Compressor Fouling Modeling: Relationship Between Computational Roughness and Gas Turbine Operation Time

2011 ◽  
Author(s):  
Francesco Melino ◽  
Mirko Morini ◽  
Antonio Peretto ◽  
Michele Pinelli ◽  
Pier Ruggero Spina
Keyword(s):  
Fluid Dynamics ◽  
Surface Roughness ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Axial Compressor ◽  
Operation Time ◽  
Compressor Stage ◽  
Performance Map ◽  
Computational Fluid Dynamics Cfd ◽  
Compressor Performance

Gas turbine axial compressor performance is heavily influenced by blade fouling; as a result, the gas turbines efficiency and producible power output decrease. Performance degradation of an axial compressor stage due to fouling can be analyzed by means of simulation through Computational Fluid Dynamics (CFD) codes. Usually these methods reproduce the deteriorated blades by increasing their surface roughness and/or thickness [1]. Another approach is the scaling of compressor stage performance maps. A model based on stage-by-stage techniques was presented in a previous work. This model is able to estimate the modifications of the overall compressor performance map as a function of the operating hours [2]. The aim of the present study is to combine these two different approaches in order to relate the increase of blade computational surface roughness with compressor operating hours.

Compressor Fouling Modeling: Relationship Between Computational Roughness and Gas Turbine Operation Time

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Francesco Melino ◽  
Mirko Morini ◽  
Antonio Peretto ◽  
Michele Pinelli ◽  
Pier Ruggero Spina
Keyword(s):  
Fluid Dynamics ◽  
Surface Roughness ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Axial Compressor ◽  
Operation Time ◽  
Compressor Stage ◽  
Performance Map ◽  
Computational Fluid Dynamics Cfd ◽  
Compressor Performance

Gas turbine axial compressor performance is heavily influenced by blade fouling. As a result, the gas turbines efficiency and producible power output decrease. Performance degradation of an axial compressor stage due to fouling can be analyzed by means of simulation through computational fluid dynamics (CFD) codes. Usually these methods reproduce the deteriorated blades by increasing their surface roughness and thickness. Another approach is the scaling of compressor stage performance maps. A model based on stage-by-stage techniques was presented in a previous work. This model is able to estimate the modifications of the overall compressor performance map as a function of the operating hours. The aim of the present study is to combine these two different approaches in order to relate the increase of blade computational surface roughness with compressor operating hours.

The Stacking of Compressor Stage Characteristics to Give an Overall Compressor Performance Map

1962 ◽  
Vol 13 (4) ◽  
pp. 349-367 ◽  
Author(s):  
M. D. C. Doyle ◽  
S. L. Dixon
Keyword(s):  
Axial Compressor ◽  
Compressor Stage ◽  
Individual Stage ◽  
Optimum Performance ◽  
Method Of Calculation ◽  
Multi Stage ◽  
Performance Map ◽  
Compressor Performance ◽  
Overall Performance ◽  
The Individual

SummaryA method of calculation is developed to compute the overall performance of a multi-stage axial compressor, from a knowledge of the individual stage characteristics, by a “stacking” technique. Compressor models are designed and their overall performance calculated. These results are compared to show, qualitatively, the effect of alterations in design and stage performance on overall performance and to find how compressors should be designed for optimum performance.

Numerical Analysis of the Effects of Non-Uniform Surface Roughness on Compressor Stage Performance

2010 ◽  
Author(s):  
Mirko Morini ◽  
Michele Pinelli ◽  
Pier Ruggero Spina ◽  
Mauro Venturini
Keyword(s):  
Surface Roughness ◽  
Gas Turbine ◽  
Traditional Approach ◽  
Fluid Dynamic ◽  
Turbine Blades ◽  
Compressor Stage ◽  
Turbine Performance ◽  
Performance Map ◽  
Overall Performance ◽  
Stage Performance

Gas turbine performance degradation over time is mainly due to the deterioration of compressor and turbine blades, which, in turn, causes a modification of the compressor and turbine performance maps. Since detailed information about the actual modification of the compressor and turbine performance maps is usually unavailable, component performance can be modeled and investigated (i) by scaling the overall performance map, or (ii) by using stage-by-stage models of the compressor and turbine and by scaling each single stage performance map to account for each stage deterioration, or (iii) by performing 3D numerical simulations, which allow to both highlight the fluid-dynamic phenomena occurring in the faulty component and grasp the effect on the overall performance of the component. In this paper, the authors address the most common and experienced source of loss for a gas turbine, i.e. compressor fouling. With respect to the traditional approach, which mainly aims at the identification of the overall effects of fouling, authors investigate a micro-scale representation of compressor fouling (e.g. blade surface deterioration and flow deviation). This allows (i) a more detailed investigation of the fouling effects (e.g. mechanism, location along blade height, etc.), (ii) a more extensive analysis of the causes of performance deterioration and (iii) the assessment of the effect of fouling on stage performance coefficients and on stage performance maps. The effects of a non-uniform surface roughness on both rotor and stator blades of an axial compressor stage are investigated by using a commercial CFD code. The NASA Stage 37 test case was used as the baseline geometry. The numerical model already validated against experimental data available in literature was used for the simulations. Different non-uniform combinations of surface roughness levels on rotor and stator blades were imposed. This makes it possible to highlight how the localization of fouling on compressor blades affects compressor performance, both at an overall and at a fluid-dynamic level.

Miniature gas turbines: Numerical study of the effects of heat transfer and Reynolds number on the performance of an axial compressor

2014 ◽  
Vol 03 (02) ◽  
pp. 1450008 ◽  
Author(s):  
Junting Xiang ◽  
Jörg Uwe Schlüter ◽  
Fei Duan
Keyword(s):  
Heat Transfer ◽  
Reynolds Number ◽  
Gas Turbines ◽  
Numerical Study ◽  
Axial Compressor ◽  
Thermal Conditions ◽  
Wall Heat Transfer ◽  
Viscous Effects ◽  
Computational Fluid Dynamics Cfd ◽  
Compressor Performance

In the present work, we focus on computational investigations of the Reynolds number effect and the wall heat transfer on the performance of axial compressor during its miniaturization. The NASA stage 35 compressor is selected as the configuration in this study and computational fluid dynamics (CFD) is used to carry out the miniaturization process and simulations. We perform parameter studies on the effect of Reynolds number and wall thermal conditions. Our results indicate a decrease of efficiency, if the compressor is miniaturized based on its original geometry due to the increase of viscous effects. The increased heat transfer through wall has only a small effect and will actually benefit compressor performance based on our study.

The Impact of Surface Roughness on Axial Compressor Performance Deterioration

2006 ◽  
Author(s):  
Elisabet Syverud ◽  
Lars E. Bakken
Keyword(s):  
Surface Roughness ◽  
Test Data ◽  
Gas Turbines ◽  
Axial Compressor ◽  
Flow Coefficient ◽  
Published Data ◽  
Flow Mechanisms ◽  
Performance Deterioration ◽  
Compressor Performance ◽  
The Impact

Axial compressor deterioration due to removable deposits is a major concern in the operation of gas turbines. It is important to fully understand the flow mechanisms in order to successfully monitor and clean the engine. A test program on the GE J85-13 jet engine quantified the increased surface roughness and the distribution of salt deposits in an axial compressor. The test data showed good agreement with published data for stage performance deterioration. This paper compares the GE J85-13 test data on surface roughness to previously published work on surface roughness in compressors. The effect of surface roughness on the stage characteristics is modeled using theory for frictional losses, blockage and deviation. The results are compared to test data. The most significant effect of increased roughness is found to be the variation in the flow coefficient.

Numerical Analysis of the Effects of Nonuniform Surface Roughness on Compressor Stage Performance

2011 ◽  
Vol 133 (7) ◽  
Author(s):  
Mirko Morini ◽  
Michele Pinelli ◽  
Pier Ruggero Spina ◽  
Mauro Venturini
Keyword(s):  
Surface Roughness ◽  
Gas Turbine ◽  
Fluid Dynamic ◽  
Turbine Blades ◽  
Compressor Stage ◽  
Nonuniform Surface ◽  
Turbine Performance ◽  
Performance Map ◽  
Overall Performance ◽  
Stage Performance

Gas turbine performance degradation over time is mainly due to the deterioration of compressor and turbine blades, which, in turn, causes a modification of the compressor and turbine performance maps. Since the detailed information about the actual modification of the compressor and turbine performance maps is usually unavailable, the component performance can be modeled and investigated by the following: scaling the overall performance map, using stage-by-stage models of the compressor and turbine, and scaling each single stage performance map to account for each stage deterioration, or performing 3D numerical simulations, which allow to both highlight the fluid-dynamic phenomena occurring in the faulty component and grasp the effect on the overall performance of each affected component. In this paper, the authors address the most common and experienced source of loss for a gas turbine, i.e., compressor fouling. With respect to the traditional approach, which mainly aims at the identification of the overall effects of fouling, authors investigate a microscale representation of compressor fouling (i.e., blade surface deterioration and flow deviation). This allows (i) a more detailed investigation of the fouling effects (e.g., mechanism, location along blade height, etc.), (ii) a more extensive analysis of the causes of performance deterioration, and (iii) the assessment of the effect of fouling on stage performance coefficients and on stage performance maps. In this paper, the effect of nonuniform surface roughness on both rotor and stator blades of an axial compressor stage is investigated by using a commercial CFD code. The NASA Stage 37 test case is considered as the baseline geometry and a numerical model already validated against experimental data available in literature is used for the simulations. Different nonuniform combinations of surface roughness levels are imposed on rotor and stator blades. This makes it possible to highlight how the localization of fouling on compressor blades affects compressor performance both at an overall and at a fluid-dynamic level.

Study on the Impact of Fouling on Axial Compressor Stage

2012 ◽  
Author(s):  
Shaowen Chen ◽  
Chen Zhang ◽  
Hui Shi ◽  
Songtao Wang ◽  
Zhongqi Wang
Keyword(s):  
Experimental Data ◽  
Surface Roughness ◽  
Mass Flow Rate ◽  
Mass Flow ◽  
Flow Rate ◽  
Axial Compressor ◽  
Compressor Stage ◽  
Term Operation ◽  
Compressor Performance ◽  
The Impact

Mechanistic research on the fouling of the compressor is necessary to delay the deterioration caused by fouling during long-term operation, and to explore methods that will lower compressor component deterioration, thereby improving the overall performance. The effects of fouling on the performance of an axial compressor stage were investigated numerically. As a representative of the realistic compressor stages, the NASA Stage 35 was considered to perform a numerical investigation by means of a commercial computational fluid dynamic code. The numerical model was validated by comparing with the experimental data available from literatures. The computed performance maps and exit parameter distributions showed a good agreement with experimental data. The model was then used to simulate the effect of fouling on compressor stage by various fouling configurations including added thickness and surface roughness levels. The mechanism of the compressor deterioration due to fouling was discussed in detail. As a result, despite the contribution of added thickness on the work capacity, it substantially narrowed the table operating ranges substantially, causing a greater effect on the overall compressor performance. The influence of roughness applied in the rotor is similar to that in the whole stage, including the drop in mass flow rate at choked and near stall point, pressure ratio, and efficiency, whereas, compressor performance slightly decreases in the stator. When the surface roughness is equal to 50 μm, the drop in mass flow rate under a low Reynolds number is less than that under normal conditions, with little influence on the stable operating range.

Development and Validation of a Model for Axial Compressor Fouling Simulation

2010 ◽  
Author(s):  
F. Melino ◽  
A. Peretto ◽  
P. R. Spina
Keyword(s):  
Gas Turbine ◽  
Power Output ◽  
Gas Turbines ◽  
Pressure Ratio ◽  
Axial Compressor ◽  
Computer Code ◽  
Performance Curves ◽  
Compressor Inlet ◽  
Compressor Performance ◽  
Development And Validation

Gas turbine axial compressor performance are heavily influenced by blade fouling; as a result, the gas turbines efficiency and producible power output decrease. In this study a model, able to evaluate the performance degradation of an axial compressor due to fouling, is developed and validated. The model is validated against experimental results available in literature and included into a computer code developed by the Authors (IN.FO.G.T.E) which is able to estimate the performance of every commercial gas turbine by using a stage stacking methods for the simulation of compressor behavior. The goal of this study is to show and discuss the change in gas turbine main performance (such as efficiency, power output, compressor inlet mass flow rate, pressure ratio) due to compressor fouling and also highlight and discuss the change in compressor stages performance curves.

Compressor Performance and Operability in Swirl Distortion

2010 ◽  
Author(s):  
Yogi Sheoran ◽  
Bruce Bouldin ◽  
P. Murali Krishnan
Keyword(s):  
Gas Turbine ◽  
Complex Geometry ◽  
Full Range ◽  
Axial Compressor ◽  
Cfd Model ◽  
Generator System ◽  
Sliding Mesh ◽  
Wide Range ◽  
Compressor Performance ◽  
The Impact

Inlet swirl distortion has become a major area of concern in the gas turbine engine community. Gas turbine engines are increasingly installed with more complicated and tortuous inlet systems, like those found on embedded installations on Unmanned Aerial Vehicles (UAVs). These inlet systems can produce complex swirl patterns in addition to total pressure distortion. The effect of swirl distortion on engine or compressor performance and operability must be evaluated. The gas turbine community is developing methodologies to measure and characterize swirl distortion. There is a strong need to develop a database containing the impact of a range of swirl distortion patterns on a compressor performance and operability. A recent paper presented by the authors described a versatile swirl distortion generator system that produced a wide range of swirl distortion patterns of a prescribed strength, including bulk swirl, twin swirl and offset swirl. The design of these swirl generators greatly improved the understanding of the formation of swirl. The next step of this process is to understand the effect of swirl on compressor performance. A previously published paper by the authors used parallel compressor analysis to map out different speed lines that resulted from different types of swirl distortion. For the study described in this paper, a computational fluid dynamics (CFD) model is used to couple upstream swirl generator geometry to a single stage of an axial compressor in order to generate a family of compressor speed lines. The complex geometry of the analyzed swirl generators requires that the full 360° compressor be included in the CFD model. A full compressor can be modeled several ways in a CFD analysis, including sliding mesh and frozen rotor techniques. For a single operating condition, a study was conducted using both of these techniques to determine the best method given the large size of the CFD model and the number of data points that needed to be run to generate speed lines. This study compared the CFD results for the undistorted compressor at 100% speed to comparable test data. Results of this study indicated that the frozen rotor approach provided just as accurate results as the sliding mesh but with a greatly reduced cycle time. Once the CFD approach was calibrated, the same techniques were used to determine compressor performance and operability when a full range of swirl distortion patterns were generated by upstream swirl generators. The compressor speed line shift due to co-rotating and counter-rotating bulk swirl resulted in a predictable performance and operability shift. Of particular importance is the compressor performance and operability resulting from an exposure to a set of paired swirl distortions. The CFD generated speed lines follow similar trends to those produced by parallel compressor analysis.

Development of the DLE Combustor for L30A Gas Turbine

2015 ◽  
Author(s):  
Toshiaki Sakurazawa ◽  
Takeo Oda ◽  
Satoshi Takami ◽  
Atsushi Okuto ◽  
Yasuhiro Kinoshita
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Nox Emission ◽  
Test Facility ◽  
Exhaust Temperature ◽  
Main Burner ◽  
Harmful Emissions ◽  
Emission Regulation ◽  
Computational Fluid Dynamics Cfd ◽  
Cfd Analyses

This paper describes the development of the Dry Low Emission (DLE) combustor for L30A gas turbine. Kawasaki Heavy Industries, LTD (KHI) has been producing relatively small-size gas turbines (25kW to 30MW class). L30A gas turbine, which has a rated output of 30MW, achieved the thermal efficiency of more than 40%. Most continuous operation models use DLE combustion systems to reduce the harmful emissions and to meet the emission regulation or self-imposed restrictions. KHI’s DLE combustors consist of three burners, a diffusion pilot burner, a lean premix main burner, and supplemental burners. KHI’s proven DLE technologies are also adapted to the L30A combustor design. The development of L30 combustor is divided in four main steps. In the first step, Computational Fluid Dynamics (CFD) analyses were carried out to optimize the detail configuration of the combustor. In a second step, an experimental evaluation using single-can-combustor was conducted in-house intermediate-pressure test facility to evaluate the performances such as ignition, emissions, liner wall temperature, exhaust temperature distribution, and satisfactory results were obtained. In the third step, actual pressure and temperature rig tests were carried out at the Institute for Power Plant Technology, Steam and Gas Turbines (IKDG) of Aachen University, achieving NOx emission value of less than 15ppm (O2=15%). Finally, the L30A commercial validation engine was tested in an in-house test facility, NOx emission is achieved less than 15ppm (O2=15%) between 50% and 100% load operation point. L30A field validation engine have been operated from September 2012 at a chemical industries in Japan.

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