Computational Validation of the Flow Through a Turbine Stage and the Effects of Rim Seal Cavity Leakage on Secondary Flows

2012 ◽  
Author(s):  
Özhan H. Turgut ◽  
Cengiz Camcı
Keyword(s):  
Validation Study ◽  
Guide Vane ◽  
Pressure Coefficient ◽  
Axial Flow ◽  
Turbine Rotor ◽  
Secondary Flows ◽  
Transitional Flow ◽  
Interface Plane ◽  
Exit Plane ◽  
Computational Validation

A computational validation study related to aerodynamic loss generation mechanisms is performed in an axial flow turbine. The 91.66 cm diameter axial flow turbine research facility has a stationary nozzle guide vane assembly and a 29 bladed HP turbine rotor. The NGV inlet and exit Reynolds numbers based on midspan axial chord are around 300000 and 900000, respectively. GRIDPRO is used as the structured grid generator. y+ values are kept below unity. The finite-volume flow solver ANSYS CFX with SST k–ω turbulence model together with the transitional flow model is employed. Experimental flow conditions are imposed at the boundaries. The computational predictions are compared to experimental data at NGV exit plane and rotor inlet plane. NGV exit plane measurements come from a previous experimental study with a five-hole probe and the data at rotor inlet plane is taken by the current authors using a Kiel probe with 3.175mm head diameter. The comparison of rotor-stator interface models shows that the stage model, which calculates the circumferentially averaged fluxes and uses as the boundary condition at the interface plane, agrees well with the experimental total pressure coefficient data at the NGV exit. The difference between the NGV only simulation and the rotor-stator simulation is emphasized. The effect of rim seal flow on the mainstream aerodynamics is investigated. This validation study shows that the effect of future geometrical modifications on the endwalls and the vane will be predicted reasonably accurately.

A Computational Validation of Turbine Nozzle Guide Vane Aerodynamic Experiments in an HP Turbine Stage

2011 ◽  
Author(s):  
O¨zhan H. Turgut ◽  
Cengiz Camcı
Keyword(s):  
Validation Study ◽  
Total Pressure ◽  
Guide Vane ◽  
Pressure Coefficient ◽  
Axial Flow ◽  
Turbine Stage ◽  
Aerodynamic Loss ◽  
Nozzle Guide Vane ◽  
Nozzle Guide ◽  
Computational Validation

A computational validation study related to aerodynamic loss generation mechanisms is performed in an axial flow turbine nozzle guide vane (NGV). The 91.66 cm diameter axial flow turbine research facility has a stationary nozzle guide vane assembly and a 29 bladed HP turbine rotor. The NGV inlet and exit Reynolds numbers based on midspan axial chord are around 300000 and 900000, respectively. The effect of grid structure on aerodynamic loss generation is investigated. GAMBIT and TGRID combination is used for unstructured grid, whereas GRIDPRO is the structured grid generator. For both cases, y+ values are kept below unity. The finite-volume flow solver ANSYS CFX with SST k–ω turbulence model is employed. Experimental flow conditions are imposed at the boundaries. The flow transition effect and the influence of corner fillets at the vane-endwall junction are also studied in this paper. Grid independence study is performed with static pressure coefficient distribution at the mid-span of the vane and the total pressure coefficient at the NGV exit. The velocity distributions and the total pressure coefficient at the NGV exit plane are in very good agreement with the experimental data. This validation study shows that the effect of future geometrical modifications on the endwalls and the vane will be predicted reasonably accurately. The current study shows that an accurately measured turbine stage geometry, a properly prepared block structured/body fitted grid, a state of the art transitional flow implementation, and realistic boundary conditions coming from high resolution turbine experiments are all essential ingredients of a successful NGV aerodynamic loss quantification via computations.

Factors Influencing Computational Predictability of Aerodynamic Losses in a Turbine Nozzle Guide Vane Flow

2016 ◽  
Vol 138 (5) ◽  
Author(s):  
Özhan H. Turgut ◽  
Cengiz Camci
Keyword(s):  
Validation Study ◽  
Total Pressure ◽  
Guide Vane ◽  
Pressure Coefficient ◽  
Transitional Flow ◽  
Turbine Stage ◽  
Aerodynamic Loss ◽  
Nozzle Guide Vane ◽  
Nozzle Guide ◽  
Aerodynamic Losses

This paper deals with the computational predictability of aerodynamic losses in a turbine nozzle guide vane (NGV) flow. The paper shows that three-dimensional (3D) computations of Reynolds-Averaged Navier Stokes (RANS) equations have the ability to adequately represent viscous losses in the presence of laminar flows, transitional regions, and fully turbulent flow areas in the NGV of an high pressure (HP) turbine stage. The Axial Flow Turbine Research Facility (AFTRF) used for the present experimental results has an annular NGV assembly and a 29-bladed HP turbine rotor spinning at 1330 rpm. The NGV inlet and exit Reynolds numbers based on midspan axial chord are around 300,000 and 900,000, respectively. A general purpose finite-volume 3D flow solver with a shear stress transport (SST) k–ω turbulence model is employed. The current computational study benefits from these carefully executed aerodynamic experiments in the NGV of the AFTRF. The grid independence study is performed with static pressure coefficient distribution at the midspan of the vane and the total pressure coefficient at the NGV exit. The effect of grid structure on aerodynamic loss generation is emphasized. The flow transition effect and the influence of corner fillets at the vane–endwall junction are also studied. The velocity distributions and the total pressure coefficient at the NGV exit plane are in very good agreement with the experimental data. This validation study shows that the effect of future geometrical modifications on the turbine endwall surfaces will be predicted reasonably accurately. The current study also indicates that an accurately defined turbine stage geometry, a properly prepared block-structured/body-fitted grid, a state-of-the-art transitional flow implementation, inclusion of fillets, and realistic boundary conditions coming from high-resolution turbine experiments are all essential ingredients of a successful turbine NGV aerodynamic loss quantification via computations. This validation study forms the basis for the successful future generation of nonaxisymmetric endwall surface modifications in AFTRF research efforts.

Influence of Leading Edge Fillet and Nonaxisymmetric Contoured Endwall on Turbine NGV Exit Flow Structure and Interactions With the Rim Seal Flow

2013 ◽  
Author(s):  
Özhan H. Turgut ◽  
Cengiz Camcı
Keyword(s):  
Flow Structure ◽  
Total Pressure ◽  
Guide Vane ◽  
Axial Flow ◽  
Leading Edge ◽  
Turbine Rotor ◽  
Rotor Blades ◽  
Constant Thickness ◽  
Computational Evaluation ◽  
Nozzle Guide

Three different ways are employed in the present paper to reduce the secondary flow related total pressure loss. These are nonaxisymmetric endwall contouring, leading edge (LE) fillet, and the combination of these two approaches. Experimental investigation and computational simulations are applied for the performance assessments. The experiments are carried out in the Axial Flow Turbine Research Facility (AFTRF) having a diameter of 91.66cm. The NGV exit flow structure was examined under the influence of a 29 bladed high pressure turbine rotor assembly operating at 1300 rpm. For the experimental measurement comparison, a reference Flat Insert endwall is installed in the nozzle guide vane (NGV) passage. It has a constant thickness with a cylindrical surface and is manufactured by a stereolithography (SLA) method. Four different LE fillets are designed, and they are attached to both cylindrical Flat Insert and the contoured endwall. Total pressure measurements are taken at rotor inlet plane with Kiel probe. The probe traversing is completed with one vane pitch and from 8% to 38% span. For one of the designs, area averaged loss is reduced by 15.06%. The simulation estimated this reduction as 7.11%. Computational evaluation is performed with the rotating domain and the rim seal flow between the NGV and the rotor blades. The most effective design reduced the mass averaged loss by 1.28% over the whole passage at the NGV exit.

Second Vane Total Pressure Loss Due to Endwall Iceform Contouring

2008 ◽  
Author(s):  
Ronald S. LaFleur
Keyword(s):  
Heat Transfer ◽  
Secondary Flow ◽  
Pressure Loss ◽  
Total Pressure ◽  
Aerodynamic Drag ◽  
Pressure Coefficient ◽  
Secondary Flows ◽  
Total Pressure Loss ◽  
Surface Shape ◽  
Exit Plane

The iceformation design method generates an endwall contour, altering the secondary flows that produce elevated endwall heat transfer load and total pressure losses. Iceformation is an analog to regions of metal melting where a hot fluid alters the isothermal surface shape of a part as it is maintained by a cooling fluid. The passage flow, heat transfer and geometry evolve together under the constraints of flow and thermal boundary conditions. The iceformation concept is not media dependent and can be used in analogous flows and materials to evolve novel boundary shapes. In the past, this method has been shown to reduce aerodynamic drag and total pressure loss in flows such as diffusers and cylinder/endwall junctures. A prior paper [1] showed that the Reynolds number matched iceform geometry had a 24% lower average endwall heat transfer than the rotationally symmetric endwall geometry of the Energy Efficiency Engine (E3). Comparisons were made between three endwall geometries: the ‘iceform’, the ‘E3’ and the ‘flat’ as a limiting case of the endwall design space. This paper adds to the iceformation design record by reporting the endwall aerodynamic performances. Second vane exit flow velocities and pressures were measured using an automated 2-D traverse of a 1.2 mm diameter five-hole probe. Exit plane maps for the three endwall geometries are presented showing the details of the total pressure coefficient contours and the velocity vectors. The formation of secondary flow vortices is shown in the exit plane and this results in an impact on exit plane total pressure loss distribution, off-design over- and under-turning of the exit flow. The exit plane contours are integrated to form overall measures of the total pressure loss. Relative to the E3 endwall, the iceform endwall has a slightly higher total pressure loss attributed to higher dissipation of the secondary flow within the passage. The iceform endwall has a closer-to-design exit flow pattern than the E3 endwall.

Mainstream Aerodynamic Effects due to Wheelspace Coolant Injection in a High-Pressure Turbine Stage: Part II — Aerodynamic Measurements in the Rotational Frame

2001 ◽  
Author(s):  
Christopher McLean ◽  
Cengiz Camci ◽  
Boris Glezer
Keyword(s):  
High Pressure ◽  
Guide Vane ◽  
Pressure Coefficient ◽  
Three Dimensional ◽  
Axial Flow ◽  
Main Stream ◽  
Turbine Stage ◽  
High Pressure Turbine ◽  
Coolant Injection ◽  
Cooling Air

The current paper deals with the aerodynamic measurements in the rotational frame of reference of the Axial Flow Turbine Research Facility (AFTRF) at the Pennsylvania State University. Stationary frame measurements of “Mainstream Aerodynamic Effects Due to Wheelspace Coolant Injection in a High Pressure Turbine Stage” were presented in part-I of this paper. The relative aerodynamic effects associated with rotor – nozzle guide vane (NGV) gap coolant injections were investigated in the rotating frame. Three-dimensional velocity vectors including exit flow angles were measured at the rotor exit. This study quantifies the secondary effects of the coolant injection on the aerodynamic and performance character of the stage main stream flow for root injection, radial cooling and impingement cooling. Current measurements show that even a small quantity (1%) of cooling air can have significant effects on the performance and exit conditions of the high pressure turbine stage. Parameters such as the total pressure coefficient, wake width, and three-dimensional velocity field show significant local changes. It is clear that the cooling air disturbs the inlet end-wall boundary layer to the rotor and modifies secondary flow development thereby resulting in large changes in turbine exit conditions. Effects are the strongest from the hub to midspan. Negligible effect of the cooling flow can be seen in the tip region.

scholarly journals Detailed Measurements of Three-Dimensional Flows and Losses Inside an Axial Flow Turbine Rotor

1994 ◽  
Author(s):  
Atsumasa Yamamoto ◽  
Junichi Tomlnaga ◽  
Takayuki Matsunuma ◽  
Eisuke Outa
Keyword(s):  
Three Dimensional ◽  
Axial Flow ◽  
Turbine Rotor ◽  
Frame Of Reference ◽  
Secondary Flows ◽  
Low Energy ◽  
Generation Process ◽  
Rotating Frame ◽  
Rotor Speed ◽  
Speed Variation

Detailed traverse measurements of three dimensional flows and the associated losses inside a turbine rotor passage were carried out in the rotating frame of reference by using small five hole Pitot tubes. Strong secondary flows including passage vortices, a leakage vortex and various separation vortices were found to occur in the passage, and they are significantly influenced by the rotor speed, variation of which corresponds to different test incidences and blade loadings. Loss generation process in the rotor is described in relation to the migration of low energy fluids which are driven by the various vortices and their interaction at different rotor incidences.

Improving Efficiency of a High Work Turbine Using Non-Axisymmetric Endwalls: Part II—Time-Resolved Flow Physics

2008 ◽  
Author(s):  
P. Schuepbach ◽  
R. S. Abhari ◽  
M. G. Rose ◽  
T. Germain ◽  
I. Raab ◽  
...  
Keyword(s):  
Flow Field ◽  
Secondary Flow ◽  
Guide Vane ◽  
Axial Flow ◽  
Fast Response ◽  
Secondary Flows ◽  
Streamwise Vorticity ◽  
Time Resolved ◽  
Flow Physics ◽  
High Work

This paper is the second part of a two part paper that reports on the improvement of efficiency of a one-and-half stage high work axial flow turbine. The first part covered the design of the endwall profiling as well as a comparison with steady probe data, this part covers the analysis of the time-resolved flow physics. The focus is on the time-resolved flow physics that lead to a total-to-total stage efficiency improvement of Δηtt = 1.0% ± 0.4%. The investigated geometry is a model of a high work (Δh/U2 = 2.36), axial shroudless HP turbine. The time-resolved measurements have been acquired upstream and downstream of the rotor using a Fast Response Aerodynamic Probe (FRAP). The paper contains a detailed analysis of the secondary flow field that is changed between the axisymmetric and the non-axisymmetric endwall profiling cases. The flowfield at exit of the first stator is improved considerably due to non-axisymmetric endwall profiling and results in reduced secondary flow and a reduction of loss at both hub and tip, as well as a reduced trailing shed vorticity. The rotor has reduced losses and a reduction of secondary flows mainly at the hub. At the rotor exit the flow field with non-axisymmetric endwalls is more homogenous due to the reduction of secondary flows in the two rows upstream of the measurement plane. This confirms that non-axisymmetric endwall profiling is an effective tool for reducing secondary losses in axial turbines. Using a frozen flow assumption the time-resolved data is used to estimate the axial velocity gradients, which are then used to evaluate the streamwise vorticity and dissipation. The non-axisymmetric endwall profiling of the first nozzle guide vane show reductions of dissipation and streamwise vorticity due to reduced trailing shed vorticity. This smaller vorticity explains the reduction of loss at mid-span, which is shown in the first part of the two part paper. This leads to the conclusion that non-axisymmetric endwall profiling also has the potential of reducing trailing shed vorticity.

scholarly journals A Time Efficient Adaptive Gridding Approach and Improved Calibrations in Five-Hole Probe Measurements

2015 ◽  
Vol 2015 ◽  
pp. 1-14 ◽  
Author(s):  
Jason Town ◽  
Cengiz Camci
Keyword(s):  
Spatial Resolution ◽  
Large Scale ◽  
Guide Vane ◽  
Axial Flow ◽  
Grid Method ◽  
Flow Fields ◽  
Adaptive Grid ◽  
Current Approach ◽  
Secondary Flows ◽  
Complex Flow

Five-Hole Probes (FHP), being a dependable and accurate aerodynamic tool, are an excellent choice for measuring three-dimensional flow fields in turbomachinery. To improve spatial resolution, a subminiature FHP with a diameter of 1.68 mm is employed. High length to diameter ratio of the tubing and manual pitch and yaw calibration cause increased uncertainty. A new FHP calibrator is designed and built to reduce the uncertainty by precise, computer controlled movements and reduced calibration time. The calibrated FHP is then placed downstream of the nozzle guide vane (NGV) assembly of a low-speed, large-scale, axial flow turbine. The cold flow HP turbine stage contains 29 vanes and 36 blades. A fast and computer controllable traversing system is implemented using an adaptive grid method for the refinement of measurements in regions such as vane wake, secondary flows, and boundary layers. The current approach increases the possible number of measurement points in a two-hour period by 160%. Flow structures behind the NGV measurement plane are identified with high spatial resolution and reduced uncertainty. The automated pitch and yaw calibration and the adaptive grid approach introduced in this study are shown to be a highly effective way of measuring complex flow fields in the research turbine.

Endwall Boundary Layer Flows and Losses in an Axial Turbine Stage

1982 ◽  
Vol 104 (1) ◽  
pp. 184-193 ◽  
Author(s):  
I. H. Hunter
Keyword(s):  
Boundary Layer ◽  
Large Scale ◽  
Experimental Studies ◽  
Axial Flow ◽  
Turbine Rotor ◽  
Secondary Flows ◽  
Boundary Layer Flows ◽  
Wall Boundary Layer ◽  
Instantaneous Position ◽  
Insight Into

In order to gain an insight into boundary layer phenomena in axial flow turbines, experimental studies were carried out on a large-scale, low speed, single stage machine. Low and high frequency instrumentation supplemented by flow visualizations were used to determine the details of the flows and losses in the stator and rotor blade rows. Measurements of the turbine stator flows, which were obtained at two different inlet wall boundary layer thicknesses, were generally consistent with typical linear cascade observations. A major difference concerned the presence of appreciable radially directed flow. Hot-wire anemometry measurements at the turbine rotor exit, revealed strong secondary flows at the high turning hub section. The flow pattern was seen to be influenced by the spacing between the two rows of blades and by the rotor’s instantaneous position with respect to the periodic flow field arising from the upstream stator row.

Mainstream Aerodynamic Effects Due to Wheelspace Coolant Injection in a High-Pressure Turbine Stage: Part II—Aerodynamic Measurements in the Rotational Frame

2001 ◽  
Vol 123 (4) ◽  
pp. 697-703 ◽  
Author(s):  
Christopher McLean ◽  
Cengiz Camci ◽  
Boris Glezer
Keyword(s):  
High Pressure ◽  
Guide Vane ◽  
Pressure Coefficient ◽  
Three Dimensional ◽  
Axial Flow ◽  
Main Stream ◽  
Turbine Stage ◽  
High Pressure Turbine ◽  
Coolant Injection ◽  
Cooling Air

The current paper deals with the aerodynamic measurements in the rotational frame of reference of the Axial Flow Turbine Research Facility (AFTRF) at the Pennsylvania State University. Stationary frame measurements of “Mainstream Aerodynamic Effects Due to Wheelspace Coolant Injection in a High Pressure Turbine Stage” were presented in Part I of this paper. The relative aerodynamic effects associated with rotor–nozzle guide vane (NGV) gap coolant injections were investigated in the rotating frame. Three-dimensional velocity vectors including exit flow angles were measured at the rotor exit. This study quantifies the secondary effects of the coolant injection on the aerodynamic and performance character of the stage main stream flow for root injection, radial cooling, and impingement cooling. Current measurements show that even a small quantity (1 percent) of cooling air can have significant effects on the performance and exit conditions of the high-pressure turbine stage. Parameters such as the total pressure coefficient, wake width, and three-dimensional velocity field show significant local changes. It is clear that the cooling air disturbs the inlet end-wall boundary layer to the rotor and modifies secondary flow development thereby resulting in large changes in turbine exit conditions. Effects are the strongest from the hub to midspan. Negligible effect of the cooling flow can be seen in the tip region.

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