Vol 63, No 10 (2016)

Perspectives of using coal in combined-cycle gas turbine units (CCGTs), which are significantly more efficient than steam power plants, have been associated with preliminary coal gasification for a long time. Due to gasification, purification, and burning the resulting synthesis gas at an increased pressure, there is a possibility to intensify the processes occurring in them and reduce the size and mass of equipment. Physical heat evolving from gasification can be used without problems in the steam circuit of a CCGT. The downside of these opportunities is that the unit becomes more complex and expensive, and its competitiveness is affected, which was not achieved for CCGT power plants with coal gasification built in the 1990s. In recent years, based on the experience with these CCGTs, several powerful CCGTs of the next generation, which used higher-output and cost-effective gas-turbine plants (GTPs) and more advanced systems of gasification and purification of synthesis gas, were either built or designed. In a number of cases, the system of gasification includes devices of CO vapor reforming and removal of the emitted CO₂ at a high pressure prior to fuel combustion. Gasifiers with air injection instead of oxygen injection, which is common in coal chemistry, also find application. In this case, the specific cost of the power station considerably decreases (by 15% and more). In units with air injection, up to 40% air required for separation is drawn from the intermediate stage of the cycle compressor. The range of gasified coals has broadened. In order to gasify lignites in one of the projects, a transfer reactor was used. The specific cost of a CCGT with coal gasification rose in comparison with the period when such units started being designed, from 3000 up to 5500 dollars/kW.

To visualize the physical processes that occur in the journal bearings of the shafting of power generating turbosets, a technique for preliminary calculation of a set of characteristics of the journal bearings in the domain of possible movements (DPM) of the rotor journals is proposed. The technique is based on interpolation of the oil film characteristics and is designed for use in real-time diagnostic system COMPACS®. According to this technique, for each journal bearing, the domain of possible movement of the shaft journal is computed, then triangulation of the area is performed, and the corresponding mesh is constructed. At each node of the mesh, all characteristics of the journal bearing required by the diagnostic system are calculated. Via shaft-position sensors, the system measures—in the online mode—the instantaneous location of the shaft journal in the bearing and determines the averaged static position of the journals (the pivoting vector). Afterwards, continuous interpolation in the triangulation domain is performed, which allows the real-time calculation of the static and dynamic forces that act on the rotor journal, the flow rate and the temperature of the lubricant, and power friction losses. Use of the proposed method on a running turboset enables diagnosing the technical condition of the shafting support system and promptly identifying the defects that determine the vibrational state and the overall reliability of the turboset. The authors report a number of examples of constructing the DPM and computing the basic static characteristics for elliptical journal bearings typical of large-scale power turbosets. To illustrate the interpolation method, the traditional approach to calculation of bearing properties is applied. This approach is based on a Reynolds two-dimensional isothermal equation that accounts for the mobility of the boundary of the oil film continuity.

The study results of ignition of organic coal-water fuel (OCWF) compositions were considered. The main problems associated with investigation of these processes were identified. Historical perspectives of the development of coal-water composite fuel technologies in Russia and worldwide are presented. The advantages of the OCWF use as a power-plant fuel in comparison with the common coal-water fuels (CWF) were emphasized. The factors (component ratio, grinding degree of solid (coal) component, limiting temperature of oxidizer, properties of liquid and solid components, procedure and time of suspension preparation, etc.) affecting inertia and stability of the ignition processes of suspensions based on the products of coaland oil processing (coals of various types and metamorphism degree, filter cakes, waste motor, transformer, and turbine oils, water-oil emulsions, fuel-oil, etc.) were analyzed. The promising directions for the development of modern notions on the OCWF ignition processes were determined. The main reasons limiting active application of the OCWF in power generation were identified. Characteristics of ignition and combustion of coal-water and organic coal-water slurry fuels were compared. The effect of water in the composite coal fuels on the energy characteristics of their ignition and combustion, as well as ecological features of these processes, were elucidated. The current problems associated with pulverization of composite coal fuels in power plants, as well as the effect of characteristics of the pulverization process on the combustion parameters of fuel, were considered. The problems hindering the development of models of ignition and combustion of OCWF were analyzed. It was established that the main one was the lack of reliable experimental data on the processes of heating, evaporation, ignition, and combustion of OCWF droplets. It was concluded that the use of high-speed video recording systems and low-inertia sensors of temperature and gas concentration could help in providing the lacking experimental information.

The results of the experimental study of the heat-transfer crisis on heat-release surfaces of annular channels with swirl and transit flow are presented. The experiments were carried out using electric heated annular channels with one and (or) two heat-release surfaces. For the organization of transit flow on a convex heat-release surface, four longitudinal ribs were installed uniformly at its perimeter. Swirl flow was realized using a capillary wound tightly (without gaps) on the ribs. The ratio between swirl and transit flows in the annular gap was varied by applying longitudinal ribs of different height. The experiments were carried out using a closed-type circulatory system. The experimental data were obtained in a wide range of regime parameters. Both water heated to the temperature less than the saturation temperature and water-steam mixture were fed at the inlet of the channels. For the measurement of the temperature of the heat-release surfaces, chromel-copel thermocouples were used. It was shown that the presence of swirl flow on a convex heatrelease surface led to a significant decrease in critical heat flows (CHF) compared to a smooth surface. To increase CHF, it was proposed to use the interaction of swirl flows of the heat carrier. The second swirl flow was transit flow, i.e., swirl flow with the step equal to infinity. It was shown that CHF values for a channel with swirl and transit flow in all the studied range of regime parameters was higher than CHF values for both a smooth annular channel and a channel with swirl. The empirical ratios describing the dependence of CHF on convex and concave heat-release surfaces of annular channels with swirl and transit flow on the geometrical characteristics of channels and the regime parameters were obtained. The experiments were carried out at the pressure p = 3.0–16.0 MPa and the mass velocity ρw = 250–3000 kg/(m²s).

Problems of metal flow-accelerated corrosion (FAC) in the pipelines and equipment of the condensate- feeding and wet-steam paths of NPP power-generating units (PGU) are examined. Goals, objectives, and main principles of the methodology for the implementation of an integrated program of AO Concern Rosenergoatom for the prevention of unacceptable FAC thinning and for increasing operational flow-accelerated corrosion resistance of NPP EaP are worded (further the Program). A role is determined and potentialities are shown for the use of Russian software packages in the evaluation and prediction of FAC rate upon solving practical problems for the timely detection of unacceptable FAC thinning in the elements of pipelines and equipment (EaP) of the secondary circuit of NPP PGU. Information is given concerning the structure, properties, and functions of the software systems for plant personnel support in the monitoring and planning of the inservice inspection of FAC thinning elements of pipelines and equipment of the secondary circuit of NPP PGUs, which are created and implemented at some Russian NPPs equipped with VVER-1000, VVER-440, and BN-600 reactors. It is noted that one of the most important practical results of software packages for supporting NPP personnel concerning the issue of flow-accelerated corrosion consists in revealing elements under a hazard of intense local FAC thinning. Examples are given for successful practice at some Russian NPP concerning the use of software systems for supporting the personnel in early detection of secondary-circuit pipeline elements with FAC thinning close to an unacceptable level. Intermediate results of working on the Program are presented and new tasks set in 2012 as a part of the updated program are denoted. The prospects of the developed methods and tools in the scope of the Program measures at the stages of design and construction of NPP PGU are discussed. The main directions of the work on solving the problems of flow-accelerated corrosion of pipelines and equipment in Russian NPP PGU are defined.

On Russian HPPs, conjugated closed-circuit cooling systems, where purge water is used as initial for water-treatment facilities, are widespread. For this reason, it is impossible to use general methods for the stabilization treatment of recycling water in order to prevent scale formation in the units of a system, namely, turbine condensers and cooling towers. In this paper, the methods for the decrease in the instability of recycling water using the methods of chemical engineering, such as stabilization and synchronization of flows and organization of recycles, are suggested. The results of an industrial experiment on the implementation of stabilization treatment of recycling water by the organization of recycle are given. The experiment was carried out on Kazan CHPP-3. The flow scheme involved the recycle of chemically purified water (CPW) for the heat network make-up to the closed-circuit cooling system. The experiment was carried out at three stages with the gradual change of the consumption of the recycle, namely, 0, 50, and 100 t/h. According to the results of experiments, the reliable decrease in the rate of the sedimentation was recorded on the units of the system, namely, turbine condenser and chimney-type cooling tower. This is caused by two reasons. Firstly, this is periodic excessive concentration of recycling water due to the nonstationary character of inlet and outlet flows. Secondly, this is seasonal (particularly, in the summer period) exceeding of the evaporation coefficient. As a result of stabilization and synchronization of flows and organization of recycles, the quality of clarified and chemically purified water for the heat network make-up increases and the corrosion of iron- and copper-containing structural materials decreases. A natural decrease in temperature drop on the operating turbine condensers is mentioned.