Effect of the Reynolds Number and Clearance Flow on the Aerodynamic Characteristics of a New Variable Inlet Guide Vane

Recently, a new type of low-loss variable inlet guide vane (VIGV) was proposed for improving a compressor’s performance under off-design conditions. To provide more information for applications, this work investigated the effect of the Reynolds number and clearance flow on the aerodynamic characteristics of this new type of VIGV. The performance and flow field of two representative airfoils with different chord Reynolds numbers were studied with the widely used commercial software ANSYS CFX after validation was completed. Calculations indicate that, with the decrease in the Reynolds number Rec, the airfoil loss coefficient ω and deviation δ first increase slightly and then entered a high growth rate in a low range of Rec. Afterwards, a detailed boundary-layer analysis was conducted to reveal the flow mechanism for the airfoil performance degradation with a low Reynolds number. For the design point, it is the appearance and extension of the separation region on the rear portion; for the maximum incidence point, it is the increase in the length and height of the separation region on the former portion. The three-dimensional VIGV research confirms the Reynolds number effect on airfoils. Furthermore, the clearance leakage flow forms a strong stream-wise vortex by injection into the mainflow, resulting in a high total-pressure loss and under-turning in the endwall region, which shows the potential benefits of seal treatment.

Experimental Aerodynamic and Aeroelastic Investigation of a Highly-Loaded 1.5-Stage Transonic Compressor with Tandem Stator

This paper experimentally investigates a highly-loaded 1.5-stage transonic axial compressor, which comprises a variable inlet guide vane, a BLISK rotor, and a variable stator in tandem arrangement. A detailed comparison between the newly designed compressor stage and a reference stage with a conventional stator design was conducted by using extensive instrumentation. Thus, steady and unsteady phenomena—focusing on the aerodynamic and aeroelastic behavior—were analyzed. Due to the new stator vane design, a higher aerodynamic stator vane loading was pursued, while the vane count was reduced. This, in turn, allowed a rotor design with an increased work coefficient. This experimental study revealed several effects of the optimized compressor stage in terms of both performance and the corresponding aerodynamics, as well as the aeroelastic behavior.

Leading edge redesign of dual-peak type variable inlet guide vane and its effect on aerodynamic performance

Recently, a new type airfoil for variable inlet guide vane (VIGV), featuring “dual-peak” surface velocity pattern at high incidence, is proposed and shows wide low-loss operation range. To further improve its performance, this paper researches the influence of leading edge (LE) thickness and shape on the loss level and surface velocity features of the “dual-peak” type airfoil. Firstly, a polynomial-based continuous-curvature leading edge design method was briefly introduced and used in the LE redesign of sample airfoils. Then, steady simulations based on Reynolds-Averaged Navier-Stokes method (RANS), carried out by commercial software CFX after grid independent study, were used to determine the aerodynamic performance, surface velocity distribution and boundary-layer behaviors of all research airfoils. Simulation results indicate that there exists an optimized range of LE relative thickness that can achieve lower airfoil loss level at high incidence condition. For Case 1 ([Formula: see text]) and Case 2 ([Formula: see text]), the optimized LE relative thickness range is [Formula: see text] and [Formula: see text]. The LE shape optimization can further reduce the maximum incidence condition loss coefficient with proportion up to 18% for airfoils with optimal LE thickness. Analysis of flow mechanism indicates that the optimized LE thickness and shape can reduce the suction spike height and subsequent adverse pressure gradient, therefore, decrease the LE separation scale and result in a lower loss coefficient. As an application, a dual peak VIGV with circular LE, presented in previous paper as the optimized VIGV, is redesigned in the LE portion according to the research findings and achieved 0.6 percent improvement in passage-averaged total pressure recovery coefficient [Formula: see text] at extreme high stagger angle point and the low-loss operation range extends with about 5°, which confirms the effectiveness of the research findings in three-dimensional environment.

Variable Guide Vane Scheduling Method Based on the Kinematic Model and Dual Schedule Curves

The variable guide vanes (VGV) of gas turbine engines are commonly utilized to expand operating range and to improve efficiency of the compressor. Guiding air flow using the VGVs in the compressor prevents aerodynamic instability by making proper incidence angle to the blades. In this study, we dealt with rig-type three-stages VGVs for developed engine tests. The three link mechanism of VGVs are linked to each other with two hydraulic actuators, and inevitably, induced hysteresis exists between vane rotations and actuators strokes, due to links with non-fully constrained degree of freedoms for easy installation and instrumentation, as well. Therefore, the adjustment of each VGVs link mechanism is required to satisfy vane angle demands. To adjust coupled three-stages VGVs link mechanism, an analytical VGV-link kinematic model was derived, and effects of two adjusting parameters (lengths of bell cranks and vertical links) were discovered. Lastly, we obtained two vane angle schedule curves from the experiments according to link moving directions, and applied them to the engine controller to minimize hysteresis of the variable inlet guide vane (VIGV). The proposed VGV adjusting and controlling method can be simply applied to the pre-designed or pre-manufactured VGVs system without mechanical compensation or additional cost.

Gas turbine efficiency and ramp rate improvement through compressed air injection

With the transition to more use of renewable forms of energy in Europe, grid instability that is linked to the intermittency in power generation is a concern, and thus, the fast response of on-demand power systems like gas turbines has become more important. This study focuses on the injection of compressed air to facilitate the improvement in the ramp-up rate of a heavy-duty gas turbine. The steady-state analysis of compressed airflow injection at part-load and full load indicates power augmentation of up to 25%, without infringing on the surge margin. The surge margin is also seen to be more limiting at part-load with maximum closing of the variable inlet guide vane than at high load with a maximum opening. Nevertheless, the percentage increase in the thermal efficiency of the former is slightly greater for the same amount of airflow injection. Part-load operations above 75% of power show higher thermal efficiencies with airflow injection when compared with other load variation approaches. The quasi-dynamic simulations performed using constant mass flow method show that the heavy-duty gas turbine ramp-up rate can be improved by 10% on average, for every 2% of compressor outlet airflow injected during ramp-up irrespective of the starting load. It also shows that the limitation of the ramp-up rate improvement is dominated by the rear stages and at lower variable inlet guide vane openings. The turbine entry temperature is found to be another restrictive factor at a high injection rate of up to 10%. However, the 2% injection rate is shown to be the safest, also offering considerable performance enhancements. It was also found that the ramp-up rate with air injection from the minimum environmental load to full load amounted to lower total fuel consumption than the design case.

Investigation of the Combined Effect of Variable Inlet Guide Vane Drift, Fouling, and Inlet Air Cooling on Gas Turbine Performance

Variable geometry gas turbines are susceptible to various malfunctions and performance deterioration phenomena, such as variable inlet guide vane (VIGV) drift, compressor fouling, and high inlet air temperatures. The present study investigates the combined effect of these performance deterioration phenomena on the health and overall performance of a three-shaft gas turbine engine (GE LM1600). For this purpose, a steady-state simulation model of the turbine was developed using a commercial software named GasTurb 12. In addition, the effect of an inlet air cooling (IAC) technique on the gas turbine performance was examined. The design point results were validated using literature results and data from the manufacturer’s catalog. The gas turbine exhibited significant deterioration in power output and thermal efficiency by 21.09% and 7.92%, respectively, due to the augmented high inlet air temperature and fouling. However, the integration of the inlet air cooling technique helped in improving the power output, thermal efficiency, and surge margin by 29.67%, 7.38%, 32.84%, respectively. Additionally, the specific fuel consumption (SFC) was reduced by 6.88%. The VIGV down-drift schedule has also resulted in improved power output, thermal efficiency, and the surge margin by 14.53%, 5.55%, and 32.08%, respectively, while the SFC decreased by 5.23%. The current model can assist in troubleshooting the root cause of performance degradation and surging in an engine faced with VIGV drift and fouling simultaneously. Moreover, the combined study also indicated the optimum schedule during VIGV drift and fouling for performance improvement via the IAC technique.

Aerodynamic Optimization of a Two-Part Variable Inlet Guide Vane in a Highly Loaded Low Pressure Compressor

Continuous reduction of fuel consumption for a wide range of operating conditions leads to a high efficiency demand for all engine parts of modern jet engines and especially the compressor. To meet these requirements a two-part Variable Inlet Guide Vane (VIGV), composed of a fixed strut and a variable flap, can be used. Besides the aerodynamic aspects, the VIGV strut is a substantial part for the structural integrity of the compressor. The aerodynamic design optimization of such a VIGV, located upstream of the first rotor of a 2.5 stage low pressure compressor, under the conditions of three different operating points is presented in this paper. In a previous study the shape of the axial gap between strut and flap was optimized without changing the envelope of both parts [1]. The new design tool SplitBlade, developed at the DLR, enables the creation of an axial gap and has been integrated in the design process of the in-house optimization tool AutoOpti. The target of the optimization was to decrease the total pressure loss coefficients for all three operating points. The design optimization presented in this paper is more complex by allowing the VIGV blade geometry to change. The basic dimensions of the VIGV such as the axial chord and the maximum profile thickness are still frozen. In total, 88 parameters are free to change in the optimization process. Additionally to the main target of loss reduction, the circumferential outflow angles are restricted to maintain the deflection of the blade and therewith the required rotor inflow conditions to ensure the operability of the entire compressor in the whole working range. The final result is a two-part VIGV with an axial gap, which is optimized in terms of total pressure losses in three operating points. Compared to a reference geometry without an axial gap, the losses are almost equal at nominal speed, and about one to two percentage points higher in the two part speed operating points.

The Use of Variable Inlet Guide Vane or Speed Control to Maintain Constant Compressor Pressure Ratio in Wet Gas Flow and Their Effect on Diffuser Stability

Improving offshore gas production requires the process compressor to be moved closer to the wellhead. This will yield such benefits as enhanced well output, longer well life and the possibility of exploiting smaller fields. However, the harsh environment, remote location and variable two-phase characteristics of an untreated gas stream pose increased challenges for operational performance and robustness. Several methods are available to ensure that a process compressor maintains constant outlet pressure regardless of inlet stream properties and flow. Two pressure-ratio control methods — variable inlet guide vanes (IGV) and variable speed — have been investigated. Their effect on diffuser stability has been tested and analysed in dry and wet conditions. Increased diffuser stability in wet conditions with IGV has been discussed and results are presented.