Handbook of Turbomachinery Second Edition Revised - Ventech!

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In a steam turbine, a thrust bearing is used to locate the rotor axially with respect to the stationary parts and at the same time carry any axial steam loads that may be imposed on the rotor. Journal bearings are used to carry the weight of the rotors and any transverse steam loads imposed on the rotor, and also to locate the rotor radially with respect to the stationary parts. A thin film of lubricant, which provides the necessary load support function, separates the journal and bearing surfaces. The function of the lubrication supply system is to provide a continuous supply of oil into the clearance space between the bearing and the rotating journal. Once the oil is within the clearance space, actual separation of the journal surface from the bearing surface is achieved by formation of the load-supporting oil film via hydrodynamic action (Fig. 52). The oil film develops because oil adheres to the journal and when the journal is rotated, it pulls some oil with it. Since the radius of the journal is smaller than the radius of the bearing, the surfaces form a converging wedge and the clearance between them will be a minimum at one circumferential position. When oil is pulled from a position with greater clearance into the position of minimum clearance, oil pressure within the film becomes established. The film pressure increases to equal the journal loads and push the journal away from the bearing. The two main criteria of bearing performance are the coefficient of friction and the minimum thickness of the oil film. When full film lubrication is achieved, the rotor glides along without any metal-to-metal contact because the oil film supports the journal. Without full film lubrication, metal-to-metal contact of the rotating journal with the bearing occurs and results in a marked increase in frictional resistance. While the resulting increase of drive torque required to overcome the increased frictional resistance is of very little concern, the side effects of increased bearing temperature and wear of the bearing and/or journal surfaces are of major concern. A closer look at the operating geometry and fluid-film pressure distribution of the journal bearing in Fig. 52 shows that the journal center, 0 0 , is displaced radically from the bearing center, 0. The resulting line of centers is not in line with the direction of the applied radial load but is at an angle to it. Choosing the angular location of maximum film thickness as a reference (o ¼ 0), the minimum film thickness will be at o ¼ 180. The solidline pressure distribution is typical for incompressible fluid-film journal bearings. In this case, positive pressures are generated within the converging film thickness zone with peak pressure obtained just before the location of minimum film thickness. The pressure is reduced to ambient pressure just after the location of minimum film thickness. Beyond this point of return to Copyright © 2003 Marcel Dekker, Inc.
Figure 52 Converging wedge and resulting pressure distribution in a hydrodynamic journal bearing. ambient pressure, an incompressible fluid cavitates (unless the ambient is a pressure environment) because of the rapidly diverging (expanding) film Copyright © 2003 Marcel Dekker, Inc.
Page 1 and 2:
D E K K E R Handbook of Turbomachin
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MECHANICAL ENGINEERING A Series of
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61 Computer-Aided Simulation in Rai
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127 Designing for Product Sound Qua
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Preface to the Second Edition The o
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Preface to the Second Edition Prefa
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Contributors Nathan G. Adams The Bo
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1 Introduction Earl Logan, Jr.*, an
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HISTORICAL BACKGROUND Earl Logan, J
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MECHANICAL AND THERMAL DESIGN CONSI
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Figure 1 Cross-section showing the
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Figure 2 Turboprop engine, TPE 331-
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Figure 4 Auxiliary power unit, APU1
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Durability. The mechanical and ther
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with time during flight. Such a typ
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experience and existing similar des
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adverse pressure gradient against w
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and its attachments. A substantial
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Figure 9 Typical high-pressure turb
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and the measurement of local heat-t
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due to cyclic operation. In additio
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the steady and transient conditions
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Table 3(a) Steps in a Three-Dimensi
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Figure 16 Schematic Goodman diagram
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occur due to particles of unburned
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pressures at critical points. These
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1. Ceramics are subject to ‘‘in
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with Transient Tests and Surface Co
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Overall engine performance goals tr
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Much of the complexity of turbomach
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End-wall boundary layers can also h
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pressure at the wake centerline. Th
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the same vaneless diffuser and shro
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from internal cooling passages, thr
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Further downstream, the wake was ev
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to its original position. This unst
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cooling film was found to trip the
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shroud static pressure and the exit
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stage in the design process allows
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Flow Physics Modeling Modeling of t
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passage to the next, assuming that
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The next step in modeling accuracy
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tend to be large, due to the necess
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Navier-Stokes equations are time-ma
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To satisfy these requirements, it i
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are discussed by a number of author
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source code, and to assign each seg
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selected locations in the flow path
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of the component designers must be
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Trends in Flow Modeling Capabilitie
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optimize the flow behavior. The eff
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20. D. Eckardt, ‘‘Flow Field An
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49. K. R. Kirtley, ‘‘An Algebra
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INTRODUCTION 3 Turbine Gas-Path Hea
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Figure 1 Maximum turbine rotor inle
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Figure 2 Intersecting S1 and S2 sur
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determination. Nothing in the simpl
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e well matched with the engine. The
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case different forms of the popular
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volume will be equal to the accumul
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Figure 9 Nusselt number vs. vane su
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Furthermore, to keep computer time
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Figure 12 Comparison of three turbu
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and small and cooled and uncooled t
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Figure 15 Miniature heat flux gauge
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Figure 17 Time resolved heat transf
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Figure 19 Surface pressure changes
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NONUNIFORM INLET FLOW All gas turbi
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Figure 22 Typical distributions of
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4. Better instrumentation for heat-
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24. R. H. Ni, ‘‘A Multiple Grid
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4 Selection of a Gas Turbine Coolin
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Re L ¼ rVL=m—Reynolds number bas
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(1,300 8F). But modern gas turbines
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during engine operation are compati
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Figure 3 Airfoil cooling techniques
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expected to increase this limit to
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1. Reduce the effect of main-stream
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P? is total inlet pressure. Tc=T? i
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thereby increasing both the skin-fr
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After four decades of advancement i
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correspondingly high coolant-side t
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component. Use of a hot cascade for
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nozzle vanes is limited by their ox
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Figure 9 Typical turbine hot sectio
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important factor to consider for tr
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Figure 10 Evolution of nozzle geome
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the exit of the combustor section f
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Figure 12 Inlet turbulence effect o
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in heat transfer as the Reynolds nu
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easonably well using correlations e
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in the section on blade cooling tha
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mass flow rate (e.g., M ¼ 1 for a
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holes. Cooling hole pattern is an i
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coolant flow with the main stream,
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above equation assumes a constant f
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Figure 15 Definition of film-coolin
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edistribution of the external heat-
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Three-Dimensional Effects The three
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In order to achieve the bulk metal
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coefficient is given by Nud ¼ hd=k
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Where G ¼ 2:24ðw=tÞ 0:1 ðReeÞ
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pressure drop. The 608/458 V-shaped
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Some of the studies have found that
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of the cooling air and the turning
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Figure 20 Impingement geometry defi
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correlated by Nu a d ¼ 0:63ðGd=m
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tangentially to the inner wall, beh
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The effectiveness of a suction surf
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vortex structure. Their studies sho
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Figure 23 Effect of preswirler pres
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component to the cooling air that c
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axial gap. A static pressure variat
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Weight, cost, and complexity constr
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Figure 28 Effectiveness of liner co
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thickness. A problem this poses is
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portion of the hole has been shown
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unacceptable engine performance pen
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analysis, in order to provide accur
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Figure 30 Application of PSP for fi
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thermocouple positioned close to th
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spray-painted black (Hallcrest, BB-
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Figure 32 Schematics of a hot casca
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the turbine static temperature (rot
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Figure 33 Experimental rig for inve
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their color when exposed to higher
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margins defined within each discipl
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them. The larger gas-path divergenc
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Figure 36 Blade-cooling selection d
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8. B. Barry, Turbine Blade Cooling:
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40. A. K. Tolpadi and M. E. Crawfor
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73. R. S. Abhari, ‘‘Comparison
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106. J. M. Owen and R. H. Rogers, F
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138. I. Egorov, G. Kretinin, I. Les
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integrity (stress levels) will have
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Figure 1 Instant entropy contours o
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Aerodynamic Interaction (Unsteady L
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Figure 3 Pitchwise time-averaged en
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The above considerations are all fo
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lades, the wavelength of the distur
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forcing and damping, and hence the
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frequency and its higher harmonics
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The two-cell pattern with a relativ
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Figure 9 Typical blade flutter boun
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field is generated to satisfy the t
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Figure 11 Instant static pressure c
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Figure 12 Calculated instantaneous
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Figure 14 Time-space static pressur
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one period Tp (neglecting change of
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It should be noted that the effects
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There are some further points to no
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Figure 17 Flow around an NACA-65 ai
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(11) for a simple case]: Where WA
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Regardless whether loosely coupled
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Several methods have been developed
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significant difference is introduce
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losses, but it may affect to a mini
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when we refine a mesh in an unstead
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8. W. S. Barankiewicz and M. D. Hat
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6 Fundamentals of Compressor Design
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Figure 3 AlliedSignal 331 turboprop
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each of the selected radii. The pro
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components of gas velocity upstream
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Observe that each of the curves for
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The conservation of angular momentu
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allowable static pressure ratio of
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Figure 7 Boundary layers and wakes
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component that is perpendicular to
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Figure 10 (a) Deflection of flow of
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increase in the downstream pressure
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Mach number at a compressor outlet
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Figure 12 Sketch of flow surface an
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useful shapes and orientations of b
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where G and oa are constant along a
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There is a good reason for this sit
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Projected Shape in Meridional Plane
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inherent flow range of the impeller
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compressors. Multistage centrifugal
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turbines. In these designs the high
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Corrections for Streamline Curvatur
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Preparation of Maps Once the losses
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that circumferential gradients meas
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Nastran, which was developed by NAS
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tests. One should take pains to pro
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e predicted in advance. Total press
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Cv Coefficient of heat at constant
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15. S. Lieblein, J. Basic Eng., Tra
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INTRODUCTION 7 Fundamentals of Turb
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Figure 1 Cross sections of generic
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espectively. Radial-inflow turbines
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Figure 4 Typical rotor blade shapes
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Figure 6 The expansion process acro
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the average for the gas flowing thr
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etween the velocity diagram and the
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gas dynamics relation p 00 p ¼ T 0
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Figure 9 Variations in turbine velo
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pressure, inlet losses are usually
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diffuser recovery, defined as Rp ¼
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different turbines easier, dimensio
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where and y ¼ T 0 in TSTD d ¼ p0
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sizing exercises where the details
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where Rth is the Reynolds number ba
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order to determine the overall turb
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The classical approach to satisfyin
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clearance. Since tip clearance repr
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turbine with an effective diffuser,
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atio ðp 0 in =pdisÞ is 3. The sta
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Automation of Calculations and Trad
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and for the rotor Zrotor ¼ ð0:1Þ
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the energy extracted and the rotor
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RADIAL-INFLOW TURBINE SIZING Differ
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interpolations from existing design
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Glassman [1], the optimum ratio of
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design fault in the radial-inflow t
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[27]. In order to avoid manufacturi
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The rotor exit critical velocity is
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The hub-to-tip radius ratio at the
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REFERENCES 1. A. J. Glassman (ed.),
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8 Steam Turbines Thomas H. McCloske
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Figure 3 Reciprocating steam engine
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This process began in the 1920s, al
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First Law of Thermodynamics The fir
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the amount of fuel burned and the p
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Figure 7 Rankine cycle temperature-
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The Mollier diagram is quite useful
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Figure 10 Theoretical Rankine cycle
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stages of the turbine is at a highe
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calculate the relevant thermodynami
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Figure 14 Steam leakage losses for
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can reveal nozzle and/or blade eros
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Figure 17 Enlarged portion of the M
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Traditionally, pressures have been
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Figure 21 Wetness thermodynamic los
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Figure 23 Radial steam turbine flow
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Figure 25 Percentage stage reaction
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The power output of the stage can b
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the LP turbines is split into paral
Page 475 and 476: Turbine Inlet Two stages in particu
Page 477 and 478: of 20%, which would cause excessive
Page 479 and 480: Figure 30 Typical low-pressure stea
Page 481 and 482: ductility and poor toughness, since
Page 483 and 484: ‘‘tramp’’ elements to minim
Page 485 and 486: End Seals End seals or packing glan
Page 487 and 488: Drains Condensate can form during s
Page 489 and 490: Figure 32 Steam turbine blade roots
Page 491 and 492: Figure 34 Cross-section view of thr
Page 493 and 494: Figure 36 Interblade shroud and Tie
Page 495 and 496: Where The influence of notch sensit
Page 497 and 498: Similarly, LP turbine blades are su
Page 499 and 500: those made of steel. Note, however,
Page 501 and 502: esult, significant attention must b
Page 503 and 504: Figure 38 Centrifugal stresses on a
Page 505 and 506: Figure 39 Centrifugal bending stres
Page 507 and 508: onto the rotating blade. These can
Page 509 and 510: Vortex shedding from blade trailing
Page 511 and 512: Figure 42 Torsional coupled vibrati
Page 513 and 514: Figure 44 Stall flutter of low-pres
Page 515 and 516: Start-Stop Transients/Overspeeds La
Page 517 and 518: (4) ellipiticity, such as caused by
Page 519 and 520: Figure 47 Campbell diagram (frequen
Page 521 and 522: Furthermore, in practice each manuf
Page 523 and 524: Figure 49 Modal diameters of a low-
Page 525: Figure 51 Three-dimensional computa
Page 529 and 530: value as the operating value of uv/
Page 531 and 532: Lubrication Supply System Design De
Page 533 and 534: Figure 56 Steam turbine oil system
Page 535 and 536: The main oil reservoir is located b
Page 537 and 538: Although a light oil does provide a
Page 539 and 540: temperatures are suspected as reaso
Page 541 and 542: There is no fixed or absolute value
Page 543 and 544: pivots incorporated in this bearing
Page 545 and 546: covers and doors. Pipe scale, rust,
Page 547 and 548: Figure 63 Mechanical hydraulic cont
Page 549 and 550: Figure 64 Steam turbine electro-hyd
Page 551 and 552: Figure 65 Steam turbine electro-hyd
Page 553 and 554: generator rotor moment of inertia h
Page 555 and 556: the turbine against overspeed. This
Page 557 and 558: an additional electronic overspeed
Page 559 and 560: Figure 68 Steam turbine protective
Page 561 and 562: 3. Need for better understanding of
Page 563 and 564: REFERENCES 1. J. C. Zink, ‘‘Ste
Page 565 and 566: No. TWDPS-1, The American Society o
Page 567 and 568: 58. A. V. Sarlashkar and T. C. T. L
Page 569 and 570: 81. IEEE Guide for Abnormal Frequen
Page 571 and 572: Atlanta, GA, Oct. 18-22, 1992, PWR-
Page 573 and 574: Performance Enhancement Program, he
Page 575 and 576: of the design process toward achiev
Page 577 and 578:
procedure capable of addressing mul
Page 579 and 580:
to achieve a specific target pressu
Page 581 and 582:
objective was to minimize the downs
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more closely represents the largest
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temperature by forming a thin film
Page 587 and 588:
such as the one described here. For
Page 589 and 590:
k is the thermal conductivity of th
Page 591 and 592:
through finite differences. Mathema
Page 593 and 594:
Figure 4 Comparison of blade cross-
Page 595 and 596:
integration of multiple disciplines
Page 597 and 598:
17. S. S. Talya, ‘‘Multidiscipl
Page 599 and 600:
INTRODUCTION 10 Rotordynamic Consid
Page 601 and 602:
Figure 1 (c) AlliedSignal 331 turbo
Page 603 and 604:
Figure 2 Rotor system displacements
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Figure 3 Elliptic lateral whirl. av
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vibration (either forward or backwa
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Figure 6 The Laval-Jeffcott rotor.
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are 1808 out of phase (i.e., the be
Page 613 and 614:
this graph is quite simple; however
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included on these types of graphs b
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on the shaft is zero. Thus, the ste
Page 619 and 620:
are uðtÞ ¼e zeott uo cos ott þ
Page 621 and 622:
satisfies the inequality O < ot 1
Page 623 and 624:
Figure 16 Laval-Jeffcott rotor tran
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Figure 18 Whirl speed map: Laval-Je
Page 627 and 628:
Figure 20 Laval-Jeffcott rotor: ste
Page 629 and 630:
Figure 22 Typical precessional mode
Page 631 and 632:
Figure 24 Examples of flexible disk
Page 633 and 634:
ackward modes, however, involve con
Page 635 and 636:
Figure 29 Steady unbalance response
Page 637 and 638:
assist in attenuating high vibratio
Page 639 and 640:
properly sizing the damper, a highl
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Figure 31 Gas turbine schematic and
Page 643 and 644:
Flexible Disk If the frequency of a
Page 645 and 646:
motion for each subsegment to form
Page 647 and 648:
Figure 35 Whirl speed map—straddl
Page 649 and 650:
Figure 37 Rotor-bearing-support str
Page 651 and 652:
DESIGN STRATEGIES AND PROCEDURES Ro
Page 653 and 654:
Figure 38 Straddle mounted rotor. (
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Figure 39 Unbalance response: strad
Page 657 and 658:
Figure 40 Double overhung rotor—d
Page 659 and 660:
earing supports are reduced. The th
Page 661 and 662:
and also increases the critical spe
Page 663 and 664:
Examples of structure modes couplin
Page 665 and 666:
REFERENCES 1. D. Childs, Turbomachi
Page 667 and 668:
section is intended to place today
Page 669 and 670:
pressure-fed propellant systems. Hi
Page 671 and 672:
normally be considered a very small
Page 673 and 674:
increase of required suction perfor
Page 675 and 676:
displaced by the F-1 oxidizer pump
Page 677 and 678:
exposure may be subjected to imping
Page 679 and 680:
the exhaust duct. Sized to create s
Page 681 and 682:
excess of 6,000 psi for consumption
Page 683 and 684:
lifetime. With very few exceptions,
Page 685 and 686:
using hydrocarbon fuel combustion p
Page 687 and 688:
can yield noticeable savings in req
Page 689 and 690:
Figure 3 Rocket engine system schem
Page 691 and 692:
Figure 6 Staged combustion system,
Page 693 and 694:
each stage. The term C0 represents
Page 695 and 696:
Figure 10 Some representative turbo
Page 697 and 698:
emembered that the second (and any
Page 699 and 700:
the greatest demands on turbopump p
Page 701 and 702:
momentum exchange between working f
Page 703 and 704:
Figure 13 Arrangement of various tu
Page 705 and 706:
pressure levels. As long as combust
Page 707 and 708:
Figure 14 Approxmate values of pump
Page 709 and 710:
liquid rocket engine systems, and e
Page 711 and 712:
above becomes a factor. This statem
Page 713 and 714:
We can then state (correctly) that,
Page 715 and 716:
Figure 15c Typical 2-D centrifugal
Page 717 and 718:
have seen that the flow rate throug
Page 719 and 720:
somewhat smaller magnitude of vecto
Page 721 and 722:
general indicator. Nss will give us
Page 723 and 724:
U ¼ rotor tangential velocity. By
Page 725 and 726:
and pump flow derived from the engi
Page 727 and 728:
In addition to shaft seals, shaft b
Page 729 and 730:
should be understood that the optim
Page 731 and 732:
stable operation is assured. In som
Page 733 and 734:
From Eq. (16) an impeller radial ou
Page 735 and 736:
Figure 18 Examples of centrifugal p
Page 737 and 738:
tional to clearance distance) with
Page 739 and 740:
I would like to conclude this secti
Page 741 and 742:
generally result in lower pump hydr
Page 743 and 744:
Figure 15h Cross-section of a typic
Page 745 and 746:
solutions of Eq. (7) for both stage
Page 747 and 748:
Figure 15k H-Q characteristics for
Page 749 and 750:
Figure 15l Typical inducer configur
Page 751 and 752:
camber) is proportionally lower. Th
Page 753 and 754:
Figure 22 Single-stage impulse turb
Page 755 and 756:
the velocity ratio K, but in somewh
Page 757 and 758:
~V and ~n ¼ fluid velocity and con
Page 759 and 760:
Fig. 25. The nature of the flow in
Page 761 and 762:
Although shrouded centrifugal impel
Page 763 and 764:
is a parasitic device, whose flow r
Page 765 and 766:
apidly than does the inducer thrust
Page 767 and 768:
Figure 30 LH2 turbopump rotor mecha
Page 769 and 770:
eplacement of a failed bearing with
Page 771 and 772:
shall see, contemporary rocket engi
Page 773 and 774:
needs of the aircraft gas turbine a
Page 775 and 776:
was increased due to engine upratin
Page 777 and 778:
12 Turbomachinery Performance Testi
Page 779 and 780:
istics. The more accurate the perfo
Page 781 and 782:
Inlet Distortion Most turbomachiner
Page 783 and 784:
Gas Thermodynamic Properties Turbom
Page 785 and 786:
ought to rest isentropically. Total
Page 787 and 788:
include not only the pressure chang
Page 789 and 790:
The circumferential placement of th
Page 791 and 792:
simply arithmetically averaging the
Page 793 and 794:
usually mounted in radial immersion
Page 795 and 796:
Figure 12(b) Radial flow angle prof
Page 797 and 798:
Figure 15 Wake rake total pressure
Page 799 and 800:
Figure 16 Blade-tip pressure traces
Page 801 and 802:
Figure 18 Typical test rig schemati
Page 803 and 804:
INSTRUMENTATION DESIGN CONSIDERATIO
Page 805 and 806:
Dynamic Pressure. Dynamic pressure
Page 807 and 808:
thermocouples. With care in constru
Page 809 and 810:
Figure 24 Typical two-dimensional f
Page 811 and 812:
Thermocouple lead wires should be i
Page 813 and 814:
Corrected Flow The flow rates used
Page 815 and 816:
pressure ratio [15]. It can be calc
Page 817 and 818:
SYMBOLS A Cross-section area Cd Dis
Page 819 and 820:
INTRODUCTION 13 Automotive Supercha
Page 821 and 822:
Figure 2 A Roots-type supercharger
Page 823 and 824:
The supercharger was in routine use
Page 825 and 826:
Table 1 Superchargers Versus Turboc
Page 827 and 828:
1960s, turbocharging was used by US
Page 829 and 830:
Roots Blower The Roots-type blower
Page 831 and 832:
speeds. The sound is caused by the
Page 833 and 834:
Figure 8b How the Ro-charger operat
Page 835 and 836:
The vanes in many designs are preve
Page 837 and 838:
Figure 11a Key components of the G-
Page 839 and 840:
Figure 11c G-Lader supercharger is
Page 841 and 842:
Figure 12b Schematic of centrifugal
Page 843 and 844:
Figure 14b Components of the typica
Page 845 and 846:
Turbine Design The turbine housing
Page 847 and 848:
inertia of the wheel assembly. Mini
Page 849 and 850:
Figure 18 (a) Turbocharger compress
Page 851 and 852:
Theoretically this efficiency is: o
Page 853 and 854:
The overall turbine efficiency incl
Page 855 and 856:
adjust the spring force to vary the
Page 857 and 858:
Figure 22b Two vanes are used to pr
Page 859 and 860:
However, the temperature has to be
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air can reduce carbon monoxide and
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Figure 25 (a) Schematic of the COMP
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this plus the fact that the exhaust
Page 867 and 868:
14 Tesla Turbomachinery Warren Rice
Page 869 and 870:
press at the time of the invention
Page 871 and 872:
can be made to simplify the equatio
Page 873 and 874:
comparison of the results of variou
Page 875 and 876:
y composing them of nested cones ra
Page 877 and 878:
26. E. Bakke, ‘‘Theoretical and
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61. M. Piesche, ‘‘Investigation
Page 881 and 882:
15 Hydraulic Turbines V. Dakshina M
Page 883 and 884:
Table 1 Variables of Interest in Tu
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Figure 1 Variation of impeller shap
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Figure 2 Flow and velocity componen
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Figure 3 Schematic diagram of Pelto
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shown in Fig. 5(see KadambiandPrasa
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classified according to the directi
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The manufacturers of hydraulic turb
Page 897 and 898:
The direction of the relative veloc
Page 899 and 900:
Table 3 Variation of Some Quantitie
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denoted by hd. Thus the efficiency
Page 903 and 904:
Figure 14 Draft tube setting. same
Page 905:
REFERENCES 1. J. J. Fritz, Small an
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Handbook of Turbomachinery Second Edition Revised - Ventech!

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