Internal Correspondence

To From Subject : : : David Cloud

Pratt & Whitney

A United Technologies Company

Anish Kumar Gupta, Kondala Rao and Nirupama CFM 56-3 CFD Analyses of Spinner, LPC, HPC, Rear Hub, LPT, HPT, Mini Disk Cavities SOW# ASD1_35411

Date EII# CC

: : :

July 22, 2006

07-635-0236
T.K. Vashist Chester Wang Ferry De Jong

REA#:

XXXXX

Conclusions: The CFD analyses for all cavities were carried out (2005-06) successfully. Necessary data for thermal analysis was provided to the Heat Transfer Group, in the form of BCON files, for carrying out Thermal Analysis. Recommendations: The BCON files generated from CFD analyses may be used for thermal analysis. Introduction

The 2-D axi-symmetric CFD analyses of Spinner, LPC, HPC, LPT Forward and Aft, and HPT Bore Aft, HPT Aft Upper, TOBI, Rear Hub (without discourager) and Mini Disk Cavities were carried out under idle and SLTO conditions to support the thermal analysis in the first phase of the investigation (2005). In the second phase four more 2D analyses were carried out (2006). Two of these four analyses were for the HPT Aft Upper cavity with inlet 3 (2V flow) at a lower radius and the other two for the Rear Hub cavity with discourager. The commercial CFD software FLUENT, version 6.2, was used for the simulations using standard k- turbulence model and enhanced wall treatment.

Discussions

The fluid domain for LPC cavity is shown in Appendix A, slide # 2. The BCs for the LPC cavity analysis under SLTO and idle conditions are shown in Slide #3 & 4 respectively. The major flow into the cavity is the buffer supply air and the main outlet is for the sealing flow for the aft seal. The domain was meshed with quad cells using Gambit meshing software. The fluid domain for the spinner cavity is shown in slide # 8. The BCs for the spinner cavity analysis under SLTO and idle conditions shown in Slide #9 & 10 respectively. The domain has two inlets and outlets. All the flows going into and out of domain are leakages. The domain was meshed using Gambit with quad cells. The fluid domain for the LPT aft cavity is shown in slide # 13. The BCs for the LPT Aft cavity analysis under SLTO and idle conditions are shown in Slide #14 & 15 respectively. The domain has two flow inlets and one flow outlet. The cavity receives major flow into the cavity from inlet-1 i.e. is 1st vane cooling flow. The domain was meshed using Gambit with quad cells. The fluid domain for the LPT Fwd cavity is shown in slide # 20. The BCs for the LPT Fwd cavity analysis under SLTO and idle conditions are shown in Slide # 21 & 22 respectively. The domain has three inlets. The major flow into the cavity comes from inlet-2 through angled holes in the stator. The flow from the main outlet 3 goes through the flange joint and pressurizes the rim cavity between LPT 1st vane and 1st rotor. The domain was meshed using Gambit with quad cells. The fluid domain for HPC cavity is shown in slide # 27. The BCs for the HPC cavity analysis under SLTO and idle conditions are shown in Slide # 28 & 29 respectively. The domain has three inlets and one outlet. The major inlet is the bore inlet other inlets are the leakage flows. The exit is at HPT disc bore. The domain was meshed using Gambit with quad cells. The fluid domain for HPT bore aft cavity is shown in slide # 32. The BCs for the HPT bore aft cavity analysis under SLTO and idle conditions shown in Slide # 33 & 34 respectively. The domain has one inlet (flow from HPC cavity entering through the HPT bore) and two outlets. The outlet at ID is major outlet for the flow leaving the cavity through HPT rear hub holes. The other outlet is for bolt leakage. The domain was meshed using Gambit with quad cells. The fluid domain for HPT aft upper cavity is shown in slide # 37. The BCs for the HPT aft upper cavity analysis under SLTO and idle conditions are shown in Slide # 38 & 39 respectively. The domain has four inlets and two outlets. The major flow into the cavity is through inlet-3 for the 2nd vane cooling flow. The major outlet is at the rim seal. The flow from outlet at ID lab seal goes to the LPT fwd cavity. The domain was meshed using Gambit with quad cells. The fluid domain for TOBI cavity is shown in slide # 42. The BCs for the TOBI cavity analysis under SLTO and idle conditions shown in Slide # 43 & 44 respectively. The domain has five inlets and three outlets. The major flows into the cavity are TOBI flow, Bye-pass flow and ID seal flow. The major flows out from

the cavity are blade flow and HPT front rim seal flow. The small amount of blade flow leaks through outlet named Blade flow leakage OD of Blade Flow outlet and join back the rim cavity at inlet named OD flow inlet. The domain was meshed using Gambit with quad cells.

The Fluid domain for the Rear Hub cavity is shown in slide # 49. The BCs for Rear Hub Cavity KE Clearance 15.8mil under SLTO and idle conditions are shown in slide # 50& 51 respectively. The Domain has one inlet and two outlets. The flow enters the cavity through the Rear Inlet and leaves the domain through the Rear Exit. The domain was meshed using Gambit with quad cells. The Fluid domain for the Mini Disk cavity is shown in slide # 54. The BCs for Mini Disk Cavity analysis under SLTO and idle conditions are shown in slides #55 and #56 respectively. The Domain has two inlets and two outlets. Major flow enters the cavity through the Inlet1 and leaves the cavity through the Exit1. The domain was meshed using Gambit with quad cells. The fluid domain for HPT aft upper cavity with inlet 3 at lower radius is shown in slide # 59. The BCs for the SLTO and Idle analyses for this configuration of the HPT aft upper cavity are same as shown in Slide # 38 & 39 respectively. The same mesh as in earlier analysis was used. The Fluid domain for the Rear Hub cavity is shown in slide # 62 and 63. The discourager and seal knife edge clearances 20 and 22 mil for the SLTO condition and 40 and 42 mil for the idle condition. The BCs for the SLTO and idle conditions are shown in slide # 64 and 65 respectively. The mesh is similar to previous analyses except in the discourager and seal knife edges regions.

Observations

For the LPC Cavity under idle condition, P between the aft seal exit and the buffer seal inlet is 0.096% P25 and P between the aft seal exit and the buffer supply inlet is about 0.069% P25. Under SLTO conditions, these Ps are 1.272% P25 and 0.98% P25. The contours of RPMF for SLTO and idle conditions are shown in slide # 5 & 6 respectively. The additional analysis was carried under SLTO conditions with the buffer air entering with 0.4 RPFM (contours in slide#7) against 0 in earlier analysis. In this additional analysis case under SLTO condition, the RPMF compared to earlier SLTO case doesnt have any appreciable change except in the vicinity of buffer supply air inlet. The P between the aft seal exit and the buffer seal inlet is 1.628% P25 and P between the aft seal exit and the buffer supply inlet is about 1.133% P25. For the Spinner Cavity under SLTO conditions, P between the Balance Feature leak exit (outlet1) and the bolt leak (inlet1) is 2.574% P25 and the P between the Balance Feature leak exit (outlet1) and the Radial Snap Leakage (inlet2) is about 2.79% P25. Under idle conditions, the P between Balance Feature leak exit (outlet1) and bolt leak (inlet1) is 0.53% P25. Except near the axis, the RPMF in most part of the cavity is about 0.95 to 1.0 under idle and SLTO conditions. The

contours of RPMF for SLTO and idle conditions are shown in slide # 11 & 12 respectively.

In the LPT Aft Cavity the flow from inlet-1 sticks to LPT stub shaft under both the conditions i.e. SLTO (Slide #16) & idle (Slide #17). The outgoing flow sticks to the rear of aft disc before joining to the gas path under SLTO condition but under idle condition the flow does not stick to rear of the aft disc. The RPMF in the cavity are similar under SLTO and idle conditions. The contours of RPMF for SLTO and idle conditions are shown in slide # 18 & 19 respectively. The flow structure for the LPT Fwd Cavity is identical under SLTO (Slide #23) and idle conditions (Slide#24) except near outlet-3 towards OD. Under SLTO conditions there is a large recirculation. The flow from inlet-2 enters the cavity at an angle of 15 19. The contours of RPMF in the CGF domain for SLTO and idle conditions are shown in slide # 25 & 26. For the HPC cavity the P between Bore Inlet and the Bore Exit under SLTO and idle conditions is 1.43 %P3 and ~2 %P3 respectively. The RPMF varies from 1.0 at the Inlets to 1.25 at bore exit under SLTO conditions compared to from 1.0 and 1.42 at under idle conditions. The contours of RPMF for SLTO and idle conditions are shown in slide # 30 & 31 respectively. For HPT bore cavity the flow structures are identical under SLTO and idle conditions. The flow enters the domain with mass wt. RPMF of 1.27 and 1.46 under SLTO and idle conditions respectively. The RPMF upstream of rear hub holes are 0.5 and 0.6 under SLTO and idle conditions respectively. The contours of RPMF for SLTO and idle conditions are shown in slide # 35 & 36 respectively. For the HPT aft upper cavity analysis under SLTO and idle conditions the flow structures are identical. In most part of the cavity RPMF is between 0.5-0.7. The flow from inlet-3 enters with mass wt. RPMF of 0.6 under SLTO condition and 0.4 under idle condition. The contours of RPMF for SLTO and idle conditions are shown in slide # 40 & 41 respectively. In the TOBI cavity analysis reverse flow is seen at the rim cavity outlet, but the flow does not go deep into the cavity for both SLTO and idle conditions. The pressure rise from the pump holes exit to blade flow outlet under SLTO and idle conditions are about 4 %P3 and 3.2 %P3 respectively. The mass wt. RPMF of TOBI flow under SLTO and idle conditions are 1.23 & 1.38 respectively. The contours of RPMF for SLTO and idle conditions are shown from slides # 45 to 48. For the Rear Hub Cavity the flow structures are identical under SLTO and idle conditions. Contours of rpmf under SLTO and idle conditions shown in slide# 52 and 53 respectively. Static Pressure drop across the cavity for SLTO and idle conditions are 33.7%P3 and 37%P3 respectively. The windage heat up in the Cavity for SLTO and idle conditions are 4.1%T31 and 8.5%T31 respectively.

The contours of RPMF under SLTO and idle conditions for the Mini Disk Cavity are shown in slide #57 and58 respectively. Cavity RPMF varies between 0.3 to 0.5 under SLTO and idle Conditions. For the HPT aft upper cavity analysis under SLTO and idle conditions, with Inlet 3 at lower radius, the flow structures are again identical. In most part of the cavity RPMF is between 0.4-0.7. The contours of RPMF for SLTO and idle conditions are shown in slide # 60 & 61 respectively. For the Rear Hub Cavity with discourager also, the flow structures are identical under SLTO and idle conditions. Contours of RPMF under SLTO and idle conditions are shown in slide # 66 to 69. Static Pressure drop across the cavity for SLTO and idle conditions are 36.3%P3 and 36%P3 respectively. The windage heat up in the Cavity for SLTO and idle conditions are 3.9%T31 and 2.3%T31 respectively. The windage heat up was less in cavity with discourager, as seal knife edge clearances were more. No general conclusion could be drawn from comparison between analyses with and without discourager, as BCs for the two set of analyses were different.

References 1. Appendix A
2.

ASDI Bangalore Reports for individual analysis, Report # 35411.1, 35411.2, 35411.3, 35411.4. 35411.5, 35411.6, 35411.7, 35411.8, 35411.9, 35411.10, 35411.11, 35411.12, 35411.13, 35411.14, 35411.15, 35411.16, 35411.17, 35411.18,18.1, 35411.19,19.1, 35411.20, 35411.21, 35411.22, 35411.23, 35411.24 and 35411.25.