Water washing of axial flow compressors: numerical study on the fate of injected droplets

Gruttola

Gabriele³

et al. 2021

E3S Web Conf.

Self Cite

Gas turbines performance losses are mainly due to the deposition of dirt on the compressor blades that needs to be periodically removed. This is the reason motivating the presence of water washing systems (WWS) in most of the compressor gas turbines. Water washing is generally achieved by installing a number of nozzles on the compressor casing and spraying water that clean the dirty surfaces of the compressor. The side effect of such a technique is the rising risk of erosion due to the impact of water droplets on the compressor blades which is even more pronounced when dealing with online water washing systems that is done while the unit is at normal load. The design of these systems must balance benefits and disadvantages associated to the process itself. The benefits can be measured in terms of water washing efficiency that is a quantity not uniquely defined. In previous works, the authors introduced some indices useful to evaluate the spatial cleaning coverage (the wet to the total surface) and the quantity of water mass actually impacting the dirty surfaces (the impacted to injected mass). On the other hand, water washing erosion is a complex phenomenon depending on several parameters, such as the mechanical properties of the blade material, the impact velocity and angle and the droplet diameter. For this reason, the WWS are strongly influenced by the adopted nozzles and by the injection conditions. The present paper aims at assessing water washing for six different injection conditions in the first stage of a real axial compressor. Two-phase CFD simulations are carried out with Ansys Fluent where a User Defined Function implemented by the authors is used to properly model water droplet erosion mechanism and to obtain all the quantities needed to evaluate the washing quality. Results confirm the strong influence of the injection conditions on the main features of the washing system. The study is part of an ongoing partnership between Baker Hughes and Sapienza University of Rome aiming at maximizing the washing of the compressor blades while maintaining the erosion under specific thresholds.

Section: Resultsmentioning

confidence: 99%

Section: Washing Efficiencymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Evaluation of water washing efficiency and erosion risk in an axial compressor for different water injection conditions

Gruttola

Gabriele³

et al. 2021

E3S Web Conf.

Self Cite

“…The mesh is composed of around 26 M tetrahedral cells, clustered in the wall regions to guarantee values of y+ ranging from 20 to 300 (the reader can refer to Ref. [20] for further details). Such range represents the interval of applicability of the standard wall function and guarantees that the near-wall turbulence is correctly solved in the framework of the adopted models.…”

Section: Models and Methodologymentioning

confidence: 99%

“…[15], we developed an erosion model based on experiments available in the open literature [16,17]. The WDE model was applied to several compressor blade geometries in the past [15,[18][19][20][21]. In all these simulations, the computation of the erosion mechanism was carried out by assuming that the profile did not change due to the erosion itself thus neglecting the variation in the fluid flow due to the profile modification.…”

Section: Introductionmentioning

confidence: 99%

Numerical Prediction of Long-Term Droplet Erosion and Washing Efficiency of Axial Compressors Through the Use of a Discrete Mesh Morphing Approach

Journal of Turbomachinery

Castorrini

Gruttola

et al. 2022

Self Cite

Online water washing represents an operation strategy commonly used to reduce compressor performance deterioration due to blade fouling. Since this kind of washing is applied when the machine operates close to full load conditions, injected droplets are strongly accelerated and consequently impact the rotor blades at high velocity, thus inducing undesirable phenomena like erosion. Here, we present a novel technique to study long-term water droplets erosion by also considering the geometry modification caused by droplets impacts. Two-phase unsteady numerical simulations were carried out, considering the injection of water droplets and their transport across the fluid flow in the first part of a real compressor, which is modeled in the region extending from the inlet to the rotor blades of the first stage. Simulations are performed on the whole machine to account for the asymmetric distribution of the spray injectors, the machine struts, inlet guide vanes (IGVs), and rotor blades. The k−ɛ realizable turbulence model with standard wall functions was coupled with the discrete phase model to track injected droplets motion. Droplets-wall interaction is modeled following the Stanton–Rutland approach aiming at detecting the effect of droplet impact (deposit, rebound, and splashing) depending on the impact conditions. Moreover, a semi-empirical erosion model developed by the authors was used to evaluate the erosion induced by the droplets injection. Material removal due to erosion is converted into nodal mesh displacement that is used by a secondary routine to implement the mesh morphing scheme. The mesh modification is applied at discrete steps to reduce the computational load. This technique is adopted to account for the blades geometry modification due to water droplet erosion leading to performance losses. Moreover, an estimation of the compressor operating life before maintenance operations is given and the water washing efficiency during the whole life of the machine is evaluated by means of proper indices. At the end of the simulation workflow, erosion phenomena are observed in all the compressor regions, especially in the rotor where erosion peaks are reached at the hub of the blades leading edge. The rotor blades wet surface was found to remain almost constant at around 50% during compressor water washing. Erosive phenomena were proved to evolve nonlinearly with time indicating the need to account for the geometry modification for obtaining an accurate prediction of the long-time process.

Liquid film formation: prediction accuracy of different numerical approaches

Evangelisti

Gabriele³

et al. 2022

J. Phys.: Conf. Ser.

Self Cite

In counteracting fouling phenomenon in gas turbines, which leads to system inefficiencies and performance degradation, water washing technique is very often adopted. Water droplets sprays are injected and, hitting the solid surfaces, remove the dirt deposition. Among the collateral undesirable phenomena related to water washing, blades erosion and liquid film formation are the most remarkable. Despite the former issue was extensively assessed by the authors in previous works, up to the authors’ knowledge the risk of liquid film formation due to water washing was scarcely investigated. Liquid film formation and spreading on a solid surface is a complex phenomenon involving a large number of physical events, such as: droplets impact on a solid surface, splashing phenomena, liquid film dragging under the effect of the carrier phase and droplets separation from the film in proximity of geometry discontinuities. In this paper, an extensively used experimental test case involving all these phenomena was used to test different numerical wall film models available in literature. The test case consists in the injection of a liquid jet in a high velocity crossflow. Some of the liquid jet mass impacts on the opposite solid surface generating a wall film which develops under the dragging effect of the crossflow. A Lagrangian approach was used to track the suspended droplets within the flow field by also considering the turbulent dispersion by means of a Random Walk model. Droplets-wall interaction is considered according to the Stanton-Rutland model, which provides the outcome of a collision (deposit, rebound or splashing), depending on the local impact conditions. If a droplet sticks on a solid boundary, a liquid film generates. Droplets atomization is also accounted for by using the Madabhushi model while Friederich separation model was selected to take into account the detachment of droplets from the film at the geometry edge. Three different numerical simulations have been performed based on different approaches used to solve the liquid film evolution, namely Eulerian one-way coupling, Eulerian two-way coupling and Lagrangian two-way coupling. Numerical results have been compared with the experimental ones from both a qualitative and a quantitative point of view. The wall film shape, its spatial distribution and the variation of the film thickness of the wall centreline have been compared between experimental and numerical simulations proving that the Lagrangian 2-way coupling approach better reproduces the liquid film dynamics observed in the experiments.