Turbomachinery Applications w ith STAR-CCM+ Fred Mendona Fred - - PowerPoint PPT Presentation

Turbomachinery Applications w ith STAR-CCM+

Fred Mendonça Fred Mendonça Turbomachinery Sector Manager

An Integrated Solution …

• A single integrated software

“The applications of the software seem to be infinite. The user-friendly

g g environment

– Geometry handling, CAD fixing,

automated meshing

seem to be infinite. The user friendly interface makes it easy to learn and a very powerful tool.” Sean Alexander, Solar Turbines Incorporated

automated meshing

– Pre-processing, multi-physics and

post processing

co po ated “Having used several industrial CFD

• Integrated into existing process

Having used several industrial CFD codes over the past 18 years, I have always found CD-adapco to be the best all round provider. As well as producing high quality software their

• Seamless integration with other

software

producing high quality software, their training and support is consistently excellent and ahead of the competition” Dr Allan Thomson, Wood Group

– Blade modeling – Optimization

Dr Allan Thomson, Wood Group

… from interaction Across the Industry

STAR-Konferenz Deutschland 2009, Berlin 9-10 Nov. 2009

The Solution of Choice for Turbomachinery Applications

Simulation in the Turbo Industry: Templated and automated meshing p g

• FOR DESIGN - Templated mesher for axial and radial devices

with tip clearances

• FOR ANALYSIS - 3D CAD import, surface repair, surface re-

meshing and automated volume meshing based on trimmed meshing and automated volume meshing based on trimmed hexahedra and polyhedra

Simulation in the Turbo Industry: Applications pp

• Turbomachinery and hydropower
• Compressors and turbines

p

• Steady-state and efficient transient

–

Using segregated and coupled solvers

• Single and multistage devices
• Single and multistage devices
• Primary, internal and leakage flows
• Conjugate Heat transfer

C l t f

• Complete performance map
• Periodic flows including flutter
• Combustion
• Transitional flows
• Aero-hydroacoustics
• Under nacelle
• Under nacelle

Some recent validations and case studies Some recent validations and case studies

Validated Simulation: Radial Compressor

• Comparison with rig measurements

– Full performance curve

3 6 3.8 4

– RPM range

3 3.2 3.4 3.6 2c/P1c 200000rpm 190000rpm 210000rpm 2.2 2.4 2.6 2.8 ssure Ratio (t/t) P2 110000rpm 150000rpm 200k181kpa 200000rpmchoke 1.4 1.6 1.8 2 Pres 150000rpm95kpa 1 1.2 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2 Corrected Air Flow (Kg/s)

Validated Simulation: Radial Compressor

• Installation effects !

– Curved inlet duct

3.6 3.8 4

– Diffuser outlet

190000 RPM 210000 RPM

2 8 3 3.2 3.4

0.6 0.65 0.68 0.7 0.72

2.2 2.4 2.6 2.8

0.74 0.75

1.4 1.6 1.8 2 1 1.2 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16 0.18 0.2

Validated Simulation: Axial Compressor

• NASA Rotor37 – AGARD-AR-355

– Comparison of High-Re and Low-Re wall resolution – Comparison of turbulence models

Pressure ratio Pressure ratio Isentropic Isentropic efficiency fficiency Isentropic Isentropic efficiency efficiency

Innovative Designs: Axial Compressor

• NASA Rotor37 – Groove analysis

– Aimed at improving low mass-flow performance

Pressure ratio Pressure ratio Isentropic efficiency Isentropic efficiency

STAR-Konferenz Deutschland 2009, Berlin 9-10 Nov. 2009

AITEB-2 WP4.2 turbine blade end-wall cooling

• Solution Timescales from “blind start”

–

CAD to CHT Polyhedral mesh : 3 HOURS

–

CHT Polyhedral Volume solution : 2 DAYS

–

Hexahedral solution (fluid only) : 3rd DAY

CAD CAD Volume Meshes Volume Meshes CAD CAD Solutions Solutions Su Surface r rface remesh mesh STAR-Konferenz Deutschland 2009, Berlin 9-10 Nov. 2009

Blade Pressure Blade Pressure Distribution Distribution

AITEB-2 WP4.2 turbine blade end-wall cooling

1.1

Bl Blade ade outer wal

• uter wall pl

plane ane at at z z = = 96.8% 96.8%

Bl ade O ut er wal l Absol Bl ade O ut er wal l Absol ut e Pr essur e Com par i son ut e Pr essur e Com par i son

0 8 0.9 1 0.6 0.7 0.8 Ps / P01 0.4 0.5

CFD - FLUENT (Non-Conjugate) EXPERIMENT

0.2 0.3 0.025 0.045 0.065 0.085 0.105 0.125

EXPERIMENT CFD - CCM+ (Conjugate) CFD - CCM+ (Non-Conjugate)

X-Coordinate (m)

STAR-Konferenz Deutschland 2009, Berlin 9-10 Nov. 2009

Wind Turbine Blade sections - NACA 64 618

The NACA 64 618 profile is chosen because it demonstrates a bucket-feature in the CD-CL curve. Trimmed m med mesh – sh –40,000 c 000 cells STAR-Konferenz Deutschland 2009, Berlin 9-10 Nov. 2009

Wind Turbine Blade sections - DU 91-W2-250

The DU 91-W2-250 profile is a dedicated wind turbine airfoil with a relative thickness of 25%. STAR-Konferenz Deutschland 2009, Berlin 9-10 Nov. 2009

Harmonic Balance – Rational for fast transient analysis of periodic flows

• Devices are commonly multi-row and multi-stage
• Stator/mounts and rotors commonly have unequal

pitches pitches

• Steady-state methods “mix-out” or “freeze” the

interaction between stator and rotor This is inaccurate interaction between stator and rotor. This is inaccurate, but efficient

• Transient methods overcome the inaccuracies by

sliding the mesh at the interface between stator and sliding the mesh at the interface between stator and

• rotor. This is accurate, but inefficient, especially when

the number of stators and rotors are unequal

• Harmonic Balance, specifically for periodic flows

affords both benefits of efficiency and accuracy. Typically costs 1/10th of equivalent transient

C rrent implementation is for ideal gases onl

• Current implementation is for ideal gases only

STAR-Konferenz Deutschland 2009, Berlin 9-10 Nov. 2009

Harmonic Balance: Stator-Rotor Wake Interaction

• D4 compressor
• Hodson

Hodson turbine turbine

Harmonic Balance: Flutter

• Flutter implementation
• For aerodynamic damping
• Imposed flutter modes
• Distorting mesh
• Variable Inter-blade phase angle

Harmonic Balance: Flutter

• Flutter implementation
• For aerodynamic damping
• Imposed flutter modes
• Distorting mesh
• Variable Inter-blade phase angle

Summary

• 1st level

2nd Level

• CD-adapco continues to pursue

– 2nd Level » 3rd Level

• 4th Level
• Integrated, Automated, Innovative

solutions for the Turbomachinery Industry

Many thanks for your Attention Many thanks for your Attention