Daniel Coren

Experimental Investigation of Turbine Stator Well Rim Seal, Re-Ingestion and Interstage Seal Flows Using Gas Concentration Techniques and Displacement Measurements

Gas turbine engine performance requires effective and reliable internal cooling over the duty cycle of the engine. Life predictions for rotating components subject to the main gas path temperatures are vital. This demands increased precision in the specification of the internal air system flows which provide turbine stator well cooling and sealing. This in turn requires detailed knowledge of the flow rates through rim seals and interstage labyrinth seals. Knowledge of seal movement and clearances at operating temperatures is of great importance when prescribing these flows. A test facility has been developed at the University of Sussex, incorporating a two stage turbine rated at 400 kW with an individual stage pressure ratio of 1.7:1. The mechanical design of the test facility allows internal cooling geometry to be rapidly re-configured, while cooling flow rates of between 0.71 CW, ENT and 1.46 CW, ENT, may be set to allow ingress or egress dominated cavity flows. The main annulus and cavity conditions correspond to in cavity rotational Reynolds numbers of 1.71 × 106 < Reϕ <1.93 × 106. Displacement sensors have been used to establish hot running seal clearances over a range of stator well flow conditions, allowing realistic flow rates to be calculated. Additionally, gas seeding techniques have been developed, where stator well and main annulus flow interactions are evaluated by measuring changes in gas concentration. Experiments have been performed which allow rim seal and re-ingestion flows to be quantified. It will be shown that this work develops the measurement of stator well cooling flows and provides data suitable for the validation of improved thermo-mechanical and CFD codes, beneficial to the engine design process.

Windage sources in smooth-walled rotating disc systems:

Abstract This article presents experimental data and an associated correlation for the windage resulting from a disc rotating in air, characteristic of gas turbine engines and relevant to some electrical machine applications. A test rig has been developed that uses an electric motor to drive a smooth bladeless rotor inside an enclosed pressurized housing. The rig has the capability of reaching rotational and throughflow Reynolds numbers representative of a modern gas turbine. A moment coefficient has been used to allow a non-dimensional windage torque parameter to be calculated and an agreement with the relevant data in the literature has been found within 10 per cent. Infrared measurements have been performed that allow direct surface temperatures of the rotating disc to be obtained. Laser Doppler anemometry measurements have been made that allow velocities in the flow field of the rotor—stator cavity to be examined and tangential velocities corresponding to rotationally and radially dominated flow conditions are shown. The importance of the flow regime in relation to the resulting windage has been identified and in particular it is noted that windage is a function not only of the ratio of rotational and radial flow dominance as defined by the turbulence parameter, but also for a given value of the turbulence parameter, the magnitude of the rotationally induced and superimposed flows. The experiments extend the range of data available for windage in rotor—stator systems and have been used to produce a correlation suitable for applications operating up to the range of Reψ=107.

Main Annulus Gas Path Interactions—Turbine Stator Well Heat Transfer

This paper summarises the work of a 5-year research programme into the heat transfer within cavities adjacent to the main annulus of a gas turbine. The work has been a collaboration between several gas turbine manufacturers, also involving a number of universities working together. The principal objective of the study has been to develop and validate computer modelling methods of the cooling flow distribution and heat transfer management, in the environs of multi-stage turbine disc rims and blade fixings, with a view to maintaining component and sub-system integrity, whilst achieving optimum engine performance and minimising emissions. A fully coupled analysis capability has been developed using combinations of commercially available and in-house computational fluid dynamics (CFD) and finite element (FE) thermo-mechanical modelling codes. The main objective of the methodology is to help decide on optimum cooling configurations for disc temperature, stress and life considerations. The new capability also gives us an effective means of validating the method by direct use of disc temperature measurements, where otherwise, additional and difficult to obtain parameters, such as reliable heat flux measurements, would be considered necessary for validation of the use of CFD for convective heat transfer. A two-stage turbine test rig has been developed and improved to provide good quality thermal boundary condition data with which to validate the analysis methods. A cooling flow optimisation study has also been performed to support a re-design of the turbine stator well cavity, to maximise the effectiveness of cooling air supplied to the disc rim region. The benefits of this design change have also been demonstrated on the rig. A brief description of the test rig facility will be provided together with some insights into the successful completion of the test programme. Comparisons will be provided of disc rim cooling performance, for a range of cooling flows and geometry configurations. The new elements of this work are the presentation of additional test data and validation of the automatically coupled analysis method applied to a partially cooled stator well cavity, (i.e. including some local gas ingestion); also the extension of the cavity cooling design optimisation study to other new geometries

Heat Transfer in Turbine Hub Cavities Adjacent to the Main Gas Path

Reliablemeans of predicting heat transfer in cavities adjacent to themain gas path are increasingly being sought by engineers involvedin the design of gas turbines. In this paper anup-dated analysis of the interim results from an extended researchprogramme, MAGPI, sponsored by the EU and several leading gasturbine manufactures and universities, will be presented. Extensive use ismade of CFD and FE modelling techniques to understand thethermo-mechanical behaviour and convective heat transfer of a turbine statorwell cavity, including the interaction of cooling air supply withthe main annulus gas. It is also important to establishthe hot running seal clearances for a full understanding ofthe cooling flow distribution and heat transfer in the cavity.The objective of the study has been to provide ameans of optimising the design of such cavities (see Figure1) for maintaining a safe environment for critical parts, suchas disc rims and blade fixings, whilst maximising the turbineefficiency by means of reducing the fuel burn and emissionspenalties associated with the secondary airflow system. The modelling methodsemployed have been validated against data gathered from a dedicatedtwo-stage turbine rig, running at engine representative conditions. Extensive measurementsare available for a range of flow conditions and alternativecooling arrangements. The analysis method has been used to informa design change which will be tested in a secondtest phase. Data from this test will also be usedto further benchmark the analysis method. Comparisons are provided betweenthe predictions and measurements from the original configuration, turbine statorwell component temperature survey, including the use of a coupledanalysis technique between FE and CFD solutions

Conjugate Heat Transfer CFD Analysis in Turbine Disc Cavities

The effect of cooling flow and its interaction with the gas path upon the flow and heat transfer within turbine disc cavities has been investigated within the five-year European Union funded research project MAGPI. This paper describes a part of the conjugate CFD analyses and validation work performed by Siemens within this research project. Validation is based upon measurement data from a dedicated two-stage axial turbine rig at the University of Sussex. A conjugate CFD model of the turbine was produced including the gas path and all disc cavities using the commercial CFD solver ANSYS CFX 12.1. The SST k-ω turbulence model has been used for much of the work. Comparisons are made to the k-e model and the more complex Reynolds Stress models. Transient and steady-state solutions are also compared and the predictions are compared to the data from the test rig. Good agreement between predicted and measured air temperatures and pressures in the turbine cavities and stator well are found for the most part, even on quite coarse meshes. Metal temperatures compare well in many places with a prediction of the absolute temperature to within a small error. There are however some regions on the first stage rotor where a reasonable difference between predicted and measured metal temperatures is consistently observed regardless of turbulence model, simulation type (steady-state or transient), and mesh density.Copyright

Heat Transfer in Turbine Hub Cavities Adjacent to the Main Gas Path Including FE-CFD Coupled Thermal Analysis

Reliable means of predicting heat transfer in cavities adjacent to the main gas path are increasingly being sought by engineers involved in the design of gas turbines. In this paper an up-dated analysis of the interim results from an extended research programme, MAGPI, sponsored by the EU and several leading gas turbine manufactures and universities, will be presented. Extensive use is made of CFD and FE modelling techniques to understand the thermo-mechanical behaviour and convective heat transfer of a turbine stator well cavity, including the interaction of cooling air supply with the main annulus gas. It is also important to establish the hot running seal clearances for a full understanding of the cooling flow distribution and heat transfer in the cavity. The objective of the study has been to provide a means of optimising the design of such cavities (see Figure 1) for maintaining a safe environment for critical parts, such as disc rims and blade fixings, whilst maximising the turbine efficiency by means of reducing the fuel burn and emissions penalties associated with the secondary airflow system. The modelling methods employed have been validated against data gathered from a dedicated two-stage turbine rig, running at engine representative conditions. Extensive measurements are available for a range of flow conditions and alternative cooling arrangements. The analysis method has been used to inform a design change which will be tested in a second test phase. Data from this test will also be used to further benchmark the analysis method. Comparisons are provided between the predictions and measurements from the original configuration, turbine stator well component temperature survey, including the use of a coupled analysis technique between FE and CFD solutions.Copyright

The Influence of Turbine Stator Well Coolant Flow Rate and Passage Configuration on Cooling Effectiveness

Market competitiveness for aero engine power plant dictates that improvements in engine performance and reliability are guaranteed a priori by manufacturers. The requirement to accurately predict the life of engine components makes exacting demands of the internal air system, which must provide effective cooling over the engine duty cycle with the minimum consumption of compressor section air. Tests have been conducted at the University of Sussex using a turbine test facility which comprises a two stage turbine with an individual stage pressure ratio of 1.7:1. Main annulus air is supplied by an adapted Rolls-Royce Dart compressor at up to 440 K and 4.8 kg s−1 . Cooling flow rates ranging from 0.71 to 1.46 Cw, ent , a disc entrainment parameter, have been used to allow ingress or egress dominated stator well flow conditions. The mechanical design of the test section allows internal cooling geometry to be rapidly re-configured, allowing the effect of jet momentum and coolant trajectory to be investigated. An important facet to this investigation is the use of CFD to model and analyse the flow structures associated with the cavity conditions tested, as well as to inform the design of cooling path geometry. This paper reports on the effectiveness of stator well coolant flow rate and delivery configurations using experimental data and also CFD analysis to better quantify the effect of stator well flow distribution on component temperatures.Copyright

Windage measurements in a rotor stator cavity with rotor mounted protrusions and bolts

This paper reports an experimental investigation of the windage associated with enclosed rotor-stator systems with superposed throughflow, as commonly found in gas turbine engines. The term windage is often used to describe the viscous heating that arises from the interaction of surfaces and fluids in rotating disc systems. Since the presence of circumferentially discreet geometric features strongly alters the magnitude of Windage measured, the physical mechanisms collectively referred to as windage in this paper are separately described as part of the discussion of results. Tests have been carried out to measure windage directly in the form of shaft torque and also rotor surface temperature. Non-dimensional flow parameters are used to expand the relevance of the data obtained, which encompasses the ranges 0.17 x 107 ≤ Reφ ≤ 1.68 x 107and 0.24 x 105 ≤ Cw ≤ 1.06 x 105 which corresponds to 0.058 ≤ λT ≤ 0.631. Data has been obtained for smooth disc geometry and also with rotor mounted protrusions of N = 3, 9 and 18; D = 10 mm, 13 mm and 16 mm diameter; H = 11 mm, high, hexagonal bolt shaped protrusions. Bi-hexagonal (twelve sided) bolts of D = 13 mm effective diameter, and height, H = 11mm, were also tested with conditions closely matched to the 13 mm hexagonal bolts. Finally, tests with 10 mm diameter, 6 mm deep, pockets were also carried out. Over the range of conditions and geometries tested, increasing the number of bolts increases the moment coefficient and windage heating. At low values of turbulent flow parameter, λT, which correspond to rotational speeds between 8000 and 10000 rev/min, increasing the diameter of the bolts shows a clear trend for both increased windage torque and average disc temperature rise. For these conditions, there also appears to be a clear reduction in windage and temperature rise with the bi-hexagonal shaped bolts compared to the equivalent diameter hexagonal bolt form. Variation in the moment coefficient with the number and diameter of bolts is attributed to variations in form drag between the different configurations. The introduction of the recesses onto the disc has very little effect on either windage heating or moment coefficient; this is attributed to the component of windage mechanism in operation and also the relatively small size in comparison to the protrusions studied here. This work contributes to the understanding of windage in gas turbines by introducing new low uncertainty data obtained at engine representative conditions and as such is of benefit to those involved with the design of internal air systems and disc fixtures

An Investigation Into Numerical Analysis Alternatives for Predicting Re-Ingestion in Turbine Disc Rim Cavities

Reliable means of predicting ingestion in cavities adjacent to the main gas path are increasingly being sought by engineers involved in the design of gas turbines. In this paper, analysis is to be presented that results from an extended research programme, MAGPI, sponsored by the EU and several leading gas turbine manufactures and universities. Extensive use is made of CFD modelling techniques to understand the aerodynamic behaviour of a turbine stator well cavity, focusing on the interaction of cooling air supply with the main annulus gas. The objective of the study has been to benchmark a number of CFD codes and numerical techniques covering RANS and URANS calculations with different turbulence models in order to assess the suitability of the standard settings used in the industry for calculating the mechanics of the flow travelling between cavities in a turbine through the main gas path.The modelling methods employed have been compared making use of experimental data gathered from a dedicated two-stage turbine rig, running at engine representative conditions. Extensive measurements are available for a range of flow conditions and alternative cooling arrangements. The limitations of the numerical methods in calculating the interaction of the cooling flow egress and the main stream gas, and subsequent ingestion into downstream cavities in the engine (i.e. re-ingestion), have been exposed. This has been done without losing sight of the validation of the CFD for its use for predicting heat transfer, which was the main objective of the partners of the MAGPI Work-Package 1 consortium.Copyright

Main Annulus Gas Path Interactions: Turbine Stator Well Heat Transfer

This paper summarises the work of a 5-year research programme into the heat transfer within cavities adjacent to the main annulus of a gas turbine. The work has been a collaboration between several gas turbine manufacturers, also involving a number of universities working together. The principal objective of the study has been to develop and validate computer modelling methods of the cooling flow distribution and heat transfer management, in the environs of multi-stage turbine disc rims and blade fixings, with a view to maintaining component and sub-system integrity, whilst achieving optimum engine performance and minimising emissions.A fully coupled analysis capability has been developed using combinations of commercially available and in-house computational fluid dynamics (CFD) and finite element (FE) thermo-mechanical modelling codes. The main objective of the methodology is to help decide on optimum cooling configurations for disc temperature, stress and life considerations. The new capability also gives us an effective means of validating the method by direct use of disc temperature measurements, where otherwise, additional and difficult to obtain parameters, such as reliable heat flux measurements, would be considered necessary for validation of the use of CFD for convective heat transfer.A two-stage turbine test rig has been developed and improved to provide good quality thermal boundary condition data with which to validate the analysis methods. A cooling flow optimisation study has also been performed to support a re-design of the turbine stator well cavity, to maximise the effectiveness of cooling air supplied to the disc rim region. The benefits of this design change have also been demonstrated on the rig. A brief description of the test rig facility will be provided together with some insights into the successful completion of the test programme. Comparisons will be provided of disc rim cooling performance, for a range of cooling flows and geometry configurations.The new elements of this work are the presentation of additional test data and validation of the automatically coupled analysis method applied to a partially cooled stator well cavity, (i.e. including some local gas ingestion); also the extension of the cavity cooling design optimisation study to other new geometries.Copyright