05 Advanced Design HP Compressor Test

European Workshop on New Aero Engine Concepts
Munich, 30 June – 1 July 2010
Advanced Design HP Compressor Test
Mark Walker, Rolls-Royce Plc
NEWAC is an Integrated Project Co-funded by the European Commission within the Sixth Framework Programme 1
© 2010 Rolls-Royce plc and NEWAC
(2002-2006) under Thematic Priority 4 Aeronautics and Space.
Background
• A higher OPR cycle with inter-cooling leads to a smaller core size
• A small core size leads to a challenging compressor design:

– Reduced aspect ratios
– Large rotor tip clearance/height values
– Trade-off between blade speed and blade height for a fixed corrected
shaft speed
• Improved core component efficiencies are required to meet these

challenges and maximise the overall SFC benefit for an inter-cooled cycle
• Advanced 3D CFD has been used iteratively to develop design

improvements
• Rig test has validated the predicted improvements
Partners
• Rolls-Royce UK
• Rolls-Royce Deutschland
• Cambridge University Whittle Laboratory
• Testing carried out at AneCom Aerotest facility.
Test Objectives
• Demonstrate improved efficiency over datum rig test compressor
• Demonstrate required level of surge margin
• Understand the compressor stage matching
• Test the rotor tip blowing system (separate presentation)
• Validate 3D CFD predictions
Advanced HP Compressor Design
• Improved gas-path and blading design
• Multiple design features optimised:

– Aerofoil leading edge profile
– Camber distribution
– Axial work distribution
– Stability enhancement features
– Stages matched closer to peak efficiency with no loss in surge
margin
Rig Background
• 6 stage High Pressure Compressor (HPC) rig
• Based upon Rolls-Royce 3-shaft HPC
• Fixed geometry aerofoils in every stage (no variable vanes)
• Inter-stage handling bleed
• Rig design is modular to allow test bed changes to a rotor tip

blowing configuration
NEWAC Rig Build 1 with the test team
Test Schedule
• Stress Survey
• Full performance characteristics to surge
• Handling bleed surveys
• Rotor blowing testing (test bed change)
• Pneumatic Area Traversing (Cobra 5-hole probe)
Compressor Map
Design Speed
Test Data
Total Pressure Ratio
Working Line
Design Speed CFD

Prediction
Target Surge Margin
High End of Flight Cycle
Low End of Flight Cycle
Non-Dimensional Inlet Mass Flow
Target Design Point Efficiency Met...
Magnitude and location of peak Design Speed

efficiency well captured by CFD
Efficiency
NEWAC Build 1
CFD Prediction
Test Data Instro

Non-Dimensional Inlet Mass Flow
Compressor Exit Profiles

P/Pmean / T/Tmean
NEWAC Build 1 P/Pav
Datum P/Pav Stronger endwall pressure

profiles due to improved
NEWAC Build 1 T/Tav blading design
Datum T/Tav
0 20 40 60 80 100
% Height
Inter-stage Analysis
• Provides key understanding of:
– Stage matching
– Off-design behaviour
– Surge trigger
– Total pressure and total temperature radial profiles
1 Stator LE Block
R S R S
Determination of the Surge Trigger (1)

• Inter-stage handling bleed survey used in conjunction with inter-stage
instrumentation data used to identify which stage trigger surge:
– At a given aerodynamic speed, compressor throttled from the working

line to surge to obtain the characteristic
– The amount of handling bleed was then adjusted and the characteristic
repeated
– The block characteristics were analysed to see in which block the limiting
flow coefficient occurred
Determination of the Surge Trigger (2)

• Shown below are examples of the block analysis undertaken
• Blocks show efficiency.work coefficient against exit flow coefficient (Va/U)
• Shows how the effect of changing inter-stage bleed effects each block
differently.
• 3D CFD points to the same block as the test data for the surge trigger
Test data for a range of bleed settings for a single block Test data compared with 3D CFD
η.∆H/U2 η.∆H/U2
CFD
Test
Exit Va/U Exit Va/U

Rig vs. CFD Radial Non-Dimensional Profile of Total Pressure

P0/P0av
NEWAC Build 1 Working Line
CFD Working Line
NEWAC Build 1 Near Surge
CFD Near Surge
% Height
Conclusions
• All scheduled testing completed
• All testing issues resolved efficiently by the AneCom test facility
• Target of +0.7% adiabatic efficiency relative to datum rig test – achieved

+0.64%
• Target surge margin exceeded at high speeds tested
• There is potential to trade some of the excess surge margin for efficiency,
for example by reducing the number of aerofoils
• Part speed surge margin meets requirements
• Close agreement between 3D CFD and test data

05 Advanced Design HP Compressor Test

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European Workshop on New Aero Engine Concepts

Munich, 30 June – 1 July 2010

Advanced Design HP Compressor Test

Mark Walker, Rolls-Royce Plc

• A small core size leads to a challenging compressor design:

• Improved core component efficiencies are required to meet these

• Advanced 3D CFD has been used iteratively to develop design

• Rig test has validated the predicted improvements

• Testing carried out at AneCom Aerotest facility.

• Demonstrate improved efficiency over datum rig test compressor

• Demonstrate required level of surge margin

• Understand the compressor stage matching

• Test the rotor tip blowing system (separate presentation)

• Validate 3D CFD predictions

Advanced HP Compressor Design

• Improved gas-path and blading design

• Multiple design features optimised:

• 6 stage High Pressure Compressor (HPC) rig

• Based upon Rolls-Royce 3-shaft HPC

• Fixed geometry aerofoils in every stage (no variable vanes)

• Inter-stage handling bleed

• Rig design is modular to allow test bed changes to a rotor tip

NEWAC Rig Build 1 with the test team

• Full performance characteristics to surge

• Handling bleed surveys

• Rotor blowing testing (test bed change)

• Pneumatic Area Traversing (Cobra 5-hole probe)

Design Speed CFD

High End of Flight Cycle

Low End of Flight Cycle

Non-Dimensional Inlet Mass Flow

Target Design Point Efficiency Met...

Magnitude and location of peak Design Speed

Test Data Instro

Compressor Exit Profiles

NEWAC Build 1 P/Pav

Datum P/Pav Stronger endwall pressure

Determination of the Surge Trigger (1)

– At a given aerodynamic speed, compressor throttled from the working

Determination of the Surge Trigger (2)

Exit Va/U Exit Va/U

Rig vs. CFD Radial Non-Dimensional Profile of Total Pressure

NEWAC Build 1 Working Line

CFD Working Line

NEWAC Build 1 Near Surge

CFD Near Surge

• All testing issues resolved efficiently by the AneCom test facility

• Target of +0.7% adiabatic efficiency relative to datum rig test – achieved

• Target surge margin exceeded at high speeds tested

• Part speed surge margin meets requirements

• Close agreement between 3D CFD and test data

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