Analysis of Leaf Seal Leakage Performance Under the Influence of Manufacturing Variations Using Experiment and Computational Fluid Dynamics

In this paper, test data are combined with results from two different computational fluid dynamics (CFD) models to investigate the leakage performance of leaf seals. Experimental data are gathered for centric rotor position using a rotating test rig at various rotational speeds, inlet pressures, and preswirl velocities. The test results are compared to brush and labyrinth seal leakage data from previous studies and reveal elevated leakage rates of the leaf seal. As the tested leaf seals are subject to thermal leaf deformation from welding during the manufacturing process, the influence of geometry variations within the leaf pack on leakage performance is investigated with the help of numerical simulations. Both a fully resolved leaf model and a modeling approach based on porous media are used. The CFD models are validated based on pressure measurements within the up- and downstream coverplate gaps at three different radii. Both CFD models show good agreement with test data for different inlet parameters. A variation of cold clearance shows moderate influence on leakage and small clearances can be brought into context with hydrodynamic lift-up indicated by experimental leakage data. Much higher sensitivity on leakage mass flow is predicted for variations in leaf spacing at the leaf root and leaf tip. The latter is discussed as an explanation for the measured leakage of the test seal with its manufacturing variations, while the first quantitatively shows optimization potential at the design stage of leaf seals.

Rotordynamic Behavior of Leaf Seals: Measurement of Frequency-Dependent Force Coefficients for Varying Inlet Parameters

While brush seals can be found in various applications for turbomachines today, leaf seals are a further development in compliant seal technology and have a lower level of maturity. Among the purported advantages are greater axial rigidity when subject to higher pressure differences and the potential for non-contacting operation due to lift-up. However, especially their rotordynamic behavior is little investigated in the literature so far. In this paper, measured rotordynamic force coefficients of a leaf seal are presented for varying inlet pressures, preswirl velocities and excitation frequencies. The leaf pack of the tested leaf seal has zero rotor cold clearance and its coverplates are designed for facilitating a lift-up effect when pressurizing the seal. Experiments were performed on a dynamic test rig with whirling rotor using active magnetic bearing technology and evaluated in the frequency domain based on the impedance method. Test results for the leaf seal reveal positive direct stiffness and an advantageous rotordynamic behavior due to significant levels of direct damping and negative cross-coupled stiffness throughout the operating parameter range. Leaf seal results are compared to brush and labyrinth seal data from previous studies for varying inlet pressures and preswirl velocities. Additional computational fluid dynamics simulations were carried out to predict the leaf deflection moment, which support the findings regarding hydrostatic lift-up from the experimental results.

Macroinvertebrates’ Pollution Tolerance Index in Calabar River, Cross River State, Nigeria

A study was undertaken to determine the macroinvertebrates pollution tolerance index (PTI) in Calabar River, Cross River state, Nigeria. Five sampling stations were chosen along the river course: Ikot Okon Abasi, Tinapa, Unicem, Marina resort and Nsidung beach which were labeled stations 1, 2, 3, 4 and 5 respectively. Physico-chemical parameters; surface water temperature, pH, dissolved oxygen (DO), biochemical oxygen demand (BOD), total dissolved solids (TDS) and total suspended solids (TSS) were measured using their respective meters while macroinvertebrates were sampled using a Van Veen grab, stained with Rose Bengal solution and identified under microscope. Macroinvertebrates pollution tolerance index was obtained using online software designed by Northern Kentucky Univeristy and Leaf Pack Network Biotic and Water Quality Calculator. The results obtained for physicochemical parameters showed the highest temperature as 29.90C in station five while the lowest was 26.40C in station one. pH was highest (6.60) in station five and lowest (5.52) in station one. DO was highest (4.4mg/L) in station four and lowest (3.0 mg/L) in station five while BOD was highest (3.2 mg/L) in station three and lowest (0.3 mg/L) in station one. An average total of 5366 macroinvertebrate individuals were encountered belonging to nine families and eleven species. Tubificidae had the lowest occurrence with 18 individuals which made up 0.3% of the total macroinvertebrates while Penaeidae had the highest occurrence with 2,455 individuals constituting 45.8% of the total count. Pollution tolerance index was highest (21) in station five and lowest (9) in station four with the water quality being generally poor. Hence, it is suggested that anthropogenic activities should be regulated and continuous monitoring of the river course should be carried out.

STUDY ON MACROZOOBENTHOS COMMUNITY IN THE WATERS OF THE RIVER AIR PERIKAN MUNICIPALITY OF PAGAR ALAM SOUTH SUMATRA

The research entitled “ Study on Macrozoobenthos Community in the Waters of the River Air Perikan Pagar Alam Municipality”, was conducted from November 2007 until March 2008. The aims of the research: to know about composition, density, diversity index, dominancy index, and similarity index, which based on the different microhabitat types. Sampling was carried out on November 2007. Five sampling stations were determined by survey method and the Purposive Sampling method was used at each sampling point to find stony, gravel, sandy and leaf pack area as a different microhabitat substrate. Twenty one orders (Ephemeroptera, Trichoptera, Diptera, Plecoptera, Collembola, Hemiptera, Odonata, Coleoptera, Lepidoptera, Megaloptera, Hymenoptera, Orthoptera, Decapoda, Plesiopora, Tricladida, Amphipoda, Isopoda, Mesogastropoda, Ctenobranchiata, Eulamellibranchiata, and Rhynchobdellida) which are consisted of 70 families and 151 genera were identified from four types of substrates on each sampling station. According to this research, station 4 has the highest in composition (80 genera), and the lowest one at station 1(33 genera). The highest abundance was 12589 ind./m2 found in the station 5, and the lowest one was in the station 1 approximately 880 ind./m2. For the diversity index value, station 3 was the highest (3.1) and the lowest one was station 5 (1.9). The Dominancy index was found in station 5 at the sandy substrates was approximately 0,8 index, which dominated by Tubifex sp. There were differences species composition on each station. Keywords : Macrozoobenthos, community, the river Air Perikan.

Computational Fluid Dynamics and Thermal Analysis of Leaf Seals for Aero-engine Application

Aero-engine gas turbine performance and efficiency can be improved through the application of compliant shaft seal types to certain sealing locations within the secondary air system. Leaf seals offer better performance than traditional labyrinth seals, giving lower leakage flows at design duties. However, for aero-engine applications, seal designs must be able to cope with relatively large off-design seal closures and closure uncertainties. The two-way coupling between temperatures of seal components and seal closures, through the frictional heat generated at the leaf–rotor interface when in contact, represents an important challenge for leaf seal analysis and design. This coupling can lead to leaf wear and loss, rotor overheating, and possibly to unstable sealing system behavior (thermal runaway). In this paper, we use computational fluid dynamics (CFD), finite element (FE) thermal analysis, and experimental data to characterize the thermal behavior of leaf seals. This sets the basis for a study of the coupled thermomechanical behavior. CFD is used to understand the fluid-mechanics of a leaf pack. The leaf seal tested at the Oxford Osney Laboratory is used for the study. Simulations for four seal axial Reynolds number are conducted; for each value of the Reynolds number, leaf tip-rotor contact, and clearance are considered. Distribution of mass flow within the leaf pack, distribution of heat transfer coefficient (HTC) at the leaf surface, and swirl velocity pick-up across the pack predicted using CFD are discussed. The experimental data obtained from the Oxford rig is used to develop a set of thermal boundary conditions for the leaf pack. An FE thermal model of the rig is devised, informed by the aforementioned CFD study. Four experiments are simulated; thermal boundary conditions are calibrated to match the predicted metal temperatures to those measured on the rig. A sensitivity analysis of the rotor temperature predictions to the heat transfer assumptions is carried out. The calibrated set of thermal boundary conditions is shown to accurately predict the measured rotor temperatures.

CFD and Thermal Analysis of Leaf Seals for Aero-Engine Application

Aero-engine gas turbine performance and efficiency can be improved through the application of compliant shaft seal types to certain sealing locations within the secondary air system. Leaf seals offer better performance than traditional labyrinth seals, giving lower leakage flows at design duties. However, for aeroengine applications, seal designs must be able to cope with relatively large off-design seal closures and closure uncertainties. The two-way coupling between temperatures of seal components and seal closures, through the frictional heat generated at the leaf-rotor interface when in contact, represents an important challenge for leaf seal analysis and design. This coupling can lead to leaf wear and loss, rotor overheating, and possibly to unstable sealing system behaviour (thermal runaway). In this paper we use CFD, FE thermal analysis, and experimental data to characterise the thermal behaviour of leaf seals. This sets the basis for a study of the coupled thermo-mechanical behaviour. CFD is used to understand the fluid-mechanics of a leaf pack. The leaf seal tested at the Oxford Osney Laboratory is used for the study. Simulations for four seal axial Reynolds number are conducted; for each value of the Reynolds number, leaf tip-rotor contact and clearance are considered. Distribution of mass flow within the leaf pack, distribution of heat transfer coefficient at the leaf surface, and swirl velocity pick-up across the pack predicted using CFD are discussed. The experimental data obtained from the Oxford rig is used to develop a set of thermal boundary conditions for the leaf pack. An FE thermal model of the rig is devised, informed by the aforementioned CFD study. Four experiments are simulated; thermal boundary conditions are calibrated to match predicted metal temperatures to those measured on the rig. A sensitivity analysis of the rotor temperature predictions to the heat transfer assumptions is carried out. The calibrated set of thermal boundary conditions is shown to accurately predict the measured rotor temperatures.

Improved Understanding of Stiffness in Leaf-Type Filament Seals

Filament seals, such as brush seals and leaf seals, are investigated as a potential improved seal for gas turbine applications. As these seals operate in contact with the rotor, a good understanding of their stiffness is required in order to minimize seal wear and degradation. This paper demonstrates that the filament and complete seal stiffness is affected in comparable magnitudes by mechanical and aerodynamic forces. In certain cases, the aerodynamic forces can also lead to an overall negative seal stiffness which may affect stable seal operation. In negative stiffness, the displacement of the seal or rotor into an eccentric position causes a resultant force, which, rather than restoring the rotor to a central position, acts to amplify its displacement. Insight into the forces acting on the seal filaments is gained by investigating a leaf seal, which consists of a pack of thin planar leaves arranged around the rotor, with coverplates on either side of the leaf pack, offset from the pack surfaces. The leaf seal is chosen due to its geometry being more suitable for analysis compared to alternative filament seals such as the brush seal. Data from two experimental campaigns are presented which show a seal exhibiting negative stiffness and a seal exhibiting a stiffness reduction due to aerodynamic effects. An empirical model for the forces acting on leaf filaments is developed based on the experimental data, which allows separation of mechanical and aerodynamic forces. In addition a numerical model is developed to analyze the flow approaching the leaf pack and the interleaf flow, which gives an insight into the causes of the aerodynamic forces. Using the empirical and numerical models together, a full picture of the forces affecting leaf stiffness is created. Validation of the models is achieved by successfully predicting seal stiffness for a further data set across the full range of operating conditions. The understanding of aerodynamic forces and their impact on filament and seal stiffness allows for their consideration in leaf seal design. A qualitative assessment of how they may be used to improve seal operation in filament seals is given.

Improved Understanding of Negative Stiffness in Filament Seals

Leaf seals have previously been proposed as an improved filament seal for gas turbine engines. Recently, a phenomenon known as negative stiffness has been reported from experimental testing. Good understanding of this phenomenon is required to ensure stable interaction between the seal and the rotor. In negative stiffness the displacement of the seal or rotor into an eccentric position causes a resultant force, which, rather than restoring the rotor to a central position, acts to amplify its displacement. The seal consists of a pack of thin planar leaves arranged around the rotor, with coverplates on either side of the leaf pack, offset from its surface. It is notable that negative stiffness only occurs when certain geometric configurations of the coverplates are employed. This paper gives insight into the fluid phenomena that contribute to the negative stiffness effect through the creation of a general 2-D model of the flow upstream of the leaf pack and between the leaves. These show that there is the capacity for the inertia force to be a significant contributor to the overall force acting on individual leaves depending on the coverplate configuration surrounding the leaf pack. The influence of a key parameter, coverplate height, is explored. Results from a test campaign with varying seal geometry are compared to the forces predicted by modeling to justify the proposed mechanisms for negative stiffness. The close agreement between the experimental and predicted data extends the previously published insight on negative stiffness to allow more general considerations for leaf seal design to be inferred.

Plastic and unpredictable responses of stream invertebrates to leaf pack patches across sandy-bottomed streams

Detrital inputs to ecosystems provide potential food sources and can produce trophic cascades, but this effect is influenced by whether species specialise in consuming or inhabiting accumulations of detritus. To test whether species are differentially associated with leaves or sand, we compared densities of stream invertebrate species in patches of leaves and bare sand in two sandy-bed creeks in south-eastern Australia, in summer and spring. We also assessed the quality of information on diet and substrate association in the literature. Most species showed no density differences between leaf and sand patches (‘microhabitat generalists’), but categorisation as generalists, leaf or sand species differed between datasets. We developed a method for identifying important effect sizes; power analyses showed that many species were true generalists, but many non-significant results were potentially Type II errors. The literature provided information that was broadly consistent with our data, but few studies publish reliable information about either diet or patch use. Our results support a contention that few Australian stream invertebrates are obligate shredders, and this may also be true for streams elsewhere. Predicting and detecting the responses of such generalist taxa to detrital inputs will be very challenging.

Negative Stiffness in Gas Turbine Leaf Seals

The stiffness of contacting shaft seals such as brush seals and leaf seals is a required characteristic to accurately predict their performance and life in the gas turbine engine. This paper describes the results of a test campaign in which a series of eccentric rotor excursions are applied at low rotational speed and engine representative pressure differences to characterise the behaviour of a prototype leaf seal. A phenomenon that may best be described as negative seal stiffness is reported. Here, the displacement of the seal rotor to an eccentric position causes a resultant force, which, rather than trying to return the rotor to a central position, acts to amplify its displacement. These data were used to develop an empirical model of the seal behaviour. It was possible to model the negative stiffness phenomenon and show that it is caused by a combination of two effects: the inherent mechanical stiffness of the leaf pack, and the aerodynamic stiffness of the seal. The latter is caused by the pressure distribution and changes in the flow field through the leaf pack as a result of the displacement of the rotor.