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PEMP

RMD510

Design of Axial Flow Turbine-1

Session delivered by:


Prof Q.
Prof. Q H.
H Nagpurwala

11 @ M S Ramaiah School of Advanced Studies, Bengaluru 1


PEMP
RMD510

Session Objectives

• To learn design procedure for axial flow turbines


• To get familiar with design prerequisites and
formulae
• To undertake design calculations for a single
stage
g gas
g turbine

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PEMP

Axial Turbine RMD510

Turbine Module

A triple-stage turbine
with single shaft system

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Nomenclature RMD510

CL blade lift coefficient


h blade height,
g heat transfer coefficient
n number of blades
S perimeter
z section modulus of blade
h/
h/c aspectt ratio
ti
k/h tip clearance/blade height ratio
s/c pitch/chord ratio
t/c thickness/chord ratio
te/s trailing edge thickness/pitch ratio
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Nomenclature (… contd.) RMD510

Yn nozzle blade loss coefficient [(p01 - p02)/(p02 - p2)]


YR rotor blade loss coefficient [(p02rel - p03rel)/(p03rel - p3)]
Yk tip-clearance loss coefficient
Yp profile loss coefficient
Ys secondary
d lloss coefficient
ffi i t
N nozzle blade loss coefficient [(T2-T’2)/(C22/2cp)]
R rotor blade loss coefficient [(T3-T’’3)/(V23/2cp)]
ct centrifugal tensile stress
gb gass be
g bending
d g sstress
ess
,R degree of reaction [(T2 – T3)/(T1 – T3)]
 flow coefficient (Ca /U)
 Stage temperature drop coefficient (2cpT01 /U2)
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T-S Diagram RMD510

Suffixes
a,, w axial,, whirl component
p
b blade
c coolant
m, r, t mean, root, tip
N, R nozzle, rotor blades
p, s pressure, suction surface
of blade

g
T-s diagram g
for a reaction stage

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Velocity Triangles RMD510

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Superimposed Velocity Triangles RMD510

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Blade Profiles RMD510

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Turbine Design-Formulae RMD510

11. Blade
Bl d lloading
di coefficient
ffi i or temperature drop
d ffi i ,
coefficient
which expresses the work capacity of a stage

U Ca tan β2  tan β3 
c p Δ Tos
Ψ 2

U U2
2 2

2 Ca
Ψ tan β2  tan β3 
U

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Turbine Design-Formulae RMD510

2 Degree
2. D off R
Reaction,
ti R
This expresses the fraction of the stage expansion which occurs in the
rotor and it is usual to define it in terms of static temperature
p drops
p rather
than pressure drops.

T2  T3
R
T1  T3
axial velocities
Ca 2  Ca3  Ca are equal

C3  C1 inlet & exit velocities


are same
Ca
R tan β 3  tan β 2 
2U
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PEMP

Turbine Design-Formulae RMD510

3 Flow
3. Fl Coefficient
C ffi i
 = Flow coefficient = Ca /U
 = 2  (tan 2 + tan 3)
R = ½  (tan 3 - tan 2)

Gas Angles
tan 3 = ½  (  / 2 + 2 R )
tan 2 = ½  (  / 2 - 2 R )
tan 3 = tan 3 - 1/
tan 2 = tan 2 + 1/
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Variation of Flow Angles RMD510

50% reaction turbine designs

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Comments RMD510

 Efficiency contours superimposed on  -  plot


 g havingg a low  and low  y
Designs yield the best stage
g efficiencies.
 Low values of  and  imply low gas velocities and hence reduced
friction losses.
 Low  means more stages for a given over all turbine output. Low 
means a larger turbine annulus area for a given mass flow.

 In industrial gas turbine when size and weight are of little consequence
and a low sfc is vital, it would be sensible to design with a low  and a
low . Certainly in the last stage a low axial velocity and a small swirl
angle 3 are desirable to keep down the losses in the exhaust diffuser.
diffuser
 For an aircraft propulsion unit, it is important to keep the weight and
frontal area to a minimum and this means using higher values of  and
. For example,
e ample  = 3 to 5 and  = 0.8 0 8 to 1.0
10

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Losses in Blade Rows RMD510

 Full line connects stagnation


states
 Chain dotted line connects
static states.
 T02 = T01 because no work is
done in the nozzles; and the
short horizontal portion of
the full line represents the
stagnation (pressure drop)
p01- p02 due to friction in the
nozzle.
 Ideally the gas in the nozzle
would be expanded from To1
to T2’ but due to friction the
T
T-ss diagram for a reaction stage temperature at the nozzle
exit is T2, higher than T2’.

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Losses in Blade Rows (… contd.) RMD510

 Loss coefficient for the nozzle blade

T2  T2' p01  p02  T02 


λN  2 and YN  YN  λN  
C2 2c p p02  p2  T2 

 Loss
L coefficient
ffi i t for
f the
th rotor
t blade
bl d

T3  T3'' p02rel  p03rel  T03rel 


λR  2 and YR  YR  λR  
V3 2c p p03rel  p3  T3 

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Losses in Blade Rows (… contd.) RMD510

 Both  and Y express the proportion of the leaving energy


which is degraded by friction.
Y can easily
il be
b measuredd in
i cascade
d test.
 is more easily used in design.
 Isentropic expansion in the whole stage would result in a
final temperature T3’ and in the rotor blade passage up to T3”.
Expansion with friction leads to a final temperature T3.

 The stage isentropic efficiency can be derived as


1
ηS 
1 Ca  λR Sec2 β3  T3 T2 λN Sec2α2 
1
2 U  tan β3  tan α2  U Ca  
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PEMP

Design Process RMD510

The complete design process for the turbine will encompass


the following steps:
• Choice of rotational speed and blade speed
• Assumption of loss coefficients for nozzle and rotor
• Choice of blade loading coefficient, flow coefficient, determination of
number of stages and degree of reaction
• Calculation of the gas angles for each stage at the mean radius
• Determination of the variation of the gas angles from root to tip
• Selection of turbine blading, using experimentally obtained cascade data
• Check on efficiency previously assumed using the cascade data.
• Estimation of overall p
performance

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PEMP

Axial Turbine Design Example RMD510

Let us consider a possible mean diameter design for the turbine,


which should be a single stage turbine if possible.
possible From cycle
calculations, the following design point specifications are
proposed for the turbine.
Mass flow rate, m = 20 kg/s
Isentropic efficiency of turbine, t= 0.9
Inlet temperature, T01 = 1100 K
Temperature drop,
drop T01-T
T03 = 145 K
Pressure ratio, p01/p03 = 1.873
I l t pressure
Inlet = 4 bar
b

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Axial Turbine Design Example RMD510

• In addition to this information, we are likely to have the


rotational
t ti l speedd fixed
fi d by
b the
th compressor, the
th design
d i off which
hi h
is always more critical than the turbine because of the
decelerating flow. Also, experience will suggest an upper
limit to the blade speed, above which the stressing difficulties
will be severe. Accordingly, we will assume:
 Rotational speed, N = 250 rev/s
 Mean blade speed, U = 340 m/s
• Finally, we shall assume a nozzle loss coefficient N of 0.05
as a reasonable first guess.

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PEMP

Single Stage Turbine RMD510

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Blade Loading Coefficient RMD510

• Assume, (a) Ca2 = Ca3


(b) C1 = C3
• Since it is a single-stage turbine the inlet velocity will be axial, i.e.
1= 0. From the data, the temperature drop coefficient is
2c p ΔT0 s 2 1.148 145  103
Ψ   2.88
U2 340 2

• This is a modest value and there is no difficulty about obtaining


the required output from a single stage in a turbojet unit wherein
high values of Ca can be used.
• Try a flow coefficient  = 0.8
• Because swirl increases the losses in the jet pipe, take 3 = 0
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PEMP

Degree of Reaction RMD510

1
tan α3  0  tan β3 
φ
tan β3 1.25

1 1 
tan β3   ψ  2R 
2φ  2 
1
1.25  1.44  2 R 
1.6

Hence R  0.28
Hence,

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Degree of Reaction (… contd.) RMD510

• A degree of reaction of only 0.28 at the mean diameter


might
g mean too low a value at the root.
• Negative values must certainly be avoided because this
would imply expansion in the nozzle followed by
recompression in the rotor and the losses would be large.
Perhaps a modest amount of swirl will bring the reaction to
a more reasonable value: we will try 3 = 10
10°..
tan α3  0.1763
tan β3  0.1763  1.25  1.426
1
1.426  1.44  2 R 
1.6
R  0.421 This is acceptable
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Velocity Triangles RMD510

• The gas angles can now be established. So far we have,

α3  10  ; β3  tan 1 1.426  54 .96 

1
tan β 2  1.44  0.842   0.3737
1.6
1
tan α 2  0.3737   1.624
0.8
β 2  20 .49  ; α 2  58.38 

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Velocity Triangles (… contd.) RMD510

• The velocity diagram can now be


sketched as in the figure.

• The next task is to calculate the density at stations 1, 2 and 3 so that the
blade height h and tip/root radius ratio (rt/rr) can be estimated. We shall
commence with station 2 because some modifications will be required if
the pressure ratio p01/p2 across the convergent nozzles is much above the
critical value, or if the Mach number relative to the rotor blades at inlet
(Mv2) exceeds about 0.75.

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Flow Parameters at Nozzle Exit RMD510

From the geometry of the velocity diagram,


Ca 2  Uφ  340  0.8  272 m/s
Ca 2
C2   272  519 m/s
cos α2 0.5242
The temperature equivalent of the outlet velocity is:
C22 519 2
T02  T2    117.3 K
2c p 2296

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Choke Condition at Nozzle Exit RMD510

Si T02  T01  1100 K ; T2  982.7 K and


Since d
2
C
T2  T2'  λN 2  0.05*117.3  5.9 K
2c p
T2'  982.7  5.9  976.8 K
p2 can be found from the isentropic relation
γ  γ 1 4
p01  T01   1104 
  '     1.607
p2  T2   976.8 
4.0
p2   2.49 bar
1.607
Ignoring the effect of friction on the critical pressure ratio,
ratio and putting
γ  1.333, we have
γ  γ 1 

p01  γ  1 
   1.853
pc  2 
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Annulus Area at Nozzle Exit RMD510

• The actual pressure ratio is 1.607, well below the critical value.
The nozzles are not choking and the pressure in the plane of the
throat is equal to p2.

p2 100 2.49
2    0.883 kg/m3
RT2 0.287 982.7
Annulus area at plane2 is
m 20
A2    0.0833 m2
ρ2Ca 2 0.883 272
Throat area of nozzles required is
m
A2 N  or A2 cos α2  0.0883 0.524  0.0437 m2
ρ2C2
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Annulus Areas at Station-1 & -3 RMD510

• Note that if the pressure ratio had been slightly above the critical
value it would be acceptable if a check (given later) on Mv2 proved
satisfactory. 2 and A2 would be unchanged, but the throat area
would then be given by m/cCc, where c is obtained from pc and
Tc and Cc corresponds to a Mach number of unity so that it can be
found from (RTc).
• We mayy now calculate the annulus area required
q in pplanes 1 and 3
as follows. Because it is not a repeating stage, we are assuming
that C1 is axial and this, together with assumptions (a) and (b) that
C1= C3 and Ca3= Ca2, yields
Ca 3 272
Ca1  C1  C3   
 276.4 m/s
cos α3 cos10
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Annulus Area at Station-1 RMD510

Temperature equivalent of the inlet (and outlet) kinetic energy is

C12 276.4 2
  33.3 K
2c p 2296
C12
T1  T01   1100  33.3  1067 K
2c p
γ  γ 1
p1  T1  4.0
   or p1   3.54 bar
p01  T01  1100 1067 4

100  3.54
ρ1   1.155 kg/m 3
0.287 1067
m 20
A1    0.0626 m 2
ρ1Ca1 1.155  276.4
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Annulus Area at Station-3 RMD510

Similarly at outlet from the stage, we have


T03  T01  ΔT0 s  1100  145  955 K
C32
T3  T03   955  33.3  922 K
2c p
p03 is given in the data by p01(p03 / p01)
γ  γ 1 4
 T3   4  922 
hence p3  p03       1.856 bar
 T03   1.873  955 
100  1.856
ρ3   0.702 kg/m 3
0.287  922
m 20
A3    0.1047 m 2
ρ3Ca 3 0.702  272
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Calculation of Blade Height RMD510

• The blade
Th bl d height
h i h andd annulus
l radius
di ratio
i at stations
i 1 2 andd
1,
3 can now be established. At the mean diameter, denoted by
suffix m,,
340
U m  2πNrm so that rm   0.216 m
2  250
• Since the annulus area is given by
U mh
A  2π rm h 
N
• The height
g and radius ratio of the annulus can be found from
AN  250  rt rm  h 2 
h   A, and 
U m  340  rr rm  h 2 
• The results are given in the table in next slide.
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Annulus Dimensions RMD510

Station 1 2 3

[ 2]
A[m 0.0626 0.0833 0.1047

h[m] 0.046 0.0612 0.077

rt/rr 1 24
1.24 1 33
1.33 1 43
1.43

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Turbine Annulus RMD510

• The turbine annulus, we have arrived at in this example, is flared


as shown in the figure.
• IIn sketching
k hi this,
hi we have
h assumedd a blade
bl d height/width
h i h / id h ratio
i off
about 3.0 and an inter-blade row spacing of about 0.25 of the
blade width. The included angle
g of divergence
g of the end-walls is
approximately 29 .

29 /2

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Comments RMD510

 An end-wall
d ll fl
flare off 29° is
i regarded
d d rather
h high,
hi h involving
i l i a risk
i k off flow
fl
separation from the inner wall where the reaction, and therefore the
acceleration, is not large; 25° has been suggested as a safe limit.
 We shall not pause for adjustment here, because the blade height/width
ratio of 3.0 is merely a rough guess to be justified or altered later when
the effect of blade stresses on the design has to be considered.
considered
 Furthermore, the choice of 0.25 for the space/blade width ratio is rather
low. A low value is desirable only to reduce the axial length and weight
of the turbine.
 Vibrational stresses are induced in the rotor blades as they pass through
th wakes
the k off the
th nozzlel blades,
bl d andd these
th stresses
t increase
i sharply
h l withith
decrease in axial space between the blade rows. A value of 0.2 is
considered as the lowest value of space/blade chord ratio, which is safe.
B t a value
But, l nearer 0.50 5 is
i often
ft usedd andd this
thi wouldld reduce
d both
b th the
th
vibrational stresses and the annulus flare.
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Check on Exit Mach Number RMD510

 If it were thought desirable to reduce the flare without


increasing the axial length of the turbine, then it would be
necessary to repeat the calculations allowing the axial velocity
to increase through the stage.
 It would be necessary to check the Mach number at exit from
the stage, M3, because if this is too high the friction losses in the
jet pipe become unduly large. For the present design we have

C3 276.4
M3    0.47
γRT3 1.333  0.287  922 1000

 Thi could
This ld be
b safely
f l increased
i d to
t reduce
d the
th flare
fl if desired.
d i d

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Check on Losses RMD510

• Finally,
Fi ll for
f this
hi preliminary
li i design
d i we have h taken
k losses
l into
i i N
account via
and s rather than N and R. The value of R implied by the design can be
found by determining (T3 – T3’’ ). Thus
 γ 1 γ
T2  p2  982 .7
''
   or T3''  1
 913 K
T3  p3  2.49 1.856  4

We also require the temperature equivalent of


the outlet kinetic energy relative to the blade

Ca 3 272
V3   
 473.5 m/s
cos β3 cos 54.96
V32 473.5 2
  97 .8 K
2c p 2296
T3  T3'' 922  913
Then λR  2   0.092
V3 / 2c p 97 .8
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PEMP

Check on Losses (… contd.) RMD510

• Had we used the following approximate relation between s , N


and R
1
ηS 
1 Ca  λR Sec2 β3  T3 T2 λN Sec2α2 
1
2 U  tan β3  tan α2  U Ca  

we would have found R to be 0.108 (which is a useful check on


the arithmetic).
• Note that R  N , which it should be by virtue of the tip leakage
loss in the rotor blades.

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Next Steps in Design
PEMP
RMD510

The next steps


p in the design
g are
a) To consider the three-dimensional nature of the flow in so
far as it affects the variation of the gas angles with radius;
b) To consider the blade shapes necessary to achieve the
required gas angles, and the effect of centrifugal and gas
bending stresses on the design;
c) To check the design by estimating N and R from the
results
lt off cascade
d tests
t t suitably
it bl modified
difi d to
t take
t k accountt off
three-dimensional flows.

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Free Vortex Design RMD510

• For free vortex design


g
a) The stagnation enthalpy ho is constant over the annulus (i.e.
dho /dr = 0),
b) The axial velocity is constant over the annulus, and
c) The whirl velocity is inversely proportional to the radius,
• Then the condition for radial equilibrium of the fluid elements,
g designed
is satisfied. A stage g in accordance with ((a),
), ((b)) and ((c))
is called a free vortex stage.

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Free Vortex Design (… contd.) RMD510

• Applying this to the stage in the figure, we can see that with
uniform inlet conditions to the nozzles then, since no work is
done by the gas in the nozzles, ho must also be constant over
the annulus at outlet. Thus condition (a) is fulfilled in the
space between the nozzles and rotor blades.

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Free Vortex Design (… contd.) RMD510

• Furthermore, if the nozzles are designed to give Ca2 = constant


and Cw2r = constant, all three conditions are fulfilled and the
condition
diti for
f radial
di l equilibrium
ilib i is
i satisfied
ti fi d in
i Plane-2.
Pl 2
• Similarly, if the rotor blades are designed so that Ca3 = constant
and Cw3r = constant,
constant it is easy to show as follows that condition
(a) will be fulfilled, and thus radial equilibrium will be achieved
in Plane-3 also. Writing  for the angular velocity we have

Ws  U Cw 2  Cw3   ωCw 2 r  Cw3 r   constant

• But when the work done per unit mass of gas is constant over the
annulus, and ho is constant at inlet, h0 must be constant at outlet
also; thus condition (a) is met.

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Free Vortex Design (… contd.) RMD510

• It is
i apparent that
h a free
f vortex design
d i is i one in
i which
hi h the
h workk
done per unit mass of gas is constant over the annulus, and to
obtain the total work output
p this specific
p value need onlyy be
calculated at one convenient radius and multiplied by the mass
flow.
• In contrast, we may note that because the density varies from root
to tip at exit from the nozzles and the axial velocity is constant,
an integration over the annulus will be necessary if the continuity
equation is to be used in Plane-2. Thus, considering a flow m
through an annular element of radius r and width r,
δm  ρ2  2πrδr  Ca 2
rt
m  2π  Ca 2  ρ2 rdr
rr

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PEMP

Comments RMD510

• For preliminary calculations, however, it is sufficiently accurate


to take the intensity of mass flow at the mean diameter as being
the mean intensity of mass flow.
• In ot
other
e words,
wo ds, tthee total
tota mass
ass flow
ow iss equal
equa to the
t e mass
ass flow
ow pe
per
unit area calculated using the density at the mean diameter
(2mCa2) multiplied by the annulus area (A2). This is one reason
why it is convenient to design the turbine on conditions at mean
diameter and use the relations which will now be derived for
obtaining the gas angles at other radii.

11 @ M S Ramaiah School of Advanced Studies, Bengaluru 45


PEMP

Free Vortex Design (… contd.) RMD510

• Using suffix m to denote quantities at mean diameter, the free vortex


variation of nozzle angle 2 may be found as follows:

Cw 2 r  rC
Ca 2 tan α2  constant
Ca 2  constant

Hence 2 at any radius r is related to 2 at the mean radius rm by


 rm 
tan α2    tan α2 m
 r 2
Si il l when
Similarly, h there
h is i swirl
i l at outlet
l from
f the
h stage
 rm 
tan α3    tan α3m
 r 3
11 @ M S Ramaiah School of Advanced Studies, Bengaluru 46
PEMP

Free Vortex Design (… contd.) RMD510

The gas angles at inlet to the rotor blade, 2, can then be found
using equation
U
tan β2  tan α2 
Ca 2
 rm   r  Um
   tan α2 m   
 r 2  rm  2 Ca 2

And similarly 3 is given by

 rm   r  Um
tan β3    tan α3m   
 r 3  rm 3 Ca 3

Now these relations can be applied to the present problem.


11 @ M S Ramaiah School of Advanced Studies, Bengaluru 47
PEMP

Free Vortex Design - Calculations RMD510

From the mean-diameter calculation we found that


α2 m  58.38 , β2 m  20.49 , α3m  10 , β3m  54.96
From the calculated values of h and rm, we have
rt = rm - (h/2) and rt = rm + (h/2)

 rm   rm   rm   rm 
and thus    1.164 ,    0.877 ,    1.217 ,    0.849
 rr  2  rt  2  rr 3  rt 3

also Um Um 1
   1.25
Ca 2 Ca 3 φ
Applying appropriate equations, we get

2 2 3 3
Tip 54.93 0 8.52 58.33
Root 62.15 39.32 12.12 51.13
11 @ M S Ramaiah School of Advanced Studies, Bengaluru 48
PEMP

Free Vortex Design – Velocity Triangles RMD510

• The variation of gas angles with radius appears as in the figure


below, which also includes the velocity triangles at root and
tip drawn to scale
scale.

11 @ M S Ramaiah School of Advanced Studies, Bengaluru 49


PEMP

Free Vortex Design – Mach Number Check RMD510

• Mv2 = V2 /(RT2) iis greatest


t t att the
th roott is
i clear
l from
f the
th velocity
l it triangles:
t i l V2 is i
then a maximum, and (RT2) is a minimum because the temperature drop
across the nozzles is greatest at the root. That there is some positive reaction at
the root is also clear because V3r  V2r . Although there is no need literally to
calculate the degree of reaction at the root, we must calculate (Mv2)r to ensure
that the design implies a safe value. Using data from the example
V2 r  Ca 2 sec β2 r  272 sec 39.32  352 m/s
/
C2 r  Ca 2 sec α2  272 sec 62.15  583 m/s
C22r 5832
T2 r  T02   1100   952 K
2c p 2294
V2 r 352
M v 2 r    0.58
γRT2 r 1.333  0.287  952 1000
• This is a modest value and certainly from this point of view a higher value of
flow coefficient  could
the flo co ld safely
safel have
ha e been used
sed in the design,
design perhaps
instead of introducing swirl at exit from the stage.
11 @ M S Ramaiah School of Advanced Studies, Bengaluru 50
PEMP

Constant Nozzle Angle Design RMD510

• As in the case of the axial compressor, it is not essential to design


for free vortex flow. Conditions other than constant Ca and Cwr
may be used to give some other form of vortex flow, which can
still satisfy the requirement for radial equilibrium of the fluid
elements In particular,
elements. particular it may be desirable to make a constant
nozzle angle one of the conditions determining the type of vortex,
to avoid having to manufacture nozzles of varying outlet angle.
This
hi requires
i particular
i l variations
i i off Ca andd Cw with
i h radius.
di
• Nozzles are designed using the relation

sin2 α2
Ca2r  constant
11 @ M S Ramaiah School of Advanced Studies, Bengaluru 51
PEMP

Constant Nozzle Angle Design RMD510

• Normally nozzle angles are greater than 60°, and quite a good
approximation to the flow satisfying the equilibrium condition is
obtained by designing with a constant nozzle angle and constant
angular momentum, i.e. 2= constant and Cw2r = constant. If this
approximation is made and the rotor blades are twisted to give
constant angular momentum at outlet also, then, as for free vortex
flow, the work output per unit mass flow is the same at all radii.
• However, the free vortex and constant nozzle angle types of
design do not exhaust the possibilities.

11 @ M S Ramaiah School of Advanced Studies, Bengaluru 52


PEMP

Session Summary RMD510

• Formulae and governing parameters for the design of axial


compressors are presented.
• D i procedure
Design d f a single
for i l stage turbine
bi is
i explained.
l i d
• Velocity triangles across the blade rows are obtained and
the choice of whirl distribution is explained.

11 @ M S Ramaiah School of Advanced Studies, Bengaluru 53

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