9th International PHOENICS User Conference Moscow, September 2002 A presentation by Dr. Paddy Phelps...
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Transcript of 9th International PHOENICS User Conference Moscow, September 2002 A presentation by Dr. Paddy Phelps...
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9th International 9th International PHOENICS User PHOENICS User
ConferenceConferenceMoscow, September 2002Moscow, September 2002
A presentation by A presentation by
Dr. Paddy PhelpsDr. Paddy Phelps
on behalf of on behalf of
Flowsolve and IAC LtdFlowsolve and IAC Ltd
September 2002
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Predicting air flow and heat transfer Predicting air flow and heat transfer in an anechoic test chamber in an anechoic test chamber
for industrial chillersfor industrial chillers
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Outline of PresentationOutline of Presentation
Industrial ContextIndustrial Context Objectives of StudyObjectives of Study Benefits of using CFDBenefits of using CFD Description of CFD ModelDescription of CFD Model Simulations performed to dateSimulations performed to date Presentation of ResultsPresentation of Results ConclusionsConclusions
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Chiller Test Chamber Chiller Test Chamber Ventilation studyVentilation study
Industrial ContextIndustrial Context Objectives of StudyObjectives of Study Benefits of using CFDBenefits of using CFD Description of CFD ModelDescription of CFD Model Simulations performed to dateSimulations performed to date Presentation of ResultsPresentation of Results ConclusionsConclusions
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Industrial ContextIndustrial Context
IAC LtdIAC Ltd design and construct a range design and construct a range of bespoke anechoic test chambers.of bespoke anechoic test chambers.
Their client in this instance was Their client in this instance was York York LtdLtd, manufacturers of air chiller , manufacturers of air chiller units for building HVAC systems. units for building HVAC systems.
York wish to improve the design of York wish to improve the design of their products by testing them at the their products by testing them at the limits of their performance envelopelimits of their performance envelope
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Industrial ContextIndustrial Context
Test chamber design brief calls for air Test chamber design brief calls for air supply temperatures at chiller intakes supply temperatures at chiller intakes to be to be uniform to within 1uniform to within 100CC . .
Chiller unit intakes are located along Chiller unit intakes are located along upper body sides and ends. upper body sides and ends.
Up to 12 ducted fans on top of unit Up to 12 ducted fans on top of unit emit highly swirling air extract flow, emit highly swirling air extract flow, several degrees different from ambient several degrees different from ambient
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Test Chamber Geometry - Test Chamber Geometry - 1 1
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IAC Ltd Chiller Test IAC Ltd Chiller Test Chamber ventilation studyChamber ventilation study
Industrial ContextIndustrial Context Objectives of StudyObjectives of Study Benefits of using CFDBenefits of using CFD Description of CFD ModelDescription of CFD Model Simulations performed to dateSimulations performed to date Presentation of ResultsPresentation of Results ConclusionsConclusions
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Objectives of StudyObjectives of Study
Use simulation tools to predict mixing of Use simulation tools to predict mixing of hot swirling extract flow with ambient hot swirling extract flow with ambient airflow inside test facility airflow inside test facility
Provide input to design of chamber air Provide input to design of chamber air supply / extract arrangements, by supply / extract arrangements, by predicting likely effect on airflow patternspredicting likely effect on airflow patterns
Confirm client criteria for uniformity of Confirm client criteria for uniformity of temperature at chiller intakes can be mettemperature at chiller intakes can be met
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Test Chamber Geometry - Test Chamber Geometry - 2 2
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Test Chamber Geometry - Test Chamber Geometry - 3 3
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Simulation Tool OptionsSimulation Tool Options
Direct ExperimentDirect Experiment• not applicable - building not yet constructednot applicable - building not yet constructed• use to confirm other predictive toolsuse to confirm other predictive tools
Wind-Tunnel ModellingWind-Tunnel Modelling• scale-up and thermal representation difficultscale-up and thermal representation difficult• problem with interpretation of resultsproblem with interpretation of results
Numerical SimulationNumerical Simulation• passive (Gaussian) dispersion modelspassive (Gaussian) dispersion models• Computational Fluid DynamicsComputational Fluid Dynamics
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IAC Ltd Chiller Test IAC Ltd Chiller Test Chamber ventilation studyChamber ventilation study
Industrial ContextIndustrial Context Objectives of StudyObjectives of Study Benefits of using CFDBenefits of using CFD Description of CFD Model Description of CFD Model Simulations performed to dateSimulations performed to date Presentation of ResultsPresentation of Results ConclusionsConclusions
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Benefits of CFD ApproachBenefits of CFD Approach
No scale-up problemNo scale-up problem Three-dimensional, steady or transientThree-dimensional, steady or transient Interrogatable predictionsInterrogatable predictions Handles effect of Handles effect of
• blockages in domainblockages in domain• recirculating flowrecirculating flow• multiple inlets and outletsmultiple inlets and outlets• multiple interacting heat sourcesmultiple interacting heat sources
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IAC Ltd Chiller Test IAC Ltd Chiller Test Chamber ventilation studyChamber ventilation study
Industrial ContextIndustrial Context Objectives of StudyObjectives of Study Benefits of using CFDBenefits of using CFD Description of CFD ModelDescription of CFD Model Simulations performed to dateSimulations performed to date Presentation of ResultsPresentation of Results ConclusionsConclusions
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Solution Domain(s)Solution Domain(s)
CHAMBER MODELCHAMBER MODEL Solution domain encompasses the test Solution domain encompasses the test
chamber up to, but not including, the chamber up to, but not including, the outlet plenumoutlet plenum• Domain 15.22m by 18.88m by 8m highDomain 15.22m by 18.88m by 8m high
PLENUM MODELPLENUM MODEL Solution domain encompasses the outlet Solution domain encompasses the outlet
plenum onlyplenum only• Domain 12.2m by 17.08m by 1.3m highDomain 12.2m by 17.08m by 1.3m high
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CFD Model Description - CFD Model Description - 11
Representation of the effects ofRepresentation of the effects of• blockage due to the presence of an blockage due to the presence of an
internal obstacle (chiller unit)internal obstacle (chiller unit)• multiple inlets and outlets for chamber air multiple inlets and outlets for chamber air • resistance and mixing in extract resistance and mixing in extract
silencerssilencers• distributed intakes on chiller sides & endsdistributed intakes on chiller sides & ends• discrete, swirling outlets on chiller topdiscrete, swirling outlets on chiller top
[ Flow inside chiller not solved for ][ Flow inside chiller not solved for ]
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CFD Model Description - CFD Model Description - 22
Dependent variables solved for :Dependent variables solved for :• pressure (total mass conservation)pressure (total mass conservation)• axial, lateral and vertical velocity componentsaxial, lateral and vertical velocity components• air/chiller effluent mixture temperatureair/chiller effluent mixture temperature• air residence time in chamber air residence time in chamber • turbulence kinetic energyturbulence kinetic energy• turbulence energy dissipation rateturbulence energy dissipation rate
Independent Variables:Independent Variables:• 3 spatial co-ordinates (x,y,z) and time3 spatial co-ordinates (x,y,z) and time
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CFD Model Description - CFD Model Description - 33
Iterative “guess and correct” solution Iterative “guess and correct” solution procedure to convergence of schemeprocedure to convergence of scheme
Typical domain size - 15x8x19 m. Typical domain size - 15x8x19 m. Around 1500 “sweeps” of domain Around 1500 “sweeps” of domain
required for convergencerequired for convergence Typical nodalisation level - 207,000Typical nodalisation level - 207,000 Convergence involves solution of around Convergence involves solution of around
2,500 million simultaneous linked 2,500 million simultaneous linked differential equationsdifferential equations
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CFD Model Description - CFD Model Description - 44
The set of partial differential equations The set of partial differential equations is solved within the defined solution is solved within the defined solution domain and on a prescribed numerical domain and on a prescribed numerical gridgrid
The equations represent conservation The equations represent conservation of mass, energy and momentum of mass, energy and momentum
The momentum equations are the The momentum equations are the familiar Navier-Stokes Equations which familiar Navier-Stokes Equations which govern fluid flowgovern fluid flow
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CFD Model Description - CFD Model Description - 55
The equations may each be written in The equations may each be written in the formthe form
D( ) /Dt + div ( U - grad ) = S{
Terms cover transience, convection, Terms cover transience, convection, diffusion and sources respectivelydiffusion and sources respectively
Equation is cast into finite volume form Equation is cast into finite volume form by integrating it over the volume of by integrating it over the volume of each celleach cell
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IAC Ltd Chiller Test IAC Ltd Chiller Test Chamber Ventilation StudyChamber Ventilation Study
Industrial ContextIndustrial Context Objectives of StudyObjectives of Study Benefits of using CFDBenefits of using CFD Description of CFD ModelDescription of CFD Model Simulations performed Simulations performed Results ObtainedResults Obtained ConclusionsConclusions
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Supply / Extract Supply / Extract Arrangements StudiedArrangements Studied
Chamber air supply arrangementChamber air supply arrangement• Straight supply ductsStraight supply ducts• Angling of supply end regionsAngling of supply end regions• Blocking middle regionBlocking middle region
Chamber air extract arrangementChamber air extract arrangement• Long side outlet ductsLong side outlet ducts• Small additional centre outletSmall additional centre outlet• Large centre outletLarge centre outlet• Small vestigial side outletsSmall vestigial side outlets
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Chamber Geometry Chamber Geometry Arrangements StudiedArrangements Studied
Effect on chiller intake temperatures of:Effect on chiller intake temperatures of:
• Friction on walls & ceilingFriction on walls & ceiling• Silencer pressure losses at inlet & Silencer pressure losses at inlet &
outlet outlet • Mid-height wall “lip” Mid-height wall “lip” • End “hood” on chillerEnd “hood” on chiller• Baffles along chiller sidesBaffles along chiller sides• ““Lip” around centre ceiling extractLip” around centre ceiling extract• ““Swirl breaker” above chillerSwirl breaker” above chiller
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Chiller Operating Conditions Chiller Operating Conditions StudiedStudied
Chamber dimensionsChamber dimensions• Dimensions 2.2 x 8..7 x 2.44 m. highDimensions 2.2 x 8..7 x 2.44 m. high• 12 outlet fans, swirl angle = 30 degrees 12 outlet fans, swirl angle = 30 degrees
Chiller “Hot” Operating ConditionChiller “Hot” Operating Condition• Inlet temperature ~ 35 deg.C Inlet temperature ~ 35 deg.C • Heat input = 951kW or 1019 kWHeat input = 951kW or 1019 kW• Air flowrate = 75 or 67 mAir flowrate = 75 or 67 m33/s/s
Chiller “Cold” Operating ConditionChiller “Cold” Operating Condition• Inlet temperature ~ 7 deg.CInlet temperature ~ 7 deg.C• Heat input = -363kW Heat input = -363kW
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Chamber Operating Chamber Operating Conditions StudiedConditions Studied
Chamber Air supply RateChamber Air supply Rate• Initially 110% of chiller throughput Initially 110% of chiller throughput
( i.e. 1.1*75 = 82.5 m( i.e. 1.1*75 = 82.5 m33/s]/s]• Subsequently increased to 90 mSubsequently increased to 90 m33/s/s
Hot Operating ConditionHot Operating Condition• Inlet supply temperature = 35 deg.C Inlet supply temperature = 35 deg.C
Cold Operating ConditionCold Operating Condition• Inlet supply temperature = 7 deg.CInlet supply temperature = 7 deg.C
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Overview of WorkscopeOverview of Workscope
34 simulations performed in 7 “stages”34 simulations performed in 7 “stages”• Stage 1Stage 1 - Original design concept; effect of - Original design concept; effect of
swirl; add small central outlet; remove swirl; add small central outlet; remove lateral offset; longer central outlet; add wall lateral offset; longer central outlet; add wall friction; hot & cold runsfriction; hot & cold runs
• Stage 2Stage 2 - chamber outflow partitioning - chamber outflow partitioning sensitivity; effect of inclining and part-sensitivity; effect of inclining and part-blocking some of supply inlets blocking some of supply inlets
• Stage 3Stage 3 - revised chiller inflow partitioning; - revised chiller inflow partitioning; Central outlet lip and vestigial side outletsCentral outlet lip and vestigial side outlets
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Overview of WorkscopeOverview of Workscope
34 simulations performed in 7 “stages”34 simulations performed in 7 “stages”• Stage 4Stage 4 - chiller swirl level; outlet silencer - chiller swirl level; outlet silencer
resistance; central outlet lip. resistance; central outlet lip. • Stage 5Stage 5 - Increase chamber air rate; chiller - Increase chamber air rate; chiller
end and side baffles; increase chiller heat end and side baffles; increase chiller heat rate and reduce throughput for “worst rate and reduce throughput for “worst case”.case”.
• Stage 6Stage 6 - Worst case run with “swirl - Worst case run with “swirl breaker”breaker”
• Stage 7Stage 7 - Air loading run with chiller off. - Air loading run with chiller off.
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IAC Ltd Chiller Test IAC Ltd Chiller Test Chamber Ventilation StudyChamber Ventilation Study
Industrial ContextIndustrial Context Objectives of StudyObjectives of Study Benefits of using CFDBenefits of using CFD Description of CFD ModelDescription of CFD Model Simulations performed Simulations performed Results ObtainedResults Obtained ConclusionsConclusions
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Original Design ConceptOriginal Design Concept
ConfigurationConfiguration• Two long low-resistance side outletsTwo long low-resistance side outlets• No central outlet No central outlet
SupplySupply• Chamber supply rate = 82.5 mChamber supply rate = 82.5 m33/s/s• Chamber supply temp = 35 deg. CChamber supply temp = 35 deg. C
““Hot” Chiller Operating ConditionHot” Chiller Operating Condition• Chiller throughtput = 75 mChiller throughtput = 75 m33/s/s• Temperature rise through chiller = 11.17 Temperature rise through chiller = 11.17
deg C deg C
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Original Design Concept:Original Design Concept:Predictions - 1Predictions - 1
Max temperature difference across Max temperature difference across chiller intake ports = 7.99 chiller intake ports = 7.99 ooCC
Min intake temperature = 35.1 Min intake temperature = 35.1 ooCC Max intake temperature = 43.1 Max intake temperature = 43.1 ooC C Mean intake temperature = 36.65 Mean intake temperature = 36.65 ooCC
Mean intake residence time = 7.46 Mean intake residence time = 7.46
secsec Max chamber residence time = 72.1 secMax chamber residence time = 72.1 sec
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Original Design Concept:Original Design Concept: Predictions - 2 Predictions - 2
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Original Design Concept:Original Design Concept: Predictions - 3 Predictions - 3
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Original Design Concept:Original Design Concept: Predictions - 4 Predictions - 4
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Original Design Concept:Original Design Concept: Initial Findings Initial Findings
Hot, highly swirling flow from chiller Hot, highly swirling flow from chiller outlet creates non-symmetric flow outlet creates non-symmetric flow patterns in chamber, despite symmetry patterns in chamber, despite symmetry of inlet, outlet and chiller locationsof inlet, outlet and chiller locations
Hot recirculating flow re-entrained into Hot recirculating flow re-entrained into chiller end intakes, creating a “hot end” chiller end intakes, creating a “hot end” and a “cold” endand a “cold” end
Intake temperature differences are Intake temperature differences are eight times desired criterion …...eight times desired criterion …...
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Stage 1 SimulationsStage 1 Simulations
Effect of chiller outlet swirl levelEffect of chiller outlet swirl level• reducing swirl improves matters …reducing swirl improves matters …
(but this is not an option)(but this is not an option) add small central outletadd small central outlet
T reduced to 4.35 T reduced to 4.35 ooCC lengthen central outletlengthen central outlet
T increases slightly to 4.85 T increases slightly to 4.85 ooCC
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Stage 1 SimulationsStage 1 Simulations
Chamber wall frictionChamber wall frictionT reduced slightly to 4.52 T reduced slightly to 4.52 ooCC
Hot and Cold OperationHot and Cold OperationT for cold operation about half that when T for cold operation about half that when
hothot
Hot operating condition will thus be the Hot operating condition will thus be the worst case for achieving the chiller worst case for achieving the chiller intake temperature uniformity criterionintake temperature uniformity criterion
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Stage 2 SimulationsStage 2 SimulationsSupply/Extract geometry Supply/Extract geometry
sensitivitysensitivity
Chamber outflow partitioning sensitivityChamber outflow partitioning sensitivity• Tinkering with outlet resistance does not Tinkering with outlet resistance does not
improve matters. improve matters. T in range 4.5 to 6T in range 4.5 to 6ooCC Inclining the outer supply inlets Inclining the outer supply inlets
• Directing outer inlet jets towards chiller Directing outer inlet jets towards chiller ends, to sweep away descending hot fluid ends, to sweep away descending hot fluid from intakes, does hot have desired effect.from intakes, does hot have desired effect.
T in range 4.5 to 5T in range 4.5 to 5ooCC
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Stage 2 SimulationsStage 2 SimulationsSupply/Extract geometry Supply/Extract geometry
sensitivitysensitivity
Blocking the lower centre supply Blocking the lower centre supply inlets inlets • Blocking the central lower inlet Blocking the central lower inlet
increases the incoming momentum of increases the incoming momentum of supply jets towards chiller sides . supply jets towards chiller sides . Does hot have very dramatic effect, Does hot have very dramatic effect, reducing reducing T by about 0.1T by about 0.1ooCC
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Stage 3 SimulationsStage 3 SimulationsSensitivity to Chiller Inflow Sensitivity to Chiller Inflow
specificationspecification
Chiller inflow partitioning (ends, Chiller inflow partitioning (ends, sides, base) derived from :sides, base) derived from :
Manufacturers EstimatesManufacturers Estimates• For hot operation, For hot operation, T is about 5.3T is about 5.3ooCC
IAC Experimental MeasurementsIAC Experimental Measurements• For comparable run, For comparable run, T is about 3.1T is about 3.1ooCC• these more reliable data used for these more reliable data used for
subsequent simulationssubsequent simulations
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Stage 3 SimulationsStage 3 SimulationsExtract geometry sensitivity Extract geometry sensitivity
Central outlet lipCentral outlet lip • Adding a deep lip around periphery of Adding a deep lip around periphery of
central roof outlet central roof outlet shouldshould allow capture allow capture of more of swirling flow from chiller top. of more of swirling flow from chiller top.
• Unfortunately, it also provides a shortcut Unfortunately, it also provides a shortcut for hot air to the ends, leading to a for hot air to the ends, leading to a dramatic increase in dramatic increase in T !T !
Moral: Not all intuitive aids work as one Moral: Not all intuitive aids work as one might expect . . .might expect . . .
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Unexpected Outcomes . . .Unexpected Outcomes . . .
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Unexpected Outcomes . . .Unexpected Outcomes . . .
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Stage 3 SimulationsStage 3 SimulationsExtract geometry sensitivityExtract geometry sensitivity
Further enlarged central outlet Further enlarged central outlet with vestigial side extract ductswith vestigial side extract ducts• Long extract ducts on each side Long extract ducts on each side
replaced by four smaller apertures at replaced by four smaller apertures at intervals; central outlet further intervals; central outlet further enlarged, but no lip. enlarged, but no lip. T falls to about T falls to about 2.72.7ooCC
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Stage 4 SimulationsStage 4 Simulations SensitivitySensitivity to chiller outlet swirl to chiller outlet swirl
levellevel
For a reference geometry & “hot” For a reference geometry & “hot” operationoperation
effect is dramatic . . . . .effect is dramatic . . . . .• for 0% swirl, for 0% swirl, T is about 0.6T is about 0.6ooCC• for 30% swirl, for 30% swirl, T is about 1.3T is about 1.3ooCC• for 100% swirl, for 100% swirl, T is about 6.0T is about 6.0ooC C
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Stage 4 SimulationsStage 4 SimulationsFurther i/o geometry sensitivityFurther i/o geometry sensitivity
Outlet silencer resistanceOutlet silencer resistance• Specification of high and low resistance Specification of high and low resistance
zones in inner and outer regions of zones in inner and outer regions of central outlet has small (~10% reduction) central outlet has small (~10% reduction) effect on effect on T T
Increase airflow from 82.5 mIncrease airflow from 82.5 m33 to 90 m to 90 m33
• Increasing ventilation rate has a greater Increasing ventilation rate has a greater effect, reducing effect, reducing T by about 25%T by about 25%
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Stage 5 SimulationsStage 5 SimulationsSensitivity to internal “baffles”Sensitivity to internal “baffles”
Side and end baffles added, to Side and end baffles added, to • channel supply air to intakes at chiller channel supply air to intakes at chiller
ends;ends;• prevent descending hot air plume being re-prevent descending hot air plume being re-
entrained into end inlets’entrained into end inlets’
Baffles and shrouds do not perform quite as Baffles and shrouds do not perform quite as envisaged . . . envisaged . . .
• Dead zones form in end shrouds, negating Dead zones form in end shrouds, negating some of supply-air channelling benefit .some of supply-air channelling benefit .
• However, However, T reduced by about two thirds T reduced by about two thirds
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Baffled and ShroudedBaffled and Shrouded- - - - Tried and rejected - - Tried and rejected - -
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Baffled and ShroudedBaffled and Shrouded- - - - Tried and rejected - -Tried and rejected - -
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Baffled and ShroudedBaffled and Shrouded- - - - Tried and rejected - -Tried and rejected - -
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Baffled and ShroudedBaffled and Shrouded- - - - Tried and rejected - -Tried and rejected - -
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Final SimulationsFinal SimulationsWorst case Operating ScenarioWorst case Operating Scenario
Chamber air flow increased to 90 Chamber air flow increased to 90 mm33/s/s
Chiller air flow reduced to 67 mChiller air flow reduced to 67 m33/s/s
Chiller heat input increased to 1051 Chiller heat input increased to 1051 kWkW
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Final Design ConceptFinal Design Concept
Geometry :Geometry :• No baffles or end hoodsNo baffles or end hoods• Normally-directed air supplyNormally-directed air supply• Side-wall ridge at mid-height Side-wall ridge at mid-height • Enlarged central extract with four small Enlarged central extract with four small
extracts along each sideextracts along each side• Shallow centre outlet “lip”Shallow centre outlet “lip”• ““Swirl Breaker” fitted between chiller Swirl Breaker” fitted between chiller
top and air extract ducttop and air extract duct
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Final Design Concept :Final Design Concept :[ wall & roof tiles removed for clarity][ wall & roof tiles removed for clarity]
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Final Design Concept :Final Design Concept : [ wall & roof tiles removed for clarity][ wall & roof tiles removed for clarity]
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Final Design Concept :Final Design Concept : [ wall & roof tiles removed for clarity][ wall & roof tiles removed for clarity]
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Final Design Concept:Final Design Concept:Predictions - 1Predictions - 1
Max temperature difference across Max temperature difference across chiller intake ports = 0.96 chiller intake ports = 0.96 ooCC
Min intake temperature = 35.01 Min intake temperature = 35.01 ooCC Max intake temperature = 35.97 Max intake temperature = 35.97 ooC C Mean intake temperature = 35.13 Mean intake temperature = 35.13 ooCC
Mean intake residence time = 4.27 Mean intake residence time = 4.27
secsec Max chamber residence time = 128 secMax chamber residence time = 128 sec
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Final Design Concept :Final Design Concept :Predictions - 2Predictions - 2
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Final Design Concept :Final Design Concept :Predictions - 3Predictions - 3
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Final Design Concept :Final Design Concept :Predictions - 4Predictions - 4
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Final Design Concept :Final Design Concept :Predictions - 5Predictions - 5
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Final Design Concept :Final Design Concept :Air flow predictionsAir flow predictions - axial plane- axial plane
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Final Design Concept :Final Design Concept :Air flow predictions - transverse planeAir flow predictions - transverse plane
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Final Design Concept :Final Design Concept :Air flow predictions - transverse planeAir flow predictions - transverse plane
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Final Design Concept :Final Design Concept :Air flow predictions - transverse planeAir flow predictions - transverse plane
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Final Design Concept :Final Design Concept :Air flow predictions - plan viewAir flow predictions - plan view
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Final Design Concept :Final Design Concept :Air flow predictions - plan viewAir flow predictions - plan view
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Final Design Concept :Final Design Concept :Air flow predictions - plan viewAir flow predictions - plan view
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Final Design Concept :Final Design Concept :Residence time ConsiderationsResidence time Considerations
Flow-averaged residence time of air Flow-averaged residence time of air in chamber is ~19 secs. Maximum in chamber is ~19 secs. Maximum predicted is 128 seconds.predicted is 128 seconds.
Region located below mid-wall lip, Region located below mid-wall lip, at non-control panel end and side, at non-control panel end and side, is the slowest clearing dead zone.is the slowest clearing dead zone.
Times contoured depict “time Times contoured depict “time following injection” into domainfollowing injection” into domain
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Final Design Concept :Final Design Concept :Residence time predictionsResidence time predictions
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Final Design Concept :Final Design Concept :Residence time predictionsResidence time predictions
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Final Design Concept :Final Design Concept :Residence time predictions atResidence time predictions at
axial section through centre of chilleraxial section through centre of chiller
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Final Design Concept :Final Design Concept :Residence time predictions at Residence time predictions at
transverse section through centre of transverse section through centre of
chillerchiller
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Final Design Concept :Final Design Concept :Residence time predictions at Residence time predictions at
transverse section through far end of transverse section through far end of
chillerchiller
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Conclusions - 1Conclusions - 1
Attainment of 1-degree or less Attainment of 1-degree or less variance in chiller intake variance in chiller intake temperatures is thwarted by the re-temperatures is thwarted by the re-entrainment of the hot swirling plume entrainment of the hot swirling plume issuing from the top.issuing from the top.
Attempts to modify air flow patterns Attempts to modify air flow patterns to rectify matters by tinkering with to rectify matters by tinkering with inlets, outlets, baffles etc. only met inlets, outlets, baffles etc. only met with partial successwith partial success
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Conclusions - 2Conclusions - 2
Breakthrough came in controlling the Breakthrough came in controlling the influence of the highly swirling chiller influence of the highly swirling chiller -outlet flow, by use of a “waffle-iron” -outlet flow, by use of a “waffle-iron” type of swirl-breaker device.type of swirl-breaker device.
This was more effective than using This was more effective than using measures to try to divert the flow measures to try to divert the flow further downstream.further downstream.
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Conclusions - 3Conclusions - 3
Final design concept can meet the Final design concept can meet the
client’s design criterion for client’s design criterion for
acceptable variance in chiller intake acceptable variance in chiller intake
temperatures.temperatures.
Some “fine-tuning” may be required Some “fine-tuning” may be required
upon final installationupon final installation
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ClosureClosure
Final ConceptFinal ConceptInitial ConceptInitial Concept
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P.S. . . . . . .P.S. . . . . . .
And so they went ahead and built And so they went ahead and built the test chamber . . . . .the test chamber . . . . .
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The fanfare of trumpetsThe fanfare of trumpets
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P.S. . . . . . .P.S. . . . . . .
But the bean counters saidBut the bean counters said
“ “ let’s try to do without the swirl breaker “let’s try to do without the swirl breaker “
and verily the measured results fell shortand verily the measured results fell short
of the client’s design specification .of the client’s design specification .
and so they put the swirl breaker back, and so they put the swirl breaker back,
and came back for more modelling , and came back for more modelling ,
to “ fine tune ” the designto “ fine tune ” the design
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The Test Chamber The Test Chamber “ as built ”“ as built ”
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Changes to model for Changes to model for “ as built “ test cell “ as built “ test cell
geometrygeometry
Smaller 10-fan unit, located symmetricallySmaller 10-fan unit, located symmetrically
and reversedand reversed Chiller intakes: uniform flux along sides Chiller intakes: uniform flux along sides
and bases of units, but not at endsand bases of units, but not at ends Anti-clockwise swirl at chiller fan outletsAnti-clockwise swirl at chiller fan outlets Prescribed, non-uniform fan outlet Prescribed, non-uniform fan outlet
temperatures; intake values computedtemperatures; intake values computed Non-uniform fan swirl profileNon-uniform fan swirl profile
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Changes to model for Changes to model for “ as built “ test cell “ as built “ test cell
geometrygeometry
Domain extended upwards to Domain extended upwards to include representation of outlet include representation of outlet plenumplenum
Non-uniform inlet flow distribution, Non-uniform inlet flow distribution, based on measured valuesbased on measured values
Triangular-section wall protrusionsTriangular-section wall protrusions “ “ Fine mesh ” swirl breakerFine mesh ” swirl breaker
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Model for “ as built “ Model for “ as built “ test cell geometrytest cell geometry
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Changes to model for Changes to model for “ as built “ test cell “ as built “ test cell
geometrygeometry
Chamber air flow up to Chamber air flow up to 92.592.5 m m33/s/s
Chiller throughflow up to Chiller throughflow up to 7272mm33/s/s
Chiller heat input down to Chiller heat input down to 869869 kW kW
Grid nodalisation up to Grid nodalisation up to 276,000276,000
cellscells
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“ “ As Built “ Test Cell As Built “ Test Cell Geometry :Geometry :
“ Fine tuning ” simulations“ Fine tuning ” simulations
Effect on intake temperature profile Effect on intake temperature profile
ofof
Uniform and non-uniform TUniform and non-uniform Tfanfan
distributionsdistributions
Swirl breaker fitmentSwirl breaker fitment
Fan swirl angleFan swirl angle
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Changes to model for Changes to model for “ as built “ test cell “ as built “ test cell
geometrygeometry
Run SpecificationRun Specification Non-uniform fan outlet Non-uniform fan outlet
temperatures, based on temperatures, based on experimental measurements. experimental measurements. Maximum temperature = 54.4Maximum temperature = 54.4ooCC
Minimum temperature = 42.6Minimum temperature = 42.6ooCC Fan swirl angle 45Fan swirl angle 45oo
“ “ As built ” swirl breaker designAs built ” swirl breaker design
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“ “ As built ” test cell As built ” test cell geometry:geometry:Flow pattern at chiller Flow pattern at chiller intakesintakes
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“ “ As built ” test cell As built ” test cell geometry:geometry:Temperatures at intake Temperatures at intake levellevel
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“ “ As built ” test cell As built ” test cell geometry:geometry:Flow patterns at fan outlet Flow patterns at fan outlet levellevel
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“ “ As built ” test cell As built ” test cell geometry:geometry:Temperatures at fan outlet Temperatures at fan outlet levellevel
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“ “ As built ” test cell: Flow As built ” test cell: Flow patterns patterns below swirl-breaker levelbelow swirl-breaker level
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“ “ As built ” cell: As built ” cell: Temperatures Temperatures
below swirl-breaker levelbelow swirl-breaker level
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“ “ As built ” test cell: Flow As built ” test cell: Flow patterns patterns at central outlet lip levelat central outlet lip level
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“ “ As built ” cell: As built ” cell: Temperatures Temperatures at central outlet lip levelat central outlet lip level
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“ “ As built ” cell : Flow As built ” cell : Flow patterns at section patterns at section through fans 3 & 4through fans 3 & 4
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“ “ As built ” cell : As built ” cell : Temperatures at section Temperatures at section through fans 3 & 4through fans 3 & 4
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“ “ As built ” cell : Flow As built ” cell : Flow patterns at section patterns at section through fans 7 & 8through fans 7 & 8
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“ “ As built ” cell : As built ” cell : Temperatures at section Temperatures at section through fans 7 & 8through fans 7 & 8
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“ “ As built ” cell : Flow As built ” cell : Flow patterns at section patterns at section through near-side fans through near-side fans
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“ “ As built ” cell : As built ” cell : Temperatures at section Temperatures at section through near-side fansthrough near-side fans
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“ “ As built ” cell : Flow As built ” cell : Flow patterns at section patterns at section through far-side fansthrough far-side fans
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“ “ As built ” cell : As built ” cell : Temperatures at section Temperatures at section through far-side fansthrough far-side fans
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“ “ As built ” test cell : As built ” test cell : Chiller intake temperature Chiller intake temperature profileprofile
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“ “ As built ” test cell : As built ” test cell : Chiller intake temperature Chiller intake temperature profileprofile
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ConclusionsConclusions
Highly non-uniform fan discharge Highly non-uniform fan discharge temperatures lead to inlet temperature temperatures lead to inlet temperature variations along length of unitvariations along length of unit
Local fluctuations can exceed 1 degree, Local fluctuations can exceed 1 degree, especially close to top of unitespecially close to top of unit
However, mixed-mean values for each However, mixed-mean values for each unit remain well below this criterionunit remain well below this criterion
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THANK YOU FOR YOUR THANK YOU FOR YOUR ATTENTIONATTENTION
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Points of ContactPoints of Contactfor further informationfor further information
Flowsolve LtdFlowsolve Ltd
Dr. Paddy PhelpsDr. Paddy Phelps
Dr. David GlynnDr. David Glynn
130 Arthur Rd.130 Arthur Rd.
Wimbledon ParkWimbledon Park
SW19 8AASW19 8AA
0208 944 09400208 944 0940
[email protected]@flowsolve.com
IAC LtdIAC Ltd
Mr. Geoff HowseMr. Geoff Howse
Mr. Greg SmithMr. Greg Smith
IAC HouseIAC House
Moorside RoadMoorside Road
WinchesterWinchester
Hants SO23 7USHants SO23 7US
01962 87300001962 873000