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Laboratory of Thermal Turbomachines National Technical University of - - PowerPoint PPT Presentation

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Laboratory of Thermal Turbomachines National Technical University of Athens (LTT/NTUA) Laboratory of Thermal Turbomachines (LTT) 1 School of Mechanical Engineering National Technical University of Athens (NTUA) National Technical University

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Laboratory of Thermal Turbomachines National Technical University of Athens (LTT/NTUA)

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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National Technical University of Athens

  • The National Technical University of Athens (NTUA) is the oldest and most prestigious

technological educational institution of Greece.

  • NTUA was established in1836, a few years after Greece gained its independence.
  • NTUA took its present form in 1917 and was organized into the Higher Schools of Civil

Engineers, Mechanical & Electrical Engineers, Chemical Engineers, Surveying Engineers and Architecture.

  • Presently, NTUA is divided into nine academic Schools, eight being for the engineering

sciences, including architecture, and one for the general sciences.

School of Mechanical Engineering School of Chemical Engineering School of Naval Engineering School of Rural Engineering School of Electrical & Civil Engineering School of Mining and Metallurgy Engineering School of Civil Engineering School of Architecture School of Applied Mathematical and Physics Science

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Laboratory of Thermal Turbomachines (LTT)

  • The Laboratory of Thermal Turbomachines (LTT) was founded in 1982 by

Professor K. Papailiou.

  • The laboratory, since its establishment, exhibited extensive and distinguished

presence in the fields of gas turbines diagnostics and modeling, in turbo machinery CFD and in experimental studies.

  • Today, it hosts two research groups:
  • Diagnostics & Modeling Group
  • Parallel CFD & Optimization Group
  • Professor K. Mathioudakis is the Lab Director since 2006. He also Heads the

Diagnostics & Modeling Group.

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Educational Activities

  • Undergraduate Classes
  • 1. Thermal Turbomachines (1D)
  • 2. Design of Thermal Turbomachines (2D)
  • 3. Gas and Steam Turbine Operation (Design & Off-Design)
  • 4. Principles of Jet Propulsion (Design & Off-Design)
  • 5. Aircraft Engine Operation (Mission Analysis, Noise etc.)
  • 6. Gas Turbine Diagnostics (Aerothermal, Vibrations etc)
  • Postgraduate
  • Gas Turbines Power Plants
  • Seminars (Indicative)
  • Power Plant Diagnostics
  • Vibrations in Turbomachinery
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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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  • A computerized Gas Turbine educational suite has been developed (VLab: Virtual

Laboratory of Gas Turbines for Naval and Aircraft Propulsion) in support of undergraduate and postgraduate courses,and a variety of tailored made (web)seminars are offered .

  • Measuring campaigns for turbomachinery components, micro-turbines testing and

innovative control methods evaluation are performed. The testing facilities can adapt to a wide variety of requirements and objectives.

  • Research has been performed for over more than 25 years and services are offered in

Engine Health Monitoring and Diagnostics, as well as the field of gas turbine performance modelling, ranging from new aero engine configuration concept analysis to multi-fidelity, multi-physics models, including special interest tipics such as weather hazards analysis (e.g. rain/hail ingestion), environmental impact of air transportation etc.

  • The Parallel CFD & Optimization group performs research and offers services in

Computational Fluid Dynamics, having developed a suite of in-house tools, a generic

  • ptimization platform based on enhanced Evolutionary Algorithms (EASY),Aero/hydrodynamic
  • ptimization tools based on adjoint methods and hybrid (gradient-based & stochastic)
  • ptimization methods.
  • The Diagnostics & Modeling Group is one of the leading academic groups in the field of

gas turbine diagnostics, with several innovative diagnostic methods developed and validated. At the same time Engine Health Monitoring Systems have been developed, built and installed in Power Plants.

LTT Activities

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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– Best paper award in Controls and Diagnostics, 1992 ASME International TURBΟ-

EXPΟ. – The annual Outstanding Service Award of the Controls and Diagnostics Committee

  • f the ASME for 2002, was granted to a member of the group.

– Best paper award in Controls and Diagnostics, 2002 ASME International TURBΟ-

EXPΟ.

– Best paper award in Education, 2003 ASME International TURBΟ-EXPΟ.

– PE Publishing Award for the best paper published in the ImechE Journal of Power and Energy, 2004.

– Best paper award in Cycle Innovations, 2012 ASME International TURBΟ-EXPΟ.

Diagnostics and Modeling Group International Distinctions

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Diagnostics and Modeling Group: Services Services (under contract or / and in collaboration)

  • Design and analysis of turbomachinery components
  • Testing of turbomachinery components and gas meters
  • Development of engine performance models & diagnostic methods
  • Design, development and installation of EHM systems
  • Development of simulation software tools
  • On site measurements and analysis
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Laboratory of Thermal Turbomachines (LTT)

 Educational Activities Test Facilities & Measurement Expertise  Engine Modeling  Diagnostic Methods Parallel CFD & Optimization

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Classes + Experimental Training

Diagnostics Course: Simulator of Mechanical fault in turbomachinery shafts

Education

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Education

Installed in Hellenic Naval Academy, Hellenic AirForce Academy and LTT/NTUA

VIRTUAL LAB for Gas Turbine Education

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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VIRTUAL LAB for Gas Turbine Education

Nozzle Calculator Flow in Compressor Cascades Rotating Stall physical demonstration

Principles of Gas Turbine components operation

Theory of compressor

  • peration

Education

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Jet Engine Performance

Πρόγραμμα προσομοίωσης λειτουργίας κινητήρα F110

VIRTUAL LAB for Gas Turbine Education Education

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Design Studies

Πρόγραμμα Υπολογισμού Turbojet

VIRTUAL LAB for Gas Turbine Education Education

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Virtual Test Facilities and Lab Exercises

Jet engine Cell Testing Axial Fan Characteristic Measurement

VIRTUAL LAB for Gas Turbine Education Education

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Laboratory of Thermal Turbomachines (LTT)

 Educational Activities  Test Facilities & Measurement Expertise  Engine Modeling  Diagnostic Methods Parallel CFD & Optimization

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Compressor Test rig - I

  • Max. Power: 750kW
  • Max. Speed: 24,000 and 80,000 RPM

(depending on gear box) Gearbox 1 Ratio: 8:1 Gearbox 2 Ratio: 26.6:1 DC Motor Speed: 3,000 RPM

Test Facilities

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Compressor Test rig - II Test Facilities

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Facilities

Experimental Investigation of Radial Compressor Faults

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Compressor-Turbine Test Rig Test Facilities

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Small Gas turbine Test (50kW) Small Tuebine test

(Small) Gas Turbine Engine and Component testing Test Facilities

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Turbocharger Testing Test Facilities

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Small Turbojet Test Cell Test Facilities

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Test Facilities

  • Low-Speed Section
  • Test stand for industrial small blowers (DIN 24163 standards)
  • Linear cascade tunnel for testing linear compressor or turbine blades and

perform detailed study of the flow field

  • A contra- rotating compressor (2 stages) test rig
  • Gas Meters Calibration Unit
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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Test Facilities

  • Low-Speed Section
  • Test stand for industrial small blowers (DIN 24163 standards)
  • Gas Meters Calibration Unit

Gas Meters Calibration Unit Test stand for industrial small blowers (DIN 24163 standards)

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Test Facilities & Measurement Expertise Wide Range of Instrumentation and Measuring Know-how

Pressure Probes and Rakes Vibration Measurements Acoustic Measurements 3-D LDV Hot Wires Mechanical Proximity

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Pressure Probes For Turbomachinery Flows (I)

Subsonic 3-hole Transonic 5-Hole 3 Hole + TC

Test Facilities & Measurement Expertise

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Pressure Probes (II): Special Applications

Long Nose probe for measurements with access restrictions, reduced interference

Test Facilities & Measurement Expertise

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Probes (III) Custom Made Miniature Probes

Miniature 5-Hole Probe for measurement in radial compressor passages

Test Facilities & Measurement Expertise

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Fast Response and Turbulence Measurements

Hot wires for Turbocharger Surge Studies Crossed Hot wire probe

Test Facilities & Measurement Expertise

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LDV for Non Intrusive Velocity Measurements

Fiber-optic 3-D Laser system measuring on an Annular Cascade

Test Facilities & Measurement Expertise

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Mechanical Behavior of Turbomachinery Components Vibration measurements

Accelerometers

  • n cartridge for

monitoring Accelerometers on turbocharger casing Shaft orbit measurement for compressor commissioning

Test Facilities & Measurement Expertise

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Laboratory of Thermal Turbomachines (LTT)

 Educational Activities Test Facilities & Measurement Expertise  Engine Modeling  Diagnostic Methods Parallel CFD & Optimization

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Modeling

Flow Field Computations for Design Test Designed Componets

(impeller designed at LTT)

Design optimization achievement

Turbomachnery Analysis, Design, Optimization

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PROOSIS PROOSIS (PRopulsion Object-Oriented Simulation Software)

  • Object-Oriented
  • Steady State
  • Transient
  • Mixed-Fidelity
  • Multi-Disciplinary
  • Distributed
  • Multi-point Design
  • Off-Design
  • Test Analysis
  • Diagnostics
  • Sensitivity
  • Optimisation
  • Deck Generation

Gas Turbine Performance Modeling

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Civil Aero-Engine Models

Rolls-Royce TRENT-772B IAE-V2500-A1 Rolls-Royce RB211-524G CFMI CFM56-7B27

GE CF34-8C1

GE CF6-80C2 Turbomeca Makila-1A1

Gas Turbine Performance Modeling

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Variety of Aero-Engine Configurations

Geared Turbofan with Active Core Contra-Rotating Turbofan

Gas Turbine Performance Modeling

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Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Industrial Engine Models

ABB GT-10 ABB GT-13E2 GE PG9171E ABB GT8 FIAT TG-20 GEC EM610 Siemens SGT-300 Siemens V64.3 GE LM6000

Gas Turbine Performance Modeling

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Marine Engine Models Gas Turbine Performance Modeling

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Models Adapted to Engine Specific Data

0.2 0.4 0.6 0.8 1 1.2 0.2 0.4 0.6 0.8 1 1.2

ηth/ηth,ref Load/Load, ref Model Measurements

0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

EGT/EGT,ref Load/Load, ref

0.5 0.6 0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

CDP/CDP,ref Load/Load, ref

Adapted Industrial GT Adapted Civil Aero-Engine

0.2 0.4 0.6 0.8 1 1.2 0.2 0.4 0.6 0.8 1 1.2

ηth/ηth,ref Load/Load, ref Model Measurements

0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

EGT/EGT,ref Load/Load, ref

0.5 0.6 0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

CDP/CDP,ref Load/Load, ref

Adapted Industrial GT Adapted Civil Aero-Engine

0.2 0.4 0.6 0.8 1 1.2 0.2 0.4 0.6 0.8 1 1.2

ηth/ηth,ref Load/Load, ref Model Measurements

0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

EGT/EGT,ref Load/Load, ref

0.5 0.6 0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

CDP/CDP,ref Load/Load, ref

Adapted Industrial GT Adapted Civil Aero-Engine

0.2 0.4 0.6 0.8 1 1.2 0.2 0.4 0.6 0.8 1 1.2

ηth/ηth,ref Load/Load, ref Model Measurements

0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

EGT/EGT,ref Load/Load, ref

0.5 0.6 0.7 0.8 0.9 1 1.1 0.2 0.4 0.6 0.8 1 1.2

CDP/CDP,ref Load/Load, ref

Adapted Industrial GT

Gas Turbine Performance Modeling

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Helicopter-Turboshaft Engine Integrated Model Integrated Helicopter-Engine Component

Variety of Engine Configurations Gas Turbine Performance Modeling

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LTT-NTUA Software Tools Sampler

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Control System Modelling

PROOSIS CONTROL LIBRARY Sensors & Actuators Volume Dynamics Tip Clearance Effects

Gas Turbine Systems Modeling

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ORIFICES ROTATING DISC CAVITIES LABYRINTH SEALS PRE-SWIRL SYSTEM DRIVE CONE CAVITY RIM SEAL ORIFICES ROTATING DISC CAVITIES LABYRINTH SEALS PRE-SWIRL SYSTEM DRIVE CONE CAVITY RIM SEAL

Secondary Air System (SAS) modelling Gas Turbine Systems Modeling

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Blade Lifing Computations

BladeLife Comp StressProfileRearrangement CycleCounting LifeApproach StrainLifeApproach StressLifeApproach

1 2

RuleOption

MINERULE DLDRULE

MinerRule

DLDRule

CreepLife Creep_Fatigue Life Rainflow Range-Pair Simplified_Rainflow L_M M_H Temperature Profile Stress Profile Data Time Step

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Component Zooming: Coupled and De-coupled Approaches

Alexiou, A., Baalbergen, E. H., Kogenhop, O., Mathioudakis K. and Arendsen, P., 2007. Advanced Capabilities For Gas Turbine Engine Performance Simulations. ASME Turbo Expo 2007, Paper Number GT-2007-27086.

Coupled De-coupled

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Aircraft Mission Simulation Software

Commercial Aircraft’s Mission Analysis Computational Model

  • Covers all segments of a modern commercial aircraft typical flight: taxi, take
  • ff, climb, cruise, descent and approach
  • It analyses the trajectory of the aircraft using basic Flight Mechanics

longitudinal equations of equilibrium between the applied forces

  • It allows the analysis of a variety of possible missions within the limits of

safety and traffic regulations

  • It delivers the overall mission results: aircraft trajectory, engine performance

along the mission, burned fuel and flight duration

  • It can be used to asses the effects of engine degradation and to optimize the

flight profile

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Aircraft Mission Simulation Software

Commercial Aircraft’s Mission Analysis Computational Model

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Payload Range – CFM56-5B4/3

Aircraft Mission Simulation Software Alternative Fuels in Aircraft Propulsion

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Quantification and Analysis of Compressor Faults on Marine Gas Turbines and Vessel’s Mission

Study of Degraded and Faulty Gas Turbines

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Quantification and Analysis of Compressor Faults on Marine Gas Turbines and Vessel’s Mission

  • 2
  • 1

1 2 3 4 5 6 Dmf(%) DCO2(%) DNOX(%) DCO(%) DUHC(%)

Deviation (%) Tip Clearance Increase

21 knots 25 knots 30 knots Max Cont

0.3 0.5 0.7 0.9 1.1 1.3 0.5 0.6 0.7 0.8 0.9 1 1.1

πC/πC,ref q/qref

healthy Tip Clearance Increase

  • 2
  • 1

1 2 3 4 5 6 Dmf(%) DCO2(%) DNOX(%) DCO(%) DUHC(%)

Deviation (%) Fouling 0.3 0.5 0.7 0.9 1.1 1.3 0.5 0.6 0.7 0.8 0.9 1 1.1

πC/πC,ref q/qref

healthy fouled

Max Cont 30 knots 25 knots 21 knots

Study of Degraded and Faulty Gas Turbines

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Tools for Noise and Emissions Environmental Aspects of Gas Turbines

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Multi-Disciplinary Design Optimization

PROOSIS executable deck in iSIGHT Fuel Burn Contour Plots

Overall Design Support

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Software Package for Helicopter Testing Automation AB212 Helicopter Flight Tests (I)

Manual Testig

Automated Testing

Operations support software

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Fault Tree Diagnosis Test parameters calculation – limits check

  • Increase test reliabiliy
  • Simplify tet procedure
  • Minimize testing time and cost

Operations support software Software Package for Helicopter Testing Automation AB212 Helicopter Flight Tests (II)

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Distributed Simulation via Web Services

Application Server PROOSIS Web Service Operation

Stage-Stacking Function

Server (NTUA)

PROOSIS

Client (NLR)

PROOSIS Web Component

Enables remote use and sharing of User Libraries over the Internet without distributing the code of the libraries

Simulation Software

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Laboratory of Thermal Turbomachines (LTT)

 Educational Activities  Test Facilities & Measurement Expertise  Engine Modeling  Diagnostic Methods Parallel CFD & Optimization

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Original Methods Developed

Gas Path Analysis (Aerothermodynamics) Fast Response Measurements

Technological Background for implementation Integrated Systems Developed

LTT/NTUA Diagnostic Methods

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11/7/2017

Perform Testing (in Lab, in situ)

(Measuring equipment, know-how)

Constitution of data collection systems

(Hardware, Software)

Test Data Analysis and Interpretation Constitution of Supporting software

(Data Analysis software, Engine Models)

Constitution of Integrated Systems

Capabilities

LTT/NTUA Diagnostic Methods

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Laboratory of Thermal Turbomachines (LTT)

 Educational Activities Test Facilities & Measurement Expertise  Engine Modeling  Diagnostic Methods Parallel CFD & Optimization

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Parallel CFD & Optimization Unit (PCOpt)

Research Activities: Development and parallelization (on CPUs and GPUs) of: 1. in-house Computational Fluid Dynamics (CFD) tools/software, 2. a generic optimization platform based on enhanced Evolutionary Algorithms (EASY), 3. Aero/hydrodynamic optimization tools based on adjoint methods, 4. Hybrid (gradient-based & stochastic) optimization methods. Applications in: turbomachines, aircraft/car aerodynamics, etc Research Group:

  • Prof. K. Giannakoglou, 4 Post-Docs, 15 PhD students.

Research Computational Infrastructure: CPU and GPU cluster with 44 Teraflop computing power in total. Funding: EU Projects (FP6/7: HISAC, ACFA, HYDROACTION, AQUAGEN, AboutFLOW, IODA, SmartAnswer, FORTISSIMO), directly from Industrial outfits (Dassault Aviation, Volkswagen, Andritz Hydro, Toyota Motor Europe, Schlumberger, etc), software developers & vendors (ICON, NUMECA, SOFISTIK, ENGYS etc), Greek companies (Hellenic Aerospace Industry, Public Power Corporation, various SMEs). Income from selling the optimization software EASY. NTUA > School Mech. Eng. > Fluids Section > Parallel CFD & Optimization Unit

  • K. Giannakoglou, Professor NTUA, kgianna@central.ntua.gr

Parallel CFD & Optimization Unit,

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CFD Simulations

Parallel CFD & Optimization Unit,

Reynolds-Averaged Navier-Stokes solvers for compressible or incompressible, steady orunsteady flows, based

  • n either the GPU-enabled in-house code and OpenFOAM.
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The Evolutionary Algorithms System (EASY)

A generic-purpose optimization platform which accommodates any evaluation tool (CFD, CSM, etc) and is particularly suitable for computationally expensive problems, since it offers:  Distributed EAs.  Built-in surrogate evaluation models (metamodels – Metamodel Assisted EAs).  Hierarchical schemes.  Asynchronous evolution on multiprocessor platforms.  Principal Component Analysis to enhance EAs and MAEAs  Cluster & Grid computing.

Parallel CFD & Optimization Unit,

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Optimization of hydraulic machines using

EASY has been purchased (open source) by Andritz Hydro and is currently used for the optimization

  • f Francis, Matrix, Kaplan, Bulp, pump & pump-turbines runners, Pelton distributers and draft tubes

coupled with in-house CFD tools. Design of the Francis runner, at 3 operating points with two objectives: (a) exit velocity profiles’ quality and (b) uniformity of the blade loading and two constraints (head and cavitation). 372 design variables, in total (with such a high number of design variables, standard EAs usually fail to provide a solution with an affordable computational time)

Parallel CFD & Optimization Unit,

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Development of (Continuous) Adjoint Methods

 For shape, flow-control, robust-design and topology optimization problems  The first continuous adjoint methods to widely-used turbulence models.  Development on the in-house codes and OpenFOAM.  Automated s/w, including parameterization and morphing tools.

Adjoint-based Sensitivity Map on the pressure and suction side of a Francis turbine, for the control of the exit swirl profile and cavitation. The Adjoint Method, apart from supporting an

  • ptimization loop, provides the Sensitivity Maps

(picture: Sensitivity Map of Lift on the Polo Car). This colored map helps the design to make decisions (blue: pull outwards, red: push inwards) in order to minimize or maximize the objective function.

Parallel CFD & Optimization Unit,

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SLIDE 65

Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

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Adjoint-Based Optimization - Applications

Baseline Optimized Baseline Optimized

Adjoint-based Shape Optimization of a 3D compressor row, for minimal viscous losses, with geometrical constraints, using the continuous adjoint method. Adjoint-based Shape Optimization of the side-mirror of a passenger car in order to reduce the noise perceived by the driver.

Baseline Optimized

Adjoint-based Shape Optimization of a Francis runner to reduce/eliminate cavitation.

Parallel CFD & Optimization Unit,

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SLIDE 66

Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

66

Adjoint-Based Optimization - Applications

gear box inlet

  • utlet

Baseline Optimized Adjoint-based Topology Optimization solidified parts of the flow passage in this HVAC duct of a passenger car, for minimum total losses (losses reduced by 45%). The shape optimization of the defroster nozzle, part of the HVAC unit of a TOYOTA car, led at a new shape with improved defrosting

  • performance. The optimized geometry complies

with manufacturing and topological constraints and reduces the time needed for defrosting the windshield by 15% .

Parallel CFD & Optimization Unit,

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SLIDE 67

Laboratory of Thermal Turbomachines (LTT) School of Mechanical Engineering National Technical University of Athens (NTUA)

67

Laboratory of Thermal Turbomachines National Technical University of Athens (LTT/NTUA)

9, Iroon Polytechniou Building O Polytechnioupoli Zografou 15780 Athens, GREECE

https://www.ltt.ntua.gr/index.php/en/contact