Numerical analysis of erosion of the rotor labyrinth seal in a geothermal turbine

Excessive erosion of the labyrinth seal of a 110 MW geothermal turbine has been investigated. This study used computational fluid dynamics (CFD) and aims to identify one cause of erosion and a possible solution for substantially reducing it. The predictions were based upon a numerical calculation using a CFD model of the labyrinth seal with a water/steam flow containing hard solid particles and solved with a commercial CFD code: Fluent V5.0. The results confirmed the existence of flow conditions that play a major role in the rotor labyrinth seal erosion. Afterwards, the flow path was simulated with changes of rotor labyrinth seal geometry, which are indeed feasible of being implemented. The results confirmed that it is possible to reduce the erosion process by approximately 80% by incorporating a steam flow deflector in the fourth stage diaphragm, which changes the steam flow direction in the inlet zone to the rotor labyrinth seal channel, resulting in a reduction in steam volumetric mass flow and hard particle velocity by about 44%.