This specification is based upon and claims the benefit of priority from Indian patent application IN 201711044794 filed on Dec. 13, 2017 and United Kingdom patent application GB 1801557.8 filed on Jan. 31, 2018, the entire contents of both of which are incorporated herein by reference.
The present disclosure concerns seals, more specifically labyrinth seals that are suitable for use in gas turbine engines.
According to a first aspect the present disclosure provides a labyrinth seal having a land that comprises an array of polygonal cells, wherein at least 50% of the cells include a planar wall that subdivides the cell.
Such a seal reduces seal leakage. Several seals are typically used in modern gas turbine engines for ventilating compressor drums and turbine rim flows that over flow at cruise. By reducing fluid leakage, the labyrinth seals of the present disclosure can reduce specific fuel consumption.
The planar wall may extend between opposite corners of the cell.
At least 50% of the cells may include a single planar wall that extends between opposite corners of the cell to subdivide the cell, the planar wall having substantially the same height as the cell.
The planar wall may extend between opposite sides of the cell. At least 50% of the cells may include a single planar wall that extends between opposite sides of the cell to subdivide the cell, the planar wall having substantially the same height as the cell.
At least 70% of the cells may include a single planar wall that subdivides the cell.
At least 80% of the cells may include a single planar wall that subdivides the cell.
At least 90% of the cells may include a single planar wall that subdivides the cell.
All of the cells may include a single planar wall that subdivides the cell.
The polygonal cells may be hexagonal. The sides of those cells may all have equal length.
The polygonal cells may be octagonal. The sides of those cells may all have equal length.
The polygonal cells may have a total of four sides. Parallel sides of those cells may have equal length. All sides of those cells may have equal length.
According to a second aspect the present disclosure provides a gas turbine engine that includes one or more of the aforementioned labyrinth seals.
The sub-dividing planar walls significantly reduce the bypass flow through the cells. This is because they reduce both the discharge coefficient and the effective area of the cells and the seal. Reducing seal leakage in gas turbine engines can reduce specific fuel consumption by such engines thus saving fuel, reducing fuel costs and benefiting the environment. The sub-dividing planar walls have the effect of reducing the cell size with only a minimal addition of metal. This is important as increasing the metal content of the seal increases the potential for increased heat being generated due to rubbing, which is why simply reducing the cell size of a conventional honeycomb labyrinth seal is undesirable. In contrast, the labyrinth seals of the present disclosure provide lower leakage than conventional honeycomb labyrinth seal and low heat generation due to rubbing.
The skilled person will appreciate that except where mutually exclusive, a feature described in relation to any one of the above aspects may be applied mutatis mutandis to any other aspect. Furthermore except where mutually exclusive any feature described herein may be applied to any aspect and/or combined with any other feature described herein.
The term “labyrinth seal” as used herein means a type of mechanical seal that provides an extended or tortuous path to minimise or ideally prevent leakage.
The term “land” as used herein means the surface of a seal that contacts an axle, pipe or shaft to provide an effective seal.
The term “array of polygonal cells” as used herein means a repeated pattern of polygonal cells arranged on a substrate. The polygonal cells have the same shape or different shape. Typically the polygonal cells have the same shape. The array of polygonal cells can take the form of a honeycomb, the cells however need not be hexagonal in form.
The term “honeycomb” as used herein means an array of polygonal cells, each cell having the same or substantially the same shape. The shape may be hexagonal to resemble beehive honeycomb, however the shape need not be so limited.
The term “planar wall” as used herein means a wall that is substantially planar in shape i.e. substantially flat.
The term “effective clearance” as used herein means the product of physical seal clearance and discharge coefficient of the seal.
The term “radial clearance”, as used herein means difference in radius of the seal stator land to the seal rotor fins.
The term “pressure ratio”, abbreviated as PR, as used herein means the ratio of seal upstream pressure to seal downstream pressure.
The term “specific fuel consumption”, abbreviated as SFC, as used herein means the fuel flow rate divided by the output thrust or power. For long-range, civil aircraft engines, a low SFC is critical as the cost of fuel is typically 15 to 25 percent of aircraft operating costs.
Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients used herein are to be understood as modified in all instances by the term “about”.
Throughout this specification and in the claims that follow, unless the context requires otherwise, the word “comprise” or variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other stated integer or group of integers.
Certain aspects or embodiments of the present disclosure are described by way of example only, with reference to the accompanying drawings. In the drawings:
The present disclosure concerns a labyrinth seal and a gas turbine engine that includes one or more such labyrinth seals. Such seals are useful, for example, to control air or liquid leakage from high pressure regions to low pressure regions in turbine engines and compressors of turbine engines.
In broad terms the labyrinth seal of the present disclosure is a land that comprises an array of polygonal cells, wherein at least 50% of the cells include a planar wall that subdivides the cell.
The land can take various forms. It is typically formed around the inner surface of an annular seal. The land is typically formed during the manufacture of the seal.
The land can be made from various materials including metals, metal alloys, plastics and composites. The choice of material is suited to the intended use of the labyrinth seal. When the labyrinth seal is intended for use in or around the combustion equipment of a gas turbine engine, the material must be able to withstand the high temperatures generated by such equipment. In certain embodiments the land is made from Hastelloy® X (aka Hast X), which is a nickel base alloy commercially available from Haynes International Inc that possesses exceptional strength and oxidation resistance up to 1204° C. (2200° F.).
The array may take various forms. It is typically formed as a repeated pattern of similarly shaped cells. Typically the cells are identically shaped. In use, the edges of the cells that extend towards the central axis of the annular seal snugly contact the external surface of the pipe(s) or shaft(s) being sealed by the seal. The array is typically formed during the manufacture of the seal.
When the labyrinth seal operates at relatively lower seal clearance, a large fraction of the seal flow bypasses thru the cells apart from the seal clearance area. Sub-dividing the cells reduces the bypass flow through the cells. This lowers the discharge coefficient and the effective bypass flow area. Reducing seal leakage in gas turbine engines can reduce specific fuel consumption by such engines thus saving fuel, reducing fuel costs and benefiting the environment.
The planar wall may extend between opposite corners of the cell or between opposite sides of the cell. It operates an axial foil that can induce vortices in the seal leakage flow e.g. the rotating seal leakage flow. It reduces the effective leakage area and thereby reduces seal leakage.
At least 50% of the cells include a single planar wall that extends between opposite corners of the cell to subdivide the cell, the planar wall having substantially the same height as the cell.
At least 50% of the cells include a single planar wall that extends between opposite sides of the cell to subdivide the cell, the planar wall having substantially the same height as the cell.
The height of the planar wall and the height of the cell may be measured from the base or underside of the land, the cells extending from the base or underside of the land.
The planar wall may sub-divide the cell into equal halves. The planar wall may sub-divide the cell into unequal halves.
The polygonal cells can take various forms. For example, the cells can be square, rectangular, hexagonal or octagonal in shape. Various polygonal cells are shown in
When the polygonal cells are square, all four sides of those cells have equal length and the array may resemble a checkerboard in pattern. Examples of square cells are shown in
When the polygonal cells are rectangular, the opposing sides of those cells have equal length. If both pairs of opposing sides have the same length, the array may resemble a checkerboard in pattern. If the pairs of opposing sides have unequal lengths, the array may resemble an elongated checkerboard in pattern. Examples of rectangular cells are shown in
When the polygonal cells are hexagonal, the sides of those cells may have equal or unequal length. When the sides are all of equal length, the array may resemble a honeycomb in pattern. When two pairs of opposing sides are of equal length and a third pair of opposing signs are of the same length that is greater than length of the other sides, the array may resemble an elongated honeycomb in pattern. Examples of hexagonal cells are shown in
The polygonal cells may be octagonal. The sides of those cells may have equal length or unequal length. Opposing sides made have the same length. One pair of opposing sides may be longer in length than the other pairs opposing sides. When two pairs of opposing sides are of equal length and the other two pairs of opposing signs are of the same length that is greater than length of the pairs of side, the array have resemble a staggered or offset pattern. Examples of octagonal cells are shown in
At least 50% of the cells include a planar wall that subdivides the cell. However at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 98%, at least 99% or 100%, of the cells may include a planar wall that subdivides the cell, more particularly at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 98%, at least 99% or 100%, of the cells may include a single planar wall that subdivides the cell. The higher the percentage of cells including a planar wall that subdivides the cell, the greater reduction in leakage is achieved. It is typically easier and less complex to manufacture a labyrinth seal where 100% of the cells include a planar wall that subdivides the cell rather than less than 100% of the cells include a planar wall that subdivides the cell.
The polygonal cells may be formed in a variety of sizes. A land comprises an array of polygonal cells where the polygonal cells may be have the same size or may be different sizes.
Typically a land comprises an array of polygonal cells where the polygonal cells have the same size. Typical sizes for the walls of polygonal cells are 1/32 inch (0.079 mm), 1/16 inch (1.588 mm) and ⅛ inch (3.175 mm) although one skilled in the art would select a size that is optimal for the intended purpose.
Typically a land comprises an array of polygonal cells where the polygonal cells and the planar walls have the same size. Typical sizes for the walls of polygonal cells and the planar walls are 1/32 inch (0.079 mm), 1/16 inch (1.588 mm) and ⅛ inch (3.175 mm) although one skilled in the art would select a size that is optimal for the intended purpose.
The labyrinth seal of the present disclosure can be manufacturing using known technologies such as node welding, additive layer manufacturing (ALM) and electro discharge machining. The choice of manufacturing depends on labyrinth seal to be made. Honeycomb labyrinth seals are produced conventionally using fabrication of stamped ribbons, or using suitable additive layer methods.
The present disclosure also provides a gas turbine engine that includes one or more of the aforementioned labyrinth seals.
The labyrinth seal of the present disclosure will now be described with reference to the drawings.
The gas turbine engine 10 works in the conventional manner so that air entering the intake 12 is accelerated by the fan 13 to produce two air flows: a first air flow into the intermediate pressure compressor 14 and a second air flow which passes through a bypass duct 22 to provide propulsive thrust. The intermediate pressure compressor 14 compresses the air flow directed into it before delivering that air to the high pressure compressor 15 where further compression takes place.
The compressed air exhausted from the high-pressure compressor 15 is directed into the combustion equipment 16 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 17, 18, 19 before being exhausted through the nozzle 20 to provide additional propulsive thrust. The high 17, intermediate 18 and low 19 pressure turbines drive respectively the high pressure compressor 15, intermediate pressure compressor 14 and fan 13, each by suitable interconnecting shaft.
Other gas turbine engines to which the present disclosure may be applied may have alternative configurations. By way of example such engines may have an alternative number of interconnecting shafts (e.g. two) and/or an alternative number of compressors and/or turbines. Further the engine may comprise a gearbox provided in the drive train from a turbine to a compressor and/or fan.
Labyrinth seals 30 of the present disclosure may be located in various locations within a gas turbine engine. They are typically located within the compressors (14 and 15) or turbines (17, 18 and 19) of a gas turbine engine.
While the labyrinth seals of the present disclosure have largely been described above with reference to their use in gas turbine engines, the labyrinth seals can be used for many other purposes that are typically suitable for labyrinth seals, especially so-called honeycomb labyrinth seals. For example the labyrinth seals are also useful in steam turbine engines, for example, to control air or liquid leakage from high pressure regions to low pressure regions in steam turbine engines.
The labyrinth seals of the present disclosure will now be further described with reference to certain examples.
The Applicant constructed three arrays of hexagonal cells having sides of equal length giving a cell size of 4.7625 mm ( 3/16 inch) where every complete cell included a planar wall that subdivided it. Each array simulated a land of a seal in planar form. As a control the Applicant constructed three arrays of hexagonal cells having equal cell size where none of the cells included a planar wall. The arrays were made from plastic. The arrays were adhered alongside each other onto a substrate to hold the arrays for testing fluid leakage. This holder holding three arrays of hexagonal cells having subdividing planar walls is shown in
A testing rig 30 was constructed to measure fluid leakage from the lands held in the holder. The testing rig is depicted diagrammatically in
The front wall 36 includes a flow inlet hole 50 through which air can be supplied into the pressure chamber 32 by a first pump (not shown). The front wall 36 also includes an outlet hole 52 through which air in the pressure chamber 32 can be evacuated from the pressure chamber 32 through the action of a second pump (not shown). The testing rig 30 has a pair of baffles 54 that are removably locatable parallel to the front wall 36. The baffles are formed to suitably restrain and engineer the flow of air in the pressure chamber 32.
The testing rig 30 formed part of an experimental set-up that is depicted as a measurement system schematic in
In use, the removable back wall of the testing rig 30 is removed so the rig is open ended and ventilates to the atmosphere. A land test piece 60, for example in the form a stepped seal, is placed into the pressure chamber 32 through the back of the testing and set against a seal locator 62 so the seal test piece is suitably located under the pressure probes 48 provided in the second lid portion 46. A land of a labyrinth seal to be measured is removably secured onto the land test piece 60. The dimensions of the land are known whereas the axial and radial clearances are determined using depth micrometre measurements. The removable window 42 is mounted in place sealing the side wall into which it is formed. Testing is started by switching on the air supply to the first pump so that air enters the pressure chamber 32 through the flow inlet hole 50 and passes through the baffles 54 towards the labyrinth seal that is located between the land test piece 60 and underside surface of the second lid portion 46 that accommodates the pressure probes 48. Excess air trapped between the front wall 36 and the baffles 54 can be removed from the pressure chamber 32 via the outlet hole 52 by activating the second pump.
The test was conducted with ambient sink pressure and the pressure ratio (Pup/Pdown) varied from 1.2 to 1.5. The rig was scaled up by 3.0 to achieve the engine level Reynolds number. Flow measurements were made using an orifice meter with an accuracy of 1%. The radial clearance was measured with feeler gauges and slip gauges. Feeler gauges were available in steps of 0.01 mm so that the necessary measurement resolution could be achieved. The radial seal clearances were set at three levels, 0.6 mm, 1.5 mm and 3 mm. The axial clearance was inferred by measuring the position of the land test piece relative to the rear end of the rig with a depth micrometer on both sides. The radial clearance was calculated knowing the geometry of the land and the land test pieces.
A gauge R&R (repeatability and reproducibility) study was conducted for the measurement of the axial and radial clearance. This involved four team members measuring eight different axial and radial clearances with two repeats. The standard deviation for the total gauge R&R for the radial clearance was 0.008 mm, hence the 95% certainty interval ±0.016 mm (2σ).
For the orifice meter repeatability test, five measurement series were taken. In each series seven readings were taken at regular intervals of 30 seconds totalling to 3 minutes per series. The first point of the first measurement series was taken as a reference point and the measured effective clearance was defined as 100%. All other readings used this value as a reference to show the deviation over time and repeats.
All readings from the various pressure and temperature sensors were fed into a LabVIEW™ (Laboratory Virtual Instrument Engineering Workbench) systems engineering design programme from National Instruments Corporation that recorded all of the data. To be able to convert the voltage readings of the pressure transducers to pressures, the calibration values for the transducers were determined prior to any testing. Additionally the software assessed the offsets (voltage reading at zero gauge pressure) of the transducers before each test run.
Mass flow through the testing rig was calculated by using an orifice meter upstream of the rig. To calculate the mass flow, pressure measurements were taken upstream and downstream of the orifice plate. Additionally the temperature of the flow through the orifice was measured. With the geometry of the orifice, the measurement system was able to calculate the mass flow through the orifice.
Having determined the mass flow rate and the pressure ratio over the labyrinth seal the effective clearance was calculated and used in all subsequent tests to compare the results. The calculation procedure for the effective clearance was implemented into the LabVIEW Programme, when it was adapted for the flow measurements.
The effective clearance (ec) was calculated using the following formula:
The baseline design (regular hexagon) seal measurement at a pressure ratio of 1.44 and 0.6 mm seal clearance was used as a reference value for the effective clearance (100%).
Using the testing rig effective clearance (%) and radial clearance (mm) were measured and flow reduction was calculated. The data are provided in Tables 1 and 2 below:
The data from Tables 1 and 2 have been represented in graphs that are presented in
Improved labyrinth seals of the present disclosure reduce seal leakage. Several seals are typically used in modern gas turbine engines for ventilating compressor drums and turbine rim flows that over flow at cruise. By reducing fluid leakage, the use of labyrinth seals of the present disclosure will reduce specific fuel consumption.
It will be understood that the disclosure is not limited to the embodiments above-described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.
Number | Date | Country | Kind |
---|---|---|---|
201711044794 | Dec 2017 | IN | national |
1801557.8 | Jan 2018 | GB | national |