IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES, VOLUME 4, ISSUE 1, JAN-JUNE /2017

ISSN (ONLINE): 2394-8442

CONJUGATE HEAT TRANSFER ANALYSIS OF DISC AND

SECONDARY AIR SYSTEM OF GAS TURBINE
[1]
Shivakumar Kandre, Shri. Siva Shankara Reddy [2] and Dr. K.S.Shashi Shekar [3]
M.Tech, Project trainee, HTG, GTRE, DRDO, 2Scientist F, HTG, GTRE, DRDO. INDIA
1
3
Professor, Mechanical Engineering Dept., SIT, Tumkur3.
Email: shivakumarkandre.met@gmail.com, 2sivashankara@gtre.org and 3kss_sit@hotmail.com
1

ABSTRACT.

In a Gas turbine, disc metal temperature distribution and temperature gradients are the most
important parameters for predicting the disc life. Therefore, it is essential to accurately predict the temperature
distribution for the disc life assessment. In order to estimate disc temperature distribution precisely, heat
transfer by internal coolant, external hot gas, and metal conduction should be simulated simultaneously by the
conjugate heat transfer method. Thus CHT Analysis is carried out for complete secondary air path of 2D Axis-
symmetry model that includes HP compressor, HP and LP Turbine disc using FLUENT 16.0 to estimate
temperature distributions in the disc as well as secondary air region. The analysis is also carried out to study the
effect of heat transfer between the discs, mainstream and secondary air. The steady state pressure based solver
is used to solve the computational working domain. Second order upwind scheme is employed for the
discretization of the flow and the turbulence equations and are solved through the segregated implicit method.
The Realizable k- model with enhanced wall treatment is used as a turbulence model. From the analysis it is
found that the temperature distributions is linear along the disc, temperature gradients are within the allowable
limit and maximum temperature values are well below the sustainable temperature of respective materials.

Keywords: Turbine and Compressor discs, Secondary air flow, Conjugate heat transfer.

I. INTRODUCTION
To improve thermal efficiency and power output, gas turbine engines operate at high temperature (1200-1500). Increase in the inlet turbine
temperature raises the amount of heat transfer to the disc. Thus variations in the temperature of disc material lead to development of thermal
stresses, which must be controlled in order to achieve desired durability of the disc. Since prevailing temperature are higher than the maximum
sustainable temperature of respective material used for disc, there is a critical need for cooling arrangement of disc for efficient operation. [1]

E.M. Sparrow et al. carried out an experiment using two parallel discs and a cylindrical shroud to measure the heat transfer coefficients and
fluid temperature distribution. The experimental apparatus include a stationary shroud and a rotating disc. The cool secondary air was passed
through the rotating disc. Various parameters were varied throughout the experiment such as coolant mass flow rate, disc cavity aspect ratio and
rotational speed. The results of heat transfer and the fluid isotherm graphs indicated that the flow pattern within the cavity was influenced the
coolant stream and the rpm of the rotating disc. [2]

X.Gan et al. did both experimental and computational study on the process of heat transfer from an electrically heated rotating disc to the
stator beside it. Heat from the disc was removed by the radial outflow of the cool secondary air. With the help of flux meter at several radial
locations local Nusselt numbers were measure with Reynolds number up to 1.2*106. Analysis has been carried out using an elliptic solver with
k-e turbulence model having low Reynolds number. Results, mainly velocities and Nusselt number were in good agreement with both
experimental and computational values. [3]

II.PROBLEM DESCRIPTION
In order to improve thermal efficiency and power output of modern military aircraft engines, engines are operating on cycle pressure ratios of
30 and turbine inlet temperatures of 1700 1900 K due to which the hot zone and the adjoining components temperatures have gone up and
consequently the thermal stresses have developed.

To Cite This Article: Shivakumar Kandre, Shri. Siva Shankara Reddy and Dr. K.S.Shashi Shekar,.
CONJUGATE HEAT TRANSFER ANALYSIS OF DISC AND SECONDARY AIR SYSTEM OF GAS
TURBINE. Journal for Advanced Research in Applied Sciences ;Pages: 422-427
423. Shivakumar Kandre, Shri. Siva Shankara Reddy and Dr. K.S.Shashi Shekar,. CONJUGATE HEAT
TRANSFER ANALYSIS OF DISC AND SECONDARY AIR SYSTEM OF GAS TURBINE. Journal for
Advanced Research in Applied Sciences; Pages: 422-427

The hot zone components, namely the compressor and turbine discs, which are some of the very critical components being responsible for
transferring the power and torque at high rotational speeds because of which they are subjected to high centrifugal and mechanical stresses.

For this accurate prediction of disc metal temperature distribution is necessary. This involves the thorough understanding of the adjacent
cavity air flows, the heat transfer mechanism between the disc and secondary air. For this, complete disc configuration along with secondary air
is being modeled and a conjugate CFD with heat transfer analysis is carried out.

A. COMPUTATIONAL DOMAIN

Fig.1. Computational Domain

The 2-D AutoCAD drawing of the complete secondary air path of the compressor, high pressure turbine and the low pressure turbine disc is
shown in fig 1. It consists of the compressor section with six discs, a part of combustion chamber liner, and the high pressure turbine disc
followed by the low pressure turbine disc and at the bottom is the turbine shaft. Computational domain is considered as a control volume on
which discretization of the flow and turbulence equations are solved.

III. GRID GENERATION

Accuracy of CFD solutions is strongly depending on grid size. The 2D grid is generated for the computational domain using triangular mesh.
The Triangular mesh is generated using Ansys pre-processor as shown in Fig. 2. In the regions where the variations of flow parameters are
expected to be high, fine grids are used for accurate simulation, maintaining value of y+ < 30 (To account for enhanced wall treatment). The
region near the wall is finely meshed to accurately visualize the boundary layer turbulence characteristics. A growth rate of 1.2 is used for grid
generation near the wall. The grid size is gradually expanded as it is situated away from wall as shown in Fig. 2.

Fig.2. Computational Grid

Since the realizable k- turbulence model in the FLUENT solver requires fine mesh at the walls for better results, grid adaptation method in
FLUENT was used to adapt the boundary layer. The y+ value is maintained below the value of 30.

Before grid adaptation after grid adaption

Fig.3. Detailed view of mesh at the clearances before and after grid adaptation
424. Shivakumar Kandre, Shri. Siva Shankara Reddy and Dr. K.S.Shashi Shekar,. CONJUGATE HEAT
TRANSFER ANALYSIS OF DISC AND SECONDARY AIR SYSTEM OF GAS TURBINE. Journal for
Advanced Research in Applied Sciences; Pages: 422-427

TABLE I. MESH INFORMATION of 2D GEOMETRY BEFORE and AFTER GRID ADAPTATION

MESH TYPE CELLS FACES NODES REMARKS

Coarse grid 1085283 1658695 573372 Y+ Greater than 30

Adaptive grid 4502013 7824938 3322886 Y+ less than 30

IV. FORMULATION AND NUMERICAL METHOD OF SOLUTION

In the present study, the flow in the computational domain is assumed to be steady, non-reacting and turbulent. The steady state pressure
based solver is used to solve the computational domain. Second order upwind scheme is used for the discretization of the flow and the turbulence
equations, and are solved through the segregated implicit method. Convergence is considered to be achieved when all the residual values are less
than 1x10-6.The Realizable k- turbulence model was used with enhanced wall treatment.

V. BOUNDARY CONDITIONS
Boundary conditions specify the flow and thermal variables on the boundaries of the physical model. They are a critical component of the
simulation and it is important that they are specified appropriately. Pressure boundary conditions are used to define the fluid pressure at flow
inlets and outlets, along with all other scalar properties of the flow. They are suitable for both incompressible and compressible flow
calculations. For a conjugate heat transfer problem, wall zone is a "double-sided wall'' i.e. wall and its shadow is created. A subset of these
thermal conditions is available, and both sides of the wall can be coupled.

While extracting the fluid side heat transfer coefficients, care was taken such that the wall chosen must have a fluid domain same as the
adjacent cell zone. The sign convention is that heat entering fluid domain is positive and heat leaving the fluid domain is negative. Flow
boundary conditions and convective boundary conditions are as shown in figure 4 and 5. Various boundary conditions and results were non-
dimensionalised by dividing respective values with minimum value in the respected group of parameters. Alphabetic letters such as A,B,C etc
are different zones of convective boundary conditions in figure 4 and 5.

OUT 2 OUT 3 IN 4 OUT 4

IN 2 IN 3
OUT 1
OUT 5

OUT 6
OUT 7

IN 1

Fig.4. Flow boundary conditions applied on 2D model

Fig.5. Convective boundary conditions applied on 2D model

425. Shivakumar Kandre, Shri. Siva Shankara Reddy and Dr. K.S.Shashi Shekar,. CONJUGATE HEAT
TRANSFER ANALYSIS OF DISC AND SECONDARY AIR SYSTEM OF GAS TURBINE. Journal for
Advanced Research in Applied Sciences; Pages: 422-427

Normalized flow boundary conditions and Convective boundary conditions are assigned to the different zones that are created. Values are
shown in table II, III and IV.

TABLE.II. FLOW BOUNDARY CONDITIONS AT THE INLETS

Parameters Inlet 1 Inlet 2 Inlet 3 Inlet 4

Total pressure 1.82 7.80 8.64 3.13

Total temperature
1.00 1.60 1.70 1.50

TABLE.III. FLOW BOUNDARY CONDITIONS AT THE OUTLETS

parameter outlet1 outlet2 outlet3 outlet4 outlet5 outlet6 outlet7

Static pressure 1.18 3.41 1.88 1.00 1.04 5.88 1.54

TABLE.IV. VARIOUS HEAT TRANSFER ZONE VALUES AT COMPRESSOR AND TURBINE SECTION

zone number Heat transfer co-efficient Temperature

A
8.56 1.20
B
5.01 1.24
C 1.45 1.23
D
1.58 1.30
E
5.57 1.31
F
12.15 1.35
G
6.05 1.37
H
1.68 1.36
I
1.81 1.43
J 6.88 1.45
K
16.59 1.52
L
18.01 1.59
M 19.83 1.68
N
19.83 1.68
O 18.19 1.73
P
25.64 1.83
Q
21.55 1.83
R
29.39 1.93
X
6.78 2.10
Y
1.33 1.86
Bearing 1
1.00 1.00
Bearing 2
6.16 1.07

A. ROTATIONAL BOUNDARY CONDITIONS

Rotational boundary conditions were assigned to the different zones of 2D Axis-symmetry model as shown in table V. HPT, LPT and HP
compressor are considered as rotating walls with suitable rotational speed.
426. Shivakumar Kandre, Shri. Siva Shankara Reddy and Dr. K.S.Shashi Shekar,. CONJUGATE HEAT
TRANSFER ANALYSIS OF DISC AND SECONDARY AIR SYSTEM OF GAS TURBINE. Journal for
Advanced Research in Applied Sciences; Pages: 422-427

TABLE V. NORMALIZED ROTATIONAL BOUNDARY CONDITIONS for DIFFERENT ZONES of COMPLETE GEOMETRY

ZONE SPEED

High pressure turbine 1.46

Low pressure turbine 1

Fluid 0
Solid stationary 0

VI. RESULTS AND DISCUSSIONS

The CHT analysis is carried out for complete secondary air path to estimate the temperature distribution in the disc and secondary air region
and also to study the effect of heat transfer between discs, mainstream and secondary air.

Fig.6. Contours of total temperature for complete geometry

Fig.7. Contours of static temperature for complete geometry

Temperature contours are plotted for complete secondary air path as shown in fig 6 and 7. It is observed that the normalised temperature
distribution is linear throughout the disc and temperature at the tip of the rim is higher and is gradually decreasing as heat conducts towards bore
and also because of secondary air coming in contact with disc where it flows from bore towards the rim. Maximum temperature is recorded with
HP turbine and is at the pre-swirl nozzle because of high pressurized gas coming out of pre-swirl nozzle with high temperature. Lower
temperature is at HPC shaft bearing because of minimum bearing convective load. Temperature gradient is maximum at 6th stage of high
pressure compressor disc.

A. TOTAL TEMPERATURE VARIATION ALONG DISC HEIGHT

Fig.8. Total temperature variations along disc height

427. Shivakumar Kandre, Shri. Siva Shankara Reddy and Dr. K.S.Shashi Shekar,. CONJUGATE HEAT
TRANSFER ANALYSIS OF DISC AND SECONDARY AIR SYSTEM OF GAS TURBINE. Journal for
Advanced Research in Applied Sciences; Pages: 422-427

Above graph shows variations of total temperature over the disc height. It is observed that total temperature is maximum at HPT disc and
minimum at the HPC 1st stage. Also, temperature of the disc is gradually decreasing from the rim section of the disc to the bore of the disc, as
disc is exposed to relatively cool air at the bore. Temperature gradient is maximum at the 6th stage of HPC. Gradients are within the allowable
limit and is as follows

T = Trim Tbore

1. MASS FLOW RATE REPORTS:

Mass flow rate reports is one of the important parameter for the convergence of the solution and it clearly signifies that, total mass or energy of
the fluid flows through a boundary of physical model. From the table number vi, it is found that mass flow rate is maximum at the inlet 3 and
minimum at inlet 2 because of varying parameters like density of the fluid, area across which fluid is flowing and velocity of the fluid. It is
observed that, net mass flow rate of 1E-03 is less than 1% of smallest mass flow at the inlet 2 of 0.192. Hence this is taken as a converged
solution.

TABLE.VI. MASS FLOW RATE REPORTS AT THE BOUNDARIES

BOUNDARIES MASS FLOW RATE (Kg/s)

inlet 1 0.670
inlet 2 0.192
inlet 3 2.429
inlet 4 1.400
outlet 1 -0.258
outlet 2 -0.478
outlet 3 -0.394
outlet 4 -0.413
outlet 5 -0.580
outlet 6 -2.143
outlet 7 -0.423
NET mass flow rate 1E-06

NOMENCLATURE
T- Temperature difference in K
Trim Temperature at the rim in K
T bore Temperature at the bore in K

VII. CONCLUSION
Conjugate heat transfer analysis is carried out for complete secondary air path that includes high pressure compressor, high pressure turbine
followed by low pressure turbine disc and also estimation of temperature distribution in the region of fluid domain and disc. The effect of
conduction and convective heat transfer on the disc metal temperature is studied to simulate secondary air cooling effectiveness. Total
temperatures of complete secondary air path are discussed with temperature distribution being linear along the disc and secondary air region.
Temperature values of all the components lie well below the maximum allowable temperature of respective material.

REFERENCES
[1]. Taruk Nada. Performance characterization of different configuration of gas turbine Vol.121, August 2013

[2]. Sparrow E.M., Eckert E.R.G., Buszkiewiez T.C., (1975), " Heat transfer and temperature field experiments in a cavity with rotation,
recirculation and coolant through flow", Journal of heat transfer/ Transaction of ASME, Vol. 89, pp. 255-268.

[3]. Gunther., andreuffrecht.,(2012), Local Measurements of Disk Heat Transfer in Heated Rotating Cavities for Several Flow Regimes,
journal of turbo machinery, vol.134,No 5, p051016-1 0510169