly improved sealing performance for the high-compactness supercritical CO2 (S-CO2) turbomachinery, but leakage-induced excitation forces have an impact on the rotor stability. In this research, we improve the rotordynamic solution based on the multi-frequency elliptic whirling model for the S-CO2 seals and investigate the leakage-induced excitation behavior of SDS depending on seal geometry and operating condition. By comparing the results of a labyrinth seal and a full-partition pocket damper seal, we prove that SDS has better rotordynamic performance for the S-CO2 compressor. The results show that increasing the pressure drop favors greater direct stiffness and effective damping of the SDS. Inlet preswirl changes the direction of fluid-response force to coincide with the rotor motion, which is detrimental to rotor stability. Changing the cavity depth has no significant effect on the dynamic characteristics of the SDS, but shortening the cavity length reduces the direct stiffness to below zero. Supplementing the number of circumferential cavities increases the direct stiffness and effective damping but results in SDS not being able to be machined directly by milling cutters. The design with 12 circumferential cavities is recommended for the 100-kW-class S-CO2 compressor.

Single-structured zero-bias hybrid gas-magnetic bearing and its rotordynamic performance

A single-structured hybrid gas-magnetic bearing (HGMB) has been proposed for frequent start/stop occasions, which eliminates foil structures or static pressure systems by using the closed magnetic poles of the active magnetic bearing (AMB) as the bushing of the gas bearing. This allows the proposed bearing to realize the functions of both AMB and gas bearing with a single bearing structure. In this paper, the bias currents of AMB, aimed for enhanced load capacity and dynamic characteristics, are omitted to reduce power consumption and heat. The combination of zero-bias AMB and rigid self-acting gas bearing in a single bearing structure is therefore proposed. The rotor orbits of gas bearing, AMB, single-structured HGMB, and single-structured zero-bias HGMB in conditions of varied horizontal and vertical external loads are simulated. The dynamic performances during the run-up processes of AMB, HGMB, and zero-bias HGMB are investigated. The electromagnetic forces of each kind of bearing are compared. Numerical results demonstrate that by applying the single-structured zero-bias HGMB, the power consumption can be significantly reduced in contrast with pure AMB and single-structured HGMB. The reduced load capacity and dynamic characteristics of zero-bias AMB can be compensated by the rigid self-acting gas bearing, making the single-structured zero-bias HGMB an ideal candidate for cryogenic, ultra-high speed as well as frequent start/stop occasions.

Transient investigations of teeth on rotor and teeth on stator modified labyrinth seals

Teeth-on-rotor (TOR) and teeth-on-stator (TOS) layouts are compared in this paper to explore better arrangement for different labyrinth seals. The diaphragm labyrinth seal (DLS) and hole diaphragm labyrinth seal (HDLS) are both redesigned into TOR and TOS layouts. To accurately predict the rotordynamics and leakage performance of different seals, a one-motion transient computational fluid dynamics (CFD) method based on the simplified multi-frequency transient method is proposed. A comparison of the experimental results, two-motion transient CFD method and proposed method showcase the better accuracy of the current method in rotordynamic performance prediction. The results shows the better rotordynamic characteristics of the TOS layout for different layouts and of the HDLS type seals for three labyrinth type seals. Even though, the TOR layout cannot increase the stability of the rotor system, a clear circumferential velocity reduction in the DLS and HDLS seals can be observed in both the TOS and TOR layouts. However, the changes in leakage performance for DLS and HDLS seals are different from those for traditional LSs. Unlike TOR-LS and TOR-HDLS, which exhibit relatively large increases in leakage compared with the TOS layout, TOR-DLS achieves a maximum 1.7% leakage reduction at a 15000 rpm rotation speed. A decrease in the jet flow length and increase in the turbulence kinetic energy in TOR-DLS compared with those in TOS-DLS further explain this abnormal phenomenon.

Enhanced rotordynamic performance under various structural arrangements of hole diaphragm labyrinth seal

In this study, we study the influence of five drilling hole arrangements on the rotordynamic and leakage performance of hole diaphragm labyrinth seal (HDLS) type seals with precise CFD analysis. Key findings reveal that hole distance significantly affects direct and cross-coupled stiffness, thereby impacting stability and leakage. Notably, the smallest hole in rectangle four holes(RF)-HDLS does not yield the minimum leakage. Vortex structure analysis, employing the Q-criterion, elucidate horizontal two holes(HT)-HDLS's superior leakage reduction owing to enhanced turbulence eddy dissipation. Seals with larger hole diameters, down single hole(DS)-HDLS and up single hole(US)-HDLS, demonstrate stable rotordynamic performance, with DS-HDLS exhibiting a notable 106.3% improvement in cross-coupled stiffness. In contrast, seals with holes positioned farther away, DS-HDLS, US-HDLS and vertical two holes(VT)-HDLS, experienced increased leakage with whirl frequency. HT-HDLS and RF-HDLS displayed a decrease, attributed to the stronger centrifugal effect. Comparing to center single hole(CS)-HDLS, VT-HDLS and US-HDLS achieved a significant 159.3% direct stiffness improvement and 432.7% reduction in cross-coupled stiffness. Despite a maximum 4.2% leakage increase, this substantial enhancement in rotor stability should not be overlooked. Moreover, all seals exhibited lower leakage rates than the traditional labyrinth seal.

Clearance compatibility and design principle of the single-structured hybrid gas-magnetic bearing

PurposeThis paper aims to study the clearance compatibility of active magnetic bearing (AMB) and gas bearing (GB) to achieve a single-structured hybrid gas-magnetic bearing (HGMB), which uses a single bearing structure to realize both the functions of gas bearing and magnetic bearing.Design/methodology/approachBecause the radial clearance size of the AMB is typically ten times larger than that of the GB, radial clearance compatibility of GB and AMB needs to maximize the radial clearance of GB by adjusting structural parameters. Parametric analysis of structural parameters of GB is explored. Furthermore, a general structural design principle based on static analysis, rotordynamic performance and system stability is established for the single-structured HGMB.FindingsLoad capacity is vastly reduced due to the enlarged radial clearance of the GB. A minimum clearance needs to be ensured by increasing the bearing diameter or width to compensate for the reduced load capacity, yet indirectly raising the bearing load. Increased bearing load is conducive to stability, yet it raises the risk of rotor abrasion. In addition, excessively large bearing diameter leads to system instability, and inappropriate bearing width affects critical speeds. A general structural design principle is established and the designed HGMB–rotor processes optimal performances.Originality/valueA single-structured HGMB is proposed to address the urgent demand for high-speed, cryogenic turboexpanders with frequent starts/stops. This design applies a single-bearing structure to realize the characteristics of both GB and AMB, greatly simplifying the implementation, reducing air friction loss and raising critical speeds. This paper provides a fresh perspective on the development of cryogenic turboexpanders for hydrogen liquefaction. It theoretically validates the feasibility and provides a design guide for a single-structured HGMB system.

Comparative Evaluation of High-Speed Bearingless Cross-Flow Fan Designs for Lithography Excimer Lasers

This study conducted a comparative evaluation of two bearingless cross-flow fan designs for applications in deep ultraviolet lithography excimer lasers, where maximizing the speed and power of the fan has a direct influence on the throughput and scanning speed of these devices. Using bearingless motor technology enables a combined generation of bearing force and drive torque and leads to a compact, hermetically sealed, and conveniently maintainable drive system. With identical bearingless motors on both rotor sides, it is possible to drive the cross-flow fan symmetrically to high rotational speeds at low torsional loads. The rotor prototypes were optimised, analysed, and pushed to high-speed operation and evaluated with respect to their rotor dynamic and fluid dynamic performance using finite element methods and experimental measurements. For both prototypes, successful numerical studies were performed, where a modal analysis enabled theoretical predictions of expected resonance frequencies, and a CFD analysis visualised local flow effects and provided cross-flow fan design comparisons. A stable operation of up to 12,000 rpm and 5500 rpm was accomplished for the two elaborated designs.

Experimental and theoretical analysis on the nonlinear rotor-dynamic performances and vibration characteristics of a novel bearing-rotor system

The abnormal vibration of the rotating shaft in propulsion system during the startup stage seriously reduces the concealment and safety of the ship navigation. This paper clarifies the rotor-dynamic and vibration performances of a new bearings-rotor coupled system. The rotor-dynamic model and the bearing-rotor coupled dynamic model under different lubrication states are established. The influences of rotating speed, external load, length-diameter ratio and other parameters on the lubrication performances and supporting behaviors of the bearings are analyzed. The variation laws of shaft vibration response under various working modules are revealed. Results of the test and theoretical have good consistency. Results enrich the theoretical system on the analysis and optimum design for such rotating systems.

Sensorless Control of SPMSM Based on High-Frequency Positive- and Negative-Sequence Current Dual-Demodulation

In surface-mounted permanent magnet synchronous motor (SPMSM) low-speed sensorless control, the high-frequency sinusoidal voltage injection method for rotor position estimation is affected by the low saturation salient rate of SPMSM and the system delay, resulting in estimation error. This paper proposes a dual-demodulation method utilizing the high-frequency positive- and negative-sequence stator current of the motor. This method is based on the principle of maximizing the effect of the salient inductance component and minimizing the significant component of noise, which improves the utilization of the current containing angle information and increases the signal-to-noise ratio of the position angle error fed to the rotor position observer. The DC bias of the current caused by system delay is also eliminated so that the accuracy of position estimation is improved. The proposed method is verified by experiment, and the results show that the accuracy of the estimated rotor position and dynamic performance of the estimator are greatly improved compared to existing methods.

Experimental analysis of hybrid VAWT and the effect of semi-cylindrical attachment to the trailing edge

Vertical axis wind turbines (VAWTs) work efficiently in low wind speed regions and varying wind directions like urban environments due to their omnidirectional capability. The current study examines experimentally the performance of the H-Darrieus VAWT having NACA 0018 airfoil by use of semi-cylindrical attachments at the trailing edge and hybridization using two bladed S-Savonius rotor with zero overlap conditions. The rotor's static torque and dynamic performances are investigated at a low wind speed of 4 m/s. The results show that the semi-cylindrical attachment increases the range of positive static torque. The static torque of Darrieus with attachment at 90° inside is more consistent, which enhances the starting capability of the Darrieus turbine with a static torque coefficient of 0.031, which is 29.7 % higher than a simple Darrieus turbine. The hybrid configuration shows maximum dynamic torque only at the 90° azimuthal position. The power coefficient of all configurations with attachments is lower than simple Darrieus due to drag created by attachments. The power coefficient value of 0.03 for hybrid configuration is the highest, with a wide range of tip speed ratio (TSR).

Experimental Force Coefficients for a Fully-Partitioned Pocket Damper Seal and Comparison to Other Two Seal Types

Abstract Labyrinth seals (LSs), honeycomb seals (HCSs) and hole-pattern seals, pocket damper seals (PDSs), and fully-partitioned damper seals (FPDSs) serve as balance pistons on the discharge side of barrel-type centrifugal compressors. These seals, facing large pressure differentials along with significant changes in gas density, produce sizeable lateral forces that impact compressor stability and rotordynamic performance. There is extensive archival data on the dynamic forced performance of LS and textured surface seals. However, the experimental database for a FPDS is insufficient, thus a comprehensive comparison of their dynamic force performance against that of textured surface seals is missing. The paper presents experimentally derived rotordynamic force coefficients for a FPDS along with a direct comparison to published data for a HCS and a LS, both similar in size and in operating conditions. The dynamic load tests with the FPDS include operation at a shaft speed (Ω) of 10 krpm (rotor surface speed of 60 m/s) while supplied with air at Pin = 70 bar and Tin =10 °C, and a discharge at Pout = 0.25, 0.5, and 0.65 of Pin. The preswirl circumferential velocity at the seal inlet is low, approximately 6% of rotor surface speed. The FPDS having eight pockets × eight axial blades produces a direct stiffness (K) increasing with excitation frequency (ω), though K < 0 for the lowest pressure ratio PR = (Pout/Pin) = 0.25. The cross-coupled stiffness (k) is invariant to frequency whereas the direct damping (C) steadily decreases as ω/Ω → 1, and then increases for larger frequencies. Hence, the effective damping coefficient (Ceff = C − k/ω) is approximately constant for ω < Ω, while increasing for higher frequencies. For the three PRs, the FPDS leakage is roughly up to 26% larger than the HCS leakage, while the 20-blade LS leaks in between both. The comparison of results shows the LS has insignificant forces compared to those from the HCS and FPDS, both producing a comparable Ceff and similar crossover frequencies (Ceff > 0). The HCS produces a large direct stiffness (K), three to four times that of the FPDS. Comparison of computational fluid dynamics (CFD) predictions for the FPDS against the experimental force coefficients shows significant differences, in particular an overestimation of direct stiffness as the frequency grows along with a lower direct damping for frequencies equal and above the shaft speed. Besides manufacturing considerations, a FPDS is a better alternative to a HCS whose large centering stiffness (K) may affect the compressor's critical speed, hence shortening the separation margin with respect to the operating speed.

Static and Rotordynamic Characteristics for Supercritical Carbon Dioxide Spiral Groove Dry Gas Seal With the Tilted Seal Ring

Abstract Supercritical carbon dioxide (SCO2) Brayton cycle has been widely used as a substitute for traditional steam cycles. As one of the key components of power-dense turbomachines, dry gas seal (DGS) has been considered one of the most suitable dynamic seal options due to its superior sealing performance. In this paper, considering the installation errors and external disturbances of the shaft end seal in a 14 MW supercritical carbon dioxide turbine, a comprehensive numerical study was conducted on the seal static and rotordynamic characteristics for four dry gas seal designs with different coning displacements. To account for the real gas effect of SCO2, a table lookup program was used to obtain the physics properties of CO2 under supercritical conditions based on the database of the National Institute of Standards and Technology (NIST). A frequency-dependent rotordynamic coefficients stiffness damping model (KC model) for SCO2 DGS and the mesh deformation technique were adapted to analyze the rotordynamic performance of the designed DGS. Steady-state numerical results of leakage rate, opening force, and steady film stiffness were analyzed and compared under four coning displacements. Transient numerical results of rotordynamic force coefficients were analyzed and studied under four coning displacement ratios and 10 vibration frequencies. Results show that the increase in coning displacement causes a 20% rise in leakage rate and a 2.4% increase in opening force. The tilted seal ring results in a maximum 30%–84% variation of the dynamic stiffness and greatly influences the damping coefficient. From a comprehensive view, the tilt of the seal rings brings undesired influences on both the static and rotor dynamic performance of SCO2 DGS. The distortion of the seal rings due to installation errors and other disturbances should be avoided as far as possible in SCO2 DGSs.

On the rotordynamic performance of an annular gas seal with self-adaptive jet slots: Comparisons to the swirl brake and shunt injection

The positive circumferential flow is the main cause of seal instability in turbomachines. This paper proposed an annular gas seal with self-adaptive jet slots (SJS). The anti-swirl jet driven by the pressure difference between the seal domains is utilized to control the circumferential flow. The circumferential flow development and rotordynamic coefficients of the SJS are numerically calculated and compared with those of the labyrinth seal with typical anti-swirl methods (swirl brake and shunt injection). Results show that the SJS has the best anti-swirl effect on circumferential flow among the studied seals, thus showing the best stability. The leakage performance of the SJS is also improved due to the fluidic barrier induced by the anti-swirl jet.

A comparative performance assessment of hydrostatic thrust bearings operating with electrorheological lubricant

PurposeAn electrorheological (ER) fluid comprises dielectric particles suspended in an insulating viscous medium. ER lubricants are considered smart lubricants. They have been applied in hydraulic valves, power transmission devices and damping systems. The purpose of this study is to investigate the performance of hydrostatic thrust bearing operating with ER lubricant.Design/methodology/approachReynold’s equation was used to model the flow of the ER lubricant in the bearing. The continuous Bingham model was used to express the viscosity of the ER lubricant as a function of yielding stress, applied electric field and shear strain rate. The Reynolds equation is solved using the finite element method (weighted residual approach) to compute the film pressure as a primary variable and the lubricant flow rate, load-carrying capacity, stiffness and damping parameters as associated performance indices.FindingsThe effects of the pocket shape, compensating elements and ER lubricant on the bearing performance were investigated. The application of ER lubricant significantly enhanced the load-carrying capacity (48.2%), stiffness (49.8%) and damping (4.95%) of the bearings. Circular and triangular pocket bearings with constant-flow valves have been reported to provide better steady-state and rotor-dynamic performances, respectively.Originality/valueThis study presents the effect of an ER lubricant on the rotor-dynamic performance of hydrostatic thrust bearings with different pocket shapes.

Effect of hole arrangement patterns on the leakage and rotordynamic characteristics of the honeycomb seal

The honeycomb seal is a vital component to reduce the leakage flow and improve the system stability for the turbomachines. In this work, a three-dimensional model is established for the interlaced hole honeycomb seal (IHHCS) and the non-interlaced hole honeycomb seal (NIHHCS) to investigate its leakage and rotordynamic characteristics by adopting computational fluid dynamics (CFD). Results show that the hole arrangement patterns have little impact on the pressure drop and turbulence kinetic energy distribution for the seals, and the IHHCS possesses a slightly lower leakage flow rate than the NIHHCS. Moreover, the numerical results also show that the NIHHCS possesses a better rotordynamic performance than the IHHCS at all investigated conditions. Both seals show a larger k and a lower Ceff with the increase of the positive preswirl ratios and rotational speeds, while the negative preswirl ratios would reduce the k and improve the Ceff. The NIHHCS possesses a higher absolute value of Ft for all operating conditions, this could explain the distinction of Ceff for both seals at different working conditions.

Static and Rotordynamic Characteristics for Two Types of Novel Hole-Pattern Seals Operating in Supercritical CO2 Turbomachinery

Abstract In this paper, two novel hole-pattern seals were assessed for applications at the balance piston in a 14 MW supercritical CO2 turbine, focusing on the improvement of the seal leakage and rotordynamic performances. These two novel hole-pattern seals were derived from the conventional straight-through hole-pattern seal (HPS) with the same sealing clearance, diameter, axial length, hole diameter and depth, including a stepped hole-pattern damper seal (SHPS) and a grooved hole-pattern damper seal (GHPS). To enhance the seal net damping capability at high inlet preswirl condition, a straight swirl brake also was designed and employed at seal entrance for each type seal. A comprehensive assessment and comparison was conducted on the conventional HPS and the present two novel hole-pattern seals (SHPS and GHPS) with a static concentric rotor. The leakage flow rates, rotordynamic force coefficients, cavity pressure, and swirl velocity developments were analyzed for three hole-pattern seal designs with/without swirl brakes at two inlet preswirl ratios (0.1, 0.5), using a transient computational fluid dynamics (CFD)-based perturbation method based on the multiple-frequency elliptical-orbit rotor whirling model and the mesh deformation technique. To take into account of real gas effect with high accuracy, a table look-up procedure based on the National Institute of Standards and Technology (NIST) database was implemented, using an in-house code, for the fluid properties of CO2 in both supercritical and subcritical conditions. Results show that the present two novel hole-pattern seals have better sealing capability, especially for the GHPS seal which leaks less by a factor of 44%. In general, the GHPS seal possesses the lowest positive effective stiffness, highest effective damping, and the lowest crossover frequency of 60–70 Hz, especially at high inlet preswirl case. From a viewpoint of the rotor stability and unbalance sensitivity analysis, the GHPS seal without entrance swirl brake is a better seal design scheme for the balance piston seal in sCO2 turbine.