Analytical Heat Transfer Correlation for a Multistage Steam Turbine in Warm-Keeping Operation With Air

2018 ◽  
Vol 141 (1) ◽  
Author(s):  
Dennis Toebben ◽  
Adrian Hellmig ◽  
Piotr Luczynski ◽  
Manfred Wirsum ◽  
Wolfgang F. D. Mohr ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Steam Turbine ◽  
Power Plants ◽  
Thermal Stresses ◽  
Fluid Dynamic ◽  
Working Fluid ◽  
Slow Rotation ◽  
Heat Transfer Correlation ◽  
Operation Conditions ◽  
Heat Transfer Correlations

Due to the growing share of volatile renewable power generation, conventional power plants with a high flexibility are required. This leads to high thermal stresses inside the heavy components which reduces the lifetime. To improve the ability for fast start-ups, information about the metal temperature inside the rotor and the casing are crucial. Thus, an efficient calculation approach is required which enables the prediction of the temperature distribution in a whole multistage steam turbine. Considerable improvements of the computing power and numerical simulation tools today allow detailed investigations of the heat transfer and the flow phenomena by conjugate-heat-transfer (CHT) simulations. However, these simulations are still restricted to smaller geometries mostly by the number of elements. This leads to coarser numerical meshes for larger geometries, and thus, to a reduced accuracy. A highly accurate three-dimensional-CHT simulation of a whole multistage steam turbine can only be conducted with huge computational expense. Therefore, a simplified calculation approach is required. Heat transfer correlations are a commonly used tool for the calculation of the heat exchange between fluid and solid. Heat transfer correlations for steam turbines have been developed in a multitude of investigations. However, these investigations were based on design or to some extent on part-load operations with steam as the working fluid. The present paper deals with the theoretical investigation of steam turbine warm-keeping operation with hot air. This operation is totally different from the conventional operation conditions, due to a different working fluid with low mass flow rates and a slow rotation. Based on quasi-steady transient multistage CHT simulations, an analytical heat transfer correlation has been developed, since the commonly known calculation approaches from the literature are not suitable for this case. The presented heat transfer correlations describe the convective heat transfer separately at vane and blade as well as the seal surfaces. The correlations are based on a CHT model of three repetitive steam turbine stages. The simulations show a similar behavior of the Nusselt-number in consecutive stages. Hence, the developed area related heat transfer correlations are independent of the position of the stage. Finally, the correlations are implemented into a solid body finite element model and compared to the fluid-dynamic simulations.

Analytical Heat Transfer Correlation for a Multistage Steam Turbine in Warm-Keeping Operation With Air

2018 ◽  
Author(s):  
Dennis Toebben ◽  
Adrian Hellmig ◽  
Piotr Luczynski ◽  
Manfred Wirsum ◽  
Wolfgang F. D. Mohr ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Steam Turbine ◽  
Power Plants ◽  
Thermal Stresses ◽  
Fluid Dynamic ◽  
Working Fluid ◽  
Slow Rotation ◽  
Heat Transfer Correlation ◽  
Operation Conditions ◽  
Heat Transfer Correlations

Due to the growing share of volatile renewable power generation, conventional power plants with a high flexibility are required. This leads to high thermal stresses inside the heavy components which reduces the lifetime. To improve the ability for fast start-ups, information about the metal temperature inside the rotor and the casing are crucial. Thus, an efficient calculation approach is required which enables the prediction of the temperature distribution in a whole multistage steam turbine. Considerable improvements of the computing power and numerical simulation tools today allow detailed investigations of the heat transfer and the flow phenomena by Conjugate-Heat-Transfer (CHT) simulations. However, these simulations are still restricted to smaller geometries mostly by the number of elements. This leads to coarser numerical meshes for larger geometries and thus, to a reduced accuracy. A highly accurate 3D-CHT simulation of a whole multistage steam turbine can only be conducted with huge computational expense. Therefore, a simplified calculation approach is required. Heat transfer correlations are a commonly used tool for the calculation of the heat exchange between fluid and solid. Heat transfer correlations for steam turbines have been developed in a multitude of investigations. However, these investigations were based on design or to some extent on part-load operations with steam as the working fluid. The present paper deals with the theoretical investigation of steam turbine warm-keeping operation with hot air. This operation is totally different from the conventional operation conditions, due to the different working fluid with low mass flow rates and a slow rotation. Based on quasi-steady transient multistage CHT simulations, an analytical heat transfer correlation has been developed, since, the commonly known calculation approaches from literature are not suitable for this case. The presented heat transfer correlations describe the convective heat transfer separately at vane and blade as well as the seal surfaces. The correlations are based on a CHT model of three repetitive steam turbine stages. The simulations show a similar behavior of the Nusselt-number in consecutive stages. Hence, the developed area related heat transfer correlations are independent of the position of the stage. Finally, the correlations are implemented into a solid body Finite-Element model and compared to the fluid-dynamic simulations.

Numerical and Analytical Investigation of Heat Transfer Mechanisms and Flow Phenomena in an IP Steam Turbine Blading During Startup

2020 ◽  
Author(s):  
Dieter Bohn ◽  
Christian Betcher ◽  
Karsten Kusterer ◽  
Kristof Weidtmann
Keyword(s):  
Heat Transfer ◽  
Reynolds Number ◽  
Steam Turbine ◽  
Convective Heat ◽  
Power Plants ◽  
Thermal Stresses ◽  
Analytical Investigation ◽  
Computational Effort ◽  
Steam Turbines ◽  
Transfer Mechanisms

Abstract As a result of an ever-increasing share of volatile renewable energies on the world wide power generation, conventional power plants face high technical challenges in terms of operational flexibility. Consequently, the number of startups and shutdowns grows, causing high thermal stresses in the thick-walled components and thus reduces lifetime and increases product costs. To fulfill the lifetime requirements, an accurate prediction of the metal temperature distribution inside these components is crucial. The objective of this paper is to understand the predominant basic heat transfer mechanisms during an IP steam turbine startup. Convective heat transport is described by means of HTC's as a function of dimensionless parameters, considering predominant flow structures. Based on steady-state and transient CHT- simulations the HTC's are derived during startup and compared to correlations from the literature. The simulations outline that the local HTC generally increases with increasing axial and circumferential Reynolds' number and is mostly influenced by vortex systems such as passage and horseshoe vortices. The HTC's at the turbine stage surfaces can be modeled with a high accuracy using a linear relation with respect to the total Reynolds' number. The comparison illustrates that the correlations underestimate the convective heat transfer by approx. 40% on average. Results show that special correlation-based approaches from the literature are a particularly efficient procedure to predict the heat transfer within steam turbines. in the design process. Overall, the computational effort can be significantly reduced by applying analytical correlations while maintaining a satisfactory accuracy.

scholarly journals Prediction of the windage heating effect in steam turbine labyrinth seals

2017 ◽  
Vol 1 ◽  
pp. ETJLRM
Author(s):  
Simon Hecker ◽  
Andreas Penkner ◽  
Jens Pfeiffer ◽  
Stefan Glos ◽  
Christian Musch
Keyword(s):  
Steam Turbine ◽  
Power Plants ◽  
Thermal Stresses ◽  
Heating Effect ◽  
Steam Turbines ◽  
Labyrinth Seals ◽  
Cfd Simulations ◽  
Application Range ◽  
Operation Conditions ◽  
The Impact

Abstract Today’s steam turbine power plants are designed for highest steam inlet temperatures up to 620°C to maximize thermal efficiency. This leads to elevated thermal stresses in rotors and casings of the turbines. Hence, temperature distributions of the components have to be predicted with highest accuracy at various load points in the design process to assure reliable operation and long life time. This paper describes the windage heating effect in full labyrinth seals used in steam turbines. An analytical approach is presented, based on CFD simulations, to predict the resulting steam temperatures. A broad application range from very low to highest Reynolds numbers representing different turbine operation conditions from partial to full load is addressed. The effect of varying Reynolds number on the flow friction behaviour is captured by using an analogy to the flow over a flat plate. Additionally, the impact of different labyrinth geometries on the friction coefficient is evaluated with the help of more than 100 CFD simulations. A meta-model is derived from the numerical results. Finally, the analytical windage heating model is validated against measurements. The presented approach is a fast and reliable method to find the best performing labyrinth geometries with lowest windage effects, i.e. lowest steam temperatures.

scholarly journals Nusselt number correlation for turbulent heat transfer of helium–xenon gas mixtures

2021 ◽  
Vol 32 (11) ◽  
Author(s):  
Biao Zhou ◽  
Yu Ji ◽  
Jun Sun ◽  
Yu-Liang Sun
Keyword(s):  
Heat Transfer ◽  
Nusselt Number ◽  
Prandtl Number ◽  
Liquid Metals ◽  
Turbulent Heat Transfer ◽  
Working Fluid ◽  
Turbulent Heat ◽  
Heat Transfer Correlation ◽  
Heat Transfer Correlations ◽  
Prandtl Numbers

AbstractA gas-cooled nuclear reactor combined with a Brayton cycle shows promise as a technology for high-power space nuclear power systems. Generally, a helium–xenon gas mixture with a molecular weight of 14.5–40.0 g/mol is adopted as the working fluid to reduce the mass and volume of the turbomachinery. The Prandtl number for helium–xenon mixtures with this recommended mixing ratio may be as low as 0.2. As the convective heat transfer is closely related to the Prandtl number, different heat transfer correlations are often needed for fluids with various Prandtl numbers. Previous studies have established heat transfer correlations for fluids with medium–high Prandtl numbers (such as air and water) and extremely low-Prandtl fluids (such as liquid metals); however, these correlations cannot be directly recommended for such helium–xenon mixtures without verification. This study initially assessed the applicability of existing Nusselt number correlations, finding that the selected correlations are unsuitable for helium–xenon mixtures. To establish a more general heat transfer correlation, a theoretical derivation was conducted using the turbulent boundary layer theory. Numerical simulations of turbulent heat transfer for helium–xenon mixtures were carried out using Ansys Fluent. Based on simulated results, the parameters in the derived heat transfer correlation are determined. It is found that calculations using the new correlation were in good agreement with the experimental data, verifying its applicability to the turbulent heat transfer for helium–xenon mixtures. The effect of variable gas properties on turbulent heat transfer was also analyzed, and a modified heat transfer correlation with the temperature ratio was established. Based on the working conditions adopted in this study, the numerical error of the property-variable heat transfer correlation was almost within 10%.

Thermal Modeling and Mechanical Integrity Based Design of a Heat Shield on a High Pressure Module Solar Steam Turbine Inner Casing With Focus on Lifetime

2014 ◽  
Author(s):  
Peter Stein ◽  
Gabriel Marinescu ◽  
Dominik Born ◽  
Michael Lerch
Keyword(s):  
Heat Transfer ◽  
Steam Turbine ◽  
Power Plants ◽  
Thermal Stresses ◽  
Fluid Velocity ◽  
Peak Stress ◽  
Heat Shield ◽  
Total Power ◽  
Steam Turbines ◽  
Technical Requirements

As part of the renewable energies and because of their low environmental impact, solar thermal power plants enjoy a wide acceptance in the public. In the past years, several projects have been launched to install plants even with a total power output level beyond 200 MW, which require large size steam turbines. Steam turbines of solar power plants face much more start-ups and shutdowns, compared to typical fossil type baseload machines. In order to provide the required lifetime of steam turbine components, i.e. in high- and intermediate-pressure modules, accurate calculation methods of temperatures and heat transfer coefficients are essential for natural cooling and start-up assessment. Beside rotors, also turbine inner casings face high thermal stresses, especially close to the inlet spiral. At these conditions high thermal stress occurs, which prevents the part to meet the technical requirements. The paper below gives a solution how to avoid this high stress and a calculation method for inner casings. A heat-shield introduced around the inlet spiral separates the active cooling domain of the turbine cavity relative to a narrow domain around the inlet spiral, where the fluid velocity is negligible. A method on how to simplify heat transfer calculations below the heat shield region is investigated and discussed. The results are verified vs. a CFD based sensitivity analysis. Finally a reduction of the peak stress on the configuration with heat-shield is demonstrated relative to the peak stress calculated without heat-shield.

scholarly journals The use of a solution of the inverse heat conduction problem to monitor thermal stresses

2019 ◽  
Vol 108 ◽  
pp. 01003
Author(s):  
Jan Taler ◽  
Piotr Dzierwa ◽  
Magdalena Jaremkiewicz ◽  
Dawid Taler ◽  
Karol Kaczmarski ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Power Plants ◽  
Thermal Stresses ◽  
Thermal Power ◽  
Temperature Fields ◽  
Thick Wall ◽  
Fluid Temperature ◽  
Unsteady Temperature

Thick-wall components of the thermal power unit limit maximum heating and cooling rates during start-up or shut-down of the unit. A method of monitoring the thermal stresses in thick-walled components of thermal power plants is presented. The time variations of the local heat transfer coefficient on the inner surface of the pressure component are determined based on the measurement of the wall temperature at one or six points respectively for one- and three-dimensional unsteady temperature fields in the component. The temperature sensors are located close to the internal surface of the component. A technique for measuring the fastchanging fluid temperature was developed. Thermal stresses in pressure components with complicated shapes can be computed using FEM (Finite Element Method) based on experimentally estimated fluid temperature and heat transfer coefficient

Dropwise Condensation on Carbon Steel Surface

2016 ◽  
Author(s):  
Fangyu Cao ◽  
Sean Hoenig ◽  
Chien-hua Chen
Keyword(s):  
Heat Transfer ◽  
Carbon Steel ◽  
Power Plants ◽  
Heat Dissipation ◽  
Low Cost ◽  
Condensation Heat Transfer ◽  
Working Fluid ◽  
High Heat Flux ◽  
Dropwise Condensation ◽  
Two Phase

The increasing demand of heat dissipation in power plants has pushed the limits of current two-phase thermal technologies such as heat pipes and vapor chambers. One of the most obvious areas for thermal improvement is centered on the high heat flux condensers including improved evaporators, thermal interfaces, etc, with low cost materials and surface treatment. Dropwise condensation has shown the ability to increase condensation heat transfer coefficient by an order of magnitude over conventional filmwise condensation. Current dropwise condensation research is focused on Cu and other special metals, the cost of which limits its application in the scale of commercial power plants. Presented here is a general use of self-assembled monolayer coatings to promote dropwise condensation on low-cost steel-based surfaces. Together with inhibitors in the working fluid, the surface of condenser is protected by hydrophobic coating, and the condensation heat transfer is promoted on carbon steel surfaces.

Calculation and Optimization of Heat Transfer between the Low Exergy Heat Source and Organic Rankine Cycle Applied to Heat Recovery Systems

2013 ◽  
Vol 597 ◽  
pp. 45-50
Author(s):  
Sławomir Smoleń ◽  
Hendrik Boertz
Keyword(s):  
Heat Transfer ◽  
Heat Source ◽  
Heat Recovery ◽  
Power Plants ◽  
Waste Heat ◽  
Organic Rankine Cycle ◽  
Optimization Procedure ◽  
Rankine Cycle ◽  
Working Fluid ◽  
Total System

One of the key challenges on the area of energy engineering is the system development for increasing the efficiency of primary energy conversion and use. An effective and important measure suitable for improving efficiencies of existing applications and allowing the extraction of energy from previously unsuitable sources is the Organic Rankine Cycle. Applications based on this cycle allow the use of low temperature energy sources such as waste heat from industrial applications, geothermal sources, biomass, fired power plants and micro combined heat and power systems.Working fluid selection is a major step in designing heat recovery systems based on the Organic Rankine Cycle. Within the framework of the previous original study a special tool has been elaborated in order to compare the influence of different working fluids on performance of an ORC heat recovery power plant installation. A database of a number of organic fluids has been developed. The elaborated tool should create a support by choosing an optimal working fluid for special applications and become a part of a bigger optimization procedure by different frame conditions. The main sorting criterion for the fluids is the system efficiency (resulting from the thermo-physical characteristics) and beyond that the date base contains additional information and criteria, which have to be taken into account, like environmental characteristics for safety and practical considerations.The presented work focuses on the calculation and optimization procedure related to the coupling heat source – ORC cycle. This interface is (or can be) a big source of energy but especially exergy losses. That is why the optimization of the heat transfer between the heat source and the process is (besides the ORC efficiency) of essential importance for the total system efficiency.Within the presented work the general calculation approach and some representative calculation results have been given. This procedure is a part of a complex procedure and program for Working Fluid Selection for Organic Rankine Cycle Applied to Heat Recovery Systems.

Application of Supercritical Fluids in Thermal- and Nuclear-Power Engineering

2021 ◽  
pp. 601-658
Author(s):  
Igor L. Pioro
Keyword(s):  
Heat Transfer ◽  
Carbon Dioxide ◽  
Supercritical Fluids ◽  
Nuclear Power ◽  
Power Plants ◽  
Thermal Power ◽  
Rankine Cycle ◽  
Working Fluid ◽  
Thermal Power Plants ◽  
Power Cycles

Supercritical Fluids (SCFs) have unique thermophyscial properties and heat-transfer characteristics, which make them very attractive for use in power industry. In this chapter, specifics of thermophysical properties and heat transfer of SCFs such as water, carbon dioxide, and helium are considered and discussed. Also, particularities of heat transfer at Supercritical Pressures (SCPs) are presented, and the most accurate heat-transfer correlations are listed. Supercritical Water (SCW) is widely used as the working fluid in the SCP Rankine “steam”-turbine cycle in fossil-fuel thermal power plants. This increase in thermal efficiency is possible by application of high-temperature reactors and power cycles. Currently, six concepts of Generation-IV reactors are being developed, with coolant outlet temperatures of 500°C~1000°C. SCFs will be used as coolants (helium in GFRs and VHTRs, and SCW in SCWRs) and/or working fluids in power cycles (helium, mixture of nitrogen (80%) and helium (20%), nitrogen and carbon dioxide in Brayton gas-turbine cycles, and SCW/“steam” in Rankine cycle).

Geothermal Power Cycle Analysis for Commercial Applicability Using Sequestered Supercritical CO2 as a Heat Transfer or Working Fluid

2011 ◽  
Author(s):  
Brian Janke ◽  
Thomas Kuehn
Keyword(s):  
Heat Transfer ◽  
Binary System ◽  
Power Plants ◽  
Power Production ◽  
Operating Conditions ◽  
Heat Transfer Fluid ◽  
Working Fluid ◽  
Direct System ◽  
Geothermal Power ◽  
The Impact

Thermodynamic analysis has been conducted for geothermal power cycles using a portion of deep ground sequestered CO2 as the working fluid. This allows energy production from much shallower depths and in geologic areas with much lower temperature gradients than those of current geothermal systems. Two different system designs were analyzed for power production with varying reservoir parameters, including reservoir depth, temperature, and CO2 mass flow rate. The first design is a direct single-loop system with the CO2 run directly through the turbine. This system was found to provide higher system efficiency and power production, however design complications such as the need for high pressure turbines, two-phase flow through the turbine and the potential for water-CO2 brine mixtures, could require the use of numerous custom components, driving up the cost. The second design is a binary system using CO2 as the heat transfer fluid to supply thermal energy to an Organic Rankine Cycle (ORC). While this system was found to have slightly less power production and efficiency than the direct system, it significantly reduces the impact of design complications associated with the direct system. This in turn reduces the necessity for certain custom components, thereby reducing system cost. While performance of these two systems is largely dependent on location and operating conditions, the binary system is likely applicable to a larger number of sites and will be more cost effective when used in combination with current off-the-shelf ORC power plants.

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