The Purdue High-Speed Small Core Turbine Facility

<div class="htmlview paragraph"> </div> <div class="htmlview paragraph"> </div> <div class="htmlview paragraph"> With the increasing need for high performance, small gas turbine engines in the 500–1000 hp class, there is a requirement for use of high turbine inlet temperature in the range of 2500 F. Engines designed at these temperatures will supply more than twice the horsepower available in present day noncooled engines. Reliable operation of the turbine component at gas temperatures that exceed the melting temperature of the materials, however, requires selection and application of an efficient and practical blade cooling method. This paper presents the design of a transpiration air cooled, single stage, high work, axial flow, small turbine suitable for 2500 F turbine inlet temperature and capable of driving an 8:1 pressure ratio 4 lb/sec compressor. The manufacturing techniques associated with incorporating transpiration cooling into the small blading and the electron beam welding of these blades to the disc to form an integrally welded rotor assembly are also discussed. The results of the experimental testing of cascade and full stage component of this small turbine design at gas temperatures to 2500 F are presented. </div> <div class="htmlview paragraph"> </div>

<abstract> <p>The paper deals with small wind turbines for grid-independent or small smart grid wind turbine systems. Not all small turbine manufacturers worldwide have access to the engineering capacity for designing an efficient turbine. The objective of this work is to provide an easy-to-handle integrated design and performance prediction method for wind turbines and to show exemplary applications.</p> <p>The underlying model for the design and performance prediction method is based on an advanced version of the well-established blade-element-momentum theory, encoded in MATLAB™. Results are (i) the full geometry of the aerodynamically profiled and twisted blades which are designed to yield maximum power output at a given wind speed and (ii) the non-dimensional performance characteristics of the turbine in terms of power, torque and thrust coefficient as a function of tip speed ratio. The non-dimensional performance characteristics are the basis for the dimensional characteristics and the synthesis of the rotor to the electric generator with its load.</p> <p>Two parametric studies illustrate typical outcomes of the design and performance prediction method: A variation of the design tip speed ratio and a variation of the number of blades. The predicted impact of those parameters on the non-dimensional performance characteristics agrees well with common knowledge and experience.</p> <p>Eventually, an interplay of various designed turbine rotors and the given drive train/battery charger is simulated. Criterions for selection of the rotor are the annual energy output, the rotor speed at design wind speed as well as high winds, and the axial thrust exerted on the rotor by the wind. The complete rotor/drive train//battery charger assembly is tested successfully in the University of Siegen wind tunnel.</p> </abstract>

This article presents an experimental and computational study of the efficiency of an unshrouded transonic turbine. This research formed part of the EU Turbine Aero-Thermal External Flows II programme. The experiments were performed in the Oxford Turbine Research Facility (previously the Turbine Test Facility at QinetiQ, Farnborough). This facility is an engine scale, short duration, rotating transonic facility, in which M, Re, [Formula: see text], and [Formula: see text] are matched to engine conditions. For these experiments, the MT1 turbine stage was installed. Historically, turbine efficiency measurements are conducted in steady state adiabatic facilities. However, short-duration facilities allow simultaneous aerodynamic and heat transfer measurements with a significant reduction in cost. An efficiency measurement system was developed for this investigation, and this is briefly described. The system allows efficiency to be evaluated to bias and precision errors of approximately ±1.45 per cent and ±0.16 per cent, respectively, to 95 per cent confidence. The results of accurate area surveys of the turbine inlet and exit flows are presented and discussed. At the turbine exit, data were taken at two traverse planes, approximately 0.5 and 4.5 rotor axial chords downstream of the rotor. The turbine efficiency was experimentally evaluated based on the data at both planes, using a number of mixing models, which are discussed and compared. The experimental result of turbine efficiency is also compared to that estimated from a mean-line prediction. Full-stage steady and unsteady computational fluid dynamics of the experiment using the Rolls-Royce HYDRA code was conducted and is also presented. The predicted and measured rotor exit flow-fields are compared at both downstream traverse planes.

Following three decades of research in short duration facilities, Purdue University has developed an alternative turbine facility in view of the modern technology in computational fluid mechanics, structural analysis, manufacturing, heating, control and electronics. The proposed turbine facility can perform both short transients and long duration tests, suited for precise heat flux, efficiency and optical measurement techniques to advance turbine aero-thermo-structural engineering. The facility has two different test sections, linear and annular, to service both fundamental and applied research. The linear test section is completely transparent for visible spectra, aimed at TRL 1 and 2. The annular test section was designed with optical access to perform proof of concepts as well as validation of turbine components at the relevant non-dimensional parameters in small engine cores, TRL 3 to 4. The large mass flow (28 kg/s) combined with a minimum hub radius to tip radius of 0.85 allows high spatial resolution. The Reynolds (Re) number extends from 60,000 to 3,000,000, based on the vane outlet flow with an axial chord of 0.06 m and a turning angle of 72 deg. The pressure ratio can be independently adjusted, allowing for testing from low subsonic to Mach 3.2. To ensure that the thermal boundary layer is fully developed the test duration can range from milliseconds to minutes. The manuscript provides a detailed description of the sequential design methodology from zero-dimensional to three-dimensional unsteady analysis as well as of the measurement techniques available in this turbine facility.

Short-duration facilities have been used for the past 35 years to obtain measurements of heat transfer, aerodynamic loading, vibratory response, film-cooling influence, purge flow migration, and aeroperformance for full-stage, high-pressure turbines operating at design-corrected conditions of flow function, corrected speed, and stage pressure ratio. This paper traces the development of experimental techniques now in use at The Ohio State University (OSU) Gas Turbine Laboratory (GTL) from initial work in this area at the Cornell Aeronautical Laboratory (CAL, later to become Calspan) from 1975 through to the present. It is intended to summarize the wide range of research that can be performed with a short-duration facility and highlight the types of measurements that are possible. Beginning with heat flux measurements for the vane and blade of a Garrett TFE 731-2 HP turbine stage with vane pressure-surface slot cooling, the challenge of each experimental program has been to provide data to aid turbine designers in understanding the relevant flow physics and help drive the advancement of predictive techniques. Through many different programs, this has involved collaborators at a variety of companies and experiments performed with turbine stages from Garrett, Allison, Teledyne, Pratt and Whitney (P/W), General Electric Aviation (GEA), Rocketdyne, Westinghouse, and Honeywell. The vane/blade interaction measurement and computational fluid dynamics (CFD) program, which ran from the early 1980s until 2000, provided a particularly good example of what can be achieved when experimentalists and computational specialists collaborate closely. Before conclusion of this program in 2000, the heat flux and pressure measurements made for this transonic turbine operated with and without vane trailing edge cooling flow were analyzed and compared to predictive codes in conjunction with engineers at Allison, United Technologies Research Center (UTRC), P/W, and GEA in jointly published papers. When the group moved to OSU in 1995 along with the facility used at Calspan, refined techniques were needed to meet new research challenges, such as investigating blade-damping and forced response, measuring aeroperformance for different configurations, and preparing for advanced cooling experiments that introduced complicating features of an actual engine to further challenge computational predictions. This required conversion of the test-gas heating method from a shock-tunnel approach to a blowdown approach using a combustor emulator to also create inlet temperature profiles, the development of instrumentation techniques to work with a thin-walled airfoil with backside cooling, and the adoption of experimental techniques that could be used to successfully operate fully cooled turbine stages (vane row-cooled, blade row-cooled, and proper cavity purge flow provided). Further, it was necessary to develop techniques for measuring the aeroperformance of these fully cooled machines.

Results of an investigation of the development of a class of highly efficient steam turbines in the 500 to 5000 horsepower range are presented; these new machines are expected to have efficiences between 70 and 85%. The turbines are based on the concept of one or more high-speed radial inflow turbine modules driving a low-speed bull gear. Each module operates then at optimal specific speed, which yields high efficiency compared to the partial admission Curtiss stages currently used. The project has two phases. Phase 1 includes investigation and interpretation of the market for small steam turbines and definition of the radial inflow turbine (RIT) configurations best suited to penetrate a significant portion of this market. Phase 1 concludes with a recommended configuration. (MCW)

This paper describes the recent innovations associated with the fabrication and application of fast-response heat flux gauges in short-duration wind-tunnel facilities in Oxford. This work has been driven by the need to measure the heat transfer in an environment with large spatial and temporal variations in surface heat flux, caused by a flow-field that has significant high-frequency periodic fluctuations in both recovery temperature and heat transfer coefficient (namely, an axial flow turbine). A new approach to the fabrication of miniature surface heat flux thin-film gauges is described; this involves the use of a pulse laser to ablate (etch) the gauge and connecting track patterns directly onto electrically insulated and platinized components. This automated technique is shown to produce gauges of high geometrical tolerance at precisely known locations, and to create arrays of gauges on the experimental components rapidly. Typically, the platinum resistance elements are 1 mm by 0.08 mm in plan form and have closely repeatable characteristics (for example, resistance and temperature coefficient). A novel technique for measuring the adiabatic wall temperature and heat transfer coefficient in short-duration facilities is also presented; this includes the capability to measure the deterministic component of these unsteady parameters in periodic (pulsating) flows. The combination of the new high spatial density gauge arrays and the capability to measure unsteady adiabatic wall temperature allows unprecedented insight into the flow physics that influences the unsteady heat flux. In particular, it has been possible to establish whether heat transfer rate fluctuations in a turbine experiment are caused by changes in flow recovery temperature or by changes in heat transfer coefficient. Some example measurements taken in a high-speed turbine test facility are described. Finally, some of the recently manufactured heat transfer gauge systems are presented.

Supercritical CO2 (sCO2) power cycles have gained prominence for their expected excellent performance and compactness. Among their benefits, they may potentially reduce the cost of Concentrated Solar Power (CSP) plants. Because the critical temperature of CO2 is close to ambient temperatures in areas with good solar irradiation, dry cooling may penalise the efficiency of sCO2 power cycles in CSP plants. Recent research has investigated doping CO2 with different materials to increase its critical temperature, enhance its thermodynamic cycle performance, and adapt it to dry cooling in arid climates. This paper investigates the use of CO2/TiCl4, CO2/NOD (an unnamed Non-Organic Dopant), and CO2/C6F6 mixtures as working fluids in a transcritical Rankine cycle implemented in a 100 MWe power plant. Specific focus is given to the effect of dopant type and fraction on optimal cycle operating conditions and on key parameters that influence the expansion process. Thermodynamic modelling of a simple recuperated cycle is employed to identify the optimal turbine pressure ratio and recuperator effectiveness that achieve the highest cycle efficiency for each assumed dopant molar fraction. A turbine design model is then used to define the turbine geometry based on optimal cycle conditions. It was found that doping CO2 with any of the three dopants (TiCl4, NOD, or C6F6) increases the cycle’s thermal efficiency. The greatest increase in efficiency is achieved with TiCl4 (up to 49.5%). The specific work, on the other hand, decreases with TiCl4 and C6F6, but increases with NOD. Moreover, unlike the other two dopants, NOD does not alleviate recuperator irreversibility. In terms of turbine design sensitivity, the addition of any of the three dopants increases the pressure ratio, temperature ratio, and expansion ratios across the turbine. The fluid’s density at turbine inlet increases with all dopants as well. Conversely, the speed of sound at turbine inlet decreases with all dopants, yet higher Mach numbers are expected in CO2/C6F6 turbines.

This paper discusses the possibility of integrating optimization techniques with the design and analysis codes normally utilized in the industrial turbine design works. The mathematical minimization procedure presented by the Authors in previous works is coupled here with industrial design codes of multistage axial flow turbines (small and large size) utilized by two Italian Companies. The new industrial optimization procedures allow increases in the efficiency of the turbines to be obtained without the need for modifications in the industrial technology normally utilized to build the machines. The assumed initial turbine design is generally coincident with the conventional — non mathematically optimized — industrial project. In all cases the optimization is achieved by utilizing the blade profiles or “Masters” of the Companies. The results obtained for the optimization of multistage turbines are presented; the advantages concerning the design time and the usefulness of the procedures are discussed.

This paper presents a comparative study of DC-DC converters with boost methods of several types of circuits that use PSPICE programming. The whole series is compared by analyzing the maximum Reinforcement stress produced. Measurement of efficiency is now added to the test. The simulation results show that the BCI circuit is able to produce the highest voltage based on testing using 12V and 24V input voltage variations. The output voltage is capable of producing a BCI 106.440 V circuit for 12V input, while a 24V BCI input produces an output voltage of 212,808 V. The efficiency calculation is obtained for the BCI circuit with an input voltage variation of 82,215 % - 82,287 %. Test based on duty cycle, BCI output voltage 363,967 V with a work cycle of 0.9 %. For load variations, this circuit produces an output voltage of 107,459 V with a duty clycle of 0.5 % and a load of 1KΩ. This research is a promising solution in the future as an effort to overcome the electricity energy crisis.

An evaluation was made of the design and hydromechanical performance characteristics for three basic turbine types: axial flow (Jonval), inward radial flow (Francis) and crossflow (Banki). A single commercially available turbine representative of each type and within the appropriate power range (<5hp) was obtained for evaluation. Specific turbine selections were based on price, availability and suitability for operation at heads of 50 feet or less and flows under 2 cubic feet per second. In general, the peak operating efficiencies of each unit tended to be lower than anticipated, falling in the range of 40 to 50%. With sufficient flow, however, significant useful power outputs up to 3 hp were obtained. While the radial flow turbine (a centrifugal pump operated as a turbine) had the lowest initial unit cost, the axial and cross flow designs exhibited more stable operation, particularly under transient loadings. The crossflow turbine had the added advantage that it was essentially self-cleaning. With further developmental effort and appropriate design modifications it should be possible to bring each of these microhydro designs to their full performance potential.

: Small radial inflow turbines have various applications in industry and are successfully being used as a major component of gas turbines and turbochargers. The performance of the turbine is of great importance for the success of these systems. Although the design of radial inflow turbines has improved in the last few years, the detailed aerodynamic study of these components still needs considerable attention. Better understanding of the flow processes involved in these machines will provide a good basis for the design of improved components and for this purpose a joint research programme has been undertaken by Cranfield, the US Army Research Office and Turbomach (San Diego). The main objective of the study was to investigate the flow processes involved in the radial inflow turbine using experimental methods. The work presented in this report describes the various steps undertaken to perform these studies together with results. The project involved two phases, the first measurements downstream of the rotor and the second measurements between the nozzle guide vanes and rotor inlet. The scope of the study was limited to two man years during which considerable success was achieved in obtaining the desired measurement but more time to further reduce this data and to compare with computational results, which was outside the scope of the present study, would have been advantageous. The studies using laser anemometry undertaken downstream of the turbine rotor indicated a swirling flow with a region of counter-rotating flow in the centre. A cobra probe was used to compare with the laser anemometry results. Both measuring techniques show similar trends of flow velocity and flow angle at various running conditions.... Radial Turbines, Laser Anemometry.

A prototype low-flow (~0.5 m/s) marine current turbine for deployment from a small unmanned mobile floating platform has been developed at Florida Atlantic University for autonomously seeking and harnessing tidal/coastal currents. The support platform is an unmanned surface vehicle (USV) in the form of a catamaran with two electric outboard motors and with capabilities for autonomous navigation. An undershot water wheel (USWW), aided by a custom flow concentrator, has been selected as the basic design for the marine current turbine, which is mounted on the stern of the USV. The concept of operation is that the unmanned surface vehicle would navigate to a designated marine current resource, autonomously anchor at the location, align itself in the current, and deploy the USWW turbine using a custom cable-lift deployment mechanism. As the USWW harnesses the local current, an onboard power-take-off (PTO) device converts the harnessed mechanical energy to electricity which is stored in onboard batteries. The selected PTO utilizes a spur drivetrain/gearbox coupled with a NuVinci Ball-continuously variable transmission (CVT). It is estimated that the small prototype turbine system will produce over 12W power for currents over 0.5 m/s. The automated anchoring system consists of an electric winch, a Rocna anchor, anchor chain/rode and a line locking mechanism designed to aid in taking tension off the winch. Preparations have been made to test and demonstrate the application of the platform in harnessing tidal currents in the Intracoastal Waterway in South Florida and coastal currents at locations off Fort Lauderdale, Florida. The preparations include obtaining the necessary environmental permits for conducting in-water testing; developing required mitigation measures in protecting local wildlife and their habitats; and identifying potential in-water test sites and surveying them for their suitability in terms of current resource, bottom type, water depth and local boat traffic. Application of the marine current turbine platform to serve as an unmanned mobile floating recharge station for small aerial drones will be demonstrated. For this purpose, the USV includes a flight deck for landing and takeoff of small aerial drones whose batteries would be recharged via a wireless direct-contact recharging pad powered by the onboard batteries. Modeling in support of turbine design and parametric studies in support of optimization of the performance of the system will be discussed. Scaling of the prototype system in terms of size and capacity will be discussed.

This chapter shows how Gilkes, as a manufacturer of water turbines for small hydroelectric schemes, solves the problem of producing a machine which is uniquely designed for each site but keeps the costs to a minimum by using a modular design concept. Turbines are selected and designed to suit the two basic parameters of a site: The effective head of water (pressure) and The flow of water available. Power available from water in a hydro-electric scheme is the product of head (pressure) and the rate of flow of water (discharge) through the turbine. For the purposes of illustrating the modular design concept, the author shall use the Gilkes Turgo Impulse Turbine. Deflectors are used to cut off or reduce the jet of water hitting the turbine runner. They serve two main functions: To control the speed of the turbine by regulating the flow of water onto the runner and To shutdown the turbine, usually in an emergency situation.

Asymmetry, as the most significant characteristic of asymmetric twin-scroll turbines, has a significant effect on the flow characteristics of asymmetric twin-scroll turbines. In this paper, the effect of asymmetry on flow parameters, efficiency, twin-scroll pressure ratio ( SPR), single admission twin-scroll flow parameters ratio ( SSMR) and twin-scroll divide wall of asymmetric twin-scroll turbines were investigated for the first time. First, several turbines with the same total critical section of twin scrolls and different asymmetries were designed, as well as several turbines with the same asymmetric twin scrolls and different heights of the divide wall. Subsequently, these asymmetric twin-scroll turbines were tested and studied on the turbine performance rig. Asymmetry had little influence on turbine flow characteristics under equal admission, but a great impact under partial and single admission. Meanwhile, SMR had a low slope linear relationship with the expansion ratio for every asymmetry turbine. Moreover, the asymmetry was approximately linear with the average single admission twin-scroll pressure ratio ( SSMR ave), which could be used to guide the early design of asymmetric twin-scroll turbines. Besides, divide wall schemes testing found that the length of divide wall had a certain effect on the SSMR ave, which is a control factor to maintain asymmetric property. Finally, the relation between the expansion ratio of small or large scroll turbines and lg(SPR) was approximately exponential function, and the exponential parameter was strongly correlated with SSMR and SSMR ave, which could be the key parameter reflecting the asymmetry.