Engineering Success by Application of Star-CCM+ for Modern Gas Turbine Design

Transcription

1 March 18 th, 2014, Vienna, Austria STAR Global Conference Engineering Success by Application of Star-CCM+ for Modern Gas Turbine Design Karsten Kusterer B&B-AGEMA GmbH, Aachen, Germany Ryozo Tanaka Kawasaki Heavy Industries, LTD., Akashi, Japan

2 B&B-AGEMA Founded in 1995, located in Aachen, Germany Independent engineering service company Company Expertise 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) combustion technology optimization of pre-mixed combustion systems Low-NO x hydrogen combustion power plant CFD / CHT Analysis & Flow Optimization of power plant components (cooling tower, valve, condenser, moisture separator, etc.) Contact: Dr.-Ing. Karsten Kusterer B&B-AGEMA GmbH Juelicher Str Aachen Ph.: Fax: info@bub-agema.de STAR Global 2014, No. 2

3 Content CHT Technology and its Role in the Design Process for Cooled Gas Turbine Components Example 1: Successful Implementation of STAR-CCM+ in the Design Process for Kawasaki L30A Development and Validation Based on Engine Results Example 2: Upgrade of an E-Class Gas Turbine Example 3: Development of New Film Cooling Technologies Conclusion and Outlook STAR Global 2014, No. 3

4 Content CHT Technology and its Role in the Design Process for Cooled Gas Turbine Components Example 1: Successful Implementation of STAR-CCM+ in the Design Process for Kawasaki L30A Development and Validation Based on Engine Results Example 2: Upgrade of an E-Class Gas Turbine Example 3: Development of New Film Cooling Technologies Conclusion and Outlook STAR Global 2014, No. 4

5 Development of the Conjugate Technique in Aachen Conjugate Heat Transfer and Flow Simulation Code Development from 1990 Prof. Dieter Bohn Institute of Steam and Gas Turbines at RWTH Aachen University ( ) B&B-AGEMA Aachen Engineering Service Company (since 1995) Conventional Method: 1. Get heat transfer conditions from adiabatic flow simulations or from correlations (!uncertainties!) for external/internal surfaces 2. Prescribe heat transfer conditions on FEM- Modell 3. Get blade temperatures as result of heat conduction calculation (!interaction phenomena with flow are not taken into account!)??????????? Full Conjugate Method 1. Conjugate calculation for internal flows, external flows, and solid body without prescription of any heat transfer coefficients (!not necessary!) for direct result of the thermal load? Conjugate Calculation Measurements Conjugate Calculation Measurements & engine test experience Final Design 1st test configuration 2nd test configuration STAR Global 2014, No. 5

6 Development of the Conjugate Technique in Aachen (2) Prof. Dieter Bohn Institute of Steam and Gas Turbines at RWTH Aachen University ( ) B&B-AGEMA Aachen Engineering Service Company (since 1995) Year Development Papers (examples) 1990 Basic Code Development st publication of of numerical results VDI Convection-cooled turbine vane validation (MarkII) for the Aachen-code CHTflow 1995 First application of CHT flow for film cooling Impact of conjugate heat transfer on leading edge film cooling st industrial application (hot spot analysis for 1st blade of industrial gas turbine) IGTC ISABE GT-150, 97-GT-23 ISTP-10, 99-GT-199 Year Application & Improvement Papers (examples) Investigation of steam-cooled vane (full 3-D conjugate investigation) Design improvement for 1st blade cooling configuration Effusion cooling for multi-layered plates (SFB561) 2001-GT-166, GT IGTC2003-TS083, GT , GT GT-132, ISABE ,GT , ISROMAC Design support for cooling system of new developed L30A gas turbine of KHI IGTC2011-ABS-0086, GT STAR Global 2014, No. 6

7 STAR-CCM+: Validation of the Conjugate Heat Transfer Capability Geometry Overview: Mark II testcase Cooling air Midspan Mesh Pressure side Suction side Prism layers Braun, R.: Conjugate Heat Transfer Calculations of Cooled Turbine Vanes with STAR-CCM+, Dynamics issue 35, 2013 STAR Global 2014, No. 7

8 Example of Modern GT Development: Full CFD/CHT Approach World s best Industrial GT Kawasaki L30A Highest PG efficiency in 30 MW class GT s RESEARCH & DEVELOPMENT FIELD TEST OPERATION COMPONENT DESIGN COMPONENT TESTING CFD / CHT / COMBUSTION VALIDATION STAR Global 2014, No. 8

9 Kawasaki L30A Overview 30 MW el simple cycle efficiency: 40% Kawasaki GT line-up (GT ) 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. References: Tanaka, R., Koji, T., Ryu, M., Matsuoka, A., Okuto, A.: Development Of High Efficient 30MW Class Gas Turbine - The Kawasaki L30A, ASMEpaper GT , Copenhagen, Denmark, June 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 GT , Copenhagen, Denmark, June 2012 STAR Global 2014, No. 9

10 Content CHT Technology and its Role in the Design Process for Cooled Gas Turbine Components Example 1: Successful Implementation of STAR-CCM+ in the Design Process for Kawasaki L30A Development and Validation Based on Engine Results Example 2: Upgrade of an E-Class Gas Turbine Example 3: Development of New Film Cooling Technologies Conclusion and Outlook STAR Global 2014, No. 10

11 Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration) KHI L30 A: Engine Test Facility CHT calculation with STAR-CCM+ STAR Global 2014, No. 11

12 Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration) sealing inlet 1 pure air cooling inlet 1 pure air main flow inlet combustion gas Outlet air mixture sealing inlet 2 pure air cooling inlet 2 pure air STAR Global 2014, No. 12

13 Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration) metal sheet inserts for impingement cooling (considered as baffles) cutback slots pin fins ribs shower head STAR Global 2014, No. 13

14 Computational Mesh mesh specifications: polyhedral mesh (13.8 million cells) direct interfaces at fluid-solid contacts periodic boundary conditions for fluid domain and solid domain prism-layers at elected fluid domain surfaces no. of layers near wall cell height abs. height green 6 6E-3mm 0.100mm blue 15 8E-4mm 0.134mm red 20 3E-4mm 0.189mm STAR Global 2014, No. 14

15 CHT calculation results pressure side temperature distribution STAR-CCM+ CHT calculation* * circumferential averaged excellent prediction of internal cooling performance internally impingement & convective cooled TIP engine test data** ** fixed position TIP: Thermal Index Paint internally convective cooled very good agreement between CHT and test data film cooling high temperature low STAR Global 2014, No. 15

16 CHT calculation results suction side temperature distribution STAR-CCM+ CHT calculation* * circumferential averaged TIP engine test data** ** fixed position TIP: Thermal Index Paint very good agreement between CHT and test data high temperature low STAR Global 2014, No. 16

17 CHT calculation results shroud temperature distribution lower shroud STAR-CCM+ CHT calculation* * circumferential averaged upper shroud high temperature low TIP engine test data** ** fixed position TIP: Thermal Index Paint STAR Global 2014, No. 17

18 Content CHT Technology and its Role in the Design Process for Cooled Gas Turbine Components Example 1: Successful Implementation of STAR-CCM+ in the Design Process for Kawasaki L30A Development and Validation Based on Engine Results Example 2: Upgrade of an E-Class Gas Turbine Example 3: Development of New Film Cooling Technologies Conclusion and Outlook STAR Global 2014, No. 18

19 Upgrade E-class Gas Turbine : 1 st Stage Vane Analyses with STAR-CCM+ detailed CHT simulation model cooling air chamber cooling air inflow flow direction main flow path outlet main flow inlet CHT-calculation set up SST-GammaRe-theta Model Full conjugate calculation Combustion gas properties for main flow air properties for cooling air 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 STAR Global 2014, No. 19

20 Upgrade E-class Gas Turbine : 1 st Stage Vane Analyses with STAR-CCM+ 1 st vane upgrade analysis with STAR-CCM+ parametric study for: redistribution of the internal cooling air TBC s of different thickness peak temperature reduction by 160 C high temperature low homogenization of the temperature distribution Benefits by application of STAR-CCM+ in upgrade design process Upgrade Solution accurate determination of the thermal conditions of cooled turbine parts fast evaluation of improved internal cooling designs reduction of experimental validations reduction of development time, effort and costs STAR Global 2014, No. 20

21 Content CHT Technology and its Role in the Design Process for Cooled Gas Turbine Components Example 1: Successful Implementation of STAR-CCM+ in the Design Process for Kawasaki L30A Development and Validation Based on Engine Results Example 2: Upgrade of an E-Class Gas Turbine Example 3: Development of New Film Cooling Technologies Conclusion and Outlook STAR Global 2014, No. 21

22 (1) (2) (3) DJFC Technology & NEKOMIMI Film Cooling Numerical Results =29 x/d=2 NEKOMIMI effect: Japanese Patent JP ear angle Film Cooling effectiveness: Experimental results x/d=5 x/d=10 ACRV Kusterer, K., Elyas, A., Sugimoto, T., Tanaka, R., Kazari, M., and Bohn, D., 2011, "The NEKOMIMI Cooling Technology: Cooling Holes with Ears for High-efficient Film Cooling," ASME-paper GT , Vancouver, Canada. b) Shaped STAR Global 2014, No. 22

23 NEKOMIMI: Highest-efficient Film Cooling Advanced NEKOMIMI holes (examples) manufacturing by EDM is possible! Film cooling effectiveness parameter variation study Adiabatic film cooling effectiveness for Blowing ratio M=1.5 film cooling effectiveness f x/d Kusterer, K., Tekin, N., Kasiri, A., Sugimoto, T., Tanaka, R., Kazari, M., Bohn, D.: Highest-Efficient Film Cooling by Improved Nekomimi film Cooling Holes - Part 2: Hot Gas Flow Conditions, ASME-paper GT , Proc. of the ASME Turbo Expo 2013, San Antonio, Texas, USA., 2013 STAR Global 2014, No. 23

24 Content CHT Technology and its Role in the Design Process for Cooled Gas Turbine Components Example 1: Successful Implementation of STAR-CCM+ in the Design Process for Kawasaki L30A Development and Validation Based on Engine Results Example 2: Upgrade of an E-Class Gas Turbine Example 3: Development of New Film Cooling Technologies Conclusion and Outlook STAR Global 2014, No. 24

25 Outlook: Full Approach for Gas Turbine Combustor Design Comprehensive numerical modeling of a modern gas turbine combustor with STAR-CCM+: air supply combustor exit fuel supply main combustion supplemental combustion Worlds best Industrial Gas Turbine Kawasaki L30A Highest PG efficiency in 30 MW Class GT s. Courtesy of Kawasaki Heavy Industries STAR Global 2014, No. 25

26 STAR-CCM+ Engineering Success for Gas Turbine Design: Conclusion The application of the STAR-CCM+ CHT technology became an essential step in the design process of cooled components in a modern Gas Turbine. The CHT capability of STAR-CCM+ has been successfully validated by test cases and based on real engine operation application experiences. Development time, effort and cost can be reduced significantly by the application of the STAR-CCM+ advanced meshing and CHT technology within the design process. STAR-CCM+ helped to reach the advanced specification goals of highest cycle efficiency of the L30A GT in its class and as well as high reliability of the hot gas components under real engine conditions at the same time. Modern pre-mixed combustors for Dry-Low-NOx operation are improved by application of STAR-CCM+ in order to further decrease emissions and keeping high combustion stability. STAR Global 2014, No. 26

27 Acknowledgement B&B-AGEMA gratefully acknowledges the permission by Kawasaki Heavy Industries, LTD., for presentation of results of our collaborative work. Nekomimi technology is also used in air brakes of High Speed Train STAR Global 2014, No. 27