Non-equilibirum condensation effects on the flow field and the performance of a low pressure steam turbine

The influence of non-equilibrium condensation on the flow field and performance of a three stage low pressure model steam turbine is examined using modern three dimensional CFD techniques. An equilibrium steam model and a non-equilibrium steam model, which accounts for both subcooling and condensation effects, are used, and have been verified by comparison with test data in an earlier publication [1]. The differences in the calculated flow field and turbine performance with these models show that the latent heat released during condensation influences both the thermodynamic and the aerodynamic performance of the turbine, leading to a change in inlet flow angles of about 5°. The calculated three dimensional flowfield is used to investigate the magnitude and distribution of the additional thermo-dynamic wetness loss arising from steam condensation under non-equilibrium flow conditions. Three simple methods are described to calculate this, and all show that this amounts to around 6.5% of the total losses at the design condition. At other load conditions the wetness losses change in magnitude and axial distribution in the turbine. © 2010 by ASME.

Crystal growth of melt-textured Nd-123 under 1% oxygen partial pressure atmosphere

Crystal growth of melt-textured Nd-123 pseudo-crystals was investigated via an isothermal solidification with top-seeding technique under a 1%O2 in N2 atmosphere. Non-steady state solidification was observed at low undercooling, in contrast to an almost linear growth at higher undercooling. Similar to processing in air, the substitution of Nd/Ba was found to decrease from the seed position to the edge of the crystal. In addition, the volume fraction of Nd-422 particles decreased in the solid as solidification proceeded. As a result of these microstructural inhomogeneities, the critical temperature and the critical current density varied within the crystal even for samples processed isothermally, despite the narrow solid solution range of the Nd-123 phase under a reduced pO2 atmosphere.

Numerical simulations of unsteady wet steam flows with non-equilibrium condensation in the nozzle and the steam turbine

Numerical techniques for non-equilibrium condensing flows are presented. Conservation equations for homogeneous gas-liquid two-phase compressible flows are solved by using a finite volume method based on an approximate Riemann solver. The phase change consists of the homogeneous nucleation and growth of existing droplets. Nucleation is computed with the classical Volmer-Frenkel model, corrected for the influence of the droplet temperature being higher than the steam temperature due to latent heat release. For droplet growth, two types of heat transfer model between droplets and the surrounding steam are used: a free molecular flow model and a semi-empirical two-layer model which is deemed to be valid over a wide range of Knudsen number. The computed pressure distribution and Sauter mean droplet diameters in a convergent-divergent (Laval) nozzle are compared with experimental data. Both droplet growth models capture qualitatively the pressure increases due to sudden heat release by the non-equilibrium condensation. However the agreement between computed and experimental pressure distributions is better for the two-layer model. The droplet diameter calculated by this model also agrees well with the experimental value, whereas that predicted by the free molecular model is too small. Condensing flows in a steam turbine cascade are calculated at different Mach numbers and inlet superheat conditions and are compared with experiments. Static pressure traverses downstream from the blade and pressure distributions on the blade surface agree well with experimental results in all cases. Once again, droplet diameters computed with the two-layer model give best agreement with the experiments. Droplet sizes are found to vary across the blade pitch due to the significant variation in expansion rate. Flow patterns including oblique shock waves and condensation-induced pressure increases are also presented and are similar to those shown in the experimental Schlieren photographs. Finally, calculations are presented for periodically unsteady condensing flows in a low expansion rate, convergent-divergent (Laval) nozzle. Depending on the inlet stagnation subcooling, two types of self-excited oscillations appear: a symmetric mode at lower inlet subcooling and an asymmetric mode at higher subcooling. Plots of oscillation frequency versus inlet sub-cooling exhibit a hysteresis loop, in accord with observations made by other researchers for moist air flow. Copyright © 2006 by ASME.

Non-reflective boundary conditions for non-uniform mean velocity inlet and outlet flows

The numerical solution of problems in unbounded physical space requires a truncation of the computational domain to a reasonable size. As a result, the conditions on the artificial boundaries are generally unknown. Assumptions like constant pressure or velocities are only valid in the far field and lead to spurious reflections if applied on the boundaries of the truncated domain. A number of attempts have been made over the past decades to design conditions that prevent such reflections. One approach is based on characteristics. The standard analysis assumes a spatially uniform mean flow field but this is often impractical. In the present paper we show how to extend the formulation to the more general case of a non-uniform mean velocity field. A number of test cases are provided and our results compare favourably with other boundary conditions. In principle the present approach can be extended to include non-uniformities in all variables.

Shock propagation and MPT noise from a transonic rotor in non-uniform flow

One of the major challenges in hig4h-speed fan stages used in compact, embedded propulsion systems is inlet distortion noise. A body-force-based approach for the prediction of multiple-pure-tone (MPT) noise was previously introduced and validated. In this paper, it is employed with the objective of quantifying the effects of non-uniform flow on the generation and propagation of MPT noise. First-of-their-kind back-to-back coupled aero-acoustic computations were carried out using the new approach for conventional and serpentine inlets. Both inlets delivered flow to the same NASA/GE R4 fan rotor at equal corrected mass flow rates. Although the source strength at the fan is increased by 45 dB in sound power level due to the non-uniform inflow, farfield noise for the serpentine inlet duct is increased on average by only 3.1 dBA overall sound pressure level in the forward arc. This is due to the redistribution of acoustic energy to frequencies below 11 times the shaft frequency and the apparent cut-off of tones at higher frequencies including blade-passing tones. The circumferential extent of the inlet swirl distortion at the fan was found to be 2 blade pitches, or 1/11th of the circumference, suggesting a relationship between the circumferential extent of the inlet distortion and the apparent cut-off frequency perceived in the far field. A first-principles-based model of the generation of shock waves from a transonic rotor in non-uniform flow showed that the effects of non-uniform flow on acoustic wave propagation, which cannot be captured by the simplified model, are more dominant than those of inlet flow distortion on source noise. It demonstrated that non-linear, coupled aerodynamic and aeroacoustic computations, such as those presented in this paper, are necessary to assess the propagation through non-uniform mean flow. A parametric study of serpentine inlet designs is underway to quantify these propagation effects. Copyright © 2011 by ASME.

Large eddy simulations in low-pressure turbines: Effect of wakes at elevated free-stream turbulence

The transition of a separated shear layer over a flat plate, in the presence of periodic wakes and elevated free-stream turbulence (FST), is numerically investigated using Large Eddy Simulation (LES). The upper wall of the test section is inviscid and specifically contoured to impose a streamwise pressure distribution over the flat plate to simulate the suction surface of a low-pressure turbine (LPT) blade. Two different distributions representative of a 'high-lift' and an 'ultra high-lift' turbine blade are examined. Results obtained from the current LES compare favourably with the extensive experimental data previously obtained for these configurations. The LES results are then used to further investigate the flow physics involved in the transition process.In line with experimental experience, the benefit of wakes and FST obtained by suppressing the separation bubble, is more pronounced in 'ultra high-lift' design when compared to the 'high-lift' design. Stronger 'Klebanoff streaks' are formed in the presence of wakes when compared to the streaks due to FST alone. These streaks promoted much early transition. The weak Klebanoff streaks due to FST continued to trigger transition in between the wake passing cycles.The experimental inference regarding the origin of Klebanoff streaks at the leading edge has been confirmed by the current simulations. While the wake convects at local free-stream velocity, its impression in the boundary layer in the form of streaks convects much slowly. The 'part-span' Kelvin-Helmholtz structures, which were observed in the experiments when the wake passes over the separation bubble, are also captured. The non-phase averaged space-time plots manifest that reattachment is a localized process across the span unlike the impression of global reattachment portrayed by phase averaging. © 2013 Elsevier Inc.

Unsteady numerical study of wet steam flow in a low pressure steam turbine

In steam power plants condensation already starts in the flow path of the low pressure part of the steam turbine, which leads to a complex three-dimensional two-phase flow. Wetness losses are caused due to thermodynamic and mechanical relaxation processes during condensation and droplet transport. The present investigation focuses on the unsteady effects due to rotor-stator interaction on the droplet formation process. Results of unsteady three dimensional flow simulations of a two-stage steam turbine are presented, whereby this is the first time that non-equilibrium condensation is considered in such simulations. The numerical approach is based on RANS equations, which are extended by a wet steam specific nucleation and droplet growth model. Despite the use of a high performance cluster the unsteady simulation has a considerably high simulation time of approximately 60 days by use of 48 CPUs. © Springer-Verlag Berlin Heidelberg 2012.