AxSTREAM v3 Flyer HydroT Eng

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SoftInWay, Inc., 15 New England Executive Park, Burlington, MA 01803 www.softinway.com

Phone: +1-781-685-4942 Fax: +1-781-685-4601

Fax: +1-781-685-4601

AxSTREAM Hydro Conceptual Design Suite

AxSTREAM Hydro

Version 3.2

Axial Hydraulic Turbine Flow Path Design,

Analysis and Optimization

2012

AxSTREAM - SoftInWay Inc. trademark. All rights reserved.

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Phone: +1-781-685-4942 Fax: +1-781-685-4601

Fax: +1-781-685-4601


1 Introduction

The AxSTREAM Hydro is a software suite for hydraulic machines multidisciplinary design, analysis and

optimization, that provides an integrated and streamlined solution for the complete flow path design process for both

radial and axial pumps and turbines, starting from initial sizing from scratch ending up 3D blade profiles at the final

phase.

Starting from preliminary design (defining basic machine performance from a few simple parameters),

AxSTREAM Hydro goes through meanline (1D) and axisymmetric (2D) analysis, profiling and 3D blade design of

the buckets, finite element analysis, finishing with export of the geometry to 3D CAD model or for CFD calculation.

AxSTREAM Hydro provides full design and analysis cycle for axial and radial hydraulic turbines in a

flexible and integrated environment. The tasks user can solve with AxSTREAM Hydro are following:

Design new machine from scratch

Analyze existing machine and its performance

Redesign, optimize and upgrade existing machines

AxTREAM Hydro supports all types of incompressible newtonian fluids, including water, oil, kerosene etc.

User can work with pre-defined default fluids or compose custom one based on known physical properties

(density, wiscosity).

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2 Hydraulic Turbine Preliminary Design (Axial_TURBO_Design License)

Preliminary Design procedure is used to create machine flow path design from scratch from a set of several

boundary conditions, geometrical parameters and taking into account specified constraints.

2.1 Turbine Solution Generator

Preliminary Design Solution Generator is used to produce a number of

variants (solutions) that satisfy specified boundary conditions within

applied constraints.

The usage of inverse solver allows to generate large amount of designs in

a short time (20,000 per min).

AxSTREAM Hydro can design completely new flow paths, or use the

unified stages with similar geometry. Maximum number of stages in the

machine equals to 50.

Generated set of solution can be explored using Design Space Explorer.

2.2 Axial Turbine Design Space Explorer

Design Space Explorer allows exploring a set of solution points

generated with Solution Generator.

Design Space Explorer gives possibility to select appropriate solutions by

specifying different types of constraints and limitations.

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2.3 Post-design Flow Path Adjustment

Post-design flow path adjustment

provides user with option to adjust

separate stages using changing their

geometric parameters, pressure

distribution on the chart or entire

machine endwall contours by spline.

S1/S2 flow path adjustment option enables users to optimize separate stages:

in pitchwise direction (S1 optimization) taking profile width with regard to pitch under criteria of loss minimization

in spanwise direction (S2 optimization) taking geometrical parameters with regard to outlet capacity and losses within the constraints on reaction, hub and tip diameters etc.

The optimization is performed using multistage random search with automatic adjustment of parameter variation

intervals at each step of the search.

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3 Streamline Solver (Axial_TURBO_Analysis License)

Streamline solver module performs meanline (1D) or axisymmetric (2D) calculation of machine, taking into

account actual characteristics of the machine geometry and boundary conditions set.

The system can perform analysis of stages with full blade rows, with only rotor or only stator, stages with counter-

rotation, and mixed flow paths with axial and radial stages.

Additional elements (ducts, diffusers etc) can be specified and calculated

In addition to the existing models of energy loss and seal leakages calculations, the user can add custom ones.

Streamline solver calculates next main

parameters of the flow path:

Power

Efficiency

Mass flow rate, volume flow rate;

Kinematic, thermodynamic parameters distribution

Losses in elements

Leakages and flow balance;

Distribution of parameters spanwise;

Lean calculation;

2D analysis uses streamline curvature method.

This module performs calculation of radial

equilibrium in the gaps between airfoil rows.

The model for profile losses, secondary losses

and leakages losses can be selected from a few

standard ones or customized.

Distribution of parameters can be visualized as

colorful gradient.

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4 Design of Experiment Optimization (AxPLAN License)

AxPLAN module uses streamline solver and can be

run in meanline or axisymmetric task formulation. It

is the main optimization tool at the last phases of

flow path design.

The AxPLAN module allows performing various

design tasks by using design of experiment (DoE)

study methods.

The experiment planning option is fully integrated

into AxSTREAM Hydro and is executed in terms of

direct problem formulation of calculation analysis,

which enables the user to make an experiment plan

using familiar formulations.

The use of AxPLAN allows users to see the results

of optimization and to define the cylinder

performance in off-design regimes.

5 Performances Maps Generator (AxMAP License)

AxMAP module uses streamline solver and can be run in

meanline or axisymmetric task formulation. It is developed

for automatic generation of turbine performance maps.

AxMAP makes possible to study the influence of operational

conditions and geometry variation on turbine performance.

The maps generation function is integrated into AxSTREAM

Hydro and uses current project

geometry for calculations.

AxMAP files can store existing

experimental data in order to compare

them with calculation results.

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6 Profiling and Blade Design (Axial_Profiling_Blade_Design License)

Profiling and Blade Design module is

used for creation and editing of 3D airfoils.

Wide range of geometrical tools and

interactive charts allows user to configure

the blades easily and in a short time.

Profiling tools provides interactive

mechanism to change profile parameters

by varying the values of inlet and outlet

angles, wedge angles and edge radii.

Profiles can be also manipulated by using

the control points of splines.

Throat (gauging angle) is preserved during

profiling manipulations.

Profiling options offer various methods of profile

optimization.

Automatic profile optimization can be performed

based on the aerodynamic criteria of profile

quality such as minimal profile losses.

Potential flow solver in profiling module

automatically calculates the distribution of

velocity, pressure, momentum thickness values

and heat transfer coefficients along the profile

outline.

In blade profiling user can take into account protective

coating thickness, edit its distribution across the profile and

receive final blade with or without coating depending on task.

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Blade designer is used for 3D blade design, shaping

and stacking. The module has options allowing

interactive graphical editing of blade geometry and

twist angles manipulation, changing the position of

profile mass center in separate sections (lean and

sweep).

In Blade designer user can control 3D curvature of the

blade and review blades in rows.

Blade designer helps user to estimate area distribution

and stresses at edges of pressure and suction sides in

real time in order to build 3D blades.

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7 Cascade CFD (Cascade CFD license)

Cascade CFD module is used for rapid 2D flow

analysis in blade channels.

The analysis is performed using full 2D CFD

formulations (Navier-Stokes, viscous with various

turbulence models (standard k-e, k-e RNG, k-w, k-w

SST models)).

The analysis results are flow charts with velocity,

pressure and other parameters distribution along the

profile outline. User can also calculate and display heat

flux and velocity vectors.

8 AxSLICE Module (AxSLICE license)

AxSLICE module is used for extraction

of profiles geometry from blades 3D models.

AxSLICE can process 3D models in

STL, IGES, CURVE formats.

AxSLICE provides special option for

extraction profiles from cloud of points obtained with laser 3D scan.

Blade model geometry: chords, blade

angles, edge diameters are

automatically recognized in a specified

number of cross-sections. Recognition

results can be immediately loaded into

AxSTREAM Hydro project. These

results can be used for automated

import and flow path calculations.

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9 ATLAS Profile Database (ATLAS License)

Atlas is a profile database management system allowing to

store blade profiles that are using in company practice or

designed right in AxSTREAM Hydro.

Profiles can be created and edited directly in ATLAS from

XY-points coordinates, arcs segments or thickness

distribution along caomberline.

Later on they can be inserted to AxSTREAM Hydro and

used for blade design purposes.

In ATLAS user can work with a number of independent

profiles databases at the same time.

10 Import of Profiles (Import_Profile License)

User can import profiles created using XY points

coordinates with the help of Import Profile module

in AxSTREAM Hydro.

AxSTREAM Hydro allows importing both separate

profiles and series of profiles in blade airfoil. The

data can be imported from file or copied from

EXCEL tables.

AxSTREAM Hydro provides interactive adjustment

of imported points with fully and semi-automatic

determination of edges and blade angles.

An imported profile can be inserted into the cascade

in the chosen position, scaled to fit chord and

inserted into the cascade, retaining the throat and

stagger angle.

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11 Structural and Modal Analysis (AxSTRESS License)

AxSTRESS module is used for express 3D structural and modal analysis of the blades using the finite element

method. The module has tools for automatical mesh generation and results post-processing.

Boundary conditions (pressures, rotation speed etc) are automatically taken from AxSTREAM Hydro project

AxSTRESS module can calculate and display Campbell diagram for single element or groups of blades.

AxSTRESS creates temporary files in CDB-format that is compatible with ANSYS. This way AxSTRESS

results can be always confirmed in ANSYS.

AxSTRESS has options to perform:

hot-to-cold state calculation to determine appropriate manufacturing conditions before

profile export

cold-to-hot state calculations. Their results can be used for scanned blades to receive them in

hot working state for calculation in AxSTREAM Hydro

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12 3D Flow Analysis (AxCFD License) AxCFD is used for 3D flow analysis in

blade-to-blade channels.

The analysis is performed using full 3D

CFD formulation (Navier-Stokes, viscous

with various turbulence models (standard

k-e, k-e RNG, k-w, k-w SST models)).

All the geometry data are transferred from

AxSTREAM Hydro project to AxCFD

automatically.

In preprocessor user can setup distribution

of boundary conditions before and after

domain, mesh quality for automated

generation and solver settings.

CFD can be calculated for individual rows,

for a stage or for entire cylinder.

The analysis results are the values of

flow rate, efficiency, kinematic and

thermodynamic parameters.

The system post-processing can

calculate the distribution of

parameters in any section of the

channel in pitchwise direction and

the distribution of parameters in the

section along profile outline.

Depending on blade temperature

specified and conditions of flow in

channel, heat transfer coefficient and

its vectors will be calculated.

CFD calculation results can be saved

for later review or compared with

other calculations and experiments

data in main program project.

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13 Geometry Export (Export License)

Export module allows users to export 3D blade geometry as DXF, IGES and

STL files to use them in CAD systems.

Blades 3D geometry can be also exported in specialized formats to different

commercial CFD and CAE software systems for 3D aerodynamic and

structural analysis (CFX, FLUENT, NUMECA, ANSYS).

Additional customized

export formats can be

added on demand.

14 AxSTREAM Database (Project Base License)

Project Base license is mandatory option for using on each

workstation and it is needed to start working with

AxSTREAM Hydro in either single user or floating license.

Project license is used as base system option managing the

available set of network licenses.

AxSTREAM database allows integration of

turbomachinery projects giving access to project data for

viewing and editing, consistency management and data

recovery, project data loading and saving.

User can modify the number of stations, profiling modes,

structural properties used in different elements of turbine, define methods of energy loss calculations, select different

units in measuring system settings used during data output, change graphical user interface language (English,

Russian).

AxSTREAM Hydro viewer helps to explore axial turbine

flow path (both meridional view and 3D blade geometry),

velocity triangles, HS-diagram, flow balance diagram,

distribution of kinematic and thermodynamic parameters of

machine.

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Phone: +1-781-685-4942 Fax: +1-781-685-4601

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AxSTREAM Hydro allows to copy and paste modules (groups of stages) or stage objects from one project to

another. This option gives capability to store company approved types of stages in the libraries and quickly assemble

them into new flow path designs.

AxSTREAM Hydro supports data exchange with MS EXCEL tables. This allows parallel initial data preparation,

i.e., without using AxSTREAM Hydro workstation, and after that it is possible to quickly transport the data to the

system.

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Phone: +1-781-685-4942 Fax: +1-781-685-4601

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AxSTREAM Hydro allows to

manage structural materials

database. Material mechanical

properties are defined in

AxSTREAM Hydro within the

temperature range. It gives a

capability to estimate accurately

values of stresses in turbine

elements. Structural materials

database can be easily

customized by user.

AxSTREAM Hydro allows to

generate user customized reports

including all project data. User

can select custom list of elements

and properties that should be

displayed in report.

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Phone: +1-781-685-4942 Fax: +1-781-685-4601

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15 AxSTREAM Hydro Licensing

Flexible licensing system allows the customer to choose the

appropriate set of modules. AxSTREAM Hydro comes with

personal (attached to defined PC) or network licenses

(floating, AxSTREAM Hydro can run on all computers

connected to network).

If there are several Project licenses, than other licenses can be

split and shared on different workstations (AxSTREAM Hydro

seats) at the same time.

Below is a table with all available modules for hydraulic

turbine design.

Module/License Description

PROJECT Base Workplace base license. Project database management

Axial TURBO Design Machine preliminary design and optimization, Stage design and optimization, Design Space Explorer

Axial TURBO Analysis Meanline (1D) and axisymmetric 2D analysis with Streamline solver

Profiling & 3D Blade Designer Planar cascades profiling, 3D blade design (stacking)

AxSTRESS 3D FEA analysis

Cascade CFD 2D CFD solution built in the profiling (if AxCFD is purchased, then Cascade CFD is included)

AxCFD 3D CFD solver

Import profile Import blade profile geometry

Export Export of blade geometry to CAD/CAE commercial packages

Atlas Storage for designed and standard company profiles

AxPLAN (DoE and optimization) Design of experiment and optimization engine

AxMAP Turbomachinery performances maps generator

AxSTREAM Fluid Calculator Calculates fluid properies

AxSTREAM Fluid Designer Tool for composing of custom gas mixtures

AxSLICE Module that is used for extraction of profiles geometry from blades 3D models and scanned clouds of points.

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Phone: +1-781-685-4942 Fax: +1-781-685-4601

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16 AxSTREAM Hydro Tutorials, Documentation and Technical Support

A full set of AxSTREAM Hydro Tutorials are available to ensure quick mastering of the software. SoftInWay also

offers excellent technical support for our customers (requires active support agreement). Our experienced

turbomachinery engineers have a wide understanding of all types of turbomachinery, and will assist you with all

your questions.

17 Turbomachinery & AxSTREAM Training

To fully master all the features of AxSTREAM Hydro, we highly recommend that you attend one of our training

classes.

AxSTREAM Hydro offers both classroom and online training. The online training makes it possible for you to

attend the training from your office. Our well known classroom training offers both advanced and fundamental

training on turbomachinery design and analysis, as well as AxSTREAM Hydro workshops

18 About SoftInWay

SoftInWay provides high quality engineering services and software products in the area of research, design and

digital prototyping of turbo-, thermo- and rotating machinery. SoftinWays software suite combines more than 500 years of in-house turbomachinery engineering expertise to help you reach optimal performance. SoftInWay is

headquartered in Burlington, MA, USA.

Email Contact:

USA (HQ) [email protected] Switzerland [email protected] India [email protected] Ukraine [email protected]

HQ Contact Info:

15 New England Executive Park

Burlington, MA 01803, USA

Main Number: 1-781-685-4942

Sales Number: 1-781-862-7867

FAX: 1-781-685-4601

For product information or assistance: [email protected]

For technical support: [email protected]

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AxSTREAM v3 Flyer HydroT Eng