Aerodynamic Performance Assessment of Part-Span Connector of Last Stage Bucket of Low Pressure Steam Turbine

2011 ◽  
Author(s):  
Hiteshkumar Mistry ◽  
Manisekaran Santhanakrishnan ◽  
John Liu ◽  
Alexander Stein ◽  
Subhrajit Dey ◽  
...  
Keyword(s):  
Steam Turbine ◽  
Low Pressure ◽  
Aerodynamic Performance ◽  
Rotor Blades ◽  
Field Analysis ◽  
Working Fluid ◽  
Steam Turbines ◽  
Structural Element ◽  
Last Stage ◽  
The Impact

Modern steam turbines often utilize very long last stage buckets (LSB’s) in their low-pressure sections to improve efficiency. Some of these LSB’s can range in the order of 5 feet long. These long buckets (aka “blades”) are typically supported at their tip by a tip-shroud and near the mid span by a part span shroud or part span connector (PSC). The PSC is a structural element that connects all the rotor blades, generally at the mid span. It is primarily designed to address various structural issues, often with little attention to its aerodynamic effects. The objective of the current work is to quantify the impact of PSC on aerodynamic performance of the last stage of a LP steam turbine by using detailed CFD analyses. A commercial CFD solver, ANSYS CFX™, is used to solve the last stage domain by setting steam as the working fluid with linear variation of specific heat ratio with temperature. A tetrahedral grid with prismatic layers near the solid walls is generated using ANSYS WORKBENCH™. The results show a cylindrical PSC reduces the efficiency of the last stage by 0.32 pts, of which 0.20 pts is due to the fillet attaching the PSC to the blade. The results also show insignificant interaction of the PSC with the bucket tip aerodynamics. The work presents a detailed flow field analysis and shows the impact of PSC geometry on the aerodynamic performance of last stage of steam turbine. Present work is useful to turbine designer for trade-off studies of performance and reliability of LSB design with or without PSC.

Numerical Model of Liquid Film Formation and Breakup in Last Stage of a Low-Pressure Steam Turbine

2017 ◽  
Vol 140 (3) ◽  
Author(s):  
Pietro Rossi ◽  
Asad Raheem ◽  
Reza S. Abhari
Keyword(s):  
Steam Turbine ◽  
Stokes Equations ◽  
Low Pressure ◽  
Liquid Films ◽  
Operating Conditions ◽  
Rotor Blades ◽  
Navier Stokes ◽  
Navier Stokes Equations ◽  
Last Stage ◽  
The Impact

Formation of thin liquid films on steam turbine airfoils, particularly in last stages of low-pressure (LP) steam turbines, and their breakup into coarse droplets is of paramount importance to assess erosion of last stage rotor blades given by the impact of those droplets. An approach for this problem is presented in this paper: this includes deposition of liquid water mass and momentum, film mass and momentum conservation, trailing edge breakup and droplets Lagrangian tracking accounting for inertia and drag. The use of thickness-averaged two-dimensional (2D) equations in local body-fitted coordinates, derived from Navier–Stokes equations, makes the approach suitable for arbitrary curved blades and integration with three-dimensional (3D) computational fluid dynamics (CFD) simulations. The model is implemented in the in-house solver MULTI3, which uses Reynolds-averaged Navier–Stokes equations κ – ω model and steam tables for the steam phase and was previously modified to run on multi-GPU architecture. The method is applied to the last stage of a steam turbine in full and part load operating conditions to validate the model by comparison with time-averaged data from experiments conducted in the same conditions. Droplets impact pattern on rotor blades is also predicted and shown.

The Effect of Stage-Diffuser Interaction on the Aerodynamic Performance and Design of LP Steam Turbine Exhaust Systems

2018 ◽  
Author(s):  
Bowen Ding ◽  
Liping Xu ◽  
Jiandao Yang ◽  
Rui Yang ◽  
Yuejin Dai
Keyword(s):  
Steam Turbine ◽  
Renewable Energy Sources ◽  
Rotor Blades ◽  
Steam Turbines ◽  
Flow Conditions ◽  
Part Load ◽  
Last Stage ◽  
Load Conditions ◽  
Turbine Exhaust ◽  
Exhaust Systems

Modern large steam turbines for power generation are required to operate much more flexibly than ever before, due to the increasing use of intermittent renewable energy sources such as solar and wind. This has posed great challenges to the design of LP steam turbine exhaust systems, which are critical to recovering the leaving energy that is otherwise lost. In previous studies, the design had been focused on the exhaust diffuser with or without the collector. Although the interaction between the last stage and the exhaust hood has been identified for a long time, little attention has been paid to the last stage blading in the exhaust system’s design process, when the machine frequently operates at part-load conditions. This study focuses on the design of LP exhaust systems considering both the last stage and the exhaust diffuser, over a wide operating range. A 1/10th scale air test rig was built to validate the CFD tool for flow conditions representative of an actual machine at part-load conditions, characterised by highly swirling flows entering the diffuser. A numerical parametric study was performed to investigate the effect of both the diffuser geometry variation and restaggering the last stage rotor blades. Restaggering the rotor blades was found to be an effective way to control the level of leaving energy, as well as the flow conditions at the diffuser inlet, which influence the diffuser’s capability to recover the leaving energy. The benefits from diffuser resizing and rotor blade restaggering were shown to be relatively independent of each other, which suggests the two components can be designed separately. Last, the potentials of performance improvement by considering both the last stage rotor restaggering and the diffuser resizing were demonstrated by an exemplary design, which predicted an increase in the last stage power output of at least 1.5% for a typical 1000MW plant that mostly operates at part-load conditions.

Sequential vs Multidisciplinary Coupled Optimization and Efficient Surrogate Modelling of a Last Stage and the Successive Axial Radial Diffuser in a Low Pressure Steam Turbine

2014 ◽  
Author(s):  
Kevin Cremanns ◽  
Dirk Roos ◽  
Arne Graßmann
Keyword(s):  
Steam Turbine ◽  
Design Process ◽  
Energy Demand ◽  
Three Dimensional ◽  
Flow Simulation ◽  
Low Pressure ◽  
Steam Turbines ◽  
Low Pressure Turbine ◽  
Pressure Steam ◽  
Last Stage

In order to meet the requirements of rising energy demand, one goal in the design process of modern steam turbines is to achieve high efficiencies. A major gain in efficiency is expected from the optimization of the last stage and the subsequent diffuser of a low pressure turbine (LP). The aim of such optimization is to minimize the losses due to separations or inefficient blade or diffuser design. In the usual design process, as is state of the art in the industry, the last stage of the LP and the diffuser is designed and optimized sequentially. The potential physical coupling effects are not considered. Therefore the aim of this paper is to perform both a sequential and coupled optimization of a low pressure steam turbine followed by an axial radial diffuser and subsequently to compare results. In addition to the flow simulation, mechanical and modal analysis is also carried out in order to satisfy the constraints regarding the natural frequencies and stresses. This permits the use of a meta-model, which allows very time efficient three dimensional (3D) calculations to account for all flow field effects.

Effect of Snubbers and Lacing Wire on Aerodynamic Performance of Last Stage Steam Turbine

2019 ◽  
Author(s):  
P. Sreekumar ◽  
Mahesh K. Varpe
Keyword(s):  
Aspect Ratio ◽  
Steam Turbine ◽  
Aerodynamic Performance ◽  
Base Line ◽  
Performance Loss ◽  
Performance Requirements ◽  
Last Stage ◽  
Lp Turbine ◽  
The Impact ◽  
Sensitive Behavior

Abstract The aerodynamics design of a steam turbine stage is an agreement between the performance requirements and the mechanical limitations. The design of last stage of the low-pressure steam (LP) turbine is the most complicated because of the blade twist and a tapered blade along with high aspect ratio due to the sharp increase in the specific volume of the steam during its expansion. The choice of higher aspect ratio for increased power generation makes the turbine blade experience the vibration due to lower modal frequencies which depend on the running speed of a turbine. Therefore, the sensitive behavior of these blades is reduced by damping the blade vibrations which comes with the penalty of aerodynamic performance. The investigation reported here discusses the impact of lacing wire and snubber mounted at 70% blade span. Both, the lacing wire and snubber aligned parallel to the rotor axis deteriorates the efficiency by 0.75% and 1.7% respectively. However, the aerodynamically shaped snubber aligned with the streamline direction recovers the efficiency to that of base line. The mechanism of streamwise aligned snubber in containing aerodynamic performance loss is quite interesting and is being discussed.

Numerical and Experimental Investigation of the Aerodynamic Excitation of a Model Low-Pressure Steam Turbine Stage Operating Under Low Volume Flow

2012 ◽  
Vol 135 (1) ◽  
Author(s):  
Benjamin Megerle ◽  
Timothy Stephen Rice ◽  
Ivan McBean ◽  
Peter Ott
Keyword(s):  
Steam Turbine ◽  
Low Pressure ◽  
Volume Flow ◽  
Operating Conditions ◽  
Single Stage ◽  
Tip Clearance ◽  
Working Fluid ◽  
Steam Turbines ◽  
Excitation Mechanism ◽  
Low Volume

The diversification of power generation methods within existing power networks has increased the requirement for operational flexibility of plants employing steam turbines. This has led to the situation where steam turbines may operate at very low volume flow conditions for extended periods of time. Under operating conditions where the volume flow through the last stage moving blades (LSMBs) of a low-pressure (LP) steam turbine falls below a certain limit, energy is returned to the working fluid rather than being extracted. This so-called “ventilation” phenomenon produces nonsynchronous aerodynamic excitation, which has the potential to lead to high dynamic blade loading. The aerodynamic excitation is often the result of a rotating phenomenon, with similarities to a rotating stall, which is well known in compressors. Detailed unsteady pressure measurements have been performed in a single stage model steam turbine operated with air under ventilation conditions. The analysis revealed that the rotating excitation mechanism observed in operating steam turbines is reproduced in the model turbine. A 3D computational fluid dynamics (CFD) method has been applied to simulate the unsteady flow in the air model turbine. The numerical model consists of the single stage modeled as a full annulus, along with the axial-radial diffuser. An unsteady CFD analysis has been performed with sufficient rotor revolutions to obtain globally periodic flow. The simulation reproduces the main characteristics of the phenomenon observed in the tests. The detailed insight into the dynamic flow field reveals information on the nature of the excitation mechanism. The calculations further indicate that the LSMB tip clearance flow has little or no effect on the characteristics of the mechanism for the case studied.

A Combined Numerical Model and Optimization for Low Pressure Exhaust System in Steam Turbine

2007 ◽  
Author(s):  
Tao Fan ◽  
Yonghui Xie ◽  
Di Zhang ◽  
Bi Sun
Keyword(s):  
Numerical Model ◽  
Flow Field ◽  
Exhaust System ◽  
Low Pressure ◽  
Aerodynamic Performance ◽  
Numerical Results ◽  
Steam Turbines ◽  
Exhaust Hood ◽  
Inhomogeneous Flow ◽  
Last Stage

Computational fluid dynamics is widely used in the aerodynamic performance analysis of the low pressure exhaust system (LPES) which consists of the exhaust hood and condenser neck. However, most of the former studies analyzed the exhaust system separately without considering the effect on flow field from the last stage. In order to get the detailed information of flow field in LPES of steam turbines and reduce energy loss, a numerical model includes condenser neck, exhaust hood and last stage was constructed. This model can describe the effect of unsymmetrical inlet flow on the aerodynamic performance of LPES, so the effect of the inhomogeneous flow from the last stage was taken into account. The Reynolds averaged N-S equations with RNG k-ε turbulence model were adopted to analyze the flow field in the exhaust system considering the interaction between the exhaust system and the last stage, the mixing plane approach was used. The combined model can provide more reasonable numerical results of LPES, it shows that the inhomogeneous flow from the last stage is one of the main reasons leading to flow separation in diffuser. The influence of inner low pressure heater and the diffuse function of the condenser neck structure are the main reasons for the nonuniform velocity distribution of the flow field at the LPES outlet. Furthermore, based on the numerical results, an optimal LPES which has better aerodynamic performance and more reasonable flow is obtained. The optimal structure has low steam resistance and low exhaust pressure, so it can increase the efficiency of turbine.

Design, Manufacturing and Testing of a New Family of Steam Turbine Low Pressure Stages

2007 ◽  
Author(s):  
Lorenzo Cosi ◽  
Jonathon Slepski ◽  
Steven DeLessio ◽  
Michele Taviani ◽  
Amir Mujezinovic´
Keyword(s):  
Power Generation ◽  
Steam Turbine ◽  
Low Pressure ◽  
Full Scale ◽  
Operating Conditions ◽  
Test Facility ◽  
Steam Turbines ◽  
Wide Range ◽  
The Family ◽  
Last Stage

New low pressure (LP), stages for variable speed, mechanical drive and geared power generation steam turbines have been developed. The new blade and nozzle designs can be applied to a wide range of turbine rotational speeds and last stage blade annulus areas, thus forming a family of low pressure stages—High Speed (HS) blades and nozzles. Different family members are exact scales of each other and the tip speeds of the corresponding blades within the family are identical. Thus the aeromechanical and aerodynamic characteristics of the individual stages within the family are identical as well. Last stage blades and nozzles have been developed concurrently with the three upstream stages, creating optimised, reusable low pressure turbine sections. These blades represent a step forward in improving speed, mass flow capability, reliability and aerodynamic efficiency of the low pressure stages for the industrial steam turbines. These four stages are designed as a system using the most modern design tools applied on Power Generation and Aircraft Engines turbo-machineries. The aerodynamic performance of the last three stage of the newly designed group will be verified in a full-scale test facility. The last stage blade construction incorporates a three hooks, axial entry dovetail with improved load carrying capability over other blade attachment methods. The next to the last stage blade also uses a three hooks axial entry dovetail, while the two front stage blades employ internal tangential entry dovetails. The last and next to the last stage blades utilize continuous tip coupling via implementation of integral snubber cover while a Z-lock integral cover is employed for the two upstream stages. Low dynamic strains at all operating conditions (off and on resonance speeds) will be validated via steam turbine testing at realistic steam conditions (steam flows, temperatures and pressures). Low load, high condenser pressure operation will also be verified using a three stage test turbine operated in the actual steam conditions as well. In addition, resonance speed margins of the four stages have been verified through full-scale wheel box tests in the vacuum spin cell, thus allowing the application of these stages to Power Generation applications. Stator blades are produced with a manufacturing technology, which combines full milling and electro-discharge machining. This process allows machining of the blades from an integral disc, and thus improving uniformity of the throat distribution. Accuracy of the throat distribution is also improved when compared to the assembled or welded stator blade technology. This paper will discuss the aerodynamic and aeromechanical design, development and testing program completed for this new low pressure stages family.

Unsteady Flow Field and Coarse Droplet Measurements in the Last Stage of a Low-Pressure Steam Turbine With Supersonic Airfoils Near the Blade Tip

2017 ◽  
Vol 139 (9) ◽  
Author(s):  
Ilias Bosdas ◽  
Michel Mansour ◽  
Anestis I. Kalfas ◽  
Reza S. Abhari ◽  
Shigeki Senoo
Keyword(s):  
Flow Field ◽  
Steam Turbine ◽  
Leading Edge ◽  
Low Pressure ◽  
Fast Response ◽  
Operating Conditions ◽  
Electricity Production ◽  
Test Facility ◽  
Steam Turbines ◽  
Last Stage

The largest share of electricity production worldwide belongs to steam turbines. However, the increase of renewable energy production has led steam turbines to operate under part load conditions and increase in size. As a consequence, long rotor blades will generate a relative supersonic flow field at the inlet of the last rotor. This paper presents a unique experiment work that focuses at the top 30% of stator exit in the last stage of an low pressure (LP) steam turbine test facility with coarse droplets and high wetness mass fraction under different operating conditions. The measurements were performed with two novel fast response probes: a fast response probe for three-dimensional flow field wet steam measurements and an optical backscatter probe for coarse water droplet measurements ranging from 30 μm up to 110 μm in diameter. This study has shown that the attached bow shock at the rotor leading edge is the main source of interblade row interactions between the stator and rotor of the last stage. In addition, the measurements showed that coarse droplets are present in the entire stator pitch with larger droplets located at the vicinity of the stator's suction side. Unsteady droplet measurements showed that the coarse water droplets are modulated with the downstream rotor blade-passing period. This set of time-resolved data will be used for in-house computational fluid dynamics (CFD) code development and validation.

Survey of Twisted Blading Development in Steam Turbines

1969 ◽  
Vol 184 (1) ◽  
pp. 449-474 ◽  
Author(s):  
A. Smith
Keyword(s):  
Steam Turbine ◽  
Low Pressure ◽  
Scale Model ◽  
Steam Turbines ◽  
Power Station ◽  
Low Pressure Turbine ◽  
Last Stage ◽  
Turbine Blading

The development of steam turbine blading with high tip to hub diameter ratios over the last 50 years has been traced with particular emphasis on the reasons for adopting twisted blading in low pressure turbines. The aerodynamic concepts of the more generally accepted design bases for twisted blading are discussed and comparisons made between the efficiencies of selected twisted designs and straight blading. Current methods in the development of transonic low pressure blading for large 3000 rev/min central power station units are also described and the paper concludes by comparing the theoretical and measured steam angles across the last stage of a one-third scale model of a 136-in tip diameter low pressure turbine.

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