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Oil Systems for Next Generation Engines-ELUBSYS Project Mid Term Achievements Aerodays Conference 2011 31st of March 2011 ELUBSYS flight Captain Nicolas.

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Presentation on theme: "Oil Systems for Next Generation Engines-ELUBSYS Project Mid Term Achievements Aerodays Conference 2011 31st of March 2011 ELUBSYS flight Captain Nicolas."— Presentation transcript:

1 Oil Systems for Next Generation Engines-ELUBSYS Project Mid Term Achievements Aerodays Conference 2011 31st of March 2011 ELUBSYS flight Captain Nicolas Raimarckers Safety instructions Fasten your seat belt Seat in upright position Switch your mobiles off Depressurisation Emergency exits Careful to instructions Please respect time slots Speakers Keep it short Others, keep your questions for the end Arttic time keeper WP leaders  Chair Flight Schedule 1

2 ELUBSYS Objectives FOCUSSED Project Achieve REAL results OUR strengths
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. FOCUS ON THE RIGHT OBJECTIVES European aero market depends of 2 major parameters: €/$ parity Fuel price High Variations of both parameters  Solutions could differ a lot (1 to 2 stop strategies) and in particular for airframe and engine technologies (TF, TP, OR, GTF) Need to propose robust solutions Project based on the needs from market and ACHIEVE REAL OBJECTIVES Bricks (TRL4-5)  useful for platform demonstration Direct use for current development project Put the technology bicks into a coherent wall allowing a real technological step. Check that the gain obtained by putting the technos together Dissemination inside your companies and through the aero community OUR STRENGTHS Quality (EC evaluation report technical+ collaborative projects) Experience (Many of you are experts. Some of you already in ATOS) Motivated TEAM TOgether Everyone Achieves More Support to the proposal for a long time JIM FORFAR

3 ELUBSYS Objectives SFC 1 of the main benefits Through Seals LOWER AIR FLOW  Further benefits by adaptation of savenge system Requires to assess the impact on the bearing chamber heat management Decreases oil consumption  requires to assess oil degradation Advanced seals and associated oil system architecture = enabling technologies for future engine needs

4 Prototype and industrialisation
Elubsys project 2008 2009 2010 2011 2012 2013 2014 2015 2004 2003 Advanced seals  TRL3 Components improvement Advanced seals  TRL 5 Advanced oil system architecture  Associated components design rules ATOS & INTRANS Elubsys – TRL 5 JTI – TRL6 Engine integration Development Prototype and industrialisation

5 Continuous evaluation of the project results through 0D model
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 0.3 l/h (oil fliow = 3000 l/h) 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

6 WP2 Housing Heat management WP4 Oil quality and coking
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 Models and experiments of bearing chamber Oil flow interruption (TM,INSA) WP3: Externals (TA) Partners : TA, MTU,SN, WSK, ULB, Cenaero Supply system (TA,ULB,Cenaero) Scavenge system (MTU,WKS) WP4: Oil Quality and Coking (SN) Partners : SN, TA, RRUK, ULB, USFD, TK,UMons) Modelling of oil behaviour (USFD+RRUK,SN) Detection of coking(SN,UMons,TK) Anti-coking coating development (UMons) WP0: Global project management (TA) WP1 Advanced Sealing WP2 Housing Heat management WP4 Oil quality and coking WP3 Externals + WP5: Scientific coordination and benefit evaluation (ULB) Partners: ULB, TA,ULG

7 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 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

8 Testing of Brush Seals (Kevlar and Steel materials)
WP1:MTU brush seal rig Bearing Chamber Rig Testing of Brush Seals (Kevlar and Steel materials) High Speed Cam

9 WP1: MTU and ULB/TA brush seal rig
Kevlar Pyrometer Ports Brush Seal ULB/TA test rig MTU test rig

10 WP1: two phase scavenge flow simulation (FIT)
high woil « wair woil » wair Bubble flow finely dispersed with a high air concentration in the core and a very low concentration near the wall Bubble flow with a high air concentration at the wall and a very low concentration in the core

11 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

12 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

13 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 offtake Baseline rounded Ramp offtake

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

15 Illustration of simplified 2-d model
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 Illustration of simplified 2-d model

16 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 Heat source

17 WP3.2: Supply System Components Optimization
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

18 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

19 Multiple inlet scavenge pump ( WSK)
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

20 Ejector Mapping (operating area)
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 different primary oil flows different seal upstream pressures deteriorated seals variable back pressure (deaerator pressure) Deaerator Tank SpeedCam Scavenge Scavenge X Pump Pump Ejector Bearing chamber

21 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.

22 WP4:Development of a lubricant degradation reduced step reaction mechanism
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 LSIS test facility and key components

23 WP4. Task 4.1- MODELLING OIL BEHAVIOUR (TK)
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) AMINES additive monitorized by RULER FTIR (3500cm-1-OH bond)-oxidation band decrease with oxidation time -Under this working condition, warning limits are between hours for 1st stage of oil degradation (additive depletion) 23

24 WP4. Task 4.2- Device development, testing and integration
Optical Particle Detector (OPD) Near Infrared sensor (NIR sensor) Magnetostrictive sensor VISCOSITY 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 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 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

25 WP4 task 4.2: NIR and OPD sensors – Future Work
NIR Spectrometer miniaturization New detector array (higher pixel n°, smaller size) No diffractive optics: optical wave selection by narrow band pass filters array ( 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 Schematic of a filter based spectrometer. Microfluidic cell Light holder

26 WP4. Task 4.2- Development & testing of QCM oil sensor
UMons 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 Bare Crystal « TiO2 » Crystal 26

27 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.

28 WP5 - Oil circuit (in Proosis)
Outside Conditions RPM BP RPM HP Primary Fluid Secondary Fluid Every red point defines 3 variables: T (K), P (Pa), mdot (kg/s) Liege, May 2010

29 WP5 Lub system 0D model

30 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: and 30

31 ELUBSYS Partner’s ELUBSYS PARTNER’S THANK YOU FOR YOUR ATTENTION!
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!


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