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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Performance evaluation of a Terry GS-2 steam impulse turbine with air-water mixtures

Terry steam turbines are widely used in various industries because of their robust design. Within the nuclear power generation industry, they are used in the Reactor Core Isolation Cooling System to remove decay heat during reactor isolation events. During the Fukushima Daiichi nuclear power station disaster in Japan in 2011, the Reactor Core Isolation Cooling System and associated Terry turbine operated for over 70 hours in Unit 2; this runtime is well beyond the expected operating duration. Theories suggest the turbine was subjected to a two-phase inlet flow, which could degrade the turbine performance. In this work, an experimental test rig was constructed to test a full-scale Terry model GS-2 steam turbine under two-phase air/water flows. Steady-state efficiency and torque performance maps of the turbine were developed over a range of turbine inlet pressures (1.38–4.83 bar or 20–70 psia), air mass fractions (0.05–1.0) and rotational speeds up to 4000 RPM. Furthermore, turbine performance followed expected trends with torque varying linearly and efficiency varying quadratically with rotational speed. In addition, high-speed images of the two-phase flow entering the turbine were also analyzed to understand how changes in inlet pressure and air mass fraction affect the flow regime and homogenization. The present tests with air–water two-phase mixtures are an important step towards providing an understanding of the full-scale Terry turbine’s behavior and performance curves under two-phase conditions. The results of this work will be combined with air/water and steam/water data gathered using a small-scale Terry ZS-1 steam turbine in order to understand the scaling relationship between large and small size Terry turbines and fluid pairs. The combined data set will enable further development of analytical models over a wide range of conditions and may be used to provide technical justification for expanded use of the Terry turbines in nuclear power plant safety systems and other systems.

42 ENGINEERING↗
DOE OSTI2022

Evaluation of Heat Transfer Enhancement on Rotational Gas Turbine Blade Internal Cooling Channel With Dimpled Surface

Abstract The present investigation represents the rotational effect on gas turbine blade internal cooling with a uniform heat flux of 2000 W/m2 at the bottom wall. The experiment was conducted with three different rpms, such as 300 rpm, 600 rpm, and 900 rpm, with Reynolds number (Re) ranging from 6000 to 50,000 with a two-pass cooling channel. The numerical investigation was conducted with the large eddy simulation (LES) technique to understand the rotational flow behavior of the cooling channel. Four distinct arrangements of dimpled cooling channel surfaces were considered with two different dimple shapes, i.e., partial spherical and leaf. It is found that the rotation effect, dimple arrangement, and design have significant influences on heat transfer. Results indicated that the partial spherical 1-row dimpled surface experienced the highest heat transfer coefficient and pressure drop. In contrast, the leaf-shaped dimpled cooling channel experienced the highest thermal efficiency.

Energy & Fuels↗
DOE OSTI2021

Loads on a Jacket-Supported Wind Turbine During Hurricane Sandy Simulation

Abstract The dynamic response of a jacket-supported offshore wind turbine under coupled wind, wave, and current fields during Hurricane Sandy is the subject of this study. To illustrate the detailed procedure related to the response evaluation of a 5-MW offshore wind turbine with a jacket support structure, we consider a single site where the water depth is 50 m. Loads are computed using two simulation tools, fast and abaqus, with partial coupling. Aerodynamic loads on the turbine rotor are first evaluated using a wind turbine model in fast with a fixed base; then, these rotor aerodynamic loads are applied as point loads at the top of a model of a tower that is supported by a jacket structure in abaqus. On the basis of stochastic simulations, we discuss the applicability of the abaqus jacket modeling and describe the characteristics and comparisons of the aerodynamic and hydrodynamic effects on loads on the jacket members. Details related to the structural model and soil–pile interaction model employed in the analyses are also discussed.

Engineering↗
DOE OSTI2026

Comparison of juvenile white sturgeon blade strike survival through a conventional and a novel hydropower turbine

Hydropower is a globally important renewable energy source with profound impacts on aquatic organisms, including direct injury and mortality to fish that move through hydropower facilities. While it is expected that the characteristics of turbine design and operation influence the type, frequency, and magnitude of injuries suffered by entrained fish, few direct comparisons exist to illustrate differences in fish survival outcomes for conventional and novel turbine designs. This study evaluated blade strike-associated injury and mortality rates for juvenile white sturgeon (Acipenser transmontanus) passed through a model-scale turbine equipped with a runner having conventional blade profiles (thin, straight leading edges) and the same turbine equipped with a runner designed for improved fish survival (thick, slanted leading edges). In both trials, head and turbine runner rotational speeds were matched to produce five blade peripheral speeds between 15.0 and 27.6 m/s. High-speed video was captured for all turbine passage events. Fish were assessed for injuries following passage, and mortalities were assessed immediately after passage and after 48 h. Conventional runner passage resulted in 42% to 78% survival after 48 h, with approximately one-third of all tested fish killed by severing. Under the same test conditions, immediate and 48 h survival rates through the novel runner were 100% except at the highest speed condition (95.6% survival at 48 h). These results clearly indicate that turbine design has a profound effect on fish survival, and suggest that thoughtful redesign of hydropower equipment could significantly ameliorate the risks of blade strike mortality.

13 HYDRO ENERGY↗
DOE OSTI2024

Seasonal variability of wake impacts on US mid-Atlantic offshore wind plant power production

Abstract. The mid-Atlantic will experience rapid wind plant development due to its promising wind resource located near large population centers. Wind turbines and wind plants create wakes, or regions of reduced wind speed, that may negatively affect downwind turbines and plants. We evaluate wake variability and annual energy production with the first yearlong modeling assessment using the Weather Research and Forecasting model, deploying 12 MW turbines across the domain at a density of 3.14 MW km−2, matching the planned density of 3 MW km−2. Using a series of simulations with no wind plants, one wind plant, and complete build-out of lease areas, we calculate wake effects and distinguish the effect of wakes generated internally within one plant from those generated externally between plants. We also provide a first step towards uncertainty quantification by testing the amount of added turbulence kinetic energy (TKE) by 0 % and 100 %. We provide a sensitivity analysis by additionally comparing 25 % and 50 % for a short case study period. The strongest wakes, propagating 55 km, occur in summertime stable stratification, just when New England's grid demand peaks in summer. The seasonal variability of wakes in this offshore region is much stronger than the diurnal variability of wakes. Overall, yearlong simulated wake impacts reduce power output by a range between 38.2 % and 34.1 % (for 0 %–100 % added TKE). Internal wakes cause greater yearlong power losses, from 29.2 % to 25.7 %, compared to external wakes, from 14.7 % to 13.4 %. The overall impact is different from the linear sum of internal wakes and external wakes due to non-linear processes. Additional simulations quantify wake uncertainty by modifying the added amount of turbulent kinetic energy from wind turbines, introducing power output variability of 3.8 %. Finally, we compare annual energy production to New England grid demand and find that the lease areas can supply 58.8 % to 61.2 % of annual load. We note that the results of this assessment are not intended to make nor are they suitable to make commercial judgments about specific wind projects.

17 WIND ENERGY↗
DOE OSTI2020

Evaluating the Effect of Vane Trailing Edge Flow on Turbine Rim Sealing

Abstract Modern gas turbine development continues to move toward increased overall efficiency, driven in part by higher firing temperatures that point to a need for more cooling air to prevent catastrophic component failure. However, using additional cooling flow bled from the upstream compressor causes a corresponding detriment to overall efficiency. A primary candidate for cooling flow optimization is purge flow, which contributes to sealing the stator–rotor cavity and prevents ingestion of hot main gas path (MGP) flow into the wheelspace. Previous research has identified that the external main gas path flow physics play a significant role in driving rim seal ingestion. However, the potential impact of other cooling flow features on ingestion behavior, such as vane trailing edge (VTE) flow, is absent in the open literature. This paper presents experimental measurements of rim cavity cooling effectiveness collected from a one-stage turbine operating at engine-representative Reynolds and Mach numbers. Carbon dioxide (CO2) was used as a tracer gas in both the purge flow and vane trailing edge flow to investigate flow migration into and out of the wheelspace. Results show that the vane trailing edge flow does in fact migrate into the rim seal and that there is a superposition relationship between individual cooling flow contributions. Computational fluid dynamics (CFD) simulations using unsteady Reynolds-averaged Navier–Stokes (URANS) were used to confirm VTE flow ingestion into the rim seal cavity. Radial and circumferential traverse surveys were performed to quantify cooling flow radial migration through the main gas path with and without vane trailing edge flow. The surveys confirmed that vane trailing edge flow is entrained into the wheelspace as purge flow is reduced. Local CO2 measurements also confirmed the presence of VTE flow deep in the wheelspace cavity.

Engineering↗
DOE OSTI2021

Evaluating the Influence of Rotor-Casing Eccentricity on Turbine Efficiency Including Time-Resolved Flow Field Measurements

Abstract The clearance that exists between the casing and turbine blade tips is one of the key drivers of efficiency in gas turbine engines. For this reason, engine manufacturers utilize precise manufacturing techniques and may use clearance control systems to minimize tip clearances to reduce associated losses. Despite these efforts, turbines typically exhibit some nominal casing ovality or rotor-casing eccentricity, and changes to blade tip clearance during operation commonly occur due to thermal and mechanical stresses. The present study investigates non-axisymmetric tip clearance effects by creating a rotor-casing eccentricity in a one-stage axial test turbine operating in a continuous-duration mode at engine-relevant conditions with engine representative hardware. A magnetic levitation bearing system was leveraged to move the turbine shaft to vary the rotor-casing eccentricity without test section disassembly. The results of this study indicate that rotor-casing eccentricity does not affect overall turbine efficiency over the range that was tested, but does locally influence efficiency and the rotor exit flow field. Comparisons of flow angle and secondary flow kinetic energy (SKE) agreed with previous studies and existing analytical methods, respectively. Collectively, these results indicate that tip clearance can be studied locally on an eccentric rotor.

Engineering↗
DOE OSTI2024

Ensemble Manufacturing Techniques for Steam Turbine Components Across Length Scales

Faster design to manufacturing requirements were sought for steam turbine components to meet the changing demands of today’s power grid of improved efficiency through operating temperature increases and enhanced operational flexibility from baseload to cyclic operations. Advances in multiple advanced manufacturing (AM) process enabled redesign of turbine components for extreme environments with the potential to reduce cost. AM is of particular interest to improve component functionality, higher temperature capability, and superior durability in large scale steam turbine applications. AM methods have an immense potential to open-up the design space by working directly with the 3D model to produce near-net shapes, enable fast design-manufacturing iterations, thereby significantly reducing product cost and lead-time up to 25 % from current baseline. However, these benefits cannot be fully realized due to the potential for unknown AM processing defects and their resultant effect upon component performance in service. Siemens is partnering with Oak Ridge National Laboratory (ORNL), Electric Power Research Institute (EPRI), and Connecticut Center for Advanced Technology (CCAT) to advance the knowledge of complex process-material interactions for desired microstructures and properties that are closely interlinked to component geometries across different length scales. The proposed program utilized an ensemble of multidisciplinary technologies to accelerate the development of materials, high-throughput experiments for their qualification, and design flexibility/topology optimization for repair/redesign of components to address critical failure mechanisms for improved performance and increased reliability of existing power plant components. The proposed activities, if successfully demonstrated for identified components, will enable paradigm shift in customized manufacturing and accelerated qualification/certification towards increased steam turbine component durability, increased turbine efficiency, and reduced CO 2 emissions in load-following environments compared to today’s technology. Technology maturation is built into the project as successful research will include customized process-component down-selection enabling AM methodologies to be incorporated directly into the existing supply chain. The specific activities of the proposed effort are: 1. Topology optimization of down-selected steam turbine parts that are amenable to additive and hybrid manufacturing for cost/performance improvement. 2. Process-structure-property relationships for five AM processes for steam turbine materials of interest to compare with conventional materials. 3. Perform part/assembly build process using advanced additive/hybrid machine tools followed by quality inspection of the built components for insight into qualification for production scale-up. Steam turbine rig testing of printed components under targeted, well monitored and characterized environmental conditions of for performance comparison of baseline and redesigned components.

36 MATERIALS SCIENCE↗
DOE OSTI2024

RAFT: Reconfigurable Array of High-Efficiency Ducted Turbines for Hydrokinetic Energy Harvesting

Diversifying the energy harvesting portfolio is crucial to achieving the ambitious goal of transitioning to clean energy by 2030. Marine hydrokinetic energy has garnered renewed interest due to its high harvesting potential in the U.S., and the resource's reliability and predictability—remaining relatively constant on a daily basis and available 24/7. However, there are currently few commercial devices capable of harnessing the energy from flowing water. This project aims to bridge that gap by designing and evaluating a novel hydrokinetic turbine concept that can efficiently harvest energy from both rivers and tidal streams. The RAFT (Reconfigurable Array of High-Efficiency Ducted Turbines) concept introduces a duct surrounding the turbine rotor and creates an array of small 5-kW units. The duct serves two primary purposes: (1) it enhances hydrodynamic efficiency by accelerating flow to the rotor, and (2) it functions as a structural component, facilitating the formation of modular arrays that lower costs. This project focuses on demonstrating this concept and validating these benefits through simulations and scaled prototype testing. The project team includes 8 faculty members and over 20 students from 3 universities, organized into three core areas: hydrodynamics, electrical systems, and structural analysis, with additional teams dedicated to system integration, environmental assessment and risk management, and tech-to-market strategy. The team successfully demonstrated the increased hydrodynamic efficiency of a ducted turbine compared to an unducted version using high-fidelity simulations and prototype tests. Moreover, design optimization efforts led to surpassing the SHARKS program's goal of 60% reduction of the levelized cost of energy with a significant margin.

13 HYDRO ENERGY↗
DOE OSTI2023

Distributed clean energy opportunities for US oil refinery operations

The oil and gas industry is increasingly seeking operational improvements to reduce costs and emissions while improving resilience. This study describes techno-economic analysis of opportunities for distributed energy resources that could be integrated to support oil and gas companies’ economic, environmental, and energy resiliency goals. Specifically, the analysis evaluates solar photovoltaics, wind turbines, battery energy storage, landfill gas, biomass, municipal solid waste-to-energy, solar steam for process heat, combined heat and power, and electrolyzers for hydrogen production at two hypothetical refineries, one located in Louisiana and the other in southern California. These technologies could reduce the sites’ consumption of grid electricity and/or natural gas and thus can help reduce emissions. This study employs the ReOPT tool and System Advisor Model to evaluate the techno-economic potential for clean energy technologies to support refineries in achieving energy goals, including energy cost savings, resiliency, and emissions reductions. Results indicate that the associated costs of emissions reductions via several distributed clean energy technologies are competitive with other emissions reduction strategies such as energy efficiency, reducing flaring, direct carbon capture and sequestration, and markets under certain conditions. There are also cost beneficial opportunities for the use of renewable energy for refining, especially for resilience, depending on local conditions such as resources and utility costs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Defense & Disaster Deployable Turbine Fact Sheet

The U.S. Department of Energy’s (DOE’s) Defense and Disaster Deployable Turbine (D3T) project is evaluating the market potential for rapidly deployable wind energy technologies. The D3T fact sheet outlines the work with military and wind industry stakeholders to develop deployable wind energy technologies that can meet the unique energy needs of defense operations and responses to humanitarian crises.

wind, defense, disaster, deployable, turbine, ener↗
DOE OSTI2024

Can mesoscale models capture the effect from cluster wakes offshore?

Long wakes from offshore wind turbine clusters can extend tens of kilometers downstream, affecting the wind resource of a large area. Given the ability of mesoscale numerical weather prediction models to capture important atmospheric phenomena and mechanisms relevant to wake evolution, they are often used to simulate wakes behind large wind turbine clusters and their impact over a wider region. Yet, uncertainty persists regarding the accuracy of representing cluster wakes via mesoscale models and their wind turbine parameterizations. Here, we evaluate the accuracy of the Fitch wind farm parameterization in the Weather Research and Forecasting model in capturing cluster-wake effects using two different options to represent turbulent mixing in the planetary boundary layer. To this end, we compare operational data from an offshore wind farm in the North Sea that is fully or partially waked by an upstream array against high-resolution mesoscale simulations. In general, we find that mesoscale models accurately represent the effect of cluster wakes on front-row turbines of a downstream wind farm. However, the same models may not accurately capture cluster-wake effects on an entire downstream wind farm, due to misrepresenting internal-wake effects.

17 WIND ENERGY↗
DOE OSTI2025

Corrosion Fatigue Life Evaluation of 17-4PH in Support of Water Filled Turbine Hubs

High cycle corrosion fatigue (HCCF) life S-N tests were conducted on wrought 17-4PH in various water environments under accelerated testing conditions. For tests conducted in aerated Columbia River water and in aerated ASTM Type IV water, at ~10 6 cycles, the HCCF stress amplitude was ~70% of the value in air. For deaerated water, the value was ~80%. These values are consist with the small amount of literature data on HCCF life of 17-4PH in water environments. The measured fatigue life both in air and water are much better than the ASME trend curve of high cycle fatigue life of moderate and high strength steels. Measured values were also much better than found in a hydropower-relevant study in the literature on cast 17-4PH. The effect of Amersite 61W on HCCF life was evaluated and found to cause very low times to specimen failure compared to all other water environments.

13 HYDRO ENERGY↗
DOE OSTI2021

A Methodology for Robust Load Reduction in Wind Turbine Blades Using Flow Control Devices

Decades of wind turbine research, development and installation have demonstrated reductions in levelized cost of energy (LCOE) resulting from turbines with larger rotor diameters and increased hub heights. Further reductions in LCOE by up-scaling turbine size can be challenged by practical limitations such as the square-cube law: where the power scales with the square of the blade length and the added mass scales with the volume (the cube). Active blade load control can disrupt this trend, allowing longer blades with less mass. This paper presents the details of the development of a robust load control system to reduce blade fatigue loads. The control system, which we coined sectional lift control or SLC, uses a lift actuator model to emulate an active flow control device. The main contributions of this paper are: (1) Methodology for SLC design to reduce dynamic blade root moments in a neighborhood of the rotor angular frequency (1P). (2) Analysis and numerical evidence supporting the use of a single robust SLC for all wind speeds, without the need for scheduling on wind speed or readily available measurements such as collective pitch or generator angular speed. (3) Intuition and numerical evidence to demonstrate that the SLC and the turbine controller do not interact. (4) Evaluation of the SLC using a full suite of fatigue and turbine performance metrics.

17 WIND ENERGY↗
DOE OSTI2022

Evaluation of obstacle modelling approaches for resource assessment and small wind turbine siting: case study in the northern Netherlands

Abstract. Growth in adoption of distributed wind turbines for energy generation is significantly impacted by challenges associated with siting and accurate estimation of the wind resource. Small turbines, at hub heights of 40 m or less, are greatly impacted by terrestrial obstacles such as built structures and vegetation that can cause complex wake effects. While some progress in high-fidelity complex fluid dynamics (CFD) models has increased the potential accuracy for modelling the impacts of obstacles on turbulent wind flow, these models are too computationally expensive for practical siting and resource assessment applications. To understand the efficacy of available models in situ, this study evaluates classic and commonly used methods alongside new state-of-the-art lower-order models derived from CFD simulations and machine learning approaches. This evaluation is conducted using a subset of an extensive original dataset of measurements from more than 300 operational wind turbines in the northern Netherlands. The results show that data-driven methods (e.g. machine learning and statistical modelling) are most effective at predicting production at real sites with an average error in annual energy production of 2.5 %. When sufficient data may not be available de novo to support these data-driven approaches, models derived from high-fidelity simulations show promise and reliably outperform classic methods. On average these models have 6.3 %–11.5 % error compared with 26 % for classic methods and 27 % baseline error for reanalysis data without obstacle correction. While more performant on average, these methods are also sensitive to the quality of obstacle descriptions and reanalysis inputs.

17 WIND ENERGY↗
DOE OSTI2024

Testing of Materials and Coatings at up to 1150°C and 300 bar for use in Oxy-Combustion Turbine

Various materials that may be used in a supercritical carbon dioxide (sCO2) oxy-fuel turbine in the 150-300 MWe size range are being evaluated in various environments of interest. The inlet of the turbine must be capable of 1,150 °C at 300 bar and the exhaust temperature is expected to be within the 725-775 °C range. The design requirements are pushing the known limits of high temperature materials. Little is known about the oxidation of the metallic alloys considered for turbine nozzles and blades or about the resilience of thermal management solutions, such as thermal barrier coatings (TBC), required to accommodate these high temperatures. The combinations of high temperature resistant materials and coatings must be tested in sCO2 to evaluate their reliability in an oxy-fuel turbine environment. A total of 13 alloys were chosen to be tested. They included bare samples, with nano deposited MCrAlY bond coat only, or with the addition of a TBC. A unique test facility was developed to expose those materials in sCO2 at up to 300 bar and 1150 °C for up to 5,000 hours. This was accomplished by placing an induction heater inside an autoclave to achieve those high temperature locally while the pressurized vessel is cooled externally. The specimens are weighed before and after exposure to determine the oxidation rate. The integrity, morphology, and composition of some of the coatings and thermally grown oxide will be investigated by scanning electron microscopy (SEM). This paper presents the up-to-date results of the testing coated and uncoated superalloys in sCO2 at up to 1150 °C and up to 300 bar performed at Southwest Research Institute.

Bocher, Florent↗
DOE OSTI2026

Oxidation of Materials and Coatings at 1000°C and 250 bar for use in Oxy-Combustion Turbine

Combinations of materials and coatings were tested in supercritical CO2 (sCO2) to evaluate their reliability in an oxy-fuel turbine being designed to operate in the 150-300 MWe size range at inlet temperatures of 1,150 °C at 300 bar and exhaust temperatures in the 725-775 °C range. Nickel alloys and stainless steels were exposed to supercritical CO2 at 1,000 °C and 250 bar for a total of over 1,500 hours. The materials were tested bare, with a nanocrystalline MCrAlY bond coat only, or with one of two types of bond coat and a thermal barrier coating. A novel test facility using a localized heat zone generated by an induction heater inside an externally cooled autoclave was developed to perform those tests. The specimens were weighed before and after exposure to determine the oxidation rate. All specimens were inspected visually, and a smaller group of coated specimens were studied using secondary electron microscopy (SEM). The integrity of the coating, and the morphology and composition of the thermally grown oxide were especially of interest for the SEM investigation. This paper presents the up-to-date results of the testing coated and uncoated superalloys in sCO2 at up to 1150 °C and up to 300 bar performed at Southwest Research Institute.

Bocher, Florent [Southwest Research Institute, San↗