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Stress Analysis and Fluid Solution of the Nozzles of the Elliott DYR Steam
Turbine

Conference Paper · February 2019

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Hamed Raissi Mohammad Shishesaz

Shahid Chamran University of Ahvaz Shahid Chamran University of Ahvaz
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 Stress Analysis and Fluid Solution of the Nozzles of the Elliott DYR
Steam Turbine

Hamed Raissi1,*, Mohammad Shishehsaz2

1,*
Corresponding author, Ph.D. of Mechanical Engineering. Shahid Chamran University of Ahvaz,
Tel: 00989128100913, h-raissi@phdstu.scu.ac.ir.
2
Professor of Mechanical Engineering Dept., Shahid Chamran University of Ahvaz.

ABSTRACT

Fluid analysis in the nozzles of the Elliott DYR steam turbine is investigated, numerically. The nozzle geometry
by means of reverse engineering was obtained. The results indicate pressure, temperature and velocity of the steam flow
in the nozzle were compared to those obtained theoretically with one dimensional method. The results indicate that,
there are good agreement between theoretical and numerical calculations. Stress distribution in the nozzle structure is
studied by transferring the results of fluid analysis to finite element analysis (FEA). Results indicate that, inlet area has
more stress compare to other areas.

Keywords: Nozzle, Fluid calculation, Stress analysis, Pressure, Temperature.

1. INTRODUCTION

The steam turbines were used to convert heat energy to mechanical work. In these machines, by expanding the
steam flow in the nozzles, potential energy converts to kinetic energy and finally led to moving the blades of the rotor.
In the steam turbines by considering the inlet pressure and temperature and also the outlet pressure, the theoretical work
can be calculated. To obtain this work, it’s important to arrange carefully the turbine parts similar to nozzles, fixed and
rotating blades. Some lectures were done about the nozzles and be referred below.
Keisari and Shams [1] studied the optimization of wet-steam nozzle shape. In this work, numerical method was
used to calculate Navier-Stokes viscous flow equations. In this regard two equation k-ω based SST turbulent model was
used to determine the pressure and temperature in the nozzle. Du et al. [2] studied a novel control approach in a radial
inflow turbine. In this paper by changing the angle of the nozzles, the efficiency of the turbine calculated in terms of
nozzle angle. Halama and Hric [3] studied numerical solution of two phase steam flow in the nozzle by Eulerian
models. In this paper the 2D model of the nozzle was considered and by expanding the Navier-Stokes viscous flow
equations and solving them, the pressure and wetness of the steam in the nozzle were calculated. Jiang et al. [4] studied
the effects of axial gap and nozzle distribution of aerodynamic force. In this investigation, three dimensional simulation
of the nozzle was considered and the aerodynamic forces in terms of time were calculated. Cai et al. [5] studied the
influence of the nozzle chamber on the erosion characteristics of solid particles. The results indicate that the erosion
condition led to a great deflection in the nozzle. Mirhoseini and Boroomand [6] studied numerically the nozzle of low
pressure steam turbines. In this paper, slip velocity between the liquid droplet and dry steam was ignored. The results
indicate the pressure in the nozzle have good agreement with those obtain by experimental approach. Amezcua et al. [7]
studied numerical calculation of the solid particle erosion in the steam turbine nozzle. In this work by using
Computational Fluid Dynamics (CFD) software, fluid dynamic simulations were done. Results indicate that by
increasing the particle diameters, erosion rate is becoming decrease. Dykas and Wroblewski [8] studied numerical
solution of the steam condensing flow in the nozzles. In this regard, numerical calculation based on CFD modeling was
done and compare with experimental methods. It was shown that there are good agreement between the numerical and
experimental results to estimate pressure in the nozzles. In ref [9], Kumar and Devarajan studied two dimensional CFD
calculation for convergent- divergent nozzle. In this regard, supersonic flow simulation in the nozzle based on the
energy and mass equations was calculated. Ding et al. [10] studied flow simulation in the high pressure steam nozzle
theoretically. The steam was assumed to be a real gas and two dimensional method was used to obtain equations. The
Rayleigh method was chosen to solve the nonlinear equations. Dykas et al. [11] studied transonic steam flow in the

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nozzle experimentally. In this regard the three dimensional model of the nozzle was made and by using some control
valves and piping, the flow simulation was carried out. The results have good agreement with those obtained by CFD
software to calculate wetness and pressure in the nozzle. Neckel and Godinho [12] studied the influence of geometry of
the convergent, divergent nozzle on its efficiency. The nozzles were used in Tesla turbine and one and two dimensional
approaches were used to calculate steam flow in the nozzles. Results have good agreement with those obtained by
experimental approach to estimate pressure in the nozzle. Abadi et al. [13] studied supersonic flow in the high pressure
steam nozzle. In this regard two phase flow simulations were studied and by solving the full Navier Stokes equations
based on a pressure base method, pressure and temperature in the nozzle were calculated. To the best author’
knowledge, there is no published work on stress distribution in a nozzle which is based on CFD calculation. Some
papers that have dealt with stress analysis. Jiang et al. [14] studied, residual stress in the nozzle which has welding joint.
In this regard a crack was assumed in the nozzle and by using FEA, the residual stress, which was rising from thermal
loads was calculated. Dehaghi et al. [15] studied, residual stresses in the nozzle which has cracked in the throat area.
The crack was generated by a bad welding process and the effects of its length, geometry and location were studied on
the residual stress. Chapuliot [16] studied stress intensity factor in the nozzle. In this regard, FEA was used to solve
stresses along the crack under pressure and thermal loads.
In spite of the extensive literature available on the behavior of the nozzles, all the previous works have focused
on fluid or stress analysis of the nozzles separately, and there are a few publications that focus on the Fluid Structure
Instruction (FSI) of the nozzles. Consequently, there still remain other questions yet to be answered. For this purpose,
this work deals with FSI simulation to answer questions about stresses, temperature and flow simulation in the nozzles.
In this regard, it becomes very important to have a full understanding of the manner of the nozzle when the steam is
moving along it.
In this investigation, the Navier-Stokes equations are used and by solving them along with CFD code by fluent
software, temperature and pressure in the nozzle are found. The present formulation is adopted to govern equations for
wet steam and superheated gases. For solving one dimension method, the entropy and enthalpy of the steam are
calculated and by considering the losses in the nozzle, the real manner of the steam is calculated.

2. DERIVATION OF GOVERNING EQUATION

Figure 1a illustrates the nozzle with the inlet and outlet conditions. For solving the one dimensional solution, the
isotropic formulations are considered as Eq. (1). It was assumed the manner of nozzle is isotropic and finally the loss
coefficient, which was obtain from experimental Ref [17] added to these formulations. In this regard, thermodynamic
analysis in nozzles base on one dimensional steady flow is carried out by applying conservation of mass, energy
equation and consider fluid to be a perfect gas, the relation 2 to 4 were obtained pressure, maximum discharge and
steam velocity, respectively in throat area.

Fig. 1. a) The numbering of thermodynamic properties of the inlet, throat and outlet of the nozzle, b) the Elliott
DYR nozzle.

S1  S2, Isotropic  S3, Isotropic (1)

n
P2  2 
 n 1 (2)

P1  n 1 

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 n 1
P 2 
m
 n. 1  n 1 (3)
A2 1  n 1 

V2 
2n

P P 
n 1 1 1 2 2
 (4)

Where in Eqs. (2) to (4), n, P1, P2, 1 , 1 , m and A2 are the adiabatic expansion index, inlet pressure, outlet
pressure, inlet specific volume, outlet specific volume, mass flow and throat area. It’s important to select suitable values
of n index. Table 1 indicates the value of n index for wet and superheated steam. After finding the value of the velocity
of the throat area (Eq. (4)), by considering Church parameter [17], the real velocity can be modified similar to Eq. (5).
In this equation, the parameter  is defined by Eq. (6).
VReal  .V2 (5)
 1.0210.164 x 0.165 x2 0.0671x3 0.0088 x4 Where V
x 2 . (6)
1000
To calculate the results in the output, in addition to the parameter  another parameter called under-expansion is
defined. This parameter is defined based on the conditions of fluid motion and nozzle properties such as its material and
surface roughness. This parameter (under-expansion) is chosen between ten to twenty percent. Eqs. (7) and (8) show the
area and velocity in the outlet of the nozzle.
  
AOutlet-Real  Aoutlet. 1  (7)
 100 
VOutlet-Real Voutlet. (8)
Where AOutlet and  are an outlet area of the nozzle in isotropic condition and under-expansion parameter,
respectively. For solving the Navier-Stokes equations in numerical method, the mass, momentum and energy equations
should be solved all together. In this regard, the K-ω standard model with the compressibility effect of the real gas
(steam) was assumed. In this model, some variables, consider as Eqs (9).

* 1; 0.52;  * 0.09;  0.072; * 1.5; M 0.25;

    t0 (9a)
TKEPrandtlNumber 2; SDRPrandtlNumber 2; EnergyPrandtlNumber 0.85; (9b)
WallPrandtlNumber =0.85;ProductionLimiterClip Factor =10; (9c)

Table 1. Adiabatic expansion index, n. [18]

Fluid n index
Wet Steam 1.135 (n=1.035+0.1x, Where x is
dryness fraction wet steam)
Superheated Steam 1.3

In K-ω model, two transport equations (10) and (11) refer to turbulent kinetic energy and turbulent frequency are
solved, respectively [19].

K-equation
  
 
 
 K  

U K     t  K   P *
   K  P (10)
t X j X  TKE  X  k  kb
j j  Prandtl Number  j
Ω-equation

    K 
 U j   X
   t 
       Pk    
2
 Pb
t X j j  SDRPrandtl Number  X j  K (11)

3. NUMERICAL RESULTS AND DISCUSSION

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 The postulated model which is shown in Fig. 1b, is a nozzle of the Elliott DYR. For deriving the geometry of the
nozzle, the Steinbichler Comet 5 Eco was used. Fig. 2 shows the cloud points and how to convert these points to three
dimensional model in Catia software.

Fig. 2. Construction of the nozzle a) Real model, b) Cloud points, c) Surface of the nozzle, d) Solid model of the
nozzle.

The initial data about the nozzle was found in the technical data sheet (DS). In the original DS, it was absorbed
that the inlet pressure, temperature and the outlet pressure in the nozzle are 41.4 bars, 400°C and 5.2 bars, respectively.
According to Eqs. (1) to (6), as shown in the table 2, the values of the throat and outlet geometrical dimensions
and thermodynamics properties can be calculated. The results compare to CFD calculation with obtaining from fluent
software. Table 2 indicates that there are small difference between two theoretical and numerical approaches.
Fig. 3 shows the variation of the velocity value in the twenty one nozzles. As shown the figure, the velocity
increase over the length of the nozzle. Fig. 4 shows the variation of the velocity along the nozzle length based on CFD
calculation. According to the figure, there is a rapid change in velocity from about 150 m/s to 630 m/s in the throat area.

Table 2. Compare one-dimensional theory and CFD results.

Methods &
Location Velocity (m/s) Diameter (mm) Enthalpy (KJ/Kg) Temperature (C)
Difference
Theory 545.94 11.96 3073.35 327.48
Throat CFD 534.03 12.00 3096.89 328.74
Difference % 2.23 0.33 0.76 0.38
Theory 984.68 13.10 2726.21 153.31
Outlet CFD 948.12 12.80 2730.29 153.25
Difference % 3.86 2.34 0.15 0.04

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 Fig. 3. Stream line vector in the nozzles.

Fig. 4. Velocity diagram along the nozzle length.

Fig. 5 shows the variation of the pressure in the twenty one nozzles. As shown the figure, the pressure decreases
over the length of the nozzle. Fig. 6 shows the variation of the pressure along the nozzle length based on CFD
calculation. According to the Fig. 6 similar to fig. 4, there is a rapid change in pressure. The pressure changes from
about 40 bar to 17 bar in the throat area.
Fig. 7 shows the variation of the Temperature in the twenty one nozzles. As shown the figure, the temperature
decrease over the length of nozzle. Fig. 8 shows the variation of the temperature along the nozzle length based on CFD
calculation. Fig. 8 shows that temperature change slowly from the inlet area to mouth of throat. The rapid variation of
temperature is happening in throat area from about 380 °C to 300 °C.

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 Fig. 5. Contour of pressure in the nozzles.

Fig. 6. Pressure diagram along the nozzle length.

Fig. 7. Contour of temperature in the nozzles.

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 Fig. 8. Temperature diagram along the nozzle length.

Fig. 9 illustrates the temperature, which has created in the nozzle structure caused by fluid flow through the
nozzles. According to the figure as expected, the temperature of the top surface is higher than the lowers. The
temperature variation along the one nozzle structure can be seen in Fig. 10.

(a) (b)

Fig. 9. Contour of temperature in the nozzles structure, a) top face of the nozzle, b) bottom face of the nozzle.

According to Fig. 10, there is a rapid variation in the nozzle structure in the space between the throat and outlet
areas. This extreme temperature change from 350 °C to 200 °C can lead to residual stresses in the nozzle structure. Fig.
11 illustrates the stress distribution based on von misses theory in the nozzle. In this figure by considering and
importing the fluid results for calculating temperature and pressure, the stress distribution in the nozzle structure can be
solved. Fig. 12 shows the variation of the Von misses stress along the fifth nozzle (Fid. 11) length. As shown in the Fig.
12, the inlet area of the nozzle has more stress than other zones. The stress along the nozzle length becomes decreased,
but in the throat area, there is a jump in the stress.

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 Fig. 10. Body Temperature diagram along the nozzle length.

Fig. 11. Contour of stress in the nozzles structure, a) top face of the nozzle, b) bottom face of the nozzle.

Fig. 12. Von-Mises stress diagram along the nozzle length.

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 4. CONCLUSION

In this study, stress and fluid analysis in the Elliott DYR steam turbine nozzle was carried out with two
theoretical and numerical methods. According to the results, values of theoretical are close to those of CFD.
Additionally, for the selected nozzle, the steam pressure, temperature, velocity, structural temperature and stress at the
base of nozzle length were drawn. Results indicate that, inlet area has more stress compare to other areas.

REFERENCES

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[17] Church, E.F, (1928). Steam turbines. McGraw Hill Co.
[18] Singh, O., (2009). Applied Thermodynamics. New Age International.
[19] ANSYS help (2017), Version R18.

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