jet engine design competition / cooling design …surface of the vane, average temperature and life...
TRANSCRIPT
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JET ENGINE DESIGN COMPETITION /
COOLING DESIGN COMPETITION IN
TURBINE ENGINES
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TABLE of CONTENTS
1. General Content of the Competition ............................................................................................... 5
2. Vane Design Technical Specifications and Restrictions ................................................................. 5
2.1. Vane Physical Limitations ...................................................................................................... 5
2.2. Vane Physical Limitations ...................................................................................................... 7
2.2.1. Design Point Inputs ......................................................................................................... 8
2.2.2. Design Point Requirements ............................................................................................. 9
3. Competition Schedule, Scoring and Evaluation.............................................................................. 9
3.1. Competition Schedule ............................................................................................................. 9
3.2. Preliminary Design Report...................................................................................................... 9
3.3. Critical Design Report .......................................................................................................... 10
3.4. Manufacturing, Assembly and Tests ..................................................................................... 11
3.5. Scoring and Evaluation of the Competition .......................................................................... 11
3.5.1. Scoring and Evaluation of the Reports.......................................................................... 11
3.5.2. Test Scoring and Evaluation ......................................................................................... 12
3.5.3. Total Scoring ................................................................................................................. 12
4. Awards .......................................................................................................................................... 12
4.1. Minimum Success Criterion for Award ................................................................................ 12
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FIGURES
Figure 1 3D view of a vane ..................................................................................................................... 6
Figure 2 Vane meridional dimensions (mm) .......................................................................................... 7
Figure 3 Larson-Miller Parameter curves ............................................................................................... 7
Figure 4 Cooling air and hot gas path details .......................................................................................... 8
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TABLES
Table 1 Design inputs ............................................................................................................................. 6
Table 2 Design requirements .................................................................................................................. 6
Table 3 Engine performance cycle .......................................................................................................... 8
Table 4 Competition schedule................................................................................................................. 9
Table 5 Scoring the reports ................................................................................................................... 11
Table 6 Preliminary design report scoring ............................................................................................ 11
Table 7 Critical design report scoring ................................................................................................... 12
Table 8 Details of cold flow test scoring .............................................................................................. 12
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1. General Content of the Competition
The competition is suited for undergraduate and graduate students. The aim of this competition is to
draw attention gas turbine engines and related technologies as an outreach activity among students.
This document presents all the rules, requirements and regulations for “Jet Engine Design Competition
/ Cooling Design Competition in Turbine Engines” within the subset of “Technology Competitions” of
the TEKNOFEST Aerospace and Technology Festival (TEKNOFEST). In this competition, the cooling
of Nozzle Guide Vanes (NGV) inside a high pressure turbine module is aimed at. Participating teams
are expected to design optimum cooling configuration for NGVs based on the design requirements
documented in here and to report it thoroughly. This document is comprised of the rules, regulations
and constraints of the competition.
Designed NGVs are going to be manufactured by TEI; cold flow tests and hot thermal paint tests are to
be conducted within TEI. Team in TEI shall provide testing support.
The deadline for the completion of application form is 15.03.2020. Participating teams shall only
provide a single design and shall involve 5 members.
Applications shall be done through the official web site “TEKNOFEST Technology Competitions“
(www.teknofest.org).
General Information: The designs for the first six teams are going to be manufactured using additive
manufacturing and to be subjected to cold flow tests proving the designed cooling flow rates. The
designs for the first three teams based on cold flow tests are going to be subjected to hot thermal paint
tests. First three teams are going to be displayed in TEI stand in exhibition day and the first design is
going to be announced at TEKNOFEST.
2. Vane Design Technical Specifications and Restrictions
The cooling design, to be placed in the turbine vane geometry provided by TEI, must be in accordance
with the specified physical limitations and meet the manufacturability, cooling and life requirements.
A 3D view of the sample vane is presented in Figure 1. Table 1 lists the overall design inputs.
2.1. Vane Physical Limitations
The dimensions given in the physical limitations are those that must be obeyed for the vane at room
temperature. The meridional dimensions of the vane are presented in Figure 2. The geometry will also
be shared in * .stp format.
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Figure 1 3D view of a vane
Table 1 Design inputs
Parameter Value Details
Design
Inputs
Performance cycle Table 3
For the vane sizing, the performance
cycle specified in Table 3 should be
used.
Geometric dimensions Figure 2
Cooling design should be made in
accordance with the vane dimensions
given in Figure 2.
Material specifications CM 247 LC
DS
The Larson-Miller curve given in Figure
3 can be used.
Table 2 Design requirements
Design
Requirements
Parameter Value Details
Max temperature [K] 1400 Maximum permitted temperature value on vane
surface
Average temperature
[K] 1250
Maximum permitted average temperature value
at vane 50% cross section
Life [hour] 5000 Creep life required by the vane
Cooling Air Ratio (%
W2) %7 W2
Maximum cooling air flow rate that can be used
in vane cooling
Back Flow Margin
(BFM) %1.1
Minimum back flow margin expected from vane
cooling design
Back flow margin percent:
The value obtained by subtracting 1 from the
ratio of air total pressure to hot gas path
pressure after cooling
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Figure 2 Vane meridional dimensions (mm)
The Larson-Miller Parameter (LMP) curves that should be used in life calculations are presented in
Figure 3. In LMP calculations, temperature should be taken in °C and time in hours.
Figure 3 Larson-Miller Parameter curves
2.2. Vane Physical Limitations
The air flow rate to be used for the turbine vane cooling design is limited to the compressor air flow
rate specified in Table 2. The design shall meet the requirements of maximum temperature on the outer
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surface of the vane, average temperature and life of 50% cross section with the specified cooling air
flow rate.
2.2.1. Design Point Inputs
The engine cycle values given in Table 3 will be used for the turbine vane cooling configuration to be
designed. The cycle values refer to the average and nominal values at certain stations of the engine.
Contest teams can make the changes they want within the geometry, which have a specified material,
dimensions and working conditions, by taking into consideration the manufacturability conditions. In
addition, as long as technical details are explained, they can use design inputs to create new inputs or
requirements.
Table 3 Engine performance cycle
Parameter Value Details
Tt4 [K] 1600 Turbine inlet average total temperature
Pt4 [kPa] 1180 Turbine inlet total pressure
OTDF (Overall temperature
distribution factor) [-] 0.2 Turbine inlet normalized maximum
temperature
W2 [kg/s] 3.20 Engine inlet air mass flow rate
W4 [kg/s] 2.72 Turbine inlet air mass flow rate
Tcooling [K] 700 Cooling air total temperature
Pcooling [kPa] 1200 Cooling air total pressure
The cooling air and hot gas flow path is shown in Figure 4.
Figure 4 Cooling air and hot gas path details
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2.2.2. Design Point Requirements
The goal of the designed cooling configurations is to achieve an optimum cooling design that will
provide the vane life requirements without exceeding the maximum cooling air flow rate that given in
Table 2. While performing this task, it is expected to be demonstrated by calculations or analyzes that
the temperature values specified in the limitations section are not exceeded. There is no specific
calculation method demanded in order to demonstrate that the requirements are fulfilled. As long as
technical details can be explained contest teams can use any method from hand calculations to complex
simulations. The values stated in the reports will be verified for manufactured prominent designs first
by cold flow tests and then thermal dye tests.
3. Competition Schedule, Scoring and Evaluation
Evaluation will be done in four different categories. Preliminary design report, critical design report,
cold flow tests and thermal paint tests will be scored.
Teams those do not submit preliminary design and / or critical design reports will not be eligible to
continue the competition. The schedule of the competition is given in Table 4.
3.1. Competition Schedule
Competition schedule is given in Table 4.
Table 4 Competition schedule
Date Details
15 March 2020 Competition application deadline
28 March 2020 Preliminary design report deadline
13 April 2020 Announcement of the teams who proceed to
critical design stage
15 June 2020 Critical design report deadline
29 June 2020 Announcement of the final teams
20 July 2020 Manufacturing of the final designs and cold flow
tests
24 August 2020 Thermal paint tests of the final designs based on
cold flow tests
14 September 2020 Announcement of the winning team
22-27 September 2020 TEKNOFEST
3.2. Preliminary Design Report
The teams are obliged to submit preliminary design reports on 28 March 2020. The following details
should be included in the preliminary design report.
• Turbine Vane Cooling Design Configuration
o Internal Channel Design (channel, holes, geometric cooling suggestions, etc.)
o Details of Cooling Configurations (film cooling, impingement, serpentine, etc.)
• Vane External Boundary Conditions
o Calculated Boundary Conditions
o Heat Transfer Coefficient Calculations
▪ eg: Flat Plate and Cylinder in Crossflow HTC etc.
• Determination of Internal Channel Flow Solution Method
o Mass Flow Rate Calculation Method
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o Pressure, Temperature, and Velocity Calculation Method
• Determination of Metal Temperature Solution Method
• Determination of Cooling Effectiveness
• Prediction of Metal Temperature
o Maximum Metal Temperature
o Bulk Metal Temperature (average)
• Determination of Life Calculation Method
The assumptions used for the design should be specified in the report. For unspecified assumptions,
points will be broken.
It is necessary to show all provided and obtained requirements, boundary conditions and constraints in
the report.
In order to proceed to the next stage of this competition, the preliminary design report (PDR) should be
submitted and approved. A qualification will be performed according to the results of the PDR and the
teams that pass the assessment will be qualified to proceed to the next stage. Teams that have passed
the critical design stage will be announced on 13 April 2020.
3.3. Critical Design Report
The teams are obliged to submit critical design reports on 15 June 2020. The following details should
be included in the critical design report.
• Turbine Vane CAD Model (*.stp, cooling details should be shown)
• Calculation Details of Preliminary Design Report (PDR)
• Back Flow Margin (BFM) Calculation
• 1-D Flow Network/Hand Calculation Results (for the internal channel cooling design)
o Explanation of Method
o MFR Results
o Pressure, Temperature, and Velocity Results
• 1-D Flow Network/Hand Calculation for the Cold Flow Test (pressure ratio will be provided)
o MFR Results
• 1-D Heat Transfer Analyses/Hand Calculation Results
o Explanation of Method
o Metal Temperature Distributions
▪ Pressure Side
▪ Suction Side
▪ Temperature distribution in the different sections
• CFD Analyses (Optional)
• Details of Life Calculations
Boundary conditions used in all analyses/calculations should be specified in the report. Teams that have
passed the critical design are obliged to demonstrate accuracy of their analysis/calculation accuracy.
(simple hand calculation and comparison with correlations, etc.) Otherwise, teams will be considered
unsuccessful. The assumptions used for the design should be specified in the report. For unspecified
assumptions, points will be broken. It is necessary to show all provided and obtained requirements,
boundary conditions, and constraints in the report.
In order to proceed to the next stage of this competition, the critical design report (CDR) should be
submitted and approved. A qualification will be performed according to the results of the CDR.
According to CDR, first six teams will be qualified to proceed to the cold flow test stage. According to
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cold flow test results, first three teams will be qualified to proceed to the thermal paint test stage. Teams
that have passed the thermal paints test stage will be announced on 29 June 2020.
3.4. Manufacturing, Assembly and Tests
Designs those have passed the CDR stage will be manufactured and tested by considering the ease of
assembly and testability within TEI. The raw material needed for manufacturing will be provided by
the organization. The best six designs those ensure the cooling design effectiveness shown in the CDR
with the use of appropriate air mass flow rate by analytical or numerical methods will be tested. The
tests will consist of two stages; in the first stage, cold flow tests will be performed and the flow function
characteristic of the blade will be determined (flow function vs. pressure ratio characteristic). In the
second stage, thermal paint tests will be performed to the best three design according to first stage tests
and cooling effectiveness will be evaluated in these tests. After the tests, the data will be evaluated and
the winning team will be determined by performance comparison (cooling air usage, cooling
effectiveness and integrity).
3.5. Scoring and Evaluation of the Competition
The scoring of the competition consists of three parts. First part is scoring the reports and second part
is scoring the cold flow test results. The final part is scoring the thermal paint test results.
3.5.1. Scoring and Evaluation of the Reports
The following table lists report scoring types and percentages. Scoring will be done out of 100 and half
of the total score will come from reports. Report scoring is given in Table 5.
Table 5 Scoring the reports
Preliminary Design Report (PDR) % 15
Critical Design Report (CDR) % 35
3.5.1.1. Preliminary Design Report Scoring
Teams those score 60 or more out of 100 from the preliminary design report will be able to move to the
critical design stage. Preliminary design report scoring details are given in Table 6.
Table 6 Preliminary design report scoring
Calculation details of vane external
flow boundary conditions
15
Vane internal cooling flow details 15
Details of vane cooling design 30
Cooling effectiveness 15
Life calculation method 15
Documentation 10
Total 100
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3.5.1.2. Critical Design Report Scoring
The six teams with the highest score will be determined according to the scoring given below. Critical
design report scoring is presented in Table 7.
Table 7 Critical design report scoring
Parameter Value Details
Max temperature [K] 20 Designs below 1400 K will take full points.
Average temperature [K] 20 Designs below 1250 K will take full points.
Life [hour] 15 Designs above 5000 hours life will take full points.
Cooling Flow Rate (% W2) 25 Designs with cooling flow rate below %7 W2 will
take full points.
Back Flow Margin (BFM) 10 Designs with %1.1 BFM will take full points.
Documentation 10
Total 100
3.5.2. Test Scoring and Evaluation
The table 8 lists the scoring types and scores. Scoring will be made out of 100 and test will constitute
half of the total score.
Table 8 Details of cold flow test scoring
Consistency of Analysis with
Measurements
Total Cooling Flow Rate 30
[1 − |𝑇𝑒𝑠𝑡 𝑅𝑒𝑠𝑢𝑙𝑡−𝐴𝑛𝑎𝑙𝑦𝑠𝑖𝑠 𝑅𝑒𝑠𝑢𝑙𝑡
𝑇𝑒𝑠𝑡 𝑅𝑒𝑠𝑢𝑙𝑡|] ∗ 𝑅𝑒𝑙𝑎𝑡𝑒𝑑 𝑆𝑐𝑜𝑟𝑒
Total Cooling Effectiveness 40
Cooling Integrity 15
Ease of Manufacturing 15
Total 100
3.5.3. Total Scoring
The total score at the end of the competition will be maximum 100 and will be calculated as follows.
Total score = 0.15 * PDR Score + 0.35 * CDR Score + 0.20 * Cold Flow Test Score + 0.30 * Thermal
Paint Test Score
4. Awards
4.1. Minimum Success Criterion for Award
The first three teams those successfully complete the cold flow tests will pass to thermal paint tests.
Those teams will be eligible for the award ranking.
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5. GENERAL RULES AND REGULATIONS
● Teams have the right to object to the concerned judge through their team leaders.
Objections can be made verbally, provided that they are submitted in writing at a later time.
Verbal objections must be put in writing within 24 hours. In any case, non-written
objections will not be taken into consideration. Objections will be finalized within 24 hours
after having examined by the judge panel.
● Each contestant is responsible for taking the necessary precautions and showing the
expected attention to his/her peers and the environment.
● Turkish Technology Team (T3) Foundation and the organisation committee reserve the
right to make any amendments to the specifications in order for the contest to take place in
accordance with the specified impartial criteria so that any violations may result in judicial
outcomes, to better meet all sorts of requirements by the contestants, to provide necessary
safety precautions and to maintain the functionality of the contest specifications.
● Having made the necessary evaluations following the application deadline, T3 Foundation
and the organisation committee reserves the right to cancel the contest given that sufficient
number of applications is not reached with the required technical knowledge and skills.
● TEKNOFEST Safety and Security Terms and Conditions will be communicated to all
contestants, delegations and concerned parties. All competing teams are responsible for
observing the safety terms and conditions specific to their respective categories specified
in TEKNOFEST Safety and Security Terms and Conditions. In this regard, with the
exception of security precautions contained in the aforementioned security instructions, it
is the contestants’ responsibility to take additional precautions arising from the systems
employed.
● T3 Foundation and the organisation committee has the right to exclude any and all teams
from the contest who do not fulfill the terms and conditions of TEKNOFEST Safety and
Security Terms and Conditions to provide a safe environment for holding the contest. T3
Foundation and organisation officials cannot be held responsible for damages arising from
the violation of terms and conditions by the contestants, delegations and concerned parties.
● Regarding the competition, the competitor hereby accepts and consents to any kind of
written or visual promotion, publication, social media and internet broadcasting to be made
by the T3 Foundation and / or TEKNOFEST before or after the competition. In addition,
the competitor agrees and submits that any and all intellectual property generated as
pertains to the competition, including but not exclusive to designs, code, and manufactured
products, belongs exclusively to the T3 Foundation and / or TEKNOFEST and that the
competitor does not have any rights to or demands on these artifacts. T3 reserves the right
to disclose all intellectual property thereby for public consumption in a manner it deems
fitting.
● In the event that a competitor infringes upon the intellectual property rights of any product,
and T3 Foundation and/or TEKNOFEST incur damages, the responsibility for such
damages will be borne entirely by the relevant participant(s).
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● All teams who qualify to compete in the contest will be given a Participation Certificate.
● STATEMENT OF LIABILITY
● Turkish Technology Team Foundation and TEKNOFEST are in no way liable for any
injury or damage caused by any entry, any entrant, or by the disqualification of an entry.
Turkish Technology Team Foundation and TEKNOFEST at large are not responsible for
ensuring teams operate their systems within the law of the Turkish Republic. The Turkish
Technology Team Foundation and TEKNOFEST, and organisation officials cannot be held
responsible for the damages inflicted upon third parties by the contestants.
Turkish Technology Team Foundation has the right to make any amendments to this
terms and conditions.