AdvancedInternalCooling

Geometries DoubleWallSchemes
Geometries
Double Wall Schemes
WithandWithoutEffectofRotation
SrinathV.Ekkad
Associate Professor
AssociateProfessor
MechanicalEngineering
g
VirginiaTech
sekkad@vt.edu
Collaborators:Dr.DigantaNarzary,JustinLamont,Preston
Stoakes,andDr.MaryAnneAlvin(NETL)

ProgrammaticRelevance
g
IGCCplantsplayakeyroleinthefutureofDOEsCleancoal
initiativebyfacilitatingprecombustionCO2 capturefrom
syngas
GasturbinesusedinIGCCaresubjectedtohighthermal
loadsandhightemperaturesalongwithresidualparticulate
andvaporcontaminantswhichcouldpotentiallyalterthe
lifeofprecisionengineeredvanesandbladesinthehotgas
path
Theproposedresearchaimstodevelopphysicsbased
modelingtoolstodevelopandpredictnewcooling
strategiesforhotcomponentsandprovideeffectivecooling
schemeswithlowcoolantusagewithdirectimpacton
h
ith l
l t
ith di t i
t
overallefficiency
Workshoulddirectlyimpactmaterialsdevelopmentand
coatingsalso
i
l

Why Double Wall Cooling?

WhyDoubleWallCooling?
Doublewallcoolingusesathingapbetweentwo
g
g p
wallstoenhanceheattransferfromthesurface
ofturbineblades
Doublewallcoolingincreasesareaforheat
transferbetweencoolingfluidandmetal
Impingementjetsandmodifiedsurfacescanbe
usedtoincreaseheattransferontheouterwall
Nothingnewaboutthisconcept hasbeen
aroundforseveraldecades

Patents on Double Wall cooling

PatentsonDoubleWallcooling

PatentsbyBunkeretal.,Ishburg andLee,Jacksonetal.,Liang,Melvinetal.

Othercoolingoptionsincludingdoublewall
g p
g
Networkoforificesconnected
bysmallpassagestocreate
impingementareasand
outward film cooling
outwardfilm
Coolairisforceintodouble
wallareathroughsmall
passagesandimpingesonthe
d
h
outerwall
Lamilloy is a standard
Lamilloyisastandard
practiceusedByRRinNorth
America(maturetechnology)

Another Existing Design

AnotherExistingDesign
System
Systemofpedestalsand
of pedestals and
ribsusedtoincrease
turbulenceandheat
transfer
Coolinggasexhausted
throughtrailingedgeof
blade
Designdoesnotuse
d
impingementcooling

LiangG,inventor;2004Oct.26.Cooling
systemforaturbinebladehavinga
doubleouterwall.UnitedStatesPatent
US 6,808,367.
US6,808,367.

Motivation&Objectives

Gasturbinebladesneedtobeeffectivelycooledtoincrease
componentlifeandreducemaintenancecosts.Thelevelof
coolingisalwaysoffsetbytheamountofcoolantused.
Increasedamountofcoolantusagedirectlyimpactstheoverall
efficiencyoftheengine.
ffi i
f th
i
Usageofdoublewallcoolingschemescanreduceoverall
coolantusagebypushingcoolantclosertotheinsideofthewall
exposedtohotgaspath.
Th
Theenhancedheattransfertothecoolantthroughthethinwall
h
dh tt
f t th
l t th
h th thi
ll
andalsoduetohighperformanceschemessuchas
impingementwillgreatlybenefitoverallandthermalefficiency
ofthesystem.
The focus is:
Thefocusis:
todevelopanoptimizationmethodologytodeterminethe
mosteffectivedoublewall/nearwallschemeforturbine
airfoilcooling.Thesecoolinggeometrieswillbeoptimized
for the highest heat transfer enhancement with low
forthehighestheattransferenhancementwithlow
pressuredropwithoptimizationsoftwareandCFD.
tostudytheeffectofrotationondoublewallcooling
Typicalturbinebladeinternal
geometriestoensureapplicabilitytorotatingblades
convectioncoolingconfiguration(Han
et.al.(1986).
tostudytheperformanceoftheoptimizedgeometry
to study the performance of the optimized geometry
workingwithOEMstocomparecoolingeffectivenessof
doublewallgeometriescomparedtocurrentcooling
schemes

Project Summary
ProjectSummary
Objective:
Exploretheuseofdoublewallcoolinginturbineblades,using
p
g
g
impingementcoolingandcombiningwithotherstandardheat
transferenhancementtechniques
Developdesignmethodologiesforoptimizeddoublewall
cooling designs for industry usage
coolingdesignsforindustryusage

Procedure:
UseCFDtoexploretheeffectivenessofimpingementcoolingin
channel flow
channelflow
UseCFDtooptimizedesignpatternofimpingementholesin
channelflow
Experimentallydetermineperformanceofoptimized
Experimentally determine performance of optimized
configurationincomparisontocurrentstandarddesigns
Alsoexperimentallystudyeffectofrotationondoublewall
coolingdesignswithintentiontooptimizewithrotationaleffects
g
g
p

StationaryOptimizationStudy

St t ith Si lifi d G
StartwithaSimplifiedGeometry
t
The
Thesimplifiedgeometryconsistsofmain
simplified geometry consists of main
channelwithanimpingementchannel
connected by an array of impingement jets
connectedbyanarrayofimpingementjets
Mainchannelmeasures1x1foralltest
sections
Impingementchanneldimensionsandlength
oftestsectionvariesbetweenthecases
f
i
i b
h

Geometry
Impingement
Impingementjetarrayis
jet array is
2xN,Nvariesinthe
optimizationstudy
Impingementchannel
confinesthespent
coolanttoexitopening
oppositeinlet

Procedure
Optimize
OptimizegeometryusingComputationalFluid
geometry using Computational Fluid
Dynamics(CFD)
Independentparameterschosenbasedonstudies
Independent parameters chosen based on studies
foundinliterature

Top
TopdesignsfromCFDoptimizationwillbe
designs from CFD optimization will be
builtforexperiments
Testsectionsconstructedfromaluminumto
Test sections constructed from aluminum to
includeconductioneffects

Optimization
Four
Fourparametersvariedtodetermineeffectof
parameters varied to determine effect of
eachonheattransferandpumpingpower
HoleDiameter(D)
Hole Diameter (D)
JettoJetSpacingRatio(L/D)
JettoWallSpacingRatio(H/D)
Jet to Wall Spacing Ratio (H/D)
Numberofrowsofholes(N)

Ai
AirflowratevariedwithNandDtomaintaina
fl
i d i hN dD
i i
jetReynoldsNumberof10,000

Optimization
A
Atotalof256test
total of 256 test
sectiondesignswere
consideredbychoosing
fourdesignpointsfor
eachparameter
Totallength,LT, held
constantwhenNis
varied

LT 11 D L / D 1 in

Range
Parameter

Min

Max

1/32

1/4

(0.794mm)

(6.35 mm)

L/D

H/D

0.5

11

Optimization
Test
Testsectiondesignsrankedbasedonheat
section designs ranked based on heat
transfercoefficientalongtheimpingement
surface h and pumping power for fluid PP
surface,h,andpumpingpowerforfluid,P
Thetwoparametersarecombinedtoforma
performance Per parameter to easily
performance,Per,parametertoeasily
comparethetestsectiondesigns
h h0
Per
PP PP , 0

Alltestsectionscomparedtobaselinedesign

Results
Number
Numberofrowsofholes,N,andJet
of rows of holes N and JettoWall
to Wall
spacingratio,H/D,appeartohavethelargest
affect on the performance parameter
affectontheperformanceparameter
JettoJetspacingratio,L/D,appearstohave
very little affect on the performance
verylittleaffectontheperformance
parameter
Thetop10performingdesignswerebuiltto
Th
10
f
i d i
b il
validateCFDstudy

Results
Rank

D (in)

L/D

H/D

Per

0.125

51.7

0.125

51.6

0 125
0.125

51 4
51.4

0.0625

50.2

0.25

50.2

0.125

49.9

0.25

49.3

0.125

48.9

0.0625

48.9

10

0.0625

48.8

Results for best design

Resultsforbestdesign
Velocity
Velocitycontoursshow
contours show
highervelocitythrough
lastrowofholes
Finaljetisdeflectedby
crossflowofexhaustgas

HighestNusselt
h
l number
b
valuesoccurunder
impingement jets
impingementjets
Exhaustgasappearsto
exitintwostreamsinline
withimpingementjets

Contoursofvelocityatplaneintersecting
impingementjets

ContoursofNusselt Numberon
impingementsurface

Future Work
FutureWork
Experimentsarebeingconductedtovalidate
CFDsimulationsoninitialtestsection
Turbulators canbeaddedtotheimpingement
p g
channeltodisruptflowofexhaustgases
Theflowdisruptionshouldallowforamoreeven
p
heattransferdistribution,aswellasreducejet
deflectionduetocrossflow
Pinfinturbulators willincreaseamountof
conductionintothemainchannelandfurther
i
increaseareaforconvectiveheattransfer
f
i h
f

MultipleArrayImpingementforLowH/ddoublewall
Multiple
Array Impingement for Low H/d double wall
cases
Study
Studyeffectofexhaust
effect of exhaust
gascrossflowwhenjet
towallspacingratiois
below1
InitialCFDstudybase
onjettojetspacing
ratio
Comparedinlineand
d l
d
staggeredarrangement
of jets
ofjets

MultipleArrayImpingementforLowH/ddoublewall
p
y p g
/
cases
Heattransferappearsto
transfer appears to
Heat
beincreasedbythewall
jetdownstreamofthe
impingementjetand
notbytheimpingement
j t
jet
Undevelopedcorejet
does not appear to
doesnotappearto
increaseheattransfer

MultipleArrayImpingementforLowH/ddoublewall
cases
2
1.8
PerformaanceParam
meter

Staggered
Staggeredarrangement
arrangement
ofjetsperformedbetter
atalljettojetspacing
ratios
Higherjettojetspacing
ratioappearsto
increaseperformance
of design
ofdesign
Futurestudywill
explore larger jet to jet
explorelargerjettojet
spacingratios

1.6
1.4
1.2
1
08
0.8
Staggered

Inline

0.6
1.5

2.5

L/D

3.5

4.5

Rotational Effects
RotationalEffects

Asimplifiedgeometrywastestedtodeterminetheeffectsof
rotationonbladeinternalcoolantchannelflow

LeadingSide(Suction)

Atypicalcoolantpassagefrom
turbinebladeismodeledinthis
experiment with simple square
experimentwithsimplesquare
geometry.

TrailingSide(Pressure)

Typicalturbinebladeinternalconvectioncooling
configuration(Hanet.al.(1986).

Therotatingrigspinsinterchangeabletestsectionsatdesired
speedswhilelowtemperatureairisinjected

NitrogenGasisventedintotheairpathbeforetestingto
chillcomponents.Thisdropsthetemperatureoftheair
beforereachingthetestsectionduringatest.
Acameraismountedtothetestsectiontoviewthecolor
change of the liquid crystals. One side is filmed at a time,
changeoftheliquidcrystals.Onesideisfilmedatatime,
sothemotorrotationdirectionisreversedwhenfilming
eithertheleadingortrailingside.

Theeffectofribtypeinrotationaltwopasschannelswas
exploredusingatransientliquidcrystaltechnique
Smooth Wall

90 Ribs

W-shape Ribs

45

Smoothwall,90 Ribbed,andW
shaperibbedwallswereexplored
inthestudy.
Eachcasewasheldata
Re=16,000andarotationalspeed
Re = 16 000 and a rotational speed
of250rpm
(Rotationnumber=0.08).
Inletdensityratio=0.10
Resultsarereportedforthe
trailingside,leadingSide,and
stationary The sides are
stationary.Thesidesare
comparedtothestationarycase.
Pitch-to-rib height ratio (P/e)=8
Blockage ratio (H/e) = 8

Thehuefromtheliquidcrystaliscalibratedwithtemperatureto
calculatetheheattransferonthesurfaces
Video

Calibration Curve

Typical Temperature response

Acurvefitgeneratesan
algebraicexpressionfor
temperaturewithrespectto
H
Huewhichisappliedtothe
hi h i
li d t th
restofthesurface

Asemiinfinitemodelisusedtodeterminethelocal
convectiveheattransferonthechannelwalls
Atransientliquidcrystaltechniqueisusedtodeterminetheheattransfer.
Forthegiventestsection,thesemiinfinitesolidmodelisvalidiftheexperimenttimesdoesnotexceed
g
p
25minutes.
Averagetesttimeislessthanaminute.
Aftercalibratingtheliquidcrystalhuewithtemperature,walltemperaturesforeachpixelateachframe
inthevideoiscalculated.
Temperatureiscalculatedatthesurface(x=0)sothemathematicalmodelusedreducesto:

h 2t
h t
T (0, t ) Ti

1 exp 2 erfc

T Ti
k
k
T :istheaveragedbulktemperaturefromtheinletandoutlet
: is the averaged bulk temperature from the inlet and outlet
Ti :istheinitialwalltemperature
T(0,t):isthewalltemperature
:isthethermaldiffusivityoftheacrylic
t:
t:isthetime
is the time

Weknowallparameters,soweareabletosolveforhnumerically

Theliquidcrystalcreatesacontinuousplotofheattransferon
q
y
p
thesurfaceofthecoolantchannel
Smooth Wall
SmoothWall

Nu / Nu
Leading

Stationary

Wshape
W
shaperibbedWall
ribbed Wall

90 ribbedWall
90
ribbed Wall

Nu / Nu
Trailing

Leading

Stationary

Nu / Nu
Trailing

Leading

Stationary

TheWribscreatethehighestheattransferinthechannel.The
smoothwallchannelhasthelowestheattransfer.

Trailing

Areaaveragesinheattransferalongthelengthofthechannel
giveestimatestothepercentdifferences
Smooth Wall

90 Ribs

W-Shaped Ribs
% Increases
Trailing Side 1st Pass
2nd Pass
Leading Side 1st Pass
2nd Pass

Smooth Wall
32
-21
-19
3

90 Ribs
13
-7
-13
24

W Ribs
0.1
-9.3
-3.3
17.2

Theribtypesaredirectlycomparedforthestationary,trailingside,andleadingside
yp
y
p
y
g
g

Stationary

Leading Side

Trailing Side

% Increases
Stationary Trailing Side Leading Side
1st Pass 90 Ribs

104

71

116

W-Ribs

260

190

325

2nd Pass 90 Ribs

35

55

76

W-Ribs

138

164

197

JetImpingementcoolingisanalternativetoribroughenedwalls
tocreatehighheattransfer
Insteadofatwopasschannel,a
radiallyy outwardchannelwith
impingementisstudiedunder
rotation

LeadingSide(Suction)

Currentresultsshowimpingement
p g
channelheighttojetdiameter
ratio(H/d)=2

TrailingSide(Pressure)

Pitchtojetdiameterratio
(P/d)=8
Typicalturbinebladeinternalconvectioncooling
configuration(Hanet.al.(1986).

Jetlengthtojetdiameterratio
(b/d)=1
Rotationalspeed=250rpm

Preliminarystationaryresultsforjetimpingementcoolingwith
crossflow effect
Flowmovesfromrightto
left.Thereisoneoutlet
fortheair,sothelaterjets
f l h ff
feeltheeffectsof
f
crossflow.
Crossflow bendsthejets
away from the wall
awayfromthewall,
reducingtheeffectiveness.
Theeffectsofcrossflow
are present in the results
arepresentintheresults,
astheaverageheat
transferreducesandthe
maximumheattransferfor
eachjetreducesasweget
closertotheexit.

Preliminaryrotationalresultsfortrailingandleadingsideswith
crossflow effect

Inrotation,boththeleadingandtrailingsideresultsarelessthanthestationaryresults
(this is expected due to previous studies by Parsons and Han (1998)
(thisisexpectedduetopreviousstudiesbyParsonsandHan(1998).
Also,thetrailingsidereducedmorethantheleadingside.Thisiscounterintuitive
becauseradially outwardflowfortwopasschannelsshowanincreaseinheattransferfor
thetrailingsideduetothefavorableeffectsoftheCoriolis force.

Futurestudiesonribroughenedandjetimpingementcooling
schemesunderrotation
Rib Roughened Walls
Further explore the W-shaped Ribs
with variations on flow orientation
of ribs and angle of ribs

Vs.

Jet Impingement
Explore rotational effects when the
impingement height is varied (H/d),
when pitch is varied (P/d), effect of
film coolant extraction vs. crossflow
exit conditions, and Jet angle with
respect to the impingement plate is
varied.

Capabilities of the Rotating Rig are

in the process of being increased.
Higher flow rates, lower
temperatures and higher rotational
speeds will be achievable.

Conclusions
Firstyearofproject
Understandingvariousparametriceffectsondouble
wallcoolingschemes
Developedanewtestrigfordetailedmeasurementsin
Developed a new test rig for detailed measurements in
rotatingframeforinternalheattransfer
Fundamentalmethodologyofoptimizationachieved
gy
p
Focusingonmorerealisticgeometriesfromhereon
Workingwithindustrytodeterminefactorsof
evaluationanddesignmethodologyfornewcooling
geometries