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ASME Turbo Expo 2011: Power for Land, Sea and Air June 6-10, 2011, Vancouver, BC Rotordynamic Force Coefficients of Bubbly Mixture Annular Pressure Seals Luis San Andres Mast-Childs Tribology Professor Turbomachinery Laboratory Texas A&M University ASME GT2011-45264 Accepted for publication J Eng. Gas Turb. Power Presentation available at http://rotorlab.tamu.edu 1 Supported by TAMU Turbomachinery Laboratory (Prof. D. Childs) Annular Pressure Seals Radial seals (annular, labyrinth or honeycomb) separate regions of high pressure and low pressure and their principal function is to minimize the leakage (secondary flow); thus improving the overall efficiency of a rotating machine extracting or delivering power to a fluid. Inter-stage seal Impeller eye or neck ring seal Balance piston seal Seals in a Multistage Centrifugal Pump or Compressor 2 Annular Pressure Seals The dynamic force response of pressure seals has a primary influence on the stability response of highperformance turbomachinery. Annular seals, although geometrically similar to plain journal bearings, show a flow structure dominated by turbulence and fluid inertia effects. Operating characteristics unique to seals are the * large axial pressure gradients, * large clearance to radius ratio (R/c) < 500, while * the axial development of the circumferential velocity determines the magnitude of cross-coupled (hydrodynamic) forces. Childs, D., 1993, Turbomachinery Rotordynamics: Phenomena, Modeling, and Analysis, John Wiley & Sons, Inc., New York, New Yor, Chap. 4. 3 Seals and rotordynamics Due to their relative position within a rotorbearing system, seals modify the system dynamic behavior. Seals typically "see" large amplitude rotor motions. This is particularly important in back-to-back compressors and longflexible multiple stage pumps Straight-Through and Back-to-back Compressors and 1st Mode Shapes Childs, D., 1993, Turbomachinery Rotordynamics: Phenomena, Modeling, and Analysis, John Wiley & Sons, Inc., New York, New Yor, Chap. 4. 4 Force Coefficients in Annular Seals L Y c stator rotorrotor X D Pa W Axial velocity Film thickness H=c+eX coseY sin Pe Axial pressure field (liquid) Seal reaction forces are functions of the fluid properties, flow regime, operating conditions and geometry. For small amplitudes of rotor lateral motion: forces are linearized with stiffness, damping and inertia force PS FX K XX FY KYX K XY x CXX CXY x M XX KYY y CYX CYY y M YX coefficients: M XY x M YY y 5 Annular Pressure Seals Intentionally roughened stator surfaces (macro texturing) reduce the impact of undesirable crosscoupled dynamic forces and improve seal stability. Annular seals acting as Lomakin bearings have potential as support elements (damping bearings) in high speed compressors and pumps. Childs, D., and Vance, J., 1997, “Annular Gas Seals and Rotordynamics of Compressors and Turbines”, Proc. of the 26th Turbomachinery Symposium, Texas A&M University, Houston, TX, September, pp. 201-220 6 Bubbly Mixture Annular Pressure Seals Justification Seals operate with either liquids or gases, but not both…… As oil fields deplete compressors work off-design with liquid in gas mixtures, mostly inhomogeneous. Similarly, oil compression station pumps operate with gas in liquid mixtures The flow condition affects compressor or pump overall efficiency and reliability. Little is known about seals operating under 2-phase conditions, except that the mixture affects seal leakage, power loss and rotordynamic force coefficients; perhaps even inducing random vibrations that are transmitted to the whole rotor-bearing system. 7 Background literature Annular Seals Experimental – Seals (two phase) Iwatsubo, T., and Nishino, T., 1993, “An Experimental Study on the Static and Dynamic Characteristics of Pump Annular Seals,“ 7th Workshop on Rotordynamic Instability Problems in High Performance Turbomachinery. Hendricks, R.C., 1987, "Straight Cylindrical Seals for High Performance Turbomachinery," NASA TP-1850 Computational – Seals (two phase) Beatty, P.A., and Hughes, W.F., 1987, "Turbulent Two-Phase Flow in Annular Seals," ASLE Trans., 30, pp. 11-18. Arauz, G., and San Andrés, L., 1998, “Analysis of Two Phase Flow in Cryogenic Damper Seals, I: Theoretical Model, II: Model Validation and Predictions,” ASME J. Tribol., 120, pp. 221-227, 228233 Arghir, M., Zerarka, M., Pineau, G., 2009 "Rotordynamic analysis of textured annular seals with mutiphase (bubbly) flow, “Workshop : “Dynamic Sealing Under Severe Working Conditions” EDF – LMS Futuroscope, October 5, 8 Background literature Mxx Annular Seals Experimental – Seals (two phase) Iwatsubo, T., and Nishino, T., 1993, “An Experimental Study on the Static and Dynamic Characteristics of Pump Annular Seals,“ 7th Workshop on Rotordynamic Instability Problems in High Performance Turbomachinery. Cxx NO description of water lubricated seal (L, D, c) or gas type….. Tests conducted at various speeds (1,5003,500 rpm) and supply pressures=1.2 - 4.7 bar. Air/liquid volume fraction b=0, 0.25, 0.45, 0.70 Kxx b, gas volume fraction increases 9 Background literature Squeeze film dampers Experimental & Physical Modeling Tao, L., Diaz, S., San Andrés, L., and Rajagopal, K.R., 2000, "Analysis of Squeeze Film Dampers Operating with Bubbly Lubricants" ASME J. Tribol., 122, pp. 205-210 Diaz, S., and San Andrés, L., 2001, "Air Entrainment versus Lubricant Vaporization in Squeeze Film Dampers: An Experimental Assessment of their Fundamental Differences,” ASME J. Eng. Gas Turbines Power, 123, pp. 871-877 Diaz, S., and San Andrés, L., 2001, “A Model for Squeeze Film Dampers Operating with Air Entrainment and Validation with Experiments,” ASME J. Tribol., 123, pp. 125-133. Diaz, S., and San Andrés, L., 2002, “Pressure Measurements and Flow Visualization in a Squeeze Film Damper Operating with a Bubbly Mixture,” ASME J. Tribol., 124, pp. 346-350. Sponsored by National Science Foundation and TAMU Turbomachinery Research Consortium, June 1998- May 2002 10 Background literature Squeeze film dampers Effect of bubbly mixtures and air ingestion on SFD forced performance CCO L=31.1 mm D=129 mm c=0.254 mm Sponsored by National Science Foundation and TAMU Turbomachinery Research Consortium, June 1998- May 2002 11 Background literature Bubbly SFD 0.6 Diaz, S., Beets, T., and San Andrés, L., 2000, “Pressure Measurements and Flow Visualization in a Squeeze Film Damper Operating With a Bubbly Mixture” hmin hmax + squeeze - squeeze 0 0 b=0.540 0.4 time [sec] 6 5 open end 30o sealed end open end sealed end 4 open end 0.3 sealed end h[mm] 0 31.1 mm Uniform Pressure Zone: Maximum Pressure Zone: Minimum Pressure Zone: Maximum Film Thickness Film Thickness Decreasing Film Thickness Increasing Onset of Positive Squeeze Minimum Gas Volume Fraction Onset of Air Ingestion Maximum Gas Volume Fraction Uniform Mixture Incoming gas from Discharge Non-Uniform Streaks (fingering) See digital videos at http://rotorlab.tamu.edu 12 SFD (CCO): c=0.254 mm, e=0.180 mm, 500 rpm, ISO VG 68 A simple model for bubbly mixtures - Homogenous mixture of 2-components; isothermal & static equilibrium - Both components move with same speed & occupy same volume Ps z Mixture density b G 1 b L W Pa Ideal gas P G Z G TS Quasi-static model – ignores bubble dynamics Gas volume fraction (known at inlet) b 1 P PV 2c S 1 1 1 PGS b S For oil, PV~0.010 bar and S=0.035 N/m, and with c=0.152 mm, PV+2S/c=0.0146 bar Diaz, S., and San Andrés, L., 2001, “A Model for Squeeze Film Dampers Operating with Air Entrainment and Validation with Experiments,” ASME J. Tribol., 123, pp. 125-133 13 U A simple model for bubbly mixtures All liquid McAdams model Mixture viscosity All gas 1.4 1.3 1.2 1.1 i for b 0.3 0.4 1 2.5 b ; L 1 G L 1 1 1 1 1 for b 0.3 G G 1 0.3 0.3 0.7 L G ; 1 0.9 mi 0.8 Cicc hitti 0.7 i Isbin i 1.3 L2 1.75 L G L G Realistic model, not depending on mass fraction 0.6 0.5 0.4 0.3 0.2 * 0.1 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 b_i Dukkler McAdams Cicchitti Isbin McAdams, W.H., Woods, W.K., and Heroman, L.C., Jr., 1942, “Vaporization inside Horizontal Tubes- II -Benzene-Oil Mixtures,” ASME Trans., 64, p.193 b 14 1 Bulk-flow Analysis of Annular Seals Ps z W Flow Continuity H H d UH WH 0 t x z U Pa Circumferential Momentum transport Axial momentum transport H H P H x 0 UH U H d U 2 H UWH x t t x z P H z 0 W 2 H WH W H d UWH z t t x z - Turbulent flow with fluid inertia effects - Mean flow velocities – average across film (h) - No accounting for strong recirculation zones - Includes round-hole and honeycomb pattern (textured surface seal) San Andrés, L., and Soulas, T., 2007, “A Bulk Flow Model for Off-Centered Honeycomb Gas Seals,” ASME J. Eng. Gas Turbines Power, 129, pp. 185-194 15 Wall shear stress differences Shear stresses H z 0 H k zW ; H x 0 RΩ k x U kr H 2 r 1 g k f Re; f am 1 cm bm H Rer , s am=0.001375; bm=5 x 105; cm=104 z 1/3 Friction factors Other Ps W U Pa - Moody’s friction factor - Not affected by flow condition (single or two component) - Actual to be determined Salhi, A., Rey, C., and Rosant, J.M., 1992, “Pressure Drop in Single-Phase and Two-Phase Couette-Poiseuille Flow,” ASME J. Fluids Eng., 114, pp.80-84 16 Bulk-flow Analysis of Annular Seals -Inlet pressure loss due to fluid inertia (Lomakin effect) - Inlet swirl determined by upstream condition (swirl-brake) -Exit pressure without recovery loss, typically. Boundary Conditions Pe Ps - 1 (1+ ) W 2, U R 2 Numerical solution for Numerical Solution realistic geometries use CFD technique (staggered grids, upwinding, etc) and predict (4) K,C,M force coefficients. Radial baffles retarding fluid swirl Ps Fluid path Seal Rotor speed z Vz rotor Vx Anti swirl brake at inlet or pressure seal 17 Model validation Air in Oil Mixture SFD Diaz, S., and San Andrés, L., 2001, “A Model for Squeeze Film Dampers Operating with Air Entrainment and Validation with Experiments,” ASME J. Tribol., 123, pp. 125-133. Tangential force t Circular Centered orbit r b, mixture volume fraction Lines: predictions, Radial force Symbols: experiments Quasi-static bubbly flow model adequate for whole range of gas volume fractions (b=0.0-1.0) 18 SFD (CCO): c=0.254 mm, e=0.120 mm, 1000 rpm, ISO VG 68 Example of analysis Rotor speed, 1,047 rad/s (10 krpm) Diameter, D 116.8 mm Supply Temperature, TS 298.3 K (25 C) Length, L 87.6 mm Supply pressure, PS 71 bar Clearance, c 126.7 mm Exit pressure, Pa 1 bar Smooth seal rr=0.0005 rs=0.001 Entrance pressure loss, 0.25 Inlet pre-swirl ratio, a mixture at PS, TS Physical properties ISO VG 2 Based on a proposed test rig 0.50 Nitrogen (N2) Viscosity, 2.14 c-Poise Viscosity, 0.0182 c-Poise Density, 784 kg/m3 Density, 80.2 kg/m3 Bulk-modulus, k 20,682 bar Molecular weight 28 Surface tension, S 0.035 N/m Compressibility, Z 1.001 Vapor pressure 0.010 bar gCP/CV 1.48 Sound speed, vs 1,624 m/s Sound speed, vs 361 m/s Density at Pa, a 1.1 kg/m3 Centered seal (e=0): No static load ~ smooth surfaces; L/D=0.75, c/R=0.002 MIX OIL with N2 Mixture volume fraction b varies (0.0-1.0) Based on available test rig Predict seal Table 1 Geometry and operating conditions of seal with mixture performance 19 Seal Flow rate vs. inlet gas volume fraction Figure 2 Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) kg/s 1.4 Flow rate 1.2 ALL liquid (24.2 GPM) inlet and exit 1.0 ALL gas: 0.8 66 GPM at seal inlet 4,694 GPM at seal exit 0.6 Leakage decreases continuou sly as gas content increases 0.4 0.2 0.0 0.0 All liquid 0.2 0.4 0.6 0.8 1.0 bS : G/L volume fraction at inlet All gas 20 Gas Mass fraction vs. inlet gas volume fraction Gas/liquid mass fraction Figure 3b Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 Gas/liquid mass content increases exponenti ally with gas volume content 0.0 All liquid 0.2 0.4 0.6 0.8 1.0 bS : G/L volume fraction at inlet All gas 21 Exit gas volume fraction vs. inlet volume fraction Gas/liquid volume fraction Figure 3b Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 Ps z W U Pa 0.0 All liquid 0.2 0.4 0.6 0.8 bS : G/L volume fraction at inlet 1.0 Gas volume fraction at exit plane increases quickly because of large pressure drop All gas 22 Axial pressure drop as gas fraction increases Figure 4 Land pressure bar Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) 80 inlet pressure loss 70 Gas bs=1.0 60 50 bs0.75 40 bs0.5 Liquid bs0.0 30 20 bs0.25 10 exit pressure = 1 bar 0 0.000 All liquid: linear pressure drop. All gas: nonlinear with rapid changes near exit plane Ps 0.020 0.040 0.060 0.080 0.100 z W axial coordinate m Exit inlet Pa 23 U Drag power loss vs. inlet volume fraction Figure 5 Power loss kW Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) 8.0 Steady decrease in power; but in region of flow transition 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0.0 All liquid 0.2 bS 0.4 0.6 0.8 1.0 : G/L volume fraction at inlet All gas 24 Max. Reynolds # vs. inlet volume fraction Reynolds number (max) Figure 6 Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) 100000 axial flow 10000 Reynolds # (max) Re-circ (exit) Re-axial (exit) laminar flow region 1000 circumferential flow 100 0.0 All liquid 0.2 0.4 0.6 0.8 1.0 bS : G/L volume fraction at inlet All gas Axial flow dominates at high volume fractions. Circumf. flow Re# decreases. Re ~ V c 25 Rotordynamic coefficients – lateral motions Seal reaction forces: FX K XX - FY KYX K XY x CXX CXY x M XX KYY y CYX CYY y M YX M XY x M YY y Model for centered operation KXX = KYY, KXY = -KYX CXX = CYY, CXY = -CYX MXX = MYY, MXY = -MYX Whirl frequency ratio WFR ~ KXY Assumes: No static load : measure of rotordynamic stability CXX Y X Force coefficients are functions of frequency w for gases, and also for a two-component (gas/liquid) mixture. 26 Seal stiffnesses vs. inlet volume fraction Figure 7a Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) SYNCHRONOUS SPEED 2.0E+08 N/m Mixture viscosity decreases Stiffnesses 1.5E+08 KXY=-KYX KXY XY=-K =-KYX YX K 1.0E+08 5.0E+07 K KXX XX=K =KYY YY 0.0E+00 0.0 0.2 0.4 0.6 0.8 1.0 -5.0E+07 -1.0E+08 bS : G/L volume fraction at inlet All liquid Liquid seal (oil) has large crosscoupled stiffness. Gas seal shows strong direct stiffness All gas 27 Synchronous speed force coefficient w Seal damping vs. inlet volume fraction Figure 7b Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) SYNC SPEED 4.0E+05 Mixture viscosity decreases N-s/m -s/m Damping 3.0E+05 CCYY =C XX =CYYYY 2.0E+05 1.0E+05 CCXY =-C XY =-CYXYX 0.0E+00 0.0 -1.0E+05 All liquid 0.2 0.4 0.6 0.8 1.0 bS : G/L volume fraction at inlet All gas Direct damping decrease s as gas content increases, but in flow transition zone Crossdamping small. 28 Whirl frequency ratio Whirl frequency ratio – Stability indicator 1.00 0.90 0.80 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.00 WFR - WFR always 0.50 for inlet swirl = 0.50 – Stable operation up to 2 x critical speed 0.0 0.2 0.4 0.6 0.8 1.0 : G/L volume fraction at inlet Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) SYNC SPEED 29 force coefficients – frequency dependency Seal reaction forces (centered seal): FX K XXw FY K XYw K XYw x CXXw CXYw x K XXw y CXYw CXXw y Force coefficients are functions of frequency w for gases, and also for a two-component (gas/liquid) mixture. Y X 30 Seal direct stiffnesses vs. whirl frequency Figure 8a Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) KXX XX=K =KYY YY K 3.0E+08 N/m 2.0E+08 B=0.0 (all liquid) B=0.05 K bs0.10 bs0.75 bs1.0 Gas 1.0E+08 bs0.05 bs0.50 0.0E+00 bs0.25 B=0.10 B=0.25 -1.0E+08 Liquid B=0.5 All liquid shows added mass effect (K-w2M). All gas (b=1) has large KXX. Note increase (*) in KXX for small b=0.1 -2.0E+08 bs0.0 B=0.75 B=1.00 (all gas) -3.0E+08 0.0 0.5 1.0 1.5 2.0 whirl frequency/rotational speed Frequency (Hz) w/ (*) b=0.1: Stiffness hardening is typical in textured gas damper seals (= negative added mass) 31 Seal cross-stiffnesses vs. whirl frequency Figure 8b Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) KK XY =-K YXYX XY =-K 3.0E+08 N/m 2.5E+08 B=0.0 (all liquid) B=0.0125 k 2.0E+08 1.5E+08 B=0.025 B=0.05 B=0.10 B=0.25 B=0.5 1.0E+08 5.0E+07 0.0E+00 0.0 All liquid shows largest bs0.10 k. Liquidbs=0 bs0.025 Crossstiffness bs0.05 decreases bs bs0.25 bs0.50 with gas bs0.75 content. bs1.0 Gas Small effect of 0.5 1.0 1.5 2.0 frequency B=0.75 B=1.00 (all gas) whirl frequency/rotational speed Frequency (Hz) w/ 32 Seal direct damping vs. whirl frequency Figure 9a Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) CXX CXX =C=C YYYY N.s/m B=0.0 (all liquid) 4.0E+05 C bs0.025 3.5E+05 bs0.05 2.5E+05 B=0.025 2.0E+05 B=0.05 1.5E+05 B=0.25 B=0.5 B=0.75 B=1.00 (all gas) Liquidbs=0 3.0E+05 bs bs0.25 B=0.0125 B=0.10 All liquid shows largest C. Same as cross-K. Small effect of frequency bs0.50 bs0.75 1.0E+05 5.0E+04 Gas, bs=1.0 0.0E+00 0.0 0.5 1.0 1.5 2.0 whirl frequency/rotational speed Frequency (Hz) w/ Cross damping coefficients are one order of magnitude lower 33 Equivalent force coefficients (Ke,Ce) Seal reaction forces (circular orbits): Ft x cos( wt ) x sin( wt ) e e w y sin( w t ) y cos( w t ) Y Radial and tangential components of force Fr K e e Ft Cew e X Ke K XX( w ) w CXY ( w ) Ce C XX w 1 wt Fr w K XY w 34 Seal equivalent stiffness vs. whirl frequency N/m 2.0E+08 Keq Figure 10a Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) 1.5E+08 1.0E+08 B=0.0 (all liquid) B=0.0125 5.0E+07 B=0.025 0.0E+00 B=0.05 B=0.10 -5.0E+07 B=0.25 B=0.5 B=0.75 -1.0E+08 0.0 B=1.00 (all gas) Ke K XX w CXY Cross damping bs0.10 small. Gas, bs=1.0 All liquid bs0.05 bs0.75 shows added mass bs0.5 effect . bs0.025 All gas bs0.25 bs0.0125 (b=1) has large Ke. Liquid,bs=0 Note 0.5 1.0 1.5 2.0 increase (*) in Ke for whirl frequency/rotational speed small b=0.1 w/ 35 Seal equivalent damping vs. whirl frequency Figure 10a Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) Ceq Ns/m 3.E+05 Liquidbs=0 bs0.10 2.E+05 1.E+05 B=0.0 (all liquid) B=0.0125 0.E+00 B=0.025 -1.E+05 bs0.25 bs0.025 B=0.05 B=0.10 B=0.25 B=0.5 bs -2.E+05 bs0.05 bs0.5 bs0.75 Gas bs1.0 Note Ce=0 at w/=0.5 -3.E+05 0.0 B=0.75 B=1.00 (all gas) Ce CXX All liquid shows largest C e. Steady decrease of Ce with gas content. 1 0.5 1.0 1.5 2.0 whirl frequency/rotational speed w K XY w/ 36 Conclusions GT2011-45264 Rotordynamic force coefficients of bubbly mixture annular pressure seals Advanced (simple) computational physics bulk-flow model for prediction of seal performance static and dynamic. Assumed homogenous mixture of two components (liquid and gas). Mixture N2 in ISO VG 2 oil (DP=71 bar, 10 krpm) 1. Leakage and power loss decrease with the gas in liquid volume content – except in transition region from laminar to turbulent flow 2. Seal force coefficients show strong dependency on whirl frequency. Cross-coupled stiffnesses and direct damping coefficients decrease steadily as gas volume fraction raises. 3. Direct stiffness coefficients show atypical behavior, in particular a mixture of gas volume fraction bS=0.1 produces stiffness hardening as the excitation frequency increases. 4. Predictions justify an experimental program to quantify the static and dynamic forced performance of annular seals operating with (bubbly) mixtures 37 GT2011-45264 Rotordynamic force coefficients of bubbly mixture annular pressure seals Questions (?) Learn more at http://rotorlab.tamu.edu © 2011 Luis San Andres 38