Analysis and simulation of combustion oscillations in a laboratory spray combustor

The unstable combustion that can occur in combustion chambers is a major problem for aeroengines and ground-based industrial gas turbines. Nowadays, CFD provides a flexible, low cost tool to supplement direct measurement. This paper presents simulations of combustion oscillations in a liquid-fuelled experimental rig at the University of Cambridge. Linear acoustic theory was used to describe the acoustic waves propagating upstream and downstream of the combustion zone and to develop inlet and outlet boundary conditions just upstream and downstream of the combustion region enabling the CFD calculation to be efficiently concentrated on the combustion zone. A combustion oscillation was found to occur with its predicted frequency in good agreement with experimental measurements. More details about the unstable combustion can be obtained from the simulation results. The approach developed here is expected to provide a powerful tool for the design and operation of stable combustion systems. Copyright © 2009 by ASME.

An experimental and computational study of the formation of a streamwise shed vortex in a turbine stage

Shear layers shed by aircraft wings roll up into vortices. A similar, though far less common, phenomenon can occur in the wake of a turbomachine blade. This paper presents experimental data from a new single stage turbine that has been commissioned at the Whittle Laboratory. Two low aspect ratio stators have been tested with the same rotor row. Surface flow visualisation illustrates the extremely strong secondary flows present in both NGV designs. These secondary flows lead to conventional passage vortices but also to an intense vortex sheet which is shed from the trailing edge of the blades. Pneumatic probe traverse show how this sheet rolls up into a concentrated vortex in the second stator design, but not in the first. A simple numerical experiment is used to model the shear layer instability and the effects of trailing edge shape and exit yaw angle distribution are investigated. It is found that the latter has a strong influence on shear layer rollup: inhibiting the formation of a vortex downstream of NGV 1 but encouraging it behind NGV 2.

Gas properties as a limit to gas turbine performance

Although increasing the turbine inlet temperature has traditionally proved the surest way to increase cycle efficiency, recent work suggests that the performance of future gas turbines may be limited by increased cooling flows and losses. Another limiting scenario concerns the effect on cycle performance of real gas properties at high temperatures. Cycle calculations of uncooled gas turbines show that when gas properties are modelled accurately, the variation of cycle efficiency with turbine inlet temperature at constant pressure ratio exhibits a maximum at temperatures well below the stoichiometric limit. Furthermore, the temperature at the maximum decreases with increasing compressor and turbine polytropic efficiency. This behaviour is examined in the context of a two-component model of the working fluid. The dominant influences come from the change of composition of the combustion products with varying air/fuel ratio (particularly the contribution from the water vapour) together with the temperature variation of the specific heat capacity of air. There are implications for future industrial development programmes, particularly in the context of advanced mixed gas-steam cycles.

Blade row interaction in a high pressure steam turbine

This paper presents a study of the three-dimensional flow field within the blade rows of a high-pressure axial flow steam turbine stage. Compound lean angles have been employed to achieve relatively low blade loading for hub and tip section and so reduce the secondary losses. The flow field is investigated in a Low-Speed Research Turbine using pneumatic and hot-wire probes downstream of the blade row. Steady and unsteady numerical simulations were performed using structured 3D Navier-Stokes solver to further understand the flow field. Agreement between the simulations and the measurements has been found. The unsteady measurements indicate that there is a significant effect of the stator flow interaction in the downstream rotor blade. The transport of the stator viscous flow through the rotor blade row is described. Unsteady numerical simulations were found to be successful in predicting accurately the flow near the secondary flow interaction regions compared to steady simulations. A method to calculate the unsteady loss generated inside the blade row was developed from the steady numerical simulations. The contribution of various regions in the blade to the unsteady loss generation was evaluated. This method can assist the designer in identifying and optimizing the features of the flow that are responsible for the majority of the unsteady loss production. An analytical model was developed to quantify this effect for the vortex transport inside the downstream blade.

Wake, shock and potential field interactions in a 1.5 stage turbine: Part I: Vane-rotor and rotor-vane interaction

The composition of the time-resolved surface pressure field around a high-pressure rotor blade caused by the presence of neighboring blade rows was studied, with the individual effects of wake, shock and potential field interaction being determined. Two test geometries were considered: first, a high-pressure turbine stage coupled with a swan-necked diffuser exit duct; secondly, the same high-pressure stage but with a vane located in the downstream duct. Both tests were carried out at engine-representative Mach and Reynolds numbers. By comparing the results to time-resolved computational predictions of the flowfield, the accuracy with which the computation predicts blade interaction was determined. It was found that in addition to upstream vane-rotor and rotor-downstream vane interactions, a new interaction mechanism was found resulting from the interaction between the downstream vane's potential field and the upstream vane's trailing edge potential field and shock.

Wake, shock and potential field interactions in a 1.5 stage turbine: Part II: Vane-vane interaction and discussion of results

The composition of the time-resolved surface pressure field around a high-pressure rotor blade caused by the presence of neighboring blade rows was studied, with the individual effects of wake, shock and potential field interaction being determined. Two test geometries were considered: first, a high-pressure turbine stage coupled with a swan-necked diffuser exit duct; secondly, the same high-pressure stage but with a vane located in the downstream duct. Both tests were carried out at engine-representative Mach and Reynolds numbers. By comparing the results to time-resolved computational predictions of the flowfield, the accuracy with which the computation predicts blade interaction was determined. Evidence was obtained that for a large downstream vane, the flow conditions in the rotor passage, at any instant in time, are close to being steady state.

Intermittency transport modeling of separated flow transition

An intermittency transport model is proposed for modeling separated-flow transition. The model is based on earlier work on prediction of attached flow bypass transition and is applied for the first time to model transition in a separation bubble at various degrees of free-stream turbulence. The model has been developed so that it takes into account the entrainment of the surrounding fluid. Experimental investigations suggest that it is this phenomena which ultimately determines the extent of the separation bubble. Transition onset is determined via a boundary layer correlation based on momentum thickness at the point of separation. The intermittent flow characteristic of the transition process is modeled via an intermittency transport equation. This accounts for both normal and streamwise variation of intermittency and hence models the entrainment of surrounding flow in a more accurate manner than alternative prescribed intermittency models. The model has been validated against the well established T3L semicircular leading edge flat plate test case for three different degrees of free-stream turbulence characteristic of turbomachinery blade applications.

The development of turbine exit flow in a swan-necked inter-stage diffuser

This paper describes both the migration and dissipation of flow phenomena downstream of a transonic high-pressure turbine stage. The geometry of the HP stage exit duct considered is a swan-necked diffuser similar to those likely to be used in future engine designs. The paper contains results both from an experimental programme in a turbine test facility and from numerical predictions. Experimental data was acquired using three fast-response aerodynamic probes capable of measuring Mach number, whirl angle, pitch angle, total pressure and static pressure. The probes were used to make time-resolved area traverses at two axial locations downstream of the rotor trailing edge. A 3D time-unsteady viscous Navier-Stokes solver was used for the numerical predictions. The unsteady exit flow from a turbine stage is formed from rotordependent phenomena (such as the rotor wake, the rotor trailing edge recompression shock, the tip-leakage flow and the hub secondary flow) and vane-rotor interaction dependant phenomena. This paper describes the time-resolved behaviour and three-dimensional migration paths of both of these phenomena as they convect downstream. It is shown that the inlet flow to a downstream vane is dominated by two corotating vortices, the first caused by the rotor tip-leakage flow and the second by the rotor hub secondary flow. At the inlet plane of the downstream vane the wake is extremely weak and the radial pressure gradient is shown to have caused the majority of the high loss wake fluid to be located between the mid-height of the passage and the casing wall. The structure of the flow indicates that between a high pressure stage and a downstream vane simple two-dimensional blade row interaction does not occur. The results presented in this paper indicate that the presence of an upstream stage is likely to significantly alter the structure of the secondary flow within a downstream vane. The paper also shows that vane-rotor interaction within the upstream stage causes a 10° circumferential variation in the inlet flow angle of the 2nd stage vane.

The development of aerodynamic performance measurements in a transient test facility

Transient test facilities offer the potential for the simultaneous study of turbine aerodynamic performance, unsteady flow phenomena and the heat transfer characteristics of a turbine stage. This paper describes the development of aerodynamic performance measurement techniques in the Oxford Rotor Facility (ORF). The solutions to the technological issues involved with transient testing presented in this paper are expected to achieve levels of precision uncertainty comparable with traditional steady flow test rigs. The theoretical background to the measurement of aerodynamic performance is presented together with a comprehensive pre-test uncertainty analysis. The instrumentation scheme for the measurement of stage mass flow rate is discussed in detail, the measurements of shaft power, total inlet enthalpy, and stage pressure ratio are also outlined. The current working section features a 62% scale, 1-1/2 stage, high-pressure shroudless transonic turbine. The required inlet flow conditions are provided by an Isentropic Light Piston Tunnel (ILPT) with a quasi-steady state run time of approximately 70ms. The testing is conducted at engine representative specific speed, pressure ratio, gas-to-wall temperature ratio, Mach number and Reynolds number.

Axial compressor response to inlet flow distortions by a CFD analysis

The usual approach to compressor design considers uniform inlet flow characteristics. Especially in aircraft applications, the inlet flow is quite often non uniform, and this can result in severe performance degradation. The magnitude of this phenomenon is amplified in military engines due to the complexity of inlet duct configurations and the extreme flight conditions. CFD simulation is an innovative and powerful tool for studying inlet distortions and can bring this inside the very early phases of the design process. This project attempts to study the effects of inlet flow distortions in an axial flow compressor trying to minimize the use computer resources and computational time. The first stage of a low bypass ratio compressor has been analyzed and its clean and distorted performance compared outlining the principal changes due to uneven flow distribution: drop in mass flow, increase in pressure and temperature ratios, decrease in surge margin. Three different studies have then been conducted to better understand the effects of the level, the type and the frequency of the distortion.

The unsteady development of a turbulent wake through a downstream low-pressure turbine blade passage

This paper presents two-dimensional LDA measurements of the convection of a wake through a low-pressure (LP) turbine cascade. Previous studies have shown the wake convection to be kinematic but have not provided details of the turbulent field. The spatial resolution of these measurements has facilitated the calculation of the production of turbulent kinetic energy and this has revealed a mechanism for turbulence production as the wake converts through the bladerow. The measured ensemble-averaged velocity field confirmed the previously reported kinematics of wake convection while the measurements of the turbulence quantities showed the wake fluid to be characterised by elevated levels of turbulent kinetic energy (TKE) and to have an anisotropic structure. Based on the measured mean and turbulence quantities, the production of turbulent kinetic energy was calculated. This highlighted a TKE production mechanism that resulted in increased levels of turbulence over the rear suction surface where boundary layer transition occurs. The turbulence production mechanism within the bladerow was also observed to produce more nearly isotropic turbulence. Production occurs when the principal stresses within the wake are aligned with the mean strains. This coincides with the maximum distortion of the wake within the blade passage and provides a mechanism for the production of turbulence outside of the boundary layer.

Secondary flows and loss caused by blade row interaction in a turbine stage

A study of the three-dimensional stator-rotor interaction in a turbine stage is presented. Experimental data reveal vortices downstream of the rotor which are stationary in the absolute frame - indicating that they are caused by the stator exit flowfield. Evidence of the rotor hub passage vortices is seen, but additional vortical structures away from the endwalls, which would not be present if the rotor were tested in isolation, are also identified. An unsteady computation of the rotor row is performed using the measured stator exit flowfield as the inlet boundary condition. The strength and location of the vortices at rotor exit are predicted. A formation mechanism is proposed whereby stator wake fluid with steep spanwise gradients of absolute total pressure is responsible for all but one of the rotor exit vortices. This mechanism is then verified computationally using a passive-scalar tracking technique. The predicted loss generation through the rotor row is then presented and a comparison made with a steady calculation where the inlet flow has been mixed out to pitchwise uniformity. The loss produced in the steady simulation, even allowing for the mixing loss at inlet, is 10% less than that produced in the unsteady simulation. This difference highlights the importance of the time-accurate calculation as a tool of the turbomachine designer.

The effect of an upstream turbine on a low-aspect ratio vane

The interaction between a high-pressure rotor and a downstream vane is dominated by vortex-blade interaction. Each rotor blade passing period two co-rotating vortex pairs, the tip-leakage and upper passage vortex and the lower passage and trailing shed vortex, impinge on, and are cut by, the vane leading edge. In addition to the streamwise vortex the tip-leakage flow also contains a large velocity deficit. This causes the interaction of the tip-leakage flow with a downstream vane to differ from typical vortex blade interaction. This paper investigates the effect these interaction mechanisms have on a downstream vane. The test geometry considered was a low aspect ratio second stage vane located within a S-shaped diffuser with large radius change mounted downstream of a shroudless high-pressure turbine stage. Experimental measurements were conducted at engine-representative Mach and Reynolds numbers, and data was acquired using a fast-response aerodynamic probe upstream and downstream of the vane. Time-resolved numerical simulations were undertaken with and without a rotor tip gap in order to investigate the relative magnitude of the interaction mechanisms. The presence of the upstream stage is shown to significantly change the structure of the secondary flow in the vane and to cause a small drop in its performance.

Vortex Transport and Blade Interactions in High Pressure Turbines

This paper presents a study of the three-dimensional flow field within the blade rows of a high-pressure axial flow steam turbine stage. Half-delta wings were fixed to a rotating hub to simulate an upstream rotor passage vortex. The flow field is investigated in a Low-Speed Research Turbine using pneumatic and hot-wire probes downstream of the blade row. The paper examines the impact of the delta wing vortex transport on the performance of the downstream blade row. Steady and unsteady numerical simulations were performed using structured 3D Navier-Stokes solver to further understand the flow field. The loss measurements at the exit of the stator blade showed an increase in stagnation pressure loss due to the delta wing vortex transport. The increase in loss was 21% of the datum stator loss, demonstrating the importance of this vortex interaction. The transport of the stator viscous flow through the rotor blade row is also described. The rotor exit flow was affected by the interaction between the enhanced stator passage vortex and the rotor blade row. Flow underturning near the hub and overturning towards the mid-span was observed, contrary to the classical model of overturning near the hub and underturning towards the mid-span. The unsteady numerical simulation results were further analysed to identify the entropy producing regions in the unsteady flow field.

Multi-objective design and optimisation of bypass outlet-guide vanes

This paper describes the development of an automated design optimization system that makes use of a high fidelity Reynolds-Averaged CFD analysis procedure to minimize the fan forcing and fan BOGV (bypass outlet guide vane) losses simultaneously taking into the account the down-stream pylon and RDF (radial drive fairing) distortions. The design space consists of the OGV's stagger angle, trailing-edge recambering, axial and circumferential positions leading to a variable pitch optimum design. An advanced optimization system called SOFT (Smart Optimisation for Turbomachinery) was used to integrate a number of pre-processor, simulation and in-house grid generation codes and postprocessor programs. A number of multi-objective, multi-point optimiztion were carried out by SOFT on a cluster of workstations and are reported herein.