Effect of the water erosion on the non-equilibrium condensation in steam turbine cascade

Abstract

In the final stage of steam turbines, droplets formed by non-equilibrium condensation continuously impact and erode the blades, leading to changes in surface roughness and leading edge erosion. This study investigates the effects of roughness changes and leading edge erosion, induced by water erosion, on non-equilibrium condensation in steam turbine cascades using numerical simulation methods. In a Moses-Stein nozzle, the mechanism of roughness influencing non-equilibrium condensation is analyzed. Subsequently, entropy generation theory is applied to assess the loss distribution caused by roughness variations in a Dykas cascade. Furthermore, flow field analysis and entropy generation theory are utilized to examine the loss distribution pattern resulting from leading edge erosion. Results show that increased roughness delays non-equilibrium condensation, reducing average outlet humidity (from 0.05351 to 0.04361 as roughness rises from 0 to 500 µm). The effect of roughness on thermodynamic entropy generation exhibits a non-linear relationship, balancing steam flow losses with mitigated phase-change-related losses at a roughness of 896 µm. Significant blade erosion (>3 mm) alters leading edge geometry, causing local flow separation and a substantial increase in airfoil losses.