Investigation on the flow-control strategy for an aggressive turbine transition ducts

After being studied for years, aggressive intermediate turbine duct is being attempted to be applied in turbine design to further improve the engine-performance. With such design, the shaft could be shortened effectively. However, under the influence of the more distorted coming-flow and stronger pressure-gradient in a real engine, the flow field would be more complicated definitely. Besides that, the upstream-rotor tip-leakage flow is a key loss-source by inducing separation. Flow-control strategies are necessary in this situation. In this paper, the flow field in an aggressive duct has been analyzed to declare the source of separation primarily. Then wide-chord blade design concept has been adopted as a control strategy firstly to realize the purpose of improving the areo-performance. After being verified, numerical method has been used in this study. Under the same aero-condition, the prototype and the modified turbine are analyzed. With this novel flow-control strategy, separation has been improved, even diminished. However, the flow structures within the blade passage are altered correspondingly. An instrumental conclusion is that the pressure loss could be decreased successfully by designing the wide-chord blade specially.

Streamwise vortex transportation and loss generation in an intermediate turbine duct

Annular S-shaped intermediate turbine ducts are used in modern turbofan engines with large by-pass ratios. To reduce the weight of an engine, the intermediate turbine ducts should be as short as possible, while keeping the loss at an acceptable level. Understanding the flow physics within the intermediate turbine ducts is the key to improve the intermediate turbine duct design. This paper aims to understand the transportation of the inlet streamwise vortices and loss generation in intermediate turbine ducts. First, cases with isolate incoming streamwise vortices at different spanwise locations and different axial velocities are investigated. The transportation of isolated vortex and loss generation are highly related to the interaction between vortex and boundary layer, which are mainly determined by the streamwise pressure gradient. When the axial velocity of the streamwise vortex is different to the main flow, the radial pressure gradient also has an effect. Then, the inlet condition of the intermediate turbine ducts is setup based on the flow field at the exit of a cascade, which contains the flow structures such as the tip leakage vortex, hub secondary vortex and the wake. The flow physics and the loss mechanism are analysed in detail. The formation mechanism of counter-rotating vortices pair and the influence of inlet vortex on loss generation within the intermediate turbine ducts are also presented.

Effects of axial length and integrated design on the aggressive intermediate turbine duct

With the increasing demand of high bypass ratio and thrust-to-weight ratio in civil aero-engine, the intermediate turbine duct between the high pressure and low pressure turbines of a modern gas turbine tends to shorter axial length, larger outlet-to-inlet area ratio and high pressure-to-low pressure radial offset. This paper experimentally and numerically investigated the three-dimensional flow characteristics of traditional (ITD1) and aggressive intermediate turbine duct (ITD2) at low Reynolds number. The baseline case of ITD1 is representative of a traditional intermediate turbine duct of aero-engine design with non-dimensional length of L/dR = 2.79 and middle angle of 20.12°. The detailed flow fields inside ITD1 and flow visualization were measured. Results showed the migration of boundary layer and a pair of counter-rotating vortexes were formed due to the radial migration of low momentum fluid. With the decreasing axial length of intermediate turbine duct, the radial and streamwise reverse pressure gradient in aggressive intermediate turbine duct (ITD2) were increased resulting in severe three-dimensional separation of boundary layer near casing surface and higher total pressure loss. The secondary flow and separation of boundary layer near the endwall were deeply analyzed to figure out the main source of high total pressure loss in the aggressive intermediate turbine duct (ITD2). Based on that, employing wide-chord guide vane to substitute “strut + guide vane”, this paper designed the super-aggressive intermediate turbine duct and realized the suppression of the three-dimensional separation and secondary flow.

Effects of Cavity Purge Flow on Intermediate Turbine Duct Flowfield

To increase the power output without adding additional stages, ultra-high bypass ratio engine, which has larger diameter low pressure turbine, attracts more and more attention because of its huge advantage. This tendency will lead to aggressive (high diffusion) intermediate turbine duct design. Much work has been done to investigate flow mechanisms in this kind of duct as well as its design criterion with numerical and experimental methods. Usually intermediate turbine duct simplified from real engine structure was adopted with upstream and downstream blades. However, cavity purge mass flow exists to disturb the duct flow field in real engine to change its performance. Naturally, the wall vortex pairs would develop in different ways. In addition to that, purge flow rate changes at different engine representative operating conditions. This paper deals with the influence of turbine purge flow on the aerodynamic performance of an aggressive intermediate turbine duct. The objective is to reveal the physical mechanism of purge flow ejected from the wheel-space and its effects on the duct flow field. Ten cases with and without cavity are simulated simultaneously. On one hand, the influence of cavity structure without purge flow on the flow field inside duct could be discussed. On the other hand, the effect of purge flow rate on flow field could be analyzed to investigate the mechanisms at different engine operating conditions. According to this paper, cavity structure is beneficial for pressure loss. And the influence concentrates near hub and duct inlet.

Numerical Simulation of ITD Flows in the Presence of HP Blade and LP Vane

Flows in an intermediate turbine duct (ITD) connecting high-pressure turbines (HPT) and low-pressure turbines (LPT) are highly complex, influenced by the upstream HP turbine flow structures. Non-uniformities originating from the duct with struts of different sizes also affect the LPT inflow conditions, resulting in reduced efficiency. The goal of this paper is to provide detailed understanding of the flow physics and loss mechanisms within the ITDs for highly efficient ITD designs. Steady and unsteady numerical simulations of flows through the ITDs in the presence of HP blade and LP vane were conducted. Effects of upstream HP blade on flow fields and loss characteristics within the ITDs are explored. The generation and propagation of wake and secondary flows through the whole configuration is described, including the fast Fourier transformation (FFT) analyses of the flow in the ITD. Results from the numerical simulations show complex flow patterns resulted from blade-strut-vane flow interactions in a high-endwall-angle duct, which are not obtainable from ITD-only simulations. Moreover, the ITD has a strong amplifying effect on the distorted inflow, and the inflow with the upstream wake and secondary flows introduces a high loss area along the casing at ITD exit. Detailed results are presented and discussed for the flow physics and loss mechanisms within the ITD.

Steady and unsteady numerical investigation of flow interaction between low-pressure turbine blade, intermediate turbine duct and power turbine vane

Flows in an intermediate turbine duct connecting low-pressure turbines and power turbines are very complex, affected by the upstream low-pressure turbine flow structures. Non-uniformities originating from the duct with struts also affect the power turbine inflow conditions, resulting in reduced efficiency. The present investigation is done to clarify the flow and loss mechanisms within the intermediate turbine duct and the power turbine. Steady and unsteady numerical investigations of the flow interaction between low-pressure turbine blade, intermediate turbine duct and power turbine vane were conducted. Effects of upstream low-pressure turbine blade on intermediate turbine duct flow fields and loss characteristics, and that of intermediate turbine duct with big and small struts on power turbine aerodynamics are explored. The generation and propagation of wake and secondary flows through the whole configuration are described. The fast Fourier transformation analyses of the flow in the low-pressure turbine blade, intermediate turbine duct and power turbine vane are also presented. Results from the steady and unsteady investigations show complex flow patterns resulted from blade–strut–vane flow interactions, which are not obtainable from intermediate turbine duct-only or power turbine-only simulations. The intermediate turbine duct has a great amplifying influence on the distorted inflow, and the inlet flow with upstream wakes and secondary flows introduces a high-loss area along the casing at intermediate turbine duct exit. Detailed results are presented and discussed for the flow physics and loss mechanisms as well as the unsteady flow evolution through the low-pressure turbine blade, intermediate turbine duct and power turbine vane.

Effect of Low-NOX Combustor Swirl Clocking on Intermediate Turbine Duct Vane Aerodynamics With an Upstream High Pressure Turbine Stage—An Experimental and Computational Study

Flow in an intermediate turbine duct (ITD) is highly complex, influenced by the upstream turbine stage flow structures, which include tip leakage flow and nonuniformities originating from the upstream high pressure turbine (HPT) vane and rotor. The complexity of the flow structures makes predicting them using numerical methods difficult, hence there exists a need for experimental validation. To evaluate the flow through an intermediate turbine duct including a turning vane, experiments were conducted in the Oxford Turbine Research Facility (OTRF). This is a short duration high speed test facility with a 3/4 engine-sized turbine, operating at the correct nondimensional parameters for aerodynamic and heat transfer measurements. The current configuration consists of a high pressure turbine stage and a downstream duct including a turning vane, for use in a counter-rotating turbine configuration. The facility has the ability to simulate low-NOx combustor swirl at the inlet to the turbine stage. This paper presents experimental aerodynamic results taken with three different turbine stage inlet conditions: a uniform inlet flow and two low-NOx swirl profiles (different clocking positions relative to the high pressure turbine vane). To further explain the flow through the 1.5 stage turbine, results from unsteady computational fluid dynamics (CFD) are included. The effect of varying the high pressure turbine vane inlet condition on the total pressure field through the 1.5 stage turbine, the intermediate turbine duct vane loading, and intermediate turbine duct exit condition are discussed and CFD results are compared with experimental data. The different inlet conditions are found to alter the flow exiting the high pressure turbine rotor. This is seen to have local effects on the intermediate turbine duct vane. With the current stator–stator vane count of 32-24, the effect of relative clocking between the two is found to have a larger effect on the aerodynamics in the intermediate turbine duct than the change in the high pressure turbine stage inlet condition. Given the severity of the low-NOx swirl profiles, this is perhaps surprising.