Velocity distributions for low pressure turbines

A parametric set of velocity distributions has been investigated using a flat plate experiment. Three different diffusion factors and peak velocity locations were tested. These were designed to mimic the suction surfaces of Low Pressure (LP) turbine blades. Unsteady wakes, inherent in real turbomachinery flows, were generated using a moving bar mechanism. A turbulence grid generated a freestream turbulence level that is believed to be typical of LP turbines. Measurements were taken across a Reynolds number range of 50,000-220,000 at three reduced frequencies (0.314, 0.628, 0.942). Boundary layer traverses were performed at the nominal trailing edge using a Laser Doppler Anemometry system and hot-films were used to examine the boundary layer behaviour along the surface. For every velocity distribution tested, the boundary layer separated in the diffusing flow downstream of the peak velocity. The loss production is dominated by the mixing in the reattachment process, mixing in the turbulent boundary layer downstream of reattachment and the effects of the unsteady interaction between the wakes and the boundary layer. A sensitive balance governs the optimal location of peak velocity on the surface. Moving the velocity peak forwards on the blade was found to be increasingly beneficial when bubblegenerated losses are high, i.e. at low Reynolds number, at low reduced frequency and at high levels of diffusion. Copyright © 2008 by ASME.

The single-phase brushless doubly-fed machine as a generator for wind turbines

This paper proposes a single-phase variant of the Brushless Doubly-Fed Machine, the Single-Phase BDFM, SPB. Like the BDFM it is a variable speed generator which requires a converter rated at only a fraction of the machine rating, using structure with no brushes. Unlike the BDFM, most of its power is delivered directly into a single-phase grid connection. As such it is a potential replacement for PM generators in small-ish wind turbines, potentially with a much lower cost. In this paper we give details of its operation, with reference to results from the first prototype SPB. We also suggest how it may be controlled, again with experimental results. © 2011 IEEE.

The effect of clearance on shrouded and unshrouded turbines at two levels of reaction

In this paper, the effect of seal clearance on the efficiency of a turbine with a shrouded rotor is compared with the effect of the tip clearance when the same turbine has an unshrouded rotor. The shrouded versus unshrouded comparison was undertaken for two turbine stage designs one having 50% reaction the other having 24% reaction. Measurements for a range of clearances, including very small clearances, showed three important phenomena. Firstly, as the clearance is reduced, there is a "break-even clearance" at which both the shrouded turbine and the unshrouded turbine have the same efficiency. If the clearance is reduced further, the unshrouded turbine performs better than the shrouded turbine, with the difference at zero clearance termed the "offset loss". This is contrary to the traditional assumption that both shrouded and unshrouded turbines have the same efficiency at zero clearance. The physics of the break-even clearance and the offset loss are discussed. Secondly, the use of a lower reaction had the effect of reducing the tip leakage efficiency penalty for both the shrouded and the unshrouded turbines. In order to understand the effect of reaction on the tip leakage, an analytical model was used and it was found that the tip leakage efficiency penalty should be understood as the dissipated kinetic energy rather than either the tip leakage mass flow rate or the tip leakage loss coefficient. Thirdly, it was also observed that, at a fixed flow coefficient, the fractional change in the output power with clearance was approximately twice the fractional change in efficiency with clearance. This was explained by using an analytical model. © 2010 by ASME.

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 earliest possible opportunity. 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 presents an analytical mean-line design study for a repeating-stage, axial-flow Low Pressure (LP) turbine. The problem of how to measure blade loading is first addressed. The analysis demonstrates that the Zweifel coefficient [1] is not a reasonable gauge of blade loading because it inherently depends on the flow angles. A more appropriate coefficient based on blade circulation is proposed. Without a large set of turbine test data it is not possible to directly evaluate the accuracy of a particular loss correlation. The analysis therefore focuses on the efficiency trends with respect to flow coefficient, stage loading, lift coefficient and Reynolds number. Of the various loss correlations examined, those based on Ainley and Mathieson ([2], [3], [4]) do not produce realistic trends. The profile loss model of Coull and Hodson [5] and the secondary loss models of Craig and Cox [6] and Traupel [7] gave the most reasonable results. The analysis suggests that designs with the highest flow turning are the least sensitive to increases in blade loading. The increase in Reynolds number lapse with loading is also captured, achieving reasonable agreement with experiments. Copyright © 2011 by ASME.

Zonal RANS-LES modeling for turbines in aeroengines

The cost of large-eddy simulation (LES) modeling in various zones of gas turbine aeroengines is outlined. This high cost clearly demonstrates the need to perform hybrid Reynolds-averaged Navier-Stokes-LES (RANS-LES) over the majority of engine zones because the Reynolds number is too high for pure LES. The RANS layer is used to cover over the fine streaks found in the inner part of the boundary layer. The hybrid strategy is applied to various engine zones, which is shown to typically give much greater predictive accuracy than pure RANS simulations. However, the cost estimates show that the RANS layer should be disposed within the low-pressure turbine zone. Also, the nature of the flow physics in this zone makes LES most sensible. © 2012 by Begell House, Inc.

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.

Winglets for Improved Aerothermal Performance of High Pressure Turbines

This paper investigates the design of winglet tips for unshrouded high pressure turbine rotors, considering aerodynamic and thermal performance simultaneously. A novel parameterization method has been developed to alter the tip geometry of a rotor blade. A design survey of un-cooled, flat-tipped winglets is performed using RANS calculations for a single rotor at engine representative operating conditions. Compared to a plain tip, large efficiency gains can be realized by employing an overhang around the full perimeter of the blade, but the overall heat load rises significantly. By employing an overhang on only the early suction surface, significant efficiency improvements can be obtained without increasing the overall heat transfer to the blade. The flow physics are explored in detail to explain the results. For a plain tip, the leakage and passage vortices interact to create a three-dimensional impingement onto the blade suction surface, causing high heat transfer. The addition of an overhang on the early suction surface displaces the tip leakage vortex away from the blade, weakening the impingement effect and reducing the heat transfer on the blade. The winglets reduce the aerodynamic losses by unloading the tip section, reducing the leakage flow rate, turning the leakage flow in a more streamwise direction and reducing the interaction between the leakage fluid and endwall flows. Generally these effects are most effective close to the leading edge of the tip, where the leakage flow is subsonic.

Large Eddy Simulation for Turbines: Methodologies, Cost and Future Outlooks

Flows throughout different zones of turbines have been investigated using large eddy simulation (LES) and hybrid Reynolds-averaged Navier–Stokes-LES (RANS-LES) methods and contrasted with RANS modeling, which is more typically used in the design environment. The studied cases include low and high-pressure turbine cascades, real surface roughness effects, internal cooling ducts, trailing edge cut-backs, and labyrinth and rim seals. Evidence is presented that shows that LES and hybrid RANS-LES produces higher quality data than RANS/URANS for a wide range of flows. The higher level of physics that is resolved allows for greater flow physics insight, which is valuable for improving designs and refining lower order models. Turbine zones are categorized by flow type to assist in choosing the appropriate eddy resolving method and to estimate the computational cost.