Single vs. Two Stage High Pressure Turbine Design of Modern Aero Engines

Abstract

In this paper, the two-stage shrouded HPT engine configuration rated at 22000 lbs thrust is used as the baseline from which a single stage HPT unshrouded design is systematically derived to evaluate the potential weight and cost advantage. The baseline thermodynamic cycle at the rated thrust level was modified in order to optimize the turbine inlet temperature, overall pressure ratio, and core flow with a single stage HPT and deliver competitive performance. The comparative study, although preliminary in depth, has led to the advantages and disadvantages associated with an unshrouded single versus a two-stage shrouded HPT design. The results compare design configuration, secondary air system, weight, safety, life, specific fuel consumption (SFC), and future thrust growth capability. The main advantages of the single stage application are reductions in cost and complexity of design, lower turbine gas temperature, and ease of maintenance. The main disadvantages are in reduced turbine polytropic/isentropic efficiency for HPC pressure ratio greater than 9, increased SFC, higher rim speed, higher HPT exit Mach number, higher bypass ratio to achieve the desired thrust level, and possibly higher weight. A quantitative statement on the reduction of engine cost/weight is premature until a detailed design and the associated cost-benefit is performed. The paper concludes by recommending that the design philosophy of the modern unmixed turbofan engine (single or two-stage HPT) leads to a balance between the selected turbine gas temperature versus the by-pass ratio in order to minimize cost and maximize the thrust-to-weight ratio and the cycle efficiency. In either ease, the expected high reliability and reduced engine cost/weight in the context of future thrust-growth capability need to be demonstrated by proven technology which seem to favor the two-stage HPT configuration.