A computational study aimed at improving the understanding of rotating instability in the LP steam turbine last stage working under low flow rate conditions is described in this thesis. A numerical simulation framework has been developed to investigate into the instability flow field. Two LP model turbine stages are studied under various flow rate conditions. By using the 2D simulations as reference and comparing the results to those of the 3D simulations, the basic physical mechanism of rotating instability is analysed. The pressure ratio characteristics across the rotor row tip are found to be crucial to the inception of rotating instability. The captured instability demonstrates a 2D mechanism based on the circumferential variation of unsteady separation flow in the rotor row. The 3D tip clearance flow is found not a necessary cause of the instability onset. Several influential parameters on the instability flow are also investigated by a set of detailed studies on different turbine configurations. The results show that the instability flow pattern and characteristics can be altered by the gap distance between the stator and rotor row, the rotor blading and the stator row stagger angle. Some flow control approaches are proposed based on the observations, which may also serve as design reference. The tip region 3D vortex flow upstream to the rotor row is also captured by the simulations under low flow rate conditions. Its appearance is found to be able to suppress the inception of rotating instability by disrupting the interaction between the rotor separation flow and the incoming flow. Finally, some recommendations for further work are proposed.

<p>The successful, efficient, and safe turbine design requires a thorough understanding of the underlying physical phenomena. This research investigates the physical understanding and parameters highly correlated to flutter, an aeroelastic instability prevalent among low pressure turbine (LPT) blades in both aircraft engines and power turbines. The modern way of determining whether a certain cascade of LPT blades is susceptible to flutter is through time-expensive computational fluid dynamics (CFD) codes. These codes converge to solution satisfying the Eulerian conservation equations subject to the boundary conditions of a nodal domain consisting fluid and solid wall particles. Most detailed CFD codes are accompanied by cryptic turbulence models, meticulous grid constructions, and elegant boundary condition enforcements all with one goal in mind: determine the sign (and therefore stability) of the aerodynamic damping. The main question being asked by the aeroelastician, ``is it positive or negative?'' This type of thought-process eventually gives rise to a black-box effect, leaving physical understanding behind. Therefore, the first part of this research aims to understand and reveal the physics behind LPT flutter in addition to several related topics including acoustic resonance effects. A percentage of this initial numerical investigation is completed using an influence coefficient approach to study the variation the work-per-cycle contributions of neighboring cascade blades to a reference airfoil. The second part of this research introduces new discoveries regarding the relationship between steady aerodynamic loading and negative aerodynamic damping. Using validated CFD codes as computational wind tunnels, a multitude of low-pressure turbine flutter parameters, such as reduced frequency, mode shape, and interblade phase angle, will be scrutinized across various airfoil geometries and steady operating conditions to reach new design guidelines regarding the influence of steady aerodynamic loading and LPT flutter. Many pressing topics influencing LPT flutter including shocks, their nonlinearity, and three-dimensionality are also addressed along the way. The work is concluded by introducing a useful preliminary design tool that can estimate within seconds the entire aerodynamic damping versus nodal diameter curve for a given three-dimensional cascade.</p> / Dissertation

O desenvolvimento de tecnologia na área de turbomáquinas é essencial ao desenvolvimento da indústria nacional e o Laboratório de Engenharia Ambiental e Térmica da Escola Politécnica da Universidade de São Paulo tem compreendido ações para este propósito. Este trabalho tem por objetivo desenvolver um compressor para uma turbina a gás de pequeno porte de 500 kW, primeiro passo para o projeto e construção da turbina como um todo. A partir da análise do ciclo termodinâmico e da análise de adimensionais, o tipo de compressor a ser utilizado foi determinado. Optou-se pelo projeto de um compressor centrífugo. Iniciou-se o projeto através de análise e correlações unidimensionais com previsão de desempenho, definindo algumas geometrias iniciais a serem avaliadas nas fases seguintes. Realizou-se a análise bidimensional do impelidor com a ferramenta computacional Vista TF que utiliza o método de curvatura de linhas de corrente. Por fim, a geometria tridimensional foi definida com uso de simulações de dinâmica de fluidos computacional. De acordo com as simulações, o compressor projetado tem desempenho condizente com os requisitos impostos. / Technology development in turbomachinery is essential to the national industry development and the Laboratory of Environmental and Thermal Engineering of the Polytechnic School of the University of São Paulo is engaged on this purpose. This work intends to design a compressor for a small 500 kW gas turbine, the first step in the whole turbine design and construction. The compressor type was determined from thermodynamical cycle and adimensional analysis. The centrifugal type compressor was chosen. The design was initialized using one-dimensional analysis and correlations with performance prediction models, defining initial geometries to be evaluated in the upcoming design phases. The impeller was analyzed with a two dimensional computational tool named Vista TF, which uses the streamline curvature method. The tridimensional geometry was defined using computational fluid dynamics. According to the simulations, the design compressor performs satisfying the imposed requirements.

Resumo: Este trabalho tem como objetivo a análise da influência de parâmetros adimensionais e grandezas dimensionais no projeto de turbomáquinas operando em diferentes situações de pressão, temperatura e vazão mássica de vapor. O trabalho é divido em duas partes principais, sendo que inicialmente são analisados os parâmetros adimensionais e as grandezas dimensionais que influenciam diretamente o valor do rendimento interno das turbomáquinas térmicas que utilizam o vapor como fluido de trabalho. Na segunda parte do trabalho são abordadas as classes de pressão e rotação específica, e sua influência no comportamento de parâmetros adimensionais. A aplicação dos resultados está diretamente ligada a especificação de turbomáquinas em sistemas de cogeração para aproveitamento de fluxos térmicos provenientes de processos, queima de combustíveis ou gases de escape de uma máquina térmica, para os quais os projetistas necessitam estimar o rendimento de tais componentes por ocasião da análise de viabilidade econômica. / Abstract: This work has as objective the analysis of the influence of dimensionless parameters and dimensional greatness in the project of turbomachinery operating in different pressure situations, temperature and flow steam. This work is shared in two main parts, which are initially analyzed the dimensionless parameters and the dimensional greatness that directly influence the internal efficiency of the thermal turbomachinery that using steam as the working fluid. In the second part of the work are accosted the classes of pressure and specific rotation, and its influence on the behavior of dimensionless parameters. The application of the results is directly linked to the specification of turbomachinery in cogeneration systems for use of heat flows from processes, burning of fuel or the exhaust gases of a thermal machine, for which the designers needs to estimate the efficiency of such components at analysis of economic feasibility. / Orientador: Paulo Magalhães Filho / Coorientador: José Nédilo Carrinho de Castro / Banca: Carlos Daniel Ebinuma / Banca: José Rui Camargo / Mestre

Les concepteurs de moteurs aéronautiques sont constamment sujets à la demande d’augmentation de puissance de la part des constructeurs d’aéronefs. Pour satisfaire à cette exigence, la température de sortie de la chambre de combustion peut être augmentée pour améliorer le rendement et la puissance de sortie du moteur. Cette élévation de température peut toutefois dépasser le point de fusion du matériau et, pour éviter les pannes de moteur, l’intégrité des aubes de la turbine repose notamment sur des systèmes de refroidissement internes,prélevant de l'air froid du compresseur. La conception de ces systèmes revient donc à maximiser l’amélioration du transfert de chaleur tout en minimisant le débit d’air via les pertes de charge afin d’éviter des pénalités de puissance du moteur. Or ces écoulements en canaux internes sont encore largement incontrôlés et mal compris. Dans le but de mieux comprendre ces écoulements en rotation se développant spatialement, ce travail porte sur l’étude via simulations numériques d’un canal de refroidissement droit, perturbé, en rotation. La configuration consiste en un canal carré équipé de 8 perturbateurs placés avec un angle de 90 degrés par rapport à l’écoulement principal. Pour les cas étudiés, des mesures PIV temporelles ont été effectuées à l'Institut VanKarman (VKI). Les conditions adiabatiques et isothermes ont été étudiées pour évaluer l’impact dela température de la paroi sur l’écoulement, en particulier dans les configurations en rotation. Les canaux statiques ainsi qu’en rotation positive et négative sont comparés avec, dans chaque cas,une prédiction d’écoulement adiabatique ou isotherme. Dans ce travail, les résultats de simulations aux grandes échelles (SGE) montrent que le modèle CFD haute fidélité est capable de reproduire les différences induites par la flottabilité sur la topologie de l'écoulement dans la région proche. Le modèle parvient également à prévoir l'augmentation (la diminution) de la turbulence autour des perturbateurs en rotation déstabilisante (stabilisante). Enfin et grâce à la SGE spatiale et temporelle complète, le développement spatial et l’instationnarité des écoulements secondaires sont analysés pour mieux comprendre leur origine et leurs différences potentielles entre les cas. Cette étude montre que la topologie du flux thermique en parois est déterminée par la structure des écoulements secondaires alors que l’intensité du flux thermique aux parois est déterminée par le niveau de fluctuations de l’écoulement dans l’espace interperturbateur / Aeronautical engine designers are constantly subject to increasing power demands from aircraft manufacturers. To satisfy this requirement, combustor outlet temperature can be increased to improve efficiency and output energy of the engine. This rise in temperature however can surpass the material melting point and to avoid engine failure, turbine blades rely on internal cooling systems. Turbine blade cooling often uses internal channels, taking cold air from the compressor flow. Design of these systems therefore resumes to maximizing heat transfer enhancement while minimizing airflow rate to avoid engine power penalties. However, such flows are still largely uncontrolled and miss-understood. In an attempt to better understand such spatially developing rotating flows, the present study deals with a computational investigation on a straight, rotating rib roughened cooling channel. The configuration consists in a squared channel equipped with 8 ribs turbulators placed with an angle of 90 degrees with respect to the flow direction. For the studied cases, time resolved two-dimensional Particle Image Velocimetry (PIV) measurements have been performed at the Van Karman Institute (VKI). Adiabatic as well as isothermal conditions have been investigated to evaluate the impact of the wall temperature on the flow, especially in the rotating configurations. Static as well as both positive and negative rotating channels are compared with, in each case, either an adiabatic or an isothermal flow prediction. In this work, Large Eddy Simulation (LES) results show that the high fidelity CFD model is able to reproduce the differences induced by buoyancy on the flow topology in the near rib region and resulting from an adiabatic or an isothermal flow in rotation. The model manages also to predict the turbulence increase (decrease) around the rib in destabilizing (stabilizing) rotation of the ribbed channels. Finally and thanks to the full spatial and temporal description produced by LES, the spatial development and the unsteadiness of secondary flows are analyzed to better understand their origin and potential differences in all a cases. This study shows that the wall heat flux topology is driven by the secondary flows structure and the wall heat flux intensity is driven by the level of flow fluctuations in the ribbed region

In this study, loss and loading characteristics of compressor tandem blades are evaluated. Whole study was focused on change of the total camber so called turning angle. Effects of camber change were investigated in terms of loss and loading characteristics. Methodology was increasing overall camber first by aligning angular positions of blades and second, if required, using more cambered airfoils. 2-dimensional cascade flow CFD analyses were performed to obtain loss-loading information of different tandem blade combinations. Acquired results were compared with the classical axial compressor blades&rsquo / loading and loss characteristics which were obtained from literature. Results showed that most of the time tandem blade configuration performed better than the single blade counterpart in 2-dimensional cascade flow. Lastly, to clarify the benefit of the study and present the gained performance in numbers, only one cascade flow CFD analysis was performed for a classical single compressor blade. Loss and loading results were compared with the tandem blade counterpart where single and tandem configurations both having the same degree of camber. It was clearly seen that tandem blade performed better again.

With increasing rotor flexibility and shaft speeds, turbomachinery undergoes large dynamic loads and displacements. Squeeze film dampers (SFDs) are a type of fluid film bearing used in rotating machinery to attenuate rotor vibration, provide mechanical isolation, and/or to tune the placement of system critical speeds. Industry has a keen interest in designing SFDs that are small, lightweight, and mechanically simple. To achieve this, one must have a full understanding of how various design features affect the SFD forced performance. This thesis presents a comprehensive analysis, experimental and theoretical, of a short (L=25.4 mm) open ends SFD design incorporating three lubricant feed holes (without a circumferential feed groove). The damper radial clearance (c=127 μm), L/D ratio (0.2), and lubricant (ISO VG2) have similar dimensions and properties as in actual SFDs for aircraft engine applications. The work presents the identification of experimental force coefficients (K, C, M) from a 2-DOF system model for circular and elliptical orbit tests over the frequency range ω=10-250Hz. The whirl amplitudes range from r=0.05c-0.6c, while the static eccentricity ranges from eS=0-0.5c. Analysis of the measured film land pressures evidence that the deep end grooves (provisions for installation of end seals) contribute to the generation of dynamic pressures in an almost purely inertial fashion. Film land dynamic pressures show both viscous and inertial effects. Experimental pressure traces show the occurrence of significant air ingestion for orbits with amplitudes r>0.4c, and lubricant vapor cavitation when pressures drop to the lubricant saturation pressure (PSAT~0 bar). Identified force coefficients show the damper configuration offers direct damping coefficients that are more sensitive to increases in static eccentricity (eS) than to increases in amplitude of whirl (r). On the other hand, SFD inertia coefficients are more sensitive to increases in the amplitude of whirl than to increases in static eccentricity. For small amplitude motions, the added or virtual mass of the damper is as large as 27% of the bearing cartridge mass (MBC=15.15 kg). The identified force coefficients are shown to be insensitive to the orbit type (circular or elliptical) and the number of open feed holes (3, 2, or 1). Comparisons of damping coefficients between a damper employing a circumferential feed groove1 and the current damper employing feed holes (no groove), show that both dampers offer similar damping coefficients, irrespective of the orbit amplitude or static eccentricity. On the other hand, the grooved damper shows much larger inertia force coefficients, at least ~60% more. Predictions from a physics based model agree well with the experimental damping coefficients, however for large orbit motion, over predict inertia coefficients due to the model neglecting convective inertia effects. Credence is given to the validity of the linearized force coefficients by comparing the actual dissipated energy to the estimated dissipated energy derived from the identified force coefficients. The percent difference is below 25% for all test conditions, and in fact is shown to be less than 5% for certain combinations of orbit amplitude (r), static eccentricity (eS), and whirl frequency (ω).

Annular seals are devices used in turbomachinery to avoid flow losses which reduce efficiency. The dynamic stability of the machine is also improved by the seal. Thus, it is an important subject to understand the flow behavior through the seal. Straight through triangular labyrinth seals are one of the most commonly used types of non-contacting annular seals. The energy dissipation through these seals is achieved by a series of teeth and cavities. As the flow passes above each tooth, a portion of its pressure energy is converted into kinetic energy. A portion of this kinetic energy is dissipated through turbulence-viscosity interaction in the cavity that follows. Moreover, some portion of the pressure energy is also lost through viscosity of the fluid. This research aims to understand the effects of flow parameters and seal geometry on these losses. This will make it possible to estimate the mass flow leakage through the seal. ANSYS Fluent is used to simulate the flow through the seal. The effect of seal geometry is studied by varying clearance, pitch, tooth height, tooth width and upstream side angle. It was found that, amongst other geometrical parameters, tooth clearance and pitch has a strong influence on carryover coefficient. Smaller values of c/s have better kinetic energy dissipation in the cavity. Carryover coefficient is also found to be a function of the Reynolds number and shaft speed. Discharge coefficient of the seal presents the overall efficiency while carryover coefficient only shows the cavity performance. Discharge coefficient is also found to be a strong function of tooth clearance, pitch, Reynolds number and shaft speed. Remaining parameters have smaller effects. It was observed that the discharge coefficient of first tooth is always lower than those of intermediate teeth. The compressibility effects are presented by using an expansion factor which is the ratio of compressible flow discharge coefficient to incompressible flow discharge coefficient. It was found that the expansion factor is fairly independent of geometrical parameters but a strong function of flow parameters. Considering the effects of seal geometry and flow parameters on carryover coefficient, discharge coefficient and expansion factor, the seal geometry is optimized to increase the kinetic energy dissipation and pressure head loss which in turn will reduce the mass flow leakage.

In both aviation and power generation, gas turbines are used as key components. An important driver of technological advance in gas turbines is the race towards environmentally friendly machines, decreasing the fuel burn, community noise and NOx emissions. Engine modifications that lead to propulsion efficiency improvements whilst maintaining minimum weight have led to having fewer stages and lower blade counts, reduced distance between blade rows, thinner and lighter components, highly three dimensional blade designs and the introduction of integrally bladed disks (blisks). These changes result in increasing challenges concerning the structural integrity of the engine. In particular for blisks, the absence of friction at the blade to disk connections decreases dramatically the damping sources, resulting in designs that rely mainly on aerodynamic damping. On the other hand, new open rotor concepts result in low blade-to-air mass ratios, increasing the influence of the surrounding flow on the vibration response.   This work presents the development and validation of a numerical tool for aeromechanical analysis of turbomachinery (AROMA - Aeroelastic Reduced Order Modeling Analyses), here applied to an industrial transonic compressor blisk. The tool is based on the integration of results from external Computational Fluid Dynamics (CFD) and Finite Element (FE) solvers with mistuning considerations, having as final outputs the stability curve (flutter analysis) and the fatigue risk (forced response analysis). The first part of the study aims at tracking different uncertainties along the numerical aeromechanical prediction chain. The amplitude predictions at two inlet guide vane setups are compared with experimental tip timing data. The analysis considers aerodynamic damping and forcing from 3D unsteady Navier Stokes solvers. Furthermore, in-vacuo mistuning analyses using Reduced Order Modeling (ROM) are performed in order to determine the maximum amplitude magnification expected. Results show that the largest uncertainties are from the unsteady aerodynamics predictions, in which the aerodynamic damping and forcing estimations are most critical. On the other hand, the structural dynamic models seem to capture well the vibration response and mistuning effects.   The second part of the study proposes a new method for aerodynamically coupled analysis: the Multimode Least Square (MLS) method. It is based on the generation of distributed aerodynamic matrices that can represent the aeroelastic behavior of different mode-families. The matrices are produced from blade motion unsteady forces at different mode-shapes fitted in terms of least square approximations. In this sense, tuned or mistuned interacting mode families can be represented. In order to reduce the domain size, a static condensation technique is implemented. This type of model permits forced response prediction including the effects of mistuning on both the aerodynamic damping as well as on the structural mode localization. A key feature of the model is that it opens up for considerations of responding mode-shapes different to the in-vacuo ones and allows aeroelastic predictions over a wide frequency range, suitable for new design concepts and parametric studies. / QC 20111125 / Turbopower, AROMA

O desenvolvimento de tecnologia na área de turbomáquinas é essencial ao desenvolvimento da indústria nacional e o Laboratório de Engenharia Ambiental e Térmica da Escola Politécnica da Universidade de São Paulo tem compreendido ações para este propósito. Este trabalho tem por objetivo desenvolver um compressor para uma turbina a gás de pequeno porte de 500 kW, primeiro passo para o projeto e construção da turbina como um todo. A partir da análise do ciclo termodinâmico e da análise de adimensionais, o tipo de compressor a ser utilizado foi determinado. Optou-se pelo projeto de um compressor centrífugo. Iniciou-se o projeto através de análise e correlações unidimensionais com previsão de desempenho, definindo algumas geometrias iniciais a serem avaliadas nas fases seguintes. Realizou-se a análise bidimensional do impelidor com a ferramenta computacional Vista TF que utiliza o método de curvatura de linhas de corrente. Por fim, a geometria tridimensional foi definida com uso de simulações de dinâmica de fluidos computacional. De acordo com as simulações, o compressor projetado tem desempenho condizente com os requisitos impostos. / Technology development in turbomachinery is essential to the national industry development and the Laboratory of Environmental and Thermal Engineering of the Polytechnic School of the University of São Paulo is engaged on this purpose. This work intends to design a compressor for a small 500 kW gas turbine, the first step in the whole turbine design and construction. The compressor type was determined from thermodynamical cycle and adimensional analysis. The centrifugal type compressor was chosen. The design was initialized using one-dimensional analysis and correlations with performance prediction models, defining initial geometries to be evaluated in the upcoming design phases. The impeller was analyzed with a two dimensional computational tool named Vista TF, which uses the streamline curvature method. The tridimensional geometry was defined using computational fluid dynamics. According to the simulations, the design compressor performs satisfying the imposed requirements.