HEAT TRANSFER ENHANCEMENT DUE TO

COOLANT EXTRACTION ON THE

COLD SIDE OF EFFUSION COOLING PLATES
Riccardo Da Soghe, A. Andreini, B. Facchini and L. Mazzei
Ergon Research s.r.l.
Via Panciatichi, 92 - 50139
Florence (Italy)
e-mail:
riccardo.dasoghe@ergonresearch.it


Presentation Outline
Introduction
Effusion cooling arrangement

Reasons and objectives of the present work

CFD computations
CFD setup
Test matrix
Validation of numerical tools
Results

Conclusions






Introduction
ACARE Vision 2020 objectives and future ICAO-CAEP standards specifically
introduce NO
x
emission abatement as one of the main goals for next
generation civil aero-engines
Research efforts dedicated to the introduction of lean premixed
combustion systems
Represent the most effective way to reach the NO
x
reduction
targets

The design of the liner cooling system which becomes more
critical

Up to 70% of the overall air mass flow is utilized for fuel
preparation and the initiation of lean combustion

Goal in combustor development
Significant reduction of the amount of coolant
3
Introduction: Effusion cooling arrangement
High efficiency cooling scheme Effusion cooling

Huge number of small holes
Recent improvements of drilling capability
Highly innovative potential
Promising acoustic damping capabilities
More uniform film protection of the
liner hot side
Significant heat sink effect
Heat removed by convection inside holes
Relevant heat extraction by the cold side
convection cooling








4
Avio NEWAC Lean Burn Combustor GT2013-94667
Courtesy of Paradigm precision
Courtesy of Paradigm precision
Introduction: Previous literature contributions
Hot side heat transfer
Pioneering works from Sasaki et al. (1979), Mayle and Camarata (1975),
Andrews (1990, 1991, 1995)
Recent works about effectiveness and heat transfer measurements on
effusion cooling systems
Papers from Scrittore et. al. (2005, 2006) as well as the recent work of Ligrani
et. al. (2012) and Martin and Thorpe (2012) report detailed description of the
effect of blowing ratio in large arrays of full coverage film cooling geometries
Range of engine representative blowing ratios
Number of rows to obtain a full developed film
Increase of film effectiveness at higher BRs when considering high free stream
turbulence
Paper from Andreini et. al. (2013) investigates adiabatic and overall
effectiveness of effusion cooling plates at different operating conditions
A correlation for overall effectiveness by the effusion geometries proposed
to help preliminary assessment of different design solutions






5
Introduction: Previous literature contributions
Cold side heat transfer
Gerendas and co-workers (2001) pointed out that in case of effusion
cooling up to 30% of the heat extracted from the liner is due to cold side
convective cooling

This evidence is explained by a heat transfer augmentation at the extraction
holes entrance
Sparrow et. al (1982), Cho et. al (1987) and Dorignac (2005): The heat transfer
coefficient augmentation at the liner cold side is motivated by stagnation regions
observed downstream the extraction holes
The heat transfer coefficient enhancement factor EF depends on the suction ratio SR

=

These studies focused on isolated extraction holes





6
Introduction: Previous literature contributions
Cold side heat transfer
Cottin et al. (2011) numerically investigate the aero-thermal field of
effusion cooling plates.

The authors pointed out an expression to correlate the cold side heat
transfer coefficient augmentation to the local suction ratio.
The coefficients of this correlation were not published
The impact of the hole spacing as well as the operating conditions of the system are
not accounted for.
The flow approaching the effusion plate is modelled as fully developed.


Correlations for the effusion plate cold side heat transfer
enhancement factor as a function of plate porosity and real engine
operating condition are NOT available in the open literature





7
Aim of the work
Analyze, by means of CFD, the flow field on the cold side of effusion
cooling plates when considering 30 angled perforations
Both geometrical and fluid-dynamic design parameters are considered to
improve the physical understanding of the fluid flow that characterize
these devices
Effusion plate porosity
Feeding channel Reynolds number
Pressure ratio across the plate
Turbulence intensity


Develop a correlation for the htc enhancement factor as a
function of both plate porosity and operating conditions

Reasons and objectives
8
Ansys

CFX-14.0
Steady state solutions, ideal gas
Numerical domain
18 cooling holes rows
Turbulence modeling
k- SST
Low Reynolds approach
Gamma-Theta transition model
Boundary conditions
Feeding channel inlet
Plug flow (uniform velocity)
Total Temperature
Turbulence intensity and length scale
Feeding channel outlet
Static pressure
Discharge Plenum
Opening condition (Pressure)
Walls
Fixed Temperature
CFD solver setup
9
Geometries
Plate porosity
1.16%
1.82%
2.84%






Operating conditions
Feeding channel Reynolds number
250000750000
Pressure ratio
1.0051.05
Turbulence intesity
32%16%
Test matrix
10
=
0.25
2

Validation of numerical setup
Holes discharge coefficient
Experimental data from Gritsch and co-workers (2001)
11
=

2

Validation of numerical setup
Heat transfer coefficient
Experimental data from Byerley (1989)
Single extraction hole arrangement
The numerical domain mimics the experimental test rig










The comparisons are done in term of Enhancement Factor EF
=

0
where = 0.021
0.8

0.5

Both line lateral averaged and area averaged profiles are considered

12
Line lateral average Area average surface
Validation of numerical setup
Line-averaged Enhancement Factor profiles
Sensitivity to mesh refinement
Three different meshes are compared
These grids were generated changing the global scale factor of 25% and +25% and hence halving and
doubling the number of elements

Mesh independence is achieved when considering the standard grid










13
Validation of numerical setup
Sensitivity to turbulence model Standard k- SST vs k- SST -Re
t








14
EF peak is always achieved at the
downstream hole edge
The effects of flow extraction is
relevant up to 8 hole diameters
downstream

Fully turbulent simulations over-predict
the EF significantly

Accordingly with Byerlay (1989) the
boundary layer downstream the
extraction hole presents a transitional
behavior

The k- SST -Re
t
improves the
agreement between the CFD and
the experiments significantly












L
i
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e
-
a
v
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r
a
g
e
d

A
r
e
a
-
a
v
e
r
a
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e
d






Results
15
Post-processing and scaling procedure
For each hole, three entities have been created
A triangle-shaped plane long 2S
x
and wide S
y
/2, where htc and EF are area averaged
A plane located in correspondence of the hole and normal to the flow, where Re, Pr,
V
feeding channel
and T
0,bulk
are calculated
A plane located within the hole, where V
hole
is calculated





The heat transfer coefficient and the EF are calculated as follow:

=

0,
; =

0


0 = 0.0243
0.8

0.4


16
Results: Effects of Pressure Ratio =1.16, Re=550k, Tu=32%
The pressure ratio across the plate affects significantly the Enhancement Factor
As the pressure ratio increase the EF parameter increase
Increase of leads to an increase of SR
17


The enhancement factor slightly
decreases moving from the
feeding channel inlet to its exit

The decreasing rate is more evident at the
first holes of the array
The EF trend becomes roughly flat when
approaching the effusion plate exit
Results: Effects of Pressure Ratio =1.16, Re=550k, Tu=32%
The enhancement factor slightly decreases moving from the feeding channel inlet
to its exit

This behavior is motived by the interplay of the eddy viscosity trend and the suction ratio trend
The eddy viscosity decrease due to both the holes bleeding and the walls presence
The SR increases due to the perforations bleeding
18
Results: Effects of Reynolds number and Turbulence intensity =1.16, =1.05
The feeding channel Reynolds number
has a weak impact on the EF
As the Re decreases the EF slight
increases
Confirms what observed in case of
isolated holes (Byerlay (1989), Andreini
et al. (2014))



The increase of the turbulence level
leads to an higher enhancement factor
The effect of the turbulence level on the
EF is modest
A reduction of Tu by 50% involves a
reduction of EF by 6%

19
Results: Effects of effusion plate porosity Re=550K, =1.05, Tu 32%
The Enhancement Factor is quite
affected by the effusion plate
porosity

As the increases, EF increases
The EF averaging procedure considers
surfaces closest to the holes leading to
higher EF mean levels
EF levels very close to the effusion holes
inlet are not influenced so much by the
parameter
As the plate porosity increases, the EF
decays from the peak value to its
minimum in a smoother way




20
Results: Effects of effusion plate porosity Re=550K, =1.05, Tu 32%
As increases, the EF decays in a
smoother way
As increases more mass flow rate per
unit length is collected close to the
holes region
The higher velocity component normal
to the wall results in a thinner boundary
layer enhancing the heat transfer
process



21
Results: CFD data reduction
The Enhancement Factor is expressed as function of the Pressure ratio
across the plate and its porosity

= 5.73 +0.89 + 5.41 +0.135









Mean error 4.8% Std. Deviation 3%
22
Conclusions
A three dimensional CFD analysis was performed in order to investigate the heat
transfer at the cold side of effusion plates
Both geometrical and fluid-dynamic design parameters have been considered
Extraction holes spacing both in streamwise and spanwise direction leading to porosity factors
typically implemented on real engines
The CFD setup has been extensively validated by means the experimental data provided
by Byerley (1989) and by Gritsch et. al
The validation campaign shows that the CFD is able to confidently catch the EF

The analysis pointed out that:
The effects of both feeding channel Reynolds number and the turbulence intensity at the
inlet of the cooling section, have a weak effect on the enhancement factor
An empirical correlation for the prediction of the cold side heat transfer coefficient
enhancement factor EF has been proposed:
It expresses the EF related to each extraction hole as a function of the pressure ratio and the
effusion plate porosity factor

23
HEAT TRANSFER ENHANCEMENT DUE TO
COOLANT EXTRACTION ON THE
COLD SIDE OF EFFUSION COOLING PLATES
Riccardo Da Soghe, A. Andreini, B. Facchini and L. Mazzei
Ergon Research s.r.l.
Via Panciatichi, 92 - 50139
Florence (Italy)
e-mail:
riccardo.dasoghe@ergonresearch.it