Off-design Operation Research Articles

Enhancing the Operating Efficiency of Mixed-Flow Pumps Through Adjustable Guide Vanes

The guide vane mixed-flow pump is a crucial component in medium-to-low-head pumping stations. The guide vanes are mostly fixed in traditional designs. The efficiency of these pumps under off-design operating conditions tends to be low, leading to higher energy consumption. This study explores the design of an adjustable guide vane for the conventional guide vane of a mixed-flow pump at a certain pumping station. Through numerical simulations and two sets of three-factor, five-level orthogonal experiments, we investigate the impact of flow rate, guide vane angle, and impeller angle on efficiency. Through numerical simulation, we identify the optimal relationships between an impeller angle of ±2° and 0° and guide vane angles of ±6°, ±3°, and 0°, focusing on the entropy production rate (EPR) as a key performance metric. The results demonstrate that adjustable guide vanes significantly improve the performance of mixed-flow pumps under off-design conditions. Efficiency increases by up to 17.71% at high flow rates, and by up to 5.48% at low flow rates. Energy consumption is notably reduced. As the flow rate and impeller blade angle vary, the adjustable guide vane rotates to match with the impeller, enhancing flow adaptation, expanding the high-efficiency operating range, and reducing overall energy consumption.

A review of condition monitoring in Francis turbines for predictive maintenance

Hydropower is one of the important sources of clean energy, where the use of the Francis turbine is the most than any other turbine. During off-design operations, turbines undergo significant fatigue loading, pressure pulsations, and vibration, which can be detrimental to the plant if operated for a long period of time. This paper aims to provide a general overview of (PdM) predictive maintenance in the context of Francis turbines showing how different parameters like strain, vibration, pressure, and acoustic emission can be measured in real-time to understand the condition of Francis turbines. Since every fault occurring in a Francis turbine has its own characteristic signature, it can be detected and diagnosed before any mishap occurs. Any deviation in the monitored signal from the reference dataset could be an indicator of fault. Appropriate filters are used to remove any noise or disturbances in the signal coming from sensors. Preprocessed signals are observed in time, frequency, or time–frequency domain for the analysis. Machine-learning has also been applied in several studies for the predictive maintenance. Although predictive maintenance can be an effective method to optimize the cost of operation and maintenance of power plants, only a few cases of its application can be found in hydropower. Moreover, there are very few reviews available on the condition monitoring of Francis turbine. This study presents a comprehensive description on various aspects of the condition monitoring, with strong emphasis on the application of online condition monitoring.

Computational Design of an Energy-Efficient Small Axial-Flow Fan Using Staggered Blades with Winglets

The present study introduces a conceptual design of a small axial-flow fan. Both individual and combined effects of blade stagger angle and winglet on the performance of the fan design are investigated in design and off-design operating conditions using a computational flow methodology. A stepwise solution, in which a proper stagger angle adjustment of a specifically generated blade profile is followed by appending a winglet at the tip of the blade with consideration of different geometrical parameters, is proposed to improve the performance characteristics of the fan. The initial model comparison analysis demonstrates that a three-dimensional, Reynolds-averaged Navier–Stokes (RANS) equation-based renormalization group (RNG) k–ε turbulence modeling approach coupled with the multiple reference frame (MRF) technique which adapts multi-block topology generation meshing method successfully resolves the rotating flow around the fan. The results suggest that the use of a proper stagger angle with the winglet considerably increases the fan performance and the fan attains the best total efficiency with an additional stagger angle of +10° and a winglet, which has a curvature radius of 6.77 mm and a twist angle of −7° for the investigated dimensioning range. The present study also underlines the effectiveness of passive flow control mechanisms of the stagger angle and winglets for energy-efficient axial-flow fans.

Off-design operation of super critical CO2 cycle integrated with reciprocating engine

This paper presents the results of simulations of a supercritical CO2 system integrated with a 180 kW nominal power piston engine. The sCO2 system consists of a compressor, expander, and four heat exchangers. The analysis delivered the optimum operating point of the system, where the sCO2 system generates an extra 18.03 kW. The main research was oriented into generation of off-design characteristics of the system, where sCO2 system were subjected to varying engine load and the system response was analyzed. The results of the calculations refer to the nominal point of the system and are given as maps of parameter changes normalized to the nominal point. The supercritical CO2 system itself is not controlled (only the speed of the turbomachinery is kept constant), while the power of this system depends on the current state of the reciprocating engine and directly influences the amount and temperature of the exhaust gases fed to the heater. The study revealed that the sCO2-biogas piston engine hybrid system would benefit from extra power generated by sCO2 when the engine operates with at least 60 % of its nominal power.

An Actuator-Disk Model Augmentation for Low-Pressure Axial Fan Simulation

Abstract Actuator-disk rotor models are important simulation tools for cost-effective industrial axial fan system analysis. Actuator-disk fan model performance, however, is constrained by the conventional use of two-dimensional airfoil coefficient input data, which limits the accuracy of the models to a narrow operating range free from significant radial blade flow. Radial blade flow is characteristic of off-design fan operation, which is often unavoidable within typical industrial fan system environments, so the enhancement of actuator-disk model performance for these conditions is desired. This paper accordingly presents a new means of robustly determining actuator-disk model coefficient inputs that are suitable for a wide range of fan operating conditions. The proposed augmented actuator-disk method (AADM) capitalizes on new insights into the unique aerodynamic behavior of low-pressure axial fan rotors. The performance of the AADM is evaluated for two different industrial cooling fans and is shown to outperform existing actuator-disk coefficient formulations through computational fluid dynamics simulations. The AADM is shown to better predict key fan performance metrics, spanwise blade force distributions, and to produce flow fields that are more physically representative (an important feature for industrial heat exchanger studies where the AADM is anticipated to be commonly applied). The AADM has been developed to be easily adopted in generic industrial fan analyses and is expected to serve as a valuable springboard for future actuator-disk fan model developments.

Simulation and validation of a Francis turbine load rejection procedure using OpenFOAM CFD code

Abstract The effect of off-design operation on the health of hydraulic turbines is known to be adverse, with substantial compromise in efficiency, due to evolvement of flow instability in the draft tube and consequent pressure fluctuation. The worst-case scenario may entail resonance between developed pressure fluctuation and system natural frequencies and therefore lead to power swings, possible mechanical vibrations and machine wear and tear. Present global energy ambition, however, necessitates frequent off-design operation and as such development of accurate numerical methods to determine the anomalous flow field in the turbomachine is mandated. To this end, a load rejecting transient operation of a model high head Francis turbine from design operating point to part load condition is simulated using a hybrid turbulence modelling approach. A detailed analysis of the draft tube velocity field is carried out after validation of the test case with experimental investigations that have discerned similar results. Spatio-temporal features, such as central flow stagnation, flow separation, central flow recirculation and development of a precessing vortex core, which are embodiments of the vortex breakdown phenomenon are thoroughly analysed and discussed. Finally, the draft tube flow is visualized using streamlines on the meridional plane and tracked as the turbine transitions from design to part load operating conditions.

Performance Analysis of a Power-to-Gas Storage System based on r-SOC

Abstract Power-To-Power (P2P) systems represent a promising technology to store the overgeneration from renewables generating a synthetic gas (mostly hydrogen or methane) and to convert the chemical carrier back into electricity during periods of energy demand peaks. In this context, the aim of this work is to propose, model and analyse an innovative P2P system that includes, as key components, a reversible Solid Oxide Cell (r-SOC) device and a reversible chemical reactor (RCR) working both as methanator and reformer. In the synthetic fuel production phase, water and electricity are converted into hydrogen by the r-SOC, which operates as an electrolyzer. Then, the hydrogen is in turn converted into synthetic methane by the RCR, operating as a methanator. During the discharge phase, instead, the RCR device operates as a reformer, fed by methane and water, and the r-SOC operates as a fuel cell, feeding the electricity production into the grid. The whole reversible P2P is modelled in Aspen HYSYS environment allowing to simulate both the design and off-design operation of the system. In addition, to increase the whole system’s performance, a heat recovery section is included in the model and optimized. Finally, a preliminary analysis to reproduce the behaviour of the system on varying the input available electric power will be analyzed and discussed, introducing and evaluating the key performance parameters for the system.

On Leakage Flows In A Liquid Hydrogen Multi-Stage Pump for Aircraft Engine Applications

Abstract A comprehensive operational characterisation of a representative, Liquid Hydrogen (LH2) aircraft engine pump is presented in this work. The implications of leakage flows are investigated in a 2-stage, high-pressure pump for a wide range of flow rates and rotational speeds, through 3D (U)RANS simulations. Two configurations are compared: a baseline model comprising the primary flow path components - inducers, impellers and volutes and a realisable pump hardware that includes hub, shroud and power unit cavities. Performance metrics, including head changes and efficiencies, are extracted both at a component and system level. Leakage flow rates of 27.6% and up to 92.9% of the overall pump flow rate are recorded at design and lowest flow points respectively. The head loss in the mid to low flow rates does not exceed 4.5%, but the efficiency diminishes by up to 13.5% at off-design operation. The component analysis indicates significant penalties in impeller efficiency. At high flow rates, the presence of leakage flows improves the overall pump performance by 43% and 27% in head rise and efficiency, due to reduced losses in volutes and connecting ducts. The characterisation of pump behaviour described in this work is crucial for developing and designing safe and predictable LH2 aircraft pumps. Contrary to LH2 pumps utilized in rocketry and for cooling in nuclear industry, aircraft pumps are required to operate with wider turn-down ratios and often at low specific speeds. Therefore, this study addresses design considerations for this enabling technology.

Effects of propeller cavitation on ship propulsion performance in off-design operating conditions

The propeller cavitation is closely related with its hydrodynamic performance. When the propeller works in the cavitating flow, the propeller hydrodynamic performance, in terms of thrust and torque coefficients, is reduced due to the propeller cavitation. When the high-speed and high-power ship sails in adverse sea, the varying loads on propeller will cause severer cavitation on propeller. The reduction in propulsion performance caused by cavitation will further affect the propulsion system, impacting the ship sailing performance and safety. The VP1304 propeller cavitation CFD simulation are conducted to validate the CFD method. Furthermore, the influence of propeller advance ratio and cavitation numbers on the performance of low-speed high-power series propeller in cavitating flow are studied and illustrated. This influence of cavitation has also been transferred to the propulsion system and this process are calculated by the ship propulsion system numerical model. Additionally, the sailing performance of ship propulsion system under off-design conditions, where the cavitation is more likely to occur, has been investigated in this article. Under severe heavy load conditions, it can even result in a complete loss of propulsion capability, posing significant risks. Therefore, it is necessary to further optimize control strategies for the propulsion system to mitigate the hazards caused by cavitation.

Guideline for Large-Scale Analysis of Centrifugal Blower Using Wall-Resolved Large Eddy Simulation

Abstract To reduce the number of prototypes during product design and accurately predict unsteady phenomena occurring at off-design points, a method for accurately predicting the performance of centrifugal blowers through numerical analysis is required. This article presents a guideline for accurately predicting the performance of centrifugal blowers using compressible flow analysis with large eddy simulation (LES). In LES analysis, it is important to have a grid resolution that resolves the minimum vortex scale near the wall (referred to as wall-resolved LES) and to consider detailed geometry such as the length of the suction pipe. The calculations in this study used a model blower, which is a scale model of a single-stage centrifugal blower for use in industrial plants. The model blower was experimentally measured for various parameters such as the blower pressure coefficient, the static-pressure-rise coefficients of the impeller and vane-less diffuser, the shaft power, and the pressure fluctuations at the inlet of the impeller and the inlet of the vane-less diffuser. The results of these measurements were compared with those obtained from the wall-resolved LES. The study confirmed that the accuracy of performance prediction can be improved to less than a 4.0% error in the blower pressure coefficient at both design and off-design operating points by resolving the minimum vortex scale with 14.6 billion-grid elements and considering the detailed geometry.

Analysis of the exergy transfers in subcritical and transcritical CO[formula omitted] ejectors and their connection with the performance of the refrigeration cycle

Ejector refrigeration systems (ERSs) operating with carbon dioxide are notoriously challenging from both design and operation perspectives. In particular, the ejector itself gives rise to special attention since it directly affects the performance of the global system. In this study, the connections between local exergy transfers within the ejector and global cycle performance are investigated by using a novel multi-scale numerical approach. Computational Fluid Dynamics (CFD) is used to generate accurate predictions of the ejector operation with access to the local flow and heat transfer features. The exergy tube analysis is applied onto the simulation results, linking local transfers within the ejector to the results at the component- and cycle-scale. A state-of-the-art ejector thermodynamic model is then calibrated onto the CFD results, and employed to determine the physically possible operation of the ERS. In addition, the metastability impact on the exergy transfers and overall system performance is investigated by comparing the CFD results of the classical Homogeneous Equilibrium Model with those obtained with the Homogeneous Relaxation Model. Notably, it is found that at fixed ejector inlet conditions, there exits an outlet pressure that maximizes the exergy transfers from primary to secondary streams. Interestingly, this work shows for the first time that the maximum exergy gain of the secondary stream appears to correlate with the maximum coefficient of performance of the system, independently of the on- or off-design operation of the ejector. Moreover, metastability generally deteriorates the performance at both scales. The results of the present study serve to pave the way towards better ejector design objectives.

Analysis of submersible axial flow pump fitted with variable IGV at design and off-design conditions

Abstract Submersible axial flow pump is capable of generating large flow rate at high efficiency and is widely used in agriculture, irrigation, water supply and drainage in factories, urban areas, etc. Pumps are always designed to operate at the designed conditions of flowrate and head, but in certain practical applications, their off- design operation seems to be more important, like if there is waterflooding due to heavy rainfall or in case of variable flowrate, variable head operations or long-distance water supply. These situations arise for limited operation (time) and hence it is not economical to change the existing pumping system. The present work deals with the analysis of submersible axial flow pump at design as well as off-design conditions. This off-design operation was controlled by the variable inlet guide vane (VIGV) with the task of making it energy efficient for all conditions. The scope of this work was to investigate the performance of selected pump at designed rotational speed, at designed flowrate (Q/Qd =1) as well as Q/Qd =0.8 and Q/Qd =1.2, using Computational Fluid Dynamics (CFD) and at various VIGV angles in the range of ±25°. The fluid flow analysis was performed using commercial CFD tool ANSYS CFX v17.0. From the numerical study, it was concluded that the performance of the considered AFP significantly increased due to the presence of VIGV at positive rotation angles. The best performance was observed for IGV angle of +25° for all flowrates. As compared to the reference case of 0° IGV rotation, the performance of the AFP increased by 28.42% in terms of head ratio and 0.235% in terms of hydraulic efficiency, for +25° IGV angle, at the designed flowrate. Also, an increment of 69.05% in terms of head ratio and 14.49% in terms of hydraulic efficiency was observed at overload condition of Q/Qd =1.2.

Impact of extracorporeal blood pump gap sizes on the performance and hemocompatibility under off-design operation.

Hemocompatibility remains the dominant challenge in rotary blood pumps, and more information on the relationship between individual pump design features, hemodynamics, and blood trauma in various operation conditions is necessary. The study evaluated the variation of gap sizes in extracorporeal blood pumps concerning their influence on blood compatibility, particularly during off-design conditions. We developed a parametric generic blood pump framework for in-silico and in-vitro design feature analysis. Thirty-six designs with varying axial and radial gap sizes between 0.5 mm and 3 mm were generated. CFD was applied to calculate and compare device hemodynamics and evaluate the performance and hemocompatibility during off-design and target operation conditions. The following quantities were analyzed: pressure difference, hemolysis potential, residence times, hydraulic efficiency, and recirculation ratio. The in-vitro prototype showed excellent agreement with in-silico predictions regarding hydraulic performance (R2 = 0.996 with a RMSE = 2.07). Our results show a modest impact of gap size variations ±10% on key metrics. Domain-resolved analyses revealed a significant contribution of the gap regions to the device's overall hemolytic performance, with an increasing contribution for off-design flow rates. Overall elevated hemolysis levels were identified if at least one gap size was held minimal. We introduced and showed the feasibility of a parametric rotary blood pump framework to systematically investigate design feature impact. Results suggest, larger and uniformly sized gaps being overall beneficial regarding hemocompatibility.

Investigation on ejector design for CO2 heat pump applications us-ing Dymola

In this paper, the Dymola modelling tool is used to study the influence of ejector design onto the whole heat pump cycle working with carbon dioxide. The cycle is built using the components provided by the TIL Modelica library. It is found that the ejector models in TIL are quite limited, namely by their inability to properly capture the on-design plateau and rapid decrease in performance in off-design operation. Therefore, an in-house state-of-the-art ejector model, originally developed in Python, is implemented as a Dymola object. This model is then calibrated onto CO2 experimental data. The operation of a simple CO2 heat pump system is investigated, with focus on the ejector sizing at fixed geometry. It is found that there exists an ejector size that maximises the COP of the cycle. Furthermore, critical ejector pressure is not reached at this optimum COP point; the ejector is operating well under the on-design regime.

Accuracy assessment of the turbomachinery performance maps correction models used in dynamic characteristics of supercritical CO2 Brayton power cycle

The supercritical CO2 Brayton cycle (SCO2BC) has emerged as a promising next-generation power generation technology due to its potential for high thermal efficiency and compact components design. Dynamic modeling of SCO2BC is crucial for understanding and analyzing its performance under design and off-design conditions. Turbomachines are critical components in SCO2BC dynamic models. While turbomachinery components are often modeled using their design-point turbomachinery performance maps (TPM), these maps become less accurate during off-design operations. Despite the existence of various TPM correction methods that ensure model validity, the implementation of the accurate ones within dynamic SCO2BC models remains scarce in the literature. This is crucial as it potentially compromises the accuracy of the obtained results. Therefore, there is a need to investigate the errors in the existing literature TPM correction models (in dynamic SCO2BC simulation) by comparing them against dynamic SCO2BC models employing a highly accurate correction method. Thus, in the current work, the common TPM correction methods from the literature are implemented in SCO2BC dynamic models and compared against a baseline mode, which uses the highly-accurate Pham method (at both the component and cycle levels). To the authors’ knowledge, this is the first work to address this research gap for the SCO2BC dynamic simulations and on both component and cycle levels. Additionally, another novelty is the usage of Simcenter Amesim software to dynamically model the SCO2BC aided with Pham model. Multible dynamic models for both the turbomachines of SCO2BC and the whole cycle are constructed and equipped with the different TPM correction methods found in literature to compare their dynamic behaviour that of Pham model. The Ideal Gas Compressibility factor (IGZ) method demonstrates a better performance than the other tested methods, as it exhibits the lowest discrepancy compared to the Pham model. Many of the other tested methods show significant errors. Furthermore, a popular hybrid correction combining IGZ and Pham (IGZ-Ph) is also investigated. Surprisingly, while seemingly beneficial, this hybrid approach negatively impacts accuracy, even resulting in predictions as if no correction was applied.

Off-design operation and performance of pumped thermal energy storage

In this article, we describe off-design models and control strategies for a Pumped Thermal Energy Storage (PTES) system that uses liquid thermal energy storage: specifically molten salt for hot storage and methanol for cold storage. Off-design conditions arise when load-following, or due to variations in storage tank temperatures or ambient temperatures. We propose a control strategy that uses inventory control to manage the mass flow rate in the thermodynamic cycles, which facilitates load following. We also propose a control strategy for the storage fluid mass flow rates, which are varied to ensure the molten salt is maintained at its design temperature. This maximizes efficiency and minimizes problems with salt freezing or degradation. The cold storage fluid mass flow rate is varied so that the cold tanks have the same state-of-charge as the hot tanks. This leads to variations in cold fluid temperature, but these variations are shown to be acceptably small (e.g. 7.5 % increase), and this control method is shown to be simpler and more efficient than an alternative strategy where tanks become unbalanced. The ambient temperature and storage tank temperatures are moved ±50 °C from the design values and the impact on power, duration, and tank temperatures is quantified. Results demonstrate that the proposed control strategy is stable and self-correcting – that is, storage temperatures converge on stable values after two-to-three charge-discharge cycles. When inputs return to design values, the system returns to its design point after two charge-discharge cycles. We also demonstrate that inventory control enables delivery of the target power output even when off-design conditions exist that would normally reduce the power output.

Model-based optimisation of solar-assisted ORC-based power unit for domestic micro-cogeneration

Integrating flat solar thermal collectors and organic Rankine cycle (ORC)-based power units in micro-cogeneration systems ensures a reduction in CO2 emissions in domestic applications. The key component of these systems is the expander, which must withstand frequent off-design operating conditions owing to the intermittent nature of the solar source. Despite being in the first stage of technological development, scroll expanders are widely adopted in small-scale applications owing to their operating flexibility and robustness. In this study, a domestic micro-cogeneration unit equipped with a scroll expander is characterised experimentally. The experimental data are used to calibrate the expander and ORC unit models. The models are used to evaluate the operating limits of the units as functions of the main operating parameters. The maximum power and efficiency are obtained as 300 W and 3 %, respectively, for hot water temperatures between 90 °C and 100 °C, close to the rated performances. Finally, the effect of adopting a dual-intake port on the expander and unit performance is assessed. The technology facilitates the widening of the operating range (20–140 g/s mass flow rate of WF) and a peak power production of 1.2 kW.

Simulations of design and high load operation of a model Francis turbine using bridged approach to turbulence modelling

Abstract Off-design operation of hydraulic turbines is contemporarily frequented for balance of variable energy intermittence in the electric grid. Being operationally highly flexible, these turbines allow a quick transition to off-design operation from the design point. However, such operational flexibility, and therefore the grid balancing capability is impeded by generation of flow instabilities like vortex breakdown during off-design operation. Vortex breakdown causes losses in efficiency and pressure recovery, pressure fluctuations and possibly mechanical vibrations in event of resonance between system natural and flow field fluctuation frequencies. While substantial experimental and numerical effort has already been made to study draft tube vortex breakdown, an accurate numerical flow characterization of the phenomenon is still a challenge. To this end, operation of a high head model Francis turbine under design and high load regimes using a bridged turbulence modelling approach is simulated. The approach allows a seamless transition between direct numerical simulation and Reynolds averaged Navier-Stokes equations. The highest attainable accuracy is limited by the mesh size. As such a satisfactory compromise between desired accuracy and invested computational effort is attained. The flow in the draft tube is free of anomalies under design specified operation. However, at high load an axial flow stagnation occurs centrally, and the flow is separated about the stagnated zone. The core of the vortex is enlarged with flow recirculation within it. Shear layers between the central stagnant zone and surrounding outflow kink and roll up transforming it into a spiral structure. In this work, a basic yet accurate numerical flow characterization of the aforementioned flow situations is achieved.

Homogeneous Equilibrium Modeling for Subcritical Flows in Liquid Rocket Engine Cooling Systems

During off-design operations of liquid rocket engines, the coolant operating conditions can easily extend from the subcritical to the supercritical regime. As a matter of fact, it is very useful to have a single software able to study the flow in this range of operating conditions, providing reliable simulations that are reasonably quick and able to accurately estimate and assess the increase in coolant temperature along the channel and the wall temperature field. This objective is pursued by extending an established approach for the study of supercritical flows to the case of subcritical heating, where a two-phase flow may occur. This is done by exploiting the so-called homogeneous equilibrium model, which has been shown to be sufficiently predictive and accurate for specific applications. With the aim of demonstrating and discussing the potential and limitations of such a single software approach, analyses are conducted on different test cases where two-phase flow is induced by cavitation or flow boiling, and results are compared with those of analytical models and experimental data. It is found that, in addition to some intrinsic limitations in the analysis of subcooled boiling flows, satisfactory agreement with experimental data is obtained in the post-critical-heat-flux regime.

Thermodynamic analysis of two very-high-temperature gas-cooled reactor-driven hydrogen and electricity cogeneration systems under off-design operating conditions

This study conducts a thermodynamic analysis for two very-high-temperature gas-cooled reactor-driven hydrogen and electricity cogeneration systems integrating an iodine-sulfur cycle and a helium turbine direct cycle under off-design operating conditions. Control strategies are proposed based on inventory control. The calculation model is established for the main components of the system under off-design conditions. Two operation modes are proposed, one is to maintain the split ratio at the reactor outlet at the rated value, and the other is to maintain the hydrogen generation rate at the rated value. The off-design performance of the two systems under partial load in two modes is analyzed. For Systems 1 and 2, the suggested lower limits of reactor thermal power are 68.80 % and 69.00 % of the rated value in mode 1, and 72.04 % and 64.98 % in mode 2. As the reactor thermal power decreases from the rated value to the suggested lower limit, in modes 1 and 2, the hydrogen-electricity efficiency of System 1 decreases from 37.46 % to 36.20 % and 31.81 %, and that of System 2 decreases from 42.40 % to 41.45 % and 35.21 %. The decrease in overall efficiency is more significant in mode 2.