Effect of Rotor-stator Axial Gap on the Tip Seal Leakage Flow of a Steam Turbine

The tip leakage flow in different axial gaps is numerically investigated based on the Reynolds-Averaged Navier-Stokes equations and k-ω SST turbulent model using commercial CFD software ANSYS Fluent. The characteristics of vortexes in the flow field of tip seal and the distribution law of rotor tip leakage loss are analyzed under the change of axial gap. The results show that the flow field in the blade tip seal undergoes complex changes with the increase of axial gap. There are two opposite vortices in the seal cavity with small axial gap, namely, the large vortex in the cavity and the small vortex near the wall of the shroud. The small vortex gradually disappears with the increase of the axial gap. When the axial gap is increased to a certain value, the reverse large vortex is formed in the cavity behind the low teeth of seal, and the leakage rate increases significantly; the steam flow angle and the mixing loss also show different changes. Based on the traditional calculation formula of tip leakage rate, a more accurate calculation formula of tip leakage rate is constructed by introducing equivalent labyrinth seal teeth to consider the variation of axial gap.