I!IUNITED 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

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 simpleheat 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 (0.3to 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 (describedin appendix B) and that the coolant supply line within the FTS is approximately 10 feet long.

- 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 telemetrycooling 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 temperaturedistribution u •

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 simplewhen 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.

- 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.

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echanical Componets &Systems Mechanical Componets &SystemsComponent Design Technology Component Design Technology Ext. 8245

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APPENDIX A

CHIEF ENGINEER'S DESIGN REVIEW

Julio C. Banks, P .E.

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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