Traupal Notes

Institute for Thermal Turbomaschinery and Machine Dynamics
Graz University of Technology Erzherzog-Johann-University
Design of Thermal Turbomachinery

Lecture at the Department of Aerospace Engineering Middle East Technical University Ankara, April 2008
Wolfgang Sanz Institute for Thermal Turbomachinery and Machine Dynamics Graz University of Technology Austria
Content

Definition of thermal turbomachinery Design details of steam turbine, gas turbine and compressors From thermodynamics to a 2D blade geometry
Velocity Triangle Euler equation Efficiency definition Dimensionless parameters Blade number
3D flow and 3D blades Loss estimation Leakage flow and sealings
Definition of thermal Turbomachinery
Thermal turbomachinery work with compressible fluids hydraulic machinery, ventilators Only rotating motion of the rotor and continuous flow and work process combustion engines Energy conversion is based on fluid flow: Stationary and rotating blades are used to transfer potential into kinetic energy Due to high rotational speed contact-free sealings are used piston ring in combustion engines Thus working range: large volume flows, not too high pressures
Steam process
Steam
Boiler: evaporation and superheating Water
Shaft to Turbine Generator Steam
Feed pump Water
Condensator
Source: Heitmeir, LN TU Graz Thermische Turbomaschinen
Steam process
Dampf
Eintritt: Wasserdampf Abtriebswelle zum Generator Wasser Turbine Austritt
Temperature entropy diagram

Idealized process without losses
Reheat cycles
Peak pressure: 170 ( 300 bar, supercritical) Condensation pressure: 0.02 0.1 bar (condensation) Peak temperature: 525 650C Power: 5 1000 MW Efficiency: 40 % (aiming at 50 % till 2020)
Source:Traupel Thermische Turbomaschinen
Steam turbine design
20/25 MW Extraction-Condensation turbine, live steam 70 bar, 5250C, extraction pressure 2,6 bar, Condensation pressure 0,032 bar
Source: Dietzel Dampfturbinen STM 7, S. 45
Radial pump for bearing lubrication Linear guiding to allow for heat expansion
Labyrinth seals
Fast response bolt closes steam supply at over-speed
Axial bearing (Axial thrust balancing)

Control valves Shaft rotating device Pipe for leakage flow from labyrinth seals
Thermo-elastic support of stator casing
Curtis stage (control stage) Live steam supply
Siemens N-class steam turbine
Siemens N-type turbines are used for normal to medium live steam conditions (100 bars, 500 C). This type of turbine has a reaction-type design that has proven itself many times over. N-type turbines can be either condensing or backpressure machines. The standard configuration allows up to two controlled extractions and/or several uncontrolled extraction points.
Source: Siemens
GE Unterlage Site 12 Ger 3582 e
Source: GE Steam turbines for STAG Combined Cycle PPlt GER3582e.pdf

High pressure turbine and two-flow condensation turbine
Source: GE Steam turbines for STAG Combined Cycle PPlt GER3582e.pdf
Steam turbine in a nuclear plant

1200 MW turbo set with 6-flow condensation turbine
Source: Siemens
Last Stage of a Condensation Turbine
High pressure turbine with inner and outer casing
Source: Siemens
Basic Principle of a Gas Turbine
Exhaust gas Fuel Air 50 70 % of turbine power Turbine Compressor Pressure ratio: usually about 15, but up to 40 and more Turbine inlet temperature (TIT): 900 - 1700C Turbine exit temperature (TET): 400 - 600C Power: 100 kW 300 MW
Source: Heitmeir LN TU Graz
Power shaft to generator
Stationary Gas Turbine

(8) Burner (7) Silo-Combustor Exit Casing Bearing (2) Turbine (4) Middle Casing (9) Transition Duct (6) Stator Blade Carrier (1) Compressor (10) Bearing (3) Inlet Casing (11) Coupling
Source: Siemens
Stationary Gas Turbine
Kawasaki STIG M7A-91ST Gas Turbine
Source: Kawasaki
10
Radial Compressor
Source: Pfleiderer, Strmungsmaschinen, S 310
Description of Fluid Ideal gas:
p v = R T
Real gas:
Enthalpy-entropy-diagram
11
Cascade
Transfer of 3D geometry to 2D linear cascade (mid section)
Source: Niehuis LN Strmungsmaschinen
Turbomachinery Stage Meridional View
Flow channel
Compressor - decreasing channel height
Turbine - increasing channel height
Source: Mnzberg
12
Turbine vs. Compressor Flow
Compressor - decelerating flow (diffuser)

Source: Flugzeugtriebwerke, Willy J.G. Brunling,
Turbine - accelerating flow (nozzle)
Radial Machine
Linear cascade of a radial machine
Source: Niehuis LN Strmungsmaschinen
13
From Thermodynamic Layout to a Turbine Cascade

Steam cycle with back-pressure turbine (simplified):
6.11 70 3362.5 480 6.11 70 3362.5 480
6.11 4.5
2813.3 178.97
Power Efficiency Turbine Dh_is
3.13 16.83 669.68
MW % kJ/kg
6.11 82
626.64 147.58
6.11 4.499
614.6 145.9
mass[kg/s] p[bar]
h[kJ/kg] t[C]
Velocity Triangles of a Turbine Stage
pressure
Impulse stage
pressure
Reaction stage
Source: Jericha LN TU Graz
14
Velocity Triangle
r r r c = w+u
Source: Traupel
Impulse Stage vs. Reaction Stage
Impulse Stage
- Higher turning, thus lower efficiency - Higher enthalpy drop - Rotor pressure difference small so partial admission possible - Smaller leakage loss (sealing at smaller radius) - Smaller axial thrust
Reaction Stage
- Better stator and rotor efficiency - Lower enthalpy drop - only full admission - Higher leakage loss - Higher axial thrust, thus thrust balancing necessary
15
h-s-Diagram of a Turbine Stage

Total enthalpy ht0=ht1
2 c1 /2
LU
Total enthalpy ht2
Specific work:
Stator Layout
2 c1 /2
for the isentropic expansion:
with a stator efficiency
the absolute velocity c1 at stator exit can be obtained
Using the continuity at stator exit the axial velocity component and thus the stator exit angle are obtained
16
Rotor Layout
for the isentropic expansion:
with a rotor efficiency
the relative velocity w2 at rotor exit can be obtained
Using the continuity at rotor exit the axial velocity component and thus the flow angle are obtained
Specific Stage Work (Euler Equation)
Axial flow at constant radius: Lu = u cu High circumferential speed (large diameter, high rotational speed) leads to high specific work!!!
17
Layout for a compressor stage

Axial compressor
Layout for a compressor stage

Radial compressor
18
Efficiency Definition
Circumferential Efficiency, valid at mid section:
Circumferential efficiency without exit loss:
Circumferential efficiency with exit loss:
Isentropic circumferential efficiency:
Inner Efficiency
Inner work: with
Stator leakage loss Rotor leakage loss Wheel friction Ventilation loss
Inner efficiency without exit loss:
Inner efficiency with exit loss:
Isentropic inner efficiency:
19
Total Efficiency
= i l m
=
i =
Total efficiency
Inner efficiency considering all stage losses
l =
m =
Volumetric efficiency considering leakage losses of shaft
Mechanical efficiency considering bearing friction, ...
Source: Bohl, Strmungsmaschinen 1, Seite 23
Dimensionless Stage Parameters

Flow Coefficient is a dimensionless volume flow:
Load Coefficient is a dimensionless enthalpy drop:

In USA:
c1=c2
20
Degree of Reaction
Definition: Isentropic enthalpy drop in rotor r = -------------------------------------------------------Isentropic stage enthalpy drop
Kinematic degree of reaction: u1=u2
Dimensionless Parameters and the Velocity Triangle

r=0
cu=2u
r=0.5
wu
su = 1
21
Degree of Reaction = 0
w2=w3
Source: Intro. Turb. Fig 2.20
Degree of Reaction = 0.5
w2<w3
Source: Intro. Turb. Fig 2.21
22
Turbines of different degree of reaction
Source: Traupel 1 STM 140
Compressor Cascade
23
Compressors of different degree of reaction
From Thermodynamic Layout to a Turbine Cascade

What is needed to design a stage? Stage enthalpy drop Rotational speed Mean diameter Degree of reaction Stator and Rotor efficiency
6.11 70 3362.5 480 6.11 70 3362.5 480
Power Efficiency Turbine Dh_is
3.13 16.83 669.68
MW % kJ/kg
6.11 4.5
2813.3 178.97
mass[kg/s] p[bar]
h[kJ/kg] t[C]
6.11 82
626.64 147.58
6.11 4.499
614.6 145.9
24
Layout of a Stage Group
(axial outflow)
Generally: Limit for short blades: Limit for long blades:
with
D mean diameter n rotational speed [rpm] u circumferential velocity V volume flow nozzle angle l blade length Di,a inner/outer diameter
Number of Stages
hst = u2 2
Isentropic stage enthalpy drop:
Stage number z:
By varying the parameters r, , , D/l and n for the first and last stage of a stage group feasible dimensions and stage number can be found!
25
Layout of reaction stages
Control stage: 20 % of turbine enthalpy drop
13 reaction stages: h_is = 536 kJ/kg V1 = 0.426 m3/s V2 = 2.75 m3/s
Excel Assumption of stator and rotor efficiency then allows the layout of the velocity triangles!
Blade Number
Zweifel method:
Zweifel investigated the ratio of the tangential force FT to an idealised tangential force FTid and found a common value of T=0.8
FTid =
2 w2 b
FT = w ax (w 2u w1u ) t
(5)
T =
FT w (w 2u w1u ) t = 2 ax 2 FTid w2 b
26
Blade Number
Zweifel method:
With T=0.8 an optimum ratio between spacing t and blade width b can be found!
T = 0,8
2 0,8 w2 t = 2 w ax w u b opt
0,8 sin 1 0,8 1 t = = 2 sin 2 sin(1 2 ) 2 sin2 2 (cot 2 cot 1 ) b opt
For compressible flows:

t = 0,8 2w ax2 w u b opt
with p=p1t-p2 The blade width b can be chosen or is given by strength considerations!
Blade Number
Alternatively following diagram by Traupel can be used to find the optimum spacing depending on the blade turning:
Source: Traupel I, 405
27
Next Step: Blade Geometry

Based on the velocity triangle the blade geometry is designed The flow channel should allow a continuous acceleration (or deceleration) The narrowest area (throat) is usually at the blade trailing edge!
Source: Bild 6.1 STM 152 Japikse Introduction into Turbomachinery
Examples for Blade Design based on Zweifel method
28
Does the flow follow the geometry?

Method of Traupel:
Continuity: Impulse in circumferential direction:
Method of Traupel
sin 2 = a ca a cos 2 = t c2 t cos a
Thus the blade exit flow angle depends on the throat der area and the Daher wird der Abstrmwinkel als Funktion der Teilung minimal throat flow angle ffnung und des Strmungswinkels an dieser Stelle erhalten.
tan 2 = 1 a cos a t
Considering the thickness of the blade trailing edge, following formula is obtained:
tg 2 =
1 a cos a t
The blade geometry has to be adapted so that 2 corresponds to the velocity triangle.
29
Turbomachinery Flow
Flow in turbomachinery is very complex: three-dimensional laminar, transitinal or turbulent unsteady with stator-rotor interaction transonic with shock boundary layer interaction high pressure gradients lead to vortices
Mach number distribution along suction and pressure side of a turbine at subsonic and transonic conditions
Instantaneous pressure distribution in a transonic turbine
30
Three-dimensional Blade Design

Until now the blade geometry was determined only for a representative mid section. But there are differences along the blade height: The circumferential velocities vary along the blade height. The radial balance between centrifugal and pressure forces leads to a radial pressure distribution. This leads to different velocity triangles along the blade height and thus a twist of the 3D blade is necessary (except for very small D/l ratios)
Three-dimensional Force Balance

Stream line in a meridional channel without blades: Force Balance in x-direction:
Force Balance in y-direction:
a ... centrifugal force by circumferential velocity b ... centrifugal force by streamline curvature c ... pressure force d ... convective force
31
Three-dimensional Force Balance

Some transformations and the assumption of isentropic flow lead to:
Assumption of no curvature and parallel-to-axis flow lead to:
Assumption of the same enthalpy drop along the radius:
Constant Nozzle Angle Design

Postulation of a constant nozzle exit angle:
Effective in the axial gap between stator and rotor

32

Starting point is the velocity triangle at mid section:
3. The constant specific work at all radii gives the relative outlet velocities! 4. u gives the absolute outlet velocities!
Only rotor blade is twisted!
The same exit angle and thus the same blade geometry for all sections! 2. Circumferential velocity u gives the relative inlet velocities! 1. The cos law gives the absolute velocity c for all radial sections!
Kinematic degree of reaction Specific volume v
Mass flow out mid in
Stator enthalpy drop

33
Free-Vortex Design
Postulation of a constant axial velocity between stator and rotor:
3D layout of a fan stage:
Rotor and stator blade are twisted!

Three-dimensional Blade Design

The linear forced vortex law reduces the turning at the blade hub, the quadratic forced vortex law also reduces the turning at the blade tip. This results in a decrease of secondary losses!
Variation of nozzle exit angle across the annulus for various vortex designs
Source: Fig 6.1 STM 152 Japikse Introduction into Turbomachinery
34
Secondary Flows
Secondary flow with tip leakage vortex

Trailing edge vortex Separating surface Passage vortex (casing) Inlet flow Casing Wall Corner vortex Tip leakage vortex Suction side Passage vortex
Hub wall
side-wall flow
Corner vortex
Secondary flow in turbines

Suction side leg of the horse-shoe vortex Passage vortex (hub)
Hp Pressure side leg of the horse-shoe vortex
Hs Suction side leg of the horse-shoe vortex
Modern 3D Blade geometry

Where do the highest secondary losses occur?
Stacking of two-dimensional sections along radius

Source: Fig. 6.1 STM 152 Japikse Introduction into Turbomachinery
35
Source: BWK 3/2005, Seite 58, Bild 3

Meridian stream lines
High mass flow density
Low mass flow density Cylindrical stator blades Bowed stator blades
36
GE-90 3D Fan Blade Design
Source: GE
Loss Calculation by Traupel

Stator/rotor efficiency:
Profile loss
Side wall friction
Additional losses
Basic profile loss due to flow turning
Mach number influence
Mach number influence
Trailing edge influence
Trailing edge influence
Circumferential efficiency: Inner efficiency:

Stator leakage loss
Stator leakage loss
Wheel friction loss
Ventilation loss
37
Tip leakage loss by Jericha
leakage efficiency
s leakage height l blade height ls blade chord length
Part Load Operation
Loss coefficent
Impulse turbine
Reaction turbine
Incidence
Losses of impulse and reaction turbine dependent on the incidence angle (Dietrichs et al, 1987)
Source: Dietrichs et al., 1987
38
Labyrinth seals
Steam turbine
Labyrinth seals to prevent steam leakage

Different sealing designs

Relative leakage flow
Lowest leakage loss
Lowest leakage loss
Flow through sealings is a repeated throttle flow

39
Estimate of sealing mass flow

Estimation of sealing gap height:
[mm]
with k = 0.6 for compressor k=0.85 for turbines with a ferritic runner k=1.3 for turbines with an austenitic runner
Estimation of sealing mass flow (simplified):
A gap area p1 pressure before first seal p2 pressure after last seal v1 specific volume before first seal z number of seal spikes flow coefficient, depending on sealing geometry
Abradable Coatings
Abradable coatings allow a reduced clearance
40
Brush Sealings
Brush sealings allow a further clearance reduction

Axial Thrust Balancing

Example of a steam turbine with control stage:
Balance piston allows balancing of axial forces
41

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Institute for Thermal Turbomaschinery and Machine Dynamics

Graz University of Technology Erzherzog-Johann-University

Design of Thermal Turbomachinery

3D flow and 3D blades Loss estimation Leakage flow and sealings

Definition of thermal Turbomachinery

Boiler: evaporation and superheating Water

Shaft to Turbine Generator Steam

Feed pump Water

Source: Heitmeir, LN TU Graz Thermische Turbomaschinen

Eintritt: Wasserdampf Abtriebswelle zum Generator Wasser Turbine Austritt

Temperature entropy diagram

Steam turbine design

Steam turbine design

Source: Dietzel Dampfturbinen STM 7, S. 45

Steam turbine design

Fast response bolt closes steam supply at over-speed

Axial bearing (Axial thrust balancing)

Source: Dietzel Dampfturbinen STM 7, S. 45

Steam turbine design

Thermo-elastic support of stator casing

Curtis stage (control stage) Live steam supply

Source: Dietzel Dampfturbinen STM 7, S. 45

Siemens N-class steam turbine

Steam turbine design

GE Unterlage Site 12 Ger 3582 e

Source: GE Steam turbines for STAG Combined Cycle PPlt GER3582e.pdf

Steam turbine design

Source: GE Steam turbines for STAG Combined Cycle PPlt GER3582e.pdf

Steam turbine in a nuclear plant

Last Stage of a Condensation Turbine

High pressure turbine with inner and outer casing

Basic Principle of a Gas Turbine

Power shaft to generator

Stationary Gas Turbine

Stationary Gas Turbine

Kawasaki STIG M7A-91ST Gas Turbine

Source: Pfleiderer, Strmungsmaschinen, S 310

Description of Fluid Ideal gas:

Transfer of 3D geometry to 2D linear cascade (mid section)

Source: Niehuis LN Strmungsmaschinen

Turbomachinery Stage Meridional View

Compressor - decreasing channel height

Turbine - increasing channel height

Turbine vs. Compressor Flow

Compressor - decelerating flow (diffuser)

Turbine - accelerating flow (nozzle)

Linear cascade of a radial machine

Source: Niehuis LN Strmungsmaschinen

From Thermodynamic Layout to a Turbine Cascade

Power Efficiency Turbine Dh_is

3.13 16.83 669.68

Velocity Triangles of a Turbine Stage

Source: Jericha LN TU Graz

Impulse Stage vs. Reaction Stage

h-s-Diagram of a Turbine Stage

Total enthalpy ht2

for the isentropic expansion:

with a stator efficiency

the absolute velocity c1 at stator exit can be obtained

Source: Jericha LN TU Graz

for the isentropic expansion:

with a rotor efficiency

the relative velocity w2 at rotor exit can be obtained