Conjugate Heat Transfer Analysis of a high loaded ...mdx2.plm.automation.siemens.com/sites/default/files/Presentation/1... · Conjugate Heat Transfer Analysis of a high loaded convection

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+

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



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

[email protected]

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



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



Content

• Introduction

• Upgrade of E-class 160 MW gas turbine






• Summary



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



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

outlet

cooling air chamber

main flow path

Calculation set up

• Segregated solver

• SST-GammaRe-theta Model full conjugate

• Exhaust gas properties



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



Content

• Introduction







• Summary



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



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



Content

• Introduction







• Summary



Reynolds-Averaged Navier-Stokes (RANS)

Linear eddy viscosity models

Algebraic models

one 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



• The predicted pressure distributions of different turbulence models agree

all very well with the test results.

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

Variation of turbulence model



Content

• Introduction







• Summary



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



Content

• Introduction







• Summary



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

Documents

Conjugate Heat Transfer Analysis of a high loaded ...mdx2.plm.automation.siemens.com/sites/default/files/Presentation/1... · Conjugate Heat Transfer Analysis of a high loaded convection