Aerodesign and Testing of an Aeromechanically Highly Loaded LP Turbine

2003 ◽  
Vol 128 (4) ◽  
pp. 643-649 ◽  
Author(s):  
F. J. Malzacher ◽  
J. Gier ◽  
F. Lippl
Keyword(s):  
High Speed ◽  
High Efficiency ◽  
Pressure Ratio ◽  
Test Facility ◽  
Performance Measurements ◽  
Two Stage ◽  
Low Pressure Turbine ◽  
High Mach ◽  
Lp Turbine ◽  
Compact Geometry

Future turbo systems for aircraft engines need very compact geometry, low weight, and high efficiency components. The geared turbofan enables the engine designer to decouple the speed of the fan and the LP turbine to combine a low speed fan with a high speed LP turbine. The low pressure turbine is a key component for this concept. The technological challenge is very much driven by the very high low-spool speed. Resulting as well from high inlet temperatures, the LP turbine needs cooling of the first stage. A new MTU LPT concept for such a high speed turbine has been developed and tested in a turbine rig. The concept consists of a two-stage turbine for extremely high speed and high stage pressure ratio (ER 2.3). This leads to extra high mechanical loading and an exotic combination of high Mach numbers (transonic) and very low Reynolds numbers. In this paper some design features are described. Some elements of the airfoil design were also tested in additional cascade tests. The two-stage turbine was tested at the Altitude Test Facility of the ILA, Stuttgart. The test setup is described including details of the instrumentation. Test data shows a good turbine performance. Measurements are also compared to 3D CFD, which is used to analyze local effects.

Aerodesign and Testing of an Aero-Mechanically Highly Loaded LP Turbine

2003 ◽  
Author(s):  
F. J. Malzacher ◽  
J. Gier ◽  
F. Lippl
Keyword(s):  
High Speed ◽  
High Efficiency ◽  
Pressure Ratio ◽  
Test Facility ◽  
Performance Measurements ◽  
Low Pressure Turbine ◽  
High Stage ◽  
High Mach ◽  
Lp Turbine ◽  
Compact Geometry

Future turbo systems for aircraft engines need very compact geometry, low weight and high efficiency components. The geared turbofan enables the engine designer to decouple the speed of the fan and the LP turbine to combine a low speed fan with a high speed LP turbine. The low pressure turbine is a key component for this concept. The technological challenge is very much driven by the very high low-spool speed. Resulting from also high inlet temperatures the LP turbine needs cooling of the first stage. A new MTU LPT concept for such a high speed turbine has been developed and tested in a turbine rig. The concept consists of a 2 stage turbine for extremely high speed and high stage pressure ratio (ER 2.3). This leads to extra high mechanical loading and an exotic combination of high Mach Numbers (transonic) and very low Reynolds Numbers. In this paper some design features are described. Some elements of the airfoil design were also tested in additional cascade tests. The 2 stage turbine was tested at the Altitude Test Facility of the ILA, Stuttgart. The test setup is described including details of the instrumentation. Test data shows a good turbine performance. Measurements are also compared to 3D CFD, which is used to analyse local effects.

Centrifugal Compressor Design and Testing in Finnish High Speed Technology

2000 ◽  
Author(s):  
J. Larjola ◽  
J. Backman ◽  
H. Esa ◽  
H. Pitkänen ◽  
P. Sallinen ◽  
...  
Keyword(s):  
Centrifugal Compressor ◽  
High Speed ◽  
High Efficiency ◽  
Pressure Ratio ◽  
Design Procedure ◽  
Speed Control ◽  
Test Facility ◽  
Motor Speed ◽  
Compressor Wheel ◽  
Performance Map

Abstract This paper reports on the design procedure to produce radial compressors for high speed applications. These compressors are directly connected to a high speed electric motor. Speed control is used instead of IGV and diffuser vane control, and this sets some additional requirements e.g. for the shape of the compressor performance map. It is required that at the design pressure ratio the compressor has a wide operating range in mass flow, when optimal speed control is used. It is also required that the high efficiency range of the compressor is as wide as possible. One-dimensional computation giving the basic geometry and performance map of the compressor is done with a non-commercial program. Then a geometry generation 3D program is used to define the whole compressor wheel geometry. The wheel geometry data is used in the flow and structure analyses. The compressor flow is calculated with a three-dimensional CFD-program, which has specially been modified for centrifugal compressor flow. Particularly in the optimization process of the volute, also time-dependent computation of the complete compressor using the sliding mesh technique is used. The performance of the final compressor geometry is measured in the University test facility and the test results are used to develop the design process. Up to this date, 15 different high speed compressors have been aerodynamically designed and tested in this design loop. The typical pressure ratio of the compressors ranges from 1.6 to 2.5.

Highly Loaded Low-Pressure Turbine: Design, Numerical, and Experimental Analysis

2010 ◽  
Author(s):  
J. T. Schmitz ◽  
S. C. Morris ◽  
R. Ma ◽  
T. C. Corke ◽  
J. P. Clark ◽  
...  
Keyword(s):  
High Speed ◽  
Numerical Solutions ◽  
Pressure Ratio ◽  
Low Pressure ◽  
Boundary Layer Transition ◽  
Layer Transition ◽  
Free Stream Turbulence ◽  
Low Pressure Turbine ◽  
The Mean ◽  
Highly Loaded

The performance and detailed flow physics of a highly loaded, transonic, low-pressure turbine stage has been investigated numerically and experimentally. The mean rotor Zweifel coefficient was 1.35, with dh/U2 = 2.8, and a total pressure ratio of 1.75. The aerodynamic design was based on recent developments in boundary layer transition modeling. Steady and unsteady numerical solutions were used to design the blade geometry as well as to predict the design and off-design performance. Measurements were acquired in a recently developed, high-speed, rotating turbine facility. The nozzle-vane only and full stage characteristics were measured with varied mass flow, Reynolds number, and free-stream turbulence. The efficiency calculated from torque at the design speed and pressure ratio of the turbine was found to be 90.6%. This compared favorably to the mean line target value of 90.5%. This paper will describe the measurements and numerical solutions in detail for both design and off-design conditions.

scholarly journals The Design and Evaluation of a High Pressure Ratio Radial Turbine

1992 ◽  
Author(s):  
K. R. Pullen ◽  
N. C. Baines ◽  
S. H. Hill
Keyword(s):  
High Pressure ◽  
High Speed ◽  
Pressure Ratio ◽  
Performance Measurements ◽  
Turbine Engine ◽  
High Pressure Ratio ◽  
Turbine Efficiency ◽  
Wide Range ◽  
Dimensional Parameters ◽  
Very High

A single stage, high speed, high pressure ratio radial inflow turbine was designed for a single shaft gas turbine engine in the 200 kW power range. A model turbine has been tested in a cold rig facility with correct simulation of the important non-dimensional parameters. Performance measurements over a wide range of operation were made, together with extensive volute and exhaust traverses, so that gas velocities and incidence and deviation angles could be deduced. The turbine efficiency was lower than expected at all but the lowest speed. The rotor incidence and exit swirl angles, as obtained from the rig test data, were very similar to the design assumptions. However, evidence was found of a region of separation in the nozzle vane passages, presumably caused by a very high curvature in the endwall just upstream of the vane leading edges. The effects of such a separation are shown to be consistent with the observed performance.

Application of Water-Lubricated Bearings in Motorized Centrifugal Air Compressor for Fuel Cell Automotives

2014 ◽  
Vol 670-671 ◽  
pp. 920-923 ◽  
Author(s):  
Ming Feng ◽  
Tian Ming Ren
Keyword(s):  
High Speed ◽  
Proton Exchange Membrane ◽  
High Efficiency ◽  
Load Capacity ◽  
Pressure Ratio ◽  
Pem Fuel Cells ◽  
Proton Exchange ◽  
Air Compressor ◽  
Rotating Speed ◽  
New Energy

Proton exchange membrane (PEM) fuel cells intended for new energy automotives require a high efficiency and reliability motorized compressor to supply pressurized air. This paper presents a study and development of a motorized centrifugal air compressor using water-lubricated bearings. Comparing the performance of water-lubricated bearing with gas-lubricated bearing, we found that under the same power consumption the load capacity of water-lubricated bearings are more suitable for high speed motorized compressor system. A prototype was built and tested to verify the possibility of the developed motorized centrifugal air compressor. The results show that the system can operate at a stable rotating speed up to 80,000 rpm. The flow rate of the pressurized air is 350Kg/h and pressure ratio is 1.52 at 60,000 rpm, with a global efficiency of approximately 80%.

Measured Performance of Two-Stage Centrifugal Compressor Under Wet Gas Conditions

2012 ◽  
Author(s):  
Matteo Bertoneri ◽  
Simone Duni ◽  
David Ransom ◽  
Luigi Podestà ◽  
Massimo Camatti ◽  
...  
Keyword(s):  
Centrifugal Compressor ◽  
Oil And Gas ◽  
Pressure Ratio ◽  
Oil And Gas Industry ◽  
Liquid Volume ◽  
Performance Measurements ◽  
Two Stage ◽  
Gas Industry ◽  
Discharge Temperature ◽  
Wet Gas

The oil and gas industry is moving forward to access the most remote gas reserves and enhance the exploitation of the existing installation or postponing their tail-end. To achieve these accomplishments several technology challenges are being unveiled. In topside upstream application both offshore and onshore, one important technology issue is the capability to compress gas with a significant amount of liquids and it assumes a special interest in case of the facilities revamping. Nevertheless is in the subsea environment where this technology issue becomes really challenging. In order to properly design and size a compressor/motor system for subsea wet gas compression, one must be able to adequately predict the compressor performance with mixed phase flow. This paper presents the results from an experimental test program which investigated the performance of a centrifugal compressor at various wet gas conditions with elevated suction pressure. Performance tests are completed on a two stage centrifugal compressor with a mixture of air and water at suction pressures of 20 bar (300 psi). The compressor is subjected to flow with liquid volume fractions ranging from 0 to 5% along three speedlines. The performance measurements are made in accordance with ASME PTC-10 specifications with an additional torque measurement on the shaft between the compressor and gearbox. At each test condition, once the liquid is injected in the air flow, an increase in pressure ratio occurs. This testifies the compressor is still able to work in presence of water. However, increasing the amount of liquid injected a decreased polytropic head together with an increased absorbed actual power by the compressor cause a deterioration of its efficiency. Moreover when liquid is introduced into the flow, the discharge temperature of the compressor reduces significantly. The performance results and trends mentioned above are reviewed in the detail in this paper.

scholarly journals Experimental and numerical tip leakage flow visualization in the LP turbine labyrinth seal

2019 ◽  
Vol 137 ◽  
pp. 01008
Author(s):  
Krzysztof Bochon ◽  
Włodzimierz Wrόblewski ◽  
Artur Szymański ◽  
Mirosiaw Majkut ◽  
Michał Strozik ◽  
...  
Keyword(s):  
Pressure Ratio ◽  
Main Idea ◽  
Labyrinth Seal ◽  
Tip Leakage Flow ◽  
Pressure Losses ◽  
Low Pressure Turbine ◽  
Flow Parameters ◽  
Ansys Cfx ◽  
Commercial Code ◽  
Lp Turbine

The subject of this publication is the identification of basic flow parameters and flow structures in the seal experimentally and compare them with CFD results. A straight-through seal with two leaning fins and smooth or honeycomb land was analysed. The sealing concept is characteristic for the tip seal of the last stage of an aircraft low-pressure turbine. Due to the limitations of the test rig the analyses presented here were conducted on a highly simplified, stationary model of the seal itself, with an axial inflow and no curvature in the circumferential direction. The characteristics of the discharge coefficient as a function of the pressure ratio for different clearances and the pressure distribution along the seal, for different pressure ratios are presented. In addition, an attempt was made to visualize the flow using the schlieren technique. The main idea of application schlieren photography was to observe the vortex and separation structures occurring during the flow through the labyrinth seal, which is the major source of pressure losses. CFD calculations were carried out using the Ansys CFX commercial code.

Numerical and Experimental Investigations of Clocking Effect in a Two-Stage Compressor With πC = 3.7

2015 ◽  
Author(s):  
Victor Mileshin ◽  
Yaroslav Druzhinin ◽  
Alexander Stepanov ◽  
Nikolay Savin
Keyword(s):  
Experimental Data ◽  
Pressure Ratio ◽  
Pressure Fluctuations ◽  
Angular Position ◽  
Tip Clearance ◽  
Test Facility ◽  
Experimental Investigations ◽  
Aerodynamic Load ◽  
Two Stage ◽  
Stall Margin

In recent years, a number of studies in Russia and abroad was completed with the aim of decreasing pressure fluctuations and losses in blade cascades by controlling the unsteady interactions of blade rows (known as “clocking effect”) [1–4]. Tests of individual stages demonstrated that the clocking effect is responsible for 1.5–2.0% in efficiency and 50% in pressure fluctuations [5]. This paper presents the results of experimental and theoretical studies of the clocking effect on gas-dynamic characteristics of a high-loaded two-stage compressor simulating the first two stages of HPC for an advanced engine. The compressor is designed with the help of up-to-date 1D, 2D and 3D direct and inverse problem solutions and distinguished by high aerodynamic loads of stages with πk=3.7 total pressure ratio, 17% stall margin and 88% adiabatic efficiency at Ncor=88% rotational speed that was demonstrated experimentally [6]. The compressor was tested at CIAM’s C-3 test facility in the assembly with d=0.5, 0.75, 1.0-mm tip clearance in both rotors (relative clearance in first stage 4.6·10−3; 6.9·10−3; 9.2·10−3 and relative clearance in second stage 9.1·10−3; 13.7·10−3; 18.3·10−3). When tested, clocking effects were checked up for separate and simultaneous changes in clocking positions of stator and rotor blade rows. Indications of a blade tip-timing system and pressure pulsation sensors were used as experimental data. Earlier, it was shown that physics of the rotor clocking is a wake interaction which modifies the behavior of a boundary layer in Rotor 2 blades. This work studies the mechanism of rotor clocking in combination with changes in angular position of Rotor 2 blades due to interactions with Rotor 1 wakes. Tests showed that changes in the clocking position of the rotor with a multiple number of Rotor 1 and Rotor 2 blades affected the static position of Rotor 2 blades causing re-position of the blades depending on the rotor clocking-position. To confirm this result, 3D unsteady aerodynamic calculation was completed with the help of NUMECA software package simulating one of the test points. This work presents the calculated and experimental data showing that vortex wakes from Rotor 1 blades extend downstream, reach Rotor 2 and cause a variable aerodynamic load and a variable blade pitch.

MAN’s New Gas Turbines for Mechanical Drive and Power Generation Applications

2013 ◽  
Author(s):  
Emil Aschenbruck ◽  
Michele Cagna ◽  
Volker Langusch ◽  
Ulrich Orth ◽  
Andreas Spiegel ◽  
...  
Keyword(s):  
Power Generation ◽  
Gas Turbine ◽  
Gas Turbines ◽  
High Efficiency ◽  
Pressure Ratio ◽  
High Heat ◽  
Product Line ◽  
Pollutant Emission ◽  
Two Stage ◽  
Exhaust Temperature

MAN Diesel & Turbo recently developed a completely new gas turbine family for the first time in its history. The first product line contains both two-shaft and single-shaft gas turbines in the 6 – 7 MW class. The two-shaft engine was thoroughly tested at MAN’s gas turbine test center, and the first engine has been delivered to a launch customer. For MAN, it constitutes a technology platform that will produce further developments and new models in the coming years. The two-shaft design makes the new gas turbine an ideal mechanical drive for both turbo compressors and pumps. This gas turbine operates to suit the optimum duty point of the driven machine; both in a wide speed and power range. The two stage power turbine design allows for a wide speed range of 45 to 105% while maintaining high efficiency. For power generation a single-shaft version has been created by adding one additional stage to the two stage high pressure turbine. The compressor pressure ratio is 15, which is high enough for achieving the highest potential efficiency for both generator and compressor drive applications. Low pollutant emission levels are achieved with MAN’s DLN combustion technology. The gas turbine exhaust temperature is sufficiently high to reach high heat recovery rates in combined heat and power cycles. Another important feature of the new gas turbine is its unrestricted suitability for taking load quickly and rapid load changes. Service costs have also been significantly improved upon. MAN opted for a sturdy and modular gas turbine construction, while not compromising on efficiency. The objective is to extend service life and shorten down time occurrences. The modular package assembly process helps to reduce routine maintenance and repair time, and ultimately package downtime.

scholarly journals The GT24/26 Low Pressure Turbine

1998 ◽  
Author(s):  
Ian K. Jennions ◽  
Thomas Sommer ◽  
Bernhard Weigand ◽  
Manfred Aigner
Keyword(s):  
Gas Turbines ◽  
Low Pressure ◽  
Thermal Design ◽  
Component Technology ◽  
Test Facility ◽  
3D Analysis ◽  
Leakage Flows ◽  
Low Pressure Turbine ◽  
Point Data ◽  
Lp Turbine

The GT24 and GT26 are the latest in a series of gas turbines from ABB. The GT24 is a 60 Hz, 183 MW turbine, while the GT26 is its (scaled) 50 Hz equivalent, producing 265 MW. They feature a 22 stage controlled diffusion aerofoil compressor, two combustors separated by a single stage high pressure turbine with a four stage low pressure (LP) turbine following the second combustor. This arrangement permits very high efficiencies while avoiding high temperatures and the need to use new, expensive materials. The first GT24 was delivered to Jersey Central Power and Light, Gilbert, New Jersey, USA, at the end of 1995 and achieved baseload operation in May 1996. The engine was highly instrumented with some 1200 measurement points to evaluate component performance. Subsequently, a through-flow datamatch to the design point data was made for the LP turbine and is compared to a full 3D multistage analysis in this paper. The 3D analysis accounts for all the cooling and leakage flows that enter the turbine flowpath and maintains a steady flow calculation by means of interface planes between each blade row that remove any circumferential non-uniformity from the computational flow field. To complement this aerodynamic analysis, some heat transfer results from the ABB GT26 test facility in Birr, Switzerland are also shown. The paper demonstrates how component technology for the first stage was verified at four universities and research centers concurrently with the design process. This experimental data supplemented the existing databases and engendered confidence in the overall aero/thermal design approach.

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