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Gas Turbines: Turbomachinery

Impact of Manufacturing Variability on Multistage High-Pressure Compressor Performance

[+] Author and Article Information
Alexander Lange1

 FTT Deutschland, GmbH, D-15745 Wildau, GermanyALange@fttgmbh.de

Matthias Voigt, Konrad Vogeler

 Technische Universität Dresden, Institute of Fluid Mechanics, D-01062 Dresden, Germany

Henner Schrapp, Erik Johann, Volker Gümmer

 Rolls-Royce Deutschland Ltd & Co KG, Compressor Aerodynamics, D-15827 Blankenfelde-Mahlow, Dahlewitz, Germany

1

Corresponding author.

J. Eng. Gas Turbines Power 134(11), 112601 (Sep 24, 2012) (8 pages) doi:10.1115/1.4007167 History: Received June 22, 2012; Revised July 14, 2012; Published September 24, 2012; Online September 24, 2012

The present paper introduces a novel approach for considering manufacturing variability in the numerical simulation of a multistage high-pressure compressor (HPC). The manufacturing process is investigated by analyzing three of a total of ten rotor rows. Therefore, 150 blades of each of the three rows were 3D scanned to obtain surface meshes of real blades. The deviation of a scanned blade to the design intent is quantified by a vector of 14 geometric parameters. Interpolating the statistical properties of these parameters provides the manufacturing scatter for all ten rotor rows expressed by 140 probability density functions. The probabilistic simulation utilizes the parametric scatter information for generating 200 virtual compressors. The CFD analysis provides the performance of these compressors by calculating speed lines. Postprocessing methods are applied to statistically analyze the obtained results. It was found that the global performance parameters show a significantly wider scatter range for higher back pressure levels. The correlation coefficient and the coefficient of importance are utilized to identify the sensitivity of the results to the geometric parameters. It turned out that the sensitivities strongly shift for different operating points. While the leading edge geometry of all rotor rows dominantly influences the overall performance at maximum efficiency, the camber line parameters of the front stages become more important for higher back pressure levels. The analysis of the individual stage performance confirms the determining importance of the front stages—especially for highly throttled operating conditions. This leads to conclusions regarding the robustness of the overall HPC, which is principally determined by the efficiency and pressure rise of the front stages.

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Copyright © 2012 by American Society of Mechanical Engineers
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Figures

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Figure 1

Washed surfaces of the multistage HPC model

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Figure 2

Thickness and camber distributions for hub and tip section of first (R1) and scanned rotor blades (R3, R6, and R9)

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Figure 3

Interpolated distribution parameters of chord length

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Figure 4

Probabilistic compressor map with one σ level (up) and 95% confidence interval for the standard deviation (down)

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Figure 5

Sensitivities of isentropic efficiency (left) and reduced mass flow (right) to geometric parameters

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Figure 6

Importance of stage efficiency to HPC efficiency

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Figure 7

Slope of speed line versus slope of efficiency curve

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Figure 8

Ranking of parameters for HPC stability

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