One of the challenges of maintaining infrastructure is deciding how best to keep the operational costs in check while delivering the highest amount of service. This is especially true for aging equipment. One option is to replace the equipment with a newer version entirely, continue to maintain the existing machine, or a third option, retrofit the current machine with updated features.
Retrofitting is a term used in the manufacturing industry to describe how new or updated parts are fitted to old or outdated assemblies to improve function, efficiency or additional features unavailable in the earlier versions.
Retrofitting, like any investment of capital requires careful thought. SoftInWay’s Manage ring Director, Abdul Nassar has put together a simple list of questions to ask yourself before committing to a retrofit project. Answering these seven questions before you start can save you considerable time and effort. Read More
This might seem like a strange question, but we get ask this a lot. The question takes the form of: Can the sales side do a proper preliminary design and select the optimal machine (turbine/compressor/pump)? Is it possible for the design and application task to be integrated in a way allowing the application team the autonomy to make decisions without going back to the engineering team every time they get an inquiry? After realizing how large of a pain point this is for our clients, we decided to solve this problem for a major turbine manufacturer in Asia and in the process, provided a time-saving solution to maximize the returns for all the stakeholders.
The challenge came with the different competencies of the sales and design team. The sales/application teams are not necessarily experts in design while designers cannot double as application engineers to meet the sales requirements.
In our efforts to solve this issue, we worked with this turbine manufacturer. We listed all of their current processes, limitation, requirements, constraints, and etc. to explore the many possible ways to resolve this pain point. In the end, there were two solutions; (1) Develop custom selection software, or (2) Leverage the AxSTREAM® platform using AxSTREAM ION™.
Developing Custom Selection Software: Developing a custom selection software specific to the manufacturer where their application team can choose the optimal turbine based on expected customer needs. Developing such a custom system requires bringing together the expertise of different teams from turbomachinery (such as aero-thermal and structural) to software developer, testing, etc. Developing such a one-off system also takes considerable time at considerable cost. This approach could solve the current problem, but with rapidly changing technologies and market requirements, this is not a viable long-term solution.
Leverage the AxSTREAM® Platform using AxSTREAM ION™: We evaluated the limitation and possibilities of utilizing our turbomachinery design platform AxSTREAM® to meet the requirement of sales/application engineering team for today’s needs and in the future. We found the organization had a greater advantage using this existing platform rather than investing in the short-term solution of developing a custom selection software. Many of the building blocks required for customization are already available to use via an interface a non-technical sales person could easily use. This platform was utilized for meeting the requirement of this turbine manufacturer saving time and cost while resolving a large pain-point for the organization.
Steam turbine technology has advanced significantly since it was first developed by Sir Charles Parson in 1884 . The concept of impulse steam turbines was first demonstrated by Karl Gustaf Patrik de Laval in 1887. A pressure compounded steam turbine based on in de laval principle was developed by Auguste Rateau in 1896. Westinghouse was one of the earliest licensee for manufacturing steam turbines obtained from Sir Charles Parson and became one of the earliest Original Equipment Manufacturers (OEM) in power generation and transmission.
Over the years, as steam turbine technology advanced, the design principles were based on either impulse type or reaction type with reaction type being more efficient. Though impulse was not as efficient as reaction type, it gained popularity due to lower cost and compact size. With advances in design and optimization methods being employed, the efficiency levels between these two types are not very distant, ranging between 2 – 5% based on the size and application. Read More
Globalization, increase in defense expenditure by different countries, economic development and growth of air traffic has all resulted in the need for various turbomachinery components. The turbomachinery industry as a whole has seen extensive growth over the last few years and is poised to grow further in the next few decades. The development of Turbomachinery components namely turbines, compressors, pumps, turbopumps, turbochargers are a niche field with the technology limited to just a handful of major players. The recent interest in Un-manned aerial vehicles for military and defense applications, the environmental concerns and rising fuel cost has paved the way for development of small gas turbines and turbomachinery for waste heat recovery systems. Since the market is large and capital cost is not very high due to the equipment size, there is greater interest among technologist and entrepreneurs to step into the business of turbomachinery.
However, turbomachinery design is still a niche field and require technical expertise, which is again limited. Naturally to get into the league of turbomachinery developers and to compete with established players many startups look at the short cuts which usually is copying of designs from existing players, scaling competitors’ products etc. Though this can help them in getting a product into the market sooner with lower cost on design, this is quite dangerous to the industry as copying designs, scaling etc. results in poor products with performance not being competitive which will lead to the premature killing of the product as a whole. For any startups in turbomachinery, they need to have state of the art product, which can compete with existing players who are well established in the industry.
In my earlier blog titled “Optimizing the Cooling Holes in Gas Turbine Blades, I wrote about how optimizing the cooling flow through turbine blades is important considering both performance and reliability. The design process differs between different designers and depends on a number of factors including expertise, availability of design tools, statistical or empirical data, corporate procedure and so on. That being said, the ultimate goal is to provide a design which is considered optimal. Though the designer is often satisfied on completion of a design and when the machine is put into operation, there is always the feeling that we could have done better if there were more resources and time. Integrating the entire design process with multidisciplinary optimization provides a great opportunity to arrive at the optimal design rapidly with less manual intervention and effort.
Figure 1 shows the integrated approach to design a cooled gas turbine using multidisciplinary tools in an optimization environment. The flow path design starts from the conceptual stage to arrive at the optimal flow path geometry, accounting for a preliminary estimate of the cooling flow. Detailed design requires accurate estimation of the cooling flow considering the actual geometries and the material temperatures. Using ID head and flow simulation tools such as AxSTREAM® NET, the cooling flow can be modelled to produce the optimal geometric dimension in an iterative process to further fine tune the flow path performance. To meet the performance and reliability objectives, multidisciplinary optimization can be achieved via the integrated modules. The process when further integrated with a CAD package can help in generating the optimized geometry that can be taken for prototype development.
Heat recovery steam generators (HRSGs) are used in power generation to recover heat from hot flue gases (500-600 °C), usually originating from a gas turbine or diesel engine. The HRSG consists of the same heat transfer surfaces as other boilers, except for the furnace. Since no fuel is combusted in a HRSG, the HRSG have convention based evaporator surfaces, where water evaporates into steam. A HRSG can have a horizontal or vertical layout, depending on the available space. When designing a HRSG, the following issues should be considered:
The pinch-point of the evaporator and the approach temperature of the economizer
The pressure drop of the flue gas side of the boiler
Optimization of the heating surfaces
The pinch-point (the smallest temperature difference between the two streams in a system of heat exchangers) is found in the evaporator, and is usually 6-10 °C, which can be seen in Figure 2. To maximize the steam power of the boiler, the pinch-point must be chosen as small as possible. The approach temperature is the temperature difference of the input temperature in the evaporator and the output of the economizer. This is often 0-5 °C.
The heating, ventilation, and air-conditioning (HVAC) system is arguably the most complex system that is installed in a house and it is responsible for a substantial amount of the total house energy used. A right-sized HVAC system will provide the desired comfort and will run efficiently. Right-sizing of a HVAC system is the selection of equipment and the designing of the air distribution system to meet the accurate predicted heating and cooling loads of the house. Rightsizing the HVAC system begins with an accurate understanding of the heating and cooling loads on a space, however, a full HVAC design involves more than just the load estimate calculation as this is only the first step of the iterative HVAC design procedure. Heating and cooling loads are dependent on the building location, sighting, and the construction of the house, whereas the equipment selection and the air distribution design are dependent upon the loads and each other.
In an internal combustion engine, combustion of air and fuel takes place inside the engine cylinder and hot gases are generated with temperature of gases around 2300-2500°C which may result in not only burning of oil film between the moving parts, but also in seizing or welding of the stationery and moving components. This temperature must be reduced such that the engine works at top efficienc, promoting high volumetric efficiency and ensuring better combustion without compromising the thermal efficiency due to overcooling. Most importantly, the engine needs to function both in the sense of mechanical operation and reliability. In short, cooling is a matter of equalization of internal temperature to prevent local overheating as well as to remove sufficient heat energy to maintain a practical overall working temperature.
It is also important to note that about 20-25% of the total heat generated is used for producing brake power (useful work). The cooling system should be designed to remove 30-35% of total heat and the remaining heat is lost in friction and carried away by exhaust gases.
Steam turbines are not just restricted to conventional or nuclear power plants, they are widely used in combined cycle power plants, concentrated solar thermal plants and also geothermal power plants. The operational requirements of a steam turbine in the combined cycle and CSP’s means that they operate under transient conditions. Even in conventional steam turbines, the market requirements are changing with requirements for faster and more frequent start-up which can result into faster deterioration of the equipment and reduced lifespan. During the startup phase, significant heat exchange takes place between the steam and the structural components that include the valves, rotor and casing. The accuracy of the life prediction is strongly affected and dependent on the accuracy of the transient thermal state prediction .
Though the expansion of steam takes place in the nozzles and blades, the influence of the leakage steam during the startup phase is significant with steam expanding through the labyrinths resulting in expansions, condensation, and increased velocities which may even reach supersonic levels. During cold start, the flow is minimal, the temperature of the metal is at room temperature and heat exchange happens between the steam and metal parts resulting in thermal stress.
To increase the overall performance of the engine and reduce the specific fuel consumption, modern gas turbines operate at very high temperatures. However, the high temperature level of the cycle is limited by the melting point of the materials. Therefore, turbine blade cooling is necessary to reduce the blade metal temperature to increasing the thermal capability of the engine. Due to the contribution and development of turbine cooling systems, the turbine inlet temperature has doubled over the last 60 years.
The cooling flow has a significant effect on the efficiency of the gas turbine. It has been found that the thermal efficiency of the cooled gas turbine is less than the uncooled gas turbine for the same input conditions (see figure 1). The reason for this is that the temperature at the inlet of turbine is decreased due to cooling and therefore, work produced by the turbine is slightly decreased. It is also known that the power consumption of the cool inlet air is of considerable concern since it decreases the net power output of the gas turbine.
With this in mind, during the design phase of gas turbine it is very important to optimize the cooling flow if you are considering both the performance and reliability. Cooled Gas turbine design is quite complicated and requires not only the right methodology, but also the most appropriate design tools, powerful enough to predict the results accurately from thermodynamics cycle to aerothermal design, ultimately generating the 3D blade.