Escuela Polit

ecnica Nacional
Facultad de Ingeniera Mec
anica

Turbomachinery Slides
Dr. Esteban Valencia, PhD, MSc, Eng
Semester 2016-A

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

1 / 29

Outline of the lecture

Velocity diagrams, design parameters and application of

thermodynamic laws.
Losses, efficiencies and preliminary axial turbine design.
Effect of reaction on efficiency and correlation of Smith
Efficient design points turbines
Stresses in the rotor, cooling of the vanes and turbine flow
characteristic
Homework(DIFFUSION WITHIN BLADE ROWS,TURBINE BLADE
COOLING)

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

2 / 29

INTRODUCTION

Figure 1. Gas Turbin

Gas Turbin (https://www.youtube.com/watch?v=dc00xYsXgTQ)

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

3 / 29

The modern axial-flow turbine developed from a long line of

inventions stretching back in time
In 1891 developed a multi-stage (15 stages) axial-flow steam
turbine, which had a power output of 100 kW at 4800 rpm.
By 1920 General Electric was supplying turbines rated at 40 MW
for generating electricity. Now achieved 1000 MW
Thesimplest approach to their analysis is to assume that the flow
conditions at a mean radius, called the pitchline
When ratio is large, as in the final stages of an aircraft or a steam
turbine, a more elaborate three-dimensional analysis is necessary
Combustor can be at temperatures of around 16000 C or more whilst
the material used to make turbine blades melt at about 12500 C

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

4 / 29

VELOCITY DIAGRAMS
The axial turbine stage comprises a row of fixed guide vanes or
nozzles (often called a stator row) and a row of moving blades or
buckets (a rotor row)
The sign convention is such that angles and velocities as drawn in
next Figure will be taken as positive throughout this chapter.
When drawing the velocity triangles it is always worth sketching the
nozzle and rotor rows beside them
within an axial turbine, the levels of turning are very high
flow is turned through the axial direction in both the rotors and
nozzles
1 Ax1 cx1 = 2 Ax2 cx2 = 3 Ax3 cx3

(ESCUELA POLITECNICA
NACIONAL)

continuity uniform

equation

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

5 / 29

VELOCITY DIAGRAMS

Figure 1. Turbine Stage Velocity Diagrams

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

6 / 29

TURBINE STAGE DESIGN PARAMETERS

Key non-dimensional parameters related with veolocity triangle
These are used in fixing the preliminary design
DESIGN FLOW COEFFICIENT
= cm /U
But

in

purely

axial

flow

machine

is

= cx /U

-A stage with a low value of implies highly staggered blades

-Relative flow angles close to tangential
-The mass flow through the turbine increases with increasing .

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

7 / 29

TURBINE STAGE DESIGN PARAMETERS

STAGE LOADING COEFFICIENT

In

h0
;
U2

adiabatic

h0 Stagnattion

turbine

h0 = Uc

Enthalpy

c
U

-High stage loading implies large flow turning and leads to highly
skewed velocity triangles
-A high stage loading is desirable because it means fewer stages are
needed to produce a required work output

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

8 / 29

TURBINE STAGE DESIGN PARAMETERS

STAGE REACTION
R = (h2 h3 ) / (h1 h3 ) (p2 p3 )/(p1 p3 )
R (p2 p3 )/(p1 p3 )
-The reaction is a statement of the blade geometries
-The reaction is more significant since it describes the asymmetry of
the velocity triangles
-50 % turbine implies velocity triangles that are symmetrical and
zero reaction turbine stage implies little pressure change through
the rotor

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17DESIGN
de mayo de 2016

9 / 29

THERMODYNAMICS OF THE AXIAL-TURBINE STAGE

(ESCUELA POLITECNICA
NACIONAL)

Figure 1. Mollier Diagram for a Turbine Stage

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND
17 de
DESIGN
mayo de 2016

10 / 29

THERMODYNAMICS OF THE AXIAL-TURBINE STAGE

W
=
m

h01 h03 = U (c2 + c3 )

In

Nozzle

no

work

is

done;

Rotor

Work

h01 = h02

In axial turbin radial velocity is neligible;

h02 h03 = (h2 h3 ) +

1 2


1 2
2
2
c2 c3
+
cx2 cx3
= U (c2 + c3 )
2
2

1
1
h2 + w22 = h3 + w32
2
2

or

1
1
1
1
h2 + w22 U22 = h3 + w32 U32
2
2
2
2

(ESCUELA POLITECNICA
NACIONAL)

h02,real = h03,real

or

I2 = I3 ; radial

considered

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

11 / 29

REPEATING STAGE TURBINES

-Applications require turbines with high power output and high

efficiency
-To allow for the reduction in fluid density that arises as the flow
expands through the turbine
-The blade height must be continuously increasing between blade
rows

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

12 / 29

REPEATING STAGE TURBINES

Requirements for a repeating stage
cx = Constant,

r = constant,

1 = 1

Starting with the definition of reaction

R = (h2 h3 ) / (h1 h3 ) = 1 (h1 h2 ) / (h01 h03 )
Development:
R =1

2
tan2 2 tan2 1
2

R=

If

(tan 3 tan 2 )
2

1 = 3

If

or

If

1 6= 3

1 = 3

-The choice of (, , and R) are largely determined by best practice and previous experience

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

13 / 29

STAGE LOSSES AND EFFICIENCY

The total-to-total efficiency is
tt =

ideal

work

actual work output

output when operate to same

back

pressure

tt = (h01 h03 ) / (h01 h03ss )

For turbines operating with a fairly low pressure ratio
tt = (h1 h3 ) / (h1 h3ss ) = (h1 h3 ) / [(h1 h3 ) + (h3 h3s ) + (h3s h3ss )]
For a finite change of enthaply in a constant pressure process
h3s h3ss
= T3 (s3s s3ss )
h2 h2s
= T2 (s2 s2s )

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

14 / 29

STAGE LOSSES AND EFFICIENCY

Loss coeficients of energy can be defined:
1
h2 h2s = c22 N ;
2

Nozzle

Row

1
h3 h3s = w32 R ; Rotor Row
2
Combining Equations
"
#1
3
R w32 + N c22 T
T2
tt = 1 +
2 (h1 h3 )
When the exit velocity is not recovered,totalto-static efficiency for
the stage is:
"
#1
T3
R w32 + N c22 T
+ c12
2
ts = (h01 h03 ) / (h01 h3ss ) = 1 +
2 (h1 h3 )

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

15 / 29

STAGE LOSSES AND EFFICIENCY

Cosidering the static temperature drop through the rotor is not

large, T3 = T2
1

R w32 + N c22
tt = 1 +
2 (h1 h3 )

1
R w32 + N c22 + c12
ts = 1 +
2 (h1 h3 )

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

16 / 29

STAGE LOSSES AND EFFICIENCY

Remembered that loss coefficients in cascade testing is on two

dimensional, however three effects are significant when can contribute
more than 50 % of total losses
So these estimates can be made of the efficiency of a proposed
turbine by Semi-empirical methods such us: Soderberg(1949),
Horlock(1966) and Mathieson(1951)
Although CFD can often accurately predict trends in efficiency
CFD can be applied only once, detailed turbine rotor and stator
geometries have been created
For a design use preliminary design methods before carrying out the
final design refinements using computational fluid dynamics.

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

17 / 29

PRELIMINARY AXIAL TURBINE DESIGN

Either fix the shapes of the velocity triangles or choosing values for
the three dimensionless design parameters, , , and R
Number of Stages:
nsttage

W
2
mU

Blade Height and Mean Radius:

Given that the axial velocity remains constant throughout each stage.
1 Ax1 = 2 Ax2 = 3 Ax3 = constant
m
2 rm H; m = mean
U
h
i
Ax = rt2 1 (rh /rt )2 ; h = hub and t = tip
Ax =

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

18 / 29

PRELIMINARY AXIAL TURBINE DESIGN

Using a know blade speed rm = U/

rt rh = H

m
U2 rm

Axial Mach Number may be known:

p
m cp T01
= Q (M1 )
Ax cos 1
Development equations:
T03
U 2 p03
=1
,
=
T01
cp T01 p01
c3
p

Cp T03

= M3

T03
T01

p /(1)



1 2 1/2
1 1+
M3
2

Number of Aerofoils and Axial Chord

Number

(ESCUELA POLITECNICA
NACIONAL)

Aeorofoils = s/b

andAxial

Chord = H/b

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

19 / 29

STYLES OF TURBINE
Zero Reaction Turbine

Figure 5. Velocity Diagram and Mollier Diagram for a Zero Reaction Turbine Stage

R=

(tan 3 tan 2 )
2

(ESCUELA POLITECNICA
NACIONAL)

2 = 3 ; If

R=0

and

h 2 = h3

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

20 / 29

STYLES OF TURBINE
50 % Reaction Turbine

Figure 6. Velocity Diagram and Mollier Diagram for a 50 % Reaction Turbine Stage

R =1

(tan 2 tan 1 )
2

= 1 =



1
tan 2 + tan 1

2 = 1 = 3

Check Example 4.1, Dixon; Six Edition

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

21 / 29

EFFECT OF REACTION ON EFFICIENCY

To more than preliminary parameters is considered, Reaction is consideres like a preliminary
dessign parameter:

Figure 7. Velocity Diagram and Mollier Diagram for a 50 % Reaction Turbine Stage

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

22 / 29

THE EFFICIENCY CORRELATION OF SMITH (1965)

8. Smith Chart
for Turbine
Stage Efficiency.
(ESCUELA POLITECNICA
NACIONAL)Figure
AXIAL-FLOW
TURBINES:
MEAN-LINE
ANALYSIS AND
17 de
DESIGN
mayo de 2016

23 / 29

THE EFFICIENCY CORRELATION OF SMITH

Dimensionless Velocity Triangles for a 50 % Reaction Turbine Stage:

fs = h0 / c12 + c22 =

h0 /U 2




c12 /U 2 + c22 /U 2

Solving Velocities Triangle:

fs =
2 +

(ESCUELA POLITECNICA
NACIONAL)

+1
2

2

+ 2 +

1
2

2 =

2
42 + 2 + 1

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

24 / 29

Dimensionless Velocity Triangles for a 50 % Reaction Turbine Stage:

fs = h0 / c12 + c22 =

h0 /U 2




+ c22 /U 2

c12 /U 2

Solving Velocities Triangle:

fs =
2 +

(ESCUELA POLITECNICA
NACIONAL)

+1
2

2

+ 2 +

1
2

2 =

2
42 + 2 + 1

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

25 / 29

THE EFFICIENCY CORRELATION OF SMITH

Figure 8. Smiths Kinetic Energy Coefficient fs and the Optimum Stage Loading

For optimum stage:

2 42 2 + 1
fs
=

(42 + 2 + 1)
p
opt = 42 + 1
p
opt.exp = 0,65 42 + 1

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

25 / 29

STRESSES IN TURBINE ROTOR BLADES

Centrifugal Stresses

Figure 9.
Centrifugal Forces
Acting MEAN-LINE
on Rotor Blade
Element AND

(ESCUELA POLITECNICA
NACIONAL)
AXIAL-FLOW
TURBINES:
ANALYSIS
17 de
DESIGN
mayo de 2016

26 / 29

STRESSES IN TURBINE ROTOR BLADES

dFc = 2 rdm

dc
dFc
=
= 2 rdr
m
m A

c
= 2
m

K=

rt

rh

"
 2 #
Ut2
rh
rdr =
1
2
rt

stress at root of tapered blade

stress at root of untapered blade

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

27 / 29

STRESSES IN TURBINE ROTOR BLADES

Figure 10. Effect of Tapering on Centrifugal Stress at Blade Root

"
 2 #
c
KUt2
rh
=
1
m
2
rt

(ESCUELA POLITECNICA
NACIONAL)

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

28 / 29

STRESSES IN TURBINE ROTOR BLADES

Figure 11. Effect of Tapering on Centrifugal Stress at Blade Root

Tb = T2 + 0,85 w22 / (2 Cp ) ;

(ESCUELA POLITECNICA
NACIONAL)

Blade

Temperature

Estimate

AXIAL-FLOW TURBINES: MEAN-LINE ANALYSIS AND

17 de
DESIGN
mayo de 2016

29 / 29