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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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Presentation on theme: "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."— Presentation transcript:

1 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 st of March 2011

2 Elubsys – Aerodays – 31/03/2011 p. 2 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. 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.

3 Elubsys – Aerodays – 31/03/2011 p. 3 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. ELUBSYS Objectives Advanced seals and associated oil system architecture = enabling technologies for future engine needs

4 Elubsys – Aerodays – 31/03/2011 p. 4 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. Elubsys project Development Elubsys – TRL 5 JTI – TRL6 Engine integration ATOS & INTRANS Advanced seals TRL3 Components improvement Prototype and industrialisation Advanced seals TRL 5 Advanced oil system architecture Associated components design rules

5 Elubsys – Aerodays – 31/03/2011 p. 5 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. ELUBSYS Objectives TargetReference (18-35klbs thrust engine)ReachedWP Fuel Burn % Secondary air loss - 60 to -90 g/s x3 bearing chamber Laby seal (100g/s) x3 bearing chamber 1 Heat generation - 6kW75kW1&2 Oil system mass -24 kg44 kg1,2&3 Oil Consumption - 60 % Oil consumption - 60 %0.3 l/h (oil fliow = 3000 l/h)1,2&3 Oil mean replacement time +150%66h4 Maintenance costs % Oil cost reduction l/year600l/year Oil System reliability %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 Elubsys – Aerodays – 31/03/2011 p. 6 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. 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 Externals WP2 Housing Heat management WP4 Oil quality and coking + WP5: Scientific coordination and benefit evaluation (ULB) Partners: ULB, TA,ULG WP0: Global project management (TA)

7 Elubsys – Aerodays – 31/03/2011 p. 7 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. 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 Elubsys – Aerodays – 31/03/2011 p. 8 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. WP1:MTU brush seal rig Bearing Chamber Rig Testing of Brush Seals (Kevlar and Steel materials) High Speed Cam

9 Elubsys – Aerodays – 31/03/2011 p. 9 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. WP1: MTU and ULB/TA brush seal rig Kevlar Pyrometer Ports Brush Seal ULB/TA test rig MTU test rig

10 Elubsys – Aerodays – 31/03/2011 p. 10 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. 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 w oil » w air w oil « w air

11 Elubsys – Aerodays – 31/03/2011 p. 11 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. 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 Elubsys – Aerodays – 31/03/2011 p. 12 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. 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 Elubsys – Aerodays – 31/03/2011 p. 13 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. 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 Elubsys – Aerodays – 31/03/2011 p. 14 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. WP2.1 and 2.2: First Test Campaign (RRD,KIT)

15 Elubsys – Aerodays – 31/03/2011 p. 15 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. 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, u oil Core airflow, u air Oil injection Inner shaft Oil droplets Scavenge (Oil exit) gravity Stationary casing s y Illustration of simplified 2-d model

16 Elubsys – Aerodays – 31/03/2011 p. 16 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. 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 Elubsys – Aerodays – 31/03/2011 p. 17 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. 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

18 Elubsys – Aerodays – 31/03/2011 p. 18 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. WP3.2: 1 st 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 Elubsys – Aerodays – 31/03/2011 p. 19 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. 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 Elubsys – Aerodays – 31/03/2011 p. 20 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. 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 Ejector Mapping (operating area) - 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

21 Elubsys – Aerodays – 31/03/2011 p. 21 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. 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 Elubsys – Aerodays – 31/03/2011 p. 22 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. 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

23 Elubsys – Aerodays – 31/03/2011 p. 23 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. WP4. Task 4.1- MODELLING OIL BEHAVIOUR (TK) -Under this working condition, warning limits are between hours for 1 st stage of oil degradation (additive depletion) 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 TemperatureGasAir Flow 150ºcAir5Nl/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)

24 Elubsys – Aerodays – 31/03/2011 p. 24 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. 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 TEKNIKERTEKNIKER Sensors will be tested on Tekniker test rig,CTA Hydraulic test rig and ULB test rig

25 Elubsys – Aerodays – 31/03/2011 p. 25 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. 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 WP4 task 4.2: NIR and OPD sensors – Future Work Schematic of a filter based spectrometer. Microfluidic cell Light holder

26 Elubsys – Aerodays – 31/03/2011 p. 26 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. 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 « TiO 2 » Crystal Bare Crystal

27 Elubsys – Aerodays – 31/03/2011 p. 27 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. 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 Elubsys – Aerodays – 31/03/2011 p. 28 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. 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)

29 Elubsys – Aerodays – 31/03/2011 p. 29 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. WP5 Lub system 0D model

30 Elubsys – Aerodays – 31/03/2011 p. 30 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. 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

31 Elubsys – Aerodays – 31/03/2011 p. 31 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. ELUBSYS Partners 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 PARTNERS THANK YOU FOR YOUR ATTENTION!


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