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5.7.1 Measured Thrust Loads Thrust load was measured by using the load cell that was installed in the motor-driven compressor (see Figure 3-1). The axial thrust was designed to be taken by the ball bearings which were configured in a back-to-back thrust bearing arrangement but is backed only by a spring loaded load cell. This means that the bearing on the turbine side of Figure 3-1 prevents the shaft from moving to towards the turbine while the bearings on compressor side are limited only by the preload applied to the load cell. The load cell can be placed on either the turbine or the compressor side, but it only measures the load in one direction. BNI expected the loads to push towards the compressor; therefore the load cell was initially set up to measure loads up to 500 lbs in this direction. However, the thrust loads at 55,000 rpm were limited to about 75-90 lbs, but the thrust was towards the turbine side. To measure this thrust the load cell had to be moved to the turbine side. This value of thrust (75-90 lbf) was sufficiently small that it falls within the expected gas bearing thrust load capability (~225 lbs). As illustrated in the previous sections one test varied the shaft speed in steps from 10,000 rpm to 40,0000 rpm while the rotor cavity pressure was held nearly constant at ~500 psia, see Figure 5-19. This test was used to develop shaft thrust load models, but was also used to illustrate the labyrinth seal leakage flow rate models. The measured and predicted thrust values are shown in Figure 5-31. The measured thrust is towards the rotor cavity (or towards the turbine end of the shaft) and is seen to be on the order of 100 lbs, and it is slightly shaft speed dependent. The magnitude of the thrust is judged to be low enough to allow the use of gas foil thrust bearings. The model for thrust uses the geometry of the compressor wheel, the shaft speed, the mass flow rate and the leakage flow rate, plus an assumed slip coefficient to estimate the gas velocity to predict the static pressure rise on the front and back face of the compressor. The static pressure is integrated with the area of the compressor to determine the axial thrust. In Figure 5-31, the slip coefficient is fit to the data, hence we see very good agreement. The slip coefficient is a very weak function of shaft speed (on the order of 75%). However, this same model, when used on other tests, provides reasonably good predictions of the thrust load. At the current time the model is quite simple but the results appear to provide reasonable estimates or the thrust. Because there can be many hundreds to a thousand of pounds of force across the front and back face of the compressor the model must subtract two very large numbers to find a total thrust that is near zero. This also makes it difficult to predict the direction and magnitude of the thrust. This is an area of future research and measurement, and further reports are expected in this area. 79PDF Image | Operation and Analysis of a Supercritical CO2 Brayton Cycle
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