c.P. No.

1180

MINISTRY OF DEFENCE (PROCUREMENT EXECUTIVE)

AERONAUTICAL RESEARCH COUNCIL CURRENT PAPERS

A Systematic

Approach

to the

Design of Radial Inflow and Mixed Flow Turbines

BY

Pd F. J. Wallace, D.Sc, PhD, Bafh Unkdy of Technology

LONDON. HER MAJESTYS STATIONERY OFFICE 1971 PRICE 52~ NET

A Systematic Radial Inflow

Approach to the Design of and Nixed Flow Turbines by F. J. Wallace

SUMMARY

The report
1.

deals with

3 aspects of the turbine

design problem: for

A simplified

one-dimensional

steady flow treatment

performance predictions on simple and multiple turbines including the case of nozzle or rotor
2.

admission choking.

A one-dimensional unsteady flow treatment for the prediction of pulse performance, again for single and multiple admission casings.

3.

A brief discussion of pseudo three-dimensional streamline curvature techniques which have been extended to include automatic isotachs, computer plOtting of streamlines, isobars as well as of the rotor geometry itself. and

*Replaces

A.R.C.32

781.

Page 2 COhTENTS
1.

2.

Introduction Steady Flow (Constant (a) Unchoked Nozzle (b) Choked Nozzle (0) Two lhtry Casing Pulse Flow Analysis Three-Dimensional Notation

Pressure)

Analysis

3. 4.

and Plotting

Programme

References Illustrations - Figures q-lob Detachable Abstract Cards

1.

INTRODUCTION

work on radial inflow turbines has been Over the last 12 years, intensive proceeding under the writer's direotion, arising out of the need to design a turbine for road traction applications operating in association with a free piston gas generator delivering gas at 4 bar (approx) and 450%. This early work (1958) led to the formulation of a simple, but nevertheless then unique, treatment covering, by one dimensional methods, both design and. off design conditions, as well as a rapid prediction technique for blade to blade pressure and velocity gradients in terms of mid-channel values of velocities and geometric properties, and derived values of the tangential acceleration (Reference 1). This treatment was later extended to analyse pulsating flow conditions in radial flow turbines, using the method of characteristics to formulate equations for wave propagation in the supply duct, volute and nozzle ring, on the one hand, and the rotor on the other, the two sets of conditions being joined by continuity, momentum and energy equations A largely Reference in the interspace experimental
5.

allowing

for

entropy

gain (References

2, 3 and 4). in

attack

on the problem was reported

separately

Reference 2 dealt exclusively with single entry turbines, whilst References 3 and 4 cover the cases of multi entry casings using either the full unsteady or a simpler quasi steady treatment.

Reference 4 incorporated several new techniques required to deal with exceptionally high pres,sure ratios leading to either nozzle or rotor choking, and .s thermodynamic analysis of interspace conditions with multi entry operation. These aspects, as well as operation with variable noeeles, were treated in a further paper (Reference 6) applying specifically to constant pressure operation of single and multi entry radial inflow turbines. by

The work covered by References 2 7 6 has been supported experimentally an extensive programme, using a range of high speed dynamometers, for both constant pressure and pulse operation.

Finally, the analytical techniques developed for radial inflow turbines have been extended to mixed flow turbines, and combined vdth throughflow and blade to blade analyses based on the work of Horlock and Hodslcinson (Reference 7), as well as with new computer graphics routines for the plotting of streamlines, isobars and isotachs, and of the rotor geometry ' itself. This integrated computer aided design approach has already b&n applied to the design, manufacture and testing of a mixed flow rotor. described, together

In the following the various techniques will be briefly with some analytical and experimental results.

Page 4 2. STEADY FLOW(CONSTANTPRESSURE) ANALYSIS (References 1 and 6)

Under this heading the most important aspect of the one-dimensional treatment will be discussed, particularly the off-design interspace model as applied to subsonic as well as sonic nozzle exit conditions. This work is taken almost in its entirety from Reference 6. It must be emphasised that the only losses explicitly taken into account are nozzle-rotor interspace irrevsrsibilities and rotor exit losses, ie the& is no recovery of exit KE. Nozzle and rotor passage losses are explicitly excluded, modified by the inclusion although the treatment can very readily be of loss coefficient as discussed in a

recent paper by Benson (8). The chief advantage of the method lies in the fact that it gives a closed solution of the off design problem and that no recourse is had to empirical incidence loss or deviation coefficients. Correlation with experimental results is surprisingly good. (a) Unchoked Nozzle (Figures The thermodynamic 1, 2 and 3) flow is that of a

model for interspace

constant pressure irreversible ('shock') (Figure 2) with sudden deflection of the leavingvelocity c2 and absolute angle a3 conditions ~2' and a2' giving a relative wz', Slip

process 22' nozzle jet (Figure 3) to velocity vector

B2' in conformity with the rotor inlet geometry. is not allowed for, but could readily be incorporated. problem is solved by the application of the enexgy and momentum equations between conditions

The shock' continuity,

2 and 2', the momentum equation giving the so-called 'shock torque' as distinct from the'impeller torque subsequently developed in the rotor itself.

Page 5 The application of the energy, continuity, and

momentum

equations

across the shock yields:

CpT2

c22 + 2 g,J
-

c22
q

CPT2' +- 2goJ
T2' "2
cot
82

+ Cc2

cm

a2

c2 sin

a2

T2

u2)

goJ

(1)
and gain

yielding

the following

solution

for the temperature

T2',

hence both the shock temperature rise As22 (where A5221 = Cp la .T2'/T2) c22 sin2 a2
0~)~

AT22' 'and entropy

+ T2' sin2 13~~goJcpT22

2 2

c2

- "2

up(c2

cos a2 - u2)
q 0

2g Jc oP

%Jp

(2)

Having determined the shock 'jump' 22' (Figure 2) the rotor end conditions 3 may be evaluated by applying continuity and energy through the rotor, and ultimately ensuring mass flow compatibility between nozzle and rotor by adjusting the initially assumed value of the interspace pressure ~2. The rotor
energy:

equations

are as follows:

y-l

92

w2 I2

+ 2goJcpT2'
[

1 -

P3 y ~2
01

+ 4

u22

absolute c$

exit =

velocity: us2 + 3 3 - 2w3ll3 co9 8,

(4)

Page 6

absolute

rvtor =

exit

angle:

W3 sin e3 sin u3 =3 torque' ~~ becomes c3 cos a3

(5)

from which the 'impeller

co9 a2' + dz
T. 1 q

1
d2 the transition 22'

(6)

2g0

whilst the 'shock' becomes:

2

torque associated

with

%h

T2' co9 a2 - c2 sin a2 - u T2

g0

(7)

The nozzle interspace

and rotor pressura

mass flow terns p2 by iteration

yielding are: 1;

the required

and c3 sin ag n d3b3 02 p3 p2 0

1 Y
(9)

%=

Page 7 Equations (1) to (9) constitute a closed system yielding the required solutions for interspace pressure p2, exit velocity c3 and exit angle a6 mass flow fi = I$ = a, and torque T = rsh + ti. The efficiency (totalto static) may be evaluated from

(10)

A comparison of calculated and experimental results for a wide range of operating conditions is given in Figures 1( and 5. It should be noted that the 'shock' model applies rotor speeds above and below the design point. (b) Choked Nozzle (High Overall The thermodynamic Pressure Ratios) equally to

(Figures

6a and b)

model used to describe

the flow under these

conditions is that of sonic conditions followed by a Prandtl Meyer expansion pressure followed

in the nozzle throat from the nozzle throat

pN to the interspace pressure p2. This, in turn, is by the constant pressure 'shock' described in the The representation of the flow is similar previous section. to that postulated by Jansen,4 but arrived at quite independently.

Page I3 The turning angle a2 - s is given by

sin2 a2 sin2 %

y + 1 (Y+1)/2(Y-l) =( 2 > Y-W I

2 Y-1 (4 3

p2 x-l-PO1 where !tu 0 p2 PO1 PN

P2 [ 0

PO1

exceeds the critical

pressure

ratio

The supersonic velocity c2 is obtained by application of the energy equation for isentropic flow. Thereafter the procedure is similar to that described in Section (a). m (Figures 7a and b) frequently met on turbochargers.

This is a form of casing

This analysis is intended primarily for unsteady flow using the quasi steady approach, ie treating the studies, flow as steady for short time intervals. Under such conditions inlet conditions at the 2 entries can differ widely and may be specified by ~01, Tel and ~02, Ts2. It is possible by the application of techniques similar to those already shock' condition conditions pcI, given to arrive at the common 'post T2' (Figure 7b) in terms of the entry

To1 a-d ~02~ Toz. The general approach is to solve iteratively for the ccmmon interspace pressure p2 until mass flow compatibility between the sum of the nozzle flows (k)l and (rfiN)2 and the rotor flow l'k is obtained.

Page 9 Figures &I, b and c show typical results obtained from the analysis compared with experimental results taken from Reference 10. 3. PULSE FLOWANALYSIS (Refemnces 2, 3 and 4)

Space precludes a detailed discussion of the methods developed. Basically, the method of characteristics has been applied to solve the mid channel equations for unsteady flow in the rotor passages, This involves detailed analysis of radial and tangential velocity end acceleration components under unsteady conditions, leading to.the inclusion of partial derivatives with respect to time as well as to radius. The resultant variables solutions for increments the rotor of the Riemann then become:

dX and dB within

dXR = +

wsin0dt

~R-~#$+~$)+cC&8~}

-7

w2rsin0dt(12

and

+y-l

wLr sin 0 dt

(13)

Thus the leading geometric passage parameters (radius r, channel depth b, inclination 9) and their derivatives, as well as the cantrifugal pressure gradient ana taken into account.

Page 10 These characteristic varsian appertaining equations are connected with the simpler to the fixed passages by the interspace

solution for the entropy function S in terns of the A characteristic incident from the nozzle and the 3 characteristic incident from the rotor derived frcm considerations similar to those leading to equation (2) and resulting in:

1
=

* (l-

S2)

2(1+ ~0s % - UN sin ~$5~ Cot 82 - u2)U2 - s'

+ where

29

cos e* 7 G.

2 [

SON - 9

$1 - f3J 1

(14)

(15)

'Ihe method has recently and FORTRANIV progrw References

been extended to 2 and 3 entry casings have been written for these cases (See

11, Nos 103 and 104).

In addition to the full unsteady flow treatment as outlined above, a simpler analysis has been completed based on the quasi steady approach, and applicable to single and 2 entry casings.

Page 11 results for single entry casing and comparisons with experiment are shown in Figures 9a and 9b, the former applying to measured and calculated pressures at different stations, and the latter to time averaged mass flow, power and efficiency. 1P refers to the pulse (characteristics) treatment, and 1Q to the quasi steady treatment. It will be observed that discrepancies between the two treatments are slight, and that therefore the much simpler quasi steady flow treetment may safely be used. 4. THREE+DIMENSIONALAND PLOTTING PROGRAMS This sectibn should be read in conjunction with Section 2, ie Typical

as an extension of the 1-D techniques and intended to form, with these, a complete design or analysis procedure. The wolJc arose, initially, out of a research project intended to lead to the design, manufacture and testing of a small mixed flow turbine having the same rotor diameter and speed as a conventional inward radial flow turbine, but required to give an increase in mass flow over the latter of the order of 30% without significant loss of total to static efficiency. Accordingly parametric studies were first undertaken using the (modified) 1-D treatment of Section 2 to establish the possibility of such an increase in mass flow subject above restrictions and without exceeding 'reasonable' blade height. Details cycling
must

to the

again be omitted, but the parameter study, systematically over many values of nozzle exit entry angle 32, 'cone angle' $I, blade b2, meridional velocity ratio j, etc. configurations

angle aNB rotor height at entry eventually satisfying

produced a small number of possible the above criteria.

Page 12 The unusual rotor geometry and the exceptionally deep channel passages demanded the subsequent application of hub-shroud and blade to blade analysis . Rather than write completely new programs, it was decided to adapt the streamline curvature treatment as developed by Horlock and The maJor Hodskinson (Reference 7), originally for compressors. modifications (I) ma& were: thus

specification of rotor geometry in analytIca form, greatly dimplifylng data input and gxvlng accurate values of derived geometric and length of normals quantities

such as curvature

(ii)

inclusion streamlines, velocity)

of a graphics isobars

subroutine

giving (lines

automatic

plots

of

and isotachs,

of constant relative (see Figure 10s)

(iii)

development of a completely new graphics package enabling external views (including isometric) and eventually sections in any arbitrary plane to be produced (see Figure

lob)

At the moment the technique is still subject to certain limitations, eg losses are not taken into account, zero exit whirl has to be assumed, and the 'drawing' package is restricted geometry adopted for the mixed flow design. to the particular

It is intended to generalise the method to include losses, to draw sections and to convert these into instructions for numerxally controlled machine tools. Similar procedures, starting with extensive use of loss coefficients analysis tool for centrifugal a more complex 1-D treatment making will be developed as a design and

compressors.

page13

b c d F
g0

acoustic velocity blade height absolute velocity rotor diameter area gravitational conversion constant

fth ft ft/S ft ft2 lb ft/lbfs2 ft lbf/Btu lb/S rev/min lbf/& ft reduced to reference pressura of reference gas at reference s

J m N P r s t T u w a 8 Y A e
P w

mechanical equivalent mass flow rate rotational speed pressure rotor radius entropy level time

of heat

(= acoustic acoustic

velocity vslooity

pressure'

temperature (absolute) peripheral velocity relative velocity absolute angle Riemann variable ratio of specific Riemann variable blade angle density angular velocity Notation upstream total head entry heats

OR ft/S
ft/s radians 'leftward' 'rightward' radians lb/ftJ radians/s wave wave

Suffix 01 2 2' 3 N R

interspace - before shock interspace - after shock or rotor rotor exit nozzle exit rotor entry

Page 14 REFERENCES No. 1 Author(s) F. J. Wallace Title. etc.

Theoretical assessment of the performance characteristics of inward ra&al flow turbines. Proc. I.Mech.E., Vol.172, No.33, 1959. Theoretxal assessment of the non-steady flow performance of inward radial flow turbires. Thermodynamics and Fluid Mechanics Conference, I.Meoh.E., Bristol, March, 1968.

F. J. Wallace and J. M. Adgey

F. J. Wallace, J. Id. Adgey and G. P. Blair

Performance

of inward radial flow

flow

turbines

under non-steady Proc. I.Mech.E., Part 1, No.10.

conditions. 1969-70, ~01.384,

F. J. Wallace and J. Miles

Performance of inward m&al flow turbines under non-steady flow conditions Gth full and partial admission. Submitted to 1.Meoh.E.

F. J. Wallace and G. P. Blair

Performance of inward radial flow turbines under conditions of pulsating flow. ASMLL,Washington Gas Turbine Paper 65-GTP-21, 1964. Conference,

F. J. Wallace, P. R. Cave and J. htiles

Performance of inward radial under steady flow conditions

flow turbines with special

reference to high pressure ratios and partial admissIon. Proc. I.Meoh.X., 1969-70, Vol.184, Part 1. Aerodynamic centrifugal Liverpool, investigation and design of compressor impellers. Ph.D. Thesis, 1967.

M. G. Hodskinson

Page 15 No. 8 Author(s) R. S. Benson Title, etc.

A review of methods for assessing loss co-efficient8 in radial gas turbines. Int. Jl Mech. En&. Sciences, October, 1970, page 905. Supersonic expansion in radial inflow turbine nozzle vanes. ASME Paper 65WA//GTP-5, 1965. A study of the performance of a twinentry radial turbine operating under steady and unsteady flow conditions. M.Sc. Thesis. UMIST, 1968.'

W. Jansen and J. E. Smith

IO

P. H..Timmis

II

Computer Aiad Design Committee

Computer programs in fluid mechanics for use in design and analysis of turbomachinery and ducting. February, 1970.

FIG. I.

TYPICAL

RADIAL

INFLOW

ROTOR

7 S OIAGRAW FOR UNwOKED CASE.

F\G

VELOCITY DIAGRAM.

FIG

4,O

i5

COMPARISON BETWEEN PREDICTED AW EXPERlMENTAiRESULTS FOR CAV TYPE 01

3io m JTo, PO,

2,o ---

-THEORETICAL
EXPERMENTAL

IC )-

2000

-\ TF
I\ I
I-5

To, = 0~ PO, = Ibf/mz

Figure

1
P

0,

I
- THEORETICAL EKPER\t.ENTAI

:OMPARISON C ETWEEN PREDICTED E L BPERIMEN TAL :IESULTS FOR (:AV TYPE 01.

Figure
500 1000

FIG 6a
TS WlTH DIAGRAM NOZZLE

CHOKING

FIG 6 b

C,Sm

VELOCITY

OIAQRAN

WlTt-4

NOZZ\,E

cHOK\NG

S3did hZl3Al13Q 3LWZ5Vd3S 0M.L e3NI 2I 37ZZON

..

S 2 ENTRY TURBINE TS DIAGRAM

FIG.

7b

FIG

8 Q . PREDICTED FOR

AND EXPERIMENTAL 2 ENTRY TURBINE.

RESULTS

0-

- -

COMPUTE0 EXPERII~ENTAL

P-

3-

3-

)IO I2 I.4 P - 01 P3 1-b I.8 2.0

SINGLE

ENTRY

CASING

(Test

2)
IP
---,Q

---

wperr*sntal

2 420 2 h /a 0 I 2 3 4 5 6 7

10 0 / 2

$ s* , h
10 0

1 \
I

7 --3
4 5 6 -7-l 7

FIG

90,

SINGLE

ENTRY

CASING

(Test

2)

* 2 I---I--tit-----1

0 I

12

16

20

,2

I6

20

24

FIG

9b

REL

VEL

STR

LINES

MIXEO

FLOW

TURBINE

ISOMElRK2

VIEW

BACK

ELEVAllObl

51%

ELEVATION

C.P. No. 1.180

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