Control of shroud leakage flows to reduce mixing losses in a shrouded axial turbine

Abstract

The losses caused by the leakage flows through the rotor tip clearance, and the mixing losses by the re-entering leakage into the main flow are considerable parts of the total losses in turbines. The main reason for the mixing losses is the different velocity components of main and leakage flows. This leads to shear stresses which cause increased turbulence and losses. This article presents a numerical investigation on three different configurations to control the leakage flows: (a) turning vanes are fixed onto the casing between the fins to turn the shroud leakage flow into the main flow direction in order to reduce the circumferential mixing losses; (b) honeycomb bands are inserted into the casing to weaken the leakage flow in the circumferential direction and reduce the circumferential mixing losses due to the special hexagon structure; and (c) downstream edge of the cavity is chamfered to reduce the radial velocity component of the leakage jet and the separation at the downstream edge, and also to reduce the streamwise mixing losses. A 1.5-stage axial turbine with high-aspect ratio blading was used in this study to investigate the sealing designs as mentioned. The flow simulation results of the three configurations were analysed and compared in this article.