Efficiency Of Gas Turbine Engines Research Articles

Numerical Investigation of the Effect of Trailing Edge Thickness of Simulated Ceramic Matrix Composite Blades on Loss Profiles

Abstract Ceramic matrix composite (CMC) is an enabling material allowing higher turbine inlet temperatures and possibly resulting in better thermal efficiency of gas turbine engines. This is because CMC layers with environmental barrier coating have significantly higher thermal limits (∼1755 K) compared with the more conventional alloyed metallic blades. CMCs possess a complex fabrication process resulting in different geometrical characteristics than metallic blades (e.g., larger trailing edge thickness, large leading-edge curvature, etc.). It is therefore desirable to assess the aerodynamic performance of the CMC blades using experimental and numerical simulations. To investigate, three different CMC blades with varying trailing edge thicknesses were numerically simulated. Both large-eddy simulation with the dynamic subgrid closure as well a recently implemented Reynolds-averaged Navier–Stokes coupled with an intermittency function-based transition model were utilized. Two sets of experimental test points with different Reynolds numbers at a given high-freestream turbulence range (Tu = ∼10–13%) were considered. The predicted pressure loading profiles, total loss distributions, and integrated loss of the three different CMC blades were computed and comparisons against the experimental data are presented herein. It was found that the mixing loss forms a larger proportion of the overall loss as the trailing edge thickness increases.

Parametric shape optimization of pin fin arrays using a multi-fidelity surrogate model based Bayesian method

The current work aims to develop a multi-fidelity Bayesian optimization methodology to reduce computation time in CFD based design optimization of an internal cooling channel of a gas turbine blade. To build energy efficient gas turbine engines, it is important to increase the turbine inlet temperature, while preventing material failure of hot gas path components. Power lost due to pumping compressed air in turbine blade internal cooling channels can affect the overall efficiency of a power cycle. While designing such a cooling channel, it is important to ensure high heat transfer within a given pressure drop budget. Design optimization using CFD typically needs a sufficient number of computationally expensive high fidelity simulations to search for an optimum design. In the current work, a multi-fidelity Gaussian process surrogate based Bayesian optimization framework has been used to design a pin fin array channel, typically used for gas turbine blade trailing edge cooling, with the goal of maximizing Nusselt number at a constrained pressure loss. Data from a cheaper, low fidelity computation model has been leveraged, along with an expensive high fidelity one, in order to search for a design configuration that maximizes heat transfer at a given pressure drop constraint. The multi-fidelity approach improves upon single fidelity optimization results, at a low additional computational cost due to usage of simulation data from the cheap lowfidelity CFD model. A multifidelity approach outperformed the previous single fidelity case, with 6% higher objective while satisfying the pressure constraint, with 2% lower computational expense and 8 fewer high fidelity data point computations.

Large eddy simulation of film cooling for a forward expansion hole under main flow oscillation

This study conducted a large eddy simulation (LES) to predict the flow structure and effectiveness of film cooling in a gas turbine. The study focused on a forward expansion hole on a flat plate with an inclined injection angle of 35° and spanwise injection angles (orientation angles) of 0° and 30° under main flow oscillation. In gas turbines, the mainstream flow can exhibit unsteadiness owing to stator–rotor interactions or freestream turbulence. Here, sinusoidal functions are used to approximate the flow oscillations, and their effects are evaluated at frequencies of 0, 8, and 32 Hz, corresponding to Strouhal numbers of 0, 0.603, and 2.413, respectively. The study aims to characterize the film cooling at two time-averaged blowing ratios: 0.5 and 1.0. The range of Strouhal numbers considered in this study is relevant to actual transonic gas turbines. The computational results obtained through LES are validated using experimental data and compared with the Reynolds-averaged Navier–Stokes simulation results. The findings demonstrate the efficiency of LES to predict accurately the distribution of spanwise film cooling effectiveness and spanwise-averaged effectiveness for forward expansion holes on turbine blades under flow oscillations. Comprehensive analyses of various aspects such as the instantaneous turbulent structures of the film cooling flow fields, time-averaged temperature, and root-mean-squared values of the coolant temperature and a proper orthogonal decomposition analysis for velocity vectors are performed. The results show that when the oscillation frequency of the main flow varied from 0 Hz to 32 Hz for a time-averaged blowing ratio of 0.5, the film cooling effectiveness for the forward expansion hole reduced significantly. However, when the frequency increased under a time-averaged blowing ratio of 1.0, the film cooling effectiveness for the hole was only slightly affected by the oscillations. Moreover, an orientation angle of 30° enhanced the film-cooling performance even under flow oscillations. Thus, this paper reports the development of highly effective film-cooling strategies that can guide researchers aiming to mitigate the adverse effects of flow oscillations, thereby enhancing the reliability and efficiency of gas turbine engines.

Microstructure and thermal barrier coating properties of plasma sprayed SrCeO3

The trend to improve the efficiency of gas turbine engines leads to an increase in requirements for thermal barrier coating (TBC) materials. Strontium cerate (SrCeO3) is a promising perovskite-like type oxide with a low thermal conductivity and moderate thermal expansion coefficient (TEC) value. In this work, TBC was applied by atmospheric plasma spraying to a nickel superalloy ZhS 32 VI, and the change in its microstructure and phase composition after thermal cycles was investigated. It was found that during spraying, SrCeO3 crystals orientated along the most densely packed directions, which led to the structuring of the coating. In the process of thermal cycling, Sr diffuses to the top coat – bond coat boundary with the formation of strontium chromate. SrCrO4 together with NiO form a layer of thermally grown oxide (TGO). TBC failed after 44 ± 3 thermal cycles of rapid heating up to 1200 °C followed by air cooling with 5 min of holding time at each stage. The absence of direct reactions of the top coat and bond coat, the TGO formation from components of both layers as well as low TEC mismatch allows to resist onset of exfoliation for about 30 cycles. The thermal conductivity value of nickel superalloy covered by SrCeO3 is only 1.65 ± 0.05 W·m−1·K−1 in the temperature range of 25–100 °C and mainly determines by top coat properties. The new experimental data being obtained highlights the prospects of the considered TBC based on SrCeO3.

Solid particle erosion in ceramic matrix composites and environmental barrier coatings: A perspective

AbstractCeramic matrix composites (CMCs) and environmental barrier coatings (EBCs) are key technologies that can enable improvements in the thermal and propulsive efficiency of gas turbine engines. However, CMCs and EBCs are susceptible to various life limiting damage modes associated with the engine operating environment such as oxidation, recession, thermomechanical stress/strain, corrosion, foreign object damage (FOD), and solid particle erosion (SPE). Despite its importance, there is a limited understanding of the SPE behavior of CMCs and EBCs in the literature. This paper reviews the status of SPE research for CMCs and EBCs and provides a perspective towards future research.

Effect of NaCl and SO2 on the stress corrosion cracking of CMSX-4 at 550°C

ABSTRACT In the pursuit of more efficient gas turbine engines, components are required to operate for longer times at elevated temperatures. This increased time in service, together with a complex loading regime, can expose the material to environmental attack. This work has demonstrated that the interaction of stress, NaCl and a sulphur-containing environment is critical to cause crack initiation in the early stages of the exposure and accelerated corrosion rates in CMSX-4 at 550°C. The effect of having small concentrations of moisture in the gaseous environment or as water crystallisation in the salt is still to be investigated. A working hypothesis is that the interaction of alkali chlorides with a sulphur-containing atmosphere is the trigger to a self-sustaining cycle where metal chloride formation, vaporisation and oxidation lead to high amounts of hydrogen injection in a rapid manner and, therefore, hydrogen embrittlement.

Microstructural Stability and Properties of New Nickel‐Base Superalloys with Varying Aluminium: Niobium Ratio

New nickel‐base superalloys with higher temperature capability are required for future, more efficient gas turbine engines. In designing such alloys, careful consideration is required of the elemental concentrations to ensure a suitable balance of properties is obtained. Herein, the phase equilibria and microstructural stability of new nickel‐base superalloys with varying Al:Nb ratio are assessed via long‐term thermal exposures at 700 °C. The alloys are analyzed using scanning and transmission electron microscopy, X‐ray diffraction, differential scanning calorimetry, and Vickers hardness testing, with the results rationalized through mechanical property predictions based on strong‐ and weak‐pair dislocation coupling mechanisms. The alloys are shown to have greater thermal stability than Inconel 718 and exhibit a pronounced hardening effect after thermal exposure. Herein, their ability for controlled age hardening and potential ease of processing is highlighted in the results.

Deformation Prediction Theory of Thermal Barrier Coatings near Cooling Holes under Thermal Cycling.

Thermal barrier coating (TBC) systems are widely adopted in gas turbine blades to improve the thermal efficiency of gas turbine engines. However, TBC failure will happen due to the thermal stress between the different layers of the TBC systems. The traditional two-layer theoretical model only considers TGO (thermally grown oxide) and a substrate in the inner cooling hole with the surface uncoated, which results in poor prediction of the deformations of the TBC systems. It should be mentioned that the effect of TBC is very important because the thickness of TBC is much larger than the TGO thickness. In this study, a new three-layer theoretical model was derived, which is composed of the cylindrical TGO and TBC mounted in the substrate with a circular hole, and the stress and strain of TGO near the cooling hole under the condition of the thermal cycles were calculated. The high temperature characteristics of TGO and the substrate including the high temperature strength and growth ratio were from the experiments. The results show that the strain of the developed three-layer model is irrelevant with increasing number of cycles, which indicates that TBC in the cooling hole significantly inhibits the deformation of TGO near the cooling hole. Therefore, aimed at confirming the feasibility of the three-layer theoretical model, the finite element analysis with coating in the cooling hole and on the surface was carried out with a three-layer axisymmetric model, which proves that the 3-layer theoretical model can predict the deformation trend near the cooling hole.

Oxidation Behaviour of New Nickel-Base Superalloys with Varying Aluminium: Niobium Ratio

New Ni-base superalloys with higher temperature capability are required for future, more efficient gas turbine engines. In designing such alloys, careful consideration is required of the elemental concentrations to ensure that a suitable balance of mechanical properties and environmental resistance is obtained. In this study, the oxidation resistance of a series of new Ni-base superalloys with varying Al:Nb ratio has been assessed through long-term exposures in air at elevated temperature. The oxide scale was characterised using scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction and quantitative measurements of oxide scale dimensions. The alloys were found to form continuous chromia scales at 700 °C and outperformed several current commercial superalloys. However, following exposure at 800 °C, significant microstructural degradation was observed due to precipitation of the δ phase.

Stability Characteristics of an Actively Valved Resonant Pulse Combustor

Abstract Resonant pulse combustors, one of the deflagration-based pressure gain combustion devices, can significantly increase thermal efficiency in gas turbine engines. This experimental study investigates the stability characteristics of a newly designed actively valved resonant pulse combustor, capable of sustained operation and meaningful stagnation pressure gain. The resonant pulse combustor was fired with liquid gasoline fuel while ion and pressure sensors captured the temporally resolved heat release and chamber pressure. First, experimental results were used to demonstrate the general operating principle of the combustor. Then, the stability characteristics of the device were investigated through frequency domain analysis of the ion probe and pressure signal traces. A low frequency oscillation (also observed in steady flames and passively valved resonant pulse combustors), was observed as the device was brought near to its blowout limit. Finally, an index was defined to predict the stability characteristics of the resonant pulse combustor by quantifying the competition between low frequency oscillations and combustion-driven resonance. Experimental results demonstrated the ability of this index to provide early prediction of a blowout event for this device.

Internal cooling sensitivity analysis to improve the thermal performance of gas turbine blade using a developed robust conjugate heat transfer method

The heat transfer simulations of turbine blades with internal cooling are faced with so many uncertainties, of which some originate from the secondary air system, including the inlet hot gas temperature and pressure and the cooling side boundary conditions, and the blade material. The main objective of this work is to carry out a suitable sensitivity analysis on a specific novel turbine vane to improve the thermal performance of its internal cooling system and to quantify how the uncertainties on the designed/calculated values can desirably/undesirably affect the maximum blade surface temperature, which can consequently affect the gas turbine engine efficiency. Furthermore, the sensitivity analysis is carried out to find the effects of uncertainties of a number of key parameters on the resulting blade temperature distribution. To arrive at trustworthy conclusions, the conjugate heat transfer (CHT) method is used to analyze the heat and fluid flow behavior. This work suitably develops a CHT-based method/solver to perform the proposed study. This method/solver uses a segregated iterative procedure, in which the outer hot gas region is simulated using the computational fluid dynamics (CFD) solver, the flow passing through the connected internal cooling passages is calculated using a 1D correlated-based solver, and the vane conduction is predicted using a 3D finite-element solver, which are fully coupled. The results show that the cooling channel wall temperature has a direct impact on the convective coefficient magnitude; especially in lower temperature regions. As a novel contribution, this work takes into account the cooling wall temperature influence on the 1D code calculations. To implement this, an artificial neural network is suitably trained to predict better convective coefficient. The results of this developed CFD-CHT code are validated against experimental data available for a benchmark vane. Eventually, the sensitivity analysis is carried on the present specific novel turbine vane.

Effects of Front Plate Geometry on Brush Seal in Highly Swirling Environments of Gas Turbine

Advanced brush seal technology has a significant impact on the performance and efficiency of gas turbine engines. However, in highly inlet swirling environments, the bristles of a brush seal tend to circumferentially slip, which may lead to aerodynamic instability and seal failure. In this paper, seven different front plate geometries were proposed to reduce the impact of high inlet swirl on the bristle pack, and a three-dimensional porous medium model was carried out to simulate the brush seal flow characteristics. Comparisons of a plane front plate with a relief cavity, plane front plate with axial drilled holes, anti-“L”-type plate and their relative improved configurations on the pressure and flow fields as well as the leakage behavior were conducted. The results show that the holed front plate can effectively regulate and control the upstream flow pattern of the bristle pack, inducing the swirl flow to move radially inward, which results in decreased circumferential velocity component. The anti-“L” plate with both axial holes and one radial hole was observed to have the best effect on reducing the swirl of those investigated. The swirl velocity upstream the bristle pack can decline 50% compared to the baseline model with plane front plate, and the circumferential aerodynamic forces on the bristles, which scale with the swirl dynamic head, are reduced by a factor of 4. This could increase the bristle stability dramatically. Moreover, the front plate geometry does not influence the leakage performance significantly, and the application of the axial hole on the front plate will increase the leakage slightly by around 3.5%.

Chemically Recuperated Gas Turbines for Offshore Platform: Energy and Environmental Performance

Currently, offshore areas have become the hotspot of global gas and oil production. They have significant reserves and production potential. Offshore platforms are energy-intensive facilities. Most of them are equipped with gas turbine engines. Many technologies are used to improve their thermal efficiency. Thermochemical recuperation is investigated in this paper. Much previous research has been restricted to analyzing of the thermodynamic potential of the chemically recuperated gas turbine cycle. However, little work has discussed the operation issues of this cycle. The analysis of actual fuel gases for the steam reforming process taking into account the actual load of gas turbines, the impact of steam reforming on the Wobbe index, and the impact of a steam-fuel reforming process on the carbon dioxide emissions is the novelty of this study. The obtained simulation results showed that gas turbine engine efficiency improved by 8.1 to 9.35% at 100% load, and carbon dioxide emissions decreased by 10% compared to a conventional cycle. A decrease in load leads to a deterioration in the energy and environmental efficiency of chemically recuperated gas turbines.

Evaluating the Influence of Rotor-Casing Eccentricity on Turbine Efficiency Including Time-Resolved Flow Field Measurements

Abstract The clearance that exists between the casing and turbine blade tips is one of the key drivers of efficiency in gas turbine engines. For this reason, engine manufacturers utilize precise manufacturing techniques and may use clearance control systems to minimize tip clearances to reduce associated losses. Despite these efforts, turbines typically exhibit some nominal casing ovality or rotor-casing eccentricity, and changes to blade tip clearance during operation commonly occur due to thermal and mechanical stresses. The present study investigates non-axisymmetric tip clearance effects by creating a rotor-casing eccentricity in a one-stage axial test turbine operating in a continuous-duration mode at engine-relevant conditions with engine representative hardware. A magnetic levitation bearing system was leveraged to move the turbine shaft to vary the rotor-casing eccentricity without test section disassembly. The results of this study indicate that rotor-casing eccentricity does not affect overall turbine efficiency over the range that was tested, but does locally influence efficiency and the rotor exit flow field. Comparisons of flow angle and secondary flow kinetic energy (SKE) agreed with previous studies and existing analytical methods, respectively. Collectively, these results indicate that tip clearance can be studied locally on an eccentric rotor.

The ultra-high efficiency gas turbine engine, UHEGT, part III: Dynamic behavior of the system in variable performance conditions

This paper investigates the dynamic behavior of an Ultra-High Efficiency Gas Turbine Engine (UHEGT) with Stator Internal Combustion. The UHEGT-technology was introduced for the first time to the gas turbine design community at the Turbo Expo 2015. In developing the UHEGT-technology, the combustion process is no longer contained in isolation between the compressor and turbine, rather distributed in the first three HP-turbine stator rows. Noticeable improvement in the engine thermal efficiency and power along with other performance advantages are brought by this technology. In the current paper, dynamic simulation is performed on the entire gas turbine engine (UHEGT) using the nonlinear dynamic simulation code GETRAN. The simulations are in 2 D (space-time) and include the majority of the engine components including rotor shaft, turbine and compressor, fuel injectors, diffuser, pipes, valves, controllers, etc. The thermo-fluid conservation laws are applied to the flow in each component which create a system of nonlinear partial differential equations that is solved numerically. Two different fuel schedules (steep rise and Gaussian) are applied to all injectors and the engine response is studied in each case. The results show that fluctuations in the fuel flow lead to fluctuations in most of the system parameters such as temperatures, power, shaft speed, etc. However, the shapes and amplitudes of the fluctuations are different and there is a time lag in the response profiles relative to the fuel schedules. It is shown that an increase in average fuel flow in the system leads to a small drop in efficiency due to the cycle change from the design point. Moreover, it is seen that the temperatures usually rise fast with increase of fuel flow, but the system tends to cool down at a slower rate as the fuel is reduced.

Судовая парогазовая энергетическая установка полузамкнутого цикла для покрытия пиковых нагрузок

A wide range of efficient gas turbine engines has been developed at UEC NPO Saturn, Russia. Those engines can be successfully used for developing a marine steam-gas semi-closed cycle power plant to compensate peak loads on ships and vessels. This compact steam-gas power plant will demonstrate high efficiency which doesn’t change significantly depending on the load when compared to conventional steam-gas power plants. Also, this solution can possibly change the diesel engine prevalence among marine power plants.

Design of a Pulsing Flow Driven Turbine

Abstract There is widespread interest in using pressure gain combustion in gas turbine engines to increase gas turbine engine efficiency and reduce fuel consumption. However, the fluctuating turbine inlet conditions inherent with pressure gain combustion cause a decrease in turbine efficiency. Designing a turbine for pulsing flow would counteract these losses. An optimization of turbine geometry for pulsing flow was conducted with entropy generation as the objective function. A surrogate model was used for the optimizations based on data extracted from two-dimensional computational fluid dynamics simulations. Optimizations run for different pulsing amplitudes informed a revised turbine design. The new turbine geometry was validated with a periodic, time-accurate simulation, and a decrease in entropy generation of 35% was demonstrated. The design recommendations were to weight the design of the turbine toward the peak of the pressure pulse, to consider the range of inlet angles and decrease the camber near the leading edge, and to reduce the blade turning.

The ultra-high efficiency gas turbine engine, UHEGT, Part II: A numerical study on reducing the stator blade surface temperature by indexing fuel injectors and using film cooling

In the Ultra-High Efficiency Gas Turbine Engine, UHEGT (introduced in our previous studies) the combustion process is no longer contained in isolation between the compressor and turbine, rather distributed within the axial gaps before each stator row. This technology substantially increases the thermal efficiency of the engine cycle to above 45%, increases power output, and reduces turbine inlet temperature. Since the combustion process is brought into the turbine stages in UHEGT, the stator blades are exposed to high-temperature gases and can be overheated. To address this issue and reduce the temperature on the stator blade surface, two different approaches are investigated in this paper. The first is indexing (clocking) of the fuel injectors (cylindrical tubes extended from hub to shroud), in which the positions of the injectors are adjusted relative to each other and the stator blades. The second is film cooling, in which cooling holes are placed on the blade surface to bring down the temperature via coolant injection. Four configurations are designed and studied via computational fluid dynamics (CFD) to evaluate the effectiveness of the two approaches. Stator blade surface temperature (as the main objective function) along with other performance parameters such as temperature non-uniformity at rotor inlet, total pressure loss over the injectors, and total power production by rotor are evaluated for all configurations. The results show that indexing presents the most promising approach in reducing the stator blade surface temperature while producing the least amount of total pressure loss.

Film cooling performance evaluation of the furcate hole with cross-flow coolant injection: A comparative study

Turbine blades are consistently exposed to high-temperature gas in an effort to increase the maximum efficiency of gas turbine engines. Therefore, a growing need exists to protect the outer surfaces from high-temperature gas. Film cooling has long been used as an active thermal protection scheme, and the shaped film-hole is one possible solution to the aforementioned problem. Based on the actual coolant supply channel of the turbine blades, the film cooling performance of a novel furcate hole fed by cross-flow coolant injection with 135-deg ribs was experimentally investigated in this study. The Reynolds numbers of the main-flow and cross-flow are 10,000 and 100,000, respectively, and the blowing ratio M ranges from 0.5 to 2.0. The adiabatic film effectiveness η and heat transfer coefficient of the furcate hole are obtained by the transient liquid-crystal measurement technique, and a detailed comparison between the furcate hole and cylindrical hole geometries, simple and compound hole, is presented. The results show that the span-wise width of the film coverage is significantly more comprehensive than that of the compound hole due to the configuration of the span-wise expansion for the furcate hole. At a lower M, the film coverage gradually narrows, and the η gradually decreases along the flow direction for the furcate hole. The heat transfer enhancement of the furcate hole is the highest among the studied cases, and the heat transfer uniformity is much impoverished. With an increasing M, the advantages of the high η of the furcate hole are gradually revealed. The degree of deflection of the film coverage gradually increases toward the +Y side. Both the effectiveness and magnitude of the span-wise η are improved at M=1.0. At a larger M of 2.0, the heat transfer enhancement is the weakest, and the heat transfer uniformity is improved. The net heat-flux reduction is introduced to comprehensively evaluate the cooling performance. The values of the traditional holes invariably decrease as M increases, whereas that of the furcate hole first increases and then decreases. As M increases to 1.0 and 2.0, the comprehensive benefits of the furcate hole become more apparent.

The ultra-high efficiency gas turbine engine, UHEGT, part I: Design and numerical analysis of the multistage system

The Ultra-High Efficiency Gas Turbine Engine (UHEGT) was introduced in our previous studies. In UHEGT, the combustion process is no longer contained in isolation between the compressor and turbine. It is rather distributed in multiple stages and integrated within the high-pressure turbine stator rows. Compared to the current most advanced conventional gas turbines, UHEGT considerably improves the efficiency and output power of the engine while reducing its emissions and size. In this study, a six-stage UHEGT turbine with three stages of stator internal combustion is designed and analyzed. The design represents a single spool turboshaft system for power generation using gaseous fuels. The preliminary flow path for each turbine stage is designed by the meanline approach and modified using Computational Fluid Dynamics (CFD). Unsteady CFD calculation (via commercial software ANSYS CFX) is used to simulate and optimize the flow and combustion process through high-pressure turbine stages. The results show a base thermal efficiency of above 45% is achieved. It shows a successful integration of the multi-stage combustion process into the high-pressure turbine stages and a highly uniform temperature distribution at the inlet of each rotor row. High temperatures in some areas on the stator blade surfaces are controlled using indexing of fuel injectors and stator blades.