Face Seal Thermal Fluid Circuit for Distortion Control
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Solution Overview
Problem
Turbomachines face challenges with thermal distortion and deformation of face seal assemblies due to thermal and pressure loads, particularly at high temperatures, high speeds, and large diameters, which limits their effectiveness and requires enhanced thermal management to reduce temperature gradients and angular misalignment.
Innovation Solution
A face seal assembly with a thermal management circuit, comprising internal cavities, fluid channels, and pressurized fluid ports, which forms a thermal hydrostatic fluid circuit to minimize temperature gradients and reduce thermal distortion by providing cooling to the seal assembly, allowing operation at higher temperatures and larger diameters without compromising leakage performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the face seal assembly operates at high temperatures and high speeds with large diameters, then the turbomachine performance is improved, but thermal distortion and deformation of the seal increase
Solution Approach 1:
The seal ring is divided into multiple segments with internal cavities and fluid channels, allowing independent thermal management of different regions. This segmentation enables targeted cooling to specific high-temperature zones without affecting the entire seal structure, thereby reducing thermal distortion while maintaining high-power operation.
Solution Approach 2:
A thermal management fluid is introduced as an intermediary substance that circulates through the internal cavities and channels of the seal ring. This fluid absorbs excess heat from the seal bearing face and other critical areas, acting as a heat transfer medium that prevents thermal distortion while allowing the turbomachine to operate at high temperatures and speeds.
2Reliability
If the seal operates with a thin fluid-film to reduce leakage, then sealing performance is improved, but thermal deformation and angular misalignment increase
Solution Approach 1:
The thermal management circuit performs preliminary cooling action on the seal ring before thermal distortion can occur. By continuously circulating cooling fluid through internal cavities and channels, the system preemptively removes heat that would otherwise cause deformation of the sealing faces, maintaining flatness and alignment critical for thin fluid-film operation.
Solution Approach 2:
The invention changes the thermal parameters of the seal ring by introducing active cooling, which alters the temperature distribution and thermal stress state. This parameter change allows the seal to maintain its geometric stability and flatness under operating conditions that would otherwise cause thermal deformation, enabling reliable thin fluid-film sealing.
3Productivity
If the diameter of the sealing ring is increased to handle larger flow rates, then turbomachine capacity is improved, but thermal distortion and coning of the seal increase
Solution Approach 1:
The thermal management system implements local quality control by providing targeted cooling to specific regions of the large-diameter seal ring. Internal cavities and fluid channels are strategically positioned to address local heat generation zones, creating non-uniform temperature distribution that compensates for the increased thermal load from larger diameter and higher flow rates.
Solution Approach 2:
The invention employs hydraulic principles by using a fluid circulation system to manage thermal loads in the large-diameter seal ring. The pressurized cooling fluid flows through internal channels, utilizing fluid dynamics to efficiently remove heat from critical areas, thereby controlling temperature gradients and preventing thermal distortion despite the increased capacity requirements.
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
The thermal hydrostatic fluid circuit effectively reduces thermal distortion and angular misalignment, enabling the face seal assembly to operate effectively at higher temperatures, increased speeds, and larger diameters while maintaining low leakage, thus enhancing the turbomachine's performance and reducing machining costs.
Implementation Method 1
The at least one internal cavity, the fluid inlet channel and the fluid outlet port define a thermal fluid circuit providing thermal management of the seal ring
Implementation Method 2
providing cooling to the seal assembly, allowing operation at higher temperatures and larger diameters without compromising leakage performance
Implementation Method 3
During normal operating conditions, a fluid-film of a pressurized fluid may separate the sealing faces from each other and prevent wear due to friction
Implementation Method 4
The face seal assembly, for example, a hydrodynamic or hydrostatic face seal assembly, typically operates with a thin fluid-film
Data Source
AI summary
A face seal assembly including a thermal fluid circuit, a turbomachine including the face seal assembly and a method of operating the turbomachine are disclosed. The face seal assembly includes a seal ring including a seal bearing face, at least one internal cavity including a cavity inlet and a cavity outlet. The face seal assembly further including a fluid inlet channel in fluid communication with the cavity inlet of the at least one internal cavity and a pressurized fluid and a fluid outlet port in fluid communication with the cavity outlet of the at least one internal cavity. The at least one internal cavity, the fluid inlet channel and the fluid outlet port define a thermal fluid circuit providing thermal management of the seal ring. In the turbomachine, the face seal assembly is disposed between a stationary component and a rotating component including a rotating component bearing face.