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Combined Three-Dimensional Fluid Dynamics and Mechanical Modeling of Brush Seals
Combined Three-Dimensional Fluid Dynamics and Mechanical Modeling of Brush Seals
Combined Three-Dimensional
e-mail: d.lelli@surrey.ac.uk
Fluid Dynamics and Mechanical
John W. Chew
e-mail: j.chew@surrey.ac.uk Modeling of Brush Seals
Fluids Research Centre,
University of Surrey, Development and application of a combined 3D computational fluid dynamics (CFD) and
Guildford GU2 7XH, UK 3D bristle bending model for brush seals is described. The CFD model is created using
commercial CFD mesh generation and solver software. A small gap is assumed between
all bristles in the CFD model so as to avoid meshing problems at contact points and
Paul Cooper allow for imperfections in bristle geometry. The mechanical model is based on linear
ALSTOM Power Limited, beam bending theory and allows large numbers of bristles to be modelled with arbitrary
Newbold Road, bristle-to-bristle contact and imported from the CFD solution. Deformed geometries may
Rugby Warwickshire, CV2 12NH, UK be exported directly to the mesh generation software, allowing iterative solution of the
coupled aerodynamic/mechanical problem. 关DOI: 10.1115/1.2103093兴
1 Introduction and pressure fields in close vicinity of the bristle pack and within
the bristle matrix affect the seal dynamics and performance. In
Brush seals are a relatively new type of aerodynamic seal for
their multiple brush seals tests, O’Neill et al. 关8兴 reported bristle
turbomachinery applications. They have found increasing indus- instability caused by the momentum of the leakage flow hitting
trial use in gas turbine aero and power generation engines over the the bristle pack. The bristle pack forms a complex porous struc-
last decade. ture blocking the flow path.
A brush seal is a set of fine diameter fibers densely packed There are two main issues arising from the balance of forces on
between retaining and backing plates. There are three main com- the bristles. One is that the bristles get packed tighter as pressure
ponents: bristle pack, front plate, and backing plate 共Fig. 1兲. It is load pushes them against the backing plate while the inward radial
convenient to divide the bristle pack into two regions: the over- flow tends to move the bristle tips toward the rotor surface 共i.e.,
hanging region, as indicated, and the outer portion. The backing blow down兲. Blow down tends to close the clearance with the
plate is positioned downstream of the bristles to provide mechani- rotor surface, yet it increases the bristle tip wear. The other issue
cal support for the bristles under the differential pressure loads. is the bristle stiffening effects when the aerodynamic forces can-
The inherent flexibility enables the seal to survive large rotor ex- not overcome the internal friction within the bristle pack and with
cursions, resulting from vibration, thermal, and centrifugal the backing ring.
growth, and rotor imbalance or eccentricity during normal opera- This is called bristle hangup. After transient rotor excursions or
tion, without sustaining appreciable permanent damage. bristle wear, the clearance should close to maintain the minimum
Several workers have confirmed that the leakage of brush seals leakage, but may not due to “hangup” at high pressure loadings.
is considerably less 共ranging from 3 to 20 times兲 than that of This introduces a hysteresis issue for increasing versus decreasing
labyrinth seals when tested at the same conditions 共see, for ex- pressure loading during operation. Additionally, swirl in the flow
ample, 关1–7兴兲. In addition to significant leakage reduction, the approaching the seal can produce other aerodynamic forces on
flexible brush seals maintain stable leakage performance for bristles at the upstream face. The flow within the bristle pack is
longer service while labyrinth seals suffer permanent performance the driving mechanism of the seal dynamics; therefore, a clear
degradation due to transient rotor excursions. The main advantage flow representation is required.
of a brush seal is the achieved minimum clearance between the The aim of the present work is to study the brush seal with a
rotor surface and bristle tips. The brush seal fits the rotor surface computational fluid dynamics 共CFD兲 analysis, considering the full
with a very small clearance or in interference; therefore it is re- three-dimensional 共3D兲 flow among the bristles, and a mechanical
ferred to as a contact seal. When contact occurs, the only flow model predicting the 3D bending behavior of bristles. The mod-
path through the seal is via voids among bristles in the overhang- eling approach is also described in Sec. 2 with results presented in
ing region. Another characteristic feature of a brush seal is that the Sec. 3. Conclusions and future work are described in Sec. 4.
bristles are inclined in the direction of rotor rotation with a typical
lay angle of 45 deg to the radial direction. The flexible bristle 2 Mathematical Modeling
bundle tolerates rotor excursions with less wear compared to other
sealing applications. The flexible bristles also close the clearance 2.1 Overview. In the present work, the capability to calculate
as they wear out or after transient rotor excursion by changing brush seal behavior is developed by combining 3D, detailed CFD,
their lay angle due to inward radial flow in the bristle pack from flow modeling with a 3D mechanical model. The method used
the radial pressure gradient. This dynamic behavior of a brush involves iterations between CFD and mechanical models. The
seal, called blowdown, maintains a good leakage performance. A three main components of the iterations are as follows:
good brush seal bibliography is given in the literature 关6兴. 1. Geometry definition and MESHING.
Flow analysis of the brush seal, which is of interest in this 2. CFD solution for the 3D flow through the bristles.
study, is a key element of research into seal behavior. The flow 3. Mechanical solution to obtain bristle displacements.
The iterative procedure is illustrated in Fig. 2. After the CFD
Contributed by the International Gas Turbine Institute 共IGTI兲 of ASME for pub- calculation is carried out, the aerodynamic forces on the bristles
lication in the JOURNAL OF TURBOMACHINERY. Manuscript received October 1, 2004;
final manuscript received February 1, 2005. IGTI Review Chair: K. C. Hall. Paper
are available. These are given as input to the mechanical model,
presented at the ASME Turbo Expo 2005: Land, Sea, and Air, Reno, NV, June 6 - 9, together with the “old” bristles’ configuration and a new deformed
2005, Paper No. GT2005-68973. geometry is calculated. Importing the new geometry to the mesh
188 / Vol. 128, JANUARY 2006 Copyright © 2006 by ASME Transactions of the ASME
Fig. 3 Simple brush seal used in the present work showing the bristle
numbers
step, the CFD solution for the initial configuration, with the un-
deformed bristles, is performed. The aerodynamic forces are ob-
tained by running a user defined function 共UDF兲 in the CFD pro-
Fig. 4 Mesh detail in the backing-ring end region „coarser gram. This function is programmed in the ”C” computing
mesh… for a deformed configuration; the figure shows the small language and calculates the aerodynamic forces on the bristles
gaps between the bristles from the flow solution. The output from the UDF is a distribution
of force per length along the bristles. For the mechanical problem
the bristle bending problem is discretized by defining a number of
mation on the code is given by Guardino and Chew 关11兴. Validity elements along the length of each bristle and approximating all
of the present calculations is discussed further in Sec. 3.2.2 forces on the bristle to point forces acting on the elements’ nodes.
The forces on these nodes are obtained by integrating the force
2.3 Meshing. The brush seal geometry contains very high as- distribution over the areas corresponding to the mechanical model
pect ratio 共L / ␦ ⬵ 1200兲 channels, between the bristles. This leads element. To get the discrete force distribution, the surface of the
to some difficulty in keeping the mesh fine enough to capture the bristles is split into 19 elements with a finer element size where
flow in the small gaps between bristles while economizing on the gradients are expected to be the largest, and coarser elsewhere.
mesh points in regions less affected by high gradients. Further The integration to get the forces acting on the mechanical
problems arise when considering the deformed geometry as it is model nodes is done using a ”C” program that takes the discrete
then not possible to perform a simple projection of a face mesh force distribution as input and returns a file, containing the forces
along a straight line. that can be used as the input file for the mechanical model. The
The mesh generator used in the present work is GAMBIT 关13兴. integration process is completely automatic.
The geometry output from the mechanical model gives a series of The deflected configuration is then calculated and output to
vertex coordinates for each bristle. In producing this geometry the files, each storing the points of a bristle. These files are then used
bristle diameter is assumed to be slightly smaller 共typically as input for the meshing software. The geometry definition and the
1.52 m for a 76 m bristle diameter兲 than the actual diameter meshing procedure are automated using a ”journal file” 共see Ref.
assumed in the bending calculation. This avoids contact between 关13兴兲. Analogous procedures are also possible for other commer-
bristles in the CFD model, and may be justified by considering cial mesh generators. To keep this meshing procedure completely
that the bristles will not be perfectly smooth and some leakage automatic, the following approach was adopted:
will occur in practice, due to geometry imperfections. The vertex
data can be read into the mesh generator. • Definition of a volume containing the finer and unstructured
Current meshes use a mix of hexahedral and tetrahedral cells. part of the mesh, but large enough to contain the deflected
Results from two meshes will be presented here. The coarser mesh bristles.
is shown in Fig. 4 and has ⬃800 000 cells. The finer mesh has • Bristles’ radius reduction to avoid bristle intersections as
⬃1 700 000 cells. Considering all the meshes used here the maxi- explained in Sec. 2.3.
mum element skewness was 0.4 and the maximum aspect ratio 18.
3 Results
2.4 CFD Solution. The flow through the bristle pack has been
calculated with the FLUENT 关12兴 CFD package, using a laminar 3.1 Simplified Geometry. The iterative coupling procedure
model. The assumption of laminar flow is justified by the low was first used to predict the 3D bending behavior of bristles in the
Reynolds number of the flow in the gaps between the bristles. For simple brush seal shown in Fig. 3. The parameters employed in
example, with a gap size of 5 m, velocity of 100 m / s, pressure this work are as summarized in Table 1 unless otherwise stated.
of 2 ⫻ 105 Pa, and temperature of 300 K, the Reynolds number is The Young’s modulus used is for a cobalt-based alloy known as
about 67. Total pressure was specified at the inlet, static pressure Haynes-25 共see Ref. 关14兴兲. Incompressible flow and an axially
was specified at the outlet, and no-slip conditions applied on all directed inflow is assumed in this simplified model. Each iterative
walls. For the axial inflow cases the flow angle was specified as calculation in the mechanical model has been continued until the
axial, otherwise the inlet “swirl” velocity was specified. An im- displacement residual was much smaller than the deflection.
plicit steady 3D solver, with a second-order upwind differencing The axial aerodynamic forces per unit length acting on each of
scheme, with the “SIMPLE” pressure-velocity coupling algo- the five bristles and the pressure field on the periodic plane of the
rithm, was used to obtain the fluid dynamics field. Once the CFD incompressible CFD solution are shown in Figs. 5 and 6. Note
solution was obtained, a UDF 共i.e., user defined function 关12兴兲 that the bristle numbering starts with the most upstream bristle,
was used to calculate the aerodynamic forces on the bristles; more and that these results are for an undisturbed pack. Strong varia-
details about this procedure will be given in Sec. 2.5. tions in aerodynamic force 共associated with strong flow varia-
tions兲 occur on the downstream bristles near the backing ring edge
2.5 Coupling Procedure. As described in Sec. 2.1 above, the position which almost divides the bristle pack into two separate
iterative solution procedure involves successive runs of the CFD regions. In this case, convergence of the coupled procedure was
solver, the mesh generator, and the mechanical model. In the first rapid, and the aerodynamic forces changed by no more than about
these cases a combined 共rather than fully coupled兲 analysis was sure distribution.
undertaken. In the combined model aerodynamic forces calculated Figure 11 shows the axial deflections for the bristle centerlines
for the undisturbed bristle pack were used in the mechanical at different pressure loadings. These show the expected trends.
model without iteration. As will be shown below the combined The aerodynamic blow-down results in a reactive force on the
model yielded very encouraging results. rotor. Although friction is neglected in the initial estimate of the
From the CFD results, the static pressure distributions near the shaft reaction, it is straightforward to correct this calculated reac-
overhanging region on the middle circumferential plane for the tion to allow for friction between bristle tips and rotor, and then
⌬P 4 and 12 bar cases are shown in Fig. 9. Note that, with the estimate the rotor torque. The essential point is that the component
assumed hexagonal packing arrangement, this plane cuts through of reaction normal to the bristle is given by the frictionless solu-
just five bristles. It is clear from the pressure field that the region tion and this must remain the same in the case with rotor/bristle
near the bristle roots is quiescent. The strongest flow develops tip friction. This procedure does not, of course, take account of
close to the backing ring corner region, as for the simplified ge- friction with the backing ring and between bristles which can also
ometry. In this case with the nonzero lay angle, the gradient in the be important. Results from this calculation, using a friction coef-
radial pressure creates a blow-down force on the bristles, pressing ficient of 0.3, chosen in the middle of the range given by Aksit
the bristle tips into the rotor. 关15兴, are shown in Fig. 12, which also includes Oxford Universi-
Aerodynamic forces on the bristles are extracted from the CFD ty’s experimental data. The experimental data was obtained from
solution and are presented in Fig. 10 for the ⌬P = 12 bar case. transient ”run-down” experiments which showed significant varia-
These graphs show the forces per unit length used to get the point
tions in torque 共see for example, Wood et al. 关10兴兲. The experi-
forces for the mechanical model. B10 is the downstream bristle in
mental results in Fig. 12 are the maximum values reported. Given
these graphs. Axial forces are positive in the streamwise direction.
the uncertainties, the agreement with the present model is consid-
Radial forces are positive when directed away from the rotor.
ered very good. Leakage flow rates were also compared with ex-
Circumferential forces are positive when directed in the usual di-
perimental data and were found to be about half the measured
rection of rotor rotation. It is clear that the maximum forces occur
on the downstream bristle. The aerodynamic blow-down force is values. This suggests that the perfect packing and interbristle
strongest near the backing ring edge, as expected from the pres- clearance assumed in the analysis may not be fully representative.
Further discussion of this is given in Sec. 3.2.4.
The deflections considered here are well within the range of
validity of the linear bending theory 共see, for example, Stango
Table 2 Brush seal parameters et al. 关16兴兲. However the model does not include “liftoff” of
bristles from the shaft surface due to axial bending. This effect
Packing type Hexagonal will be of order d / L times the axial deflection. However here it is
Total number of bristles 10 appropriate to replace the full bristle length L by the length of the
Lay angle ⌽ 40 deg bristle overhanging the backing ring. This gives a possible liftoff
Bristle length L 13.35 mm of about 10 m. In practice this may be countered by the blow-
Height of bristle overhang H 1.00 mm down effects due to the forces in the radial and circumferential
Bristle diameter D 0.100 mm directions. Note also that the mechanical model does allow liftoff
Young’s modulus E 2.25⫻ 1011 N / m2 or blowdown due to forces in the radial and circumferential direc-
Minimum initial clearance between bristles ␦ 0.004 mm tions.
Number of bristle elements K 20
Initial rotor interference Zrotor 0.00 mm 3.2.3 Swirling Inlet Flow. The model used above was ex-
tended to include the effect of inlet swirl. Results were obtained
Fig. 13 Large pack bristle tips. The dashed lines indicate the
slipping planes in the pack; ---- initial position;—last
position,—backing ring.
Acknowledgment
Financial support for this work from ALSTOM Power Limited
is gratefully acknowledged. The authors also wish to thank col-
Fig. 11 Bristle deflections in the axial-radial plane „a… 4 bar „b… leagues at ALSTOM, the University of Surrey, and the University
7 bar „c… 12 bar of Oxford for their technical input. This includes the brush seal
test data referred to in this report which was generated at the
University of Oxford.
fully coupled procedure, with CFD mesh generation for the de-
formed geometries being the main difficulty. The results obtained Nomenclature
give insight into brush seal behaviour and there is considerable BR ⫽ Backing ring
scope for further development and exploitation of the method, D ⫽ Diameter of bristle
particularly as the available computing power continues to im- d ⫽ Bristle deflection
prove. d* ⫽ Normalized bristle deflection 共=d / D兲
Torque predictions from the model are in good agreement with H ⫽ Backing ring overhang height
experimental data. Leakage flows appear to be underpredicted, but K ⫽ Number of bristle elements
these will be sensitive to the packing and inter-bristle clearance L ⫽ Actual bristle length