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Proceedings of ASME Turbo Expo 2013: Turbine Technical Conference and Exposition
GT2013
June 3-7, 2013, San Antonio, Texas, USA
GT2013-95469
Marcus Thern
Div. of Thermal Power
Engineering
Dept. of Energy sciences
Lund University
SE-221 00 LUND, Sweden
Tel: +46 222 41 12
marcus.thern@energy.lth.se
Magnus Genrup
Div. of Thermal Power
Engineering
Dept. of Energy sciences
Lund University
SE-221 00 LUND, Sweden
Tel: +46 222 92 77
magnus.genrup@energy.lth.se
ABSTRACT
The development of advanced computational fluid dynamic
codes for turbine design does not substitute the importance of
mean-line codes. Turbine design involves mean-line design,
through-flow design, airfoil design, and finally 3D viscous
modeling. The preliminary mean-line design continues to play
an important role in early design stages. The aim of this paper
was to present the methodology of mean-line designing of axial
turbines and to discuss the computational methods and
procedures used. The paper presents the Lund University Axial
Turbine mean-line code (LUAX-T). LUAX-T is a reducedorder through-flow tool that is capable of designing highly
loaded, cooled axial turbines. The stage computation consists of
three iteration loops cooling, entropy, and geometry iteration
loop. The stage convergence method depends on whether the
stage is part of the compressor turbine (CT) or power turbine
(PT) stages, final CT stage, or final PT stage. LUAX-T was
developed to design axial single-and twin-shaft turbines, and
various working fluid and fuel compositions can be specified.
LUAX-T uses the modified Ainley and Mathieson loss model,
with the cooling computation based on the m*-model. Turbine
geometries were established by applying various geometry
correlations and methods. The validation was performed
against a test turbine that was part of a European turbine
development program. LUAX-T validated the axial PT of the
test turbine, which consisted of two stages with rotational speed
13000 rpm. LUAX-T showed good agreement with the
available performance data on the test turbine. The paper
presented also the mean-line design of an axial cooled twinshaft turbine. Design parameters were kept within limits of
current practice. The total turbine power was 109 MW, of
which the CT power was 55 MW. The CT was designed with
two stages with a rotational speed of 9500 rpm, while the PT
had two stages with a rotational speed of 6200 rpm. The total
cooled
turbines,
NOMENCLATURE
A
Area [m2]
B
Axial chord [m]
C
Absolute velocity [m/s]
Ca
Axial velocity [m/s]
Cm
Meridional velocity [m/s]
Cr
Radial velocity [m/s]
Cu
Tangential velocity [m/s]
CC
Combustion chamber
CFD
Computational fluid dynamic
Cp
Specific heat ratio [kJ/kgK]
CP
Pressure recovery coefficient [-]
CT
Compressor turbine
f
Fuel-to-air ratio
h, H
Enthalpy [kJ/kg]
HONC, h/c
Aspect ratio [-]
HONB
Axial aspect ratio [-]
HTC
Heat transfer coefficient [W/m2K]
I
Rothalpy [kJ/kg]
LUAX-T
Lund University Axial Turbine
M
Mach number [-]
m
Mass flow [kg/s]
m*
Dimensionless mass flow [-]
N
Rotational speed [rpm]
OTDF
Overall temperature distribution
factor
p
PR
P.S
PT
Q
r
RTDF
S
SONB
SONC
S.S
Pressure [bar]
Pressure ratio [-]
Pressure side
Power turbine
Tuning factor
Radius [m]
Radial temperature distribution factor
Pitch [m]
Spacing-to-axial chord [-]
Spacing-to-chord [-]
Suction side
T
TEONO
TIT
TONC
U
V
Wpump
W
YP
YS
YTE
YCL
YF
Z
Temperature [C or K]
Trailing edge thickness-to-chord [-]
Turbine inlet temperature [C]
Thickness-to- chord [-]
Blade speed [m/s]
Velocity [m/s]
Pump work [kW]
Relative velocity [m/s]
Profile losses [-]
Secondary losses [-]
Trailing edge losses [-]
Clearance losses [-]
Film losses [-]
Zweifel number [-]
Greek symbols
rad
Heat transfer coefficient by radiation [kJ/kgK]
Efficiency [%]
Density [kg/m3]
Subscripts
a
b
c
c,in
c,out
in
f
g
mix
o
out
p
rel
rtr
s
Air
Blade
Coolant
Coolant in
Coolant out
Inlet
Fuel
Gas
Mixing
Total
Outlet
Pressure
Relative
Rotor
Static
str
sw
th
TT
TS
Stator
Swirl
Throat
Total-to-total
Total-to-static
INTRODUCTION
Efficient turbine design comprises preliminary mean-line
design, through-flow design, airfoil design and 3D viscous
modeling. Despite development of advanced computational
fluid dynamic (CFD) codes, mean-line design continues to be
an important tool in designing turbines. Mean-line design is
essentially applied during the early stages of turbine design
when geometries, velocities and angles are not known. The
mean-line design assumes that there is a mean streamline along
the turbine and that the flow conditions on the streamline are
representative of the entire turbine. In mean-line design, the
major turbine geometries such as blade radius, blade height and
inlet and outlet blade angles are determined. In this stage, the
turbine annulus and chord, spacing and shape of the blade are
also established. Turbine design is an iterative process and it is
common to shift from through-flow or airfoil design stage back
to the preliminary mean-line design. The mean-line design
requires that many factors be considered and weighed against
each other to achieve a competitive turbine design. Cooling is
an important factor in turbine design and must be considered in
the early stages. Cooling affects not only the entropy generation
in the turbine but also the generated turbine geometry. Some
commercial codes are available for calculating and performing
turbine mean-line design [1-4] but not all of them consider
cooling during the design process. Mean-line design
methodology is not commonly discussed in the literature,
although many papers review the methods and correlations
used in axial turbine design [5-7]. The present paper discussed
the one-dimensional mean-line design methodology for axial
turbines. The developed numerical model was based on the
conservation of mass, momentum and energy. The paper
presented also the Lund University Axial Turbine mean-line
code (LUAX-T). LUAX-T was developed to calculate singleand twin-shaft turbines. Various working fluids and fuel
compositions can be also specified in LUAX-T. Cooling was
estimated at the beginning of the turbine computation, thereby
incorporating its influence in the turbine design.
METHOD
LUAX-T calculations comprise of two main calculation
procedures, stage convergence calculations and stage design
calculations, (Figure 1). In the stage convergence calculations
the stage convergence method is determined depending on the
stage location in the turbine. Stage design calculations contain
stator and rotor calculations. Figure 1 showed LUAX-T
calculations structure where turbine design parameters are
specified prior to computation. These parameters are number of
stages, rotational speed, turbine inlet conditions and other
design parameters. Furthermore in the case of twin-shaft
turbines; the compressor turbine power must be specified.
p1
Total
Stages
Yes
No
CP
k 1
2
k 1
M21
End
TurbineStage
StageCalculations
Yes
To,Po,m,Cm
FirstStage
No
InletConditions
InletConditions
Stage
Stator
Rotor
m U
C
1
C
r
Geometry calculation
The turbine calculations are based on a cylindrical polar
coordinate system with axial, tangential and radial axes [11].
Axial velocity (Ca), radial velocity (Cr), tangential velocity
(Cu), meridional velocity (Cm), absolute velocity (C) and
absolute velocity projection on the axial plane are shown in
Figure 6. The velocity relationships are derived from velocity
triangles and are used later in the geometry calculations
(Equation 9).
C
C cos
C tan, C
cos
C cos
cos
sin
cos
sin
cos
cos
sin
f
m
a
m
c
m
in
m
out
m
r
B
r
B
0.8
10
14
Stator
Rotor
12
10
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
cos ]
11
12
Film losses along the blade profile are calculated via a generic
rectangular velocity distribution around the blade. The velocity
distribution was developed by Denton [23, 24] to generate
700
Cooling calculation
The turbine cooling mass flow is computed from the m*-model.
Holland [25] and Barry [26] presented the m*-model, which was
originally based on the standard blade approach adopted by
Hall [27]. The m*-model identified the main factors affecting
the blade cooling. The m*-model described the heat transfer
from the hot gases through the blade metal toward the coolant.
The cooling model was defined by employing three
dimensionless parameters.
S.S
600
500
400
300
200
P.S
100
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
The total enthalpy of the mixed flow was calculated from the
energy balance over the selected control volume:
m H
m H
13
m C
,
m C
14
16
T,
T
T,
T,
17
T
T
T
T
15
m C
HTC A
18
min
TIT
PRTT
pin
Min
Performance data
kg/s
11.7
C
935
3.18
bar
3.45
0.193
To
Ts
To,rel
po
ps
po,rel
M
C
C
C
bar
bar
bar
Rotor in
935.00
877.60
882.90
3.36
2.61
2.67
0.63
C
bar
bar
bar
-
Stator in
830.90
825.10
2.03
1.97
0.20
Stator out
830.90
767.80
1.98
1.46
0.69
Rotor in
830.90
769.40
776.00
1.98
1.47
1.52
0.68
Rotor out
830.90
824.10
884.30
2.03
1.96
2.60
0.22
Rotor out
712.70
702.40
777.70
1.05
0.99
1.47
0.29
To
Ts
To,rel
po
ps
po,rel
M
C
bar
bar
bar
-
Stator in
935.00
928.58
3.45
3.37
0.19
Stator out
935.00
874.57
3.41
2.71
0.60
Rotor in
935.00
876.67
882.93
3.40
2.72
2.79
0.59
Rotor in
817.31
752.28
758.74
2.05
1.57
1.61
0.65
Rotor out
676.04
663.22
761.05
1.08
1.02
1.55
0.30
0.3
0.28
0.26
0.24
0.22
0
Rotor out
817.31
809.23
885.28
2.10
2.03
2.71
0.23
0.02
0.04
0.06 0.08
0.1
Axial length [m]
0.12
0.14
0.16
To
Ts
To,rel
po
ps
po,rel
M
Stator out
817.31
750.37
2.06
1.57
0.66
0.32
Radius [m]
Stator out
935.00
875.90
3.36
2.59
0.64
C
bar
bar
bar
-
0.34
Stator in
817.31
809.23
2.10
2.03
0.23
To
Ts
To,rel
po
ps
po,rel
M
TS
TT
%
%
Stage 1
Test turbine LUAX-T
84.73
84.53
89.57
89.97
Stage 2
Test turbine LUAX-T
85
83.50
91.69
90.45
Cooled turbine
LUAX-T was used to design a conventional twin-shaft cooled
gas turbine. Due to lack of validation data from commercial
cooled gas turbines, design parameters were kept within
acceptable limits [8]. The total turbine power was 109 MW, of
which the CT power was 55 MW. The CT consisted of two
stages with rotational speed 9500 rpm. The PT was designed in
two stages with rotational speed 6200 rpm. The parametric data
is shown in Table 7.
kg/s
C
m/s
0.8
100
1400
23
90
0.7
0.6
Radius [m]
minlet
TIT
PRTT
Cm
0.4
0.3
CT
S/c
rhub/rtip
h/c
Z
Stage 1
0.93/0.82
0.84/0.84
0.98/1.5
0.81/0.87
Stage 3
0.91/0.81
0.72/0.69
1.8/2.8
0.84/0.78
Stage 4
0.76/0.63
0.64/0.62
3.0/3.9
0.82/0.77
PR
p
/
Stage 1
1.35
0.34
1.95
0.39
58/46
CT
Stage 2
1.1
0.46
1.94
0.39
34/17
Stage 3
1.4
0.36
2.14
0.45
-
PT
Stage 4
1.36
0.46
2.6
0.45
-
YP
YS
YCL
YTE
YF
Ytotal
%
%
%
%
%
%
CT
Stage 1
2.83/3.26
2.47/2.73
0/6
0.55/0.82
0.82/0.72
6.7/13.6
0.2
PT
Stage 2
0.83/0.82
0.81/0.77
1.5/2.1
0.91/0.95
Stage 2
1.67/1.58
2.43/2.06
0/3.32
0.43/0.51
0/0
4.5/7.3
PT
Stage 3
Stage 4
2.82/3.45 2.88/2.23
1.83/1.48 1.49/1.24
0/4.87
0/3.00
0.26/0.48 0.30/0.42
0/0
0/0
4.9/10.29 4.67/6.96
0.5
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
10
ACKNOWLEDGMENT
This research has been funded by the Swedish Energy Agency,
Siemens Industrial Turbomachinery AB, Volvo Aero
Corporation and the Royal Institute of Technology through the
Swedish research program TURBOPOWER. The support of
which is gratefully acknowledged.
The development of LUAX-T would not been possible without
the work done by David Olsson, Jonas Svensson and Bjrn
Nyberg.
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11