AND PERFORMRINCE OF A TIJO-STRGE EMENEEEEEE …
Transcript of AND PERFORMRINCE OF A TIJO-STRGE EMENEEEEEE …
AD-R14l 796 AERODYNRMIC DESIGN AND PERFORMRINCE OF A TIJO-STRGE 1/3
A XIAL-FLOW COMPRESSOR (..(IJ) IOWA STATE UNIV AMESENGINEERING RESEARCH INST M D HATHAWAY ET AL. DEC 83
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M. D. HATHAWAYT. H. OKIISHIDECEMBER 1983
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AERODYNAMIC DESIGN AND PERFORMANCEOF A TWO-STAGE, AXIAL-FLOWCOMPRESSOR (BASELINE)
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~Qualified requestors may obtain additional copies from the~Defense Documentation Center; all others should apply.. to the National Technical Information Service.
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ENGINEERINGRESEARCHENGINEERINGRESEARCHENGINEERINGRESEARCHENGINEERINGRESEARCHENGINEERINGRESEARCH
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TECHNICAL REPORT
AERODYNAMIC DESIGN AND PERFORMANCEOF A TWO-STAGE, AXIAL-FLOW
COMPRESSOR (BASELINE)N ~'rRFC~ ~r 1'C1 (KJS.C)
CI- * ov7 nd Mchael D. HathawayI).-12. Theodore H. Oklilhi
'~apprO~December 1983
u.ATTKSW J.K" raiu~vs~c.,TeGbfliOl Inf 0mt~ni~O
DEPARTMENT OF MECHANICAL ENGINEERINGISU-R-As-41 ENGINEERING RESEARCH INSTITUTEERI Projeocts 1394,1490, 1645 IOWA STATE UNIVERSITY, AMES
.1,7.
UnclassifiedSECURITY CL ASSIFICATION OF
THIS PAGL (1Wh.. flCI. t.v.rd)
REPORT DOCUMENTATION PAGE i0.-kI( ~COMNPLETINC. PORM
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i*. TITL Sat~bll)5 TYPE OF REPORT A PERIOD COVERED
Technical Report-Aerodynamic Design and Performance of aTwo-Stage, Axial-Flow Compressor (Baseline)1Ocoe 1980Nvmbr92
6. PERFORMING ORO. REPORT NUMBER
___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ ___ TCRL-247. A UT HO0R(m) S. CONTRACT OR GRANT NUMBER(a)
Michael D. Hathaway F92-3K02
Theodore H. Okiishi F92-3K02
9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT. PROJECT, TASKrurbomachinery Components Research Laboratory AREA A WORK UNIT NUMBERS
Engineering Research Institute/Department of (91IIOL FMechanical Engineering 307I Ac
Iowa State University, Ames, Iowa 50011 ~c?,i-1I. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE I
Air Force Office of Scientific Research December 1983Directorate of Aerospace Sciences (AFOSR/NA) 13 NUMBER OF PAGES
Boiling Air Force Base, Washington, D.C. 190 pages14. MONITORING AGENCY NAME &ADDRESS(iI different from, Controlling Office) 15. SECURITY CLASS. (of this report)
Unclassified15a. DECLASSIFICATION/DOWNGRADING
SCHEDULE
16. DISTRIBUTION STATEMENT (of this Report)
Approved for Public Release; Distribution Unlimited
17. DISTRIBUTION STATEMENT (of the abstract entered in Block 20, If different fromt Report)
I1. SUPPLEMENTARY NOTES
19. KEY WORDS (Continue on revess side It nece.ssary and Identify by block number)
aixial-flow turbomachineryaxial-flow compressor
V ~'multistage axial-flow compressor
20 ABSTRACT (Continue on reverse side If necessary and Identify by block number)
A two-stage, baseline configuration, low-speed, axial-flow research
co~mpressor was designed, built and tested at design flow. The design,
fabrication and data acquisition and reduction details are described.
Time-averaged, spatially detailed and overall flow and aerodynamic
* performance data for design flow operation of the compressor are presented
and discussed.
DD JA 7 1473 EDITION OF I NOV 6S IS OBSOLETE _______ HSPG
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Unclassified iv*lECURITy CLA. IFICATION OF THIS PAGE(Wihten Dera £FeAved)
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TABLE OF CONTENTS
Page* I
SYMBOLS AND NOTATION ix
LIST OF FIGURES xiii
LIST OF TABLES xvii-I
1. INTRODUCTION 1
2. RESEARCH COMPRESSOR FACILITY 3
2.1. Axial-Flow Research Compressor 3
2.1.1. Aerodynamic Design 3
2.1.2. Mechanical Design 9
2.1.3. Blade Fabrication and Installation 13
2.2. Probe and Stationary Blade Row Actuators 20
2.3. Pressure and Temperature Sensing Instrumentation 21
2.4. Computer Control System 22
2.5. Calibration Equipment 23
3. EXPERIMENTAL PROCEDURE AND DATA REDUCTION 27
3.1. Calibration 29
3.1.1. Cobra Probe Yaw-Angle Calibration in Free-
Stream Portion of Flow 31
" 3.1.2. Cobra Probe Calibration in Wake Portion of
Flow 31
3.1.3. Spanwise Calibration of the Cobra Probe 33
-. 3.1.4. Scanivalve Pressure Transducer Calibration 33 53.2. Data Aquisition 37
• 3.2.1. Overall Performance Map 37
3.2.2. Time-Averaged Measurements 39 .
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vi
3.3. Data Reduction 42
3.3.1. Flow-Field Parameters 43
3.3.2. Performance Parameters 45
4. PRESENTATION AND DISCUSSION OF DATA 47
4.1. Error Analysis 47
4.2. Overall Performance Map 51
4.3. Spatially Detailed Time-Averaged MeasurementResults 57
4.4. Comparisons of Circumferential-Mean Data with
Design Code Predictions 86
5. SUMMARY AND CONCLUSIONS 111
6. RECOMMENDATIONS FOR FURTHER RESEARCH 113
7. REFERENCES 115
8. ACKNOWLEDGEMENTS 117
9. APPENDIX A: CORRELATIONS USED IN NASA DESIGN CODE 119
9.1. Blade Loss 119
9.2. Incidence and Deviation Angle 121
10. APPENDIX B: NASA DESIGN CODE RESULTS 123
11. APPENDIX C: COMPUTER PROGRAMS AND DATA STORAGE 155
12. APPENDIX D: PARAMETER EQUATIONS 157
12.1. General Parameters 157
12.1.1. Basic Fluid Properties 157
12.1.2. Blade-Element Location 159
12.2. Flow-Field Parameters 159
12.2.1. Point and Circumferential-Average BladeElement Quantities 159
12.2.2. Global Parameters 163 %lei
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vii
12.2.3. Performance Parameters (based on cobra
probe measurements) 1646
12.2.4. Performance Parameters Used in GeneratingPerformance Map 166
13. APPENDIX E: TABULATION OF EXPERIMENTALLY DETERMINEDDATA 169
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SYMBOLS AND NOTATION
2A compressor flow passage annulus area, m
c blade chord length, m
FCC comparison of integrated and venturi flow coefficients 0(Eq. 12.34), percent
g local acceleration of gravity, m/s2
2Sc gravitational constant, 1.0 kgm/Ns
H total head with respect to barometric pressure (Eq. 12.5or 12.48), Nm/kg
h static head with respect to barometric pressure, Nm/kg
h barometric pressure, m of Hg* hg
h annulus outer-surface end-wall static head with respect toww4 barometric pressure (Eq. 12.9 or 12.10), Nm/kg
i incidence angle (Fig. 12.1; Eqs. 12.25 or 12.27), deg
P barometric pressure (Eq. 12.1), N/m2atm
P t total pressure with respect to barometric pressure, m ofwater
P annulus outer-surface static wall pressure with respect to 'w barometric pressure, m of water
PHH percent passage height from hub (Eq. 12.4), percent
Qa integrated volume flow 5ate at probe-traversing measurementstations (Eq. 12.32), m /s
V 3Q venturi volume flow rate (Eq. 12.30), m Is
V
R gas constant, Nm/kg*K
r radius from compressor axis, m
RPM rotor rotational speed, rpm
S circumferential space between blades, blade pitch,m or deg
T compressor drive motor torque, Nm
-. .-
p.,-
4 .,
t temperature, *K
tbaro barometer ambient temperature, OK
t blade section maximum thickness, mmax
U rotor blade velocity (Eq. 12.14), m/s
V absolute velocity (Fig. 12.1; Eq. 12.12 or 12.13), m/s
""VI relative velocity (Eqs. 12.21 or 12.22), m/s
V tangential component of absolute fluid velocity (Fig. 12.1;Eqs. 12.17 or 12.18), m/s
Vt tangential component of relative fluid velocity (Eqs. 12.19or 12.20), m/s
V axial component of fluid velocity (Fig. 12.1; Eqs. 12.15 or12.16 and 12.47), m/s
Y circumferential traversing position, deg
absolute flow angle with respect to axial directiony (Fig. 12.1; Eqs. 12.7 or 12.8), deg
relative flow angle with respect to axial directiony .(Eqs. 12.23 or 12.24), deg
.20 specific weight of water manometer fluid (Eq. 12.3), N/m
2 3YHg specific weight of mercury, N/m
Pvent differential pressure across venturi, m of water
6 deviation angle (Fig. 12.1; Eqs. 12.26 or 12.28), deg
lrl hydraulic efficiency (Eqs. 12.42, 12.43, and 12.44)
K blade angle, angle between tangent to blade camber line andaxial direction (Fig. 12.1), deg
p density of air (Eq. 12.2), kg/m3
a blade row solidity
. flow coefficient (Eq. 12.29)
integrated flow coefficient at probe-traversing measurementa stations (Eq. 12.33)
v venturi flow coefficient (eq. 12.31)
- . .
%,. 5(' ' .' . .' ' " . ",- . . . . - . . - . . . . . . • .. . . . , , . . . . - , . .
xi
1P head-rise coefficient (Eqs. 12.36 through 12.41 and 12.49,12.50)
W total-head losss coefficient (Eqs. 12.45 and 12.46)
Additional General Subscripts
h annulus inner surface, hub
i ideal
me mechanical
overall overall compressor
pm torque meter based performance parameters
R rotor
. S stator
stage stage
t annulus outer surface, tip
1 blade-row inlet
2 blade-row outlet
'-4 IR first rotor
2R second rotor
iS first stator
2S second stator
Superscripts
relative to rotor
- average; blade-to-blade circumferential average value O
l mass-averaged in the radial direction
cross-section average
.F %
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'
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LIST OF FIGURES0
Page
Figure 2.1 Schematic of baseline compressor showingoriginal and redesigned components. 4
Figure 2.2 Representative rotor blade sections at threespanwise locations. 6
Figure 2.3 Representative stator blade sections at threespanwise locations. 7
Figure 2.4 Meridional-plane view of redesigned section ofbaseline compressor with each ring assemblyidentified. 10
Figure 2.5 Schematic diagram showing axial location ofprobe measurement stations relative to adjacentblade rows (dimensions in mm). 12
Figure 2.6 Radial and circumferential interlock design ofouter ring assembly. 14
Figure 2.7 Probe access hole configuration. 15
Figure 2.8 Schematic of blade fabrication showinglaminates sandwiching trunnion spline. 17
Figure 2.9 Representative eyelash drawing. 18
Figure 2.10 Schematic diagram of data acquisition system. 24
Figure 3.1 Baseline compressor overall performance curveand operating point. 28
Figure 3.2 Logic diagram of data acquisition system. 30
Figure 3.3 Cobra probe yaw-angle total-head calibrationcurve in free stream portion of flow for flowcoefficient = 0.587 at 2400 rpm. 32
Figure 3.4 Cobra probe total-head calibration curve in wake
portion of flow for flow coefficient = 0.587at 2400 rpm. 34
Figure 3.5 Cobra and Kiel probe comparison behind first rotorand first stator for flow coefficient = 0.587at 2400 rpm (Y/SS 0.0). 35
xiv
Figure 3.6 Blade cascade showing circumferentialmeasurement window. 41
Figure 4.1 Predicted and measured overall performance data. 52
Figure 4.2 Blade-to-blade distribution of time-averagedtotal head for flow behind the first and secondstage rotors (# = 0.587 at 2400 rpm). 58
Figure 4.3 Blade-to-blade distribution of time-averagedtotal head for flow behind the first and secondstage stators (# = 0.587 at 2400 rpm). 61
Figure 4.4 Spanwise distribution of circumferential-meandata for flow behind the first and second stagerotors (# = 0.587 at 2400 rpm). 67
- Figure 4.5 Spanwise distribution of circumferential-mean
data for flow behind the first and second stagestators (# = 0.587 at 2400 rpm). 70
Figure 4.6 Contour map of the distribution of total headbehind each blade row (0 = 0.587 at 2400 rpm).Data enhancement employed. 74
Figure 4.7 Locations of actual data points used inconstructing the contour map behind the firststator. 78
Figure 4.8 Contour map of the distribution of total headbehind the first stator (0 0.587 at 2400 rpm).No data enhancement. 79
Figure 4.9 Comparisons of measured circumferential-meanincidence and deviation angles for both stages( = 0.587 at 2400 rpm). 83
Figure 4.10 Comparisons of measured and predicted velocitytriangles behind the first rotor (0 = 0.587 at2400 rpm). 87
Figure 4.11 Comparisons of measured and predicted velocitytriangles ahead of the second rotor (0 = 0.587at 2400 rpm). 88
Figure 4.12 Comparisons of measured and predicted velocitytriangles behind the second rotor (0 = 0.587 at2400 rpm). 89
Figure 4.13 Comparisons of the measured and predictedspanwise distributions of circumferential-meanaxial velocity (4 0.587 at 2400 rpm). 91
.p.4,. . . .%,," .,,. -..
xv
Figure 4.14 Comparisons of the measured and predictedspanwise distributions of circumferential-meandata for the first and second stage rotors
= 0.587 at 2400 rpm). 94
Figure 4.15 Comparisons of the measured and predictedspanwise distributions of circumferential-meandata for the first and second stage stators
= 0.587 at 2400 rpm). 97
Figure 4.16 Spanwise distributions of design code rotorblade angles. 101
Figure 4.17 Spanwise distributions of design code statorblade angles. 104
Figure 4.18 Comparisons of measured and predicted spanwisedistributions of blade loss for each blade row
= 0.587 at 2400 rpm). 105
Figure 9.1 Blade loss correlation curves used in NASAdesign code. 120
Figure 10.1 Typical rotor and stator blade sections usingmanufacturing coordinates. 154
Figure 12.1 Sketch showing nomenclature and sign conventions(all positive except as noted) for slow-responseinstrument parameters. 158
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xvii
LIST OF TABLES
Page
Table 4.1 Uncertainty estimates of measurement parameters. 48
Table 4.2 Flow coefficient comparison between venturi andintegrated measurement station flow coefficients. 51
-. - Table 4.3 Rotor, stator, stage, and overall performance
parameters. 85
Table 10.1 Design code input parameters. 124
Table 10.2 Design code predictions of aerodynamic parameters. 132
Table 10.3 Design code stage and overall performancepredictions. 143
Table 10.4 Rotor blade manufacturing coordinates generatedby NASA design code. 144
Table 10.5 Stator blade manufacturing coordinates generatedby NASA design code. 149
- Table 13.1 Point-by-point distributions of circumferentialsurvey data. 171
Table 13.2 Circumferentially-averaged flow-field parameters. 190
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1. INTRODUCTION
A significant portion of the inefficiency of axial-flow turbo-
machines is associated with viscous and turbulent flow phenomena in
the boundary layers which develop on blade surfaces and on annulus hub
and casing walls. For example, large secondary flow losses can
accompany the complex, three-dimensional flow patterns of annulus-wall
boundary layers passing through blade rows. This behavior affects
both local work transfer and the management of the flow in subsequent
blade rows. It can be appreciated, therefore, why there has been
considerable interest in the possibility of reducing axial-flow turbo-
machine stationary-blade-row secondary and end-wall flow losses by
incorporation of unusual blade configurations (e.g., Mitchell and
Soileau [I; Wisler [2]; Senoo, Taylor, Batra, and Hink [31).
In order to initiate a local program of research to provide a
_. clearer understanding of the potential for better controlling the
secondary and end-wall flows in axial-flow turbomachines, a suitable
baseline research compressor was required. The existing three-stage,
axial-flow compressor [4] of the Iowa State University Turbomachinery
Components Research Laboratory was evaluated for possible service in 9
this capacity. It was decided that the best course of action would
involve the design and fabrication of new blades which would be more
representative of conventional compressors. However, much of the
rest of the existing compressor rig such as drive system, inlet flow
. path, and flow-rate control and measurement duct could be used with
the new blades to form the baseline compressor. The design of the new O
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baseline blades was accomplished with the aid of a NASA computer code
[51 and included the following considerations:
1. Higher blade-chord Reynolds numbers than were previously
attainable with the three-stage compressor blading.
2. A better blade material which would be more durable than
that already available.
3. Conventional blade-section shapes.
4. A favorable ratio of number of rotor blades to number of
stator blades.
5. Elimination of inlet guide vanes.
In order to use as much of the existing compressor rig as possible
while also achieving a significantly higher blade-chord Reynolds number,
a two-stage configuration without inlet guide vanes was selected.
Fiberglass blades were fabricated and fitted into specially made flow-
path rings to form the baseline compressor.
This report is intended to document in detail important aspects
of the design, fabrication, and aerodynamic testing of the baseline
compressor configuration. Subsequent reports will deal with specific
stator blade modifications for possibly improved control of end-wall
and secondary flows as well as related tests and comparisons of data.
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2. RESEARCH COMPRESSOR FACILITY
The axial-flow research compressor and data acquisition system of
the Iowa State University Engineering Research Institute/Mechanical
Engineering Department Turbomachinery Components Research Laboratory
were used to accomplish the research described in this report. The
compressor, instrumentation, data acquisition system, and calibration
equipment are described in this section.
2.1. Axial-Flow Research Compressor
Aerodynamic considerations mentioned earlier led to the design
of a new two-stage, baseline, axial-flow research compressor configur-
ation. An existing three-stage axial-flow compressor [4] was modifiediP
to form the baseline compressor. Much of the existing compressor such
.- as the drive system, inlet flow-path, and flow-rate control and
measurement duct were incorporated into the current system. A schematic
of the baseline compressor rig which indicates the extent of the re-
designed section is shown in Figure 2.1.
2.1.1. Aerodynamic Design
Aerodynamic design of the two-stage baseline compressor was
accomplished with the aid of an axial-flow compressor design code [5]
developed at NASA Lewis Research Center. The aerodynamic portion of
the code assumes steady, axisymmetric flow and uses a streamline
curvature method for the iterative solution--between blade rows--of
the property, continuity, and momentum equations with empirical
subsonic flow viscous loss correlations provided by the user (see
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Appendix A). Coupled with the aerodynamic solution iterations, is a
blade design procedure which constructs blade elements on specified
conical surfaces and then stacks them on a user defined axis (see
Reference [51). These blade elements are positioned in the flow with
incidence and deviation angle correlations selected by the user (see
Appendix A). After aerodynamic and blade design solution convergence
has been achieved, blade fabrication information consisting of coor-
dinates for several blade sections--formed by the intersection of
planes perpendicular to the radial direction and the blade at differ-
ent radii--are provided by the code. Blade sections between elements
are obtained by interpolation. Examples of such blade sections at
three spanwise locations are shown in Figure 2.2, for the baseline
rotor blade, and Figure 2.3, for the baseline stator blade.
. The baseline compressor was designed to have high reaction stages
typical of transonic compressor configurations. Further, a uniform
spanwise distribution of total pressure was prescribed for each rotor
exit. The stators were designed to discharge fluid axially and inlet
guide vanes were not used.
J. ~The coordinates of the annular flow path for the existing4S
compressor were retained in the baseline compressor to allow use of the
existing inlet and exit flow sections. A rotor speed of 2400 rpm was
selected as it was considered to be the maximum safe level obtainable
with the existing equipment. A mass flow-rate of 5.25 lb/s (2.29 Kg/s)
was established from preliminary design trials with a simple radial
equilibrium based computer code [61 developed by Detroit Diesel Allison
for NASA. An overall compressor pressure ratio of 1.0125 was obtained
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. -.. . - .. . " •--." •" "•". .. ". . "-". .°".". "- -". .""" . " .''""-..'''.V .'''-. " - "',-* '.-.-.-"" . .-S-- . . " -
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-0.80 -0.40 0.0O0 0. 40 0.80in.
L I I I-2.0O0 -1.0O0 0.00 1.00 2.0
AXIAL DISTANCE, cm
Figure 2.2 Representative rotor blade sections at three spanwiselocations.
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with the codes--with the rotor tip diffusion factor limit specification
of 0.4 being the only aerodynamic limit reached during the design I-".
process. Circular arc blade-elements were selected as they were con-
sidered suitable for the low Mach number service involved. For the
baseline configuration, blade chord and leading and trailing edge radii O
were held constant across the span. The blade maximum thickness to
chord ratio was varied linearly from 0.1 at the blade root to 0.06 at
the other extremity. In order to maximize the blade chord Reynolds
-[. number, the rotor chord length was made as large as possible while
- .[ still allowing two stages to fit within the predetermined flow path.
The selected rotor chord length, 2.39 in (6.07 cm), coupled with a
reasonable value of rotor tip solidity (1.0) yielded 21 rotor blades.
At design point, the blade chord Reynolds number was on the order of
51.8 X 10 . To achieve a reasonable ratio of number of rotor blades to
number of stator blades, the acoustics-related guidelines of Reference
[71 were used which set the number of stator blades at 30. A stator
chord length equal in value to the rotor chord length resulted in a
reasonable stator solidity (1.4 at the tip) and was thus adopted. The
aspect ratio of each blade row was 1.0. A radial stacking axis through
the center of gravity of each blade element was considered appropriate 6
'S for the baseline rotor and stator blades. Additional blade parameters .
.and blade fabrication coordinates are given in Appendix B. Annulus-wall
blockage factors (see Appendix B) were estimated, keeping in mind that
specifying smaller than anticipated blockage is conservative. If
blockage is higher than specified, the flow in the mid-span region will
S be accelerated and loading will be relieved. On the other hand, if
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blockage is less than specified, the flow in the mid-span region willlId. tend to be accelerated less and loading will increase. Tabulated
velocity diagram output from the NASA aerodynamic design code are
provided in Appendix B.
2.1.2. Mechanical Design
Except for the blades, all machining and fabrication of the base-
line compressor was performed in the Iowa State University Engineering
Research Institute Machine Shop. The geometry of the baseline compres-
sor as well as improvements in the original compressor mechanical
design are described in this section.
A meridional-plane view of the redesigned portion of the compressor
rig is shown in Figure 2.4. The basic components of the baseline com-
pressor consist of eleven independent rings which facilitate disassembly
and reassembly of the compressor flow-path. The five inner rings
4;-' (M201 to MH203) which make up the hub flow path are mounted on the
original rotor drum and are held in place by friction. Four indepen-
dent circumferentially and radially interlocking rings (MHil01 to MH104)
-make up the outer casing of the baseline compressor. The two stator
blade row supporting rings (MH105) are mounted in circular tracks in
the outer casing, formed by rings (M]1101 to MH104), to permit independ-
ent circumferential positioning of each stator blade row about the com-
pressor axis of rotation. The stator blade rows can, thus, be moved
circumferentially during tests by means of a circumferential motion
k' actuator which is mechanically linked to each stator blade row mounting
ring (M1l05) through slots provided in the outer casing rings. Cylin-
drical trunnion holes were used in each stator and rotor support ring
..
. --. .
.- e ." s ' %. . , , . , '. , . . . ." ' -'- - .. ". . . ". ". ". S S , - -. .. - - - .
10
ULLI>-
-- 4
cnn
-4 -
00
0r-4
rmI-
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Cd0cli C:0u 4i1
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(MI05, MH201) to facilitate blade attachment and to simplify readjust-
ment of blade setting angles. For the present study, both rotor blade
row rings (MH201) were positioned circumferentially during assembly
so that the blade stacking axes for each rotor row were in line axially.
Since no discernible difference in compressor aerodynamic noise level
was noticed for different relative circumferential positions of the
stator rows with respect to each other it was decided that, for this
study, the stator blade rows would also be aligned so that their
stacking axes were in line axially. Probe traversing stations were
arranged in line axially and positioned upstream of the first rotor
V blade row, downstream of the second stator blade row, and between all
other blade rows. The axial location of each probe measurement station
.. relative to adjacent blade rows is shown in Figure 2.5. Static pressure-
tap holes, spaced 90 degrees apart circumferentially, were also provided
at each probe hole axial location.
Several improvements to the original compressor were achieved
during the redesign effort and are described herein. Binding and
sticking during circumferential rotation of the stator rows was
avoided in the baseline compressor with the aid of teflon pads. The
teflon pads were placed around the full circumferential extent of
both vertical edges of each stator blade row supporting ring (MH105).
Ten equally spaced teflon pads were also attached to the outer cylin-
drical surface of each stator blade row supporting ring. The teflon
pads eliminated metal-to-metal contact on all sliding surfaces which
-at.' ,resulted in smooth operation of the stator blade row support rings
during circumferential positioning. Some of the binding problems
. . ... e
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experienced in an earlier build were attributed to poor radial and
ilcircumferential positioning of the outer annulus rings. This problem
was eliminated by matching the outer annulus rings so that each ring
interlocked both radially and circumferentially with adjacent rings
(see Figure 2.6). Reference marks were provided at each coupling
point to insure proper circumferential positioning of both stator and
rotor blade rows.
Anticipated tests of blade-fillet geometry effects on stator
performance required that at least one of the stator blade rows be
provided with a stationary flow path at the stator tip. Since the
rotor drum surface is the annulus hub, it was necessary to extend an
aluminum skirt upstream from the outlet duct hub contour in order to
provide a stationary hub surface for the second stage stator. Both
*.. the rotor drum and outlet duct hub contour were provided with a
circumferential recess to allow for adequate running clearance between
the rotor drum and the aluminum skirt, and to insure sufficient con-
tinuity of the hub contour. The circumferential recess in the down-
stream rotor ring (MH203) is shown in Figure 2.4.
The probe access holes were designed to facilitate mounting and
dismounting of the probe actuator assembly. A keyway configuration
(see Figure 2.7) was chosen since it provided minimal intrusion into
the flow path and yet permitted insertion of all anticipated probe
configurations.
2.1.3. Blade Fabrication and Installation
Fabrication of the blades for the baseline compressor was per-
formed at Dayton Scale Model Company, Dayton, Ohio. Several materials
°~. -. .° . ° o o ° o o ° . °°..... .- .. .. o . . ,% .° . - -. - -.- -.- - . ° -• - - ,- - - . °
14
MH101MH10
MH101MH10
Figure~~~_ 2. ailadcrufrnilitrokdsg fotrrn
assemb y. '7
15
(0. 1875 in)
(0120 n
SIZ
10 TIMES SIZE
Figure 2.7. Probe access hole configuration.
16
such as aluminum, plastic, and fiberglass were considered for possible
use in the construction of the blades. Molded blades constructed with
a fiberglass reinforced epoxy resin material were selected as being
most appropriate for this application.
Rotor and stator blade section coordinates at eleven different
radii (see Appendix B) were generated from the design code for use in
construction of a master rotor blade and master stator blade. These
coordinates were also used to produce ten times size drawings of each
blade section, on mylar, for use in checking the shape of the master
and actual blades. The master blades, constructed of aluminum, were
used to manufacture molds for both the rotor and stator blades. The
fiberglass reinforced epoxy resin material, in sheet form, was cut to
the general shape of the blade and stacked in layers in the mold
bottom, sandwiching a spine which protruded from the trunnion base for
the blades (see Figure 2.8). Each fiberglass layer was stacked so that
the glass fibers of adjacent layers were perpendicular. The mold top
was then put in place and the entire mold assembly was placed in a
press which slowly applied pressure while also heating the fiberglass
to an appropriate temperature to insure complete filling of the mold
and bonding of the fiberglass laminates. Upon cooling, each blade was
removed from the mold and the leading and trailing edge radii were
checked under a microscope and dressed if necessary. Ten times size
"eyelash" profiles (see Figure 2.9) of each blade section, correspond-
ing to the blade sections of the mylar drawings, were produced at each
,. step of the manufacturing process. These eyelash drawings of the
master blades and a few representative finished blades were compared
% .. . . .
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19
to the mylar drawings to insure precision control. The maximum devia-
tion from the mylar drawings was less than 0.005 inches (0.127 mm)
along the entire blade surface. The trunnion base for the blades was
a machined cylindrical plug with an extended flat spine on one end to
which the fiberglass blades could be formed around, and a threaded
stud on the other end for attachment to the blade mounting ring (see
Figure 2.8). This simple trunnion design allowed for easy adjustment
of blade setting angles and facilitated blade attachment to the
mounting rings. The length of the trunnion base was made slightly
less than the depth of the corresponding holes in the blade mounting
rings to prevent any intrusion into the flow. After all stator and
J% rotor blades were attached to their respective blade mounting rings,
specially made gauges were used to insure correct adjustment of blade
setting angles. The blade setting angles were checked at the blade
root and mid-span and found to be within 0.25 degrees of the design
setting angles for all blades. The stator blade mounting rings and
the rotor drum assembly, with rotor blade mounting rings installed,
were placed on a lathe and a high speed grinding tool was used to
grind the blade tips to an appropriate radius. The grinding insured
that the blades would conform to the curvature of the end-walls with a
mean clearance of 0.034 inches (0.864 mm) (1.4% span) for each blade
row. Silicon rubber glue was then used to fill in the gap between the
rotor root section and rotor hub in order to provide a smooth transi-
tion between the blade and the rotor drum surface. A caulking com-
pound, Mortite (Mortell Company, Kankakee, Illinois), was used to seal
the gap between the stator blade root and stator blade mounting ring.
(-°
.. .
-. . , .
:7 • -17 7 7 . -V. " "7
20
No attempt was made to provide a particular fillet radius, however,
the fillet was made as small as was practical. The entire rotor drum
% ,assembly was dynamically balanced for smooth operation up to 3600 rpm.
2.2. Probe and Stationary Blade Row Actuators
A circumferential motion actuator [41 was used to control circum-
ferential positioning of the stator blade rows during testing. The
actuator was connected to each stator blade row mounting ring through
- .:*an adjustable hand-screw link. Each blade row mounting ring could
then be moved independently or simultaneously. The circumferential
. .- position of each stator blade row was determined from calibrated scales,
marked in degrees, which were attached to the outer casing. The scales
were marked such that positive circumferential angles were in the
direction of rotor rotation. The zero degree circumferential position
was set with the aid of reference scribe marks on the stator blade
mounting rings and outer annulus rings such that the probe was posi-
tioned circumferentially in the flow midway between two stator stacking
axes. The circumferential positions of the actuator were determined by
monitoring the voltage from a linear potentiometer. The potentiometer
was calibrated to indicate the circumferential position of the
actuator through a linear least-squares fit. The circumferential
position of each stator blade row was ascertained by recording the
circumferential position of the actuator in degrees as determined from
.% of each blade row when the circumferential position of the actuator was
. .......
,~~~~~~~~~~~~~~~~~~.',.,..,-,-.-...... . .-..- -...--....... ...................... -........ ,..... .,....;; :,; .,, : .. '. '. '. '- -.--' - " " '. '. .-' . ..." " . .- .- . - . .*- . . . .. . .' .. . .. .
21
at zero. The actuator system could be used to determine the circum-
ferential position of the stator blade rows to within ±0.05 degrees
(Y/S5 = 0.004).
A probe actuator (L. C. Smith Company model BBS-3180) was used for
probe yaw-angle and immersion positioning. Mechanical digital counters
as well as linear potentiometers were used to determine the probe yaw-
angle and immersion positions which were calibrated to indicate the
extent of their respective motions using a linear least-squares fit.
The probe actuator could be used to set the probe yaw-angle and immer-
sion to within ±0.05 degrees and ±0.1 mm, respectively. A probe
actuator control indicator (L. C. Smith Company model DI-3R) and probe
actuator switchbox (L. C. Smith Company model DI-3R-SB4) were used to '-.
control the probe actuator.
2.3. Pressure and Temperature Sensing Instrumentation
A scanivalve pressure-port selector actuator system (Scanivalve M
Company model 48D3-1) including a strain-gauge pressure transducer
(Scanivalve Company model PDCR22), a signal conditioner (Endevco model
4470), and an amplified bridge circuit conditioner (Endevco model
4476.2A) were used to obtain all quantitative pressure measurements.
4' A scanivalve actuator control box (Scanivalve Company model CTLR2/S2-S6)
6 was used to control and monitor selection of up to 48 separate pressure
ports. Transducer voltage was correlated with pressures from four
separate reference columns using a linear least-squares fit. A pre-
* cision micromanometer (Meriam model 34FB2) was used as a standard for -
,../ , ... . , .,. .,.., , # .,, . , :::,: .. :. .... . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .y.. . . . . ...... . .'.. . . . ..' .-
~ *%*A * 4. AX * . ..A ~ ~ .. %
, . .. , .•.*, . F, - , .S. . . - - - - , So .
22
calibration of all pressure measurements. All pressure probes, static
pressure taps, etc., were connected to the pressure-port scanivalve. A
cobra probe (United Sensor type CA-120-24-F-18-CD)--capable of measur-
ing flow angle and total pressure--was considered to be most suitable
for use in the baseline compressor and was relied on for all slow-
response (time-averaged) measurement tests. A Kiel probe (United
Sensor type KBC-24-L-22-W) was used as a standard of calibration for
all total-pressure measurements. A depth micrometer was used to insure
correct radial positioning of the probe in the actuator. The probe
yaw-angle was set by placing the probe actuator assembly in a uniform
nozzle flow and insuring that the side-port pressures balanced when
the actuator yaw-angle counter read zero. Annulus-wall static-pressure
taps were provided at all probe axial measurement locations. Static-
pressure taps were also located at the inlet and throat of the venturi.
Copper-constantan thermocouples were used to measure room air tempera-
ture, compressor inlet temperature, and venturi throat temperature.
Precision mercury-in-glass thermometers were used to calibrate all
thermocouples. A mercury-in-glass barometer (Princo Instruments, Inc.V.
model B-222) was used to measure atmospheric pressure.
2.4. Computer Control System
A desk top computer (Commodore PET model 2001-32) and digital
voltmeter (Hewlett Packard model 3455A) were used in conjunction with
a multiple channel voltage scanner (Hewlett Packard model 3495A) to
provide automatic control of the data acquisition process. A schematic:"a
V...
,-
.'.
,,,,. "..,,. -.--.
23I. -1
of the data acquisition system is shown in Figure 2.10. The computer
controlled data acquisition system was used to control probe and
circumferential motion actuators, to control the scanivalve pressure-
port selection actuator, and to allow automatic reading of individual
thermocouple voltages and all pressures. The data acquisition system
also allowed for on-line calibration of the pressure transducer used -
for all pressure measurements. A tape cassette and printer were inter-
faced with the computer to record on tape and paper all pertinent data.
The computer was also interfaced with a central disk-storage unit (UNIX)where all pertinent data and computer programs were also stored.
Because of limited printing and plotting capabilities of the desk top
computer, the Iowa State University Computation Center computing system
-' (National Semiconductor AS6) was utilized for data reduction, tabula-
tion, and plotting.
2.5. Calibration Equipment
An air nozzle, described in detail in Reference [4], provided a
uniform nozzle exit velocity suitable for checking probe yaw-angle and
total-pressure calibrations. A pressure reference system [8] was used
to enable on-line calibration of the scanivalve pressure transducer
used for all quantitative pressure measurements. The pressure reference
system consisted of four columns of water, balance scales, and glass P
tubes inserted to an arbitrary depth in each column. The glass tubes
were connected with tygon tubing to the scanning valve. The pressures,
in volts, from each column were read individually and correlated, using P
.... .. .44.4*,,.,* 4 .. . . .. ,,
.4o .. .. . . . • - .*4 o.. . - ..S [ [ ,.-i " " "" " - . . " ' " - •. . - - • . -. -- - - .,
24
PRESSURE
I TO BE READ
SYSTEM
PCONTTOLLER
FMPLTFER
POSITIONER J
COILTTE
TE14PERATURES ATNE SSTM
Fiur 2.1 BcE diagra ofLAG daaCcqANtonsstE.R
CIRCL04RENTIA
MOTION
25
a linear least-squares fit, with the true column pressures. A pre-
cision micromanometer was used in conjunction with the balance scales
to calibrate, using a linear least-squares fit, the pressure of each
column with its corresponding weight. Correlation coefficients of
0.99999 or better could be achieved consistently.
% I
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-4'j:':-
- U . . .. . . . . . . . . . . . . U - L - -
27
3. EXPERIMENTAL PROCEDURE AND DATA REDUCTIONmpU.-.
.- - The objective of the experimental procedure included: 1) gener-
ating an accurate overall performance map in order to establish the
operating characteristics of the baseline compressor over a large
operating range, and 2) obtaining spatially detailed time-averaged
measurements of total pressure and flow angle between adjacent blade
rows, at one flow rate (design condition), in order to determine
pertinent velocity triangle information for comparison with the values
associated with the compressor design code.
The time-averaged measurements were obtained at several span
locations between blade rows, using appropriate probes, with the
,''U. compressor operating at the same design point used in the compressor
design code; i.e. 2400 rpm, with a flow coefficient of 0.587 as shown
*. - in Figure 3.1. The rotor speed was maintained to within ±1 rpm. The
.... flow coefficient was calculated from equilibrium venturi flow meter
data and ambient conditions. Adjustments of the flow to maintain the
reference flow coefficient value were made by moving the throttle plate
at the exit of the diffuser section. Using this procedure, it was
possible to maintain the flow coefficient to within ±0.0005 of the
reference value.
A data acquisition program was written for the PET computer to
control the step-by-step procedures of the experimental tests. Data
were either entered into the computer by the operator or read by the
computer through an interface from the digital voltmeter. The data
acquisition program consisted of seven major parts as shown in the
i - . ,- .- ,.-,.,-,,.-.,, .,.~~~~~....,....:....,....../...-....,.... ........- ,,.........-,........._..........,.....,......,......,-......,.....
-W -. S
28
0.5-
> 0.4/
zS
0.3-
U
0.10.3
0.
0. 0. 0.2 0. 240.RP
VENUR FLO OPRTNCOFITNT.J..
Fi.31Bsln0opesr vrl efrac uv
an peain oit
0.17
.-. ... ,-
9029
logic diagram of Figure 3.2. These parts were:
1. Set flow coefficient and measure test conditions.
2. Input probe survey position parameters.
3. Position probe radially and in your plane. ""
4. Determine circumferential survey parameters with oscilloscope
wake trace.
5. Yaw-null cobra probe in free-stream portion of flow.
6. Measure cobra probe pressures and shroud end-wall static
pressures.
7. Print out data and store data on magnetic disk.'0
In addition, data reduction programs were written for the mainframe
computer (National Semiconducter AS6) to accept data and preliminary
results recorded on disk, and to perform the calculations required to
obtain final results. All data and computer programs stored on tape
(cassette or reel) are listed in Appendix C.
3.1. Calibration
A micromanometer and a mercury-in-glass thermometer were used
respectively as standards for pressure and temperature calibration.
Calibrations of all electronic components used in this experimental
investigation were performed at the Iowa State University Engineering
Research Institute Electronic Shop. Before each test, approximately
one hour of running time was allowed for the electronic instiimeutation
to warm up and for the laboratory and compressor fluid temperatures to
reach equilibrium values.
14 7
30
Ln
w -
---- a.1 = -
V) V) 3c Lnioi<WmwLi.
Lu w i Ln/ l
- DW ; L )a:<L
=-) j - (0
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a'.LL 0a'Q -aLL i
co~CD M V)
= aJ.ce LJ V) CL == LL
9.LL L-C
'a,.) W LA .i LjC
ae= 'a= cF = - : 4=D LJ =D m W LLJ 3 < U g .
7 9 c co ) v) :D I cn :) V--a o (D V) V) LU LnCL C d.1< 0 i -j LJ cc L- L&
< = Li LLJix 4-
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2c C) 3
31
All time-averaged measurements of total pressure and flow yaw- jangle were obtained using the cobra probe. Extensive total-pressure
and yaw-angle measurement calibrations with the cobra probe in a uni-
form nozzle exit flow have already been documented in Reference [4].
This section will, therefore, deal only with verifying cobra probe
measurements in the compressor. Kiel probe data were used to validate
the cobra probe measurements. The Kiel probe provides accurate total-
pressure information for probe yaw-angles within ±45.0 degrees of the
true flow angle, see Figure 3.3.
3.1.1. Cobra Probe Yaw-Angle Calibration in Free-Stream Portion of Flow
Since total-pressure measurements using the cobra probe are
sensitive to flow angle, it is necessary to determine how accurately the
probe yaw-angle must be set in order to achieve accurate total-pressure
measurements. A comparison of cobra probe and Kiel probe total-pressure
measurements from -45.0 degrees to +45.0 degrees of probe yaw-angle is
shown in Figure 3.3. The test was made behind the first stator,
station 3, 50% span, Y/S. = 0.0 (free-stream) operating at the design
point flow conditions. The results indicate that the cobra probe will
give fairly accurate total-pressure measurements, ±2.0 Nm/Kg, (±0.45%),
if the probe yaw-angle is set within ±5.0 degrees of the true flow angle.
3.1.2. Cobra Probe Calibration in Wake Portion of Flow
Using the cobra probe to measure total pressures can be very
inaccurate if the probe yaw-angle is set too far from the true flow
angle (see Figure 3.3). This can be a significant problem in regions
of high total-pressure gradients, such as in stator wakes, where the
cobra probe cannot be used to accurately determine the true flow angle.
%J % I[loll
0~i 32
5.00
CD CD4.00- Q) CD
~3.0O C CN'
o FIRST STATOR EXIT50% SPAN FROM HUB C
x
~2.00 0 COBRA PROBEAKIEL PROBECDD
V.~ 1.00 C) o
O.OIt
-48.0 -36.0 -24.0 -12.0 0.0 12.0 24.0 36.0PROBE YAW ANGLE, DEGREES
Figure 3.3 Cobra probe yaw-angle total-head calibrationcurve in free stream portion of flow for
a.-.,flow coefficient 0.587 at 2400 rpm.
/*'
' ' ' * -.- - - . 77 -77P-7771- -rr r .7 i
In order to circumvent this problem, the cobra probe yaw-angle in the
wake region is set to the integrated-average free-stream flow angle
measured by the cobra probe. A comparison of the cobra probe and Kiel
probe measurements--with the Kiel probe set at the integrated-average
.- free-stream flow angle--is shown in Figure 3.4. This comparison test
was made behind the second stator, station 5, 50% span, operating at
the design point flow conditions. The results show very good agreement
in the free-stream regions, +5.0 Nm/Kg (±0.6%). The wake region data
also show good agreement in total-pressure levels, but some slight
shifting of the wake position is evident.
-'.. 3.1.3. Spanwise Calibration of the Cobra Probe
A spanwise comparison of cobra probe and Kiel probe total-head
measurements are shown in Figure 3.5 for flows behind the first rotor
and first stator. The results show fairly good agreement between the
cobra probe and Kiel probe measurements, less than 10.0 Nm/Kg (1.7%)
difference, except near the end-walls where the difference was as much
as 17 Nm/Kg (4.5%). The larger error near the end-walls was suspected
to be due to wall effects. Total-head measurements behind the first
rotor were generally better than behind the first stator.
3.1.4. Scanivalve Pressure Transducer Calibration
On line pres. ure-transducer calibration was accomplished using a
pressure reference system consisting of water columns and triple-beam
r balances. The pressure reference system is described in detail in
Reference 18]. The system provides four reference pressures against
I-.' which the pressure transducer can be calibrated. The pressure trans-
ducer is calibrated every time the flow coefficient is to be readjusted
%, .
Z . . . . . . . . . . .
34
10.00
SECOND STATOR EXIT50% SPAN FROM HUB
* - 0~9.00
8.00 - 0. COBRA PROBE
,L' KIEL PROBE
CS
~7.00
6.001III0.00 0.20 0.40 0.60 0.80 1.00
FRACTION OF STATOR BLADE PITCH, Y/Ss
* . Figure 3.1& Cobra probe total-head calibration curve in wake portion offlow for flow coefficient -0.587 at 2400 rpm.
lip
-,- , 79. 1 . - T, " . W-
35
6.00FIRST ROTOR EXIT
0 COBRA PROBEZ KIEL PROBE
5.00 -
N
4.00[
5.00FIRST STATOR EXIT
.Co-r
4.00
3.00 I I t I0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
Figure 3.5 Cobra and Kiel probe comparison behind first rotor and firststator for flow coefficient - 0.587 at 2400 rpm (Y/S S = 0.0).
00
.%.%
.S..
-p...
.' . . .. . - . , - . . - . . . : . , _ . ,,. . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . • . . . . . - . . . . . . . . -
36
. prior to taking any total-pressure measurement. Periodic on-line
recalibration of the pressure transducer helps reduce thermal drift
and other transient errors inherent in strain-gauge transducers of
this type. Tests have shown that the reference pressures can be deter-
mined with resolution better than 0.003 inches (0.076 mm) of water.
All pressure reference columns are calibrated using the precision micro-
manometer. Calibration of the pressure reference system is performed
once every three months or more often as needed.
An additional water column is used to provide a back pressure to
the scanivalve transducer in order to insure that the pressure trans-
ducer is always displaced from zero. This eliminates errors from
having the transducer pressure fluctuate around zero. On-line cali-
bration of the pressure transducer consists of a linear least-squares
correlation of transducer output voltage versus the known reference
column pressures. The reference column pressures are determined from>.
%" linear least-squares correlation equations entered into the computer
which have been previously determined from a calibration of column
pressure versus column weight. Therefore, it is only necessary to
weigh each column prior to testing in order to determine the reference
column pressures. During on-line calibration, each column pressure
and transducer voltage recorded is referenced to one of the columns,
the same column each time. Again, this is done in order to reduce
_. errors due to thermal drift as well as other transient errors between
successive readings. In addition, it helps insure that the linear
correlation goes through zero, as it should. As mentioned earlier,
this procedure consistently provided a linear correlation coefficient
-:,.-
, .- _ ', -' . -. . - .... . . . . .. ...... . ., •* * . , ..-.. . -. . .. .... '.. --. V. .
37
of transducer voltage versus column pressure of 0.99999 or better. The
calibration is repeated if this correlation criterion is not met.
,, 3.2. Data Aquisition
The data acquisition procedure consisted of obtaining two types of
information: overall performance data, and spatially detailed time-
averaged measurements of total pressure and flow angle between adjacent
blade rows. The details of obtaining both types of measurements are
described below.
3.2.1. Overall Performance Map
The overall performance map parameters are based on compressor
drive motor torque meter measurements (to establish the compressor
ideal head rise), static-head measurements at the compressor exit (to
estimate the actual head rise), and venturi flow rate measurements (to
determine the compressor flow coefficient). The above procedure was
used to quickly and accurately establish a performance map for the
baseline compressor. The method for establishing the compressor exit
total head relies on the stator exit swirl being zero and, therefore,
the static head at that station being a constant across the span. The
venturi-measured flow rate was used to determine the average axial
velocity at the compressor exit which, since the swirl is zero, is also
the fluid velocity. Using the measured circumferentially-averaged
static head and the computed average fluid velocity at the compressor
exit, the compressor exit total head was determined. The actual head
rise delivered to the working fluid could then be determined by
b • • .S
38
referencing the compressor exit total head to the total head at the
compressor inlet (atmospheric conditions, zero velocity).
The measurements involved in establishing the performance map were
obtained as follows. With the compressor operating at 2400 rpm, the_I.
diffuser exit throttle plate was adjusted to provide incremental con-
trol of the compressor flow rate. At each flow rate, venturi flow
meter measurements, torque meter measurements, and compressor exit
static-head measurements were recorded along with other pertinent
data related to the operating and ambient conditions. The torque meter
measurements were obtained with the compressor drive motor floating on
air bearings while various weights were added to the torque arm in
order to balance the drive motor torque. A calibrated meter employing
an incremental load transducer consisting of a solid-state gauge bridge
on a cantilevered beam was used to resolve torque arm loads to within
±0.0125 Kg. The meter was calibrated to read from 0.0 Kg to 1.0 Kg full
scale. Meter fluctuations due to motor vibrations and minute torque
fluctuations reduced torque measurement accuracy to within ±0.25 Kg.
Static-head measurements at the compressor exit were obtained from four
equally spaced (circumferentially) outer annulus-wall static pressure
taps. The measurements were made while decreasing the flow rate from
maximum flow rate unti1 stall occurred and then repeating the measure-
ments from stall to the maximum flow rate. The stall limit was
accurately established by adjusting the flow rate until a slight
disturbance at the diffuser exit would instigate a full span stall,
which was audibly detectable. Once the stall flow rate was determined,
measurements were made just before and after stall.
4.k"'.'"-
'p-
39
3.2.2. Time-Averaged Measurements
Time-averaged total pressure and flow angle data variation in the
radial, axial, and circumferential directions of the compressor flow
field were obtained with the cobra probe set at five passage height
locations of 10%, 30%, 50%, 70%, and 90% of span from the hub--ahead of
and behind each of the rotating and stationary blade rows--at several
circumferential positions over one stator pitch. In addition, outer
annulus-wall four-hole-averaged static-pressure measurements were made
at each axial measurement location. The steps followed to obtain these
data are described below.
Prior to testing, several preliminary setups were accomplished.
The cobra probe was mounted in the probe actuator and the probe yaw-
angle zero was set by balancing the side-tube pressures with the probeIp.
immersed in the calibration nozzle jet. The probe radial positioning
was set using a depth micrometer. The probe actuator mechanical
counters were set to read zero yaw-angle for compressor axial flow and
5.6 inches (14.22 cm) for contact with the hub surface. Thus, the
.. counters would indicate true probe angular and radial positions. All
calibrations were performed through the data acquisition system with
sthe PET computer controlling the calibration procedures. Before each
test, the scanivalve pressure reference system columns were refilled
with water to predetermined levels and each column was reweighed. The
reference column ice bath was checked and reiced if necessary.
The following miscellaneous data were recorded by the computer for
-. each test to insure the attainment of intended measurement conditions.
a7t,
- V...- ° ° o Q . °. 4j°S. ° :8 $\ "2.'° . '° .-. . .- . .. - . . . <.* - .. . .. . . . • °
40
1. Probe axial measurement station number, (see Figure 2.5)
2. Compressor rpm
3. Static pressure difference across venturi throat, N/m2
4. Barometer ambient temperature, degrees Kelvin
25. Barometric pressure, N/m
6. Temperature at compressor inlet, degrees Kelvin.2' m2 K i
7. Static pressure at venturi throat, N/n
8. Temperature at venturi throat, degrees Kelvin
9. Date
10. Time
The circumferential surveys were made by moving the stators
circumferentially past a stationary probe located at one of the probe
axial measurement stations at the proper depth of immersion. Figure 3.6
- shows, to scale, the axial position and extent of each circumferential
measurement window as well as the circumferential survey coordinate
" direction. A qualitative trace of total pressure versus circumferential
position with the probe set at the approximate average flow angle was
recorded on an X-Y storage oscilloscope screen from the electrical
signals of the strain-gauge pressure transducer and the circumferential
motion potentiometer. The trace was used in selecting the spacing of
circumferential measurement points and in determining the extent and
position of the wake and free-stream regions. For each survey,
measurements were made over one stator blade pitch. The circumferen-
e , tial measurement positions in the wake and free-stream regions were
% determined by the computer, based on the number of free-stream circum-
ferential measurement positions desired and the circumferential measure-
%J ,
"-.-
"'" ." "" g " " "
41
MEASUREMENTx x STATION 1
FIRSTROTOR
MEASUREMENT
STATION 2
.- FIRSTSTATOR
MEASUREMENT
STATION 3
SECOND
-,. MEASUREMENT" - STATION 4
SECONDSTATOR
MEASUREMENT
i0.0 0 STATION 5
Y/SS
Figure 3.6. Blade cascade showing cicumferential measurement window.
........... .... ,... .. . . . .. . . .
. S. -. ,...
"S*
42
ment increment desired in the wake region. Flow angle measurements
were made by balancing the cobra probe side-tube pressures through a
computer controlled algorithm or by manual over-ride with the aid of a
) N U-tube manometer. Flow angle measurements were made at every flow
* .field measurement point behind a rotor blade row and at free-stream
.. measurement positions only behind stator blade rows. The circum-
. ferentially-integrated-average free-stream flow angle was thenI DI-
determined with the computer acquisition program and this flow angle
was used when making total-pressure measurements in the corresponding
--.'. stator wake regions of each circumferential survey. The probe yaw-
angle, circumferential position, and total pressure were recorded at
each circumferential measurement point. After the last measurement
at each circumferential survey was taken, the miscellaneous data,
-" flow-field data, and measured circumferentially-averaged static head
were printed out and stored on magnetic disk for reduction at a later
time.
.. 3.3. Data Reduction.? ,-'
Preliminary reduction of the time-averaged data was performed
during data acquisition and consisted of determining primary flow-field
values of total head, static head, and absolute flow angle. These
primary values were then read into the data reduction program where -
other flow-field parameters such as absolute velocity, relative
velocity, incidence angle, deviation angle, etc., were calculated along
with their circumferentially-averaged values. Finally, overall rotor, "
.'., -' . 5 . . . . . .-
*,.. .. .. .- h . . .
43
stator, and stage performance parameters such as ideal head-rise (Euler
* . turbine equation based values), actual head-rise, efficiencies, and
losses were determined. The flow was assumed incompressible for all
*" - calculations as the velocities involved Mach number levels less than
0.2. Integrated values were computed using a spline-fit integration
[9]. A complete list of all quantities and equations used in reducing
the data is presented in Appendix D.
3.3.1. Flow-Field Parameters
The total head was determined at each flow field measurement point
from the cobra probe measured total pressure. Circumferentially-
averaged values of total head and absolute flow angle were determined
for each radial position at every axial measurement station. All
circumferential averages except for flow angle averages behind stator
" blade rows were determined by integrating over one stator blade pitch.
The circumferentially-averaged absolute flow angles behind stator blade
rows were obtained by integrating over the free-stream portion only.-p'... The static head was assumed to be circumferentially constant, and the
V radial distribution of static head was determined at each radial posi-
tion for every axial measurement station by solving the radial equi-
librium equation in the following form:
2-dh 2 sin (H-h)dr r (see Reference [4]) 3.1
using the Runge-Kutta numerical technique [10]. The circumferential-
averaged outer annulus-wall static he3d was used as an initial value,
and the solution was obtained by marching radially toward the hub at
%-N.
A%. ..
.- - . r C
, - 44
increments of 5% of passage height. The circumferentially-averaged
-. values of total head and absolute flow angle required at each step of
the Runge-Kutta solution were obtained by a second-order Lagrange inter-
polation of their measured radial distributions.
From the radial distributions of total head, absolute flow angle,
and static head; the circumferentially-averaged absolute velocity was
determined at each radial position for every axial measurement station.
With the circumferentially-averaged absolute velocity and the flow angle
determined, the following circumferentially-averaged variables were
calculated at each radial position for every axial measurement station.
* 1. Axial velocity, m/s, Eq. 12.16
2. Absolute tangential velocity, m/s, Eq. 12.18
3. Relative tangential velocity, m/s, Eq. 12.20
4. Relative velocity, m/s, Eq. 12.22
5. Relative flow angle, degrees, Eq. 12.24
6. Blade incidence angle, degrees, Eq. 12.25 and Eq. 12.27
7. Blade deviation angle, degrees, Eq. 12.26 and Eq. 12.28
8. Flow coefficient, Eq. 12.29
In addition, for each axial measurement station, an annulus cross-
section integrated flow coefficient was calculated for comparison with
the flow coefficient determined from venturi flow meter data. In
determining the annulus cross-section flow rate and corresponding flow
coefficient, the axial velocities at the hub and shroud end-wall
surfaces were assumed equal to zero.
9._,... ..........1,.,., .. _... .... ... . . . .. ... . .
-45
3.3.2. Performance Parameters
The actual and ideal (Euler turbine equation based) head-rise
coefficients and their ratio (hydraulic efficiency) were determined at
each of the five radial positions for both rotor rows, stages, and for
the overall compressor. Total-head loss coefficients were also deter-
mined for each rotor and stator blade row. In addition, radially
mass-averaged values of each of the above quantities were determined
for both rotor rows, stages, and for the overall compressor (see
Appendix E). The above parameters were calculated from spatially
detailed time-averaged measurements and circumferentially-averaged
• . values of the previous section.
Performance map parameters and mechanical efficiency were calcu-
"- lated from motor torque-meter measurements and the overall head-rise
ft ,across the compressor. The overall head-rise for the performance map
was determined from the measured venturi flow rate and the circumferen-
tially-averaged static head at the outer annulus-wall of the last axial
measurement station.
ft.'.%
" . -
0,o.
0' f,
U-L
47
4. PRESENTATION AND DISCUSSION OF DATA
The results of the torque meter related performance measurements
and the slow-response (time-averaged) data are presented and discussed
in this section. Comparisons between these measured results and cor-
responding calculated values associated with the design code are also
presented and discussed. The design code results are tabulated in 3Appendix B. The experimentally determined data are tabulated in .
Appendix E. In gra,hing the results, all data variation curves--except
for the performance curves--were drawn with interpolated curves through
the actual data points. Smooth curves were drawn through the per- C
formance map data using a least-squares fit. All measured data points
are graphed with a symbol marking the actual data point. The design
code results are represented with continuous curves.
4.1. Error Analysis
Measurement errors associated with the primary measurement quan-
tities and flow-field parameters are presented in Table 4.1. Repre-
sentative values of each primary measurement quantity and flow-field
parameter are presented, along with their estimated uncertainty and Ipercentage of error. The uncertainties of the flow-field parameters
were determined using the procedures of Kline and McClintock [11I based
on the estimated uncertainties associated with the primary measurement
quantities. The estimates of the uncertainties of the primary measure-
ment quantities were based on the repeatability of the measurements,| -04
and comparisons with the Kiel probe in the case of total pressure
,"7
S ' .°• " ' .• " . " . " . -• -. .. . . °
,' '.' ...... ... .... .- .. . . . . .. .. . . . . .. . • . .. .. . . . -.. .. .. .. . . ..~ .. . ...
48
Table 4.1. Uncertainty estimates of measurement parameters.
Typical Estimated UncertaintyFlow Parameters Symbol Values (20-to-1 odds)
Primary measurements
Temperature t 299 deg. K 0.25 deg. K (0.08%)
Transducer pressure Pt 52.0 mm Hg 1.2 mm Hg (2.2%)tS
Absolute flow angle B 20.0 deg. 1.0 deg. (5.0%)y
Barometric pressure P 735 mm Hg 0.03 mm Hg (0.003%)atm
Torque T 4.0 Kg 0.03 Kg (0.6%)
Flow field parameters
Absolute velocity V 30.0 m/s 0.3 m/s (1.1%)
Axial velocity V 28.0 m/s 0.4 m/s (1.3%)Z
Absolute tangentialvelocity V 10.3 m/s 0.5 m/s (4.9%)
y
Relative flow angle B' 50.0 deg. 0.6 deg. (1.1%)y
Performance parameters 5
Actual head-risecoefficient k 0.17 0.004 (2.3%)
Ideal head-risecoefficient %P . 0.19 0.02 (8.7%)1
Hydraulic efficiency 0.88 0.07 (8.0%)
Rotor total-head losscoefficient wR 0.05 0.03 (60.0%)
Stator total-head losscoefficient w 0.06 0.02 (33.0%)
Ideal work coefficient W. 0.4 0.005 (1.3%)1. Opm .
Mechanical efficiency lme 0.75 0.01 (1.8%) S
...
49
measurements. The uncertainty levels given in Table 4.1 are generally
* - consistent with the random scatter observed in the results. It should
*-" be noted that the uncertainty levels tend to be higher near the end-
walls (see Figure 3.5).
Of the primary measurement quantities, absolute flow angle
measurements have the most uncertainty, primarily because of the total-
pressure gradients affecting the cobra probe yaw-angle measurements.
Behind the stator blade rows, ascertaining the circumferential extent
of the free-stream--particularly near the end-walls--was difficult.
Comparisons of total-head measurements obtained using a cobra probe
and Kiel probe were presented in section 3.1. These comparisons
show that even with the uncertainties of determining the absolute flow
angle, the cobra probe gives a fairly accurate measure of the totalIS
head. Performance parameters based on the Euler turbine equation ideal
head-rise, however, are highly dependent on the accuracy of the absolute
flow angle measurements (see Table 4.1). It would be reasonable to
*" conclude, therefore, that very little confidence can be afforded the
Euler turbine equation based performance parameters. The effect of
torque measurement accuracy on the torque based performance parameters
is also given in Table 4.1. The torque based efficiencies are more
reliable than the Euler turbine equation based efficiencies, but only
as an indicator of relative measure. The torque based efficiencies
e.." were very repeatable, but were highly dependent on the mechanical
characteristics of the compressor and drive motor which affected the
absolute measure of the efficiencies. Since the torque meter based
efficiencies were affected by bearing friction and other mechanical
Z.I
".' -"' "-" ,, . . . ."""""''- -' """- --- """""" - -.:- - .""""'"- - - -""""""- - .: '''.."' . .-.. . . . .. . ..I' ""
' ,. 50 -.,
losses, they are not reliable as an absolute measure of efficiency.
However, with precautions they are a reasonable indicator of relative
measure of efficiency.
All time-averaged measurements were obtained with the throttle
plate adjusted so that the venturi flow coefficient was within ± 0.0005
of the desired flow coefficient of 0.587. An integrated average flow
coefficient based on the spanwise distribution of circumferential-mean
axial velocity--as determined from cobra probe measurements--served
as a check between venturi based and cobra probe based flow coeffi-
cients. Comparisons of the integrated flow coefficients and venturi
flow coefficient for each axial measurement station are given in
Table 4.2. The integrated flow coefficient was obtained by two dif-
ferent approaches; 1) using the extrapolated circumferential-mean
axial velocity at the end-walls, and 2) by considering the circum-
ferential-mean axial velocity to be zero at the end-walls. A spline-
fit integration routine [9] was used to perform the integration. Even
2 with only five spanwise measurement locations, the integrated-average
flow coefficients--based on zero axial velocity at the end-walls--
compared very favorably with the venturi based flow coefficients. The
integrated flow coefficients--based on extrapolated circumferential-
mean axial velocity at the end-walls--were consistently higher than the
venturi based flow coefficients.
"2"
-%
're.4.t
. -i Q , ' ",~r.. •* .. "W .q.- * • . V .. ". '° -" ° . . .. .
51
Table 4.2. Flow coefficient comparison between venturi and integratedmeasurement station flow coefficients.
V extrapolated to endwall V = 0.0 at endwallz z
Flow FlowCoefficient CoefficientComparison Comparison
Station Percent Station Percent
1 6.0 1 1.0
2 4.4 2 -0.2
3 2.5 3 -1.9
4 3.4 4 -1.0
5 o.8 5 -2.9
4.2. Overall Performance Map
The results of the torque meter related performance tests are
- presented in Figure 4.1. Overall compressor head-rise coefficient,
work coefficient, and efficiency variations with flow coefficient are
plotted. The curves were obtained by recording venturi flow rate,
compressor exit (station 5) shroud static pressure, and drive motor
.... torque. The venturi flow rate was used to determine the average axial
velocity at the exit of the compressor. Since swirl was virtually non-
* .~ existent at the compressor exit, the static pressure was presumed
constant across the span; thus making it possible to determine repre-'• . .
sentative total pressures and subsequent head-rise coefficient at the
compressor exit. The torque meter measurements were used to determine
'.' .. .. o. • % , ... . ., . -. '• '°'. ' . V. ." .' . . . '.. •..,.. . . ...... -.- . .. • .... . .. *.' • -" ... . .
'" ---,---.-.',. .-. - .. '°- -'-'--..--'.-''- - ,''-. " " < ,. , ". -- "" .-"-".3 . •.' .- ,- - *. .' .. -.-. -
".' .-"52
0.80
.-- , 0.70
I- 0.60
0.50-
0.402400 RPM
+ TORQUE METER RELATED TESTS
4. .** E
Q DETAILED MEASUREMENTS0.30 * PREDICTED
0.20 --0.20 0.30 0.40 0.50 0.60 0.70
,DA VENTURI FLOW COEFFICIENT
(a) WORK COEFFICIENT
a.Figure 4.1 Predicted and measured overall performance data.
...... ......... ............ ..... .. l
* . - p * S . . - 6-
53
40.6
0.50
LU
.40.0
0.30
S0.40
240 RPM
0.0
0.0 0.0 04 .5 .0 07
0o 0 DETILE MESUEMENTISEOFIIN
0.10r 4. PREDICTED.
.4%
54
1.00
2400 RPM
+ TORQUE METER RELATED TESTS0.90',0 DETAILED MEASUREMENTS0.90 K PREDICTED
0.80
.70
,l",(.)
U-
*~* 0.70
.a_
0.60 "
0.50
0.401III0.20 0.30 0.40 0.50 0.60 0.70
VENTURI FLOW COEFFICIENT(c) EFFICIENCY
rFigure 4.1 concluded.
I,
,,,)
;L•'.
the work coefficient from Equation 13.50. Also noted in Figure 4.1
are the design point overall head-rise coefficient and hydraulic
efficiency as determined from the detailed time-averaged measurements
and Euler turbine equation based ideal head-rise, as well as the design
point overall hydraulic efficiency and head-rise coefficient predicted
from the design code. Both measured efficiencies corresponding to the
design point flow coefficient are significantly lower than the pre-
dicted efficiency. The reason for this discrepancy will be explored
further in a later section (4.4. Comparisons of Circumferential-Mean
Data with Design Code Predictions).
As mentioned in the previous section, the Euler turbine equation-
based performance parameters are highly dependent on the accuracy of
the absolute flow angle measurements and are, therefore, unreliable
measures of compressor performance. Although the relative character-
istics of the performance curves depicting work coefficient and
efficiency variations with flow coefficient proved to very repeatable,
the absolute values of each curve were sensitive to the mechanical
characteristics of the compressor, such as bearing friction. These
mechanical effects appeared as shifts in the absolute magnitudes of
the torque measurements which tended to move the level of the work
coefficient and efficiency curves, but did not significantly affect
the relative aspects of each curve. The head-rise coefficient curve
was consistently repeatable and compared favorably with the design
point overall head-rise coefficient determined from the detailed time-
averaged measurements, thus lending credence to the procedure used in
determining the head rise versus flow coefficient performance curve.
°. %
- :,. . . . .:... . . % .. .'-....... ? .:. .... ......... .. .
10156
Because of the effects of bearing friction on torque measurements, the
performance curves could not be used for absolute predictions of the
compressor performance. Thus, no means were available for comparing
the design program efficiency predictions.
To obtain an accurate performance map which could be used for
absolute as well as relative measures of efficiency, the compressor
should be run without blading to measure the tare torque; thus obtain--Ib •
ing corrections for bearing friction and other mechanical effects.
Without regreasing the bearings and with the blades reinstalled, a new
performance map could be generated from which the tare torque is sub-
tracted. This procedure was not attempted because of insufficient
time.
The curve of compresscr efficiency variations with flow coeffi-
cient shows an uncharacteristic flat portion where the efficiency is
essentially constant over a range of flow coefficient values. The flat
portion of the efficiency curve may be due to the fact that blade
losses were constant over a range of incidence angles. However, there
may also be some over-riding effect that is causing slight improvements
in efficiency to be "washed out." For example, Wisler [2] shows a con-
.. siderable Reynolds number effect on compressor efficiency for a low-"
speed four-stage axial-flow compressor. Wisler's results show a
-P... flattening of the efficiency curves as the Reynolds number is decreased.
The Reynolds number range examined by Wisler was 1.0 X 105 to 4.0 x 105.
The Reynolds number for the baseline compressor is about 1.8 X 105.
Further discussion of the constancy of compressor efficiency over a
range of flow rates may be found in Reference 12.
,'
57
4.3. Spatially Detailed Time-Averaged Measurement Results
• "Detailed time-averaged aerodynamic data were obtained in the
baseline compressor at numerous circumferential positions for 10%, 30%,
50%, 70%, and 90% span locations--measured from the hub, ahead of and .
behind each blade row. The axial measurement locations and circum-
ferential survey windows relative to each blade row are shown in
Figure 3.6 for one spanwise location. Figure 3.6 should be referred .
to when analyzing the figures in this section. All total-head measure-
ments presented in this report are referenced to atmospheric conditions.
Graphs of the blade-to-blade distribution of total head for all spanwise
-. '. locations at each axial measurement station are illustrated. Figure 4.2
is for flows behind the first- and second-stage rotors, and Figure 4.3
is for flows behind the first- and second-stage stators. The data for p
flow behind the second rotor (Figure 4.2) indicate a peculiar pattern
involving two regions of lower total head. This unexpected trend is
explained in Reference 12. The detailed time-averaged measurement data
.: were used to obtain circumferential-mean values of total head, flow
angle, and absolute velocity. The spanwise distributions of these
circumferential-mean quantities are shown in Figure 4.4, for ti ws
behind the first- and second-stage rotors, and in Figure 4.5, for flows
behind the first- and second-stage stators. The graphs of the spanwise
distributions of circumferential-mean total head and axial velocity "
behind each blade row (Figure 4.4 and 4.5) show significantly lower
total head and axial velocities at the 90% from hub measurement loca-
tion indicating higher losses near the shroud end-wall there. Evidence P
A-.
. . . . . . . . .. . . . . . . . . . . . . . . . . .
58
5.00
FIRST ROTOR EXIT
4.0
SECOND ROTOR EXIT -
8.0
FIRST ROTOR EXIT V
4. 50
SECOND ROTOR EXIT
.8.5
0.00 0.20 0.40 0.60 0.80 1.00 1.10 .FRACTION OF STATOR PITCH I(b 70% SPAN FROM HUB
Figure 4.2 Blade-to-blade distribution of time-average total head for '
flow behind the first and second stage rotors (4=0.587~s at 2400 rpm).
4 -%
__7.
* 4 59
5.50FIRST ROTOR EXIT
4.50Q
SECOND ROTOR EXIT
.77.50 IIp0 (c) 50% SPAN FROM HUB
00
8.50
SECOND ROTOR EXIT
7.50 10.00 0.20 0.40 0.60 0.80 1.00 1.10
FRACTION OF STATOR PITCH(d) 30% SPAN FROM HUB
Figure 4.2 continued.
p..
60
5.50
FIRST ROTOR
0 .0(
x
01
SECOND ROTOR EXIT
7.00 III0.00 0.20 0.40 0.60 0.80 1.00 1.10
FRACTION OF STATOR PITCH(e) 10% SPAN FROM HUB
Figure 4.2 concluded.
9LA
:W -. 6 -. a* I -. . . . . . .
61
.5.4.50
4.50(p
%S~. E
.2.50
0.5
01.50
-0.50
0.00 0.20 0.40 0.60 0.80 1.00 1.10FRACTION OF STATOR PITCH
(a) 90% SPAN FROM HUB
Figure 4.3 Blade-to-blade distribution of time-average total head forflow behind the first and second stage stators (~=0.587at 2400 rpm).
62
9.00
8.00
CJ7.00'
6.0
4 .000.0 02 .006008 .0 11
FRACSECON STTF EXIT PTC
(a) 90% SPAN FROM HUB
Figure 4.3 continued.
63
3.00
~3.0
2.00
0 FIRST STATOR EXIT
C1.00 III
8.0
7.00
6.00 SECOND STATOR EXIT
up0.00 0.20 Q.40 0.60 0.80 1.00 1.20
FRACTION OF STATOR PITCH
(b) 70% SPAN FROM HUB
Figure 4.3 continued.
643
3.00
*-2.00
Cj FIRST STATOR EXIT
9.5
* 8.5
7.50
6.50
SECOND STATOR EXIT
a... 5.50 I0.00 0.20 0.40 0.60 0.80 1.00 1.10
FRACTION OF STATOR PITCH
()50% SPAR FROM HUB
Figure 4.3 continued.
a.
W. 2
65
5.00
p.003.00
E2.00 FIRST STATOR EXIT
x0 .5
*8.5
.50
5.50,
Fiue . cnine
lot.5
66
5.00
4.00-
)U
3.00
A= 2.00.14
0,p. FIRST STATOR EXIT
- x
.. 1.0o I I I I
- .0
7.00-
SECOND STATOR EXIT
6.00I0.00 0.20 0.40 0.60 0.80 1.00 1.10
FRACTION OF STATOR PITCH(e) 10% SPAN FROM HUB
Figure 4.3 concluded.
J .) ,.:, ...:-+ ,. ..:..-,'.,'..:z , ,-. ; :/-;-;-:.-.. .-- -:.- .-'.-.... .'.-.' .'.: ..........---.:--...--:.. :..,:-..:.-:.. ..,>->. -.:.,i
I J .",' L J" -.'.,"..-.''. ' ..'' -" , ."w :w: ' . .'. :,'"" '% % -, " . ''- ,-,-,'.-'"' . . , ", "",:,". " "S
S5.0
E5O FIRST ROTOR EXIT
44 x 4.001
9.50 SECOND ROTOR EXIT
Vi8.50 -'
-I
LL7.501 1 1 1 1 I
~, 0.00 20.0 40.0 60.0 80.0 100.0PERCENT SPAN FROM HUB
(a) TOTAL HEAD
Figure 4.4 Spat'.wise distribution of circumferential-mean data for flow SP behind the first and second stage rotors (~=0.587 at 2400
rpm).
68
26.0
26.00 FIRST ROTOR EXIT Icz
Ls
S22.00
1800
261.00 III
SECOND ROTOR EXIT
~- 22.00
z
(b BOLT LO NL
Fiue4. otiud
117 W.2..
69
32.00
I-
30.00
C 28.001 II
S33.00
SECOND ROTOR EXIT
.- 3.0
293.00
29.00 1
0.00 20.0 40.0 60.0 80.0 100.0PERCENT SPAN FROM HUB
* (C) AXIAL VELOCITY
Figure 4.4 concluded. I
* . 70
4.50
FIRST STATOR EXITj
'3.50
SECOND STATOR EXIT
S8.00Jj
U.
7.001II0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
(a) TOTAL HEAD
- Figure 4.5 Spanwise distribu~tion of circumferential-mean data for flowbehind the first and second stage stators (~=0.587 at2400 rpm).
. ...* . .'V%
71
4.00
LULU
.~..M 0.00
LU
39
S-4.00 FIRST STATOR EXIT
U,
S4.00
S0.00 .
LU
-4.00 SECOND STATOR EXIT
0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
.4 1 (b) ABSOLUTE FLOW ANGLE
Figure 4.5 continued.
4%
72
34.00
FIRST STATOR EXIT
32.00
30.00
280 -S
26.0
32.00
27! 3.001
PERSECON STATN EXITHUW XA VLCT
Fiue4. ocldd
73'a--
of hub end-wall effects appears behind the second rotor and stator as
seen by the appreciable decrease in total head and axial velocity levels
there.
Circumferential-radial plane contour maps of total-head variation
at each axial measurement location are presented in Figure 4.6.
Figure 4.7 shows the locations of the actual data points used in con-
structing the contour map for station 3. The single-stator pitch data
actually acquired were repeated over two stator blade pitches in order
to afford better visualization of the flow pattern. The abscissa and
ordinate correspond to fraction of blade pitch, Y/Ss, and percent span
location measured from the hub, PHH. The actual data were taken
between Y/SS = 0.0 to Y/SS = 1.0. In order to provide a smoother repre-
sentation of the flow pattern, a data enhancement option provided by
the contour plotting program was utilized. The data enhancement option
was only employed in the radial direction since there were an adequate
number of points available in the circumferential direction. For each
contour map, an additional five enhanced data points between each pair
of actual data points in the radial direction were requested. For the
contour map of station 3, there were five circumferential survey line I
segments consisting of an equal number of data points--for this case
51--therefore, the total number of enhanced data points was ((5-1)*5*51)
= 1020. The data of station 3 without enhancement are shown in
Figure 4.8 for comparison with enhanced data contours of Figure 4.6(b).
The contours with enhanced data are a slightly smoother representationII of the flow field. Trends, however, are not significantly altered by
iN the enhancement process.
a-- "i* . - . . a
74
(a) FIRST ROTOR EXIT STATION 2TIP
go% 90%
co 70
.2 o%
.30% 30U-
10% HB 1p
-0.50 0.-
000 0.00
FRACTION OF STATOR PITCH
KEY-ftCURVE CURVE
LAB EL VALUE1 O.415O00E 03 Nm/kg2 0.430000E 03 Nm/kg3 0.445000E 03 Nm/kg4 0.460000E 03 Nm/kg
ft5 0.475000E 03 Nm/kg
Figure 4.6 Contour map of the distribution of total head behind eachblade row ()=0.587 at 2400 rpm). Data enhancementemployed.
ITIP
/5 -U
gok 0
cO 1 ak 7j(b)o FIS50AOREITSATOw
0 S
U-U
T T - -. T
-0...50 0.00 0.50
FRACTION OF STATOR PITCH
KEY
CURVE CURVE4...LABEL VALUE
1 0.150000E 03 Nm/kg2 0.200000E 03 Nm/kg3 0.250000E 03 Nm/kg4 0.300000E 03 Nm/kg
I..5 0.350000E 03 Nm/kg6 0.380000E 03 Nm/kgA7 0.410000E 03 mk8 0.430000E 03 Nm/kg9 0O.450000E 03 Nm/kg10 0.470000E 03 Nm/kg
* -. Figure 4.6 continued.
J... 76
()SECOND ROTOR EXIT STATION 4TIP
co -7 0% -70
ejS
50% 50%
U.7.00
FRCINOU-AO IC
-KEY
4 0.80000E0.00/k
CUV CURVOOE 0 mk
10 0.930000E 03 Nm/kg
2 iur 4.600 03 ng ed.
77
(d) SECOND STATOR EXIT STATION-5- TIP
7---
90k.0
co I 70S
0.0
0-50 -0-5
00 7.
0S
FRACTION OF STATOR PITCH
KEY
CURVE CURVELABEL VALUE1 0.550000E 03 Nm/kg2 0.600000E 03 Nm/kg3 0.650000E 03 Nm/kg4 O.700000E 03 Nm/kg "5 0.750000E 03 Nm/kg6 0.800000E 03 Nm/kg
v7 0.830000E 03 Nm/kg8 0.860000E 0 Nm/kg
49 0.880000E 03 Nm/kg 410 0.900000E 03 Nm/kg l
Figure 4.6 concluded.
78
0FIRST STATOR EXIT STATION 3
TIP
90% 9ox
03 0
mmm~~ m m mmm .m m mU-1
5-. 30% 3,
p5-4
-0 5 0 .0 0 0 .5 0 7 0'.5 FRACTION OF STATOR PITCH
NOTE: SINGLE PITCH DATA ACTUALLY ACQUIRED REPEATED OVER TWO
STATOR BLADE PITCHES FOR VISUALIZATION ENHANCMENT
Figure 4.7 Locations of actual data paints used in constructing the
contour map behind the first stator.
U,- 79
FIRST STATOR EXIT STATION 3
TIP
00
050 0.050 p-1.0 7.-
FRACTION OF STATOR PITCH
KEY
CURVE CURVELAB3EL VALUE1 0.150000E 03 Nm/kg2 0.200000E 03 Nm/kg3 0.250000E 03 Nm/kg4 0.300000E 03 Nm/kg5 0.350000E 03 Nm/kg6 0.380000E 03 Nm/kg7 0.410000E 03 Nm/kg*8 0.430000E 03 Nm/kg9 0.450000E 03 Nm/kg 0
'N10 0.470000E 03 Nm/kg
Figure 4.8 Contour map of the distribution of total head behind thefirst stator (4=0.587 at 2400 rpm). No data enhancement.
A,
80
The contour map of total-head variation behind the first rotor,
Figure 4.6(a), indicates a fairly uniform total pressure level distri-
bution with some evidence of an end-wall loss region (lower total head) -
from about 70% span to the shroud end-wall. The majority of the span
from about 10% to 70% span is at about the same total head level,
except at about 30% span where there is a core of slightly higher
total-head fluid.
The contour map for flow behind the first stator, Figure 4.6(b),
shows very well defined stator blade wakes involving steep gradients in
total head and the lower total-head values. Again, the shroud end-wall
region from about 70% span to the shroud end-wall consists of lower
,6 total head fluid associated with end-wall related losses. The highest
total head--as for the first rotor exit flow--occurs at about 30% span.
%The second rotor exit contour map, Figure 4.6(c), involves a very
nonuniform total head variation in contrast to the fairly uniform total
head distribution found behind the first rotor. Zierke and Okiishi
[3] discussed the large influence of rotor/stator wake interaction on
rotor exit total-head distribution when stator wakes are chopped and
transported through a downstream rotor blade row. Evident from the
contour map of flow behind the second rotor, in Figure 4.6(c), are two
regions of lower total-head fluid (as mentioned earlier in discussing
Figure 4.2) along the span. Several possible explanations for the
occurrence of these two regions of lower total-head fluid were investi-
gated. The wakes of upstream struts used to support the inlet bell
housing were eliminated as a possible cause of this trend since they
remained stationary relative to the probe during any circumferential
[j~%J
81
survey and, thus, would not show up as a circumferential variation of/IS-. total pressure. Only those compressor components which moved relative
S.. to the probe were considered further. Potential flow effects upstream
from the second stator leading edge were considered next, although they
seemed an unlikely cause; no evidence of this kind of effect was ob-
served behind the first rotor. Subsequent tests with the first stage
stators held stationary during a circumferential survey demonstrated
that as the second stage stators only were traversed circumferentially
relative to the probe, the first rotor exit flow total-head remained
essentially constant with no evidence of either region of low total-
head fluid appearing. Similar tests, with the second stator held
stationary while the first stator was circumferentially traversed
relative to the probe, resulted in both regions of low total-head
fluid appearing. Both regions of low total-head are, thus, quite
clearly related to the first stator blade row. This unusual observa-
tion has been studied further. Heated first stator wake fluid was
tracked through the first rotor row and a logical explanation of the
appearance of the two regions of lower total-head fluid behind the
first rotor may be found in Reference 12.
The second stator exit contour map, Figure 4.6(a), shows the same
end-wall loss region near the shroud end-wall region--from about 70%
span to the shroud end-wall--and the same core of high total-head fluid
at about 30% span as found in the other contour maps. The unusual wake
contours were studied further (Reference 12). Adjustment of the contour
plotting procedure resulted in more conventional wake contour lines.
4-St- . . . . ... .-. "'
. . .. . . . . . . . . . . . . . .
82
The core of high total-head fluid at about 30% span, apparent at
all stations, suggests that there was no significant radial migration
' of fluid. This is to be partly expected because the hub and shroud
end-walls are parallel. Further, the rotor and stator boundary layer]I
flows were probably not substantially separated from the blade sur-
faces and, thus, as was demonstrated by Dring, Joslyn, and Hardin 114],
little radial migration of blade surface flow should have been antici-
pated. Hub end-wall loss regions could only be detected in the second-
stage contour maps. The difference between the extent of hub and shroud
loss regions indicates that the shroud losses are higher as discussed
further in the next section (4.4. Comparisons of Circumferential-Mean
., .Data with Design Code Predictions).
Comparisons of the spanwise distributions of the measured rotor
and stator incidence and deviation angles for both stages are shown in
Figure 4.9. Analysis of this figure indicates that the rotor deviation
angles are about the same for both stages; whereas, the first rotor is
*....operating with greater negative incidence. The first-stage stator is
also operating with slightly more negative incidence and its deviation
angles are considerably greater than for the second-stage stator.
Although the stator exit circumferential-mean absolute flow angles are
difficult to determine accurately, the difference in stator deviation
angles are much larger than the estimated uncertainty of the absolute
flow angle measurements (see Table 4.1). The negative incidence angles
experienced by both stages resulted in the compressor not operating at
optimum efficiency--a consequence already seen in the overall perform-
* - ance map results (see Figure 4.1). Table 4.3 shows head-rise coeffi-
V.
-'#;-;~~~~~....................... ............. :-...'.. -. ..-..- .: .:.... "... ,- '..:... -..... : -.-.-....
83
4.00ROTOR
0.00 *0
4.0
4.000 FIRST STAGE STATOR
SSECOND STAGE
-0.00
-4. 000.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
(a) INCIDENCE ANGLE
2" Figure 4.9 Comparisons of measured circumferential-mean incidence and4.4.deviation angles for both stages (4=0.587 at 2400 rpm).
4.o
z -
ii A* 11-6 -1.L ill- ~ 4.......- . . . .. . .
AD-R14i 796 AERODYNAMIC DESIGN AND PERFORMANCE OF R TNO-STGE21
I ARXIAL-FLOW COMPRESSOR (.. (U) IONA STATE UNIV AMES
U R ENGINEERING RESEARCH INST M D HATHAWAY ET AL. DEC 93
p NCLASSIFIED ISU-ERI-RES-8478 AFOSR-TR-84-47 F/G 2/5 NL
~~~r~~ .s ~ ... .~ . . .-- . .
,j+.
Ll .6
' °~
14-0 11112 .0
1111 ----
.91.8
'I4
IIIJL25 .4 1.6
,U"
MICROCOPY RESOLUTION TEST CHARPT--
S-.. --
%%
-2
4..
,C.",
* * *. Ci
iF 1 r , g + v ' .,o .. , ° ., ° ., .• .. I =°
484
8.0
.4.0 84
*~4%~%
8.00
STATOR
8.00 0 IS-TG
4.' 4.001
Fiur .9 cocudd
-. ... -. . -7ii
85
Table 4.3. Rotor, stator, stage, and overall performance parameters.
First Stage
R stage WR us ~ R ~stage
10.0 0.179 0.167 -0.016 0.055 1.042 0.96930.0 0.183 0.171 -0.014 0.054 1.040 0.97150.0 0.178 0.165 0.018 0.060 0.949 0.87870.0 0.176 0.160 0.035 0.075 0.893 0.81190.0 0.170 0.133 0.078 0.0193 0.769 0.599
Mass*Averaged 0.178 0.160 0.025 0.083 0.926 0.833
Second Stage
PH R 1Pstage WR WS FIR ristage0
10.0 0.156 0.141 0.120 0.070 0.728 0.658
30.0 0.172 0.158 0.067 0.063 0.830 0.76050.0 0.173 0.163 0.049 0.044 0.864 0.81570.0 0.176 0.163 0.049 0.059 0.858 0.79690.0 0.194 0.168 0.048 0.136 0.870 0.752
MassAveraged 0.175 0.159 0.063 0.071 0.833 0.760
Ove ral1l"
'1 overall 1 overall
10.0 0.307 0.796
30.0 0.329 0.85750.0 0.328 0.846 .70.0 0.323 0.80390.0 0.300 0.676
MassAveraged 0.319 0.795
86
cient, blade losses, and hydraulic efficiencies for both stages and for
the overall compressor. The performance parameters are based on the
Euler turbine equation ideal-head rise and are subject to large errors
(see Table 4.1). Even considering these large errors, the first stage
is apparently operating more efficiently than the second stage.
4.4. Comparisons of Circumferential-Mean Data withDesign Code Predictions S
Comparisons of the velocity triangles for the circumferential-mean
measurements and the design code calculated results are presented in
Figure 4.10 (for flow behind the first rotor), Figure 4.11 (for flow
ahead of the second rotor), and Figure 4.12 (flow behind the second
rotor). Inspection of these velocity triangles shows very good agree-
ment between the measured and predicted rotor exit relative flow
angles, except near the end-walls. This indicates apparent success of
the rotor deviation angle prediction option. Also apparent, is the
higher axial velocity level of the measured data and the poor agreement
between measured and predicted absolute flow angles for almost all
cases shown. It is suggested that the differences in measured and
predicted absolute flow angles behind the rotors are primarily due to
the differences in predicted and measured axial velocity levels. Since
the axial velocity levels can be related to the end-wall blockage esti-
mates, this observation indicates that poor blockage estimates were
used in the design process. From the calibration tests in section
3.1, the cobra probe was found to be able to accurately measure the
total pressure as long as the probe was yawed to within ±5.0 degrees
.. v
87
I- 00
C))
La5, ccCL.
-- N D
w 6-1 CIA m, m, Mam
CD ! .v . * ". : z44
/00/L
w0)
S.4:%
44
too
I- 4-p
0l 0! 0l 11 p
LN A,04 I -,
88
A.A
J~ A A/ / i
/ I *- ~ 00
$4.CD 41 r
f (/ ) u4c*41 8 0 0 4
I- I-. 10 0 0 r U~ r. r -~ N IA
0IAU ~ ID~0 0 0~~ ~ -. >
Qa Q 0 U . . 0 u i-
w0 w OO a,.- =0 0 Q 141.11
4) 0
4--a' I 4-4
40
/ / 0
a.. aa Lac- I- I-oow w
-a.-. 0 0 m~ m. a, cc 01 - v :r c
04 acooc 0 OD0
%c' -O. ~ ~ 00~CJ ICI
89
ClI
PI 00
a ua 00kn r4' 00
U, v- 5 %r--%
01-0
I~ 4.
v,.. m LU 000 c ra ce -(I) m co
oj "! "! -wa -wLa2 ;
f" cmm-
* .~ ~ O ~ ~ L~O O v. OIQjmn - In -- ,- - 0
%a %
90
of the true absolute flow angle. The estimated uncertainty in the p
absolute flow angle measurement for 20-to-i odds is ±1.0 degrees (see
Table 4.1). Static head measurements were found to be constant across
the span as expected, and were estimated to be accurate to within p
±5.0 Nm/Kg for 20-to-i odds (see Table 4.1). Since absolute velocity
is a function of the difference between the total and static head, it
is estimated that the uncertainty in absolute velocity should be no
more than ±0.34 m/s for 20-to-i odds (see Table 4.1). Given these
observations, if the rotor exit absolute flow angle was truly in error
by a significant amount, this error should also be evidenced as an
error in the rotor exit relative flow angles. Since this is not the
case, the large differences in measured and predicted rotor exit
absolute flow angles must be predominantly due to the axial velocity
discrepancies. Inspection of Figure 4.10--first rotor exit at 90%
span--shows good agreement between the measured and predicted axial
velocities and, as expected, also shows good agreement between the
measured and predicted absolute and relative flow angles. On the other
hand, discrepancies between measured and predicted relative flow angles
at the inlet of the second rotor were due to errors in measured absolute
flow angles as well as differences in axial velocity levels. As men-
tioned in section 4.1, the difficulty in ascertaining the circum-
• ferential extent of the free-stream and wake regions behind the stator
blade rows adversely affects the precision of those circumferential-
mean absolute flow angles determined from the measured data.
Figure 4.13 shows a comparison between measured and predicted
circumferential-mean axial velocities ahead of and behind each blade
oI
'p 1 W
91
34.0oo
,y .- STATION 1
30.00
0 MEASURED"- PREDICTED
- 26.001
.34.00 .?-."STATION 2
30.00
-F
":'-:" 26.001 1. 34.00
u. STATION 3|--J
30.00
26.00 I I I I I0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB-,,-
-4
Figure 4.13 Comparisons of the measured and predicted spanwisedistributions of circumferential-mean axial velocity
= 0.587 at 2400 rpm).
5?..
--" " '-'- " ... .. ...- " '" " " ". ' : :.. . . . .: .::"::.:.: i::::".i :. ?q : ',' 'd * ." .. -4- -.- "."" .........."" " " " "
W. K ..T.
92
34.00STATION 4
S30.00
< 26.00,
34.00STATION 5
S30.00- 00MEASURED
' -PREDICTED
26.00 II0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
Figure 4.13 concluded.
93
row. The measured axial velocities are higher than the predicted
axial velocities except near the shroud end-wall. As shown in the
contour maps of the previous section (see Figure 4.6), there was a
.' loss region (lower total-head fluid) near the shroud end-wall. The
lower total-head fluid corresponded to lower axial velocities. In
order to achieve the design point flow coefficient, the actual midspan
axial velocities would have to be larger to compensate for the lower
axial velocities near the shroud end-wall, thus explaining the higher
measured midspan axial velocities. Subsequent tests using tuft probes
showed that the flow was separating at the shroud lip of the compres-
sor inlet bell housing. This behavior contributed to a larger shroud
*- end-wall boundary layer than might be expected normally. Subsequent
tests with a new inlet have all but eliminated flow separation at the
=- 2 inlet of the compressor.
, - Spanwise distributions of the circumferential-mean values of total
head, incidence angles, and deviation angles are shown for the first-
and second-stage rotors in Figure 4.14, and for the first- and second-
stage stators in Figure 4.15. The comparisons of the measured and
predicted spanwise distributions of circumferential-mean total head
behind both rotor and stator rows (Figure 4.14 (a) and 4.15 (a)) show
-VI significantly lower measured total-head levels than predicted by the
design code, and less measured energy addition per stage as well as
less overall energy addition than predicted by the design code. As
mentioned earlier in connection with the velocity triangle plots
(Figures 4.10, 4.11, and 4.12), the measured axial velocities were
generally higher than predicted by the design code (also see Figure
% .:
*" "-.." " " - . " " % ' ,' ' ' - ' . . . . " . . " . ". " " " " "
#2..",,, r " " ,, :. ' . ' . , .... ". ", . . : i; .:. Y ."': ,. . :",:.;
6.00 FIRS" ROTOR EXIT
5.00
* IEC
c~4.00
0
3.001 1 1 1' 10.50 __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
wjSECOND ROTOR EXIT
9.50
0 MEASURED- PREDICTED
8.50
7.501*0.0 20.0 40.0 60.0 80.0 100.0
N PERCENT SPAN FROM HUB
(a) TOTAL HEAD
__Figure 4.14 Comparisons of the measured and predicted spanwisedistributions of circumferential-mean data for the
first and second stage rotors (4=0.587 at 2400 rpm).
J*. ...
4.00 FIRST ROTOR INLET
LUJ
LUJ
0.00
LUJ
LU
-4.00
4.00 0 MEASURED SEODROTOR INLET
S0.00LU
-40
-.00.00 20.0 40.0 60.0 FR M H B80.0 100.0
PERCENT SPAN FO U
(b) INCIDENCE ANGLE
Figure 4.1.4 continued-
96
8.00FIRST ROTOR EXIT
LaJ
0.0
8.00
4 .00
-
r I-L
0.0010.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
(c DEVIATION ANGLE
* ~.Figure 4.14 concluded.
97
5.50FIRST STATOR EXIT
4.50
............................
3.50
2.50 III
~11.00SECOND STATOR EXIT
z10.00
S.9 . 0 0
.0
.,4 .00 1
oa MEASUREDAFigure~~~~~~~~~ 41CoprsnoftemaueanprdcdPREDITE
v ditiuin fcrufreta-endt o h
0.0s 20.0 40.0 n 60.0e 80.0or 0.0 t20 p)
98j
4.00FIRS STTOR NLE
UU
4.00 FIS TTO NE
LU
Ua
SEON STTO-LE
L. 0.00
U
-4.00,0.00~SEON 2TAT0 INLET.8.010.
PERCET SPN FRM HU(b-NCDNE NL
Fiue41-cniud
99
8.00 FIRST STATOR EXIT
UD
.4.00
0OMEASURED-- PREDICTED
0.00 III
8 .00
U.'
IL
SECOND STATOR EXIT
0.00 II0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
(C) DEVIATION ANGLE
Figure 4.15 concluded.
d4,
100
4.13). The higher measured axial velocities resulted in less measured
flow turning than was predicted. With less measured flow, turning the
measured energy addition would be less than predicted, as is shown in
Figure 4.14 (a) and Figure 4.15 (a). The measured circumferential-mean
.- total head is consistently lowest at the shroud which again shows
effects due to the higher shroud end-wall losses as a result of the
-" " flow separation at the shroud lip of the inlet bell housing. The
measured total head behind the second rotor and stator is also low
near the hub which is due to hub end-wall effects beginning to appear
there.
*..' As found from inspection of the velocity triangles, the first-stage
rotor measured and predicted deviation angles (Figure 4.14 (c)) compared
favorably. Flow behind the second rotor exit shows slightly poorer
agreement between the measured and predicted deviation angles. The
poorer agreement between the measured and predicted deviation angles
for the second-stage rotor is due to the fact that the second-stage
.. blade angles for the actual compressor and design code are different
(see Figure 4.16). For economic reasons, both stages of the actual
compressor were designed based on the first-stage blading of the
design code. The actual second-stage rotor exit blade angles are
greater than the design code blade angles, and since the measured and
predicted relative flow angles were about the same this resulted in
smaller deviation angles than predicted by the design code. Figures
4.16 and 4.14 (c) show that the design code blade exit angles for the
first rotor are greater than those for the second rotor, and that the
design code deviation angles are slightly greater for the second rotor
-Ri
.. ...
"" -". .. . - .- . . . .- - . - - . '- - -- " " -' .- "' "' '- " " '- ' " " - " ".i i i". ?.i'-. > - ".'" .' .
- - . . . . . . .v VW- .- - -
.5.. 101
ROTOR
66.00-
62.00-
_j 58.00
U.'
J*IJ-. SECOND STAGE
Note: First-stage blade angles50.00used for both stages of
baseline compressor.
0.00 20.0 40.0 60.0 80.0 100.0-~PERCENT SPAN FROM HUB
Figure 4.1.6 Spanwise distributions of design code rotor blade angles.
.
.5
102
50.00ROTOR
* 46.00p
S42.00
LL;
S38.00-Lii
-FIRST STAGE--SECOND STAGE
Note: First-stage blade angles:1.0 used for both stages of
baseline compressor.
.1 ~ ~ ~ 2.00 -0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM HUB
Figure 4.16 concluded
_P P -_ 7
{ .:0
103
than for the first rotor. The actual blade exit angles for the first
and second rotors were the same, and the actual deviation angles for
the first and second rotors were about the same. The good agreement
between measured and predicted deviation angles indicates that the
deviation angle prediction correlation used in the design code (see
Appendix A) is quite good. Measured incidence angles (Figure 4.14 (b))
were lower than desired for both rotors. However, these incidence
angle differences did not result in appreciable deviation angle differ-
ences. Measured stator incidence angles (Figure 4.15 (b)) show poor
agreement with predicted stator incidence angles. Comparisons of the
measured and predicted stator deviation angles (Figure 4.15 (c)) also
show poor agreement. The reason for the poor agreement between
measured and predicted stator deviation angles in contrast to the good
agreement between measured and predicted rotor deviation angles is
partially due to the greater uncertainty in absolute flow angle measure-
ments behind a stator blade row (see Table 4.1). However, not all of
the difference between the measured and predicted stator deviation angles
can be accounted for by the measurement uncertainty. No satisfactory
explanation has been found for the additional differences in measured
and predicted stator deviation angles, except to blame the deviation
angle prediction method used. A comparison of the stator blade angles
for both stages is shown in Figure 4.17.
The spanwise distributions of the measured and predicted blade
loss coefficients for each blade row are shown in Figure 4.18. The
difficulty in accurately predicting blade losses is evidenced by the
large discrepancies between the measured and predicted blade losses.
*, S
104
34.00STATOR
U 30.00- FIRST STAGEILU SECOND STAGE
LUj
0 Note: First-stage blade angles fW used for both stages of
baseline compressor.-z 26.00--/.
LI.'220
lop
0.00
STATOR
U,
, -4.00'V 0
0.0 20. 40060080010.
PERCENT SPAN FROM HUB
Figure 4.17 Spanwise distributions of design code stator blade angles.
105
0.20FIRST STAGE
0.16-
0.12
U-
LI.
'~0.08
0.0
-VJ
-0.0
PERCENT ERROR BANDHU
.,
% -00 60.00. 004.08. 0.
106
0.24SECOND STAGE
0.20
V. 0.16
0 MEASURED- PREDICTED
IERROR BANDB0.12
cc
0.0
0.08
0.04
0.0 0.20 0.40 0.60 0.80 100.0PERCENT SPAN FROM HUB
(a) ROTOR LOSS
Figure 4.18 Continued.
ho
107
0.24
0.20
FIRST STAG3E
0.16
LAA.
0.1
0.08 -
0.0
0.00
0 MEASURED- PREDICTED
ERROR BAND
-0.04,III0.00 20.0 40.0 60.0 80.0 100.0
PERCENT SPAN FROM4 HUB(b) STATOR LOSS
Figure 4.18 Continued.
%.%
.4-rz ~
'IL
108
0.0SECOND STAGE
0.16
'.LA.
0.12
0.08
J(J
- PREDICTE
*ERROR BAND
(b) STTO LOS
Figur 0.00onlued
$A
109
Although the uncertainties in the measured loss coefficients are quite
large, the design code blade loss predictions are generally lower than
the measured losses. Thus, it seems the blade loss correlation used in
-. the design code (see Appendix A) is inadequate. With the lower pre-
* - dicted losses and higher predicted overall energy addition, the pre-
dicted overall efficiency would be expected to be much higher than the
measured overall efficiency, as is shown in Figure 4.1 (c).
.
5. SUMMARY AND CONCLUSIONS
A two-stage baseline research compressor has been designed which
has resulted in:
1. Higher blade-chord Reynolds numbers than were previously
attainable with three-stage compressor blading.
2. A better blade material which would be more durable than
that already available.
3. Conventional blade-section shapes.
4. A favorable ratio of number of rotor blades to number of
stator blades.
5. Elimination of inlet guide vanes.
This baseline compressor can provide a suitable means for evaluat-
ing specific stator blade modifications for possible improved control
of end-wall and secondary flows. The data acquisition system and
computer programs developed during this research program are expected
to aid in the acquisition and reduction of associated time-averaged
measurements.
Some limitations of the design code used to design the baseline
compressor have been observed. The blade loss prediction correla-
tions (see Appendix A) were shown to be inadequate. The deviation
angle correlation (see Appendix A) proved to be quite accurate for
predicting rotor but not stator blade deviation angles.
A curious pattern of total head distribution was observed down-
stream of the second rotor. The relationship between the observed
distribution of rotor exit total head and the interaction between
*; .--. . * ~ * - *. . . U ... -
. . .. . . . . . . .
112
upstream stator wakes and the rotor has been studied further and is
discussed in another report (Reference 12).
Z%,
6;.
113
6. RECOMMENDATIONS FOR FURTHER RESEARCH
The next phase of research included tests of a specific stator
blade geometry designed for improved control of end-wall and secondary
flows (see Reference 12). A stator blade geometry, designed for
improved control of end-wall and secondary flows, was selected and
p ~tested in conjunction with the baseline compressor described in this
report.
Relative to the compressor design code used to design the baseline
compressor, it is clear that improvements in stator blade deviation
angle and rotor and stator blade loss prediction correlations are
required. These correlation methods were developed in the 1950s from
two-dimensional cascade tests of fairly conventional blade sections
(i.e., parabolic, circular arc, double circular, etc.). Periodically
unsteady effects due to blade wake chopping, transport, and interaction
.. should also be investigated further to help explain the unusual total-
head distribution behind the second rotor of the research compressor.
LS-
A,'.
4.-'.
r.-. .;-; **. . .. . . .. . . . . . .
?. ",, ,..
115
7. REFERENCES
1. Mitchell, W. S., and Soileau, J. F. "Turbine Exit Guide Vane
Program." AFAPL-TR-77-75, November 1977. .•
2. Wisler, D. C. "Core Compressor Exit Stage Study, Volume lI-Data
and Performance Report for the Baseline Configurations." NACA
CR-159498, November 1980.
3. Senoo, Y., Taylor, E. S., Batra, S. K., and Hink, E. "Control of 61
Wall Boundary Layer in an Axial Compressor." Gas Turbine
Laboratory Report No. 59, Massachusetts Institute of Technology,
June 1960.
4. Schmidt, D. P., and Okiishi, T. H. "Multistage Axial-Flow Turbo-
machinery Wake Production, Transport, and Interaction." ISU-ERI- . .
Ames-77130, TCRL-7, November 1976.
5. Crouse, J. E., and Gorrell, W. T. "Computer Program for Aerodynamic
and Blading Design of Multistage Axial-Flow Compressors." NASA
Technical Paper 1946, 1981.
6. Bryans, A. C., and Miller, M. L. "Computer Program for Design of
% Multistage Axial-Flow Compressors." NASA CR-54530, 1967.
7. Sofrin, T. G. "Aircraft Turbomachinery Noise, Fan Noise." Notes -O
from the Course in the Fluid Dynamics of Turbomachinery, Iowa
State University, Ames, Iowa, 1973.
8. Morgan, B. D. "A Water Column Balance Pressure Reference System."
Unpublished Report, Department of Mechanical Engineering, Iowa
State University, Ames, Iowa 1979.
4 9. Greville, T. N. E. Theory and Applications of Spline Functions.
New York: Academic Press, 1967.
.-
° .PREVIOUS PAGE...""" --ll IS BLANK.i,
- .[ -r. r * * .
116
10. Wylie, C. R. Advanced Engineering Mathematics. New York:
McGraw-Hill Book Company, Inc., 1975.
11. Kline, S. J., and McClintock, F. A. "Describing Uncertainties in
Single Sample Experiments." Mechanical Engineering, 75 (1953),
3-8.
-~.12. Tweedt, D. L., and Okiishi, T. H. "Stator Blade Row Geometry
Modification Influence on Two-Stage Axial-Flow Compressor Aero-
dynamic Performance." ISU-ERI-Ames-84179, TCRL-25, December 1983.
13. Zierke, W. C., and Okiishi, T. H. "Measurement and Analysis of?. .-
4
the Periodic Variation of Total Pressure in an Axial-Flow
Compressor Stage." ISU-ERI-Ames-81121, TCRL-18, November 1980.
14. Dring, D. P., Joslyn, H. D., and Hardin, L. W. "An Investigation
of Axial Compressor Rotor Aerodynamics." Transactions of the ASME,
Journal of Engineering for Power 104, No. I (January, 1982):
- .. 84-96.
15. Johnson, I. A., and Bullock, R. 0., eds. "Aerodynamic Design of
Axial-Flow Compressors." U.S. NASA SP-36, 1965.
Ae.
• ° %"A
St 117
8. ACKNOWLEDGMENTS
We would like to express our appreciation to our colleagues of the
Iowa State University Engineering Research Institute/Mechanical
Engineering Department Turbomachinery Components Research Laboratory
for their assistance and encouragement, in particular, Daniel L. Tweedt
for his help in obtaining and reducing data and George K. Serovy for
his helpful comments. We are also grateful to Leon Girard and Kurt
Ante for their dispatch of related machining, and to the staff of the
Iowa State University Engineering Research Institute/Office of Edi-
torial Services/Technical Illustration for their patience and expertise ,
in editing the text and in helping to prepare the many figures and
. tables in this report. Finally, we acknowledge the support of the Air
Force Office of Scientific Research (James D. Wilson - Contract Monitor)
throughout.
I-o
..
:'.,i'- D
-. .. . . . .
119
" 9. APPENDIX A: USER-DEFINED CORRELATIONS USED IN NASA DESIGN CODE
Advanced compressor design codes frequently require the user to
input various empirical correlations of blade profile losses and
incidence and deviation angles, and annulus-wall blockage factors. The
various user-defined correlations required as input to the NASA design
code are presented in this section. The actual tabular input to the
design code is given in Appendix B. The variables used in the correla-
tion parameters are defined in the symbols and notation section.
9.1. Blade Loss
The blade loss correlations used are illustrated in Figure 9.1.
The loss curves are typical of annular cascade tests of double-circular-mSarc blades as used in the baseline compressor. The correlating param-
eters are:
Loss aramter cosp ,SLoss parameter 2 approximate measure of blade wake
momentum thickness to chord ratio.
where 0 c/s
v2 (rVy) - (rV)D-factor 1- - +
V1 o(r 1 + r2)v 1
* Percent span from hub
The trends shown are similar to those indicated in Figure 203 of
Reference 115].
15 BLANK
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w!~ ~ -_z~- 7,7
120
K:-2.00 pROTOR BLADE LOSSHI STREAML INES
100% SPAN
1.50 -FROM HUB
90%
1.00
80%
0.50000
0.001
0.50'STATOR BLADE LOSS ALL STREAMLINES
0.00.0.20 0.30 0.40 0.50 0.60 0.70
DIFFUSION FACTOR
Figure 9.1 Blade loss correlation curves used inNASA design code.
121
**,-'..
'9.2. Incidence and Deviation Angle
The design code provided several options for the incidence and
- :-:deviation angle correlations. A two-dimensional incidence angle cor-4..
relation was considered suitable for the baseline compressor design.
Carter's rule was selected for the deviation angle correlation. Both
correlations are described below.
The incidence angle correlation is described in Chapter VI of
~... Reference 15 in the form of:
i =i +nO0
where n is obtained from Figure 138 of Reference 15 as a function of
C" and K1
0= blade camber angle
1= (K) (K) (i incidence angle for zero cambersh 1 t 10
where (io) is obtained from Figure 137 of Reference 1510
(Ki) 0.7 for double circular arc bladessh
(K) is obtained from Figure 142 of Reference 15 as a
function of t /c• ,i-.,max
The deviation angle correlation (Carter's rule) described in
Chapter VII of Reference 15 is
mc mO
where m is obtained from Figure 160 of Reference 15 for circular arci c
blades.
'7-. . . . . . . . .- '
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0:4 123
10. APPENDIX B: NASA DESIGN CODE RESULTS
The output from the NASA design code is presented in the following
tables. Table 10.1 lists all input parameters and user-defined corre-
lations, in tabular form, required for the design code analysis.
Table 10.2 lists the aerodynamic output (e.g., velocity triangle in-
formation, blade element performance, etc.) for 11 streamlines at each
axial computation station. The NASA design code gives the streamline
radial positions as a percentage of the blade span measured from the
shroud end-wall, whereas, the convention used for all data figures in
this report is percent span measured from the hub end-wall. Table 10.3 p
lists the stage and overall mass-averaged aerodynamic performance param-
eters. Table 10.4 and Table 10.5 list the manufacturing coordinates at
17 spanwise locations for the rotor blade and stator blade, respectively.
Only the first stage stator and rotor blade manufacturing coordinates
generated from the NASA design code are given as they were used for
both stages of the baseline compressor. Figure 10.1 shows representa-
tive rotor and stator blade sections and associated manufacturing
coordinate nomenclature.
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11. APPENDIX C: COMPUTER PROGRAMS AND DATA STORAGE
The computer programs used during this research program are listed
in this section. These programs as well as all experimental data and
reduced data results are stored on magnetic tapes (cassette or reel)
and are indexed according to tape and file numbers as specified below.
Actuator position correlation program: Linear least-squarescorrelation between actuator potentiometer voltage readout andactuator motion for probe and circumferential positioningactuators; cassette 1, file 1
Slow-response data acquisition program: Acquisition of time-averaged total-head and flow angle survey data; cassette 2, file 1
Compressor overall performance acquisition program: Acquisitionof compressor torque meter based performance data; cassette 2,file 2
Time-averaged data reduction program A: Reduction of time-averaged data to obtain point flow-field parameters andcircumferentially-averaged flow-field parameters (a plottingoption is available); tape DSMDH, file 16
Time-averaged data reduction program B: Reduction of time-averaged data to obtain rotor, stator, stage, and overallperformance parameters; cassette 3, file 1
Contour map generation program: Generates contour maps of pointflow-field parameters over two stator pitches behind any bladerow; tape DSMDH, file 15
Data uncertainty: From estimates of primary measurementuncertainties calculates, using the procedure of Kline andMcClintock [11], the uncertainty estimates for all flow-fieldand performance parameters; cassette 3, file 2
Time-averaged data, station 1: Storage of circumferential surveydata at 10%, 30%, 50%, 70%, and 90% span locations including probedata, outer annulus-wall static-head data, and test conditionparameters; tape COMP, file 1
Time-averaged data, station 2: Storage of circumferential surveydata at 10%, 30%, 50%, 70%, and 90% span locations including probedata, outer annulus-wall static-head data, and test conditionparameters; tape COMP, file 2
* ""p. --..- -. .- - - -. -,' . . ..- '.' - .'.'.- -.€ -.- -' -. '- -. " . ' --- - -.,. - . -'-'- - -' '- -. . -..i. ' .'. .. .
156
Time-averaged data, station 3: Storage of circumferential survey
data at 10%, 30%, 50f, 70%, and 90% span locations including probe 6data, outer annulus-wall static-head data, and test conditionparameters; tape COMP, file 3
Time-averaged data, station 4: Storage of circumferential surveydata at 10%, 30%, 50%, 70%, and 90% span locations including probedata, outer annulus-wall static-head data, and test conditionparameters; tape COMP, file 4
Time-averaged data, station 5: Storage of circumferential surveydata at 10%, 30%, 50%, 70%, and 90% span locations including probedata, outer annulus-wall static-head data, and test condition
parameters; tape COMP, file 5
Reduced time-averaged data, station 1: Storage of results of datareduction program A; tape COMP, file 6
Reduced time-averaged data, station 2: Storage of results of datareduction program A; tape COMP, file 7
Reduced time-averaged data, station 3: Storage of results of datareduction program A; tape COMP, file 8
Reduced time-averaged data, station 4: Storage of results of datareduction program A; tape COMP, file 9
Reduced time-averaged data, station 5: Storage of results of datareduction program A; tape COMP, file 10
10
4-.
I,
157
12. APPENDIX D: PARAMETER EQUATIONS
The equations used in calculating the time-averaged and performance
parameters are presented in this section. The symbols used in the equa-
tions are defined in the symbols and notation section and the sign
conventions are shown in Figure 12.1. Circumferentially or radially
.-
averaged parameters were obtained using a spline-fit integration scheme--,
12.1. General Parameters
12.1.1. Basic Fluid Properties
'.9°
2Barometric pressure, N/n
Patn = hg@t (1.0-0.00018 (tiaro-273.15)) Yhg@273o' eba ro
12.1
*3. Density of air, kg/n
.4.
Patmp Rt 12.2R t
3Specific weight of water, N/in 3
"H20 = I (996.86224 + 0.1768124 t - 459.67)- 2.64966 x 10 -
12.3
.-IO• "" '" " "' " " " "° " " " "" "" " • " % ". " " % '% %$ % " ",'% "% - " " " %" " "" " ' "'"~ "" '*' " "* " '" ,€ " • " " "' ""
* N..158
Y911N K V'
YVV
K V
y Vi
-I...
STATOR
US/K
VV~
V SY
2
v2
Figure 12.1 Sketch showing nomenclature and sign conventions(al p os itivye except as noted) for si ow-response
% instrtlment parometers.
W--~~~~ 7.y ---.
159
12.1.2. Blade-Element location
Percent passage height from hub:
PHH r-0.14224 x 100 12.40.06096
12.2. Flow-Field Parameters
12.2.1. Point and Circumferential-Average Blade Element Quantities "
Total head, Nm/kg:
P tyH 0H = 2 12.5
p
and
SIH dY 12.6SJS " S
0
Absolute flow angle behind rotors (see Figure 12.1 for sign
convention), degrees:
ScfPy P dY 12.7
S 0
Absolute flow angle behind stators (see Figure 12.1 for sign
convention), degrees:
py acoss PdY'" Y~freestream ro s y.-
L. freestream""'
-
160
Annulus outer surface endwall static head, Nm/kg:
P YjqwHO
2h = 12.9w p
-
- and
S..-
S.S
hS f P dY 12.10
- I - 0
.4,.
Static head (radial equilibrium equation), Nm/kg:
"'. d 2 sin y(-h)dh _ _ _ _ 12.11
dr r
Absolute fluid velocity, m/s:
V = ' 2 g (H-h) 12.12cp
and
-. Ja.
S1 0 V dY 12.13=Ss
Blade velocity, m/s:-'
rnRPHU= 30.0 12.14-30.
~.- .. '
..... .
161
Axial component of absolute fluid velocity, m/s:
V Vcos~ 12.15z y
and
V =Vcos 12.16z y
Tangential component of absolute fluid velocity (see Figure 12.1
* . for sign convention), m/s:
V Vsin~ 12.17y y
and
V =Vsin p12.18y y
Tangential component of relative fluid velocity (see Figure 12.1
., for sign convention), m/s:
V =U-V 12.194.y y
and
V =U- 12.20y y
-4Relative fluid velocity, m/s:
V = (V ')2 +(V )2 12.21y z
I .,
162
and
V VV' 2 - 2 12.22y
• Relative tangential flow angle (see Figure 12.1 for sign convention),
degrees:
I,.- 9(V13 tan 1 12.23
.J I
and
5. V
I-..,
Incidence angle for rotors (see Figure 12.1 for sign convention),
degrees:
1y -K 12.25R y,1,R 1,R
"J S
Deviation angle for rotors (see Figure 12.1 for sign convention),
- degrees:
6R y,2,R - K2 ,R 12.26
,~ .o
5%o o
-' ' •
_.-_%°
%° , °
S: O
.-'oV , .. o . - o .o ' . • . - ., - .. . - , - -. * ' . . . . - . . ° ' . . - o ,- ' o % . . - . ' - - . ' .
Al" ""' ."-"."-"-; . ... _-,' '., ,, .,-,-". -"- .''-""'-'-'''' '.-.." '. ,,' "-" '. "",""' .. I ' ,- - . ,", .,;".
163
Incidence angle for stators (see Figure 12.1 for sign convention),
degrees:
s- K 12. 27
lS y,l,S KS
" . Deviation angle for stators (see Figure 12.1 for sign convention),
:!!'i.!idegrees:",
S6S = Py,2,S K K2,S 12.28
Flow coefficient:
Z 12.29
4,..
12.2.2. Global Parameters3 14m3/s :
Venturi volume flow rate, m /s:
2gy AP"."-" vent
Qv 0.05229 2 12.30
:.**-*.'.
Venturi flow coefficient:
Q r= At 12.31
q . .. . . .
.. Ut
1 ..W.. -..T. 7W . r rW.. .. C
164
Integrated volume flow rate at probe axial measurement locations,
3m /S:
Q = 2n t r12.32a frh
LIntegrated flow coefficient at probe axial measurement stations:
aat
Integrated and venturi flow-coefficient comparison, percent:
a -,
FCC a vX 100 12.34 N2-v
General radial mass-average parameter equation (let be any
g eneral parameter):
] VZ r drh
h 12.35
frt V z,2 rr d
rh
12.2.3. Performance Parameters (based on cobra probe measurements)
Actual total-head rise coefficient for rotor:
4# HR 12.36'A R 2
t
%*
165
Actual total-head rise coefficient for stage:
g (H -H )c 2,S 1,R 12.37stage 2
Ut
Actual total-head rise coefficient for overall compressor:
g (H 2 2 Hl )- 2,2 12.38
1Poverall U2 L223
t
Ideal total-head rise coefficient for rotor:
U(V - V )-vT y,2,R y1,R123
i,R2
Ideal total-head rise coefficient for stage:
U(V - Vy I'S y1PR
i=tg 2 yp12.40
Ideal total-head rise coefficient for overall compressor:
4f +P ='P 12.41i,overall 1,1R i,2R
Hydraulic efficiency for rotor:
rl 12.42
Hydraulic efficiency for stage:
%P
stage124
*...... .. *. . ...... *.** 1.43 r
.........................
.5 ***'
166
Hydraulic efficiency for overall compressor:
~overall W 1 veal 24i ,overall
Total-head loss coefficient for rotor:
UR 2 W 12.45
(VlR
Total-head loss coefficient for stator:
WS -2g (H 2, Is 12.46c (V 2)
i's
12.2.4. Performance Parameters Used in Generating Performance Map
Cross-section average absolute velocity at the exit of the second
' ~ stator assuming zero swirl, m/s:
Qv
*V 12.47z,2,2S,pm A
Cross-section average total-head at the exit of the second
stator assuming constant circumferentially average static-head,
Nm/kg:
H =h+V1242,2S,pm w,2,2S,pm 2,2S,pm124
4ZI b
.4.7-7%
167
Actual head-rise coefficient for overall compressor:
2,2Spm124overall,pm 2
U t
Ide.'-l work coefficient:
4 - TYCRPI 12.50IPM 3OpQ U2
V t
Mechanical efficiency:
"overall ,pm 1.5ne % .~~ 25
*44
IM
Ito
Zee.
169
13. APPENDIX E: TABULATION OF EXPERIMENTALLY DETERMINED DATA
The time-averaged data obtained ahead of and behind each blade row
are tabulated in this section. All data were obtained at the design
point flow condition predicted by the design code (i.e., 2400 rpm at a
flow coefficient of 0.587). The measured point-by-point distributions
of various flow-field parameters are listed in Table 13.1. The corre-
sponding circumferentially-averaged flow-field parameters are listed
in Table 13.2. The axial locations of the measurement locations with
respect to the blade rows are depicted in Figure 2.5, for a radial
(spanwise) view, and Figure 3.6, for the circumferential survey window.
Total head and static head were measured with respect to atmospheric
pressure. The sign conventions for flow angles, incidence angles, and
deviation angles are shown in Figure 12.1. A complete listing of
mathematical symbols is given in the SYMBOLS AND NOTATION section. The
definitions of the Fortran variables used in the computer output
listings of Tables 13.1 and 13.2 are:
o BETA R = Relative flow angle, yy
o BETA Y = Absolute flow angle, fy.y
o FC = Flow coefficient, *.
o HS = Static head with respect to atmospheric pressure, h,
Nm/kg.
o IT = Total head with respect to atmospheric pressure, H,
- -. Nm/kg.
o PHIH = Percent passage height from hub, PHH.
o V = Absolute velocity, V, m/s.
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o VY = Tangential component of absolute fluid velocity, V, m/s.
o VZ = Axial component of fluid velocity, V, m/s.
o VYR = Tangential component of relative fluid velocity, V , m/s.
0 Y/SS = Circumferential spacing, Y/Ss "
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