Computational Fluid Dynamics Study of Erosion on 900 MW Steam Turbine ND-45 Blades Using 3D Scanning

Abstract

This paper presents a comprehensive study on the impact of erosion on the flow characteristics through the blade of the last stage of a 900 MW steam turbine. The primary objective is to understand how surface erosion, caused by prolonged steam exposure, affects flow behavior and the overall efficiency of a 900 MW class turbine. The research process began with a 3D scan of the turbine blade, using advanced laser scanning technology to create a detailed geometric model. As one of the longest blades used in steam turbines, it posed both a technical challenge and was an innovative aspect of this study. The resulting 3D model served as the basis for numerical simulations using Computational Fluid Dynamic (CFD) methods, which allowed for the analysis of steam flow over the eroded blade surface. Key flow parameters, including velocity, pressure, and turbulence, were assessed to determine the impact of erosion. The study revealed significant changes in flow characteristics depending on the degree of erosion, providing valuable insights for turbine optimization and maintenance. The novelty of this research lies not only in the use of advanced scanning technologies but also in analyzing one of the longest blades in industrial practice, with findings that could enhance turbine efficiency and inform new erosion risk management strategies.