Turbomachinery Applications w ith STAR-CCM+ Fred Mendonça Fred Mendonça Turbomachinery Sector Manager
An Integrated Solution … “The applications of the software A single integrated software g g seem to be infinite. The user-friendly seem to be infinite. The user friendly • interface makes it easy to learn and a environment very powerful tool.” – Geometry handling, CAD fixing, Sean Alexander, Solar Turbines Incorporated co po ated automated meshing automated meshing – Pre-processing, multi-physics and post processing “Having used several industrial CFD Having used several industrial CFD codes over the past 18 years, I have always found CD-adapco to be the Integrated into existing process • best all round provider. As well as producing high quality software their producing high quality software, their training and support is consistently Seamless integration with other excellent and ahead of the • competition” software Dr Allan Thomson, Wood Group Dr Allan Thomson, Wood Group – Blade modeling – Optimization
… 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 Complete performance map l t f • 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 – RPM range 4 3.8 3.6 3 6 3.4 200000rpm 3.2 190000rpm 2c/P1c 3 210000rpm ssure Ratio (t/t) P2 2.8 110000rpm 2.6 150000rpm 2.4 200k181kpa 2.2 200000rpmchoke Pres 150000rpm95kpa 2 1.8 1.6 1.4 1.2 1 0 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 – Diffuser outlet 4 3.8 3.6 3.4 210000 RPM 3.2 3 190000 RPM 2 8 2.8 0.65 2.6 0.6 0.7 2.4 0.68 2.2 0.72 2 0.75 0.74 1.8 1.6 1.4 1.2 1 0 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 Isentropic Isentropic efficiency efficiency fficiency
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) : 3 rd DAY – Volume Meshes Volume Meshes CAD CAD 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 Bl ade O Bl ade O ut er wal l Absol ut er wal l Absol ut e Pr essur e Com ut e Pr essur e Com par i son par i son 1.1 Blade Bl ade outer wal outer wall pl plane ane at at z z = = 96.8% 96.8% 1 0.9 0 8 0.8 Ps / P01 0.7 0.6 0.5 0.4 CFD - FLUENT (Non-Conjugate) EXPERIMENT EXPERIMENT 0.3 CFD - CCM+ (Conjugate) CFD - CCM+ (Non-Conjugate) 0.2 0.025 0.045 0.065 0.085 0.105 0.125 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 C D -C L 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 1/10 th 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 • CD-adapco continues to pursue • – 2nd Level 2nd Level Integrated, Automated, Innovative • » 3rd Level solutions for the Turbomachinery Industry 4th Level - Many thanks for your Attention Many thanks for your Attention
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