SEALING, A hypothetical turbine cooling and sealing arrangement,A generator cooling system,Labyrinth seals.

Fig. 9-5 A hypothetical turbine cooling and sealing arrangement.

SEALING :
12. Seals are used to prevent oil leakage from the engine bearing chambers, to control cooling airflows

and to prevent ingress of the mainstream gas into the turbine disc cavities.
13. Various sealing methods are used on gas turbine engines. The choice of which method is
dependent upon the surrounding temperature and pressure, wearability, heat generation, weight, space
available, ease of manufacture and ease of installa- tion and removal. Some of the sealing methods are
described in the following paragraphs. A hypothetical turbine showing the usage of these seals is shown in
fig. 9-5.

A centrifugal breather, A thread-type oil filter,A typical pressure and scavenge filter,LUBRICATING OILS

Fig. 8-11 A thread-type oil filter.

27. In some engines, to minimize the effect of the dynamic loads transmitted from the rotating
assemblies to the bearing housings, a 'squeeze film' type of bearing is used (fig. 8-9). They have a small
clearance between the outer race of the bearing and housing with the clearance being filled with oil. The
oil film dampens the radial motion of the rotating assembly and the dynamic loads transmitted to the
bearing housing thus reducing the vibration level of the engine and the possibility of damage by fatigue.

28. To prevent excessive air pressure within the oil tank, gearboxes and bearing chambers, a vent to
atmosphere is incorporated within the lubrication system. Any oil droplets in the air are separated out
by a centrifugal breather prior to the air being vented overboard. Some breathers may incorporate a
porous media, forming de-aerator segments, which improves the efficiency of the oil separation (fig, 8-10)

Principle of a gear pump

20. The most common type of oil distribution device is a simple orifice which directs a metered amount of
oil onto its target. These jet orifices are positioned as close to the target area as possible to overcome the
possibility of the local turbulent environment deflecting the jet of oil. The smallest diameter of a jet
orifice is 0.04 inch which allows a flow of 12 gallons per hour when operating at a pressure of 40 lb. per
sq. in. The use of restrictors upstream can reduce the flow rate if required.

Fig. 8-5 Principle of a gear pump.

21. All engines transfer heat to the oil by friction, churning and windage within a bearing chamber or
gearbox. It is therefore common practice to fit an oil cooler in recirculatory oil systems. The cooling
medium may be fuel or air and, in some instances, both fuel-cooled and air-cooled coolers are used.

22. Some engines which utilize both types of cooler may incorporate an electronic monitoring system

which switches in the air-cooled cooler only when it is necessary. This maintains the ideal oil temperature

and improves the overall thermal efficiency. 

Internal air system,General internal airflow pattern,COOLING

 Internal air system :



INTRODUCTION

Fig. 9-1 General internal airflow pattern.

1. The engine internal air system is defined as those airflows which do not directly contribute to the engine thrust. The system has several important functions to perform for the safe and efficient operation of the engine. These functions include internal engine and accessory unit cooling, bearing chamber sealing prevention of hot gas ingestion into the turbine disc cavities, control of bearing axial loads, control of turbine blade tip clearances (Part 5) and engine anti-icing (Part 13). The system also supplies air for the aircraft services. Up to one fifth of the total engine core mass airflow may be used for these various functions.

An electronically operated bleed valve system

Fig. 3-18 An electronically operated bleed valve system.

Fig. 3-19 Typical types of fan blades.

32. For casing designs the need is for a light but rigid construction enabling blade tip clearances to be accurately maintained ensuring the highest possible efficiency. These needs are achieved by using aluminium at the front of the compression system followed by .alloy steel as compression temperature increases. Whilst for the final stages of the compression system, where temperature requirements possibly exceed the capability of the best steel, nickel based alloys may be required. The use of titanium in .preference to aluminium and steel is now more common; particularly in military engines where its high rigidity to density ratio can result in significant weight reduction. With the development of new manufacturing methods component costs can now be maintained at a more acceptable level in spite of high initial material costs.

A typical rotor blade showing twisted contour

Fig. 3-12 A typical rotor blade showing
twisted contour.

26. The rotor blades are of airfoil section (fig. 3-12) and usually designed to give a pressure gradient along their length to ensure that the air maintains a reasonably uniform axial velocity. The higher pressure towards the tip balances out the centrifugal action of the rotor on the airstream. To obtain these conditions, it is necessary to ’twist’ the blade from root to tip to give the correct angle of incidence at each point. Air flowing through a compressor creates two boundary layers of slow to stagnant air on the inner and outer walls. In order to compensate for the slow air in the boundary layer a localized increase in blade camber both at the blade tip and root has been introduced. The blade extremities appear as ifformed by bending over each corner, hence the term’end-bend’.Stator vanes
27. The stator vanes are again of airfoil section and are secured into the compressor casing or into stator vane retaining rings, which are themselves secured to the casing (fig. 3-13). The vanes are often assembled in segments in the front stages and may be shrouded at their inner ends to minimize the vibrational effect of flow variations on the longer vanes. It is also necessary to lock the stator vanes in such a manner that they will not rotate around the casing.
OPERATING CONDITIONS
28. Each stage of a multi-stage compressor possesses

Methods of securing blades to disc and Rotors of drum and disc construction

Fig. 3-11 Methods of securing blades to disc.

Fig. 3-10 Rotors of drum and disc
construction.

23. The construction of the compressor centres around the rotor assembly and casings. The rotor shaft is supported in ball and roller bearings and coupled to the turbine shaft in a manner that allows for any slight variation of alignment. The cylindrical casing assembly may consist of a number of cylindrical casings with a bolted axial joint between each stage or the casing may be in two halves with a bolted centre line joint. One or other of these construction methods is required in order that the casing can be assembled around the rotor. Rotors

Principles of operation - Pressure and velocity changes through an axial compressor.

Fig. 3-9 Pressure and velocity changes
through an axial compressor.

19. During operation the rotor is turned at high speed by the turbine so that air is continuously induced into the compressor, which is then accelerated by the rotating blades and swept rearwards onto the adjacent row of stator vanes. The pressure rise results from the energy imparted to the air in the rotor which increases the air velocity. The air is then decelerated (diffused) in the following stator passage and the kinetic energy translated into pressure. Stator vanes also serve to correct the deflection given to the air by the rotor blades and to present the air at the correct angle to the next stage of rotor blades. The last row of stator vanes usually act as air straighteners to remove swirl from the air prior to entry into the combustion system at a reasonably uniform axial velocity. Changes in pressure and velocity that occur in the airflow through the compressor are shown diagrammatically in fig. 3-9. The changes are accompanied by a progressive increase in air temperature as thepressure increases.
20. Across each stage the ratio of total pressures of outgoing air

THE AXIAL FLOW COMPRESSOR

Fig. 3-7 Typical axial flow compressors.

THE AXIAL FLOW COMPRESSOR
13. An axial flow compressor (fig. 3-7 and fig. 3-8 consists of one or more rotor assemblies that carry blades of airfoil section. These assemblies are mounted between bearings in the casings which incorporate the stator vanes. The compressor is a multi-stage unit as the amount of pressure increase by each stage is small; a stage consists of a row of rotating blades followed by a row of stator vanes. Where several stages of compression operate in series on one shaft it becomes necessary to vary the stator vane angle to enable the compressor to operate effectively at speeds below the design condition. As the pressure ratio is increased the incorporation of variable stator vanes ensures that the airflow is directed onto the succeeding stage of rotor blades at an acceptable angle, ref. para. 30, Airflow Control.

Fig. 3-8 Typical triple spool compressor.

14. From the front to the rear of the compressor, i.e. from the low to the high pressure end, there is a

Construction - Typical impellers for centrifugal compressors

Construction
10. The construction of the compressor centres around the impeller, diffuser and air intake system. The impeller shaft rotates in ball and roller bearings and is either common to the turbine shaft or split in the centre and connected by a coupling, which is usually designed for ease of detachment. Impellers
11. The impeller consists of a .forged, disc with integral, radially disposed vanes on one or both sides (fig. 3-5) forming convergent passages in conjunction with the compressor casing. The vanes may be swept back, but for ease of manufacture straight radial vanes are usually employed. To ease the air from axial flow in the entry duct on to the rotating impeller, the vanes in the centre of the impeller are curved in the direction of rotation. The curved sections may be integral with the radial vanes or formed separately for easier and more accurate manufacture.Diffusers
12. The diffuser assembly may be an integral part of the compressor casing or a separately attached assembly. In each instance it consists of a number of vanes formed tangential to the impeller. The vane passages are divergent to convert the kinetic energy into pressure energy and the inner edges of the vanes are in line with the direction of the resultant airflow from the impeller (fig. 3-6). The clearance between the impeller and the diffuser is an important factor, as too small a clearance will set up aerodynamic buffeting impulses that could be transferred to the impeller and create an unsteady airflow and vibration.

Fig. 3-6 Airflow at entry to diffuser.

 

 

Fig. 3-5 Typical impellers for centrifugal
compressors.

THE CENTRIFUGAL FLOW COMPRESSOR

THE CENTRIFUGAL FLOW COMPRESSOR

Fig. 3-3 Pressure and velocity changes
through a centrifugal compressor.

5. Centrifugal flow compressors have a single or double-sided impeller and occasionally a two-stage, single sided impeller is used, as on the Rolls-Royce Dart. The impeller is supported in a casing that also contains a ring of diffuser vanes. If a double-entry impeller is used, the airflow to the _rear side is reversed in direction and a plenum chamber is required. Principles of operation
6. The impeller is rotated at high speed by the turbine and air is continuously induced into the centre of the impeller. Centrifugal action causes it to flow radially outwards along the vanes to the impeller tip, thus accelerating the air and also causing a rise in pressure to occur. The engine intake duct may contain vanes that provide an initial swirl to the air entering the compressor.

Fig. 3-4 Impeller working clearance and
air leakage.

Airflow systems.

Fig. 2-5-1 Airflow systems

THE RELATIONS BETWEEN PRESSURE, VOLUME AND TEMPERATURE

THE RELATIONS BETWEEN PRESSURE, VOLUME AND TEMPERATURE 

Fig. 2-3 An airflow through divergent and convergent ducts.

7. During the working cycle of the turbine engine, the airflow or ’working fluid’ receives and gives up heat, so producing changes in its pressure, volume and temperature. These changes as they occur are closely related, for they follow a common principle that is embodied in a combination of the laws of Boyle and Charles. Briefly, this means that the product of the pressure and the volume of the air at the various stages in the working cycle is proportional to the absolute temperature of the air at those stages. This relationship applies for whatever means are used to change the state of the air. For example, whether energy is added by combustion or by compression, or is extracted by the turbine, the heat change is directly proportional to the work added or taken from the gas.

Working cycle and airflow

INTRODUCTION
1. The gas turbine engine is essentially a heat engine using air as a working fluid to provide thrust. To achieve this, the air passing through the engine has to be accelerated; this means that the velocity or kinetic energy of the air is increased. To obtain this increase, the pressure energy is first of all increased, followed by the addition of heat energy, before final conversion back to kinetic Energy in the form of a high velocity jet efflux.
WORKING CYCLE

Fig. 2-1 A comparison between the working cycle of a turbo-jet engine and a piston engine.

2. The working cycle of the gas turbine engine is similar to that of the four-stroke piston engine. However, in the gas turbine engine, combustion occurs at a constant pressure, whereas in the piston engine it occurs at a constant volume. Both engine cycles (fig. 2-1) show that in each instance there is induction, compression, combustion and exhaust.
These processes are intermittent in the case of the piston engine whilst they occur continuously in the gas turbine. In the piston engine only one stroke is utilized in the production of power, the others being involved in the charging, compressing and exhausting of the working fluid. In contrast, the turbine engine eliminates the three ’idle’ strokes, thus enabling more fuel to be burnt in a shorter time;hence it produces a greater power output for a given size of engine.

Rolls-Royce/Snecma Olympus

Rolls-Royce RB37 Derwent 1

A straight-through version of the reverse-flow Power Jets W2B, known as the W2B/26, was developed by the Rover Company from 1941 to 1943. Taken over by Rolls-Royce in April 1943 and renamed the Derwent, it passed a 100hr. test at 2000 lb thrust in November 1943 and was flown at that rating in April 1944. The engine powered the Gloster Meteor III which entered service in 1945.

A turbo-rocket engine.

Fig. 1-12 A turbo-rocket engine.

20. The turbo-rocket engine (fig. 1-12) could be considered as an alternative engine to the turbo/ram jet; however, it has one major difference in that it carries its own oxygen to provide combustion,
21. The engine has a low pressure compressor driven by a multi-stage turbine; the power to drive the turbine is derived from combustion of kerosine and liquid oxygen in a rocket-type combustion chamber. Since the gas temperature will be in the order of 3,500 deg. C, additional fuel is sprayed into the combustion chamber for cooling purposes before the gas enters the turbine. This fuel-rich mixture (gas) is then diluted with air from the compressor and the surplus fuel burnt in a conventional afterburning system.
22. Although the engine is smaller and lighter than the turbo/ram jet, it has a higher fuel consumption. This tends to make it more suitable for an interceptor or space-launcher type of aircraft that requires high speed, high altitude performance and normally has a flight plan that is entirely accelerative and of short duration.

A turbo/ram jet engine.

Fig. 1-10 Comparative propulsive efficiencies

16. At aircraft speeds below approximately 450 miles per hour, the pure jet engine is less efficient than a propeller-type engine, since its propulsive efficiency depends largely on its forward speed; the pure turbo-jet engine is, therefore, most suitable for high forward speeds. The propeller efficiency does, however, decrease rapidly above 350 miles per hour due to the disturbance of the airflow caused by the high blade-tip speeds of the propeller. These characteristics have led to some departure from the use of pure turbo-jet propulsion where aircraft operate at medium speeds by the introduction of a combination of propeller and gas turbine engine.
17. The advantages of the propeller/turbine combination have to some extent been offset by the introduction of the by-pass, ducted fan and propfan engines. These engines deal with larger comparative airflows and lower jet velocities than the pure jet engine, thus giving a propulsive efficiency (Part 21) which is comparable to that of the turbo-prop and exceeds that of the pure jet engine (fig. 1-10).

Mechanical arrangement of gas turbine engines.

Fig. 1-9-2

Basic mechanics

 

Fig. 1-9-1

Mechanical arrangement of gas turbine engines.

PRINCIPLES OF JET PROPULSION

Fig. 1-4 Hero’s engine - probably the earliest
form of jet reaction.

6. Jet propulsion is a practical application of Sir Isaac Newton’s third law of motion which states that, ’for every force acting on a body there is an opposite and equal reaction’. For aircraft propulsion, the ’body’ is atmospheric air that is caused to accelerate as it passes through the engine. The force required to give this acceleration has an equal effect in the opposite direction acting on the apparatus producing the acceleration. A jet engine produces thrust in a similar way to the engine/propeller combination. Both propel the aircraft by thrusting a large weight of air backwards (fig. 1-3), one in the form of a large air slipstream at comparatively low speed and the other in the form of a jet of gas at very high speed.
7. This same principle of reaction occurs in all forms of movement and has been usefully applied in many ways. The earliest known example of jet reaction is that of Hero’s engine (fig. 1-4) produced as a toy in 120 B.C. This toy showed how the momentum of steam issuing from a number of jets could impart an equal and opposite reaction to the jets themselves, thus causing the engine to revolve.

Fig. 1-5 A garden sprinkler rotated by the
reaction of the water jets.

8. The familiar whirling garden sprinkler (fig. 1-5) isa more practical example of this principle, for themechanism rotates by virtue of the reaction to thewater jets. The high pressure jets of modern