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STEAM NOZZLES
5.1. INTRODUCTION
In steam turbines, the overall transformation of heat energy of steam into
mechanical work takes place in two stages. The available energy of steam is first
converted into kinetic energy and then this kinetic energy is transformed into mechanical
work. The first step is accomplished with devices called steam nozzles.
A steam nozzle is a duct or passage of smoothly varying cross sectional area
which converts heat energy of steam into kinetic energy. The shape of nozzle is designed
such that it will perform this conversion of energy with minimum loss.
When steam flows through a nozzle, expansion of steam takes place. During this
expansion, the pressure of steam decreases and also the heat content (Enthalpy). With the
expenditure of enthalpy, the velocity and specific volume increase. Also, with the
expansion of steam, there will be condensation of steam with varying dryness fraction.
The mass of steam passing through any section of nozzle remains constant. So,
the variation of pressure and the cross section of nozzle depend upon the velocity,
specific volume and dryness fraction of steam. The velocity increases continuously from
entrance to exit of the nozzle.
The cross section of the nozzles may be circular, rectangular, elliptical or square.
The smallest section in the nozzle is known as throat.
The nozzles are used in steam and gas turbines, jet engines, for propulsion of
rocket motors, flow measurements, in injectors for pumping water, in ejectors for
removing air from condensers etc. The major function of nozzles is to produce a jet of
steam or gas with high velocity to drive steam or gas turbines. So, the nozzles are located
just before the steam or gas turbines. When the nozzles velocity gas is produced and there
will be no question of condensation and hence dryness fraction
When the nozzles are used with steam turbines, they perform the following functions.
1. They convert part of heat energy of steam (obtained from boiler) into kinetic
energy.
2. In case of impulse turbines (details of steam turbines are given in the chapter - steam
turbines), the nozzles direct the jet of high velocity steam against the blades of rotor
which then convert the kinetic energy of steam into mechanical (shaft) work.
In case of reaction turbines, the nozzles discharge high velocity steam on to the rotor
blades. The reactive force of steam against the nozzle produces motion of rotor and work
is obtained. When a fluid is decelerated in a duct or passage (velocity decreases) causing
a rise in pressure during the travel along the stream, then the duct or passage is known as
- Diffuser. Diffusers are extensively used in centrifugal, axial flow compressors, ramjets
and combustion chambers etc.,
We study about steam nozzles only - Nozzles in which the working fluid is steam.
5.2. TYPES OF STEAM NOZZLES
There are three important types of steam nozzles:
1. Convergent nozzie.
2. Divergent nozzle.
3. Convergent - divergent nozzle.
Fig.5.2: A Nozzle
Fig 5.3 shows the expansion on P-V and T-S diagrams.
kg/sec
m2
m/sec
m3/kg
According to continuity equation, mass flow rate at any section remains constant.
So, for steady flow of fluid,
A1C1
A2C2
C
m =A. V
=
=
= constant
V s1
V s2
s
mVs = A.C
The fig.5.5 shows the variation of velocity, specific volume and area along the
length of a nozzle. It is assumed that equal pressure drop occurs in each unit length of the
nozzle.
Fig.5.5: Variation of Velocity, Specific Volume and Area along the length of a Nozzle
At high pressures, the specific volume increases at first slowly as pressure drops
while velocity increases at a faster rate. As the expansion proceeds, the specific volume
increases faster than velocity. So, as we proceed from high pressure p1 to a low pressure
p2 at the exit of the nozzle, the area decreases to a minimum and then increases resulting
convergent divergent form of the nozzle.
The point in the nozzle where area is minimum is called throat and the pressure at
the throat is called - critical pressure. At this section; the mass flow per unit area is
maximum.
The velocity of fluid at the throat of a nozzle operating at its designed pressure
ratio (when the flow rate is maximum) is equal to velocity of sound, and it is called Sonic velocity. The flow upto throat is sub sonic and the flow after throat is supersonic
(greater than velocity of sound).
In nozzles, accelerated flow takes place - the velocity increases and pressure
decreases with the flow of fluid. If the fluid velocity is less than the sound or sonic
velocity, then the area of the nozzle must decreases; i.e., the nozzle must converge which
results in converging portion. As we know, the velocity increases continuously in a nozzle
from inlet to exit.
After throat, the fluid velocity becomes greater than sonic velocity and to
accelerate flow; the area must increase or thenozzle must diverge resulting in diverging
portion of nozzle.
The ratio of fluid velocity to local sound velocity is known as - Mach
number.
The fig.5.6 shows a general form of convergent - divergent nozzle. (Also called De-lavel
nozzle)
For a steady flow process (without any accumulation of the fluid between inlet and exit),
by the principle of conservation of energy;
Energy at entrance or inlet = Energy at exit.
Work done in forcing 1kg of steam into nozzle+ Initial internal energy + Initial kinetic
energy +Initial potential energy + Heat supplied if any from the surroundings
= Work done in sending out 1 kg of steam from nozzle +Final internal energy +
Final kinetic energy + Final potential energy +Work done if any to the surroundings.
P1 v1 + u1+
1 2
C +gZ1 + q = P2 v2 +u2+
2 1
1 2
C +gZ2+ w
2 2
1 2
C = h2 +
2 1
1 2
C
2 2
This is the steady flow energy equation of a nozzle. In this equation; the effect of friction
is not considered.
5.7. FLOW OF STEAM THROUGH A CONVERGENT - DIVERGENT NOZZLE
The fig.5.7 shows a convergent - divergent nozzle.
AB '
AC
h AhB '
h A hC
hact
= h
isen
The efficiency of a nozzle generally varies from 0.85 to 0.95. The efficiency of a
nozzle depends upon the following factors:
1.
2.
3.
4.
5.
6.
7.
8.
C 22
C 21
=
+ (hd)
2
2
Neglecting the velocity of entering steam or velocity of approach;
C 22
2
(hd)
c22 = 2 hd =2000 hd
c2 = 2000 hd
= 44.72
hd
m/sec.
In actual practice, always certain amount of friction exits between steam and the
surfaces of the nozzle. This reduces the enthalpy drop by 10-15 percent and hence the exit
velocity of steam is also reduced correspondingly.
Considering the effect of friction;
c2 = 44.72 Khd
K = Nozzle efficiency or coefficient of nozzle.
5.11. VELOCITY COEFFICIENT
In the problems of nozzles, sometimes, the term velocity coefficient is used for
accounting the effects of friction.
Velocity coefficient is defined as the ratio of actual exit velocity to exit velocity
when the flow is isentropic for the same pressure drop.
Velocity coefficient =CV =
CB'
Actual heat drop
=
CC
isentropic heat drop
The velocity coefficient depends upon the dimensions of the nozzle, roughness of the
nozzle walls, velocity of flow, friction etc.
=
Let
- N/m2
- m3/kg
- N/m2
m3/kg
- m2
- m/sec.
-
We know that
p1n v1 = p2 v2n
This equation gives mass of steam in kgs/sec flowing through a nozzle for a pressure drop
from p1to p2
5.13. CRITICAL PRESSURE RATIO
From equation (4); the rate of mass flow of steam per unit is given by:
The mass flow per unit are has maximum value at 'throat' which has minimum area.
The value of pressure ratio (p2/p1) at throat can be calculated from equation (5)
corresponding to maximum value of m/A. Except the ratio (p2/p1), all other terms in this
equation are constant. So, m/A will be maximum when
is maximum.
Differentiating the above expression with respect to (p2/p1) and equating to zero for a
maximum discharge per unit area.
The ratio (p2/p1) is known as - Critical pressure ratio and its value depends upon
the value of index n. The pressure at throat is known as - Critical pressure and the ratio
of pressure at minimum cross section i.e., throat (p2) to initial pressure - pressure at
entrance (p1) is known as critical pressure ratio. The area of throat of all steam
nozzles should be designed on this ratio.
The following table gives approximate values of index n and corresponding
values of critical pressure ratio.
Initial Condition of Steam
Super heated or super saturated
Dry saturated
Wet
Value of Index n
1.300
1.135
1.113
(1.035 + 0.1 x1)
The above equation represents the local velocity of sound in steam at pressure p2
and density 2 = 1/v2. So, the velocity of steam in adiabatic and frictionless flow reaches
the velocity of sound in steam at throat and this velocity is known as - Sonic velocity.
When friction is present, sonic velocity in steam occurs just beyond throat.
The critical pressure gives the velocity of steam at throat equal to velocity of
sound. In a convergent - divergent nozzle, the flow in convergent portion of nozzle is sub
sonic (less than the velocity of sound), sonic at throat and in divergent portion, it is
supersonic (More than the velocity of sound). For a convergent - divergent nozzle, the
cross sectional area of throat fixes the mass flow through the nozzle for fixed inlet
conditions.
To increase the velocity of steam above sonic velocity (To supersonic velocity) by
expanding the steam below critical pressure, divergent portion for the nozzle is necessary.
5.15. DIAMETERS OF THROAT AND EXIT FOR MAXIMUM DISCHARGE
Consider a convergent - divergent nozzle. The fig. 5.11 shows h-s diagram for the
nozzle.
If the nozzle is convergent, then, the nozzle terminates at throat and hence throat
is the exit of the nozzle.
For a convergent - divergent nozzle; consider the flow of steam from entrance to exit.
Enthalpy drop =he = h1-h3
Velocity of steam at exit =
Mass of steam discharged
Fig. 5.12(a).
So, the divergent portion should have sufficient length so that steam has enough
time to occupy the full cross sectional area thus resulting in drop of pressure and increase
in kinetic energy. This requires gradual increase in area. In practice, the length of nozzle
from throat to exit is such that the included cone angle is about 10 as shown in Fig.
5.12(c).
5.17. SUPER SATURATED OR META STABLE FLOW
When a super heated vapour expands adiabatically or isentropically, the vapour
begins to condense when saturated vapour line is reached. As expansion continues below
this line into wet region, condensation proceeds gradually and steam becomes more and
more wet there is always a stable mixture of steam and condensate (liquid) at any point
during expansion. This type of expansion is in thermal equilibrium and is shown in Fig.
5.13 on T-s and h-s diagrams.
vapour phases is delayed. The expansion takes place very rapidly and condensation can't
keep pace with expansion and lags behind. Due to this, the steam remains in an
unnatural dry or super heated state.
The steam in such conditions is said to be 'super - saturated' or ' meta - stable'. It is
also called - Super cooled steam and its temperature at any pressure is less than the
saturation temperature; corresponding to that pressure. The flow of super saturated steam
through the nozzle is called - super saturated or meta stable or non - equilibrium flow.
Super saturation means that steam doesn't condense at the saturation temperature
corresponding to the pressure as it occurs in case of equilibrium pressure as it occurs in
case of equilibrium flow.In the state of 'super saturation', the steam is under cooled to a
temperature less than that corresponding to its pressure; hence, the density of steam
increases and hence the measured discharge increases than the calculated theoretical
discharge. Experiments showed that in the absence of dust; dry saturated steam when
suddenly expanded, doesn't condense until its density is about 8 times that of saturated
vapour of the same pressure.
The reasons for super saturated flow are:
1. The flow of steam is so rapid that it doesn't allow time for transfer of heat. It may
take about 0.001 second only for steam to travel from inlet to exit of nozzle.
2. There may not be any dust particles which generally form nucleus for
condensation. At a certain instant, the supersaturated steam condenses suddenly
to its natural state.
Thus, flow of steam through a nozzle may be regarded as either ideal adiabatic or
adiabatic flow modified by friction and super saturation.
The fig. 5.14 shows the super saturated flow on T-s and h-s diagrams.
condensation of steam DF, sufficient amount of heat is released which raises the
temperature back to saturation temperature.
Following relations may be used for solving problems on super saturated flow:
3.