An important problem that arises in the design and the performance of axial flow turbines is the understanding, analysis, prediction and control of secondary flows. Sieverding1 has given a review of secondary flow literature, covering up to 1985. In this paper a brief review of pre-1985 work is given, and then a survey of open literature secondary flow investigations since the Sieverding review is presented. Most of the studies reviewed deal with plane or annular cascade flows. Tip clearance effects are not covered. The basic secondary flow picture for a turbine cascade, as measured and verified by a number of investigators is described. Recent work that shows refined secondary flow vortex structures is examined. A flow parameter based on inlet boundary layer properties used to predict horseshoe vortex swirl is presented. Work on secondary flow loss reduction, involving airfoil geometry, endwall fences and endwall contouring is briefly reviewed. A new leading edge bulb geometry that has demonstrated impressive loss reduction is considered. It is concluded that accurate routine prediction of secondary flow losses has not yet been achieved, and must await either a better turbulence model or more experiments to reveal new endwall loss production mechanisms. Lastly, loss is examined from the standpoint of entropy generation.

Secondary Flows in Axial Turbines—A Review

A gas turbine engine assembly (10), includes a core gas turbine engine (12), a low-pressure turbine (14) coupled to the core turbine engine, a counter-rotating fan assembly (16) coupled to the low-pressure turbine, and a booster compressor (24) coupled directly to the low-pressure turbine such that the booster compressor and the low-pressure turbine rotate in the same direction.

Gas turbine engine assembly and methods of assembling same

The effects of surface roughness on gas turbine performance are reviewed based on publications in the open literature over the past 60 years. Empirical roughness correlations routinely employed for drag and heat transfer estimates are summarized and found wanting. No single correlation appears to capture all of the relevant physics for both engineered and service-related (e.g., wear or environmentally induced) roughness. Roughness influences engine performance by causing earlier boundary layer transition, increased boundary layer momentum loss (i.e., thickness), and/or flow separation. Roughness effects in the compressor and turbine are dependent on Reynolds number, roughness size, and to a lesser extent Mach number. At low Re, roughness can eliminate laminar separation bubbles (thus reducing loss) while at high Re (when the boundary layer is already turbulent), roughness can thicken the boundary layer to the point of separation (thus increasing loss). In the turbine, roughness has the added effect of augmenting convective heat transfer. While this is desirable in an internal turbine coolant channel, it is clearly undesirable on the external turbine surface. Recent advances in roughness modeling for computational fluid dynamics are also reviewed. The conclusion remains that considerable research is yet necessary to fully understand the role of roughness in gas turbines.

A Review of Surface Roughness Effects in Gas Turbines

The primary focus of this paper is convective heat transfer in axial flow turbines. Research activity involving heat transfer generally separates into two related areas: predictions and measurements. The problems associated with predicting heat transfer are coupled with turbine aerodynamics because proper prediction of vane and blade surface-pressure distribution is essential for predicting the corresponding heat transfer distribution. The experimental community has advanced to the point where time-averaged and time-resolved three-dimensional heat transfer data for the vanes and blades are obtained routinely by those operating full-stage rotating turbines. However, there are relatively few CFD codes capable of generating three-dimensional predictions of the heat transfer distribution, and where these codes have been applied the results suggest that additional work is required. This paper outlines the progression of work done by the heat transfer community over the last several decades as both the measurements and the predictions have improved to current levels. To frame the problem properly, the paper reviews the influence of turbine aerodynamics on heat transfer predictions. This includes a discussion of time-resolved surface-pressure measurements with predictions and the data involved in forcing function measurements. The ability of existing two-dimensional and three-dimensional Navier-Stokes codes to predict the proper trends of the time-averaged and unsteady pressure field for full-stage rotating turbines is demonstrated. Most of the codes do a reasonably good job of predicting the surface-pressure data at vane and blade midspan, but not as well near the hub or the tip region for the blade. In addition, the ability of the codes to predict surface-pressure distribution is significantly better than the corresponding heat transfer distributions. Heat transfer codes are validated against measurements of one type or another. Sometimes the measurements are performed using full rotating rigs, and other times a much simpler geometry is used. In either case, it is important to review the measurement techniques currently used. Heat transfer predictions for engine turbines are very difficult because the boundary conditions are not well known. The conditions at the exit of the combustor are generally not well known and a section of this paper discusses that problem. The majority of the discussion is devoted to external heat transfer with and without cooling, turbulence effects, and internal cooling. As the design community increases the thrust-to-weight ratio and the turbine inlet temperature, there remain many turbine-related heat transfer issues. Included are film cooling modeling, definition of combustor exit conditions, understanding of blade tip distress, definition of hot streak migration, component fatigue, loss mechanisms in the low turbine, and many others. Several suggestions are given herein for research and development areas for which there is potentially high payoff to the industry with relatively small risk.

Convective Heat Transfer and Aerodynamics in Axial Flow Turbines

▪ Abstract The flow in turbomachines is unsteady due to the relative motion of the rows of blades. In the low-pressure turbine, the wakes from the upstream bladerows provide the dominant source of unsteadiness. Because much of the blade-surface boundary-layer flow is laminar, one of the most important consequences of this unsteadiness is the interaction of the wakes with the suction-side boundary layer of a downstream blade. This is important because the blade suction–side boundary layers are responsible for most of the loss of efficiency and because the combined effects of random (wake turbulence) and periodic disturbances (wake velocity defect and pressure fields) cause the otherwise laminar boundary layer to undergo transition and eventually become turbulent. This article summarizes the process of wake-induced boundary-layer transition in low-pressure turbines and the loss generation processes that result. Particular emphasis is placed on how the effects of wakes may be exploited to control loss genera...

Bladerow interactions, transition, and high-lift aerofoils in low-pressure turbines

A linear design system, already in use for the forward and inverse design of three-dimensional turbine aerofoils, has been extended for the design of their end walls. This paper shows how this method has been applied to the design of a nonaxisymmetric end wall for a turbine rotor blade in linear cascade. The calculations show that nonaxisymmetric end wall profiling is a powerful tool for reducing secondary flows, in particular the secondary kinetic energy and exit angle deviations. Simple end wall profiling is shown to be at least as beneficial aerodynamically as the now standard techniques of differentially skewing aerofoil sections up the span, and (compound) leaning of the aerofoil. A design is presented that combines a number of end wall features aimed at reducing secondary loss and flow deviation. The experimental study of this geometry, aimed at validating the design method, is the subject of the second part of this paper. The effects of end wall perturbations on the flow field are calculated using a three-dimensional pressure correction based Reynolds-averaged Navier-Stokes CFD code. These calculations are normally performed overnight on a cluster of work stations. The design system then calculates the relationships between perturbations in the end wall andmore » resulting changes in the flow field. With these available, linear superposition theory is used to enable the designer to investigate quickly the effect on the flow field of many combinations of end wall shapes (a matter of minutes for each shape).« less

Nonaxisymmetric Turbine End Wall Design: Part I— Three-Dimensional Linear Design System

The Durham Linear Cascade has been redesigned with the nonaxisymmetric 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 overturning 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.

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Nonaxisymmetric Turbine End Wall Design: Part II—Experimental Validation

This paper describes a program of work, largely experimental, which was undertaken with the objective of developing an improved blade profile for the low-pressure turbine in aero-engine applications. Preliminary experiments were conducted using a novel technique. An existing cascade of datum blades was modified to enable the pressure distribution on the suction surface of one of the blades to be altered. Various means, such as shaped inserts, an adjustable flap at the trailing edge, and changing stagger were employed to change the geometry of the passage. These experiments provided boundary layer and lift data for a wide range of suction surface pressure distributions. The data were then used as a guide for the development of new blade profiles. The new blade profiles were then investigated in a low-speed cascade that included a set of moving bars upstream of the cascade of blades to simulate the effect of the incoming wakes from the previous blade row in a multistage turbine environment. Results are presented for two improved profiles that are compared with a datum representative of current practice. The experimental results include loss measurements by wake traverse, surface pressure distributions, and boundary layer measurements. The cascades were operated over a Reynoldsmore » number range from 0.7 {times} 10{sup 5} to 4.0 {times} 10{sup 5}. The first profile is a laminar flow design that was intended to improve the efficiency at the same loading as the datum. The other is a more highly loaded blade profile intended to permit a reduction in blade numbers. The more highly loaded profile is the most promising candidate for inclusion in future designs. It enables blade numbers to be reduced by 20%, without incurring any efficiency penalty. The results also indicate that unsteady effects must be taken into consideration when selecting a blade profile for the low-pressure turbine.« less

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Development of Blade Profiles for Low-Pressure Turbine Applications

This paper describes the redesign of the HP turbine of the Rolls-Royce Trent 500 engine, making use of non-axisymmetric 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 [1], had already demonstrated significant potential for reducing turbine secondary losses using non-axisymmetric 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 [2], is discussed in detail.Copyright © 2001 by ASME

Improving the Efficiency of the Trent 500 HP Turbine Using Non-Axisymmetric End Walls: Part 1 — Turbine Design

An axial flow turbomachine has at least one circumferential row of aerofoil members in which at least one of the two end walls (33) between successive blades (30) is given a non-axisymmetric profile to modify the boundary layer flow at the wall. In one form of the profile, a convex region (33) adjacent each member pressure surface (35) and a complementary concave region (34) adjacent each member suction surface (34) extend over at least a major part of the blade chord lengths to reduce the transverse pressure gradient and thereby reduce vortical energy losses. In another form of the profile, at least one end wall (33) has complementary convex and concave regions (50,51) extending through the zone of the trailing edges of the members (30) on the suction end pressure surface sides (34,35) respectively of each member, thereby to reduce over turning of the flow. Both forms of profiling can be employed in combination.

Neil William Harvey

Papers

Nonaxisymmetric Turbine End Wall Design: Part I— Three-Dimensional Linear Design System

Nonaxisymmetric Turbine End Wall Design: Part II—Experimental Validation

Development of Blade Profiles for Low-Pressure Turbine Applications

Improving the Efficiency of the Trent 500 HP Turbine Using Non-Axisymmetric End Walls: Part 1 — Turbine Design

Bladed ducting for turbomachinery