Elubsys – Aerodays – 31/03/2011 p. 1 Ce document est la propriété du Consortium ELUBSYS. Il ne peut être reproduit ou communiqué sans son autorisation.

Elubsys – Aerodays – 31/03/2011 p. 1

Ce document est la propriété du Consortium ELUBSYS. Il ne peut être reproduit ou communiqué sans son autorisation préalable et écrite.This document is the property of ELUBSYS Consortium. It may not be reproduced or communicated without its permission.

Oil Systems for Next Generation Engines-ELUBSYS Project Mid Term Achievements

Aerodays Conference 2011

31st of March 2011



ELUBSYS Objectives

• FOCUSSED Project– FP7 Workplan

– ACARE Goals

– Relation with CleanSky

– Green + Cost Efficient + Time Efficient

• Achieve REAL results – Technology bricks for future projects

– Design practices for direct implementation

– Continuous evaluation tool to assess overall impact

– Dissemination

• OUR strengths– High quality & experience of partners

– Motivated T.E.A.M.



Rationale

Major objectives : Ecology, Economy, Safety

DOC reduction SFC Oil consumptionKey factors

Engine upgrade /

Lube system upgrade

Lube system impacts

Elubsys

Advanced architecture (Open rotor, GTF)

Advanced sealing technology

(brush seals, ventless housings)

Lighter equipment and more dependable

system

Pump capacity

Housing heat management

Oil residency time

New externals technology

Pumps study

Vent port study/ heat managementScavenge piping

Seal performancesOil coking study

Scavenge system simplification

Rationale

Major objectives : Ecology, Economy, Safety

DOC reduction SFC Oil consumptionKey factors

Engine upgrade /

Lube system upgrade

Lube system impacts

Elubsys

Advanced architecture (Open rotor, GTF)

Advanced sealing technology

(brush seals, ventless housings)

Lighter equipment and more dependable

system

Pump capacity

Housing heat management

Oil residency time

New externals technology

Pumps study

Vent port study/ heat managementScavenge piping

Seal performancesOil coking study

Scavenge system simplification

clamping tube

winding wire

bristles

Front plateBacking Plate

(Air mass flow)

clamping tube

winding wire

bristles

Front plateBacking Plate

(Air mass flow)

ELUBSYS Objectives

Advanced seals and associated oil system architecture

= enabling technologies for future engine needs



Elubsys project

Development

Elubsys – TRL 5

JTI – TRL6

Engine integration

ATOS & INTRANS

Advanced seals TRL3

Components improvement

Prototype and industrialisation

2008 2009 2010 2011 2012 2013 2014 201520042003

Advanced seals TRL 5

Advanced oil system architecture

Associated components design rules

No seal pressurizationby Air compressor

Air cabin

Air-oil mix

No seal pressurizationby Air compressor

Air cabin

Air-oil mix



ELUBSYS Objectives

Target Reference (18-35klbs thrust engine) Reached WP

Fuel Burn - 0.7 %

Secondary air loss

- 60 to -90 g/s x3 bearing chamber

Laby seal

(100g/s) x3 bearing chamber

1

Heat generation - 6kW 75kW 1&2

Oil system mass -24 kg 44 kg 1,2&3

Oil Consumption - 60 %

Oil consumption - 60 % 0.3 l/h (oil fliow = 3000 l/h) 1,2&3

Oil mean replacement time

+150% 66h 4

Maintenance costs - 4-5 %

Oil cost reduction - 400 l/year 600l/year

Oil System reliability

+ 4-5 % 1. Delation of vent pipe- 2. Brush seal reliability -3.Cocking detection and prevention

1,2,3&4

Continuous evaluation of the project results through 0D model



ELUBSYS WP & Partners • WP1: Advanced Brush Seals for Bearing Chambers (MTU)

• Partners : MTU, RRUK, ITP, ULB, FIT, UNOTT, SN, • Activities:

– Performance and endurance validation for different types of seals (MTU,SN)

– Impacts on bearing chamber

• WP2: Bearing Chamber Flow and Heat Transfer (RRD)• Partners : RRD, TA, RRUK, SN, TM,ULB,INSA, UoB,

UNIKARL, UNOTT• Activities:

– Models and experiments of bearing chamber– Oil flow interruption (TM,INSA)

• WP3: Externals (TA)• Partners : TA, MTU,SN, WSK, ULB, Cenaero• Activities:

– Supply system (TA,ULB,Cenaero)– Scavenge system (MTU,WKS)

• WP4: Oil Quality and Coking (SN)• Partners : SN, TA, RRUK, ULB, USFD, TK,UMons)• Activities:

– Modelling of oil behaviour (USFD+RRUK,SN)– Detection of coking(SN,UMons,TK)– Anti-coking coating development (UMons)

WP1 Advanced Sealing

WP3 ExternalsW

P2

Ho

usi

ng

H

eat

man

agem

ent

WP

4 Oil q

uality an

d co

king

+ WP5: Scientific coordination and benefit evaluation (ULB)

Partners: ULB, TA,ULG

WP0: Global project management (TA)



WP1 Advanced brush seals for bearing chambers

• Partners: MTU, RRUK, SN, ITP, ULB, FIT, UNOTT

• Objectives– To investigate performances of advanced brush seals for bearing chamber including:

• Kevlar brush seal: measure of frictional heat (using pyrometer) under different overlap conditions and rotational speeds (up to 22000 rpm) , impact of oil coking on the stiffness and efficiency of the seals (MTU)

• Carbon brush seal: endurance tests ( 8000 h) with different overlaps (SN)• Carbon brush seals on ULB/TA test rig under extreme conditions ( hot T°, reverse P, High/low speed)

– To study the two-phase flow behaviour, heat transfer and pressure loss in the scavenge pipe when brush seals are used and the vent pipes removed (FIT)

– To investigate the effect on bearing chamber thermal behaviour of the reduced air flow anticipated through brush seals and optimise the bearing chamber thermal design:

• Design optimisation with a CFD model and also a thermo-mechanical model of a real engine Tail Bearing Housing (TBH). Through a sensitivity analysis the benefits of advance sealing technologies when applied to a real component will be evaluated (RRUK, ITP)

• CFD model of the bearing chamber investigated under the first objective (MTU rig) will be created and the data compared to experimental data (RRUK, UNOTT) code validation

– Bearing Chamber Design Optimisation and Sensitivity analysis



WP1:MTU brush seal rig

Bearing Chamber Rig

Testing of Brush Seals (Kevlar and Steel materials)

High Speed Cam



WP1: MTU and ULB/TA brush seal rig

Kevlar

Pyrometer Ports

Brush Seal

Motor frame

Oil level

Oil injector Air

Brush seals

Oil recuperation cycle

Thermal oil bath

Heated chamber

Electric motor

Oil

Electric immersion Heating elements

ULB/TA test rig

MTU test rig



WP1: two phase scavenge flow simulation (FIT)

Bubble flow finely dispersed with a high air concentration in the core and a very low concentration near the wall

low

high

Bubble flow with a high air concentration at the wall and a very low concentration in the core

woil » wairwoil « wair



WP1 CFD Model: TBH model and MTU test rig

• Real Engine TBH Simulation (RRUK,ITP)– 2 phase CFD Methodology for Real Engine Bearing

Chamber• Application of film model developed by UNott in WP2 to an

industrial case;

• Inform but also use CFD modelling Methodology developed in WP2

– Supply of thermal data to ITP for thermo-mechanical model

• CFD model of MTU bearing chamber (RRUK, UNott)

+comparison with test results



WP2: Bearing Chamber Flow and Heat Transfer

CHALLENGES• Relation to ACARE goals (Advisory Council Aeronautics Res. EU)

– enabler of higher operating temperatures for better SFC=> supports general design trend

– weight reduction by reduced heat and cooler size for SFC=> includes reduction of unit cost

– less development cost by advanced and faster methods– higher reliability (avoidance of oil leakage)

=> reduce operation costs and maintenance effort• State of the Art

– Bearing chamber design based on experience or try&error• Intended Progress

– Make bearing chamber design variants predictable



WP2: Objectives• Improve scavenge and vent port

performance as well as heat transfer (RRD,KIT)

• Optimize CFD modelling for 2-phase flows in bearing chambers (RRUK,UoB, UNott)

• Predict heat transfer in bearings during oil flow interruption (TM)

Grooved offtakeBaseline rounded

Ramp offtake

Heat sources

Cage

Balls

Outer ring

Inner ring

1

2

3

4

5

Heat sourcesHeat sources

Cage

Balls

Outer ring

Inner ring

1

2

3

4

5



WP2.1 and 2.2: First Test Campaign (RRD,KIT)



WP2.1 and 2.2: Bearing Chamber CFD Strategy

- Develop wall film model

(alternative: apply Volume of Fluids method)

- Test in simplified 2-D geometry

- Integrate into 3-D CFD Program

- Validate for rig geometries- Extend to engine

representative geometries

Oil film, uoil

Core airflow,

uair

Oil injection

Inner shaft

Oil droplets

Scavenge (Oil exit)

gravity

Stationary casing

s

y

wT

( , )T y s ( )sT s

Illustration of simplified 2-d model



WP2.3: Oil Flow Interuption (TM)

• Context: in case of oil pump defusing unsteady thermo mechanical behavior

– Consequences on the bearing ?

• Analytical study ( INSA):– Power losses: drag and hydrodynamic rolling

traction force

– Thermal network analysis

– Aerodynamic approach ( CFD model and wind tunnel test)

• TM will perform tests on a partial rig to validate the hypothesis performed during modelling

– Steady state tests

– Oil shut off tests

• Measurements:– Cfriction, Axial load,Q, V shaft– T°in, T° out, T°outer race

3

drag D m mP .LV .P C .d

0,66

0,022 0,871 2 4,25. . .

2

r

UP Q a G W

5

13

10

6

7

9

9

8

1

212

11

12

4

312

5

13

10

6

7

9

9

8

1

212

11

12

4

312

Heat sinkHeat sink

Heat source



• Partners: TA and ULB• Supply system influence on the pump

performance:– Hydraulic circuit (inlet length, roughness)– Accessories connected (strainers, valves,...)

local head loss

• Air content in the oil and his influence (cavitations & air content in the pump):

– Macro bubbles, dissolved gas, micro-bubbles– Dissolved gases in Mobil Jet 2 oil measured by

chromatography ->up to 12% in volume, N2 and 02

• Visual oil analysis:• Tubular sight glass & camera• Particle Tracking Velocimetry

New practical rules for Supply system design

WP3.2: Supply System Components Optimization



WP3.2: 1st test campaign

• First test campaign finishes- analyses in progress

• Results: big influence of air content on pump performances (reduced Pout, pulsation,…)

• Problem detected air accumulation in the visualisation cell

Probable cause: divergent before visualisation cell

Identified solution: divergent before elbow

visible improvement: reduction of air volume and turbulence

• New test campaign foreseen in June with test rig improvements



WP 3.3 : Scavenge system and vent component optimisation

Multiple inlet scavenge pump ( WSK)

BRG cavity Y

BRG cavity X

Common outlet

• Scavenge pump design – completed

• Test rig modifications – completed

• Hardware & Instrum purchasing – completed

• Assembly of pump in progress

• Beginning of testing – March 2011



WP3.3 :Scavenge system MTU ejector

• 1D analytical tool for designing 2 phases flow ejectors has been created

• CFD simulation is ongoing

• Ejector hardware in quarz glass for high speed camera visualization

• Different sprayers (i.e. flat cone, hollow cone, solid cone etc) will be used

• Delivery of H/W and start of testing in March 2011

D1 [mm] D2 [mm] D3 [mm] D4 [mm] g ° F °

s [mm] Lu [mm] LD [mm] LTP [mm]

Total Ejector Length = mm

2,30 17,00

85,00

119,00

90

70

2.4406

30,03

294,00

16,4

3 4

Design Point

0,7

0,8

0,9

1

1,1

1,2

1,3

1,4

1,5

0 5000 10000 15000 20000 25000 30000 35000

V2 [l/h]=Vair+Vbearing-oil(=500l/h)

Pt4

/ P

t2 [

--]

0

20

40

60

80

100

120

DP

sca

ven

ge

line

bea

rin

g c

ham

ber

-to

-Pt2

[

kPa]

Pt1=1600kPa Pt4=101,325kPaV1=800l/h

Pt1=1600kPa Pt4=90kPaV1=800l/h


Pt1=700kPa Pt4=101,325kPaV1=500l/h

Pt1=700kPa Pt4=90kPa V1=500l/h


PT1=300kPa Pt4=101,325kPaV1=277l/h

PT1=300kPa Pt4=90kPaV1=277l/h


Edgel Systemline NOM/NOM108kPa upstream

Edgel Systemline DET/DET108kPa upstream

Edgel Systemline NOM/NOM111,5kPa upstream

Edgel Systemline DET/DET111,5kPa upstream

Edgelsystemline NOM/NOM130kPa upstream

Edgel Systemline DET/DET130kPa upstream

DP Scavenge Line DET/DET130kPa upstream

DP Scavengeline DET/DET111,5kPa upstream

Pt1 ascendingV1 ascending

P upstream seal = 1.115bar

Pt4 ascending


DP scavenge line,P upstream seal = 130kPa

DP scavenge line,P upstream seal = 111,5kPa


- different primary oil flows

- different seal upstream pressures

- deteriorated seals

- variable back pressure (deaerator pressure)

Scavenge Pump Ejector

Scavenge Pump

SpeedCam

Deaerator Tank

X

Bearing chamber



ELubSys – WP4 Input for Aerodays

WP 4: Oil quality and coking

• Objectives– Predict oil behaviour in a complex environment (oil condition, temperatures…)

– Develop sensors able to analyse oil condition under severe engine environment (Temperature, vibrations)

– Develop anti-coking coatings

• Participant roles in the WP4– RRUK + SHEFFIELD INIVERSITY : to develop and validate numerical methods of characterising and

predicting oil ageing and degradation in complex aero transmission systems.– SHEFFIELD INIVERSITY : Experimental validation of developed coatings for the reduction of oil deposition on

heated tubes.

– Snecma + UMons : to develop a sensor to monitor the oil condition in the engine– Snecma + UMons : to develop a coating able to prevent oil coking (sump walls, vent tubes, supply tubes)– ULB : test the different sensors in real oil conditions and test the anti-cocking coating– TA and Tekniker : assess integration of sensors in oil system– Tekniker will contribute in the sensor design and development, micro manufacturing, assembly and test,

as well as in chemical fluid characterisation.



Development of a specific oil ageing code by USFD

• Selection of reduced step reaction mechanism for lubricant ageing

• Translation of a reacting system into a system of Ordinary Differential Equations

• Decomposition of the reaction rate optimisation method for parallel computation

• Validation on a typical reaction and ODE system

Next steps• Code development completed next step

focused on experimental aspects• Running the LSIS to generate samples of

appropriately aged gas turbine oil, • TK to analyse the samples so that mass

fraction concentration can be used as inputs for the optimisation of the reaction rate parameters for the suggested lubricant degradation reacting scheme

WP4:Development of a lubricant degradation reduced step reaction mechanism

LSIS test facility and key components



WP4. Task 4.1- MODELLING OIL BEHAVIOUR (TK)

-Under this working condition, warning limits are between 400-800 hours for 1st stage of oil degradation (additive depletion)

4000,0 3600 3200 2800 2400 2000 1800 1600 1400 1200 1000 800 600 450,0

0,0

2

4

6

8

10

12

14

16

18

20

22

24

26

28

30

32

34

36

38

40

42

44

46

48

50

52

54

55,8

cm-1

%T

0

100

200

300

400

500

600

700

800

900

0,0 2,5 5,0 7,5 10,0 12,5 15,0

Equipment: . ID: <mixed>Test: Red 100 µl Sample ID:

Ru

ler

Nu

mb

er

Seconds

OX01-OH OX01-144H OX01-408H OX01-888H OX01-1560H

AMINES additive monitorized by RULER

FTIR (3500cm-1-OH bond)-oxidation band decrease with oxidation time

TK Progress Overview: oil characterisation

ARTIFICIAL AGEING OF MOBIL JET II Temperature Gas Air Flow

150ºc Air 5Nl/min

-Most representative techniques usable to check oil degradation are:*RULER: electrochemical analysis (Antioxidant additives control)*FTIR Infrared spectroscopy (OH band for acid compound generation)*AN determination of titration (for Acid compound generation)



Sensor to measure the oil degradation.

The sensor has been tested in industrial applications for water and insoluble content monitoring in oil .

Oil degradation prediction

Sensor able to detect• particles size and shape • air bubbles in oil

Generates a report with the count and classification following ISO standard

Minimum size detected : 1µm

Near Infrared sensor (NIR sensor)

Optical Particle Detector (OPD) Magnetostrictive sensor VISCOSITY

WP4. Task 4.2- Device development, testing and integration

Sensor to measure the Oil Viscosity.

The sensor has been tested at laboratory scale.

Oil degradation prediction TEKNIKER

Sensors will be tested on Tekniker test rig,CTA Hydraulic test rig and ULB test rig



• NIR Spectrometer miniaturization

– New detector array (higher pixel n°, smaller size)

– No diffractive optics: optical wave selection by narrow band pass filters array ( 400-1000 nm

– Autonomous electronic

• OPD sensor improvement

– Software changes( back ground homogenization, bubbles and particles distinction, shape classification following lab system analyses)

– Housing adaptation to aeronautical requirements

– Electronics for autonomous functionality and communication protocol

– Choice of CMOS camera modules

– New illumination device

WP4 task 4.2: NIR and OPD sensors – Future Work

Schematic of a filter based spectrometer.

Microfluidic cell

Light holder



WP4. Task 4.2- Development & testing of QCM oil sensorUMons sensor: PROGRESS overview

• QCM sensor characteristics:

- Measure the change in frequency of a quartz crystal resonator

- Highly effective at determining the affinity of molecules to functionalized surfaces

- Surface functionalization: MIP - sol-gel technique

- Principle validated on a lab sensor version

• Next step: Oil sensor integration: from Lab to Aircraft

• Testing: on ULB test rig installed on a derivation

« TiO2 » Crystal

Bare Crystal



ELubSys - WP5

WP 5: Scientific coordination and Benefit evaluation

• Objectives– To coordinate all scientific and technical aspects of the project

– To develop an overall global 0D model for the whole lubrication system, as an evaluation tool of developed technology from ELubSys

– To optimise the gains achieved by ELubSys through a systematic evaluation of the results achieved in the WPs 1-4.

• Participant roles in the WP5– University of Liège and University of Brussels (ULB) : to develop and validate a 0D global model of

the GTE lubrication system and validate it based on experimental data from all partners.

– University of Liège and ULB : estimate with this model the benefits obtained from the ELubSys novel aspects introduced by the different WPs using the ELubSys obtained experimental and simulation data

– Techspace Aero: experimental validation of the full 0D model

– ULB : organisation of the complete scientific coordination (e.g. between the different CFD and CSM softwares used) and of the scientific dissemination.



WP5 - Oil circuit (in Proosis)

Liege, May 2010

RPM BP

RPM HP

Outside Conditions

Primary Fluid

Secondary Fluid

• Every red point defines 3 variables: T (K), P (Pa), mdot (kg/s)



WP5Lub system 0D model

•



Achievability of the final objectives• Conclusion

Risk analysis at T0+18M No High Risk, only 3 medium risks (rigs delays on WP1 and WP2 and risk on technology transfer for WP4)

• Limited delays on the experimental activities

• Budget spending under technical status allows increased effort for the remaining 18 months Sticks to the 36 months objective

• Budget well under the effort Compliant with Budget allocation

•Public Web site: www.elubsys.eu and www.elubsys.com



ELUBSYS Partner’s • WP1: Advanced Brush Seals for Bearing Chambers

• Partners : MTU, RRUK, Sn, ITP, ULB, FIT, UNOTT

• WP2: Bearing Chamber Flow and Heat Transfer • Partners : RRD, TA, RRUK, Sn, TM,ULB,INSA,

UoB, UNIKARL, UNOTT

• WP3: Externals • Partners : TA, MTU,Sn, WSK, ULB, Cenaero

• WP4: Oil Quality and Coking • Partners : Sn, TA, RRUK, ULB, USFD, TK

• WP5: Scientific coordination and benefit evaluation

• Partners: ULB, TA,ULG

ELUBSYS PARTNER’S THANK YOU FOR YOUR ATTENTION!

Elubsys – Aerodays – 31/03/2011 p. 1 Ce document est la propriété du Consortium ELUBSYS. Il ne peut être reproduit ou communiqué sans son autorisation.

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