Application of a Creep Damage Constitutive Model for the Rotor of a 1000 MW Ultra-Supercritical Steam Turbine

A damage-based creep constitutive model for a wide stress range is applied to the creep analysis of a 1000 MW ultra-supercritical steam turbine, the inlet steam of which reaches 600°C and 35 MPa. In this model, the effect of complex multi-axial stress and the nonlinear evolution of damage are considered. To this end, the model was implemented into the commercial software ABAQUS using a user-defined material subroutine code. The temperature dependent material constants were identified from the experimental data of advanced heat resistant steels using curve fitting approaches. A comparison of the simulated and the measured results showed that they reached an acceptable agreement. The results of the creep analysis illustrated that the proposed approach explains the basic features of stress redistribution and the damage evolution in the steam turbine rotor over a wide range of stresses and temperatures.

Advanced Water Droplet Erosion Protection for Modern Low Pressure Steam Turbine Steel Blades

Blades for low pressure steam turbines operate in flows of saturated steam containing water droplets. The water droplets can impact rotating last stage blades mainly on the leading edge suction sides with relative velocities up to several hundred meters per second. Especially on large blades the high impact energy of the droplets can lead to a material loss particularly at the inlet edges close to the blade tips. This effect is well known as “water droplet erosion”. The steam turbine manufacturer use several techniques, like welding or brazing of inlays made of erosion resistant materials to reduce the material loss. Selective, local hardening of the blade leading edges is the preferred solution for new apparatus Siemens steam turbines. A high protection effect combined with high process stability can be ensured with this Siemens hardening technique. Furthermore the heat input and therewith the geometrical change potential is relatively low. The process is flexible and can be adapted to different blade sizes and the required size of the hardened zones. Siemens collected many years of positive operational experience with this protection measure. State of the art turbine blades often have to be developed with precipitation hardening steels and/or a shroud design to fulfill the high operational requirements. A controlled hardening of the inlet edges of such steam turbine blades is difficult if not impossible with conventional methods like flame hardening. The Siemens steam turbine factory in Muelheim, Germany installed a fully automated laser treatment facility equipped with two co-operating robots and two 6 kW high power diode laser to enable the in-house hardening of such blades. Several blade designs from power generation and industrial turbines were successfully laser treated within the first year in operation. This paper describes generally the setup of the laser treatment facility and the application for low pressure steam turbine blades made of precipitation hardening steels and blades with shroud design, including the post laser heat treatments.

Experimental and Numerical Investigation of Partial Admission of a Radial Turbocharger Turbine for Improved Off-Design Operation

A new partial admission concept for turbocharger turbine operation at off-design is designed and investigated numerically and experimentally in a turbocharger test rig. This new concept is called MEDUSA (Multiple Exhaust Duct with Source Adjustment) and is based on a partial admission turbine system consisting of several separate flow channels that connect the cylinder of the engine and individual nozzle segments of the turbine. The turbine flow is adjusted by the chosen admission rate according to the available exhaust enthalpy. In the present study, a reference turbocharger has been equipped with a four segment partial admission system instead of its conventional Waste-Gate scroll. The numerical results indicate similar loss mechanisms compared to an axial turbine stage, when partial admission is applied. Based on a stator design optimization, a design was chosen for manufacturing and testing on the turbocharger test rig. Despite the fact that the turbocharger efficiency at partial admission for the MEDUSA-system drops, a higher turbine expansion ratio can be achieved to obtain the same compressor operating point. These results indicate an enhanced use of the available exhaust enthalpy at part-load conditions, thus improving the turbocharger performance at low end torque engine speeds.

Numerical Investigation on the Vibration of Steam Turbine Inlet Valves and the Feedback to the Dynamic Flow Field

The power output of steam turbines is controlled by steam turbine inlet valves. These valves have a large flow capacity and dissipate in throttled operation a huge amount of energy. Due to that, high dynamic forces occur in the valve which can cause undesired valve vibrations. In this paper, the structural dynamics of a valve are analysed. The dynamic steam forces obtained by previous computational fluid dynamic (CFD) calculations at different operating points are impressed on the structural dynamic finite element model (FEM) of the valve. Due to frictional forces at the piston rings and contact effects at the bushings of the valve plug and the valve stem the structural dynamic FEM is highly nonlinear and has to be solved in the time domain. Prior to the actual investigation grid and time step studies are carried out. Also the effect of the temperature distribution within the valve stem is discussed and the influence of the valve actuator on the vibrations is analysed. In the first step, the vibrations generated by the fluid forces are investigated. The effects of the piston rings on the structural dynamics are discussed. It is found, that the piston rings are able to reduce the vibration significantly by frictional damping. In the second step, the effect of the moving valve plug on the dynamic flow in the valve is analysed. The time dependent displacement of the valve is transferred to CFD calculations using deformable meshes. With this one way coupling method the response of the flow to the vibrations is analysed.

Damping Behavior of Blades From Small Radial Turbines

Next to excitation forces and the dynamic properties of mistuned structures the damping behavior is a key feature to evaluate the dynamic turbine blade response and thus the HCF life of a bladed disk (blisk). Just as the determination of the mistuning properties and the assessment of the vibration excitation, the evaluation of damping is also subject to uncertainty especially considering the wide operating range of a small radial turbine of a turbocharger. Since the total damping is composed of material damping, structural damping and aerodynamic damping, which are affected by parameters, like the eigenform of the vibration, the magnitude of the vibration amplitude and aerodynamic properties, the total damping can be strongly dependent on the operating conditions. The study at hand provides results from investigations that allow estimating the contribution of aerodynamic damping on the total damping. Experimental and numerical analysis of radial turbines from turbochargers for vehicular engines with variable turbine inlet vanes were performed. Measurements under different environmental conditions such as at rest and during operation, as well as unsteady CFD calculations and, coupled flow and structural calculations were carried out. A change in total damping could be found depending on the density of the surrounding gas by vibration measurements in operation on the hot gas test bench. But it was also shown that the total damping is decisively influenced by the mistuning of the structure. On one side the structural damping is varied by the variation in mistuned blade vibration amplitudes and otherwise the aerodynamic damping is influenced by the different inter blade phase angles (IBPA ) due to the mistuning, which is a symptom of geometric differences and material inhomogeneity in the wheels. Finally, the estimated total damping values were utilized in forced response calculations using a mistuned FE-model of a real turbine and excitation forces from unsteady CFD calculation. The magnitudes of the measured vibration amplitudes were compared with results from numerical analysis to validate the numerical model with focus on the investigation about the total damping. The deviation between the results was ±10% for different eigenforms and excitation orders.

Radial Inflow Turbine Design Through Multi-Disciplinary Optimisation Technique

Multidisciplinary design optimisation (MDO) is nowadays widely employed to obtain advanced turbomachines design. The aim of this work is to provide a complete tool for the aeromechanical design of a radial inflow gas turbine. The high rotational speed of such machines, especially if used for micro cogenerative power plants, coupled with high exhaust gas temperature, exposes blades to really high centrifugal and thermal stresses; thus the aerodynamics optimisation has to be necessarily coupled with the mechanical one. Such an approach involves two different computational tools: a fully 3D Reynolds Averaged Navier-Stokes (RANS) solver is used for the aerodynamic optimisation, while an open source Finite Element Analysis (FEA) solver is employed for the mechanical integrity assessment. The geometry parameterization is handled with a commercial tool that employs b-spline advanced curve for blades and vanes definition. The aerodynamic mesh generation is managed via dedicated tools provided by the CFD software and it is a fully structured hexahedral multi-block grid. The FEA mesh is built by means of a harmonic map approach, which is able to provide high quality second order unstructured grid preserving geometrical features starting from boundary surfaces of the fluid domain. The finite element calculation provides stresses, displacements and eigenmodes that are used for mechanical integrity assessments while the CFD solver provides performance parameters and local thermodynamic quantities. Due to the high computational cost of both these two solvers, a metamodel, such as an artificial neural network, is employed to speed up the process. The interaction between two codes, the mesh generation and the post processing of the results is obtained via in-house developed scripting modules. Results obtained are presented and discussed.

The Analyses for the Casing Improvements of the MPM-20 Engine

The operational issues of a small turbojet engine MPM – 20 are discussed. The engine was created by modifying the Soviet turbostarter TS – 20B/21 designed for short-term operation. It is necessary to make structural modifications that allow for the long-term operational premise of the engine. For this purpose, several analyses were focused on the thermally stressed parts. The first, a material analysis carried out on the outer casing of the combustion chamber and on the combustor liner reveals information about the mechanical properties of these structural nodes. It was necessary since there is no documentation of the engine with this information. Another analysis of the infrared emission spectra is important for monitoring operational conditions, especially from the temperature point of view. Subsequent stress analysis of the casing is based on results from previous analyses. It was used to observe the behaviour of the casing as operational conditions changed. This revealed a dangerous increase of thermally induced stress levels as temperature increased up to 150°C. Various structural modifications can be made in the future with these results, such as an application of a protective coating on the casing and combustor liner of the engine.

On-Line Prediction of Temperature and Stress in Steam Turbine Components Using Neural Networks

Considered here are Nonlinear Auto-Regressive neural networks with exogenous inputs (NARX) as a mathematical model of a steam turbine rotor used for the on-line prediction of turbine temperature and stress. In this paper on-line prediction is presented on the basis of one critical location in a high pressure steam turbine rotor, according to power plant common measurements, i.e., turbine speed, turbine load as well as steam temperature and pressure before turbine control valve. In order to obtain neural networks that will correspond to the temperature and stress the critical rotor location, an FE rotor model was built. Neural networks trained using the FE rotor model not only have FEM accuracy, but also include nonlinearity related to nonlinear steam turbine expansion, nonlinear heat exchange inside the turbine and nonlinear rotor material properties during transient conditions. Simultaneous neural networks are algorithms which can be implemented in turbine controllers. This allows for the application of neural networks to control steam turbine stress in industrial power plants.

Numerical Investigations of Tangential Direction Cooling in the Intermediate Pressure Cylinder (IPC)

The cooling protection of the hot end is the key technique for ultra-supercritical steam turbine to cool the hot components. In this paper, the internal flow mechanism and cooling characteristics in the tangential direction cooling channel in the intermediate pressure cylinder (IPC) are investigated using the method of computational fluid dynamics. Various turbulence models and mesh sizes are evaluated (the k-ε model, the k-ω model, the SST model). Also, calculated results of the nonrotating bottom wall are compared with the experimental results in a previous research to show the reliability of the CFD program used. Detailed predictions of the contours of velocity, pressure and temperature are carried out. The focus of this study is to investigate the effects of inlet Mach number, turbulent Prandtl number, rotational wall speed, and inlet turbulence intensity on the cooling effectiveness of the vortex channel. The inlet Mach number, the turbulent Prandtl number, the rotational wall speed and the inlet turbulence intensity varied from 0.315 to 0.512, from 0.71 to 1.0, from 0 to 3000rpm, and from 1% to 10%, respectively. Results show that the parameters have different effects on the cooling effectiveness of the vortex cooling chamber. The cooling effect of the vortex channel increases with increasing inlet Mach number and rotational wall speed, while decreases with the increasing turbulent Prandtl number. As the inlet turbulence intensity increases, the cooling effect increases firstly, and then decreases.

Lifetime Assessment of Steam Turbine Casing

Nowadays, in order to accommodate electrical grids that include fluctuating supplies of green energy, more and more fossil power plants are increasingly required to start up and shut down frequently. The increased number of stress cycles leads to a significant reduction of lifetime. In this paper, numerous load cycles of steam turbine casing including various start up and shut down conditions were numerically investigated by using the finite element analysis (FEA). The total strain throughout the cycles was directly calculated by the elastic-plastic material model. The delta equivalent total strain was determined by rainflow count method, and the assessment of lifetime was evaluated.