Gas film vibration inside dry gas seal gap

Renat Badykov Houston Wood

Samara National Research University University of Virginia
Samara, Russia Charlottesville, USA
renatbadykov@gmail.com hgw9p@virginia.edu

Sergei Falaleev Alexander Vinogradov

Samara National Research University Samara National Research University
Samara, Russia Samara, Russia
sergey_falaleev@mail.ru a.s.vinogradov@list.ru

Abstract—This paper provides a numerical technique to
determine the dynamic characteristics of a gas film inside a dry
gas seal gap based on steady-state and transient CFD
calculations. Two dry gas seals with spiral grooves were studied.
Steady-state calculation results were compared with the
experimental data. The transient dry gas seal model was created
to obtain the dynamic characteristics of a gas film. This model is
able to take into account the mutual influence of stator and rotor
rings on a gas film. This is made by adding the mesh deformation
within very small range (from 2 to 10 microns) along with adding
for the mesh the ability to move freely within a big range (up to
500 microns). FSI simulation was added to solve Reynolds-
averaged Navier-Stokes equations and dynamic equations of
rigid body motion together. Using steady-state and transient gas
film models, dynamic and static opening forces were obtained for
the different gap values. Gas film stiffness was calculated. In
order to determine the oscillation frequency of a gas film, Fourier
transform was applied.
Keywords—dry gas seal; gas film stiffnessm; axial vibration
I. INTRODUCTION
There are a number of different types of gas seals, which
are used in mechanisms of various types. Two main criteria
determine what seal type is better for certain application. These
criteria are operational lifetime and sealing performances (in
other words, leakage). A labyrinth seal is the most widely used.
This seal type is very simple and reliable; however, this type of
seal has the highest leakage. Contact seals were widely used in
leakage between stator ring (6) - stator (9) and rotor ring (1) -
rotor (3). Spiral grooves pump gas inward. The action of the
gas flowing across the seal generates an opening force (W) that
keeps a gap (h) (typically about 2-5 microns). In order to
maintain the normal operation of the seal, the gap opening
force must be equal a gas closing force, which is the sum of a
high pressure on the external face of a stator ring (WOUT) and a
spring force (WSP). However, in practice, the gap opening force
could be significantly greater or smaller than the closing force
(by 11 times) under the increased rotor vibrations [1]. These
operation modes may lead to a seal failure. This issue prevents
the application of this seal type to different power units, like
aircraft engines.
There are a number of oscillations during a dry gas seal
operation: radial, angular (due to an axial eccentricity,
manufacturing imperfections or an assembly misalignment)
and axial (due to a rotor runout). A dry gas seal is able to track
the axial rotor vibration, but this ability is limited. If the gap
increases, the opening force decreases. The closing force
becomes greater than the opening force and an initial gap gets
back. Similarly, if the gap narrows, the opening force increases.
The closing force becomes lower than opening force and a gap
gets back again. However, the increased axial oscillation leads
to a wide opening of a sealing gap and to the subsequent
contact between the sealing rings.
9 8
Wsp P2 gas dg 1
W out W
3
calculated

the aircraft engines of the previous generations. This seal type

domain

4
has the lowest leakage, but these seals have relatively low
r0
2 4
operation lifetime less than 6000 hours [1]. There is a seal type
rg

that combines both benefits described above. This is a dry gas

rb

seal. Currently, dry gas seals are widely used in the ground gas P1 7 6 5 5
h
r1

pumping units. This seal type has high sealing performance and
long operational lifetime. 


A dry gas seal (Fig. 1) usually consists of a rotor ring (1), b2

with grooves on its face (2). Rotor ring is attached to a rotor (3) W=Wsp+ Wout b1
with a self-adjustment possibility. The axial movement of the
rotor ring is limited by sleeves (5). Stator ring (6) is pressed to 
the rotor ring, by a set of springs (8) through a follower ring
(7). Additional elastomeric sealing rings (4) are used to prevent Fig. 1. Dry gas seal with spiral groove (operating principle and design)
978-1-5386-4785-1/18/$31.00 ©2018 IEEE
 It is necessary to determine safe operating condition and
boundaries where a seal works without the contact and
Interface P2 Outside pressure
Frozen Rotor
destruction. The main issue is to determine the dynamic
characteristics of a seal gas film. 1
It should be mentioned that the idea of a dry gas seal comes
from the spiral groove bearings. First original study of the Interface
2 Interface
Stage/Frozen Rotor
spiral groove bearings was made by Whipple in 1947 [2]. From Frozen Rotor
1980th to 1990s there was an explosion in analytic methods. Gap
Among them were E. Muijderman [3], I. Green, I., Etsion [4]
and B. Ruan [5], who created theory bases for calculation
techniques. Those techniques are currently used in industry.
P1 3 Inside pressure

Starting from the late 1990th scientists start to use numerical

techniques to determine the sealing performances created
semianalytical models. B. Miller, I. Green [6-7] and B. Ruan

[8] were the first who started to study a dry gas seal using finite Fig. 2. Steady state gas film model (three domains)
element method. Works [9-11] are focusing on the
investigation of a seal operation using steady state CFD models Different turbulence models were used in order to choose
of a dry gas seal. Those models provide good results for the the most accurate one. A roughness of the sealing rings faces is
normal operational conditions; however, a seal could work taking into account. Boundary types of the Inlet and Outlet are
under rotor vibrations. Those conditions lead to compression of the Opening. This boundary type allows gas to go from the gap
a sealing gas film within a big range [12]. In some cases, through the inlet under. It is especially important if the pressure
compression can lead to a leakage through the inlet gap. S. Lee in the gap becomes greater than the inlet pressure P2. There is
and X. Zheng started to consider the axial vibrations and the one significant assumption here. Stator and rotor faces of the
stator misalignments in their finite element models [13]. gap are considered to be a plane parallel to each other in this
Almost all analytical techniques were created to analyze a dry model, while in reality, they are tilted and deformed [19].
gas seal with spiral grooves. But finite element method can be Spiral grooves are made according to a parametric form of the
easily applied to study different types of dry gas seals, like logarithmic spiral equation (where t is angle):
bidirectional grooves [14]. In the most recent works [14-17]
scientists continue to update their steady state models to
investigate different aspects of a dry gas seal operation, without (1)
considering of the transient effects. Y. Chen, J. Jiang, and X.
Peng recently provide the transient sealing performance
analysis using seal kinematic and CFD models of the seal
Seal design parameters and operational boundary
under axial and angular excitations, however, they used linear
conditions of R. Gabriel seal [20] are used to solve this model.
gas film dynamic coefficients in the kinematic mode [18].
The parameters are presented in the Table 1.
Those coefficients are strongly nonlinear due to the
compression of the gas film and the absence of permanent mass At the beginning, the total number of element did not
flow rate through the input and output. exceed 10 million. The main mesh criteria are a number of
elements in the gap to describe the flow in the axial direction.
This work is focusing on using the transient CFD model of
The number of elements was reduced to one million after
a dry gas seal to determine the dynamic characteristic of a seal.
conducting several additional simulations (Fig. 3).
This model solves Reynolds-averaged Navier-Stokes equations
and dynamic equations of rigid body motion together using
two-way Fluid-Solid Interaction (FSI). All models are prepared TABLE I. PARAMETERS OF THE GABRIEL’S SEAL
in commercial code Ansys CFX 18. Those models could be
Parameter Value
used to provide a seal operation analysis under the high rotor
vibration. Outside radius (r0, mm) 77.78
Inside radius (r1, mm) 58.42
Groove radius (rg, mm) 69
II. CFD MODELS Groove angle (, degree) 15
As a first step, a steady state CFD model was created (Fig. Ridge width/groove width (b1/b2) 1
2). It is symmetrical in the circumferential direction. Three Groove depth (dg, micron) 5
domains were used to simulate the flow in the sealing gap. First Sealing gap (h, micron) 3.05
domain is the outside pressure, the second one is the gap itself Outside pressure (P2, kPa) 4585.2
and the third one is inside pressure. The second domain is Inside pressure (P1, kPa) 101.3
rotational, the first and third ones are stationary. The
Outside temperature (T2, K) 303
connection between the first and the second domains is made
by adding the Frozen Rotor interface or Stage (where the Rotational speed (, RPM) 10380
outside pressure connects with the groove inlet). The Closing Force (W, N) 33168.7
connection between the second and the third domains is the Number of grooves 12
Frozen Rotor interface too. Gas air
 Interface 1 P2 Subdomain
Frozen Rotor Oscillation
Wout
1
Wsp 3 Axial
Oscillation
Subdomain Subdomain
Rigid Body
P1 2 Unspecified
Interface 3 Interface 2
General Connection  Frozen Rotor

- specified mesh motion - rotational domain

Fig. 3. CFD model with a gap mesh
The aspect ratio of the core elements must not exceed 100,
while the aspect ratio of the core elements near the wall must
not exceed 1000 [21]. It is also important to check Y+
coefficient that has to be less than one. Mesh is made of cubes
and prisms elements. Those elements are oriented in the axial
direction of the seal to provide mesh deformation for transient
model. The steady state model can be easily solved using a
desktop computer with 16GB RAM and 4 cores processor 2500
Hz (approximately 3-4 hours).
A steady state model of a seal is used to verify the whole
simulation technique, to compare simulation results with the
experiment and to get the static characteristics of the gas film
(leakage, static stiffness, average opening force). However, this
model cannot be used to analyze the seal operation under the
high rotor vibrations.
To obtain the dynamic characteristics of a seal or find out a
gas film behavior under the high rotor vibrations, a transient
gas film model was created (Fig. 4). It is two domain model
with three subdomains (the first one is a rotational domain, the
second one is stationary). It was decided to eliminate from the
simulation the Outside pressure domain (Fig. 2) due to a
significant increase of the calculation time, while it does not
improve the accuracy of the final results. The mesh of the
Oscillation subdomain can be moved, but cannot be deformed.
The mesh of Unspecified Subdomain can be moved and
deformed. The meshes of the Oscillation and the Fixed
Subdomain were made undeformable in order to keep the size
of near the walls elements. The harmonic axial oscillation is
applied to the Oscillation Subdomain. This model still can be
solved using the desktop computer but depending on the
boundary conditions or the size of a seal it might need a cluster.
- rigid body mesh motion - stationary domain
- unspecified mesh deformation
Fig. 5. Full transient FSI model of a seal
This model does not require any analytical techniques to
determine the dynamic stiffness of a gas film (this is a main
issue for the seal analysis under the high rotor vibrations). It is
possible because Reynolds-averaged Navier-Stokes equations
and dynamic equations of rigid body motion are solving
together. For these purposes, FSI simulation is added. This is
three domains model. It is necessary to use the additional
domain 3 (the stationary one) in order to create the interaction
between Rigid Body (stator ring mass + mass of a following
ring) and Fluid (a gas film). Ansys CFX 18 does not support
the interaction of the Rigid Body and the rotational domain.
This is also a reason for adding an additional interface Frozen
Rotor 1 between the rotational and the stationary domains in
the gap. The external closing force and the springs force are
taken into account. All mesh elements can be moved, at the
same time the elements in the Unspecified subdomain can be
deformed. This model does require access to a cluster. The
calculation process takes a significant time depending on the
excitation signal (harmonic rotor oscillation) and the size of a
seal. It took 132 hours for a cluster (16 Intel Xeon processors
and 256Gb RAM) to get results presented in this paper.
These models were created and studied using two seals
design. First one is the seal studied by R Gabriel [20]. The
second one is the seal created in Samara University by S.
Falaleev [22]. It is also the dry gas seal with spiral grooves.
Parameters for the second seal are presented in the Table 2.
TABLE II. PARAMETERS OF THE FALALEEV’S SEAL

Next step is a full transient FSI model of the seal (Fig. 5). Parameter Value
This model is used to verify the dynamic models of a dry gas Outside radius (r0, mm) 112.5
seal and results obtained by previous models. Inside radius (r1, mm) 89.85
Groove radius (rg, mm) 101
Subdomain
P2 Subdomain Groove angle (, degree) 13.5
Fixed Oscillation Ridge width/groove width (b1/b2) 1
1 Groove depth (dg, micron) 5
Axial Sealing gap (h, micron) 2.2
Oscillation
Subdomain Outside pressure (P2, kPa) 6180.8
Unspecified Inside pressure (P1, kPa) 101.3
P1 2 Outside temperature (T2, K) 298
Interface 1
Frozen Rotor Rotational speed (, RPM) 5500
 Closing Force (W, N) 74843
Number of grooves 12
Fig. 4. Transient gas film model with mesh deformation Gas air
 III. RESULTS AND DISCUSSIONS TABLE III. STEADY STATE RESULTS FOR THE FIRST INVESTIGATED SEAL

Several calculations of the steady state model of the seal Opening Leakage,
Case
were conducted using the different settings and turbulence Force, (kN) (g/s)
models (Tab. 3). The results of numerical simulations were Gabriel’s experiment 33.17 0.332
compared with R. Gabriel results. Despite the fact that steady Laminar/ (domain 2) 32.14 0.572
state three domain model (Fig. 2) determines the opening force SST/ (domain 2) 32.29 0.543
(i.e. pressure distribution in the sealing gap) more accurately SST/ Rough walls, (domain 2) 32.62 0.463
(opening force error is 0.15%), the presence of the Outside SST/ Int. Froz. Rotor/ (domains 2,3) 32.84 0.361
pressure domain significantly increases the calculation time. It SST/ Int. Froz. Rotor
was decided to eliminate this domain from the simulation. All 32.86 0.338
Rough walls/ (domains 2, 3)
further investigations were conducted using the marked case in
table 3 (2 domain SST model with rough walls). SST/ Int. Froz. Rotor
33.22 0.281
Rough walls, (domains 1, 2, 3)
The pressure distribution in the gap is shown in Figure 6. It SST/ Int. Stage
is unevenly distributed in the circumferential direction. The 33.19 0.447
Rough walls, (domains 1, 2, 3)
point of the maximum gas compression is located on a higher
radius than the groove radius (rg). Results of the pressure TABLE IV. STEADY STATE RESULTS FOR THE SECOND SEAL
distribution in a radial direction are presented in Figure 7. The
dashed lines represent the maximum and the minimum values Opening Leakage,
Case
of the pressure on a certain radius. The difference between the Force, (kN) (g/s)
maximum and the minimum pressure riches 1 MPa. In some Falaleev’s experiment 75.75 0.55
cases when a seal operates with a presence of the high rotor Simulation 80.68 0.53
vibration, this pressure difference in the circumferential
direction can cause the waviness of the seal [23].
The static opening force was obtained for the different gap
values (Fig. 9). It was compared with R. Gabriel calculation
results. The results are different when the gap is smaller than 2
microns. This can be explained by a consideration of a rings
tilting by R. Gabriel in his calculations. Than the dependence
of the opening force on a sealing gap was represented by the
polynomial function of the fifth order. The static gas film
stiffness is obtained by differentiation of the polynomial
function (Fig. 10).
In order to determine the dynamic characteristics of a seal
Fig. 6. Pressure distribution for the equilibrium gap the transient gas film model (Fig. 4) is used. It is possible to
determine the dynamic opening force applying the excitation
Table 4 presents the simulation results for the Falallev’s signal to the Oscillation Subdomain. The dynamic opening
seal. The leakage error riches 8.5%. This error can be caused force strongly depends on the amplitude and the frequency of
by the assumption of a plane parallel gap made for the model. the excitation signal, i.e. it depends on the velocity of the gas
The stator and rotor rings faces are tilted and deformed when a film compression. Then the dynamic stiffness can be calculated
seal operates. However, for the first investigated seal the results using the resulting data. The initial gap for the calculation is 5
are consistent well with the experimental data (the opening microns. Harmonic oscillation was applied. The excitation
force error is 1%; the leakage error is 2%). This can be frequency is 173 Hz, generated due to the rotor runout. The
explained by the higher stiffness of the sealing rings in the first average amplitude is 0.110 mm [1].
case. High rings stiffness leads to a smaller tilting amplitude The pressure distribution for the squeezed 2 microns gap is
and smaller deformations of sealing rings. The simulation presented in Figure 11. The maximum pressure in the gap is
results of the pressure distribution in a radial direction for the almost 3 times greater than the outside pressure. This results in
Falaleev’s seal are presented in Figure 8. The difference negative mass flow rate through the inlet.
between maximum and minimum pressure exceeds 1.3 MPa.

Fig. 7. Pressure distribution in radial direction (the first investigated seal) Fig. 8. Pressure distribution in radial direction (the second investigated seal)
 Fig. 9. Dependence of the opening force on a sealing gap

Fig. 12. Mass flow rate in the inlet and outlet for the excitation signals:
1. Freq. 173 Hz, ampl. 0.11 mm 2. Freq. 50 Hz, ampl. 0.05 mm

Fig. 10. Static gas film stiffness

The flow leaks mostly through the groove. The seal leakage
(mass flow rate through the gap outlet) is almost constant for
the both excitations (Fig. 12). It can be explained by the
Fig. 13. Positions of sta tor and rotor rings
influence of two opposite factors. The first one is a gap obtained by transient simulation for the first investigated seal
decreasing while the second one is pressure grows in the gap.
Next, the result of the full transient simulation was It was found out that the gap and the opening force oscillate
obtained. The results for the excitation with 173 Hz frequency with two frequencies near the equilibrium values. The lower
and 0.110 mm amplitude are shown in Figure 13. This is the frequency corresponds to the excitation caused by rotor runout
graph of the excitation and response signal in mm and gap (173 Hz). While the higher frequency is hundred times bigger
changes in microns. The excitation signal corresponds to the than the harmonic excitation (20.2 kHz). It can be explained by
movements of the rotor ring, while the response signal the compressions of the gas film near the equilibrium position.
corresponds to the movement of the stator ring. The difference
between those signals is the gap value. The contact between
rotor ring and stator ring is absent for the present operation
conditions, i.e. the stator ring of the seal successfully tracks the
movement of the rotor ring.
In order to determine the gap frequency, Fourier transform
(FFT) was applied. The opening force and the gap data have
been prepared for the analysis. The average opening force
(opening force for the equilibrium gap in this case) was
subtracted from the force data, obtained by the simulation of
the full transient seal model (Fig. 14). Similarly, the
equilibrium gap value was subtracted from the gap data (Fig.
15). Two spectrums are similar to each other.

Fig. 11. Pressure distribution for the squeezed 2 m gap Fig. 14. FFT analysis of the opening force data for the first investigated seal
(excitation signal with frequency 173 Hz and amplitude 0.110 mm)

Fig. 15. FFT analysis of the gap data for the first investigated seal
Those frequencies have been found for the operation of the
second investigated seal. For the harmonic excitation with 92
Hz frequency and 0.150 mm amplitude, the lower frequency is
92 Hz, while the higher frequency is 41.8 kHz.
IV. CONCLUSIONS
1. Static opening force and gas film stiffness were
determined by calculation of the steady state model. Initial
condition for a transient calculation was obtained. Calculation
results for the first investigated seal are different within 2%
from the experiment data. While the calculation results for the
second investigated seal are different within 8% from the
experiment data. This can be explained by the higher stiffness
of the sealing rings in the first case, which makes the
assumption of a plane parallel gap possible. A high rings
stiffness leads to a smaller tilting amplitude and smaller
deformations of sealing rings.
2. The nonlinear dynamic stiffness of a gas film can be
determined by the calculation of the transient gas film model.
This model considers not only the compression of the gas film
but also a presence of the reverse flow through the gap inlet
under the rotor vibrations.
3. This paper presents the simulation results of the full
transient seal model on nominal operational conditions. A gap
and the opening force oscillate with two frequencies near the
equilibrium values. The lower frequency corresponds to the
harmonic excitation, while the higher frequency could be
hundred times bigger than the first one. However, this model
can also be used to simulate a seal operation under the high
rotor vibrations (in that case a sealing gap behavior would be
completely different and the contact between sealing rings
could be detected).
ACKNOWLEDGMENT
This work was supported in part by ROMAC lab.
(University of Virginia, School of Engineering and Applied
Science). This support is gratefully acknowledged. Fulbright
Scholar Program provided the finances.
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