Most designers associate drilled nozzles in turbomachinery with something exotic, uncharted, and specific only to a minuscule amount of high-loaded turbines operating with a high-pressure drop. Meanwhile, many engineers are not aware that this nozzle design has been applied since the very first turbomachines.
Karl Gustaf Patrik de Laval patented a turbine with asymmetric convergent-divergent nozzles in 1888. At that time the shape of the nozzle allowed him to reach more effective kinetic energy transformation and have an entirely new level of turbine performance.
Over a hundred years later, drilled nozzles (or asymmetric nozzles, Laval’s nozzles) have been extensively used in rocket engines, flying vehicles, driving turbines, ORC turbines, and other units for which low cost and weight-dimension constraints play an important role.
Despite the wide application range of turbines with these nozzles, each has its own specific features.
The main characteristics of drilled nozzles in a turbine (Fig. 2) are the partial admission input, high heat drop per first stage, low reaction, and a low number of stages.
For these turbines, the most critical point during the design process is the first nozzle design. The first supersonic nozzle provides the throughput of the turbine. The main kinetic energy transformation and the main portion of the available isentropic heat drop relates to the first nozzles. As a result, the Mach number at the outlet section of nozzles can reach 3.0 and even be higher. To operate in such regimes, the convergent-divergent vane channels are preferable. Read more
The Achilles heel of turbochargers has always been the time between pressing your foot to the gas pedal and waiting for the engine to respond with the desired power. This lapse in engine response, commonly termed turbo lag, is what has hindered turbochargers from delivering optimal performance. The aim of a turbocharger is to provide more power, better efficiency and less lag in power delivery. Engine efficiency is becoming more important than ever before, leading to the development of smaller engines. However, the power requirements are not decreasing which means the loss in engine displacement from small designs must be picked up with alternative technologies, such as turbochargers, which can help improve power delivery and fuel economy.
Electric turbochargers (e-turbos) provide a solution to eliminating turbo lag while adding additional performance benefits. This allows for larger turbocharger designs which can provide larger power and efficiency gains, stay cooler over longer periods of use, and drastically improve engine responsiveness. Garrett Motion are developing e-turbos for mass market passenger vehicles set for launch in 2021, with a claimed fuel efficiency improvement of up to 10%. When used on diesel engines, this e-turbo could be up to a 20% reduction in NOx emissions. In most cases, fuel efficiency will be improved by about 2 – 4%. Other manufacturers such as Mitsubishi and BorgWarner are already developing their own electric turbos and are expected to have announcements in the near future matching the trend in e-turbo development.
This is an excerpt from the Siemens Blog. You can read the full version here.
Originally written By Chad Custer on March 11, 2020
We live in the day of automatic. It seems like every day there is a new task that can be handled automatically. Smart thermostats make sure the house is comfortable when returning from work. Home lighting themes customize an ambiance based on who is home and the time of day. Automatic delivery of your household goods ensures you’re never out of toothpaste. The automatic potato peeler saves you from having to peel potatoes by hand…ok, well maybe that’s going too far. The point is that technology is great for taking care of tasks based on rules or schedules so that you can focus on more important things.
The pervasiveness of automation makes it even more annoying if once you get to work and sit down to run a simulation, you need to fine-tune settings and fiddle with parameters. Or, even worse, if it’s necessary to babysit a challenging case to make sure it runs as expected. Now, there likely was a time in your professional life when diving head-first into the details of flow solvers was interesting and, dare I say, fun. I know it was for me and if you’re reading this blog, then I bet it was for you too 😊. In fact, when it’s possible to set aside time to dig into some new and different case, it’s still fun to research the best methods to use and how to apply them.
Daily work is different, though. Timelines are always shorter. More data is always needed. Your attention is always split between half-a-dozen urgent tasks, not to mention the ever-growing list of work that you keep meaning to get to once you have time. Forget tuning simulation methods for each case, you need to set up the case once knowing that it will run quickly, reliably and give accurate answers. Read More
When you think of shock waves, I would wager that you picture a supersonic jet zooming past overhead. Or maybe you have experienced the famous (or infamous) “sonic boom” that accompanies shock waves attached to airplane engines. The engineering challenges associated with the often-troublesome behavior of shock waves is present in all scales, from carefully designing the bodywork of the aforementioned fighter jets, to the equally intricate details of flow passages and blade design in turbomachinery. The first step in taking into account the effect of shock waves is to understand what they are. In this post we will be reviewing a short introduction into what shock waves are and a few applications where they might be relevant.
What are shock waves?
Shockwaves are non-isentropic pressure perturbations of finite amplitude and from the second law of thermodynamics we can say that shockwaves only form when the Mach number of the flow is larger than 1. We can distinguish between normal shocks and oblique shocks. In normal shocks, total temperature is constant across the shock, total pressure decreases and static temperature and pressure both increase. Across oblique shocks, flow direction changes in addition to pressure rise and velocity decrease. Read More
Despite the deepening understanding of the essence of gas-dynamic processes and the development of computational methods, simpler design methods such as scaling and trimming remain in demand in turbomachinery engineering. The main advantage of these approaches over design from scratch is simplicity and its inexpensive nature due to the small-time expenditure and lower demand from computational resources. Good predictive accuracy of the performance and efficiency of the resulting machines is based on the use of an existing machine with well-known characteristics as a prototype.
Conversely, using the prototype imposes restrictions on the use of scaling and trimming methods. It is almost impossible to get a new design with pressure and efficiency higher than that of the prototype. Also, in cases where it is required to obtain performance that is significantly different from the prototype, the inherent reliability of the original prediction may be insufficient.
Easy to apply and general, valid, scaling laws are needed for design and application engineers. The scaling laws are needed for the purposes of:
Predicting the full-scale performance machine from model test data obtained from a scaled machine
Obtaining a family of machines with different performances on the basis of one well-tested machine
Experimental performance and efficiency testing on a full-size model of large machines such as fans to ventilate tunnels and mines or to move combustion air and smoke gas in power plants may be impractical due to the high energy costs and geometric limitations of the experimental stand. In these cases, a scale model is used. And although complete similarity is not maintained, for example, in terms of the Reynolds number, the correction factors in most cases are well known and the prediction accuracy is high.
The method involves the implementation of the flow path of the designed fan or compressor on a scale to the prototype. This means that all linear dimensions (e.g. diameters, blade chord, axial length, etc.) must be multiplied by the scaling factor (SF). The angular dimensions (e.g. blade angles at inlet and outlet, stagger angle, etc.) remain unchanged.
When scaling, it is assumed that parameters such as Pressure Ratio, circumferential velocity (U), and axial velocity (Cz) are equal for the designed machine and the prototype. Thus:
The condition of equality of the Reynolds criteria is not ensured, since the designed compressor and the prototype do not have the same diameters of the rotor with the equality of other parameters that determine the number of Rew. This design guarantees the practical accuracy of the calculated characteristics, provided that the gas movement in the flow path is turbulent. It is known that for “physical” values of the Reynolds numbers
the flow remains turbulent and the inequality of the Reynolds numbers of the designed compressor and the prototype has little effect on the gas-dynamic characteristics.
To determine the efficiency of low-pressure fans, a well-known formula is usually used:
An example of obtaining a stage of an axial compressor by the scaling method is shown in Figure 1.
The disadvantages of the scaling method include the need to change the rotor speed. This can be relevant for industrial installations, where the rotation speed is often limited and tied to the frequency of the electrical network current. Additionally, the need to change the overall dimensions can be a limiting factor, especially if it is necessary to increase productivity significantly, and the installation location for the turbomachine is limited. In some cases, maintaining full geometric similarity is impossible for technological or constructive reasons. For example, the minimum value of the tip clearance may be limited by the operating conditions of the rotor (not touching the rotor against the housing) or the impossibility of obtaining a small clearance if the scaling is carried out from a large prototype to a small model.
Centrifugal fans are a type of turbomachine equipment widely used in all kinds of modern and domestic life. Centrifugal fans were developed as highly efficient machines, and the design is still based on various empirical and semi-empirical rules proposed by fan designers. Due to these various rules, there are different methodologies used to design impellers and other components.
Centrifugal fans consist of an impeller in a casing with a spirally shaped contour, shown in Figure 1 (left side). The air enters the impeller in an axial direction and is discharged at the impeller’s outer periphery. The airflow moves along the centrifugal direction (or radial direction). Centrifugal fans can generate relatively high pressures, as compared with axial flow fans. For axial flow fans, the pressure rise is small, about be few inches of water.
Generally, centrifugal fans have three types of blades: forward blade, backward blade, and radial blade. The characteristic curve of these three kinds of centrifugal fans is shown on the right side in Figure 1.
Sizing Using Cordier Diagram
Centrifugal fans (most turbomachines) can be classified based on specific speed (Ns) and specific diameters (Ds) as shown in Figure 2. Specific speed is a criterion at which a fan of unspecified diameter would run to give unit volume flow and pressure. The correlation for a specific speed and specific diameter can be seen here:
where, ‘N’ is rotational speed (RPM), ‘Q’ is flow rate (ft3/sec), ‘H’ is head (ft), ‘D’ is diameter (ft) Read More
Due to concerns about air travel’s impact on climate change, research and development into electric aircraft has been ongoing for several years. Within the last decade several startups as well as larger corporations have been developing electric or hybrid electric aircraft (Ros, 2017). The ultimate goal is to Conduct long (>500 miles), full-electric commercial flights with large aircrafts capable of carrying 100’s of passengers, but this will require at least 5-10 more years of development. Luckily, smaller electric aircraft designed for short-range flights (<500 miles) with anywhere from 1-20 passengers have already been tested successfully utilizing electric batteries, a hybrid-electric system and even a hydrogen fuel cell. With these advances, emission-free air travel is closer than you think.
Examples of full-electric aircraft designs include the Airbus E-Fan 1.0 and E-Fan 1.1 (Airbus Group), shown in Figure 1. These two-person aircraft utilize two ducted, variable-pitch fans, shown in Figure 2. Each fan is powered by a 30-kW electric motor. The motors are powered by several lithium-ion battery packs stored in the wings. While the aircraft only provides an hour of flight time, the batteries can recharge in approximately one hour and can be easily be swapped in and out.
There are several reasons besides climate change why electric aircraft should be developed from a business perspective (Figure 3). Short and mid-range regional flights make up a significant portion of all flights around the world. The current flight range of electric aircraft is limited to these short and mid-range fights. Additionally, shorter flights spend relatively more time taking off and landing than cruising at high altitudes, which makes shorter trips less energy efficient. While short, regional flights are economically unattractive for large commercial aircraft, a smaller aircraft with less fuel consumption may provide a valuable alternative. Read More
Pumps are machines that transfer liquids from suction to discharge by converting mechanical energy from a rotating impeller into what is known as head. The pressure applied to the liquid forces the fluid to flow at the required rate and to overcome frictional losses in piping, valves, fittings, and process equipment.
When it comes to pump selection, reliability and efficiency go hand-in-hand. Generally, a pump that has been selected and controlled properly for its normal operating points will operate near its best efficiency point (BEP) flow, with low forces exerted on the mechanical components and low vibration — all of which result in optimal reliability.
There are several factors like process fluid properties, end use requirements, environmental conditions, pump material, inlet conditions, and others which should be considered while selecting pumps for industrial applications. Selecting the right pump type and sizing it correctly are critical to the success of any pump application. Pumping applications include constant or variable flow rate requirements, serving single or networked loads, and consisting of open loops (nonreturn or liquid delivery) or closed loops (return systems).
Some crucial factors considered while pump selections include:
Fluid Properties: The pumping fluid properties can significantly affect the choice of pump. Key considerations include:
Acidity/alkalinity and chemical composition. Corrosive and acidic fluids can degrade pumps and should be considered when selecting pump materials.
Operating temperature: Pump materials and expansion, mechanical seal components, and packing materials need to be considered with pumped fluids that are hotter than 200°F.
Solids concentrations/particle sizes: When pumping abrasive liquids such as industrial slurries, selecting a pump that will not clog or fail prematurely depends on particle size, hardness, and the volumetric percentage of solids.
Specific gravity: It affects the energy required to lift and move the fluid and must be considered when determining pump power requirements.
Vapor pressure and Viscosity: Proper consideration of the fluid’s vapor pressure will help to minimize the risk of cavitation. High viscosity fluids result in reduced centrifugal pump performance and increased power requirements. It is particularly important to consider pump suction-side line losses when pumping viscous fluids.
Materials of Construction: It is always required to check the compatibility of materials of construction with the process liquid or any other liquids the pump might encounter. The initial cost of these materials is normally the first consideration. The operational costs, replacement costs and longevity of service and repair costs will, however, determine the actual cost of the pump during its lifetime. Charts are available to check the chemical compatibility and identify the most appropriate materials of construction for the pump.
The impact of the impeller material on the life of a pump under cavitation conditions is shown in Figure 1. As an example, changing from mild steel (reliability factor of 1.0) to stainless steel (reliability factor of 4.0) would increase the impeller life from cavitation damage by a factor of four. Hard coatings, such as certain ceramics, can also increase the impeller life under cavitating conditions.
Pump Sizing and Performance Specifications: The desired pump discharge is needed to accurately size the piping system, determine friction head losses, construct a system curve, and select a pump and drive motor. Process requirements can be achieved by providing a constant flow rate, or by using a throttling valve or variable speed drives. Read More
Update – February 28, 2023: AxCYCLE and AxSTREAM NET are our legacy software packages replaced by AxSTREAM System Simulation. System Simulation was born out of the union of the legacy AxCYCLE and AxSTREAM NET.
This is an excerpt from a technical paper, presented at the ASME Turbo Expo 2020 online conference and written by Leonid Moroz, Maksym Burlaka, Tishun Zhang, and Olga Altukhova. Follow the link at the end of the post to read the full study!
The attempts to simulate transient and steady-state sCO2 cycles off-design performance were performed by numerous authors , , , , and . Some of them studied the dynamic behavior of regulators, some studied different control strategies or off-design behavior in different scenarios, which definitely has certain utility in the development of the reliable technology of sCO2 cycle simulation. Nevertheless, they used rather simplified models of components, especially turbomachinery and heat exchangers, which are of crucial importance to correctly simulate cycle performance.
The authors of this paper attempted to apply the digital twin concept to a simulation of off-design and part-load modes of the sCO2 bottoming cycle considering real machine characteristics and performance, which nobody tried to apply in this area.
On IGTC Japan 2015, SoftInWay Inc. has published a paper “Evaluation of Gas Turbine Exhaust Heat Recovery Utilizing Composite Supercritical CO2 Cycle”. The paper considered combinations of different bottoming sCO2 cycles for a specific middle power gas turbine. It mainly studied the advantages of different types of sCO2 cycles to increase the power production utilizing GTU waste heat.
The present paper is a further study based on that so the Cycle 2  from that previous paper was selected as the sCO2 bottoming PGU layout in the present paper for subsequent analysis. The cycle is a combination of recompression cycle and simple cycle which offers 16.13 MW as output. GE LM6000-PH DLE gas turbine, was used as the heat source for bottoming PGU. According to GE official brochure , the GE LM6000 offers 40 MW to over 50 MW with up to 42% efficiency and 99% fleet reliability in a flexible, compact package design for utility, industrial and oil and gas applications. GE LM6000-PH DLE provides 53.26 MW output with exhaust temperature at 471 ℃ and exhaust flow at 138.8 kg/s. (This information came from GE products specification from 2015. It appears that GE continuously modifying the parameters of its turbines along with the naming of different modifications. Therefore, today’s parameters and configuration names might be slightly different comparing to 2015) Exhaust gas pressure was assumed to be 0.15 MPa. These parameters were taken to analyze the bottoming PGU and are presented below in TABLE 1.
The digital twin (DT) concept is the developing technology that allows simulation of object behavior during its life cycle or in specified time due to changing ambient conditions, for example. The DT is applicable for performance tuning, digital machine building, healthcare, smart cities, etc  that allows decreasing the time and costs of development and optimize the object on the developing stage. GE has raised DT concepts for power plants to continually improves its ability to model and track the state of the plants .
In the context of this paper, DT is a simulation system comprised of physicist-based models organized in a special algorithmic structure that allows simulating the behavior of sCO2 PGU under alternating ambient conditions and grid demands.
The DT in this study was created utilizing AxSTREAM® Platform, which includes multiple software tools. The following software tools were utilized in this study: AxCYCLE™ was used to perform cycle thermodynamic calculation; solution generator in AxSTREAM® helped with finding possible machine geometry with given boundary conditions when performing preliminary design for compressors and turbines at design point; parameters and performance of turbomachinery including mass flow rate, pressure, power, efficiencies, etc. were calculated by Meanline/Streamline solver in AxSTREAM® for design and off-design conditions; AxSTREAM NET™ is a 1D system modeling solver and it was introduced here to simulate performance of heat exchangers (HEX) and pressure drop in the pipes involved in the cycle; AxSTREAM ION™ was used to integrate all modules and tools together in one simulation system. Read More
Update – March 1, 2023: AxSTREAM NET is our legacy software replaced by AxSTREAM System Simulation. System Simulation was born out of the union of the legacy AxCYCLE and AxSTREAM NET software packages.
A pump is hardware that feeds energy to a fluid (e.g. Water) to flow through channels. Pumps are used, for example, to direct water out of the ground, to transport drinking or sewerage water over large distances in combined pipe networks or to discard water from polders. In any practical application, the pump needs to work with its best performance. It is also important to check that the flow rate and head of the pump are within the required specifications, which are normally presented as the Pump Characteristic curves. These plots play an important role in understanding the region in which the pump needs to be operated thus ensuring the life of the pump.
Pump Characteristic Curves
The performance of any type of pump can be shown graphically, which can be based on either the tests conducted by the manufacturer or the simulations done by the designer. These plots are presented as Pump Characteristic Curves. The hydraulic properties of any pump (e.g. Centrifugal Pump) can be described by the following characteristics.
Net Positive Suction Head (NPSH) Curve
The Q-H curve gives the relation between the volume flow rate and the pressure head, i.e. the lower the pump head, the higher the flow rate. Q-H curves are provided by the manufacturer of the pump and can normally be considered as simple quadratic curves. Read More