Detection of Blade Mistuning in a Low Pressure Turbine Rotor Resulting from Manufacturing Tolerances and Differences in Blade Mounting

For a serious prediction of vibration characteristics of any structure, a detailed knowledge of the modal characteristic is essential. This is especially important for bladed turbine rotors. Mistuning of the blading of a turbine rotor can appear due to manufacturing tolerances or because of the blading process itself due to unequal mounting of the blades into the disk. This paper investigates the mistuning of the individual blades of a low pressure turbine with respect to the effects mentioned above. Two different rotors with different aerodynamic design of the blades were investigated. The blades were mounted to the disk with a so-called hammer head root which is especially prone to mounting irregularities. For detailed investigations, the rotor was excited with a shaker system to detect the forced response behavior of the individual blades. The measurements were done with a laser vibrometer system. As the excitation of rotor structure was held constant during measurement, it was possible to detect the line of nodes and mode shapes as well. It could be shown that the assembly process has an influence on the mistuning. The data were analyzed and compared with numerical results. For this, different contact models and boundary conditions were used. The above described characterization of modal behavior of the rotor is the basis for the upcoming aeroelastic investigations and especially for the blade vibration measurements of the rotor, turning with design and off-design speeds.

Effects of stator bending on pressure field and loss of transonic turbine stage

To study effects of the upstream flow field changing on the downstream flow field of transonic turbine, different three-dimensional bowed blades, which are the stator blades of transonic turbine stage, were designed in this paper. And then numerical calculations were carried out. The effects on downstream flow field were studied and analyzed in detail. Results show that, at the middle of stator blades, although the increasing Maeh number causes the increase of shock-wave strength and friction, the middle flow field of downstream rotors is improved obviously. It is an important change in transonic condition. This causes the loss of the rotor＇ s middle part decreased greatly. Correspondingly, efficiency of the whole transonic stage can be increased.

Effects of Freestream Turbulence,Reynolds Number and Mach Number on the Boundary Layer in a Low Pressure Turbine

In order to investigate the aerodynamics of a high speed low pressure turbine works in high Mach number and low Reynold number environment,the effect of freestream turbulence(FST)on the boundary layer development on the high speed low pressure turbine under different Reynolds numbers(Re)is numerically investigated.Large eddy simulation is adopted here with a subgrid scale model of Wall Adapting Local Eddy viscosity(WALE).Cases with Re ranging from 100000 to 400000 under an exit Mach number(Ma)of 0.87 have been considered at low and high FST levels.A low Ma case(0.17)under very low Re has also been studied under both low and high FST.It is found that higher Re or FST level leads to earlier transition.Re has a greater effect than FST on the development of boundary layer.The effect of FST on the boundary layer depends on the Re.The boundary layer development shows totally different behaviors under different Ma.A separation bubble could be formed under low Ma while no attachment could be detected under high Ma.The FST has a stronger effect on the separated boundary layer under low Ma,which could eliminate the separation in the present study.For all the cases under low FST,the Kelvin-Helmholtz instability is the dominate mechanism in the transition process.For the low Ma case with high FST,the streamwise streaks play a dominant role in the transition process.For the high Ma cases with high FST,both the streamwise streaks and Kelvin-Helmholtz instability work in the transition process.The streamwise streaks play a more important role when the Re increased.

Preparation and characterization of LPPS NiCoCrAlYTa coatings for gas turbine engine

NiCoCrAlYTa coatings have been deposited onto an aircraft gas turbine engine blade using a LPPS unit equipped with a computerized robot. Optimal processing conditions, including spray parameters, the trajectory of the robot, and the synchronized movements between the torch and the blade, have been developed for superior coating properties. Transferred arc treatment, providing a preheating and a cleaning of the substrate surface, enhances the adherence of the coatings to the substrate. The resulting LPPS coatings show dense and uniform characteristics with ideal hardness, and good corrosion resistance to cycle oxidation.

Numerical investigation on bowed blades of large meridional expansion Turbine

To improve the performance of the Turbofan engine,several measures should be considered during design process.Such measures,relating to aerodynamic characteristic design,include the maximum enthalpy per stage,the shortest axial length,the minimum blade rows and the highest efficient in design and off design condition.To satisfy theses design characters,the meridian geometry of the engine will be excurvature at a high degree transition part between HP and LP turbines.The study is to investigate the effect of blade bowing on flow loss at blade tip and root of the type of turbine.Such turbine,tending towards separation,with severe secondary flow at the tip and strong radial flow at exit,was simulated by the 3D N-S solver Numerca,and there were several different stacking line bowing schemes in all.The results show that tip negative bowing and root positive bowing is able to weaken radial flow,consequently reduce the flow loss at the tip and root.

Pressure fluctuation propagation of a pump turbine at pump mode under low head condition

Pressure fluctuation at the vaneless space and vanes passages is one of the most important problems for the stable operation of a pump turbine. The fluctuation appears in any operating condition. Much research has been done on the pressure fluctuation of hydraulic machinery. However, the details of pressure fluctuation propagation of the pump turbine at the pump mode have not been revealed. The modem pump turbine with high water head requires the runner to be ＂flat＂, which would induce pressure fluctuation more easily than the low head pump turbine. In this article, a high head pump turbine model is used as the re- search object. As the pressure fluctuation at off-design point is more serious than at the design point, the low head condition is chosen as the research condition. Pressure fluctuation at the vaneless space and vanes passages is predicted by the computa- tional fluid dynamics method based on k-co shear stress transport model. The experiment conducted on the test rig of the Har- bin Institute of Large Electrical Machinery is used to verify the simulation method. It proves that the numerical method is a feasible way to research the fluctuation under this operating condition. The pressure fluctuation along the passage direction is analyzed at time and frequency domains. It is affected mainly by the interaction between the runner and vanes. In the circumferential direction, the influence of the special stay vane on the pressure fluctuation is got. The amplitude in the high-pressure side passage of that vane is lower than that in the other side. The study provides a basic understanding of the pressure fluctua- tion of a pump turbine and could be used as a reference to improve the operation stability of it.

分流叶片对液力透平压力脉动的影响

为揭示分流叶片对低比转速液力透平性能的影响,以一台低比转速离心泵(n_(s)=33)反转作液力透平为例,设计出4种不同分流叶片数的叶轮(复合叶轮),通过CFX软件对原始叶轮和4种复合叶轮进行数值模拟并对比分析。结果表明,4种新模型在最优工况下效率和水头均有所提高,其中当分流叶片数Z=6+6时液力透平的性能最佳,在最优工况下效率、水头分别提高了2.23%、6.83%;叶轮内压力分布更加均匀;叶轮进口漩涡区域减弱;内部各个监测点压力系数、脉动幅值均小于原始模型,说明分流叶片可以降低液力透平内部的压力脉动、提升透平机组运行的稳定性。研究结果可为低比转速液力透平性能提升提供参考。

16m双柱立车在核电汽轮机低压内缸研制中的必要性分析

本文根据自主型核电汽轮机低压内缸结构、尺寸、重量、精度,加工现状,以及核电汽轮机发展趋势和市场前景,提出了添制16 m双柱立车在核电汽轮机低压内缸研制中的必要性,同时拟定了机床的主要技术参数。

Effect of Leading-Edge Optimization on the Loss Characteristics in a Low-Pressure Turbine Linear Cascade

This paper presents a numerical study on the aerodynamics loss reduction characteristics after the leading-edge(LE) optimization in a low-pressure turbine linear cascade. The LE was optimized with a simple and practical method of "Class Function/Shape Function Transformation Technique"(CST). The simulation conditions, covering the whole working range, were independently determined by incidence, Reynolds number and Mach number. Quantitative loss analyses were carried out with a loss breakdown method based on volumetric integration of entropy production rates. To understand the reason of loss reduction, the local sources at different operating points were identified with entropy production rates. The results showed that LE optimization with the CST method played a positive role in decreasing the total losses, and the working range with lower loss was extended. The profile loss and the endwall loss were significantly reduced by the LE optimization, which were also verified to be the major causes of the total loss reduction by loss breakdown. The decrease of profile loss can be attributed to the boundary layer near the LE region and the boundary layer of downstream at off-design incidence. The reduction mostly came from the pressure side at negative incidence, while came from the suction side at the positive incidence. The endwall loss was decreased markedly about 2.5%–5% by the LE optimization at the incidence of-12°, which was 1% at the incidence of 12°. The mechanism for the endwall loss reduction at different incidences was different from each other. At negative incidence, the LE optimization diminished the corner separation vortex on the pressure side. While at positive incidence, the benefits came from three aspects, i.e., reduced suction LE separation bubbles close to the endwall, reduced passage vortex strength, and weakened shear process between passage vortex and trailing shed vortex. The loss of the downstream zone was relatively lower than that of the profile losses and the endwall losses. The effect of LE optimization on the loss of the downstream zone at different conditions was complex and it depended both on the profile boundary layer behavior at the suction trailing edge and on the passage vortex strength.

High fidelity numerical simulations on the unsteady flow field of low-pressure turbine cascades with and without upstream disturbance at moderate Reynolds number

This paper numerically investigates the aerodynamic performance of the T106A low-pressure turbine based with different inflow conditions at moderate Reynolds number by using high performance computing based on high order unstructured methods.Two different inflow conditions respectively of uniform and disturbed are considered,while for the latter a small circular cylinder is placed upstream of the cascade to generate wake turbulence as a long-standing disturbance.A high order Fourier-spectral/hp element method is employed to solve the flow dynamics in the cascade of high complex geometries.Flow transition characteristics are quantified in terms of the distribution of cascade wall surface pressure and friction coefficient,the distribution of wake profile pressure loss and the evolution characteristics of boundary layer flow structures as well.The numerical results show that the current numerical simulations accurately predict the flow transition performance of low-pressure turbine cascades and capture the effects of wake-generated disturbance on the cascade,which is shown to effectively modify the flow transition performance as compared with the uniform inflow case.

A Comparison of Experimental and Numerical Studies Performed on a Low-Pressure Turbine Blade Cascade at High-Speed Conditions, Low Reynolds Numbers and Various Turbulence Intensities

This paper focuses on a comparison of experimental and numerical investigations performed on a low-pressure mid-loaded turbine blade at operating conditions comprised of a wide range of Math numbers （from 0.5 - 1.1）, Reynolds numbers （from 0.4e＋5 - 3.0e＋5）, flow incidence （-15 - 15 degrees） and three levels of free-stream tur- bulence intensities （2, 5 and 10%）. The experimental part of the work was performed in a high-speed linear cas- cade wind tunnel. The increased levels of turbulence were achieved by a passive grid placed at the cascade inlet. A two-dimensional flow field at the center of the blade was traversed pitch-wise upstream and downstream the cascade by means of a five-bole probe and a needle pressure probe, respectively. The blade loading was measured using the surface pressure taps evenly deployed at the blade mid-span along the suction and the pressure side. The inlet turbulence was investigated using the constant temperature anemometer technique with a dual sensor probe. Experimentally evaluated values of turbulent kinetic energy and its dissipation rate were then used as inputs for the numerical simulations. An in-house code based on a system of the Favre-averaged Navier-Stokes equation closed by a two-equation k-co turbulence model was adopted for the predictions. The code utilizes an algebraic model of bypass transition valid both for attached as for separated flows taking in account the effect of free-stream turbulence and pressure gradient. The resulting comparison was carried out in terms of the kinetic en- ergy loss coefficient, distributions of downstream wakes and blade velocity. Additionally a flow visualization was performed by means of the Schlieren technique in order to provide a further understanding of the studied phe- nomena. A few selected cases with a particular interest in the attached and separated flow transition are compared and discussed.

Experimental Analysis of the Aerodynamic Performance of an Innovative Low Pressure Turbine Rotor

In the present work the aerodynamic performances of an innovative rotor blade row have been experimentally investigated. Measurements have been carried out in a large scale low speed single stage cold flow facility at a Reynolds number typical of aeroengine cruise, under nominal and off-design conditions. The time-mean blade aerodynamic loadings have been measured at three radial positions along the blade height through a pressure transducer installed inside the hollow shaft, by delivering the signal to the stationary frame with a slip ring. The time mean aerodynamic flow fields upstream and downstream of the rotor have been measured by means of a five-hole probe to investigate the losses associated with the rotor. The investigations in the single stage research turbine allow the reproduction of both wake-boundary layer interaction as well as vortex-vortex interaction. The detail of the present results clearly highlights the strong dissipative effects induced by the blade tip vortex and by the momentum defect as well as the turbulence production, which is generated during the migration of the stator wake in the rotor passage. Phase-locked hot-wire investigations have been also performed to analyze the time-varying flow during the wake passing period. In particular the interaction between stator and rotor structures has been investigated also under off-design conditions to further explain the mechanisms contributing to the loss generation for the different conditions.

Numerical Investigation of the Interaction between Mainstream and Tip Shroud Leakage Flow in a 2-Stage Low Pressure Turbine

The pressing demand for future advanced gas turbine requires to identify the losses in a turbine and to understand the physical mechanisms producing them. In low pressure turbines with shrouded blades, a large portion of these losses is generated by tip shroud leakage flow and associated interaction. For this reason, shroud leakage losses are generally grouped into the losses of leakage flow itself and the losses caused by the interaction between leakage flow and mainstream. In order to evaluate the influence of shroud leakage flow and related losses on turbine performance, computational investigations for a 2-stage low pressure turbine is presented and discussed in this paper. Three dimensional steady multistage calculations using mixing plane approach were performed including detailed tip shroud geometry. Results showed that turbines with shrouded blades have an obvious advantage over unshrouded ones in terms of aerodynamic performance. A loss mechanism breakdown analysis demonstrated that the leakage loss is the main contributor in the first stage while mixing loss dominates in the second stage. Due to the blade-to-blade pressure gradient, both inlet and exit cavity present non-uniform leakage injection and extraction. The flow in the exit cavity is filled with cavity vortex, leakage jet attached to the cavity wall and recirculation zone induced by main flow ingestion. Furthermore, radial gap and exit cavity size of tip shroud have a major effect on the yaw angle near the tip region in the main flow. Therefore, a full calculation of shroud leakage flow is necessary in turbine performance analysis and the shroud geometric features need to be considered during turbine design process.

超低负荷工况下汽轮机末级运行特性及其优化机制探索

构建以新能源为主体的新型电力系统,对燃煤发电机组深度调峰和超低负荷运行提出了越来越严苛的要求,进而对汽轮机组低负荷安全运行提出了越来越严峻的挑战。采用数值模拟方法,基于低负荷工况下汽轮机末级运行性能的深入分析,着重研究探索了不同解决方案在超低负荷工况下的工作机理与优化效果。研究发现,当机组从中低负荷下降到超低负荷时,末级叶片附近出现间隙涡、回流涡和分离涡等涡群,其范围随着负荷的减小逐渐扩大。低负荷工况降低机组背压和低压缸切缸运行是弱化汽轮机涡流、提高末级性能的有效途径,二者结合使用效果更佳。例如,在20%热耗率验收(THA)工况条件下,将背压从4.9 k Pa降低到2.5 k Pa,使得末级涡群影响范围明显减小,转子叶片转矩从–38 N·m增加到73N·m,末级运行性能明显改善。在10%THA工况下,采用降低背压和低压缸切缸相结合可使叶顶间隙涡完全消失,回流涡和分离涡的径向长度都减小50%以上;优化后的动叶转矩增加了约130 N·m,末级运行性能改善效果显著。

基于IGWO-SVM的汽轮机低负荷下主蒸汽压力优化研究

为提高汽轮机低负荷下的运行效率,需要对主蒸汽压力进行优化。根据机组实际运行数据,采用支持向量机(SVM)算法建立了热耗率预测模型,并利用改进的灰狼优化(IGWO)算法优化SVM模型超参数;在此基础上,利用IGWO算法在低负荷下的可行压力区间进行寻优,得到了优化后的汽轮机滑压曲线,并且进行了实例验证。结果表明:利用IGWO算法优化的热耗率预测模型能够对低负荷下的热耗率进行准确预测;优化后机组在低负荷下的热耗率均有所下降,在负荷为223.83 MW时,热耗率降低了505.96 kJ/(kW·h),降低幅度最大。研究结果表明所提的优化方案可以有效提高汽轮机低负荷下的热经济性。

不同开度可调涡轮导叶前缘气膜冷却效果研究

针对变循环发动机的可调低压涡轮导叶开展了不同开度下的前缘气膜冷却效果研究。采用数值仿真的方法,研究了5种典型导叶开度下的导叶表面压力系数分布规律,探究了开度与冷气吹风比对叶片前缘气膜出流特性和覆盖特性的影响规律。结果表明:导叶开度的减小导致前缘的气动驻点位置向压力面方向移动,造成前缘冷气射流更多地流向吸力面侧,使吸力面气膜冷却效率提高;此外,导叶开度的减小导致吸力面与压力面的冷气贴壁效果都有提高,但两者的具体机理不同。导叶开度的变化对前缘气膜孔最佳吹风比影响较小,不同开度下的最佳吹风比都在1.0附近。由于导叶开度为0°时滞止线位于气膜孔排4之上,堵塞效应显著,与开度为5°、−5°条件相比,面平均气膜冷却效率降低了13.6%。

裂解气压缩机技术更新与节能探讨

对某乙烯装置裂解气压缩机GB-201存在的操作难度大、压缩机效率低、能耗高等问题进行分析发现,机组存在服役时间长、机体内密封不严和油环老化、内部窜气、三段出口超压等设备隐患,为此,采用抽汽量大的高效透平驱动机及高效三元叶轮压缩机,对压缩机组及附属设备进行整体更新。改造后,在相同工况下,压缩机效率明显提高,有效改善了装置的能耗,为乙烯装置裂解气压缩机解决此类问题提供了宝贵的经验。

超低压蒸汽透平内部流动特性分析

超低压蒸汽余热回收透平成套装备是一种新型蒸汽回收装置,能够实现对超低压蒸汽余热的高效回收。该装备内部流场在变工况运行过程时较为复杂,复杂流动诱发的振动会严重危害机组的安全运行。文章针对不同进汽流量下的蒸汽透平机组稳态流场特性和压力脉动特性进行了分析。研究结论显示,进汽流量降低时,流场出口处从末级动叶叶根开始出现回流,并且进一步从此叶根向叶顶以及次末级扩张;低流量工况下,末级叶片叶顶的动静叶间隙出现诱发振动的涡流,导致叶顶处压力脉动出现宽频带。

纤维增强复合材料涡轮轴失效模式分析方法验证

针对连续纤维增强复合材料涡轮轴结构失效模式分析问题,基于宏-细观力学跨尺度分析方法,建立了与轴结构试验件尺寸相符合的有限元仿真计算模型,预测轴结构的危险位置并计算应变和位移响应,与试验结果进行对比验证。通过研究层合板主偏轴之间的关系应力的转化,将危险单元各个方向的宏观应力响应计算结果转化到细观力学RVE模型上,即为细观力学RVE模型受载情况;建立细观力学代表性体积元(RVE)模型,通过编程模拟实现模型的周期性边界条件,模拟复合材料轴结构损伤演化情况,并计算纤维增强复合材料应力响应,确定失效包线,结合损伤演化过程判别轴结构危险位置失效模式。开展复合材料失效模式验证试验,通过声发射及扫描电镜技术,实现对失效过程中不同失效模式的判别。将模拟仿真计算结果与试验结果对比分析,验证连续纤维增强复合材料涡轮轴结构失效模式分析方法的有效性。

反动式工业汽轮机超高转速大流量低压级组优化

杭汽轮引进的西门子反动式工业汽轮机低压扭叶级组在转速和热力性能方面已经无法满足现有市场的需求。针对上述问题,采用优化算法对该系列叶型进行优化,同时,引入了斜T型叶根和枞树型叶根,改进了T型末叶根骑缝螺杆锁紧结构,提高了叶片和转子的材料等级,此外,还通过分析已运行的同类型低压级组的运行数据,推算出优化后级组的最大许用质量流量。综上,优化后的级组子午面尺寸未发生改变,总总效率较优化前最高提高了2.5%,最高连续转速提高了20%,且通流能力保持不变。