Hostname: page-component-cd9895bd7-hc48f Total loading time: 0 Render date: 2024-12-22T21:06:36.447Z Has data issue: false hasContentIssue false

The impact of gas turbine compressor rotor bow on aircraft operations

Published online by Cambridge University Press:  06 December 2017

E.O. Smith*
Affiliation:
University of New South Wales, School of Engineering and Information Technology, Canberra, Australia Royal Australian Air Force, Russell Offices, Department of Defence, Canberra, Australia
A.J. Neely
Affiliation:
University of New South Wales, School of Engineering and Information Technology, Canberra, Australia
H. Palfrey-Sneddon
Affiliation:
University of New South Wales, School of Engineering and Information Technology, Canberra, Australia Australian Army, Russell Offices, Department of Defence, Canberra, Australia

Abstract

When a gas turbine engine is shut down it will develop a circumferential thermal gradient vertically across the compressor due to hot air rising from the cooling metal components and pooling at the top. As the hot compressor rotor drum and casing cool and contract in the presence of this thermal gradient, they do so non-uniformly and therefore will bend slightly, in a phenomenon known as rotor bow. Starting an engine under bowed conditions can result in damage, representing a risk to both airworthiness and operational capability. This study consolidates some preliminary findings by the authors relating to the drivers for rotor bow, such as engine geometry, aircraft-engine integration and rotor temperature on shutdown. The commercial and military operational considerations associated with rotor bow are also discussed, including limitations which may result from a bowed rotor; the influence of operations including the final flight and descent profiles, taxi procedures and rapid turnaround requirements; as well as some practical solutions which may be implemented to reduce the impact of rotor bow.

Type
Research Article
Copyright
Copyright © Royal Aeronautical Society 2017 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

1. Newkirk, B. Shaft rubbing, Mechanical Engineering, 1926, 48, (8), pp 830-832.Google Scholar
2. Dimarogonas, A.D. A study of the Newkirk Effect in turbomachinery, Wear, 1974, 28, (3), pp 369-382.CrossRefGoogle Scholar
3. Marinescu, G. and Ehrsam, A. Experimental investigation into thermal behavior of steam turbine components. Part 2 – natural cooling of steam turbines and the impact on LCF life, ASME Turbo Expo, no. GT2012-68759, 11-15 June 2012, American Society of Mechanical Engineers, Copenhagen, Denmark.CrossRefGoogle Scholar
4. Marinescu, G., Sell, M., Ehrsam, A. and Brunner, P.B. Experimental investigation into thermal behavior of steam turbine components: Part 3 – startup and the impact on LCF life, ASME Turbo Expo 2013: Turbine Technical Conference and Exposition, no. GT2013-94356, 3-7 June 2013, American Society of Mechanical Engineers, San Antonio, Texas, US.CrossRefGoogle Scholar
5. Marinescu, G., Stein, P. and Sell, M. Experimental investigation into thermal behavior of steamturbine components: Part 4 natural cooling and robustness of the over-conductivity function, ASME Turbo Expo 2014: Turbine Technical Conference and Exposition, no. GT2014-25247, 16-20 June 2014, American Society of Mechanical Engineers.CrossRefGoogle Scholar
6. Walsh, P. and Fletcher, P. Gas Turbine Performance, 2nd ed. Blackwell Science, Oxford Malden, Massachusetts, US.CrossRefGoogle Scholar
7. Yamaguchi, K., Ishii, H. and Takagi, M. A method for predicting vibration of a thermal bending rotor (calculation method using fem software and elemental experiment), Nippon Kikai Gakkai Ronbunshu, C Hen/Transactions of the Japan Society of Mechanical Engineers, Part C, 2002, 68, (11), pp 3151-3156.Google Scholar
8. Kang, C.H., Hsu, W.C., Lee, E.K. and Shiau, T.N. Dynamic analysis of gear-rotor system with viscoelastic supports under residual shaft bow effect, Mechanism and Machine Theory, 2011, 46, (3), pp 264-275.CrossRefGoogle Scholar
9. Sawicki, J.T., Montilla-Bravo, A. and Gosiewski, Z. Thermomechanical behavior of rotor with rubbing, Int J of Rotating Machinery, 2003, 9, (1), pp 41-47.CrossRefGoogle Scholar
10. Pennacchi, P. and Vania, A. Accuracy in the identification of a generator thermal bow, J of Sound and Vibration, 2004, 274, (1–2), pp 273-295.CrossRefGoogle Scholar
11. Born, D., Stein, P., Marinescu, G., Koch, S. and Schumacher, D. Thermal modelling of an intermediate pressure steam turbine by means of conjugate heat transfer – simulation and validation, ASME Turbo Expo 2016: Turbine Technical Conference and Exposition, 13-17 June 2016, American Society of Mechanical Engineers, Seoul, South Korea.CrossRefGoogle Scholar
12. Pratt & Whitney, ‘Operating Instructions for the PW4000 Series Commercial Turbofan Engines in the A300-600 and A310 Airplanes, Operator Manual, 2008.Google Scholar
13. Bombardier, Global 5000 BR710-20 power plant manual, Operator Manual, 2005.Google Scholar
14. Taylor, H. Rubbing shafts above and below resonant speed, General Electric Technical Information Series, 1924, 16709.Google Scholar
15. Dimarogonas, A.D. An analytic Study of the Packing Rub Effect in Rotating Machinery. PhD Thesis, 1970, Rensselaer Polytechnic Institute.Google Scholar
16. Goldman, P., Muszynska, A. and Bently, D.E. Thermal bending of the rotor due to rotor-to-stator rub, Int J of Rotating Machinery, 2000, 6, (2), pp 91-100. Cited By (since 1996): 1.CrossRefGoogle Scholar
17. Bachschmid, N., Pennacchi, P. and Vania, A. Thermally induced vibrations due to rub in real rotors, J of Sound and Vibration, 2007, 299, (4–5), pp 683-719. Cited By (since 1996): 12.CrossRefGoogle Scholar
18. Nicholas, J.C., Gunter, E.J. and Allaire, P.E. Effect of residual shaft bow on unbalance response and balancing of a single mass flexible rotor—Part I: Unbalance response, J of Engineering for Power, 1976, 98, (2), pp 171-181.CrossRefGoogle Scholar
19. Patel, T.H. and Darpe, A.K. Study of coast-up vibration response for rub detection, Mechanism and Machine Theory, 2009, 44, (8), pp 1570-1579.CrossRefGoogle Scholar
20. Zhu, X.Z., He, W. and Yuan, H.Q. Effects of steady temperature field on vibrational characteristics of a rotor system, Dongbei Daxue Xuebao/J of Northeastern University, 2008, 29, (1), pp 113-116.Google Scholar
21. Yuan, H.Q., Zhu, X.Z., Li, D. and Wen, B.C. Dynamic characteristics of transient thermal starting up of a rotor system, Zhendong yu Chongji/J of Vibration and Shock, 2009, 28, (7), pp 33-37.Google Scholar
22. Sawicki, J.T., Padovan, J. and Al-Khatib, R. The dynamics of rotor with rubbing, Int J of Rotating Machinery, 1999, 5, (4), pp 295-304.CrossRefGoogle Scholar
23. Ahmad, S. Rotor casing contact phenomenon in rotor dynamics – literature survey, J of Vibration and Control, 2010, 16, (9), pp 1369-1377.CrossRefGoogle Scholar
24. Baldassarre, L. and Fontana, M. Modeling of rotor bow during hot restart in centrifugal compressors, 39th Turbomachinery Symposium, 2010, Houston, Texas, US.Google Scholar
25. Von Groll, G. and Ewins, D.J. On the dynamics of windmilling in aero-engines, IMechE Conference Transactions, 2000, 6, pp 721-730.Google Scholar
26. Marinescu, G., Mohr, W.F., Ehrsam, A., Ruffino, P. and Sell, M. Experimental investigation into thermal behavior of steam turbine components temperature measurements with optical probes and natural cooling analysis, J of Engineering for Gas Turbines and Power, 2014, 136, (2), p 021602.CrossRefGoogle Scholar
27. Marinescu, G., Stein, P. and Sell, M. Natural cooling and startup of steam turbines: Validity of the over-conductivity function, J of Engineering for Gas Turbines and Power, 2015, 137, (11), p 112601.CrossRefGoogle Scholar
28. Born, D., Stein, P., Marinescu, G., Koch, S. and Schumacher, D. Thermal modeling of an intermediate pressure steam turbine by means of conjugate heat transfer simulation and validation, J of Engineering for Gas Turbines and Power, 2017, 139, (3), p 031903.CrossRefGoogle Scholar
29. Topel, M., Jöcker, M., Paul, S. and Laumert, B. Differential expansion sensitivity studies during steam turbine startup, J of Engineering for Gas Turbines and Power, 2016, 138, (6), p 062102.CrossRefGoogle Scholar
30. Reddy, V.V., Selvam, K. and De Prosperis, R. Gas turbine shutdown thermal analysis and results compared with experimental data, ASME Turbo Expo 2016: Turbomachinery Technical Conference and Exposition, no. GT2016-56601, 13-17 June 2016, American Society of Mechanical Engineers, Seoul, South Korea.Google Scholar
31. Tisarev, A., Falaleev, S., Koch, C., Nagorski, M. and Staudacher, S. Natural cooling affecting the restart of micro gas turbine, ASME Turbo Expo 2016: Turbine Technical Conference and Exposition, no. GT2016-56982, 13-17 June 2016, American Society of Mechanical Engineers, Seoul, South Korea.CrossRefGoogle Scholar
32. UK Ministry of Defence, The aircrew for a 31 Squadron, Royal Air Force Tornado GR4 scramble to their aircraft at Kandahar airfield in Afghanistan to support troops on the ground in Helmand Province, 06 Jun 13. http://www.defenceimagery.mod.uk/fotoweb/archives/5042-Downloadable%20Stock%20Images/Archive/RAF/45157/45157228.jpg.Google Scholar
33. Flottau, J. and Norris, G. Airlines praise Airbus A320neo performance, but engine issues remain, Aviation Week, 24 Mar 2017.Google Scholar
34. Masiol, M. and Harrison, R. M. Aircraft engine exhaust emissions and other airport-related contributions to ambient air pollution: A review, Atmospheric Environment, 2014, 95, pp 409-455.CrossRefGoogle ScholarPubMed
35. Scott, A. United Technologies CEO expects Pratt engine fix by February, 10 Dec 2015. http://www.reuters.com/article/us-utc-engines-idUSKBN0TU02U20151211.Google Scholar
36. Hemmerdinger, J. Pratt and Whitney fix will cut PW1100G start-up delay in half, 18 Apr 16 2016. https://www.flightglobal.com/news/articles/pw-fix-will-cut-pw1100g-start-up-delay-in-half-424321/.Google Scholar
37. Smith, E. and Neely, A. Shaft thermal bow modelling in gas turbines - an initial study, 21st International Symposium on Air Breathing Engines, 9-13 September 2013, Busan, Korea.Google Scholar
38. Smith, E. and Neely, A. The use of porosity to simulate the presence of aerofoils on a gas turbine shaft under natural cooling, Australasian Fluid Mechanics Conference, 8-11 December 2014, Melbourne, Australia.Google Scholar
39. Smith, E. and Neely, A. The effect of aircraft integration design on gas turbine shaft thermal bow and the Newkirk Effect, ASME Turbo Expo 2014: Turbine Technical Conference and Exposition, no. GT2014-25511, 16-20 June 2014, American Society of Mechanical Engineers, Düsseldorf, Germany.CrossRefGoogle Scholar
40. Smith, E. and Neely, A. The effect of compressor shaft geometry on shaft thermal bow due to natural convection, ASME Turbo Expo 2015: Turbine Technical Conference and Exposition, no. GT2015-42940, 2015, American Society of Mechanical Engineers, Montréal, Canada.CrossRefGoogle Scholar
41. Smith, E., Neely, A., and Butcher, A. Experimental observations of a gas turbine compressor rotor shaft analogue under natural cooling, ASME Turbo Expo 2016: Turbine Technical Conference and Exposition, no. GT2016-56800, 13-17 June 2016, American Society of Mechanical Engineers, Seoul, South Korea.Google Scholar
42. Smith, E. A Parametric Study of Compressor Rotor Thermal Bow in Aerospace Gas Turbines, PhD Thesis, 2017, UNSW Canberra, Canberra, Australia.Google Scholar
43. Plackett, R.L. and Burman, J.P. The design of optimum multifactorial experiments, Biometrika, 1946, pp 305-325.CrossRefGoogle Scholar
44. Palfrey-Sneddon, H. Parametric Study of the Thermal Behaviour of a Gas Turbine Compressor During Descent and Taxi, Undergraduate Thesis, 2016, UNSW Canberra, Canberra, Australia.Google Scholar
45. Khadilkar, H. and Balakrishnan, H. Estimation of aircraft taxi fuel burn using flight data recorder archives, Transportation Research Part D: Transport and Environment, 2012, 17, (7), pp 532-537.CrossRefGoogle Scholar
46. Morris, R., Chang, M.L., Archer, R., Cross, E.V., Thompson, S., Franke, J., Garrett, R., Malik, W., McGuire, K. and Hemann, G. Self-driving aircraft towing vehicles: A preliminary report, Workshops at the 29th AAAI Conference on Artificial Intelliegence, 25-26 January 2015, Austin Texas.Google Scholar
47. Richard, M. G. Taxibot robotic tug reduces airplane emissions and noise pollution, 2013. http://www.treehugger.com/aviation/taxibot-reduces-airplane-emissions-and-noise-pollution.html.Google Scholar
48. Schier, M., Rinderknecht, F., and Hellstern, H. Electric wheel hub motor for aircraft application, Int J of Renewable Energy Research (IJRER), 2012, 1, (4), pp 298-305.Google Scholar
49. Abd Allah Makhloof, M., Elsayed Waheed, M., and El-Raouf Badawi, U. A. Real-time aircraft turnaround operations manager, Production Planning & Control, 2014, 25, (1), pp 2-25.CrossRefGoogle Scholar
50. Idris, H.R., Delcaire, B., Anagnostakis, I., Hall, W.D., Clarke, J.-P., Hansman, R.J., Feron, E. and Odoni, A.R. Observations of departure processes at logan airport to support the development of departure planning tools, 2nd USA/Europe Air Traffic Management R&D Seminar, 1998, pp 1-4.CrossRefGoogle Scholar
51. Gittell, J.H. Cost/quality trade-offs in the departure process? Evidence from the major us airlines, Transportation Research Record, 1995, 1480, p 25.Google Scholar
52. Jaw, L.C. and Mattingly, J.D. Aircraft Engine Controls: Design, System Analysis, and Health Monitoring, AIAA Education Series, 2009, Reston, Virginia, US.CrossRefGoogle Scholar
53. May, R.D., Csank, J., Lavelle, T.M., Litt, J.S. and Guo, T.-H. A high-fidelity simulation of a generic commercial aircraft engine and controller, AIAA Paper, 2010, 6630, p 2010.Google Scholar
54. Drwiega, A. A decade of change for australias military helicopters, Aviation Today, 01 Jun 2013. http://www.aviationtoday.com/rw/military/dod/A-Decade-of-Change-for-Australias-Military-Helicopters_79364.html#.VyBFgDD5gdU.Google Scholar
55. Ross, S. and Agin, T. Methods and systems for mitigating distortion of gas turbine shaft, 2011. http://www.google.com/patents/EP2305986A2?cl=en [Patent].Google Scholar
56. Topel, M., Genrup, M., Jcker, M., Spelling, J. and Laumert, B. Operational improvements for startup time reduction in solar steam turbines, J of Engineering for Gas Turbines and Power, 2015, 137, (4), p 042604.CrossRefGoogle Scholar
57. Bae, J., Breuer, K.S. and Tan, C.S. Active control of tip clearance flow in axial compressors, ASME Turbo Expo 2003, collocated with the 2003 International Joint Power Generation Conference, no. GT2003-38661, 16-19 June 2003, American Society of Mechanical Engineers, Atlanta, Georgia, pp 531-542.CrossRefGoogle Scholar
58. Dann, A., Dhopade, P., Bacic, M., Ireland, P. and Lewis, L. Experimental and numerical investigation of annular casing impingement arrays for faster casing response, J of Engineering for Gas Turbines and Power, 2017, 139, (9), p 092603.CrossRefGoogle Scholar
59. van Paridon, A., Dann, A., Ireland, P. and Bacic, M. Design and development of a full-scale generic transient heat transfer facility (THTF) for air system validation, ASME Turbo Expo 2015: Turbine Technical Conference and Exposition, no. GT2015-42391, 15-19 June 2015, American Society of Mechanical Engineers, Montréal, Canada.CrossRefGoogle Scholar