An experimental, Aerodynamic Evaluation of Design Choices for a Low-Pressure Compressor Transition Duct

2021 ◽  
pp. 1-42
Author(s):  
A Duncan Walker ◽  
Ian Mariah ◽  
Chris Hall
Keyword(s):  
Guide Vane ◽  
Integrated Design ◽  
Axial Compressor ◽  
Low Pressure ◽  
Flow Coefficient ◽  
Low Flow ◽  
Test Facility ◽  
Minimum Length ◽  
Complex Flow ◽  
Fully Integrated

Abstract The S-shaped duct which transfers flow from the low-pressure fan to the engine core in large civil turbofans presents a challenging problem. Aerodynamically it has a spatially and temporarily varying inlet flow combined with a complex flow field which develops under the combined influence of pressure gradients and streamline curvature. It must also accommodate the transfer of structural loads and services across the main gas path. This necessitates the use of structural vanes which can compromise aerodynamics, introduce unwanted component interactions, and erode performance. This must all be achieved with minimum length/weight and without flow separation. This paper presents a comprehensive aerodynamic evaluation of three design options for a transition duct containing (i) a long-chord, structural compressor outlet guide vane, (ii) a aerodynamically optimal but non-structural outlet guide vane in conjunction with a small number of load bearing struts and (iii) a fully integrated outlet guide vane and strut design. Evaluation was performed using a low-speed test facility incorporating a 1½ stage axial compressor and engine representative transition duct. Measured data suggest that all the options were viable. However, the aerodynamic vane and discrete struts produced the lowest system loss with the other two options being comparable. The performance of the structural vane was sensitive to off-design conditions producing a notable increase in loss at a low flow coefficient. The optimized aerodynamic vanes were much less sensitive to off-design conditions whilst the fully integrated design showed only very small changes in loss.

An Experimental, Aerodynamic Evaluation of Design Choices for a Low-Pressure Compressor Transition Duct

2020 ◽  
Author(s):  
A. Duncan Walker ◽  
Ian Mariah ◽  
Chris Hall
Keyword(s):  
Guide Vane ◽  
Integrated Design ◽  
Low Pressure ◽  
Flow Coefficient ◽  
Low Flow ◽  
Test Facility ◽  
Minimum Length ◽  
Complex Flow ◽  
Fully Integrated ◽  
Pressure Compressor

Abstract The S-shaped duct which transfers flow from the low-pressure fan to the engine core of modern large civil turbofans presents a challenging design problem. Aerodynamically it must accommodate a spatially and temporarily non-uniform inlet in conjunction with a complex flow field which will develop under the combined influence of pressure gradients and streamline curvature. It must also allow for the transfer of structural loads and services across the main gas path. This necessitates the use of structural vanes which can compromise aerodynamics, introduce unwanted component interactions and erode performance. Furthermore, this must all be achieved with minimum length/weight and without flow separation. This paper presents a comprehensive aerodynamic evaluation of three options for a low-pressure compressor transition duct containing (i) a long-chord, structural compressor outlet guide vane, (ii) a more aerodynamically optimal but non-structural outlet guide vane in conjunction with a small number of discrete radial load bearing struts and (iii) a fully integrated outlet guide vane and strut design. Evaluation was performed using a fully annular, low-speed test facility incorporating a 1 ½ stage axial compressor and transition duct representative of an engine design. Aerodynamic data were produced from miniature five-hole probe area traverses conducted at several locations with compressor/duct. The data suggest that all the options were viable. However, the aerodynamic vane and discrete struts produced the lowest system loss with the other two options being comparable. The performance of the structural vane was seen to be sensitive to off-design conditions producing a notably increased loss at a low flow coefficient. The more optimized aerodynamic vanes were much less sensitive to off-design conditions whilst the fully integrated design showed only very small changes in loss.

Integrated Outlet Guide Vane Design for an Aggressive S-Shaped Compressor Transition Duct

2012 ◽  
Vol 135 (1) ◽  
Author(s):  
A. D. Walker ◽  
A. G. Barker ◽  
J. F. Carrotte ◽  
J. J. Bolger ◽  
M. J. Green
Keyword(s):  
Gas Turbines ◽  
Static Pressure ◽  
Pressure Field ◽  
Guide Vane ◽  
Integrated Design ◽  
Axial Compressor ◽  
Test Facility ◽  
Speed Test ◽  
Duct Geometry ◽  
System Length

Within gas turbines the ability to design shorter aggressive S-shaped ducts is advantageous from a performance and weight saving perspective. However, current design philosophies tend to treat the S-shaped duct as an isolated component, neglecting the potential advantages of integrating the design with the upstream or downstream components. In this paper, such a design concept is numerically developed in which the upstream compressor outlet guide vanes are incorporated into the first bend of the S-shaped duct. Positioning the vane row within the first bend imparts a strong radial gradient to the pressure field within the vane passage. Tangential lean and axial sweep are employed such that the vane geometry is modified to exactly match the resulting inclined static pressure field. The integrated design is experimentally assessed and compared to a conventional nonintegrated design on a fully annular low speed test facility incorporating a single stage axial compressor. Several traverse planes are used to gather five-hole probe data which allow the flow structure to be examined through the rotor, outlet guide vane and within the transition ducts. The two designs employ almost identical duct geometry, but integration of the vane row reduces the system length by 21%. Due to successful matching of the static pressure field, the upstream influence of the integrated vane row is minimal and the rotor performance is unchanged. Similarly, the flow development within both S-shaped ducts is similar such that the circumferentially averaged profiles at duct exit are almost identical, and the operation of a downstream component would be unaffected. Overall system loss remains nominally unchanged despite the inclusion of lean and sweep and a reduction in system length. Finally, the numerical design predictions show good agreement with the experimental data thereby successfully validating the design process.

Integrated OGV Design for an Aggressive S-Shaped Compressor Transition Duct

2011 ◽  
Author(s):  
A. D. Walker ◽  
A. G. Barker ◽  
J. F. Carrotte ◽  
J. J. Bolger ◽  
M. J. Green
Keyword(s):  
Gas Turbines ◽  
Static Pressure ◽  
Pressure Field ◽  
Guide Vane ◽  
Integrated Design ◽  
Axial Compressor ◽  
Test Facility ◽  
Speed Test ◽  
Duct Geometry ◽  
System Length

Within gas turbines the ability to design shorter aggressive S-shaped ducts is advantageous from a performance and weight saving perspective. However, current design philosophies tend to treat the S-shaped duct as an isolated component, neglecting the potential advantages of integrating the design with the upstream or downstream components. In this paper such a design concept is numerically developed in which the upstream compressor outlet guide vanes are incorporated into the first bend of the S-shaped duct. Positioning the vane row within the first bend imparts a strong radial gradient to the pressure field within the vane passage. Tangential lean and axial sweep are employed such that the vane geometry is modified to exactly match the resulting inclined static pressure field. The integrated design is experimentally assessed and compared to a conventional non-integrated design on a fully annular low speed test facility incorporating a single stage axial compressor. Several traverse planes are used to gather five-hole probe data which allow the flow structure to be examined through the rotor, outlet guide vane and within the transition ducts. The two designs employ almost identical duct geometry, but integration of the vane row reduces the system length by 21%. Due to successful matching of the static pressure field, the upstream influence of the integrated vane row is minimal and the rotor performance is unchanged. Similarly the flow development within both S-shaped ducts is similar such that the circumferentially averaged profiles at duct exit are almost identical, and the operation of a downstream component would be unaffected. Overall system loss remains nominally unchanged despite the inclusion of lean and sweep and a reduction in system length. Finally, the numerical design predictions show good agreement with the experimental data thereby successfully validating the design process.

The Influence of Fan Root Flow on the Aerodynamics of a Low-Pressure Compressor Transition Duct

2019 ◽  
Author(s):  
A. D. Walker ◽  
I. Mariah ◽  
D. Tsakmakidou ◽  
H. Vadhvana ◽  
C. Hall
Keyword(s):  
Gas Turbines ◽  
Pressure Ratio ◽  
Axial Compressor ◽  
Pressure Profile ◽  
Low Pressure ◽  
Secondary Flows ◽  
Test Facility ◽  
Inlet Flow ◽  
Flat Profile ◽  
Bypass Ratio

Abstract To reduce fuel-burn and CO2 emissions from aero gas turbines there is a drive towards very-high bypass ratio and smaller ultra-high-pressure ratio core engine technologies. However, this makes the design of the ducts connecting various compressor spools more challenging as the higher required radius change increases their aerodynamic loading. This is exacerbated for the duct which feeds the engine core as it must accept the relatively low-quality flow produced by the fan root. This is characterised by a hub-low pressure profile and large secondary flow structures which will inevitably increase loss and the likelihood of flow separation. Additionally, the desire for shorter, lighter nacelles means that the engine intake may be unable provide a uniform inlet flow to the fan when the aircraft is at an angle of attack or subject to cross winds. Any inlet distortion this generates can also further degrade the quality of the flow entering the core of the engine. This paper uses a combination of experiments and CFD to examine the effects of the inlet flow on the aerodynamics of an engine section splitter and transition duct designed to feed the low-pressure spool of a high bypass ratio turbofan. A fully annular test facility incorporating a 1½ stage axial compressor was used to compare the system performance of a rotor that produced a nominally flat profile with one that had a notably hub deficient flow. A RANS CFD model, employing a mixing plane between the rotor and Engine Section Stator (ESS) and a Reynolds Stress turbulence model, was then validated and used to further investigate the effects of increased inlet boundary layer thickness and bulk swirl distortion at rotor inlet. Overall, changes to the inlet condition were seen to have a surprisingly small effect on the flow at duct exit — i.e. the flow presented to the downstream compressor. Changes to the inlet did, however, generate increased secondary flows and degrade the performance of the ESS. This resulted in notably increased total pressure loss; in excess of 12% for the hub-low inlet and in excess of 30% at high inlet swirl where the flow in the ESS separated. However, the increased ESS wake structures, and the enhanced mixing, delayed separation in the duct suggesting that, overall the design was reasonably robust, albeit with a significant penalty in system loss.

Numerical Validations of Secondary Flows and Loss Development Downstream of a Highly Loaded Low Pressure Turbine Outlet Guide Vane Cascade

2007 ◽  
Author(s):  
Johan Hja¨rne ◽  
Valery Chernoray ◽  
Jonas Larsson ◽  
Lennart Lo¨fdahl
Keyword(s):  
Numerical Simulations ◽  
Secondary Flow ◽  
Incompressible Flows ◽  
Guide Vane ◽  
Low Pressure ◽  
Flow Fields ◽  
Secondary Flows ◽  
Test Facility ◽  
Low Pressure Turbine ◽  
Highly Loaded

In this paper 3D numerical simulations of turbulent incompressible flows are validated against experimental data from the linear low pressure turbine/outlet guide vane (LPT/OGV) cascade at Chalmers in Sweden. The validation focuses on the secondary flow-fields and loss developments downstream of a highly loaded OGV. The numerical simulations are performed for the same inlet conditions as in the test-facility with engine-like properties in terms of Reynolds number, boundary-layer thickness and inlet flow angles with the goal to validate how accurately and reliably the secondary flow fields and losses for both on- and off-design conditions can be predicted for OGV’s. Results from three different turbulence models as implemented in FLUENT, k-ε Realizable, kω-SST and the RSM are validated against detailed measurements. From these results it can be concluded that the RSM model predicts both the secondary flow field and the losses most accurately.

Effect of Stator Variability on Axial Compressor Performance

2019 ◽  
Author(s):  
Kirubakaran Purushothaman ◽  
N. R. Naveen Kumar ◽  
Vidyadheesh Pandurangi ◽  
Ajay Pratap
Keyword(s):  
Guide Vane ◽  
Flow Analysis ◽  
Axial Compressor ◽  
Axial Flow ◽  
Low Pressure ◽  
Inlet Guide Vane ◽  
Jet Engines ◽  
Stator Blade ◽  
And Performance ◽  
Flow Compressor

Abstract Variability in stator vanes is a widely used technique to improve the stability and efficiency of axial flow compressor in gas turbine engines. Most of the modern aircraft jet engines use variable stator vanes in both low pressure and high pressure compressors primarily for off-design performance. This study discusses in detail about the effect of stator variability in a three stage low pressure axial compressor at design and off-design conditions. Computational flow analysis were carried out for the three stage low pressure compressor with variability in inlet guide vane and first stage stator blade. Detailed investigation on flow physics was carried out in rotor blade passages with stator variability. At off-design speeds, the reduction in flow velocity is lower than the reduction in blade tip speed. This leads to mismatch in flow angles and inlet blade angles causing high incidence and large flow separation in blade passage. This results in poor aerodynamic stability of the axial compressor at off-design speeds. In this study, aerodynamic performance of compressor is evaluated from 70% to 100% design speeds with different stagger angle setting of inlet guide vane at each speed. Further, to improve 2nd stage rotor performance, variability was introduced in 1st stage stator blade and performance was evaluated. Compressor test results are compared with CFD data for design and off-design speeds.

The Characteristics of Rotating Instabilities in Low Pressure Steam Turbines at Low Volume Flow Operation

2015 ◽  
Author(s):  
Roland Sigg ◽  
Timothy Rice
Keyword(s):  
Renewable Energy Sources ◽  
Low Pressure ◽  
Rotating Stall ◽  
Operating Conditions ◽  
Flow Coefficient ◽  
Low Flow ◽  
Small Scale ◽  
Steam Turbines ◽  
Original Design ◽  
Low Load

For flexible operation steam turbines may operate occasionally at low load. Operation away from the original design regime looks set to be an increasing trend mainly due to the presence of intermittently available renewable energy sources in the grid. This paper sets out an approach for considering low flow effects on turbine designs. At low load operating conditions rotating instabilities (RIS) can occur in the rear stages of LP steam turbines. The instabilities are comparable in many ways to rotating stall in compressors. Ideally the turbine blade natural frequencies should be designed to avoid the frequencies generated by the RIS system. The characteristics of RIS systems were experimentally investigated to understand the dependency with both flow coefficient and exhaust configuration. Correlations have been developed to characterize the dynamic pressure amplitudes and the fractional speed of the RIS moving around the wheel. The presented correlation based method is shown calibrated for a specific blade design. Two different test rigs provide the basis for the work presented. A low pressure model steam turbine provided detailed information for key blade/exhaust combinations. A simplified small scale air turbine was used to provide additional input for the behavior with alternative exhaust back wall position. Observations of the characteristic RIS behavior from model turbine tests are set in context with observed changes in the flow field.

Preliminary Investigation Into the Effects of a Compressor Rim Purge Flow on OGV/Pre-Diffuser and Combustion System Aerodynamics

2017 ◽  
Author(s):  
A. D. Walker ◽  
B. Koli ◽  
P. A. Beecroft
Keyword(s):  
Guide Vane ◽  
Preliminary Investigation ◽  
Axial Compressor ◽  
Test Facility ◽  
Combustion System ◽  
Guide Vanes ◽  
Mainstream Flow ◽  
Purge Flow ◽  
Inlet Conditions ◽  
The Impact

As aero gas turbine designs strive for ever greater efficiencies the trend is for engine overall pressure ratios to rise. Although this provides greater thermal efficiency it means that cycle temperatures also increase. Traditionally turbines have been the focus of cooling schemes to enable them to survive high temperatures. However, it is envisaged that the compressor delivery air will soon reach temperatures which mean they may require similar cooling strategies to the turbine. One such concept is akin to that of a turbine “rim purge flow” which ensures that hot, mainstream flow does not get ingested into rotor cavities. However, the main gas path in compressors is generally more aerodynamically sensitive than in turbines and introduction of a purge flow may be more penalizing. It is important to understand the impact such a flow may have on the primary gas path flow of a compressor and the downstream combustion system aerodynamics. This paper presents a preliminary investigation into the effects of a purge flow which enters the main gas path immediately upstream of the high pressure compressor outlet guide vane (OGV) row. Initial, simplified, CFD predictions clearly demonstrated the potential of the purge flow to negatively affect the OGV/pre-diffuser and alter the inlet conditions to the combustion system. Consequently, an experimental assessment was carried out using an existing fully annular, isothermal test facility which incorporated a bespoke 1.5 stage axial compressor, engine relevant outlet guide vanes, pre-diffuser and downstream combustor geometry. Using CFD to guide the process the test rig was modified to allow a metered airflow to be introduced upstream of the outlet guide vanes. Importantly the flow was directed up the face of the rotor such that it picked up a representative swirl component prior to injection into the main gas path. The experimental data confirmed the CFD results and importantly demonstrated that the degradation in the combustor inlet flow resulted in an increased combustion system loss. At the proposed purge flow rate, equal to ∼1% of the mainstream flow, these effects were small with the system loss increasing by ∼4%. However, at higher purge flow rates (up to 3%) these effects became notable and the OGV/pre-diffuser flow degraded significantly with a resultant increase in the combustion system loss of ∼13%.

Influence of Inflow Turbulence and Distortion on a Two-Stage Low Pressure Axial Turbine at Low Reynolds Numbers

2016 ◽  
Author(s):  
Christian H. Schulze ◽  
Jan Habermann ◽  
Stephan Staudacher ◽  
Martin G. Rose ◽  
Udo Freygang
Keyword(s):  
Guide Vane ◽  
Suction Side ◽  
Low Pressure ◽  
Test Facility ◽  
Homogeneous Distribution ◽  
Two Stage ◽  
Nozzle Guide Vane ◽  
Inflow Turbulence ◽  
Aero Engines ◽  
Nozzle Guide

A two-stage low pressure turbine, developed by MTU Aero Engines AG (MTU), has been tested in the altitude test facility of the Institute for Aircraft Propulsion Systems (ILA) at Stuttgart University. The focus was on the change in the turbines behaviour to a rise in inflow turbulence levels and inflow distortion at flight conditions. Hence, the turbine flow with a clean inlet was compared to two cases with a built in turbulence grid prior to the first vane at a Reynolds number of 75,000. Data was collected in the inflow and inside the turbine using radial and area probe traverses. The observed rise in inflow turbulence level and the inflow distortion impacted the first turbine nozzle guide vane. Static pressure tappings and thin film gauges show changes in separation as well as transition location on the vane’s suction side. Five hole probe and 3D hot film probe measurements show distinct changes in secondary flow patterns as well as nozzle guide vane wakes. The changes lead to a higher blade row efficiency and a more homogeneous distribution of turbulence intensity at stator exit.

scholarly journals The Influence of Fan Root Flow on the Aerodynamic of a Low-Pressure Compressor Transition Duct

2019 ◽  
Vol 142 (1) ◽  
Author(s):  
A. Duncan Walker ◽  
Ian Mariah ◽  
Dimitra Tsakmakidou ◽  
Hiren Vadhvana ◽  
Chris Hall
Keyword(s):  
Pressure Ratio ◽  
Axial Compressor ◽  
Pressure Profile ◽  
Low Pressure ◽  
Secondary Flows ◽  
Test Facility ◽  
Navier Stokes ◽  
High Pressure Ratio ◽  
Fuel Burn ◽  
Bypass Ratio

Abstract To reduce fuel-burn and emissions, there is a drive toward higher bypass ratio and smaller high-pressure ratio core engines. This makes the design of the ducts connecting compressor spools more challenging as the higher radius change increases aerodynamic loading. This is exacerbated at inlet to the engine core by fan root flow which is characterized by a hub-low-pressure profile and large secondary flow structures. Additionally, shorter, lighter nacelles mean that the intake may not provide a uniform inlet flow when the aircraft is at an angle of attack or subject to cross winds. Such inlet distortion can further degrade the flow entering the engine. A combination of experiments and computational fluid dynamics (CFD) has been used to examine the effects on the aerodynamics of an engine section splitter (ESS) and transition duct designed to feed the low-pressure spool of a high bypass ratio turbofan. A test facility incorporating a 1½ stage axial compressor was used to compare system performance for a flat rotor exit profile to one with a hub deficient flow. Validated Reynolds averaged Navier–Stokes (RANS) CFD was then used to further investigate the effects of increased inlet boundary layer thickness and bulk swirl distortion at rotor inlet. These changes were seen to have a surprisingly small effect on the flow at the duct exit. However, increased secondary flows were observed which degraded the performance of the ESS and significantly increased loss. Nevertheless, the enhanced mixing delayed separation in the duct suggesting that overall the design was reasonably robust albeit with increased system loss.

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