AxSTREAM Hydro Conceptual Design Suite

AxSTREAM Hydro
Version 3.2

Axial Hydraulic Turbine Flow Path Design, Analysis and Optimization

2012

AxSTREAM - SoftInWay Inc. trademark. All rights reserved.

AxSTREAM Hydro Conceptual Design Suite

Introduction

The AxSTREAM Hydro is a software suite for hydraulic machines multidisciplinary design, analysis and optimization, that provides an integrated and streamlined solution for the complete flow path design process for both radial and axial pumps and turbines, starting from initial sizing from scratch ending up 3D blade profiles at the final phase. Starting from preliminary design (defining basic machine performance from a few simple parameters), AxSTREAM Hydro goes through meanline (1D) and axisymmetric (2D) analysis, profiling and 3D blade design of the buckets, finite element analysis, finishing with export of the geometry to 3D CAD model or for CFD calculation. AxSTREAM Hydro provides full design and analysis cycle for axial and radial hydraulic turbines in a flexible and integrated environment. The tasks user can solve with AxSTREAM Hydro are following: Design new machine from scratch Analyze existing machine and its performance Redesign, optimize and upgrade existing machines AxTREAM Hydro supports all types of incompressible newtonian fluids, including water, oil, kerosene etc. User can work with pre-defined default fluids or compose custom one based on known physical properties (density, wiscosity).

AxSTREAM Hydro Conceptual Design Suite

Hydraulic Turbine Preliminary Design (Axial_TURBO_Design License)

Preliminary Design procedure is used to create machine flow path design from scratch from a set of several boundary conditions, geometrical parameters and taking into account specified constraints.

2.1

Turbine Solution Generator

Preliminary Design Solution Generator is used to produce a number of variants (solutions) that satisfy specified boundary conditions within applied constraints. The usage of inverse solver allows to generate large amount of designs in a short time (20,000 per min). AxSTREAM Hydro can design completely new flow paths, or use the unified stages with similar geometry. Maximum number of stages in the machine equals to 50. Generated set of solution can be explored using Design Space Explorer.

2.2

Axial Turbine Design Space Explorer

Design Space Explorer allows exploring a set of solution points generated with Solution Generator. Design Space Explorer gives possibility to select appropriate solutions by specifying different types of constraints and limitations.

AxSTREAM Hydro Conceptual Design Suite

2.3

Post-design Flow Path Adjustment

Post-design flow path adjustment

provides user with option to adjust separate stages using changing their geometric parameters, pressure distribution on the chart or entire machine endwall contours by spline.

S1/S2 flow path adjustment option enables users to optimize separate stages: in pitchwise direction (S1 optimization) taking profile width with regard to pitch under criteria of loss minimization in spanwise direction (S2 optimization) taking geometrical parameters with regard to outlet capacity and losses within the constraints on reaction, hub and tip diameters etc.

The optimization is performed using multistage random search with automatic adjustment of parameter variation intervals at each step of the search.

AxSTREAM Hydro Conceptual Design Suite

3 Streamline Solver (Axial_TURBO_Analysis License)

Streamline solver module performs meanline (1D) or axisymmetric (2D) calculation of machine, taking into account actual characteristics of the machine geometry and boundary conditions set.

The system can perform analysis of stages with full blade rows, with only rotor or only stator, stages with counterrotation, and mixed flow paths with axial and radial stages. Additional elements (ducts, diffusers etc) can be specified and calculated In addition to the existing models of energy loss and seal leakages calculations, the user can add custom ones. Streamline solver calculates next main parameters of the flow path: Power Efficiency Mass flow rate, volume flow rate; Kinematic, thermodynamic parameters distribution Losses in elements Leakages and flow balance; Distribution of parameters spanwise; Lean calculation;

2D analysis uses streamline curvature method. This module performs calculation of radial equilibrium in the gaps between airfoil rows. The model for profile losses, secondary losses and leakages losses can be selected from a few standard ones or customized. Distribution of parameters can be visualized as colorful gradient.

AxSTREAM Hydro Conceptual Design Suite

Design of Experiment Optimization (AxPLAN License)

AxPLAN module uses streamline solver and can be run in meanline or axisymmetric task formulation. It is the main optimization tool at the last phases of flow path design. The AxPLAN module allows performing various design tasks by using design of experiment (DoE) study methods. The experiment planning option is fully integrated into AxSTREAM Hydro and is executed in terms of direct problem formulation of calculation analysis, which enables the user to make an experiment plan using familiar formulations. The use of AxPLAN allows users to see the results of optimization and to define the cylinder performance in off-design regimes.

Performances Maps Generator (AxMAP License)

AxMAP module uses streamline solver and can be run in meanline or axisymmetric task formulation. It is developed for automatic generation of turbine performance maps. AxMAP makes possible to study the influence of operational conditions and geometry variation on turbine performance. The maps generation function is integrated into AxSTREAM Hydro and uses current project geometry for calculations. AxMAP files can store existing experimental data in order to compare them with calculation results.

AxSTREAM Hydro Conceptual Design Suite

Profiling and Blade Design (Axial_Profiling_Blade_Design License)

Profiling and Blade Design module is used for creation and editing of 3D airfoils. Wide range of geometrical tools and interactive charts allows user to configure the blades easily and in a short time.

Profiling tools provides interactive mechanism to change profile parameters by varying the values of inlet and outlet angles, wedge angles and edge radii.

Profiles can be also manipulated by using the control points of splines. Throat (gauging angle) is preserved during profiling manipulations. Profiling options offer various methods of profile optimization. Automatic profile optimization can be performed based on the aerodynamic criteria of profile quality such as minimal profile losses.

Potential flow solver in profiling module automatically calculates the distribution of velocity, pressure, momentum thickness values and heat transfer coefficients along the profile outline. In blade profiling user can take into account protective coating thickness, edit its distribution across the profile and receive final blade with or without coating depending on task.

AxSTREAM Hydro Conceptual Design Suite

Blade designer is used for 3D blade design, shaping and stacking. The module has options allowing interactive graphical editing of blade geometry and twist angles manipulation, changing the position of profile mass center in separate sections (lean and sweep). In Blade designer user can control 3D curvature of the blade and review blades in rows. Blade designer helps user to estimate area distribution and stresses at edges of pressure and suction sides in real time in order to build 3D blades.

AxSTREAM Hydro Conceptual Design Suite

Cascade CFD (Cascade CFD license)

Cascade CFD module is used for rapid 2D flow analysis in blade channels. The analysis is performed using full 2D CFD formulations (Navier-Stokes, viscous with various turbulence models (standard k-e, k-e RNG, k-w, k-w SST models)). The analysis results are flow charts with velocity, pressure and other parameters distribution along the profile outline. User can also calculate and display heat flux and velocity vectors.

AxSLICE Module (AxSLICE license)

AxSLICE module is used for extraction of profiles geometry from blades 3D models. AxSLICE can process 3D models in STL, IGES, CURVE formats. AxSLICE provides special option for extraction profiles from cloud of points obtained with laser 3D scan. Blade model geometry: chords, blade angles, edge diameters are automatically recognized in a specified number of cross-sections. Recognition results can be immediately loaded into AxSTREAM Hydro project. These results can be used for automated import and flow path calculations.

AxSTREAM Hydro Conceptual Design Suite

ATLAS Profile Database (ATLAS License)

Atlas is a profile database management system allowing to store blade profiles that are using in company practice or designed right in AxSTREAM Hydro. Profiles can be created and edited directly in ATLAS from XY-points coordinates, arcs segments or thickness distribution along caomberline. Later on they can be inserted to AxSTREAM Hydro and used for blade design purposes. In ATLAS user can work with a number of independent profiles databases at the same time.

10 Import of Profiles (Import_Profile License)

User can import profiles created using XY points coordinates with the help of Import Profile module in AxSTREAM Hydro. AxSTREAM Hydro allows importing both separate profiles and series of profiles in blade airfoil. The data can be imported from file or copied from EXCEL tables. AxSTREAM Hydro provides interactive adjustment of imported points with fully and semi-automatic determination of edges and blade angles. An imported profile can be inserted into the cascade in the chosen position, scaled to fit chord and inserted into the cascade, retaining the throat and stagger angle.

AxSTREAM Hydro Conceptual Design Suite

11 Structural and Modal Analysis (AxSTRESS License)

AxSTRESS module is used for express 3D structural and modal analysis of the blades using the finite element method. The module has tools for automatical mesh generation and results post-processing. Boundary conditions (pressures, rotation speed etc) are automatically taken from AxSTREAM Hydro project AxSTRESS module can calculate and display Campbell diagram for single element or groups of blades. AxSTRESS creates temporary files in CDB-format that is compatible with ANSYS. This way AxSTRESS results can be always confirmed in ANSYS. AxSTRESS has options to perform: hot-to-cold state calculation to determine appropriate manufacturing conditions before profile export cold-to-hot state calculations. Their results can be used for scanned blades to receive them in hot working state for calculation in AxSTREAM Hydro

AxSTREAM Hydro Conceptual Design Suite

12 3D Flow Analysis (AxCFD License)

AxCFD is used for 3D flow analysis in blade-to-blade channels. The analysis is performed using full 3D CFD formulation (Navier-Stokes, viscous with various turbulence models (standard k-e, k-e RNG, k-w, k-w SST models)). All the geometry data are transferred from AxSTREAM Hydro project to AxCFD automatically. In preprocessor user can setup distribution of boundary conditions before and after domain, mesh quality for automated generation and solver settings. CFD can be calculated for individual rows, for a stage or for entire cylinder. The analysis results are the values of flow rate, efficiency, kinematic and thermodynamic parameters. The system post-processing can calculate the distribution of parameters in any section of the channel in pitchwise direction and the distribution of parameters in the section along profile outline. Depending on blade temperature specified and conditions of flow in channel, heat transfer coefficient and its vectors will be calculated. CFD calculation results can be saved for later review or compared with other calculations and experiments data in main program project.

AxSTREAM Hydro Conceptual Design Suite

13 Geometry Export (Export License)

Export module allows users to export 3D blade geometry as DXF, IGES and STL files to use them in CAD systems. Blades 3D geometry can be also exported in specialized formats to different commercial CFD and CAE software systems for 3D aerodynamic and structural analysis (CFX, FLUENT, NUMECA, ANSYS). Additional customized export formats can be added on demand.

14 AxSTREAM Database (Project Base License)

Project Base license is mandatory option for using on workstation and it is needed to start working with AxSTREAM Hydro in either single user or floating Project license is used as base system option managing available set of network licenses. AxSTREAM database allows integration of turbomachinery projects giving access to project data viewing and editing, consistency management and data recovery, project data loading and saving. each license. the

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User can modify the number of stations, profiling modes, structural properties used in different elements of turbine, define methods of energy loss calculations, select different units in measuring system settings used during data output, change graphical user interface language (English, Russian).

AxSTREAM Hydro viewer helps to explore axial turbine flow path (both meridional view and 3D blade geometry), velocity triangles, HS-diagram, flow balance diagram, distribution of kinematic and thermodynamic parameters of machine.

AxSTREAM Hydro Conceptual Design Suite

AxSTREAM Hydro allows to copy and paste modules (groups of stages) or stage objects from one project to another. This option gives capability to store company approved types of stages in the libraries and quickly assemble them into new flow path designs.

AxSTREAM Hydro supports data exchange with MS EXCEL tables. This allows parallel initial data preparation, i.e., without using AxSTREAM Hydro workstation, and after that it is possible to quickly transport the data to the system.

AxSTREAM Hydro Conceptual Design Suite

AxSTREAM Hydro allows to manage structural materials database. Material mechanical properties are defined in AxSTREAM Hydro within the temperature range. It gives a capability to estimate accurately values of stresses in turbine elements. Structural materials database can be easily customized by user. AxSTREAM Hydro allows to generate user customized reports including all project data. User can select custom list of elements and properties that should be displayed in report.

AxSTREAM Hydro Conceptual Design Suite

15 AxSTREAM Hydro Licensing

Flexible licensing system allows the customer to choose the appropriate set of modules. AxSTREAM Hydro comes with personal (attached to defined PC) or network licenses (floating, AxSTREAM Hydro can run on all computers connected to network). If there are several Project licenses, than other licenses can be split and shared on different workstations (AxSTREAM Hydro seats) at the same time. Below is a table with all available modules for hydraulic turbine design. Module/License PROJECT Base Axial TURBO Design Axial TURBO Analysis Profiling & 3D Blade Designer AxSTRESS Cascade CFD AxCFD Import profile Export Atlas AxPLAN (DoE and optimization) AxMAP AxSTREAM Fluid Calculator AxSTREAM Fluid Designer AxSLICE Description Workplace base license. Project database management Machine preliminary design and optimization, Stage design and optimization, Design Space Explorer Meanline (1D) and axisymmetric 2D analysis with Streamline solver Planar cascades profiling, 3D blade design (stacking) 3D FEA analysis 2D CFD solution built in the profiling (if AxCFD is purchased, then Cascade CFD is included) 3D CFD solver Import blade profile geometry Export of blade geometry to CAD/CAE commercial packages Storage for designed and standard company profiles Design of experiment and optimization engine Turbomachinery performances maps generator Calculates fluid properies Tool for composing of custom gas mixtures Module that is used for extraction of profiles geometry from blades 3D models and scanned clouds of points.

AxSTREAM Hydro Conceptual Design Suite

16 AxSTREAM Hydro Tutorials, Documentation and Technical Support

A full set of AxSTREAM Hydro Tutorials are available to ensure quick mastering of the software. SoftInWay also offers excellent technical support for our customers (requires active support agreement). Our experienced turbomachinery engineers have a wide understanding of all types of turbomachinery, and will assist you with all your questions.

17 Turbomachinery & AxSTREAM Training

To fully master all the features of AxSTREAM Hydro, we highly recommend that you attend one of our training classes. AxSTREAM Hydro offers both classroom and online training. The online training makes it possible for you to attend the training from your office. Our well known classroom training offers both advanced and fundamental training on turbomachinery design and analysis, as well as AxSTREAM Hydro workshops

18 About SoftInWay
SoftInWay provides high quality engineering services and software products in the area of research, design and digital prototyping of turbo-, thermo- and rotating machinery. SoftinWays software suite combines more than 500 years of in-house turbomachinery engineering expertise to help you reach optimal performance. SoftInWay is headquartered in Burlington, MA, USA.

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HQ Contact Info: 15 New England Executive Park Burlington, MA 01803, USA Main Number: 1-781-685-4942 Sales Number: 1-781-862-7867 FAX: 1-781-685-4601 For product information or assistance: Sales@SoftInWay.com For technical support: Tech_Support@SoftInWay.com