At the large scale turbine rig (LSTR) at Technische Universität Darmstadt, Darmstadt, Germany, the aerothermal interaction of combustor exit flow conditions on the subsequent turbine stage is examined. The rig resembles a high pressure turbine and is scaled to low Mach numbers. A baseline configuration with an axial inflow and a swirling inflow representative for a lean combustor is modeled by swirl generators, whose clocking position toward the nozzle guide vane (NGV) leading edge can be varied. A staggered double-row of cylindrical film cooling holes on the endwall is examined. The effect of swirling inflow on heat transfer and film cooling effectiveness is studied, while the coolant mass flux rate is varied. Nusselt numbers are calculated using infrared thermography and the auxiliary wall method. Boundary layer, turbulence, and five-hole probe measurements as well as numerical simulations complement the examination. The results for swirling inflow show a decrease of film cooling effectiveness of up to 35% and an increase of Nusselt numbers of 10–20% in comparison to the baseline case for low coolant mass flux rates. For higher coolant injection, the heat transfer is on a similar level as the baseline. The differences vary depending on the clocking position. The turbulence intensity is increased to 30% for swirling inflow.

The aerothermal interaction of the combustor exit flow on the first vane row has been examined at the Large Scale Turbine Rig (LSTR) at Technische Universität Darmstadt (Darmstadt, Germany). A baseline configuration of axial inflow and a variation of swirling combustor inflow have been studied. The nozzle guide vane (NGV) featured endwall cooling, airfoil film cooling and a trailing edge slot ejection as well as NGV-rotor wheel space purge flow. CO 2 is injected for coolant flow tracing. The results are compared to five hole probe (5HP) measurements. The experiments for the baseline configuration are accompanied by numerical simulations using a passive scalar tracking method to validate the results and study the propagation of the coolant flow. The endwall coolant injection is detected to influence the pressure losses in the NGV. It has an impact on the Trailing Edge (TE) coolant ejection as well. For swirling combustor inflow, increased NGV pressure losses and increased mixing of Rear Inner Discharge Nozzle (RIDN) coolant and main flow is observed. An influence of the clocking position of the swirler to the vane is detected. Additional losses within the NGV row can be assigned to the swirler by means of flow tracing.

The spoiling effects of rim seal flow are studied at the Large Scale Turbine Rig (LSTR) at Technische Universität Darmstadt. Detailed flow field measurements and efficiency measurements were performed for various ingress and egress setups and will be presented in this paper. Efficiency measurements show an efficiency decrease as the rim seal mass flow is increased. Five hole probe measurements upstream and downstream of the second stator row show that an increasing rim seal mass flow leads to an increased pressure loss across the stator, to altered incidence angles and to an intensification of secondary flow structures within the lower 50% span. Static pressure taps at the stator profile primarily show altered aerodynamic loading with increased rim seal air. In addition, the end wall profile pressure was measured at the stator 2 hub. It can be seen that seal air injection causes increased pressure fluctuations on the platform. Temperature measurements with a temperature difference between rim seal and main annulus flow show that rim seal air primarily enters the passage vortex.

Further improvements of gas turbine design can be expected if realistic turbine inlet conditions are applied. These include discrete swirl cores and hot spots which exit from the combustion chamber. A large scale turbine rig is currently reconfigured at Technische Universität Darmstadt to analyse the effect of realistic swirl intensity on turbine flow and heat transfer. A comparison is to be made between swirling and axial inflow conditions. The swirl generator causes a recirculation zone inside the combustion chamber. As a result, the total pressure at turbine inlet is reduced at midspan and increased near the end walls. In addition, incidence angles of ±15° occur at hub and casing of the nozzle guide vane (NGV). This swirl and the shape of the pressure profile are typical for modern lean combustion concepts which are relevant to reduce emissions like NOX. During the design of the test rig, computational flow simulations are carried out. Different swirl orientations and clocking positions are investigated in advance. Depending on these parameters, there is a potential of 0.5 % efficiency between the optimal and the worst configuration. Comparing swirling with axial inflow conditions, an efficiency deficit of more than 2 % has been found which is mainly due to the increased turbulence level for swirling flow. In addition, heat transfer through the NGV hub is increased by approximately 20%. This paper aims for understanding the generation of these aerodynamic and thermal losses to allow for their elimination in future engine designs. Therefore, the most complex case of a realistic swirl generator is successively simplified towards a case with axial inflow: Two-dimensional inflow conditions including discrete swirl and loss cores are compared to radial distributions of inflow variables and globally constant values. The influence of swirling inflow, total pressure profile and turbulence level are simulated separately in order to identify their individual impact on aerodynamic and thermal losses.

Focusing on the experimental analysis of the effect of variable inlet flows on aerodynamics, efficiency and heat transfer of a modern high pressure turbine, the Large Scale Turbine Rig (LSTR) at Technische Universität Darmstadt has been extensively redesigned. The LSTR is a full annular, rotating low speed turbine test rig carrying a scaled 1.5-stage (NGV1 - Rotor - NGV2) axial high-pressure turbine geometry designed by Rolls-Royce Deutschland to match engine-realistic Reynolds numbers. To simulate real turbine inflow conditions, the LSTR is equipped with a combustor simulator module including exchangeable swirlers. Other inflow conditions include axial or turbulent inflow as well as altered relative positions of swirl cores and NGVs by traversing. To investigate combustor-turbine interaction, the LSTR offers a large variety of optical and physical access ports as well as high flexibility to the application of measurement techniques. An elaborate secondary air system enables the simulation of various cooling air flows. The turbine section is equipped with film-cooled NGVs, a hub side seal air injection between NGVs and rotor, as well as a hub side RIDN cooling air injection module designed to provide realistic turbine flow conditions. Exchangeable hub side RIDN-plates allow for investigation of different coolant injection geometries. Measurement capabilities include 5-hole-probes, Pitot and total temperature rakes, as well as static pressure taps distributed along NGV radial sections and at the hub side passage endwall. The NGV passage flow can be visualized by means of Particle Image Velocimetry (PIV). Hot Wire Anemometry (HWA) will be used for time-resolved measurements of the turbulence level at several positions. The distributions of heat transfer and film cooling effectiveness are acquired using infrared thermography and CO2-gas tracing.