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Impeller blades for centrifugal turbopumps designed quickly with help of computer program. Generates blade contours and continually subjects them to evaluation. Checks physical parameters to ensure they are compatible with required performance and recycles design if criteria not met. Program written for centrifugal turbomachinery, also adapted to such axial pump components as inducer blades and stator vanes.
The research is reported which was conducted to develop devices for measuring vibrations and deflections of parts, such as impellers, shafts, turbine wheels, and inducers in operating turbopumps. Three devices were developed to the breadboard stage: ultrasonic Doppler transducer, flash X-rays, and light-pipe reflectance. It was found that the X-ray technique is applicable to the shaft assembly and the turbine seal of the J-2 pump, and the light-pipe-reflectance device appears to be ideal for cryogenic pump sections.
This report describes the research tasks during the past year. The research was mainly in the area of computational grid generation in support of CFD analyses of turbomachinery components. In addition to the grid generation work, a numerical simulation was obtained for the flow through a centrifugal gas compressor using an unstructured Navier-Stokes solver. Other tasks involved many different turbomachinery component analyses. These analyses were performed for NASA projects or for industrial applications. The work includes both centrifugal and axial machines, single and multiple blade rows, and steady and unsteady analyses. Over the past five years, a set of structured grid generation codes were developed that allow grids to be obtained fairly quickly for the large majority of configurations we encounter. These codes do not comprise a generalized grid generation package; they are noninteractive codes specifically designed for turbomachinery blade row geometries. But because of this limited scope, the codes are small, fast, and portable, and they can be run in the batch mode on small workstations. During the past year, these programs were used to generate computational grids were modified for a wide variety of configurations. In particular, the codes or wrote supplementary codes to improve our grid generation capabilities for multiple blade row configurations. This involves generating separate grids for each blade row, and then making them match and overlap by a few grid points at their common interface so that fluid properties are communicated across the interface. Unsteady rotor/stator analyses were performed for an axial turbine, a centrifugal compressor, and a centrifugal pump. Steady-state single-blade-row analyses were made for a study of blade sweep in transonic compressors. There was also cooperation on the application of an unstructured Navier-Stokes solver for turbomachinery flow simulations. In particular, the unstructured solver was used to analyze the flow through a centriftio compressor impeller.
The point of departure (POD) turbopump concept was reviewed and finalized. The basis for the POD was the configuration presented in the Aerojet proposal. After reviewing this proposal concept, several modifications were made. These modifications include the following: (1) the dual pump discharge arrangement was changed to a single discharge; (2) commonality of the turbine inlet manifold with the advanced launch system (ALS) liquid oxygen (LOX) TPA was dropped for this program; (3) the turbine housing flange arrangement was improved by relocating it away from the first stage nozzles; (4) a ten percent margin (five percent diameter increase) was built into the impeller design to ensure meeting the required discharge pressure without the need for increasing speed; (5) a ten percent turbine power margin was imposed which is to be obtained by increasing turbine inlet pressure if required; and (6) the backup concept, as an alternative to the use of cast impellers, now incorporates forged/machined shrouded impellers, rather than the unshrouded type originally planned.
Prediction of rotordynamic behavior for high energy concentration centrifugal pumps is a challenging task which still imposes considerable difficulties. While the mechanical modeling of the rotor is solved most satisfactorily by finite element techniques, accurate boundary conditions for arbitrary operating conditions are known for journal bearings only. Little information is available on the reactive forces of annular seals, such as neck ring and interstage seals and balance pistons, and on the impeller interaction forces. The present focus is to establish reliable boundary conditions at annular seals. For this purpose, a full scale test machine was set up and smooth and serrated seal configurations measured. Dimensionless coefficients are presented and compared with a state of the art theory.
As part of an internal research and development project, NASA Marshall Space Flight Center (MSFC) has been developing a high specific impulse 9,000-lbf LOX/LH2 pump-fed engine testbed with the capability to throttle 10:1. A Fuel Turbopump (FTP) with the ability to operate across a speed range of 30,000-rpm to 100,000-rpm was developed and analyzed. This small size and flight-like Fuel Turbopump has completed the design and analysis phase and is currently in the manufacturing phase. This paper highlights the manufacturing and processes efforts to fabricate an approximately 20-lb turbopump with small flow passages, intricately bladed components and approximately 3-in diameter impellers. As a result of the small scale and tight tolerances of the hardware on this turbopump, several unique manufacturing and material challenges were encountered. Some of the technologies highlighted in this paper include the use of powder metallurgy technology to manufacture small impellers, electron beam welding of a turbine blisk shroud, and casting challenges. The use of risk reduction efforts such as non-destructive testing (NDT) and evaluation (NDE), fractography, material testing, and component spin testing are also discussed in this paper.
Two types of advanced seals for liquid oxygen (LOX) turbopumps were investigated. One was a spiral-groove face seal whose function is to seal high-pressure LOX at the impeller end of the turbopump. The other was a floating-ring, Rayleigh-step, helium buffered seal used to prevent LOX ingress to the turbine side of the unit. For each seal type, two sizes were investigated (50 and 20 mm). A turbine-driven test rig was designed and manufactured, and a test program was completed on the 50 mm floating-ring, Rayleigh-step, helium buffered seal. Significant results were: vaporization in the flow path could cause failure by overheating; therefore, the spiral-groove pumping portion of the seal that provides the fluid film must circulate fluid without disruption if vaporization occurs in the sealing dam. This is successfully accomplished by a pressure-balanced spiral-groove concept that is described. The spiral-groove configuration is affected by turbulence in the fluid film and pressure drops due to fluid inertia at sudden contractions. The net results of these effects are deep grooves, large operating films, and high power loss when compared against seals operating with laminar films. Turbulence and inertia are induced by the high-density and low-viscosity characteristics of LOX. The program clearly pointed out the need to consider system environmental factors such as thermal and centrifugal distortions and rotor vibrations in the seal design.
The high pressure turbomachinery of the Space Shuttle Main Engine has the highest power-to-weight ratio of any operational machine known. Subsynchronous rotor whirl of the high pressure oxygen turbopump occurred in development testing at full-power level (109 percent thrust). The means by which the turbopump was successfully uprated is presented herein. The subsynchronous motion was determined to be driven by impeller destabilizing forces in combination with low net damping and bearing degradation. The degradation resulted from ball wear due primarily to an excessive loading condition of operating too near the lightly damped rotor second critical speed while under a large static load and, secondarily, from reverse bearing loading or loss of internal clearance and coolant during simulated flight conditions. The rotor response was reduced by stiffening the shaft and supports, optimizing the stiffness and damping of annular seals, and increasing the bearing deadband. The uprated oxygen turbopump configuration was verified by converting the pump and bearing support into a load cell for the purpose of systematically quantifying the load reduction benefits relative to baseline turbopumps. The damped second critical speed margin and the load sharing have been substantially improved which has resulted in reduced bearing loads for improved service life of the machine at full-power level.
A finite-difference, three-dimensional incompressible Navier-Stokes formulation to calculate the flow through turbopump components is utilized. The solution method is based on the pseudocompressibility approach and uses an implicit-upwind differencing scheme together with the Gauss-Seidel line relaxation method. Both steady and unsteady flow calculations can be performed using the current algorithm. In this work, the equations are solved in steadily rotating reference frames by using the steady-state formulation in order to simulate the flow through a turbopump inducer. Eddy viscosity is computed by using an algebraic mixing-length turbulence model. Numerical results are compared with experimental measurements and a good agreement is found between the two. Included in the appendix is a paper on incompressible viscous flow through artificial heart devices with moving boundaries. Time-accurate calculations, such as impeller and diffusor interaction, will be reported in future work.
This viewgraph presentation provides an overview of the computational approach to developing a ventricular assist device (VAD) which utilizes NASA aerospace technology. The VAD is used as a temporary support to sick ventricles for those who suffer from late stage congestive heart failure (CHF). The need for donor hearts is much greater than their availability, and the VAD is seen as a bridge-to-transplant. The computational issues confronting the design of a more advanced, reliable VAD include the modelling of viscous incompressible flow. A computational approach provides the possibility of quantifying the flow characteristics, which is especially valuable for analyzing compact design with highly sensitive operating conditions. Computational fluid dynamics (CFD) and rocket engine technology has been applied to modify the design of a VAD which enabled human transplantation. The computing requirement for this project is still large, however, and the unsteady analysis of the entire system from natural heart to aorta involves several hundred revolutions of the impeller. Further study is needed to assess the impact of mechanical VADs on the human body
The investigation of the flow in a centrifugal pump indicated that the flow patterns in frictional fluid are fundamentally different from those in frictionless fluid. In particular, the dead air space adhering to the section side undoubtedly causes a reduction of the theoretically possible delivery head. The velocity distribution over a parallel circle is also subjected to a noticeable change as a result of the incomplete filling of the passages. The relative velocity on the pressure side of the vane, which for passages completely filled with active flow would differ little from zero even at comparatively lower than normal delivery volume, is increased, so that no rapid reverse flow occurs on the pressure side of the vane even for smaller delivery volume. It was established, further, that the flow ceases to be stationary for very small quantities of water. The inflow to the impeller can be regarded as radial for the operating range an question. The velocity triangles at the exit are subjected to a significant alteration in shape ae a result of the increased peripheral velocity, which may be of particular importance in the determination of the guide vane entrance angle.
A methodology (and hardware and software to implement the methodology) has been developed as a means of investigating coupling between certain rotordynamic and hydrodynamic phenomena in turbomachines. Originally, the methodology was intended for application in an investigation of coupled rotordynamic and hydrodynamic effects postulated to have caused high synchronous vibration in the space shuttle s high-pressure oxygen turbopump (HPOTP). The methodology can also be applied in investigating (for the purpose of developing means of suppressing) undesired hydrodynamic rotor/stator interactions in turbomachines in general. The methodology and the types of phenomena that can be investigated by use of the methodology are best summarized by citing the original application as an example. In that application, in consideration of the high synchronous vibration in the space-shuttle main engine (SSME) HPOTP, it was determined to be necessary to perform tests to investigate the influence of inducer eccentricity and/or synchronous whirl motion on inducer hydrodynamic forces under prescribed flow and cavitation conditions. It was believed that manufacturing tolerances of the turbopump resulted in some induced runout of the pump rotor. Such runout, if oriented with an inducer blade, would cause that blade to run with tip clearance smaller than the tip clearances of the other inducer blades. It was hypothesized that the resulting hydraulic asymmetry, coupled with alternating blade cavitation, could give rise to the observed high synchronous vibration. In tests performed to investigate this hypothesis, prescribed rotor whirl motions have been imposed on a 1/3-scale water-rig version of the SSME LPOTP inducer (which is also a 4-biased inducer having similar cavitation dynamics as the HPOTP) in a magnetic-bearing test facility. The particular magnetic-bearing test facility, through active vibration control, affords a capability to impose, on the rotor, whirl orbits having shapes and whirl rates prescribed by the user, and to simultaneously measure the resulting hydrodynamic forces generated by the impeller. Active control also made it possible to modulate the inducer-blade running tip clearance and consequently effect alternating blade cavitation. The measured hydraulic forces have been compared and correlated with shroud dynamic-pressure measurements.