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1 TurboPower – TURB32: TurboAero TURB32: TurboAero Cavity Purge Flows in High Pressure Turbines Project Leader: Jens Fridh Supervisors: Jens Fridh, Björn.

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Presentation on theme: "1 TurboPower – TURB32: TurboAero TURB32: TurboAero Cavity Purge Flows in High Pressure Turbines Project Leader: Jens Fridh Supervisors: Jens Fridh, Björn."— Presentation transcript:

1 1 TurboPower – TURB32: TurboAero TURB32: TurboAero Cavity Purge Flows in High Pressure Turbines Project Leader: Jens Fridh Supervisors: Jens Fridh, Björn Laumert PhD Student: Johan Dahlqvist

2 2 TurboPower – TURB32: TurboAero Project Participants Joint Venture Royal Institute of Technology Department of Energy Technology (KTH), Stockholm Siemens Industrial Turbines (SIT), Finspång GKN Aerospace, Trollhättan University Funding Swedish Energy Agency

3 3 TurboPower – TURB32: TurboAero Presentation Outline Background Objectives Methodology Test Turbine Project Progress Project Plan

4 4 TurboPower – TURB32: TurboAero Background 1/5 - Overview Test Turbine, KTH-Siemens

5 5 TurboPower – TURB32: TurboAero Background 2/5 – Identified Regions of Interest Mixing Losses Rim Seal Flow Wheelspace Flow

6 6 TurboPower – TURB32: TurboAero Background 3/5 – Mixing Losses Main annulus mixing losses investigated through control volume approach by Denton. Entropy increase due to angle difference, flow rate and temperature ratio. Cooling flow impact on cycle efficiency studied by Young. Losses are divided into components: Flow losses in cooling channels Mixing losses upon entry in main flow, including heat transfer and kinetic losses Dissipation coefficient Cavity PurgeCavity Suction

7 7 TurboPower – TURB32: TurboAero Background 4/5 – Rim Seal Flow Ingress of hot gases into wheelspace may harm temperature sensitive components Influenced by upstream stator wakes, downstream rotor pressure fields, purge flow rate, rotational speed, rim seal geometry… Isothermal Surface

8 8 TurboPower – TURB32: TurboAero Background 5/5 – Wheelspace Flow Purge flow and geometry dependent Large scale rotating pressure structures Found under certain circumstances in wheelspace Risk of local unpredicted ingress of hot gas May cause rotor vibrations reducing bearing lifetime 364 Hz406 Hz Frequency Spectra Measurement Gas Mixing CFD Pressure Distribution CFD

9 9 TurboPower – TURB32: TurboAero Objectives Determine cavity purge loss effects Quantitatively to provide data for development of industry loss correlation software Qualitatively for scientific understanding Associate rim sealing effectiveness with cavity purge flow rate for given geometry Ingress effects should be predicted to minimize the use of purge flow and avoid unnecessary efficiency penalties Determine possibilities for investigation of rotating pressure structures Find design and operating criteria to minimize effects Predictability to help avoid harmful mechanical and thermal effects due to ingress and vibrations

10 10 TurboPower – TURB32: TurboAero Methodology 1/3 – Experimental Investigation Detailed steady and unsteady measurements Probe traverse in main annulus flow for flow-field investigation Seed gas (CO 2 ) for determination of seal effectiveness Fast pressure measurements in cavity for pressure gradients and pressure structure identification Performance measurements Torque measurement, compensated for bearing losses Rotational speed measurement Flow entropy change measurement through stage with hot-wire and pressure Mass flow measurement with orifice plate Cavity purge flow density variation Under investigation, for replication of density ratio present in commercial machines

11 11 TurboPower – TURB32: TurboAero Methodology 2/3 – Numerical Investigations (CFD) Validate with experimental measurements To achieve detailed flow analysis beyond possibilities of measurements Possibility to further alter cavity and rim seal geometry and study the influences Initial investigation in search of rotating pressure structures in present turbine geometry

12 12 TurboPower – TURB32: TurboAero Methodology 3/3 – Rotor Blisk Commissioning Commercially common cavity geometry Investigate influence of cavity change Obtain results applicable to available products Instrumentation with slipring

13 13 TurboPower – TURB32: TurboAero Test Turbine INLET OUTLET Traverse equipment Cable lead-through for sliprings

14 14 TurboPower – TURB32: TurboAero New measurement points in cavity Traverse locations Key Characteristics: Stage pressure ratio: 1.23 Velocity ratio: 0.47 (Stage loading: 2.26) Degree of reaction: 0.17 Low aspect ratios: 0.7-1.3 Test Turbine

15 15 TurboPower – TURB32: TurboAero Test Turbine Facility

16 16 TurboPower – TURB32: TurboAero Project Progress 1/3 – Literature Study The aspects of cavity, sealing and main annulus flow are investigated separately in the literature, with regard to cavity purge flows The connection between the three regions is however not investigated thoroughly (only for simplified conditions in CFD) The aspect of density ratio is not investigated in detail, and is interesting look further into

17 17 TurboPower – TURB32: TurboAero Project Progress 2/3 – Experiment Preparation New load envelope investigation Through-flow simulations for increased pressure ratio and speed with in-house software: Done Complete test program: Under development Turbine speed upgrade (7000 → 13000 rpm) Bearing upgrade: Ongoing Measurement equipment upgrade Torque meter overhaul: Ongoing New aerodynamic probes: Purchased New measurement points: Decided New traverse equipment: Decided Density ratio facility CO 2, nitrogen, compressed air investigated CO 2 most promising

18 18 TurboPower – TURB32: TurboAero Project Progress 3/3 – Rotor Blisk Production Trial aluminum manufacture test ongoing at KTH 3-axis CNC Machine, milling from two sides 5/54 blades 3D scan to validate Important lessons for establishing a complete prototyping chain at KTH Collaboration SIT-GKN for mechanical and aerodynamic design

19 19 TurboPower – TURB32: TurboAero MSc Theses Frist thesis scheduled to start September 2013 CFD Investigation of Rotating Pressure Structures in Rotor- Stator Disc Cavity Systems Project proposal published Additional theses planned Further numerical investigations Possibly some experimental investigations and other aspects

20 20 TurboPower – TURB32: TurboAero Project Plan Today

21 21 TurboPower – TURB32: TurboAero Deliverables WP 1.1 Literature study (performance, aerolosses: stator-rotor cavity) D 1.120131031Literature study report WP 1.2EQUIP: New measurement points, new pneumatic probe, traverse system D 1.2.120130531New measurement points physically implemented on test object D 1.2.220130531New probe commissioned D 1.2.320130531New traverse system commissioned WP 1.3 Turbine upgrade (bearings) D 1.320130630Test Turbine commissioned after bearing overhaul WP 1.4 EXP1: Performance & intensive area traverse measurements (wide operating envelope with variation in speed, pressure ratio and mass flow, stator-rotor cavity purge flow <5% m main, density ratio  main /  purge ) D 1.4.120140331Validation database established D 1.4.220140831MSc thesis 2 (performance, axial load - EXP) WP 1.5EXP2: Cavity purge measurements (secondary flow and losses in rotor with a new rim seal geometry). D 1.520150831Paper 1, draft (performance, cavity purge flow - EXP) WP 2.1CFD1: feasibility analysis for cavity pressure structure analysis in experimental rig D 2.120140230MSc thesis 1 (cavity pressure structures investigation) WP 2.2CFD2: comparative study with experimental results D 2.220140831Paper 2, draft (performance, cavity purge flow - CFD/EXP) WP 2.3CFD3: geometry variation study (rim seal). D 2.320140930MSc thesis 3 (geometry variation - CFD) WP 2.4Synthesis of EXP1-2 D 2.4.120141130Tek Lic thesis D 2.4.220150531Paper 3, draft (rim seal geometry - CFD/EXP) WP 3.1BLISK1: Aerodynamic/mech. design - unshrouded rotor blisk (SIT/KTH), increased reaction degree D 3.120130531Aerodynamic design of rotor blisk delivered (CAD/CFD) WP 3.2BLISK2: Aeromechanical analysis - unshrouded rotor blisk (GKN) D 3.220140331Analysis report of rotor blisk delivered WP 3.3BLISK3: Manufacturing - unshrouded rotor blisk (KTH) D 3.320150430Manufactured rotor blisk delivered (hardware) WP 3.4BLISK4: Commissioning - unshrouded rotor blisk (KTH) D 3.420150615Commissioning report WP 3.5EXP3: Performance & area traverse - rotor blisk. Wide operating range (speed, pressure ratio, cavity purge flow) D 3.520151231MSc thesis 3 (blisk/performance - CFD) WP 3.6Synthesis of EXP3: D 3.620151231Paper 4 (blisk performance - EXP/CFD)

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