Unsteady Effects OF A Generic Non-Axisymmetric Rotor Endwall Contour ON A 1 Stage Turbine Test RIG AT OFF Design Conditions
Unsteady Effects OF A Generic Non-Axisymmetric Rotor Endwall Contour ON A 1 Stage Turbine Test RIG AT OFF Design Conditions
Unsteady Effects OF A Generic Non-Axisymmetric Rotor Endwall Contour ON A 1 Stage Turbine Test RIG AT OFF Design Conditions
GT2014
June 16 – 20, 2014, Düsseldorf, Germany
GT2014-25524
ABSTRACT that of the annular rotor. The rotor outlet flow was thus more
With the current drive to improve fuel efficiency and reduce uniform due to the more dispersed vortex system. As seen with
emissions, in gas turbine engines various methods have been in- the experimental results, the extent of the change due to the con-
vestigated. Previously it has been shown that a generic rotor toured rotor changes with loading. The differences present in the
endwall contour could improve the efficiency of a 1 ½ stage test decreased loading case being relatively insignificant.
turbine at design conditions. The current investigation looked It was concluded that the generic contour does not intro-
at the increased and decreased loading conditions to determine duce any unsteady effects at off design conditions that were not
if the contour introduces detrimental effects at off design condi- observed in the design case.
tions.
A previous unsteady analysis of the design condition found
that the contoured rotor does have an effect on the flow field, NOMENCLATURE
reducing the magnitude of the hub endwall secondary flow region α Absolute yaw angle (◦ )
as well as reducing fluctuations in the velocity. S Span (mm)
Experimental results showed that the increased load case C Absolute velocity (m/s)
presented with an increase in hub endwall secondary flow struc- W Relative velocity (m/s)
ture when compared to the design case. This increase was to be φ Flow Coefficient (-)
expected due to the increased turning of the flow due to the in-
creased loading operating condition. The contoured rotor had Subscripts:
a weaker hub endwall secondary flow system, with the high mo- t Tangential
mentum flow distributed more in the span wise direction. The x Axial
variation in the velocity was also found to be smaller for the 3 Rotor outlet
contoured rotor. stage From stator inlet to rotor outlet
The decreased loading case showed similar improvements,
but the extent of the change was less due to the lower turning of
the flow (due to a faster rotor).
INTRODUCTION
The numerical results show that the hub endwall secondary
Several researchers have been shown that secondary flows
flow vortex of the contoured rotor was not as tightly wrapped as
and the resulting losses [1, 2, 3, 4] exist in turbomachinery. Sec-
ondary losses are those losses that occur due to the endwall
∗ Address all correspondence to this author.
not tested in this investigation, the rotor speeds tested can be seen
in Table 3. The instrumentation can be seen in Table 2
The Durham cascade blade profile used by Ingram [3] was
used at the hub to allow the use of a similar generic hub end-
wall contouring. The tip and the stators were designed using the
inverse design method [11] such that the rig had the operating
conditions as listed in Table 1. Fig. 3 shows a 3D representation
of the final hub endwall contour as used in the current investiga-
FIGURE 4: CONVENTIONS USED FOR ANGLES AND VE-
tion.
LOCITIES
Primary Instrumentation
Secondary Instrumentation
Unsteady Flow Mapping TSI Model 1240 Standard Cross Flow “X” Probe ±0.77% mean velocity
Tangential Traverse Custom cable system Better than 0.01◦
Radial and Custom two component backlash free 0.01mm
Yaw traverse traverse driven by Cool Muscle® drives 0.1◦
unsteady velocity field, the absolute rotor exit flow angle vari-
ation is required. The probe was rotated using a custom yaw
traverse as shown in Table 2. To reduce the effects of hysteresis
TABLE 3: SPANWISE DISTRIBUTION OF YAW ANGLE
the probe was always rotated the same direction, in cases where
USED DURING UNSTEADY TESTING
the opposite direction of rotation was required the angle was ex-
ceeded then rotated back.
Test Case Rotor Speed Incidence
(RPM) Angle (◦ ) The FFT’s presented were taken of the raw data (all 65536
samples), and not the phase lock averaged data to prevent
Increased loading 1907 +5◦ elimination of potentially interesting frequencies (ambient noise
would be consistent). The raw data was parsed such that the start
Decreased loading 2820 −5◦
and end of the data set were at the same phase with respect to the
rotor location (i.e. rectangular window).
TABLE 4: SPANWISE DISTRIBUTION OF YAW ANGLE
USED DURING UNSTEADY TESTING
1 m/s
1 m/s
1 m/s
0 0
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
Velocity magnitude (m/s) Velocity magnitude (m/s)
FIGURE 6: INCREASED LOADING CASE: COMPARISON OF VELOCITY MAGNITUDE DOWNSTREAM OF THE ROTOR
Multiples of blade passing frequency (-) Multiples of blade passing frequency (-)
0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
100 100
90 90
80 80
70 70
Spanwise Location (%)
60 60
50 50
40 40
30 30
20 20
10 10
1 m/s
1 m/s
0 0
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 0 3 6 9 12 15 18 21 24 27 30 33 36 39 42
Velocity magnitude (m/s) Velocity magnitude (m/s)
FIGURE 7: REDUCED LOADING CASE: COMPARISON OF VELOCITY MAGNITUDE DOWNSTREAM OF THE ROTOR
parison between the numerical and experimental results. Sned- The contour plots in Fig. 10 and Fig. 11 show that at approx-
den et al. [15] found a similar difference, however there was a imately mid span the hub endwall secondary flow vortex system
difference between the annular and contoured results evident in has reduced in strength for the contoured rotor, as can be seen
both numerical and experimental results. by the reduced underturning (blue contour at “A”) and overturn-
ing (red contour at “B”). In other words there was an increase
As seen by Dunn et al. [19] for the design case, the compari- in relative yaw angle in the under-turned region, while having
son of the flow in the tip leakage region was not as well predicted a reduction to relative yaw angle in the overturned region. The
as would be expected. It was speculated that this difference was contoured rotor relative outlet flow angle having one less contour
due to the experimental setup that was independent of measure- level. The relative velocity magnitude contour in Fig. 11 shows a
ment technique. Both steady and unsteady experimental results hub endwall secondary flow vortex structure which was slightly
(using different measurement principles, 5 hole probe as opposed reduced in size in both azimuthal and spanwise directions.
to hotfilm) show similar differences in the tip leakage region and
therefore cannot be attributed to sampling technique. Looking at the tip leakage vortex in Fig. 10 and 11 it can be
90 90
80 80
70 70
Spanwise Location (%)
50 50
40 40
30 30
20 20
FIGURE 8: COMPARISON OF THE ANNULAR AND CONTOURED FFT MAGNITUDE AT THE BLADE PASSING FREQUENCY
1000
Design Annular Contoured Annular CFD Contoured CFD
Relative Yaw Angle (deg)
(%)
an
Sp
0 10 20 30 40 50 60 70 80
100 100
90 90
80 80
70 70
60 60
Span (%)
Span (%)
50 50
40 40
30 30
20 20
10 10
0 0
0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70
Relative Yaw Angle (deg) Relative Velocity (m/s)
FIGURE 9: INCREASED LOADING CASE: COMPARISON OF ANNULAR AND CONTOURED CFD AND EXPERIMENTAL
RESULTS
seen that the tip region (specifically in the region of the vortex) in blade loading. The numerical and experimental results show
for both the annular and contoured have negligible differences. reasonable correlation, except at the tip and hub endwall sec-
ondary flow vortex as discussed previously.
FIGURE 10: INCREASED LOADING CASE: COMPARISON OF ANNULAR AND CONTOURED CFD RELATIVE OUTLET
FLOW ANGLE CONTOURS
FIGURE 11: INCREASED LOADING CASE: COMPARISON OF ANNULAR AND CONTOURED CFD RELATIVE VELOCITY
MAGNITUDE
found for the design case, [19]. and modified to prevent the blade from rubbing against the cas-
The steady CFD analysis of Snedden et al. [15] showed that ing. Transfer of the engineering blue to the casing indicated the
the tip leakage flow of the annular and contoured rotor were sig- blades that rubbed, but it also indicated the region of rub on the
nificantly different when compared to the difference seen in the casing. Using this it was found the axial chord of the rotor blade
unsteady results presented above. Since Snedden et al. [15] used at the tip was smaller than the region of rub (i.e. the axial chord
the same mesh as used in the current investigation, using the during operation). Which implies that the blade (which was man-
same turbulence model and solver settings, thus it was felt that ufactured from polyamide) flexes in the tip region during testing.
the differences in annular and contoured steady state numerical The rotor exit relative yaw angle in Fig. 9a and 12a agrees well
results due to the tip leakage flows was due to unsteadiness in the with this as it shows the flow under-turns in both increased load-
flow that could not be dealt with using a steady state solver. ing and decreased loading cases. With the rotor blade acting as
In order to investigate the cause of the experimental differ- a cantilever with the thinnest point being the blade tip it was ex-
ence of the contoured and annular rotor tip flow in this and previ- pected that the influence of this flexure would reduce with span,
ous investigations, the test rig was scrutinised. At the start of the yet be consistent between annular and contoured rotor. This is
test campaign it was found that some of the blades rubbed against born out of the correlation of the numerical and experimental re-
the casing. Using a high contrast dye these blades were identified sults below 70% span. The extent of the flexure will form part of
(%)
an
Sp
0 10 20 30 40 50 60 70 80
100 100
90 90
80 80
70 70
60 60
Span (%)
Span (%)
50 50
40 40
30 30
20 20
10 10
0 0
0 10 20 30 40 50 60 70 80 0 10 20 30 40 50 60 70
Relative Yaw Angle (deg) Relative Velocity (m/s)
FIGURE 12: DECREASED LOADING CASE: COMPARISON OF ANNULAR AND CONTOURED CFD AND EXPERIMENTAL
RESULTS
FIGURE 13: DECREASED LOADING CASE: COMPARISON OF ANNULAR AND CONTOURED CFD RELATIVE OUTLET
FLOW ANGLE CONTOURS
FIGURE 14: DECREASED LOADING CASE: COMPARISON OF ANNULAR AND CONTOURED CFD RELATIVE VELOCITY
MAGNITUDE