Summer 2013 Internship Exit Presentation

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Beverly Lloyd
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1 Summer 2013 Internship Exit Presentation Matt Stinson Heat Transfer Group 7/26/2013 Mentor: Luzeng Zhang Heat Transfer Manager: Hee-Koo Moon

2 Harbor Drive Evacuation Map

3 Presentation Outline Personal Background Projects Heat Exchanger Addition to Scaled Cascade Rig Phantom Cooling Data Processing and Analysis Experimental Pressure Sensitive Paint Numerical CFD Summer Fun Acknowledgements Questions

4 Personal Background From Federal Way, WA Education B.S. in ME (2009), Purdue University Minor in EE Ph.D. in ME (2014), University of Minnesota Minor in AE Studying film-cooling on turbine endwalls

to winter months Objectives Research and design/select a heat exchanger to cool air in wind tunnel Consider various

5 Heat Exchanger Addition to Scaled Cascade Rig Background Scaled cascade utilizes pressure sensitive paint technique High temperatures in tunnel leads to low luminescent intensity and relatively high noise level Facility use is limited to winter months Objectives Research and design/select a heat exchanger to cool air in wind tunnel Consider various coolant sources Design how heat exchanger fits into current system Schematic of Scaled Cascade Rig T-250 Stage 1 Nozzle Cascade

6 Specific Requirements/Goals Heat exchanger requirements Air flow rates up to 7000 SCFM at 10 psig Cool air by at least 30 F / below 170 F Limit air side pressure drop to 0.5 psi Additional ~20 F T_in = 88 F Required ~10 F T_in = 68 F Spencer Blower Temperature Outlet Curve (Inlet T = 68 F)

7 Heat Exchanger Design Design basics Thermally balanced designs are most economical Shell and Tube Heat Exchanger ( ha ) = ( ha) h c Finned surfaces tend to be more economical, but limit operating conditions Tube-Fin Heat Exchanger Plate-Fin Heat Exchanger

8 Tube-Fin Heat Exchanger Commonly used in car radiators and HVAC applications Cross-flow arrangement Individually finned Rugged High heat transfer Continuously finned Inexpensive Low pressure drop Left: Individual fins, Right: Continuous plate fins

9 Will it work? Example performance Fixed tube-fin layout Variable rows Variable face area Variable water coolant Inlet Conditions: Air: 7000 SCFM, p in = 10 psig, T in = 200 F Water: T in = 85 F Relationships T 5 N p A A 0. N fr rows rows 2 fr Temperature drop, F Heat Exchanger Performance L=24", N=2, pdrop=0.020 psi L=24", N=6, pdrop=0.058 psi L=36", N=2, pdrop=0.005 psi L=36", N=6, pdrop=0.013 psi L=30", N=4, pdrop=0.017 psi gal/min

10 Selected Heat Exchanger Design conditions Air 8000 SCFM T in = 200 F, p in = 10 psig Water T in = 85 F Air-side performance Δp = 0.07 psi Water-side performance Δp = gpm Heat exchanger specs Weight = 500 lb Flange-to-flange = 50 Max Width = 46 5 Price: $ Air Temperature Drop, F Heat Exchanger Performance Treated Water Intermediate Fouling Untreated Water Water Flow, gal/min

11 Coolant Source 1. Cooling tower water Evaporative cooling Already in service Capable of meeting coolant demands Fouling concerns 2. Closed loop chiller Significant footprint Increased costs No fouling concerns

material, slow to foul Maintain flow rates above 4 ft/s (25 GPM) High shear stress, controls

12 Fouling Control Fouling control steps 1/8 mesh screen pre-filter Protects against macrofouling Copper tubes Naturally antimicrobial, controls biofouling Smooth-walled material, slow to foul Maintain flow rates above 4 ft/s (25 GPM) High shear stress, controls fouling buildup Maximum water temperature maintained below 140 F Controls precipitation fouling Limescale Biofoul

5 gpm) Galvanic corrosion Protects against erosion corrosion Maintenance recommendations Cycle

13 Corrosion Control and Maintenance Corrosion control steps Insulating connectors at heat exchanger inlet/outlet Protects against galvanic corrosion Maintain water flow rates less than 6 ft/s (37.5 gpm) Galvanic corrosion Protects against erosion corrosion Maintenance recommendations Cycle water at least twice a week Controls against corrosion and biofilm buildup Erosion corrosion around a bend

14 Heat Exchanger Location Options 1. On Roof Easy access Roof supports heat exchanger Section needed for venturi flow straightener 2. At blower outlet Structure required to support heat exchanger 3. At blower inlet Structure required to support heat exchanger Ducting unchanged No driving temperature difference Current Blower and Ducting Installation

15 Heat Exchanger Installation Making room in ducting for Heat Exchanger Heat Exchanger Installation Location

16 Heat Exchanger Support Table Table to support heat exchanger

17 Table Safety Rails and Stairs Table safety rails and stair installation

18 View Including Solar Perimeter Fence Street View

Phantom Cooling Background Phantom cooling is a branch of film cooling in which secondary flows are doing the cooling Examples 1. Nozzle surface coolant cools the adjacent endwall surface 2.

19 Phantom Cooling Background Phantom cooling is a branch of film cooling in which secondary flows are doing the cooling Examples 1. Nozzle surface coolant cools the adjacent endwall surface 2. Nozzle surface coolant cools downstream blade surface Understanding phantom cooling leads to more optimized cooling schemes Objectives PSP Clean up PSP results for display CFD Build macro to extract spanwise averaged temperatures along blade surface Determine blade surface adiabatic effectiveness Run additional CFD cases to determine maximum cooling PS and SS coolant cooling the endwall surface Spent nozzle coolant cooling blade suction surface

Tecplot Showerhead (SH1-6) Pressure side (PS1) Suction side

20 PSP Image Processing Used matlab script to clean noise Optimized old matlab script 2 min process 10 sec Got experience with Tecplot Showerhead (SH1-6) Pressure side (PS1) Suction side (SS2) Suction side (SS1) Figures prior to cleaning Figures after cleaning

21 CFD Analysis Velocity triangle analysis Cooling ejection cylinder a) VR=0.4, b) VR=0.5, c) VR=0.6 Top View of T-65 Blade Cascade Model with eight cooling hole positions

22 CFD Postprocessing CFD result files Built macro to extract spanwise averaged temperature along wall Sample results VR = 0.4, hole position 6 Velocity Streamlines at blade mid-span Temperature contour at blade mid-span

23 Blade Surface Effectiveness Average Blade Wall Adiabatic Effectiveness (Definition 1) 0.1 Definition 1: Approximate definition VR04 η aw T = T aw c0 T T 0 0 eta 0.05 VR VR PS s/c SS Average Blade Wall Adiabatic Effectiveness (Definition 2) Definition 2: Proper definition eta VR04 VR05 VR06 η T aw r T = T = T aw c0 0 T T r r 2 V (1 r) 2c p r 3 Pr PS s/c SS

24 Summer Fun Taco Tuesday Hiking El Cajon Cowles Mountain Mount Woodson Torrey Pines Iron Mountain Three Sisters San Diego Zoo Scenery Weather

25 Acknowledgements Thank you to the following: Luzeng Zhang Hee-Koo Moon John Mason Gail Doore Rotation Engineers Fellow Interns UTSR Program Kelsey Stinson Eric Eggett Don Mariani Juan Yin Kevin Liu Archie French Tim Bridgeman Don Leroux

26 Questions

Complete HVAC Capability. Central Station Air Handling Units. Publication No. WT-CSX-0616A

Complete HVAC Capability. Central Station Air Handling Units. Publication No. WT-CSX-0616A Publication No. WT-CSX-0616A Central Station Air Handling Units Complete HVAC Capability Horizontal Draw-Thru to Size 65 Vertical Draw-Thru to Size 50 1000 to 60,000 CFM Forward Curved or Airfoil Wheels