Transcript
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C41
Aerodays 2011, Madrid
Main Annulus Gas Path Interactions in Gas Turbines
(MAGPI)R&T Project within the 6th Framework programme of the European Union
Duration: 1.Sep.2006 – 31.Aug.2011
Presented by M. Klingsporn, RRD, Co-ordinator
Rolls-Royce Deutschland
SNECMA
Rolls-Royce
Avio
Siemens
Alstom
ITP
MTU
Turbomeca
University of Surrey
University of Sussex
Karlsruhe Institute of Technology
University of Darmstadt
University of Florence
University of Madrid (UPM)
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C42
MAGPI Project Objectives
� Technical Challenges
– Understanding of interactions between annulus gas flow and air system (unsteady, 3-dimensional, interaction with blades)
� Objectives
– Reduce turbine rim sealing air mass flow
– Improve turbine efficiency / minimise flow distortions caused bysealing air e.g. by better geometry
– Improve CFD tools for complex interactions between air system and main gas path (turbines and compressor)
� Expected Benefits
– SFC, component life, reliability, development cost, better tools
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C43
Technical Work Packages
� WP1: Effects of Cooling System/Main Annulus Gas Interactions – Rotor Heat Transfer – RR lead -- TSW rig at Univ Sussex
� WP2: Spoiling Effects of Sealing Flows on Turbine Performance-- ITP lead -- LSTR rig at Univ Darmstadt
� WP3: Fundamental Studies on Heat Transfer and Aerodynamic Spoiling-- MTU lead -- Linear Cascade rig at Univ Karlsruhe
� WP4: Compressor Bleed-- SN lead -- Outer bleed offtake rig at Univ Karlsruhe
… many partners involved in more than one WP …
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C44
WP1 Heat Transfer in Typical Turbine Stator Well
�Main annuluswith hot gas
�Cooling air
� Ingestion
� Interstagesealleakage
Cooling air
Hot gas
ingestion
Cooling air
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C45
WP1 Heat Transfer Test Facility (Univ Sussex)
� Two-stage high speed turbine rig running at engine representative conditions
� Temperature measurements for different cooling system configurations
Two stage turbine
~10000 rpm
400 kW
PR = 2.5:1
Inlet
3.3 bar (absolute)
4.9 kg/s
170 °C
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C46
WP1 Coupled CFD/FE Analysis
�CFD for gas flow ------- FE for metal temperature
coupled via heat transfer between gas and metal
�Various meshes (structured, unstructured, cells 6 mio)
�Different codes and turbulence models (Fluent, Hydra...)
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C47
WP1 Heat Transfer – Coupled CFD/FE ResultsExcellent agreement between measurements and predictions (No cooling flow)
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C48
WP1 CFD/FE Coupling with Moving Mesh Capability
� Transient deflections can be included (Univ Surrey)
�Better representation of e.g. engine acceleration
Axisymmetric metal deflections
computed by SC03
Corresponding 3D deformed
CFD model
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C49
WP1 CFD Results on Cooling Effectiveness
�Optimum cooling air supply
�Disc rim air more efficient
Cooling Effectiveness =Thot -TcoldTwall -Tcold
turbine stage efficiency
cooling flow
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C410
WP2 Large Scale Turbine Rig Studies – Set-up
Main Annulus Flow
Seal Air Stator1
ME01 ME02 ME03 ME04 ME05
Seal Air Stator2
Univ. Darmstadt
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C411
WP2 Large Scale Turbine Rig – First Results
� Five-hole-probe measurements at ME04; view from rear
�Comparison CFD – experiment: good agreement!
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C412
WP3 Cascade Rig Tests for Optimization
�Different seals studied: axial, shingled, compound
Measurable effect
due to geometry
variation !
a
2,2,
2,1,
statot
tottot
PP
PP
−
−=ζ
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C413
WP3 Optimization Procedure
� DoE approach applied
� Optimum geometry aims to:
– Minimize loss and/or secondary kinetic energy SKEH
– Maintain sealing effectiveness
� Full parameterisation of cavity and rim geometry
� Meshing strategy: stretching grid
� Response surface:
– Genetic Algorithm based optimization
– Test on various objective function
� Computational costs
– 96% is computational time -check for new strategy?
0.14
0.12
0.10
0.016
0.008
0.000
0.008
0.006
0.004
0.02
0.01
0.00
0.008
0.004
0.000
0.006
0.004
0.002
0.062
0.060
0.058
0.020
0.015
0.010
1.008
1.004
1.000
0.020
0.015
0.010
0.008
0.006
0.004
0.015
0.010
0.005
0.010
0.005
0.000
0.006
0.004
0.002
SK
EH
LO
SS
A
Sealing_eff
ecti
veness_4
B B1 C C1 e f g h rr1 rr2
Matrix Plot of SKEH, LOSS, Sealing_effe vs A, B, B1, C, C1, e, f, ...
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C414
WP3 Results of Optimization
� Reduction in Gap A involves reduction in losses, control of rim seal entrained vortex
� For other parameters not easy do determine clear trends
� Reduction of up to ~30% in losses due to the presence of cavity and rim seal flows
� Optimized rim seal to be experimentally validated
Baseline rim seal Minimum losses (Y) Minimum secondary kinetic
energy (SKEH)
Gap A
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C415
WP4 Compressor Bleed Offtake Studies
�Optimization of exit tube and manifold design
2 rows of Blades
Manifold & Exit
tubes
Off take Primary
flow
Bleeding
flow
Static pressure versus position in the manifold
(kPa)
80
82
84
86
88
90
92
94
SLOT_1_BIG_1
EXIT First prediction:
Less pressure
distortion with 4
vs 1 exit tubes
(© Rolls-Royce Deutschland)
10001886:1999-12-20
Main Annulus Gas Path Interactions in Gas Turbines
Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C416
Summary
�MAGPI provided reliable rig test datato validate CFD/FE methods
�Effective coupled CFD/FE convective heat transfermethod demonstrated – will be applied as design tool
�Alternative cooling flow configuration could improvecooling effectiveness
�Effect of different rim seal geometries on hot gas ingestion and pressure loss studied – optimization applied
� In work:
� Large scale turbine rig results and CFD validation
�Flow and heat transfer in bleed air offtake systems
� Thanks to
�All MAGPI partners for contributions and support
�European Commission for financial support
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