Pressure drop and cavitation investigations on static helical-grooved square, triangular and curved cavity liquid labyrinth seals

► Design and testing of newer and novel helical-grooved profiles of labyrinths capable of ensuring high pressure drops even at low liquid flow rates. ► Implementation of genetic algorithm in the optimization of labyrinth seal through surrogate modelling means. ► Application of CFD in three-dimensional fluid flow and cavitation analysis for static helical grooved labyrinth seals. Sodium cooled Fast Breeder Reactors (FBR) form the second stage of India's Nuclear power programme. Through a narrow annular space in the grid plate assembly of a prototype FBR, a very low leakage flow of liquid metal sodium should pass, experiencing a stipulated high pressure drop, and without much cavitation. To achieve this, a suitable labyrinth seal is required to be developed for use in the annulus. Water is employed as the model testing liquid which is estimated to experience a pressure drop ratio of 10.5 at the rated leakage flow. Previously studied circular or sinusoidal-grooved square, triangular or curved cavity labyrinth seals were unable to meet this value. In the present work, Computational Fluid Dynamics (CFD) analyses are carried out on Helical-grooved Square cavity Labyrinth Seals (HSLS), using commercial code Fluent. It is found that the geometrical configuration of the grooves plays a major role on the pressure drop. Experimental results reveal close agreement with CFD predictions. An optimal configuration of this square cavity seal is identified by applying genetic algorithm (GA) using commercial packages. It meets just about 24% of the targeted value. Later, using parametric CFD analyses, a Helical-grooved Triangular cavity Labyrinth Seal (HTLS) and different Helical-grooved Curved cavity Labyrinth Seals (HCLS) are analysed. The most favourable profile is tested and found to reach the required pressure drop. CFD cavitation analyses predict the intensity of cavitation in these seals to be below prohibitive levels.