High-speed Gas Turbine Research Articles

Engineering-Physical Method for Determining the Thermal Conductivity of Objects with Micrometric Thickness and a Complex Structure

Introduction. The application of functional coatings on products, the performance properties of which are localized in the surface layer is a trend in modern mechanical engineering and materials science. The issues considered in this regard are relevant, in particular, for thermal-barrier coatings of turbine blades of steam and gas turbine engines. It is worth mentioning the materials that experience significant thermal loads during operation. In this case, the lack of reliable methods for predicting the thermophysical properties of the coating seems to be a problem. The work objective is to create a computational and analytical methodology for determining the thermal conductivity of coatings. This approach is based on experimental data and takes into account structural parameters of the material.Materials and Methods. The experiments were carried out with the blades of a high-speed gas turbine of a locomotive engine made of heat-resistant chromium-nickel alloy Inconel 713LC. An experimental multiphase coating of the Nb-Ti-Al intermetallic system with a thickness of about 80 microns was applied using vacuum ion-plasma technology. The two-beam scanning electron microscope Zeiss CrossBeam 340 was used in the work. The thermal conductivity of the coatings was determined by an experimental technique based on the measurement of the contact potential difference (CPD). Numerical values of this difference were obtained using a mirror galvanometer with high voltage sensitivity. A special signal amplifier and a USB oscilloscope were used to record the readings.Results. The calculation apparatus of the thermal conductivity determination technique is based on the experimental values of ∆φ CPD:– for the base metal (Inconel 713LC) +846 mkV;– for the coating Nb-Ti-Al – 90 mkV.The solution to the problem of the distribution of particles in a force field with a potential difference ∆φ is described by the Boltzmann distribution. Starting from the obtained result, we get:– CPD at the boundary of the contacting metals;– energy and thermal conductivity of the Fermi level;– electron relaxation time.The multidirectional influence that the dimensional differences of the particles of the second phase have on the effective thermal conductivity is considered. For this case, a dimensionless value of the effective thermal conductivity in the direction of each axis and the effective thermal conductivity of the composite are found. Porosity is taken into account according to the Maxwell – Aiken dependence and introduced into the general calculation system. The thermal conductivity of Nb-Ti-Al is established: λNbTiAl = 4,76 W/m.K. Thus, the thermal barrier coating Nb-Ti-Al fully meets its functional purpose.Discussion and Conclusion. The method of determining thermal conductivity described in the article is applicable only to conductive consolidated materials or composites with a continuous conductive matrix. The presented work completes the initial stage of creating a computational and analytical model for predicting the thermal conductivity of materials and coatings. The results of testing the model for materials with a complex structure showed its satisfactory accuracy. This indicates the expediency of using the two considered elements of the model. The first one is the instrumental measurement of the CPD. The second one is taking into account the features of the structural and phase state of the material. With the development of the model, it is expected to overcome its weaknesses:– the impossibility of using non-conductive objects to determine the thermal conductivity;– a significant decrease in the accuracy of determining thermal conductivity for materials and coatings with a gradient structure.

Design of a Combined Magnetic and Gas Dynamic Bearing for High-Speed Micro-Gas Turbine Power Plants with an Axial Gap Brushless Generator

The development of modern energy is moving towards distributed generation, in which numerous sources of different capacities are connected into a single network. This makes it possible to increase the reliability of the entire system, since the probability of the failure of several energy sources at the same time is small. One of the major possibilities of distributed generation is the generation of electric energy based on high-speed gas turbines. The main advantage of these sources are high specific energy indicators, which improve with increasing rotation speed. However, it is technically difficult to realize the advantages of high-speed devices. It is necessary to abandon the step-down gearbox for the generator and directly connect it to a high-speed turbine, use high-strength materials that can withstand the load from centrifugal forces, abandon traditional plain bearings, and use special supports. Installations with generators that have a radial rotor design are the most widespread. The main problem with generators of this type is that the rotor diameter is limited by the mechanical strength from centrifugal forces and the power can be increased only by increasing the axial length. At the same time, only two supports can be used for a radial structure; this leads to a decrease in the rigidity of the shaft and the occurrence of resonant frequencies during acceleration. In addition, radial generators have unreasonably large losses in the stator magnetic circuit, which increase with increasing speed and are difficult to remove from a limited volume. For this reason, radial structures have exhausted their reserves and cannot develop further in the direction of increasing the speed of rotation. This article proposes the design of a high-speed gas turbine installation based on a generator of a fundamentally different design. This is a multi-section generator with an axial air gap. The electric machine has a diamagnetic armature, which eliminates magnetic losses and allows for increased efficiency and simplification of the design. A large number of rotor sections can be used as supports for a gas-dynamic bearing, which greatly increases the rigidity of the structure and eliminates resonant frequencies during acceleration. The main structural difference from existing designs is the use of two types of bearings at the same time: magnetic bearings and gas-dynamic bearings. Magnetic bearings ensure operation at low speeds during acceleration, and gas-dynamic bearings ensure the rotation of the rotor and its rigidity at high speeds. Analysis of developments in this area shows that this solution is innovative. The proposed design required study of both the power part, including the axial inductor and the diamagnetic armature, and the combined support. This article shows the results of the development of a combined suspension and provides calculations of magnetic and gas-dynamic bearings for a gas turbine installation of 100 kW and 70,000 rpm. The results of the study can be applied to a number of gas turbine installations from 10 kW to 500 kW. The authors consider this concept to be competitive with modern analogues that have a radial generator design.

Синтез и анализ комбинированного магнитного и газодинамического подвеса для модельного ряда высокоскоростных микрогазотурбинных энергоустановок нового поколения

The modern power industry is characterized by intense development of distributed generation, with which numerous sources of different capacities are connected into a single network. This makes it possible to improve the reliability of the entire system, since the probability of several sources to fail simultaneously is quite low. Electric generation based on high-speed gas turbine units accounts for a significant share in the overall balance, due to which scientific research and new engineering solutions in this area are important and relevant. An innovative design of a high-speed gas turbine unit based on a switched axial generator is proposed. This electrical machine has a diamagnetic armature, which eliminates magnetic losses, due to which better efficiency of the power unit is achieved and its design is simplified. The high speed of rotation and the presence of critical resonant rotor speeds generated the need to adopt appropriate engineering decisions in regard of its supports. A combined suspension involving the use of magnetic and gas-dynamic bearings is proposed. The magnetic bearings support the gas turbine unit operation at low speeds during its acceleration, and the gas-dynamic bearings support its operation at high nominal speed. The generator design and the combined suspension layout are shown. The numerical analyses of magnetic and gas-dynamic bearings for a gas turbine unit for a capacity of 100 kW and rotation speed of 70 000 rpm are given. The study results can be used for a series of gas turbine units with capacities ranging from 10 to 500 kW. In our opinion, this concept is competitive with modern analogs with a radial generator design.

Effect of Laser Shock Peening on Fatigue Life at Stress Raiser Regions of a High-Speed Micro Gas Turbine Shaft: A Simulation Based Study

Fatigue failure due to stress raiser regions on critical rotating components in gas turbine engines, such as the shaft, is a crucial aspect. Methods to reduce these stresses and improve fatigue life are a source of ongoing research. Laser shock peening is a method where compressive residual stresses are imparted on the stress raisers of such components. However, numerical based studies on multiple laser shock peening applied to stress raisers is under-researched. Hence, this study will attempt to predict the fatigue life at fillet radii step induced stress raiser regions on a high-speed gas turbine engine shaft by utilization of laser shock peening. The objective of this study was achieved by developing a more computational efficient finite element model to mimic the laser shock peening process on the fillet radii step induced stress raiser regions of a shaft. A modified laser shock peening simulation method for effective prediction of the residual stress field was introduced. Furthermore, the fatigue life improvement due to laser shock peening was predicted by employing Fe-safe fatigue software. From the results, the modified laser shock peening simulation method provided accurate prediction of the residual stress field with a reduced computational time of over 68% compared to conventional methods. The fatigue life revealed an improvement of 553% due to laser shock peening, which is comparable to similar findings in the literature. Hence, from the findings and results achieved, the developed finite element model can be an appropriate tool to assist in the fatigue life estimation of laser shock peening applied to stress raisers.

Numerical Optimization of a Stall Margin Enhancing Recirculation Channel for an Axial Compressor

A proof of concept is provided by computational fluid dynamic simulations of a new recirculating type casing treatment. This treatment aims at extending the stable operating range of highly loaded axial compressors, so to improve the safety of sorties of high-speed, high-performance aircraft powered by high specific thrust engines. This casing treatment, featuring an axisymmetric recirculation channel, is evaluated on the NASA rotor 37 test case by steady and unsteady Reynolds Averaged Navier Stokes (RANS) simulations, using the realizable k-ε model. Flow blockage at the recirculation channel outlet was mitigated by chamfering the exit of the recirculation channel inner wall. The channel axial location from the rotor blade tip leading edge was optimized parametrically over the range −4.6% to 47.6% of the rotor tip axial chord c z . Locating the channel at 18.2% c z provided the best stall margin gain of approximately 5.5% compared to the untreated rotor. No rotor adiabatic efficiency was lost by the application of this casing treatment. The investigation into the flow structure with the recirculating channel gave a good insight into how the new casing treatment generates this benefit. The combination of stall margin gain at no rotor adiabatic efficiency loss makes this design attractive for applications to high-speed gas turbine engines.

Defining the Field of Existence of Shrouded Blades in High-Speed Gas Turbines

This work provides a method for determining the region of existence of banded blades of gas turbines for aircraft engines based on the analytical evaluation of tensile stresses in specific characteristic sections of the blade. This region is determined by the set of values of the parameter, which forms the law of distribution of the cross-sectional area of the cross-sections along the height of the airfoil. When seven independent parameters (gas-dynamic, structural and strength) are changed, the choice of the best option is proposed at the early design stage. As an example, the influence of the dimension of a turbine on the domain of the existence of banded blades is shown.

Effect of Fatigue Damage Parameter on the Cumulative Life of a Turbine Rotor Under Multiaxial Loading

The effect of the fatigue damage parameter on the cumulative life of a high-speed turbine rotor has been estimated through finite element approach. Two most commonly used multiaxial fatigue damage models based on critical plane approach-Fatemi Socie (FS) model, and Kandil Brown and Miller model (KBM) have been used to estimate the fatigue life. Structural integrity test was carried out in spin test facility to validate the simulation results. KBM model for fatigue life estimation and LMP model for creep damage predicted a cumulative life within a factor of 1.5 scatter band of the experimental value. The combination of FS model for fatigue life estimation and LMP model could predict cumulative life only within a scatter band of 2. Some of the shortcomings attributed to LDS method can be obviated using a suitable fatigue damage parameter. The study provides invaluable input and confidence for the life prediction of high-speed gas turbine rotors.

Dynamic stability experiments of compliant foil thrust bearing with viscoelastic support

In order to reduce the complexity of machine construction and improve the mechanical efficiency, high speed rotation machineries usually implement self-acting gas bearings to substitute the traditional oil-lubricated bearings. This paper presents test results of a gas thrust bearing with viscoelastic support which is designed for high speed turbo-machinery. The gas bearing, which belongs to compliant foil bearings, consists of a top thin metal foil and a bottom thin rubber foil. Static and stability experiments are conducted on a high speed gas turbine test rig. The static results indicate that the structural stiffness of test bearing generally increases with the increase in axial load and the decrease in thickness of bottom foil. In the rotation tests, rotor runs stably with small vibration amplitude, which is dominant in waterfall plot during whole speed up procedure. It shows that test bearing has preferable stability characteristics for high speed gas turbines.

Near-Contact Laser Surface Textured Dry Gas Seals

A new concept of a near-contact gas seal is experimentally investigated. A simulated gas face seal for a high-speed gas turbine engine is used for the investigation. A baseline conventional contacting-type seal is compared with an identical seal that was laser surface textured (LST) to turn it into a near-contact gas seal. Results show the potential benefits of the new concept in terms of smoother running, lower friction torque, and lower face temperature at 12,000 RPM over a range of face loading.

On the Frictional Damping Characterization of Compliant Bump Foils

High-speed rotor systems use either fluid film or rolling element bearing supports, depending upon their design and operating constraints. Regardless of bearing type used, these systems require specific bearing and support stiffness and damping characteristics to achieve the desired stable and low vibration operation. Building upon the technology of thin metallic corrugated bump foils presently used in a particular class of film riding hydrodynamic bearings, a novel corrugated bump foil damped mount is introduced which provides stiffness and damping for application with rolling element bearings. These damping elements are capable of operating at elevated temperatures where implementation of conventional squeeze film dampers is ruled out. The frictional damping results from micro-slip motions between the bump foils and the mating surfaces. A semi-empirical model, based on a one degree of freedom model was developed in which damping is replaced by an equivalent frictional force in order to gain insight into the dynamic friction coefficient of the individual damping element interfaces. Experimental results, obtained in the form of hysteresis loops were compared to the developed model with good agreement. The variation in damping and dynamic coefficient of friction was found to be dependent primarily upon three factors: vibration frequency, amplitude of motion and applied static load. These parameters were tested within the range of 50–1400 Hz, 2.54–12.7 micron and 45–135 N, respectively. The tests were conducted at room and 538°C ambient temperatures under both dry and vapor phase lubricated conditions. Using the resulting empirical data, several bearing dampers were designed, built and tested in a small, high-speed gas turbine engine simulator. The tested novel foil dampers were capable of operating reliably under extremely high levels of shaft imbalance (i.e., 320 times greater than the air bearing supported with specification of 0.0002 oz-in) even while operating at temperatures to 560°C. These results show the great potential for wide application of these dampers on gas turbine engines and high-speed rotating machinery.

Royal Navy Experience of Propulsion Gas Turbines and How and Why This Experience is Being Incorporated Into Future Designs

The Royal Navy (RN) has in-service experience of both marinized industrial and aero derivative propulsion gas turbines since the late 1940s. Operating through a Memorandum of Understanding (MOU) between the British, Dutch, French, and Belgian Navies the current in-service propulsion engines are marinized versions of the Rolls Royce Tyne, Olympus, and Spey aero engines. Future gas turbine engines, for the Royal Navy, are expected to be the WR21 (24.5 MW), a 5 to 8 MW engine and a 1 to 2 MW engine in support of the All Electric Ship Project. This paper will detail why the Royal Navy chose gas turbines as prime movers for warships and how Original Equipment Manufacturers (OEM) guidance has been evaluated and developed in order to extend engine life. It will examine how the fleet of engines has historically been provisioned for and how a modular engine concept has allowed less support provisioning. The paper will detail the planned utilization of advanced cycle gas turbines with their inherent higher thermal efficiency and environmental compliance and the case for all electric propulsion utilizing high speed gas turbine alternators. It will examine the need for greater reliability/availability allowing single generator operation at sea and how by using a family of 3 engines a nearly flat Specific Fuel Consumption (SFC) down to harbour loads can be achieved. [S0742-4795(00)01203-5]

Rolling Element Bearing Monitoring Using High Gain Eddy Current Transducers

A technique is described which provides early detection of rolling element bearing failure through direct observation of the bearing outer race with a high-gain eddy current probe. Data is presented that compares REBAM™—Rolling Element Bearing Activity Monitor—to traditional monitoring approaches that employ case mounted velocity and acceleration transducers. Generally, the REBAM approach simplifies the analysis of bearing condition because of its proximity to the bearing and its insensitivity to extraneous vibration sources due to the relative mounting approach employed. A summary of field results is presented and its suitability to high speed gas turbine monitoring is discussed.

Waste Heat Recovery On Multiple Low-Speed Reciprocating Engines

With rising fuel costs, energy conservation has taken on added significance. Installation of waste heat recovery units (WHRU's) on gas turbines is one method used in the past to reduce gas plant fuel consumption. More recently, waste heat recovery on multiple reciprocating compressor engines also has been identified as having energy conservation potential. This paper reviews the development and implementation of a WHRU for multiple low-speed engines at the Katy (TX) gas plant. WHRU's for these engines should be differentiated from high-speed engines and gas turbines in that low-speed engines produce low-frequency, high-amplitude pulsating exhaust. The design of a WHRU system must take this potentially destructive pulsation into account. At Katy, the pulsation forces were measured at high-amplitude frequencies and then used to design a pulsation filter and structural stiffness into the various components of the WHRU to minimize vibration and improve system reliability.

Hydrogen as an activating fuel for a tidal power plant

Ocean tides, as an environmentally clean and inexhaustible natural source of energy, can be used as one alternative for replacing fossil fuels. But because the tides are dependent on the moon phases, which do not always coincide with the time of human activity, tidal projects usually require a special system for the accumulation of energy for off-peak periods. The production of hydrogen by electrolysis can be considered one such system. This paper outlines the method by which hydrogen produced during off-peak tidal power plant operation can be used as an activating fuel to furnish the same plant during the peak-load demands. With our approach (see [1]) the energy of the tide is converted into the energy of compressed air by means of specialized chambers which are put on the ocean bed. Ocean water from the dammed region passes through the chamber where it works as a natural piston compressing air in the upper part of the closure. For the peak periods the compressed air can be heated by combustion of the stored hydrogen, and expanded through high-speed gas turbine generators. For the off-peak periods, the energy of non-heated compressed air is used for the production of the hydrogen fuel. In this case the total electric output of the power plant would be decreased somewhat because the losses of the energy would be taken for the production of the hydrogen fuel.

Gas Turbine Engine Mainshaft Roller Bearing-System Analysis

An interdisciplinary systems analysis is presented for high-speed gas turbine engine mainshaft roller bearings which will enable the designer to meet the demands for ever higher rotative speeds and operating temperatures. The latest elastohydrodynamic experimental traction data are included. Analytical results cite a need for better definition of the rolling friction portion of the total traction. A fluid mechanics model for the detailed analysis of fluid drags is developed based upon a turbulent vortex-dominated flow and includes the effect of lubricant flow through the bearing. A complete thermal analysis including dynamic and thermal effects upon bearing dimensions and resulting clearances is also included. Heat transfer coefficients are given in detail. Shaft power loss and cage slip predictions as a function of load, speed, and lubricant supply correlate well with available experimental data.

高速気動車の開発

高速気動車の開発

Design and development of four light-weight high-speed marine gas turbines for electric generator drive12

During the last eight years, four high-speed marine gas turbines for driving generators have been designed, developed and put into operation. Two were base-load machines designed for operating at full tropical ambient temperature (100° F), and two we

Design and Development of Four Light-Weight High-Speed Marine Gas Turbines for Electric Generator Drive

During the last eight years, four high-speed marine gas turbines for driving generators have been designed, developed and put into operation. Two were base-load machines designed for operating at full tropical ambient temperature (100°F), and two were simple emergency and stand-by sets. The two base-load sets and one emergency were built under contract for the Admiralty while the other emergency set was built for the Merchant Navy. A brief description of the most important features of these engines is followed by the main body of the paper which deals with the six most outstanding problems that were encountered during their design and development.

A 24,000-rpm alternator for aircraft

DESIGNED TO BE DRIVEN at 24,000 rpm by a gas turbine, the G-80 alternator is a 50-kw generator for supplying a-c power to 3-phase 208/120-volt 400-cycle aircraft electric systems. This equipment combines the lightness of high-speed electric rotating equipment with the possibility of direct connection to a high-speed gas turbine, thereby eliminating gearing and replacing the noise and vibration of the reciprocating engine with the comparatively quiet and smooth flow of power from the turbine.