UTSR Summer Fellowship: Siemens Energy Lincoln DiLorenzo PG GT EN LGT RC TURB SP August 4 th, 2017

Transcription

1 UTSR Summer Fellowship: Siemens Energy Lincoln DiLorenzo PG GT EN LGT RC TURB SP August 4 th, 2017

2 Agenda Background Patent Search Heat Transfer Validation Conclusion Page 2

3 Background From Billings, MT Undergrad at Montana State University Mechanical Engineering major Aerospace and Mathematics minors Graduating Spring 2018 Page 3

4 Patent Search Goal Find and collect patents related to AM applied to gas turbine components Organize and place patents in accessible location to save time in future Results 175 patents narrowed down to 64 Additional 49 patents uploaded to database Categories Blade/vane (11), ring segment (5), other components (19), repair (5), material (9), process/system (64) Uploaded to database PowerPoint file summarizing and depicting pictures of each patent Page 4

5 Patent Search: Example Gas Turbine Blade with Corrugated Tip Wall Patent No.: US A1 Siemens (Campbell C, Kulkarni A, Eshak D, James A, Behling P, Kamel A) Filed: Apr. 27, 2016 Advantage: The weight of the turbine blades is reduced thus the design of ever larger machines is facilitated. The core stiffness is improved by the reduced length and core positioning is facilitated. The turbine blade is easy to manufacture and has higher yield, and the turbine engine efficiency is increased. Page 5

6 Patent Search: Example Method for Additively Constructing Internal Channels Patent No.: US A1 United Technologies Corp Filed: Jan. 14, 2015 Advantage: The cooling air flowing through the channel is not blocked and the component is actively cooled as efficiently as designed. The cooling channels are effectively operated at their intended efficiency levels and the high-volume additive production is effectively achieved. The post-processing costs are effectively minimized. The more effective and smaller volume internal cooling channels are effectively utilized. Page 6

7 Patent Search: Example Method for Additively Manufacturing an Article Made of a Difficult-to-Weld Material Patent No.: US A1 Alstom Technology Filed: Jun. 13, 2014 Advantage: The article with reduced number of voids, cracks and pores, and improved mechanical properties is easily manufactured. Page 7

8 Heat Transfer Validation Gas Turbine Cooling: Moving from Macro to Micro Cooling Claims coolant reductions up to 25% and thermal gradient reductions of 50% Simple back calculations led to discrepancies in numbers presented Goal Replicate work to validate or debunk claims Page 8

9 Heat Transfer Validation Discrepancy Air properties at 608 C and 20.4 bar k=0.062 W/m/K HTC=3190 and 1262 W/m 2 /K for skin and bulk respectively Page 9

10 Heat Transfer Validation: Thermal Gradient Problem Setup Micro Cooling (ANSYS Mechanical APDL, MATLAB post processing) Bulk Cooling (Excel) Similar to micro cooling Conditions in micro channel were applied to cavity surface 1D series composite wall Page 10

11 Heat Transfer Validation: Thermal Gradient Results Bulk Cooling Percent difference: % Page 11

12 Heat Transfer Validation: Thermal Gradient Results Bulk Cooling Percent difference: % Page 12

13 Heat Transfer Validation: Thermal Gradient Results Bulk Cooling Percent difference: % Page 13

14 Heat Transfer Validation: Thermal Gradient Results Micro Cooling Percent difference: % Page 14

15 Heat Transfer Validation: Thermal Gradient Results Micro Cooling Percent difference: % Page 15

16 Heat Transfer Validation: Thermal Gradient Results Micro Cooling Percent difference: % Page 16

17 Heat Transfer Validation: Thermal Gradient Results Bulk Cooling vs. Micro Cooling Temperature gradient: K K Bulk cooling was up to 1.8 times the maximum found in micro cooling Bunker: Bulk cooling was up to 2.3 times maximum of micro cooling 90.4 K for bulk cooling and 39 K for micro cooling Page 17

18 Heat Transfer Validation: Coolant Savings Problem Setup Bulk cooling Simple 3-pass serpentine mid-chord cooling circuit Micro cooling Array of 200 channels covering same external surface area as bulk cooling Page 18

19 Heat Transfer Validation: Coolant Savings Results Air properties at 608 C and 20.4 bar Coolant flow percent difference: 25.4% Page 19

20 Heat Transfer Validation Conclusion Results met expected trends Unsure why differences between Bunker and calculations exist Micro cooling offers better cooling than bulk cooling Thermal gradient reduction of 45% Coolant flow reduction of 25.4% Savings can result in improvements in overall thermal efficiency and power output of gas turbines Page 20

21 Conclusion Positive experience overall Learning experience Engineering ANSYS Mechanical, NX, plastic 3D printing, AM, gas turbine Professional Corporate structure, communication, importance of smaller things Improvements Apartment hunting Technical work Progress meetings Get permissions prior to start of internship (Linux account, etc) Highlights Tours FAST Warehouse, Casselberry Labs, Wind Power Facility, Power Diagnostics Center and Simulation Room Executive Speaker Series Page 21

22 Thank You Lincoln DiLorenzo PG GT EN LGT RC TURB SP UTSR Intern Page 22