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STAR GLOBAL CONFERENCE
17 March 2015, San Diego (USA)
Development of Advanced Film Cooling
Technologies for Industrial Gas Turbine
Applications with STAR-CCM+®
Anis Haj Ayed, Karsten Kusterer, Ryozo Tanaka
Anis Haj Ayed
B&B-AGEMA GmbH, Aachen, Germany
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Contents
Background: Modern Gas Turbine Cooling Design
Development of Advanced Film Cooling Technologies
The Double Jet Film Cooling
The Nekomimi Film Cooling
Design Exploration & Experimental Validation
Summary
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“Kawasaki L30A”: Application of Modern CFD Tools
World‘s best Industrial GT “Kawasaki L30A”Highest PG efficiency in 30 MW class GT’s
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“Kawasaki L30A” Overview
30 MWel simple cycle efficiency: 40%
References:
Kawasaki 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
Successful implementation of
STAR-CCM+ in cooled turbine design
process for:
Design of extensively cooled vanes
and blades for real engine application
and to reach advanced design
specifications.
Acceleration of the design process by
reducing number of test configurations
until product readiness and, thus, to
reduce development costs.
Investigation of innovative cooling
technologies for hot gas components.
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KHI L30 A: Engine Test Facility
Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration)
CHT calculation with STAR-CCM+
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Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration)
main flow inlet
combustion gas
hot gas outlet
cooling inlet 1
pure air
cooling inlet 2
pure air
sealing inlet 2
pure air
sealing inlet 1
pure air
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lowhightemperature
CHT calculation results – pressure side temperature distribution
very good
agreement between
CHT and test data
STAR-CCM+ CHT calculation** circumferential averaged
TIP engine test data** ** fixed position
excellent prediction of internal cooling performance
internally
impingement & convective cooled
internally
convective cooled
film cooling
TIP: Thermal Index Paint
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Why improving film-cooling ?
minimize cooling air consumption maximize efficiency
minimize mixing losses with hot gas maximize efficiency
Minimize solid material temperature maximize lifetime
Understanding film-cooling flow phenomena is
key to improve turbine airfoil design
The Need for Cooling Technology Improvement
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Kidney Vortex Pair
typical lift-off situation
The Problem of Cylindrical Holes: Jet Lift-off Situation
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adf ,film cooling effectiveness
hole exit
Typical lift-off situation
cylindrical hole
Kidney Vortex Pair
The Problem of Cylindrical Holes: Jet Lift-off Situation
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Basic Improvement Concepts
2. Anti-Vortex generation: Formation of vortices inside the cooling jet with opposite
flow direction than the typical Kidney-vortex and, thus, preventing the jet lift-off.
walllateral distribution of
cooling air
lateral distribution of
cooling air
hot gasAnti-counter-
rotating vortices
cooling air cooling air
1. Enhanced cooling air diffusion concepts: Special hole exit shapes and diffusor-
type holes in order to reduce the cooling air momentum at the hole exit and increase
the lateral spreading of cooling air. Shaped holes are state-of-the-art, but special
progressive concepts are under development.
hot gas flow
cooling air flow
lateral spreading
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Combination of two cooling jets from cylindrical holes with lateral injection angle
1 2Anti – Kidney Vortex
adf ,
2
1
1Single jet with
lateral
component
2Single jet with
lateral
component
(mirror case)
1+2
DJFC
1
2
1
2
The Double Jet Film Cooling Technology: DJFC
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Transfer of the DJFC principle to a single hole concept:
(1) Shifting the 2nd hole of the DJFC concept to the same streamwise x-position as the 1st hole
(2) Merging the two holes(3) Replacing the air supplies with one cylindrical supply channel, additional
finalizing of the contour
NEKOMIMI technology („cat ears“)
b=29°
„ear angle“
(1) (2) (3)
The Nekomimi Film Cooling Technology
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Design Exploration
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Film Cooling Effectiveness of different Configurations
ηf,ad
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0 5 10 15 20 25 30
Fil
m C
oo
lin
g E
ffe
cti
ve
nes
s [
-]
x/D [-]
Shaped Hole
First Nekomimi
Manufac. Nekomimi
Variation 1
Variation 2
Variation 3
Variation 4
Variation 5
Variation 6
variation 4
+ 200 %
Laterally Averaged Film Cooling Effectiveness of different Configurations
first Nekomimishaped
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Jet In Cross Flow Structure Comparison with Shaped Holes
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Advanced NEKOMIMI Cooling: Manufacturing Examples
NEKOMIMI „real“ size manufacturing by EDM in flat plate metal sheet
view along cylinder axis (D=0.5 mm)onview (2 different hole types)
NEKOMIMI sketch for parameter description
Electrical Discharge Machining (EDM) sample
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 5 10 15 20 25 30
Fil
m C
oo
lin
g E
ffe
cti
ve
nes
s [
-]
x/D [-]
Experimental Validation of Film Cooling Effectiveness
shapedfirst Nekomimi
manuf. Nekomimi
variation 3
variation 4
+ 300 %
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Summary
Numerical analyses with STAR-CCM+ helped understand the interaction
between film cooling jet and hot gas stream along gas turbine blades.
This allowed:
development of new, high efficient film cooling technologies
systematic exploration of design potential and alternatives
Increase of Film cooling effectiveness (up to 2.5 times higher) compared
to conventional technologies