Modern gas turbine engine designers are challenged with aggressive power, cycle efficiency and operational life requirements. Those targets are directly related with turbine inlet temperature, material selection and design choices. Increasing turbine inlet temperature, increases cycle efficiency and power output; however, operational life is adversely affected. To optimize these contradicting targets, cooling and sealing design choices must be carefully selected, which is the main responsibility of Secondary Air Systems design engineer. Altair Flow Simulator© (FS) is an integrated one-dimensional flow, thermal, and combustion modeling software that can be used for conceptual as well as detailed design and analysis for any thermo-fluid system design application. This paper reviews the FS modeling methods that are commonly used for SAS design. The methods to be reviewed include rotating orifice, rotor-stator cavity, and labyrinth seals. The component modeling results are validated by comparing literature test data, company owned test data, and Computational Fluid Dynamics (CFD) analysis. Discharge coefficients for orifices, swirl ratio for rotating cavities and leakage values for smooth-land labyrinth seals are investigated throughout the paper.
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