The flow at the combustor turbine interface of power generation gas turbines with can combustors is characterized by high and nonuniform turbulence levels, lengthscales, and residual swirl. These complexities have a significant impact on the first vanes aerothermal performance and lead to challenges for an effective turbine design. To date, this design philosophy mostly assumed steady flow and thus largely disregards the intrinsic unsteadiness. This paper investigates the steady and unsteady effects of the combustor flow with swirl on the turbines first vanes. Experimental measurements are conducted on a high-speed linear cascade that comprises two can combustors and four nozzle guide vanes (NGVs). The experimental results are supported by a large eddy simulation (LES) performed with the inhouse computational fluid dynamics (CFD) flow solver TBLOCK. The study reveals the highly unsteady nature of the flow in the first vane and its effect on the heat transfer. A persistent flow structure of concentrated vorticity is observed. It wraps around the unshielded vane's leading edge (LE) at midspan and periodically oscillates in spanwise direction due to the interaction of the residual low-pressure swirl core and the vane's potential field. Moreover, the transient behavior of the horseshoe-vortex system due to large fluctuations in incidence is demonstrated.
Shroud leakage flow undergoes little change in the tangential velocity as it passes over the shroud. Mixing due to the difference in tangential velocity between the main stream flow and the leakage flow creates a significant proportion of the total loss associated with shroud leakage flow. The unturned leakage flow also causes negative incidence and intensifies the secondary flows in the downstream blade row. This paper describes the experimental results of a concept to turn the rotor shroud leakage flow in the direction of the main blade passage flow in order to reduce the aerodynamic mixing losses. A threestage air model turbine with low aspect ratio blading was used in this study. A series of different stationary turning vane geometries placed into the rotor shroud exit cavity downstream of each rotor blade row was tested. A significant improvement in flow angle and loss in the downstream stator blade rows was measured together with an increase in turbine brake efficiency of 0.4 %.
Three-dimensional steady multistage calculations, using the mixing plane approach, are compared with experimental measurement in a low-speed three-stage model turbine. The comparisons are made with two levels of shroud seal clearance, one representative of a real turbine and one with minimal seal clearance and almost no shroud leakage. Three different calculations are compared. The first computes the main blade path with no modeling of shroud leakage. The second includes a simple model of shroud leakage using sources and sinks on the end-walls, and the third is a multiblock calculation with all leakage paths and cavities computed. It is found that neglect of shroud leakage makes the computed velocity profiles and loss distributions significantly different to those measured. Simple modeling of shroud leakage gives some improvement but full calculation of the leakage flows and cavities is necessary to obtain good agreement between calculation and measurement.
This paper describes a new modular experimental facility that was purpose-built to investigate flow interactions between the combustor and first stage nozzle guide vanes (NGVs) of heavy duty power generation gas turbines with multiple can combustors. The first stage turbine NGV is subjected to the highest thermal loads of all turbine components and therefore consumes a proportionally large amount of cooling air that contributes detrimentally to the stage and cycle efficiency. It has become necessary to devise novel cooling concepts that can substantially reduce the coolant air requirement but still allow the turbine to maintain its aerothermal performance. The present work aims to aid this objective by the design and commissioning of a high-speed linear cascade, which consists of two can combustor transition ducts and four first stage NGVs. This is a modular nonreactive air test platform with engine realistic geometries (gas path and near gas path), cooling system, and boundary conditions (inlet swirl, turbulence level, and boundary layer). The paper presents the various design aspects of the high pressure (HP) blow down type facility, and the initial results from a wide range of aerodynamic and heat transfer measurements under highly engine realistic conditions.
Blade lean, i.e., nonradial blade stacking, has been intensively used over the past in the design process of low aspect ratio gas and steam turbines. Although its influence on turbine efficiency is not completely understood, it has been proved as an effective way of controlling blade loading and secondary flows on blade passage endwalls. Three-dimensional blade designs in modern industrial practice are usually carried out using clean endwalls. The influence of the leakage flows on three-dimensional blade design is traditionally neglected. This paper presents an experimental study where two different stator blades, with different levels of compound lean, were tested in a low speed three-stage model turbine with the shroud leakage flow geometry representative of industrial practice. The experimental measurements were compared with numerical tests, conducted on the same blade geometries. The influence of the compound lean on the stator flow field was analyzed in detail. In order to analyze the combined effects of both the stator hub and the rotor shroud leakage flow on the blade lean, in the second part of the paper a numerical study on a two stage turbine with both leakage flow paths representative of a real turbine was carried out. Performance of three different stator blade designs (two different levels of compound lean and a straight blade) was investigated. The aim of this study is to understand the mechanism and the consequence of the stator blade lean on stage performance in an environment with leakage flows and associated cavities.
The flow at the combustor turbine interface of power generation gas turbines with can combustors is characterized by high and non-uniform turbulence levels, lengthscales and residual swirl. These complexities have a significant impact on the first vanes aerothermal performance and lead to challenges for an effective turbine design. To date, this design philosophy mostly assumed steady flow and thus largely disregards the intrinsic unsteadiness. This paper investigates the steady and unsteady effects of the combustor flow with swirl on the turbines first vanes. Experimental measurements are conducted on a high-speed linear cascade that comprises two can combustors and four nozzle guide vanes. The experimental results are supported by a Large Eddy Simulation performed with the inhouse CFD flow solver TBLOCK. The study reveals the highly unsteady nature of the flow in the first vane and its effect on the heat transfer. A persistent flow structure of concentrated vorticity is observed. It wraps around the unshielded vane’s leading edge at midspan and periodically oscillates in spanwise direction due to the interaction of the residual low-pressure swirl core and the vane’s potential field. Moreover, the transient behavior of the horseshoe-vortex system due to large fluctuations in incidence is demonstrated.
Imperfections in the turbine annulus geometry, caused by the presence of the shroud and associated cavity have a significant influence on the aerodynamics of the main passage flow path. In this paper the datum shroud geometry, representative of steam turbine industrial practice, was systematically varied and numerically tested. The study was carried out using a three-dimensional multi-block solver, which modelled the flow in a 1.5 stage turbine. The following geometry parameters were varied: - Inlet and exit cavity length, - Shroud overhang upstream of the rotor leading edge and downstream of the trailing edge, - Shroud thickness for fixed casing geometry and shroud cavity depth, and - Shroud cavity depth for the fixed shroud thickness. The aim of this study was to investigate the influence of the above geometric modifications on mainstream aerodynamics, and to obtain a map of the possible turbine efficiency changes caused by different shroud geometries. The paper then focuses on the influence of different leakage flow fractions on the mainstream aerodynamics. This work highlighted the main mechanisms through which leakage flow affects the mainstream flow and how the two interact for different geometrical variations and leakage flow mass fractions.
Imperfections in the turbine annulus geometry, caused by the presence of the shroud and associated cavity, have a significant influence on the aerodynamics of the main passage flow path. In this paper, the datum shroud geometry, representative of steam turbine industrial practice, was systematically varied and numerically tested. The study was carried out using a three-dimensional multiblock solver, which modeled the flow in a 1.5 stage turbine. The following geometry parameters were varied: inlet and exit cavity length, shroud overhang upstream of the rotor leading edge and downstream of the trailing edge, shroud thickness for fixed casing geometry and shroud cavity depth, and shroud cavity depth for the fixed shroud thickness. The aim of this study was to investigate the influence of the above geometric modifications on mainstream aerodynamics and to obtain a map of the possible turbine efficiency changes caused by different shroud geometries. The paper then focuses on the influence of different leakage flow fractions on the mainstream aerodynamics. This work highlighted the main mechanisms through which leakage flow affects the mainstream flow and how the two interact for different geometrical variations and leakage flow mass fractions.
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