NASA Technical Reports Server (NTRS) 20060050746: Design and Analysis of a Turbopump for a Conceptual Expander Cycle Upper-Stage Engine

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Source of Acquisition
NASA Marshall Space Flight Center
DESIGN AND ANALYSIS OF A TURBOPUMP
FOR A CONCEPTUAL EXPANDER CYCLE
UPPER-STAGE ENGINE
D. Domey, J. Rothermel, L. Griffin, R. Thornton, J. Forbes, S. Skelley
NASA Marshall Space Flight Center
MSFC, AL
F. Huber
Riverbend Design Services
Palm Beach Garden, FL
Symposium on Advances in Nunerical ModeEnQ of Aerodynamics and Hydrodynamicsi n Turbomachinery
-I
Outline
Motivation
Numerical method
Numerical simulations
- vaneless diffuser
-
vaned diffuser
Conclusions
Symposium on Advances in Nunerical Modelingo f Aerodynamics and Hydrodynamicsi n Turbomachinery
1
Motivation * J
Develop technologies to be applied to CLVlCEV
engine programs
+
- analytical tools IDr neanline analysis and 3D CFD
- mechanical design
- water flow tests
Design a conceptual expander-cycle upper stage engine
Demonstrate the design using water flow testing
I Symposium on Advances in Nunerical Mocblng of Aerodynamicsa nd Hydrodynamics in Turbomachinery
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Numerical Methods I
Meanline analysis and geometry generation
Pump Design
- Concepts NREC design suite
Agile Engineering Design System@, PUMPALO, CCADO
Diffuser design
- Riverbend Design Services pump design code
Symposium on Advances in Nmarical Modeling of Aerodynamics and Hydrodynamics in Turbomachinery
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. I
-
Numerical Methods II
PHANTOM CFD code
Three-dimensional, unsteady N-S equations
Generalized Equation Set formulation
-
Handles liquids and gases
-
Incompressible, compressible and supersonic flow
-
Preconditioning for incompressible flows
Implicit, time marching, finite difference scheme
3rd order spatially, 2nd order temporally accurate
Modified Baldwin-Lomax turbulence model
Overlaid 0- and H-grids
Symposium on Advances in Nmerical Modeins of Aerodynamicsa nd Hydrodynamicsi n Turbomachinery
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Numerical Methods 111
MPI for parallel simulations
Fluid property routines
- Perfectgas
- Real fluid property routines for xenon, N,, H,, H,O, O,, RP,
CH, CO, NH, ,, MMH and N204
-
Two types of real fluid property routines
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Routines provided by J. Oefelein of Sandia Labs
liquid and gas
- Solve equations of state, etc.
-
Routines derived from the NlST tables liquid and
gas
- Surfaces generated from splines of data
3
I'
Design Requirements for Water Flow Rig
Operate in existing water flow facility
977 gpm flow rate
Rotational speed of 3600 RPM
70% flow coefficient throttling capability
Diffuser vanelvolute radius and passage constraints due to
rig requirements
-
vanes must accommodate 17 bolts
e Actual engine was designed to have two stages, but the
water flow model designed to have one stage
Symposium on Advances in Nunerical Modelng OF Aerodynamics and Hydrodynamicsi n Turbomachinery
Guide Vane and Impeller Design
Head-flow Meanline Performance
18
16
t
14
30
12
3 1
g
08
2
06
04
03 05 07 09 11
Symposium on Advances in Numerical Modelingo f Aerodynamics and Hydrodynamics in Turbomachinery
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Guide Vane and Impeller Design
rll
Mean Streamtube Analysis
0 10 20 30 40 50 SO 70 80 90 100 110
X Meridional Length
Streamlines Impeller pressure rise
Symposium on Advaneas in Nunerical Modebng of Aerodynamics and Hydrodynamicsi n Turbomachinery
Guide Vane and Impeller Design
Final Pump Desian
1. 15 inlet guide vanes
2. Impeller with 7 main
blades and 7 splitter
blades
Symposium on Advancer in Numerical Modelingo f Aerodynamicsa nd Hydrodynamicsi n Turbomachinew
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4w
CFD for IGV, Impeller, Vaneless Diffuser
Computational grid contains
1 4.75 million grid points
y+ values of -4 on endwalls
I 1 1 y+ value of -Io n airfoils
I
full 360 deg modeled
I Simulations run on 72-106
i processors of an SGI Altix
plitter blade
I
Symposium on Advances in Nunericrl ModeCng d Aerodynamicsa nd Hydrodynamics in Turbomachinery
CFD for IGV, Impeller, Vaneless Diffuser
Timeaveraged static pressure (psi)
Ar-
t
h
I
Symposium on Advances in Nunerical Modelingo f Aerodynamicsa nd Hydrodynamics in Turbomachinery
6
4F
CFD for IGV, Impeller, Vaneless Diffuser
Relative total pressure h i )
A
y P -
Timaaveraged Instantaneous
Symposium on Advances in Numerical Modeling of Aerodynamics and Hydrodynamics in Turbomachinery
CFD for IGV, Impeller, Diffuser
Performance predicted by meanline and CFD codes
1.1 I I
5
1.0
i: ::
NE1- ESS
0.7
U
0.6
0.5
:::
.-
-
-Head coefficient Meanline
Y 0.2 -
!5 --Impeller Efficiency CFD
0.1
0.5 0.6 0.7 0.8 0.9 1.0
Normalized Flow Coefficient
Symposium on Advances in Numerical ModeEngo f Aerodynamics and Hydrodynamics in Turbomachinery
7
CFD for IGV, Impeller, Vaneless Diffuser
Impeller inlet and exit flow
1. o
0.0
0.8
0.7
0.6
C
Z0.S
u)
0.4
0.3
0.2
0.1
0.0
-20 -15 -10 3 0 5 10 15 20
1st Stage Impeller Flow Angles (deg)
,
Symposium on Advancer in Nunerical Mdngo f Aerodynamics and Hydrodynamics in Turbomachinery
CFD for IGV, Impeller, Vaned Diffuser
-c
I I I I
Variable Optimum Actual
I I I I
L/W, 4.00 2.60
17 diffuser vanes
chord of vane limited by
collector
SYmpOSiUm on Advances in Nunerical Modeling of Aerodynamics and Hydrodynamics in Turbomachinery
8
CFD for IGV, Impeller, Vaned Diffuser w
Timeaveraged loading on the impeller and diffuser
-
-
L O l 2 3 4 5 6 0 II I 2I . 3I . I l . 5
Arc Length (in) Arc Length (in)
Impeller Diffuser
Symposium on Advances in Nunerical Modeling of Aerodynamics and Hydrodynamics in Turbomachinery
. I
CFD for IGV, Impeller, Vaned Diffuser A -
Unsteadiness on the impeller trailing edge with downstream diffuser vanes
h
L d
400 om2 Lom -& ?Tk+ 001 0012 0014
Time (sec)
Pressure trace Pressure decomposition
1 ~~
Vane passing frequency = 1 0 2 0 4
Symposium on Advances in Numerical Modeling of Aerodynamics and Hydrodynamics in Turbomachinery
9
CFD for IGV, Impeller, Vaned Diffuser I
Unsteadiness on the diffuser leading edge with the upstream impeller
z
t:IM
E
Pressure trace Pressure decomposition
1 Blade passing frequency = 840 Hz 1
SympOtium on Advances in Nunerical ModeCng of Aerodynamics and Hydrodynamics in Turbomachinery
Water Flow Tests
Symposium on Advances in Numerical Modelng of Aerodynamics and Hydrodynamics in Turbomachinery
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