Endwall Contouring, Using Continuous Diffusion Technology, A Breakthrough Technology and its Application to a Three-Stage High Pressure Turbine Introduced.

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Endwall Contouring, Using Continuous Diffusion Technology, A Breakthrough Technology and its Application to a Three-Stage High Pressure Turbine Introduced by Turbomachinery Performance and Flow Research Laboratory, Texas A&M University Sponsored by DOE, National Energy Technology Laboratory Efficiency Improvement by Endwall Contouring TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri

Project DE-FOA ASME-IGTI-2011 June TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri Pressure difference between suction and pressure side causes: Systems of secondary vortices Generation of induced drag forces Total pressure reduction Secondary flow losses Efficiency decrease Introduction: Endwall Secondary Flow, Reduction

Project DE-FOA ASME-IGTI-2011 June TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri Breakthrough Technology, Disclosure of Invention TAMUS 3259 Unlike methods available in the literature, the Continuous Diffusion Technology introduced by TPFL is physics based and can be applied to P, IP, and LP turbines and compressors regardless the load coefficient, flow coefficient and degree of reaction. Details are explained in the ASME paper GT Presented at the ASME-IGTI-Turbo-Expo 2011, June 06-10, 2011, Vancouver, Canada

Project DE-FOA ASME-IGTI-2011 June TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri TPFL Research Turbine Used for Endwall Contouring Research A Three-stage Turbine Rotor with two Independent Coolant Flow Loops Mainstream Flow Rotor-Seal Ejection Cooling Platform Discrete Hole Film Cooling Tow Independent Coolant Loops for Coolant Injection from Stator-Rotor Seal and Downstream Film Cooling Holes

Project DE-FOA ASME-IGTI-2011 June Numerical Methodology  Steady state models used, convergence was assessed through monitoring of:  Equation RMS and maximum residual values  Inlet and exit mass flow  Area-averaged pressure and velocity at turbine exit  Turbulence model  Shear Stress Transport (SST) model  CFX Automatic wall treatment employed  Switches between wall functions to a low-Reynolds number near wall formulation  Requires y + <2, and at least near-wall nodes  Boundary conditions  Pt in, Tt in, P b  Fixed rotation speed  Adiabatic and non-slip conditions on the wall TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University

Project DE-FOA ASME-IGTI-2011 June Numerical Simulation Mesh  Rotor mesh has over 2 million elements  Extensive grid sensitivity tests  Wall regions use 22 nodes  The entire model involves over 9 million elements TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri

Project DE-FOA ASME-IGTI-2011 June Blade Loading of Second Rotor TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri Blade Loading at Hub Geometry needs to be further optimized. Geometry needs to be further optimized

Project DE-FOA ASME-IGTI-2011 June Blade Loading of Second Rotor  Pressure distribution at two different span locations TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri Geometry needs to be further optimized. Blade Loading at Hub Blade Loading at 2% Span Rad distance from hub 1.3 mm

Project DE-FOA ASME-IGTI-2011 June Continuous Diffusion Technology Applied to Endwall sign  The design of contouring considers both the direction of streamlines and pressure gradient near hub. Currently there is no positive portion. TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri

Project DE-FOA ASME-IGTI-2011 June Pressure Distribution at Hub  Comparison of pressure distributions TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri reference case partial contouring extended new contouring

Project DE-FOA ASME-IGTI-2011 June Total Pressure Loss Coefficient for Second Rotor TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri

Project DE-FOA ASME-IGTI-2011 June TPFL: The Turbomachinery Performance and Flow Research Laboratory Texas A&M University M. T. Schobeiri Efficiency Improvement Using New Technology From Literature TPFL Conventional Designs