Experience Gained from Designing Exhaust Hoods of Large Steam Turbines Using Computational Fluid Dynamics Techniques

Abstract

Experience gained from designing exhaust hoods for modernized versions of K-175/180-12.8 and K-330-23.5-1 steam turbines is presented. The hood flow path is optimized based on the results of analyzing equilibrium wet steam 3D flow fields calculated using up-to-date computation fluid dynamics techniques. The mathematical model constructed on the basis of Reynolds-averaged Navier–Stokes equations is validated by comparing the calculated kinetic energy loss with the published data on full-scale experiments for the hood used in the K-160-130 turbine produced by the Kharkiv Turbine-Generator Works. Test calculations were carried out for four turbine operation modes. The obtained results from validating the model with the K-160-130 turbine hood taken as an example were found to be equally positive with the results of the previously performed calculations of flow pattern in the K-300-240 turbine hood. It is shown that the calculated coefficients of total losses in the K-160-130 turbine hood differ from the full-scale test data by no more than 5%. As a result of optimizing the K-175/180-12.8 turbine hood flow path, the total loss coefficient has been decreased from 1.50 for the initial design to 1.05 for the best of the modification versions. The optimized hood is almost completely free from supersonic flow areas, and the flow through it has become essentially more uniform both inside the hood and at its outlet. In the modified version of the K-330-23.5-1 turbine hood, the total loss coefficient has been decreased by more than a factor of 2: from 2.3 in the hood initial design to a value of 1.1 calculated for the hood final design version and sizes adopted for developing the detailed design. Cardinally better performance of both the hoods with respect to their initial designs was achieved as a result of multicase calculations, during which the flow path geometrical characteristics were sequentially varied, including options involving its maximally possible expansion and removal of the guiding plates producing an adverse effect.