Int. J. Turbomach. Propuls. Power, Volume 8, Issue 3 (September 2023) – 17 articles

The influence of unsteady wakes incoming from the upstream stages is of high relevance in modern high-speed, low-pressure turbines (LPT) operating at transonic exit Mach numbers and low Reynolds numbers for their potential to trigger transition and influence the separation of the boundary layer on the blade suction side. The aim of this paper is the experimental characterization of the influence of incoming wakes on the 2D aerodynamics of a high-speed LPT cascade operating at a low Reynolds number and transonic exit Mach number. A detailed analysis of the status of the flow along the blade under investigation and its impact on the profile loss are presented for a range of Mach numbers from 0.70 to 0.95 and Reynolds numbers from 70k to 120k under steady and unsteady inflow conditions. Tests were conducted at on- and off-design engine realistic conditions in the VKI S-1/C wind tunnel on the SPLEEN C1 transonic cascade. The wakes incoming from an upstream blade row have been replicated using a set of rotating bars, which shed wakes at an engine-representative reduced frequency ($f^{+}=0.95$) and flow coefficient ($\Phi =0.80$). A set of densely instrumented traversable blades were used to sample the surface pressure distributions. The development of the boundary layers along the blade suction side is examined through quasi-wall shear stress obtained with surface-mounted hot-film sensors. Wake traverses were carried out downstream of the cascade with a miniaturized L-shaped five-hole probe to characterize the blade losses. The introduction of periodic incoming wakes promotes variations in the flow topology over the blade. The effect on the suction side separation bubble is shown to depend on the exit flow conditions. At low Mach numbers, the incoming wakes determine a reduction in the size of the bubble; in contrast, this effect is not registered as the exit Mach number increases. Consistently, a high dependence of the unsteady wake effect on the profile loss on the exit Reynolds and Mach numbers is demonstrated. Full article

The present work reports an experimental study of the leakage flow in a low-speed fan ring. Existing 2D Particle Image Velocimetry (PIV) measurements taken in a meridional plane in front of the rotor gap have been further processed and analyzed by means of the Proper Orthogonal Decomposition (POD). Three values of the dimensionless pressure rise across the rotor have been investigated. Namely, attention has been focused on the intermediate case—the one for which a strong radial oscillation in the leakage flow has been observed: POD results have shown that, in this condition, the leakage flow exhibits periodic radial oscillations that are not correlated to the periodic blade passing. Moreover, such coherent motions have been found to promote turbulence transport at different radial positions, whereas rotor-related oscillations have a negligible effect in this sense. The present POD procedure can be generally applied to turbomachinery flows to characterize their unsteady behavior beside the classical phase-averaging methods based on rotor-related quantities. The present approach is novel for the study of leakage flow dynamics in axial fans. Full article

Typically installed in a rotor-only configuration, low-pressure axial fans discharge directly into a free atmosphere and the discharge shows a strong swirl component. Since such designs, without guide vanes, cannot convert the dynamic pressure in the swirl component back into static pressure, the dynamic pressure is usually considered a loss. However, the radial equilibrium shows that a significant part of the kinetic energy contained in this swirl component is recovered as static pressure in the free atmosphere. This additional pressure increase has been sparsely researched. A comparison between two configurations with and without outlet guide vanes allows for the formulation of an evaluation criterion of the rotor-only configuration. Utilizing this evaluation criterion, the investigation of velocity profiles corresponding to generic rotor designs shows promise in terms of pressure recovery for new designs. Full article

This paper derives and validates an analytical model for acoustic boundary conditions on a can-annular gas turbine combustion system composed of discrete cans connected to an open annulus upstream of a turbine. The analytical model takes one empirical parameter: a connection impedance between adjacent cans. This impedance is extracted from time-marching computations of two-can sectors of representative combustors. The computations show that reactance follows the Rayleigh conductivity, while resistance takes a value of order 0.1 as a weak function of geometry. With a calibrated value of acoustic resistance, the analytical model reproduces can-to-can transfer functions predicted by full-annulus computations to within 0.03 magnitude at compact frequencies. Varying the combustor–turbine gap length, both model and computations exhibit a minimum in reflected energy, which drops by 63% compared to the datum gap. A parametric study yields a design guideline for gap length at the minimum reflected energy, allowing the designer to maximise transmission from the combustion system and reduce damping requirements. Full article

Experimental results for the transient heat transfer characteristics over a flat plate and over a plate with V-shaped ribs were compared to numerical results from a coupling environment applying FEM and CFD. In order to simulate transient effects in the cooling process of engine components during typical flight missions, the temperature and the velocity at the inlet of the channel were varied over time. The transient temperature distribution at the plate was measured using infrared thermography. Five different plate materials (perspex, PEEK, quartz, aluminum, and steel) were considered to investigate the influence of thermal conduction on the heat transfer between solid and fluid depending on the Biot number. The experimental results represent a reference database for a Python-based coupling environment applying CalculiX (FEM) and ANSYS CFX (CFD). The results were additionally compared to numerical results simulating the complete transient conjugated heat transfer with CFD. A good agreement between the numerical and the experimental results was achieved using different coupling sizes at different Biot numbers for the flat plate and the plate with V-shaped ribs. Full article

The tip gap region of an axial compressor rotor is a source of complex flows, inducing losses and stability issues. Recent works have proven the ability of blowing high-speed jets in the tip region to improve the surge margin of an axial compressor stage with a narrow tip gap configuration. However, the tip gap size can evolve during the compressor lifetime, possibly affecting its performance and operability. The objective is to evaluate the performance of an active flow control system on a compressor with different tip gap sizes. The present work is based on the single-stage compressor CME2 located at the Laboratory of Fluid Mechanics of Lille and equipped with actuators blowing at the rotor tip leading edge. Configurations with two different values of the tip gap to chord ratio (0.6% and 2.4%) are experimentally tested. RANS simulations are also performed. The effect of tip gap sizes and tip blowing on the flow topology and compressor performance is evaluated (surge margin improvement of the order of 200% for the larger tip gap size). Full article

Even if wind tunnel tests and simulations have confirmed that tubercles can influence the behaviour of a profile, research in the field of axial pumps has so far been lacking. However, previous studies cannot be transferred to the application of axial pumps, since the requirements for the profile geometry as well as the Reynolds number range differ. The present study aims to address this research gap by performing a CFD simulation with a profile common for axial pumps, the Goe11K, testing four different tubercle configurations. At the same time, this simulation is a preliminary study for experimental tests. The results show that certain tubercle configurations improve the behaviour of the profile in the post-stall area, i.e., increase the lift of the profile at large angles of attack (α). In general, the curve of the profiles with tubercles runs more evenly, without the drastic drop in lift. This improved property comes at the expense of lower maximum lift and increased drag at lower α. With regard to the use of axial pumps, it can be concluded that there are advantages, particularly in the partial load range. These could ultimately enlarge the operation range of an axial pump. Full article

A hybrid two-phase flow solver is proposed, based on an Euler–Euler two-fluid model with continuous blending of a Volume-of-Fluid method when phase interfaces of coherent gas pockets are to be resolved. In a preceding study on a two-dimensional bladed research pump with reduced rotational speed, the transition from bubbly flow to coherent steady gas pockets observed in optical experiments with liquid/gas flow could be well captured by the hybrid solver. In the present study, the experiments and solver validation are extended to an industrial-scale centrifugal pump with twisted three-dimensional blades and elevated design rotational speed. The solver is combined with a population balance model, and a scale-adaptive turbulence model is employed. Compared to the two-dimensional bladed pump, the transition from agglomerated bubbles flow to attached gas pockets is shifted to larger gas loading, which is well captured by the simulation. The pump head drop with increasing gas load is also reproduced, showing the hybrid solver’s validity for realistic pump operation conditions. Full article

This paper presents a numerical analysis of the influence of the von Karman vortex shedding at the blade trailing edge on the hydrodynamics of a recently installed small hydro Francis turbine manifesting very loud and high-frequency acoustic pulsations when operating close to the nominal load. A reduced single-passage numerical model is developed to reduce the computational effort of the simulation while ensuring high accuracy in the assessment of fluid flow. The accuracy of the proposed numerical approach is investigated by comparing the frequency spectrum of the experimentally acquired acoustic frequency and the numerical pressure signals, confirming the nature of the machine’s vibrations. The validated numerical model represents a useful tool for an in-depth analysis of the machine’s hydrodynamics in the preliminary design phases. The proposed approach represents a valid alternative to the traditional correlation-based approach for the evaluation of the von Karman shedding frequency with less computational effort compared with a transient simulation of the entire machine. Full article

Double-regulated Kaplan turbines with adjustable guide vanes and runner blades offer a high degree of flexibility and good efficiency for a wide range of operating points. However, this also leads to a complex geometry and flow guidance with, for example, vortices of different sizes and strengths. The flow in a draft tube is especially challenging to simulate mainly due to flow phenomena, like swirl, separation and strong adverse pressure gradients, and a strong dependency on the upstream flow conditions. Standard simulation approaches with RANS turbulence models, a coarse mesh and large time step size often fail to correctly predict performance and can even lead to wrong tendencies in the overall behavior. To reveal occurring flow phenomena and physical effects, a scale-resolving hybrid RANS-LES simulation on a block structured mesh of about 400 million hexahedral elements of a double-regulated five-blade model Kaplan turbine is carried out. In this paper, first, the results of the ongoing simulation are presented. The major part of the simulation domain is running in LES mode and seems to be properly resolved. The validation of the simulation results with the experimental data shows mean deviations of less than 0.8% in the global results, i.e., total head and power, and a good visual agreement with the three-dimensional PIV measurements of the velocity in the cone and both diffuser channels of the draft tube. In particular, the trend of total head and the results for the draft tube differ significantly between the scale-resolving simulation and a standard RANS simulation. The standard RANS simulation exhibits a highly unsteady behavior of flow, which is not observed in the experiments or scale-resolving simulation. Full article

In the current study, full-stage unsteady simulations were performed to investigate rotating instability inception mechanisms in a particularly large tip clearance centrifugal compressor with a vaneless diffuser and a volute. Four operating points along a speed line were analysed to understand the influence of the mass flow reduction on flow structures. Close to the peak efficiency, an unsteady interaction between the tip clearance vortices and splitter blades was observed. Considering other studies, the influence of the tip gap size was analysed. Then, a large-scale vortex shedding from the leading edges of the main blades was detected when the stage operated near the maximum pressure ratio. It was demonstrated that shed vortices were caused by the combination of the radial gradient of the tangential velocity under the tip vortex and the reverse backflow near the casing. Previous studies on axial compressors refer to these vortical structures as backflow vortices. These vortices cause a significant increase in the incidence angle in the tip region. Full article

Due to the increasingly high turbine inlet temperatures, heat transfer analysis is now, more than ever, a vital part of the design and optimization of high-pressure turbine rotor blades of a modern jet engine. The present study aimed to find out how shape deviation and in-service deterioration affect heat exchange patterns on the rotor blade. The rotor geometries used for this analysis are represented by a set of high-resolution 3D structured light scans of blades with the same number of in-service hours. An automatic meshing technique was employed to generate high-resolution meshes directly on the scanned rotor geometries, which captured all the surface features with high fidelity. Steady-state 3D RANS flow simulations with a k-ω SST turbulence model were conducted on a one-and-a-half stage computational domain of the scanned geometries. First, the distribution of the heat transfer coefficient was calculated for each blade; then, a correlation was sought between the heat transfer coefficient and parametrized shape deviation, to assess the impact of each parameter on HTC levels. Full article

Off-design condition of a rotor blade cascade with and without platform cooling was experimentally investigated. The ability of the gas turbine to operate down to 50% to 20% of its nominal intake air flow rate has an important consequence in the change in the inlet incidence angle, which varied from nominal to −20°. Platform cooling through an upstream slot simulating the stator-to-rotor interface gap was considered. The impact of rotation on purge flow injection was simulated by installing fins inside the slot to give the coolant flow a tangential direction. Aerodynamic measurements to quantify the cascade aerodynamic loss and secondary flow structures were performed at Ma_2is = 0.55, varying the coolant to main flow mass flow ratio (MFR%) and the incidence angle. The results show that losses strongly increase with MFR. A negative incidence allows a reduction in the overall loss even when coolant is injected with a high MFR. The more negative the incidence, the greater the loss reduction. Full article

The efficiency assessment of a high-pressure turbine (HPT) stage is complicated by the presence of upstream and downstream purge flows. In fact, the efficiency calculation is often based on mass flow-averaged values of total temperature at the stage inlet and outlet planes. Moreover, the purge flow distribution in the annulus is usually unknown and therefore assumed to be uniform. This paper presents and applies an alternative method to calculate the efficiency of a fully purged HPT stage. Such a definition relies on seed gas concentration measurements at the HPT stage outlet plane to determine the outlet purge flow distribution. After comparing the alternative method to the standard definition (based on the assumption of uniform purge) for the nominal purge case, the efficiency variation between the case with nominal purge and the case without purge is investigated. Full article

An experimental investigation of the local flow field in a Wells turbine has been conducted, in order to produce a detailed analysis of the aerodynamic characteristics of the rotor and support the search for optimized solutions. The measurements were conducted with a hot-wire anemometer (HWA) probe, reconstructing the local three-dimensional flow field both upstream and downstream of a small-scale Wells turbine. The multi-rotation technique has been applied to measure the three velocity components of the flow field for a fixed operating condition. The results of the investigation show the local flow structures along a blade pitch, highlighting the location and radial extension of the vortices which interact with the clean flow, thus degrading the turbine’s overall performance. Some peculiarities of this turbine have also been shown, and need to be considered in order to propose modified solutions to improve its performance. Full article

The purpose of the paper is to characterize the aerodynamic behavior of a rotor-downstream hub cavity rim seal in a high-pressure turbine (HPT) stage. The experimental data are acquired in the Transonic Test Turbine Facility at the Graz University of Technology: the test setup includes two engine-representative turbine stages (the last HPT stage and first LPT stage), with the intermediate turbine duct in between. All stator-rotor cavities are supplied with purge flows by a secondary air system, which simulates the bleeding air from the compressor stages of the real engine. The HPT downstream hub cavity is provided with wall taps and pitot tubes at different radial and circumferential locations, which allows the performance of steady pressure and seed gas concentration measurements for different purge mass flows and HPT vanes clocking positions. Moreover, miniaturized pressure transducers are adopted to evaluate the unsteady pressure distribution, and an oil flow visualization is performed to retrieve additional information on the wheel space structures. The annulus pressure asymmetry depends on the HPT vane clocking, but this is shown to have negligible impact on the minimum purge mass flow required to seal the cavity. However, the hub pressure profile drives the distribution of the cavity egress in the turbine channel. The unsteady pressure field is dominated by blade-synchronous oscillations. No non-synchronous components with comparable intensity are detected. Full article

In the coming carbon-neutral era, industrial gas turbines (GT) will continue to play an important role as energy conversion equipment with high thermal efficiency and as stabilizers of the electric power grid. Because of the transition to a clean fuel, such as hydrogen or ammonia, the main modifications will lie with the combustor. It can be expected that small and medium-sized gas turbines will burn fewer inferior fuels, and the scope of cogeneration activities they are used for will be expanded. Industrial gas turbine cycles including CCGT appropriate for the carbon-neutral era are surveyed from the viewpoint of thermodynamics. The use of clean fuels and carbon capture and storage (CCS) will inevitably increase the unit cost of power generation. Therefore, the first objective is to present thermodynamic cycles that fulfil these requirements, as well as their verification tests. One conclusion is that it is necessary to realize the oxy-fuel cycle as a method to utilize carbon-heavy fuels and biomass and not generate NO_x from hydrogen combustion at high temperatures. The second objective of the authors is to show the required morphology of the cooling structures in airfoils, which enable industrial gas turbines with a higher efficiency. In order to achieve this, a survey of the historical development of the existing cooling methods is presented first. CastCool^® and wafer and diffusion bonding blades are discussed as turbine cooling technologies applicable to future GTs. Based on these, new designs already under development are shown. Most of the impetus comes from the development of aviation airfoils, which can be more readily applied to industrial gas turbines because the operation will become more similar. Double-wall cooling (DWC) blades can be considered for these future industrial gas turbines. It will be possible in the near future to fabricate the DWC structures desired by turbine cooling designers using additive manufacturing (AM). Another conclusion is that additively manufactured DWC is the best cooling technique for these future gas turbines. However, at present, research in this field and the data generated are scattered, and it is not yet possible for heat transfer designers to fabricate cooling structures with the desired accuracy. Full article