The present invention relates to a leaf seal for effecting a seal between two coaxial, relatively rotating components.
With reference to
The gas turbine engine 10 works in a conventional manner so that air entering the intake 11 is accelerated by the fan 12 to produce two air flows: a first air flow A into the intermediate pressure compressor 13 and a second air flow B which passes through the bypass duct 22 to provide propulsive thrust. The intermediate pressure compressor 13 compresses the air flow A directed into it before delivering that air to the high pressure compressor 14 where further compression takes place.
The compressed air exhausted from the high-pressure compressor 14 is directed into the combustion equipment 15 where it is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the high, intermediate and low-pressure turbines 16, 17, 18 before being exhausted through the nozzle 19 to provide additional propulsive thrust. The high, intermediate and low-pressure turbines respectively drive the high and intermediate pressure compressors 14, 13 and the fan 12 by suitable interconnecting shafts.
Leaf seals are formed from sections of leaf material appropriately presented in order to create a seal surface from juxtaposed leaf edges of respective leaves in an assembly. Typically the leaves are arranged circumferentially about a rotating shaft in order to present the leaf edges and therefore the seal surface towards that shaft in order to provide a seal barrier. Typically, spacer members are provided between each leaf in order to correctly arrange the seal elements for presentation of the leaf edges and therefore the seal surface. These spacers may be independent components or integrally formed with each leaf. The leaf edges and so the seal surface effectively floats upwards and downwards relative to a rotating surface.
In a gas turbine engine, leaf seals may be used to form a seal between a static component and a rotating component, between two relatively rotating components, or even between two static components in order to maintain a relatively high pressure on one side of the seal and relatively low pressure on the other.
Leaf seals such as those shown in
However, such coverplates also influence the blow-up and blow-down performance of the seal (as discussed, for example in H. Nakane et al., The Development of High-Performance Leaf Seals, Trans. ASME, Vol. 126, April 2004, pp. 342-350). To control blow-down and blow-up, the ratio of the front coverplate to leaf pack distance and the rear leaf pack to coverplate distance needs to be controlled accurately. Excessive blow-down can lead to accelerated leaf wear and excessive blow-up leads to increased leakage.
With low differential pressures applied across the seal the blow-down is proportional to the differential pressure applied across the seal (as discussed, for example in G Franceschini et al., Improved Understanding of Blow-down in Filament Seals, Journal of Turbomachinery, 132(4), October 2010, p. 041004 TURBO-09-1028). When substantial differential pressures are applied across the leaf seal, the leaves are deflected axially by the pressure, as shown in
US 2003/0068224 proposes a leaf seal having a high pressure side plate which is arranged at a high pressure side and a low pressure side plate which is arranged at a low pressure side so as to hold a leaf pack therebetween. A flexible plate is arranged between the leaf pack and the high pressure side plate, and is fixed to the pack so that it does not separate therefrom.
US 2008/0265514 proposes a leaf seal having a leaf pack which is located in the cavity between a rigid front wall and a rigid back wall. The front and back walls are slidably movable so that the distance between the walls can be varied to change the widths of a gap between the front wall and the leaf pack and of a gap between the back wall and the leaf pack.
An aim of the present invention is to provide performance improvements in leaf seals.
In a first aspect, the present invention provides a leaf seal for effecting a seal between two, coaxial, relatively rotating components, the leaf seal having an annular pack of stacked leaves or a plurality of axially arranged annular packs of stacked leaves, the or each pack being mountable to one of the components with its leaves extending towards the other component such that the leaf edges of the pack are presented for wiping contact with the other component;
the leaf seal further having upstream and downstream coverplates at the respective axial ends of the seal, each coverplate being spaced from the adjacent annular pack by a respective axial gap, and, when viewed in the axial direction, each coverplate covering at least a portion of the radial extent of the adjacent pack;
wherein the upstream and/or the downstream coverplate is flexible to axially deflect under differential pressures which the seal experiences in operation.
Advantageously, by having an upstream and/or a downstream coverplate which flexibly deflects under differential pressure, the width of the respective axial gap can be controlled in operation, e.g. to reduce or eliminate blow-down and hence to reduce or eliminate torque.
For example, in a case of zero clearance at rest between the leaf edges and the other component, there is zero contact load between the leaf edges and the other component. However, for an axially stiff pack and axially stiff coverplates, the blow-down would generally increase linearly with differential pressure. Therefore, to reduce torque, it can be desirable for the downstream coverplate to flex open slightly (i.e. deflect to increase the respective axial gap) with applied differential pressure relative to the pack and/or the upstream coverplate to flex closed slightly (i.e. deflect to decrease the respective axial gap) with applied differential pressure.
In a case of positive clearance at rest between the leaf edges and the other component, again there is zero contact load between the leaf edges and the other component. However here it can be desirable to induce a small amount of blow-down to close the clearance. Thus, compared to the zero clearance case, the downstream coverplate may not need to flex open as much as with applied differential pressure and/or the upstream coverplate may not need to flex closed as much with applied differential pressure.
In a case of contact load at rest between the leaf edges and the other component, it is generally desirable to induce blow-up to offset the blow-down that typically occurs with increasing differential pressure. In this way, the loading between the leaf edges and the other component can be reduced or eliminated as the pressure increases. This can be achieved by the downstream coverplate opening more than for the equivalent zero clearance case with applied differential pressure and/or the upstream coverplate closing more than for the equivalent zero clearance case with applied differential pressure.
In a second aspect, the present invention provides a method of controlling blow-down or blow-up in a leaf seal, the method including the steps of:
In a third aspect, the present invention provides a method of applying overspeed control to relatively rotating components, the method including the steps of:
Thus, in the method of the third aspect, blow-down, which is often seen as undesirable, is advantageously used to provide overspeed control by means of the retarding torque.
In a fourth aspect, the present invention provides a method of applying overspeed control to relatively rotating components, the method including the steps of:
The multiple pack leaf seal of the fourth aspect is thus an alternative to the single pack leaf seal of the third aspect.
Optional features of the invention will now be set out. Unless indicated otherwise, these are applicable singly or in any combination with any one of the aspects of the invention as described above.
Preferably, the or each pack is mountable to one of the components such that the leaf edges of that pack are presented for wiping contact with the other component. The components can be a rotor shaft and a casing for the shaft. Typically, the or each pack is mounted to the radially outer component.
Each coverplate typically extends radially from a root distal the leaf edges of the adjacent pack to an edge proximal the leaf edges of the adjacent pack.
Preferably, the ratio (h4/t3) of either or each coverplate is equal to or greater than 5, and more preferably equal to or greater than 10 or 20, where h is the radial distance in metres from the distal root to the proximal edge of the coverplate, and t is the thickness in metres of the coverplate. Such a value for the ratio can allow the or each coverplate to be sufficiently flexible to respond to pressure and deflect axially, e.g. so that either or both of the upstream and downstream gaps can retain its initial unpressurized width, or so that either or both of the upstream and downstream gaps can close or open slightly in order to modify the blow-down with changing differential pressure.
The single pack (of the first or third aspect), or either or both of the most-upstream and the most-downstream packs (of the first or fourth aspect) may be configured to deflect axially under said differential pressures, and the upstream and/or the downstream coverplate may be flexible to axially deflect under said differential pressures such that, at the maximum differential pressure experienced in operation, the width of the respective axial gap at the coverplate edge proximal the leaf edges of the adjacent pack may be within ±20%, and preferably within ±10%, of the width of the gap at that position at zero differential pressure.
At the maximum differential pressure experienced in operation, the single pack (of the first or third aspect), or the most-upstream pack (of the first or fourth aspect) may deflect axially by an amount that, relative to the undeflected position of the pack, moves the upstream side of the pack in the downstream direction by an amount that, at its leaf edges, is equivalent to at least about 15%, and preferably at least about 30%, of the width of the upstream gap at the coverplate edge proximal the leaf edges at zero differential pressure. Likewise, at the maximum differential pressure experienced in operation, the single pack (of the first or third aspect) or the most-downstream pack (of the first or fourth aspect) may deflect axially by an amount that, relative to the undeflected position of the pack, moves the downstream side of the pack in the downstream direction by an amount that, at its leaf edges, is equivalent to at least about 15%, and preferably at least about 30%, of the width of the downstream gap at the coverplate edge proximal the leaf edges at zero differential pressure.
The leaf seal can be used, for example, in gas and steam turbines, and jet engines. However, it may also be used in other applications, e.g. where sealing between a high and low pressure region is required along a shaft.
Further optional features of the method of the second aspect of the invention will now be set out.
The single pack (of the second aspect), or either or both of the most-upstream and the most-downstream packs (of the second aspect) may deflect axially under the differential pressure such that, at the maximum differential pressure, the width of the respective axial gap is within ±20%, and preferably within ±10%, of the width of the gap at the coverplate edge proximal the leaf edges at zero differential pressure. Preferably, the respective axial gap at the coverplate edge proximal the leaf edges is maintained substantially unchanged over the range of differential pressures experienced in operation. Alternatively, the amount of blow-down may be increased by the axial deflection of the or each coverplate, e.g. to apply a retarding torque on the other component. According to another option, however, the amount of blow-up may be increased by the axial deflection of the or each coverplate.
Further optional features of the invention are set out below.
Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:
a) to (c) show schematically respective longitudinal cross-sections through a leaf pack and housing of seal assemblies of first to third embodiments of the present invention;
a) to (c) show respective schematic longitudinal cross-sections corresponding to the first to third embodiments of
a) to (e) show schematically respective options for shaping a front coverplate in order to produce coverplate flexibility.
Leaf seal assemblies according to the present invention may have coverplates which, by their flexibility, axially deflect under the application of the pressure to provide control of the axial gap between the coverplate and the adjacent leaf pack. For example, it is possible to match the axial deflection of the coverplate with the axial deflection of the leaf pack to ensure that the gap between the cover plate and leaf pack does not substantially depart from the nominal gap when a pressure condition is applied.
a) to (c) show schematically longitudinal cross-sections through the leaf pack and housing of leaf seal assemblies of respectively first to third embodiments of the present invention for sealing between an outer casing and a rotor shaft. Each leaf seal has a pack of leaves 132 secured in a housing comprising a backing ring 134 with upstream 135 and downstream 135′ coverplates. In
A target for the axial deflection can be principally to keep the gap between the cover plate and the leaf pack constant with the application of differential pressure. However, there may be reasons why a different objective should be set. One example, due to thermal mismatch in rotor to casing radial gap, more blow-down may be required at low differential pressure than at high differential pressure so that a rear coverplate gap x′ which opens slightly with pressure compared to the front gap x can give a slight blow-up configuration as the pressure difference across the leaf seal is increased. Hence, by appropriate adjustment of coverplate flexibility, it is possible to fit the behaviour of the leaf seal to the specific thermal and movement cycle in an engine. Ultimately an aim can be to “tune” the leaf seal to an engine cycle by ensuring that the seal inner bore rests close to the shaft at a number of different operating points in the cycle.
As can be seen in
If, by suitable configuration of the flexible rear coverplate 135′, the rear gap x′ is made to increase relative to the front gap x, then the leaf seal can exhibit blow-up with increasing pressure, which may be beneficial for some seals.
The deflection δ of a coverplate is given by:
where h is the radial distance from the root to the edge of the coverplate (see
By matching coverplate flexibility to the axial deflection of the leaf pack, a seal can be run at higher pressure differentials without excessive blow-down causing high contact loads and hence elevated torques. Additionally or alternatively, the leaf seal blow-down behaviour with pressure can be altered so that a desirable blow-down or blow-up can be achieved at various pressures. For example, the leaf seal can thus be better matched to follow an engine cycle. A further advantage of adopting flexible coverplates is that the seal can be made more lightweight, which can be particularly beneficial in aerospace applications.
Although blow-down is generally seen as undesirable, control of the gaps between coverplates and leaf pack can be used to deliberately produce blow-down when the pressure differential reaches a predetermined level, e.g. associated with engine overspeed. The leaf pack can then function as a mechanical brake, with the blow-down urging the leaves heavily against the shaft to exert a significant retarding torque on the shaft. The air flow through the leaves can function as a cooling flow for the frictional heating thus-produced, allowing the brake to operate continuously. In this application, suitable control of the gaps may be achievable even with rigid coverplates.
While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. For example, in the above embodiments, the leaf packs are mounted to a radially outer housing and their leaves extend towards an inner rotor. However, in other embodiments, the packs could be mounted to a radially inner component and their leaves extend towards an outer component. Further, in the above embodiments, the seal assemblies have single leaf packs, but in other embodiments each assembly could have a plurality of axially arranged packs, the coverplates being spaced from respectively the most-upstream and the most-downstream of the annular packs by respective axial gaps. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
All references referred to above are hereby incorporated by reference.
Number | Date | Country | Kind |
---|---|---|---|
1202104.4 | Feb 2012 | GB | national |