STAR Global Conference 2013 March 18 - 20, Orlando, USA Conjugate Heat Transfer Analysis of a high loaded convection cooled Vane with STAR-CCM+ René Braun, Karsten Kusterer, B & B-AGEMA, Aachen, Germany
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 engineering your visions STAR Global Conference 2013, Orlando, No. 2
Introduction: B&B-AGEMA • 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, Contact: test-rig realization, advisory service Dr.-Ing. research in cooling technologies (e.g. innovative film cooling) Karsten Kusterer Power Plant B&B-AGEMA GmbH CFD / CHT Analysis & Flow Optimization of power plant components Juelicher Str. 338 52070 Aachen (cooling tower, valve, condenser , moisture separator, etc.) Ph.: +49-241-56878-0 Thermodynamic Process Calculations & Optimization Fax: +49-241-56878-79 info@bub-agema.de www.bub-agema.de engineering your visions STAR Global Conference 2013, Orlando, No. 3
New Design of hot gas path of KHI L30A B&B-AGEMA contribution for KHI L30A (30 MW el simple cycle efficiencies >40%) is published and acknowledged by KHI: Tanaka, R., Koji, T., Ryu, M., Matsuoka, A., Okuto, A.: KHI GT line-up (GT2012-68668) 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 Highest efficient film-cooling is an essential technology to reach high efficiency: engineering your visions STAR Global Conference 2013, Orlando, No. 4
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 engineering your visions STAR Global Conference 2013, Orlando, No. 5
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 1 st 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 engineering your visions STAR Global Conference 2013, Orlando, No. 6
E-class gas turbine 1st vane CHT calculation cooling air inflow cooling air chamber flow d irection main flow path outlet main flow inlet vane mesh specification Calculation set up • Fluid: 7.04 million volume cells • Segregated solver • Solid 1.04 million volume cells • SST-GammaRe-theta Model full conjugate • Prism layer around outside airfoil: • Exhaust gas properties 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 engineering your visions STAR Global Conference 2013, Orlando, No. 7
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 of 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 engineering your visions STAR Global Conference 2013, Orlando, No. 8
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 engineering your visions STAR Global Conference 2013, Orlando, No. 9
NASA Turbine Vane Mark II test case: geometrical & mesh model Geometry Overview Midspan Mesh neglect of endwalls local refinements (symmetry plane) midspan cooling air Prism layers => y + < 1 engineering your visions STAR Global Conference 2013, Orlando, No. 10
NASA Turbine Vane Mark II test case: boundary condition Boundary Conditions for vane calculation of Mark II test case: Inlet Periodicity Inlet main flow total pressure: 3.37 bar total temperature: 788 K twist-free inflow Mach number: 0.19 Outlet 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 Inlet 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 Outlet 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 engineering your visions STAR Global Conference 2013, Orlando, No. 11
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 engineering your visions STAR Global Conference 2013, Orlando, No. 12
STAR-CCM+ turbulence models STAR-CCM+ Algebraic models Linear eddy one equation Spalart-Allmaras- viscosity models models Model Reynolds- SST- Nonlinear eddy Two euqation Averaged Navier- k-Omega Models GammaReTheta- viscosity models models Stokes (RANS) Model Large Eddy Reynolds stress Realizable k- Simulation (LES) models k-Epsilon Models Epsilon Model Detached Eddy Simulation (DES) V2F Model Direct numerical Simulation (DNS) • Calculations are done with the coupled solver engineering your visions STAR Global Conference 2013, Orlando, No. 13
Variation of turbulence model • The predicted pressure distributions of different turbulence models agree all very well with the test results. engineering your visions STAR Global Conference 2013, Orlando, No. 14
Variation of turbulence model • 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 engineering your visions STAR Global Conference 2013, Orlando, No. 15
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 engineering your visions STAR Global Conference 2013, Orlando, No. 16
Callibration of transition model Re-theta Pressure side Suction side • Later onset location of transition • Less over prediction after first Re_theta shock • More under prediction at pressure side Re_theta : momentum thickness Reynolds number engineering your visions STAR Global Conference 2013, Orlando, No. 17
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 engineering your visions STAR Global Conference 2013, Orlando, No. 18
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