summer 2013 internship exit presentation · summer 2013 internship exit presentation matt stinson...
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![Page 1: Summer 2013 Internship Exit Presentation · Summer 2013 Internship Exit Presentation Matt Stinson Heat Transfer Group . 7/26/2013 . Mentor: Luzeng Zhang . Heat Transfer Manager: Hee-](https://reader035.vdocuments.us/reader035/viewer/2022070806/5f04a9a87e708231d40f159a/html5/thumbnails/1.jpg)
Summer 2013 Internship Exit Presentation
Matt Stinson Heat Transfer Group
7/26/2013
Mentor: Luzeng Zhang
Heat Transfer Manager: Hee-Koo Moon
![Page 2: Summer 2013 Internship Exit Presentation · Summer 2013 Internship Exit Presentation Matt Stinson Heat Transfer Group . 7/26/2013 . Mentor: Luzeng Zhang . Heat Transfer Manager: Hee-](https://reader035.vdocuments.us/reader035/viewer/2022070806/5f04a9a87e708231d40f159a/html5/thumbnails/2.jpg)
Harbor Drive Evacuation Map
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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
![Page 4: Summer 2013 Internship Exit Presentation · Summer 2013 Internship Exit Presentation Matt Stinson Heat Transfer Group . 7/26/2013 . Mentor: Luzeng Zhang . Heat Transfer Manager: Hee-](https://reader035.vdocuments.us/reader035/viewer/2022070806/5f04a9a87e708231d40f159a/html5/thumbnails/4.jpg)
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
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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
T-250 Stage 1 Nozzle Cascade Schematic of Scaled Cascade Rig
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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
Spencer Blower Temperature Outlet Curve (Inlet T = 68 F)
Required ~10 F cooling @ T_in = 68 F
Additional ~20 F cooling @ T_in = 88 F
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Heat Exchanger Design
• Design basics – Thermally balanced
designs are most economical •
– Finned surfaces tend to be more economical, but limit operating conditions
ch hAhA )()( =
Shell and Tube Heat Exchanger
Tube-Fin Heat Exchanger
Plate-Fin Heat Exchanger
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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
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Will it work?
• Example performance – Fixed tube-fin layout
– Variable rows
– Variable face area
– Variable water coolant
– Inlet Conditions: • Air: 7000 SCFM,
pin = 10 psig, Tin = 200 F
• Water: Tin = 85 F
• Relationships –
– 2fr
rows
ANp ∝∆
rowsfr NAT 5.0∝∆
0 10 20 30 40 50 60 70 80 90 1000
10
20
30
40
50
60
70
80
90
100
gal/min
Tem
pera
ture
dro
p, F
Heat Exchanger Performance
L=24", N=2, pdrop=0.020 psiL=24", N=6, pdrop=0.058 psiL=36", N=2, pdrop=0.005 psiL=36", N=6, pdrop=0.013 psiL=30", N=4, pdrop=0.017 psi
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Selected Heat Exchanger
• Design conditions – Air
• 8000 SCFM • Tin = 200 F, pin = 10 psig
– Water • Tin = 85 F
• Air-side performance – Δp = 0.07 psi
• Water-side performance – Δp = 2.5 psi @ 25 gpm
• Heat exchanger specs – Weight = 500 lb – Flange-to-flange = 50” – Max Width = 46” – Price: $8000 0
5
10
15
20
25
30
35
40
45
50
20 25 30 35 40
Air
Tem
pera
ture
Dro
p, F
Water Flow, gal/min
Heat Exchanger Performance
Treated Water
Intermediate Fouling
Untreated Water
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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
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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
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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) • Protects against erosion
corrosion
• Maintenance recommendations – Cycle water at least twice a
week • Controls against corrosion and
biofilm buildup
Galvanic corrosion
Erosion corrosion around a bend
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Heat Exchanger Location Options
Current Blower and Ducting Installation
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
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Heat Exchanger Installation
Making room in ducting for Heat Exchanger Heat Exchanger Installation Location
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Heat Exchanger Support Table
Table to support heat exchanger
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Table Safety Rails and Stairs
Table safety rails and stair installation
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Street View
View Including Solar Perimeter Fence
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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
Spent nozzle coolant cooling blade suction surface PS and SS coolant cooling the endwall surface
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PSP Image Processing
• Used matlab script to clean noise – Optimized old matlab script
• 2 min process 10 sec
• Got experience with Tecplot
Figures prior to cleaning Figures after cleaning
Showerhead (SH1-6)
Pressure side (PS1)
Suction side (SS1)
Suction side (SS2)
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CFD Analysis
Top View of T-65 Blade Cascade Model with eight cooling hole positions
Cooling ejection cylinder a) VR=0.4, b) VR=0.5, c) VR=0.6
Velocity triangle analysis
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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
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Blade Surface Effectiveness
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
-1.5 -1 -0.5 0 0.5 1 1.5 2
eta
PS s/C SS
Average Blade Wall Adiabatic Effectiveness (Definition 1)
VR04
VR05
VR06
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
-1.5 -1 -0.5 0 0.5 1 1.5 2
eta
PS s/C SS
Average Blade Wall Adiabatic Effectiveness (Definition 2)
VR04
VR05
VR06
00
0
∞
∞
−−
=TTTT
c
awawη
rc
rawaw TT
TT
∞
∞
−−
=0
η
pr c
VrTT2
)1(2
0∞
∞∞ −−=
3 Pr≈r
Definition 1: Approximate definition
Definition 2: Proper definition
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Summer Fun
• Taco Tuesday
• Hiking – El Cajon
– Cowles Mountain
– Mount Woodson
– Torrey Pines
– Iron Mountain
– Three Sisters
• San Diego Zoo
• Scenery
• Weather
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Acknowledgements
• Thank you to the following: – Luzeng Zhang
– Hee-Koo Moon
– John Mason
– Gail Doore
– Eric Eggett
– Don Mariani
– Juan Yin
– Kevin Liu
– Archie French
– Tim Bridgeman
– Don Leroux
– Rotation Engineers
– Fellow Interns
– UTSR Program
– Kelsey Stinson
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Questions