This thesis documents the results of high pressure testing of hole-pattern annular gas seals conducted at the Texas A&M University's Turbomachinery Laboratory. The testing conditions were aimed at determining the test seals sensitivity to pressure ratio, inlet fluid preswirl, rotor speed, and rotor to seal clearance. The rotordynamic coefficients showed only small changes resulting from the different pressure ratios tested. Only the damping terms at the lower frequencies showed some influence. One other notable result from the testing of different pressure ratios is that the seals were tested in a choked flow condition, and there was not a significant change in the seal behavior when the seals transitioned to the choked condition. The inlet fluid preswirl only had a notable effect on the cross-coupled stiffness in the larger clearance tests. These results lead to the conclusion that a swirl brake could have some rotordynamic value, but only if the seals have sufficiently large clearance. Conversely this also means that if hole-pattern seals are being implemented with a small clearance, then a swirl brake would not be an effective way to improve the rotordynamic stability of the system. The only significant effect that the rotor speeds had on the rotordynamic coefficients were that the cross-coupled coefficients increased as the rotor speed increased. This is the expected result because as the rotor speed increases there is a greater shear force on the gas as it passes through the seal resulting in more fluid circumferential velocity, which results in stronger cross-coupled coefficients. The changes in clearance resulted in drastic changes in the magnitude of the coefficients. The smaller clearance yielded much higher coefficients than the larger clearance. All of the rotordynamic coefficients were predicted well by ISOTSEAL. The code was found to do a good job predicting the seal leakage as well. This gives more credence to the coefficients and leakage that ISOTSEAL predicts.

This thesis documents the results of high pressure testing of hole-pattern annular gas seals conducted at the Texas A&M University's Turbomachinery Laboratory. The testing conditions were aimed at determining the test seals sensitivity to pressure ratio, inlet fluid preswirl, rotor speed, and rotor to seal clearance. The rotordynamic coefficients showed only small changes resulting from the different pressure ratios tested. Only the damping terms at the lower frequencies showed some influence. One other notable result from the testing of different pressure ratios is that the seals were tested in a choked flow condition, and there was not a significant change in the seal behavior when the seals transitioned to the choked condition. The inlet fluid preswirl only had a notable effect on the cross-coupled stiffness in the larger clearance tests. These results lead to the conclusion that a swirl brake could have some rotordynamic value, but only if the seals have sufficiently large clearance. Conversely this also means that if hole-pattern seals are being implemented with a small clearance, then a swirl brake would not be an effective way to improve the rotordynamic stability of the system. The only significant effect that the rotor speeds had on the rotordynamic coefficients were that the cross-coupled coefficients increased as the rotor speed increased. This is the expected result because as the rotor speed increases there is a greater shear force on the gas as it passes through the seal resulting in more fluid circumferential velocity, which results in stronger cross-coupled coefficients. The changes in clearance resulted in drastic changes in the magnitude of the coefficients. The smaller clearance yielded much higher coefficients than the larger clearance. All of the rotordynamic coefficients were predicted well by ISOTSEAL. The code was found to do a good job predicting the seal leakage as well. This gives more credence to the coefficients and leakage that ISOTSEAL predicts.

To reduce manufacturing cost and time, a hole-pattern seal incorporating holes of larger diameter (12.19 mm (0.48 inches)) has been proposed. Experimental leakage and rotordynamic coefficients for this new seal design are presented. This experimental data was compared to theoretical results generated by ISOTSEAL a program developed by Kleynhans and Childs. Finally, the performance of this new hole-pattern seal was compared to a hole-pattern seal tested by Wade. The experiments are configured to investigate the influence of changes in pressure ratio, preswirl, rotor speed, and clearances on seal characteristics. Due to stator stability issues, the peak inlet pressures had to be varied to allow for testing. Consequently, to study the effect of inlet preswirl and clearance, data were non-dimensionalized or normalized. Cross-coupled coefficients were relatively frequency-independent while direct coefficients were functions of excitation frequency. For all test cases, the seal developed negative direct stiffness at low frequencies. Tests showed that pressure ratio had minimal effect on rotordynamic coefficients. Non-dimensional cross-coupled stiffness increased with increasing preswirl causing the seal to become less stable with increasing preswirl. Cross coupled stiffness increased with increasing running speed. Two clearances: 0.1 mm (4 mils) and 0.2 mm (8 mils) were tested. The results demonstrated that non-dimensionalized stiffness is greater for the smaller clearance. The larger clearance develops larger normalized direct damping values, and has enhanced stability. Rotordynamic predictions are poor for cross-coupled coefficients. Generally, ISOTSEAL over-predicts direct stiffness and under-predicts direct damping. Negative stiffness was not predicted by ISOTSEAL. Predictions do improve for the smaller clearance. ISOTSEAL does a good job of predicting non-dimensional leakage. Non-dimensionalized direct and effective stiffness were greater for the "old" hole-pattern seal tested by Wade. However, the "new" seal generally developed greater normalized direct damping and exhibited a lower cross-over frequency. Non-dimensionalized leakage was greater for the seal tested here. Production of this new seal proved to be more difficult than originally thought. The price of the new seal cost approximately the same as an original hole-pattern seal.

The determination of the leakage and consequently the friction factor is an important part of analyzing the flow through a seal. This is done experimentally by means of a flat plate tester, which allows for the simplified representation of the seal pattern on a flat plate surface tested under a range of clearances and pressure drops. The setup mounts a smooth plate opposite a second plate which may be smooth or have a roughened surface while the separation between plates is held constant. The present study analyzes the phenomenon of friction factor 'upset' ? wherein it was seen that as the pressure drop across the parallel plates is increased, there is a sudden increase in the friction factor (i.e. a decrease in flow rate) at a certain Reynolds number and for any further increase in the pressure differential, the friction factor shows the expected trend and decreases slowly. This phenomenon was initially believed to be an anomaly in the rig and was attributed to choking at an upstream flow control valve. The present author differs from that view and hypothesized that the reason for the abrupt change is linked to the flow mechanics of the system and the current study analyzes the same. Preliminary analysis of available data has established that the cause for the 'upset' was not related to the switch from a normal mode resonance driven by the Helmholtz frequency of the cavities on the stator to a shear layer instability, as was seen earlier by Ha. The friction factor jump for this case is therefore proposed to be due to a change of the instability modes as the fluid passes over the cavities in the plate. A detailed analysis of the physics of the flow will be carried out via a numerical simulation using a Large Eddy Simulation (LES) model from ANSYS Fluent. Results will be validated through comparisons with experimental data from the flat plate test rig.

This thesis presents the results of high supply (up to 84 bar) pressure testing of hole-pattern annular gas seals performed at the Texas A & M Turbomachinery Laboratory in College Station, TX. The test variables were chosen to determine the influence of pressure ratio, rotor speed, and negative preswirl on seal performance. Preswirl signifies the circumferential fluid flow entering a seal, and negative preswirl indicates a fluid swirl in the direction opposite of rotor rotation. Changes in pressure ratio had only small effects on most rotordynamic coefficients. Cross-coupled stiffness showed slightly different profiles through the mid-range of excitation frequencies. Pressure ratio showed some influence on direct and cross-coupled damping at low excitation frequencies. Rotor speed significantly affected both cross-coupled stiffness and cross-coupled damping. As rotor speed increased, the magnitude of cross-coupled rotordynamic coefficients increased due to the positive fluid swirl induced by rotor rotation. For the low rotor speed, negative inlet preswirl was able to overpower the positive rotor induced fluid rotation, producing a negative cross-coupled stiffness. This outcome showed that, for hole-pattern seals, positive fluid swirl does indeed produce positive cross-coupled stiffness coefficients and negative fluid swirl produces negative cross-coupled stiffness coefficients. The addition of negative preswirl greatly reduced cross-coupled rotordynamic coefficients, while direct rotordynamic terms were unaffected. Cross-over frequency signifies the excitation frequency where effective damping transitions from a negative value to a positive value with increasing excitation frequency. Peak effective damping was increased by 50 percent and cross-over frequency reduced by 50 percent for high-negative preswirl versus zero preswirl results. This led to the conclusion that a reverse swirl could greatly enhance the stability of hole-pattern balance piston seals. A two-control-volume model that uses the ideal gas law at constant temperature (ISOT) was used to predict rotordynamic coefficients and leakage. This model predicted direct rotordynamic coefficients well, but greatly under predicted cross-coupled rotordynamic coefficients especially at high negative preswirls. The model predicted seal leakage well at low pressure ratios, but showed increasing error as the pressure ratio was increased. These results showed that the prediction model could not adequately estimate cross-coupled rotordynamic coefficients for a hole-pattern seal with negative inlet preswirl and requires modification to do so.

Annular gas seal clearances were simulated with closely spaced parallel plates using a Flat?Plate tester. The device is designed to measure the pressure gradient along the test specimen. The main function of the Flat?Plate tester is to provide friction factor data and measure dynamic pressure oscillations. A detailed description of the test facility is described, and a theory for determining the friction factor is reviewed. Three clearances were investigated: 0.635, 0.381, and 0.254 mm. Tests were conducted at three different inlet pressures (84, 70, and 55 bars), producing Reynolds numbers range from 50,000 to 700,000. Three surface configurations were tested including smooth?on-smooth, smooth?on?hole, and hole?on?hole. The Hole?pattern plates are identical with the exception of the hole depth. The results indicate that, for the smooth?on?smooth and smooth?on?hole configurations, the friction factor remains constant or increases slightly with increasing Reynolds numbers. Moreover, the friction factor increases as the clearance between the plates increases. However, the results from the hole?on-hole configurations are quite different. A "friction?factor jump" phenomenon was observed, and the Helmholtz frequency was detected on the frequency spectra.

No description available.

Rotordynamic instability problems in turbomachinery have become more important in recent years due to rotordynamic components with higher speeds and higher power densities. These features typically lead to increased instability risk in rotor dynamic components as fluids-structure interactions take place. In addition, critical damage of rotordynamic components can result from high level vibrations of supporting bearing system, where the reduced rotor speed can lead to system operating near the rotor critical speed. Therefore, increased accuracy in modeling of rotordynamic components is required to predict the potential instability issues in high performance rotordynamic design. The instability issue may potentially be eliminated in design stage by varying the characteristics of the unstable components. One such turbomachinery component is the annular pressure seal. The annular pressure seals are specifically designed to prevent the fluid leakage from high pressure stage to low pressure stage in turbomachinery. Typical annular pressure seals have two different flow regions, an annular jet-flow region between the rotor and stator, and cylindrical or circumferential indentions on the stator/rotor surface that serve as cavities where flow recirculation occurs. As the working fluid enters the cavities and recirculates, the kinetic energy is reduced, resulting in a reduction of leakage flow. The current challenge is to model with higher precision the interaction between the rotordynamic components and the working fluid. In this dissertation, this challenge was overcome by developing a hybrid Bulk Flow/CFD method to compute rotordynamic responses for the annular pressure seals. In addition, design of experiments studies were performed to relate the surface patterning with the resulting rotordynamic response for the annular pressure seals, in which several different geometry specifications were investigated. This study on annular pressure seal design generated regression models for rotordynamic coefficients that can be used as optimization guidelines. Research topics related to the annular pressure seals were presented in this dissertation as well. The reduced order model of both hole-pattern seals and labyrinth seals were investigated. The results showed that the flow field representing the flow dynamics in annular pressure seals can be expressed as a combination of first three proper orthogonal decomposition modes. In addition, supercritical state of carbon dioxide (sCO2) process fluid was examined as the working fluid in a preliminary study to better understand the effects on annular pressure seals. The results showed that the performance and stability in the annular pressure seals using sCO2 as process fluid can both be improved. / Doctor of Philosophy / This dissertation focused on understanding the correlations between surface patterning and rotordynamic responses in the annular pressure seals. The annular pressure seals are a specific type of rotordynamic component that was designed to prevent the fluid leakage from high pressure stage to low pressure stage in turbomachinery. As the working fluid enters the cavities and recirculates, the kinetic energy is reduced, resulting in a reduction of leakage flow through the annular pressure seals. Rotordynamic instability becomes an issue that may be related to the annular pressure seals in some cases. In recent years, rotordynamic components with higher rotor speeds and higher power densities are commonly used in industrial applications. These features could lead to increased instability risk in rotor-bearing systems as fluids-structure interactions take place. Therefore, high precision modeling of the rotodynamic components is required to predict the instability issues in high performance rotordynamic design. The instability issue may potentially be eliminated in design stage by varying the characteristics of the potentially unstable components. In this study, the surface patterning and rotordynamic responses were investigated for several different annular pressure seal models with a hybrid Bulk Flow/Computational Fluid Dynamics method. This dissertation provides for the first time regression models for rotordynamic coefficients that can be used as optimization guidelines. Research topics related to the annular pressure seals were presented in this dissertation as well. The reduced order model of both hole-pattern seals and labyrinth seals were investigated. The results showed that the flow field representing the flow dynamics in annular pressure seals can be expressed as a combination of first three proper orthogonal decomposition modes. In addition, supercritical state of carbon dioxide (sCO2) process fluid was examined to better understand the effects of working fluid on annular pressure seals. The results showed that the performance and stability in the annular pressure seals using sCO2 as process fluid can both be improved.

No description available.