Antonio Giovanni Perdichizzi

The Effect of an Upstream Ramp on Cylindrical and Fan-Shaped Hole Film Cooling: Part II — Adiabatic Effectiveness Results

The present companion papers report the results of an experimental investigation on possible beneficial effects of an upstream ramp on discrete hole film cooling. This analysis was carried out on a flat plate model. Two hole geometries have been considered: cylindrical and fan-shaped with conical expanded exit. To compare different cooling schemes, a combined aero-thermal analysis was performed. Tests have been carried out at low speed and low inlet turbulence intensity level, with blowing ratios varied in the range 0.3–1.0. Part I was focused on the aerodynamic analysis: it has been shown that the introduction of a ramp is always detrimental, as it gives a strong loss increase (+5%). Fan-shaped hole was instead the best solution, as it gives losses comparable with the cylindrical one, reduced turbulence mixing and jet dilution. Part II of this paper faces the thermal analysis. The thermal behaviour of the cooled surface has been analysed using the wide banded TLC’s technique, so to obtain adiabatic effectiveness distributions. Additional air temperature measurements have been carried out by traversing a thermocouple downstream of injection holes. The upstream ramp was found to provide a thermal protection improvement (+40%) only at low blowing rate in the case of cylindrical hole. The application of a ramp upstream of a fanshaped hole was instead detrimental for all blowing conditions. The fan shaped hole geometry with no ramp resulted to be the best solution also in terms of adiabatic effectiveness (50% higher than the cylindrical one at BR = 0.5).Copyright

The Effect of an Upstream Ramp on Cylindrical and Fan-Shaped Hole Film Cooling: Part I — Aerodynamic Results

The present companion papers report the results of an experimental investigation on possible beneficial effects of an upstream ramp on discrete hole film cooling. This analysis was carried out on a flat plate model. Two hole geometries have been considered: cylindrical and fan-shaped with conical expanded exit. To compare different cooling schemes, a combined aero-thermal analysis was performed. Tests have been carried out at low speed and low inlet turbulence intensity level, with blowing ratios varied in the range 0.3–1.0. The aerodynamic investigation has been performed through the measurements of discharge coefficients and detailed flow field measurements. Surveys were carried out by traversing a flattened Pitot tube. Additional turbulence measurements have been carried out by means of hot wire traverses. All this information, together with the adiabatic effectiveness results presented in Part II of this paper, allowed drawing a comprehensive picture of the complex aero-thermal flow field in the injection region. The upstream ramp provided a moderate improvement in the case of cylindrical holes, as it allows the coolant to diffuse someway, before interacting with the mainflow, but it produced also a significant increase of aerodynamic losses. The fan shaped hole geometry without the ramp resulted to be the best solution, as it provides a coolant injection with a good lateral spreading and a low turbulence level.Copyright

Endwall Film Cooling Through Fan-Shaped Holes With Different Area Ratios

The present paper reports on the aero-thermal performance of a nozzle vane cascade, with film cooled endwalls. The coolant is injected through four rows of cylindrical holes with conical expanded exits. Two endwall geometries with different area ratios have been compared. Tests have been carried out at low speed (M = 0.2), with coolant to mainstream mass flow ratio varied in the range 0.5–2.5%. Secondary flow assessment has been performed through 3D aerodynamic measurements, by means of a miniaturized 5-hole probe. Adiabatic effectiveness distributions have been determined by using the wide banded thermochromic liquid crystals (TLC) technique. For both configurations and for all the blowing conditions, the coolant share among the four rows has been determined. The aerothermal performance of the cooled vane have been analyzed on the basis of secondary flow effects and laterally averaged effectiveness distributions; this analysis was carried out for different coolant mass flow ratios. It was found that the smaller area ratio provides better results in terms of 3D losses and secondary flow effects; the reason is that the higher momentum of the coolant flow is going to better reduce the secondary flow development. The increase of the fan-shaped hole area ratio gives rise to a better coolant lateral spreading, but appreciable improvements of the adiabatic effectiveness were detected only in some regions and for large injection rates.Copyright

Fan-Shaped Hole Effects on the Aero-Thermal Performance of a Film Cooled Endwall

The present paper investigates the effects of a fan-shaped hole endwall cooling geometry on the aero-thermal performance of a nozzle vane cascade. Two endwall cooling geometries with four rows of holes were tested, for different mass flow rate ratios: the first configuration is made of cylindrical holes, whereas the second one features conical expanded exits and a reduced number of holes. The experimental analysis is mainly focused on the variations of secondary flow phenomena related to different injection rates, as they have a strong relationship with the film cooling effectiveness. Secondary flow assessment was performed through downstream 3D aerodynamic measurements, by means of a miniaturized 5-hole probe. The results show that at high injection rates, the passage vortex and the 3D effects tend to become weaker, leading to a strong reduction of the endwall cross flow and to a more uniform flow in spanwise direction. This is of course obtained at the expense of a significant increase of losses. The thermal behavior was then investigated through the analysis of adiabatic effectiveness distributions on the two endwall configurations. The wide banded TLC’s technique was used to determine the adiabatic wall temperature. Using the measured distributions of film cooling adiabatic effectiveness, the interaction between the secondary flow vortices and the cooling jets can be followed in good detail all over the endwall surface. Fan-shaped holes have been shown to perform better than cylindrical ones: at low injection rates, the cooling performance is increased only in the front part of the vane passage. A larger improvement of cooling coverage all over the endwall is attained with a larger mass flow rate, about 1.5% of core flow, without a substantial increase of the aerodynamic losses.Copyright

Design, Validation and Verification of Film Cooling on Gas Turbine Rotor Endwall

This paper describes the design process carried out to introduce film cooling coverage on the hub platform of a first turbine blade in order to protect from hot gas corrosion the trailing edge platform region. The different steps described consist in a design phase, a validation by experimental tests, the production follow up and verification feedbacks. The first stage endwall is a critical region due to secondary flows overheating; critical areas have been identified by 3D thermal analysis and confirmed through damage reports. A design phase has been carried out to determine the cooling holes configuration in terms of position, number, inclination and diameter. A CFD analysis allowed to define the hot gas streamlines near the pressure side fillet region in order to identify the best holes arrangement to ensure a proper thermal coverage; the thermal effectiveness and coverage length has been subsequently verified by means of an experimental activity developed by University of Bergamo. On the basis of the experimental results a 3D thermal analysis of the new holes configuration has highlighted the improvement in terms of local wall temperature reduction. Finally the new film holes have been introduced in the machining cycle of the blade and realized by electrochemical drilling. During a maintenance inspection after 20000 operating hours an endoscope investigation has confirmed the improvement obtained, showing no substantial signs of overheating.

GT Inlet Air Boosting and Cooling Coupled With Cold Thermal Storage in Combined Cycle Power Plants

Investigation results of compressor inlet air boosting and cooling, applied to combined cycle power plants, are presented and discussed. Gas turbine performances may be reduced by site altitude and inlet losses due to air ducts and filters. Increasing inlet pressure by fans allows the restoring of gas turbine power output and efficiency at least to ISO reference conditions. Coupling such a system with inlet air cooling may completely suppress the temperature increase given by inlet air compression and the pressure losses through air coils as well; therefore, by this way, a further increase of electric energy production can be achieved. An in-house simulation code, developed for evaluating inlet air cooling system performance by cool thermal storage, has been adapted in order to also simulate off-design behaviour of boosting applied to combined cycle plants. A 127 MW reference power plant, operating in the Italian scenario, has been considered. Inlet pressure increase has been evaluated with and without inlet cooling, and in comparison with inlet cooling solution alone. Both thermodynamic and economical results have been analyzed. A parametric analysis on both system sizing parameters has been carried out. Best solution was found in coupling boosting to inlet cooling system through cool thermal storage; it produced an important increase in electric energy production. Location site influence on investment pay-back proved to be less important compared to the solution with inlet air cooling system alone.Copyright

Aero-Thermal Performance of a Rotor Blade Cascade With Stator-Rotor Seal Purge Flow

The present paper investigates the effects of purge flow from a stator-rotor seal gap on the aerodynamic and thermal performance of a rotor blade cascade. Particular attention is paid to thermal results in the leading edge area that is typically difficult to protect. Experimental tests have been performed on a seven-blade cascade of a high-pressure rotor stage of a real gas turbine at low Mach number (Ma2is = 0.3). To simulate the rotational effect in a linear cascade environment, a number of inclined fins have been installed inside the stator-rotor gap, making the coolant flow to exit with the right tangential velocity component. Tests have been carried out at different blowing conditions, with mass flow rate ratios up to 2.0%. Aerodynamic effects of purge flow on secondary flow structures were surveyed by traversing a 5-hole miniaturized pressure probe in a plane 0.08cax downstream of the trailing edge. Film cooling effectiveness distributions on the end wall platform were obtained by using Thermochromic Liquid Crystals technique. Results allowed to investigate the effect of purge flow injection from the upstream gap on the secondary flows development and on the thermal protection capability. Purge flow injection of 1.0% reduced secondary flow losses and was found to effectively protect the front end wall region, up to about 0.5cax downstream of the leading edge. Increasing the purge flow up to 1.5%–2.0% provided a better thermal protection not only stream wise, but also in the region close to the leading edge because of the weakened washing activity of the horseshoe vortex.Copyright

Inlet Air Cooling Applied to Combined Cycle Power Plants: Influence of Site Climate and Thermal Storage Systems

The paper presents the results of an investigation on inlet air cooling systems based on cool thermal storage, applied to combined cycle power plants. Such systems provide a significant increase of electric energy production in the peak hours; the charge of the cool thermal storage is performed instead during night time. The inlet air cooling system also allows the plant to reduce power output dependence on ambient conditions. A 127 MW combined cycle power plant operating in the Italian scenario is the object of this investigation. Two different technologies for cool thermal storage have been considered: ice harvester and stratified chilled water. To evaluate the performance of the combined cycle under different operating conditions, inlet cooling systems have been simulated with an in-house developed computational code. An economical analysis has been then performed. Different plant location sites have been considered, with the purpose to weigh up the influence of climatic conditions. Finally, a parametric analysis has been carried out in order to investigate how a variation of the thermal storage size affects the combined cycle performances and the investment profitability. It was found that both considered cool thermal storage technologies perform similarly in terms of gross extra-production of energy. Despite to that, ice harvester shows higher parasitic load due to chillers consumptions. Warmer climates of plant site resulted to increase more the amount of operational hours than power output augmentation; investment profitability is different as well. Results of parametric analysis showed how important may be, for economical results, the size of inlet cooling storage.Copyright

Modeling, construction and monitoring of a Plus-Energy building in Dubai

This work presents the performance analysis of the very first Energy+ building in Dubai certified by the German Passive House Institute. The analysis is presented as comparison between numerical predictions and the first available monitored data. Trnsys is the software used to create the energy model, including both thermal envelope and HVAC system. The use of highly insulating materials, together with a design aimed to reduce the solar heat gains, allows for minimizing cooling loads. A 40 kW PV field, coupled to a 25 kWh battery storage and to a high-efficiency air-cooled electric chiller, fulfills the electric and cooling demand, making the building energy-autonomous. The study demonstrates the high accuracy of the energy model, able to predict precisely the building cooling loads, the energy production and the cooling system performance. The Energy+ building, inaugurated in November 2016, is a pioneering pilot-project and it represents an advance in the field of sustainable construction for all Arabic area.

Aero-Thermal Performance of a Nozzle Vane Cascade with a Generic Non Uniform Inlet Flow Condition - Part II: Influence of Purge and Film Cooling Injection

In the present paper, the influence of the presence of an inlet flow non uniformity on the aerodynamic and thermal performance of a film cooled linear nozzle vane cascade is fully assessed. Tests have been carried out with platform cooling, with coolant ejected through a slot located upstream of the leading edge. Cooling air is also ejected through a row of cylindrical holes located upstream of the slot, simulating a combustor cooling system. An obstruction was installed upstream of the cascade at variable tangential and axial position to generate a flow non uniformity. The cascade was tested at a high inlet turbulence intensity level (Tu1 = 9%) and at a constant inlet Mach number of 0.12 and nominal cooling condition. Aero-thermal characterization of vane platform was obtained through 5-hole probe and end wall adiabatic film cooling effectiveness measurements. Results show a relevant negative impact of inlet flow non uniformity on the cooled cascade aerodynamic and thermal performance. Higher film cooling effectiveness and lower aerodynamic losses are obtained when the inlet flow non uniformity is located at mid pitch, while lower effectiveness and higher losses are obtained when it is aligned to the vane leading edge. Moving the non uniformity axially or changing its blockage only marginally influences the platform thermal protection.