Search

This paper describes the redesign of the HP turbine of the Rolls-Royce Trent 500 engine, making use of nonaxisymmetric end walls. The original, datum turbine used conventional axisymmetric end walls, while the vane and (shrouded) rotor aerofoil profiles were nominally the same for the two designs. Previous research on the large-scale, low-speed linear cascade at Durham University (see Hartland et al., 1998, “Non-Axisymmetric End Wall Profiling in a Turbine Cascade,” ASME 98–GT-525), had already demonstrated significant potential for reducing turbine secondary losses using nonaxisymmetric end walls-by about one third. This paper shows how a methodology was derived from the results of this research and applied to the design of the single-stage Trent 500-HP turbine (model rig). In particular, the application of a new linear design system for the parametric definition of these end wall shapes (described in Harvey et al., 1999, “Non-Axisymmetric Turbine End Wall Design: Part I Three-Dimensional Linear Design System,” ASME 99–GT-337) is discussed in detail.

The adsorption characteristics of heavy metals: cadmium(II), chromium(III), copper(II), nickel(II), lead(II), and zinc(II) ions by kaolin (kaolinite) and ballclay (illite) from Thailand were studied. This research was focussed on the pH, adsorption isotherms of single-metal solutions at 30–60 °C by batch experiments, and on ion selectivityin mixed and binary combination solutions. It was found that, except Ni, metal adsorption increased with increased pH of the solutions and their adsorption followed both Langmuir and Freundlich isotherms. Adsorption of metals in the mixture solutions by kaolin was: Cr > Zn > Cu ≈ Cd ≈ Ni > Pb, and for ballclay was: Cr > Zn > Cu > Cd ≈ Pb > Ni. The adsorption of metals was endothermic, with the exception of Cd, Pb and Zn for kaolin, Cu and Zn for ballclay. Kaolin and ballclay exhibited relatively hard Lewis base adsorption site. The presence of other metals may reduce or promote the adsorption of heavy metals. The presence of Cr3+ induced the greatest reduction of metal adsorptiononto kaolin, as did the presence of Cu2+ for ballclay.

This paper describes a detailed study into the unsteady boundary layer behavior in two high-lift and one ultra-high-lift Rolls-Royce Deutschland LP turbines. The objectives of the paper are to show that high-lift and ultra-high-lift concepts have been successfully incorporated into the design of these new LP turbine profiles. Measurements from surface mounted hot film sensors were made in full size, cold flow test rigs at the altitude test facility at Stuttgart University. The LP turbine blade profiles are thought to be state of the art in terms of their lift and design philosophy. The two high-lift profiles represent slightly different styles of velocity distribution. The first high-lift profile comes from a two-stage LP turbine (the BR710 cold-flow, high-lift demonstrator rig). The second high-lift profile tested is from a three-stage machine (the BR715 LPT rig). The ultra-high-lift profile measurements come from a redesign of the BR715 LP turbine: this is designated the BR715UHL LP turbine. This ultra-high-lift profile represents a 12 percent reduction in blade numbers compared to the original BR715 turbine. The results from NGV2 on all of the turbines show “classical” unsteady boundary layer behavior. The measurements from NGV3 (of both the BR715 and BR715UHL turbines) are more complicated, but can still be broken down into classical regions of wake-induced transition, natural transition and calming. The wakes from both upstream rotors and NGVs interact in a complicated manner, affecting the suction surface boundary layer of NGV3. This has important implications for the prediction of the flows on blade rows in multistage environments.

This paper shows how it is possible to reduce the number of blades in LP turbines by approximately 15 percent relative to the first generation of high lift blading employed in the very latest engines. This is achieved through an understanding of the behavior of the boundary layers on high lift and ultra-high lift profiles subjected to incoming wakes. Initial development of the new profiles was carried out by attaching a flap to the trailing edge of one blade in a linear cascade. The test facility allows for the simulation of upstream wakes by using a moving bar system. Hot wire measurements were made to obtain boundary layer losses and surface-mounted hot films were used to observe the changes in boundary layer state. Measurements were taken at a Reynolds number between 100,000 and 210,000. The effect of increased lift above the datum profile was investigated first with steady and then with unsteady inflow (i.e., with wakes present). For the same profile, the losses generated with wakes present were below those generated by the profile with no wakes present. The boundary layer behavior on these very high lift pressure distributions suggested that aft loading the profiles would further reduce the profile loss. Finally, two very highly loaded and aft loaded LP turbine profiles were designed and then tested in cascade. The new profiles produced losses only slightly higher than those for the datum profile with unsteady inflow, but generated 15 percent greater lift.

A three-dimensional steady viscous finite volume pressure correction method for the solution of the Reynolds-averaged Navier–Stokes equations has been used to calculate the heat transfer rates on the end walls of a modern High Pressure Turbine first-stage stator. Surface heat transfer rates have been calculated at three conditions and compared with measurements made on a model of the vane tested in annular cascade in the Isentropic Light Piston Facility at DERA, Pyestock. The NGV Mach numbers, Reynolds numbers, and geometry are fully representative of engine conditions. Design condition data have previously been presented by Harvey and Jones (1990). Off-design data are presented here for the first time. In the areas of highest heat transfer, the calculated heat transfer rates are shown to be within 20 percent of the measured values at all three conditions. Particular emphasis is placed on the use of wall functions in the calculations with which relatively coarse grids (of around 140,000 nodes) can be used to keep computational run times sufficiently low for engine design purposes.

In this paper the mixing of stator wakes in turbomachinery is considered. An extension is made to the existing model of Denton (1993, ASME J. Turbomach., 115, pp. 621–656) which addresses the effects of acceleration before mixing. Denton showed that if a total pressure wake was accelerated, mixing loss diminished, and vice versa. Here a total temperature wake is shown to exhibit a reverse trend. An attempt is also made to understand better the work transfer process between a stator wake and a rotor. The paper concentrates on axial turbines, but a brief look at compressors is included. It is argued that the free-stream work is not the same as the wake work, and the concept of “Differential Work” is introduced. A simple steady velocity triangle based model is proposed to give an estimate of the ratio of wake work to free-stream work (μ, see later). The model is compared to an unsteady CFD result to offer some verification of the assumptions. It is concluded that the rotodynamic work process tends to reduce total pressure wake depths in turbines and compressors and therefore mixing losses. The mixing loss due to total temperature wakes is less strongly affected by the differential work process. [S0889-504X(00)00801-1]

The movement of85Sr,137Cs,54Mn and60Co in the 50 cm soil profile was studied with and without the presence of plant roots (triticum aestivum) in order to investigate the influence of roots and depth contamination upon the migration of radionuclides. The water table was maintained manually at 3 cm from the bottom. The physiochemical characteristics (Eh Fe−2, NH4+, pH and moisture content) as well as the total and extractable radioactivity were investigated. In the discrete contamination, where the location of contamination varied within the soil profile (0–5, 25–30 or 45–50 cm from the top), the influence of location upon the movement of these radionuclides was also studied. It was found that the changes in the soil physicochemical characteristics influenced the mobility of the four radionuclides. The extractability of54Mn and60Co was significantly increased in the reducing region of the soil, whereas that of85Sr,137Cs was not. Plant roots excerted significant effects upon the soil characteristics, via, reducing the Eh pH and moisture content of the soil; increasing the extractability of both54Mn and60Co from the depth of 35 cm downwards. Radionuclide migration occurred via physicochemical and biological transport. The biological transport via plant roots was of particular importance for137Cs. Location of contamination had a significant influence upon the mobility of radionuclides. The migration of radionuclides was in the sequence of contamination in middle>bottom>top. The degree of the influence varied with radionuclides concemed. In the top layer contamination, the rank of the migration from the contamination layers, on the other hand54Mn,60Co and137Cs were more mobile and the movement was:85Sr∼54Mn∼60Co>137Cs. In the middle and bottom contamination layers, on the other hand,54Mn and60Co and137Cs were more mobile and the movement was85Sr∼54Mn∼60Co>137Cs. The results provide evidence conceming the soil-root interaction influencing the transfer efficiency of radionuclides from below the soil surface into the human food chain.

Non-axisymmetric end wall profiling is now a well established design methodology in axial flow turbines, used principally to improve their aerodynamic efficiency by reducing secondary loss. However, profiled end walls (PEWs) have yet to find an in-service application in a gas turbine compressor. This two-part paper presents the results of a number of studies, both experimental and computational, into the potential aerodynamic benefits of applying PEWs in axial flow compressors. The first paper reports research carried out using a linear compressor stator cascade at Cambridge University. The datum geometry was based on previous research with this cascade. The PEW geometry was generated using a method that had been proven to reduce secondary loss in turbine blade rows. Data was taken on the datum and PEW geometries in the form of exit area traverses and surface static pressure measurements. The experiments demonstrated improvements to the exit flow field in terms of local reductions in the loss and under-turning in the secondary flow region due to the PEW. It was found that the original design method had over estimated the benefits of the PEW. The datum and PEW geometries were further analysed using state-of-the-art CFD (Computational Fluid Dynamics). The CFD is shown to achieve very good agreement with measurement at the design condition and a reasonable, qualitative match at off-design. It is concluded that the PEW geometry, though not optimum, effected predictable changes to the compressor stator flow field. The mechanisms for these effects are discussed and conclusions are drawn for taking the work forward. In particular, a mechanism is identified whereby the PEW enhances the cross-flow on the end wall and the subsequent radial migration of the secondary flow adjacent to the aerofoil suction surface. The control of corner stall by means of this flow mechanism is highlighted as a possible area for further investigation. This is followed up in the second paper, which presents a computational study of applying PEWs to a multi-stage HP compressor.Copyright © 2008 by Rolls-Royce plc

Non-axisymmetric end wall profiling is now a well established design methodology in axial flow turbines, used principally to improve their aerodynamic efficiency by reducing secondary loss. However, profiled end walls (PEWs) have yet to find an in-service application in a gas turbine compressor. This two-part paper presents the results of a number of studies, both experimental and computational, into the potential aerodynamic benefits of applying PEWs in axial flow compressors. The second paper describes an investigation into PEWs as a means of suppressing stator hub corner stall. An in-house design optimisation system (SOPHY) was applied to a typical embedded stator row in a multi-stage HP compressor. This enabled a new PEW geometry to be defined which is shown to be an effective alternative to 3-D aerofoil shaping in controlling stator hub corner stall. The results of this new study and of the work described in the first paper have been combined in a further investigation. PEWs were applied to an HPC with purely 2-D blading, which exhibited extensive stator hub corner stall at off-design conditions. CFD analysis showed that stator hub corner stall was successfully suppressed by the PEWs. It is concluded that PEWs can significantly affect the end wall flow field and have similar effects on corner stall as 3-D blading. The potential for improving the performance of axial flow compressors using PEWs is discussed. To successfully achieve any such improvements, extensive computational resources that are dedicated to design optimisation will be required.Copyright © 2008 by Rolls-Royce plc

The composition of the time-resolved surface pressure field around a high-pressure rotor blade caused by the presence of neighbouring blade rows is investigated with the individual effects of wake, shock and potential field interaction being determined. Two test geometries are considered: first, a high-pressure turbine stage coupled with a swan-necked diffuser exit duct; secondly, the same high-pressure stage but with a vane located in the downstream duct. Both tests were conducted at engine-representative Mach and Reynolds numbers and experimental data was acquired using fast-response pressure transducers mounted on the mid-height streamline of the HP rotor blades. The results are compared to time-resolved computational predictions of the flowfield in order to aid interpretation of experimental results and to determine the accuracy with which the computation predicts blade interaction. In the first half of this paper it is shown that, in addition to the two main interaction mechanisms (upstream vane-rotor and rotor-downstream vane interactions, presented in Miller et al. [1]) a third interaction occurs. This new interaction mechanism is shown to be caused by the interaction between the downstream vane’s potential field and the upstream vane’s trailing edge potential field and shock. The unsteady rotor surface static pressure fluctuations caused by this interaction are shown to occur on the late rotor suction surface at a frequency corresponding to the difference in the numbers of upstream and downstream vanes. The second part to the paper discusses the mechanisms that cause vane-rotor-vane interaction. The rotor’s operating point is periodically altered as it passes the downstream vane. It is shown that for a large downstream vane, the flow conditions in the rotor passage, at any instant in time, are close to being steady state.

The composition of the time-resolved surface pressure field around a high-pressure rotor blade caused by the presence of neighboring blade rows is investigated, with the individual effects of wake, shock and potential field interaction being determined. Two test geometries are considered: first, a high-pressure turbine stage coupled with a swan-necked diffuser exit duct; secondly, the same high-pressure stage but with a vane located in the downstream duct. Both tests were conducted at engine-representative Mach and Reynolds numbers, and experimental data was acquired using fast-response pressure transducers mounted on the mid-height streamline of the HP rotor blades. The results are compared to time-resolved computational predictions of the flowfield in order to aid interpretation of experimental results and to determine the accuracy with which the computation predicts blade interaction. The paper is split into two parts, the first investigating the effect of the upstream vane on the unsteady pressure field around the rotor (vane-rotor interaction) and the second investigating the effect of the downstream vane on the unsteady pressure field around the rotor (rotor-vane interaction). The paper shows that at typical design operating conditions shock interaction from the upstream blade row is an order of magnitude greater than wake interaction and that with the design vane-rotor inter-blade gap the presence of the rotor causes a periodic increase in the strength of the vane trailing edge shock. The presence of the potential field of the downstream vane is found to affect significantly the rotor pressure field downstream of the Mach one surface within each rotor passage.

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.

Thin film heat transfer gauges have been instrumented onto flexible plastic substrates which can be adhesively bonded to plastic or metal models. These new gauges employ standard analysis techniques to yield the heat flux to the model surface and have significant advantages over gauges fired onto machinable glass or those used with metal models coated with enamel. The main advantage is that the construction of the gauges is predictable and uniform, and thus calibration for thickness and geometric properties is not required. The new gauges have been used to measure the heat transfer to an annular turbine nozzle guide vane in the Oxford University Cold Heat Transfer Tunnel. Engine-representative Mach and Reynolds numbers were employed and the free-stream turbulence intensity at NGV inlet was 13%. The vanes were either precooled or preheated to create a range of different thermal boundary conditions. The gauges were mounted on both perspex and aluminium NGVs and the heat transfer coefficient was obtained from the surface temperature history using either a single layer analysis (for perspex) or double layer (for aluminium) analysis. The surface temperature and heat transfer levels were also measured using rough and polished liquid crystals under similar conditions. The measurements have been compared with computational predictions.

Aerodynamic and heat transfer measurements have been made on the hub and casing endwalls of an annular cascade of high pressure nozzle guide vanes. The measurements have been made over a range of engine representative Mach and Reynolds numbers and with large levels of freestream turbulence intensity. The transient liquid crystal technique has been employed, which has the advantage of yielding full surface maps of heat transfer coefficient. Computational predictions and aerodynamic measurements of Mach number distributions on the endwall surfaces are also presented, along with surface-shear flow visualisation using oil and dye techniques. The heat transfer results are discussed and interpreted in terms of the secondary flow and Mach number patterns.

Detailed measurements of surface static pressures and heat transfer rates on the aerofoil and hub end wall of an annular nozzle guide vane (in the absence of a downstream rotor) are presented. Heat transfer rates have been measured using thin film gauges in an annular cascade in the Pyestock Isentropic Light Piston Cascade. Test Mach numbers, Reynolds numbers and cascade geometry are fully representative of engine conditions. The results of 3-D calculations of surface Mach number and 2-D calculations of aerofoil heat transfer are presented and compared with the measurements. A new method of calculating end wall heat transfer using the axisymmetric analogue for three-dimensional boundary layers is described in detail. The method uses a 3-D Euler solver to calculate the inviscid surface streamlines along which heat transfer coefficients are calculated. The metric coefficient which describes the lateral convergence or divergence of the streamlines is used to include three-dimensional effects in the calculation. The calculated heat transfer rates compare well with the measured values. Reference is made to surface flow visualization in the interpretation of the results.

The interaction between a high-pressure rotor and a downstream vane is dominated by vortex-blade interaction. Each rotor blade passing period two co-rotating vortex pairs, the tip-leakage and upper passage vortex and the lower passage and trailing shed vortex, impinge on, and are cut by, the vane leading edge. In addition to the streamwise vortex the tipleakage flow also contains a large velocity deficit. This causes the interaction of the tip-leakage flow with a downstream vane to differ from typical vortex blade interaction. This paper investigates the effect these interaction mechanisms have on a downstream vane. The test geometry considered was a low aspect ratio second stage vane located within a S-shaped diffuser with large radius change mounted downstream of a shroudless high-pressure turbine stage. Experimental measurements were conducted at engine-representative Mach and Reynolds numbers, and data was acquired using a fastresponse aerodynamic probe upstream and downstream of the vane. Time-resolved numerical simulations were undertaken with and without a rotor tip gap in order to investigate the relative magnitude of the interaction mechanisms. The presence of the upstream stage is shown to significantly change the structure of the secondary flow in the vane and to cause a small drop in its performance.