On real-time creep damage prediction for steam turbine

In this paper, in order to solve the calculation problem of creep damage of steam turbine rotor, a real-time calculation method based on finite element model is proposed. The temperature field and stress field of the turbine rotor are calculated using finite element analysis software. The temperature data and stress data of the crucial positions are extracted. The data of temperature, pressure, rotational speed, and stress relating to creep damage calculation are normalized. A real-time creep stress calculation model is established by multiple regression method. After that, the relation between stress and damage function is analyzed and fitted, and creep damage is calculated in real-time. A creep damage real-time calculation system is constructed for practical turbine engineering. Finally, a numerical simulation experiment is designed and carried out to verify the effectiveness of this novel approach. Contributions of present work are that a practical solution for real-time creep damage prediction of steam turbine is supplied. It relates the real-time creep damage prediction to process parameters of steam turbine, and it bridges the gap between the theoretical research works and practical engineering.

Design and analysis of a segmented blade for a 50 MW wind turbine rotor

Extreme-size wind turbines face logistical challenges due to their sheer size. A solution, segmentation, is examined for an extreme-scale 50 MW wind turbine with 250 m blades using a systematic approach. Segmentation poses challenges regarding minimizing joint mass, transferring loads between segments and logistics. We investigate the feasibility of segmenting a 250 m blade by developing design methods and analyzing the impact of segmentation on the blade mass and blade frequencies. This investigation considers various variables such as joint types (bolted and bonded), adhesive materials, joint locations, number of joints and taper ratios (ply dropping). Segmentation increases blade mass by 4.1%–62% with bolted joints and by 0.4%–3.6% with bonded joints for taper ratios up to 1:10. Cases with large mass growth significantly reduce blade frequencies potentially challenging the control design. We show that segmentation of an extreme-scale blade is possible but mass reduction is necessary to improve its feasibility.

Performance Analysis of Organic Rankine Cycle with the Turbine Embedded in a Generator (TEG)

The organic Rankine cycle (ORC) is a thermodynamic cycle in which electrical power is generated using an organic refrigerant as a working fluid at low temperatures with low-grade enthalpy. We propose a turbine embedded in a generator (TEG), wherein the turbine rotor is embedded inside the generator rotor, thus simplifying turbine generator structure using only one bearing. The absence of tip clearance between the turbine rotor blade and casing wall in the TEG eliminates tip clearance loss, enhancing turbine efficiency. A single-stage axial-flow turbine was designed using mean-line analysis based on physical properties, and we conducted a parametric study of turbine performance, and predicted turbine efficiency and power using the tip clearance loss coefficient. When the tip clearance loss coefficient was applied, turbine isentropic efficiency and power were 0.89 and 20.42 kW, respectively, and ORC thermal efficiency was 4.81%. Conversely, the isentropic efficiency and power of the turbine without the tip clearance loss coefficient were 0.94 and 22.03 kW, respectively, and the thermal efficiency of the ORC was 5.08%. Therefore, applying the proposed TEG to the ORC system simplifies the turbine generator, while improving ORC thermal efficiency. A 3D turbine generator assembly with proposed TEG structure was also proposed.

Flutter Behavior of Highly Flexible Two- and Three-bladed Wind Turbine Rotors

With the progression of novel design, material, and manufacturing technologies, the wind energy industry has successfully produced larger and larger wind turbine rotor blades while driving down the Levelized Cost of Energy (LCOE). Though the benefits of larger turbine blades are appealing, larger blades are prone to aero-elastic instabilities due to their long, slender, highly flexible nature, and this effect is accentuated as rotors further grow in size. In addition to the trend of larger rotors, new rotor concepts are emerging including two-bladed rotors and downwind configurations. In this work, we introduce a comprehensive evaluation of flutter behavior including classical flutter, edgewise vibration, and flutter mode characteristics for two-bladed, downwind rotors. Flutter speed trends and characteristics for a series of both two- and three-bladed rotors are analyzed and compared in order to illustrate the flutter behavior of two-bladed rotors relative to more well-known flutter characteristics of three-bladed rotors. In addition, we examine the important problem of blade design to mitigate flutter and present a solution to mitigate flutter in the structural design process. A study is carried out evaluating the effect of leading edge and trailing edge reinforcement on flutter speed and hence demonstrates the ability to increase the flutter speed and satisfy structural design requirements (such as fatigue) while maintaining or even reducing blade mass.

Principles of Imitation for the Loading of the Test Bench for Gas Turbines of Gas Pumping Units, Adequate to Real Conditions

The purpose of the study is to analyze the prospects for the development of loading methods for gas turbines as well as to develop a mathematical model that adequately describes the real operating conditions of the loading system at various loads and rotation speeds. A comparative analysis of the most common methods and technical means of loading the shafts of a free turbine at gas turbine plants intended for operation as part of gas pumping units is presented. Based on the results of the analysis, the expediency of using the loading model “Free Power Turbine Rotor–Hydraulic Brake” as a load simulation is shown. Recommendations for the creation of an automation system for the load testing of power plants have been developed. Mathematical models and Hardware-in-the-Loop simulation models of power plants have been developed and tested. One of the most important factors that predetermine the effectiveness of the loading principle is the possibility of software implementation of the loading means using software control systems that provide the specified loading parameters of the gas turbine.