Hot Turbine Guide Vane Performance Improvement With Metal Additive Manufacturing at Siemens Energy

2021 ◽  
Author(s):  
Ilya Fedorov ◽  
Dikran Barhanko ◽  
Magnus Hallberg ◽  
Martin Lindbaeck
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbine ◽  
Performance Improvement ◽  
Guide Vane ◽  
Original Design ◽  
Trailing Edges ◽  
Portfolio Development ◽  
Turbine Guide Vane ◽  
Actual Operation

Abstract Additive manufacturing (AM) of gas turbine components has been suggested as a measure to improve performance and create other value additions in several research papers. This paper focuses on application of AM for gas turbine performance improvement considering industrial scale of this activity at Siemens Energy. Efficient cooling designs, made possible by AM, are considered not only from the standpoint of cooling characteristics, but also inherent challenges, arising in the complete chain of manufacturing processes: from powder removal to coating. Practical limitations of cooling scheme complexity are discussed and the benefits of in-wall cooling, enabled by AM, are described. It is shown that thin cooled trailing edges, enabled by the AM, provide considerable reduction of losses. It is demonstrated that production challenges can be successfully overcome, and the components can be manufactured with the required quantity and according to the original design intent. The sequence and progress of AM components long-term validation in the field engines are discussed and illustrated with actual operation experience. The development of the AM vane was executed in line with the roadmap of AM portfolio development in Siemens Energy and supports the strategy of commercial validation and full commercial release of AM components..

Aerodynamic Characteristics of a Redesigned Turbine

2007 ◽  
Author(s):  
Vladimir Vassiliev ◽  
Norbert Mooslechner ◽  
Mikhail Kostege ◽  
Andrei Granovskiy
Keyword(s):  
Gas Turbine ◽  
Performance Improvement ◽  
Design Process ◽  
Aerodynamic Characteristics ◽  
Original Design ◽  
Performance Improvements ◽  
Expected Performance

The aero-redesign of a 50 Hz Gas Turbine GT13D3A is presented. The modifications enabling performance improvements are described, and the aero-design process is briefly discussed as well. The aerodynamic characteristics of an upgraded turbine (GT13DM) are compared with the original design (GT13D3A) and with the measurements in the field. The measurements confirmed the expected performance improvement.

scholarly journals Heat Transfer Over Non-Porous and Porous Smooth End Wall of a Linear Guide Vane in the Presence of Freestream Turbulence

1999 ◽  
Author(s):  
Artem A. Khalatov ◽  
Sergey V. Shevtsov ◽  
Nick Syred
Keyword(s):  
Heat Transfer ◽  
Boundary Conditions ◽  
Gas Turbine ◽  
Guide Vane ◽  
Three Dimensional ◽  
Axial Component ◽  
Wall Heat Transfer ◽  
Freestream Turbulence ◽  
Turbine Guide Vane ◽  
End Wall

The end wall of a gas turbine guide vane is one of turbine components where cooling is extremely complex due to a three-dimensional fluid flow and heat transfer nature. Most existing end wall heat transfer data were obtained over a non-porous surface with no effect of freestream turbulence. In real situations the typical turbulence level in front of a guide vane varies widely and reaches 25–30 % in some modern gas turbine engines. No doubt, this factor should be taken into account in the design of end wall cooling systems. New experimental results are presented in this paper describing the effect of freestream turbulence on local heat transfer over non-porous and porous smooth end walls of the same configuration. A linear scaled-up model of a real gas turbine guide vane was employed in the experimental programme. Decay of the axial freestream turbulence in a space between adjacent blades was measured and two simplified versions of the experimental correction functions describing the effect of freestream turbulence on local end wall heat transfer were obtained. The derived correction functions include the axial component of freestream turbulence and should be envisaged as a first attempt to define quantitatively the effect of freestream turbulence over an end wall in different conditions. It was found that both correction functions are virtually identical and agree satisfactorily with the published experimental data, reflecting the effect of freestream turbulence over a flat plate. It confirms the approximately common character of freestream turbulence influence for different boundary conditions. It was concluded that further experimental studies of three-dimensional turbulent structure over an end wall for various boundary conditions are required to develop more exact correlations.

Topology Optimization in Structural Design of a LP Turbine Guide Vane: Potential of Additive Manufacturing for Weight Reduction

2014 ◽  
Author(s):  
Joona Seppälä ◽  
Andreas Hupfer
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Weight Reduction ◽  
Design Space ◽  
Guide Vane ◽  
Aircraft Engine ◽  
Optimization Methods ◽  
Optimization Constraints ◽  
Turbine Guide Vane ◽  
Optimal Material

A low pressure turbine guide vane of an aircraft engine is structurally redesigned for additive manufacturing (AM). AM is known to provide more design freedom than conventional manufacturing methods, which encourages the implementation of numerical optimization methods in the design process in order to reduce weight by eliminating unneeded material. One such method is called topology optimization (TO), which finds the optimal material distribution inside a fixed design space. Using commercial software, TO is conducted to find the optimal geometry. The guide vane is subject to gas loads. During optimization, constraints for bending deformation and Eigen frequencies are applied. The design space consists of the airfoil interior and the shrouds, leaving aerodynamic surfaces untouched. Several TO approaches are examined and the result is preliminarily evaluated in a stationary coupled temperature-displacement FEA with take-off loading conditions. The results indicate a potential weight reduction of 19% but with a rise in temperature gradients. An enlarged shroud geometry would enable even greater weight reduction.

scholarly journals Numerical Investigation of a Radially Cooled Turbine Guide Vane Using Air and Steam as a Cooling Medium

Computation ◽  
2021 ◽  
Vol 9 (6) ◽  
pp. 63
Author(s):  
Sondre Norheim ◽  
Shokri Amzin
Keyword(s):  
Numerical Model ◽  
Gas Turbines ◽  
Guide Vane ◽  
Axial Direction ◽  
Average Error ◽  
Inlet Temperature ◽  
Average Temperature ◽  
Cooling Medium ◽  
Turbine Guide Vane ◽  
Steam Cooling

Gas turbine performance is closely linked to the turbine inlet temperature, which is limited by the turbine guide vanes ability to withstand the massive thermal loads. Thus, steam cooling has been introduced as an advanced cooling technology to improve the efficiency of modern high-temperature gas turbines. This study compares the cooling performance of compressed air and steam in the renowned radially cooled NASA C3X turbine guide vane, using a numerical model. The conjugate heat transfer (CHT) model is based on the RANS-method, where the shear stress transport (SST) k−ω model is selected to predict the effects of turbulence. The numerical model is validated against experimental pressure and temperature distributions at the external surface of the vane. The results are in good agreement with the experimental data, with an average error of 1.39% and 3.78%, respectively. By comparing the two coolants, steam is confirmed as the superior cooling medium. The disparity between the coolants increases along the axial direction of the vane, and the total volume average temperature difference is 30 K. Further investigations are recommended to deal with the local hot-spots located near the leading- and trailing edge of the vane.

Performance improvement of inverted two-dimensional perovskite solar cells using a non-fullerene acceptor as the trap passivator

2021 ◽  
Author(s):  
Eun-Cheol Lee ◽  
Zhihai Liu
Keyword(s):  
Solar Cells ◽  
Power Conversion Efficiency ◽  
Performance Improvement ◽  
High Power ◽  
Power Conversion ◽  
Perovskite Solar Cells ◽  
Two Dimensional ◽  
High Power Conversion Efficiency ◽  
Long Term Stability

Recently, Ruddlesden–Popper two-dimensional (2D) perovskite solar cells (PSCs) have been intensively studied, owing to their high power conversion efficiency (PCE) and excellent long-term stability. In this work, we improved the...

Material Selection Issues for a Nozzle Guide Vane Against Service-Induced Failure

2017 ◽  
Vol 139 (5) ◽  
Author(s):  
Xijia Wu ◽  
Zhong Zhang ◽  
Leiyong Jiang ◽  
Prakash Patnaik
Keyword(s):  
Gas Turbine ◽  
Material Selection ◽  
Guide Vane ◽  
Failure Process ◽  
Inelastic Strain ◽  
Grain Boundary Sliding ◽  
Deformation Mechanisms ◽  
Strain Component ◽  
Combustion Gas ◽  
Nozzle Guide

Nozzle guide vanes (NGV) of gas turbine engines are the first components to withstand the impingement of hot combustion gas and therefore often suffer thermal fatigue failures in service. A lifting analysis is performed for the NGV of a gas turbine engine using the integrated creep–fatigue theory (ICFT). With the constitutive formulation of inelastic strain in terms of mechanism-strain components such as rate-independent plasticity, dislocation glide-plus-climb, and grain boundary sliding (GBS), the dominant deformation mechanisms at the critical locations are thus identified quantitatively with the corresponding mechanism-strain component. The material selection scenarios are discussed with regards to damage accumulated during take-off and cruise. The interplay of those deformation mechanisms in the failure process is elucidated such that an “optimum” material selection solution may be achieved.

Application of RANS and LES to the Prediction of Flows in High Pressure Turbine Components

2011 ◽  
Author(s):  
Nicolas Gourdain ◽  
Laurent Y. M. Gicquel ◽  
Remy Fransen ◽  
Elena Collado ◽  
Tony Arts
Keyword(s):  
Heat Transfer ◽  
Vortex Shedding ◽  
Guide Vane ◽  
Unsteady Flows ◽  
Separated Flow ◽  
Heat Fluxes ◽  
Boundary Layer Transition ◽  
Wall Heat Transfer ◽  
Layer Transition ◽  
Turbine Guide Vane

This paper investigates the capability of numerical simulations to estimate unsteady flows and wall heat fluxes in turbine components with both structured and unstructured flow solvers. Different numerical approaches are assessed, from steady-state methods based on the Reynolds Averaged Navier-Stokes (RANS) equations to more sophisticated methods such as the Large Eddy Simulation (LES) technique. Three test cases are investigated: the vortex shedding induced by a turbine guide vane, the wall heat transfer in another turbine guide vane and a separated flow phenomenon in an internal turbine cooling channel. Steady flow simulations usually fail to predict the mean effects of unsteady flows (such as vortex shedding) and wall heat transfer, mainly because laminar-to turbulent transition and the inlet turbulent intensity are not correctly taken into account. Actually, only the LES (partially) succeeds to accurately estimate unsteady flows and wall heat fluxes in complex configurations. The results presented in this paper indicate that this method considerably improves the level of physical description (including boundary layer transition). However, the LES still requires developments and validations for such complex flows. This study also points out the dependency of results to parameters such as the freestream turbulence intensity. When feasible solutions obtained with both structured and unstructured flow solvers are compared to experimental data.

Experimental Studies of Leading Edge Contouring Influence on Secondary Losses in Transonic Turbines

2012 ◽  
Author(s):  
Ranjan Saha ◽  
Jens Fridh ◽  
Torsten Fransson ◽  
Boris I. Mamaev ◽  
Mats Annerfeldt
Keyword(s):  
Gas Turbine ◽  
Guide Vane ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Leading Edge ◽  
Secondary Flows ◽  
Noticeable Effect ◽  
Flow Angle ◽  
Wide Range ◽  
Contour Plots

An experimental study of the hub leading edge contouring using fillets is performed in an annular sector cascade to observe the influence of secondary flows and aerodynamic losses. The investigated vane is a three dimensional gas turbine guide vane (geometrically similar) with a mid-span aspect ratio of 0.46. The measurements are carried out on the leading edge fillet and baseline cases using pneumatic probes. Significant precautions have been taken to increase the accuracy of the measurements. The investigations are performed for a wide range of operating exit Mach numbers from 0.5 to 0.9 at a design inlet flow angle of 90°. Data presented include the loading, fields of total pressures, exit flow angles, radial flow angles, as well as profile and secondary losses. The vane has a small profile loss of approximately 2.5% and secondary loss of about 1.1%. Contour plots of vorticity distributions and velocity vectors indicate there is a small influence of the vortex-structure in endwall regions when the leading edge fillet is used. Compared to the baseline case the loss for the filleted case is lower up to 13% of span and higher from 13% to 20% of the span for a reference condition with Mach no. of 0.9. For the filleted case, there is a small increase of turning up to 15% of the span and then a small decrease up to 35% of the span. Hence, there are no significant influences on the losses and turning for the filleted case. Results lead to the conclusion that one cannot expect a noticeable effect of leading edge contouring on the aerodynamic efficiency for the investigated 1st stage vane of a modern gas turbine.

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