Comparison of 2D and 3D Airfoils in Combination With Non Axisymmetric End Wall Contouring: Part 2 — Numerical Investigations

2016 ◽  
Author(s):  
Oliver Curkovic ◽  
Tobias W. Zimmermann ◽  
Manfred Wirsum ◽  
Andrew Fowler ◽  
Kush Patel
Keyword(s):  
Secondary Flow ◽  
Gas Turbines ◽  
Potential Method ◽  
Labyrinth Seals ◽  
Flow Losses ◽  
Positive Effects ◽  
Flow Phenomena ◽  
2D And 3D ◽  
End Wall ◽  
The Impact

Secondary flow phenomena have a considerable part in the efficiency loss in turbomachinery. A potential method to reduce these secondary flow losses is tangential end wall contouring inside the blade passages. The present paper is the second of two papers which investigate the impact of tangential end wall contouring on 2D and 3D airfoils compared to a baseline configuration. The first paper summarizes the experimental investigation on a 2-stage air driven turbine test rig located at the Institute of Power Plant Technology, Steam and Gas Turbines RWTH Aachen University. To enhance the impact of the tangential end wall contours (TEWC) on the near wall flow, the rotor cavities are sealed by means of combined brush- and labyrinth seals. The stator cavities are sealed by labyrinth seals, only. This paper investigates the flow phenomena using CFD with the commercial software package ANSYS 15.0©. The brush seals are modeled by using the porous body approach and are calibrated using pressure drop measurements across the first rotor cavity. The experimental data will be presented and is used to validate the numerical model. For this, circumferential plots for the measurement planes are shown. In addition a detailed description of the changes in vortex formations as well as blade loading will be given for the various configurations. Finally a discussion of the impact on the turbine’s efficiency is given. It has been found, that for steady CFD simulations the use of stage interfaces suppresses the positive effects of the tangential end wall contour onto the downstream blade row.

Comparison of 2D and 3D Airfoils in Combination With Non Axisymmetric End Wall Contouring: Part 1 — Experimental Investigations

2016 ◽  
Author(s):  
Tobias W. Zimmermann ◽  
Oliver Curkovic ◽  
Manfred Wirsum ◽  
Andrew Fowler ◽  
Kush Patel
Keyword(s):  
Gas Turbines ◽  
Experimental Investigations ◽  
Test Rig ◽  
Second Stage ◽  
Beneficial Impact ◽  
Flow Phenomena ◽  
2D And 3D ◽  
End Wall ◽  
Constant Section ◽  
Turbine Blading

Tangential end wall contouring is intended to improve turbomachinery blading efficiency. This paper is the first of a series of two papers. It summarizes the experimental investigation of a test turbine with end wall contoured vanes and blades. Constant section airfoils as well as optimized 3D high pressure steam turbine blading in baseline and end wall contoured configurations have been examined in a 2 stage axial turbine test rig at the Institute of Power Plant Technology, Steam and Gas Turbines (IKDG) of RWTH Aachen University. The test rig is driven with air. Brush seals are implemented within the casing sided cavities to minimize the leakage flow near the tip end walls, where the contouring is also applied. The pressure and temperature data that is recorded in three axial measuring planes are plotted to visualize the change in flow structure. This has shown that the efficiency is increased for 2D airfoils by means of end wall contouring, which is caused by a homogenized inflow to the second stage. However the efficiency of the first stage suffers, the end wall contouring is beneficial for the performance of the engine. Both phenomena (an efficiency loss in stage one and an improvement of the performance in stage two) have also been measured for the optimized 3D configurations thus it can be expected that end wall contouring has also a beneficial impact on the performance of multi row turbines. The second part of this paper presents the results of numerical investigations of end-wall contoured blades. It will demonstrate how the secondary flow phenomena are influenced by end-wall contours. The simulations are validated with measured data from the test rig.

Aerothermal Investigations of Mixing Flow Phenomena in Case of Radially Inclined Ejection Holes at the Leading Edge

1999 ◽  
Vol 122 (2) ◽  
pp. 334-339 ◽  
Author(s):  
Dieter E. Bohn ◽  
Karsten A. Kusterer
Keyword(s):  
Secondary Flow ◽  
Gas Turbines ◽  
Flow Analysis ◽  
Three Dimensional ◽  
Leading Edge ◽  
Suction Side ◽  
Back Side ◽  
Stagnation Line ◽  
Flow Phenomena ◽  
The Impact

A leading edge cooling configuration is investigated numerically by application of a three-dimensional conjugate fluid flow and heat transfer solver, CHT-flow. The code has been developed at the Institute of Steam and Gas Turbines, Aachen University of Technology. It works on the basis of an implicit finite volume method combined with a multiblock technique. The cooling configuration is an axial turbine blade cascade with leading edge ejection through two rows of cooling holes. The rows are located in the vicinity of the stagnation line, one row on the suction side, the other row is on the pressure side. The cooling holes have a radial ejection angle of 45 deg. This configuration has been investigated experimentally by other authors and the results have been documented as a test case for numerical calculations of ejection flow phenomena. The numerical investigations focus on the aerothermal mixing process in the cooling jets and the impact on the temperature distribution on the blade surface. The radial ejection angles lead to a fully three-dimensional and asymmetric jet flow field. Within a secondary flow analysis, the cooling fluid jets are investigated in detail. The secondary flow fields include asymmetric kidney vortex systems with one dominating vortex on the back side of the jets. The numerical and experimental data show a respectable agreement concerning the vortex development. [S0889-504X(00)00102-1]

scholarly journals Aerothermal Investigations of Mixing Flow Phenomena in Case of Radially Inclined Ejection Holes at the Leading Edge

1999 ◽  
Author(s):  
Dieter E. Bohn ◽  
Karsten A. Kusterer
Keyword(s):  
Flow Field ◽  
Secondary Flow ◽  
Gas Turbines ◽  
Leading Edge ◽  
Suction Side ◽  
Pressure Side ◽  
Blade Surface ◽  
Cooling Fluid ◽  
Flow Phenomena ◽  
Vortex Systems

A leading edge cooling configuration is investigated numerically by application of a 3-D conjugate fluid flow and heat transfer solver, CHT-Flow. The code has been developed at the Institute of Steam and Gas Turbines, Aachen University of Technology. It works on the basis of an implicit finite volume method combined with a multi-block technique. The cooling configuration is an axial turbine blade cascade with leading edge ejection through two rows of cooling holes. The rows are located in the vicinity of the stagnation line, one row is on the suction side, the other row is on the pressure side. The cooling holes have a radial ejection angle of 45°. This configuration has been investigated experimentally by other authors and the results have been documented as a test case for numerical calculations of ejection flow phenomena. The numerical domain includes the internal cooling fluid supply, the radially inclined holes and the complete external flow field of the turbine vane in a high resolution grid. Periodic boundary conditions have been used in the radial direction. Thus, end wall effects have been excluded. The numerical investigations focus on the aerothermal mixing process in the cooling jets and the impact on the temperature distribution on the blade surface. The radial ejection angles lead to a fully three dimensional and asymmetric jet flow field. Within a secondary flow analysis it can be shown that complex vortex systems are formed in the ejection holes and in the cooling fluid jets. The secondary flow fields include asymmetric kidney vortex systems with one dominating vortex on the back side of the jets. The numerical and experimental data show a good agreement concerning the vortex development. The phenomena on the suction side and the pressure side are principally the same. It can be found that the jets are barely touching the blade surface as the dominating vortex transports hot gas under the jets. Thus, the cooling efficiency is reduced.

Life Prediction of Power Turbine Components for High Exhaust Back Pressure Applications: Part I — Disks

2015 ◽  
Author(s):  
Dipankar Dua ◽  
Brahmaji Vasantharao
Keyword(s):  
Steady State ◽  
Secondary Flow ◽  
Gas Turbines ◽  
Life Prediction ◽  
Creep Damage ◽  
Back Pressure ◽  
System Level ◽  
Cyclic Life ◽  
Power Turbine ◽  
The Impact

Industrial and aeroderivative gas turbines when used in CHP and CCPP applications typically experience an increased exhaust back pressure due to pressure losses from the downstream balance-of-plant systems. This increased back pressure on the power turbine results not only in decreased thermodynamic performance but also changes power turbine secondary flow characteristics thus impacting lives of rotating and stationary components of the power turbine. This Paper discusses the Impact to Fatigue and Creep life of free power turbine disks subjected to high back pressure applications using Siemens Energy approach. Steady State and Transient stress fields have been calculated using finite element method. New Lifing Correlation [1] Criteria has been used to estimate Predicted Safe Cyclic Life (PSCL) of the disks. Walker Strain Initiation model [1] is utilized to predict cycles to crack initiation and a fracture mechanics based approach is used to estimate propagation life. Hyperbolic Tangent Model [2] has been used to estimate creep damage of the disks. Steady state and transient temperature fields in the disks are highly dependent on the secondary air flows and cavity dynamics thus directly impacting the Predicted Safe Cyclic Life and Overall Creep Damage. A System-level power turbine secondary flow analyses was carried out with and without high back pressure. In addition, numerical simulations were performed to understand the cavity flow dynamics. These results have been used to perform a sensitivity study on disk temperature distribution and understand the impact of various back pressure levels on turbine disk lives. The Steady Sate and Transient Thermal predictions were validated using full-scale engine test and have been found to correlate well with the test results. The Life Prediction Study shows that the impact on PSCL and Overall Creep damage for high back pressure applications meets the product design standards.

scholarly journals LES and RANS Analysis of the End-Wall Flow in a Linear LPT Cascade: Part I — Flow and Secondary Vorticity Fields Under Varying Inlet Condition

2018 ◽  
Author(s):  
R. Pichler ◽  
Yaomin Zhao ◽  
R. D. Sandberg ◽  
V. Michelassi ◽  
R. Pacciani ◽  
...  
Keyword(s):  
Boundary Layer ◽  
Secondary Flow ◽  
Flow Characteristics ◽  
Flow Region ◽  
Secondary Flows ◽  
Wall Boundary Layer ◽  
Wall Boundary ◽  
Wall Flow ◽  
End Wall ◽  
The Impact

In low-pressure-turbines (LPT) around 60–70% of losses are generated away from end-walls, while the remaining 30–40% is controlled by the interaction of the blade profile with the end-wall boundary layer. Experimental and numerical studies have shown how the strength and penetration of the secondary flow depends on the characteristics of the incoming end-wall boundary layer. Experimental techniques did shed light on the mechanism that controls the growth of the secondary vortices, and scale-resolving CFD allowed to dive deep into the details of the vorticity generation. Along these lines, this paper discusses the end-wall flow characteristics of the T106 LPT profile at Re = 120K and M = 0.59 by benchmarking with experiments and investigating the impact of the incoming boundary layer state. The simulations are carried out with proven Reynolds-averaged Navier–Stokes (RANS) and large-eddy simulation (LES) solvers to determine if Reynolds Averaged models can capture the relevant flow details with enough accuracy to drive the design of this flow region. Part I of the paper focuses on the critical grid needs to ensure accurate LES, and on the analysis of the overall time averaged flow field and comparison between RANS, LES and measurements when available. In particular, the growth of secondary flow features, the trace and strength of the secondary vortex system, its impact on the blade load variation along the span and end-wall flow visualizations are analysed. The ability of LES and RANS to accurately predict the secondary flows is discussed together with the implications this has on design.

Analysis and Evaluation of the Impact of Different Blade Loadings on a 2-Stage Turbine With Shrouded Blades

2011 ◽  
Author(s):  
Dieter Bohn ◽  
Stephan Schwab ◽  
Michael Sell
Keyword(s):  
Flow Field ◽  
Gas Turbines ◽  
Labyrinth Seal ◽  
Rotor Blades ◽  
Analysis And Evaluation ◽  
Passage Vortex ◽  
Flow Phenomena ◽  
Two Stages ◽  
Shrouded Rotor ◽  
The Impact

An important goal in the development of turbine bladings is to increase the efficiency in order to achieve an optimized use of energy resources. For that purpose a detailed understanding of flow phenomena is required. This paper presents an experimental investigation of the impact of varying blade loadings on the flow field and leakage flow. The investigations were conducted on a 2-stage axial turbine at the Institute of Steam- and Gas Turbines, RWTH Aachen University. The flow field for different blade loadings has been determined at the inlet and outlet as well as between the two stages. Consequently, the inhomogeneity at the outlet of each stage, depending on the blade loading, may be investigated. The homogeneity at the outlet has been evaluated by using the secondary kinetic energy coefficient and the formation of the passage vortex has therefore been emphasized. Furthermore, the loading impact on the leakage mass flow and the leakage main flow interaction has been estimated. On this account, the pressure loss in each cavity within the labyrinth seal of the first shrouded rotor blades is detected. The impact on the efficiency of different loadings has moreover been determined. The efficiency has been ascertained by using 5-hole probes and temperature probes after each stage. The investigations mentioned above have been conducted on a 2D-blade profile and serve as a baseline for future profiled end wall studies. The goal of the endwall contoured blades shall reduce the passage vortex and with it, the under- and overturning which ultimately leads to a more homogeneous outflow from the stage.

Reducing Secondary Flow Losses in Low-Pressure Turbines With Blade Fences: Part I — Design in an Engine-Like Environment

2019 ◽  
Author(s):  
Filippo Rubechini ◽  
Matteo Giovannini ◽  
Andrea Arnone ◽  
Daniele Simoni ◽  
Francesco Bertini
Keyword(s):  
Secondary Flow ◽  
Passive Control ◽  
Optimization Procedure ◽  
Detailed Comparison ◽  
Low Pressure ◽  
Secondary Flows ◽  
Flow Losses ◽  
Stator Vane ◽  
The One ◽  
The Impact

Abstract This paper deals with the design of passive control devices for reducing the impact of secondary flows on the aerodynamics of low-pressure turbine (LPT) stages. A novel kind of device is introduced which consists of shelf-like fences to be added to the blade surface. Such a device is intended to hinder the development of secondary flows, thus reducing losses and flow turning deviation with respect to the straight blade. The first part of this work is devoted to the design of the blade fences, whereas the second part addresses the experimental validation of the device. The blade fences are designed on a LPT stator vane, in an engine-like environment. As secondary flows generated by one blade row produce their major effects on the downstream one, and hence on the stage performance, the assessment is performed on a stator-rotor configuration. Steady calculations are considered for the design, then the optimal geometry is verified via unsteady calculations to include the effects of the actual interaction. The geometry and layout of the blade fences are effectively handled by means of a parametric approach, which enables the fast generation of several configurations. An optimization procedure, based on Artificial Neural Networks (ANNs) is exploited to drive the fences design. The analysis of the relative merit of each solution is carried out using a state-of-the-art CFD approach. Finally, a detailed comparison between the original blade and the one equipped with fences is presented, and the physical mechanisms responsible for the mitigation of secondary flow losses are discussed in detail.

Development of Cavity Shapes of Labyrinth Seals Through CFD Analysis

2013 ◽  
Author(s):  
Mohana Rao Ramanadham ◽  
Balakrishna Gaja ◽  
Sravan Kumar Kanchanapally
Keyword(s):  
Secondary Flow ◽  
Gas Turbines ◽  
Axial Flow ◽  
Labyrinth Seal ◽  
Geometric Shape ◽  
Working Fluid ◽  
Leakage Flow ◽  
Labyrinth Seals ◽  
Primary Flow ◽  
Flow Through

Axial flow compressors of Gas turbines use labyrinth seals to prevent the backflow of the working fluid. However some fluid will leak through the seals due to the clearance provided between the stationery and rotating components and due to the pressure difference across the seals, which affects the efficiency. The geometric shape of the seal plays an important role in influencing the fluid flow through the seals and the leakage rate. The flow through the seals consists of the primary flow and the secondary flow. The secondary flow is the flow through the cavity which is associated with vortex currents and tends to obstruct the primary flow. The geometric shape of the cavity is varied to study its effect on the vortex and resultant leakage flow through the seals. The curvatures of the seal and the distance of the seal tip to the end of the seal are the main parameters considered to arrive at the desired cavity which helps to create the required whirling action and to reduce the velocity of the leakage flow. Gambit software is used for modeling the geometry and Fluent software is used for the analysis. Axi-symmetric pressure based analysis is carried out using the standard κ-ε turbulence. The results of the standard cavity are compared with different variants. The flow velocity and mass flow is studied at different locations of the seal. The results indicate that by optimizing the shape of the seal cavity, the leakage through the labyrinth seal can be reduced.

Numerical Study of the Flow Past an Axial Turbine Stator Casing and Perspectives for its Management

2017 ◽  
Author(s):  
Hakim T. K. Kadhim ◽  
Aldo Rona ◽  
Hayder M. B. Obaida ◽  
J. Paul Gostelow
Keyword(s):  
Secondary Flow ◽  
Numerical Study ◽  
Three Dimensional ◽  
Design Tool ◽  
Flow Strength ◽  
Ansys Fluent ◽  
Axial Turbine ◽  
Pressure Loss Coefficient ◽  
Flow Losses ◽  
End Wall

The interaction of secondary flow with the main passage flow results in entropy generation; this accounts for considerable losses in turbomachines. Low aspect ratio blades in an axial turbine lead to a high degree of secondary flow losses. A particular interest is the reduction in secondary flow strength at the turbine casing, which adversely affects the turbine performance. This paper presents a selective review of effective techniques for improving the performance of axial turbines by turbine end wall modifications. This encompasses the use of axisymmetric and non-axisymmetric end wall contouring and the use of fences. Specific attention is given to non-axisymmetric end walls and to their effect on secondary flow losses. A baseline three-dimensional steady RANS k-ω SST model, with axisymmetric walls, is validated against experimental measurements from the Institute of Jet Propulsion and Turbomachinery at the Rheinisch-Westfälische Technische Hochschule (RWTH) Aachen, Germany, with comparative solutions generated by ANSYS Fluent and OpenFOAM. The predicted performance of the stator passage with an axisymmetric casing is compared with that from using a contoured casing with a groove designed using the Beta distribution function for guiding the groove shape. The prediction of a reduced total pressure loss coefficient with the application of the contoured casing supports the groove design approach based on the natural path of the secondary flow features. This work also provided an automated workflow process, linking surface definition in MATLAB, meshing in ICEM CFD, and flow solving and post-processing OpenFOAM. This has generated a casing contouring design tool with a good portability to industry, to design and optimize new turbine blade passages.

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