Compressible Flow (air) and Heat Transfer Cooling of a Telemetry Package used in IGT (Industrial Gas Turbines)

1. I!I
UNITED
TECHNOLOGIES
PRATT&WHITNEVInternal Correspondence
Government Engine Business
To: K.K. Landis
From: E.J. Fichtel
Subject: Appreciation Memo for the TP&M FT8 Project
Date: 9 Dec. 1992
cc: M.J. Ford, E.R. Roesch
I would like to acknowledge the dedicated effort Julio Banks
provided on the FT8 Telemetry Project. Julio was
responsible for the heat transfer analysis on this unique
telemetry package and for providin9 a cooling scheme to
ensure proper telemetry operation ln the severe turbine
environment. Julio was very thorough in his analysis and
worked closely with Design Engineeering to provide a cooling
scheme with plenty of margin under worst case test
conditions.
Julio was a valued member of our team and his support through
all phases of this project was much appreciated.
nn~
E.J. Fichtel
P&W GEB 51 Rev. 2/88
Julio C. Banks, MSME, PE, CGC
Thermo-structural Consultatn
e-mail: Sell-A-Vision@Outlook.com

2. PRATI &WHITNEY
Engineering Division South
INTERNAL CORRESPONDENCE
To: Ed Fichtel
From: Julio C. Banks
Subject: Final Report of the FT8 Telemetry Package Cooling Study
Date: August 1, 1991
cc: K. K. Landis, E. M. Beverly
ABSTRACT
A detailed thermal analysis was performed on the Turbo Power and Marine
(TP&M) FT8 engine telemetry package. The main objective of this study was
to design a cooling system that maintains the telemetry package below the
200 of design limit. Several cooling methods were considered and included
air, oil and Freon systems. Feasibility considerations of the different
cooling systems indicated air cooling to be the least complex cooling scheme
and preliminary analysis indicated that air cooling was feasible thus it was
~, selected as the most practical design alternative.
The cooling configuration IJses convective air cooling techniques and simple
heat shields to minimize radiation and convection heating effects. The
design provides adequate cooling at the maximum heat load condition which
occurs at a rotor speed of 6500 RPM. Post test heat soak-back is controlled
by continuing to use shop air during the cool-down period.
In summary, shop air at a minimum flow rate of 0.30 Lbm/sec and 80 F supply
temperature should maintain the FT8 telemetry package's electronics
temperature under 200°F. The design contains provisions for up to twice the
minimum flow of cooling air if necessary. Health instrumentation is
provided to monitor/validate the FT8 telemetry package temperatures &static
pressures during the test and soak-back period.
DISCUSSION
The Turbo Power and Marine FTS engine shown in figure 1 is the test article
onto which the telemetry package is to be mounted. Figure 2 is a closer
look of the aft end of the FTS engine and shows the shop air flow rate (0.3
to 0.6 lbm/sec) with supply temperature of 80°F. Notice also in figure 2
that the cooling air is to be metered thru a sharp edge orifice (described
in appendix B) and that the coolant supply line within the FTS is
approximately 10 feet long.

3. - 2 - August 2, 1991
Figure 3 shows the FT8 telemetry package full scale drawing while figure 4
shows the design features. The key characteristics of the FT8 telemetry
cooling system were presented at a Chief Engineers review and a copy of the
presentation material is included as appendix A.
Figure A.3 ;s a schematic of the FTS telemetry packagers boundary conditions
and material map. It contains the external convective boundary film
coefficients &temperatures (h &Tf); the conduction source temperature; as
well as the cooling air conditions entering the package (0.3 Lbm/sec and 95
F). The rotorts maximum speed is 6500 RPM as shown in the lower left
corner, and the labyrinth seal leakage flow and temperature are indicated.
The heat load sources have been ranked and are shown in figure A.4. It can
be seen that the heat load due to windage is a major contributor at 6500 RPM
and is comparable to the sum of the rest of the contributors (excluding the
coolant suppy pipe).
A coolant flow &pressure distribution map of the telemetry package is shown
in figure A.5. This distribution was configured using the common modeler
V169 and it is shown (in figure A.6) to produce a uuniform temperature
distributionu
•
RESULTS
.~ The application of the boundary conditions &design constraints as outlined
in the discussion section of this report, yielded the thermal results
described in this section.
The Common Heat transfer Analysis Program, CHAP, was used to perform this
cooling study of the FT8 telemetry package. CHAP uses the finite difference
heat transfer technique. Figure A.6 shows the temperatures resulting from
CHAP superimposed on the nodal break-up of the telemetry package geometry.
The cooling air flow rate at this condition is 0.3 Lbm/Sec and the Telemetry
transmitters (nodes 201, 202, 205 &206) are about 170 F. Also the coolant
system has the capacity to flow at up to 0.6 Lbm/sec if necessary to further
reduce the transmitterst temperature.
It should be noted that the study demonstrated that air cooling supplied at
80 F and pressure up to 100 psia is a feasible scheme. The design is simple
when compared to the possible use of oil or Freon for cooling. The
telemetry wiring will be routed through the supply air line and ;s not
expected to present any difficulty to the cooling system. The use of
thermal insulation was kept to a minimum to minimize the introduction of
uncertainties in the event of degradation of the insulation.

4. - 3 - August 1, 1991
CONCLUSIONS
The main objective of maintaining the FT8 Telemetry Package's electronics
under 200°F has been shown to be feasible using shop air for coolant.
Figure 5 shows that the operating supply total pressure is predicted to be
under 100 psia in the required cooling flow rate range of 0.3 to 0.60
Lbm/Sec, assuming the coolant pipe supply air temperature is 80°F. The
design contains provisions for up to twice the minimum flow rate of shop air
if necessary. FT8 telemetry package health instrumentation is provided to
monitor and validate the system during operation and heat soak-back period.
The shop air flow is controlled via a chocked sharp edge orifice thus the
flow can be controlled by the supply total pressure.
O(2d&~
. Ban s ~~echanical Componets &Systems Mechanical Componets &Systems
Component Design Technology Component Design Technology
Ext. 8245

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10. APPENDIX A
CHIEF ENGINEER'S DESIGN REVIEW
Julio C. Banks, P.E.

11. FT8 TELEMETRY PACKAGE COOLING
CHIEF ENGINEER'S DESIGN REVIEW
May 29, 1991
Julio C. Banks
• Cooling Schematic of the System
• Boundary Conditions and Materials Map
• Air Coolant Map:
Flow (Lbm/Sec), Pressure (psia) and Temperature (OF)
• Health Instrumentation
• Results:
a) Shop Air Requirements
1. Flow - 0.3 to 0.6 Lbm/Sec
2. Pres - 50. to 100. psia
3. Temp - 80°F (Max. Source Temp.)
• Conclusion:
Air cooling of the FT8 telemetry package is feasible.
Transmitters & coils are cooled below 200°F limit.

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** MATERIAL~SSTEEL 1C A SIN G
.2840 100.0 .09430 100.0 105.0 0.0~,
I 600.0 .09580 600.0 131.8 0.0
SSTEEL 2S HIE L D
.2840 100.0 .09430 100.0 0.360 0.0
I 600.0 .09580 600.0 0.360 0.0
A I R 3 A I R ---­
.2840 100.0 .09430 100.0 0.360 0.0
I 600.0 .09580 600.0 0.360 0.0
ROTOR 4TATANIUM--­
.2840 100.0 .12800 100.0 50.00 0.0
I 525.0 .13200 875.0 84.00 0.0
COILS 5E POX Y
.2840 100.0 .09430 100.0 9.60 0.0
I 600.0 .09580 600.0 9.60 0.0
SEALS 6RUBBER LAND
.2840 100.0 .09430 100.0 1.78 0.0
I 600.0 .09580 600.0 1.78 0.0
GROVE 7ROTOR/SHAFT
.2840 100.0 .09430 100.0 40.2 0.0
I 600.0 .09580 600.0 40.2 0.0
EPOXY 8TRANSMITTER
.2840 100.0 .09430 100.0 29.9 0.0
I 600.0 .09580 600.0 29.9 0.0
WEIGH 9TRANS. STUB
.2840 100.0 .09430 100.0 4.8 0.0
I 600.0 .09580 600.0 4.8 0.0
--" WEIGH 10SMALL BOLTS
.2840 100.0 .12800 100.0 11.1 0.0
I 525.0 .13200 875.0 11.1 0.0
WEIGH 11LARGE BOLTS
.2840 100.0 .09430 100.0 18.2 0.0
I 600.0 .09580 600.0 18.2 0.0
AIR 25 AIR
.000096 0.00 0.240 0.0 0.162
400. 0.246 400. 0.272
800. 0.258 800. 0.366
1200. 0.269 1200. 0.450
1600. 0.276 1600. 0.528
2000. 0.282 2000. 0.600
2400. 0.288 2400. 0.672

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2/18191
Telemetry Heat Transfer Study
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