Axial Flow Compressor Real-Time Tip Clearance Analysis and Experimental Verification

Tip clearance has great influence on the performance of multistage axial compressors including efficiency, pressure rise, mass flow, as well as matching. This paper reports a study into the influence of tip clearance on the performance and matching of a 5-stage axial compressor by a numerical method. Different tip clearances from 0% to 5.0% span which represents the typical range of tip clearance in modern multistage axial compressors were simulated and analyzed. The results show that as tip clearance increases from 0% to 5.0% span, the choked mass flow decreases by about 21.8%, the peak pressure ratio decreases by about 43.1% and the peak efficiency decreases about 14.3 percents. As tip clearance increases, the efficiency of the whole compressor decreases in a parabolic manner not linearly as previous suggested, which is partially attributable to the cantilevered stators considered in this paper and primarily due to the mismatching of different stages. It is of great importance to control the tip clearance. When tip clearance increases, the front stage tends to work near surge condition and the rear stage tends to work near choke condition, which leads to lower efficiency than in the middle stages. A weight was defined to evaluate each stage’s contribution to the whole compressor’s efficiency deficit caused by the increase of tip clearance. Front and rear stages contribute more to the efficiency deficit than the middle stages, which indicates that more attention should be paid on front and rear stages to improve the performance of multistage axial compressors. In order to evaluate the matching of multistage axial compressors with a quantified method, a new parameter named “Peak Efficiency Deviation (PED)” was defined based on the difference between each stage’s operating efficiency and its peak efficiency. The mass flow of multistage axial compressors should be well considered to make the PED parameter to be close to zero as possible. In the most commonly used range of tip clearance from 0.5% to 3.0% span, the PED varies little within 0.4 percent, which is only about 8.4% of the peak efficiency deficit at 1.5% span tip clearance. So, the PED could be small within a wide range of tip clearances if the matching of the compressor is perfect at design tip clearance.

The present study is focused on the sound generation due to the rotor tip clearance flow interaction with stator in an axial flow fan. A hybrid URANS/Goldstein’s equations method is applied to calculate the unsteady flow and tone noise in a high loaded axial-flow fan with different rotor tip clearance. The numerical simulation results show that the main sound sources of fan tip clearance tone noise are concentrated in the leading edge of downstream stator blades. It is found that when the rotor tip clearance increases from zero to 2.5 mm (0.94% relative blade height), the mass flow of the fan decreases by about 2% and the efficiency of the fan decreases by about 1 percentage, and the sound power level at 1BPF forward tone increases by 1.47dB, and that of backward tone increases by 0.65dB. However, the influence of tip clearance on the tone noise intensity at 2BPF and 3BPF is more complex, and the variation range is less than 1dB. It is found that the wake width and wake strength at the rotor exit increase with the increase of tip clearance. The tip secondary flow caused by rotor clearance seriously affects the circumferential inhomogeneity of stator leading edge inflow conditions.

Gas turbines normally have the rotating and stationary parts. The rotational blades always need clearance to rotation. Blade tip clearance is one of the important parameters affecting performance, safety and stability of a gas turbine engine. However, it is difficult to measure the tip clearance accurately during the tests. The numerical studies are important methods to study the tip clearance effects. Tip clearance effects have been studied for a long time. However, there are still many aspects that are not fully understood and industries still don’t have a good way to perform design with minimum tip clearance losses. In the gas turbine design, the tip clearance considerations are very critical for both performance and reliability. In this paper, we perform the numerical study on the tip clearance impacts during the aerodynamic design, especially the blade loading through blade counts. The study found that the proper blade loading could reduce the tip clearance sensitivity and reduce the tip clearance losses. In the cases of reasonable number of blades, the effect of clearance on the total pressure loss and efficiency had a linear relationship. But in the cases of small number of blades, the effect of clearance on the total pressure loss and efficiency is no longer linear. The study helped turbine designers to consider blade loading and tip clearance together during the turbine design.

This paper presents a study on a centrifugal compressor stage aerodynamics. The influence of the blade tip clearance on performances of the centrifugal impeller and also on the diffuser is taken into consideration for the overall optimization process. Also a stress analysis has been carried out to investigate the stresses and strains of the blade. The impeller was designed for a pressure ratio of 4:1, a mass flow of 8.1 kg/s at 22 000 rpm. Three cases have been studied: first without a tip clearance, the second one with tip clearance and the third case which studies an optimized geometry for the vaned diffusers. Through a designer driven optimization process, the recirculation zone that appears in the diffuser was reduced by half. Following the numerical analysis some differences were noted between the three cases in terms of both global results and particular flow details. One of the main differences is given by the power consumed by the impeller. Due to the elimination of the tip clearance (shrouded impeller), the power consumed by the impeller was reduced by 72 kW and the efficiency increased by 2.2%. In the case of diffusers analysis, was noticed an improvement in stage efficiency of 8.2%.

Tip clearance in hydraulic machines may complicate the fluid–structure interaction (FSI) effects. In this investigation, a mode-based approach (modal work) is evaluated and employed to quantitatively predict the added mass, added stiffness, and hydrodynamic damping ratio, in relation to the first-order bending mode of a vibrating hydrofoil. The investigated relative tip clearance ranges from 0.067% to 2% of the span length. The predicted vortex shedding frequency, natural frequency, and hydrodynamic damping ratio of the hydrofoil are in good agreement with the previously published experimental results, with relative deviations within 9.92%, 6.97%, and 11.23%, respectively. Simulation results show that the added mass, added stiffness, and hydrodynamic damping ratio increase inversely as the tip clearance increases. In particular, as the relative tip clearance increases from 0.067% to 2%, the added mass in still water, the added stiffness, and hydrodynamic damping ratio at a velocity of 10 m/s decrease by 18.66%, 9.36%, and 27.99%, respectively. As the tip clearance increases, the inversely increased pressure difference between the upper and lower surfaces of the vibrating hydrofoil is the main reason for the inversely increased hydrodynamic damping ratio. This is due to the energy leakages via the tip clearance region increase as the tip clearance increases, which may cause less fluid force to resist the vibration of the hydrofoil, resulting in less negative modal work done by the fluid load on the hydrofoil.

Numerical study of the tip clearance flow in miniature gas turbine compressors

Large tip clearances typically in the region of six percent exist in the high pressure stages of compressors of industrial gas turbines. Due to the relatively short annulus height and significant blockage, the tip clearance flow accounts for the largest proportion of loss in the HP. Therefore increasing the understanding of such flows will allow for improvements in design of such compressors, increasing efficiency, stability and the operating range. Experimental and computational techniques have been used to increase the physical understanding of the tip clearance flows through varying clearances in a linear cascade of controlled-diffusion blades. This paper shows two unexpected results. Firstly the loss does not increase with clearances greater than 4% and secondly there is an increase of blade loading towards the tip above 2% clearance. It appears that the loss production mechanisms of the pressure driven tip clearance jet do not increase as the clearance is increased to large values. The increase in blade force is attributed to the effect of the strong tip clearance vortex which does not move across the blade passage to the pressure surface, as is often observed for high stagger blading. These results may be significant for the design of HP compressors for industrial gas turbines.

An experimental and computational study of tip clearance effects on a transonic turbine stage

Influences of age-related deterioration on the increase in rotor tip gap width are discussed numerically. In the gas turbine examined in the present study, there are two kinds of geometries around the rotor blade tip. In the first stage, there is clearance between the blade tip and the casing without any seal structures. On the other hand, there is a shroud and seal fin on the rotor blade tip. The blade geometries were measured using a 3-D scanner in a working power plant, and the tip clearances were varied by changing the casing contour. Steady-state CFD simulations were carried out. Tip gap widths were varied by shifting the casing wall. For simplicity, the blade geometries were not changed. The influence of tip clearance was examined by changing the geometries in each stage separately. Boundary conditions were determined using the previously developed hybrid method of heat balance analysis and CFD simulation, which can simulate the operating conditions of a working gas turbine. The results showed that the turbine performance degradation could spread to the following stage. Observation of entropy fields revealed that the increase in the tip leakage flow affected the flow in the following nozzle, and the loss increased.

A new approach for a compressor casing design has been developed using new design possibilities offered by additive manufacturing technologies. Tip clearance behaviour is a serious problem in compressor design leading to increased aerodynamic losses and limiting the operating range of a compressor through a decrease in surge margin. Efforts are necessary to minimise the tip clearance in the load cycle of an engine. The approach presented in this work uses auxetic structures in a double-walled compressor casing with the aim to force the radial expansion behaviour of the inner casing wall in order to adapt the casing to the rotor. The studies of the casing and the calculations of the transient rotor displacement are carried out by using coupled-temperature-displacement calculations using commercial FEM-tools. Elements which influence the radial expansion of the casing are identified with the aim of generating a modular system for future compressor casing developments. So the casing elements are adaptable to the radial expansion of a certain rotor. An improved tip clearance behaviour in relevant operating points is achieved. In the latter part of the paper, practical design considerations are made as the auxetic structures are integrated into the CAD model of an existing compressor casing. Design challenges are also briefly discussed. This paper presents a new potential application of additive manufacturing technologies in future aero engine design. The focus of this paper is on the practical implementation of the new design freedom using the example of a compressor casing. The advantages for the overall engine performance as well as identified problems are also discussed qualitatively.

In the gas turbine, gaps inevitably exist between the stationary and rotating parts. To improve the performance of gas turbines, tip leakage flow through the gaps must be minimized. The labyrinth seal increases the flow resistance by placing a number of teeth to minimize leakage flow. The labyrinth seal is still adopted in many fields because of its relatively high thermal resistance, simple structure, and wide pressure range. In this paper, the effects of geometric parameters (straight and stepped with solid land, tip clearance, number of teeth, and tooth front angle) on leakage flow were experimentally studied and the seal performance was described using the flow function. Also, flow visualization within the labyrinth seal was conducted using the Schlieren method. The dimensionless tip clearance (C/a) was adjusted from 0.8 to 3.3 (where a is tooth tip width) and the pressure ratio was adjusted from 1.1 to 3.0. The tooth front angle of the stepped seal was 90° and 60°. Results show that the flow function increased as the pressure ratio increased, however it tended to remain constant if the pressure ratio was higher than 2.0. At the same test condition, the flow function of the stepped labyrinth seal was smaller than that of the straight seal for all tested pressure ratios. Also, the seal performance was better for larger number of teeth, smaller tip clearance, and smaller tooth front angle cases. Based on the measured results, a new correlation for the labyrinth seals was suggested.

Deep sea oil resources worldwide possess great potential for exploration; however, multiphase medium technology requires urgent development. The multiphase pump has achieved great success as one of the most advanced machinery in underwater oil and gas exploration. Tip clearance is inevitable between the rotating and stationary components of the multiphase pump. In this study, tip clearance sizes of 0.0, 0.2, 0.5, and 0.8 mm are selected to investigate the effect of tip clearance on energy performance and flow characteristics of a multiphase pump. Results show that pressure rises decrease by 10.72%, 24.96%, and 41.39% with gas volume fraction = 0% under different tip clearance sizes, while the pressure rises decrease by 17.10%, 25.35%, and 38.11% with gas volume fraction = 10%. The dominant frequencies and maximum amplitudes of pressure fluctuation rise with the increase in tip clearance. The entrainment effect between the tip leakage flow and main flow in the impeller strengthens with the increase in tip clearance size; the induced vortex area and leakage flow rate also increase.

Clearance leakage losses of axial compressor rotors and stators have a major impact on the overall compressor performance. The clearance heights in the last stages (high pressure stages) of a gas turbine compressor are very large in comparison to the low pressure stages due to mechanical constraints and small blade heights. The reduction of clearance leakage losses in a high pressure stage still holds an important potential for the overall performance improvement at design point conditions. In the following work, a method for tip clearance loss reduction by circumferential casing contouring above a high pressure stage rotor with a constant clearance height is presented. The subsonic compressor blade provides Siemens HPA-Family [1, 2, 3] airfoils. Starting over with a 3D-Optimization of the mentioned rotor casing the work additionally refers to the aerodynamic effects and the off design performance of the optimized geometry. It has been found that an optimized casing and blade tip contour lead to a smaller overall clearance mass flow and lower pressure loss coefficient of the clearance flow so that the endwall blockage is reduced and the stage performance is improved by about 0.35% at design point conditions. Furthermore it was found that the performance improvement drops with increasing exit pressure to about 0.1% close to stall conditions. At lower exit pressure values the optimized geometry provides an additional performance improvement in comparison to the baseline configuration.

Rotating Instability (RI) occurs at off-design conditions in axial compressors, predominantly in rotor configurations with large tip clearances. Characteristic spectral signatures with side-by-side peaks below the blade passing frequency are typically referred to RI located in the clearance region next to the leading edge (LE). Each peak can be assigned to a dominant circumferential mode. RI is the source of the clearance noise and an indicator for critical operating conditions. Earlier studies at an annular cascade pointed out that RI modes of different circumferential orders occur stochastically distributed in time and independently from each other, which is contradictory to existing explanations of the RI. Purpose of the present study is to verify the generality with regard to axial rotor configurations. Experiments were conducted on a laboratory axial fan stage mainly using unsteady pressure measurements in a sensor ring near the rotor LE. A mode decomposition based on cross spectral matrices was used to analyze the spectral and modal RI patterns upstream of the rotor. Additionally, a time-resolved analysis based on a spatial Discrete-Fourier-Transform was applied to clarify the temporal characteristics of the RI modes and their potential interrelations. The results and a comparison with the previous findings on the annular cascade corroborate a new hypothesis about the basic RI mechanism. This hypothesis implies that instability waves of different wavelengths are generated stochastically in a shear layer resulting from a backflow in the tip clearance region.

This paper describes how the fundamental effects of inlet flow distortion on the performance of gas turbines can be evaluated with any engine performance program that employs an integrated parallel compressor model. In this simulation method, both pressure and temperature distortions are quantified with coefficients, which relate the pressure (respectively temperature) in the spoiled sector to the value in the clean sector. In single spool compressor engines, the static pressure at the exit of the clean sector equals that of the distorted sector. This hypothesis does not hold true with multispool compressor engines because the short intercompressor ducts, which often contain struts or vanes, do not allow the mass flow transfer over the sector borders, which would be required for balancing the static pressures. The degree of aerodynamic coupling of compressors in series can be described in the performance simulation program by the simple coupling factor introduced in this paper. There are two fundamentally different reasons for the change in engine performance: First, there is the impact of the flow distortion on the component efficiencies and thus the thermodynamic cycle and second there are performance changes due to the actions of the control system. From the engine system simulation results, it becomes clear why inlet flow distortion has only a minor impact on the thermodynamic cycle if the comparison of the two operating conditions (with clean and distorted inlet flow) is made at the properly averaged engine inlet conditions. For each compressor, the parallel compressor theory yields two operating points in the map, one for the clean sector and one for the spoiled sector. The performance loss due to the distortion is small since the efficiency values in the two sectors are only a bit lower than the efficiency at a comparable operating point with clean inlet flow. However, the control system of the engine can react to the inlet flow distortion in such a way that the thrust delivered changes significantly. This is particularly true if a compressor bleed valve or a variable area nozzle is opened to counteract compressor stability problems. Especially, using recirculating bleed air for increasing the surge margin of a compressor affects the performance of the engine negatively. Two examples show clearly that the pros and cons of recirculating bleed can only be judged with a full system simulation; looking at the surge line improvement alone can be misleading.