Challenges in Aero Engine Performance Modeling

As is the case with every machinery, manufacturers want to improve their products. This is especially true for aero engines, where even a small improvement in fuel consumption can lead to an advantage on the market. But with any type of propulsion equipment, regulations also play an important role, specifically that certain noise levels or CO¬¬2 emissions should not be exceeded. These factors combine to make the process of developing and manufacturing an aero engine anything but simple. In today’s blog, we’ll take a look at these challenges in more detail and briefly touch upon development strategies to account for such challenges.

PW 1000G
Figure 1: BERLIN – APRIL 26, 2018: The stand of MTU Aero Engines and high-bypass geared turbofan engine family Pratt & Whitney PW1000G. Exhibition ILA Berlin Air Show 2018.

In general, engineers have two options to develop a better engine. The first is to create a completely new design, like implementing a geared turbofan, which takes a lot of time and research. An example of this is the PW1000G engine from Pratt and Whitney, which was in development during the late 1990s and had its first flight test in 2008 [1]. This approach is less common which is reflected by other manufacturers who are backing down from the idea of using geared turbofans due to weight and reliability concerns [2]. The second option and this is the common method, is to gradually improve existing engines. This however brings new challenges, because simply improving one engine component does not necessarily mean that part of the machine will work well together with the rest of the machine. Furthermore, the design process for aero engines is very time-consuming. A general overview is shown in Figure 1. The process starts with an assumption for certain performance characteristics, for example, efficiencies for a compressor. After that, a cycle analysis is performed where the design point and off-design behavior are determined. With the newly gained information, the design process of the single component takes place. Upon successful creation of the component which satisfies all requirements, the process moves to the test phase. In this phase, the designed machine will be evaluated through experimental testing or intensive CFD studies. Modifications will be made if necessary to reach the desired operating conditions. Since changes were made to the geometry, these changes need to be investigated in an additional cycle analysis to understand how they will affect the overall engine performance. This process repeats until a converged solution is found. Read More

How Work Distribution Between the Stages of an Axial Multistage Compressor Affect Compressor Characteristics

One of the important factors affecting compressor performance is the distribution of work between compressor stages.

There can be many different axial compressors with the same design point value for efficiency, airflow and pressure ratio and all of these compressors will meet the required parameters at the design point. Compressors operate in a variety of modes. Many compressors are equipped with a turning inlet guide vane (IGV) or guide vane (GV). At the same time, the question of the number of stages with a turning IGV or GV, at what angle to turn them, and whether the maximum efficiency will be the same remains unresolved. To answer this, designers need to compare the impact of the distribution of work between compressor stages at the design point on the compressor characteristic. This allows you to choose the form of work distribution to achieve the specified parameters of the compressor in off-design modes of operation. This also allows you to obtain the required degree of pressure ratio and airflow at a given frequency of rotation of the compressor rotor. This analysis is necessary for jet engines since the compressor works in conjunction with the combustion chamber, turbine, and nozzle. This can also be carried out for other applications of multistage compressors.

With the help of AxSTREAM and ION, studies were carried out on multistage compressors with various shapes of the flow path, a different number of stages, and a different distribution of work among the stages.

Figure 1. Calculated typical characteristics of a multi-stage, variable compressor.

The problem is considered in the following formulation:

Influencing factor:

  • Distribution of work on compressor stages.

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Variable parameter:

  • Compressor operating mode.

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Axial compressor type:

  • With fixed IGV or GV.
  • With turn of IGV or GV.

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Additional task for the compressor with turn IGV or GV:

  • Develop a criterion for the required number of compressor stages with restagger angle of the blades IGV or GV.

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The compressor is taken from the article sourced at the end of this post Read More

Rotor Dynamics Study of 4-Stage Compressor – from Theory to Application

Rotating machines have huge and important roles in our daily life although we may rarely think about them. Steam turbines at electrical power plants rotate the electrical generator shafts which produce electricity coming into our homes and offices. Driving to or from work, the reciprocating cycle in your vehicle’s internal combustion engine results in rotation of the transmission and the wheels of vehicles, while the electric car wheel operation is a result of induction motor rotation. If you get on an airplane, rotation of the turbo reactive gas turbine engine produces the effective thrust to sustain flight by moving, compressing and throwing the gas behind the plane. We can even find the useful effects of rotation in our kitchens when we are blending the food or washing our closes.

Although these rotating machines are different, the approaches to modelling their rotor dynamics are pretty much the same, since similar processes occur in rotating parts which differ in their vibrations from the non-rotating machines.

Do you remember the example of rotating washing machine? Have you ever seen it jumping on the floor trying to squeeze out your closet? We bet you have. This is the simplest example of the increased unbalance affecting the amplitudes of machine vibrations. Washing machines are designed to experience these noticeable vibrations during their operation without breaking. But the steam turbine or compressor rotors which have the tight clearances between the impellers and the casing can not boast of that leeway. In addition to that, the excessive vibrations significantly influence the machine’s useful life due to the increased fatigue.
This is why the rotor dynamics predictions are one of the most important parts of rotating machine analyses. And although they may seem easier than comprehensive stress-strain investigations of machine components, in some cases the rotor dynamics analysis can be trickiest part.

Usually, the rotor dynamics analyses are divided into lateral and torsional stages depending on the nature of rotor response to be used. They are discussed in different types of standards (API [1], ISO [2], etc.). Let’s consider the example of the lateral vibrations of a 4 stage compressor rotor with an operational speed of 8856 rpm.

Fig. 1 - 4 Stage Compressor Rotor
Fig. 1 – 4 Stage Compressor Rotor

This rotor rotates in the 4 pad tilting, pad oil film journal bearings. The characteristics of these bearings should be determined carefully to ensure that there will not be an excessive wear, heat generation or friction in them. Read More

Digital Engineering Modern Turbomachinery Design Platforms

Automatic Turbocharger Compressor Design 

In the age of green energy and increased efforts to minimize our carbon footprint,  the design of a turbocharger plays an important role in reducing engine fuel consumption and emissions while increasing the performance.  When developing an engine with a turbocharger, the general approach is to select a turbocharger design from a product list. The primary issue with this approach is that it does not cover 100% of the requirements of engine characteristics, i.e. it has non-optimal construction for the engine being developed. The operational characteristics of an engine directly depends on the interactions between the system components. This non-optimal construction will always lead to a decrease in the engine’s performance. In addition, the iteration process of turbocharger selection is time and resource consuming.

That is why the most optimal way to develop an engine with turbocharging is to design a turbocharger from scratch; wherein the operational points of compressor needed to satisfy the engine’s optimal operation are known, i.e. compressor map (Figure 1). But how do we quickly get a compressor map? Even at the preliminary design level, the design of turbocharger flow path requires dozens of hours for high-level engineers. And what about less experienced engineers?

Figure 1 Compressor Map Generated in AxSTREAM
Figure 1 Compressor Map Generated in AxSTREAM®

Incorporating a digital engineering approach with a turbomachinery design platform such as  AxSTREAM® allows designers to find the compressor design with all the required constraints which correspond to the specified compressor map needed. The design process is presented in Figure 2. Read More

Turbo-compressor Technologies for Aviation Fuel Cell Systems: Operational Requirements and Development Trends

Introduction

Fuel cells are an important driver in the current energy system landscape with significant impact on the technology base and economic growth. Global fuel cell system shipments saw a 10% increase in 2020, totaling 1.3GW. The transport sector continues to lead with a growth of 25% on the number of units shipped globally.

The recent years have seen the launch of many projects aimed at the development of fuel cell systems for aviation powerplants. In this context, the effective integration of turbomachinery components is key in driving the overall performance and the economic viability of this technology. These aspects are the topic of this blog.

Fuel Cell Technology

Fuel cells are devices which convert the chemical energy of a fuel directly into electricity by electrochemical reactions. A fuel cell element has a matching pair of electrodes (anode and cathode) separated by an electrolyte. An appropriate flow of fuel (e.g. hydrogen) and oxidizer (frequently oxygen) is delivered to the electrodes: the resulting reaction produces electricity and water plus an amount of heat. The simplicity of this process is shown in Figure 1.

Fuel Cell Conceptual Scheme
Figure 1. Fuel Cell Conceptual Scheme (Source).

There are many advantages: efficiency, reliability, low noise, and compactness, all while implementing an environmentally progressive solution. The application potential is also very diversified, sometimes in very critical fields.

Read More

Scaling and Trimming in Axial Compressors and Fans

Introduction

Despite the deepening understanding of the essence of gas-dynamic processes and the development of computational methods, simpler design methods such as scaling and trimming remain in demand in turbomachinery engineering. The main advantage of these approaches over design from scratch is simplicity and its inexpensive nature due to the small-time expenditure and lower demand from computational resources. Good predictive accuracy of the performance and efficiency of the resulting machines is based on the use of an existing machine with well-known characteristics as a prototype.

Conversely, using the prototype imposes restrictions on the use of scaling and trimming methods. It is almost impossible to get a new design with pressure and efficiency higher than that of the prototype. Also, in cases where it is required to obtain performance that is significantly different from the prototype, the inherent reliability of the original prediction may be insufficient.

Scaling Method

Easy to apply and general, valid, scaling laws are needed for design and application engineers. The scaling laws are needed for the purposes of:

  1. Predicting the full-scale performance machine from model test data obtained from a scaled machine
  2. Obtaining a family of machines with different performances on the basis of one well-tested machine

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Experimental performance and efficiency testing on a full-size model of large machines such as fans to ventilate tunnels and mines or to move combustion air and smoke gas in power plants may be impractical due to the high energy costs and geometric limitations of the experimental stand. In these cases, a scale model is used. And although complete similarity is not maintained, for example, in terms of the Reynolds number, the correction factors in most cases are well known and the prediction accuracy is high.

The method involves the implementation of the flow path of the designed fan or compressor on a scale to the prototype. This means that all linear dimensions (e.g. diameters, blade chord, axial length, etc.) must be multiplied by the scaling factor (SF). The angular dimensions (e.g. blade angles at inlet and outlet, stagger angle, etc.) remain unchanged.

When scaling, it is assumed that parameters such as Pressure Ratio, circumferential velocity (U), and axial velocity (Cz) are equal for the designed machine and the prototype. Thus:

Trimming and Scaling Formula 1

The condition of equality of the Reynolds criteria is not ensured, since the designed compressor and the prototype do not have the same diameters of the rotor with the equality of other parameters that determine the number of Rew. This design guarantees the practical accuracy of the calculated characteristics, provided that the gas movement in the flow path is turbulent. It is known that for “physical” values of the Reynolds numbers

Trimming and Scaling Formula 2

the flow remains turbulent and the inequality of the Reynolds numbers of the designed compressor and the prototype has little effect on the gas-dynamic characteristics.

To determine the efficiency of low-pressure fans, a well-known formula is usually used:

Trimming and Scaling Formula 3

An example of obtaining a stage of an axial compressor by the scaling method is shown in Figure 1.

Figure 1 - Axial Compressor Stage Scaling
Figure 1 – Axial Compressor Stage Scaling

The disadvantages of the scaling method include the need to change the rotor speed. This can be relevant for industrial installations, where the rotation speed is often limited and tied to the frequency of the electrical network current. Additionally, the need to change the overall dimensions can be a limiting factor, especially if it is necessary to increase productivity significantly, and the installation location for the turbomachine is limited. In some cases, maintaining full geometric similarity is impossible for technological or constructive reasons. For example, the minimum value of the tip clearance may be limited by the operating conditions of the rotor (not touching the rotor against the housing) or the impossibility of obtaining a small clearance if the scaling is carried out from a large prototype to a small model.

Read More

APPLICATION OF DIGITAL TWIN CONCEPT FOR SUPERCRITICAL CO2 OFF-DESIGN PERFORMANCE AND OPERATION ANALYSES

This is an excerpt from a technical paper, presented at the ASME Turbo Expo 2020 online conference and written by Leonid Moroz, Maksym Burlaka, Tishun Zhang, and Olga Altukhova. Follow the link at the end of the post to read the full study! 

Introduction

The attempts to simulate transient and steady-state sCO2 cycles off-design performance were performed by numerous authors [1], [2], [3], [4], and [5]. Some of them studied the dynamic behavior of regulators, some studied different control strategies or off-design behavior in different scenarios, which definitely has certain utility in the development of the reliable technology of sCO2 cycle simulation. Nevertheless, they used rather simplified models of components, especially turbomachinery and heat exchangers, which are of crucial importance to correctly simulate cycle performance.

The authors of this paper attempted to apply the digital twin concept to a simulation of off-design and part-load modes of the sCO2 bottoming cycle considering real machine characteristics and performance, which nobody tried to apply in this area.

On IGTC Japan 2015, SoftInWay Inc. has published a paper “Evaluation of Gas Turbine Exhaust Heat Recovery Utilizing Composite Supercritical CO2 Cycle”. The paper considered combinations of different bottoming sCO2 cycles for a specific middle power gas turbine. It mainly studied the advantages of different types of sCO2 cycles to increase the power production utilizing GTU waste heat.

The present paper is a further study based on that so the Cycle 2 [6] from that previous paper was selected as the sCO2 bottoming PGU layout in the present paper for subsequent analysis. The cycle is a combination of recompression cycle and simple cycle which offers 16.13 MW as output. GE LM6000-PH DLE gas turbine, was used as the heat source for bottoming PGU. According to GE official brochure [7], the GE LM6000 offers 40 MW to over 50 MW with up to 42% efficiency and 99% fleet reliability in a flexible, compact package design for utility, industrial and oil and gas applications. GE LM6000-PH DLE provides 53.26 MW output with exhaust temperature at 471 ℃ and exhaust flow at 138.8 kg/s. (This information came from GE products specification from 2015. It appears that GE continuously modifying the parameters of its turbines along with the naming of different modifications. Therefore, today’s parameters and configuration names might be slightly different comparing to 2015) Exhaust gas pressure was assumed to be 0.15 MPa. These parameters were taken to analyze the bottoming PGU and are presented below in TABLE 1.

SELECTED SET OF GE LM6000-PH DLE PARAMETERS
TABLE 1: SELECTED SET OF GE LM6000-PH DLE PARAMETERS

The digital twin (DT) concept is the developing technology that allows simulation of object behavior during its life cycle or in specified time due to changing ambient conditions, for example. The DT is applicable for performance tuning, digital machine building, healthcare, smart cities, etc [8] that allows decreasing the time and costs of development and optimize the object on the developing stage. GE has raised DT concepts for power plants to continually improves its ability to model and track the state of the plants [9].

In the context of this paper, DT is a simulation system comprised of physicist-based models organized in a special algorithmic structure that allows simulating the behavior of sCO2 PGU under alternating ambient conditions and grid demands.

The DT in this study was created utilizing AxSTREAM® Platform, which includes multiple software tools. The following software tools were utilized in this study: AxCYCLE™ was used to perform cycle thermodynamic calculation; solution generator in AxSTREAM® helped with finding possible machine geometry with given boundary conditions when performing preliminary design for compressors and turbines at design point; parameters and performance of turbomachinery including mass flow rate, pressure, power, efficiencies, etc. were calculated by Meanline/Streamline solver in AxSTREAM® for design and off-design conditions; AxSTREAM NET™ is a 1D system modeling solver and it was introduced here to simulate performance of heat exchangers (HEX) and pressure drop in the pipes involved in the cycle; AxSTREAM ION™ was used to integrate all modules and tools together in one simulation system. Read More

Performance Testing of Axial Compressors

Performance testing is a key part of the design and development process of advanced axial compressors.  These are widely used in the modern world and can be found in nearly every industry, and include the core compressor for aeropropulsion turbofan engines, as well as aeroderivative gas turbine engines for power generation.  An example of this are the turbine engines shown in Figure 1 and 2, which feature an industrial gas turbine and a high bypass ratio turbofan engine with a multistage high-pressure core compressor. The development time of these machines can involve numerous expensive design-build-test iterations before they can become an efficient and competitive product. This places a great importance on the accuracy of the data taken during the performance tests during the development of the compressor since the test data taken is often used to anchor the loss models within the design tools. Modern axial compressors typically have high aerodynamic loadings per stage for improved system efficiency and requires precise aerodynamic matching of the stages to achieve the required pressure ratio with high efficiency. Variable geometry inlet guide vanes and stators in the first few stages are typically required to provide acceptable operability while maintaining high efficiency and adequate stall margin.

Industrial gas turbine for power generation.
Figure 1. Industrial gas turbine for power generation. Source
Figure 2. Turbofan engine for aeropropulsion.
Figure 2. Turbofan engine for aeropropulsion. Source

Performance Testing of Axial Compressors

Axial compressors all undergo a thorough design and development phase in which performance testing is vital to their ultimate success as a product. Performance testing during the development phase of these high-power density machines can ensure that the design meets the specified requirements or can identify a component within the turbomachine which falls short of its expected performance, and may require further development, and possible redesign. Performance testing can also ensure that the unit can meet all the conditions specified and not merely the guaranteed condition. Aerodynamic performance testing multistage axial compressors during the early part of development is often done in phases. The development test program is planned and executed with a design of experiments approach and includes varying the air flow and shaft rotational speed as well as the variable geometry schedule in order to fully characterize the compressor. In the first phase, the front block of the compressor is built and tested at corrected (referenced) air flow rate, inlet pressure, temperature and shaft rotational speed. Instrumentation includes utilizing traditional rakes and surveys at the exit, to obtain spanwise distributions of pressure, temperature, and flow angles. Testing in phases is typically done for two reasons. Read More

Willis Carrier, Air Conditioning, and His Contribution to Mechanical Engineering and HVAC Systems

Welcome to this special edition of the SoftInWay blog! While we at SoftInWay are known for helpful articles about designing various machines, retrofitting, and rotor dynamics, we believe it is also important to examine the lives of some of the men and women behind these great machines.

Commonly listed among the greatest mechanical engineering inventions of the 20th Century, the air conditioning system has gone from basic use in refrigeration to a staple of living in many countries. Locales that were previously borderline uninhabitable for people sensitive to heat or poorer air quality, became available, thanks to this device that could be installed in homes and businesses. But who invented the air conditioning system?

A portrait photograph of Willis Carrier in 1915

Willis Haviland Carrier (1876-1950) was born on November 26th, 1876 in Angola, a small town in Upstate New York just outside of Buffalo. Carrier was the inventor of modern air conditioning as we know it. While other forms of air conditioning had been around for millennia, what Carrier invented was utterly life-changing for those who were able to use it, and work/live in air-conditioned environments.  His work has been so influential on modern HVAC engineering and the world in general, that his legacy company has a website in his honor.

Read More

Rotor Dynamics Challenges in High-Speed Turbomachinery for HVAC Applications

In comparison to large steam and gas turbines, the rotating equipment found in heat ventilation and air conditioning (HVAC) applications is often seen as more simplistic in design. However, sometimes a simpler model of a rotating machine does not mean a simpler approach can be used to accurately investigate its rotor dynamics behavior. For example, a large number of effects should be taken into account for single-stage compressors used in HVAC applications. Three important ones include:

  1. High values of rotational speeds above the first critical speed;
  2. Rigid rolling element bearing used in the design and therefore a relatively flexible foundation which should be modeled properly;
  3. Aerodynamic cross-coupling adding additional destabilizing forces to the structure.

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All these effects should be modeled properly when performing lateral rotor dynamics analyses of HVAC machines. And, in some cases, this simpler model can prove a much more challenging task than building the complex model of a steam turbine rotor.

Let’s consider a seemingly simple example of a high-speed single-shaft compressor for HVAC application (Figure 1). It consists of the compressor and motor rotors, the flexible coupling connecting them, the ball bearings connecting the rotors to the bearing housing joined with the compressor volute, and the structural support.

Fig. 1 - Single stage compressor model
Fig. 1 – Single-stage compressor model [1]
The compressor rotor is connected with the motor through a flexible coupling. Its lateral vibrations can be considered uncoupled from the motor rotor vibrations, and the lateral rotor dynamics model appears pretty straightforward (Figure 2).

Fig. 2 - Rotor dynamics model of the single stage compressor rotor
Fig. 2 – Rotor dynamics model of the single-stage compressor rotor

However, additional factors are discovered if you include the mechanical properties of the supporting structure when considering the lateral rotor dynamics calculations. These factors are very important to an accurate model. Read More