Imran Qureshi

Developments in Hot-Streak Simulators for Turbine Testing

The importance of understanding the impact of hot-streaks, and temperature distortion in general, on the high pressure turbine is widely appreciated, although it is still generally the case that turbines are designed for uniform inlet temperature—often the predicted peak gas temperature. This is because there is an insufficiency of reliable experimental data both from operating combustors and from rotating turbine experiments in which a combustor representative inlet temperature profile has accurately been simulated. There is increasing interest, therefore, in experiments that attempt to address this deficiency. Combustor (hot-streak) simulators have been implemented in six rotating turbine test facilities for the study of the effects on turbine life, heat transfer, aerodynamics, blade forcing, and efficiency. Three methods have been used to simulate the temperature profile: (a) the use of foreign gas to simulate the density gradients that arise due to temperature differences, (b) heat exchanger temperature distortion generators, and (c) cold gas injection temperature distortion generators. Since 2004 three significant new temperature distortion generators have been commissioned, and this points to the current interest in the field. The three new distortion generators are very different in design. The generator designs are reviewed, and the temperature profiles that were measured are compared in the context of the available data from combustors, which are also collected. A universally accepted terminology for referring to and quantifying temperature distortion in turbines has so far not developed, and this has led to a certain amount of confusion regarding definitions and terminology, both of which have proliferated. A simple means of comparing profiles is adopted in the paper and is a possible candidate for future use. New whole-field combustor measurements are presented, and the design of an advanced simulator, which has recently been commissioned to simulate both radial and circumferential temperature nonuniformity profiles in the QinetiQ/Oxford Isentropic Light Piston Turbine Test Facility, is presented.

Effect of Simulated Combustor Temperature Nonuniformity on HP Vane and End Wall Heat Transfer: An Experimental and Computational Investigation

This paper presents experimental measurements and computational predictions of surface and end wall heat transfer for a high-pressure (HP) nozzle guide vane operating as part of a full HP turbine stage in an annular rotating turbine facility, with and without inlet temperature distortion (hot streaks). A detailed aerodynamic survey of the vane surface is also presented. The test turbine was the unshrouded MT1 turbine, installed in the Turbine Test Facility (previously called Isentropic Light Piston Facility) at QinetiQ, Farnborough, UK. This is a short-duration facility, which simulates engine-representative M, Re, nondimensional speed, and gas-to-wall temperature ratio at the turbine inlet. The facility has recently been upgraded to incorporate an advanced second-generation combustor simulator, capable of simulating well-defined, aggressive temperature profiles in both the radial and circumferential directions. This work forms part of the pan-European research program, TATEF II. Measurements of HP vane and end wall heat transfer obtained with inlet temperature distortion are compared with results for uniform inlet conditions. Steady and unsteady computational fluid dynamics (CFD) predictions have also been conducted on vane and end wall surfaces using the Rolls-Royce CFD code HYDRA to complement the analysis of experimental results. The heat transfer measurements presented in this paper are the first of their kind in that the temperature distortion is representative of an extreme cycle point, and was simulated with good periodicity and with well-defined boundary conditions in the test turbine.

Analysis on the Effect of a Nonuniform Inlet Profile on Heat Transfer and Fluid Flow in Turbine Stages

This paper presents an investigation of the aerothermal performance of a modern unshrouded high pressure (HP) aeroengine turbine subject to non-uniform inlet temperature profile. The turbine used for the study was the MT1 turbine installed in the QinetiQ Turbine Test Facility (TTF) based in Farnborough (UK). The MT1 turbine is a full scale transonic HP turbine, and is operated in the test facility at the correct non-dimensional conditions for aerodynamics and heat transfer. Datum experiments of aero-thermal performance were conducted with uniform inlet conditions. Experiments with non-uniform inlet temperature were conducted with a temperature profile that had a non-uniformity in the radial direction defined by (T(max) - T(min))/(T) over bar = 0.355, and a non-uniformity in the circumferential direction defined by (T(max) - T(min))/(T) over bar = 0.14. This corresponds to an extreme point in the engine cycle, in an engine where the non-uniformity is dominated by the radial distribution. Accurate experimental area surveys of the turbine inlet and exit flows were conducted, and detailed heat transfer measurements were obtained on the blade surfaces and end-walls. These results are analysed with the unsteady numerical data obtained using the in-house HybFlow code developed at the University of Firenze. Two particular aspects are highlighted in the discussion: prediction confidence for state of the art computational fluid dynamics (CFD) and impact of real conditions on stator-rotor thermal loading. The efficiency value obtained with the numerical analysis is compared with the experimental data and a 0.8% difference is found and discussed. A study of the flow field influence on the blade thermal load has also been detailed. It is shown that the hot streak migration mainly affects the rotor pressure side from 20% to 70% of the span, where the Nusselt number increases by a factor of 60% with respect to the uniform case. Furthermore, in this work it has been found that a nonuniform temperature distribution is beneficial for the rotor tip, contrary to the results found in the open literature. Although the hot streak is affected by the pressure gradient across the tip gap, the radial profile (which dominates the temperature profile being considered) is not fully mixed out in passing through the HP stage, and contributes significantly to cooling the turbine casing. A design approach not taking into account these effects will underestimate to rotor life near the tip and the thermal load at mid-span. The temperature profile that has been used in both the experiments and CFD is the first simulation of an extreme cycle point (more than twice the magnitude of distortion all previous experimental studies): it represents an engine-take-off condition combined with the full combustor cooling.

A hot-streak (combustor) simulator suited to aerodynamic performance measurements

Abstract A new hot-streak (combustor) simulator has been designed and implemented in a turbine test facility at QinetiQ Farnborough (the QinetiQ Isentropic Light Piston Facility, ILPF) to study the impact of temperature distortion on high pressure (HP) turbine efficiency, aerodynamics, and heat transfer. The ILPF is an engine scale, short duration, rotating transonic turbine test facility, in which M, Re, Tg/Tw, and The hot-streak simulator is a second-generation design, in which cold gas is introduced into a hot mainstream though radial and circumferential slots upstream of the turbine stage. The simulator is rotatable, so the effect of clocking (relative circumferential position of hot streak and nozzle guide vane leading edge) can easily be investigated. An emphasis was placed on accurate measurement of turbine inlet enthalpy flux so that the impact of hot streaks on turbine efficiency could be investigated. The hot-streak simulator differs from all previous systems in that a pronounced radial and circumferential temperature profile has been generated, with a hot-streak to vane count of 1:1. The profile is very well matched (non-dimensionally) to the target profile, which is a combustor temperature profile measured in a modern operating engine at the most extreme point in the cycle. The most accurate area survey of a simulated temperature profile has been conducted to date, and this demonstrates that the simulator offers an exceptionally high degree of circumferential symmetry and run-to-run repeatability. The design and commissioning of the simulator is described, and the measured temperature profiles are compared with the target profile.

A combustor-representative swirl simulator for a transonic turbine research facility

Tighter aircraft emissions regulations have let to considerable improvement in gas turbine combustion in the past few decades. Modern combustors employ aggressive swirlers to increase mixing and to improve flame stability during the combustion process. The flow at combustor exit can therefore have high residual swirl. The impact of this swirl on the aerodynamic and heat transfer characteristics of the HP turbine stage has not yet received much attention. In order to investigate the effects of swirl on the HP turbine stage, an inlet swirl simulator has been designed and commissioned in an engine scale, short duration, rotating transonic turbine facility. The test facility simulates engine representative Mach number, Reynolds number, non-dimensional speed and gas-to-wall temperature ratio at the turbine inlet. The target swirl profile at turbine stage inlet was based upon extreme exit swirl conditions for a modern low-NO x combustor with peak yaw and pitch angles over ±40°. A number of candidate swirler designs were considered during a pilot study that was conducted in a subsonic wind tunnel to achieve suitable swirler design. The swirl simulator was developed based upon the pilot study results, which achieved a good match to the target profile after commissioning in the facility. This article mainly deals with the design and development of the swirl generator. It presents the experimental and computational results of the pilot study, followed by the description of the installation and commissioning of the swirl simulator on the test facility. Novel instrumentation was required to survey the swirl profile, which is also described. A comparison of the measured and computational aerodynamic results with and without swirl, at 10 per cent and 90 per cent span of HP nozzle guide vane is also presented. The comparison highlights significant impact of swirl on the vane incidence angle, and therefore a considerable affect on the loading distribution of the vane.

HP Vane Aerodynamics and Heat Transfer in the Presence of Aggressive Inlet Swirl

Modern lean burn combustors now employ aggressive swirlers to enhance fuel-air mixing and improve flame stability. The flow at combustor exit can therefore have high residual swirl. A good deal of research concerning the flow within the combustor is available in open literature. The impact of swirl on the aerodynamic and heat transfer characteristics of a HP turbine stage is not well understood, however. A combustor swirl simulator has been designed and commissioned in the Oxford Turbine Research Facility (OTRF), previously located at QinetiQ, Farnborough UK. The swirl simulator is capable of generating an engine-representative combustor exit swirl pattern. At the turbine inlet plane, yaw and pitch angles of over +/-40 degrees have been simulated. The turbine research facility used for the study is an engine scale, short duration, rotating transonic turbine, in which the non-dimensional parameters for aerodynamics and heat transfer are matched to engine conditions. The research turbine was the unshrouded MT1 design. By design, the centre of the vortex from the swirl simulator can be clocked to any circumferential position with respect to HP vane, and the vortex-to-vane count ratio is 1:2. For the current investigation, the clocking position was such that the vortex centre was aligned with the vane leading edge (every second vane). Both the aligned vane and the adjacent vane were characterised. This paper presents measurements of HP vane surface and endwall heat transfer for the two vane positions. The results are compared with measurements conducted without swirl. The vane surface pressure distributions are also presented. The experimental measurements are compared with full-stage three-dimensional unsteady numerical predictions obtained using the Rolls Royce in-house code Hydra. The aerodynamic and heat transfer characterisation presented in this paper is the first of its kind, and it is hoped to give some insight into the significant changes in the vane flow and heat transfer that occur in the current generation of low NOx combustors. The findings not only have implications for the vane aerodynamic design, but also for the cooling system design.Copyright

Analysis on the Effect of a Non-Uniform Inlet Profile on Heat Transfer and Fluid Flow in Turbine Stages

This paper presents an investigation of the aerothermal performance of a modern unshrouded high pressure (HP) aeroengine turbine subject to non-uniform inlet temperature profile. The turbine used for the study was the MT1 turbine installed in the QinetiQ Turbine Test Facility (TTF) based in Farnborough (UK). The MT1 turbine is a full scale transonic HP turbine, and is operated in the test facility at the correct non-dimensional conditions for aerodynamics and heat transfer. Datum experiments of aero-thermal performance were conducted with uniform inlet conditions. Experiments with nonuniform inlet temperature were conducted with a temperature profile that had a non-uniformity in the radial direction defined by (Tmax −Tmin )/T = 0.355, and a non-uniformity in the circumferential direction defined by (Tmax −Tmin )/T = 0.14. This corresponds to an extreme point in the engine cycle, in an engine where the non-uniformity is dominated by the radial distribution. Accurate experimental area surveys of the turbine inlet and exit flows were conducted, and detailed heat transfer measurements were obtained on the blade surfaces and end-walls. These results are analysed with the unsteady numerical data obtained using the in-house HybFlow code developed at the University of Firenze. Two particular aspects are highlighted in the discussion: prediction confidence for state of the art computational fluid dynamics (CFD) and impact of real conditions on stator-rotor thermal loading. The efficiency value obtained with the numerical analysis is compared with the experimental data and a 0.8% difference is found and discussed. A study of the flow field influence on the blade thermal load has also been detailed. It is shown that the hot streak migration mainly affects the rotor pressure side from 20% to 70% of the span, where the Nusselt number increases by a factor of 60% with respect to the uniform case. Furthermore, in this work it has been found that a nonuniform temperature distribution is beneficial for the rotor tip, contrary to the results found in the open literature. Although the hot streak is affected by the pressure gradient across the tip gap, the radial profile (which dominates the temperature profile being considered) is not fully mixed out in passing through the HP stage, and contributes significantly to cooling the turbine casing. A design approach not taking into account these effects will underestimate to rotor life near the tip and the thermal load at mid-span. The temperature profile that has been used in both the experiments and CFD is the first simulation of an extreme cycle point (more than twice the magnitude of distortion all previous experimental studies): it represents an engine-take-off condition combined with the full combustor cooling. The research was part of the EU funded TATEF2 (Turbine Aero-Thermal External Flows 2) programme.Copyright

Effect of Simulated Combustor Temperature Nonuniformity on HP Vane and Endwall Heat Transfer: An Experimental and Computational Investigation

This paper presents experimental measurements and computational predictions of surface and endwall heat transfer for a high-pressure (HP) nozzle guide vane (NGV) operating as part of a full HP turbine stage in an annular rotating turbine facility, with and without inlet temperature distortion (hot-streaks). A detailed aerodynamic survey of the vane surface is also presented. The test turbine was the unshrouded MT1 turbine, installed in the Turbine Test Facility (previously called Isentropic Light Piston Facility) at QinetiQ, Farnborough UK. This is a short duration facility, which simulates engine representative M, Re, non-dimensional speed and gas-to-wall temperature ratio at the turbine inlet. The facility has recently been upgraded to incorporate an advanced second-generation combustor simulator, capable of simulating well-defined, aggressive temperature profiles in both the radial and circumferential directions. This work forms part of the pan-European research programme, TATEF II. Measurements of HP vane and endwall heat transfer obtained with inlet temperature distortion are compared with results for uniform inlet conditions. Steady and unsteady CFD predictions have also been conducted on vane and endwall surfaces, using the Rolls-Royce CFD code HYDRA to complement the analysis of experimental results. The heat transfer measurements presented in this paper are the first of their kind in the respect that the temperature distortion is representative of an extreme cycle point measured in the engine situation, and was simulated with good periodicity and with well defined boundary conditions in the test turbine.Copyright