Showing papers on "Tip clearance published in 2019"

Spatial-temporal evolution of tip leakage vortex in a mixed flow pump with tip clearance

Abstract: Tip clearance in pump induces tip leakage vortex (TLV), which interacts with the main flow and leads to instability of flow pattern and decrease of pump performance. In this work, the characteristics of TLV in a mixed-flow pump are investigated by the numerical simulation using shear stress transport (SST) k–ω turbulence model with experimental validation. The trajectory of the primary tip leakage vortex (PTLV) is determined, and a power function law is proposed to describe the intensity of the PTLV core along the trajectory. Spatial–temporal evolution of the TLV in an impeller revolution period T can be classified into three stages: splitting stage, developing stage, and merging stage. The TLV oscillation period TT is found as 19/160 T, corresponding to the frequency 8.4 fi (fi is impeller rotating frequency). Results reveal that the TLV oscillation is intensified by the sudden pressure variation at the junction of two adjacent blades. On analysis of the relative vorticity transport equation, it is revealed that the relative vortex stretching item in Z direction is the major source of the splitting and shedding of the PTLV. The dominant frequency of pressure and vorticity fluctuations on the PTLV trajectory is 8.4 fi, same as the TLV oscillation frequency. This result reveals that the flow instability in the PTLV trajectory is dominated by the oscillation of the TLV. The blade number has significant effect on pressure fluctuation in tip clearance and on blade pressure side, because the TLV oscillation period varies with the circumferential length of flow passage.

Energy performance and flow characteristics of a multiphase pump with different tip clearance sizes

Abstract: Deep sea oil resources worldwide possess great potential for exploration; however, multiphase medium technology requires urgent development. The multiphase pump has achieved great success as one of...

Numerical Analysis of Mechanical Energy Dissipation for an Axial-Flow Pump Based on Entropy Generation Theory

Abstract: Mechanical energy dissipation is a major problem affecting hydraulic machinery especially under partial-load conditions. Owing to limitations of traditional methods in evaluating mechanical energy dissipation, entropy generation theory is introduced to study mechanical energy dissipation with varying discharge and tip clearance intuitively through numerical simulations in an axial-flow pump. Results show that the impeller and diffuser are the main domains of mechanical energy dissipation, respectively accounting for 35.32%–55.51% and 32.61%–20.42% of mechanical energy dissipation throughout the flow passage. The mechanical energy dissipation of the impeller has a strong relation with the hump characteristic and becomes increasingly important with decreasing discharge. Areas of high turbulent dissipation in the impeller are mainly concentrated near the blades’ suction sides, and these regions, especially areas near the shroud, extend with decreasing discharge. When the pump enters the hump region, the distributions of turbulent dissipation near the shroud become disordered and expand towards the impeller’s inlet side. Unstable flows, like flow separation and vortices, near the blades’ suction sides lead to the high turbulent dissipation in the impeller and hump characteristic. Turbulent dissipation at the tip decreases from the blade leading edge to trailing edge, and regions of high dissipation distribute near the leading edge of the blade tip side. An increase in tip clearance for the same discharge mainly increases areas of high turbulent dissipation near the shroud and at the tip of the impeller, finally reducing pump performance.

Numerical investigation of tip flow dynamics and main flow characteristics with varying tip clearance widths for an axial-flow pump:

Abstract: The effects of varying tip clearance widths on tip flows dynamics and main flows characteristics for an axial-flow pump are studied employing computational fluid dynamics method. An analysis is pre...

On Blockage Effects for a Tidal Turbine in Free Surface Proximity

Abstract: Experiments with a three-bladed, constant chord tidal turbine were undertaken to understand the influence of free surface proximity on blockage effects and near-wake flow field. The turbine was placed at various depths as rotational speeds were varied; thrust and torque data were acquired through a submerged sensor. Blockage effects were quantified in terms of changes in power coefficient and were found to be dependent on tip speed ratio and free surface to blade tip clearance. Flow acceleration near turbine rotation plane was attributed to blockage offered by the rotor, wake, and free surface deformation. In addition, particle image velocimetry was carried out in the turbine near-wake using time- and phase-averaged techniques to understand the mechanism responsible for the variation of power coefficient with rotational speed and free surface proximity. Slower wake propagation for higher rotational velocities and increased asymmetry in the wake with increasing free surface proximity was observed. Improved performance at high rotational speed was attributed to enhanced wake blockage, and performance enhancement with free surface proximity was due to the additional blockage effects caused by the free surface deformation. Proper orthogonal decomposition analysis revealed a downward moving wake for the turbine placed in near free surface proximity.

Numerical Simulation of the Tip Leakage Vortex Characteristics in a Semi-Open Centrifugal Pump

Abstract: Tip leakage vortex has an important influence on the performance of semi-open centrifugal pumps. Simulations based on the three-dimensional Reynolds-Averaged Navier–Stokes were conducted to study the structural characteristics of tip leakage vortex and its effects on the internal flow field, and the Shear Stress Transport k-ω turbulence model was used to simulate the whole flow passage of centrifugal pumps with tip clearances of 0 mm and 1 mm. Then, the tip leakage vortex was analyzed using the relative vorticity transport equation. The numerical data and experimental results agreed well. The leakage vortex formed in the tip clearance led to 18.7% and 14.4% decrease in head and efficiency under design condition, respectively, and the bigger the flow rate, the fast the performance decreased. Tip leakage vortex formed at the leading edge of the blade moved along the suction surface. Whereas the tip leakage vortex formed near the middle of the blade extended to the pressure surface of the adjacent blade. This phenomenon deteriorated the flow field and induced passage vortex, thereby reducing the static pressure and blade load and changing the static pressure distribution law. The formation and development of leakage vortex could be attributed to the relative vortex stretching the term. The Coriolis force term could reflect the change of vorticity caused by leakage flow, and the viscous diffusion term served as the vorticity source.

Vortex dynamic characteristics of unsteady tip clearance cavitation in a waterjet pump determined with different vortex identification methods

Abstract: The cavitating flow field in waterjet pumps is complex, especially tip leakage cavitation (TLC), which has been a puzzle to researchers for decades. In this study, high-speed video (HSV) of the instantaneous inner structures of tip cavitation flow is used to show the evolution of TLC. Numerical simulation is conducted with the scale adaptive simulation (SAS) turbulence model and Zwart-Gerber-Belamri (ZGB) cavitation model to understand the cavitation-vortex interaction in the blade tip region. The predicted cavitation performance curve exhibits reasonable agreement with the experimental results, and the time-dependent vapor iso-surfaces (αv = 0.1) are consistent with HSV at different times in a typical cycle. Numerical simulation results show that cavitation can enhance the turbulent kinetic energy in the unstable vortex cavitation region and downstream tip leakage vortex region along the blade. Different vortex identification methods, including vorticity, Q criterion, λci, λ2 criterion, Ω, and Liutex/Rortex, are investigated. Analysis and comparison of the iso-surfaces of the different vortex identification methods indicate that the Ω and Liutex iso-surfaces can effectively predict the tip leakage vortex core and vortex pair in the unstable vortex cavitation region. Analysis of the fifth clip contours shows that no obvious difference exists between Q and λ2 criteria in terms of predicting the vortex core. All vortex identification methods can accurately predict the tip separation vortex in the blade tip region, but only the Ω and Liutex iso-surfaces can predict weak vortices in the cavitation region. The influence of the small parameter e of the Ω method on tip vortex identification is also discussed.

Flow and Fast Fourier Transform Analyses for Tip Clearance Effect in an Operating Kaplan Turbine

Abstract: The Kaplan turbine is an axial propeller-type turbine that can simultaneously control guide vanes and runner blades, thus allowing its application in a wide range of operations. Here, turbine tip clearance plays a crucial role in turbine design and operation as high tip clearance flow can lead to a change in the flow pattern, resulting in a loss of efficiency and finally the breakdown of hydro turbines. This research investigates tip clearance flow characteristics and undertakes a transient fast Fourier transform (FFT) analysis of a Kaplan turbine. In this study, the computational fluid dynamics method was used to investigate the Kaplan turbine performance with tip clearance gaps at different operating conditions. Numerical performance was verified with experimental results. In particular, a parametric study was carried out including the different geometrical parameters such as tip clearance between stationary and rotating chambers. In addition, an FFT analysis was performed by monitoring dynamic pressure fluctuation on the rotor. Here, increases in tip clearance were shown to occur with decreases in efficiency owing to unsteady flow. With this study’s focus on analyzing the flow of the tip clearance and its effect on turbine performance as well as hydraulic efficiency, it aims to improve the understanding on the flow field in a Kaplan turbine.

Experimental and Numerical Investigation on the Tip Leakage Vortex Cavitation in an Axial Flow Pump with Different Tip Clearances

Abstract: The tip gap existing between the blade tip and casing can give rise to tip leakage flow and interfere with the main flow, which causes unstable flow characteristics and intricate vortex in the passage. Investigation on the tip clearance effect is of great important due to its extensive applications in the rotating component of pumps. In this study, a scaling axial flow pump used in a south-north water diversion project with different sizes of tip clearances was employed to study the tip clearance effect on tip leakage vortex (TLV) characteristics. This analysis is based on a modified turbulence model. Validations were carried out using a high-speed photography technique. The tip clearance effect on the generation and evolution of TLV was investigated through the mean velocity, pressure, and vorticity fields. Results show that there are two kinds of TLV structures in the tip region. Accompanied by tip clearance increasing, the viscous loss in the tip area of the axial flow pump increases. Furthermore, the tip clearance effect on pressure distribution in the blade passage is discussed. Beyond that, the tip clearance effect on vortex core pressure and cavitation is studied.

Effect of Tip Clearance on Rotating Stall in a Mixed-Flow Pump

Abstract: The non-uniform disturbance in the circumferential direction is the main cause for the occurrence of rotating stall in turbomachinery. In order to study the effect of tip clearance leakage flow on rotating stall, the mixed-flow pump models with different tip clearances are numerically simulated, and then the energy performance curves and internal flow structures are obtained and compared. The results show that the computed pump efficiency and the internal flow field of the pump from numerical simulation are in good agreement with the experimental results. A saddle region appears in the energy performance curves of the three tip clearances, and with decrease in tip clearance, the head and efficiency of the mixed-flow pump increase and the critical stall point shifts, and the stable operating range of the mixed-flow pump decreases, which indicates that the mixed-flow pump stalls easily for smaller tip clearance. Under the deep stall condition, the influence of the leakage flow in the end wall area increases gradually with decrease in clearance. For small clearance, the leakage flow moves away from the suction surface to some distance to form a number of leakage vortex strips with the mainstream flow and flows over the leading edge of the next blade and then flows downstream into different flow passages, generating backflow and secondary flow separation at the blade inlet, which seriously damages the spatial structure of the inlet flow. This results in the earlier occurrence of stall. With increase in clearance, the leakage vortex develops along the radial direction towards the middle of the flow channel and large flow separation occurs in the downstream channel, which induces deep stall. For 0.8mm clearance, the whole impeller outlet passage is almost blocked by the backflow of the guide vane inlet, and a deep stall is induced.

Development of a PVDF Sensor Array for Measurement of the Dynamic Pressure Field of the Blade Tip in an Axial Flow Compressor.

Abstract: Tip clearance flow in axial flow compressor is unavoidable and responsible for pressure losses and noise generation and influences the stability of the compressor. However, necessary flow measurement in the blade tip region is a great challenge due to the small gap width as well as the structure limitation. In this paper, a polyvinylidene fluoride (PVDF) piezoelectric-film sensor array is developed to capture the dynamic pressure field over the blade tip in an axial flow compressor. The PVDF sensor array with 40 evenly distributed sensing points is fabricated directly on a 30 μm thick aluminum-metalized polarized PVDF film through photolithography. Dynamic calibration of the sensor is accomplished using acoustic source as excitation and a microphone as a reference. The test pressure range is up to 3.5 kPa and the sampling frequency is 20 kHz. The sensor presents a high signal-to-noise ratio and good consistency with the reference microphone. Sensitivity, frequency response, linearity, hysteresis, repeatability as well as the influence of temperature are also investigated through the calibration apparatus. The calibration gives credence to the relevance and reliability of this sensor for the application in dynamic pressure field measurement. The sensor is then applied to an actual measurement in a compressor. The output of the PVDF sensor array is also compared with the results of common pressure transducers, and the features of the dynamic pressure filed are discussed. The results indicate that the PVDF sensor array is capable of the dynamic pressure field measurement over the blade tip, and superior to the conventional approaches in installation, spatial resolution, frequency response, and cost. These advantages indicate its potential broad application in pressure measurement, especially for the complex spatial surface or thin-walled structure, such as the blade surface and the thin casing wall of the compressor.

Entropy Generation Analysis in a Mixed-Flow Compressor with Casing Treatment

Abstract: Casing treatments (CT) can effectively extend compressors flow ranges with the expense of efficiency penalty. Compressor efficiency is closely linked to loss. Only revealing the mechanisms of loss generation can design a CT with high aerodynamic performance. In the paper, a highly-loaded mixed-flow compressor with tip clearance of 0.4 mm was numerically studied at a rotational speed of 30,000 r/min to reveal the effects of axial slot casing treatment (ASCT) on the loss mechanisms in the compressor. The results showed that both isentropic efficiency and stall margin were improved significantly by the ASCT. The local entropy generation method was used to analyze the loss mechanisms and to quantify the loss distributions in the blade passage. Based on the axial distributions of entropy generation rate, for both the cases with and without ASCT, the peak entropy generation rate increased in the rotor domain and decreased in the stator domain during throttling the compressor. The peak entropy generation in rotor was mainly caused by the tip leakage flow and flow separations near the rotor leading edge for the mixed-flow compressor no matter which casing was applied. The radial distributions of entropy generation rate showed that the reduction of loss in the rotor domain from 0.4 span to the rotor casing was the major reason for the efficiency improved by ASCT. The addition of ASCT exerted two opposite effects on the losses generated in the compressor. On the one hand, the intensity of tip leakage flow was weakened by the suction effect of slots, which alleviated the mixing effect between the tip leakage flow and main flow, and thus reduced the flow losses; On the other hand, the extra losses upstream the rotor leading edge were produced due to the shear effect and to the heat transfer. The aforementioned shear effect was caused by the different velocity magnitudes and directions, and the heat transfer was caused by temperature gradient between the injected flow and the incoming flow. For case with smooth casing (SC), 61.61% of the overall loss arose from tip leakage flow and casing boundary layer. When the ASCT was applied, that decreased to 55.34%. The loss generated by tip leakage flow and casing boundary layer decreased 20.54%) relatively by ASCT.

Modelling and experimental validation of active and passive eddy current sensors for blade tip timing

Abstract: To monitor the vibration of blades in rotating machinery, the contactless method called Blade Tip Timing (BTT) is widely used. blade vibration and clearance are important diagnostic features for condition monitoring, including the detection of blade cracks. To perform the BTT technique, optical sensors were widely used by industry due to their high accuracy, but the main drawback of these systems is their low tolerance to the presence of contaminants. To overcome this downside, eddy current sensors are a good alternative for health monitoring applications in gas turbines due to their insensitivity to contaminants and debris. This type of sensor has been used by many researchers, predominantly on the experimental side to investigate BTT systems and there is a lack of modelling to support the measurement system design. This paper fills the gap between experiments and modelling for the particular case of a blade rotating past eddy current sensors. Hence the novelty of this paper is the simulation of the BTT application using detailed quasi-static finite element models of the electro-magnetic field to estimate the outputs from active and passive eddy current sensors. A test rig composed of a bladed disk with 12 blades clamped to a rotating shaft was designed and manufactured in order to validate the proposed models with experimental measurements. Finally, a parametric study is presented to show the effect of the blade tip clearance and the rotational speed on the accuracy of the BTT measurement. This leads to better understanding of the sources of error in the time of arrival of the blades passing the sensor and hence insight into the blade vibration measurement accuracy.

Creep-Based Reliability Evaluation of Turbine Blade-Tip Clearance with Novel Neural Network Regression.

Abstract: To reveal the effect of high-temperature creep on the blade-tip radial running clearance of aeroengine high-pressure turbines, a distributed collaborative generalized regression extremum neural network is proposed by absorbing the heuristic thoughts of distributed collaborative response surface method and the generalized extremum neural network, in order to improve the reliability analysis of blade-tip clearance with creep behavior in terms of modeling precision and simulation efficiency. In this method, the generalized extremum neural network was used to handle the transients by simplifying the response process as one extremum and to address the strong nonlinearity by means of its nonlinear mapping ability. The distributed collaborative response surface method was applied to handle multi-object multi-discipline analysis, by decomposing one “big” model with hyperparameters and high nonlinearity into a series of “small” sub-models with few parameters and low nonlinearity. Based on the developed method, the blade-tip clearance reliability analysis of an aeroengine high-pressure turbine was performed subject to the creep behaviors of structural materials, by considering the randomness of influencing parameters such as gas temperature, rotational speed, material parameters, convective heat transfer coefficient, and so forth. It was found that the reliability degree of the clearance is 0.9909 when the allowable value is 2.2 mm, and the creep deformation of the clearance presents a normal distribution with a mean of 1.9829 mm and a standard deviation of 0.07539 mm. Based on a comparison of the methods, it is demonstrated that the proposed method requires a computing time of 1.201 s and has a computational accuracy of 99.929% over 104 simulations, which are improvements of 70.5% and 1.23%, respectively, relative to the distributed collaborative response surface method. Meanwhile, the high efficiency and high precision of the presented approach become more obvious with the increasing simulations. The efforts of this study provide a promising approach to improve the dynamic reliability analysis of complex structures.

Effects of tip clearance size on the unsteady flow behaviors and performance in a counter-rotating axial flow compressor:

Abstract: This paper presents the studies performed to better understand the effects of increased tip clearance size on the unsteady flow behaviors and overall performance under the rotor–rotor interaction e...

Effects of leakage vortex on aerodynamic performance and loss mechanism of steam turbine

Abstract: To avoid friction, a clearance between the rotor blade tip and the cylinder is needed in a steam turbine. As a result, the leakage flow is formed under the pressure difference which mixes with the ...

Tip-Bed Velocity and Scour Depth of Horizontal-Axis Tidal Turbine with Consideration of Tip Clearance

Abstract: The scouring by a tidal turbine is investigated by using a joint theoretical and experimental approach in this work. The existence of a turbine obstructs a tidal flow to divert the flow passing through the narrow channel in between the blades and seabed. Flow suppression is the main cause behind inducing tidal turbine scouring, and its accelerated velocity is being termed as tip-bed velocity (Vtb). A theoretical equation is currently proposed to predict the tip-bed velocity based on the axial momentum theory and the conservation of mass. The proposed tip-bed velocity equation is a function of four variables of rotor radius (r), tip-bed clearance (C), efflux velocity (V0) and free flow velocity (V∞), and a constant of mass flow coefficient (Cm) of 0.25. An experimental apparatus was built to conduct the scour experiments. The results provide a better understanding of the scour mechanism of the horizontal axis tidal turbine-induced scour. The experimental results show that the scour depth is inversely proportional to tip-bed clearance. Turbine coefficient (Kt) is proposed based on the relationship between the tip-bed velocity and the experimental tidal turbine scour depth. Inclusion of turbine coefficient (Kt) into the existing pier scour equations can predict the maximum scour depth of a tidal turbine with an error range of 5–24%.

On the Effects of Tip Clearance and Operating Condition on the Flow Structures Within an Axial Turbomachine Rotor Passage

Abstract: Effects of tip clearance size and flowrate on the flow around the tip of an axial turbomachine rotor are studied experimentally. Visualizations and stereo-particle image velocimetry (PIV) measurements in a refractive index-matched facility compare the performance, leakage velocity, and the trajectory, growth rate, and strength of the tip leakage vortex (TLV) for gaps of 0.49% and 2.3% of the blade chord, and two flowrates. Enlarging the tip clearance delays the TLV breakup in the aft part of the rotor passage at high flowrates but causes earlier breakup under pre-stall conditions. It also reduces the entrainment of endwall boundary layer vorticity from the separation point where the leakage and passage flows meet. Reducing the flowrate or tip gap shifts the location of the TLV detachment from the blade suction side (SS) upstream to points where the leakage velocity is 70–80% of the tip speed. Once detached, the growth rates of the total shed circulation are similar for all cases, i.e., varying the gap or flowrate mostly shifts the detachment point. The TLV migration away from the SS decreases with an increasing gap but not with the flowrate. Two mechanisms dominate this migration: initially, the leakage jet pushes the TLV away from the blade at 50% of the leakage velocity. Further downstream, the TLV is driven by its image on the other side of the endwall. Differences in migration rate are caused by the smaller distance between the TLV and its image for the narrow gap, and the increase in initial TLV strength with decreasing flowrate and gap.

Experimental Investigation of Inductive Sensor Characteristic for Blade Tip Clearance Measurement at High Temperature.

Abstract: Turbine tip clearance of aero-engine is important to engine performance. Proper tip clearance can reduce the gas leakage over turbine blade tips and improve the engine efficiency of turbo machinery and reduce the fuel consumption. Therefore, accurate tip clearance measurement is essential. The inductive measurement method is one of the non-contact distance measurement methods, which has the characteristics of high sensitivity, fast response speed, and strong anti-interference ability. Based on the principle of inductive sensor measuring tip clearance, the ambient temperature change may cause the material electromagnetic performance change for the conductivity and permeability varies with temperature. In order to verify the temperature effect on the sensor performance, the repeated calibration experiments were carried out to obtain the sensor repeatability error of 5.4%. Then, the sensor was calibrated in the range of 0 mm–4 mm clearance at temperature from 600 °C to 1000 °C and obtained the measurement error of 4.6%. Results indicate when the temperature ranged from 600 °C to 1000 °C, clearance measurement error is smaller than the sensor repeatability error so the temperature effect on the sensor characteristics can be ignored. This conclusion makes the sensor promising for monitoring the blade tip clearances at various temperature environment.

Numerical analysis for the effect of tip clearance in a low specific speed mixed-flow pump:

Abstract: To study the influence of tip clearance on performance (external characteristics, pressure fluctuation and tip loss) of a low specific speed mixed-flow pump, unsteady simulation was performed for t...