(MAGPI) - EUROPA - TRIMIS

(© Rolls-Royce Deutschland)

10001886:1999-12-20

Main Annulus Gas Path Interactions in Gas Turbines

Aerodays 2011, 30.3.-1.4.2011, Madrid – 2C41

Aerodays 2011, Madrid


(MAGPI)R&T Project within the 6th Framework programme of the European Union

Duration: 1.Sep.2006 – 31.Aug.2011

Presented by M. Klingsporn, RRD, Co-ordinator

Rolls-Royce Deutschland

SNECMA

Rolls-Royce

Avio

Siemens

Alstom

ITP

MTU

Turbomeca

University of Surrey

University of Sussex

Karlsruhe Institute of Technology

University of Darmstadt

University of Florence

University of Madrid (UPM)


10001886:1999-12-20



MAGPI Project Objectives

� Technical Challenges

– Understanding of interactions between annulus gas flow and air system (unsteady, 3-dimensional, interaction with blades)

� Objectives

– Reduce turbine rim sealing air mass flow

– Improve turbine efficiency / minimise flow distortions caused bysealing air e.g. by better geometry

– Improve CFD tools for complex interactions between air system and main gas path (turbines and compressor)

� Expected Benefits

– SFC, component life, reliability, development cost, better tools


10001886:1999-12-20



Technical Work Packages

� WP1: Effects of Cooling System/Main Annulus Gas Interactions – Rotor Heat Transfer – RR lead -- TSW rig at Univ Sussex

� WP2: Spoiling Effects of Sealing Flows on Turbine Performance-- ITP lead -- LSTR rig at Univ Darmstadt

� WP3: Fundamental Studies on Heat Transfer and Aerodynamic Spoiling-- MTU lead -- Linear Cascade rig at Univ Karlsruhe

� WP4: Compressor Bleed-- SN lead -- Outer bleed offtake rig at Univ Karlsruhe

… many partners involved in more than one WP …


10001886:1999-12-20



WP1 Heat Transfer in Typical Turbine Stator Well

�Main annuluswith hot gas

�Cooling air

� Ingestion

� Interstagesealleakage

Cooling air

Hot gas

ingestion

Cooling air


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WP1 Heat Transfer Test Facility (Univ Sussex)

� Two-stage high speed turbine rig running at engine representative conditions

� Temperature measurements for different cooling system configurations

Two stage turbine

~10000 rpm

400 kW

PR = 2.5:1

Inlet

3.3 bar (absolute)

4.9 kg/s

170 °C


10001886:1999-12-20



WP1 Coupled CFD/FE Analysis

�CFD for gas flow ------- FE for metal temperature

coupled via heat transfer between gas and metal

�Various meshes (structured, unstructured, cells 6 mio)

�Different codes and turbulence models (Fluent, Hydra...)


10001886:1999-12-20



WP1 Heat Transfer – Coupled CFD/FE ResultsExcellent agreement between measurements and predictions (No cooling flow)


10001886:1999-12-20



WP1 CFD/FE Coupling with Moving Mesh Capability

� Transient deflections can be included (Univ Surrey)

�Better representation of e.g. engine acceleration

Axisymmetric metal deflections

computed by SC03

Corresponding 3D deformed

CFD model


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WP1 CFD Results on Cooling Effectiveness

�Optimum cooling air supply

�Disc rim air more efficient

Cooling Effectiveness =Thot -TcoldTwall -Tcold

turbine stage efficiency

cooling flow


10001886:1999-12-20



WP2 Large Scale Turbine Rig Studies – Set-up

Main Annulus Flow

Seal Air Stator1

ME01 ME02 ME03 ME04 ME05

Seal Air Stator2

Univ. Darmstadt


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WP2 Large Scale Turbine Rig – First Results

� Five-hole-probe measurements at ME04; view from rear

�Comparison CFD – experiment: good agreement!


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WP3 Cascade Rig Tests for Optimization

�Different seals studied: axial, shingled, compound

Measurable effect

due to geometry

variation !

a

2,2,

2,1,

statot

tottot

PP

PP

−

−=ζ


10001886:1999-12-20



WP3 Optimization Procedure

� DoE approach applied

� Optimum geometry aims to:

– Minimize loss and/or secondary kinetic energy SKEH

– Maintain sealing effectiveness

� Full parameterisation of cavity and rim geometry

� Meshing strategy: stretching grid

� Response surface:

– Genetic Algorithm based optimization

– Test on various objective function

� Computational costs

– 96% is computational time -check for new strategy?

0.14

0.12

0.10

0.016

0.008

0.000

0.008

0.006

0.004

0.02

0.01

0.00

0.008

0.004

0.000

0.006

0.004

0.002

0.062

0.060

0.058

0.020

0.015

0.010

1.008

1.004

1.000

0.020

0.015

0.010

0.008

0.006

0.004

0.015

0.010

0.005

0.010

0.005

0.000

0.006

0.004

0.002

SK

EH

LO

SS

A

Sealing_eff

ecti

veness_4

B B1 C C1 e f g h rr1 rr2

Matrix Plot of SKEH, LOSS, Sealing_effe vs A, B, B1, C, C1, e, f, ...


10001886:1999-12-20



WP3 Results of Optimization

� Reduction in Gap A involves reduction in losses, control of rim seal entrained vortex

� For other parameters not easy do determine clear trends

� Reduction of up to ~30% in losses due to the presence of cavity and rim seal flows

� Optimized rim seal to be experimentally validated

Baseline rim seal Minimum losses (Y) Minimum secondary kinetic

energy (SKEH)

Gap A


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WP4 Compressor Bleed Offtake Studies

�Optimization of exit tube and manifold design

2 rows of Blades

Manifold & Exit

tubes

Off take Primary

flow

Bleeding

flow

Static pressure versus position in the manifold

(kPa)

80

82

84

86

88

90

92

94

SLOT_1_BIG_1

EXIT First prediction:

Less pressure

distortion with 4

vs 1 exit tubes


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Summary

�MAGPI provided reliable rig test datato validate CFD/FE methods

�Effective coupled CFD/FE convective heat transfermethod demonstrated – will be applied as design tool

�Alternative cooling flow configuration could improvecooling effectiveness

�Effect of different rim seal geometries on hot gas ingestion and pressure loss studied – optimization applied

� In work:

� Large scale turbine rig results and CFD validation

�Flow and heat transfer in bleed air offtake systems

� Thanks to

�All MAGPI partners for contributions and support

�European Commission for financial support

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(MAGPI) - EUROPA - TRIMIS