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Component data are essential for modelling the overall performance of gas turbines. The component characteristics are not easily obtained, and much of the data are proprietary and not available in the open literature. Several methods are available for estimating component characteristics and are briefly described. The requirements of users and manufacturers are quite different, but both can produce fully credible performance models.
Flow components and instrumentation resistance to high temperature lithium impingement in separator materials study for liquid metal magnetohydrodynamic power system
In support of the Fundamental Aeronautics Program, Subsonic Rotary Wing Project, further gas turbine engine studies have been performed to quantify the effects of advanced gas turbine technologies on engine weight and fuel efficiency and the subsequent effects on a civilian rotary wing vehicle size and mission fuel. The Large Civil Tiltrotor (LCTR) vehicle and mission and a previous gas turbine engine study will be discussed as a starting point for this effort. Methodology used to assess effects of different compressor and turbine component performance on engine size, weight and fuel efficiency will be presented. A process to relate engine performance to overall LCTR vehicle size and fuel use will also be given. Technology assumptions and levels of performance used in this analysis for the compressor and turbine components performances will be discussed. Optimum cycles (in terms of power specific fuel consumption) will be determined with subsequent engine weight analysis. The combination of engine weight and specific fuel consumption will be used to estimate their effect on the overall LCTR vehicle size and mission fuel usage. All results will be summarized to help suggest which component performance areas have the most effect on the overall mission.
The results of the Combustor Component Performance analysis as developed under the Energy Efficient Engine (EEE) program are presented. This study was conducted to demonstrate the aerothermal and environmental goals established for the EEE program and to identify areas where refinements might be made to meet future combustor requirements. In this study, a full annular combustor test rig was used to establish emission levels and combustor performance for comparison with those indicated by the supporting technology program. In addition, a combustor sector test rig was employed to examine differences in emissions and liner temperatures obtained during the full annular performance and supporting technology tests.
The over-all component performance characteristics of the J71 Type IIA three-stage turbine were experimentally determined over a range of speed and over-all turbine total-pressure ratio at inlet-air conditions af 35 inches of mercury absolute and 700 deg. R. The results are compared with those obtained for the J71 Type IIF turbine, which was previously investigated, the two turbines being designed for the same engine application. Geometrically the two turbines were much alike, having the same variation of annular flow area and the same number of blades for corresponding stator and rotor rows. However, the blade throat areas downstream of the first stator of the IIA turbine were smaller than those of the IIF; and the IIA blade profiles were curve-backed, whereas those of the IIF were straight-backed. The IIA turbine passed the equivalent design weight flow and had a brake internal efficiency of 0.880 at design equivalent speed and work output. A maximum efficiency of 0.896 occurred at 130 percent of design equivalent speed and a pressure ratio of 4.0. The turbine had a wide range of efficient operation. The IIA turbine had slightly higher efficiencies than the IIF turbine at comparable operating conditions. The fact that the IIA turbine obtained the design equivalent weight flow at the design equivalent operating point was probably a result of the decrease in the blading throat areas downstream of the first stator from those of the IIF turbine, which passed 105 percent of design weight flow at the corresponding operating point. The third stator row of blades of the IIA turbine choked at the design equivalent speed and at an over-all pressure ratio of 4.2; the third rotor choked at a pressure ratio of approximately 4.9
Component performance and flight operations of X-15 research airplane program, considering engine, auxiliary power and propellant system
The over-all component performance characteristics of a J71 experimental three-stage turbine with 97 percent design stator areas were determined over a range of speed and pressure ratio at inlet-air conditions of approximately 35 inches of mercury absolute and 700 degrees R. The turbine break internal efficiency at design operating conditions was 0.877; the maximum efficiency of 0.886 occurred at a pressure ratio of 4.0 at 120 percent of design equivalent rotor speed. In general, the turbine yielded a wide range of efficient operation, permitting flexibility in the choice of different modes of engine operation. Limiting blade loading of the third rotor was approached but not obtained over the range of conditions investigated herein. At the design operating point, the turbine equivalent weight flow was approximately 105 percent of design. Choking of the third-rotor blades occurred at design speed and an over-all pressure ratio of 4.2.
This report presents an enhanced performance evaluation of the emergency power system (EPS) and high-pressure core spray (HPCS) emergency diesel generators (EDGs) at U.S. commercial nuclear power plants. This report evaluates component performance over time using (1) Institute of Nuclear Power Operations (INPO) Industry Reporting and Information System (IRIS) data from 1998 through 2024 and (2) maintenance unavailability performance data from Mitigating Systems Performance Index (MSPI) Basis Document data from 2002 through 2024. The objective is to show estimates of current failure probabilities and rates related to EDGs, trend these data on an annual basis, determine if the current data are consistent with the probability distributions currently recommended for use in Nuclear Regulatory Commission (NRC) probabilistic risk assessments, show how the reliability data differ for different EDG manufacturers and for EDGs with different ratings; and summarize the subcomponents, causes, detection methods, and recovery associated with each EDG failure mode. The EDG failure modes considered are fail to start (FTS), fail to load and run (FTLR), and fail to run after one hour of operation (FTR>1H). Engineering analyses were performed with respect to time-period and failure mode without regard to the actual number of EDGs at each plant. The factors analyzed include subcomponent, failure cause, detection method, recovery, manufacturer, and EDG rating. The following increasing trends were identified for EDGs for the most recent 10-year period: • EPS and HPCS EDG frequency of start demands (demands per reactor year) • EPS and HPCS EDG frequency of FTLR demands • EPS and HPCS EDG frequency of run>1H hours. The following decreasing trends were identified for EDGs for the most recent 10-year period: • EPS EDG FTR>1H failure rate • EPS EDG unreliability • EPS and HPCS EDG frequency of FTR>1H events (failures per reactor year).
Nuclear-grade structural graphite is extensively utilized in the core designs of various advanced nuclear reactors. In the reactor environment, graphite is subjected to prolonged exposure to extreme conditions, including high temperatures, radiation, and potentially molten salt and oxygen. Such exposure can induce several degradation mechanisms in graphite, including nonuniform volumetric strains caused by irradiation and thermal expansion, leading to stresses that may compromise the performance of graphite components. Assessing component integrity requires accurate models of graphite's thermomechanical response. This report documents the Bayesian calibration of thermomechanical properties for nuclear-grade graphite and their application to graphite component modeling and simulation using the Grizzly code. As part of this work, uncertainty-quantified models were developed for the elastic modulus, coefficient of thermal expansion, irradiation-induced dimensional change, and irradiation-induced creep for graphite grades IG-110, NBG-18, NBG-17, PCEA, and 2114. Using a hierarchical Bayesian approach, multiple experimental data sources were combined to develop Gaussian process models for the properties. Using the Kennedy O'Hagan framework, the uncertainties due to inadequacies in the model and the inherent spread in the experimental data were quantified for three different models. These uncertainty-quantified models, with a model-form correction, were subsequently applied to a coupled-physics simulation of representative graphite components, revealing that the uncertainties have a large impact on the components' deformation.
An analytical investigation was made to determine from component performance characteristics the effect of air bleed at the compressor outlet on the acceleration characteristics of a typical high-pressure-ratio single-spool turbojet engine. Consideration of several operating lines on the compressor performance map with two turbine-inlet temperatures showed that for a minimum acceleration time the turbine-inlet temperature should be the maximum allowable, and the operating line on the compressor map should be as close to the surge region as possible throughout the speed range. Operation along such a line would require a continuously varying bleed area. A relatively simple two-step area bleed gives only a small increase in acceleration time over a corresponding variable-area bleed. For the modes of operation considered, over 84 percent of the total acceleration time was required to accelerate through the low-speed range ; therefore, better low-speed compressor performance (higher pressure ratios and efficiencies) would give a significant reduction in acceleration time.
Flexible manufacturing methods are needed to reduce the cost of using advanced composites in structural applications. One method that allows for this is the stretch forming of long discontinuous fiber materials with thermoplastic matrices. In order to exploit this flexibility in an economical way, a thorough understanding of the relationship between manufacturing and component performance must be developed. This paper reviews some of the recent work geared toward establishing this understanding. Micromechanics models have been developed to predict the formability of the material during processing. The latest improvement of these models includes the viscoelastic nature of the matrix and comparison with experimental data. A finite element scheme is described which can be used to model the forming process. This model uses equivalent anisotropic viscosities from the micromechanics models and predicts the microstructure in the formed part. In addition, structural models have been built to account for the material property gradients that can result from the manufacturing procedures. Recent developments in this area include the analysis of stress concentrations and a failure model each accounting for the heterogeneous material fields.
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This report presents an enhanced performance evaluation of motor-operated valves (MOVs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from calendar year 1998 through 2024 as reported in the Institute of Nuclear Power Operations (INPO) Industry Reporting and Information System (IRIS). The MOV failure modes considered are fail to open or close (FTOC), fail to operate or control (FTOP), and spurious operation (SO). The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire study period. The following increasing trend was identified for MOVs for the most recent 10-year period: • Low-demand MOV frequency of FTOC demands (demands per reactor year). The following decreasing trends were identified for MOVs for the most recent 10-year period: • Low-demand MOV FTOC failure probability • High-demand MOV SO failure rate • Low-demand MOV frequency of FTOC events (failures per reactor year) • High-demand MOV frequency of SO events (failures per reactor year).
This report presents an enhanced performance evaluation of turbine driven pumps (TDPs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from calendar year 1998 through 2024 as reported in the Institute of Nuclear Power Operations (INPO) Industry Reporting and Information System (IRIS). The TDP failure modes considered for standby systems are fail to start (FTS), fail to run (FTR) for one hour of operation (FTR=1H), FTR after one hour of operation (FTR>1H), and for normally running systems FTS and FTR. An eight hour unreliability estimate is also calculated and trended. The component reliability estimates and the reliability data are trended for the most recent 10 year period while yearly estimates for reliability are provided for the entire study period. No increasing trends were identified for TDPs for the most recent 10 year period.
This report presents an enhanced performance evaluation of motor-driven pumps (MDPs) at U.S. commercial nuclear power plants. The data used in this study are based on the operating experience failure reports from calendar year 1998 through 2024 as reported in the Institute of Nuclear Power Operations (INPO) Industry Reporting and Information System (IRIS). The MDP failure modes considered for standby systems are fail to start (FTS), fail to run (FTR) for one hour of operation (FTR=1H), FTR after one hour of operation (FTR>1H), and for normally running systems FTS and FTR. An eight-hour unreliability estimate is also calculated and trended. The component reliability estimates and the reliability data are trended for the most recent 10-year period while yearly estimates for reliability are provided for the entire study period.
Manufacturing and assembly phases play a crucial role in providing products that meet the strict functional specifications associated with rotating machinery components. The errors resulting during the manufacturing and assembly of such components are correlated with the vibration and noise emanating from the final system during its operational lifetime. Vibration and noise are especially unacceptable elements in high-risk systems such as helicopters, resulting in premature component degradation and an unsafe flying environment. In such applications, individual components often are subject to 100% inspection prior to assembly, as well as during operation through rigorous maintenance, resulting in increased product development cycles and high production and operation costs. In this work, we focus on providing designers and manufacturing engineers with a technique to evaluate vibration modes and levels for each component or subsystem prior to putting them into operation. This paper presents a preliminary investigation of the correlation between vibrations and manufacturing and assembly errors using an experimental test rig, which simulates a simple bearing and shaft arrangement. A factorial design is used to study the effects of: 1) different manufacturing instances; 2) different assembly instances; and, 3) varying shaft speeds. The results indicate a correlation between manufacturing or assembly errors and vibrations measured from accelerometers. Challenges in developing a tool for DFM are identified, followed by a discussion of future work, including a real-world application to helicopter transmission vibrations.
The fan configuration for the general Electric/NASA Energy Efficient Engine was selected following an extensive preliminary design study. The fan has an inlet radius ratio of 0.342 and a specific flowrate of 208.9 Kg/sec/sq. m (42.8 1bm/sec/sq. ft). The design corrected tip speed is 411.5 m/sec (1350 ft/sec) producing a bypass flow total-pressure ratio of 1.65 and a core flow total-pressure ratio of 1.6. The design bypass ratio is 6.8. The aerodynamic design point corresponds to the maximum climb power setting at Mach 0.8 and 10.67 Km (35,000 ft) altitude. The fully-instrumented fan component was tested in the Lynn Large Fan Test Facility in 1981. The overall performance results, reported herein, showed excellent fan performance with the fan meeting all of its component test goals of flow, efficiency and stall margin.
A compressor optimization study defined a 10 stage configuration with a 22.6:1 pressure ratio, an adiabatic efficiency goal of 86.1%, and a polytropic efficiency of 90.6%; the corrected airflow is 53.5 kg/s. Subsequent component testing included three full scale tests: a six stage rig test, a 10 stage rig test, and another 10 stage rig test completed in the second quarter of 1982. Information from these tests is used to select the configuration for a core engine test and an integrated core/low spool test. The test results will also provide data base for the flight propulsion system. The results of the test series with both aerodynamic and mechanical performance of each compressor build are presented. The second 10 stage compressor adiabatic efficiency was 0.848 at a cruise operating point versus a test goal of 0.846.