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HEAT TRANSFER IN VANES AND BLADES

(MENTOR GRAPHICS CORP., RUSSIA);

K.V. OTRYAHINA

(PAO NPO SATURN, RUSSIA).

W H I T E P A P E R

M E C H A N I C A L A N A L Y S I S

w w w . m e n t o r . c o m

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

ABSTRACT

The heat transfer performance of internal cooling passages inside gas turbine vanes and blades is one of

importance to the design engineers because higher cooling effectiveness generally allows increased turbine

temperatures, which increases its efficiency.

For design optimization of high temperature turbines, CFD tools are widely used. But it should be noted that each

calculation is connected with huge computational problems. And in order to overcome them, experts with high

qualifications are required. In the meantime design of the construction is the responsibility of design engineers

who do not generally have the expertize in computational fluid dynamics. So, there is a growing need for design

engineers to have a CFD tool. This CFD tool should work together with the CAD system, be reliable, robust, give the

same quality of the results as other CFD tools and not require a high qualification in CFD.

This paper presents the results of CAD-Embedded, CFD software FloEFD for evaluation of thermal and temperature

conditions of vanes and blades. The FloEFD approach is based on two main principles: direct use of native CAD as

the source of geometry information; and synergy of full 3D CFD modeling, combined with simpler engineering

methods in cases where the mesh resolution is insufficient for a full 3D simulation.

To validate the CFD code in the field of heat transfer in gas turbine vanes and blades three independent

experiments are selected. For each case consideration is given to particular parameters of conjugate heat transfer

which is computed and compared with published tests.

Firstly, temperature and heat transfer coefficient in the real test conditions for a vane with profile C3X are

calculated. In the second case, convective heat transfer on the steam turbine vane is considered. The temperature

distribution in the vane is evaluated. The specificity of the case, is that the experimental test rig represents a

rectangular duct containing a three-vane cascade. In the third-, FloEFD simulation, film-cooled first-stage turbine

vanes are presented. Relatively simple geometry of the model allows the user to demonstrate the contribution of

the film effect to the cooling process.

Finally, a numerical calculation for real industrial high-pressure turbine blades is performed. Complicated internal

cooling systems, includes channels filled with intensifiers. By taking the inlet gas parameters setting, circumferential

distortion is taken into account. The cooling air flowing out of the axial clearance is also considered in the

calculation.

1. INTRODUCTION

One of the real problems of the design of advanced gas turbine engines is the development of effective cooling

methods for the turbine vanes and blades. Due to competition, continuous improvement and increased

complexity, advanced cooling technology is required in the design of turbine engine parts. In view of the material

and time costs for experimental research, CFD has been accepted by turbomachinery companies as one of the

main methods for evaluating the performance of new designs. Industrial CFD applications range from classic single-

and multi blade-row simulations in steady and transient mode to heat transfer and combustion chamber

simulations. Depending on the type of machine, physical and geometrical effects have to be taken into account. A

complicating factor is the necessity to carry out parametric studies that consider several geometric options in the

process of designing the cooling systems. This normally takes a lot of time to generate mesh models due to the

mesh resolution required in the boundary layer.

The objective is to investigate the possibility of using CAD embedded CFD codes for numerical simulation of

conjugate heat transfer, using a specific approach for solid-fluid interfaces, boundary layer treatment, and heat flux

calculations.

w w w. m e nto r. co m

2 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Mesh generators in traditional CFD are usually based on body-fitted algorithms, which are widely used for solving

industrial problems. As a rule, for complicated geometries unstructured meshes are used, formed by constructing

irregularly distributed nodes. A characteristic of body-fitted meshes is that they are highly sensitive to the quality of

the CAD geometry. FloEFD technology is based upon an alternative approach which uses an improved immersed-

body mesh. In this approach the creation of the mesh starts independently from the geometry itself and the cells

can arbitrarily intersect the boundary between solid and fluid. This makes it possible to use a Cartesian-based mesh

which is one of the key elements of Meshing Technology of the CAD/CFD Bridge for CAD-embedded CFD. As a

result of using Cartesian-based meshes, there are cells which are located fully in solid bodies (solid cells), in the fluid

(fluid cells) and cells intersecting the immersed boundary (partial cells) (Sobachkin et al, 2013). In FloEFD, Cartesian

mesh for all the test and industrial cases described in the paper, was created without the need for time-consuming

manual input, and using the completely automatic mode of the software.

The main issue for Cartesian immersed-body meshes is the use of the boundary layers approach on coarse meshes.

To account for wall effects Two-Scale Wall Function (2SWF) approach (Mentor Graphics, 2011) describing viscous

interaction of the turbulent airflow with the walls is used. That approach consists of two methods for coupling the

boundary layer calculation with the solution of the bulk flow: 1) a thin boundary layer treatment that is used when

the number of cells across the boundary layer is not enough for direct, or even simplified, determination of the

flow and thermal profiles; 2) a thick boundary layer approach when the number of cells across the boundary layer

exceeds that required to accurately resolve the boundary layer. In intermediate cases, a compilation of the two

above approaches is used. The 2SWF approach automatically applies an appropriate model of boundary layer

(thin, thick or intermediate case) for which the mesh resolution conditions are satisfied.

In addition to specifying the basic mesh in manual mode and creating the local meshes around the body and its

parts, to speed up calculation of the problem and obtain quality results Solution Adaptive Refinement (SAR)

procedure is used. This combined approach allows the user to start a calculation on a coarse mesh and get more

accurate results by refining mesh during calculation in the areas of the largest gradient of parameters. Since the

combined approach reduces the number of necessary SAR stages and the number of mesh cells in resulting

computational meshes, it also reduces the total calculation time (Mentor Graphics, 2016).

3. TEST CASES

3.1. VANE NASA C3X

The experimental object was represented as a linear

array. Each cascade employed three vanes,

characteristic of a first-stage turbine. Geometry

parameters of vane and cooling channels were

taken from Hylton et al (1983). Each of the vanes was

cooled by an array of ten radial cooling holes. The

vanes were fabricated of ASTM type 310 stainless

steel, which has a relatively low thermal

conductivity.

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3 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Coolant Parameters such as average temperature and mass flow rate are presented in Table 1. The average heat

transfer coefficient (a) for each cooling hole was calculated from empirical relation of Nusselt number with

Reynolds and Prandtl numbers:

Nu D = Cr ^0.022 $ Pr0.5 $ Re0D.8h = a $ D/m (1)

Where D is the hole diameter, is thermal conductivity. The Re for each cooling channel was determined from the

measured flow rate, the cooling hole diameter, and viscosity based on the average coolant temperature. Cr is a

function of Pr, ReD, and x/D, which corrects the Nu expression for a fully developed thermal boundary layer to

account for thermal entrance region effects.

Channel 1 2 3 4 5 6 7 8 9 10

D, mm 6.3 6.3 6.3 6.3 6.3 6.3 6.3 3.1 3.1 3.1

Cr 1.118 1.118 1.118 1.118 1.118 1.118 1.118 1.056 1.056 1.056

G, g/sec 7.79 6.58 6.34 6.66 6.52 6.72 6.33 2.26 1.38 0.68

T, K 371 375 360 364 344.5 399 359 358 418 450

The calculations were performed under the following boundary conditions. Gas inlet temperature was equal to

783K. Inlet pressure was fixed at a level of 3.217 bars. Gas outlet pressure was fixed at a level of 1.87 bars.

The HMN (High Mach Number) solver was used for calculations. This explicit numerical solver is based on a

modified Godunov`s method. These results were obtained with several refinements that were performed during

the calculation by the SAR procedure.

The task was considered in 2D statement. Three mesh configurations were analyzed. For coarse mesh the M1

number of cells was about 25,500, for medium mesh M2~48,000, for fine mesh M4~121,400 cells. These meshes had

the same topology, but basic mesh density was varied. Around the central vane all cells were additionally refined

by two levels and into cooled channels by three levels.

The calculation results for each mesh are presented in Figure 2. Figures 3 and 4 show temperature and heat transfer

coefficient distributions along surface of the vane. Negative distances indicate the probe positions on the pressure

side. Positive values indicate the suction side locations of temperature measurements. The peak in heat transfer

coefficient distribution is observed on the suction side of the vane. This one can be explained by a more rapid

laminar-turbulent transition in the boundary layer as compared to the experiment where this transition was also

observed, but was smoother.

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4 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Figure 4: Comparison of calculations with measurements for heat transfer coefficient distribution

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5 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Maximum and average values of calculation discrepancies are showed in Table 2. Reasonable mesh convergence

can be found here. The results obtained even for the coarse mesh have a good agreement with experimental data

and can be used for further analysis.

Suction Side Pressure Side Suction Side Pressure Side Suction Side Pressure Side

Max. error, % 4.70 3.58 3.01 3.33 2.83 3.25

Aver. error, % 1.28 1.55 1.33 1.41 1.09 1.04

Investigations on the thermal efficiency potential of steam cooling, have been carried out experimental work Bohn

et al (2002). Geometrical configuration consists of a rectangular duct containing a three-vane cascade. The central

vane can be convectively cooled by supplying steam to 22 straight radial cooling passages. Geometry parameters

of the experimental object are presented in Figure 5.

The axial chord length (L) was equal to 30.7mm; vane height was equal to 76.7mm. The thermocouples T1 to T9 are

located in the middle section of the vane inside bore-holes of 0.5mm diameter. The arrangement of the cooling

passages and their corresponding diameters are illustrated in a middle section of the vane. The vanes were

fabricated of X5CrNi18-10 alloy.

The calculations were performed under the following boundary conditions. Gas inlet temperature was equal to

826.33K. Gas outlet pressure was fixed at a level of 1 atmosphere. Total mass flow rate of steam was set as 7 g/sec.

Cooling steam was distributed evenly. Inlet temperature of cooling holes was equal to 468.67 . Outlet pressure

was fixed at level of 2.8 atmospheres. The steam was treated as a real gas. Results were obtained using Low-

Compressible (LC) solver.

The calculations were performed with several mesh configurations. For coarse mesh M1 383.000 cells were

generated, for fine mesh M2~1.121.400 cells were done.

w w w. m e nto r. co m

6 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Computed temperature distribution along the profile of the vane for both mesh configurations are shown in Figure

6. The temperature values in experimental points are almost identical to each other and are in good agreement

with the experiment. The only difference is observed for thermocouple T6, which is located on the suction side,

closer to the trailing edge. The maximum discrepancies are 9.8% for mesh configuration M1 and 13.9% for mesh

configuration M2. The average discrepancies are 2.8% and 3.2% respectively.

Figure 6: Comparison of computed solid temperature in the vane with measured one

Figure 7 shows the computed temperature distribution on both sides of the vane for the mesh configuration M1.

Figure 8 shows the computed temperature in the inlet (2% of the height), the middle (50% of height) and outlet

(98% of the height) sections of the vane for the mesh configuration M1.

Figure 7: Surface temperature distribution on the suction side (left) and the pressure side (right) of the vane

w w w. m e nto r. co m

7 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Figure 8: Internal temperature distribution for a) inlet section; b) middle section; c) outlet section of the vane

The solid temperature field shows the even distribution inside the vane. Temperatures at the leading edge are

slightly higher for all sections. Very high temperatures are found at the trailing edge. The cooling efficiency is

insufficient here. As a result, the temperature gradient is very high in this region.

A showerhead film cooled vane with five rows of staggered cylindrical cooling holes is used in Nasir et al (2008).

The vane cascade consists of four full vanes and two partial vanes. The number of cooling holes on the stagnation

region row is 17. Cooling flow is injected at 90 angle to the freestream and 45 angle to the span of the vane.

Overview and dimensions of the test vane are presented in figure 9.

Figure 9: Profile view of showerhead film cooled vane (left) and section view of stagnation row of holes (right)

The coolant to freestream mass flux or blowing ratio, BR, is defined as:

pC uC mC

BR = = (2)

p3 u3 A holes p i u i

Where c and uc are coolant parameters; and u are free stream parameters; mc is the coolant mass flow rate;

Aholes is sum area of holes, i and ui are inlet parameters.

The mode corresponding M=0.57 and BR=1.5 was chosen for numerical simulation. The gas inlet temperature was

equal to 393.15K. Inlet temperature of the coolant was equal to 299.15 . Gas outlet pressure was fixed at a level of 1

atmosphere. The air was used in the capacity of the coolant and hot gas. The computational mesh with about

133,000 cells was used.

w w w. m e nto r. co m

8 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Taw - Tr

i= , (3)

Tc - Tr

Where Taw is the temperature of an assumed adiabatic wall, Tc is temperature of the coolant, Tr is recovery

temperature. The recovery temperature is experimentally measured in a high speed flow from no film case.

Figure 10 shows the local Mach number distributions on the vane without film cooling holes. It is plotted against

non-dimensional surface distance s/C. The Mach number distribution varies smoothly along the pressure side. The

flow on the suction side continuously accelerates up to the throat area (s/C = 0.51). Figure 11 shows the adiabatic

film cooling efficiency distributions on both surfaces. The numerical efficiency trend exhibits continuous decay

downstream of the coolant injection, on the surfaces of the vane. The average error comparing with the

experimental data is about 5.6% for the pressure side and about 13.3% for the suction side. The maximum error

occurs on the suction side and is around 22.1%.

Figure 10: Comparison of computed and measured smooth vane Mach number

Figure 11: Comparison of computed and measured adiabatic film cooling effectiveness

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9 [ 1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Figure 12 shows the distribution of the gas temperature (left) and cooling air streamlines with the Mach number

distribution on the air-gas channel (right).

Figure 12: Gas temperature distribution (left) and cooling air streamlines with the Mach number distribution (right)

The rotor blade of interest is used by NPO Saturn as a test case for CFD software. The detailed description of a

similar blade can be found in Vinogradov et al (2016). A general view of the blade and the internal channels are

shown in figure 13. The blade is made of heat-resistant alloy ZS32. Ceramic coating (a thickness of 0.02-0.03 mm

with thermal conductivity =2-3 W/(mK)) which serves to insulate components from large and prolonged heat

loads by utilizing thermally insulating materials.

Figure 13: CAD model of simulated blade (left) and its internal passages (right)

w w w. m e nto r. co m

10 [1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Relatively cold air is passed through the passages inside the turbine blade. A complicated internal cooling system

includes serpentary channels with rib turbulators. The coolant goes out of the blade through holes located on the

blade tip. The remaining coolant is ejected from the trailing edge of the profile.

As for previous test cases evaluation of the temperature distribution of the blade was made by means of conjugate

heat transfer simulation. Ceramic heat barrier coating was taken into account as the thermal resistance with

equivalent parameters. Numerical simulation included modeling of mainstream gas flow, airflow through the

internal channels of the blade, as well as heat transfer in solid and between fluid and solid by convection. The

computational mesh with about 944,000 cells was used.

The radial distribution of total pressure and temperature in the inlet flow was taken into account. The last one was

the result of a gas-dynamic calculation made in 3D Euler software and used as a boundary condition for current

simulation. Gas outlet pressure was fixed at a level of 8.24 bars. Coolant air temperature was equal to 442C and

pressure was fixed at a level of 9.9 bars. Rotating velocity of the blade was equal to 15,720 rpm.

Figure 14: Comparison of computed and measured surface temperature along the profile

in shroud section and middle section of the blade

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11 [1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

Shroud and middle sections of the blade were taken for comparison of numerical simulations with experimental

data (see figure 14). Marked on the figure range of ratio error is 10%. Note that the difference between

computations and experimental data is within this ratio for pressure side of the blade both for the shroud and

middle section. For the suction side of the blade, agreement with the experimental data is a bit worse, particularly

in shroud section. Calculation discrepancies are estimated at the level of 15%.

Figure 15 and 16 show pressure and cooling air temperature distributions along flow streamlines as well as surface

metal temperature field on both side of the blade are in a good concordance with qualitative evaluates.

Calculated gas mass flow rate through the blade row is equal to 29.94 kg/sec. Mass flow rate through one blade is

equal to 0.027 kg/sec. This is caused by the heat exchange with a hot metal blade and the coolant air temperature

increment is about 110C. Obtained results are also in a good agreement with qualitative estimations.

Figure 15: Flow streamlines colored by pressure (left) and the cooling air temperature (right) into passages

Figure 16: Distribution of solid temperature on the pressure side (left) and on the suction side (right)

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12 [1 3]

Using modern CAD-Embedded CFD code for numerical simulation of heat transfer in vanes and blades

5. CONCLUSIONS

Obtained computation results for simple test models are in a good agreement with experimental data. The

predicted blade temperature distribution and flow through the blade, for an industrial convective cooled turbine

blade are also in good agreement with the available experimental data in the qualitative and quantitative aspects.

It is shown that using a Cartesian-based mesh, coupled with some engineering techniques enables acceptable

accuracy on far coarser meshes than when compared with traditional CFD approaches. Therefore computations of

fluid flow and heat transfer for even complex 3D cases take relatively modest computational resources. The

combination of good performance for relatively coarse mesh, high level of automation and usability, make modern

CAD-embedded codes quite adequate and a useful CFD tool for engineering, numerical simulation of heat transfer

in vanes and blades.

6. REFERENCES

Bohn, D., Wolff, A., Wolff, M., Kusterer, K. (2002), Experimental and Numerical Investigation of a Steam-Cooled Vane,

Proceedings of ASME Turbo Expo, GT-2002-30210, the Netherlands, Amsterdam, June 3-6, 2002.

Hylton, L.D., Mihelc, M.S., Turner, E.R., Nealy, D.A., and York, R.E. (1983) Analytical and Experimental Evaluation of the

Heat Transfer Distribution Over the Surface of Turbine Vanes, NASA Paper No. CR-168015.

Mentor Graphics Corporation (2011) Enhanced Turbulence Modeling in FloEFDTM, MGC 02-11, TECH9670-w, Mentor

Graphics Corporation, 2011

Nasir, S., Bolchoz, T., Ng, W.F., Zhang, L.J., Moon, H.K., Anthony, R.J. (2008) Showerhead Film Cooling Performance of

a Turbine Vane at High Freestream Turbulence in a Transonic Cascade, ASME IM-ECE-2008-66528, 2008.

Sobachkin, A.A., Dumnov, G.E. (2013) Numerical Basis of CAD-Embedded CFD, Proceedings of NAFEMS World

Congress NWC 2013, Austria, Salzburg, June 09-12, 2013.

Vinogradov, K.A., Kretinin, G.V., Otryahina, K.V., Didenko, R.A., Karelin, D.V., Shmotin, Y.N. (2016) Robust optimization

of the HPT blade cooling and aerodynamic efficiency, ASME GT2016-56195, 2016.

2017 Mentor Graphics Corporation, all rights reserved. This document contains information that is proprietary to Mentor Graphics Corporation and may

be duplicated in whole or in part by the original recipient for internal business purposes only, provided that this entire notice appears in all copies.

In accepting this document, the recipient agrees to make every reasonable effort to prevent unauthorized use of this information. All trademarks

mentioned in this document are the trademarks of their respective owners.

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