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Rob Murphy Academic Advisor: Dr. Andrew C. Nix
Heat Transfer Group
Supervisor: John Mason Group Manager: Hee-Koo Moon
Mentor: Yong Kim
University Turbine Systems Research
Fellowship 2011
Coriolis Rig Heat Loss Validation and New Test Section Design
Caterpillar Confidential: Green
Learning Experience Acknowledgements
About Me Projects
Agenda
- Coriolis Rig Heat Loss Validation - Coriolis Rig Endwall Investigation - New Test Section Design
Caterpillar Confidential: Green
About Me
Education: • West Virginia University – Morgantown, WV
• Bachelor of Aerospace Engineering • Bachelor of Mechanical Engineering
• Master of Mechanical Engineering (May 2012) • Advisor: Dr. Andrew C. Nix
• Focus: Gas Turbine Heat Transfer • Thesis Topic: Study of the Effects of Particulate Deposition on Heat Transfer
• National Energy Technology Laboratory (NETL) – Morgantown, WV • Oak Ridge Institute of Science and Education (ORISE) Fellow 2011
• Mentor: Doug Straub • Duties: Assist in setup of LDV system, particle seeder installation, assist in other Turbine Project areas
Activities: • Engineers Without Borders
• Nicaragua Water Filtration Project Lead • President
• College Recruiter
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Coriolis Rig Background
• Background - Coriolis Rig examines the effects of rotation on
internal cooling schemes
- Two wing-shaped arms
• Up to 750RPM • Temperatures at 120F, 140F and 180F
- 3-Pass Serpentine Channel • Heaters on Pressure Side, Suction Side
and endwall region of test section
• Two cases: Smooth Channel and Trip Strip
• Objectives - Validate Current Heat Loss Model in ANSYS
Thermal Workbench
- Examine Endwall Region in ANSYS to examine low heater outputs during trip strip runs
- Design new test section for future cooling schemes
Caterpillar Confidential: Green
Corilois Rig Model Setup
• Step 1: Start with current model provided by Solar
• Step 2: Cut away sections to get the area that will be analyzed
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Coriolis Rig Model Setup
• Step 3: Insert Required Components such as: copper plates, silicon inserts, insulation and aluminum wing
Aluminum Shell
Silicon Spacer
Polystyrene Insulation
Copper Plates
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Corilois Rig ANSYS Thermal Analysis
• Imported model into ANSYS
• Applied Thermal Properties to Components
• Meshed Model
• Begin Applying Boundary Conditions
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Coriolis Rig ANSYS Boundary Conditions
• Law of Symmetry - Highlighted in Blue
- Modeled by applying perfect insulation to the front, top and right side of the model
• Natural Convection
- Highlighted in Yellow
- Simulating the low heat transfer occurring in the channels that house the wires
• Perfectly Insulated channel to simulate the insulation present in the actual heat loss test
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Coriolis Rig Outer Heat Loss Boundary Condition
• Outer Convective Heat Transfer Coefficients were calculated using Newton’s law of cooling
• h values were calculated for each rotational case
( )avgcageavgwingsurface TTAQh
,, −=
RPM h (BTU/hr-ft^2-F)
0 6.78350 7.64600 9.29750 10.27
Table 1: h Values at Four RPM Cases
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Coriolis Rig Heat Loss BC Application
• For 0 RPM Case the h value was applied to the entire outer surface
• For the rotating cases the h value was applied on the two faces highlighted to the right. The other part of the face was given a low h value to simulate its attachment to the wing
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Coriolis Rig Heat Loss Results
• 0 RPM Heat Loss Case ANSYS vs. Experimental
• 350 RPM Heat Loss Case ANSYS vs. Experimental
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Coriolis Rig Heat Loss Results
• 600 RPM Heat Loss Case ANSYS vs. Experimental
• 750 RPM Heat Loss Case ANSYS vs. Experimental
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Coriolis Rig Heat Loss Validation Conclusions
• Most Plate Temperatures were within 5% of experimental data
• Plate 15 was off my more than 10% in most cases due to an instrumentation error
• These results prove that the heat loss assumption is valid.
- The heat can only escape out of the outer faces with the current setup so the correlation between the ANSYS and Experimental plate temperatures validate the assumption
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Coriolis Rig Endwall Analysis
• Ran Model with Flow Cases
• Model Setup the same except in the channel
• Convective Heat Transfer Coefficients that were calculated by Solar engineers in a previous data reduction project were applied to the plates, spacers and walls of the channel
• With the heat loss validated results should be accurate within the margin of error if the heat transfer coefficients were calculated correctly
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Coriolis Rig Endwall Results
• Low Flow 0 RPM Smooth Channel Case ANSYS vs. Experimental
• Low Flow 0 RPM Trip Strip Case ANSYS vs. Experimental
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Coriolis Rig Endwall Conclusions
• Good Correlation (<10%) for most of the first pass plates
• The second pass plates had a discrepency that increased along the flow path. This was believed to be caused by a heat flux that would be coming through the wall separating the 2nd and 3rd pass. This heat flux was not modeled in the current setup.
• There is a distinct difference at the endwall regions. The smooth case has a similar trend to the experimental data and matches up well. The trip strip data does not match up well and has the opposite trend of the experimental data.
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Coriolis Rig Endwall Conclusions
• The endwall was examined to look for instrumentation or thermocouple errors but none were found.
• Since the heat loss scheme was validated and there were no instrumentation errors found, the author believes that there must be some unknown flow patterns not being considered in the current data reduction scheme. With the HTC values calculated in the data reduction the plate temperatures should be lower than what was recorded in the experimental data.
• Future tests are being planned to examine what effects changing the flow pattern will have on the endwall region.
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Coriolis Rig New Test Section Design
• New test section design will have two channels
- One channel will have pin-fins and the other will have trip strips
• Two channels are part of new cooling scheme for turbine blades
• Analytical studies showed a heat transfer degradation on the suction side so a new test section will examine that
• No geometric values will be provided for the model because they are proprietary property of Solar Turbines, Inc.
Caterpillar Confidential: Green
Coriolis Rig New Test Section Core
• Constructed core from geometry taken at a cross section of the actual design
• Formed two straight channels that are 5X scale of actual blade
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Coriolis Rig Copper Plate Design
• The core was used to create the negative space in the channels
• Once the channels were created copper plates of both channels were made
Caterpillar Confidential: Green
Coriolis Rig New Test Section Sides
• Once the plates were completed they were assembled together to form the pressure (top) and suction (bottom) side of the new test section.
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Coriolis Rig Future Work
• These items were not completed at the time this presentation was due
• Create entrance length for test section to mimic entrance length of actual cooling passage
• Size heaters based on ratios using actual engine conditions
• Place channels for thermocouple wiring on model
• Contact vendors to order new material for test section and heater manufacturing
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Learning Experiences
• Programs
- ProE
- ANSYS Workbench
• Skills
• Modeling 3D Heat Transfer Problems
• Performing Diagnostics on Model
• Test Section Design
• Coriolis Effects on Heat Transfer
• Troubleshooting Experimental Data Reduction
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Acknowledgements
• WVU - Dr. Andrew C. Nix
- CAFEE
• SwRI
- Dr. Klaus Brun
- Andrea Barnett
• NETL
- Doug Straub
Yong Kim
Ross Myers
Gail Doore
Archie French
Steve Pointon
Charmaine Gary
Matt Mayer
Hee-Koo Moon
John Mason
Tim Bridgman
Heat Transfer Group
The Rotations
The Interns
Everyone else who helped…