多级透平综合性能试验器设计及1.5级透平联合调试验证

李夫庆; 石䶮; 周晟鋆; 黄单; 彭生红; 狄广强; 宋航

doi:10.13224/j.cnki.jasp.20250297

多级透平综合性能试验器设计及1.5级透平联合调试验证

doi: 10.13224/j.cnki.jasp.20250297

李夫庆^1,,
石䶮¹,
周晟鋆^1,*, ,,
黄单¹,
彭生红¹,
狄广强¹,
宋航²

1.
中国联合重型燃气轮机技术有限公司，上海 200131
2.
中航工程集成设备有限公司，北京 102206

详细信息

作者简介:
李夫庆（1984-），男，高级工程师，硕士，主要从事重型燃气轮机试验技术研究。E-mail：lifuqing@spic.com.cn

通讯作者:
周晟鋆（1994-），男，工程师，硕士，主要从事重型燃气轮机试验技术研究。E-mail：zhoushengyun@spic.com.cn

中图分类号: V231.1
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- 被引次数: 0
出版历程
- 收稿日期: 2025-06-22
- 网络出版日期: 2026-07-28

Design of multi-stage turbine comprehensive performance test rig and joint commissioning verification of 1.5-stage turbine

1.
China United Gas Turbine Technology Company，Limited，Shanghai 200131，China
2.
CAPDI Integration Equipment Company，Limited，Aviation Industry Corporation of China，Beijing 102206，China

摘要

摘要:
重型燃气轮机气冷透平内部的流动与传热现象复杂且高度耦合，准确预测这些现象对透平部件研发成功至关重要。为满足透平部件试验需求，本文研发了一种大流量、高转速、高功率的多级透平综合性能试验器，用于透平关键部件的气动和冷却试验验证。根据主流重型燃气轮机指标和相似模化理论，提出了试验需求参数计算方法。试验器主流进气总压为0.2～0.8 MPa、进气总温为573～773 K、主流最大流量为110 kg/s、最高输出功率为30 MW及最大转速为5000 r/min。试验器由气源系统、主气进气系统、排气系统、冷气进气系统及传动系统等子系统组成，针对各子系统的流场均匀性、气锤效应、排气温度控制、冷气调节能力和传动轴系的转子动力学特性进行了详细分析和优化，提出了激波后最高压力在设计压力的1.3倍以内，膨胀波后最低压力大于0 kPa，温度变化率小于0%作为空气管道设计和设备选型的准则。通过对1.5级配置透平试验件的试验验证，完成了试验器调试。试验录取的设计点能量平衡效率为86%，轴功效率为76%，各工况下能量平衡效率比轴功效率高出4%～13%，为透平设计中功率损失的精确量化提供了试验依据，采用试验验证对试验功率损失进行了分析，试验功率损失包括轴承摩擦功率损失、鼓风损失和泄漏损失。试验调试结果表明：试验器结构稳定，运行平稳，能够满足设计要求，并具备承担多级透平综合性能试验的能力。
- 透平试验器 /
- 相似模化 /
- 性能试验 /
- 系统设计 /
- 试验调试
Abstract:
The flow and heat transfer phenomena within the air-cooled turbine of heavy-duty gas turbines are highly complex and coupled. Accurately predicting these phenomena is critical to the successful development of turbine components. To meet the test validation requirements for turbine components, this paper developed a multi-stage turbine comprehensive performance test facility with high mass flow rate, high speed, and high power output. This facility was designed for aerodynamic and cooling performance verification of key turbine components. Based on the specifications of the typical heavy-duty gas turbine and similarity scaling theory, a calculation method for testing requirements was proposed. The test facility operates with inlet total pressures ranging from 0.2 to 0.8 MPa, inlet total temperatures from 573 to 773 K, a maximum mass flow rate of 110 kg/s, a maximum output power of 30 MW, and a maximum speed of 5000 r/min. The facility comprises subsystems including an air supply system, inlet system, exhaust system, cooling air inlet system, and transmission system. Detailed analyses and optimizations were conducted for flow field uniformity, pneumatic hammer effects, exhaust temperature control, cooling air regulation capacity, and rotor dynamic characteristics of the drive train. Design criteria were established, such as limiting the maximum post-shock pressure to ≤1.3 times the design pressure, ensuring post-expansion wave pressures above 0 kPa, and maintaining a temperature variation rate below 20% for air piping design and equipment selection. Commissioning of the test rig was accomplished via test validation with a 1.5-stage turbine test article. The measured energy balance efficiency was 86% and the shaft power efficiency was 76% at the design point, Under different conditions the measured energy balance efficiency exceeded the shaft power efficiency by 4%—13%, which provides a basis for the accurate power loss quantification in turbine design. Analysis of testing power losses, including bearing friction losses, windage losses, and leakage losses, was conducted through testing verification. The commissioning results demonstrated that the test facility exhibits stable structural integrity and smooth operation, meeting the design requirements and possessing the capability to conduct comprehensive performance testing of multi-stage turbines.
- turbine test rig /
- similarity scaling /
- performance test /
- system design /
- test commission

HTML

图 1 国际重型燃气轮机透平参数分布

Figure 1. Turbine parameters of International heavy duty gas turbine

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图 2 试验器总体方案原理流程图

Figure 2. Overall scheme piping and instrument diagram of test rig

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图 3 试验器总体方案三维图

Figure 3. Overall scheme 3D model of test rig

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图 4 主气进气系统几何模型（单位：mm）

Figure 4. Geometric model of main air inlet system （unit：mm）

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图 5 中间截面速度和静压分布云图

Figure 5. Velocity, static pressure contours at the mid-section

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图 6 出口截面无附面层静压和总压分布云图

Figure 6. Static and total pressure without boundary layer contours at the exit section

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图 7 压力和温度随时间和位置分布图

Figure 7. Pressure and temperature distribution over time and location

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图 8 排气系统三维模型

Figure 8. 3D model of exhaust system

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图 9 排气系统各截面温度分布云图

Figure 9. Sectional temperature contours of the exhaust system

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图 10 排气系统流线和相对压力分布图

Figure 10. Streamlines and relative pressure contours of exhaust system

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图 11 分配器三维模型（单位：mm）

Figure 11. 3D model of the distributer （unit：mm）

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图 12 分配器内流速和静压云图

Figure 12. Velocity and static pressure contours of the distributer

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图 13 试验器传动系统组成

Figure 13. Composition of the transmission system of test rig

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图 14 轴系计算模型

Figure 14. Shaft calculation model

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图 15 试验器轴系正反进动Campbell图

Figure 15. Campbell diagram of forward and backward precession of the test rig shaft system

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图 16 效率特性曲线

Figure 16. Efficiency characteristic curve

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图 17 流量特性曲线

Figure 17. Corrected mass flow characteristic curve of

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图 18 折合轴功率随膨胀比的变化曲线

Figure 18. Corrected shaft power curve with expansion ratio

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图 19 能量平衡效率试验值与计算值对比

Figure 19. Test values comparison with calculated values of energy balance efficiency

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图 20 轴功效率试验值与计算值对比

Figure 20. Test values comparison with calculated values of shaft power efficiency

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图 21 试验件转速-功率随时间变化曲线

Figure 21. Speed-power with time curve of the test piece

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图 22 功率差-轴向推力-时间曲线

Figure 22. Power difference-axial thrust with time curve

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图 23 变冷气流量试验效率曲线

Figure 23. Efficiency curve of variable cooling air flow rate

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表 1 试验需求参数与试验器设计参数

Table 1. Test required and design parameters of test rig

参数	需求值	设计值
主气进气总压/MPa	>0.52	0.8
主气进气总温/K	>748	773
主气进气流量/（kg/s）	>103	110
排气总压/MPa	>0.3	0.35
排气总温/K	>625	703
冷气进气总压/MPa	>主气进气总压	0.9
冷气进气总温/K	308～340	308～353
冷气进气流量/（kg/s）	>20.6	25
最大转速/（r/min）	>4625	5000
最大输出功率/MW	>25	30

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表 2 冷气系统支路阀门直径

Table 2. Throttling device diameter of cooling air system

阀门编号	直径/mm
#1	200
#2	200
#3	200
#4	150
#5	150
#6	150
#7	50

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表 3 冷气系统支路流量变化

Table 3. Branch air flow variations of cooling air system

参数	变化率/%
2号流量	−23.31
变化最大	9.54
变化最小	1.54
总流量	−0.87

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表 4 透平试验器轴系无阻尼临界转速

Table 4. Undamped critical speed of turbine rig shaft

模态	转速/（r/min）	主导转子
1	2617（反进）/2732（正进）	试验件
2	2950（反进）/3008（正进）	试验件
3	3988（反进）/4420（正进）	中间轴
4	4766（反进）/5166（正进）	中间轴
5	6706（反进）/7002（正进）	水力测功器
6	7397（反进）/7973（正进）	水力测功器
7	5516（反进）/8193（正进）	试验件

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表 5 安全保护参数及限制值

Table 5. Safety protection parameters and limit values

参数	报警值	停机值
水力测功器振动速度/（ mm/s）	4	6
水力测功器轴承温度/K	358	368
中间轴振动速度/（mm/s）	4	6
中间轴振动位移/mm	0.13	0.195
中间轴轴承温度/K	368	378
中间轴滑油回油温度/K	353	363
调试试验件振动速度/（mm/s）	4.5	9.3
试验件振动位移/mm	0.071	0.133
试验件轴承温度/K	368	378
试验件滑油回油温度/K	353	363
试验件轴向推力/kN	100	120

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