Article(id=1222513217218273373, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1222513210519970621, articleNumber=null, orderNo=null, doi=10.19666/j.rlfd.202302019, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1676131200000, receivedDateStr=2023-02-12, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1769399464181, onlineDateStr=2026-01-26, pubDate=1700841600000, pubDateStr=2023-11-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1769399464181, onlineIssueDateStr=2026-01-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1769399464181, creator=13701087609, updateTime=1769399464181, updator=13701087609, issue=Issue{id=1222513210519970621, tenantId=1146029695717560320, journalId=1210938733613449225, year='2023', volume='52', issue='11', pageStart='1', pageEnd='198', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1769399462585, creator=13701087609, updateTime=1769405983425, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1222540560984957089, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1222513210519970621, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1222540560984957090, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1222513210519970621, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=57, endPage=66, ext={EN=ArticleExt(id=1222513217482514546, articleId=1222513217218273373, tenantId=1146029695717560320, journalId=1210938733613449225, language=EN, title=Numerical investigation on the wall roughness of a supercritical carbon dioxide axial turbine, columnId=1222513211350442816, journalTitle=Thermal Power Generation, columnName=Special topic on supercritical carbon dioxide cycle power generation technology, runingTitle=null, highlight=null, articleAbstract=

A comparative analysis between simulation and test with roughness is carried out for a supercritical carbon dioxide (S-CO2) axial turbine with different operating conditions, focusing on the roughness impact of the turbine performance. The results show that the numerical calculation method of wall roughness is able to assess the performance of the turbine at different load conditions accurately. Compared with test result, the maximum efficiency error is 1.82 percentage point. Wall roughness degrades the overall performance of the turbine, with a maximum efficiency drop of 2.8 percentage point at Ra1.6 roughness level during the five working condition, and the turbine stage roughness has a more obvious effect on the turbine performance. In addition, the more severe of wall roughness, the greater reduction of turbine efficiency. In non-design operating conditions, the efficiency drops by 11.6 percentage point at Ra6.3 roughness level. The wall roughness exacerbates flow separation of pressure surface, causing greater friction losses and serious affecting of turbine performance. The research can provide technical support for the design and performance simulation of S-CO2 axial turbines.

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针对某型超临界二氧化碳(S-CO2)轴流透平,结合不同工况试验测试结果进行了带粗糙度的仿真与测试的对比分析,重点讨论了壁面粗糙度对机组性能的影响。研究结果表明:采用的壁面粗糙度数值计算方法能够较为准确地评估透平不同负荷工况性能;与测试结果相比,效率误差最大为1.82百分点;壁面粗糙度使得透平整体性能下降,对于本透平开机升功率过程中5个工况,在Ra1.6粗糙度等级下效率最大下降2.8百分点,且涡轮级粗糙度对透平性能影响更加明显;壁面粗糙程度越严重,涡轮级效率下降越大;在非设计工况,粗糙度达到Ra6.3等级时效率最大下降11.6百分点,壁面粗糙度加剧了动叶压力面的流动分离,造成了较大的摩擦损失,严重影响透平性能。研究成果为后续S-CO2透平设计与性能研究提供了技术支撑和依据。

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王磊(1984),男,硕士,高级工程师,主要研究方向为叶轮旋转机械气动、噪声等,

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王磊(1984),男,硕士,高级工程师,主要研究方向为叶轮旋转机械气动、噪声等,

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Journal of Propulsion Technology, 2020, 41(8): 1710-1719., articleTitle=Experimental investigation of surface roughness on flow around forward-skewed compressor blade, refAbstract=null)], funds=[Fund(id=1241137073772622430, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, awardId=2018YFB1501004-4, language=EN, fundingSource=National Key Research and Development Program of China(2018YFB1501004-4), fundOrder=null, country=null), Fund(id=1241137073860702813, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, awardId=2018YFB1501004-4, language=CN, fundingSource=国家重点研发计划项目(2018YFB1501004-4), fundOrder=null, country=null)], companyList=[AuthorCompany(id=1241137059222581288, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, xref=1., ext=[AuthorCompanyExt(id=1241137059230969896, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, 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journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Fig.9, caption=Total pressure loss distribution along flow direction of first stage rotor, figureFileSmall=hR857vmXWOcE5NSZ3yZlBg==, figureFileBig=lI8/eMfxSXcCN/bYW63H3A==, tableContent=null), ArticleFig(id=1241137066168349092, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=图9, caption=第1级动叶沿流向总压损失分布, figureFileSmall=hR857vmXWOcE5NSZ3yZlBg==, figureFileBig=lI8/eMfxSXcCN/bYW63H3A==, tableContent=null), ArticleFig(id=1241137066264818089, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Fig.10, caption=Total pressure loss distribution along flow direction of second stage stator, figureFileSmall=RA2cUYMz2DlhxEzQUftwYA==, figureFileBig=jvjut5vBaFeScHoX4oePxw==, tableContent=null), ArticleFig(id=1241137066323538349, tenantId=1146029695717560320, journalId=1210938733613449225, 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tableContent=null), ArticleFig(id=1241137068429078997, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Fig.14, caption=The total pressure at different height on the outlet of first stage rotor, figureFileSmall=mTXgTbhH202zm3d8jrwu0A==, figureFileBig=+xMFzBPv/gFZ2asQ3KrI1w==, tableContent=null), ArticleFig(id=1241137068529742296, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=图14, caption=第1级动叶出口沿叶高总压分布, figureFileSmall=mTXgTbhH202zm3d8jrwu0A==, figureFileBig=+xMFzBPv/gFZ2asQ3KrI1w==, tableContent=null), ArticleFig(id=1241137068651377114, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Fig.15, caption=The total pressure at different height on the outlet of second stage stator, figureFileSmall=X/fZsP7pdVgurklOo8r8Cw==, figureFileBig=l+S+kfYrig2zIHh+12WkjQ==, tableContent=null), 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outlet duct, figureFileSmall=EGyn9uTZc6tpnV9YZSrHsA==, figureFileBig=5mFW3oc22AWm3ebxrCTL+g==, tableContent=null), ArticleFig(id=1241137069955805701, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=图22, caption=排气管道总压损失分布, figureFileSmall=EGyn9uTZc6tpnV9YZSrHsA==, figureFileBig=5mFW3oc22AWm3ebxrCTL+g==, tableContent=null), ArticleFig(id=1241137070039691784, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Fig.23, caption=The total entropy on cross-section of exhaust housing, figureFileSmall=xL0lm8HpaRXONqILwhp3sw==, figureFileBig=RRzSbhdRdRtPuojR5zDccQ==, tableContent=null), ArticleFig(id=1241137070110994954, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=图23, caption=排气壳体中截面熵分布, figureFileSmall=xL0lm8HpaRXONqILwhp3sw==, figureFileBig=RRzSbhdRdRtPuojR5zDccQ==, tableContent=null), 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figureFileBig=4YpBqYrSznHfNnF29c++AQ==, tableContent=null), ArticleFig(id=1241137071096656438, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Fig.29, caption=The static pressure distribution of different height on rotor, figureFileSmall=J78hsIuBrh2JMUWlSmGvEw==, figureFileBig=h+fLuqdg0FbM5Tg1IfLM9A==, tableContent=null), ArticleFig(id=1241137071176348216, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=图29, caption=动叶不同叶高叶片表面静压分布, figureFileSmall=J78hsIuBrh2JMUWlSmGvEw==, figureFileBig=h+fLuqdg0FbM5Tg1IfLM9A==, tableContent=null), ArticleFig(id=1241137072661131833, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Fig.30, caption=The friction coefficient distribution of rotor surface, figureFileSmall=Hlkc+uDVEuT+t8FlXGbZag==, figureFileBig=XaKrID7r+p94/4D3h44Ijw==, tableContent=null), ArticleFig(id=1241137072862458430, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=图30, caption=动叶表面摩擦系数分布, figureFileSmall=Hlkc+uDVEuT+t8FlXGbZag==, figureFileBig=XaKrID7r+p94/4D3h44Ijw==, tableContent=null), ArticleFig(id=1241137072946344512, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Tab.1, caption=

The first wall grid setting

, figureFileSmall=null, figureFileBig=null, tableContent=
项目内容
粗糙度等级ksRa0.8Ra1.6Ra3.2Ra6.3
第1层网格高度/mm0.002 00.004 00.006 50.015 0
), ArticleFig(id=1241137073021841987, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=表1, caption=

壁面第1层网格设置

, figureFileSmall=null, figureFileBig=null, tableContent=
项目内容
粗糙度等级ksRa0.8Ra1.6Ra3.2Ra6.3
第1层网格高度/mm0.002 00.004 00.006 50.015 0
), ArticleFig(id=1241137073084756550, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Tab.2, caption=

The parameters of each working condition

, figureFileSmall=null, figureFileBig=null, tableContent=
工况进口总压/MPa进口总温/K出口静压/MPa转速/(r·min-1)发电功率/kW
110.38633.357.458 9981 300
210.81707.857.468 9941 850
312.06778.158.089 0112 550
412.83801.458.439 0163 000
513.44843.958.519 0163 650
), ArticleFig(id=1241137073160254025, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=表2, caption=

计算各工况参数

, figureFileSmall=null, figureFileBig=null, tableContent=
工况进口总压/MPa进口总温/K出口静压/MPa转速/(r·min-1)发电功率/kW
110.38633.357.458 9981 300
210.81707.857.468 9941 850
312.06778.158.089 0112 550
412.83801.458.439 0163 000
513.44843.958.519 0163 650
), ArticleFig(id=1241137073227362892, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Tab.3, caption=

Comparison of total pressure loss on turbine component channel

, figureFileSmall=null, figureFileBig=null, tableContent=
项目光滑壁
面总压损失/kPa
粗糙壁面总压损失/kPa总压损失增加值/kPa总压损失百分比/%
进气壳体41.843.01.22.9
第1级静叶通道121.8167.345.537.4
第1级动叶通道143.2160.517.312.1
第2级静叶通道164.3182.518.211.1
第2级动叶通道102.9109.66.76.5
排气壳体62.784.722.035.1
), ArticleFig(id=1241137073298666064, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=表3, caption=

透平各部件通道总压损失对比

, figureFileSmall=null, figureFileBig=null, tableContent=
项目光滑壁
面总压损失/kPa
粗糙壁面总压损失/kPa总压损失增加值/kPa总压损失百分比/%
进气壳体41.843.01.22.9
第1级静叶通道121.8167.345.537.4
第1级动叶通道143.2160.517.312.1
第2级静叶通道164.3182.518.211.1
第2级动叶通道102.9109.66.76.5
排气壳体62.784.722.035.1
), ArticleFig(id=1241137073365774930, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Tab.4, caption=

The total pressure loss distribution of inlet and outlet housing

, figureFileSmall=null, figureFileBig=null, tableContent=
项目光滑壁面总压损失粗糙壁面总压损失总压损失增加值
进气管道2.83.10.3
进气蜗壳39.039.90.9
排气管道21.830.58.7
排气蜗壳40.954.213.3
), ArticleFig(id=1241137073428689492, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=表4, caption=

进排气壳体总压损失分布

, figureFileSmall=null, figureFileBig=null, tableContent=
项目光滑壁面总压损失粗糙壁面总压损失总压损失增加值
进气管道2.83.10.3
进气蜗壳39.039.90.9
排气管道21.830.58.7
排气蜗壳40.954.213.3
), ArticleFig(id=1241137073512575574, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=EN, label=Tab.5, caption=

The distribution of wall roughness level

, figureFileSmall=null, figureFileBig=null, tableContent=
粗糙度等级壁面类型壁面外观情况
Ra0.8光滑壁面微辨加工痕迹方向
Ra1.6光滑壁面可辨加工痕迹方向
Ra3.2半光面不可见加工痕迹
Ra6.3半光面微见加工痕迹
), ArticleFig(id=1241137073604850265, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1222513217218273373, language=CN, label=表5, caption=

壁面粗糙度等级分布

, figureFileSmall=null, figureFileBig=null, tableContent=
粗糙度等级壁面类型壁面外观情况
Ra0.8光滑壁面微辨加工痕迹方向
Ra1.6光滑壁面可辨加工痕迹方向
Ra3.2半光面不可见加工痕迹
Ra6.3半光面微见加工痕迹
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壁面粗糙度对超临界二氧化碳透平性能影响数值研究
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王磊 1, 2 , 霍文浩 1, 3 , 唐国庆 1 , 但光局 1 , 孙冬婷 1 , 李扬 1 , 文俊 1
热力发电 | 超临界二氧化碳循环发电技术专题 2023,52(11): 57-66
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热力发电 | 超临界二氧化碳循环发电技术专题 2023, 52(11): 57-66
壁面粗糙度对超临界二氧化碳透平性能影响数值研究
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王磊1, 2 , 霍文浩1, 3, 唐国庆1, 但光局1, 孙冬婷1, 李扬1, 文俊1
作者信息
  • 1.重庆江增船舶重工有限公司,重庆 402263
  • 2.船用涡轮增压器研发重庆市工业和信息化重点实验室,重庆 402263
  • 3.船舶与海洋工程特种装备和动力系统国家工程研究中心,上海 201108
  • 王磊(1984),男,硕士,高级工程师,主要研究方向为叶轮旋转机械气动、噪声等,

Numerical investigation on the wall roughness of a supercritical carbon dioxide axial turbine
Lei WANG1, 2 , Wenhao HUO1, 3, Guoqing TANG1, Guangju DAN1, Dongting SUN1, Yang LI1, Jun WEN1
Affiliations
  • 1.Chongqing Jiangjin Shipbuilding Industry Co., Ltd., Chongqing 402263, China
  • 2.Key Laboratory of Marine Turbocharger Research, Chongqing Industry and Information Technology, Chongqing 402263, China
  • 3.National Engineering Research Center of Special Equipment and Power System for Ship and Marine Engineering, Shanghai 201108, China
出版时间: 2023-11-25 doi: 10.19666/j.rlfd.202302019
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针对某型超临界二氧化碳(S-CO2)轴流透平,结合不同工况试验测试结果进行了带粗糙度的仿真与测试的对比分析,重点讨论了壁面粗糙度对机组性能的影响。研究结果表明:采用的壁面粗糙度数值计算方法能够较为准确地评估透平不同负荷工况性能;与测试结果相比,效率误差最大为1.82百分点;壁面粗糙度使得透平整体性能下降,对于本透平开机升功率过程中5个工况,在Ra1.6粗糙度等级下效率最大下降2.8百分点,且涡轮级粗糙度对透平性能影响更加明显;壁面粗糙程度越严重,涡轮级效率下降越大;在非设计工况,粗糙度达到Ra6.3等级时效率最大下降11.6百分点,壁面粗糙度加剧了动叶压力面的流动分离,造成了较大的摩擦损失,严重影响透平性能。研究成果为后续S-CO2透平设计与性能研究提供了技术支撑和依据。

超临界二氧化碳  /  轴流透平  /  壁面粗糙度  /  试验测试

A comparative analysis between simulation and test with roughness is carried out for a supercritical carbon dioxide (S-CO2) axial turbine with different operating conditions, focusing on the roughness impact of the turbine performance. The results show that the numerical calculation method of wall roughness is able to assess the performance of the turbine at different load conditions accurately. Compared with test result, the maximum efficiency error is 1.82 percentage point. Wall roughness degrades the overall performance of the turbine, with a maximum efficiency drop of 2.8 percentage point at Ra1.6 roughness level during the five working condition, and the turbine stage roughness has a more obvious effect on the turbine performance. In addition, the more severe of wall roughness, the greater reduction of turbine efficiency. In non-design operating conditions, the efficiency drops by 11.6 percentage point at Ra6.3 roughness level. The wall roughness exacerbates flow separation of pressure surface, causing greater friction losses and serious affecting of turbine performance. The research can provide technical support for the design and performance simulation of S-CO2 axial turbines.

supercritical carbon dioxide  /  axial turbine  /  wall roughness  /  experiments
王磊, 霍文浩, 唐国庆, 但光局, 孙冬婷, 李扬, 文俊. 壁面粗糙度对超临界二氧化碳透平性能影响数值研究. 热力发电, 2023 , 52 (11) : 57 -66 . DOI: 10.19666/j.rlfd.202302019
Lei WANG, Wenhao HUO, Guoqing TANG, Guangju DAN, Dongting SUN, Yang LI, Jun WEN. Numerical investigation on the wall roughness of a supercritical carbon dioxide axial turbine[J]. Thermal Power Generation, 2023 , 52 (11) : 57 -66 . DOI: 10.19666/j.rlfd.202302019
对于叶轮旋转机械,由于加工工艺的不同,叶片、壳体等表面呈现不同的粗糙程度。随着机组运行时间增加,腐蚀、积垢及磨损等会造成旋转叶片偏离设计工况甚至失效,而壁面粗糙度增大则是其最直接的表现形式[1-2]。姚君等[3]通过在透平叶片表面粘贴不同型号砂纸来研究粗糙度对透平叶栅气动性能的影响。试验结果表明:透平总压损失随着粗糙度增大而增大;在叶片表面粘贴200号耐水砂纸,损失增幅超过50%。David Linden[4]对服役37个月的压气机进口导叶进行观察,由于点蚀等造成孔径甚至达到3.2 mm,深度为0.8 mm。霍武军等[5]对海军航空兵所用发动机压气机叶片的观察测量也表明,海洋环境下叶片表面的点蚀蚀孔孔径可达20~30 μm,由于蚀孔内聚集H+、Cl、SO42–等,有的蚀坑深度可达0.1~0.2 mm。
近些年,国内外的一些学者开展了针对旋转机械壁面粗糙度的相关研究[6-20],但目前尚无针对超临界二氧化碳(S-CO2)轴流透平壁面粗糙度的研究发表。为此,本文针对某S-CO2机组轴流透平结合不同工况试验测试结果进行了带粗糙度的仿真与测试的对比分析,重点讨论了壁面粗糙度对机组性能的影响,为S-CO2轴流透平设计与性能研究提供了技术支撑和依据。
本文S-CO2透平三维仿真采用NUMECA软件求解RANS方程,湍流模型选取SA模型,并采用Extented Wall Function壁面函数,即在雷诺时均方程涡黏性模型近壁面处理中加入粗糙度的影响。NUMECA软件的粗糙度模型是基于对壁面函数的修正。对于粗糙壁面,近壁面的对数率速度型线仍然存在,只是相比水力光滑条件更靠近壁面,因此可以不考虑黏性底层。NUMECA中考虑粗糙度影响的壁面函数为:
uuτ=1κlnyd0νuτ+BoΔU+
ΔU+=1κlnks+Bo*+e(a1ks++a2)
ks+=uτksν
式中:u为已知距离壁面y处的流体切向速度;uτ为壁面摩擦速度;κ为冯卡门常数0.41;Bo为依赖于壁面粗糙度的常数5.36;ks为壁面粗糙凹凸的平均高度,与粗糙度的衡量参数壁面轮廓算术平均偏差Ra相对应;d0为零位移平面高度,当粗糙度较小时为0,对于大的粗糙度壁面,将壁面移到距离真实的d0位置;ν为运动黏度;常数a1=−0.764 9,a2=1.9,Bo*=8.5−Bo
需要注意的是,对于粗糙壁面,其第1层网格中心至壁面的距离应大于ks+d0,即第1层网格应处于完全湍流层;本次研究的粗糙度ks在6.3 μm以内,因此按d0=0设置。本次研究的透平整机模型如图1所示。计算透平为2级,使用NUMECA/ Autogrid5生成结构化网格,其中涡轮级叶冠的迷宫密封与叶片相连。为了保证高精度的数据传递,叶片采用HOH型网格拓扑结构,密封与叶片连接处网格节点一一对应,形成完全匹配交界面(图2)。进排气壳体采用非结构网格,分别如图3图4所示。对于不同壁面粗糙度,在涡轮级动叶、静叶、叶冠以及进排气壳体等固壁面进行了不同的第1层网格处理,具体设置见表1
本文研究的两级轴流透平已在用户现场完成调试和应用,运行状态稳定,在透平机组开机升功率过程中测量了5个工况的透平整机性能。为了验证本次采用的粗糙度数值方法的有效性,针对这5个工况开展了整机(涡轮级+进排气壳体)带粗糙度的性能仿真计算,各工况计算参数见表2
根据本透平机组的加工精度,粗糙度等级选取为Ra1.6。将计算结果与测试结果进行对比,结果如图5所示。由图5可见:带粗糙度的仿真曲线能够较好地贴合测试结果;工况1—工况5效率偏差依次为−0.86百分点、0.24百分点、1.16百分点、1.47百分点和1.82百分点,说明采取的粗糙度仿真方法在预测S-CO2透平机组性能方面具有一定的精确度。
为了研究壁面粗糙度对透平性能的影响,针对透平光滑壁面与粗糙度等级为Ra1.6的粗糙壁面分别进行了计算,图6图7为透平效率与流量对比。由图6图7可见,壁面粗糙度使透平各工况效率下降,流量减小。工况1—工况5效率依次降低0.8百分点、0.4百分点、2.5百分点、2.0百分点、2.8百分点;流量依次降低2.1%、2.8%、2.4%、2.5%、1.6%,各工况流量下降趋势基本一致。由以上对比可知,壁面粗糙度导致透平性能整体呈下降趋势。
为进一步说明透平各部件壁面粗糙度的影响,统计了工况4涡轮级各通道内的总压损失(总压损失为进口总压与当地总压之差)对比,结果见表3。由表3可见,与光滑壁面相比,考虑粗糙度后各部件的总压损失呈整体增加趋势。另外,粗糙度的引入导致涡轮2级叶片通道内总压损失增加87.7 kPa,大于进排气壳体内损失增加值(23.2 kPa),说明涡轮级对粗糙度的影响更加敏感。
图8图11为涡轮级内各级叶片沿流动方向的总压损失分布。由图8图11可见:壁面粗糙度导致各级叶片的总压损失都有一定的增加,削弱了各级叶片的膨胀做功能力;且对于各级静叶,在叶片中前部位(0~50%相对弦长)保持较小的总压损失,在叶片中后部位(50%~100%相对弦长)总压损失明显增大,说明静叶的流动损失主要分布于叶片中后部位;而对于动叶在整个弦长范围内,总压损失呈持续增加趋势,在引入壁面粗糙度的影响后各级叶片仍保持相应的损失趋势。
图12为涡轮级中截面相对马赫数分布对比。由图12可见,粗糙度的引入并未对整体流场造成影响。结合粗糙度数值计算方法可知,粗糙度对壁面摩擦损失产生影响。对于各级静叶,气流均在叶片中后部加速,因此粗糙度引起的总压损失增加主要分布于叶片的中后部位;各级转子叶片气流仅在前缘小范围流速较低,因此呈现出整个弦长范围都保持恒定的总压损失增值。
图13图16为各级静叶与动叶通道出口沿叶高总压分布。
对比可见,各叶片通道出口粗糙壁面的总压在大部分叶高范围内都小于光滑壁面,说明在叶片通道内的流动受到壁面粗糙度的影响。对于第1级静叶,在5%~95%叶高范围内出口总压基本保持恒定,粗糙度引起出口总压降低。对于第2级静叶,在5%~70%叶高范围内出口总压保持恒定,粗糙度引起出口总压降低;而在70%~100%叶高范围内由于受第1级动叶的影响,出口总压相比5%~70%叶高范围内总压明显有下降趋势,且粗糙度对出口总压的影响明显减弱。对于第1级与第2级动叶,在10%~95%叶高范围内粗糙度引起出口总压降低,而在0~10%叶高范围内由于端壁二次流的原因,粗糙度的影响较小。由以上分析可见,粗糙度对叶片通道出口总压的影响沿叶高方向各有差异。
以第2级动叶为例,图17图18为从叶片进口至出口各截面的总压与熵分布对比。由图17图18可见,壁面粗糙度使得涡轮级叶片通道内叶片流动方向以及叶高方向的总压都有所降低,熵增数值进一步升高,由此造成更大的流动损失。
进气壳体由进气管道与进气蜗壳组成,排气蜗壳由排气管道与排气蜗壳组成,其结构分别如图19图20所示。经计算,进排气壳体各部分总压损失见表4。由表4可见:考虑粗糙度后,进排气壳体总压损失都有所增加,且进气壳体增加较少,进气管道、进气蜗壳分别为0.3 kPa与0.9 kPa;排气壳体受粗糙度影响较大,排气管道、排气蜗壳总压损失增加达到8.7 kPa与13.3 kPa。
图21为气流从进气管道到进入蜗壳内部典型的12个截面总压损失系数。由图21可见,壁面粗糙度使得各截面总压损失增加,降低进气壳体性能。由于粗糙度对进气壳体影响较小,各截面总压损失增加值较小。
图22为气流从排气蜗壳进入排气管道内部典型的15个截面总压损失曲线。由图22可见,壁面粗糙度使得各截面总压损失增加,降低排气壳体性能,且越接近排气蜗壳截面,粗糙度引起的总压损失增值越大。图23为排气壳体中截面熵分布对比,可见粗糙壁面引起更多的流动损失。
根据国家标准GB/T 1031—2009粗糙度等级对应的壁面类型与壁面外观情况见表5。对于本次S-CO2透平加工工艺,壁面粗糙度存在Ra0.8、Ra1.6、Ra3.2、Ra6.3 4种等级。以透平第一级为研究对象,对于测试工况4,选取以上4种粗糙度等级进行仿真并与光滑壁面对比,结果如图24图25所示。
图24图25可见,随壁面粗糙程度越严重,涡轮级效率下降越大,而粗糙度对流量的影响较小。图26统计了不同粗糙度在各工况引起的效率降低值。由图26可见:在1.2~1.6膨胀比范围内,粗糙度引起涡轮级效率下降值基本稳定;当达到Ra6.3等级时,效率下降4.2百分点。对于1.1以下较小膨胀比工况,粗糙度导致级效率明显下降,当达到Ra6.3等级时效率最大下降了11.6百分点。
选取效率变化临界工况膨胀比1.1进行研究,图27为不同粗糙壁面50%叶高的涡轮级流动分布。由图27可见,对于静叶,各等级粗糙壁面流动情形相同,且流动良好,没有出现流动分离。而对于动叶,在此工况下,在叶片前缘的流动存在一定的攻角,对于光滑壁面与Ra1.6粗糙壁面,动叶附近流动较好;而对于Ra3.2与Ra6.3粗糙壁面,在叶片压力面产生分离漩涡。可见,壁面粗糙度使得透平整体性能下降,且由于本透平尺寸较小,其性能对粗糙度较为敏感,在非设计工况(膨胀比1.1),Ra3.2粗糙度等级即开始对涡轮级产生影响。
为了进一步揭示粗糙度对涡轮级尤其动叶的流动影响,选取了光滑壁面与Ra3.2粗糙壁面进行分析,图28为动叶压力面的极限流线对比。由图28可见,对于光滑壁面,由于进口攻角导致在40%~100%叶高范围内叶片前缘存在明显的分离线,再附线对应着叶片流道内的通道涡流体再次冲击附着到叶片表面,在分离线与再附线之间为通道涡对应的分离区,表现在叶片表面为从叶根到叶顶的径向分离流动。对于光滑壁面,在20%以下叶高还存在1个分离区,但影响范围较小。对于粗糙壁面,在整个叶高范围内都存在明显的分离线,在分离线与再附线之间为通道涡对应的分离区。通过对比可见,粗糙壁面的分离区范围更大,且在50%以下叶高范围内呈现为逆向流动,对叶片表面以及通道内流动产生较大影响。
由以上分析可见,粗糙度对本透平涡轮级叶片近壁面流动产生较大影响,因此可从叶片表面静压分布进行分析,结果如图29所示。由图29可见,从10%~90%叶高,压力面与吸力面静压分布线存在交叉,说明叶片进口流动存在一定攻角。光滑壁面与粗糙壁面吸力面静压沿弦长方向基本保持一致,整体呈现降压膨胀趋势,说明流动较好。而在压力面静压分布具有较大区别:在10%叶高,光滑壁面从10%~40%相对弦长范围内压力缓慢上升,对应极限流线图内20%以下叶高的分离区,而对于粗糙壁面首先在10%~15%相对弦长静压保持恒定,然后急剧上升,形成扩压减速区,在此弦长范围内粗糙壁面的减速扩压程度相比光滑壁面更为剧烈,对应着流动分离更为严重;对于50%叶高,光滑壁面压力面仍保持光滑曲线分布,而粗糙壁面静压先降低然后以较大的逆压梯度上升,且直至50%相对弦长静压才开始降低,对应着极限流线图中粗糙壁面的分离区范围更大,流动更为紊乱;在90%叶高,光滑壁面与粗糙壁面压力面直至80%相对弦长才开始降压膨胀,与极限流线图中较大的分离区对应,严重影响叶片的膨胀做功能力。
粗糙度对本透平涡轮级叶片粗糙度对近壁面流动的影响可用表面摩擦系数进行评估,本次计算叶片表面摩擦系数定义为:
Cf=τ12ρU2
式中:Cf为表面摩擦系数;τ为壁面剪切力;ρ为参考密度;U为参考速度。
图30为动叶50%叶高表面摩擦系数沿弦长方向分布。由图30可见,对于压力面与吸力面粗糙壁面,摩擦系数都大于光滑壁面,说明粗糙壁面在近壁面造成更多的摩擦损失。另外,对于压力面在1%~40%相对弦长范围内粗糙壁面的摩擦系数明显大于其他弦长范围,这正是由在此弦长范围内的分离流动所致,从而造成了叶片表面较大的摩擦损失。综上所述,对于本透平涡轮级,在膨胀比1.1非设计工况,由于攻角导致近壁面流动在叶片前缘压力面产生流动分离,而壁面粗糙度进一步加剧了分离程度,使得在整个叶高范围内都存在分离区,造成了较大的摩擦损失,严重影响涡轮级性能。
1)基于试验测试数据验证了本文采用的S-CO2透平壁面粗糙度仿真方法的有效性与可靠性。与测试结果相比,效率误差最大为1.82百分点。
2)壁面粗糙度使得透平整体性能下降,针对本透平开机升功率过程中5个工况进行仿真研究得到:在Ra1.6粗糙度等级下效率最大下降2.8百分点,且涡轮级的粗糙度对透平性能影响更加明显。
3)壁面粗糙程度越严重,涡轮级效率下降越大;在非设计工况,粗糙度达到Ra6.3等级时效率最大下降11.6百分点,壁面粗糙度加剧了动叶压力面的流动分离,造成了较大的摩擦损失,严重影响透平性能。
  • 国家重点研发计划项目(2018YFB1501004-4)
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2023年第52卷第11期
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doi: 10.19666/j.rlfd.202302019
  • 接收时间:2023-02-12
  • 首发时间:2026-01-26
  • 出版时间:2023-11-25
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  • 收稿日期:2023-02-12
基金
National Key Research and Development Program of China(2018YFB1501004-4)
国家重点研发计划项目(2018YFB1501004-4)
作者信息
    1.重庆江增船舶重工有限公司,重庆 402263
    2.船用涡轮增压器研发重庆市工业和信息化重点实验室,重庆 402263
    3.船舶与海洋工程特种装备和动力系统国家工程研究中心,上海 201108
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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
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