START: Advanced Cooling Design Studies and … Library/Events/2017/utsr/track2/Thole... · START:...

START: Advanced Cooling Design Studiesand Turbine Rim Seal Results

Brian Knisely, Ivan Monge‐Concepcion, Shawn SirokaMike Barringer, Reid Berdanier, Jeremiah Bunch, David Johnson, Jeremy Neal, and Karen Thole

November 2017

Atul Kohliand many others

Patcharin BurkeRichard Dennisand many others

2

The overall goal of the DOE project is to advance cooling of turbine components with the aim of improving efficiencies and lowering costs

Specific goals include:1) demonstrate increased turbine efficiency by reducing cooling flow to the turbine through the systematic studies of Reynolds number, cooling flowrates, and airfoil cooling designs;

2) determine the appropriate scaling parameters for different testing environments including Virginia Tech, U Pitt, and DOE‐NETL.

Siw, Chyu, and Alvin, 2015

Ramesh, Ramirez, Ekkad, Alvin, 2016

3

DOE Project StatusTask 2 – Facility UpgradeTask 3 – Cooled Blade DesignTask 4 – InstrumentationTask 6 – Advanced Manufacturing

Progress to Date

Turbine Sealing Test ResultsFull Span vs Partial Span

4

Task 1.0 –Project Management, Planning and Reporting

Task 2.0 – Facility Upgrade Planning and Execution Second compressor and heater integration

Task 3.0 – Cooled Blade Design and Manufacturing ‐‐A cooled blade airfoil design will be completed by Pratt & Whitney‐‐ Rainbow blade ring to include baseline and five configurations

Task 4.0 – Instrumentation Upgrades and Validation ‐‐Unsteady pressures; rotating data acquisition; long wave infrared radiation detection

Task 5.0 Cooled Blade Testing‐‐ Testing will be done on the full blade ring containing five different cooling configurations different cooling flow rates, Reynolds numbers, Mach numbers and other relevant parameters for each of the five configurations.

Task 6.0 Evaluation of Advanced Manufacturing Methods

There are six specific tasks for: Improving Turbine Efficiencies through Heat Transfer and Aerodynamics Research in START

Several important flow conditions in the turbine main gas path and secondary air system are at engine relevant scaling parameters

Parameter at Blade Inlet AeroEngine

START (I)Single Compressor

(2014‐2015)

START (II)Two Compressors

(2016)

Coolant‐to‐Mainstream Density Ratio / 2.0 1.0 ‐ 1.3 1.0 ‐ 2.0

Stage Pressure Ratio , / , 2 1.5 ‐ 2.5 1.5 – 2.5

Rotational Reynolds Number 2.0 x 107 + 1 x 107 2 x 107

Rotational Speed rpm 15000+ 11000 11000

Mass flow rate lbm/s 25+ 12.5 25

Pressure PSIA 100’s 60‐80 60‐80

Axial Reynolds Number 3 x 105 3 x 105 3 x 105

Vane Exit Mach Number Ma 0.7 0.7 0.7

Airfoil Geometry (True Engine Scale) Span Full Half Full

Turbine Inlet Temp Secondary Coolant Temp F ~ 2500

~ 100025040

75040

5

The facility upgrades were completed and benchmarked in spring 2017

6

The delivery system for the turbine cooling air includes a heat exchanger, moisture separator, filter, and manifold system

Turbine Cooling AirP = 60‐80 psiaT = 40 Fm = 2 lbm/s (1600 SCFM)

Shell‐and‐Tube Heat Exchanger

MoistureSeparator

Filter Manifold

Manifold1st Vanes

ManifoldTOBI

Turbine Flow Meters

(Low P Loss)

Flow Control Valves

(Electronically Actuated)

Air From CompressorP = 60‐80 psiaT = 250 Fm = 2 lbm/s (1600 SCFM)

* * * *

Glycol/Water

Manifold2nd Vanes ROBI

Manifold2nd Vanes AWS

.

.

10 Hoses

7

8

Full‐span vanes and blades were installed by increasing the main gas path area

The Phase 1 turbine was a 1.5 stage design while the Phase 2 is a 1.0 stage design including the following features

Parameter Phase 1 Phase 2

Turbine Stage 1.5 1.0

Blade Tip Clearance (/S [%]) 3.8 3.3, 5.8

Vane ‐ Rim Seal Design Double Overlap Double Overlap

Vane ‐ Rim Cavity Purge Holes 150 150

Vane

Disk

GEOMETRY FEATURE

VANES BLADES

Phase 1 Phase 2 Phase 1 Phase 2

Span Half Full Half Full

Manufacturing Additive Cast/Machined Cast/Machined Cast/Machined

Mate Face Gaps Sealed Sealed Dampers Dampers

Film Cooling Holes None Airfoil/Platform = SealedTrailing Edge = Open

None All Open

9

0

2

4

6

8

10

12

14

0 5 10 15 20 25 30

Burner Firing

Rate (M

Btu/hr)

Main Gas Path Flowrate (lbm/sec)

START Rig Burner Chart

750 F

600 F

Main Gas Path Temperature (F)

500 F

400 F

300 F

Twin Burner

Single Burner

The new combustion heater is currently configured for DOE testing using a single burner

Single Burner

Chamber Sight Port

Phase 2

10

The new combustion heater was successfully commissioned for both long‐duration steady thermal tests and transient ramp tests

Long Duration Steady Tests

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

0 30 60 90 120Time (minutes)

Turbine inlet temperature, T0,in/Tamb

Turbine mass flow rate, ṁ/ṁavg

Vane pressure ratio, Pex/P0,in

Tests have been run as long as 12 hours

250

270

290

310

330

350

370

390

410

430

0 500 1,000 1,500 2,000

Tempe

rature (°F)

Time (Seconds)

11

0

0.0005

0.001

0.0015

0.002

0.0025

0.003

0.0035

1 1.2 1.4 1.6 1.8 2

Mass F

low Param

eter per hole

[lbm*R

^.5/(s*p

sia)/#ho

les]

Pressure Ratio, P0/PS

150 open, 7/1/1490 open, 7/1/1460 open, 7/1/1430 open, 7/1/1415 open, 7/21/145 open, 7/23/142017‐06‐15 Test #1

After installation of new capabilities, numerous experiments were conducted to ensure accurate measurements

P0 PS

Phase 1 = 150Phase 1 = 90Phase 1 = 60

Phase 1 = 5Phase 2 = 150

Phase 1 = 30Phase 1 = 15

# of Purge Holes

FP / N = Mass Flow Parameter Per Hole =lbmR0.5

s psia #holes

FP P ,

, .

12

Shakedown testing included measuring the aerodynamic loading on the 1st Vane airfoil surfaces and good agreement was found to CFD

13

0.4

0.5

0.6

0.7

0.8

0.9

1

0 0.2 0.4 0.6 0.8 1

P/Pt,in

S/Smax

Phase 1

CFDVane AVane B

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0 0.2 0.4 0.6 0.8 1

P/Pt,in

S/Smax

Phase 2

CFDVane AVane B

Nor

mal

ized

Pre

ssur

eV

aria

tion,

P

P0 [p

sig]

Nor

mal

ized

Tem

pera

ture

Var

iatio

n,

T P0 [d

egF]

The turbine inlet pressure and thermal fields were also surveyed using multiple circumferential Kiel probes and thermocouples

Temperature VariationRelative to Average

(F)

Pressure VariationRelative to Average

(PSIG)

14

15

Three RadialTraverses

One Radial‐CircumferentialTraverse

The turbine inlet pressure and thermal fields were surveyed using multiple radial traverses with Kiel probes and thermocouples

15

Courtesy of D. Straub, DOE‐NETL 16

1

NETL Baseline 2

NETL ‘Trailing Edge’

3 NETL

‘Antivortex’

4 NETL ‘Double

Wall’

5 NETL ‘TrEAD’

Leading Edge

Internal Impingement cooling

Impingement cooling

Impingement cooling

Impingement cooling

Impingement cooling

External Showerhead Showerhead Showerhead Showerhead Showerhead

Pressure Surface

Internal Serpentine with ‘V’ Discrete Trip Strips

Serpentine with ‘V’ Discrete Trip Strips

Serpentine with Discrete ‘V’ Trip Strips

Partially Bridged Pedestal Double Wall


External 7‐7‐7 Shaped Hole

7‐7‐7 Shaped Hole

Shaped Antivortex Tripod Hole



Suction Surface

Internal Serpentine with ‘V’ Discrete Trip Strips





External 7‐7‐7 Shaped Hole





Trailing Edge

Internal

Triple Chamber, Double Impingement, Trip Strips, and Pedestals

High Solidity Diamond Pedestal Array



High Solidity Diamond Pedestal Array

External

Diffused Partitioned Pressure Side Cut





Task 3.0 – Cooled Blade Design and Manufacturing

1NETL Baseline

2NETL ‘Trailing

Edge’

3NETL

‘Antivortex’

4NETL ‘Double

Wall’

4NETL ‘TrEAD’

PW subcontract status: internal core design for all blades complete, thermal and structural assessments in progress

Double Impingement

vs.Diamond Pedestals

Shapedvs.

Tripod Holes

Serpentinevs.

Double Wall

Baselinevs.

Advanced

Approved for public release

Task 4.0 – Instrumentation Upgrades and Validation

18 18

Blade tip clearance probes were installed and calibrated

19

Heat transfer into the blades will also be measured using thin film heat flux gauges both purchased and manufactured in‐house at PSU

Anthony et al. 2011

Courtesy of PrOXisense

Digital telemetry hardware will allow HFG operation

Gages will be procured from Oxford University (PrOXisense) and manufactured at PSU

21

1000

μm

1300 μm

25 μm

1200 μm

200 μm

252 μm

254 μm

700 μm

700 μm

100 μm

Oxford 2015 Design

AFRL 2016 Design

Oldfield 1986 Design

Penn State Design

HFG sensing elements are being made smaller with increased sensitivity using modern fabrication technology

Single Grain of Salt

22

Penn State’s Nano Fabrication Lab will provide the equipment to make the complex heat flux gauges

Polyimide FilmRelease tape

Silicon Wafer

1. Adhere Polyimide to Silicon wafer and prepare surface

2. Spin coat a chemical resist to

the surface


Silicon Wafer

Resist

3. Develop resist


Silicon Wafer

Resist

Radiation Source

Mask


Silicon Wafer

ResistResist

4. Prepare to deposit metal


Silicon Wafer

ResistResist

5. Sputter metal of sensor material

Metal


Silicon Wafer

6. Strip resist, leaving the final metal

Metal

23

70 80 90 100 110 120 130 140 150 160 170

78

80

82

84

86

88

90

Temperature [C]

Res

ista

nce

[Ohm

]

mim13

R = 6.63e+01*(1+2.26e-03*T+-4.11e-07*T^{2}); R^2 = 1.0000Raw data

The CVD eqn constants are alpha = 2.22e-03 delta = 1.85e+00

Temperature C

Typical Calibration Curve

Resistance Ω

Fluke Calibration Oil Bath

254 μm

0.05CAccuracy

The HFG sensing elements are each calibrated to within 0.05C

Single Sided Heat Flux Gauge Probe

24

Courtesy of Limmat Scientific

The new high frequency response aero‐probe and data acquisition system arrive soon and allow time resolved spatial maps of pressure

Porreca et al. [2007]

Regina et al. [2014]

25

Task 6.0: Evaluation of Advanced Manufacturing Methods Public film cooling configurations are being tested in a engine scale test rig with metal AM coupons

25

Co‐flow and counter‐flow coolant inlets

ZnSe window for IR measurements

7‐7‐7 public shaped hole from Schroeder & Thole (2014)

Bi and hc/h∞matched to engine

Film cooling coupons were manufacture using laser powder bed fusion in two different build orientations

Material: Hastelloy® X Machine: EOS M280 DMLS machine

27

SEM micrographs show high levels of roughness in the diffuser and metering section of AM film holes

(black regions on surfaces are paint)

1x Vertical(D=0.015”)

1x EDM(D=0.015”)

2x Angled(D=0.030”)

28

The build direction affects the type of roughness in the hole, which affects film performance

M = 1.2 M = 3.02x Ang

2x Vert

Hole Scale

Build Dir

Chan Height

MfgMethod Ra/D*

2x Ang 1.7D AM 0.022x Vert 1.7D AM 0.01

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

φCoolant

Mainstream

Co‐flow

29

0.4

0.45

0.5

0.55

0.6

0.65

0.5 1 1.5 2 2.5 3 3.5 4M

In‐hole convection dominates overall effectiveness near the exit of the hole

φh

Hole Scale

Build Dir

ChanHeight

MfgMethod Ra/D*

1x Ang 1.7D AM 0.041x Vert 1.7D AM 0.022x Ang 1.7D AM 0.022x Vert 1.7D AM 0.01

φh

Coolant

Mainstream

Co‐flow

31

Vane Vane

150 purge holes

The first test campaign after the facility upgrades were completed was to compare full and partial span turbine sealing results

33

31

CO2 concentration measurements are made through static pressure taps using a gas analyzer, sampling system, and mass flow controllers

Concentration Effectiveness

CO2

Mass Flow Controller

Secondary Air Supply

Sampling System

Mass Flow Controller

c∞~0

cs=1%

Gas Analyzer, c

Plenum

Siemens Ultramat 6

Alicat

Sealing effectiveness does not scale with purge‐to‐main gas path flow ratios

43

Sealing effectiveness levels at low purge flows scale better with pressure ratio across the purge holes (similar to momentum flux ratio)

37

Inflection point in the data was detected in sealing effectiveness, which occurred when rim seal and rim cavity pressures agreed

35

38

The normalizing parameter proposed by Owen et al. [2012] showed good scaling of the data but does not agree with theoretical model

∗

/ //

∗

= where = 0

Key Findings to Date

40

The START facility has been upgraded to integrate the second compressor and combustor; benchmarking of the facility with the full span airfoils are complete; significant instrumentation upgrades have been completed and are continuing

Design for the turbine airfoils integrating the baseline and advanced cooling configurations are progressing

Comparison of sealing effectiveness levels for full‐span and partial‐span airfoils have been made; purge flow‐to‐main gas path flow ratios do not scale the effectiveness

Questions?

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