GT-POWER FAMILARISATION SIMULATING THE INTERCOLER AND CALCULATING THE PRESSURE DROP AND HEAT TRANSFER ACROSS THE COOLER

1. Explore the GUI of GT SUITE and list down modules available with brief description.

GT-ISE : It is Gamma Technologies -Integrated Simulation environment, GT-ISE is the main interface where models are built, simulation settings are declared and simulations are launched.It is a place where various components are brought into a project map and connected together to form a model.

GEM3D: It converts 3D CAD models into 1D GT-SUITE models. It is a 3D-graphical pre-processer that combines, building and importing tools used to create 1D-gt suite models from 3d models.

COOL3D: GT-SUITE is the ideal modelling platform for vehicle cooling analysis.GT-suite models can be used to anlyse pressure drop,flow distribution and thermal performance of liquid circuits that cool heat-generating components.The separate COOL3D tool allows for 3D model building and automatic export of underhood cooling module.

VT DESIGN:It is a graphical pre-processor tool for valve train and cam design.

GT-SPACECLAIM:It is a 3D CAD tool, in which CAD models and preparation can be done.

GT-POST:Once simulation is complete,results are viewed in the GT-POST. It is a graphical interface that enables viewing and manipulating of the data collected from the smulation

INTEGRATED OPTIMIZATION:Every GT license includes full access to a builtin optimizer that allows optimization of any combination model.

DISTRIBUTED COMPUTING:Distributed computing enables models with multiple cases to be divided among the many cores of a cluster with multiple execution noodes, resulting in significant reduction in overall time to obtain results. Every GT license includes full access to a distributedcomputing

DOE&DOE POST:DOE Design tool and DOE -POST (Design of experiments),GT-SUITE includes comprehensive tools for Design of Experiments (DOE) creation,analysis and optimization

GT-SUITE contains all GT libraries and capabilities.The ideal choice for full vehicle design and analysis,GT-SUITE offers an all-inclusive package that provides an important cost advantage to users.

ENGINE PERFORMANCE AND ACOUSTICS

EXHAUST AFTERTREATMENT

EVAPORATIVE EMISSIONS

COOLING SYSTEMS AND THERMAL MANAGEMENT

AIR CONDITIONING/WASTE HEAT RECOVERY

FUEL INJECTION

HYDRAULIC AND PNEUMATICS

LUBRICATION CIRCUITS

VEHICLE AND HEV FUEL ECONOMY AND PERFORMANCE

TRANSMISSION AND SHIFT QUALITY

CRANKTRAIN AND CRANKSHAFT DYNAMICS

VALVE TRAIN KINEMATICS AND DYNAMICS

TIMING AND FRONT END DRIVE SYSTEMS

BATTERY MODELLING-ELECTRICAL EQUIVALENT

CONTROLS

IN ADDITION TO THE ABOVE,GT ALSO BUNDLES VARIOUS TOOLS AND MODELS:

Tools:

GT-AutoLion:integrate autolion battery models directly into GT-SUITE\'s electrical and thermal domains

GT-power-xRT:tool dedicated to running detailed GT-POWER engine models on HiL platforms

GT-SUITE-RT:to run GT-SUITE models on HiL platforms

CONVERGE Lite:sub-licensed from convergent science

GT-SPACECLAIM:sub-licensed from spaceclaim

GT-LINEARIZATION:linearization of models for control development

MODELS:

Lithium Ion Battery-dynamic battery model

Electric Motor-dynamic motor model sub-licensed from JMAG

FRM Engine Database-set of 23 fast-running engine models representative of modern engines

2. Locate following settings:

• Time control flag
• Time step and solution control
• Integrator/Solver type
  

1) Time control flag is in RUN SET UP

2) Time step and solution control is at Flow cotrol

3)Integrator/solver type is at ODE control

3. Explore intercooler tutorial and note down all settings of:

• Run setup
• Advanced setup
• Plot setup
• Output setup

Time control TAB

Time control flag is continous

Maximum simulation duration(Time) is in sec 0.5

Minimum simulation duration(Time) is in sec ignore

Automatic shut-off when steady state ON

Main driver(Defines Periodic Frequency)-automatic

Initialization TAB

Initialization state is user_imposed

part attributes is selected

Flow control TAB

Part Name List Object Identifying Circuits belong to- default settings

Time Step and Solution Control Object-Explicit

ODE control TAB

Part Name List Object Identifying Circuits Belonging to Column-default
Matrix Sparse Format Solver (BETA for CSR)-skyline
Matrix (Node Order) Optimization Method-cuthill-Mckee
Integrator/Solver Type-Explicit-Runge-Kutta
Time Step and Solution Control Object-Explicit-default
Time Step Output Frequency-default
Solve All Circuits Together (Single Solution Cluster for the Column)-selected
Displacement SS Tolerance for Auto Shut-Off-ignore
Velocity Steady-State Tolerance for Auto Shut-Off-ignore
Torque Imbalance Tolerance for Auto Shut-Off-def(=0.002)
Consecutive Cycles/RLT Update Intervals for Steady-State-1
Modal Analysis Property Object-ignore
Matrix Inversion Scheme (electrical sol. only)-SVD

SIGNAL control TAB

All settings are default or ignore

THERMAL CONTROL TAB

Thermal Wall Calculation Interval-default
Thermal Wall Steady-State Tolerance for Auto Shut-off-ignore
Convergence Threshold for Flow Solver Skipping-ignore
Number of Thermal Calculation Intervals to Skip Flow Solver-ignore
Periods at Initial Wall Temperature (WallTempSolver only)-default

ConvergenceRLT

RLT Convergence checks for steady-state auto shut-off

Advanced setup:

General TAB:

All settings are either Default or ignore

Flow TAB:

Bend Loss Table
Gibbs Equilibrium Calculation
Adjust Nitrogen Molecular Weight to Compensate For Argon
Air Object for Ref Stoich AF Ratio (or value for multi-fuel models)
Dump 2nd law output?
Dead State for 2nd Law Output
More Conservative Timestep Limit for Single-Volume Pipes
More Conservative Timestep Limit for Flowsplits with Small Holes
More Conservative Timestep Limit for Absorbing Flowsplits (Wool)
Stable Flow Through Cylinders at Large Timesteps
Cylinder Efficiency Analysis
Improved Stagnation Condition Calculation in Turbomachinery Templates
Alternative Calculation of Laminar Flow Losses in FMTs
Alternative Orifice Calibration Method for FlowPDropSimple Objects
Improved Calculation of Default Pressure Loss Coefficient for Diffusers
Improved Implicit Solver Global Residual Definition
Improved FluidRefrigerant Properties Lookup
Improved Scavenging Profiles Lookup
PipeTable Treated as a Solver Compound
Use Min/Max Temperature Limits when Evaluating Properties
Use Faster Momentum Calculation
Mass Fraction Threshold to avoid Underflow Slowdown
Transport Properties for Species without Data
Clausius-Clapeyron Based Saturation Curve Calculation for Water
Alternate Solver for Improved Stability (Explicit Only)
Alternate Implicit Solver for Faster Convergence of Multi-Fluid Flows
Automatic Detection of IVC for Cylinder RLT Determination

Mechanics TAB:

Gravitational Acceleration Vector-ignore

Restart TAB:

VersionChanges TAB:

Version Setting for Non-itemized Changes
Detailed Evolution Flags (GT Use Only)
Acoustics
Improved Linear Analysis Calculation for Non-default Orifices Connected to Boundary Condition
Improved Linear Analysis Calculation for PipeRoundFlexWall
Corrected Resistance for Absorbing Flowsplits (Wool)
Improved Steady Thermal Solution for Absorbing Flowsplits (Wool)
Compressors, Turbines, Pumps
Fix Turbine Template RLTs with more than 1 Inlet
Improved Enthalpy Calculation for Pumps
Improved Friction Calculation for Internal Turbine Wastegate
Turbine/Compressor: Improved Temperature of Exiting Gas
Controls
Improved Initialization of Controls Components
Improved \'time\' Variable for Controls Components Equations
Fix Model Convergence Check if Controller Deactivation is Used
Corrected Initialization for PIDController
Corrected Indices for Product and PIDController Templates
Corrected SignalGenPhaseFiringOrder for Main Driver with Non-Zero Start of Cycle
Cranktrain
Corrected Calculation of Avg. Engine Speed (when actuated)
Improved Integration of EngineCrankTrain RLT\'s
Improved Integration of EngineCrankTrain Cycle-Averaged Sensors
Corrected Actuation of Oil and Coolant Temperatures for EngFrictionSR
Cylinders
Fix Cylinder Heat Transfer Rate and CrankTrain Inst. Heat Rejection Rate Sensors (RT Solver)
Corrected Valve Heat Transfer for Cylinder Pressure Analysis
Improved EVO Detection for Cylinder Heat Transfer
Fix EngCylinder Heat Transfer RLT
Fix Maximum Temperature RLTs
Correct Improper Disabling of In-Cylinder Radiation
Corrected GTI_Cylinder Real Gas Option
Improvements to EngCylFlame for Non-SITurb Use
Corrected Knock Induction Time Integral RLT for SITurb
Include Fresh H2O and CO2 in the Diluent Concentration for Kinetics-Fit-Gasoline Knock Model
Fix Cylinder Slaving
Allow Actuation of Combustion Attributes Until Start of Combustion
Correction to non-standard MEP RLTs
Corrected Cylinder Emissions RLTs When Using Emissions Map
Piston Pin Offset Correction
Corrected Shifting and Smoothing of Pressure for Multi-cycle TPA
Enable Knock Calculations at Start of Cycle
Improved Vol. Eff. for Cylinders in 2+4 Stroke Mode
Improved Normalization of Combustion Quantities
Fix CCV calculations for the FVV model
Corrected FluidMixture handling in EngCylInit for non Fuel Species
Fixed Initialization of some Cylinder Heat Transfer Models
Allow Radiation Heat Transfer for SI Combustion
Fix Dynamic Compression Ratio RLT for Piston Position Actuation
Fix Calculations for EngCylCombDualFuel
Rebalance Species Mass Fractions when Using Soot Model
Fix PreChamber Calculations
Data
Corrected XYZPoints Behavior when Upper/Lower Boundaries Intersect
Corrected Non-Default Units for Excel Array Data
Improved Truncation of Data in XYTable
Improved Moving Average Algorithm
Use Correct Driver for ProfileAngles when in Load Mode
Correct ProfilePeriod Lookup when TimeControl is \'Continuous\'
Corrected Conversion of Non-Defaults Units in XYZFunction
Corrected RLTDependenceMulti Lookup
Corrected Conversion of Non-Default Units in RLTDependenceMulti
Friction & Tribology
Composite Surface Roughness Calculation Method
Corrected Mean Surface for Roughness Parameter Extraction (Tomanik/McCool)
Corrected Effect of Lubricated Pad Position on Piston Friction
Corrected Impedance Maps for Side-pressurized Bearing
Electrical
Improved Initialization of Electromagnetics Components
Corrected Stator Motion when Incoming
Improved Explicit Electromagnetics Solution
Fix Fuel Cell Calculations
Flow, Other
Improved Solution for EndEnvironmentTPA
FlowPDropTableRef and FlowPDropLossCoef: Improved Handling of Low Flow Data
Fix Altitude Correction with Previous Case Initialization
Improved FluidReservoir Solution if Liquid/Gas Interface Crosses a Port
Improved Tank3D Solution if Liquid/Gas Interface Crosses a Port
Fluid Properties
Improved Evaluation of Fluid Properties
Improved Combustion Calculations
Improved Calculation of Latent Heat when Condensing Using \"on_wall\"
Improved Run-time Evaluation of Fluid Properties
Improved Enthalpy for FluidNASA-LiqGas below Minimum Temperature of Fitting Range
Heat Exchangers
Corrected Heat Transfer Area When Scaling MatrixHA
Corrected Volume Calculation for Multi-Pass HXs
Improved Pressure Drop Correlation for Refrigerant HXs
Improved HxNuMap(Refrig) Correlation
Improved FlowPDrop Regression with Humid Air Condensation
Improved HxNuMap* Preprocessing
Corrected Louver-Fin Correlation
Improved Results for HxGeomGeneral with Single Volume
Hydraulic
Improved Jet Force Calculation for Spools
Corrected Maximum Area for SpoolNotchGeometry(MH)
Corrected Non-Linear Spring for FluidPistonAndSpring
Injectors
Improved Solution for GT-POWER Injectors
Improved Handling of Transient Injector Quantities
Correct Calculation of Global CA for valves and injectors
Improved Solution when Injecting into Burner
Miscellaneous
Corrected Explicit Euler ODE Integration
Corrected End of Cycle Detection for ODE Circuits using ISS
Alternative Maximum Timestep for Models Without Thermal Parts
Remove 0.0008 sec Cylinder Timestep Restriction
Parallel Processing Fixes
Improved Driver Angle Sync. for Multi-Circuits Models using ISS
Improved Consistency of Part Order Read by Solver
Improved Unit Handling for Arrays
Improved Unit Handling for Temperature Shift Attributes
Orifices, Valves, Throttles
Improved Flow Calculation in Valves, Throttles
Update Valve Lift Profile at Local Start of Cycle
Improved Logic for Valve Type Detection
Corrected Valve RLTs
Enable Part Override for Valve Reference Diameter
Allocate Valve Lift Profiles per Parts
Improved Solution for Orifices with Thickness
Apply Laminar Face Friction Multiplier in Orifices
Improved Discharge Coefficient Calculation for Contractions
Corrected Flow Area for Multiple Holes in Orifice (Implicit Solver)
Allow Valve*Conn to Use Driver from Adjacent EngCrankcase Part
Corrected Area for Select Valves in Hydraulics/Pneumatics (Simple) Library
Corrected XYTable Usage for CD in ValveActuLiftAreaCon
Pipes, FlowSplits
Improved Solution for FlowSplitTRight
Use Geometric Area for Pipe and FlowSplit Friction Loss
Fix Non-Circular Pipe improved_friction_bend Flow Loss Model
Enable transient profile in puddle fuel fraction in port
Fix for switching condense/evaporate option case by case
Thermal
Always Model Liner Inlay as Separate FE Structure
Improved Lookup Accuracy for F.E. Cylinder Structure Gas Boundary Conditions
Improved Laminar Heat Transfer Model
Improved Thermal-Flow Solution Method
Corrected Conduction for PipeCrossSection and PipeRectangle
Improved Thermal Solution For FlowSplitNode
Fix EngCylTWallSoln Time Step for Multiple ODE Circuits
Fix Effective Gas Temperature for Calculated Wall Temperature
Fix Port to Head Conduction Heat Trans. Area
Improved Thermal Wool Solution for Continuous Simulations
Fix Flowsplit and FluidMachineChamber Heat Transfer Coefficient If Port Area is 0
Fix RLT for Piston Skirt Net Heat Transfer Rate
Fix def Piston/Bore Area Ratio for Custom FE Cylinder
Improved Execution Sequence for Thermal Solution
Corrected Thermocouple Solution When the Same Thermocouple is Used in Multiple Parts
Corrected Expansion Diameter Calculation in FluidMachineChamber
Corrected Thermal Solution Initialization
Fix External HTC behavior in Temperature parts
Corrected Thermocouple Temperature Initialization
Uncategorized
Enable Mass & Energy Balance Correction in CFDFieldImport
Fix Detection of Refrigerant Circuits

PATHS TAB:

Paths Specified Explicitly Below
Paths Array Reference Object

MISCFILES:

Additional Files to Send (Distributed Runs) ign
File Type ASCII

PLOT SET UP:

All default setting are provided

OUTPUT SET UP:

DATA STORAGE TAB:

RLT Calculation Interval -0.05

Storage Level for All Parts NOT Listed Below-ALL
Storage Level for \"Exception\" Parts Listed Below-ALL
\"Exception\" Parts List-Ignore

GENERAL TAB:

Legend for Plot Header (OBSOLETE)-default

Timestep plot -on

Suppress.brf file(file not available not available in future)-on

GT-POST SETUP TAB:

X-Axis RLT for Case Sweep Plots-default
X-Axis RLT for Time RLT Plots (only used in Periodic Circuits)
Automatically Compare RLT Results with External Data

FLOW TAB:

Calculate Water Saturation (Dew) Temperature RLT-LastRL Interval
Store Flow and Engine Results Summary in .out File?-No

ODE-MECH TAB:

ODE Solver Numerics Results-ignore
Mechanical Model 2-D Plot and Animation Object-ignore
Kinematic Model 2-D Plot and Animation Object-ignore
Frequency Analysis 2-D Plot and Animation Object-ignore
Mechanical Model 3-D Plot and Animation Object-ignore

SCOREBOARDRLTS TAB:

Cranktrain- Engine
Cylinder -Cylinder
Turbo -Turbo
Lubrication- Lubrication
Detailed Injector -Injector
Vehicle -Vehicle
Heat Exchanger -HeatExchangers
Refrigerant Flow Machinery- RefrigFlowMach
Battery -Battery

USER SCOREBOARD RLTS TAB:

All values are default or ignore

END OF RUN TABLES TAB:

Location of Model Configuration Sweep -Case_Setup
Parameter Defining Configurations- ign
Results for each Model Configuration in Column or Row- Column
EndOfRunTable Object 1 -ign
EndOfRunTable Object 2 -ign
EndOfRunTable Object 3 -ign
EndOfRunTable Object 4 -ign
EndOfRunTable Object 5 -ign

4. Problem:

Given

• Diameter of cooler inlet and outlet pipe= 50 mm
• Length of the CAC= 1000 mm
• Inlet mass flow rate = 1200 kg/ h at 100 degC
• Outlet pressure 2 bar at 30 deg C

• Calculate the total heat transfer at Charge air cooler (CAC)
• Calculate pressure drop across CAC

First have enter the values in GT-ISE, inlet and outlet that is 50mm, outlet is default value as input diameter,and length is 1000mm.

Here at inlet mass flow rate is 1200kg/hr at temperature 100C

At outlet pressure is 2 bar at temperature of 30c.

As per the given problem after entering the above values, now we can execute the program which intern opens post processing tool that is GT-POST.Where can check the pressure drop across air cooler and heat transfer across air cooler.

After giving the inputs and now for execution it asks the values in time control tab , maximum simulation duration time given is 30 seconds.

The steady state is achieved and simulation run and achieved the results with help of GT-POST

Pressure drop across CAC is :1.10E-5 bar

Total heat transfer at Charge air cooler is 7.554 KW