March 18th, 2014, Vienna, Austria

STAR Global Conference

Engineering Success by Application of

Star-CCM+ for Modern Gas Turbine Design

Karsten Kusterer

B&B-AGEMA GmbH, Aachen,

Germany

Ryozo Tanaka

Kawasaki Heavy Industries, LTD.,

Akashi, Japan

engineering your visions

STAR Global 2014, No. 2

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Contact:

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

info@bub-agema.de

www.bub-agema.de

• Founded in 1995, located in Aachen, Germany

• Independent engineering service company

• Company Expertise

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)

combustion technology

optimization of pre-mixed combustion systems

Low-NOx hydrogen combustion

power plant

CFD / CHT Analysis & Flow Optimization of power plant

components (cooling tower, valve, condenser, moisture

separator, etc.)

engineering your visions

STAR Global 2014, No. 3

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Content

CHT Technology and its Role in the Design Process for

Cooled Gas Turbine Components

Example 1: Successful Implementation of STAR-CCM+

in the Design Process for Kawasaki L30A Development

and Validation Based on Engine Results

Example 2: Upgrade of an E-Class Gas Turbine

Example 3: Development of New Film Cooling

Technologies

Conclusion and Outlook

engineering your visions

STAR Global 2014, No. 4

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Content

CHT Technology and its Role in the Design Process for

Cooled Gas Turbine Components

Example 1: Successful Implementation of STAR-CCM+

in the Design Process for Kawasaki L30A Development

and Validation Based on Engine Results

Example 2: Upgrade of an E-Class Gas Turbine

Example 3: Development of New Film Cooling

Technologies

Conclusion and Outlook

engineering your visions

STAR Global 2014, No. 5

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Conjugate Heat Transfer and Flow Simulation Code Development from 1990

Conventional Method:

1. Get heat transfer conditions from adiabatic

flow simulations or from correlations

(!uncertainties!) for external/internal

surfaces

2. Prescribe heat transfer conditions on FEM-

Modell

3. Get blade temperatures as result of heat

conduction calculation (!interaction

phenomena with flow are not taken into

account!)

Full Conjugate Method

1. Conjugate calculation for internal

flows, external flows, and solid

body without prescription of any

heat transfer coefficients (!not

necessary!) for direct result of the

thermal load

? ? ? ?

? ?

?

? ?

?

?

?

Development of the Conjugate Technique in Aachen

Final

Design

Conjugate

Calculation

Measurements

Conjugate

Calculation

Measurements

& engine test

experience

1st test configuration 2nd test configuration

Prof. Dieter Bohn Institute of Steam and Gas Turbines at RWTH Aachen University (1990 - 2010)

B&B-AGEMA Aachen Engineering Service Company (since 1995)

engineering your visions

STAR Global 2014, No. 6

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Development of the Conjugate Technique in Aachen (2)

Prof. Dieter Bohn Institute of Steam and Gas Turbines at RWTH Aachen University (1990 - 2010)

B&B-AGEMA Aachen Engineering Service Company (since 1995)

Year Development Papers (examples)

1990 Basic Code Development 1990-1994

1994 1st publication of of numerical results VDI-1109

1995 Convection-cooled turbine vane validation (MarkII) for the Aachen-code CHTflow IGTC1995-108

1995 First application of CHT flow for film cooling ISABE95-7105

1996-2000 Impact of conjugate heat transfer on leading edge film cooling 96-GT-150,

97-GT-23

1997-1998 1st industrial application (hot spot analysis for 1st blade of industrial gas turbine) ISTP-10,

99-GT-199

Year Application & Improvement Papers (examples)

2001-2002 Investigation of steam-cooled vane (full 3-D conjugate investigation) 2001-GT-166,

GT2002-20210

2003 – 2004 Design improvement for 1st blade cooling configuration IGTC2003-TS083, GT2003-

38369, GT2004-53719

1998 -2010 Effusion cooling for multi-layered plates (SFB561)

2001-GT-132, ISABE2005-

1072,GT2008-50378,

ISROMAC13-2010-004

2009 -2012 Design support for cooling system of new developed L30A gas turbine of KHI IGTC2011-ABS-0086,

GT2012-68679

engineering your visions

STAR Global 2014, No. 7

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

STAR-CCM+: Validation of the Conjugate Heat Transfer Capability

Geometry Overview: Mark II testcase

Cooling air

Prism layers

Midspan Mesh

Braun, R.: Conjugate Heat Transfer Calculations of Cooled Turbine Vanes with STAR-CCM+, Dynamics issue 35, 2013

Pressure side Suction side

engineering your visions

STAR Global 2014, No. 8

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Example of Modern GT Development: Full CFD/CHT Approach

RESEARCH & DEVELOPMENT

COMPONENT DESIGN

CFD / CHT / COMBUSTION VALIDATION

COMPONENT TESTING

FIELD TEST OPERATION

World‘s best Industrial GT

“Kawasaki L30A” Highest PG efficiency in

30 MW class GT’s

engineering your visions

STAR Global 2014, No. 9

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

“Kawasaki L30A” Overview

30 MWel simple cycle efficiency: 40%

References:

Kawasaki 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

Successful implementation of

STAR-CCM+ in cooled turbine design

process for:

Design of extensively cooled vanes

and blades for real engine application

and to reach advanced design

specifications.

Acceleration of the design process by

reducing number of test configurations

until product readiness and, thus, to

reduce development costs.

Investigation of innovative cooling

technologies for hot gas components.

engineering your visions

STAR Global 2014, No. 10

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Content

CHT Technology and its Role in the Design Process for

Cooled Gas Turbine Components

Example 1: Successful Implementation of STAR-CCM+

in the Design Process for Kawasaki L30A Development

and Validation Based on Engine Results

Example 2: Upgrade of an E-Class Gas Turbine

Example 3: Development of New Film Cooling

Technologies

Conclusion and Outlook

engineering your visions

STAR Global 2014, No. 11

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

KHI L30 A: Engine Test Facility

Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration)

CHT calculation with STAR-CCM+

engineering your visions

STAR Global 2014, No. 12

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration)

main flow inlet

combustion gas

Outlet

air mixture

cooling inlet 1

pure air

cooling inlet 2

pure air

sealing inlet 2

pure air

sealing inlet 1

pure air

engineering your visions

STAR Global 2014, No. 13

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

cutback slots pin fins ribs shower head

metal sheet inserts for

impingement cooling

(considered as baffles)

Kawasaki L30A: 1st Stage Vane Geometry (Test Configuration)

engineering your visions

STAR Global 2014, No. 14

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Computational Mesh

no. of layers near wall cell height abs. height

green 6 6E-3mm 0.100mm

blue 15 8E-4mm 0.134mm

red 20 3E-4mm 0.189mm

mesh specifications:

polyhedral mesh (13.8 million cells)

direct interfaces at fluid-solid contacts

periodic boundary conditions for fluid domain

and solid domain

prism-layers at elected fluid domain surfaces

engineering your visions

STAR Global 2014, No. 15

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

low high temperature

CHT calculation results – pressure side temperature distribution

very good

agreement between

CHT and test data

STAR-CCM+ CHT calculation* * circumferential averaged

TIP engine test data** ** fixed position

excellent prediction of internal cooling performance

internally

impingement & convective cooled

internally

convective cooled

film cooling

TIP: Thermal Index Paint

engineering your visions

STAR Global 2014, No. 16

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

low high temperature

CHT calculation results – suction side temperature distribution

STAR-CCM+ CHT calculation* * circumferential averaged

TIP engine test data** ** fixed position

very good agreement

between CHT and test

data

TIP: Thermal Index Paint

engineering your visions

STAR Global 2014, No. 17

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

low high temperature

STAR-CCM+

CHT calculation* * circumferential averaged

TIP engine test data** ** fixed position

CHT calculation results – shroud temperature distribution

lower shroud upper shroud

TIP: Thermal Index Paint

engineering your visions

STAR Global 2014, No. 18

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Content

CHT Technology and its Role in the Design Process for

Cooled Gas Turbine Components

Example 1: Successful Implementation of STAR-CCM+

in the Design Process for Kawasaki L30A Development

and Validation Based on Engine Results

Example 2: Upgrade of an E-Class Gas Turbine

Example 3: Development of New Film Cooling

Technologies

Conclusion and Outlook

engineering your visions

STAR Global 2014, No. 19

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

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

CHT-calculation set up

SST-GammaRe-theta Model

Full conjugate calculation

Combustion gas properties for main

flow

air properties for cooling air

Upgrade E-class Gas Turbine : 1st Stage Vane Analyses with STAR-CCM+

detailed CHT simulation model

engineering your visions

STAR Global 2014, No. 20

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Upgrade Solution

1st vane upgrade analysis with

STAR-CCM+

parametric study for:

• redistribution of the internal cooling air

• TBC‘s of different thickness

peak temperature reduction by 160

C

homogenization of the temperature

distribution

Benefits by application of STAR-CCM+ in

upgrade design process

accurate determination of the thermal

conditions of cooled turbine parts

fast evaluation of improved internal

cooling designs

reduction of experimental validations

reduction of development time, effort and

costs

Upgrade E-class Gas Turbine : 1st Stage Vane Analyses with STAR-CCM+

low high temperature

engineering your visions

STAR Global 2014, No. 21

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Content

CHT Technology and its Role in the Design Process for

Cooled Gas Turbine Components

Example 1: Successful Implementation of STAR-CCM+

in the Design Process for Kawasaki L30A Development

and Validation Based on Engine Results

Example 2: Upgrade of an E-Class Gas Turbine

Example 3: Development of New Film Cooling

Technologies

Conclusion and Outlook

engineering your visions

STAR Global 2014, No. 22

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

DJFC Technology & NEKOMIMI Film Cooling

(1) (2) (3)

„ear angle“

=29

b) Shaped

x/D=2

x/D=5

x/D=10

NEKOMIMI effect:

Numerical Results

ACRV

Film Cooling effectiveness: Experimental results

Kusterer, K., Elyas, A., Sugimoto, T., Tanaka, R., Kazari, M., and Bohn, D., 2011,

"The NEKOMIMI Cooling Technology: Cooling Holes with Ears for High-efficient Film Cooling," ASME-paper GT2011-45524, Vancouver, Canada.

Japanese Patent JP2011196360

engineering your visions

STAR Global 2014, No. 23

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

NEKOMIMI: Highest-efficient Film Cooling

Advanced NEKOMIMI holes (examples)

x/D

film cooling effectiveness f

Adiabatic film cooling effectiveness for

Blowing ratio M=1.5

parameter

variation

study

manufacturing by EDM is possible!

Kusterer, K., Tekin, N., Kasiri, A., Sugimoto, T., Tanaka, R., Kazari, M., Bohn, D.: Highest-Efficient Film Cooling by Improved Nekomimi film Cooling

Holes - Part 2: Hot Gas Flow Conditions, ASME-paper GT2013-95042, Proc. of the ASME Turbo Expo 2013, San Antonio, Texas, USA., 2013

Film cooling effectiveness

engineering your visions

STAR Global 2014, No. 24

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Content

CHT Technology and its Role in the Design Process for

Cooled Gas Turbine Components

Example 1: Successful Implementation of STAR-CCM+

in the Design Process for Kawasaki L30A Development

and Validation Based on Engine Results

Example 2: Upgrade of an E-Class Gas Turbine

Example 3: Development of New Film Cooling

Technologies

Conclusion and Outlook

engineering your visions

STAR Global 2014, No. 25

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Comprehensive numerical modeling of a modern gas turbine

combustor with STAR-CCM+:

Outlook: Full Approach for Gas Turbine Combustor Design

main combustion

combustor exit

fuel supply

supplemental

combustion

air supply

Worlds best Industrial Gas Turbine „Kawasaki L30A“

Highest PG efficiency in 30 MW Class GT‘s.

Courtesy of Kawasaki Heavy Industries

engineering your visions

STAR Global 2014, No. 26

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

STAR-CCM+ Engineering Success for Gas Turbine Design: Conclusion

The application of the STAR-CCM+ CHT technology became an essential step

in the design process of cooled components in a modern Gas Turbine.

The CHT capability of STAR-CCM+ has been successfully validated by test

cases and based on real engine operation application experiences.

Development time, effort and cost can be reduced significantly by the

application of the STAR-CCM+ advanced meshing and CHT technology within

the design process.

STAR-CCM+ helped to reach the advanced specification goals of highest

cycle efficiency of the L30A GT in its class and as well as high reliability of

the hot gas components under real engine conditions at the same time.

Modern pre-mixed combustors for Dry-Low-NOx operation are improved by

application of STAR-CCM+ in order to further decrease emissions and

keeping high combustion stability.

engineering your visions

STAR Global 2014, No. 27

© B&B-AGEMA GmbH. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty

is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Acknowledgement

B&B-AGEMA gratefully acknowledges the permission by Kawasaki Heavy

Industries, LTD., for presentation of results of our collaborative work.

Nekomimi technology is also used in air

brakes of High Speed Train