Crowdsourced Innovation A Next Generation Integrated Software Environment for Turbomachinery Cycle & Component Design, Analysis and Optimization

Transcription

1 Crowdsourced Innovation A Next Generation Integrated Software Environment for Turbomachinery Cycle & Component Design, Analysis and Optimization Turbo Expo 2015 Tuesday, June 16, 2015 Turbomachinery Mastered softinway.com

2 Agenda SoftInWay Background Adding Dimensions to the First Code In-house Development Present & Future of the Software Suite Crowdsourced Innovation Education Conclusions

3 About SoftInWay Founded in 1999, we are an international engineering company headquartered in Burlington, Massachusetts. SoftInWay Inc. specializes in developing efficient turbomachinery by offering our flagship software, AxSTREAM 3.4 and AxCYCLE, as well as consulting services and educational courses. The only company which does the complete development of every software, performs technical support and does consulting on turbomachinery We have five offices design, worldwide: analysis, and optimization Burlington, in-house. Massachusetts New York City, New York Zug, Switzerland Bangalore, India Kharkov, Ukraine We provide more than 200 companies with our software with 50+ engineers and more than 600 years of combined experience. 3

4 Scientific Management Team Dr. Leonid Moroz Founder & CEO Dr. Boris Frolov Director of Engineering Dr. Govorushenko Chief Scientist Dr. Romanenko Structural Expert Mr. Petr Pagur Director of Strategic Development 30+ years industrial & research experience Lead designer for AxSTREAM Formerly with NPO TURBOATOM Expertise in flow path design of gas turbines and steam turbines, analysis of transient operating conditions and in thermal field testing (220MW 1000 MW) 35+ years of industrial & research experience Expert in long blade aeromechanics with numerous publications & patents Formerly with GE Energy, Russia PhD thesis on Optimization with controlled reaction 30+ years of academic, Research and Industrial experience Co-authored 2 books on turbine design and optimization Has more than 80 publications on turbomachinery PhD on Axial Turbine Optimal Design Methods 24+ years of academic and research experience PhD in Machine Dynamic and Strength 15+ years experience in programming & numerical methods 25+ years experience in IT & CAD Formerly Chief of Turbomachinery CAD at TURBOATOM Key developer of AxSTREAM and AxCYCLE Head of Technical Support for AxCYCLE 4

5 Capabilities & Reach AxSTREAM 3.4 Suite AxSTREAM Hydro AxCYCLE AxCFD Engineering Services Education Classroom Workshops Online Courses STU 5

6 Engineering Services 1. Project Definition and Technical Specifications 2. Research & Development to Support New Designs 3. Preliminary Design & Feasibility Studies 4. Analysis of Existing Machine 5. Turbomachinery Retrofitting & Upgrades 6. FEA/CFD Analysis 7. Heat Transfer Simulations 8. Rotor Dynamics 9. Complete Design Process 10. Mechanical Design of Components Executed more than 70 consulting projects since inception to Industry and Research Organizations 6

7 Flagship Product of SoftInWay AxSTREAM 3.4 is a multidisciplinary design, analysis and optimization software that provides a fully integrated and streamlined solution encompassing the complete flow path design process from concept to 3D blade, all in a seamless interactive user interface. AxSTREAM Pro AxSTREAM Hydro AxSTREAM Edu AxSTREAM Lite 7

8 Examples Technical Support Always there to address your needs. Simple questions License requests Extensive questions Feature requests 1. How to correctly position the blade in AxSLICE TM. 2. The difference between the efficiencies used in the software. 1. License creation/renewal 2. Addition of new modules to existing license. 1. Details about loss models. 2. Effect of design and machine parameters on overall result. 1. Incorporation of a new fluid in AxCYCLE TM 2. Additional features like tilting of the first nozzle, rotor hub taper variation in the Preliminary Design module, etc. 1 hour 1 hour 1 business day Dependent on project 8

9 Present & Future of the Software Suite Software developed cross-industries Technologies can be adopted and implemented for a specific industry and become readily available for the other. Benefits from research world that is state-of-the-art equipment and can be used in other applications. Customer & employee-driven features (through our consulting services & technical support)

10 Adding Dimensions Come to booth #616 to learn about what s AxCFD & AxSTRESS (1 st gen) AxSTREAM V.3 released AxCYCLE AxSTRESS (2 nd gen) coming soon Diagonal compressor AxCFD standalone Fluid toolbox AxSTREAM for axial compressor AxSLICE AxSTREAM Hydro AxSTREAM for radial machines AxSTREAM for axial turbine AxSTREAM development starts SoftInWay is founded as a consulting company 10

11 Adding Dimensions From 1D conceptual design code to complete package of turbomachinery component & thermodynamic system Includes import & export Fully integrated tool with seamless data transfer From design to analysis and back within a few clicks without needs to import/export. Eliminates human error. Express FEA & CFD Module-driven pricing for the AxSTREAM & AxCYCLE, future tools

12 Crowdsourced Innovation 12

13 AxSLICE Project: Axisymmetric calculation of aero and thermodynamic parameters of an existing axial compressor for Nationaal Lucht- en Ruimtevaartlaboratorium Problem: Client needed a reliable, accurate and time efficient tool to extract necessary data to run streamline calculation on the machine. Solution: Development of AxSLICE which extracts geometric information at different spanwise locations from CAD models or clouds of points for analysis in AxSTREAM. For axial, radial, mixed-flow, counter-rotating turbines, pumps and compressors

14 AxSTRESS Project: Design of axial turbine with consideration of structural integrity for several OEMs in Europe, America and Asia. Problem: Usually a long and tedious iteration process between aerodynamic and structural analysis to design long blades with complex stacking. For example an 18-in blade was designed through 10 design iterations. Solution: Creation of AxSTRESS Full 3D structural (FEA) static, modal and harmonic analysis Includes attachment design, Campbell and interference diagrams generation Automatic user-defined mesh generator with geometry, materials and aerodynamic loads automatically inherited from the project/axcfd runs. Thanks to AxSTREAM s fully integrated architecture blades can be designed and used in AxSTRESS while preserving attachments and settings.

15 Customizable Leakage Models Project: Steam turbine design for Doosan Heavy Industries Problem: Accurate calculation of custom seals Solution: In AxSTREAM leakage and cooling flows balance as well as axial loads are calculated taking in account radial and axial clearances, sealing details, flow parameters, etc. Special infrastructure to use specific leakage models based on proprietary/known seals Flow diagram with leakages and cooling flows

16 Inductions Project: Steam turbine design for Peter Brotherhood Problem: No existing capability in AxSTREAM to account for inductions in turbomachinery analysis Solution: Created (in 3 days) the ability to use different formulations for inductions (including cooling flows), extractions, and recycling of fluid inside the flow path Flow diagram with induction flows

17 Material Properties Library Project: Design of blade using proprietary material for an OEM Problem: Need for additional and customizable materials database Solution: Development of AxSTREAM s fully customizable materials library with embedded items. Shareable material databases.

18 Loss Model Project: Design of a transonic axial compressor for Reaction Engines Problem: Client wanted to run calculations using a loss model specific to the application Solution: Implementation in AxSTREAM of a specific loss model able to model transonic flows in axial compressors.

19 Fluid Designer Project: Design of a small axial turbine for ITRI for ORC application Problem: Use of user-defined range for fluid properties accurate calculation Solution: Creation of Fluid Designer to create customized fluid files for single elements or userdefined mixtures for their specific range of applications Uses the NIST REFPROP database Additional functionalities of the Fluid Toolbox: Fluid properties calculator Fluid file generator for products of combustion

20 Axi-Radial Compressor Project: Design of a unmanned aerial vehicle s engine for Kutrieb research Problem: Determine the configuration giving the highest efficiency-to-weight ratio for the compressor of the gas turbine engine Solution: Development of axi-radial compressor element in AxSTREAM for design, analysis and optimization Combines advantages of both axial and centrifugal compressors

21 Diagonal Compressor Project: Design of a diagonal compressor for NAL Problem: Absence of diagonal compressor capability in AxSTREAM Solution: Development of diagonal compressor element in AxSTREAM for design, analysis and optimization Reduces component radial dimensions (vs centrifugal compressors) High performances Flow Path and 3D model of the diagonal flow compressor Performance map showing pressure ratio vs mass flow rate

22 Drilled & Reamed Nozzles Project: Design of a steam turbine with drilled and reamed nozzles for an Indian OEM Problem: Absence of such element in AxSTREAM and loss model for this type of component Solution: Implementation in AxSTREAM of D&R nozzles Creation of specific loss models based on experimental and numerical results for the configurations studied

23 AxCYCLE Project: Design of an organic Rankine cycle for a small, American consulting company Problem: Client needed easy-to-use, accurate and conceptual tool for simulation of heat balance for a range of ORC fluids Solution: Birth of AxCYCLE for thermodynamic simulation and heat balance calculation of entire cycles from restricted amount of known data Only thermodynamic data is used no need for mechanical or geometric data). Perfect for both the conceptual phase of a system as well as the analysis of an existing cycle.

24 AxCYCLE (continued) In addition to the tool itself some AxCYCLE components & functionalities where also implemented based on client requests, such as: Process diagram representation Addition of new components (real gas mixers, cooling towers, etc.) Expansion of fluid library Development of embedded optimization tool Cooling flows calculation in gas turbine applications

25 Education Our educational resources were createdfrom client requests to learn about fundamentals and steam turbines. Our training courses are both classroom-based and online, and can be requested and customized based on client needs. Free trial licenses are awarded after the training sessions. Our classes include: Steam and Gas Turbine Design Centrifugal Compressor Axial Compressor Axial and Centrifugal Pump Turbocharger Design and Performance Matching Design of Waste Heat Recovery System Heat Balance Calculation of Steam Cycles and Combined Cycles and Supercritical CO2 with AxCYCLE Thanks to our five global offices training is brought closer to our clients : Burlington, Massachusetts New York City, New York Zug, Switzerland Bangalore, India Kharkov, Ukraine

26 Education On a budget but still wanting to receive great training? If so you can opt for one or several of the following options: SoftInWay Turbomachinery University SoftInWay s new learning resource for on-demand classes, as requested by users Self-paced, online turbomachinery courses, exams, and certifications. Accompanying design/redesign, analysis, & optimization software packages More classes added regularly Tutorials and help files to go through hands-on practice with the software for beginners, engineers wanting to refresh on a particular module or desiring to learn about a new feature Free technical webinars every 6 weeks discussing the latest trends and developments of the industry.

27 Conclusions Rapidly-evolving, robust software suite that fits the needs of every application and industry. Starting from 1D conceptual design code for axial turbines to full design, analysis and optimization of axial, radial, mixed-flow, diagonal and counterrotating turbines, pumps and compressors plus thermodynamic cycles analysis in 15 years. Features driven by clients need throughout all industries. Work with a company: that uses, develops, and supports the Industry. Have ideas? Come visit our Booth 616 and let s chat. Also, feel free to join us for an industry networking Santos. You can pick up directions and information at our booth.

28 Contact Europe Contact: Phone: SoftInWay Switzerland GmbH Baarerstrasse Zug, Switzerland United States (HQ) Contact: info@softinway.com Phone: New England Executive Park Burlington, MA New York City Contact : info@softinway.com Phone: Madison Ave. New York, NY Just Released: SoftInWay Turbomachinery University Visit our online learning center to take self-paced course and exams to learn turbomachinery design certifications. Visit for detailed information 28