U.S. patent application number 15/346001 was filed with the patent office on 2017-02-23 for individually compliant segments for split ring hydrodynamic face seal.
The applicant listed for this patent is GENERAL ELECTRIC COMPANY. Invention is credited to Rahul Anil Bidkar, Karimulla Shaik Sha, Azam Mihir Thatte, Xiaoqing Zheng.
Application Number | 20170051620 15/346001 |
Document ID | / |
Family ID | 54066941 |
Filed Date | 2017-02-23 |
United States Patent
Application |
20170051620 |
Kind Code |
A1 |
Thatte; Azam Mihir ; et
al. |
February 23, 2017 |
INDIVIDUALLY COMPLIANT SEGMENTS FOR SPLIT RING HYDRODYNAMIC FACE
SEAL
Abstract
Embodiments of the present disclosure are directed toward a face
seal including a stator ring configured to be disposed about a
rotor of a turbine, wherein the stator ring includes a first ring
segment and a second ring segment which are circumferentially split
and configured to cooperatively form the stator ring, and bearing
elements disposed between the first and second ring segments and
configured to enable relative axial motion between the first and
second ring segments at interfaces between the first and second
ring segments. The stator ring further includes hydrodynamic
surface features on surfaces of the first and second ring segments
configured for facing the rotor, wherein the hydrodynamic surface
features comprise Y-shaped grooves each comprising a stem portion
extending from a middle region of stator ring and splitting into
inner and outer branches extending towards inner and outer
diameters of the stator ring and terminating prior to the inner and
outer diameters.
Inventors: |
Thatte; Azam Mihir;
(Arlington, MA) ; Sha; Karimulla Shaik;
(Anantapur, IN) ; Bidkar; Rahul Anil; (Niskayuna,
NY) ; Zheng; Xiaoqing; (Niskayuna, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GENERAL ELECTRIC COMPANY |
Schenectady |
NY |
US |
|
|
Family ID: |
54066941 |
Appl. No.: |
15/346001 |
Filed: |
November 8, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14226583 |
Mar 26, 2014 |
9534502 |
|
|
15346001 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F05D 2220/31 20130101;
F01D 11/001 20130101; Y02E 20/16 20130101; F01D 1/04 20130101; F01D
11/003 20130101; F05D 2240/53 20130101 |
International
Class: |
F01D 11/00 20060101
F01D011/00 |
Claims
1. A system, comprising: a steam turbine; and a face seal of the
steam turbine, comprising: a rotor ring coupled to a rotor of the
steam turbine; and a stator ring coupled to a stationary housing of
the steam turbine, wherein the stator ring is circumferentially
split into a plurality of circumferential segments with one or more
bearing elements disposed between each of the plurality of
circumferential segments, wherein the one or more bearing elements
are configured to enable relative axial movement of the plurality
of segments relative to one another, hydrodynamic surface features
on a sealing surface of at least one of the rotor ring and the
stator ring facing the other of the rotor ring and the stator ring,
wherein the hydrodynamic surface features comprise Y-shaped grooves
each comprising a stem portion extending from a middle region of
the rotor ring or the stator ring and splitting into inner and
outer branches extending towards inner and outer diameters of the
rotor ring or the stator ring respectively.
2. The system of claim 1 wherein the inner and outer branches of
the Y-shaped grooves terminate prior to the respective inner and
outer diameters.
3. The system of claim 2 further comprising a plurality of holes
for feeding a gas into the stem portions of respective ones of the
Y-shaped grooves.
4. The system of claim 1 wherein the rotor ring comprises the
Y-shaped grooves.
5. The system of claim 1 wherein the stator ring comprises the
Y-shaped grooves.
6. The system of claim 5 wherein the Y-shaped grooves are situated
on the circumferential segments.
7. The system of claim 5 further comprising a plurality of pads
configured to extend from the circumferential segments, wherein the
Y-shaped grooves are situated on the plurality of pads.
8. A turbine, comprising: a rotor; a stationary housing disposed
about the rotor; and a face seal disposed about the rotor,
comprising: a rotor ring coupled to or integral with the rotor; and
a stator ring coupled to the stationary housing, wherein the stator
ring comprises: a first segment; a second segment; and at least two
bearing elements, wherein the first and second segments are
circumferentially split, and the at least two bearing elements are
disposed between the first and second segments, and wherein the
first segment, the second segment, and the at least two bearing
elements cooperatively form the stator ring, hydrodynamic surface
features on a sealing surface of at least one of the rotor ring and
the stator ring facing the other of the rotor ring and the stator
ring, wherein the hydrodynamic surface features comprise Y-shaped
grooves each comprising a stem portion extending from a middle
region of the rotor ring or the stator ring and splitting into
inner and outer branches extending towards inner and outer
diameters of the rotor ring or the stator ring respectively.
9. The turbine of claim 8 wherein the inner and outer branches of
the Y-shaped grooves terminate prior to the respective inner and
outer diameters.
10. The turbine of claim 9 further comprising a plurality of holes
for feeding a gas into the stem portions of respective ones of the
Y-shaped grooves.
11. The turbine of claim 8 wherein the rotor ring comprises the
Y-shaped grooves.
12. The turbine of claim 8 wherein the stator ring comprises the
Y-shaped grooves.
13. The system of claim 12 wherein the Y-shaped grooves are
situated on the first and second segments.
14. The system of claim 12 further comprising a plurality of pads
configured to extend from the first and second segments, wherein
the Y-shaped grooves are situated on the plurality of pads.
15. A system, comprising a stator ring configured to be disposed
about a rotor of a turbine, wherein the stator ring comprises a
first ring segment and a second ring segment which are
circumferentially split and configured to cooperatively form the
stator ring, at least one bearing element disposed between the
first and second ring segments and configured to enable relative
axial motion between the first and second ring segments at
interfaces between the first and second ring segments, hydrodynamic
surface features on surfaces of the first and second ring segments
configured for facing the rotor, wherein the hydrodynamic surface
features comprise Y-shaped grooves each comprising a stem portion
extending from a middle region of stator ring and splitting into
inner and outer branches extending towards inner and outer
diameters of the stator ring and terminating prior to the inner and
outer diameters.
16. The system of claim 15 further comprising a plurality of holes
for feeding a gas into the stem portions of respective ones of the
Y-shaped grooves.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of and claims priority to
U.S. Non-Provisional application Ser. No. 14/226583, entitled
"INDIVIDUALLY COMPLIANT SEGMENTS FOR SPLIT RING HYDRODYNAMIC FACE
SEAL," filed on 26 Mar. 2014, and published as US20150275684, the
disclosure of which is hereby incorporated by reference.
BACKGROUND
[0002] The subject matter disclosed herein relates to
turbomachines, and, more particularly, to face seals for reducing
or blocking flow leakage between various components of a
turbomachine.
[0003] Turbomachines include compressors and/or turbines, such as
gas turbines, steam turbines, and hydro turbines. Generally,
turbomachines include a rotor, which may be a shaft or drum, which
support turbomachine blades. For example, the turbomachine blades
may be arranged in stages along the rotor of the turbomachine. The
turbomachine may further include various seals to reduce or block
flow (e.g., working fluid flow) leakage between various components
of the turbomachine. For example, the turbomachine may include one
or more face seals configured to reduce or block flow leakage
between the shaft (e.g., rotating shaft) and a housing of the
turbomachine. Unfortunately, traditional face seals may be
difficult to assemble and/or may be susceptible to large face
deformation that may result in premature wear or performance
degradation.
BRIEF DESCRIPTION
[0004] In one embodiment, a system includes a steam turbine and a
face seal of the steam turbine. The face seal comprises a rotor
ring coupled to a rotor of the steam turbine; and a stator ring
coupled to a stationary housing of the steam turbine, wherein the
stator ring is circumferentially split into a plurality of
circumferential segments with one or more bearing elements disposed
between each of the plurality of circumferential segments, wherein
the one or more bearing elements are configured to enable relative
axial movement of the plurality of segments relative to one
another. The face seal further comprises hydrodynamic surface
features on a sealing surface of at least one of the rotor ring and
the stator ring facing the other of the rotor ring and the stator
ring. The hydrodynamic surface features comprise Y-shaped grooves
each comprising a stem portion extending from a middle region of
the rotor ring or the stator ring and splitting into inner and
outer branches extending towards inner and outer diameters of the
rotor ring or the stator ring respectively
[0005] In another embodiment, a turbine comprises a rotor, a
stationary housing disposed about the rotor, and a face seal
disposed about the rotor. The face seal comprises a rotor ring
coupled to or integral with the rotor; and a stator ring coupled to
the stationary housing. The stator ring comprises a first segment,
a second segment, and at least two bearing elements, wherein the
first and second segments are circumferentially split, and the at
least two bearing elements are disposed between the first and
second segments, and wherein the first segment, the second segment,
and the at least two bearing elements cooperatively form the stator
ring. The stator ring further comprises hydrodynamic surface
features on a sealing surface of at least one of the rotor ring and
the stator ring facing the other of the rotor ring and the stator
ring. The hydrodynamic surface features comprise Y-shaped grooves
each comprising a stem portion extending from a middle region of
the rotor ring or the stator ring and splitting into inner and
outer branches extending towards inner and outer diameters of the
rotor ring or the stator ring respectively.
[0006] In another embodiment, a system includes a stator ring
configured to be disposed about a rotor of a turbine, wherein
stator ring comprises a first ring segment and a second ring
segment which are circumferentially split and configured to
cooperatively form the stator ring, and at least one bearing
element disposed between the first and second ring segments and
configured to enable relative axial motion between the first and
second ring segments at interfaces between the first and second
ring segments. The stator ring further comprises hydrodynamic
surface features on surfaces of the first and second ring segments
configured for facing the rotor, wherein the hydrodynamic surface
features comprise Y-shaped grooves each comprising a stem portion
extending from a middle region of stator ring and splitting into
inner and outer branches extending towards inner and outer
diameters of the stator ring and terminating prior to the inner and
outer diameters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0008] FIG. 1 is a schematic of an embodiment of a combined cycle
power generation system having a gas turbine system, a steam
turbine, and a heat recovery steam generation (HRSG) system;
[0009] FIG. 2 is a partial cross-sectional view of an embodiment of
a steam turbine, illustrating a face seal of the steam turbine;
[0010] FIG. 3 is a partial cross-sectional view of a turbomachine,
illustrating an embodiment of a face seal of the turbomachine;
[0011] FIG. 4 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating a split-ring
configuration of the primary sealing ring;
[0012] FIG. 5 is a partial cross-sectional view of a turbomachine,
illustrating an embodiment of a face seal of the turbomachine;
[0013] FIG. 6 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating locally compliant
sealing pads of the primary sealing ring;
[0014] FIG. 7 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating locally compliant
sealing pads of the primary sealing ring;
[0015] FIG. 8 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating locally compliant
sealing pads of the primary sealing ring;
[0016] FIG. 9 is a partial perspective view of an embodiment of a
primary sealing ring of the face seal, illustrating a spring
biasing a locally compliant sealing pad of the primary sealing
ring;
[0017] FIG. 10 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating an arrangement of
locally compliant sealing pads of the primary sealing ring;
[0018] FIG. 11 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating an arrangement of
locally compliant sealing pads of the primary sealing ring;
[0019] FIG. 12 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating a surface feature of
the primary sealing ring; and
[0020] FIG. 13 is a perspective view of an embodiment of a primary
sealing ring of the face seal, illustrating a surface feature of
the primary sealing ring.
DETAILED DESCRIPTION
[0021] Embodiments of the present disclosure are directed toward
improved face seals having features configured to reduce leakage
across the face seal and improve performance and longevity of the
face seal. As will be appreciated, the face seal may include a
primary ring (e.g., a stationary ring) which forms a sealing
relationship or interface with a mating ring (e.g., a rotating
ring). For example, the primary ring and the mating ring may be
configured to reduce or block leakage of a working fluid across the
face seal. In certain embodiments, the primary ring may have a
split configuration with a bearing element, such as rolling
interface. More specifically, the primary ring may include two or
more segments which cooperatively form the primary ring, and the
primary ring may include one or more rolling interfaces (e.g.,
bearing elements) between the two or more segments. For example,
one or more pins or other rounded elements may be disposed between
the two or more segments when the two or more segments are in
abutment with one another. In the manner described below, the
bearing element (e.g., rolling interface) between the two or more
segments may enable low-friction relative movement (e.g., axial
movement) between the two or more segments of the primary ring. In
this way, each of the segments of the primary ring may achieve its
own hydrodynamic equilibrium with respect to the mating (e.g.,
rotating) ring of the face seal. Furthermore, the rolling
interfaces of the primary ring may be configured to absorb or
support a radial pressure or load from each of the segments of the
primary ring.
[0022] In certain embodiments, the primary ring of the face seal
may include locally compliant hydrodynamic pads configured to
engage with the mating ring. That is, each of the locally compliant
hydrodynamic pads of the primary ring may be configured to form a
separate sealing relationship with the mating ring. Specifically,
each of the hydrodynamic pads may be individually biased toward the
mating ring (e.g., by a spring coupled to the primary ring). In
this way, each of the hydrodynamic pads can individually conform to
the dynamically changing orientation of the mating ring, thereby
improving the overall sealing interface and leak blockage between
the primary ring and the mating ring. Additionally, the
hydrodynamic pads may ensure that the segmented primary ring closes
in toward the mating ring in a more uniform manner to avoid cocking
or partial contacting between the primary ring and mating ring.
Additionally, as described in detail below, each of the
hydrodynamic pads may block direct contact between the primary ring
and the mating ring while also reducing elevated leakage gaps.
[0023] It should be noted that in the following discussion,
reference may be made to contact between various components of the
face seal (e.g., primary ring, mating ring, hydrodynamic pads,
etc.). However, it should be appreciated that reference to contact
between such components may encompass very small gaps (e.g.,
0.01-0.25 mm gaps) between such components, or parts of the
components, rather than actual contact between such components.
[0024] Turning now to the drawings, FIG. 1 is a schematic block
diagram of an embodiment of a conventional combined cycle system 10
having various turbomachines in which face seals of the present
disclosure may be used. Specifically, the turbomachines may include
face seals which may include a primary ring having a split
configuration with rolling interfaces and/or a primary ring with
locally compliant hydrodynamic pads. As shown, the combined cycle
system 10 includes a gas turbine system 11 having a compressor 12,
combustors 14 having fuel nozzles 16, and a gas turbine 18. The
fuel nozzles 16 route a liquid fuel and/or gas fuel, such as
natural gas or syngas, into the combustors 14. The combustors 14
ignite and combust a fuel-air mixture, and then pass hot
pressurized combustion gases 20 (e.g., exhaust) into the gas
turbine 18. The turbine blades 22 are coupled to a rotor 24, which
is also coupled to several other components throughout the combined
cycle system 10, as illustrated. For example, the turbine blades 22
may be arranged in stages. In other words, the turbine blades 22
may be circumferentially arranged about the rotor 24 at various
axial locations of the rotor 24. As the combustion gases 20 pass
through the turbine blades 22 in the gas turbine 18, the gas
turbine 18 is driven into rotation, which causes the rotor 24 to
rotate along a rotational axis 26. In certain embodiments, the gas
turbine 18 may include face seals configured to reduce or block
undesired leakage of the combustion gases 20 across rotor-stator
gaps within the turbine. Eventually, the combustion gases 20 exit
the gas turbine 18 via an exhaust outlet 28 (e.g., exhaust duct,
exhaust stack, silencer, etc.).
[0025] In the illustrated embodiment, the compressor 12 includes
compressor blades 30. The compressor blades 30 within the
compressor 12 are also coupled to the rotor 24 and rotate as the
rotor 24 is driven into rotation by the gas turbine 18 in the
manner described above. As with the turbine blades 22, the
compressor blades 30 may also be arranged in stages. As the
compressor blades 30 rotate within the compressor 12, the
compressor blades 30 compress air from an air intake into
pressurized air 32, which is routed to the combustors 14, the fuel
nozzles 16, and other portions of the combined cycle system 10.
Additionally, the compressor 12 may include face seals configured
to block undesired leakage of the pressurized air 32 across various
rotor-stator gaps within a compressor.
[0026] The fuel nozzles 16 mix the pressurized air 32 and fuel to
produce a suitable fuel-air mixture, which combusts in the
combustors 14 to generate the combustion gases 20 to drive the
turbine 18. Further, the rotor 24 may be coupled to a first load
34, which may be powered via rotation of the rotor 24. For example,
the first load 34 may be any suitable device that may generate
power via the rotational output of the combined cycle system 10,
such as a power generation plant or an external mechanical load.
For instance, the first load 34 may include an electrical
generator, a propeller of an airplane, and so forth.
[0027] The system 10 also includes a steam turbine 36 for driving a
second load 38 (e.g., via rotation of a shaft 40 of the steam
turbine 36). For example, the second load 38 may be an electrical
generator for generating electrical power. However, both the first
and second loads 34 and 38 may be other types of loads capable of
being driven by the gas turbine system 11 and the steam turbine 36.
In addition, although the gas turbine system 11 and the steam
turbine 36 drive separate loads (e.g., first and second loads 34
and 38) in the illustrated embodiment, the gas turbine system 11
and steam turbine 36 may also be utilized in tandem to drive a
single load via a single shaft.
[0028] The system 10 further includes the heat recovery steam
generator (HRSG) system 42. Heated exhaust gas 44 from the gas
turbine 18 is transported into the HRSG system 42 to heat water to
produce steam 46 used to power the steam turbine 36. As will be
appreciated, the HRSG system 42 may include various economizers,
condensers, evaporators, heaters, and so forth, to generate and
heat the steam 46 used to power the steam turbine 36. The steam 46
produced by the HRSG system 42 passes through turbine blades 48 of
the steam turbine 36. As similarly described above, the turbine
blades 48 of the steam turbine 36 may be arranged in stages along
the shaft 40, and the steam turbine 36 may include face seals to
block undesired leakage of steam 46 across various rotor-stator
gaps within the steam turbine 36. As the steam 46 pass through the
turbine blades 48 in the steam turbine 36, the turbine blades 48 of
the steam turbine 36 are driven into rotation, which causes the
shaft 40 to rotate, thereby powering the second load 38.
[0029] In the following discussion, reference may be made to
various directions or axes, such as an axial direction 50 along the
axis 26, a radial direction 52 away from the axis 26, and a
circumferential direction 54 around the axis 26 of the compressor
12, the gas turbine 18, or steam turbine 36. Additionally, as
mentioned above, while the face seals described below may be used
with any of a variety of turbomachines (e.g., compressors 12, gas
turbines 18, or steam turbines 36) the following discussion
describes improved face seals in the context of the steam turbine
36.
[0030] FIG. 2 is a partial cross-sectional view of the steam
turbine 36, illustrating a position of a face seal 100 within the
steam turbine 36. As mentioned above, the steam turbine 36 may
include one or more face seals 100 for reducing or blocking leakage
of a working fluid (e.g., steam 46) across various rotor-stator
gaps within the steam turbine 36.
[0031] In the illustrated embodiment, the steam turbine 36 includes
a casing 60, an inner shell 62, and sealing components 64 disposed
about the shaft 40 of the steam turbine 36. As shown, steam 46
enters the steam turbine 36 through an inlet 66 to an inlet side 68
of the steam turbine 36. As described above, the steam 46 may drive
rotation of the turbine blades 48, thereby driving rotation of the
shaft 40. As shown, some of the sealing components 64 form a
tortuous path (e.g., a tortuous sealing path) between a stator
component 70 of the steam turbine 36 and the shaft 40 of the steam
turbine 36. As will be appreciated, although the steam 46 is
directed towards the turbine blades 48 within the steam turbine 36,
a portion of the steam 46 may leak through a leakage region 72 of
the steam turbine 36, which may reduce the efficiency of the steam
turbine 36. Accordingly, the steam turbine 36 also includes the
face seal 100 to block or reduce steam 46 flow leakage within the
steam turbine 36.
[0032] FIG. 3 is a partial cross-sectional view of the steam
turbine 36, illustrating an embodiment of the face seal 100, which
is configured to block or reduce steam 46 flow leakage from a first
region 102 (e.g., an upstream region) to a second region 104 (e.g.,
a downstream region) in the endpacking area. Specifically, the face
seal 100 includes a primary ring 106 (a stationary ring) and a
mating ring 108 (a rotor ring). The primary ring 106 is attached to
the inner shell 62 of the steam turbine 36 and is moveable in the
axial direction 50 only. For example, the primary ring 106 may be
attached to a stationary housing 110 through a secondary seal 118
and anti-rotation feature 128. The mating ring 108 (rotor ring) may
be an integral part of the shaft 40 (or rotor), or could be a
service-friendly separated component coupled to the shaft 40.
Furthermore, the mating ring 108 is secured to the shaft 40 of the
steam turbine 36 through mechanical assembling. More specifically,
the mating ring 108 is secured to the shaft 40 by a first retaining
flange 112 and a second retaining flange 114. The first and second
retaining flanges 112 and 114 cooperatively axially restrain the
mating ring 108 to the shaft 40. For example, brazing, welding,
mechanical fasteners (e.g., bolt 116), friction fits, threading, or
other retaining mechanisms may be used to secure the mating ring
108 to the first and second retaining flanges 112 and 114 and
secure the first and second retaining flanges 112 and 114 to the
shaft 40. Bolt 116 tightens flange 114 against the shaft 40 and the
flange 112, while preventing compression of and hence any tilting
of rotating ring 108. As the shaft 40 is driving into rotation by
the steam 46 flowing through the turbine blades 48, the mating ring
108 will also be driven into rotation.
[0033] Furthermore, the secondary seal 118 (e.g., an annular seal)
is disposed between the primary ring 106 and the stationary housing
110. With the secondary seal 118 in place, leakage between the
stationary housing 110 and primary ring 106 is limited, meanwhile
allowing the primary seal ring 106 to move axially away or toward
the rotating mating ring 108 (rotor ring) to accommodate any rotor
40 translation in axial direction 50 due to different thermal
expansion of rotor 40 relative to stationary housing 110, or due to
thrust reversal. The secondary seal 118 diameter, or conventionally
called pressure-balance diameter, is selected to control primary
ring 106 closing force. Similarly, a seal 120 is disposed between
the mating ring 108 and the first retaining flange 112. The seals
118 and 120 are stationary seals. They may block leakage of steam
46 or other working fluid between the face seal 100 and the
stationary housing 110 and shaft 40. As will be appreciated, in
other embodiments, the face seal 100 may include other numbers or
types of seals to block steam 46 or other working fluid flow
between various components of the face seal 100 and the steam
turbine 36.
[0034] As shown, the primary ring 106 and the mating ring 108 form
a sealing interface 122. As mentioned above, the sealing interface
122 is configured to reduce or block leakage of steam 46 or other
working fluid from the first region (high pressure region) 102
(e.g., an upstream region) to the second region 104 (low pressure
region) (e.g., a downstream region) of the steam turbine 36. There
is a backing portion 126, in which a spring 129 is disposed within
a recess 130 and is coupled to the primary ring 106 and exerts an
axial force on the primary ring 106. In this manner, the primary
ring 106 may be biased toward the mating ring 108 of the face seal
100 to create the seal interface 122. Specifically, as the spring
129 exerts a biasing force on the primary ring 106, a face 132 of
the primary ring 106 may be urged toward a face 134 of the mating
ring 108. Additionally, while the embodiment shown in FIG. 3
illustrates one spring 129 disposed within one recess 130 of the
backing portion 126, other embodiments may include multiple springs
129 disposed within respective recesses 130 about a circumference
of the backing portion 126. Similarly, in other embodiments, each
recess 130 may include multiple springs 129 configured to bias the
primary ring 106 toward the mating ring 108.
[0035] As the mating ring 108 spins with respect to the primary
ring 106, the hydrodynamic features (e.g., grooves or pads
described in FIGS. 10-13) create a circumferential gradient in the
film thickness (gap between primary ring 106 and mating ring 018)
that generates hydrodynamic pressure at the interface (at faces
132, 134) and hence a separation force that keeps the face 132 from
contacting face 134 during motion. This happens when the
hydrodynamic opening force is larger than the net closing force
created by external pressure acting on primary ring 106 and by the
spring 129. By selecting the surface features (grooves, pads etc.)
of the primary ring 106 and/or mating ring 108, dimensions of the
primary and mating ring 106 and 108, and the spring 129 force, a
desired equilibrium "riding" gap between the primary ring 106 and
mating ring 108 can be obtained. The leakage volume of steam/gas is
determined by the size of this equilibrium riding gap. If some
additional force (e.g., a transient force due to thermal or
pressure transients in operation) causes the mating ring 108 to
move towards the primary ring 106, the gap decreases below the
equilibrium value. This reduced gap causes an increase in the
hydrodynamic force at the interface between the primary ring 106
and the mating ring 108. This increased hydrodynamic force resists
the additional force (e.g., a transient force due to thermal or
pressure transients in operation) and avoids contact between the
primary ring 106 and the mating ring 108 that otherwise would have
occurred due to the additional force. At this point, the dynamic
equilibrium is regained at a slightly smaller gap between the
primary ring 106 and the mating ring 108. On the other hand if the
transient perturbations reduce the net closing force, then the
hydrodynamic force drops below its original design value and the
dynamic equilibrium is regained at a slightly larger gap between
the primary ring 106 and the mating ring 108 compared to the
original design value. Such a dynamic non-contact operation while
maintaining an almost constant small gap allows the face seal 100
to operate without mechanical degradation while maintaining very
small leakage. As will be appreciated, the surface features of the
primary ring 106 and mating ring 108 responsible for creating
hydrodynamic pressure distribution and hydrodynamic film stiffness
(as well as dimensions and shape of the primary and mating ring 106
and 108 and the spring 129 responsible for creating closing force)
can be selected so as to achieve a desired equilibrium riding gap
size, and hence desired leakage characteristics and non-contact
operation.
[0036] As discussed in detail below, in certain embodiments of the
face seal 100, the primary ring 106 may have a split configuration.
More particularly, the primary ring 106 may include two or more
circumferentially split or divided segments that cooperatively form
the primary ring 106. Additionally, the backing portion 126 may
have a split configuration. Furthermore, a joint interface between
two segments of the primary ring 106 may include a roller
interface. As such, in the manner described below, the roller
interfaces may enable relative axial movement between the two or
more segments of the primary ring 106. In this way, face seal 100
performance may improve. For example, the relative axial movement
between segments of the primary ring 106 may reduce or control
undesired leakage gaps of the face seal 100, improve dynamic
equilibrium of the face seal 100, and/or reduce mechanical wear and
degradation of the various components of the face seal 100 during
operation of the steam turbine 36. Furthermore, the split
configuration of the primary ring 106 may enable the use of the
face seal 100 with larger turbines (e.g., steam turbines 36)
because the split configuration allows the face seal 100 to be
assembled at a particular axial location directly instead of having
to slide the face seal 100 from one end of the rotor (shaft) 40,
which may not be possible in large diameter turbines. This is one
of the major advantages offered by the individually compliant split
ring design.
[0037] FIG. 4 is a perspective view of the primary ring 106 of the
face seal 100. In particular, the illustrated embodiment of the
primary ring 106 has a split configuration. That is, the primary
ring 106 is circumferentially split into multiple segments.
Specifically, in the illustrated embodiment, the primary ring 106
includes a first segment 150 and a second segment 152, and the
first and second segments 150 and 152 cooperatively form the
primary ring 106. In other words, the first and second segments 150
and 152 join together to form the primary ring 106. In particular,
the first and second segments 150 and 152 join at joint interfaces
154. As described in further detail below, the joint interfaces 154
are configured to enable relative axial movement of the first and
second segments 150 and 152 of the primary ring 106 by including a
rolling member at the joint interfaces 154. Additionally, while the
illustrated embodiment includes the first and second segments 150
and 152, other embodiments may include other numbers of segments
(e.g., 3, 4, 5, 6, or more) that are circumferentially split and
cooperatively form the primary ring 106. Furthermore, in certain
embodiments, the backing portion 126 may also have a segmented
configuration. For example, in the illustrated embodiment, the
first segment 150 of the primary ring 106 also includes a first
segment 158 of the backing portion 126. Similarly, the second
segment 152 of the primary ring 106 also includes a second segment
162 of the backing portion 126. However, in other embodiments, the
backing portion 126 and the primary ring 106 may each have
different numbers of segments.
[0038] As mentioned above, the first and second segments 150 and
152 abut one another at the joint interfaces 154 of the primary
ring 106. The segment joint interface 154 features overlapped,
stepped interfaces to reduce direct leaking path across the joint
interface 154. As shown, each joint interface 154 includes a first
joint face 164, a second joint face 166, and a roller joint face
168. In particular, the first joint face 164 and the roller joint
face 168 of each joint interface 154 are circumferentially 54
offset from one another and generally extend in the radial 52
direction. Additionally, the second joint face 166 of each joint
interface 154 extends between the first joint face 164 and the
roller joint face 168 in the circumferential 54 direction. As such,
each joint interface 154 has a generally L-shaped configuration. In
other words, the first and second segments 150 and 152 of the
primary ring 106 are split along generally L-shaped lines. For
example, the first joint face 164 extending generally in the radial
52 direction and the second joint face 166 extending generally in
the circumferential 54 direction join together to form an L-shape.
Similarly, the second joint face 166 extending generally in the
circumferential 54 direction and the roller joint face 168
extending generally in the radial 52 direction join together to
form an L-shape. In the manner described below, this L-shaped
configuration of the joint interfaces 154 between the first and
second segments 150 and 152 of the primary ring 106 provides a
sealing relationship between the first and second segments 150 and
152 while enabling relative axial movement between the first and
second segments 150 and 152 when the primary ring 106 is assembled.
The L-shaped configuration prevents leakage from the outer diameter
of the primary ring 106 because any potential leakage along roller
joint face 168 is blocked at the second (e.g., vertical) joint face
166. In other words, the L-shaped configuration creates a tortuous
flow path to enable a reduction in leakage. Furthermore, along the
first joint face 164, shims (e.g., thin metal shims) may be placed
to further reduce any potential leakage.
[0039] As will be appreciated, during operation of the steam
turbine 36, an outer diameter pressure (e.g., a radially inward
pressure represented by arrows 170) of the primary ring 106 may be
greater than an inner diameter pressure (e.g., a radially outward
pressure represented by arrows 172) of the primary ring 106.
Consequently, the primary ring 106 of the face seal 100 may
experience a radially inward net pressure. Without a bearing
element 174 (roller pins) on the interface 168 to absorb the inward
loading, the radially inward net pressure acting on the primary
seal 106 could cause the first and second segments 150 and 152 to
be flush or abut one another at the first joint interface 164 and
the second joint face 166 of each joint interface 154. Contact
between those interfaces would prevent free relative axial movement
between segments 150 and 152. Therefore, the first and second joint
faces 164 and 166 are designed to have a minimal gap while the
radially inward net pressure load is carried by the roller pins
(e.g., the bearing elements 174) on the interface 168. In certain
embodiments, the first and second segments 150 and 152 may be
manufactured to have tight tolerances at the first and second joint
faces 164 and 166 to minimize the gap and improve the sealing of
the joint interfaces 154. Additionally or alternatively, the joint
interfaces 154 may include seal strips disposed in the first joint
faces 164 to improve sealing of the joint interfaces 154. The
sealing between the first and second joint faces 164 and 166 helps
block undesired leakage of steam 46 or other working fluid across
segment joints of the face seal 100. Furthermore, in the
illustrated embodiment, the symmetrical orientation of the joint
interfaces 154 (e.g., first and second joint faces 164 and 166)
about a vertical axis 173 of the primary ring 106 reduces lateral
pressure imbalance.
[0040] As mentioned above, the joint interfaces 154 of the primary
ring 106 each include the roller joint face 168. More specifically,
each of the roller joint faces 168 includes one or more roller pins
174 disposed between the first and second segments 150 and 152. The
cylindrical shape of the roller pins 174 enable the roller joint
faces 168 to carry or transfer the radially inward net pressure
acting on the primary ring 106 while still enabling the first and
second segments 150 and 152 of the primary ring 106 to axially
(e.g., in the direction 50) move relative to one another. In this
manner, each of the first and second segments 150 and 152 may
achieve its own hydrodynamic equilibrium with respect to the mating
ring 108 during operation of the steam turbine 36. More
specifically, as the first and second segments 150 and 152 are free
to move axially independently of one another, any relative tilt
between the first and second segments 150 and 152 would be
corrected by corresponding hydrodynamic pressures on the first and
second segments 150 and 152 (e.g., larger hydrodynamic pressures on
the segment that is closer to the mating ring 108 compared to the
other segment). The self-correcting hydrodynamic pressure may cause
the segments to move axially relative to the other segment until a
dynamic equilibrium is re-gained. As a result, the first and second
segments 150 and 152 may operate or "ride" at their respective
equilibrium positions with respect to the mating ring 108 while
reducing the occurrence of rubbing between the first and second
segments 150 and 152 and the mating ring 108. In this manner,
mechanical degradation of the face seal 100 may be reduced, face
seal 100 life span may be improved, and maintenance may be
reduced.
[0041] FIG. 5 is a partial cross-sectional view of an embodiment of
the face seal 100, illustrating the primary ring 106 having locally
compliant hydrodynamic pads 200. Specifically, the locally
compliant hydrodynamic pads 200 are disposed in and adjacent the
primary ring 106 facing the mating ring 108 of the face seal 100.
That is, the illustrated locally compliant hydrodynamic pad 200 is
disposed within a pocket or recess 202 of the primary ring 106.
Additionally, the hydrodynamic pads 200 may each be biased towards
the mating ring 108 by one or more springs 204 (e.g., coil spring).
As a result, the hydrodynamic pads 200 are configured to engage
with the mating ring 108. One of the functions of the locally
compliant hydrodynamic pad 200 is to engage the mating ring 108
before the majority of the primary ring face 132 comes close to the
mating ring face 134. The locally compliant hydrodynamic pad 200
also helps align the primary ring 106 properly with the mating ring
108. Furthermore, in certain embodiments, each of the hydrodynamic
pads 200 may have a micron length-scale profile (e.g., on axial
face 206 of the hydrodynamic pad 200) with axial groove depth
variations in the circumferential direction 54 of each hydrodynamic
pad 200 and/or in the radial direction 52 of each hydrodynamic pad
200 to generate a specific profile of hydrodynamic pressure on each
hydrodynamic pad 200 to help the face seal 100 maintain non-contact
operation. Similarly, it should be noted that primary ring sealing
face 208 and/or the mating ring sealing face 210 of may also have
various profiles or surface features to improve hydrodynamic
load-bearing performance of the face seal 100, as discussed in
detail below.
[0042] As mentioned, the spring 204 is disposed within the
respective pocket or recess 202 of the primary ring 106. That is,
the recess 202 is formed in the primary ring 106 that faces the
mating ring 108 of the face seal 100 when the face seal 100 is
assembled. As will be appreciated, the spring 204 is designed to
allow certain degrees of freedom for the hydrodynamic pad 200. For
example, the spring 204 may allow a first translational degree of
freedom in an out of the plane of the primary ring 106 (e.g.,
movement in the axial direction 50), a second rotating degree of
freedom rocking or pivoting in the circumferential direction 54,
and a third rotating degree of freedom rocking or pivoting in the
radial direction 52. Therefore, the hydrodynamic pad 200 may better
conform to the mating ring 108 orientations and/or distortions. As
a result, the hydrodynamic pad 200 may block contact between the
primary ring 106 and the mating ring 108, while also blocking the
formation of large leakage gaps between the primary ring 106 and
the mating ring 108 of the face seal 100. In other words, the
hydrodynamic pad 200 enables the primary ring 106 to maintain a
"hydrodynamically locked in" position with respect to the mating
ring 108. A local closing force facilitated by individual pocket
spring 204 and a local hydrodynamic opening force facilitated by
individual pad 200 help the primary ring 106 perform with precision
so as to achieve a dynamic equilibrium with respect to the mating
ring 108 without contacting the mating ring 108. This can help
prevent or reduce rubs when the operating forces are trying to form
a wedge shaped gap between the primary ring 106 and mating ring
108. During such an event, the pads 200 on the primary ring 106
that are closer to the mating ring 108 will tend to generate a
larger hydrodynamic opening force and will compress corresponding
local springs 204 farther into the backing portion 126 compared to
the pads 200 that are away from the mating ring 108. This radial
difference in opening force will create a nutation of the primary
ring 106 and will try to make the wedge shaped gap parallel. The
ability of the face seal 100 to ride with such a parallel gap
reduces the possibility of rubbing. In this manner, rubbing and
mechanical degradation between the primary ring 106 and mating ring
108 may be reduced while still maintaining the leakage of steam 46
to a very low designed value. As will be appreciated, a reduction
in mechanical degradation of components of the face seal 100 may
reduce steam turbine 36 down time and maintenance costs and may
increase the useful life of the face seal 100 components, while a
reduction of steam 46 leakage may improve efficiency of the steam
turbine 36.
[0043] As mentioned above, the axial face 206 of each hydrodynamic
pad 200 may have various profiles to improve operation of the face
seal 100. For example, the face 206 of one or more hydrodynamic
pads 200 may have a converging profile in the direction of rotation
(e.g., in the circumferential direction 54) to enable hydrodynamic
force generation as the mating ring 108 spins past them in one
direction (e.g. clockwise). In other embodiment pads 200 can have a
wavy profile to enable bi-directional operation of the steam
turbine 36. In another embodiment, the face 206 of one or more
hydrodynamic pads 200 may have a step in the radial direction 52
that forms a dam section against radially 52 inward flow of steam
46 to generate an additional dynamic pressure component (due to
flow impingement) that will improve hydrodynamic pressure
distribution. Such features may help reduce tolerance demand or
requirements of various face seal 100 components. It should be
noted that the sealing face 208 of the primary ring 106 and the
sealing face 210 of the mating ring 108 may also have various
profiles or surface features to improve hydrodynamic load-bearing
performance of the face seal 100.
[0044] Furthermore, the number of springs 204 biasing each
hydrodynamic pad 200 and the position of the springs 204 relative
to the respective hydrodynamic pad 200 may vary in different
embodiments. For example, in the illustrated embodiment, the
hydrodynamic pad 200 is biased toward the mating ring 108 by one
spring 204 that is generally coupled to a center of the
hydrodynamic pad 200. In other embodiments, each hydrodynamic pad
200 may have multiple springs 204 biasing the hydrodynamic pad 200
toward the mating ring 108. For example, each hydrodynamic pad 200
may be biased toward the mating ring 108 by four springs 204 with
one spring 204 coupled to a respective corner of the hydrodynamic
pad 200 (see FIG. 8). For further example, in certain embodiments,
each hydrodynamic pad 200 may include one spring 204 coupled to the
hydrodynamic pad 200 offset from the center (e.g., radially 52
inward or radially 52 outward) of the hydrodynamic pad 200. Leaf
springs could be used instead of the coil springs shown.
[0045] FIGS. 6 and 7 are perspective views of an embodiment of the
primary ring 106 of the face seal 100, illustrating locally
compliant hydrodynamic pads 200 of the primary ring 106. As
mentioned above, each of the locally compliant hydrodynamic pads
200 may be supported by one or more springs 204. As a result, each
of the hydrodynamic pads 200 can move individually (e.g.,
irrespective of other hydrodynamic pads 200) in and out of the
plane of the primary ring 106. In this manner, each of the
hydrodynamic pads 200 may conform to the dynamically changing
orientation of the mating ring 108 arising from thermal,
pressure-driven, and/or transient forces.
[0046] In the illustrated embodiment, the primary ring 106 includes
six locally compliant hydrodynamic pads 200 spaced substantially
equidistantly about the primary ring 106 in the circumferential
direction 54. However, in other embodiments, the primary ring 106
may include other numbers of hydrodynamic pads 200 and/or
hydrodynamic pads 200 arranged in other configurations, as
discussed below. For example, in the illustrated embodiment, the
hydrodynamic pads 200 have substantially similar positions along
the primary ring 106 in the radial direction 52. However, in other
embodiments, the hydrodynamic pads 200 may be radially 52
staggered. For example, one hydrodynamic pad 200 may have a first
radial 52 position, and adjacent hydrodynamic pads 200 may have a
second radial 52 position, thereby creating a staggered arrangement
circumferentially 54 around the primary ring 106.
[0047] Furthermore, the illustrated embodiment of the primary ring
106 includes the first and second segments 150 and 152, as
similarly described above with respect to FIG. 4. Additionally, the
joint interfaces 154 of the primary ring 106 include the roller
pins 174 to enable relative axial 50 movement of the first and
second segments. However, it should be noted that other embodiments
of the primary ring 106 may include the locally compliant
hydrodynamic pads 200 but not a segmented configuration. Similarly,
in other embodiments, the primary ring 106 may include a segmented
configuration but not the locally compliant hydrodynamic pads 200
described above.
[0048] FIGS. 8 and 9 are perspective views of other embodiments of
the primary ring 106 of the face seal 100, illustrating locally
compliant hydrodynamic pads 200 of the primary ring 106.
Specifically, FIG. 8 illustrates the primary ring 106 having
locally compliant hydrodynamic pads 200, where each locally
compliant hydrodynamic pad 200 is biased toward the mating ring 108
by four springs 204 within the respective recess 202cut through the
face of the primary ring 106. As shown, each recess 202 includes
one spring 204 in each of the four corners of the recess 202. Such
an arrangement provides the ability to tune the spring 204
stiffness at the four corners of the pad 200 individually so as to
provide desired moment characteristics to correct for any tilt bias
in the primary ring 106. For example, by increasing the stiffness
of the springs 204 at the top corners, one can make area near the
outer diameter of the pad 200 less compliant with respect to the
inner diameter, thus causing fluid film thickness locally higher at
the inner diameter of the pad 200 than at the outer diameter so as
to compensate for any tilt-producing operational phenomenon that
causes inner diameter film thickness to be lower than the outer
diameter film thickness. In the illustrated embodiment, the springs
204 are coil springs, however, in other embodiments, the springs
204 may be other types of springs, such as leaf spring or beams.
FIG. 9 illustrates an embodiment of the primary ring 106 having
locally compliant hydrodynamic seals 200, where each of the locally
complaint hydrodynamic seals 200 are biased by a respective bellow
spring 300 disposed within the respective recess 202 of the primary
ring 106. By selecting the thickness of the bellows, spacing
between bellow turns and number of turns, one can achieve the
desired force and structural moment characteristics of compliant
mechanism of the pad to resist any aerodynamic moments (e.g. due to
windage) that are trying to de-stabilize the hydrodynamic
performance of the seal. While each locally complaint hydrodynamic
seal 200 is biased by one bellow spring 300 in the illustrate
embodiment, other embodiments may include other numbers of bellow
springs 300.
[0049] FIGS. 10 and 11 are perspective views of other embodiments
of the primary ring 106 of the face seal 100, illustrating another
arrangement of the locally compliant hydrodynamic pads 200 of the
primary ring 106. Specifically, in FIGS. 10 and 11, the primary
ring 106 includes a first, radially inward set 310 of locally
compliant hydrodynamic pads 200, and a second, radially outward set
312 of locally compliant hydrodynamic pads 200. Additionally, the
first, radially inward set 310 and the second, radially outward set
312 of locally compliant hydrodynamic pads are staggered
circumferentially 54 about the primary ring 106 with respect to one
another. However, in other embodiments, the first, radially inward
set 310 and the second, radially outward set 312 may not be
circumferentially staggered relative to one another. Additionally,
as will be appreciated, the first, radially inward set 310 and the
second, radially outward set 312 may have the same or different
numbers of locally compliant hydrodynamic pads 200. Furthermore, in
FIG. 11, each of the second, radially outward set 312 of locally
compliant hydrodynamic pads 200 includes a surface treatment 314.
Specifically, each of the second, radially outward set 312 of
locally compliant hydrodynamic pads 200 includes a micron
length-scale profile or grooves 314 on the respective face 206 of
each hydrodynamic pad 200. As will be appreciated, the micro-scale
profile or grooves 314 on the respective face 206 of each
hydrodynamic pad 200 may generate additional pressure towards an
inner diameter 316 of the primary ring 106, thus providing
additional hydrodynamic separation force to keep the primary ring
106 from contacting the mating ring 108.
[0050] FIGS. 12 and 13 are perspective views of other embodiments
of the primary ring 106 of the face seal 100, illustrating various
surface treatments or features formed on the sealing face 208 of
the primary ring 106. For example, in FIG. 12, the sealing face 208
of the primary ring 106 includes grooves 320 (e.g., spiral
grooves), which extend from an outer diameter 322 toward an inner
diameter 324 of the sealing face 208. As will be appreciated, the
grooves 320 may be recesses formed in the sealing face 208 that
extend toward, but not all the way to, the inner diameter 324 of
the sealing face 208. Rather, each groove 320 has a dam portion
326. As such, steam 46 or other gas may enter the grooves 320 from
the outer diameter side during operation of the steam turbine 36
and flow through the grooves, accelerating along the curvature of
the grooves, towards the dam portion 326 of each groove 320 and
finally impinges against the dam portion 326, thus creating a
dynamic pressure rise so as to provide the hydrodynamic separation
force. In this manner, the grooves 320 may enable the generation of
additional pressure toward the inner diameter 324 of the primary
ring 106. In FIG. 13, the sealing face 208 of the primary ring 106
includes Y-shaped grooves 330. As shown, each Y-shaped groove 330
extends from the middle of sealing face 208 toward both outer
diameter 322 and the inner diameter 324 starting from a stem
portion 332 to form a Y-shaped groove 330 which is terminated
before reaching the inner and outer diameters. As steam 46 or other
gas is fed into the Y-shaped grooves 330 through hole 334. The
Y-shaped grooves 330 pumps fluid toward both outer diameter 322 and
the inner diameter 324 simultaneously to generate hydrodynamic
pressure in the regions near the outer or inner diameters 322 or
324 of the primary ring 106. With such a Y shaped configuration of
the grooves, the outer branch and inner branch of the Y shape
provide the self-correcting hydrodynamic forces needed to follow
any coning of the mating ring sealing face 210.
[0051] As will be appreciated, each of the features (e.g., surface
treatments and/or profiles) of the embodiments discussed above may
be included individually or in any combination with one another as
a part of one or more of the different components of the face seal
100. For example, the hydrodynamic features shown on the primary
sealing face 208 in FIGS. 12 and 13 can be applied to the mating
ring sealing face 210 while the primary sealing face 208 is a blank
flat surface. Additionally, one of ordinary skill in the art will
appreciate that the various arrangements, surface treatments, and
other features discussed above may have other configurations, which
are considered within the scope of the present disclosure.
[0052] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *