整体针翅管滑油冷却器强化换热及数值计算研究
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摘要
在核电站中,轴承是不可或缺的重要部件,有效地延长轴承的使用寿命是确保核电设备持续、安全、稳定运行的基础。对轴承的润滑,一般采用滑油将轴承产生的热量带出,通过冷却器得到合适的滑油温度后,重新进入轴承。因此,滑油冷却器对保障核电站的安全,起到重要作用,研究滑油冷却器的换热机理与强化特性,对提高整个核电系统的国产化率、提高核电设备可靠性,实现设备的小型化都具有重要意义。
在工程中,滑油冷却器换热管大多数采用光管,存在传热效率不高、体积大、结构复杂的不足。本文在参考大量国内外资料基础上,选用了换热效果好的整体针翅管和光管组合在一起作为换热元件,充分利用针翅和光管管间可以自支撑的特点,设计为混合管束,结合工程实际情况,将壳侧滑油流动设计为双流程,管侧冷却水设计为单流程。同时为了解滑油冷却器壳侧滑油的真实流动情况,在滑油冷却器两侧采用透明有机玻璃板,进行可视化实验研究。为弥补实验的不足,对滑油冷却器进行数值计算模拟研究。本文的主要研究工作和结果如下：
1.本文以68#汽轮机润滑油为工质,对设计的新型滑油冷却器进行了大量实验研究。通过实验发现：在润滑油进口温度55℃,冷却水进口温度24℃；油流量20.7m3/h,冷却水流量20m3/h的设计工况下,其总传热系数达到420W/(m2·K),单位体积换热量达到1190kW/m3。经过分析研究发现,滑油流速是影响滑油冷却器换热特性和阻力特性的主要因素；冷却水温度和流速对滑油冷却器的换热性能也有一定的影响,但对阻力特性影响不大；滑油冷却器的放置方式对其传热特性影响很小；通过对实验数据分析与回归,得出实验关联式,可供工程设计人员使用。
2.在此基础上,将新型滑油冷却器与双流程圆形滑油冷却器和单流程方形滑油冷却器实验结果加以对比。结果表明：新设计的滑油冷却器,在总传热系数和单位体积换热量都较高,换热性能优越,达到了强化传热和设备小型化的目的。在相同壳侧雷诺数下,新型双流程方形滑油冷却器与双流程圆形滑油冷却器相比,在设计工况下,前者的总传热系数是后者的1.1～1.3倍,单位体积换热量是后者的1.2-1.4倍,方形比圆形布管更能使滑油冷却器进一步小型化；通过对相同横截面积的双流程滑和单流程油冷却器的对比发现：双流程总传热系数和单位体积换热量分别是单流程滑油冷却器的0.73～0.88倍和0.80～0.91倍,而阻力有较大增加,单流程效率高。
3.通过对新型滑油冷却器的两侧采用透明有机玻璃板,对实验进行可视化研究,观察到润滑油不同流量时,壳侧滑油的流动情况。发现滑油并不是纯粹的单相流,同时夹杂微小气泡,在一定范围流量下,第二流程小气泡会聚和形成气弹,而第一流程任意流量时都不会出现。在此基础上分析了气泡对换热的影响机理,得到滑油在不同流量时的宝贵视频资料和照片,以供下一步分析研究。
4.由于滑油冷却器实验压力较小,一般不超过1MPa,而工程设计要求在4.5MPa,设计的滑油冷却器能否满足工程应用要求尚需要解答。本文对新设计的方形封头和壳体进行应力设计计算,并利用ANSYS软件进行应力数值模拟计算,很好的解决实验设备能否应用工程实际的问题,弥补了实验的不足,并为新研制滑油冷却器的优化选型提供依据。
5.采用FLUENT软件,对整体针翅管滑油冷却器进行数值计算模拟研究。利用多孔介质模型对壳侧滑油的速度场、温度场和压力场进行了数值模拟,得到这些滑油参数在壳侧内部的分布情况。结果表明,针翅的存在激发了流体的边界层分离和湍动,从而强化了传热,但是流体在滑油冷却器在横截面上流动不均匀,导致温度分布不均匀,数值计算结果和实验值吻合良好。
In the nuclear power plant, the bearing is an indispensable component, so effectively extending the service life of bearings is the foundation to ensure sustained, safe and stable operation for nuclear power facilities. For the lubrication of bearing, generally, we use lubrication oil to bring out the heat generated by bearing and re-enter into bearing after acquiring the right temperature with cooler. Therefore, the oil cooler is important to keep safety of nuclear power plant. Furthermore, researching the heat transfer mechanism and enhancement characteristics of oil cooler is very important to increase the localization rate of nuclear system, reliability of facilities and to achieve equipment miniaturization.
In the project, plain tubes commonly are used as heat exchanger components in the oil cooler, which have disadvantages of low heat transfer efficiency, bulky and complicated structure. On the basis of a large number of domestic and international references, in this paper, entire pin-fin tube and fluorescent tubes were chose as heat exchanger, and designed mixed bundle using their self-supporting characteristic, moreover, design shell-side oil flow to dual process and tube side of the cooling water to single side according to the actual project. Meanwhile, visible study was conducted by using the transparent plexiglass plate both sides in the oil cooler in order to obersive the real flowing situation of shell-side lubrication oil. To compensate for the lack of experiment, the numerical simulation calculations was also conducted. The main work and results of this paper are given as follows:
1. In this paper, to test new oil cooler, lots of experiments were conducted and68#turbine oil was used as working fluid. The result showed that heat transfer coefficient was420W/(m2-K))and heat per unit volume was1190kW/m3when the oil inlet temperature is55℃, cooling water inlet temperature is24℃, oil flow is20.7m3/h and cooling water flow is20m3/h. After the research, the speed of oil flow, as the key factor, was found to affect heat transfer and resistance characteristics of oil cooler. The temperature and flow of cooling water also can affect heat transfer to a certain extent and have little effect on the resistance characteristics. To oil cooler, the way of placement has little effect on heat transfer characteristics. By analysis and regressing experiment data, the experimental correlation formula was obtained, that can be used for project engineers.
2. On this base, the experiment data of dual-process round oil cooler and that of single square oil cooler were compared. And the results showed that heat transfer coefficient and heat per unit volume of new oil cooler are higher, and it also can achieve the goal of enhancing heat transfer and miniaturizing equipment. Under the same shell-side Re, compared dual-process square oil cooler to round one, the former one had1.1～1.3times overall coefficient of heat transfer,1.2-1.4times heat per unit volume and it also had0.73～0.88times overall heat transfer coefficient as well as0.80-0.91times heat per unit volume than single square oil cooler.
3. In the visible study, flowing situation of shell-side lubrication oil was observed with different flow. Some situations were found that oil was not pure single phase flow in the first flowing, mixed some small bubbles, in a certain range, in the second flow small bubbles could converge and become gas bombs, however, this situation cannot emerge within any first flow. And on the base of it, the mechanism of bubble influencing on heat transfer was analyzed and the precious video and photos were gained with different flow can be for furthermore study.
4. Because of low experimental pressure of oil cooler (<1Mpa) rather than engineering designing request (4.5Mpa), the oil cooler whether can meet the engineering requirements or not still need to be answered. In order to make sure the experiment whether can be used in practical situation or not, to compensate for the lack of experiment, and to provide a basis for designing the new oil cooler, calculation of the stress of new square head and shell and a stress numerical simulation with ansys software were conducted.
5. FLUENT software was used to study on simulation of overall pin-fin tube oil cooler data. Using porous media model to study on velocity, temperature and pressure contour of shell-side oil can help acquire the inner distribution of them. The result showed that pin-fin stimulated separation and turbulence of fluid boundary layer and enhanced heat transfer; however fluid was non-uniform flowing in the cross-section of the oil cooler and leaded to non-uniform temperature distribution. But the numerical results and experiment data were in good agreement.
在工程中,滑油冷却器换热管大多数采用光管,存在传热效率不高、体积大、结构复杂的不足。本文在参考大量国内外资料基础上,选用了换热效果好的整体针翅管和光管组合在一起作为换热元件,充分利用针翅和光管管间可以自支撑的特点,设计为混合管束,结合工程实际情况,将壳侧滑油流动设计为双流程,管侧冷却水设计为单流程。同时为了解滑油冷却器壳侧滑油的真实流动情况,在滑油冷却器两侧采用透明有机玻璃板,进行可视化实验研究。为弥补实验的不足,对滑油冷却器进行数值计算模拟研究。本文的主要研究工作和结果如下：
1.本文以68#汽轮机润滑油为工质,对设计的新型滑油冷却器进行了大量实验研究。通过实验发现：在润滑油进口温度55℃,冷却水进口温度24℃；油流量20.7m3/h,冷却水流量20m3/h的设计工况下,其总传热系数达到420W/(m2·K),单位体积换热量达到1190kW/m3。经过分析研究发现,滑油流速是影响滑油冷却器换热特性和阻力特性的主要因素；冷却水温度和流速对滑油冷却器的换热性能也有一定的影响,但对阻力特性影响不大；滑油冷却器的放置方式对其传热特性影响很小；通过对实验数据分析与回归,得出实验关联式,可供工程设计人员使用。
2.在此基础上,将新型滑油冷却器与双流程圆形滑油冷却器和单流程方形滑油冷却器实验结果加以对比。结果表明：新设计的滑油冷却器,在总传热系数和单位体积换热量都较高,换热性能优越,达到了强化传热和设备小型化的目的。在相同壳侧雷诺数下,新型双流程方形滑油冷却器与双流程圆形滑油冷却器相比,在设计工况下,前者的总传热系数是后者的1.1～1.3倍,单位体积换热量是后者的1.2-1.4倍,方形比圆形布管更能使滑油冷却器进一步小型化；通过对相同横截面积的双流程滑和单流程油冷却器的对比发现：双流程总传热系数和单位体积换热量分别是单流程滑油冷却器的0.73～0.88倍和0.80～0.91倍,而阻力有较大增加,单流程效率高。
3.通过对新型滑油冷却器的两侧采用透明有机玻璃板,对实验进行可视化研究,观察到润滑油不同流量时,壳侧滑油的流动情况。发现滑油并不是纯粹的单相流,同时夹杂微小气泡,在一定范围流量下,第二流程小气泡会聚和形成气弹,而第一流程任意流量时都不会出现。在此基础上分析了气泡对换热的影响机理,得到滑油在不同流量时的宝贵视频资料和照片,以供下一步分析研究。
4.由于滑油冷却器实验压力较小,一般不超过1MPa,而工程设计要求在4.5MPa,设计的滑油冷却器能否满足工程应用要求尚需要解答。本文对新设计的方形封头和壳体进行应力设计计算,并利用ANSYS软件进行应力数值模拟计算,很好的解决实验设备能否应用工程实际的问题,弥补了实验的不足,并为新研制滑油冷却器的优化选型提供依据。
5.采用FLUENT软件,对整体针翅管滑油冷却器进行数值计算模拟研究。利用多孔介质模型对壳侧滑油的速度场、温度场和压力场进行了数值模拟,得到这些滑油参数在壳侧内部的分布情况。结果表明,针翅的存在激发了流体的边界层分离和湍动,从而强化了传热,但是流体在滑油冷却器在横截面上流动不均匀,导致温度分布不均匀,数值计算结果和实验值吻合良好。
In the nuclear power plant, the bearing is an indispensable component, so effectively extending the service life of bearings is the foundation to ensure sustained, safe and stable operation for nuclear power facilities. For the lubrication of bearing, generally, we use lubrication oil to bring out the heat generated by bearing and re-enter into bearing after acquiring the right temperature with cooler. Therefore, the oil cooler is important to keep safety of nuclear power plant. Furthermore, researching the heat transfer mechanism and enhancement characteristics of oil cooler is very important to increase the localization rate of nuclear system, reliability of facilities and to achieve equipment miniaturization.
In the project, plain tubes commonly are used as heat exchanger components in the oil cooler, which have disadvantages of low heat transfer efficiency, bulky and complicated structure. On the basis of a large number of domestic and international references, in this paper, entire pin-fin tube and fluorescent tubes were chose as heat exchanger, and designed mixed bundle using their self-supporting characteristic, moreover, design shell-side oil flow to dual process and tube side of the cooling water to single side according to the actual project. Meanwhile, visible study was conducted by using the transparent plexiglass plate both sides in the oil cooler in order to obersive the real flowing situation of shell-side lubrication oil. To compensate for the lack of experiment, the numerical simulation calculations was also conducted. The main work and results of this paper are given as follows:
1. In this paper, to test new oil cooler, lots of experiments were conducted and68#turbine oil was used as working fluid. The result showed that heat transfer coefficient was420W/(m2-K))and heat per unit volume was1190kW/m3when the oil inlet temperature is55℃, cooling water inlet temperature is24℃, oil flow is20.7m3/h and cooling water flow is20m3/h. After the research, the speed of oil flow, as the key factor, was found to affect heat transfer and resistance characteristics of oil cooler. The temperature and flow of cooling water also can affect heat transfer to a certain extent and have little effect on the resistance characteristics. To oil cooler, the way of placement has little effect on heat transfer characteristics. By analysis and regressing experiment data, the experimental correlation formula was obtained, that can be used for project engineers.
2. On this base, the experiment data of dual-process round oil cooler and that of single square oil cooler were compared. And the results showed that heat transfer coefficient and heat per unit volume of new oil cooler are higher, and it also can achieve the goal of enhancing heat transfer and miniaturizing equipment. Under the same shell-side Re, compared dual-process square oil cooler to round one, the former one had1.1～1.3times overall coefficient of heat transfer,1.2-1.4times heat per unit volume and it also had0.73～0.88times overall heat transfer coefficient as well as0.80-0.91times heat per unit volume than single square oil cooler.
3. In the visible study, flowing situation of shell-side lubrication oil was observed with different flow. Some situations were found that oil was not pure single phase flow in the first flowing, mixed some small bubbles, in a certain range, in the second flow small bubbles could converge and become gas bombs, however, this situation cannot emerge within any first flow. And on the base of it, the mechanism of bubble influencing on heat transfer was analyzed and the precious video and photos were gained with different flow can be for furthermore study.
4. Because of low experimental pressure of oil cooler (<1Mpa) rather than engineering designing request (4.5Mpa), the oil cooler whether can meet the engineering requirements or not still need to be answered. In order to make sure the experiment whether can be used in practical situation or not, to compensate for the lack of experiment, and to provide a basis for designing the new oil cooler, calculation of the stress of new square head and shell and a stress numerical simulation with ansys software were conducted.
5. FLUENT software was used to study on simulation of overall pin-fin tube oil cooler data. Using porous media model to study on velocity, temperature and pressure contour of shell-side oil can help acquire the inner distribution of them. The result showed that pin-fin stimulated separation and turbulence of fluid boundary layer and enhanced heat transfer; however fluid was non-uniform flowing in the cross-section of the oil cooler and leaded to non-uniform temperature distribution. But the numerical results and experiment data were in good agreement.
引文
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