Professional Documents
Culture Documents
Klaus Steff
Manager of Development Mechanics
Rainer Gausmann
Development Engineer
and
Marcus Schmidt
Development Engineer
Siemens Energy Sector, Oil & Gas Division
Duisburg, Germany
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ABSTRACT
For many application fields of turbocompressors the rotor
stability has become the most important part of the rotordynamic
analysis. A comprehensive knowledge of these seal forces is
mandatory to ensure an adequate overall design of the compressor
as early as the quotation phase. While in earlier times the focus was
on the balance drum contribution as the major source of excitation,
it has in the meantime become evident that the effects from
the impeller eye-seals also have to be considered as a further
destabilizing contribution. However, up to now the task of
measurement of impeller-eye-seal dynamic coefficients has
remained a major challenge.
This paper presents a new approach for generation of high-quality
data on a unique full-scale high-pressure test rig, in which specific
attention is paid to impeller-eye seals. The applied strategy combines
results from the test rig obtained from different methods with
findings from computational fluid dynamic (CFD) investigations.
The publication of dimensional data offers further use of these
results within the turbomachinery community.
INTRODUCTION
In the mid-seventies the instabilities of the Kaybob (Smith,
1974) and Ekofisk (Cochrane, 1976) compressors erased the
former belief that the gas-seal forces are negligible quantities.
More than 30 years of research and development have taken place
since then, but a reliable determination of these destabilizing forces
seems to be still an issue of highest interest, as outlined below. This
high importance is also driven by the continuously changing
requirements on centrifugal compressor duties.
As oil fields deplete in the accessible regions of the world,
oil companies are forced to search for oil in fields located in
increasingly difficult environments, at increasing depth below
ground, and increasing remoteness from the markets. Frequently
this remoteness leads to liquefaction of huge amounts of natural
gas in large liquefied natural gas (LNG) plants; this is one of the
currently booming markets.
In other cases it is necessary to reinject gas into the oil reservoir,
where the trend is toward higher well-head pressures. This is not
only to boost oil field production; more and more of the new fields
have a less favorable gas composition, e.g., with extremely high
H2S content. In such cases reinjection is also driven by ecological
considerations. These are also the key driver for other emerging
markets such as CO2 compression. There are various ways of
processing this greenhouse gas, ranging from enhanced oil
recovery (EOR) via CO2 sequestration into underground storage to
transportation, in particular from fossil power plants through
dedicated pipelines.
In these markets, which are currently highlighted, dynamic seal
forces play a decisive role in rotordynamics and consequently in
the overall compressor design. Beyond these applications there are
many other compressors, in which competition between vendors
leads to a removal of too large safety margins and which requires
accurate knowledge of the dynamic seal forces. In any case, an
inaccurate prediction may result in unstable, excessive vibrations
during shop-testing oreven worseduring commissioning of the
unit or they may also appear later in the production phase. The
ongoing trend for expanded size and power rating of projects leads
to an increasing commercial risk of late delivery or downtime.
The latest edition of API 617 (2002) now accounts for the
relevance of the dynamic seal forces and asks explicitly for a
stability analysis. Since there is no generally accepted method for
determination of the dynamic seal forces, very different
approaches are in use and lead to a very wide spread of rotor
stability results. This has been demonstrated most impressively in
a recent paper of Kocur, et al. (2007), in which the result of a
comprehensive survey on tilting-pad journal-bearing and gas-labyrinth
seal coefficients is published. For a complete set of given input
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
55
FUNDAMENTAL CONSIDERATIONS
FOR SEAL FORCE DETERMINATION
simulation.
Anchor
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For the impeller-eye labyrinths, which are the focus of this paper,
this general format is not needed. However, examination of the
results for positive and backward motion indicates clearly that the
classical stiffness and damping model with direct and cross-coupled
coefficients is an inadequate model. Therefore, the linear model for
the transfer functions D and E as described in Schmied, et al.
(2002), is expanded to fit the measured forces also by inertia terms
mR and mQ in the following way:
This results in the radial and tangential forces over the orbit radius e:
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
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Validation of Calibration
Since a number of correction and calibration steps were
implemented, the overall system complexity and the data-processing
software with a lot of conversions are far from trivial. Therefore the
authors looked for means that are suitable for overall validation
purposes of the entire calibration rather than relying on proper
combination of several localized measures. Ideally, the simplest
quantities are used for this validation, like the two following items.
An elastic bar with rigid support on one end was mounted and
attached to the rotor identically with the quill shaft used for the
normal drive as shown in Figure 7. The stiffness of this elastic
bar was determined to be k=1.49 lbf/mils (0.26 N/m) for the
nonrotating shaft using the implemented identification software.
The direct measurement of this stiffness on a simple external device
with rigid support on one end and a precisely known gravity load at
exactly the same axial location was k=0.71 lbf/mils (0.125 N/m).
Static Calibration
The force-current-characteristic (F,I-characteristic) was determined
at the bearing suppliers laboratory for an array of eccentric
positions of the journal in the bearing stator (Figure 6). These data
form the basis of the static calibration and the determination of
magnetic bearing linear coefficients ki and ks. In order to obtain a
good linear F,I-characteristic in the operating point the magnetic
bearings are designed for a high bias current of 7. Ampere.
For the well-known bearing force (rotor mass under gravity
only) and a measured bearing-control current it is possible to
derive the shaft position relative to the magnetic center from the
array of F,I-curves.
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
masses this accuracy was even better, like 0.015 lb (7. gram)
deviation for an attached mass of 0.342 lb (155. gram). From these
two accuracy figures an average uncertainty of k =0.90 lbf/mils
(0.157 N/m) can finally be stated for this identification method.
59
Perform measurement
Excite rotor to circular forward precession, orbit radius e=0.394
Save
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60
The inputs of the actuators are the control currents of the four
bearing axes; the outputs of the rotor are the displacements at the
four sensor locations.
The model is extended by taking into account the seal force
acting on the center of the rotor. Since the seal force is acting on the
center, the displacement of the center has to be considered as an
extra output as indicated in Figure 14, resulting into a 66 transfer
function matrix.
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
61
the orbit, i.e., the shaft surface rotates with a frequency rel =(!),
while the stator surface rotates at wall =(!).
The upstream and downstream parts of the test rig are defined in
a fixed absolute system.
NUMERICAL ANALYSIS
For a circular motion around the center of the stator, seal forces can
be modeled according to Equation (5). To determine the dynamic-seal
properties the rotor is shifted in the plane (x,y) vertical to the axis
of rotation (z), i.e., with an orbit eccentricity of E = [ex, ey]. For the
G = [e , 0].
time t=0, the orbit eccentricity is reduced to E(t=0)
x
G
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Figure 20. Different Models Used for the Test Rig Simulation.
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
63
Another important result from the CFD studies is the finding that
the annular downstream area following the last labyrinth-seal tip has
a significant influence on the flow field. It is mainly that part of
the mesh that leads to a longer period of simulation to achieve
convergence. Counter-rotating vortices as shown in Figure 24 can
develop in the gap and in the large cavity. The radial and tangential
forces generated downstream of the seal cannot be neglected.
Figure 22. Mesh Details as Used for the Simulation of the Test Rig.
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
65
Figure 29. Comparison of Averaged Measurements and CFDPredicted Dynamic Cavity Pressure.
The composition of the radial and tangential force from the direct
and cross-coupled coefficients is shown in the equation below,
whereby relating this force to the orbit amplitude e converts these
forces into dynamic stiffnesses in N/m.
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
Figure 34. CFD Results for the Flow Path from Impeller Outlet to
Impeller-Eye Seal.
Having the flow along the cavity incorporated in the model, it is
only one further step to predict the pressure profiles acting on the
impeller shroud by basically the same methodology as applied for
the seal itself. Such an analysis would then allow predicting both
the forces generated in the shroud cavity as well as within the
impeller-eye seal. In Figure 35 the radial force and in Figure 36 the
tangential force is shown. The overall forces acting on the impeller are
presented together with the shares of the individual sections of flow:
a) From the area of the labyrinth seal (input data different from
Table 2)
b) From the shroud area in front of the first labyrinth tip up to the
outer diameter of the impeller
c) From the axial length of the shroud thickness at the outer
diameter of the impeller
Figure 35. CFD Results for the Total Radial Force on the Shroud
and its Buildup.
Figure 36. CFD Results for the Total Tangential Force on the Shroud
and its Buildup.
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CONCLUSION
The core element of this project is a revamped test rig, which
enables measurements to be taken up to a frequency of more than
400. Hz; the rotor can be moved on a circular orbit in forward as
well as in backward direction. This feature allows determination of
the complete set of general seal-transfer functions.
Very high efforts were related to the static and dynamic
calibration of the system and its validation. The important
determination of the residual uncertainty is often missing in
other experimental work. This is of particular importance for the
investigation of the short impeller-eye seals, which are very hard to
measure, since they cause much smaller forces than the long
balance-drum seals. To the authors knowledge this has not been
done successfully before.
A key issue of this paper is the comparison of the results as
obtained from different methods. It is unique to determine the
stiffness, damping, and inertia coefficients of impeller-eye seals by
two different methods of force measurement using the magnetic
bearings, by measurement of the dynamic pressures in all seal
cavities, and also by computational fluid dynamics and to compare
all these results with each other.
One important finding is the evidence of the existence of
gas inertia forces in these labyrinth seals. They were verified in
particular in the radial force with all four methods.
Computational fluid dynamics is a powerful tool to complement
the experimental work. The first step was the detailed CFD
analysis using best practice style CFD meshes to calculate the
dynamic properties of the seals tested. With the available test data
it was possible to fine-tune and calibrate the CFD analysis. Based
on this combined knowledge additional numerical results can be
generated for geometry variations that are not tested. This approach
will enhance the database to cover in the end the complete range of
geometries of relevance for turbocompressors from small to large
sizes and from low- to high-pressure applications.
Based on numerical analysis, additional effects of importance
within a real compressor will be addressed. Here the labyrinth-seal
inlet-conditions of impeller-eye seals and the effects of the forces
generated in the shroud cavity shall be mentioned as examples of
these effects. As an example, one result of these effects showed that
the forces of the impeller-eye seal are larger than the forces acting
onto the impeller shroud. However, further work needs to be done
in this field.
All analytical and experimental data are merged into a simplified
tool for the designers day-to-day work. With this tool, parameter
studies and rotordynamic optimizations can be handled easily
and effectively.
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NOMENCLATURE
A
dR,dQ
D
D(s),E(s)
e
ex,ey
E
G
F
F1,F2
FAMB
FBearing,gap
FInertia
FLaby
FTotal,gas
Fr,Ft
Fx,Fy
Ggyro
G
GAD,GDA
GI44,Ga42,Gb22,Gc22
GLaby
GPlant
GRotor+Actuator
GSensor
Hxx,Hxy,Hyx,Hyy
I
GI
Actuator
j
ki,ks
kR,kQ
kstat,kdyn
K
L
m
M
mR,mQ
p
{
p
q
qMidNode
qsensor
r
t
Ti,Ts
U
UPlant
w
x
G
x,y
x1,x2
Y
YPlant
rel
wall
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Benckert, H., 1980, Strmungsbedingte Federkennwerte in
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INVESTIGATIONS ON THE DYNAMIC
COEFFICIENTS OF IMPELLER EYE LABYRINTH SEALS
BIBLIOGRAPHY ON
CFD-RELATED LITERATURE
Arghir, M., Defaye, C., and Frene, J., 2006, The Lomakin
Effect in Annular Gas Seals under Choked Flow Conditions,
ASME Turbo Expo 2006: Power for Land, Sea and Air,
Barcelona, Spain.
Athavale, M. M. and Hendricks, R. C., 1996, A Small
Perturbation CFD Method for Calculation of Seal
Rotordynamic Coefficients.
69
ACKNOWLEDGEMENT
The authors thank the management of the Siemens Energy
Sector, Oil & Gas Division, for publication permission. The
contributions to this project from many persons, all of whom
cannot be listed here, are highly appreciated.
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