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
engineering your visions
STAR Global Conference 2013, Orlando, No. 3
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
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 4
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 5
Content
• Introduction
• Upgrade of E-class 160 MW 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
engineering your visions
STAR Global Conference 2013, Orlando, No. 6
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 7
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 8
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 9
Content
• Introduction
• Upgrade of E-class 160 MW 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
engineering your visions
STAR Global Conference 2013, Orlando, No. 10
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 11
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 12
Content
• Introduction
• Upgrade of E-class 160 MW 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
engineering your visions
STAR Global Conference 2013, Orlando, No. 13
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 14
• The predicted pressure distributions of different turbulence models agree
all very well with the test results.
Variation of turbulence model
engineering your visions
STAR Global Conference 2013, Orlando, No. 15
• 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
engineering your visions
STAR Global Conference 2013, Orlando, No. 16
Content
• Introduction
• Upgrade of E-class 160 MW 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
engineering your visions
STAR Global Conference 2013, Orlando, No. 17
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
engineering your visions
STAR Global Conference 2013, Orlando, No. 18
Content
• Introduction
• Upgrade of E-class 160 MW 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
engineering your visions
STAR Global Conference 2013, Orlando, No. 19
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