汽轮机动叶片的可靠性设计方法

提出了汽轮机叶片可靠性设计方法,介绍了叶片可靠性的含义和计算方法。该方法以概率论和统计学为基础,把汽轮机叶片的静应力、动应力、叶片疲劳强度、叶片安全倍率、叶片振动频率和激振力频率处理为随机变量,通过试验数据的统计分析和计算,确定有关随机变量的分布参数。使用概率设计法、应力与强度干涉模型确定汽轮机叶片疲劳强度和振动设计的可靠度。文中给出了叶片疲劳强度的动应力设计法和安全倍率设计法以及第一种调频叶片、第二种调频叶片和整圈连接叶片组的振动可靠性设计的计算公式和一些应用实例。使用这些方法,可以在设计阶段确定汽轮机叶片设计的可靠度,为汽轮机叶片的可靠性设计提供了科学的依据。     

Development of secondary flows in the stator of a model turbine

Measurements are described which show the development of the secondary flows through the stator blades in a single stage model turbine. The build of the turbine is intended to simulate a stage in the HP cylinder of a steam turbine and three different thicknesses of inlet boundary layers are studied. Flow visualisation of the inlet boundary fluid shows the development of the horseshoe vortex round the blade leading edge. Probe measurements upstream and downstream of the trailing edge plane show how the passage vortices are developed and how they influence the distribution of losses across the annulus.     

大型汽轮机部件低周疲劳安全寿命的设计和评定

文中提出了汽轮机部件低周疲劳安全寿命的设计和评定方法。介绍了汽轮机部件低周疲劳安全寿命的含义和计算方法。该方法以概率论和统计学为基础，把汽轮机部件的低周疲劳寿命处理为随机变量，对低周疲劳试验数据进行统计分析来确定材料低周疲劳寿命的分布参数，使用可靠性理论来确定汽轮机部件的低周疲劳安全寿命。文中给出了低周疲劳寿命服从正态分布和对数正态分布时汽轮机部件低周疲劳安全寿命的计算方法和应用实例。该方法考虑了汽轮机运行参数随机性和材料低周疲劳特性离散性的影响，为汽轮机部件低周疲劳寿命的设计、评定和诊断提供了科学的依据。     

Research on 1:2 subharmonic resonance and bifurcation of nonlinear rotor-seal system

The 1:2 subharmonic resonance of the labyrinth seals-rotor system is investigated, where the low-frequency vibration of steam turbines can be caused by the gas exciting force. The empirical parameters of gas exciting force of the Muszynska model are obtained by using the results of computational fluid dynamics (CFD). Based on the multiple scale method, the 1:2 subharmonic resonance response of the dynamic system is gained by truncating the system with three orders. The transition sets and the local bifurcations diagrams of the dynamics system are presented by employing the singular theory analysis. Meanwhile, the existence conditions of subharmonic resonance non-zero solutions of the dynamic system are obtained, which provides a new theoretical basis in recognizing and protecting the rotor from the subharmonic resonant failure in the turbine machinery.     

Prediction of losses in the flow through the last stage of low‐pressure steam turbine

In this paper, the numerical modelling of the flow through the low‐pressure steam turbine last stage was presented. On the basis of predicted wet steam flow‐field, the aerodynamic as well as thermodynamic losses were estimated. For calculations of the wet steam steady flow‐field three numerical methods were employed. The first method was a streamline curvature method (SCM). The commercial CFD code (CFX‐TACflow) and an in‐house code, both solving the 3‐D RANS equations, were the next two methods. In the wet steam region, by means of all three methods, the equilibrium flow was modelled. Additionally, the in‐house CFD code was used for modelling of the non‐equilibrium steam condensing flow. In this work, the comparison of the cascade loss coefficient for stator and rotor and selected flow parameters for the stage were presented, compared and discussed. Copyright © 2006 John Wiley & Sons, Ltd.     

Influence of steam leakage through vane,gland, and shaft seals on rotordynamics of high-pressure rotor of a 1,000 MW ultra-supercritical steam turbine

A comparative analysis of the influence of steam leakage through vane, gland, and shaft seals on the rotordynamics of the high-pressure rotor of a 1,000 MW ultra-supercritical steam turbine was performed using numerical calculations. The rotordynamic coefficients associated with steam leakage through the three labyrinth seals were calculated using the control-volume method and perturbation analysis. A stability analysis of the rotor system subject to the steam forcing induced by the leakage flow was performed using the finite element method. An analysis of the influence of the labyrinth seal forcing on the rotordynamics was carried out by varying the geometrical parameters pertaining to the tooth number, seal clearance, and inner diameter of the labyrinth seals, along with the thermal parameters with respect to pressures and temperatures. The results demonstrated that the steam forcing with an increase in the length of the blade for the vane seal significantly influences the rotordynamic coefficients. Furthermore, the contribution of steam forcing to the instability of the rotor is decreased and increased with increases in the seal clearance and tooth number, respectively. The comparison of the rotordynamic coefficients associated with steam leakage through the vane seal, gland seal, and shaft seal convincingly disclosed that, although the steam forcing attenuates the stability of the rotor system, the steam turbine is still operating under safe conditions.     

Determination of heat transfer coefficients in steam turbines

A method for the determination of heat transfer coefficients is described which is particularly suited for measurements inside steam turbine cylinders and buckets. The heat transfer coefficients are derived from the temperature frequency characteristics of the walls. Correlations are made between the time-dependent fluid temperature and the corresponding signal received by a detector just below the wall's surface. The natural stochastic temperature variation within a steam turbine can be used as test signal. Measurements in a 2 Megawatt steam turbine demonstrate, that the signal's power density is sufficiently high and the attenuation low within the important frequency range of 1/s ? ω? 10/s. The experimental verification of the method in a steam tunnel showed good results.     

Solar pond/fuel assisted water desalination plant

This article presents a thermodynamic analysis for a proposed hybrid system suitable for producing power or fresh water for small communities. The system includes a power generation loop and a desalination loop. These loops can work separately to produce power or combined to produce fresh water. The power loop comprises a solar pond, flashing chamber, vapour compressor VCI, steam superheater, steam turbine and a steam condenser. The desalination loop includes a vapour compressor VCII, vertical tube evaporator unit, multi stag flash feed heater and a heat rejection steam condenser. Hot water from the pond (97°C) is introduced into the flashing chamber and the generated steam is compressed to 125 kPa. Then the steam is superheated (using fuel) to a temperature of 315°C and is allowed to expand in a low pressure steam turbine exhausting into a condenser at 10 kPa. The turbine & VCI are mounted on the same shaft and the balance in the power generated can be used either as shaft power available or specifically for driving a desalination loop. This could be either a reverse osmosis RO or a vapour compression system. However, the analysis showed that the second one is more efficient than the RO. The VCII, driven by the turbine, is working across a 3-VTE multi effect unit associated with a 13-stage MSF feed heater coupled with an end condenser at 10kPa. Calculations showed that the power loop of a 100 m × 100 m solar pond assisted by 13 percent of its heat requirements, using fossil fuel, can generate 70 kW shaft power with a basic efficiency of 15%. When this loop is combined with a VC/VTE-MED unit a 200 t/day of fresh water can be produced at a PR of 9.4 and a thermal energy consumption (fuel) of 31 kJ/kg water produced which is less than any other system including the RO.     

Numerical investigation of the effect of inlet condition on self‐excited oscillation of wet steam flow in a supersonic turbine cascade

Self‐excited oscillation can be induced due to the interaction between condensation process and local transonic condition in condensing flow, which is an important problem in wet steam turbine. With an Eulerian/Eulerian numerical model, the self‐excited oscillation of wet steam flow is investigated in a supersonic turbine cascade. Owing to supercritical heat addition to the subsonic flow in the convergent part of the cascade, the oscillation frequency decreases with increased inlet supercooling. Mass flow rate increases in the oscillating flow due to the greater supersaturation in condensation process, while the increase will be suppressed with the flow oscillation. Higher inlet supercooling leads to the fact that the condensation process moves upstream and the loss increases. Moreover, some predictions of oscillation effects on outflow angle and aerodynamic force are also presented. Finally, heterogeneous condensations with inlet wetness and periodic inlet conditions, as a result of the interference between stator and rotor, are discussed. Copyright © 2008 John Wiley & Sons, Ltd.     

基于电容法的温度对舰船汽轮机油分水性影响研究

依据汽轮机油与水的介电常数差值大,其混合相作为电介质,会发生电容值变化显著的原理,采用同轴圆柱形电容作为测试传感器,选取符合世界主流海军舰船汽轮机油产品规范的8个油样,利用电容法对比研究室温(18~24 ℃)和54 ℃对油样的分水性影响规律,选取了分水性变化明显的油样进行分水后油层微观形貌分析. 试验结果表明:在54 ℃条件下,从油水混合到分离结束,电容值-时间曲线重合度更高,油水均匀混合重复性好,表现出了优于室温的重复性和稳定性;分水速率曲线具有良好的重复性,验证了电容法评定汽轮机油分水性的可靠性,在相同温度下分水速率和破乳化时间受水相分布与运动态势影响小;确定用电容法评定汽轮机油分水性时,环境温度选择54 ℃为最佳;作用机理分析说明,温度是影响舰船汽轮机油分水性的关键指标.      

Flux schemes based finite volume method for internal transonic flow with condensation

This paper describes the development of numerical method for the solution of condensing steam flow in internal aerodynamics problems. The numerical method is based on the fractional step method, where the resulting set of ODEs is solved by the two‐stage Runge–Kutta method and the homogeneous set of PDEs by a finite volume method. The flow does not contain both phases (gas and liquid) in the whole domain, therefore we discuss properties of used finite volume methods in several cases of single‐phase transonic flow in a channel and a turbine cascade. We present numerical results of two‐phase flow of condensing steam in 2D nozzle achieved by several numerical methods and show the differences in results caused by numerical diffusion. Copyright © 2010 John Wiley & Sons, Ltd.     

汽轮机轮盘热处理残余应力分析

百万核电汽轮机红套低压转子工作环境的蒸汽参数较低,各级轮盘均处于湿度较大的工作区域,易产生应力腐蚀,引起裂纹萌生和扩展．为提高轮盘的抗腐蚀能力,降低工作应力是一个有效的方法．通过热处理方法,在轮盘表面形成预压应力以抵消部分旋转拉应力是可行的方法,而产生适当深度和大小的预压应力则需对热处理过程进行谨慎的设计．本文以汽轮机轮盘为研究对象,建立轴对称有限元模型,通过对ABAQUS软件的二次开发,实现对轮盘热处理过程的温度场及应力场进行数值模拟．计算综合考虑了非线性的材料热物性参数、力学性能参数、表面换热系数及不同材料组织转变的相变潜热、热物性参数和力学参数,通过对不同热处理方法得到的残余应力场的比较,获得了较合理的水冷方式,为热处理工艺确定提供参考．     

A study of thermal nonequilibrium effects in low-pressure wet-steam turbines using a blade-to-blade time-marching technique

A theoretical analysis of the wet-steam flow in the low pressure cylinder of a 500 MW steam turbine using a blade-to-blade time-marching computer program is described. The calculating method can compute most types of wet-steam flow found in LP turbines, including those involving both primary and secondary nucleations in transonic and supersonic blading with shock waves. In particular, condensing flows in highly staggered rotor tip sections can be computed without difficulty. Extensive results are presented showing the effect of departures from thermal equilibrium on the blade surface pressure and velocity distributions, the blade outlet relative flow angle, the mass flow coefficient and the thermodynamic loss coefficient. On the basis of the analysis, recommendations are made concerning the application of nonequilibrium wet-steam theory to steam turbine design.     

接触状态对叶根轮槽应力分布影响的研究

汽轮机叶片叶根、轮槽连接区域常因加工误差及磨损等原因导致接触状态的改变,从而改变整个区域应力分布并大大降低汽轮机的使用寿命。本文运用数字光弹性技术实验测试了长叶片叶根、轮槽在不同接触状态下的应力分布情况,同时结合有限元进行了仿真计算。结果表明,叶根、轮槽对称接触时,全部齿同时接触的应力集中系数最小且分布较均匀;而当部分接触齿产生间隙时,接触状态发生显著变化,应力集中系数明显增大;尤其是当左右齿非对称接触时,最大应力集中系数明显增大且应力分布不均匀。本文研究可为叶根、轮槽的优化设计、加工以及叶片的装配、维护提供实验依据。     

Suppression of harmonic perturbations and bifurcation control in tracking objectives of a boiler–turbine unit in power grid

In the presence of harmonic disturbances, boiler–turbine units may demonstrate quasi-periodic behaviour due to the occurrence of various types of bifurcation. In this article, a nonlinear model of boiler–turbine unit is considered in which drum pressure, electric output and drum water level are controlled via manipulation of valve positions for fuel, steam and feed-water flow rates. For bifurcation control in tracking problem, two controllers are designed based on gain scheduling and feedback linearization (FBL). To investigate the efficiency of control strategies, three cases are considered for desired tracking objectives (a sequence of steps, ramps/steps, and a combination of them). According to the results, FBL controller works successfully in suppression of harmonic perturbations and consequently bifurcation control. As it is implemented, quasi-periodic solutions (caused by Hopf bifurcation) are vanished; leading to the appearance of periodic solutions with low amplitudes. Consequently, appropriate tracking performance with less oscillatory behaviour is observed for the drum pressure, electric output, and drum water level (desirable for the power grid). In addition, when FBL controller is used, less control efforts are predicted for the bifurcation control.     

Resonant-vibration fatigue testing

Techniques are described for the fatigue testing of components, such as turbine buckets, used in large steam turbines and generators. Fatigue of these large structures, which have relatively high unit damping, is obtained through the use of resonant-vibration systems. An electromagnetic drive serves as the source of excitation. The drive system is designed to produce the maximum force from a given-size magnet. Control of the amplitudes of vibration, for very long periods, is obtained through the use of an automatic amplitude control, the stability of which maintains the amplitude with a variation of less than 2 percent. Three specific fatigue-testing techniques described are:

1. 1.
   The fatigue of complete weld sections for large numbers of cycles (500 million), which required dynamic bending moments of greater than 6000 ft-lb to produce failure.     
   
   

汽轮机转子的温度场及热应力场计算

利用积分变换法导出了蒸汽温升率连续变化时汽轮机转子的温度场和热应力场计算公式。本公式可直接应用于转子的应力监测与控制。和差分法相比，解析法的数据处理速度快，能满足快速监测、及时跟踪与控制的要求。关键词：汽轮机转子；温度场；热应力场     

A numerical study of droplet motion/departure on condensation of mixture vapor using lattice Boltzmann method

Droplet motion/departure, which is governed by external force acceleration coefficient, droplet radius and surface wettability on solid surfaces under external forces such as gravitational force, play a significant role in characterizing condensation heat transfer, especially when high fractional non-condensable gases (NCG) present. However, due to the challenge in visualizing the vapor/steam velocity field imposed by droplet motion/departure, the detailed mechanism of droplet motion/departure on condensing surfaces has not been completely investigated experimentally. In this study, droplet motion/departures on solid surfaces under external forces and their interactions with steam flow are simulated using two dimensional (2D) multiphase lattice Boltzmann method (LBM). Large external force acceleration coefficient, droplet radius and contact angle, lead to large droplet deformation and high motion/departure velocity, which significantly shortens the droplet residual time on the solid surface. Our simulation shows that steam vortices (lateral velocity) induced by droplet motion/departure can greatly disturb the vapor flow and would be intensified by increasing external force acceleration coefficient, droplet radius, and contact angle. In addition, the location of vortex center shifts in the ascending direction with increase of these factors. The average lateral velocities induced by droplet motion/departure at various conditions are obtained. The mass transfer resistance is substantially reduced owing to the droplet motion/departure, leading to an enhanced heat flux. The experimental results are compared to validate the influence of droplet motion/departure on condensation heat transfer performance, especially for steam–air mixture with the presence of high fractional NCG.     

Steam condensing flow modeling in turbine channels

The numerical method for modeling of the transonic steam flows with homogeneous and/or heterogeneous condensation has been presented. The experiments carried out for the Laval nozzles, for 2-D turbine cascades and for a 3-D flow in real turbine were selected to validate an in-house CFD code adjusted to the calculations of the steam condensing flows in complicated geometries. The sensitivity of the condensation model and difficulties in the validation process of the CFD code have been discussed. These difficulties limit the possibilities of verification and improvement of the condensation theory based on the existing experimental data.     

A numerical modelling of stator–rotor interaction in a turbine stage with oscillating blades

In real flows unsteady phenomena connected with the circumferential non-uniformity of the main flow and those caused by oscillations of blades are observed only jointly. An understanding of the physics of the mutual interaction between gas flow and oscillating blades and the development of predictive capabilities are essential for improved overall efficiency, durability and reliability. In the study presented, the algorithm proposed involves the coupled solution of 3D unsteady flow through a turbine stage and the dynamics problem for rotor-blade motion by the action of aerodynamic forces, without separating the outer and inner flow fluctuations. The partially integrated method involves the solution of the fluid and structural equations separately, but information is exchanged at each time step, so that solution from one domain is used as a boundary condition for the other domain. 3-D transonic gas flow through the stator and rotor blades in relative motion with periodicity on the whole annulus is described by the unsteady Euler conservation equations, which are integrated using the explicit monotonous finite volume difference scheme of Godunov–Kolgan. The structural analysis uses the modal approach and a 3-D finite element model of a blade. The blade motion is assumed to be constituted as a linear combination of the first natural modes of blade oscillations, with the modal coefficients depending on time. A calculation has been done for the last stage of the steam turbine, under design and off-design regimes. The numerical results for unsteady aerodynamic forces due to stator–rotor interaction are compared with results obtained while taking into account blade oscillations. The mutual influence of both outer flow non-uniformity and blade oscillations has been investigated. It is shown that the amplitude-frequency spectrum of blade oscillations contains the high-frequency harmonics, corresponding to the rotor moving past one stator blade pitch, and low-frequency harmonics caused by blade oscillations and flow non-uniformity downstream from the blade row; moreover, the spectrum involves the harmonics which are not multiples of the rotation frequency.