Design Innovation Papers

Aerodynamic Optimization of High-Pressure Turbines for Lean-Burn Combustion System

[+] Author and Article Information
Shahrokh Shahpar

e-mail: Shahrokh.Shahpar@Rolls-Royce.com

Stefano Caloni

e-mail: Stefano.Caloni@Rolls-Royce.com
CFD Methods, Design System Engineering,
Rolls-Royce plc,
Derby DE24 8BJ, UK

Contributed by the Turbomachinery Committee of ASME for publication in the Journal of Engineering for Gas Turbines and Power. Manuscript received October 3, 2012; final manuscript received October 25, 2012; published online April 23, 2013. Editor: Dilip R. Ballal.

J. Eng. Gas Turbines Power 135(5), 055001 (Apr 23, 2013) (11 pages) Paper No: GTP-12-1388; doi: 10.1115/1.4007977 History: Received October 03, 2012; Revised October 25, 2012

Modern lean-burn combustors make use of high flow swirl to maintain flame stability. The swirling flow can persist downstream of the turbine first vane, changing the loading on the rotor, leading to a reduction in efficiency. This paper presents the results of an automatic optimization study carried out to mitigate the effect of high swirling flow on a high pressure turbine stage. A high-fidelity computational fluid dynamics (CFD)-based design optimization using a multipoint approximation (response surface) method is carried out to produce a new vane and a new rotor configuration with a significantly improved aerodynamic performance. It is demonstrated that the novel optimization methodology can cope well with a number of near equality constraints needed for a practical design.

Copyright © 2013 by ASME
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Fig. 1

Optimization loop using the SOPHY system

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Fig. 2

Schematic of zooming of trust regions in MAM

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Fig. 3

SILOET turbine stage geometry (ST1)

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Fig. 4

PADRAM multiblock mesh for the (a) NGV and (b) rotor, (c) detailed close-up of the NGV trailing edge and (d) rotor TE

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Fig. 5

PADRAM high stagger mesh topology

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Fig. 6

Vane and rotor radial positions where the design modifications are applied

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Fig. 7

Skew parameter effect on the blade geometry, radial distribution of the design parameter (on the left), original shape (in the middle), the modified shape (on the right)

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Fig. 8

Sweep applied to the vane geometry

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Fig. 9

Lean applied to the vane geometry

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Fig. 10

PADRAM recambering at the LE and TE

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Fig. 11

Film cooling rows and TE coolant slot on the original and the modified blade

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Fig. 12

Gas turbine engine scheme

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Fig. 13

SILOET inlet boundary conditions—vane LE positions shown by dash lines

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Fig. 14

Streamlines for uniform condition (on the left) and with swirl boundary condition (on the right)

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Fig. 15

Loading of NGVs with uniform and swirl inlet conditions

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Fig. 16

The MAM optimization history—no Hydra-PADRAM failure in the whole optimization

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Fig. 17

Optimum NGV shape superimposed on the datum

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Fig. 18

Static pressure distributions for the datum and optimum vane sections

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Fig. 19

Radial distribution of the axial and tangential velocities at the vane exit plane

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Fig. 20

Contours of axial velocity (datum design on the left, optimum on the right)

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Fig. 21

CPL difference between baseline and optimum

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Fig. 22

Shape of the optimized rotor, LE and TE views

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Fig. 23

Static pressure distributions for the datum and optimum rotor blade sections

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Fig. 24

Entropy contour at 95% span of rotor blade (datum is shown on left, optimized blade on the right)




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