The influence of turbine stator well coolant flow rate and passage configuration on cooling effectiveness

Market competitiveness for aero engine power plant dictates that improvements in engine performance and reliability are guaranteed a priori by manufacturers. The requirement to accurately predict the life of engine components makes exacting demands of the internal air system, which must provide effective cooling over the engine duty cycle with the minimum consumption of compressor section air. Tests have been conducted at the University of Sussex using a turbine test facility which comprises a two stage turbine with an individual stage pressure ratio of 1.7:1. Main annulus air is supplied by an adapted Rolls-Royce Dart compressor at up to 440 K and 4.8 kg s-1. Cooling flow rates ranging from 0.71 to 1.46 Cw, ent, a disc entrainment parameter, have been used to allow ingress or egress dominated stator well flow conditions. The mechanical design of the test section allows internal cooling geometry to be rapidly re-configured, allowing the effect of jet momentum and coolant trajectory to be investigated. An important facet to this investigation is the use of CFD to model and analyse the flow structures associated with the cavity conditions tested, as well as to inform the design of cooling path geometry. This paper reports on the effectiveness of stator well coolant flow rate and delivery configurations using experimental data and also CFD analysis to better quantify the effect of stator well flow distribution on component temperatures. Copyright © 2011 by Rolls-Royce plc.

Experimental investigation of turbine stator well rim seal, reingestion and interstage seal flows using gas concentration techniques and displacement measurements

Gas turbine engine performance requires effective and reliable internal cooling over the duty cycle of the engine. Life predictions for rotating components subject to the main gas path temperatures are vital. This demands increased precision in the specification of the internal air system flows which provide turbine stator well cooling and sealing. This in turn requires detailed knowledge of the flow rates through rim seals and interstage labyrinth seals. Knowledge of seal movement and clearances at operating temperatures is of great importance when prescribing these flows. A test facility has been developed at the University of Sussex, incorporating a two stage turbine rated at 400 kW with an individual stage pressure ratio of 1.7:1. The mechanical design of the test facility allows internal cooling geometry to be rapidly re-configured, while cooling flow rates of between 0.71 CW, ENT and 1.46 C W, ENT, may be set to allow ingress or egress dominated cavity flows. The main annulus and cavity conditions correspond to in cavity rotational Reynolds numbers of 1.71×106< Reφ <1.93×106. Displacement sensors have been used to establish hot running seal clearances over a range of stator well flow conditions, allowing realistic flow rates to be calculated. Additionally, gas seeding techniques have been developed, where stator well and main annulus flow interactions are evaluated by measuring changes in gas concentration. Experiments have been performed which allow rim seal and re-ingestion flows to be quantified. It will be shown that this work develops the measurement of stator well cooling flows and provides data suitable for the validation of improved thermo-mechanical and CFD codes, beneficial to the engine design process. Copyright © 2011 by Rolls-Royce plc.

Fault-tolerant model predictive control of a wind turbine benchmark

This paper aims to solve the fault tolerant control problem of a wind turbine benchmark. A hierarchical controller with model predictive pre-compensators, a global model predictive controller and a supervisory controller is proposed. In the model predictive pre-compensator, an extended Kalman Filter is designed to estimate the system states and various fault parameters. Based on the estimation, a group of model predictive controllers are designed to compensate the fault effects for each component of the wind turbine. The global MPC is used to schedule the operation of the components and exploit potential system-level redundancies. Extensive simulations of various fault conditions show that the proposed controller has small transients when faults occur and uses smoother and smaller generator torque and pitch angle inputs than the default controller. This paper shows that MPC can be a good candidate for fault tolerant controllers, especially the one with an adaptive internal model combined with a parameter estimation and update mechanism, such as an extended Kalman Filter. © 2012 IFAC.

Vibration response of a wind-turbine planetary gear set in the presence of a localized planet bearing defect

In a wind-turbine gearbox, planet bearings exhibit a high failure rate and are considered as one of the most critical components. Development of efficient vibration based fault detection methods for these bearings requires a thorough understanding of their vibration signature. Much work has been done to study the vibration properties of healthy planetary gear sets and to identify fault frequencies in fixed-axis bearings. However, vibration characteristics of planetary gear sets containing localized planet bearing defects (spalls or pits) have not been studied so far. In this paper, we propose a novel analytical model of a planetary gear set with ring gear flexibility and localized bearing defects as two key features. The model is used to simulate the vibration response of a planetary system in the presence of a defective planet bearing with faults on inner or outer raceway. The characteristic fault signature of a planetary bearing defect is determined and sources of modulation sidebands are identified. The findings from this work will be useful to improve existing sensor placement strategies and to develop more sophisticated fault detection algorithms. Copyright © 2011 by ASME.

Self-excited circumferential instabilities in a model annular gas turbine combustor: Global flame dynamics

In this paper the global flame dynamics of a model annular gas turbine combustor undergoing strong self-excited circumferential instabilities is presented. The combustor consisted of either 12, 15 or 18 turbulent premixed bluff-body flames arranged around an annulus of fixed circumference so that the effect of flame separation distance, S, on the global heat release dynamics could be investigated. Reducing S was found to produce both an increase in the resonant frequency and the limit-cycle amplitudes of pressure and heat release for the same equivalence ratio. The phase-averaged global heat release, obtained from high-speed OH- chemiluminescence imaging from above, showed that these changes are caused by large-scale modifications to the flame structure around the annulus. For the largest S studied (12 flame configuration) the azimuthal instability produced a helical-like global heat release structure for each flame. When S was decreased, large-scale merging or linking between adjacent flames occurred spanning approximately half of the annulus with the peak heat release concentrated at the outer annular wall. The circumferential nature of the instability was evident from both the pressure measurements and the phase-averaged OH- chemiluminescence showing the phase of the heat release on either side of the annulus to be ≈180°apart and spinning in the counter clockwise direction. Both spinning and standing modes were found but only spinning modes are considered in this paper. To the best of the authors knowledge, these are the first experiments to provide a phase-averaged picture of self-excited azimuthal instabilities in a laboratory-scale annular combustor relevant to gas turbines. © 2012 The Combustion Institute. Published by Elsevier Inc. All rights reserved.

Flow field of a model gas turbine swirl burner

The flow field of a lab-scale model gas turbine swirl burner was characterised using particle imaging velocimetry (PIV) at atmospheric condition. The swirl burner consists of an axial swirler, a twin-fluid atomizer and a quartz tube as combustor wall. The main non-reacting swirling air flow without spray was compared to swirl flow with spray under unconfined and enclosed conditions. The introduction of liquid fuel spray changes the flow field of the main swirling air flow at the burner outlet where the radial velocity components are enhanced. Under reacting conditions, the enclosure generates a corner recirculation zone that intensifies the strength of the radial velocity. Comparison of the flow fields with a spray flame using diesel and palm biodiesel shows very similar flow fields. The flow field data can be used as validation target for swirl flame modeling. © (2013) Trans Tech Publications, Switzerland.

Blade Loading and Its Application in the Mean-Line Design of Low Pressure Turbines

In order to minimize the number of iterations to a turbine design, reasonable choices of the key parameters must be made at the preliminary design stage. The choice of blade loading is of particular concern in the low pressure (LP) turbine of civil aero engines, where the use of high-lift blades is widespread. This paper considers how blade loading should be measured, compares the performance of various loss correlations, and explores the impact of blade lift on performance and lapse rates. To these ends, an analytical design study is presented for a repeating-stage, axial-flow LP turbine. It is demonstrated that the long-established Zweifel lift coefficient (Zweifel, 1945, "The Spacing of Turbomachine Blading, Especially with Large Angular Deflection" Brown Boveri Rev., 32(1), pp. 436-444) is flawed because it does not account for the blade camber. As a result the Zweifel coefficient is only meaningful for a fixed set of flow angles and cannot be used as an absolute measure of blade loading. A lift coefficient based on circulation is instead proposed that accounts for the blade curvature and is independent of the flow angles. Various existing profile and secondary loss correlations are examined for their suitability to preliminary design. A largely qualitative comparison demonstrates that the loss correlations based on Ainley and Mathieson (Ainley and Mathieson, 1957, "A Method of Performance Estimation for Axial-Flow Turbines," ARC Reports and Memoranda No. 2974; Dunham and Came, 1970, "Improvements to the Ainley-Mathieson Method of Turbine Performance Prediction," Trans. ASME: J. Eng. Gas Turbines Power, July, pp. 252-256; Kacker and Okapuu, 1982, "A Mean Line Performance Method for Axial Flow Turbine Efficiency," J. Eng. Power, 104, pp. 111-119). are not realistic, while the profile loss model of Coull and Hodson (Coull and Hodson, 2011, "Predicting the Profile Loss of High-Lift Low Pressure Turbines," J. Turbomach., 134(2), pp. 021002) and the secondary loss model of (Traupel, W, 1977, Thermische Turbomaschinen, Springer-Verlag, Berlin) are arguably the most reasonable. A quantitative comparison with multistage rig data indicates that, together, these methods over-predict lapse rates by around 30%, highlighting the need for improved loss models and a better understanding of the multistage environment. By examining the influence of blade lift across the Smith efficiency chart, the analysis demonstrates that designs with higher flow turning will tend to be less sensitive to increases in blade loading. © 2013 American Society of Mechanical Engineers.

A policy dimension required for technology roadmapping: Learning from the emergence of Chinese wind turbine industry

Innovation policies play an important role throughout the development process of emerging industries in China. Existing policy and industry studies view the emergence process as a black-box, and fail to understand the impacts of policy to the process along which it varies. This paper aims to develop a multi-dimensional roadmapping tool to better analyse the dynamics between policy and industrial growth for new industries in China. Through reviewing the emergence process of Chinese wind turbine industry, this paper elaborates how policy and other factors influence the emergence of this industry along this path. Further, this paper generalises some Chinese specifics for the policy-industry dynamics. As a practical output, this study proposes a roadmapping framework that generalises some patterns of policy-industry interactions for the emergence process of new industries in China. This paper will be of interest to policy makers, strategists, investors and industrial experts. Copyright © 2013 Inderscience Enterprises Ltd.

A Novel System for Reducing Turbo-Lag by Injection of Compressed Gas into the Exhaust Manifold

A key challenge in achieving good transient performance of highly boosted engines is the difficulty of accelerating the turbocharger from low air flow conditions (“turbo lag”). Multi-stage turbocharging, electric turbocharger assistance, electric compressors and hybrid powertrains are helpful in the mitigation of this deficit, but these technologies add significant cost and integration effort. Air-assist systems have the potential to be more cost-effective. Injecting compressed air into the intake manifold has received considerable attention, but the performance improvement offered by this concept is severely constrained by the compressor surge limit. The literature describes many schemes for generating the compressed gas, often involving significant mechanical complexity and/or cost. In this paper we demonstrate a novel exhaust assist system in which a reservoir is charged during braking. Experiments have been conducted using a 2.0 litre light-duty Diesel engine equipped with exhaust gas recirculation (EGR) and variable geometry turbine (VGT) coupled to an AC transient dynamometer, which was controlled to mimic engine load during in-gear braking and acceleration. The experimental results confirm that the proposed system reduces the time to torque during the 3rd gear tip-in by around 60%. Such a significant improvement was possible due to the increased acceleration of turbocharger immediately after the tip-in. Injecting the compressed gas into the exhaust manifold circumvents the problem of compressor surge and is the key enabler of the superior performance of the proposed concept.

Crowbarless fault ride-through of the brushless doubly fed induction generator in a wind turbine under symmetrical voltage dips

The brushless doubly fed induction generator (BDFIG) shows commercial promise for wind power generation due to its lower cost and higher reliability when compared with the conventional DFIG. In the most recent grid codes, wind generators are required to be able to ride through a low-voltage fault and meet the reactive current demand from the grid. A low-voltage ride-through (LVRT) capability is therefore important for wind generators which are integrated into the grid. In this paper, the authors propose a control strategy enabling the BDFIG to successfully ride through a symmetrical voltage dip. The control strategy has been implemented on a 250-kW BDFIG, and the experimental results indicate that the LVRT is possible without a crowbar. © 1982-2012 IEEE.

Turbine blade tip heat transfer in low speed and high speed flows

In this paper, high and low speed tip flows are investigated for a high-pressure turbine blade. Previous experimental data are used to validate a CFD code, which is then used to study the tip heat transfer in high and low speed cascades. The results show that at engine representative Mach numbers the tip flow is predominantly transonic. Thus, compared to the low speed tip flow, the heat transfer is affected by reductions in both the heat transfer coefficient and the recovery temperature. The high Mach numbers in the tip region (M>1.5) lead to large local variations in recovery temperature. Significant changes in the heat transfer coefficient are also observed. These are due to changes in the structure of the tip flow at high speed. At high speeds, the pressure side corner separation bubble reattachment occurs through supersonic acceleration which halves the length of the bubble when the tip gap exit Mach number is increased from 0.1 to 1.0. In addition, shock/boundary-layer interactions within the tip gap lead to large changes in the tip boundary-layer thickness. These effects give rise to significant differences in the heat-transfer coefficient within the tip region compared to the low-speed tip flow. Compared to the low speed tip flow, the high speed tip flow is much less dominated by turbulent dissipation and is thus less sensitive to the choice of turbulence model. These results clearly demonstrate that blade tip heat transfer is a strong function of Mach number, an important implication when considering the use of low speed experimental testing and associated CFD validation in engine blade tip design. Copyright © 2009 by ASME.