Rotor Secondary Flows Research Articles

Experimental Investigation of Tip Design Effects on the Unsteady Aerodynamics and Heat Transfer of a High-Speed Turbine

Abstract While modern engine manufacturers devote significant efforts to the development of reliable and efficient machines, the introduction of novel, optimized components in the hot gas path represents a risky opportunity. Accurate experimental and numerical data are critical to assess the impact of new technologies on the harsh engine environment. The present study addresses the impact of a selection of high-performance rotor blade tips on the aerodynamic and heat flux field of a high-pressure turbine (HPT) stage. A combined numerical and experimental approach is employed to characterize the interaction of the tip leakage flow with the rotor secondary flows and the casing heat transfer mechanisms for each individual tip geometry. The turbine stage is tested at engine-scaled conditions in the rotating turbine facility of the von Karman Institute. In the present study, the turbine rotor is operated in rainbow configuration to allow the simultaneous testing of multiple blade tip geometries. Reynolds-averaged Navier–Stokes (RANS) simulations are employed to predict the aerodynamic and thermal fields of the individual profiles using test-calibrated boundary conditions. Isothermal steady computations are performed at different wall temperatures to compute the adiabatic wall temperature and the heat transfer convective coefficient. Low-order models are used to represent the over-tip thermal field and the driving heat transfer mechanisms. The time-resolved outlet flow is characterized using a vortex tracking technique and high-frequency aerodynamic measurements to identify the rotor secondary flow structures.

Impact of High-Pressure-Turbine Purge Flow on the Evolution of Turbulence in a Turbine Vane Frame

Abstract This paper describes the measurement and postprocessing of turbulence data. The experiments were carried out in a two-stage, two-spool transonic turbine test rig at the Institute for Thermal Turbomachinery and Machine Dynamics at the Graz University of Technology, which includes relevant purge and turbine rotor tip leakage flows. The test setup consists of a high-pressure turbine (HPT) stage, a turbine vane frame (TVF) with turning struts and splitters, and a counter-rotating low-pressure turbine (LPT) to allow engine realistic measurements. Time-resolved area traverse measurements have been performed for three different operating conditions in three measurement planes downstream of the HPT rotor, which enable the measurement of the turbulence quantities at the TVF inlet and outlet as well as the LPT outlet. The turbulence quantities are evaluated using triaxial- and single hot-film probes by means of Constant-Temperature-Anemometry, and their results were validated with five-hole probe (FHP) measurements. Ensemble- and time-averaging, as well as Fourier transforms, were applied for data reduction. It is shown how the turbulence intensity and integral length scale vary over different purge flowrates (PFR). The acquired measurement data illustrate that the interaction of the ejected purge flow with mean flow enhances the turbulent mixing in the secondary flow structures at the TVF inlet and TVF outlet, respectively. Furthermore, the flow downstream of the LPT rotor is affected by TVF and LPT rotor secondary flow structures, which are identified as high turbulence regions. These regions strongly depend on the purge flowrate. These results acquired under engine realistic rig flow conditions enable a deeper understanding of the relationship between loss and turbulence quantities and will help improve the application of computational fluid dynamics turbulence models to turbomachinery modeling.

Impact of Swirling Entropy Waves on a High Pressure Turbine

AbstractThe harsh environment exiting modern gas turbine combustion chamber is characterized by vorticity and temperature perturbations, the latter commonly referred as entropy waves. The interaction of these unsteadiness with the first turbine stage causes non-negligible effects on the aerodynamic performance, blade cooling, and noise production. The first of these drawbacks is addressed in this paper by means of an experimental campaign: entropy waves and swirl profile are injected upstream of an axial turbine stage through a novel combustor simulator. Two injection positions and different inlet conditions are considered. Steady and unsteady experimental measurements are carried out through the stage to address the combustor-turbine interaction characterizing the injected disturbance, the nozzle, and rotor outlet aerothermal field. The experimental outcomes show a severe reduction of the temperature perturbation already at stator outlet. The generated swirl profile influences significantly the aerodynamic, as it interacts with the stator and rotor secondary flows and wakes. Furthermore, the clocking position changes the region most affected by the disturbance, showing a potential modifying the injection position to minimize the entropy wave and swirl profile impact on the stage. Finally, this work shows that in order to proficiently study entropy waves, the unsteady aerodynamic flow field stator downstream has to be addressed.

The Effects of Reynolds Number on the Stall and Pre-Stall Behavior of Compact Axial Compressors

Abstract Compact axial compression systems are of interest to the domestic appliance industry. The associated low Reynolds number leads to high losses compared to large-scale compressors due to a transitional flow field with large regions of separation. This paper investigates how Reynolds number variations affect the three-dimensional and unsteady flow field in a compact compressor both pre-stall and in stall. An experimental study has been conducted using a scaled-up single-stage axial compressor across a Reynolds number range of 104–105. Steady and unsteady casing static pressure measurements, along with rotor upstream and downstream unsteady velocity measurements, have been used to observe the rotor flow field. As the Reynolds number is reduced below a critical value, 60,000 in the case of the compressor studied, the pressure rise coefficient of the compressor rapidly decreases. The exact value of the critical Reynolds number is expected to vary with the compressor geometry. This fall-off in performance corresponds to an increase in the compressor rotor secondary flows. Prior to stall, a broadband hump at around 50% of the blade passing frequency is present in the near-field casing static pressure spectra. At Reynolds numbers below the critical value, multiple equally spaced peaks also appear around the peak of the broadband hump. The spacing of these peaks has been found to be exactly equal to the measured stall cell speed once rotating stall is established. When operating in stall, the stall cell is found to increase in circumferential size and slow down as Reynolds number decreases. The measured spectra and observed flow structures show that disturbances exist prior to stall at frequencies consistent with the frequencies within stall. The size and shape of the stall cells that form are related to the extent of the three-dimensional flow field present prior to stall. Below a critical value, all of these flow features are highly sensitive to Reynolds number.

The Interactions of Turbine Hot Streak and Leakage Flow from the Inter-Platform Gap

ABSTRACTThe paper presents the effects of the leakage flow from the inter-platform gap on the migration of hot streak in a first stage turbine by three-dimensional unsteady Reynolds-Averaged Navier-Stokes simulations. Five circumferential positions of the hot streak are considered. The comparisons between the results with/without slot leakage show significant differences. The leakage changes the hot streak in the vane passage significantly and it protects the vane suction surface trailing from the hot gas. The leakage also changes the secondary flow and results in forming a new couple of vortices in the vane passage. In general, rotor passage, the hot gas usually gathers in the rotor hub and the pressure surface. In the present study, the leakage coolant from upstream slot is entrained to the unsteady rotor secondary flows and transported toward the rotor hub and pressure surface effectively. The cooling effect is related to the relative circumferential positions between the hot streaks and slot. When the hot streak is positioned at the slot suction side, the time-averaged temperature reduction on the blade leading edge can be more than twice of that for the hot streak at the slot pressure side.

Hot Streak Evolution in an Axial HP Turbine Stage

This paper presents the results of an experimental study on the evolution of hot streaks generated by gas turbine burners in an un-cooled high-pressure turbine stage. The prescribed hot streaks were directed streamwise and characterized by a 20% over-temperature with respect to the main flow at the stage inlet. The hot streak was injected in four different circumferential positions with respect to the stator blade. Detailed temperature and aerodynamic measurements upstream and downstream of the stage, as well as in-between the blade rows, were performed. Measurements showed a severe temperature attenuation of the hot streaks within the stator cascade; some influence on the aerodynamic field was found, especially on the vorticity field, while the temperature pattern resulted in severe alteration depending on the injection position. Downstream of the rotor, the jet spread over the pitch above the midspan and was more concentrated at the hub. Rotor secondary flows were also enhanced by hot streaks.

Investigation of Nonaxisymmetric Endwall Contouring and Three-Dimensional Airfoil Design in a 1.5-Stage Axial Turbine—Part I: Design and Novel Numerical Analysis Method

This paper presents the results of the analysis of different 3D designs for the first stator and the rotor of a 1.5-stage turbine test rig. A tangential endwall contouring for the hub and the shroud, a bowed profile stacking, and a combination of those have been designed for the first stator. In addition, a tangential endwall contouring has been designed for the hub of the unshrouded rotor. Part I of this two-part paper deals with the design process and the numerical analysis of the results. All designs have been optimized using the stage efficiency as target function. For the design of the 3D stator vanes, the optimization led to an unexpected result: The secondary flow vortex strength increased. However, the secondary flow pattern is rearranged by the 3D-designing, leading to a smoother radial exit flow angle distribution. A subsequent reduction of the rotor losses overcompensates the higher stator losses. In order to understand how the 3D vanes affect the stator secondary flow pattern, a detailed analysis of vortex stretching and vortex dissipation is presented in this paper. With this approach, the various impacts of the 3D designs on the secondary flow vortices' strength can be quantified. In addition, the potential theory effect of the self-induced velocity is introduced here in order to explain the effects of a tangential endwall contouring on the trajectory of the pressure side leg of the horseshoe vortex (HVps). To the best of our knowledge, both approaches are new for the analysis of turbine secondary flows. The impact of the stronger but rearranged stator secondary flow on the rotor secondary loss development is analyzed by means of unsteady simulations. The results show that the rotor secondary flow can be effectively reduced through a proper stator secondary flow pattern. In Part II of this paper, the analysis of extensive experimental results validates and supplements the numerical analysis.

Design and performance prediction of radial ORC turboexpanders

In this paper, a zero-dimensional model for the design of radial turbo-expanders for ORC applications is discussed, with special reference to the estimation of losses and efficiency; a comparison between different fluids (R134a, R1234yf, R236fa, R245fa, Cyclohexane, N-Pentane) is presented and discussed, referring to a typical small-size application (50kW). In the model, different methods for the design of radial turbines are screened, with special attention to the estimation of losses, for which correlations from literature are used. Real Equations Of State (EOS) are applied to the expansion process in place of the traditionally adopted Mach relationships for ideal gas, which is a significant advancement for modeling organic fluids in ORC, often operating near to critical conditions. The results show that the total to total efficiency of the designed machines range between 0.72 and 0.80, depending on the considered fluid. Generally, higher efficiency (1.5–2.5% points) can be achieved adopting backswept-bladed rotors. The most significant losses come from the rotor secondary flows, due to the high curvature of blade profiles combined to the large pressure gradient. The best performing fluids are R236fa and R245fa, followed by R134a and R1234yf.Finally, starting from the developed design tool, an off-design analysis of turbo-expanders is presented. Once the design data are available, the characteristic curves of the expander at variable temperature, pressure and fluid mass flowrate at the expander inlet for different values of the specific speed are built. It is thus possible to evaluate the performance of the radial expanders when working far from design point. This analysis, demonstrated for R134a, shows that the total to static efficiency has a relatively modest sensitivity to the off design of the expansion ratio, especially at corrected speed below the design value.

The Effect of Coolant Injection on the Endwall Flow of a High Pressure Turbine

This paper presents a study of the effects of two types of hub coolant injection on the rotor of a high pressure gas turbine stage. The first involves the leakage flow from the hub cavity into the mainstream. The second involves a deliberate injection of coolant from a row of angled holes from the edge of the stator hub. The aim of this study is to improve the distribution of the injected coolant on the rotor hub wall. To achieve this, it is necessary to understand how the coolant and leakage flows interact with the rotor secondary flows. The first part of the paper shows that the hub leakage flow is entrained into the rotor hub secondary flow and the negative incidence of the leakage strengthens the secondary flow and increases its penetration depth. Three-dimensional unsteady calculations were found to agree with fast response pressure probe measurements at the rotor exit of a low speed test turbine. The second part of the paper shows that increasing the injected coolant swirl angle reduced the secondary flow penetration depth, improves the coolant distribution on the rotor hub, and improves stage efficiency. Most of the coolant however, was still found to be entrained into the rotor secondary flow.

Hot Streak and Vane Coolant Migration in a Downstream Rotor

This paper describes a method of improving the cooling of the hub region of high-pressure turbine (HPT) rotor by making better use of the unsteady coolant flows originating from the upstream vane. The study was performed computationally on an engine HPT stage with representative inlet hot streak and vane coolant conditions. An experimental validation study of hot streak migration was undertaken on two low-speed test facilities. The unsteady mechanisms that transport hot and cold fluid within the rotor hub region are first examined. It was found that vortex-blade interaction dominated the unsteady transport of hot and cold fluid in the rotor hub region. This resulted in the transport of hot fluid onto the rotor hub and pressure surface, causing a peak in the surface gas temperatures. The vane film coolant was found to have only a limited effect in cooling this region. A new cooling configuration was thus examined which exploits the unsteadiness in rotor hub to aid transport of coolant towards regions of high rotor surface temperatures. The new coolant was introduced from a slot upstream of the vane. This resulted in the feed of slot coolant at a different phase and location relative to the vane film coolant within the rotor. The slot coolant was entrained into the unsteady rotor secondary flows and transported towards the rotor hub-pressure surface region. The slot coolant reduced the peak time-averaged rotor temperatures by a similar amount as the vane film coolant despite having only a sixth of the coolant mass flow.

Three Dimensional Clocking Effects in a One and a Half Stage Transonic Turbine

This paper presents an experimental investigation of the flow field in a high-pressure transonic turbine with a downstream vane row (1.5 stage machine) concerning the airfoil indexing. The objective is a detailed analysis of the three-dimensional aerodynamics of the second vane for different clocking positions. To give an overview of the time-averaged flow field, five-hole probe measurements were performed upstream and downstream of the second stator. Furthermore in these planes additional unsteady measurements were carried out with laser Doppler velocimetry in order to record rotor phase-resolved velocity, flow angle, and turbulence distributions at two different clocking positions. In the planes upstream of the second vane, the time-resolved pressure field has been measured by means of a fast response aerodynamic pressure probe. This paper shows that the secondary flows of the second vane are significantly modified by the different clocking positions, in connection with the first vane modulation of the rotor secondary flows. An analysis of the performance of the second vane is also carried out, and a 0.6% variation in the second vane loss coefficient has been recorded among the different clocking positions.

A Parametric Study of the Blade Row Interaction in a High Pressure Turbine Stage

An extensive experimental analysis on the subject of the unsteady periodic flow in a high subsonic high pressure (HP) turbine stage has been carried out at the Laboratorio di Fluidodinamica delle Macchine of the Politecnico di Milano (Italy). In this paper the aerodynamic blade row interaction in HP turbines, enforced by increasing the stator and rotor blade loading and by reducing the stator-rotor axial gap, is studied in detail. The time-averaged three-dimensional flowfield in the stator-rotor gap was investigated by means of a conventional five-hole probe for the nominal (0 deg) and highly positive (+22 deg) stator incidences. The evolution of the viscous flow structures downstream of the stator is presented to characterize the rotor incoming flow. The blade row interaction was evaluated on the basis of unsteady aerodynamic measurements at the rotor exit, performed with a fast-response aerodynamic pressure probe. Results show a strong dependence of the time-averaged and phase-resolved flowfield and of the stage performance on the stator incidence. The structure of the vortex-blade interaction changes significantly as the magnitude of the rotor-inlet vortices increases, and very different residual traces of the stator secondary flows are found downstream of the rotor. On the contrary, the increase in rotor loading enhances the unsteadiness in the rotor secondary flows but has a little effect on the vortex-vortex interaction. For the large axial gap, a reduction of stator-related effects at the rotor exit is encountered when the stator incidence is increased as a result of the different mixing rate within the cascade gap.

Desensitization of the Flowfield from Rotor Tip-Gap Height by Casing-Air Injection

This paper presents an investigation that aims to desensitize the flowfield of an unshrouded high-pressure gas-turbine stage from the radial clearance between the rotor tip and the casing. A novel method of cooling-air injection from the rotor casing into the rotor tip region is applied. The injection opposes the tip-leakage flow and affects the development of the rotor secondary flow. In a previous investigation, an increase of stage efficiency of 0.55 percentage points was achieved with an injection of 0.7% of the core mass flow. The present study investigates the effect of the injection on the flowfield for two different rotor tip clearances. Measurements conducted with a two-sensor fast-response pressure probe provide data describing the time-resolved behavior of flow angles and pressures as well as turbulence intensity. The experimental investigation is done on the tip-gap heights of 0.65 and 1.00% span and injection mass flow rates representing 0, 0.7, and 1% of the turbine core mass flow. The results show that an increasing injection rate reduces the difference of rotor exit flow angle and flow unsteadiness between the two different tip-gap heights. The stage efficiency increases with injection for both tip-gap cases, whereas identical values are obtained at the injection rate of 1 % of the turbine mass flow.

Control of Rotor Tip Leakage Through Cooling Injection From the Casing in a High-Work Turbine

This paper presents an experimental investigation of a novel approach for controlling the rotor tip leakage and secondary flow by injecting cooling air from the stationary casing onto the rotor tip. It contains a detailed analysis of the unsteady flow interaction between the injected air and the flow in the rotor tip region and its impact on the rotor secondary flow structures. The experimental investigation has been conducted on a one-and-1/2-stage, unshrouded turbine, which has been especially designed and built for the current investigation. The turbine test case models a highly loaded, high pressure gas turbine stage. Measurements conducted with a two-sensor fast-response aerodynamic probe have provided data describing the time-resolved behavior of flow angles and pressures, as well as turbulence intensity in the exit plane of the rotor. Cooling air has been injected in the circumferential direction at a 30 deg angle from the casing tangent, opposing the rotor turning direction through a circumferential array of ten equidistant holes per rotor pitch. Different cooling air injection configurations have been tested. Injection parameters such as mass flow, axial position, and size of the holes have been varied to see the effect on the rotor tip secondary flows. The results of the current investigation show that with the injection, the size and the turbulence intensity of the rotor tip leakage vortex and the rotor tip passage vortex reduce. Both vortices move toward the tip suction side corner of the rotor passage. With an appropriate combination of injection mass flow rate and axial injection position, the isentropic efficiency of the stage was improved by 0.55 percentage points.

Stator-clocking effects on the unsteady interaction of secondary flows in a 1.5-stage unshrouded turbine

Effects of stator clocking on the unsteady interaction of stator and rotor secondary flows and performance are investigated in a 1.5-stage, high-pressure turbine. Due to the low aspect ratio design of the blade rows, vortical structures dominate the inlet flow field of the second stator row. Therefore the interaction of first stator and rotor secondary flows in relation to the stator-clocking position must be considered in order to achieve an optimized multi-stage performance. Four different stator-clocking positions are studied in this experimental investigation. The data comprise unsteady and steady probe measurements, which are acquired downstream of the rotor and the second stator blade row of a 1.5-stage, unshrouded turbine. A two-sensor fast response aerodynamic probe technique is used in the measurement campaign. It is found that multi-row interaction effects of vortical secondary flow features dominate the loss creation in turbine stages having low aspect ratio geometries. The periodic interaction of shed passage vortices of the first stator with secondary flow structures of the rotor creates regions characterized by reduced total pressure and increased turbulence, and entropy at fixed locations relative to the subsequent stator. Circumferential position of these interaction regions defines the spanwise distribution of total pressure loss in the downstream stator. Stator-clocking controls the spanwise distribution of loss in high-pressure turbines. However, the potential of reducing the loss is limited due to the three-dimensional nature of the flow, and hence, the non-uniform effect of a clocking position on the spanwise performance of a downstream stator.

3-D Numerical Calculation of the Local Entropy Generation Rates in a Radial Compressor Stage

The flow field in a low-ns radial compressor stage is computed by means of a LES simulation performed with a commercial CFD package. Radial and tangential secondary flows are identified both in the rotor and in the diffuser. In the latter, a regime of transient stall with a blockage region oscillating between the two sidewalls is observed. Rotor secondary flows influence the diffuser regime, and some of the diffuser instabilities seem to be phase-locked to some of the unsteady large flow structures detectable in the rotor. The entropy generation rate is computed locally, to assess if and where the design could be improved. Our results confirm that entropy generation maps (both in space and time) provide designers with detailed and unequivocal information about the causes of the intrinsic flow irreversibilities.

A Loosely Coupled Unsteady Flow Simulation of a Single Stage Compressor

A steady/unsteady, three-dimensional Navier- Stokes solver that utilizes a semi-implicit, pressure-based solution procedure is developed to simulate the three-dimensional, incompressible flow through a single stage compressor. The present numerical scheme features the implementation of a second-order plus fourth-order artificial dissipation formulation to prevent the numerical oscillation due to central differencing schemes. A low-Reynolds-number form of the two-equation turbulence model is used to account for the turbulence effects. For unsteady flow computations, the coupling between the mean flow properties and the turbulence is enhanced by an inner-iteration procedure during each time step. The steady flow field in the rotor passage is computed first. This is used as input for the computation of the unsteady flow in the subsequent stator. The predicted unsteady pressure on the stator blades and unsteady velocities at several locations inside the passage are compared with the experimental data. The unsteady pressures on the stator blade surfaces are in good agreement with the experimental data. The predicted unsteady velocity components at various locations inside the stator blade rows are generally smaller than the measured values in the endwall regions. The phase, angle variations of the unsteady velocity are in good agreement with the measured values. The effects of the rotor wake, secondary and tip clearance flows on the unsteady flow through the subsequent stator are studied. An attempt is also made to quantify the contributions of incoming tip leakage flows and the endwall boundary layers on the unsteady flow through the downstream stator. It was found that the endwall boundary layers and tip leakage flows have a much stronger influence on the unsteady flow development than the wake.

Three-Dimensional Interactions in the Rotor of an Axial Turbine

This article presents a study of the development of the three-dimensional flowfield within the rotor blades of a low-speed, large-scale axial flow turbine. Measurements have been performed in the rotating and stationary frames of reference. Time-mean data have been obtained using miniature five-hole pneumatic probes, whereas the unsteady development of the flow has been determined using three-axis subminiature hot-wire anemometers. Additional information is provided by the results of blade-surface flow-visualization experiments and surfacemounted hot-film anemometers. The development of the stator exit flow, as it passes through the rotor blades, is described. Unsteady data suggest that the presence of the rotor secondary and tip leakage flows restricts the region of unsteady interaction to near midspan when the stator wakes and secondary flows are adjacent to the suction surface. Surface-mounted hot-film data show that this affects the suction-side laminar-turbulent transition process. © 1995 American Institute of Aeronautics and Astronautics, Inc., All rights reserved.

Blade Row Interaction in a Multistage Low-Pressure Turbine

The objective of this work was to enhance the understanding of unsteady flow phenomena in multistage low-pressure turbines. For this purpose, hot-film probe measurements were made downstream of every rotor blade row of a five-stage low-pressure turbine. Rotor–rotor interaction and stator–rotor interaction were observed to have a profound influence on the flow through the low-pressure turbine. Interaction of rotors of different turbine stages occurred owing to the influence of the wakes shed by one rotor blade row upon the flow through the next downstream rotor blade row. This wake-induced rotor–rotor interaction resulted in strongly amplitude-modulated periodic and turbulent velocity fluctuations downstream of every rotor blade row with the exception of the most upstream one. Significantly different wake depths and turbulence levels measured downstream of every rotor blade row at different circumferential positions evidenced the effect of the circumferentially nonuniform stator exit flow upon the next downstream rotor blade row. Stator-rotor interaction also strongly influenced the overturning and the under-turning of the rotor wakes, caused by the rotor secondary flows, in the rotor endwall regions. Low rotor wake overturning and underturning, i.e., reduced rotor secondary flow influence, were observed to correlate well with low rotor wake turbulence levels.

Redistribution of an inlet temperature distortion in an axial flow turbine stage

The results of an experimental program aimed at determining the extent of the redistribution of an inlet temperature distortion in an axial flow turbine stage are presented. The program was conducted in a large-scale, low-speed, single-stage turbine where air, seeded with CO2, was introduced at one circumferential location upstream of the inlet guide vane. The migration of the seeded air through the turbine was determined by sensing CO2 concentration inside the stage. A temperature distortion was introduced by heating the seeded air. The CO2 concentration contours measured downstream of the vane showed h'ttle change with heating, indicating that the vane flowfield was relatively unaffected by the introduction of the temperature distortion. However, the CO2 contours observed on the rotor airfoil surfaces for the case with inlet heating indicated segregation of hot and cold gas with the higher temperature gas migrating to the pressure side and the lower temperature gas migrating to the suction side. Significant increases in rotor secondary flow were also observed. Two separate physical mechanisms are postulated to explain the observed experimental trends. Calculations performed by using a three-dimensional Euler solver show qualitative agreement with the experimental data.