Investigation of converging slot-hole geometry for film cooling of gas turbine blades

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1 Project Report 2010 MVK160 Heat and Mass Transport May 12, 2010, Lund, Sweden Investigation of converging slot-hole geometry for film cooling of gas turbine blades Tobias Pihlstrand Dept. of Energy Sciences, Faculty of Engineering, Lund University, Box 118, Lund, Sweden ABSTRACT 1 This report evaluates the thermal performance of a new film cooling scheme for turbine blades. The geometry of the cooling holes is the converging slot hole, or console, which is compared to conventional geometries such as cylindrical and fan-shaped holes. The performance of the console geometry is calculated using CFD with a two-layer turbulence model and the results are compared with experimental data. The results show that the console geometry has very good thermal performance with enhanced and more uniform lateral spreading compared to the conventional geometries such as the cylindrical hole and the shaped hole. NOMENCLATURE T temperature U velocity M blowing ratio D hole diameter x downstream coordinate z spanwise coordinate Greek Symbols η adiabatic film cooling effectiveness ρ density Subscripts aw adiabatic wall c coolant free stream the blade-material. A modern gas turbine can have a turbine inlet temperature as high 2000 K which requires very sophisticated cooling techniques, especially for the first stage. Since the cooling air is extracted from the compressor, extensive cooling results in a penalty on the thermal efficiency. Minimizing coolant flow and increasing the efficiency of the cooling schemes is critical. Over the years the cooling techniques and bladematerials have evolved significantly to withstand the increasing firing temperature, the development of different cooling schemes can be seen in figure 1. Film cooling with internal convection and impingement is extensively used today. Future cooling techniques include transpiration cooling through a porous blade wall. Transpiration cooling is superior to conventional cooling schemes, however structural issues and clogging of the pores have limited the success of transpiration cooling and as of today no gas turbine manufacturer have successfully implemented this cooling scheme. The blade-materials and manufacturing skills have also evolved significantly. High temperature super alloys are in wide spread use today. Ceramic coatings are also incorporated to some extent due to its capability to withstand extreme temperatures. However the ceramic coating is very fragile and gas turbine manufacturers must still rely on modern internal and external cooling methods as will be described later on. Abbreviations console converging slot-hole NGV nozzle guide vane TIT turbine inlet temperature INTRODUCTION 2 The thermal efficiency and the specific work output of the gas turbine are dependent on the pressure ratio and turbine inlet temperature (TIT). This has resulted in an increase in turbine inlet temperature ever since the introduction of the gas turbine and a gas temperature well above the melting point of 1 All CFD calculations by [3] 2 Fundamental understanding of blade cooling from [1],[2] Figure 1: Effectiveness of different cooling schemes [2] 1

2 Blade cooling A typical modern turbine blade relies on both internal and external cooling which can be seen in figure 2. The cooling air is extracted from the compressor and transported through ducts to the vane, rotor, hub, endwall and the rotor discs. Figure 2: Schematic picture of a cooled turbine blade [1] The blade can be divided into three zones, namely the leading edge, midzone (pressure and suction side) and the trailing edge. The leading edge is cooled internally by jet impingement where the coolant is then discharged through small holes in the blade wall to form a protective film. The pressure and suction side is cooled internally by multi-pass ducts with forced convection and some discharge through the wall to provide external film cooling. The internal cooling can be enhanced with rib turbulators as can be seen in figure 2. The ribs trip the boundary layer causing it to separate, form a recirculation zone and later reattach. A variety of geometrical configurations is available for rib turbulators. The trailing edge is very thin and incorporates pin-fins and sometimes dimples to increase the heat transfer area and promote turbulence. As mentioned before film cooling is in extensive use today and major research has been put into this area. The film cooling effectiveness is dependent on a large number of parameters such as blowing ratio, hole shaping, hole spacing, momentum flux ratio and external surface curvature to name a few. This report will focus on the converging slot-hole film cooling of gas turbine blades. Film cooling Film cooling incorporates the discharge of cooling air through holes in the blade wall into the boundary layer of the airfoil. The ejected coolant forms a protective film that insulates the blade surface from the hot gases. As mentioned before the cooling effectiveness of film cooling is dependent on a large number of different parameters, among them shaping of the film holes plays an important role. As the distance from the ejection hole increases the cooling effectiveness decreases as a result of mixing between hot gases and coolant. Designing the shape of the hole so that the film is broadened can decrease the loss of cooling effectiveness. The blowing ratio, M, also plays an important role in the effectiveness of film cooling. A too high blowing ratio can result in poor cooling performance due to too high coolant ejection velocity causing lift-off. Film cooling also introduces aerodynamic losses which should be minimized. Film cooling with ejection through slots provides a uniform film but introduces structural difficulties. As a result research has been focused on arrays of discrete holes providing the most uniform film possible. Converging slot-hole (console) is a new hole geometry that tries to offer the advantages of slots while keeping the structural benefits of discrete holes. The hole geometry can be seen in figure 4. PROBLEM STATEMENT 3 The new hole geometry is compared to cylindrical holes and shaped holes by a numerical simulation. The numerical results of the cylindrical holes are compared to the experimental results by Sinha et al. [6]. The shaped holes and converging slot-holes are then compared to the cylindrical holes. The flow is treated as incompressible and the pressure velocity-coupling is by SIMPLEC. The turbulence model for this flow case is a two-layer approach, where the viscous regions near the wall are modeled with a one-equation model and the outer core flow is modeled with the standard k-ε model, for more details see [3]. The blade wall is approximated as a flat plate, for which there is a vast amount of experimental data for different types of cooling hole geometries. The computational domain and the geometry for the converging slot-hole, the cylindrical hole and the shaped hole can be seen in figure 3 and 4. D is diameter and is set to 12.7 mm in this case, x is the downstream coordinate and z is spanwise coordinate, where z = 0 corresponds to the symmetry plane at the centerline of the hole. Figure 3: Computational domain and hole geometries [3] 3 Geometry and grid by [3] 2

3 Figure 4: Geometry for the converging slot-hole [3] Figure 5: Laterally averaged adiabatic film cooling effectiveness at M=0.5 [3] The grid is a multi-block grid consisting of three blocks; one for the external flow, one for the injection channel with hole and a third one for the plenum. The plenum is included in the computational domain for a better prediction of the velocity profile at the coolant ejection hole. The main stream flow velocity was set to U = 20 m/s, to conform to experiments. The density ratio of the injected coolant and free stream is kept at ρ c /ρ = 2 as in experimental setups. For a more detailed description of the grid and all the boundary conditions see [3]. RESULTS 4 All the different hole geometries are evaluated at a blowing ratio of M=0.5 and M=1.0, where the blowing ratio is defined as M = ρ cu c. To be able to compare the effectiveness of the ρ U different holes, the adiabatic film cooling effectiveness is introduced as η = T T aw, where T aw is the adiabatic wall T T c temperature, T c is the coolant temperature and T is the free stream temperature. The laterally averaged adiabatic film cooling effectiveness can be seen in figure 5 and 6, where the results are also compared to results by Sinha et al. [6]. As can be seen from the figures the console geometry performance is superior to the shaped hole and the cylindrical hole. This is even more pronounced for the higher blowing ratio. The shaped hole performs better than the cylindrical hole, especially for the high blowing ratio case. The low laterally averaged adiabatic film cooling effectiveness of the cylindrical holes near the hole at high blowing ratio is due to liftoff. Figure 6: Laterally averaged adiabatic film cooling effectiveness at M=1.0 [3]. The spanwise local adiabatic film cooling effectiveness downstream of the cooling holes at x/d=1, 3, 15 measured from the downstream edge of the hole can be seen in figure 7,8 and 9. As can be seen the spanwise adiabatic cooling effectiveness is much better for the console than for the conventional hole geometries which is due to enhanced spreading. The increase of cooling effectiveness for the console at large z/d is due to the interaction with vortices from other converging slot holes. 4 All calculations and results by [3] 3

4 Figure 7: Local adiabatic film cooling effectiveness at x/d=1 [2] Figure 8: Local adiabatic film cooling effectiveness at x/d=3 [3] Figure 9: Local adiabatic film cooling effectiveness at x/d=15 [3] LITERATURE SURVEY Sargison et al. [4,5] presented a two-part paper where converging slot-hole film cooling was compared to a fanshaped hole geometry and cylindrical holes for both a flat plate and on a model of an NGV at engine representative conditions. The flat plate experiments indicated that the console and fanshaped holes had similar thermal performance but a significant advantage for the console in terms of aerodynamic losses. The conclusion from the NGV model was that the heat flux at the suction side was reduced significantly with the console compared to fan-shaped holes, despite using less coolant. The heat flux at the pressure side was similar for the console and the fan-shaped holes near the first row of cooling holes. Further downstream the heat flux for the console was higher than for the fan-shaped holes, but this was obtained with a mass flow of coolant for the console of 60 % and 70 % of the amount for the fan-shaped geometry. The console geometry also showed significantly less aerodynamic losses compared to the fanshaped geometry even though the thermal performance of the console was similar or higher than for fan-shaped geometry. CONCLUSIONS The new film cooling technique with converging slot-holes shows similar performance in terms of cooling as fan-shaped holes which is in use today. The console can accomplish this with less coolant and significantly reduced aerodynamic losses. The performance for both the fan-shaped holes and converging slot-holes is superior to that of conventional cylindrical holes. However more research must be put in to be able to evaluate the structural characteristics for blades with converging slot-hole film cooling. REFERENCES [1] Han, J, 2004, Recent Studies in Turbine Blade Cooling, International Journal of Rotating Machinery, 10(6) 2004, pp

5 [2] Moustapha, H., Zelesky, M.F., Baines, N.C., and Japikse, D., 2003, Axial and Radial Turbines, Concepts ETI, Inc., Book chapter: Turbine Durability And Cooling [3] Azzi, A., Jubran, B.A., 2007, Numerical modeling of film cooling from converging slot-hole, Heat and Mass Transfer, 2007, Vol. 43, pp [4] Sargison, J.E., Guo, S.M., Oldsfield, M.L.G., Lock, G.D., and Rawlinson, A.J., 2002, A Converging Slot- Hole Film-Cooling Geometry Part 1: Low-Speed Flat-Plate Heat Transfer and Loss, Journal of Turbomachinery, 2002, Vol. 124, pp [5] Sargison, J.E., Guo, S.M., Oldsfield, M.L.G., Lock, G.D., and Rawlinson, A.J., 2002, A Converging Slot- Hole Film-Cooling Geometry Part 2: Transonic Guide Vane Heat Transfer and Loss, Journal of Turbomachinery, 2002, Vol.124, pp [6] Sinha, A.K., Bogard, D.G., and Crawford, M.E., 1991, Film-cooling effectiveness downstream of a single row of holes with variable density ratio, Journal of Turbomachinery, 1991, Vol.113, pp

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