Unsteady Loss in a High Pressure Turbine Stage

Stephen John Payne Trinity College

A thesis submitted in partial fulfilment of the requirements of the degree of Doctor of Philosophy at the University of Oxford, Hilary Term 2001 Department of Engineering Science University of Oxford

Unsteady Loss in a High Pressure Turbine Stage

Stephen John Payne Trinity College

A thesis submitted in partial fulfilment of the requirements of the degree of Doctor of Philosophy at the University of Oxford, Hilary Term 2001

Abstract
The widespread use of the gas turbine as a means of aircraft propulsion has provided a considerable impetus to improving its efficiency. This is largely achieved by improving the individual component efficiencies. However, without a greater understanding of the unsteady flow field, in particular the flow mechanisms that cause loss, it is difficult to obtain further improvements. The work performed for this thesis is thus concerned with a detailed investigation into the unsteady loss mechanisms found in a high pressure turbine stage at engine-representative conditions, and with possible means of reducing their effects in order to improve the engine efficiency.

Since entropy is the only means of quantifying loss, experimental measurements have been made of the unsteady entropy field at stage exit using an aspirating probe. A dedicated facility in Oxford enables these measurements to be made at engine-representative conditions. The frequency response of the aspirating probe has been examined in detail, both theoretically and experimentally, and the measurement accuracy optimised. The entropy measurements have been used to identify the loss mechanisms and to estimate their effects on the stage efficiency individually, allowing blade designers to focus on suitable design improvements more effectively. The measurements have also been used to validate numerical predictions of the loss, both qualitatively and quantitatively, aiding in the development of future predictions.

Close to the end walls, the unsteady Mach number and flow angle have also been measured. These measurements have aided in the interpretation of the loss structure and its effects on the flow field. Throughout, existing experimental results have been used for comparison with the measurements and numerical predictions. By considering all the experimental measurements, design recommendations, with the aim of removing or reducing the effects of the loss mechanisms, and hence increasing the stage efficiency, have been made.

Acknowledgements
Give thanks to the Lord for He is good. His love endures for ever, Psalm 136, v. 1.

No man is an island, and this one is no exception. The work that I have been fortunate enough to spend the last three years working on would not have been possible without the help of a great number of people, to all of whom I am very grateful.

Firstly, I would like to thank my supervisors, Professor R.W. Ainsworth and Dr. R.J. Miller, to whom I owe a great deal. Their support, advice and guidance, not to mention their enthusiasm, have been absolutely invaluable in keeping me on the straight and narrow. Many thanks are due to the Engineering and Physical Sciences Research Council as well for funding me over the last three years.

Thanks are also due to all those at Osney, who have made it such a pleasant three years, in particular the Rotor Group: Roger Moss, for his ever-willing help and advice, especially with the writing of this Thesis, Charles Thomas and others. None of the experimental work would have been possible without the dedication of Kevin Grindrod, who kept the Rotor Facility running in the face of much adversity, and Nigel Brett. Thanks also to those who have kept me entertained around the building and elsewhere: you know who you are! Thanks particularly to Anton and Helen, for being such amazing friends and support over the last three years.

I have been fortunate enough to teach some wonderful undergraduates at many colleges during my three years, in particular at Exeter last year and at St. John's and Univ. this year. Teaching has frequently kept me going, not just financially, and I am looking forward to watching their progress in the future. Thank you to all my undergraduates, past and present, at Corpus Christi, Exeter, Jesus, Merton, New, St. Catherine's, St. Hilda's, St. John's, Trinity and University colleges, who really are too numerous to name here. Thank you to all my fellow tutors as well for their help and advice.

It is, of course, down to my parents that I have reached this far: only by their love and encouragement over the last three years. Thanks also to my sister for being herself. This thesis is dedicated to them, but, perhaps more importantly, to the greater glory of God, to whom be praise and glory for ever and ever. Amen.

O LORD, our Lord, how majestic is your name in all the earth! You have set your glory above the heavens. From the lips of children and infants you have ordained praise because of your enemies, to silence the foe and the avenger. When I consider your heavens, the work of your fingers, the moon and the stars, which you have set in place, what is man that you are mindful of him, the son of man that you care for him? You made him a little lower than the heavenly beings and crowned him with glory and honour. You made him ruler over the works of your hands; you put everything under his feet: all flocks and herds, and all the beasts of the field, the birds of the air, and the fish of the sea, all that swim the paths of the seas. O LORD, our Lord, how majestic is your name in all the earth!

Psalm 8, The Bible, New International Version

Contents
Nomenclature Chapter 1: Introduction
1.1 Overview 1.2 Gas turbine theory 1.3 Scope of current research

i 1
1 2 3

Chapter 2: Review of the High Pressure Turbine Flow Field

2.1 Introduction 2.2 Three-dimensional steady flow field 2.3 Loss mechanisms 2.3.1 Two-dimensional loss mechanisms 2.3.1.1 Boundary layer loss 2.3.1.2 Shock loss 2.3.1.3 Mixing loss 2.3.1.4 Wake structure 2.3.1.5 Two-dimensional cascade loss measurements 2.3.2 Three-dimensional loss mechanisms 2.3.2.1 End wall loss 2.3.2.2 Tip leakage loss 2.3.3 Summary 2.4 Blade row interaction 2.4.1 Two-dimensional blade row interaction 2.4.1.1 Wake interaction 2.4.1.2 Shock wave interaction 2.4.1.3 Potential flow interaction 2.4.2 Three-dimensional blade row interaction 2.5 Summary and conclusions

5
5 5 7 8 8 11 12 13 14 15 16 21 24 24 25 25 27 28 28 32

Chapter 3: Modifications to the Oxford Rotor Facility

3.1 Introduction 3.2 Description 3.3 Operating Point 3.4 Instrumentation improvements 3.5 AGV opening improvements

33
33 33 35 36 37

3.6 Summary and conclusions

43

Chapter 4: Hot Wire Anemometry

4.1 Introduction 4.2 Theory of operation 4.2.1 General hot wire equation 4.2.2 Steady state solution 4.2.3 Nusselt number dependence 4.2.4 Temperature dependence 4.3 Frequency response 4.3.1 Previous research 4.3.2 Complete theoretical solution 4.3.3 Frequency response of wire supports 4.3.4 Steady state response 4.3.5 General frequency response 4.3.6 Summary 4.4 Calibration 4.5 Measurement accuracy 4.6 Summary and conclusions

44
44 44 45 47 48 49 50 50 51 53 53 55 56 57 63 66

Chapter 5: The Aspirating Probe

5.1 Introduction 5.2 Theory of operation 5.3 Optimisation of probe design 5.4 Frequency response 5.4.1 Steady state probe performance 5.4.2 Low frequency probe performance 5.4.3 High frequency probe performance 5.4.3.1 Experimental validation 5.4.3.2 Comparison with numerical predictions 5.4.4 Summary 5.5 Measurement accuracy 5.6 Summary and conclusions

68
68 68 70 71 74 79 81 85 88 91 92 94

Chapter 6: Unsteady Loss Measurements

6.1 Introduction 6.2 Time-resolved radial loss variation 6.2.1 Loss structure

95
95 95 96

6.2.2 Comparison with numerical predictions 6.2.3 Stage efficiency 6.2.4 Summary 6.3 Time-resolved radial and circumferential loss variation 6.3.1 Time-resolved flow field 6.3.1.1 Tip leakage vortex 6.3.1.2 Wake 6.3.1.3 Lower passage vortex 6.3.2 Time-mean flow field 6.3.3 Stage efficiency 6.3.4 Summary 6.4 Summary and conclusions 6.4.1 Blade design conclusions 6.4.2 Use of Unstrest in blade design

97 98 101 102 102 107 108 108 109 112 115 116 118 118

Chapter 7: Tip Flow Measurements

7.1 Introduction 7.2 Experimental procedure 7.3 Tip flow measurements 7.3.1 Rotor exit flow field 7.3.2 Downstream vane inlet flow field 7.3.3 Summary 7.4 Design conclusions

120
120 120 121 122 126 130 131

Chapter 8: Hub Flow Measurements

8.1 Introduction 8.2 Experimental procedure 8.3 Hub flow measurements 8.3.1 Flow structure 8.3.2 Downstream vane inlet flow field 8.3.3 Summary 8.4 Design conclusions 8.4.1 Blade design conclusions 8.4.2 Use of Unstrest in blade design

133
133 133 134 135 139 141 142 142 143

Chapter 9: Summary and Conclusions

9.1 Overview 9.2 Experimental techniques

144
144 144

9.3 Experimental results 9.3.1 Flow structure 9.3.2 Stage efficiency 9.4 Design conclusions 9.5 Use of Unstrest in blade design

146 146 148 148 149

References