Conjugate Heat Transfer Analysis of a high loaded convection cooled - - PowerPoint PPT Presentation

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Conjugate Heat Transfer Analysis of a high loaded convection cooled - - PowerPoint PPT Presentation

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STAR Global Conference 2013 March 18 - 20, Orlando, USA Conjugate Heat Transfer Analysis of a high loaded convection cooled Vane with STAR-CCM+ Ren Braun, Karsten Kusterer, B & B-AGEMA, Aachen, Germany Content Introduction Upgrade

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STAR Global Conference 2013

March 18 - 20, Orlando, USA René Braun, Karsten Kusterer, B&B-AGEMA, Aachen, Germany

Conjugate Heat Transfer Analysis of a high loaded convection cooled Vane with STAR-CCM+

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engineering your visions STAR Global Conference 2013, Orlando, No. 2

Content

  • Introduction
  • Upgrade of E-class 160MW gas turbine
  • NASA Vane Mark II test case
  • Geometrical and mesh model
  • Boundary condition for test case calculation
  • Variation of turbulence model and validation with experimental data
  • Calibration of transition model Re-theta
  • Summary
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Contact:

Introduction: B&B-AGEMA

Dr.-Ing. Karsten Kusterer B&B-AGEMA GmbH Juelicher Str. 338 52070 Aachen Ph.: +49-241-56878-0 Fax: +49-241-56878-79 info@bub-agema.de www.bub-agema.de

  • Founded in 1995, located in Aachen, Germany
  • Independent engineering service company
  • Company Expertise

 Core Competence in turbomachinery  Compressor and turbine design for steam & gas turbines

  • component design & re-design, technology development, reviews,

test-rig realization, advisory service

  • research in cooling technologies (e.g. innovative film cooling)

 Power Plant

  • CFD / CHT Analysis & Flow Optimization of power plant components

(cooling tower, valve, condenser , moisture separator, etc.)

  • Thermodynamic Process Calculations & Optimization
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B&B-AGEMA contribution for KHI L30A (30 MWel simple cycle efficiencies >40%) is published and acknowledged by KHI:

Highest efficient film-cooling is an essential technology to reach high efficiency: KHI GT line-up (GT2012-68668)

Tanaka, R., Koji, T., Ryu, M., Matsuoka, A., Okuto, A.: Development Of High Efficient 30MW Class Gas Turbine - The Kawasaki L30A ASME-paper GT2012-68668, Copenhagen, Denmark, June 2012. Taniguchi, T., Tanaka, R., Shinoda, Y., Ryu, M., Moritz, N., Kusterer, K. : Application of an Optical Pyrometer to Newly Developed Industrial Gas Turbine ASME-paper GT2012- 68679, Copenhagen, Denmark, June 2012

New Design of hot gas path of KHI L30A

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Content

  • Introduction
  • Upgrade of E-class 160 MW gas turbine
  • NASA Vane Mark II test case
  • Geometrical and mesh model
  • Boundary condition for test case calculation
  • Variation of turbulence model and validation with experimental data
  • Calibration of transition model Re-theta
  • Summary
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Upgrade of E-class 160 MW gas turbine with STAR-CCM+

Upgrade designs are performed based on a „Delta“-analysis:

(1) Simplified multi-stage analysis (2) Reference case & conditions (3) Upgrade case & conditions (4) Improved configuration case(s) (5) Similarity operation check (gradients, eigenfrequencies etc.)

Example: Upgrade of 1st Vane

  • increase of turbine inlet temperature
  • CHT calculation of actual design with new condition
  • CHT calculation with TBC application
  • CHT calculation with redesign of inner cooling path

configuration and TBC application

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E-class gas turbine 1st vane CHT calculation

flow direction

vane mesh specification

  • Fluid: 7.04 million volume cells
  • Solid 1.04 million volume cells
  • Prism layer around outside airfoil:

28 layers, 1.15e-6 m first cell height

  • Prism layer inside flow path:

15 layers, 1.6e-6 m first cell height

  • local refinement area on suction side

cooling air inflow main flow inlet

  • utlet

cooling air chamber main flow path Calculation set up

  • Segregated solver
  • SST-GammaRe-theta Model full conjugate
  • Exhaust gas properties
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Upgrade of E-class 160 MW gas turbine with STAR-CCM+

Project Experiences

  • STAR-CCM+ is preferred tool at B&B-AGEMA for full three-dimensional

conjugate heat transfer and flow analysis of hot gas path components

  • Results and experiences of many projects have shown excellent agreement
  • f calculated results for STAR-CCM+ and for real behavior
  • STAR-CCM+ is excellent tool for complex and advanced application of real

gas turbine configurations of various types and OEM’S Theoretical background

  • Understanding and validation of available models and applications within

STAR-CCM+ are fundamental and necessary for analyzing of complex three-dimensional components. INFLUENCE OF TURBULENCE MODEL VARIATION

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Content

  • Introduction
  • Upgrade of E-class 160 MW gas turbine
  • NASA Vane Mark II test case
  • Geometrical and mesh model
  • Boundary condition for test case calculation
  • Variation of turbulence model and validation with experimental data
  • Calibration of transition model Re-theta
  • Summary
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NASA Turbine Vane Mark II test case: geometrical & mesh model Geometry Overview Midspan Mesh

neglect of endwalls (symmetry plane) midspan cooling air

Prism layers => y+ < 1 local refinements

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NASA Turbine Vane Mark II test case: boundary condition

Inlet Inlet Outlet Outlet Periodicity

Boundary Conditions for vane calculation of Mark II test case:

Inlet main flow total pressure: 3.37 bar total temperature: 788 K twist-free inflow Mach number: 0.19 Outlet main flow static pressure: 1.68 bar Boundary conditions cooling holes hole heat transfer coefficient temperature 1 1943.47 W/m²K 336.39 K 2 1881.45 W/m²K 326.27 K 3 1893.49 W/m²K 332.68 K 4 1960.62 W/m²K 338.86 K 5 1850.77 W/m²K 318.95 K 6 1813.36 W/m²K 315.58 K 7 1871.88 W/m²K 326.26 K 8 2643.07 W/m²K 359.83 K 9 1809.89 W/m²K 360.89 K 10 3056.69 W/m²K 414.85 K

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Content

  • Introduction
  • Upgrade of E-class 160 MW gas turbine
  • NASA Vane Mark II test case
  • Geometrical and mesh model
  • Boundary condition for test case calculation
  • Variation of turbulence model and validation with experimental data
  • Calibration of transition model Re-theta
  • Summary
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Reynolds- Averaged Navier- Stokes (RANS) Linear eddy viscosity models Algebraic models

  • ne equation

models Two euqation models Nonlinear eddy viscosity models Reynolds stress models Large Eddy Simulation (LES) Detached Eddy Simulation (DES) Direct numerical Simulation (DNS) k-Omega Models k-Epsilon Models Spalart-Allmaras- Model SST- GammaReTheta- Model Realizable k- Epsilon Model V2F Model

STAR-CCM+

STAR-CCM+ turbulence models

  • Calculations are done with the coupled solver
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  • The predicted pressure distributions of different turbulence models agree

all very well with the test results. Variation of turbulence model

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  • In laminar region, most turbulence models have large differences from

test data.

  • Only SST model agrees well with test data within laminar region.
  • SST model has an over prediction at suction side after first shock.
  • SST model is a little under predicted at pressure side.

Suction side Pressure side

Variation of turbulence model

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Content

  • Introduction
  • Upgrade of E-class 160 MW gas turbine
  • NASA Vane Mark II test case
  • Geometrical and mesh model
  • Boundary condition for test case calculation
  • Variation of turbulence model and validation with experimental data
  • Calibration of transition model Re-theta
  • Summary
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Re_theta

  • Later onset location of transition
  • Less over prediction after first

shock

  • More under prediction at pressure

side

Suction side Pressure side

Re_theta: momentum thickness Reynolds number

Callibration of transition model Re-theta

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Content

  • Introduction
  • Upgrade of E-class 160 MW gas turbine
  • NASA Vane Mark II test case
  • Geometrical and mesh model
  • Boundary condition for test case calculation
  • Variation of turbulence model and validation with experimental data
  • Calibration of transition model Re-theta
  • Summary
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Summary

NASA test case

  • The calculated pressure predictions match with test data very well for all

turbulence models

  • All turbulence model show quite different surface temperature predictions,

especially in laminar region of suction side

  • SST model tends to show the best agreement with test data for temperature

prediction among all turbulence models Overall

  • Understanding of implemented models and applications in STAR-CCM+ are

necessary to use the “right tool” within STAR-CCM+ and thus, to maximize the quality of simulations

  • B&B-AGEMA continuously validate new or updated implemented methods

within STAR-CCM+ to ensure best quality simulations

  • STAR-CCM+ is preferred tool for CHT and flow calculations