Luca Ripamonti

Validation of Conjugate Heat Transfer Predictions on Labyrinth Seals and Novel Designs for Improved Component Lifetime

Cyclic lifetime assessment of steam turbine components has become increasingly important for several reasons. In the last years and decades the nominal steam temperatures and pressures were further increased to improve cycle efficiency. In addition, the market constantly demands increased flexibility and reliability for given lifetime exploiting the limits of the existing materials. A number of components in a steam turbine are critical in the focus of lifetime predictions such as the rotor and front stage blades, the inner casing and the area of labyrinth seals connected to the life steam. For this reason, it becomes extremely important to rely on accurate predictions of local temperatures and heat-transfer-coefficients of components in the steam path. The content of this paper aims on the validation of the numerical tools based on CHT (conjugate heat transfer) approach against experimental data of a labyrinth seal regarding discharge coefficients and measured heat transfer coefficients. Furthermore, a real steam turbine application has been optimized in design and operation to improve lifetime. The improved prediction of temperature and heat transfer allowed novel designs of labyrinth seals of a single flow high-pressure turbine and a combined intermediate and low-pressure turbine, which helped to strongly increase the component lifetime of a steam turbine rotor by more than 100%.Copyright

Service-cycle component-feature specimen thermo-mechanical fatigue testing

Abstract This paper reviews the methodology adopted in a Swiss Research Collaboration to devise a component-feature representative specimen geometry and the TMF cycle parameters necessary to closely simulate arduous steam turbine operating duty. Implementation of these service-like experimental conditions provides a practical indication of the effectiveness of deformation and crack initiation endurance predictions. Comprehensive post test inspection provides evidence to demonstrate the physical realism of the laboratory simulations in terms of the creep-fatigue damage generated during the benchmark tests. Mechanical response results and physical damage observations are presented and their practical implications discussed for the example of a 2%CrMoNiWV rotor service cycle.