O. Brunn, Ulrich Harbecke, T. Mokulys, V. Salit, M. Schwarz, Felix Dornbusch
{"title":"Improved LP-Stage Design for Industrial Steam Turbines","authors":"O. Brunn, Ulrich Harbecke, T. Mokulys, V. Salit, M. Schwarz, Felix Dornbusch","doi":"10.1115/GT2020-14375","DOIUrl":"https://doi.org/10.1115/GT2020-14375","url":null,"abstract":"\u0000 This publication deals with the improvement of the design and life steam testing of a low-pressure steam turbine module for utilization in industrial applications. Extensive numerical investigations were carried out and validated with experimental measurements. For the validation of the final blade design, the LP module was integrated and tested in a 12.5MW steam turbine test rig. During the balancing of the rotor in a vacuum chamber, tip-timing and strain gage measurements were conducted for testing the mechanical behavior of the airfoils. In the succeeding assembly of the steam turbine, tip-timing probes and flow measurement probes were integrated around the LP module to evaluate the blade load and performance under realistic conditions. To obtain a good understanding of the improved performance and mechanical behavior the thermodynamic tests were carried out under no-load, part load and design load conditions to cover the whole operating range of the LP stages. The paper also describes how an existing rotor from the test rig could be retrofitted, to accommodate the new turbine stages with additive manufacturing of the base material on the shaft.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"50 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131557678","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A. Corsini, G. Delibra, M. Giovannelli, G. Lucherini, S. Minotti, S. Rossin, L. Tieghi
{"title":"Prediction of Ventilation Effectiveness for LM9000 Package With Machine Learning","authors":"A. Corsini, G. Delibra, M. Giovannelli, G. Lucherini, S. Minotti, S. Rossin, L. Tieghi","doi":"10.1115/GT2020-14916","DOIUrl":"https://doi.org/10.1115/GT2020-14916","url":null,"abstract":"\u0000 Gas turbines usually are installed inside an enclosure, which is used as protection from the external environment and to provide an acoustic insulation. A ventilation system is required to control the temperature inside the enclosed volume and to dilute any potential gas leakage that may come from faulty pipes or flanges. The system has to be properly designed to avoid any unexpected explosion which would generate an overpressure not contained by enclosure walls. The most common approach to predict the effectiveness of the ventilation system requires to perform CFD analyses, which are very expensive in computational terms. A new approach has been proposed by authors, using machine learning and artificial neural networks (ANN) to identify the poorly ventilated zones. This methodology has been further developed, optimized and applied to a real gas turbine packages of new generation. In the present paper the authors will show the application of this procedure to the LM9000 package and the comparison with the results predicted using conventional CFD techniques. The tangible improvement introduced by this methodology is that the computational time is reduced from about three weeks with the common CFD approach to few minutes. The artificial neural network is developed in a Python environment that is applied during the CFX post-process phase of a steady state CFD simulation, providing results equivalent to unsteady CFD simulation. Besides the immediate benefits of this particular application, the suggested approach looks to be a great candidate to substitute the conventional and time-consuming CFD simulations with a fast post-processing algorithm that is able to learn and self-optimize as long as it is used.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"56 2 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124336446","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"A Nitrogen Oxides Emission Prediction Model for Gas Turbines Based on Interpretable Multilayer Perceptron Neural Networks","authors":"Dawen Huang, Shanhua Tang, Dengji Zhou","doi":"10.1115/GT2020-15478","DOIUrl":"https://doi.org/10.1115/GT2020-15478","url":null,"abstract":"\u0000 Gas turbines, an important energy conversion equipment, produce Nitrogen Oxides (NOx) emissions, endangering human health and forming air pollution. With the increasingly stringent NOx emission standards, it is more significant to ascertain NOx emission characteristics to reduce pollutant emissions. Establishing an emission prediction model is an effective way for real-time and accurate monitoring of the NOx discharge amount. Based on the multi-layer perceptron neural networks, an interpretable emission prediction model with a monitorable middle layer is designed to monitor NOx emission by taking the ambient parameters and boundary parameters as the network inputs. The outlet temperature of the compressor is selected as the monitorable measuring parameters of the middle layer. The emission prediction model is trained by historical operation data under different working conditions. According to the errors between the predicted values and measured values of the middle layer and output layer, the weights of the emission prediction model are optimized by the back-propagation algorithm, and the optimal NOx emission prediction model is established for gas turbines under the various working conditions. Furthermore, the mechanism of predicting NOx emission value is explained based on known parameter influence laws between the input layer, middle layer and output layer, which helps to reveal the main measurement parameters affecting NOx emission value, adjust the model parameters and obtain more accurate prediction results. Compared with the traditional emission monitoring methods, the emission prediction model has higher accuracy and faster calculation efficiency and can obtain believable NOx emission prediction results for various operating conditions of gas turbines.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"16 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125108909","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Investigations Into Aerodynamic Performance of Turbine Stages With Flexible Shroud Seals","authors":"Xin Yan, W. Yabo, Kang Zhang, Xinbo Dai, Kun He","doi":"10.1115/GT2020-14329","DOIUrl":"https://doi.org/10.1115/GT2020-14329","url":null,"abstract":"\u0000 The present paper utilizes a numerical method to investigate the effect of flexible shroud seals, including the forward bending flexible seals and backward bending flexible seals, on aerodynamic performance of high pressure steam turbine stages. At first, the wear performance of flexible seal is analyzed with the Finite Element Analysis method. It shows that wear in flexible strip is so small that only the installation clearance needs to be considered in operation process. Then, by replacing the labyrinth shroud seals with flexible shroud seals, the aerodynamic efficiency, outlet flow angle distributions, and reaction degree distributions in two-stages are obtained. At three installation clearances, interactions between leakage flow and main flow, as well as the flow patterns in flexible shroud seals, are visualized and also compared with the original design case. The numerical results indicate that turbine stages configured with forward bending flexible shroud seals have a very close aerodynamic performance to those configured with conventional labyrinth shroud seals at the same clearance, whereas the turbine stages configured with backward bending flexible seals have lower total-total isentropic efficiency than those with conventional labyrinth shroud seals. By replacing the conventional labyrinth shroud seals with forward bending flexible shroud seals (at the same clearance), the aerodynamic efficiency, outlet flow angles, limiting streamlines, secondary flow patterns in shroud region and reaction degree distributions in stages are almost not affected. Since the forward bending flexible seal allows relatively smaller installation clearance than the conventional labyrinth seal, application of this kind of seal in rotor blade tip gap is much beneficial to achieve lower leakage rate and higher aerodynamic performance in large power steam turbine stages.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"80 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123957973","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Lukas Pehle, P. Łuczyński, Tae-Young Jeon, M. Wirsum, W. Mohr, K. Helbig
{"title":"Comparison of Steam Turbine Pre-Warming and Warm-Keeping Strategies Using Hot Air for Fast Turbine Start-Up","authors":"Lukas Pehle, P. Łuczyński, Tae-Young Jeon, M. Wirsum, W. Mohr, K. Helbig","doi":"10.1115/GT2020-14281","DOIUrl":"https://doi.org/10.1115/GT2020-14281","url":null,"abstract":"\u0000 Adaptability of coal-based power generating units to accommodate renewable energy sources is becoming increasingly important. In order to improve flexibility, reduce start-up time and extend the life cycle, General Electric has developed solutions to pre-warm/warm-keep steam turbines using hot air.\u0000 In this paper two main contributions to optimize the warming arrangements are presented. Firstly, the calibrated model of a 19-stage IP steam turbine is analyzed regarding time-dependent mass flow rates in a pre-warming mode. The influences on the duration time of the process and the thermally induced stress are investigated. This investigation utilizes a detailed 3D hybrid (HFEM-numerical FEM and analytical) model of the turbine including the rotor, inner casing and blading for computationally-efficient determination of transient temperature fields in individual components. The thermal boundary conditions are calculated by means of heat transfer correlations developed for this purpose. Moreover, a separate FEM model allows for the implementation of a structural mechanical analysis. As a result of this investigation, the pre-warming time can be further reduced while simultaneously lowering the thermal load in the components.\u0000 Secondly, selected pre-warming strategies are compared with the warm-keeping scenarios. This analysis is aimed at a minimum thermal energy use required for a reheating of air in a warming arrangement. Hence, the pre-warming and warm-keeping operating strategies are evaluated with regard to their energy demand before start-up. Thus, based on the duration of standstill, the most energy-efficient turbine warming strategy can be chosen to ensure hot start-up conditions.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116859691","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Thrust Force Measurements in an Axial Steam Turbine Test Rig","authors":"D. Stasenko, N. Rao, D. Narzary","doi":"10.1115/GT2020-14673","DOIUrl":"https://doi.org/10.1115/GT2020-14673","url":null,"abstract":"\u0000 Large mechanical drive steam turbines used in the oil & gas industry are operating at increasingly higher inlet pressure, generating higher shaft power. Those higher power requirements result in larger disk diameters and surface areas. High thrust forces can be a result, due to both the high inlet pressure and large disk surface area. Industry standards require oversizing of thrust bearings to handle uncertainty in thrust predictions. These factors make improvement in thrust prediction accuracy and mitigation strategies important.\u0000 A full-size, axial flow steam turbine test rig capable of measuring turbine thrust, and static pressure in the upstream rotor-stator cavity was built and commissioned. The test rig was operated in single stage configuration for the tests reported here. The rotor disk had balance holes and stationary axial face seals near the disk rim. The face seals divide the upstream rotor-stator cavity into inner and outer circumferential cavities. The rotor-stator cavity upstream of the rotor disk was instrumented, on the stationary wall, to measure the radial and circumferential pressure distribution. Bearing thrust was measured with load cells. Tests varied nominal pressure ratios (1.2, 1.5, 2.0 and 3.0), velocity ratios (0.35–0.6), admission fractions (0.25–1.0) and shaft leakage flow rates.\u0000 Circumferential pressure asymmetry, due to partial admission operation, was confined to the outer cavity. The inner cavity pressure coefficient was circumferentially uniform at all operating points. The average pressure coefficient in the upstream rotor-stator cavity generally decreased as the shaft leakage flow rate coefficient increased. Increased leakage flow rate coefficient also increased the magnitude of the upstream directed or negative thrust.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"2 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132500149","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Application of Artificial Neural Network Based Gas Path Diagnostics on Gas Pipeline Compressors","authors":"S. M. Suleiman, Yi-Guang Li","doi":"10.1115/GT2020-15062","DOIUrl":"https://doi.org/10.1115/GT2020-15062","url":null,"abstract":"\u0000 This paper presents the development of an artificial neural network (ANN) Gas Path Diagnostics (GPD) technique applied to pipeline compression system for fault detection and quantification. The work detailed the various degradation mechanisms and the effect of such degradations on the performance of natural gas compressors. The data used in demonstrating the ANN diagnostics is so derived using an advanced thermodynamic performance simulation model of integrated pipeline and compressor systems, which has embedded empirical compressor map data and pipeline resistance model. Implantation of faults within the model is in such a way to account for faults degradations caused by fouling, erosion and corrosion, of various degrees of severities, to obtain wide range of corresponding simulated “true” measurements. In order to account for uncertainties normally encountered in field measurements, Gaussian noise distribution was combined with simulated true measurements, which depends on the instrument’s tolerances. Furthermore, since judicious measurements selection are crucial in ensuring flawless GPD predictions, a sensitivity and correlation analysis of the available measurements revealed that discharge temperature, rotational speed and torque are the most effective measurements for the diagnostics with acceptable degrees of accuracies. The measurements observability technique is a novel approach in pipeline compressor diagnostics. Analytical case studies of the developed method show that, a selected ANN architecture can detect and quantify faults related to degradation in efficiency and flow capacities in the presence of instrument error, varied operational and environmental conditions.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"97 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133877415","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ji Daohui, Mei Ziyue, Jiang Wei, C. Xiang, Danmei Xie, Yue Yanan
{"title":"Numerical Calculation of Seal Clearance Change in Installation Process of a 1000MW Nuclear Steam Turbine HIP Casing","authors":"Ji Daohui, Mei Ziyue, Jiang Wei, C. Xiang, Danmei Xie, Yue Yanan","doi":"10.1115/GT2020-15130","DOIUrl":"https://doi.org/10.1115/GT2020-15130","url":null,"abstract":"\u0000 During installation process, most of 1000MW-class nuclear power steam turbines will undergo certain deformations due to their own big size and heavy weight, which will change seal clearances in the steam passage. The clearance change will affect steam turbine’s efficiency, and may cause rubbing faults and even strong abnormal vibration, affecting the safety of the steam turbine. Moreover, limited by the complex structure and measurement method, it is difficult to measure deformation and seal clearance accurately, so it is necessary to study the change tendency of the clearance in the installation process.\u0000 In this paper, a HIP (High and Intermediate Pressure) casing of a 1000MW nuclear steam turbine was taken as the research object, and its 3D geometry model is established based on Pro/E software. By using ANSYS WORKBENCH, we calculated the deformation of the HIP casing during installation with five steps, which are named as: ① lower casing with lower diaphragms, ② step ① + upper diaphragms, ③ step ② + upper casing, ④ step ③ + bolting, and ⑤ replacing the support. Then we analyzed the change of the seal clearance during the installation process by deformation differences of some points under different conditions.\u0000 The calculation results show that the maximum deformation of the HIP Casing during the installation process occurs in the middle of casing close to the IP (Intermediate Pressure) casing. The relative change of the clearance during the whole process is 0.6–0.8 mm. The change of seal clearance is largest at the first-stage of IP casing, and it can be 0.8mm during replacement of the support.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"90 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116586789","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Radheesh Dhanasegaran, A. Uusitalo, T. Turunen-Saaresti
{"title":"Dynamic Modelling of Small Scale and High Temperature ORC System Using Simulink and CoolProp","authors":"Radheesh Dhanasegaran, A. Uusitalo, T. Turunen-Saaresti","doi":"10.1115/GT2020-15314","DOIUrl":"https://doi.org/10.1115/GT2020-15314","url":null,"abstract":"\u0000 In the present work, a dynamic model has been developed for the small-scale high-temperature ORC experimental test rig at the LUT University that utilizes waste heat from a heavy-duty diesel engine exhaust. The experimental facility consists of a high-speed Turbogenerator, heat exchanger components such as recuperator, condenser, and evaporator with a pre-feed pump to boost the working fluid pressure after the condensation process constituting a cycle. The turbogenerator consists of a supersonic radial-inflow turbine, a barske type main-feed pump, and a permanent magnet type generator components connected on a single shaft. Octamethyltrisiloxane (MDM) is the chosen organic working fluid in this cycle. Matlab-Simulink environment along with the open-source thermodynamic and transport database Cool-Prop has been chosen for calculating the thermodynamic properties of the dynamic model. A functional parameter approach has been followed for modeling each block component by predefined input and output parameters, aimed at modeling the performance characteristics with a limited number of inputs for both design and off-design operations of the cycle. The dynamic model is validated with the experimental data in addition to the investigation of exhaust gas mass flow regulation that establishes a control strategy for the dynamic model.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"22 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132729770","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Numerical Simulation of a Particle in Air Flow Around a Turbine Blade","authors":"Ippei Oshima, M. Furuichi","doi":"10.1115/GT2020-14752","DOIUrl":"https://doi.org/10.1115/GT2020-14752","url":null,"abstract":"\u0000 The Steam turbine is widely used for generating electricity, in the thermal, nuclear and geothermal power generation systems. A wet loss is known as one of the degrading factors of the performance. To reduce the amount of liquid phase generated by condensation and atomization from nozzles, the prediction of the distribution of liquid mass flow rate inside the turbine is important. However, the quantitative understanding and the prediction method of the liquid flow inside the turbine remain unclear because physics inside a turbine is consisting of complex multiscale and multiphase events. In the present study, we proposed a theoretical model predicting the motion of droplet particles in gas flow based on Stokes number whose model does not require numerical simulation. We also conducted the numerical validation test using three-dimensional Eulerian-Lagrangian simulation for the problem with turbine blade T106. The numerical simulation shows that the particle motion is characterized by the Stokes number, that is consistent with the assumption of the theoretical model and previous studies. When Stokes number is smaller than one, the particle trajectory just follows the gas flow streamline and avoids the impacts on the surface of T106. With increasing Stokes number, the particles begin to deviate from the gas flow. As a result, many particles collide with the surface of T106 when the Stokes number is approximately one. When the Stokes number is extremely larger than one, particles move straight regardless of the background gas flow. The good agreements between the theoretical predictions and numerical experiment results justify the use of our proposed theoretical model for the prediction of the particle flow around the turbine blade.","PeriodicalId":171265,"journal":{"name":"Volume 9: Oil and Gas Applications; Organic Rankine Cycle Power Systems; Steam Turbine","volume":"42 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2020-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122881477","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}