Laboratory Apparatus For Gas Turbine Combustion Development

122 Pages·2017·7.13 MB·English

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Open Access Theses Theses and Dissertations
Summer 2014
Laboratory Apparatus For Gas Turbine
Combustion Development
Dustin Lee Cruise
Purdue University
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Cruise, Dustin Lee, "Laboratory Apparatus For Gas Turbine Combustion Development" (2014).Open Access Theses. 418.
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LABORATORY APPARATUS FOR GAS TURBINE COMBUSTION
DEVELOPMENT
A Thesis
Submitted to the Faculty
of
Purdue University
by
Dustin Lee Cruise
In Partial Fulfillment of the
Requirements for the Degree
of
Master of Science in Mechanical Engineering
August 2014
i
Purdue University
West Lafayette, Indiana
ii
To my wife, Denise.

i i
iii
ACKNOWLEDGEMENTS
My most sincere gratitude is extended to Professor Galen King and
Professor Hukam Mongia for letting me share in this experience with them.
Although most students only have one academic advisor, I have had the privilege
of two of the most experienced and knowledgeable professors on this campus. I
owe my academic success, and a large portion of my personal growth, to their
varied backgrounds and experience, and most importantly their patience with me
during this process.
To my colleague, Nathan Toner, I thank for his many selfless contributions
to my work, from the translation table to the LabVIEW codes used for automation.
I also wish to thank the undergraduate assistants that have passed
through our lab. I would not have been able to complete the translation table
without the many hours Julian Merkison and Sean Stevens spent helping me to
design and manufacture it. Matthew Clark was an instrumental part of the
experimental team, doing whatever was necessary to keep the fire lit. I’m sure all
i ii
of these students will find great success in their future endeavors.
To my wife, Denise, I thank her for her endless encouragement, focus,
and balance, during this journey we’ve had together. I can’t wait for the next part
with her, and the many other adventures after.
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TABLE OF CONTENTS
Page
LIST OF TABLE ....................................................................................................vi
LIST OF FIGURES .............................................................................................. vii
ABSTRACT ......................................................................................................... xii
CHAPTER 1. INTRODUCTION ........................................................................ 1
1.1 Motivation ...................................................................................... 1
1.2 Background ................................................................................... 3
1.2.1 NASA ERA Technology ........................................................... 3
1.2.2 Variable Geometry .................................................................. 5
1.3 Overview of Thesis ........................................................................ 7
CHAPTER 2. LAB INFRASTRUCTURE ........................................................... 8
2.1 Introduction .................................................................................... 8
2.2 Facilities ........................................................................................ 8
2.3 Measurement and Instrumentation .............................................. 13
2.4 CCD Camera ............................................................................... 14
2.5 Laboratory Automation ................................................................ 20
2.6 Conclusion and Future Work ....................................................... 20
CHAPTER 3. LDI COMBUSTOR DESIGN ..................................................... 23
3.1 Introduction .................................................................................. 23
3.2 LDI Combustor Design ................................................................ 24
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3.2.1 Need for Developmental Combustor ..................................... 24
3.2.2 Existing Burner ...................................................................... 25
3.2.3 LDI Design Features ............................................................. 26
3.2.4 Purdue Class Contributions ................................................... 36
3.3 LDI Test Results .......................................................................... 38
3.3.1 GTCI Swirler Development .................................................... 39
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Page
3.3.2 GTCII Injector Position Study ................................................ 39
3.3.3 Chemiluminescence Imaging ................................................ 41
3.3.4 Combustion Instabilities ........................................................ 54
3.4 Conclusions and Future Work ..................................................... 59
CHAPTER 4. OPTICAL TRANSLATION TABLE ............................................ 60
4.1 Introduction .................................................................................. 60
4.2 Mechanical Design ...................................................................... 64
4.3 Electrical Design .......................................................................... 71
4.4 Conclusions and Future Work ..................................................... 77
CHAPTER 5. CONCLUSION ......................................................................... 79
5.1 Lab Infrastructure ........................................................................ 79
5.2 LDI Combustor Design ................................................................ 79
5.3 Optical Translation Table ............................................................. 80
5.4 Future Work ................................................................................. 80
LIST OF REFERENCES .................................................................................... 82
APPENDICES
Appendix A. LDI Combustor Design Drawings ................................................... 84
Appendix B. LabVIEW Wiring Diagrams ............................................................. 98
VITA ................................................................................................................. 104

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vi
LIST OF TABLE
Table .............................................................................................................. Page
Table 1: Camera settings during testing. ............................................................ 44
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i
vii
LIST OF FIGURES
Figure ............................................................................................................. Page
1-1 History of ICAO NOx regulations for engines. The NASA ERA N+2
generation goal is a 75% reduction of the CAEP/6 NOX standard by
2020. .......................................................................................................... 2
1-2 Woodward’s ERA concept for using arrays of Swirler-Venturi Lean
Direct Injectors (SV-LDI). The center injector in each 9 point module
is used as a pilot [4]. .................................................................................. 5
2-1 Overhead view of lab layout showing optics tables, combustor
location on translation table (red), main air line (green), gas regulator
panel, and mass flow controllers. ............................................................... 9
2-2 Overhead layout of liquid fuel line (pink) running from gas cabinet,
where fuel tank and N2 bottle are stored, to experiment. Fuel tank is
pressurized by N2 bottle and metered by panel near experiment. ........... 12
2-3 JENOPTIK’s CoastalOpt 105 mm UV-Vis SLR lens with aperture
range f/4.5 –f/32, and focus adjustment of .5 m – infinity [19]. ................. 15
2-4 CoastalOpt 105 mm transmission curve showing excellent
transmission from 250 nm to 650 nm [19]. ............................................... 15
2-5 JAI 4200CL-UV image sensor body, with C-mount lens interface, and
Camerlink serial communication to frame grabber [20]. ........................... 16
2-6 Transmission curve of Kodak KAI-4021 image sensor used in JAI
v
4200 UV CCD camera. UV sensitive option allows transmission at ii
310 nm with quantum efficiency of 8% [21]. ............................................. 16
2-7 JAI’s Dualtap software used to adjust sensor settings and debug
camera through serial command line. ...................................................... 17
2-8 Main VI showing camera controls to set number of images to capture,
and capture button that begins automated capture process. Images
are automatically saved to a file specified. ............................................... 18
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Figure Page
2-9 Edmund’s Optics 436nm band-pass CH* filter, with 10 nm FWHM
and 95% efficiency at 436 nm. ................................................................. 19
2-10 Hoya Optics U340 Schott UV glass filter. Filter has above 80%
efficiency at 310 nm, but is wider than most band-pass filters used for
chemiluminescence and is still being evaluated. ..................................... 19
2-11 Main VI for lab automation. Main user inputs are flow controller
enable button (“Flame ON”), desired equivalence ratio and pressure
drop, and camera controls. ...................................................................... 22
3-1 LDI cutaway view showing main components: fuel injector, venturi,
swirler, and burner housing. ..................................................................... 25
3-2 Original tube combustor that was reconfigured for LDI. Base plate, 4”
confinement, coflow circuit, and sintered dome were reused. Photo
courtesy of Andrew C. Nobel. .................................................................. 26
3-3 NASA-Woodward Swirl-Venturi Lean Direction Injection concept [22]. .... 27
3-4 Liquid mixer vs. gaseous mixer dimensions. Diameter of gaseous
injector reduced to nominal size for manufacturability. ............................ 27
3-5 GTCI designed swirler with fin added to aid in mixing. This feature
would not have been practical with traditional machining, but with 3D
printing, it was no more difficult than a normal swirler. ............................ 29
3-6 Interface between swirler and venturi. The wire ring installed on the
venturi expands into a groove of the swirler providing an axial force to
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keep the swirler on the venturi. The anti-rotation tab engages a iii
pocket on the venturi to keep the swirler form rotating. ........................... 30
3-7 Split burner housing to allow installation of swirler. Once installed, the
fuel injector is guided into the swirler until the burner housing halves
engage. The clamp plate, which holds the burner housing in place, is
then secured with over-center latches. .................................................... 31
3-8 Bushing that fuel injector slides in. The top bushing is an aluminum
insert into the sintered disc (orange). The bottom bushing is a
precision bored hole polished to reduce friction and wear. ...................... 32
3-9 Firgelli L12-50-100-I linear actuator used for fuel injector movement. ..... 33
3-10 Firgelli linear actuator mounted to burner housing by bracket (red),
and micrometer clamp (blue). .................................................................. 33