J. Kubiak

Special Instrumentation and Hydraulic Turbine Flow Measurements Using a Pressure-Time Method

The objective of the work was to evaluate the efficiency of a hydraulic turbine by means of the flow measurement, for a given water head. The hydraulic turbine of 180 MW output has been in service for 20 years. The real value of efficiency was needed in order to proceed with minor/mayor modifications to improve it. In a case of a runner deterioration the pressure-time (the Gibson) method was chosen to proceed with a test for flow determination. However, to measure the pressure in the penstock no access from the external space of the penstock was found, so the special instrumentation had to be developed, which could be installed inside different sections of the penstock for determination of the pressure as required by the Gibson method. After the successful installation of the pressure transducers and a special hermetic capsule, from which a cable was laid through the manhole to the control room, the test was carried out at different loads applying the Gibson method. Simultaneously, the instrumentation for the Winter-Kennedy method was installed and calibrated during the test. In the paper all the turbine measured characteristics are given and discussed. It was concluded that the efficiency of the hydraulic turbine was still high and no modifications were necessary. Having instruments calibrated for the Winter-Kennedy method other curves can be obtained at different heads.Copyright

Modelling of the flow at the last stage blade tenon in a geothermal turbine using renormalization group theory turbulence model

A bi-dimensional modelling investigation of the flow in the last stage of a 110 MW geothermal turbine has been conducted. The study was based upon a Renormalization Group Theory turbulence model. The results confirmed the existence of flow conditions which may play a main role in the erosion of the L-0 stage blade tenon, which had been detected in periodic overhauls. According to predicted results the relationship between erosion and flow patterns might exist due to: (1) a vapour jet hitting directly on tenon surface at velocities around 65 m/s; (2) a low-pressure region identified with recirculating flow, which may be causing cavitation on the damaged surface. Afterwards, the flow was simulated with changes on the geometry and grid. These changes are, indeed, practically feasible of being implemented. The simulations showed that it is possible to reduce the erosion process by enlarging a flat region close to the L-0 rotor stage. Namely, this change of geometry produces a flow pattern that diminishes the strength of recirculation flow making it possible to reduce both the flow rate through tenon region and its velocity on tenon surface. The pressure drop diminishes as well, clearly reducing a risk of cavitation.

Simulation of the effect of scale deposition on a geothermal turbine

Dissolved chemicals contained in geothermal steam can lead to corrosion, erosion and deposition of scale on turbine blades, reducing their useful life. In addition, deposits on the blading system reduce the flow area of the turbine. The first-stage nozzle group is typically most affected by deposition of scale although scale may be present in other parts of the system. The most common deposits are of silica and calcium carbonate. This decreases the output capacity and efficiency of the turbine. This paper presents the results of simulations on the effect of scale deposition in the first-stage nozzle group on the steam pressure before and after the first stage, output capacity and efficiency of the turbine. By measuring the steam pressure before and after the first stage the change in the flow area can be estimated. A method of monitoring the percentage of nozzle plugging in real time is proposed. The method can be applied to any turbine that is susceptible to scale deposition.

Numerical Analysis of the Blade Forces Caused by Wake/Blade Interaction in the Last Stage of a Steam Turbine

In a steam turbine stage there is an interaction between blades and the flow field. The blades are subjected to the forces caused by the flow field, but also the flow field is affected by the blades and its movement. The nozzle wakes cause uneven pressure field downstream and produce alternating forces on blades which lead to blade vibrations. Some of the vibrations originated in this way may damage the blades and affect the turbine performance. The results of numerical computations about the forces acting on the blades as a result of the variations in the flow field in the axial clearance rotor-stator in the last stage of a 110 MW steam turbine are presented. The analysis is focused on discussing the pressure field because it is necessary for further computation of the useful life time. The flow field was resolved using computational fluids dynamics and the computed pressure field was integrated around the blades to get the forces acting on blades. These computed dynamical forces will be used in the blade useful life estimation and in the investigation to the failure causes of these blades. The Navier-Stokes equations are resolved in two and three dimensions using a commercial program based on finite-volume method. 2-D and 3-D geometry models were built to represent the dimensional aspects of the last stage of the turbine. Periodic boundary conditions were applied to both sides of a periodic segment of the 2-D and 3-D models with the purpose of reducing computational efforts. The computations were conducted in steady state and transient conditions. The results show that the force magnitude acting on blades has an harmonic pattern. Finally a Fourier analysis was used to determine the coefficients and frequency of a Fourier equation which can be used to calculate the alternating stresses on the blade in order to predict the useful life of the blades. Also, the pressure and velocity fields are shown between the diaphragm and rotor blades along the axial clearance.Copyright

Failure of last-stage turbine blades in a geothermal power plant

This paper presents an investigation into causes of failure of geothermal steam turbine blades. Several L-0 blades of geothermal steam turbines of 110 MW capacity suffered failures, causing forced outages of the turbines. To assess the causes of failure, the natural frequencies of the blades installed on the rotor were measured in the laboratory. The measured frequencies were compared with the natural frequencies calculated through a finite-element analysis (FEA) of the blade. The FEA was also used to calculate the vibratory stresses on the blade numerically. Also, the investigation analyzed the operational data and the history of the blade failures on several rotors of different units from the same system. The results of previous repairs were reviewed, and metallurgical investigations were conducted to identify the mechanical and metallurgical modes of failure. The results of the investigation showed that the fracture of two blades was attributed to installation and manufacturing errors and aggravated by general deterioration of the blades. The deterioration was caused by the erosion and corrosion process that resulted from moisture condensation in the steam.

Heat Transfer and Thermal Mechanical Stress Distributions in Gas Turbine Blades

In this paper the distributions of heat transfer and thermal mechanical stress in the metal blade surface are investigated. The stream that surrounds the blade was considered at the time that the cooling airflow runs through the blade interior. Cooling channel flow and gases were simulated using a finite volume program, Fluent. The conjugate problem was addressed using coupled domains solid-fluid. Beside the numerical approach, measurements of metal blade surface temperature distributions based on the temperature sensitive paint technique, TSP, were conducted. The cooling effectiveness was compared showing good agreement between computational/experimental results. Additionally to laboratory conditions, finite volume results were obtained for real engine operating conditions. These results were used to establish temperature boundary conditions into a second computational model programmed in ANSYS, based on finite elements. This second model allowed calculating the distribution of thermo-mechanical stress in the blade material. The results show the temperature distribution in the blade surface. Based on this, the heat transfer rate was calculated finding it as a strong function of position. The cooling effectiveness was also calculated, which in turn performs with less variation over the sections of the blade under investigation. Following, the thermal effects in the metal blade surface lead to calculate the stress distribution. Differences in stresses magnitude were also found, suggesting a strong correlation between heat transfer and stress in the metal blade surface.Copyright

Influence of Cooling Flow Rate Variation on Gas Turbine Blade Temperature Distributions

Temperature and flow rate of combustion gases and cooling stream are essential conditions for blade integrity in gas turbines. Since the combustion products pass directly to the first stage of blades high thermal stresses can develop, so the temperature field in the blade material must be controlled to avoid damage and/or reduction of blade useful life. This paper discusses an investigation on the influence of cooling airflow reduction on blade life. The flow rate reduction under consideration may be due to malfunctions of the compressor such like deposits or partial blockage in the blade ducts. It has been reported that air discharge from the compressor can be reduced up to 15% of the nominal rate due to deposits related with impurities contained in the environment. In this work an evaluation of the effect of reducing the cooling airflow rate on the temperature distribution on the blades surface is attempted. The flow stream that surrounds the blade together with the cooling airflow in the blade interior channels were characterized in the laboratory. Fields of temperature on the blade surface were obtained using the temperature sensitive paint technique, TSP. Thermocouple measurements were used for punctual temperatures as a reference. The results showed the regions of possible thermal stresses concentration as a function of cooling airflow rate variations. Additionally, the problem was resolved computationally in conjugate mode, considering both fluid streams external and internal plus heat conduction at the interior of the blade material. The computer model is used to simulate other conditions not addressed in the experiment. The paper discusses the comparison of numerical to experimental results and discusses the methodology for further work.Copyright

Measurement of the Flow in a 170 MW Hydraulic Turbine Recording the Pressure-Time Rise in One Section of the Penstock

The objective of the present work is to evaluate the performance of a hydraulic turbine by means of the measurement of flow using the Gibson method based on recording pressure–time rise in one section of the penstock and relate it to the pressure in the upper reservoir to which the penstock is connected. Volumetric flow is determined by integration of the time function of a differential pressure (between the section and the inlet to the penstock). Flow measurement was possible this way because the influence of penstock inlet was negligible as far as an error of the measurement is concerned. The paper presents the results obtained with this method for the case of a 170 MW hydraulic turbine. The length of the penstock was 300 m. Previous experience and a standard IEC-41-1991 were the criteria adopted and applied. An efficient and fast acquisition system including a 16 bit card was used. The flow rate was calculated using a computer program developed and tested on several cases. The results obtained with the Gibson method were used for calibration of the on-line flow measuring system based on the Winter-Kennedy principles. This last method is used for continuous monitoring of the turbine flow rate. Having calculated the flow rate and output power the efficiency is calculated for any operating conditions. A curve showing the best operating conditions based on the highest efficiency is presented and discussed. Flow simulation allowed having an estimation of a flow recirculation region size.Copyright

Modelling of the flow at the rotor disc in a geothermal turbine of 110 MW

Abstract To elucidate an excessive erosion damage produced by solid particles in the fourth stage rotor disc of a 110 MW double flow geothermal turbine, a bi-dimensional modelling investigation has been conducted. The study was based on a set of results from a computational model using a Reynolds stress, RSM, turbulence model. The predicted results confirmed characteristic flow conditions that may play a main role in the serious erosion of the fourth stage rotor disc governor side, which has been detected in periodic overhauls. The results show a jet of vapour that hits the disc transition radius surface at velocities around 112 m/s. These conditions are produced by the flow outgoing from the labyrinth seal, which passes through a drastic cross-section reduction in the last seal strip. The flow was then simulated introducing specific changes to the geometry and the grid in order to modify the flow patterns favourably. Actually, the suggested changes have been envisaged indeed to be practically feasible of being implemented. The new results showed that it is possible to reduce the erosion process up to 86% by increasing the distance from the labyrinth seal to the rotor disc, which produces a 38% velocity reduction of the vapour flow in that zone. The design proposed in this work produces a flow pattern of a lower velocity on disc surface together with a modified angle of flow incidence. Furthermore, the proposed design also reduces a recirculating flow at the exit of the last seal strip. Based on these results, an analysis of erosion against velocity demonstrates that the redesigned rotor disc proposed here leads to the duplication of the time period used at present between maintenance repairs.

The Effect of Boundary Layer Separation on Accuracy of Flow Measurement Using the Gibson Method

The Gibson method utilizes the effect of water hammer phenomenon (hydraulic transients) in a pipeline for flow rate determination. The method consists in measuring a static pressure difference, which occurs between two cross-sections of the pipeline as a result of a temporal change of momentum from t0 to t1 . This condition is induced when the water flow in the pipeline is stopped suddenly using a cut-off device. The flow rate is determined by integrating, within a proper time interval, the measured pressure difference change caused by the water hammer (inertia effect). However, several observations demonstrate that changes of pipeline geometry like diameter change, bifurcations, or direction shift by elbows may produce an effect on the computation of the flow rate. The paper focuses on this effect. Computational simulations have shown that the boundary layer separates when the flow faces sudden changes like these mentioned to above. The separation may reduce the effective cross section area of flow modifying a geometry factor involved into the computation of the flow rate. The remainder is directed to quantify the magnitude of such a factor under the influence of pipeline geometry changes. Results of numerical computations are discussed on the basis of how cross section reductions impact on the geometry factor magnitude and consequently on the mass flow rate.Copyright