Buffer Fluid Delivery System for Gas Turbine Shaft Seals
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Solution Overview
Problem
Gas turbine engines consume significant amounts of pressurized air for labyrinth seals, leading to increased fuel consumption due to the energy draw from the compressor, especially in high-temperature environments where traditional seals are required.
Innovation Solution
A buffer fluid delivery system that includes a heat exchanger to cool the buffer air before delivery to shaft seals and provides redundant air supply routes, reducing the need for high-pressurized air consumption by using less air-consuming seals in high-temperature areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If labyrinth seals are used in high-temperature areas, then the seals can withstand high-temperature conditions, but they require a significant amount of pressurized buffer air which increases fuel consumption
Solution Approach 1:
The buffer air supply system is segmented into multiple independent routes (first route with heat exchanger, second route without heat exchanger) that can operate independently or in combination. This allows the system to provide buffer air through different paths depending on operational conditions, reducing overall buffer air consumption while maintaining seal functionality in high-temperature environments.
Solution Approach 2:
The system changes the temperature parameter of the buffer air by incorporating a heat exchanger in the first route. By cooling the buffer air before delivery to the shaft seal, the system can achieve better sealing performance with reduced buffer air flow requirements, thereby reducing fuel consumption while maintaining temperature resistance.
2Reliability
If pressurized air is extracted from the compressor for buffer air supply, then shaft seals can function properly, but it creates an energy draw that increases overall fuel consumption
Solution Approach 1:
The buffer air supply is segmented into multiple routes where the first route includes a heat exchanger for cooling the air. This segmentation allows the system to deliver cooled buffer air that requires less mass flow to achieve the same sealing effect, thereby reducing the energy draw from the compressor while maintaining seal reliability.
Solution Approach 2:
A heat exchanger is introduced as an intermediary component in the first route to cool the buffer air before it reaches the shaft seal. This intermediary device pre-cools the air, reducing the amount of compressed air needed to maintain proper seal function, thus reducing the energy draw from the compressor.
3Reliability
If multiple routes are provided for buffer air supply, then redundancy is achieved, but the system complexity increases
Solution Approach 1:
The buffer air supply system is divided into two distinct routes: the first route with a heat exchanger for cooled air supply, and the second route without a heat exchanger for direct supply. This segmentation provides redundancy while keeping each route relatively simple in design and operation.
Solution Approach 2:
The buffer air supply system is designed with multi-functionality by incorporating both a cooled air route and an uncooled air route. This universal design allows the system to operate in different modes depending on conditions, providing redundancy without requiring completely separate independent systems, thereby limiting the increase in complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system reduces overall fuel consumption by minimizing the amount of bleed air extracted from the compressor and allows for the installation of less fluid-consuming seals in high-temperature environments, promoting efficient operation and redundancy in buffer air supply.
Implementation Method 1
a heat exchanger disposed along the first route to facilitate heat transfer between buffer fluid in the one or more first conduits and a cooling fluid
Data Source
AI summary
Systems and methods for delivering a buffer fluid to a shaft seal of a gas turbine engine are provided. An exemplary system includes, a buffer fluid source, one or more first conduits providing fluid communication between the buffer fluid source and the shaft seal along a first route, and one or more second conduits providing fluid communication between the buffer fluid source and the shaft seal along a second route different from the first route. A heat exchanger is also disposed along the first route to facilitate heat transfer between buffer fluid in the one or more first conduits and a cooling fluid.