Retrofittable Solutions Capability for Gas Turbine Compressors

The increasing introduction of renewable energy capacity has changed the perspective on the operation of conventional power plants, introducing the necessity of reaching extreme off-design conditions. There is a strong interest in the development and optimization of technologies that can be retrofitted to an existing power plant to enhance flexibility as well as increase performance and lower emissions. Under the framework of the European project TURBO-REFLEX, a typical F-class gas turbine compressor designed and manufactured by Ansaldo Energia has been studied. Numerical analyses were performed using the TRAF code, which is a state-of-the-art 3D CFD RANS/URANS flow solver. In order to assess the feasibility of lower minimum environmental load operation, by utilizing a reduction in the compressor outlet mass-flow rate, with a safe stability margin, two different solutions have been analyzed: blow-off extractions and extra-closure of Variable Inlet Guide Vanes. The numerical steady-state results are compared and discussed in relation to an experimental campaign, which was performed by Ansaldo Energia. The purpose is to identify the feasibility of the technologies and implementation opportunity in the existing thermal power plant fleet.

Preliminary Design Guidelines for Considering the Vibration and Noise of Low-Speed Axial Fans Due to Profile Vortex Shedding

This paper presents a critical overview on worst-case design scenarios for which low-speed axial flow fans may exhibit an increased risk of blade resonance due to profile vortex shedding. To set up a design example, a circular-arc-cambered plate of 8% relative curvature is investigated in twofold approaches of blade mechanics and aerodynamics. For these purposes, the frequency of the first bending mode of a plate of arbitrary circular camber is expressed by modeling the fan blade as a cantilever beam. Furthermore, an iterative blade design method is developed for checking the risky scenarios for which spanwise and spatially coherent shed vortices, stimulating pronounced vibration and noise, may occur. Coupling these two approaches, cases for vortex-induced blade resonance are set up. Opposing this basis, design guidelines are elaborated upon for avoiding such resonance. Based on the approach presented herein, guidelines are also developed for moderating the annoyance due to the vortex shedding noise.

Design and Parametric Analysis of a Supersonic Turbine for Rotating Detonation Engine Applications

Pressure gain combustion is a promising alternative to conventional gas turbine technologies and within this class the Rotating Detonation Engine has the greatest potential. The Fickett–Jacobs cycle can theoretically increase the efficiency by 15% for medium pressure ratios, but the combustion chamber delivers a strongly non-uniform flow; in these conditions, conventionally designed turbines are inadequate with an efficiency below 30%. In this paper, an original mean-line code was developed to perform an advanced preliminary design of a supersonic turbine; self-starting capability of the supersonic channel has been verified through Kantrowitz and Donaldson theory; the design of the supersonic profile was carried out employing the Method of Characteristics; an accurate evaluation of the aerodynamic losses has been achieved by considering shock waves, profile, and mixing losses. Afterwards, an automated Computational Fluid Dynamics (CFD) based optimization process was developed to find the optimal loading condition that minimizes losses while delivering a sufficiently uniform flow at outlet. Finally, a novel parametric analysis was performed considering the effect of inlet angle, Mach number, reaction degree, peripheral velocity, and blade height ratio on the turbine stage performance. This analysis has revealed for the first time, in authors knowledge, that this type of machines can achieve efficiencies over 70%.

Numerical Steady and Transient Evaluation of a Confined Swirl Stabilized Burner

Lean premixed combustion technology became state of the art in recent heavy-duty gas turbines and aeroengines. In combustion chambers operating under fuel-lean conditions, unsteady heat release can augment pressure amplitudes, resulting in component engine damages. In order to achieve deeper knowledge concerning combustion instabilities, it is necessary to analyze in detail combustion processes. The current study supports this by conducting a numerical investigation of combustion in a premixed swirl-stabilized methane burner with operating conditions taken from experimental data that were recently published. It is a follow-up of a previous paper from Farisco et al., 2019 where a different combustion configuration was studied. The commercial code ANSYS Fluent has been used with the aim to perform steady and transient calculations via Large Eddy Simulation (LES) of the current confined methane combustor. A validation of the numerical data has been performed against the available experiments. In this study, the numerical temperature profiles have been compared with the measurements. The heat release parameter has been experimentally and numerically estimated in order to point out the position of the main reaction zone. Several turbulence and combustion models have been investigated with the aim to come into accord with the experiments. The outcome showed that the combustion model Flamelet Generated Manifold (FGM) with the k-ω turbulence model was able to correctly simulate flame lift-off.

Transport of Swirling Entropy Waves through an Axial Turbine Stator

The transport of entropy waves and their impact on the stage aerodynamics are still open questions. This paper shows the results of an experimental campaign that focuses on the swirling entropy waves advection through an axial turbine stator. The research aims at quantifying the aerodynamic impact of the swirling entropy waves on the first nozzle and characterizing their transport. The disturbance is generated by a novel entropy wave generator that ensures a wide set of different injection parameters. The device injects the disturbance axially, four different clocking positions are investigated. Measurements show a severe temperature attenuation of the swirling entropy wave at stator outlet. The high temperature location changes with the injection position as a result of the different interaction with the stator secondary flows. Depending on the injection position, the aerodynamic flow field is strongly perturbed by the injected swirl profile, instead the entropy wave effect is negligible.

Data Driven Modal Decomposition of the Wake behind an NREL-5MW Wind Turbine

The wake produced by a utility-scale wind turbine invested by a laminar, uniform inflow is analyzed by means of two different modal decompositions, the proper orthogonal decomposition (POD) and the dynamic mode decomposition (DMD), in its sparsity-promoting variant. The turbine considered is the NREL-5MW at tip-speed ratio λ=7 and a diameter-based Reynolds number of the order 108. The flow is simulated through large eddy simulation, where the forces exerted by the blades are modeled using the actuator line method, whereas tower and nacelle are modeled employing the immersed boundary method. The main flow structures identified by both modal decompositions are compared and some differences emerge that can be of great importance for the formulation of a reduced-order model. In particular, a high-frequency mode directly related to the tip vortices is found using both methods, but it is ranked differently. The other dominant modes are composed by large-scale low-frequency structures, but with different frequency content and spatial structure. The most energetic 200 POD modes account for ≈20% only of the flow kinetic energy. While using the same number of DMD modes, it is possible to reconstruct the flow field to within 80% accuracy. Despite the similarities between the set of modes, the comparison between these modal-decomposition techniques points out that an energy-based criterion such as that used in the POD may not be suitable for formulating a reduced-order model of wind turbine wakes, while the sparsity-promoting DMD appears able to perform well in reconstructing the flow field with only a few modes.

Experimental and Numerical Analysis of a Compressor Stage under Flow Distortion

On many occasions, fan or compressor stages have to face azimuthal flow distortion at inlet, which affects their performance and stability. These flow distortions can be caused by external events or by some particular geometrical features. The aim of this work is to propose a joined numerical and experimental analysis of the flow behavior in a single axial compressor stage under flow distortion. The distortions are generated by different grids that are placed upstream to the rotor. Experimentally, the flow analysis is based on the measurements obtained by a series of unsteady pressure sensors flush-mounted at the casing of the machine rotor. URANS computations are conducted using the elsA software. The flow distortion is simulated by a drop of stagnation pressure ratio at the inlet boundary condition. The study is focusing first on the ability of a pressure drop, imposed as an inlet boundary condition in CFD, to reproduce accurately the effect of a flow distortion. The analysis is conducted using singular value decomposition (SVD) and dynamic mode decomposition (DMD). A special attention is then paid, on the experimental level, to the arising of rotating stall, from the onset of the instability up to completely developed stall cells.

Turbine Broadband Noise Predictions Using Linearised Frequency Domain Navier-Stokes Solvers

A linear frequency domain Navier-Stokes solver is used to retain the influence of turning, thickness, and main geometric parameters on turbine broadband noise. The methodology has been applied to predict the broadband interaction noise produced by a representative low-speed low-pressure turbine section. The differences in the spectra with respect to those yielded by state-of-the-art flat plate based methodologies are up to 6 dB. The differences are caused by multiple effects that semi-analytical methodologies do not account for. The most important are blade thickness and turning, which have been studied separately to quantify their impact on the broadband noise footprint. The influence of changing the turbine operating conditions has been discussed as well. The outlet sound pressure level scales with the third and second power of the inlet and outlet Mach number, respectively, for constant turbulence intensity, within most of the frequency range considered.

The High-Speed Cascade Wind Tunnel at the Bundeswehr University Munich after a Major Revision and Upgrade

Since its first operation in 1956 at DFL Braunschweig and after its movement to Munich, the High-Speed Cascade Wind Tunnel (HGK) at Bundeswehr University Munich is intensively used for fundamental and application-oriented research on aero-thermodynamics of turbomachinery bladings. Numerous systematic airfoil design studies were performed over the last decades. Thanks to the HGK facility, which enables thorough and detailed cascade testing at turbomachinery-relevant conditions, many of those airfoils for different purposes finally made it into turbomachinery applications. Nowadays, the HGK still provides very useful contributions to the understanding of the complicated flow in compressor and turbine bladings, and thereby extends the knowledge on relevant physical phenomena. As a consequence of the intense usage, this unique test facility was subject to a major revision and upgrade. The performed changes are presented within this paper including an overview on new capabilities in terms of the extended operating range, the data acquisition system, and the recently available measurement equipment.

Machine Learning Based Sensitivity Analysis of Aeroelastic Stability Parameters in a Compressor Cascade

Aeroelastic instabilities such as flutter have a crucial role in limiting the operating range and reliability of turbomachinery. This paper offers an alternative approach to aeroelastic analysis, where the sensitivity of aerodynamic damping with respect to main flow and structural parameters is quantified through a surrogate-model-based investigation. The parameters are chosen based on previous studies and are represented by a uniform distribution within applicable intervals. The surrogate model is an artificial neural network, trained and tested to achieve an error within 1% of the test data. The quantity of interest is aerodynamic damping and the datasets are obtained from a linearised aeroelastic solver. The sensitivity of aerodynamic damping with respect to the input variables is obtained by calculating normalised gradients from the surrogate model at specific operating conditions. The results show a quantitative comparison of sensitivity across the different input parameters. The outcome of the sensitivity analysis is then used to decide the most appropriate action to take in order to induce stability in unstable operating conditions. The work is a preliminary study, carried out on a simplified two dimensional compressor cascade and it is aimed at proving the validity of a data-driven approach in studying the aeroelastic behaviour of turbomachinery. To the best of the authors’ knowledge, this is the first time a data-driven flutter model has been investigated. The initial results are encouraging, indicating that this approach is worth pursuing in the future. The presented framework can be used as a redesign tool to enhance the flutter stability of an existing blade.