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This report presents test results obtained during an investigation of the performance of a single-cylinder, high-speed, compression-ignition test engine when using multiple-orifice fuel-injection valve nozzles in which the number and the direction of the orifices were varied independently.
The objective of the Innovative High Temperature Aircraft Engine Fuel Nozzle Program was to design and evaluate a nozzle capable of operating at a combustor inlet air temperature of 1600 F (1144 K) and a fuel temperature of 350 F (450 K). The nozzle was designed to meet the same performance requirements and fit within the size envelope of a current production dual orifice fuel nozzle. The design approach was to use improved thermal protection and fuel passage geometry in combination with fuel passage surface treatment to minimize coking at these extreme fuel and air temperatures. Heat transfer models of several fuel injector concepts were used to optimize the thermal protection, while sample tube coking tests were run to evaluate the effect of surface finish, coatings and tube material on the coking rate. Based on heat transfer analysis, additional air gaps, reduced fuel passage flow area and use of ceramic tip components reduced local fuel wetted wall temperatures by more than 200 F (100 K) when compared to a current production fuel nozzle. Sample tube coking test results showed the importance of surface finish on the fuel coking rate. Therefore, a one micro-inch (0.025 micron) roughness was specified for all fuel passage surfaces. A novel flow divider valve in the tip was also employed to reduce weight, allow room for additional thermal protection, and provide back pressure to reduce the risk of fuel vaporization. The fuel nozzle was fabricated and evaluated in a series of high temperature coking tests. Initial results of these tests indicate that thermal protection and surface treatments were partially successful in preventing nozzle fouling, but additional refinement of the internal flowpath is needed to prevent buildup of coke particles that partially blocked the spin slots which meter the nozzle fuel flow.
This report presents test results obtained at the Langley Memorial Aeronautical Laboratory of the National Advisory Committee for Aeronautics during an investigation to determine the relative performance of a single-cylinder, high-speed, compression-ignition engine when using fuel injection valve nozzles with different numbers, sizes, and directions of round orifices. A spring-loaded, automatic injection valve was used, centrally located at the top of a vertical disk-type combustion chamber formed between horizontally opposed inlet and exhaust valves of a 5 inch by 7 inch engine.
Method and system for adjusting a measured reheat outlet steam temperature (“RPV”) to approximate a reheat outlet steam temperature setpoint (“RSP”) in a boiler. An RPV is compared to an RSP. If the RPV is less than the RSP and a position of a fuel nozzle tilt (“TILTPV”) is below a high limit of the fuel nozzle tilt (“TILTHIGH”), the TILTPV is increased while a flow rate of a secondary flue gas recirculation (“SFGRPV”) is kept constant. If the RPV is less than the RSP and the TILTPV is at the TILTHIGH, the SFGRPV is increased. If the RPV is greater than the RSP and the SFGRPV is greater than a low limit of flow rate of the SFGR (“SFGRLOW”), the SFGRPV is decreased, while the TILTPV is kept constant. If the RPV is greater than the RSP and the SFGRPV is at the SFGRLOW, the TILTPV is decreased.
The fellowship work this summer will be in support of the development of a fuel mixer for a liquid fuel reformer that is upstream of a fuel cell. Tasks for the summer shall consist of design of a fuel mixer, setup of the laser diagnostics for determining the degree of fuel mixing, and testing of the fuel mixer. The fuel mixer shall be a venturi section with fuel injected at or near the throat, and an air swirler upstream of the venturi. Data to determine the performance of the mixer shall be taken using a Phase Doppler Particle Analyzer (PDPA).
In fiscal year 2003, test cell 23 of the Research Combustion Laboratory (RCL 23) at the NASA Glenn Research Center was upgraded with the addition of gaseous hydrogen as a working propellant and the addition of a 450-psig air-supply system. Test flexibility was further enhanced by upgrades to the facility control systems. RCL 23 can now test with gaseous hydrogen flow rates up to 0.05 lbm/sec and jet fuel flow rates up to 0.62 lbm/sec. Research airflow rates up to 3 lbm/sec are possible with the 450-psig supply system over a range of inlet temperatures. Nonvitiated, heated air is supplied from a shell and tube heat exchanger. The maximum nonvitiated facility air temperature is 1100 F at 1.5 lbm/sec. Research-section exhaust temperatures are limited to 3200 F because of material and cooling capacity limits. A variety of support systems are available depending on the research hardware configuration. Test section ignition can be provided via either a hydrogen air torch system or an electronic spark system. Emissions measurements are obtained with either pneumatically or electromechanically actuated gas sample probes, and the electromechanical system allows for radial measurements at a user-specified axial location for measurement of emissions profiles. Gas analysis data can be obtained for a variety of species, including carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NO and NOx), oxygen (O2), unburnt hydrocarbons, and unburnt hydrogen. Facility control is accomplished with a programmable logic control system. Facility operations have been upgraded to a system based on graphical user interface control screens. A data system is available for real-time acquisition and monitoring of both measurements in engineering units and performance calculations. The upgrades have made RCL 23 a highly flexible facility for research into low emissions gas turbine combustor concepts, and the flame tube configuration inherently allows for a variety of fuel nozzle configurations to be tested in a cost-effective manner. RCL 23 is poised to be a leading facility for developing modern low-emission fuel nozzles for use with jet fuel and alternative fuels.
Parker Hannifin Corporation developed the 3-Zone fuel nozzle for NASA's Environmentally Responsible Aviation Program to meet NASAs target of 75 LTO NOx reduction from CAEP6 regulation. The nozzle concept was envisioned as a drop-in replacement for currently used fuel nozzle stem, and is built up from laminates to provide energetic mixing suitable for lean direct injection mode at high combustor pressure. A high frequency fuel valve was also developed to provide fuel modulation for the pilot injector. Final testing result shows the LTO NOx level falling just shy of NASAs goal at 31.
A crash-fire protection system is described which will suppress the ignition of crash-spilled fuel that may be ingested by a T-56 turbo-propeller engine. This system includes means for rapidly extinguishing the combustor flame, means for cooling and inerting with water the hot engine parts likely to ignite engine ingested fuel, and means for blanketing with bromotrifluoromethane massive metal parts that may reheat after the engine stops rotating. Combustion-chamber flames were rapidly extinguished at the engine fuel nozzles by a fuel shutoff and drain valve. Hot engine parts were inerted and cooled by 42 pounds of water discharged at seven engine stations. Massive metal parts that could reheat were inerted with 10 pounds of bromotrifluoromethane discharged at two engine stations. Performance trials of the crash-fire protection system were conducted by bringing the engine up to takeoff temperature, actuating the crash-fire protection system, and then spraying fuel into the engine to simulate crash-ingested fuel. No fires occurred during these trials, although fuel was sprayed into the engine from 0.3 second to 15 minutes after actuating the crash-fire protection system.
Low-emission combustor designs are prone to combustor instabilities. Because active control of these instabilities may allow future combustors to meet both stringent emissions and performance requirements, an experimental combustor rig was developed for investigating methods of actively suppressing combustion instabilities. The experimental rig has features similar to a real engine combustor and exhibits instabilities representative of those in aircraft gas turbine engines. Experimental testing in the spring of 1999 demonstrated that the rig can be tuned to closely represent an instability observed in engine tests. Future plans are to develop and demonstrate combustion instability control using this experimental combustor rig. The NASA Glenn Research Center at Lewis Field is leading the Combustion Instability Control program to investigate methods for actively suppressing combustion instabilities. Under this program, a single-nozzle, liquid-fueled research combustor rig was designed, fabricated, and tested. The rig has many of the complexities of a real engine combustor, including an actual fuel nozzle and swirler, dilution cooling, and an effusion-cooled liner. Prior to designing the experimental rig, a survey of aircraft engine combustion instability experience identified an instability observed in a prototype engine as a suitable candidate for replication. The frequency of the instability was 525 Hz, with an amplitude of approximately 1.5-psi peak-to-peak at a burner pressure of 200 psia. The single-nozzle experimental combustor rig was designed to preserve subcomponent lengths, cross sectional area distribution, flow distribution, pressure-drop distribution, temperature distribution, and other factors previously found to be determinants of burner acoustic frequencies, mode shapes, gain, and damping. Analytical models were used to predict the acoustic resonances of both the engine combustor and proposed experiment. The analysis confirmed that the test rig configuration and engine configuration had similar longitudinal acoustic characteristics, increasing the likelihood that the engine instability would be replicated in the rig. Parametric analytical studies were performed to understand the influence of geometry and condition variations and to establish a combustion test plan. Cold-flow experiments verified that the design values of area and flow distributions were obtained. Combustion test results established the existence of a longitudinal combustion instability in the 500-Hz range with a measured amplitude approximating that observed in the engine. Modifications to the rig configuration during testing also showed the potential for injector independence. The research combustor rig was developed in partnership with Pratt & Whitney of West Palm Beach, Florida, and United Technologies Research Center of East Hartford, Connecticut. Experimental testing of the combustor rig took place at United Technologies Research Center.
A series of experiments was carried out in order to produce design data for a premixing prevaporizing fuel-air mixture preparation system for aircraft gas turbine engine combustors. The fuel-air mixture uniformity of four different system design concepts was evaluated over a range of conditions representing the cruise operation of a modern commercial turbofan engine. Operating conditions including pressure, temperature, fuel-to-air ratio, and velocity, exhibited no clear effect on mixture uniformity of systems using pressure-atomizing fuel nozzles and large-scale mixing devices. However, the performance of systems using atomizing fuel nozzles and large-scale mixing devices was found to be sensitive to operating conditions. Variations in system design variables were also evaluated and correlated. Mixing uniformity was found to improve with system length, pressure drop, and the number of fuel injection points per unit area. A premixing system capable of providing mixing uniformity to within 15 percent over a typical range of cruise operating conditions is demonstrated.
The operational characteristics of a J57-P1 turbojet engine have been investigated at altitudes between 15,000 and 66,000 feet in the Lewis altitude wind tunnel. Included in this study is a discussion of fuel nozzle coking, the altitude operating limits with and without the standard engine control, the compressor surge characteristics, and the engine starting and windmilling characteristics. Severe circumferential turbine outlet temperature gradients which occurred at high altitude as a result of fuel nozzle coking were alleviated by the manufacturer's change in the fuel flow divider schedule and in a nozzle gasket material. Compressor air bleed is required to prevent surge of the outboard compressor in the low engine speed region. The maximum altitude at which the engine was operated without the control was about 66,000 feet at 0.8 flight Mach number and at a reduced engine speed to avoid compressor surge; with the engine control in operation, the altitude operating limit is reduced to approximately 59,000 feet. The maximum altitude at which the engine was started was about 40,000 feet.
Dispensers are the top cause of maintenance events and down-time at hydrogen fueling stations. In an effort to help characterize and enable improvements in dispenser reliability, an extensive accelerated lifetime testing set-up was designed and built at NREL involving components typically part of dispensing operations at fueling stations. Device Under Test (DUTs) included different components such as normally open valves, normally closed valves, fueling nozzles, breakaways devices and filters. Conditions of testing included pressures, and flow rates similar to light duty fuel cell electric vehicles fueling at -40°C, and -20°C for thousands of cycles in hydrogen. Tested components (failed and non-failed) were disassembled at SNL and polymeric O-rings were carefully retrieved and cataloged for chemical and physical characterization. Data collected was compared to similar O-rings from unexposed or non-tested components for hydrogen effects, and failure modes. Degradation analyses, based on select polymer chemistries common across all component types, their location within components, visual assessment of damage coupled with strong hydrogen effects from chemical characterization, was completed and presented to NREL and DOE. Overall, the failure rate amongst the components was not as high as expected for the test conditions. Among the component types tested, breakaways were the most susceptible to damage under these test conditions, with fueling nozzles a close second. The proper combination of selection of the right polymer and optimum component design was found to make a strong difference in component reliability under severe dispenser operating conditions. Physical degradation of polymers, rather than chemical changes due to low temperature hydrogen exposure, is more prevalent as failure mode for these test conditions. The nature and the extent of the degradation was much less at -20°C as compared to -40°C. The damage and failure rates were higher at lower temperatures than at higher test temperatures. As expected, increasing the number of cycles at the lowest test temperature (-40°C) increased damage. This indicates that cycling at the low temperature of -40°C required by SAE J2601 can reduce component life in fuel dispensing operations
The overall objective of this test program was to demonstrate and evaluate the capability of the Rich-burn/Quick-mix/Lean-burn (RQL) combustor concept for HSR applications. This test program was in support of the Pratt & Whitney and GE Aircraft Engines HSR low-NOx Combustor Program. Collaborative programs with Parker Hannifin Corporation and Textron Fuel Systems resulted in the development and testing of the high-flow low-NOx rich-burn zone fuel-to-air ratio research fuel nozzles used in this test program. Based on the results obtained in this test program, several conclusions can be made: (1) The RQL tests gave low NOx and CO emissions results at conditions corresponding to HSR cruise. (2) The Textron fuel nozzle design with optimal multiple partitioning of fuel and air circuits shows potential of providing an acceptable uniform local fuel-rich region in the rich burner. (3) For the parameters studied in this test series, the tests have shown T3 is the dominant factor in the NOx formation for RQL combustors. As T3 increases from 600 to 1100 F, EI(NOx) increases approximately three fold. (4) Factors which appear to have secondary influence on NOx formation are P4, T4, infinity(sub rb), V(sub ref,ov). (5) Low smoke numbers were measured for infinity(sub rb) of 2.0 at P4 of 120 psia.
A scanning radiometer was used to determine the effect of airstream velocity on the mean drop diameter of water sprays produced by pressure atomizing and air atomizing fuel nozzles used in previous combustion studies. Increasing airstream velocity from 23 to 53.4 meters per second reduced the Sauter mean diameter by approximately 50 percent with both types of fuel nozzles. The use of a sonic cup attached to the tip of an air assist nozzle reduced the Sauter mean diameter by approximately 40 percent. Test conditions included airstream velocities of 23 to 53.4 meters per second at 293 K and atmospheric pressure.
A scanning radiometer was used to determine the effect of airstream velocity on the mean drop diameter of water sprays produced by pressure atomizing and air atomizing fuel nozzles used in previous combustion studies. Increasing airstream velocity from 23 to 53.4 meters per second reduced the Sauter mean diameter by approximately 50 percent with both types of fuel nozzles. The use of a sonic cup attached to the tip of an air assist nozzle reduced the Sauter mean diameter by approximately 40 percent. Test conditions included airstream velocities of 23 to 53.4 meters per second at 293 K and atmospheric pressure.
The purpose of the tests covered by this report was to obtain specific information on the rate of penetration of the spray from a simple injection nozzle, having a single orifice with a diameter of 0.015 inch when injecting into compressed gases. The results have shown that the effects of both chamber and fuel pressures on penetration are so marked that the study of sprays by means of high-speed photography or its equivalent is necessary if the effects are to be appreciated sufficiently to enable rational analysis. It was found for these tests that the negative acceleration of the spray tip is approximately proportional to the 1.5 power of the instantaneous velocity of the spray tip.
Facility modifications have been completed to an existing combustor flametube facility to enable testing with gaseous hydrogen propellants at the NASA Glenn Research Center. The purpose of the facility is to test a variety of fuel nozzle and flameholder hardware configurations for use in aircraft combustors. Facility capabilities have been expanded to include testing with gaseous hydrogen, along with the existing hydrocarbon-based jet fuel. Modifications have also been made to the facility air supply to provide heated air up to 350 psig, 1100 F, and 3.0 lbm/s. The facility can accommodate a wide variety of flametube and fuel nozzle configurations. Emissions and performance data are obtained via a variety of gas sample probe configurations and emissions measurement equipment.
Two-phase flow in pneumatic two-fluid fuel nozzles was investigated experimentally to determine the effect of atomizing-gas density and gas mass-flux on liquid-jet breakup in sonic-velocity gas-flow. Dropsize data were obtained for the following atomizing-gases: nitrogen; argon; carbon dioxide; and helium. They were selected to cover a gas molecular-weight range of 4 to 44. Atomizing-gas mass-flux ranged from 6 to 50 g/sq cm-sec and four differently sized two-fluid fuel nozzles were used having orifice diameters that varied from 0.32 to 0.56 cm. The ratio of liquid-jet diameter to SMD, D sub o/D sub 32, was correlated with aerodynamic and liquid-surface forces based on the product of the Weber and Reynolds number, We*Re, and gas-to-liquid density ratio, rho sub g/rho sub l. To correlate spray dropsize with breakup forces produced by using different atomizing-gases, a new molecular-scale dimensionless group was derived. The derived dimensionless group was used to obtain an expression for the ratio of liquid-jet diameter to SMD, D sub o/D sub 32. The mathematical expression of this phenomenon incorporates the product of the Weber and Reynolds number, liquid viscosity, surface tension, acoustic gas velocity, the RMS velocity of gas molecules, the acceleration of gas molecules due to gravity, and gas viscosity. The mathematical expression encompassing these parameters agrees well with the atomization theory for liquid-jet breakup in high velocity gas flow. Also, it was found that at the same gas mass-flux, helium was considerably more effective than nitrogen in producing small droplet sprays with SMD's in the order of 5 micrometers.