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Proceedings of GT2005

ASME Turbo Expo 2005: Power for Land, Sea and Air
June 6-9, 2005, Reno-Tahoe, Nevada, USA

GT2005-68276

AEROTHERMODYNAMIC DESIGN AND NUMERICAL SIMULATION OF RADIAL INFLOW


TURBINE IMPELLER FOR A 100kW MICROTURBINE
Zhengping FENG, Qinghua DENG, Jun LI
Institute of Turbomachinery, Xian Jiaotong University
Xian 710049, P.R.China
Tel: +86-29-82665062, Fax: +86-29-82665062
E-mail: zpfeng / qhdeng / junli@mail.xjtu.edu.cn

ABSTRACT
The high aerodynamic performance, strength reliability
and vibration reliability are three aspects of radial inflow
turbine impellers design. This paper mainly presents an
investigation on the first aspect but take into account the
strength evaluation for a 100kW microturbine unit. Firstly, a
thermodynamic design of the radial inflow turbine is carried
out, and some important parameters are obtained. Then, the
traditional cylinder parabolic geometrical design method is
applied to the impeller design. The results of FEM evaluation
show the impellers maximum stress exceeds the limitations
of the impeller material, and the magnitude of centrifugal
stress has distinct difference between the suction and the
pressure side at the impeller hub. Therefore, a positive axial
displacing method and its combination with skewing
technique are proposed and developed to solve the strength
problem, and the final impeller is designed with inlet relative
flow incidence angle of the impeller reaches -32 degree from
the radial direction. The numerical analyses using FEM and
CFD codes indicate that the final designed impeller satisfies
the strength requirements and shows good aerodynamic
performance. Furthermore, a 3D Navier-Stokes solver is
applied to evaluate the aerodynamic performance of the radial
inflow turbine under stage environment and to investigate the
detailed flow characteristics of the final designed impeller. As
a result, the radial inflow turbine of 100kW microturbine unit
has high aerodynamic performance with good consideration
on the terms of turbine structure and stress limitations.
INTRODUCTION
Research on microturbines has been paid much attention
because microturbine is an important power unit for
distributed generation (DG) or distributed energy resource
(DER). As the radial inflow turbine is the key part of the
microturbine, the aerodynamic performance and strength
requirements of the turbine directly influence the economics
and safety of the DG and DER.

Radial inflow turbines have established their place in


many industrial applications, and their attractive features of
simplicity, reliability, fast response, low emissions, and
multi-fuel capabilities made them as the ideal prime movers of
the microturbine in DG/DER within the power range of
25-300kW [1,2,3]. However, aerothermodynamic design of a
radial inflow turbine impeller is still a challenge due to its
high rotational speed and high inlet temperature in the
microturbine application.
In this paper, an aerothermodynamic design method is
presented. It is applied to the design procedure of the radial
inflow turbine impeller for a 100kW microturbine unit, and
investigated with aid of numerical simulation. At present,
there are two main profiling generation methods applied in the
design of radial inflow turbine impeller. One is the large
deflection blade design method, which was introduced by Tan
et al [4], and extended to 3-D flows and applied to a radial
inflow turbine design by Zangeneh [5]. The other is the
cylinder parabolic geometrical design method proposed by
Huang [6]. Moreover, Ebaid et al [7] described a unified
approach for designing a radial inflow gas turbine at
60,000rpm and maximum of 60kW electrical power output.
Recently, Watanabe et al [8] presented the optimization of
microturbine aerodynamics using CFD, inverse design and
FEM structural analysis, and Guo [9] investigated blade
vibration of a radial inflow turbine impeller for microturbines.
For 100kW microturbine radial inflow impeller, the
profiling design must take both aerodynamic performance and
strength limitations into consideration because the impeller
has high rotational speed over 60,000rpm and the turbine has
high inlet total temperature about 1173.15K at the design
condition. A combined design method with the positive axial
displacing and skewing on the basis of the cylinder parabolic
geometrical design method is developed to design the radial
inflow turbine impeller. Numerical simulation is then applied
to analyze the internal flow characteristics of the impeller
using the 3D Navier-Stokes solver. The results demonstrate
that the impeller has high aerodynamic performance while
satisfying the microturbine structure and stress limitations.

Copyright 2005 by ASME

NOMENCLATURE

Cr3
m
m&
N
n

p 0
p2
R1
R2
R3
R4
R7
T0
U0
U2
Z1
Z4

1
3

B00M

Outlet flow velocity at the meridional plane


Circumferential half thickness at the arbiartry radius
position of the exducer outer endwall surface
Mass flow rate
Rotational speed
Circumferential half thickness at the arbiartry radius
position of the exducer inner endwall surface
Inlet total pressure
Outlet static pressure
Radius of the exducer rotor outer wall at the hub
Radius of the exducer rotor outer wall at the shroud
Radius of the exducer rotor inner wall at the hub

radial inflow turbine for a typical microturbine is redesigned


to check its thermodynamic parameters and geometrical
configuration parameters. The basic thermodynamic
parameters of the typical microturbine are described as
following:
Pressure ratio: 3.7
Inlet temperature: 1203.15K
Rotational speed: 65000r/min
Fuel: CH4
Fuel coefficient: 0.13127
The obtained main geometrical sizes of the radial inflow
turbine using the presented design method are well agreed
with that of the reference design [10]. Then, the radial inflow
turbine for the 100kW microturbine is designed using the
presented aerothermodynamic method. The basic design
parameters of the radial inflow turbine for the 100kW
microturbine are shown in Table 1.

Radius of the working rotor at the shroud

Table 1 Basic design parameters of the radial


inflow turbine for 100kW microturbine

Radius of the exducer rotor inner wall at the shroud


Inlet total temperature

Design parameters

Spouting velocity

p
T
m&
N
p2

Tip speed of the impeller


Axial coordinate of the exducer rotor outer wall at
the hub
Axial coordinate of the exducer rotor outer wall at
the shroud
Angle between the outer endwall and radial surface
Angle between the inner endwall and radial surface
Fuel coefficient
Blade angle of mean radius at the exducer rotor

0M
R
Z
M
2
4

Blade angle of shroud at the exducer rotor outer


endwall
Half blade thickness difference between the working
and exducer rotor at the inner wall
Maximum of the blade central parabola
circumferential surrounding angle at the mean
radius of the exducer rotor outer endwall
Radial angle between the pressure surface and
suction surface
Axial angle between the pressure surface and
suction surface
Blade thickness of the exducer rotor outer wall at
the mean radius
Blade thickness of the exducer rotor outer wall at
the shroud
Blade thickness of the working rotor at the shroud

Units

360.0

kPa

1173.15

1.006

kg s

61000

r min

106.77

kPa

The detailed thermodynamic design results of the radial


inflow turbine for the 100kW microturbine are described in
Reference [11]. It is well known that the aerodynamic
performance of both the radial inflow turbine and the axial
turbine is dominated by two major performance parameters as
follows [11]:

outer endwall
0
B 02

Values

Velocity ratio = U 2 / V0

Exit flow coefficient = = Cr3 / U 2


The velocity ratio is a direct measurement of the blade
loading, and the exit flow coefficient for a radial inflow
turbine is an indirect measurement of the specific speed.
State-of-the-art levels for the total-to-static efficiency of
the uncooled radial inflow turbine are shown in Fig.1,
indicating that peak efficiencies are obtained with the velocity
ratios close to 0.7 and the exit flow coefficients about 0.2 to
0.3[12].

Cr3/U2 AXIAL EXIT/TIP SPEED VELOCITY RATIOLog scale

AEROTHERMODYNAMIC DESIGN
Fig. 1

To demonstrate the reasonability and accuracy of the


presented aerothermodynamic design program, at first, a

Attainable efficiency levels of the radial


inflow turbines [12]

Copyright 2005 by ASME

The application limitations of the radial inflow turbines


in Fig.1 are described as following:
(1) Total-static efficiency including exhaust diffuser;
(2) Turbines impeller tip diameter from 158.75 to
266.7mm;
(3) Inlet blade angle 90;
(4) Pressure ratio 3.0 to 5.0;
(5) Axial clearance/Tip diameter 0.005 to 0.01.
In Fig.1, the blue round point indicates the design point
of the presented radial inflow turbine for the 100kW
microturbine. Therefore, the designed machine can obtain a
high isentropic efficiency, as its major performance
parameters located near the envelop of high isentropic
efficiency of the radial inflow turbines.
The exit flow coefficient of the presented design equals
0.3106 and exceeds the upper limitation. However, the
isentropic efficiency of the presented design achieves 87%.
The larger exit flow coefficient leads to the higher
exhaust velocity and causes the larger exhaust loss. However,
the higher exhaust velocity can lead to decrease the exhaust
area and then the exit tip diameter of the radial inflow impeller,
which can increase the power ratio of the impeller contributed
by the inertia. Thus the isentropic efficiency of the radial
inflow turbine can be increased. In addition, the higher exit
flow coefficient allows applying the comparative lower
strength limitation of the materials used in the radial inflow
impeller.

In general, the radial inflow turbine impeller consists of


two parts: the working wheel and exducer wheel. The working
wheel is always designed with the radial linear blade due to its
strength limitation. The cylinder parabolic geometrical design
method is utilized to generate the exducer wheel profile.
The axial length of the blade at the different radius
positions for the exducer wheel is determined as:

Z0 = Z1 (R R1 )tan1 (R R3 )tan3

(1)

where 1 generally ranges from 20 to 10, and 3 ranges


from 10 to 0.
The axial distance between the specified position ( Z , R )
at the exducer inner endwall surface is obtained by:

Z ' = Z (R R3 )tan 3

(2)

The parabolic equation at the cylinder cross section of


the central parabolic surface of the exducer blade is
formulated as:

Y = aZ 't

(3)

where, t is calculated by the following equation:

t=

Z 0M

(4)

0
R M 0M tan B0M

Assumed a =

Y0
Z 0t

, thus the maximum radian length at

the radial section of the central parabolic curve, Y0 , can be


calculated by:

Y0 =

R + Ra
Z 0M

0
R M + R a t tan B0M

(5)

The circumferential coordinates of the central parabolic


surface is formulated as:

Fig. 2 Basic geometrical size of designed radial


inflow turbine impeller for a 100kW microturbine
Figure 2 shows the main geometrical parameters of the
radial inflow turbine impeller for a 100kW microturbine using
the present aerothermodynamic design method.

(6)

Then the circumferential coordinates of the pressure


surface is calculated by:

P =

IMPELLER DESIGN
The cylinder parabolic geometrical design method is
applied to generate the parabolic surface of the blade as a first
step. This design method can result in the ruled surface and
non ruled surface according to its geometrical characteristics,
but the aerodynamic performance of the blade for the ruled
surface and non ruled surface shows the similar aerodynamic
performance [6]. The pressure surface and suction surface at
the hub and shroud are generated respectively, and here the
ruled surface of the blade is obtained.

R + Ra
Z0M
Z' t

(
)
0
RM + Ra R t tanB0M
Z

Y0 + (m n) Z ' t n
(
) +
Z
Z
R

(7)

And the circumferential coordinates of the suction


surface is calculated by:

S =

Y0 (m n) Z ' t n
(
)
Z
Z
R

(8)

where n is the circumferential half thickness at the arbiartry


radius position of the exducer inner endwall surface:

Copyright 2005 by ASME

n=

4
+ Z 4 tan z + (R4 R3 )tan R +
2
2
2

Z7 tan z

R
2 + tan

(R R3 )
R7 R3
2

(9)

The better aerodynamic performance of the designed impeller


is predicted numerically. Figure 4(b) gives the stress
distribution of the impeller, and it indicates that the maximum
stress decreases 640MPa as compared with that of the design
using the non axial displacing method. The designed impeller
can satisfy the stress requirement of the selected material on
the whole.
1670 MPa

and m is the circumferential half thickness at the arbiartry


radius position of the exducer outer endwall surface:

m=

1 2
R R
M
2
+ 2
(

0
0
0
3 sinB02
R2 RM sinB0M
sinB02

) (10)

Thus, the circumferential thickness of the exducer is


obtained by:

Z' t
t = 2 (m n )(
) + n
Z

(11)
(a)

The equation of the circumferential thickness of the


working rotor blade is written as:

t = 4 + 2(Z4 Z)tan

Z
2

+ 2(R4 R)tan

R
2

R2 Z0M tanB02 RM Z02tanB0M


Z02tanB0M Z0M tanB02

Fig. 3 3D front outline (a) and stress distribution (b)


of the designed impeller using cylinder parabolic
geometrical design method

(12)

A commercial software ANSYS is adopted to evaluate


the strength status of the impeller, and in structural analysis
the fillet along blade root is properly modeled thus obtainning
accurate numerical results. More detailed information about
FEM analysis of the impeller can be referred to another paper
by Xie et al [13].
The 3D front outline of the radial inflow impeller using
the above design method is shown in Fig. 3(a). The axial
position of the parabolic surface coincidents with the
rotational axial of the impeller. In this case, the aerodynamic
performance predicted using the numerical simulation can
meet the requirements, but the local stress of 1670MPa caused
by the centrifugal force is predicted by FEM simulation, and
the value exceeds the allowable stress of the impeller
materials. Figure 3(b) gives the stress distribution of the
designed impeller. Obviously, this impeller does not satisfy
the material strength requirements.
The FEM analysis indicates that the stress at the pressure
surface of the impeller blade at the hub is higher than that of
the suction surface. To satisfy the materials strength
requirements, a special design method is presented, which
moves the axis of the parabolic surface and deviate the
rotational axis of the impeller. The derived equation of the
axial displacing is described as:

Ra =

(b)

1030 MPa

(a)

(b)

Fig. 4 3D front outline (a) and stress distribution (b)


of the designed impeller using positive axial
displacing and cylinder parabolic geometrical design
method

(13)

This method is called the positive axial displacing


method because the axis deviation distance has the positive
value.
Figure 4(a) shows the 3D front outline of the radial
inflow impeller using the positive axial displacing method.

(a)

(b)

Fig. 5 3D front outline (a) and stress distribution (b)


of the designed impeller using positive axial
displacing and skewing method

Copyright 2005 by ASME

To decrease the impeller stress further, a new method


combined with positive axial displacing means and skewing
technique is developed to redesign the impeller. The impeller
blade is divided into 11 cross sections from the hub to the
shroud. Then these 11 cross sections stacks according to the
exducer barycenter. Figure 5(a) shows the 3D front outline of
the impeller blade using the positive axial displacing and
skewing method. Fig. 5(b) gives the stress distribution of the
designed impeller using the the positive axial displacing and
skewing method. The maximum stress decreases greatly to the
550MPa and completely satisfies the strength requirement of
the impeller materials. Table 2 gives the geometrail control
parameters of the impeller.
Table 2 Geometrical control parameters of positive
axial displacing and skewing design method
Control Parameters

Values

Units

4
Z
R
2
m
1
0m
0bom

1.1
1.0
5.0
0.6
1.65
5.0
38.0
28.0

mm

mm
mm

105%
102%
99%
96%
93%
90%
87%
84%
81%
78%

Case1
Case2
Case3

Isentropic Efficiency

Fig. 6

Mass Flow Rate / %

Aerodynamic performances comparison of


three cases

From the three design cases we can see that the


maximum stress is reduced continuously from original design,
positive axial displacing to final positive axial displacing and
skewing method, but the aerodynamics performances and
mass flow rates of these three impellers dont have distinct
difference as shown in Fig. 6. The aerodynamics
performances and mass flow rates are predicted by numerical
calculation for the whole turbine stage and based on that of
100kW microturbine design condition. It should be pointed
out that the final impeller designed by the positive axial
displacing and skewing method has the best aerodynamic
performance with highest isentropic efficiency and smallest
mass flow rate. More detailed information about CFD analysis
of impellers will be presented in the following sections.

typical 3D turbulent flow due to its high rotational speed and


complex geometrical shape. To investigate the flow
characteristics of the designed impeller accurately, 3D
Navier-Stokes equations are applied in the present numerical
simulation. The 3D turbulent Navier-Stokes equations are
solved using the commercial software of the NUMECA
Euranus [14]. The Spalart-Allmaras one equation turbulence
model is used to simulate the turbulent flow. The four-step
Runge-Kutta algorithm is adopted to ensure numerical time
integration, and an implicit residual smoothing method is used
to get high CFL.
H-I type structural multi-block grid is applied, and the
grid number of impeller passage is set to be 314,275, with the
grid numbers of 33, 65, and 129 in the circumferential, radial,
and streamline directions, respectively. The tip clearance
effect on the aerodynamic performance is taken into account,
but the impeller blade deformation and resulting change in the
tip clearance have not been considered. The gap grid numbers
at impeller tip region is set to be 47,821, with the grid
numbers of 17, 29 and 97 in the circumferential, radial, and
streamline directions, respectively. The grid is refined at the
near-wall, endwall, leading edge, and trailing edge of the
impeller blade. The computational grid of the radial inflow
impeller is shown in Fig. 7.
Flow condition is set to be the design condition, with
inlet total pressure of 351.115kPa, stagnation temperature of
1073.8K and inlet relative flow angle of negative 32 degree
from the radial direction. The static pressure of 106.773kPa is
defined as boundary condition at the impeller outlet. The
rotational speed of the impeller is set to be 61,000r/min.
The aerodynamic performance parameters of the
designed radial inflow impeller using the 3D Navier-Stokes
solver are well agreed with that of the aerothermodynamic
design. In addition, the results of stage numerical calculation
of the radial inflow turbine including the guided vane and
impeller are also consistent with the aerothermodynamic
design. The aerodynamic performance of the designed radial
inflow turbine illustrates the high aerodynamic performance
and meets the design requirements.
Figure 8 shows the relation between the velocity ratio
and the isentropic efficiency of the final designed radial
inflow turbine at the off-design conditions [10]. The isentropic
efficiency reaches the maximum of 87% when the velocity
ratio equals 0.7. This demonstrates the reasonability of the
velocity ratio and incidence in the presented thermodynamic
design. Inlet relative flow angle of negative 32 degree from
radial direction is the appropriate incidence angle for the
radial inflow impeller.

NUMERICAL SIMULATION
The flow field in the designed radial inflow impeller is a

Fig. 7

Computational grid of the impeller

Copyright 2005 by ASME

Fig. 8 Relation between isentropic efficiency and


velocity ratio of the radial inflow turbine at off-design
conditions
Figure 9 shows the static pressure distributions of three
typical cross sections at the hub, mid-span and shroud of the
impeller. From the hub to the shroud, the pressure difference
between the pressure surface and the suction surface increases
gradually. This means the blade load increases from the hub to
the shroud. At the leading edge, the pressure difference
between the pressure surface and suction surface also

increases. Both on the pressure surface and the suction surface,


the static pressure decreases gradually from the leading edge
at the three typical cross sections. At the trailing edge, the
intensity of the expansion at the hub is lower than that of at
the mid-span and the shroud.
Figure 9 also shows the pressure difference reaches the
lowest on the hub surface. The pressure difference almost
equals zero from the half axial chord position to the trailing
edge. At the 30% axial distance upstream the trailing edge, the
pressure value of the pressure surface at the hub is smaller
than that of the shroud and mid-span. However, the pressure
value of the suction surface at the hub is larger than that of the
shroud and the mid-span.
The static pressure distribution of the six cross sections
along the meridional direction are shown in Fig. 10. The pressure
difference decreases at the hub surface along the meridional
direction, while the pressure difference increases at the shroud
surface along the meridional direction. This means that leakage
loss at the tip clearance near the trailing edge is larger than that of
near the leading edge. The aerodynamic performance of the radial
inflow turbine is largely influeneced by the tip clearance at the
trailing edge as compared with that at the leading edge. This
results are well agreed with the experimental data and numerical
analysis presented in references [15,16,17].

P.S.
P.S.

Shroud

Shroud
S.S.
S.S.
Hub

Fig. 9 Static pressure distribution at the hub,


midspan and shroud surface of the impeller

Hub

Fig. 10 Static pressure distribution from the inlet to


exit along meridional direction of the impeller

Copyright 2005 by ASME

Fig. 11 Relative Mach number distribution at


midspan of the impeller

(a)

(b)

Fig. 12 Calculated streamline pattern near suction


surface (a) and near pressure surface (b) of the
impeller

region of impeller inlet near the pressure surface. The low


relative Mach number area is formed by the large negative
incidence at inlet of the impeller. This is also illustrated in Fig.
12 and Fig. 13.
The calculated limiting streamline patterns near the
suction surface and pressure surface of the designed radial
inflow impeller are shown in Fig. 12. In Fig. 12(a), at the inlet
of the suction surface, the flow passes along the meridional
direction, but under the effect of the larger negative incidence
and transverse pressure gradient at the hub, the flow is
extruded at the suction surface of the hub, then it moves
toward the shroud along the suction surface. This flow
prevents the fluid to move from the leadingedge along the
suction surface. Therefore, there exists a separation line
between these two fluid flows.
Fig. 12(b) shows the calculated limiting streamline
pattern near the pressure surface. The small separation area at
the entrance area is generated due to the larger negative
incidence near the pressure surface.
The flow patterns in the central area shows the radial
immigration of flows from the hub to the shroud. The flow is
directly toward to the shroud position at the pressure surface
from the hub. Then this flow meets the main flow area due to
the pressure action at the pressure surface of the shroud. The
flow immigrates towards the hub in the exit area. From Fig.
12(b), the limiting streamline moves the hub due to the
pressure difference between the hub and shroud at the
pressure surface in the flow fields at the 30% axial chord
upstream trailing edge.
The 3D streamline patterns in the impeller passage is
shown in Fig. 12. The inlet flow near the suction surface is
extruded to the hub. The streamline pattern near the suction
surface is similar with the limiting streamline pattern shown in
Fig. 12(a). The inlet flow near the pressure surface is similar
to the limiting streamline pattern shown in Fig. 12(b) and
extruded to the shroud. The main flow in the impeller passage
passes smoothly along the meridional direction.
Finally, based on the above aerothermodynamic design
and numerical simulation, an impeller is produced for the
prototype of a 100kW microturbine unit. Fig.14 shows the real
radial inflow turbine impeller, and experimental investigation
on its flow characteristics as well as on aerodynamic
performance of the turbine will be conducted in near future.

Fig. 13 Calculated streamline pattern in the


passage of designed impeller
The relative Mach number distribution at midspan of the
impeller is shown in Fig.11, and it can be seen it is quite well
distributed. The value of relative Mach number is lower in the

Fig. 14 The radial inflow turbine impeller for the


prototype of a 100kW microturbine unit

Copyright 2005 by ASME

CONCLUSIONS
The investigations on the aerothermodynamic design,
impeller profiling design, and CFD analysis for aerodynamic
performance of the radial inflow turbine for a 100kW
microturbine are conducted in this paper.
The influence of the velocity ratio and exit flow
coefficient on the aerodynamic performance is discussed
based on the thermodynamic design results. It is found that the
higher exit velocity ratio should be chosen in order to
decrease the exit height of the impeller when the mass flow
rate has larger value. This can also decrease the stress level for
the strength design of the impeller.
The radial inflow turbine impeller, designed by the
traditional cylinder parabolic modeling method, is of general a
radial blade type, but its strength requirement can only be
satisfied when its tip speed is relative smaller based on the
FEM prediction. To overcome this shortcoming, a combined
design method with positive axial displacing and skewing
techniques is developed, and a new impeller is redesigned
with good aerodynamic performance and strength reliability. It
is found that the tip speed of the designed impeller can reach
about 600m/s while meeting the strength requirement of the
material. Also, large negative incidence can be adopted to
make use of the advantages of flow characteristics of the
radial inflow turbine impeller, and in the present case the
incidence of the impeller reaches negative 32 degree. The
complex internal turbulent flow characteristics of the designed
radial inflow turbine impeller are simulated using a 3D
Navier-Stokes solver, and analyzed in details. The results
demonstrate that the impeller has high aerodynamic
performance with good consideration on the terms of
microturbine structure and stress limitations.
ACKNOWLEDGMENTS
The research work was sponsored by the National High
Technology Research and Development Program of China Design and Development of a 100kW Microturbine
(No.2002AA503020). In addition, the authors wish to thank
Dr. XIE Yonghui for his work on the FEM analysis of the
radial inflow turbine impeller.
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Copyright 2005 by ASME

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