# NUMERICAL SIMULATION OF GAS TURBINE BLADE COOLING FOR ENHANCEMENT OF HEAT TRANSFER OF THE BLADE TIP

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3 IJRET: International Journal of Research in Engineering and Technology eissn: pissn: DESCRIPTION OF COMPUTATIONAL MODEL 3.1 Summary of Model The numerical model considered in this study is a two pass serpentine channel with sharp 18 turn. A schematic diagram of the geometrical models used in this study is shown in Fig. 4. The two-pass channels have rectangular cross-section with an aspect ratio of 1:2 (the flow spanwise width in the y-direction, is the half of the channel height in the z-direction), where the shorter walls are the turbine pressure side and suction side. Each channel is and 69.9 mm with a hydraulic diameter of mm. The lengths of the inlet channel (first-pass) and the outlet channel (second-pass) are about ten hydraulic diameters, and both the inlet and outlet channels are smooth without any turbulators. The internal separation rib (divider) is assumed to be 25.4 mm thick so that the full tip-wall cap section is by mm. A distance of 88.9 mm is used for the flow gap between the divider and the tip-wall. The smoothtip two-pass channel is used as a baseline for performance comparison with the protruded-tip two-pass channels. Other numerical details are similar to those of Bunker s geometrical model. The surfaces studied for the internal tip are also similar to those studied by Bunker [1]. 3.2 Computational Details To investigate the temperature distributions and the heat transfer augmentation in the three dimensional flow field, a k-ε turbulence modeling was selected. The pressure and velocity were linked by Semi Implicit Method for Pressure Linked Equation (SIMPLE) scheme. The finite modeling was conducted in Ansys Fluent 14.. The Fluent code uses finite volume method to solve the governing equations of the flow. Mesh generation was done in Ansys Mesh Modeler. This study examined turbulent flow and the heat transfer characteristics for a smooth tipped surface and the protruded surface were also checked for enhancement in heat transfer 3.3 Selection of Turbulence Model A realizable k-ε turbulence model was selected based on the previous studies. The realizable k-ε model is very effective in case of flows which involve sudden turns involving sharp streamline curvatures. As the flow involves a 18 sharp turn it is recommended to use this turbulence model for the current simulation. The flow features like separation, recirculation and impingement are quite accurately resolved by this turbulence model. 3.4 Governing Equations The governing equations for the flow are as expressed below Continuity equation [2] D. V Dt Momentum equation X-momentum Du p Dt x x Y-momentum Dv p Dt y x Z-momentum Dw Dt xx xy p y x Energy Equation for fluid [2] uit x 3.5 Boundary Conditions i i xz yx y yy y yz y z zx zy z z i zz t T (( ) ) x Pr Pr x f x f f Although the heat transfer on the leading and trailing walls are important for gas turbine blade design, the heat transfer enhancement of a protruded tip-wall over that of a smooth tip-wall is the major concern of this paper. Therefore, except for the external smooth tip-wall, the remaining walls are assumed to be adiabatic. A constant heat flux is prescribed on the bottom wall. No-slip velocity conditions are applied at all walls. A uniform velocity (different for different Re) and temperature are set at the inlet and an outflow condition is chosen at the outlet. A turbulence intensity level of 1 % and the hydraulic diameter are used to compute the turbulence quantities at the inlet. Due to the conjugation of fluid and solid heat transfer, the boundary conditions for the interfaces between the dimple surfaces and the internal dimpled tip-cap surface are automatically coupled. The fluid is assumed to be incompressible with constant thermal physical properties and the flow is assumed to be three dimensional, turbulent, steady and non-rotating. The working fluid is dry air. In this study, because of high Reynolds numbers and the complicated computational model, the standard wall functions of the k-ε model 2 equation models are applied on the walls for the near wall treatment. The convergence criterion for continuity, momentum, k and e equations is 1^4but 1^7 for the energy equation. 3.6 Grid Dependence Study A grid dependence test is carried out in order to select the appropriate mesh before simulating the flow. The details of the mesh independence will be included in a separate study paper. For the grid independence test four different grid were chosen cells, cells, cells and cells studied. Various parameters like temperature, z y Volume: 3 Issue: 9 Sep-214, 37

4 Nu Δp (pressure drop) IJRET: International Journal of Research in Engineering and Technology eissn: pissn: pressure and eddy viscosity were evaluated over these grids. It was found that the grids with cells and cells showed the closest results amongst the four. Hence in order to avoid the computational time and also to reduce computational resources the grid with cells was selected for further simulations. 3. RESULTS AND DISCUSSIONS 3.1 Definition of Parameters This study Bunker [1] Before explaining the results the following parameters are defined Re (Reynolds number) Fig. 6 Pressure drop for current study and Bunker s [1] experimental results for a smooth tip two pass channel The local Nusselts number is given by The overall Nusselts number is given by 3.2 Validation of Model hd Nu k Before finalizing the simulation and processing further calculations we need to validate the results It is seen from Fig 5 and Fig 6 that the values of the numerical results are in accordance with the experimental results of Bunker [1] with a maximum deviation less than 15 %. The results have been simulated using the realizable k-ε turbulence model with a standard wall function. A good agreement between the experimental results and the current computational model has been achieved. This validates our numerical simulations h This study Bunker [1] After the model validation the results have been computed for different configurations of the tip i.e. by modifying the surface of the tip with arrangement of pins at different locations and with different dimensions as explained further. Also the mass flow rates from numerical and calculated results have been compared. Both the results give almost the same values indicating the simulated model is valid. The values are a listed in the Table 1. Param eter Mass Flow Rate( kg/s) Study Nume rical Calcul ated % deviat ion Table 1 Re=2 Re=3 Re=35 Re= nil In order to understand the flow patterns and the temperature regions the temperature contours over the tip surface have been plotted. Fig 7 shows the temperature contours for a smooth surface at a Reynolds number Re=2. From the temperature contours it is seen that the corners of the tip are the portions which are more vulnerable to high temperatures. Re Fig. 5 Nusselts number for current study and Bunker s [1] experimental results for a smooth tip two pass channel Fig. 7 Temperature contour for smooth channel at Re=2 Volume: 3 Issue: 9 Sep-214, 38

5 IJRET: International Journal of Research in Engineering and Technology eissn: pissn: OVERALL COMPARISONS Two types of surfaces were compared. The configuration of the two surfaces were same only the heights of the pins used at the corners were different, more height in the latter case. The configuration is as shown in the fig.8. Fig. 8 a) Case I - D=.5 cm, H=1 cm (H/D=1:2) b) Case II - D=.4 cm, H=.8 cm (H/D=1:2) Case I: - Pin fins of diameter 5 mm with a height of 1 mm. The area added by the fins accounts to sq.cm by each pin fin. Therefore the total area added by 4 pins for Case I is 7.65 sq.cm Case II: - Pin fins of diameter 4 mm with a height of 8 mm. The area added by the fins accounts to sq.cm by each pin fin. Therefore the total area added by 4 pins for Case I is sq.cm (c) Fig 9 a) Streamlines of smooth surface at Re=2 b) Streamlines of pin finned surface Case I at Re=2 c) Streamlines of pin finned surface Case II at Re=2 4.2 Velocity Vectors of the Three Surfaces 4.1 Streamlines of Case I & Case II as Compared to Smooth Surface From fig 7.16 it is seen that the flow does not produce any type of whirls while taking the turn. It is also evident that the flow interacts with the pin fins at the corners thus enhancing the heat transfer of the tip at the corners as well as over the other surface. Volume: 3 Issue: 9 Sep-214, 39

6 Pressure drop Δp Nusselts Number Nu h IJRET: International Journal of Research in Engineering and Technology eissn: pissn: Smooth Surface Case I Case II Reynolds Number (c) Fig 1 Velocity Vectors of three surface at Re=45 Fig 1 shows the velocity vectors of smooth tip two pass channel and pin finned tip two pass channel. It can be clearly seen that due to the pin fins turbulence is created at the corners of the tip region. The flow interacts with surface of the tip due to the pins and also remains near the pins for a considerable amount of time. After heating there is time for the flow to mix with the incoming cooling fluid, thereby improving cooling at the tip section. 4.3 Comparisons of the Three Surfaces Reynolds Number Re Reynolds Number Re Smooth Surface Case I Case II Smooth surface Case I Case II (c) Fig 11.a) Nusselts number comparison of three surfaces b) Pressure drop comparison of three surfaces c) Heat transfer coefficient comparison of three surfaces From fig 11 it can be seen that the values of Nusselts number and surface heat transfer coefficient are greater for the pin finned surfaces as compared to the smooth surface. The pressure drop values are alost same for all the three surfaces. 5. CONCLUSIONS From the above studies the following conclusions can be made Pin fins can prove to be a great heat transfer enhancement tool if configured in proper numbers and arrangement. Compared to the smooth surface the pin finned surfaces provided an additional area for heat transfer. The pin fins provided at the corners and at the periphery of the tip force the vortices generated towards the tip wall thereby improving the turbulent mixing of the heated fluid with the incoming cold fluid. The pin fins provided also helped in uniform distribution of heat over the tip. The heat transfer enhancement of the pin finned surfaces is about 1.5 times higher than that of the smooth surface. All the augmentation has been obtained at a pressure drop of less than 1 %. REFERENCES [1] Ronald S. Bunker, The Augmentation of Internal Blade Tip-Cap Cooling by Arrays of Shaped Pins, Journal of Turbomachinery, OCTOBER 28, Vol. 13 / [2] Gongnan Xie, Bengt Sundén. Numerical predictions of augmented heat transfer of an internal blade tip-wall by hemispherical dimples, International Journal of Heat and Mass Transfer 53 (21) [3] Gongnan Xie, Bengt Sundén, Computational Analysis of Pin-Fin Arrays Effects on Internal Heat Volume: 3 Issue: 9 Sep-214, 4

7 IJRET: International Journal of Research in Engineering and Technology eissn: pissn: Transfer Enhancement of a Blade Tip Wall, Journal of Heat Transfer, MARCH 21, Vol. 132 / [4] Gongnan Xie, Bengt Sundén,Weihing Zhang, Comparisons of Pins/Dimples,Protrusions cooling concepts for a turbine blade tip wall at high Reynolds numbers, Journal of Heat Transfer, June 211,Vol.133/ [5] Robert KIML, Sadanari MOCHIZUKI, Akira MURATA and Matej SULITKA, Rib-Induced Secondary Flow Structures inside a High Aspect Ratio Trapezoidal Channel, Proceedings of the International Gas Turbine Congress 23 Tokyo November 2-7, 23. [6] Je-Chin Han, Recent Studies in Turbine Blade Cooling, International Journal of Rotating Machinery, 1(6): , 24. [7] Ravi Teja, S. Krishna Chaitanya, Case study on Turbine Blade Internal Cooling, International Journal of Engineering Research & Technology ISSN: , (IJERT) Vol. 2 Issue 3, March 213 ISSN: [8] Ana Paula P. dos Santos, Claudia R. Andrade and Edson L. Zaparoli, Comparison of Different Gas Turbine Inlet Air Cooling Methods, World Academy of Science, Engineering and Technology [9] S. Gupta, A. Chaube, Verma, Review on Heat Transfer Augmentation Techniques: Application in Gas Turbine Blade Internal Cooling, Journal of Engineering Science and Technology Review 5 (1) (212) Volume: 3 Issue: 9 Sep-214, 41

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