abstract: Efficient performance of gas turbines depends, among several parameters, on the mainstream gas entry temperature. At the same time, transport of this high temperature gas into the rotor-stator cavities of turbine stages affects the durability of rotor disks. This transport is usually countered by installing seals on the rotor and stator disk rims and by pressurizing the cavities by injecting air (purge gas) bled from the compressor discharge. The configuration of the rim seals influences the magnitude of main gas ingestion as well as the interaction of the purge gas with the main gas. The latter has aerodynamic and hub endwall heat transfer implications in the main gas path. In the present work, experiments were performed on model single-stage and 1.5-stage axial-flow turbines. The turbines featured vanes, blades, and rim seals on both the rotor and stator disks. Three different rim seal geometries, viz., axially overlapping radial clearance rim seals for the single-stage turbine cavity and the 1.5-stage turbine aft cavity, and a rim seal with angular clearance for the single-stage turbine cavity were studied. In the single-stage turbine, an inner seal radially inboard in the cavity was also provided; this effectively divided the disk cavity into a rim cavity and an inner cavity. For the aft rotor-stator cavity of the 1.5-stage turbine, a labyrinth seal was provided radially inboard, again creating a rim cavity and an inner cavity. Measurement results of time-average main gas ingestion into the cavities using tracer gas (CO2), and ensemble-averaged trajectories of the purge gas flowing out through the rim seal gap into the main gas path using particle image velocimetry are presented. For both turbines, significant ingestion occurred only in the rim cavity. The inner cavity was almost completely sealed by the inner seal, at all purge gas flow rates for the single-stage turbine and at the higher purge gas flow rates for 1.5-stage turbine. Purge gas egress trajectory was found to depend on main gas and purge gas flow rates, the rim seal configuration, and the azimuthal location of the trajectory mapping plane with respect to the vanes. / Dissertation/Thesis / M.S. Mechanical Engineering 2010

<p>  </p> <p>In gas turbines, the hot gas exiting the combustor can be as high as 2000 ^oC, and some of this hot gas enter into the space between the stator and rotor disks (wheelspace). Since the hot gas entering with its high temperatures could damage the disks, hot-gas ingestion must be minimized. This is done by using rim seals and by introducing a flow of cooler air from the compressor (sealing flow) into the wheelspace. </p> <p>Ingress and egress into rim seals are driven by the stator vanes, the rotor and its rotation, and the rotor blades. This study focuses on the first-stage turbine, where ingress could cause the most damage and has two parts. The first part focuses on understanding ingress and egress driven by the rotor and its rotation, known as rotationally-induced ingress, by studying ingress about an axial seal in a stator-rotor configuration without vanes and without blades. The second part focuses on understanding ingress and egress driven by stator vanes, known as externally-induced ingress, by studying a stator-rotor configuration with vanes but no blades, where the ratio of the external Reynolds number to the rotational Reynolds number is 0.538. For both parts, solutions were generated by wall-resolved large-eddy simulation (LES) based on the WALE subgrid model and by Reynolds-averaged Navier-Stokes (RANS) based on the SST model. For both stator-rotor configurations, the grid-independent solutions obtained were compared with available experimental data.   </p> <p>Results obtained for the configuration without vanes and blades show Kelvin-Helmholtz instability (KHI) to form even without swirl from the hot-gas flow and to create a wavy shear layer on the rotor. Also, Vortex shedding (VS) occurs on the backward-facing side of the seal and impinges on the rotor side of the seal. The KHI and VS produce alternating regions of high and low pressures about the rotor-side of the axial seal, which cause ingress to start on the rotor side of the seal. Results obtained for the configuration with vanes but no blades show both LES and RANS to correctly predict the coefficient of pressure, C_p, upstream of the axial seal. However, only LES was able to correctly predict the sealing effectiveness. This shows C_p by itself maybe is inadequate in quantifying externally-induced ingress. One reason why RANS was unable to predict sealing effectiveness is significantly under predicting the pressure drop on the rotor surface, which affected the pressure variation along the hot-gas path and hence the pressure difference across the axial seal, which ultimately drives ingress. </p>