Open Eng.

2015; 5:399–410

Symkom 2014 Open Access

Andrey Rusanov, Roman Rusanov, and Piotr Lampart*

Designing and updating the flow part of axial and

radial-axial turbines through mathematical
modeling
DOI 10.1515/eng-2015-0047 the process of improving the flow passages is the use of
Received Feb 20, 2015; accepted Oct 21, 2015 computational fluid dynamics (CFD) [4, 5].
Studies of physical processes taking place in the flow
Abstract: The paper describes an algorithm for the design
systems and ways to improve them by solving design tasks
of axial and radial-axial type turbines. The algorithm is
and developing methods of CFD have been carried out at
based on using mathematical models of various levels of
the A. N. Podgorny Institute of Mechanical Engineering
complexity – from 1D to 3D. Flow path geometry is de-
Problems of the National Academy of Sciences of Ukraine
scribed by means of analytical methods of profiling using
(IPMach) for more than 50 years. A great contribution to
a limited number of parameters. 3D turbulent flow model
the development of these methods was first given by profs.
is realised in the program complex IPMFlow, developed
George Proskura and Leonid Shubenko-Shubin [6, 7], then
based on the earlier codes FlowER and FlowER-U. Exam-
by profs. George Sokolowski, Vitali Gnesin and Sergey
ples of developed or modernized turbines for different-
Yershov [8, 9]. At IPMach software systems FlowER and
purpose power machines are presented. They are: an ex-
FlowER-U have been developed, designed to calculate spa-
pansion turbine, ORC turbine and cogeneration medium-
tial viscous flows in turbomachines [10, 11]. These pro-
pressure turbine.
grams have been widely used in many research and devel-
Keywords: expansion turbine; ORC turbine; cogeneration opment centers [12, 13]. Since 1995 there has been a close
medium-pressure turbine; CFD; axial turbine; radial-axial cooperation in the field of testing and developing CFD
turbine codes for turbomachinery applications with the Szewalski
Institute of Fluid-Flow Machinery of the Polish Academy of
Sciences in Gdansk. Works carried out at IFFM headed first
by prof. Jerzy Krzyżanowski, then continued by prof. An-
1 Introduction
drzej Gardzilewicz aimed also at increasing flow efficiency
and optimisation of turbine blading systems [14, 15].
With an ever-growing shortage of energy resources one of
An approach to the design of flow parts for stages of
the main requirements for modern turbine plants is their
axial and radial-axial type turbines based on the use of
high efficiency. The increased efficiency of turbomachines
mathematical models of various levels of complexity is
is possible as a result of their gas-dynamic perfection [1–3].
presented in this paper [16, 17]. 3D turbulent flow model
On the other hand, flow improvements in turbomachinery
is realized in the program complex IPMFlow, which origi-
are not yet fully exhausted. They are possible by optimis-
nates from programs FlowER and FlowER-U. Examples of
ing plane sections of the blades, 3D blade profiling, special
turbomachines developed with the help of the described
profiling of meridional contours, etc. Especially helpful in
algorithm are presented – an expansion turbine, ORC tur-
bine and cogeneration medium-pressure turbine.

Andrey Rusanov: A.N. Podgorny Institute of Mechanical

Engineering Problems, NASU, Kharkov, Ukraine; Email: ru-
2 An algorithm for the designing of
sanov@ipmach.kharkov.ua flow parts stages of turbine
Roman Rusanov: The Szewalski Institute of Fluid-Flow Machinery,
PAS, Gdańsk, Poland; Email: rrusanov@imp.gda.pl
*Corresponding Author: Piotr Lampart: The Szewalski Insti- An algorithm for the design of turbine axial and radial-
tute of Fluid-Flow Machinery, PAS, Gdańsk, Poland; Email: lam- axial types is introduced in Figure 1. The first step is a
part@imp.gda.pl

© 2015 A. Rusanov et al., published by De Gruyter Open.

This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivs 3.0 License.
mmetric equations [18, 19]. To construct the full three-dimensional geometry of the flow
t on the basis of the obtained geometric characteristics, analytical methods of profiling of
w parts are used. These methods allow us to build turbine stages of axial and radial-axial
es. 400 | A. Rusanov et al.

parts are used. These methods allow us to build turbine

stages of axial and radial-axial types.
Calculations of three-dimensional flows in the result-
ing flow parts of turbine stages are performed using the
program complex IPMFlow. Most 3D calculations are per-
formed on coarse grids (with a relatively small number
of cells). The refined grids are used only for final calibra-
tion calculations. The algorithm of designing turbine flow
parts can be automated. To do this, methods for solving
optimization tasks should be used to automate the pro-
f 3D geometry of the flow part cess of analysing the results and generate new values of
variable parameters (geometric characteristics of the flow
hod of parameterization and analytical profiling is used for building geometry of
part) [20–24]. An automated approach usually requires
bine blades [41]. The blade is given by an arbitrary setseveral
of flat profiles,
hundred each
to several of iterations [18, 25].
thousand
idered in the Cartesian coordinate system with the x-axis parallel to the axis of
nd the y-axis coinciding with the cascade front (Fig. 2).
Figure 1: Flowchart of turbine stage flow designing
Figure 1. Flowchart of turbine stage flow designing 3 3D flow calculation method
Calculations of three-dimensional flows in the resulting flow parts of Theturbine
software complex IPMFlow implements the follow-
stages
performed using the program complex IPMFlow. Most 3D calculations are ing performed
elements ofonthe mathematical model: the Reynolds-
rse grids (with a relatively small number of cells). The refined grids are used only for
averaged final
nonstationary Navier-Stokes equations [26–29],
bration calculations. The algorithm of designing turbine flow parts can be automated.
several To turbulence models, including an SST
differential
this, methods for solving optimization tasks should be used to automate the process model
two-parameter of of turbulence of Menter [30–33] and
lysing the results and generate new values of variable parameters (geometric
implicit quasi-monotone high-order ENO-scheme [34–36].
racteristics of the flow part) [20-24]. An automated approach usually To requires several
account for thermodynamic properties of the work-
ndred to several thousand iterations [18, 25].
ing medium, an analytical interpolation method is used
for approximating equations of the formulation IAPWS-
3D flow calculation method
The software complex IPMFlow implements the following elements 95 [37, 38].of
Thethe
results of computations obtained from the
thematical model: the Reynolds-averaged nonstationary Navier-Stokes equations [26-29], the necessary reliability in the quali-
code IPMFlow have
tative
eral differential turbulence models, including an SST two-parameter model of structure
turbulenceof the flow and in the quantitative charac-
teristics of
Menter [30-33] and implicit quasi-monotone high-order ENO-scheme [34-36]. To accountthe isolated turbine cascades and turbine as a
whole [39,
thermodynamic properties of the working medium, an analytical interpolation 40]. is
method
d for approximating equations of the formulation IAPWS-95 [37, 38]. The results of
mputations obtained from the code IPMFlow have the necessary reliability in the
litative structure of the flow and in the quantitative characteristics of the isolated turbine
cades and turbine as a whole [39, 40]. 4 Building of 3D geometry of the
flow part
A method of parameterization and analytical profiling
is used for building geometry of axial flow turbine
Figure 2: Profile cascade blades [41]. The blade is given by an arbitrary set of flat
Figure 2. Profile cascade profiles, each of which is considered in the Cartesian co-
ordinate system with the x-axis parallel to the axis of the
ades are defined
preliminarybycalculation
plane profiles (Fig.characteristics
of geometrical 2) described of by leading and trailing
turbine, and the y-axis coinciding with the cascade front
and pressure
the curves. The leading
flow part using and trailing
relatively simple methods, edges
based onare circle arcs. The suction
(Fig. 2).
solving one-dimensional or quasi-axial-symmetric equa-
urves are polynomials of the 5-th and 4-th order, respectively: The blades are defined by plane profiles (Fig. 2) de-
tions [18, 19]. To construct
5
the full three-dimensional ge-
scribed by leading and trailing edges, suction and pressure

y ( x)  a i x , ai  const
ometry of the flow part on thei basis of the obtained geomet-
ric characteristics, analytical
i 0
methods of profiling of flow
(1)leading and trailing edges are circle arcs. The
curves. The
suction and pressure curves are polynomials of the 5-th
4

y ( x)  ai xi , ai  const (2)
i 0
put data for building of the profile cascade are: bx – profile width, α1 – camber
le; r1 – leading edge radius; α2ef – cascade effective angle; r2 – trailing edge
scade pitch; α – "bevel" angle of pressure curve, α = α + α ; α , α –
ent associated with it. Initial data for the construction of the meridional endwalls are: Komentarz [SM1]: There is a word
rmin − maximum and minimum radiuses of the rotor channel; xmax  rotor width; lin, lex
missing here

t and exit heights; inhub , ex

hub
in ,  ex − angles of the tip and hub endwalls at the inlet
, tip tip

Designing and updating turbines through mathematical modeling | 401

xit (Fig. 3).

After the determination of the suction surface as well

as the leading and trailing edges, coefficients of the pres-
sure curve (2) are found from the following set of equa-
tions:
⎧
⎪
⎪ y p (x1p ) = y1p
⎪
′
⎪
⎨y p (x1p ) = tan (α1 − ∆α)
⎪
⎪
⎪
y′′p (x1p ) = y′′p,O (5)
{︀ }︀
⎪
⎪
⎪y p (x2p ) = y2p
⎪
⎪
⎪
⎪
⎩ ′
y p (x2p ) = tan α2p

where x1p , y1p , x2p , y2p are coordinates of the tangency

points with the leading/trailing edge circles, which can
be found from the assumed angle α1 − ∆α at the leading
edge and angle α2p at the trailing edge. The angle α2p is
Figure 3: View of the rotor in the meridional plane
Figure 3. View of the rotor in the meridional plane found from the range between α2ef and α2s so as to assure
the minimum curvature of the pressure curve (Fig. 2) or
and 4-th order, respectively: α2s − ∆α2 is given.
5
∑︁ For building the radial-axial turbine stage, a method
y(x) = ai xi , a i = const (1) described in [42] is used (Fig. 3). The leading edge is as-
i=0 sumed parallel to the rotational axis x, the trailing edge is
normal to the axis of rotation.
4
Tip and hub endwalls are described by the curves con-
∑︁
y(x) = ai xi , a i = const (2)
i=0 sisting of an arc and a straight segment associated with
it. Initial data for the construction of the meridional end-
The input data for building of the profile cascade are: walls are: r max , r min - maximum and minimum radiuses of
b x - profile width, α1 - camber line inlet angle; r1 - leading the rotor channel; x max rotor width; l in , l ex - inlet and exit
edge radius; α2ef - cascade effective angle; r2 - trailing edge heights; α hub hub tip tip
in , α ex , α in , α ex - angles of the tip and hub
radius, t - cascade pitch; α2c - "bevel" angle of pressure endwalls at the inlet and exit (Fig. 3).
curve, α∞ = α2s + α2c ; ∆α1 , ∆α2 - leading and trailing edge The blade is defined on two sections of rotational sur-
angles. 1p, 2p, 1s, 2s denote points of conjugation of the faces of the tip and hub endwalls. The sections are de-
input and output edges with the suction and pressure side scribed by coordinates: rφ - along the circumference; s -
curves (Fig. 2). distance from the leading edge. Profile coordinates on ro-
Coefficients which describe the suction curve (1) are tational surfaces of the tip and hub endwalls are found as
found from the following set of equations: a sum of coordinates for the mean line rφ ml (Fig. 4a) and
profile thickness ∆rφ (Fig. 4b):
⎧
′
⎪y s (x1s ) = tan (α1 + ∆α1 )
⎪
⎪
y′′s (x1s ) = y′′s,O
⎪ {︀ }︀
rφ(s) = rφ ml (s) + ∆rφ(s) (6)
⎪
⎪
⎪
⎪
⎪
⎨y (x ) = y
⎪
s O 0
(3) The mean line is a 3-rd order polynomial (Fig. 4a):
′
⎪y s (x O ) = tan (α O )
⎪
3
⎪
⎪ ∑︁
y s (x2s ) = y2s ai si
⎪
⎪
⎪
⎪
⎪ rφ ml = (7)
⎩ ′
⎪ i=0
y s (x2s ) = tan {α2s }
where a i - coefficients. The profile, symmetrical with re-
where x1s , y1s , x2s , y2s are coordinates of the tangency
spect to the mean line, is composed of: 1-2 - leading edge;
points with the leading/trailing edge circles, which are de-
2-3 - arc circle; 3-4 - straight interval; 4-5 - trailing edge.
termined by the given angle α1 + ∆α1 at the inlet edge. Pa-
The initial data for building the profile are: b s - pro-
rameters α2s and y′′O in equation (3) are chosen in a way to
file width; β in , β ex - mean line angles at the leading and
provide the assumed value of throat O and assure the min-
trailing edge; r in , r ex - leading/trailing edge radiuses; c max
imum curvature of the curves (1). The throat can be calcu-
- maximum profile thickness; ∆α - leading edge angle; d -
lated from the cascade pitch and effective angle
distance from the trailing edge, where the second deriva-
O = t cos α2ef (4) tive of the mean line equals 0 (Fig. 4).
 the leading edge. Profile coordinates on rotational surfaces of the tip and hub endwalls are
found as a sum of coordinates for the mean line rφml (Fig. 4а) and profile thickness rφ
(Fig. 4b):
402 | A. Rusanov et al. r (s)  r ml (s)  r (s) (6)

а b
Figure 4: Blade section: a - blade mean line; b - blade
Figure thickness
4. Blade with respect
section: to the mean
а − blade meanlineline;
b − blade thickness with respect to the mean line
Table 1: Basic geometric dimensions of the flow part
The mean line is a 3-rd order polynomial (Fig. 4а):
Nr Parameter
3 Size, mm
1 D1 , diameter of
rml  the si
ai stator leading edge 406.10 (7)
i 0
2
where ai − coefficients. TheDprofile,
2 , mean symmetrical
diameter of the withstator 320.26
respect to the mean line, is composed
3 D , diameter of the stator trailing edge 284.28
of: 1-2 − leading edge; 2-3 − arc circle; 3-4 − straight interval; 4-5 − trailing edge.
3
4 for
The initial data D4 , building
diameterthe of the rotorare:
profile bs −edge
leading profile width;
270.00βin, βex − mean line
angles at the leading
5 and D trailing
5 , edge;
diameter of rthe
in, r
rotor
ex − leading/trailing
shaft edge radiuses; cmax −
80.10
maximum profile thickness;
6 α − leading
l1 , channel heightedge at theangle; d − distance
rotor inlet from the trailing edge,
7.15
where the second derivative
7 of the mean
l2 , channel heightlineatequals 0 (Fig.
the rotor 4).
output 27.90
8 b, axial dimension of rotor blades 65.00
4. Examples of design and modernization of flow parts of different-purpose power
machinery

5 Examples of design
4.1. Turbine and
for a turbo-expander unit operating in a complex gas preparation plant
With the help of the developed algorithm, the flow part of a turbine has been designed
modernization of flow
for a turbo expander parts of
MTDA-3,0-10,4-MP-U2 [43] (manufacturer "Turbogaz").
different-purpose power
A view of the basic geometric characteristics of the designed flow part is shown in
Fig. 5 and Table 1. The rotor is of a radial-axial type with a radial stator.
machinery
5.1 Turbine for a turbo-expander unit
operating in a complex gas preparation
plant

With the help of the developed algorithm, the flow part of

Figure
Figure 5: Turbine 5. Turbine
of turbo expanderof turbo expander
a turbine has been designed for a turbo expander MTDA-
3,0-10,4-MP-U2 [43] (manufacturer "Turbogaz"). Table 1. Basic geometric dimensions of the flow part
№ de-
A view of the basic geometric characteristics of the Parameter
MP-U2 in the Timofeevskii oil gas condensate field Size,
(Fig.mm10)
1 Dis1, diameter
signed flow part is shown in Fig. 5 and Table 1. The rotor of the stator leading edge
in the Hadiach Poltava region. The performed tests con- 406.10
2 D2, mean diameter of the stator 320.26
of a radial-axial type with a radial stator. firmed all the declared characteristics.
3 D3, diameter of the stator trailing edge 284.28
Figs. 6 and 7 show visualization of the stator flow4 forD4, diameter of the rotor leading edge 270.00
the nominal mode and the minimum and maximum 5 flow
D5, diameter of the rotor shaft 80.10
rates. It is seen that in all modes, despite significant6 posi- 5.2 height
l1, channel ORCatcogeneration
the rotor inlet plant turbine 7.15
tive and negative angles of attack, the flow is without7 sepa-
l2, channel height at the rotor output 27.90
8 b, axial dimension of rotor blades
ration. Fig. 8 shows the integral characteristics of the flow Several variants of axial and radial-axial turbines 65.00 for a
part in different modes obtained on the basis of their per- cogeneration ORC unit of power output 100 kW were de-
Figs. 6 and 7 show visualization of the stator flow for the nominal mode and th
formance. It is seen that the resulting internal efficiency
minimumofand signed
maximum [44]. Therates.
flow turbines
It is are
seendesigned
that in alltomodes,
operate on MDM
despite significant positiv
the flow part throughout the range is greater than and92%. as a working
negative angles medium.
of attack, the flowThe is pressure drop in the
without separation. Fig.turbine
8 shows the integr
The currently developed turbine flow part ischaracteristics
shown in bladingof the flow part in
system is different
equal to modes
70. Theobtained on the basis
inlet parameters ofde-
are their performanc
It is seen that the resulting internal efficiency of the flow part throughout the range is great
Fig. 9. It is mounted on a turbo-expander MTDA-3,0-10,4- termined as: pressure - 12 bar, temperature 553.5 K. For
than 92%.
The currently developed turbine flow part is shown in Fig. 9. It is mounted on a turb
expander MTDA-3,0-10,4-MP-U2 in the Timofeevskii oil gas condensate field (Fig. 10)
the Hadiach Poltava region. The performed tests confirmed all the declared characteristics.
 and negative angles of attack, the flow is without separation. Fig. 8 shows the integral
characteristics of the flow part in different modes obtained on the basis of their performance.
It is seen that the resulting internal efficiency of the flow part throughout the range is greater
than 92%.
The currently developed turbine flow partand
Designing is shown in turbines
updating Fig. 9. Itthrough
is mounted on a turbo-
mathematical modeling | 403
expander MTDA-3,0-10,4-MP-U2 in the Timofeevskii oil gas condensate field (Fig. 10) in
the Hadiach Poltava region. The performed tests confirmed all the declared characteristics.
a – the minimum flow; b - the nominal mode; c - the maximum flow

a b c
Figure 6. Contours of static pressureaand velocity vectors. b c
a – the minimum flow;ofbstatic
Figure 6: Contours - the nominal
pressure mode;
and velocity c - the
vectors.
Mid-blade-to-blade maximum
Mid-blade-to-blade
meridional flow of
Figure 7. Contours of static
meridional
section the pressure
section
rotor: and
of the velocity
rotor: vectors.
a - the Mid-span
minimum flow; blade-to-blade
b - the
nominal mode; c - the maximum flow section of the rotor: a – the minimum flow; b - the nominal mode; c - the maximum flow
a – the minimum flow; b - the nominal mode; c - the maximum flow

a b c
a b
Figure 7. Contours of static pressure and velocitycvectors. Mid-span blade-to-blade
Figure
of 7:static
Contours of static pressure and velocity vectors. Mid-span
7. Contours pressure
section of and velocity
the rotor: a – thevectors.
minimum flow;blade-to-blade
Mid-span section of the rotor: a – the minimum flow; b - the nomi-
blade-to-blade
b - the nominal mode; c - the maximum flow
nal mode; c - the maximum flow
f the rotor: a – the minimum flow; b - the nominal mode; c - the maximum flow
Figure 8. Operating characteristics of the flow part

Figure 9. The manufactured rotor

Figure 9: The manufactured rotor

Figure 8. Operating characteristics of the flow part

Figure
Figure 8:8. Operating
Operating characteristics
characteristics of the flow partof the flow part

the cogeneration ORC installation, the temperature in the

condenser is set at 363 K at the saturation pressure of
0.17 bar. The meridional section of the axial turbine for
9000 rev/min is presented in Fig. 11, whereas turbine geo-
metric characteristics are collected in Table 2.
This flow part consists of 7 stages. The first three
Figure 10: Expansion
rotor turbineturbine
MTDA-3,0-10,4-MP-U2
Figure
stages have a partial admission. The last three 9. The
stages Figure 10. Expansion
manufactured
have MTDA-3,0-10,4-MP-U2
3D shaped blades (Fig. 12). Endwall contours are also 3D
4.2. ORC cogeneration plant turbine
Several variants of axial and radial-axial turbines for a cogeneration ORC
power output 100 kW were designed [44]. The turbines are designed to operate on MD
working medium. The pressure drop in the turbine blading system is equal to 70. Th
parameters are determined as: pressure – 12 bar, temperature 553.5 K. For the cogen
Figure 9. The manufactured rotor
ORC installation, the temperature in the condenser is set at 363 K at the saturation pres
 404 | A. Rusanov et al.

Table 2: Geometric characteristics of the blading system for turbine 2

stage exit swirl angles are near 0. The obtained velocity vectors are regular (Fig. 13, 14). The
flow efficiency of the turbine is equal to 84.2 % (the tip leakage loss is not included).
Stage
1 2 3 4 5 6 7
number
Partial
0.25 0.4 0.75 1 1 1 1
admission
Figure 10. Expansion turbine MTDA-3,0-10,4-MP-U2
α0 , deg 0 0 0 0 0 0 0
α1 , deg 4.2. ORC
77.72 78
cogeneration plant turbine 78 77 77 77 77
β1 , deg 61.64875 64.77799
Several variants of axial 63.319066
and radial-axial63.56912
turbines for a63.7599
cogeneration62.15225
ORC unit of49.8569
are stage 7 rotor 7
β2 , deg power−65.52
output 100 kW were designed
−67.86 [44]. The turbines
−67.86 −67.86 designed
−67.08to operate on MDM as a −66.3
−65.52
working medium. The pressure drop in the turbineFigure blading system issections
equal to 70. The inlet
α2 , deg 15.5785 −3.317 7.18631 −17.691 −13.43267 of stator
12. Hub-to-tip 3.485 7.4917
and rotor blades for stages 5-7
parameters are determined as: pressure – 12 bar, temperature 553.5and K. isometric
For the cogeneration
view of stage 7
r mid , mmORC installation,
58 63.61 58.92 62.6 70 80.9
the temperature in the condenser is set at 363 K at the saturation pressure of 101.68
l, mm 0.17 bar.15.283 15.3
The meridional section of15.7958 15.1035
the axial turbine 23.08715
for 9000 rev/min is presented38.21
in Fig. 11,62.0338
whereas turbine geometric characteristics are collected in Table 2.

are near
stage exit0.swirl
The angles
obtained arevelocity
near 0. The vectors are regular
obtained velocity (Fig. 13, are
vectors 14). TheS 7 (Fig. 13, 14). The
sectionregular
R7
Figure 11: Meridional section of turbine 2 Figure 11. Meridional of turbine 2
urbine is equal to
flow efficiency of 84.2 % (theistip
the turbine leakage
equal loss%is(the
Таbleto2.84.2
Geometric
not included).
tip leakage
characteristics loss
of the is notsystem
blading included).
for turbine 2
Figure 13. Velocity vectors colored by Mach number
Stage in a meridional section at the mid blade-to-blade distance of stage 7
1 2 3 4 5 6 7
number
Partial
0.25 0.4 0.75 1 1 1 1
admission
α0, deg 0 0 0 0 0 0 0
α1, deg 77.72 78 78 77 77 77 77
β1, deg 61.64875 64.77799 63.319066 63.56912 63.7599 62.15225 49.8569
β2, deg -65.52 -67.86 -67.86
Figure 14. -67.86
Velocity -67.08
vectors
Figure -65.52
14.colored
Velocity -66.3colored
byvectors
Mach numberby Mach number
α2, deg
stage exit swirl angles are near 0. The 15.5785
obtained velocity -3.317
vectors are regular (Fig.7.18631
in 14).
13, The -17.691 in-13.43267
a blade-to-blade section at the 3.485
mid-span 7.4917
a blade-to-blade section atstage
of 7
the mid-span of stage 7
rmidto, mm
flow efficiency of the turbine is equal 58leakage loss63.61
84.2 % (the tip 58.92
is not included). 62.6 70 80.9 101.68
l, mm 15.283 A15.3
view and15.7958basic A 15.1035
geometric
view 23.08715
andcharacteristics
basic geometric 38.21
of an 62.0338 radial-axial
alternative
characteristics turbineradial-axial
of an alternative flow tu
part are shown in Figure
part are15shown
and Table 3. The
in Figure 15rotor rotational
and Table speed
3. The rotoris rotational
equal to 14000
speed rev/min.
is equal to 1400
This flow part consists of 7 stages. The first three stages S 7 have a partial admission. The R7
age 7 stage 7last three stages have 3Drotor shaped7blades (Fig. 12). Endwall rotorcontours7 are also 3D shaped there.
Таble 3. Geometric Таble
characteristics
3. Geometric of characteristics
flow path for radial-axial
of flow pathturbine
for radial-axial turbin
The blade loading is optimal
rin, S with
rex, the
S velocity coefficients
lrinin,, SS Figure u/c
14: Velocity on the
0Tvectors level rof
colored 0.45. number
by Mach The in a blade-to-
rlexex,, SS lz,
in, S
S rlex
in, RS z, S, R rlinin, R rmid.ex
mid.ex lex, R, R lz,
in, R
R lex, R
Figure 12: Hub-to-tip sections of stator and rotor blades for stages blade5.43section at 57
the mid-span
Figure 12. Hub-to-tip sections of stator
232,96 and
199 rotor
5.43 blades
232,96 199 for 5.43 stages 185 of stage
5-7
5.43 85.105
57
7 5.43
185 70.19
85.105 11
5.43 70.19
Hub-to-tip sections of stator and rotor blades for stages 5-7
5–7 and isometric view of stage 7
and isometric and isometric rotor
stage 7 view of stage 7
view 7 of stage 7

Figure 12. Hub-to-tip sections of stator and rotor blades for stages 5-7
and isometric view of stage 7

S7 R7
Meridional section
Meridional section Isometric view Isometric view
Figure 13:Figure 13. vectors
Velocity Velocity colored
vectors colored
by Machby Mach
numbernumber
in a meridional
in a meridional section at the mid blade-to-blade distance of stage 7
section at the mid blade-to-blade distance of stage 7Figure 15. View Figure the15:
ofFigure View
flow
15. of theof
system
View flow
for system for radial-axial
theradial-axial
flow system turbine – variant
turbine
for radial-axial– variant
1 1
turbine – variant 1
S7 Although the flowAlthough Rflow
system consists
the 7 ofsystem
only one stage which
consists of onlyconsumes
one stageawhich
large pressure
consumes a larg
S7 drop, flow R 7 drop,
pictures look flow
favourable
picturesforlook
thisfavourable
variant (Fig.
for16-19). The maximum
this variant Mach
(Fig. 16-19). Thenumber
maximum Ma
in the entire
Figure 13. Velocity vectors flowinby
colored domain
theMach does
entire not domain
flow
number exceed does
2. The notflow patterns
exceed 2. Thedo flow
not exhibit
patternsshock
do not exh
phenomena or separations.
phenomena As or
a result, the flow
separations. As efficiency is flow
a result, the high efficiency
and equalsis88.5
high%and
(theequals
tip 88.5
ure 13. in a meridional
Velocity sectionby
vectors colored atMach
the mid blade-to-blade
number
leakage loss is not leakage
included).
distance of stage 7
loss is not included).
onal section at the mid blade-to-blade distance of stage 7
 Designing and updating turbines through mathematical modeling | 405

Table 3:Meridional
Geometric characteristics of flow path for
section radial-axial
Isometric view turbine

Figure 15. View of the flow system for radial-axial turbine – variant 1
Rin , S Rex , S lin , S lex , S z, S Rin , R Rmid.ex , R lin , R lex , R z, R
Although the flow system consists of only one stage which consumes a large pressure
232,96 199
drop, flow pictures look favourable for this variant 5.43
(Fig. 16-19). 5.43 Mach57number 185
The maximum 85.105
S 5.43 70.19 11 R
in the entire flow domain does not exceed 2. The flow patterns do not exhibit shock
phenomena or separations. As a result, the flow efficiency is high and equals 88.5 % (the tip Figure 17. Velocity vectors colored by Mach number
leakage loss is not included). S a blade-to-blade section at the mid blade spanR
in
Figure 17. Velocity vectors colored by Mach number
in a blade-to-blade section at the mid blade span

S R S R
Figure 18. Static pressure contours
Figure 16. Velocity vectors colored by Mach number
Figure 16:inVelocity vectors colored by Mach number in a meridional in a meridional
Figure 18: Static pressuresection at theinmid
contours blade-to-blade
a meridional section
section at the
The medium-pressure
a meridional section at the mid blade-to-blade distance
section at the mid blade-to-blade distance S
flow part of the new modification R
of a T-100 turbine
mid blade-to-blade section
which is marked as T-125/150-12,8Figure was 18.
also developed.
Static The main objective of the desig
pressure contours
to get the internal efficiency in avalue
meridional
notsection
less atthan
the mid blade-to-blade
2.5% higher section
than for the medium pr
cylinder of the existing turbine T-120/130-12,8.
First, calculations and analysis of flow in the existing turbine were made. Fro
obtained results the following activities to improve gas-dynamic efficiency were propos
 change to more modern profiles and using blades with a variable profile alo
blade height starting from S stage 6 (expected gain in efficiency R of 1.0-2.0%);
 change in Figure shape19. of peripheral meridional contours within interstage
Static pressure contours in a blade-to-blade section at the mid blade span gaps to
flow separation in these areas (the expected gain in efficiency R
of 0.5-1.0%);
S
4.3. Cogeneration medium-pressure turbine
S
 Rreplacement of shroud and interdisc seals to more modern (the expected g
Figure
Figure 17: Velocity 17. Velocity
vectors vectors
colored colorednumber
by Mach by Machin efficiencyFigure
number
a blade-to-
19.19:
ofFigure Static
1.0-1.5%). pressure
Static contours
pressure in a blade-to-blade
contours section section
in a blade-to-blade at the mid
at blade span
in a blade-to-blade section at the mid blade span the mid blade span
blade section at the mid blade span Figs. 20 4.3.
andCogeneration
21 show medium-pressure
a view of theturbine
new T-125/150-12,8 medium-pressure turbin
part.
shaped there. The blade loading is optimal with the ve-
locity coefficients u/c0T on the level of 0.45. The stage exit
swirl angles are near 0. The obtained velocity vectors are
regular (Fig. 13, 14). The flow efficiency of the turbine is
equal to 84.2% (the tip leakage loss is not included).
A view
S and basic geometric characteristics R of an al-
ternative radial-axial turbine
Figure 18. Staticflow part
pressure are shown in Fig-
contours
in a meridional section at the mid blade-to-blade section
ure 15 and Table 3. The rotor rotational speed is equal to
14000 rev/min.
Although the flow system consists of only one stage
which consumes a large pressure drop, flowFigure pictures20. look Figure 20: Three-dimensional
Three-dimensional visualization
visualization of aofnew
a newT-125/150-12,8
T-125/150-12,8 CMP turbi
favourable for this variant (Fig. 16–19). The maximum CMP turbine
Mach number in the entire flow domain does notIn exceed
the new2. medium-pressure flow part, the first five stages blades are mad
The flow patterns do not exhibit shock phenomena constant or sep-
profile sections
S R 12,8 wasalong the height,
also developed. Theand
maintheobjective
remainingof thestages
designhave variable
arations. As a result, the flow efficiency is high and
sections equals
along the was
height
Figure 19. Static pressure contours in a blade-to-blade section at the mid blade span
to get the internal efficiency value not less than 2.5% peripheral co
(see Fig. 21). To reduce the flow separation,
88.5% (the tip leakage loss is not included). have a smoother shape higherand
thanthe
for rotor bladespressure
the medium startingcylinder
from stage
of the 7exist-
are performed w
4.3. Cogeneration medium-pressure turbine increasing chord along the blade height (see
ing turbine T-120/130-12,8.
Fig. 21 and 22).
First, calculations and analysis of flow in the existing
5.3 Cogeneration medium-pressure turbine turbine were made. From the obtained results the follow-
ing activities to improve gas-dynamic efficiency were pro-
The medium-pressure flow part of the new modification
posed:
of a T-100 turbine series, which is marked as T-125/150-

Figure 21. Meridional section of the flow part of the T-125/150-12,8 CMP turbi
 change to more modern profiles and using blades with a variable profile along the
blade height starting from stage 6 (expected gain in efficiency of 1.0-2.0%);
 change in shape of peripheral meridional contours within interstage gaps to reduce
406 | A. Rusanovflow et al.separation in these areas (the expected gain in efficiency of 0.5-1.0%);
 replacement of shroud and interdisc seals to more modern (the expected gain in
efficiency
Table 4: Eflciency of CMP of 1.0-1.5%).
T-125/150-12,8 turbine stages
Figs. 20 and 21 show a view of the new T-125/150-12,8 medium-pressure turbine flow
part. Stage Eflciency without Eflciency including
number moisture losses,% moisture losses,%
1 89.85 89.85
2 91.85 91.85
3 91.03 91.03
4 91.76 91.76
5 92.22 92.22
6 91.96 91.96
7 92.56 92.56
8 93.37 93.25
9 93.47 91.96
Figure 20. Three-dimensional
10 visualization
93.48 of a new 90.25
T-125/150-12,8 CMP turbine
11 92.97 87.65
In the new medium-pressure flow part, the first five stages blades are made with
12 92.93 85.6 stages have variable profile
constant profile sections along the height, and the remaining
13 (see Fig. 21).
sections along the height 93.32
To reduce the flow85.1
separation, peripheral contours
have a smoother shape14and the rotor93.49 83.59
blades starting from stage 7 are performed with the
increasing chord along the blade height (see Fig. 21 and 22).

Figure
Figure 21: Meridional section21. Meridional
of the section
flow part of the of the flow
T-125/150-12,8 CMPpart of
turbine the T-125/150-12,8 CMP turbine

S1 R1 S2 R2 S3 R3

S1 R1 S2 R2 S3 R3

S4 R4 S5 R5 S6 R6

S7 R7 S8 R8 S9 R9

S 10 R 10 S 11 R 11 S 12 R 12

S 13 R 13 S 14 R 14

Figure 22. Blade profiles of the newT-125/150-12,8 CMP turbine

Figure 22: Blade profiles of the newT-125/150-12,8 CMPFig.
We can see from turbine
23 and Table. 4 that all stages of a new construction have a
higher efficiency. The total efficiency of the proposed construction, not including humidity
losses is estimated at 92.3%, and with humidity losses - 90.1%. Visualization of the results in
the middle blade-to-blade sections presented in Fig. 24 exhibits favorable flow patterns. Using
new smooth profiles leads to a more monotonous static pressure distribution on the blades
 surfaces (Fig. 25). Flow separation inDesigning
the meridional plane atturbines
and updating the periphery
throughdoes not feature
mathematical modeling | 407
any longer (Fig. 26).

Efficiency, %
96

94

92

90

88

86

84

82

80

Stage
78
1 2 3 4 5 6 7 8 9 10 11 12 13 14

■ – Т-120/130-12,8; ■ – Т-125/150-12,8;
– Efficiency without moisture loss;
– Efficiency including moisture losses

Figure 23: The flow eflciency of turbine blading systems in turbines CMP T-120/130-12,8 and T-125/150-12,8

Figure 23. The flow efficiency of turbine blading systems in turbines

CMP T-120/130-12,8 and T-125/150-12,8

Table 4. Efficiency of CMP T-125/150-12,8 turbine stages

Stage number Efficiency without moisture losses, % Efficiency including moisture losses, %
1 89.85 89.85
2 91.85 91.85
3 91.03 91.03
4 a 91.76 b 91.76
5 92.22 92.22
6 91.96 91.96
7 92.56 92.56
8 93.37 93.25
9 93.47 91.96
10 93.48 90.25
11 92.97 87.65
12 92.93 85.6
13 93.32 85.1
14 93.49 83.59

c d

e f

Figure 24: Static pressure contours

Figure 24.and velocity
Static vectors
pressure in stators
contours and rotors
and velocity at theinmid
vectors spanand
stators blade-to-blade
rotors at the sections
mid of turbine CMP T-
125/150-12,8: a - S 1st stage;
span R 1st stage; c - S
b – blade-to-blade 8th stage;
sections d - R 8th
of turbine CMP T-125/150-12,8:
stage; a –fS–1st
e - S 14th stage; stage;
R 14 b – R 1st
th stage
stage; c – S 8th stage; d – R 8th stage; e – S 14th stage; f – R 14th stage
 408 | A. Rusanov et al.

P, МPа P, МPа
3.4 3.4

3.2 3.2

3.0 3.0

2.8 2.8
_ _
P, МPа 2.6 P, МPа b 2.6 b
3.4 3.4
0.0 0.2 0.4 0.6 0.8 1.0 0.0 0.2 0.4 0.6 0.8 1.0
3.2 3.2

3.0 3.0
a b
2.8 2.8
P, МPа _ P,_ МPа
2.6 0.65 b 2.6 0.65 b
0.0 0.2 0.4 0.6 0.8 1.0 0.0 0.2 0.4 0.6 0.8 1.0

a 0.60 b 0.60

0.55 0.55
P, МPа P, МPа
0.65 0.65

0.50 0.50
0.60 0.60
_ _
0.55 0.45 0.55 b 0.45 b
0.0 0.2 0.4 0.6 0.8 1.0 0.0 0.2 0.4 0.6 0.8 1.0
0.50 0.50

0.45 b
_
0.45 c _
b d
0.0 0.2 0.4 0.6 0.8 1.0 0.0 0.2 0.4 0.6 0.8 1.0
P, МPа P, МPа
0.07 0.07
c d
P, МPа P, МPа
0.07 0.06 0.07 0.06

0.06 0.06
0.05 0.05
0.05 0.05
0.04 0.04
0.04 0.04
_ _
_
_
0.03 0.03 b 0.03 b 0.03 b b
0.0 0.2 0.4 0.60.0 0.8 0.2 1.0 0.0
0.4 0.20.6 0.4 0.8 0.6 1.00.8 1.0
0.0 0.2 0.4 0.6 0.8 1.0

e f
e f
Figure 25. The pressure distribution along the surface profile of the upgraded stators
Figureof25: The pressure distribution along
a – S the surfaceb profile
– R 1st of the upgraded
c – Sthe stators and rotors of turbine CMP T-125/150-12,8: a - S 1st
and rotors turbine Figure
CMP 25. The pressure
T-125/150-12,8: distribution
1st stage; along
stage; 8thsurface profile of the upgraded stators
- R 1st d
stage; b stage; stage;
–and c - S 8
R 8throtors
th stage; d - R 8th stage; e - S 14th stage; f - R 14th stage
– Sturbine
stage; eof 14th stage; f – R 14th stage
CMP T-125/150-12,8: a – S 1st stage; b – R 1st stage; c – S 8th
stage; d – R 8th stage; e – S 14th stage; f – R 14th stage
• replacement of shroud and interdisc seals to more
modern (the expected gain in efficiency of 1.0–1.5%).
Figs. 20 and 21 show a view of the new T-125/150-12,8
medium-pressure turbine flow part.
In the new medium-pressure flow part, the first five
stages blades are made with constant profile sections
along the height, and the remaining stages have variable
profile sections along the height (see Fig. 21). To reduce
the flow separation, peripheral contours have a smoother
S R shape and the rotor blades starting from stage 7 are per-
Figure Figure 26:pressure
26. Static Static pressure
contourscontours and velocity
and velocity vectors
vectors in in the plane at
the meridional formed
mid with the increasing chord along the blade height
blade-to-blade
meridional plane at middistance for the stator
blade-to-blade and rotor
distance ofstator
for the stage 8and (see Fig. 21 and 22).
rotor of stage 8 We can see from Fig. 23 and Table 4 that all stages of
a new construction have a higher efficiency. The total effi-
S R
• change to more modern profiles and using blades ciency of the proposed construction, not including humid-
with a variable
Figure 26. profile
Staticalong the blade
pressure heightand
contours start- ity losses
velocity is estimated
vectors at 92.3%, and
in the meridional planewith
at humidity
mid losses
ing from stage 6 (expected blade-to-blade distance
gain in efficiency 90.1%. Visualization of the
for the stator and rotor of stage 8
of 1.0– results in the middle blade-
2.0%); to-blade sections presented in Fig. 24 exhibits favorable
• change in shape of peripheral meridional contours flow patterns. Using new smooth profiles leads to a more
within interstage gaps to reduce flow separation in monotonous static pressure distribution on the blades sur-
these areas (the expected gain in efficiency of 0.5– faces (Fig. 25). Flow separation in the meridional plane at
1.0%); the periphery does not feature any longer (Fig. 26).
 Designing and updating turbines through mathematical modeling | 409

28 (in Russian)
6 Conclusions [14] Krzyżanowski J., Gardzilewicz A., Lampart P., Badur J., Kardaś
D., On some applications of CFD in design and modernisa-
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K., Elszkowski J., Increasing the eflciency of cylindrical stages
or modernized turbines for different-purpose power ma-
of impulse turbines with the help of 3D flow computations, Proc.
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