David Gregory-Smith

Nonaxisymmetric Turbine End Wall Design: Part II—Experimental Validation

The Durham Linear Cascade has been redesigned with the nonaxisymmetric profiled end wall described in the first part of this paper, with the aim of reducing the effects of secondary flow. The design intent was to reduce the passage vortex strength and to produce a more uniform exit flow angle profile in the radial direction with less overturning at the wall. The new end wall has been tested in the linear cascade and a comprehensive set of measurements taken. These include traverses of the flow field at a number of axial planes and surface static pressure distributions on the end wall. Detailed comparisons have been made with the CFD design predictions, and also for the results with a planar end wall. In this way an improved understanding of the effects of end wall profiling has been obtained. The experimental results generally agree with the design predictions, showing a reduction in the strength of the secondary flow at the exit and a more uniform flow angle profile. In a turbine stage these effects would be expected to improve the performance of any downstream blade row. There is also a reduction in the overall loss, which was not given by the CFD design predictions. Areas where there are discrepancies between the CFD calculations and measurement are likely to be due to the turbulence model used. Conclusions for how the three-dimensional linear design system should be used to define end wall geometries for improved turbine performance are presented.

The Effect of End-Wall Profiling on Secondary Flow and Loss Development in a Turbine Cascade

The potential for loss reduction by using non-axisymmetric end-wall profiling has been demonstrated in the so called “Durham” cascade (Hartland et al [1]) and in a turbine representative rig (Brennan et al [2] and Rose et al [3]). This paper aim to enhance the understanding of end-wall profiling. It describes detailed measurements from upstream to downstream through the Durham cascade. The measurements cover the profiled end-wall used by Hartland, a second generation end-wall design (Gregory-Smith et. al. [4]) and the planar reference case. Considerable effort has gone into refining the measurement technique used in the cascade and new results are presented for traverses downstream which capture more accurately the flow near the end-wall. These measurements show the development of loss and secondary flow throughout the blade row. It is shown that end-wall profiling has a dramatic effect on the flow patterns in the early part of the blade row which then translates to a loss reduction later in the blade row. Comparison with CFD results aids the understanding of the role of the reduced horseshoe vortex in this process.Copyright

Investigation of a novel secondary flow feature in a turbine cascade with end wall profiling

A novel secondary flow feature, previously unreported for turbine blading as far as the authors are aware, has been discovered. It has been found that it is possible to separate part of the inlet boundary layer on the blade row end wall as it is being over-turned and rolled up into the passage vortex. This flow feature has been discovered during a continuing investigation into the aerodynamic effects of non-axisymmetric end wall profiling. Previous work, using the low speed linear cascade at Durham University, has shown the potential of end wall profiling for reducing secondary losses. The latest study, the results of which are described here, was undertaken to determine the limits of what end wall profiling can achieve. The flow has been investigated in detail with pressure probe traversing and surface flow visualization. This has found that the inlet boundary locally separates, on the early suction side of the passage, generating significant extra loss which feeds directly into the core of the passage vortex. The presence of this new feature gives rise to the unexpected result that the secondary flow, as determined by the exit flow angle deviations and levels of secondary kinetic energy, can be reduced while at the same time the loss is increased. CFD was found to calculate the secondary flows moderately well compared with measurements. However, CFD did not predict this new feature, nor the increase in loss it caused. It is concluded that the application of non-axisymmetric end wall profiling, although it has been shewn to be highly beneficial, can give rise to adverse features that current CFD tools are unable to predict. Improvements to CFD capability are required in order to be able to avoid such features, and obtain the full potential of end wall profiling.

Non-Axisymmetric Turbine End Wall Design: Part II — Experimental Validation

The Durham Linear Cascade has been redesigned with the non-axisymmetric profiled end wall described in the first part of this paper, with the aim of reducing the effects of secondary flow. The design intent was to reduce the passage vortex strength and to produce a more uniform exit flow angle profile in the radial direction with less over turning at the wall. The new end wall has been tested in the linear cascade and a comprehensive set of measurements taken. These include traverses of the flow field at a number of axial planes and surface static pressure distributions on the end wall. Detailed comparisons have been made with the CFD design predictions, and also for the results with a planar end wall. In this way an improved understanding of the effects of end wall profiling has been obtained.The experimental results generally agree with the design predictions, showing a reduction in the strength of the secondary flow at the exit and a more uniform flow angle profile. In a turbine stage these effects would be expected to improve the performance of any downstream blade row. There is also a reduction in the overall loss, which was not given by the CFD design predictions. Areas where there are discrepancies between the CFD calculations and measurement are likely to be due to the turbulence model used.Conclusions for how the three-dimensional linear design system should be used to define end wall geometries for improved turbine performance are presented.Copyright

An experimental study of reverse compound lean in a linear turbine cascade

Abstract This paper describes a detailed experimental investigation into the effects of reverse compound lean (RCL) in a highly loaded axial turbine cascade. The geometry was designed using fully three-dimensional viscous CFD calculations to achieve a reduction in secondary flow. Traverses were made upstream and downstream with three-hole and five-hole probes to quantify the effects on the flow and losses produced by the leaned blade compared with a prismatic blade. These measurements were supplemented with blade static pressure measurements and surface flow visualization. It was found that the RCL blade produced higher overturning at the end-wall accompanied by higher secondary loss but this was constrained closer to the end-wall. Near mid-span, the turning was reduced slightly but the overall turning for the row was unaltered. The mid-span showed much less loss, so that overall the loss was reduced by 11 per cent. An understanding of these effects may be gained by consideration of the three-dimensional effects produced by the RCL.

The Application of Non-Axisymmetric Endwall Contouring in a Single Stage, Rotating Turbine

As turbine manufacturers strive to develop machines that are more efficient, one area of focus has been the control of secondary flows. To a large extent these methods have been developed through the use of computational fluid dynamics and detailed measurements in linear and annular cascades and proven in full scale engine tests. This study utilises 5-hole probe measurements in a low speed, model turbine in conjunction with computational fluid dynamics to gain a more detailed understanding of the influence of a generic endwall design on the structure of secondary flows within the rotor. This work is aimed at understanding the influence of such endwalls on the structure of secondary flows in the presence of inlet skew, unsteadiness and rotational forces. Results indicate a 0.4% improvement in rotor efficiency as a result of the application of the generic non-axisymmetric endwall contouring. CFD results indicate a clear weakening of the cross passage pressure gradient, but there are also indications that custom endwalls could further improve the gains. Evidence of the influence of endwall contouring on tip clearance flows is also presented.Copyright

Experiments and Computations on Large Tip Clearance Effects in a Linear Cascade

Large tip clearances typically in the region of 6% exist in the high pressure (HP) stages of compressors of industrial gas turbines. Due to the relatively short annulus height and significant blockage, the tip clearance flow accounts for the largest proportion of loss in the HP. Therefore increasing the understanding of such flows will allow for improvements in design of such compressors, increasing efficiency, stability, and the operating range. Experimental and computational techniques have been used to increase the physical understanding of the tip clearance flows through varying clearances in a linear cascade of controlled-diffusion blades. This paper shows two unexpected results. First the loss does not increase with clearances greater than 4% and second there is an increase in blade loading toward the tip above 2% clearance. It appears that the loss production mechanisms of the pressure driven tip clearance jet do not increase as the clearance is increased to large values. The increase in blade force is attributed to the effect of the strong tip clearance vortex, which does not move across the blade passage to the pressure surface, as is often observed for high stagger blading. These results may be significant for the design of HP compressors for industrial gas turbines.

Non-axisymmetric turbine end wall profiling.

Abstract A design method for profiling the end wall to reduce secondary flow has been reported previously. A profile has been tested in the Durham Linear Cascade and the results confirmed the design method. This paper describes the design and testing of a second-generation end wall, where the profiling is more suited to a real turbine. The new end wall has been tested in the linear cascade and a comprehensive set of measurements have been taken. These include traverses of the flow field upstream and downstream of the blade row, surface static pressure distributions on the end wall and flow visualization. Comparisons have been made with the results with a planar end wall and the earlier profiled end wall. Observed reductions in exit angle deviations are even greater than for the first design, although the loss reduction is not as great. The results verify the design, confirming profiled end walls as a means of reducing secondary flow, kinetic energy and loss. Overall an improved understanding of the effects of end wall profiling has been obtained although further work is required in this area.

Non-Axisymmetric Turbine End Wall Design: Part I — Three-Dimensional Linear Design System

A linear design system, already in use for the forward and inverse design of three-dimensional turbine aerofoils, has been extended for the design of their end walls.This paper shows how this method has been applied to the design of a non-axisymmetric end wall for a turbine rotor blade in linear cascade. The calculations show that non-axisymmetric end wall profiling is a powerful tool for reducing secondary flows, in particular the secondary kinetic energy and exit angle deviations. Simple end wall profiling is shown to be at least as beneficial aerodynamically as the now standard techniques of differentially skewing aerofoil sections up the span, and (compound) leaning of the aerofoil. A design is presented which combines a number of end wall features aimed at reducing secondary loss and flow deviation. The experimental study of this geometry, aimed at validating the design method, is the subject of the second part of this paper.The effects of end wall perturbations on the flow field are calculated using a 3-D pressure correction based Reynolds Averaged Navier-Stokes CFD code. These calculations are normally performed overnight on a cluster of work stations. The design system then calculates the relationships between perturbations in the end wall and resulting changes in the flow field. With these available, linear superposition theory is used to enable the designer to investigate quickly the effect on the flow field of many combinations of end wall shapes (a matter of minutes for each shape).Copyright

Reduction in Secondary Flows and Losses in a Turbine Cascade by Upstream Boundary Layer Blowing

The effect of upstream tangential blowing on the secondary flows has been studied in a turbine cascade of rotor blades. The aim is to reduce the secondary flows and losses, but in the evaluation an accounting procedure for the energy for blowing is required. The experimental results show that the effect of the increasing blowing is first to thicken the inlet boundary layer, giving greater secondary flow and more loss, and then as re-energisation of the inlet boundary layer takes place together with increasing counter streamwise vorticity, the passage vortex is progressively weakened, with a corresponding reduction in loss. Low rather than high angle blowing is shown to be more effective as the jet is kept closer to the end wall, and strong similarities could be obtained with the flow patterns from previous work with a skewed inlet boundary layer. However when the energy for inlet blowing is included, no net gain is achieved due mainly to the mixing loss of the injected air. Overall gains may be achievable, if combined with such features as injection for film cooling.Copyright