Modelling Vortex Generating Jet-Induced Transition in Low-Pressure Turbines

The current design of low-pressure turbines (LPTs) with steady-blowing vortex generating jets (VGJ) uses steady computational fluid dynamics (CFD). The present work aims to support this design approach by proposing a new semi-empirical transition model for injection-induced laminar-turbulent boundary layer transition. It is based on the detection of cross-flow vortices in the boundary layer which cause inflectional cross-flow velocity profiles. The model is implemented in the CFD code TRACE within the framework of the γ-Reθ transition model and is a reformulated, re-calibrated, and extended version of a previously presented model. It is extensively validated by means of VGJ as well as non-VGJ test cases capturing the local transition process in a physically reasonable way. Quantitative aerodynamic design parameters of several VGJ configurations including steady and periodic-unsteady inflow conditions are predicted in good accordance with experimental values. Furthermore, the quantitative prediction of end-wall flows of LPTs is improved by detecting typical secondary flow structures. For the first time, the newly derived model allows the quantitative design and optimization of LPTs with VGJs.

Inverse Design of 3D Multi-Stage Transonic Fans at Dual Operating Points

Semi-inverse design is the automatic re-cambering of an aerofoil, during a computational fluid dynamics (CFD) calculation, in order to achieve a target lift distribution while maintaining thickness, hence “semi-inverse”. In this design method, the streamwise distribution of curvature is replaced by a stream-wise distribution of lift. The authors have developed an inverse design code based on the method of Hield (2008) which can rapidly design three-dimensional fan blades in a multi-stage environment. The algorithm uses an inner loop to design to radially varying target lift distributions, an outer loop to achieve radial distributions of stage pressure ratio and exit flow angle, and a choked nozzle to set design mass flow. The code is easily wrapped around any CFD solver. In this paper, we describe a novel algorithm for designing simultaneously for specified performance at full speed and peak efficiency at part speed, without trade-offs between the targets at each of the two operating points. We also introduce a novel adaptive target lift distribution which automatically develops discontinuous changes of calculated magnitude, based on the passage shock, eliminating erroneous lift demands in the shock vicinity and maintaining a smooth aerofoil.

A New Inlet Distortion and Pressure Loss Based Design of an Intake System for Stationary Gas Turbines

This paper presents a new design for a Compressor Inlet Manifold (CIM) for a land-based power generation Gas Turbine (turbine). The CIM is the component of the Inlet System (IS) that is directly connected to the turbine via the Compressor Inlet Case (CIC). The design philosophy is to use low fidelity but fast and automated CFD (Computational Fluid Dynamics) for design iterations and then confirm the design with detailed higher accuracy CFD before proceeding to engine tests. New design features include contouring the wall to minimize areas of flow separation and associated unsteadiness and losses, and improvement of the flow quality into the compressor. The CIM in a land-based turbine acts as a nozzle whereas the inlet of an aircraft acts as a diffuser. The flow also enters the CIM at 90 deg to the engine axis. This leads to a pair of counter rotating vortices at the compressor inlet. Three main sources of flow distortions at the face of the compressor are identified: flow separations at outer walls of the IS and CIM struts and the counter rotating vortices. The higher accuracy CFD analysis including the complete IS, CIM and the first compressor stage, simulates the effect of these distortions on the compressor front stage at design conditions. A range of inlet distortion parameters are used to evaluate the inlet design. The well known DC60 based criterion derived from aircraft engines and other less known but published parameters are able to give an indication of how the compressor surge margin of stationary gas turbines is affected.

A Novel Combination of Adaptive Tools for Turbomachinery Airfoil Shape Optimization Using a Real-Coded Genetic Algorithm

An automated shape optimization methodology for a typical heavy-duty gas turbine (GT) compressor rotor blade section is presented in this paper. The approach combines a Non-Uniform Rational B-Spline (NURBS) driven parametric geometry description, a two-dimensional flow analysis, and a Genetic Algorithm (GA)-based optimization route. The objective is minimizing the total pressure losses for design condition as well as maximizing the airfoils operating range which is an assessment of the off-design behavior. To achieve the goal, design optimization process is carried out by coupling an established MATLAB code for the Differential Evolution (DE)-based optimum parameterized curve fitting of the measured point cloud of the airfoils’ shape, a blade-to-blade flow analysis in COMSOL Multiphysics, and a developed real-coded GA in MATLAB script. Using the combination of these adaptive tools and methods, the first results are considerably promising in terms of computation time, ability to extend the methodology for three-dimensional and multidisciplinary approach, and last but not least airfoil shape performance enhancement from efficiency and pressure rise point of view.

On the Coupling of Direct Design and Optimization Techniques for Mitigating the Turbomachinery Performance Test Risk

Automatic optimization techniques have been used in recent years to facilitate more rapid analyses of different design options with multiple performance objectives. Typically, this process has been used during new product development. In this paper, a design system is presented, which enables the multipoint, multi-objective optimization of the centrifugal compressor stage aerodynamic components. Moreover, it is applied to a design modification of a multistage compressor, during the manufacturing cycle, for risk mitigation. The system is based on the application of the Isight code for coupling of one dimensional direct design and analysis with multi-objective genetic algorithms, design of experiment, and response surface method. The design system was applied to a redesign of the diffuser, crossover, and return channel of two stages in a multistage compressor. The geometry parameterization is performed by a one dimensional analysis method where the diffuser width, crossover inlet and exit width and associated inner and outer radii, are used to describe the meridional flow path while holding the return vane geometry unchanged. Centrifugal compressor performance parameters, such as polytropic head and efficiency at the client rated point, head rise to surge, and choke flow capacity are evaluated during the optimization process. The example confirmed the validity of the system to perform the optimization of turbomachine components in a time efficient manner to meet production schedule. The system also allowed for a sensitivity analysis of the impact of geometry parameters on the aerodynamic performance, contributing to the development of guidelines for manufacturers to design new products and mitigate the performance risk on test floor.

Effect of Turbulent Intensity and Axial Gap on Turbine Heat Transfer Using Steady and Harmonic Models

The knowledge of heat loads on the turbine is of great interest to turbine designers. Turbulence intensity and stator-rotor axial gap plays a key role in affecting the heat loads. Flow field and associated heat transfer characteristics in turbines are complex and unsteady. Computational fluid dynamics (CFD) has emerged as a powerful tool for analyzing these complex flow systems. Honeywell has been exploring the use of CFD tools for analysis of flow and heat transfer characteristics of various gas turbine components. The current study has two objectives. The first objective aims at development of CFD methodology by validation. The commercially available CFD code Fine/Turbo is used to validate the predicted results against the benchmark experimental data. Predicted results of pressure coefficient and Stanton number distributions are compared with available experimental data of Dring et al. [1]. The second objective is to investigate the influence of turbulence (0.5% and 10% Tu) and axial gaps (15% and 65% of axial chord) on flow and heat transfer characteristics. Simulations are carried out using both steady state and harmonic models. Turbulence intensity has shown a strong influence on turbine blade heat transfer near the stagnation region, transition and when the turbulent boundary layer is presented. Results show that a mixing plane is not able to capture the flow unsteady features for a small axial gap. Relatively close agreement is obtained with the harmonic model in these situations. Contours of pressure and temperature on the blade surface are presented to understand the behavior of the flow field across the interface.

Design-Optimization Approach to Multistage Axial Contra-Rotating Turbines

Air Turbo Rocket engines, suitable for high-speed propulsion, require compact turbomachinery. This paper presents the design of an innovative multi-stage turbine mounted at the hub of a counter-rotating fan. Hence, the turbine airfoils are required to deliver high torque at low peripheral speeds. The design methodology specifically developed for this fourteen-stage turbine relies on two successive optimization cycles. The first one is based on a through-flow 1D code. This optimization cycle explores a vast set of possible design solutions. In a second step, an optimization using a 3D high fidelity RANS defines the 3D airfoil geometry. In order to accelerate the entire design procedure, a special routine was developed to morph the 1D results into the required info for the 3D optimization. Both the 1D and 3D optimizations are based on differential evolution algorithm.

Evaluation of RANS Transition Modeling for High Lift LPT Flows at Low Reynolds Number

High lift low pressure turbine airfoils have complex flow features that can require advanced modeling capabilities for accurate flow predictions. These features include separated flows and the transition from laminar to turbulent boundary layers. Recent applications of computational fluid dynamics based on the Reynolds-averaged Navier-Stokes formulation have included modeling for attached and separated flow transition mechanisms in the form of empirical correlations and two- or three-equation eddy viscosity models. This study uses the three-equation model of Walters and Cokljat [1] to simulate the flow around the Pack B and L2F low pressure turbine airfoils in a two-dimensional cascade arrangement at a Reynolds number of 25,000. This model includes a third equation for the development of pre-transitional laminar kinetic energy (LKE), and is an updated version of the Walters and Leylek [2] model. The aft-loaded Pack B has a nominal Zweifel loading coefficient of 1.13, and the front-loaded L2F has a nominal loading coefficient of 1.59. Results show the updated LKE model improves predicted accuracy of pressure coefficient and velocity profiles over its previous version as well as two-equation RANS models developed for separated and transitional flows. Transition onset behavior also compares favorably with experiment. However, the current model is not found suitable for wake total pressure loss predictions in two-dimensional simulations at extremely low Reynolds numbers due to the predicted coherency of suction side vortices generated in the separated shear layers which cause a local gain in wake total pressure.

Simulating Periodic Unsteady Flows Using Cubic-Spline Based Time Collocation Method

Time periodical unsteady flows are typical in turbomachinery. Simulating such flows using conventional time marching approach is most accurate but extremely time consuming. In order to achieve a better balance between accuracy and computational expenses, a cubic-spline based time collocation method is proposed. In this method, the time derivatives in the Navier-Stokes equations are obtained by using the differential quadrature method, in which the periodical flow variables are approximated by cubic-splines. Thus, the computation of a time-periodical flow is substituted by several coupled quasi-steady flow computations at sampled instants. The proposed method is then validated against several typical turbomachinery periodical unsteady flows, i.e., transonic compressor rotor flows under circumferential inlet distortions, single stage rotor-stator interactions and IGV-rotor interactions. The results show that the proposed cubic-spline based time collocation method with appropriate time sampling can well resolve the dominant unsteady effects, whilst the computational expenses are kept much less than the traditional time-marching simulation. More importantly, this paper provides a framework on the basis of time collocation method in which one may choose more compatible test functions for the concerned specific unsteady flows so that the better modeling of the flows can be expected.

Study and Verification of Continuous Adjoint System for Aerodynamic Optimization in Turbomachinery Cascades

This paper is a further study of the authors’ previous work on the continuous adjoint method based on the variation in grid node coordinates and Jacobi Matrices of the flow fluxes. This method simplifies the derivation and expression of the adjoint system, and reduces the computation cost. In this paper, the differences between the presented and the traditional methods are analyzed in details by comparing the derivation processes and the adjoint systems. In order to demonstrate the reliability and accuracy of the adjoint system deduced by the authors, the presented method is applied to different optimal problems, which include two inverse designs and two shape optimizations in both 2D and 3D cascades. The inverse designs are implemented by giving the isentropic Mach number distributions along the blade wall for 2D inviscid flow and 3D laminar flow. The shape optimizations are implemented with the objective function of the entropy generation in flow passage for 2D and 3D laminar flows. In the 3D optimal case, this method is validated by supersonic turbine design case with and without mass flow rate constraint. The numerical results testify the accuracy of this adjoint method, which includes only the boundary integrals, and furthermore, the universality and portability of this adjoint system for inverse designs and shape optimizations are demonstrated.