Characterization of Cavitation Instabilities in Rocket Engine Turbopump Inducers


Book Description

Characterized by super-synchronous rotation of cavities around the periphery of rocket engine turbopump inducers, rotating cavitation is the primary cavitation instability considered in this thesis. A recently developed hypothesis for rotating cavitation onset is assessed through novel experimental analysis and a previously developed body force modeling approach using the MIT inducer, representative of the design of the Space Shuttle main engine low-pressure oxidizer pump inducer. A previously developed temporal and spatial Fourier decomposition, known as Traveling Wave Energy (TWE) analysis, of experimental unsteady inlet pressure measurements of the cavitating MIT inducer is demonstrated. TWE analysis offers several advantages over the current experimental analysis methods, resolving frequency, spatial mode shapes, and rotation direction of cavitation phenomena. Cut-on/cut-off behavior between rotating cavitation and alternate blade cavitation is observed, supporting the hypothesis that alternate blade cavitation is a necessary precursor to rotating cavitation onset. TWE is adapted for use on high speed borescope video data taken in the same experimental campaign. The frequency content extracted is qualitatively correlated with the results from the pressure data, establishing TWE as a viable tool for quantitative analysis of optical data. The video TWE results indicate that cavitation instability signatures are uniform in the radial direction, suggesting that a pressure transducer array can be established as the primary detection method for rotating cavitation and thereby simplifying test setups. A body force based modeling approach typically used for aero-engine compressor stability prediction is assessed for use in predicting rotating cavitation. A previously developed inducer-specific body force model formulation is validated in a representative compressor geometry, capturing global performance across the characteristic within 7%. However, the model exhibits convergence issues when applied to the inducer, hypothesized to be due to sensitivity in the inducer's loss characteristics. The investigation suggests the low flow coefficient design of the inducer drives the loss sensitivity and is the root cause behind the model's convergence issues. The results indicate the body force model is valid for the higher flow coefficient designs and lower stagger angles typically found in aero-engine compressors and fans. Suggestions for desensitizing the model for the inducer as well as further diagnostics defining the limiting geometry case for body force modeling are made.




Forced Response Measurements of Cavitation Dynamics in a Rocket Engine Turbopump Inducer


Book Description

Cavitation is a serious concern in liquid fueled launch vehicle propulsion systems which operate at high speeds to meet the engine thrust requirements. There are several types of cavitation instabilities, but of concern in this work is one-dimensional planar oscillations known as cavitation surge. In a launch vehicle the resulting dynamic behavior can lead to thrust oscillations and couple with the structures of the launch vehicle, leading to POGO instability (named after the POGO jumping stick) that can cause catastrophic failure. This thesis introduces a foundation for a method of forced response characterization of cavitating inducers and presents for the first time, damping ratio and natural frequency measurements of surge dynamics using a forced response system identification approach over different cavitation numbers. Cavitation dynamics have been experimentally characterized in the past via transmission matrices. In this work, dynamic pressure and velocity measurements were used to form transfer functions of the cavitating inducer. Experimental guidelines were developed to increase the stiffness of the structure to isolate fluid perturbations, condition the flow downstream of the inducer using honeycomb and wire mesh elements which increased the signal-to-noise ratio of the velocity measurements by 28%, and signal processing techniques to average and smooth the measurements.




Cavitation Instabilities and Rotordynamic Effects in Turbopumps and Hydroturbines


Book Description

The book provides a detailed approach to the physics, fluid dynamics, modeling, experimentation and numerical simulation of cavitation phenomena, with special emphasis on cavitation-induced instabilities and their implications on the design and operation of high performance turbopumps and hydraulic turbines. The first part covers the fundamentals (nucleation, dynamics, thermodynamic effects, erosion) and forms of cavitation (attached cavitation, cloud cavitation, supercavitation, vortex cavitation) relevant to hydraulic turbomachinery, illustrates modern experimental techniques for the characterization, visualization and analysis of cavitating flows, and introduces the main aspects of the hydrodynamic design and performance of axial inducers, centrifugal turbopumps and hydo-turbines. The second part focuses on the theoretical modeling, experimental analysis, and practical control of cavitation-induced fluid-dynamic and rotordynamic instabilities of hydraulic turbomachinery, with special emphasis on cavitating turbopumps (cavitation surge, rotating cavitation, higher order cavitation surge, rotordynamic whirl forces). Finally, the third part of the book illustrates the alternative approaches for the simulation of cavitating flows, with emphasis on both modeling and numerical aspects. Examples of applications to the simulation of unsteady cavitation in internal flows through hydraulic machinery are illustrated in detail.




A Body Force Model for Cavitating Inducers in Rocket Engine Turbopumps


Book Description

Modern rocket engine turbopumps utilize cavitating inducers to meet mass and volume requirements. Rotating cavitation and higher order cavitation instabilities have frequently been observed during inducer testing and operation and can cause severe asymmetric loading on the inducer blades and shaft, potentially leading to failure of the inducer. To date no broadly applicable design method exists to characterize and suppress the onset of cavitation instabilities. This thesis presents the development of a body force model for cavitating inducers with the goal of enabling interrogation of the onset of rotating cavitation and higher order cavitation instabilities and characterization of the governing uid dynamic mechanisms. Building on body force models of gas turbine compressors for compressor stability, the model introduces an additional force component, the binormal force, to capture the strong radial flows observed in inducer ow fields. The body forces were defined and the methodology was successfully validated for two test inducers, a helical inducer and a more advanced design resembling the Space Shuttle Main Engine Low Pressure Oxidizer Pump. The head rise characteristic of each test inducer was captured with less than 4% error across the operating range and the extent of the upstream backflow region was predicted to within 18% at every operating condition. Several challenges with the blade passage model were encountered during the course of the research and the diagnostics performed to investigate them are detailed. An extension of the body force model to two-phase flows was formulated and preliminary calculations with the extended model are presented. The preliminary two-phase results are encouraging and pave the way for future assessment of rotating cavitation instabilities.




Fluid Dynamics of Cavitation and Cavitating Turbopumps


Book Description

The book focuses on the fluid dynamics of cavitation with special reference to high power density turbopumps, where it represents the major source of performance and life degradation. While covering the more fundamental aspects of cavitation and the main kinds of cavitating flows, there is focus on the hydrodynamics and instabilities of cavitating turbopumps. The book also illustrates the alternative approaches for modeling and engineering simulation of cavitating flows.







Hydrodynamics of Pumps


Book Description

Hydrodynamics of Pumps is a reference for pump experts and a textbook for advanced students. It examines the fluid dynamics of liquid turbomachines, particularly pumps, focusing on special problems and design issues associated with the flow of liquid through a rotating machine. There are two characteristics of a liquid that lead to problems and cause a significantly different set of concerns than those in gas turbines. These are the potential for cavitation and the high density of liquids, which enhances the possibility of damaging, unsteady flows and forces. The book begins with an introduction to the subject, including cavitation, unsteady flows and turbomachinery, basic pump design and performance principles. Chapter topics include flow features, cavitation parameters and inception, bubble dynamics, cavitation effects on pump performance, and unsteady flows and vibration in pumps - discussed in the three final chapters. The book is richly illustrated and includes many practical examples.




Fluid Machinery and Fluid Mechanics


Book Description

"Fluid Machinery and Fluid Mechanics: 4th International Symposium (4th ISFMFE)" is the proceedings of 4th International Symposium on Fluid Machinery and Fluid Engineering, held in Beijing November 24-27, 2008. It contains 69 highly informative technical papers presented at the Mei Lecture session and the technical sessions of the symposium. The Chinese Society of Engineering Thermophysics (CSET) organized the First, the Second and the Third International Symposium on Fluid Machinery and Fluid Engineering (1996, 2000 and 2004). The purpose of the 4th Symposium is to provide a common forum for exchange of scientific and technical information worldwide on fluid machinery and fluid engineering for scientists and engineers. The main subject of this symposium is "Fluid Machinery for Energy Conservation". The "Mei Lecture" reports on the most recent developments of fluid machinery in commemoration of the late professor Mei Zuyan. The book is intended for researchers and engineers in fluid machinery and fluid engineering. Jianzhong Xu is a professor at the Chinese Society of Engineering Thermophysics, Chinese Academy of Sciences, Beijing.







Cavitation-Induced Vibrations in a Two-Bladed Rocket Engine Inducer


Book Description

Experimental investigation of cavitation induced vibrations in a 2-bladed water model inducer was performed for inlet flowrates ranging from 70% to 120% of the design flowrate and over a range of inlet cavitation numbers representative of a typical rocket engine operation. Dynamic (high frequency) pressure transducers were used to record fluctuating pressures along inducer housing (stationary reference frame) up to 2500 Hz, i.e. about 30 times the shaft speed. Data were obtained in two axial planes: one 0.08 diameters upstream and one 0.37 diameters downstream relative to the inducer blade leading edge tip plane. Flow visualization data at conditions typical of tip vortex instabilities at high cavitation number and sheet cavitation are presented and correlated to dynamic signature. Dynamic spectrum of the 2-bladed inducer is compared to data representative of the environment in a 4-bladed rocket engine inducer. The differences in the dynamic characteristics between the 2-bladed and 4-bladed inducers and the potential implications to inducer design decisions for lowering the impact of cavitation induced vibrations in turbomachinery are discussed.