Optimisation of fuel usage and steam availability in the power and steam plant of a paper mill

This paper presents the results of a project aimed at minimising fuel usage while maximising steam availability in the power and steam plant of a large newsprint mill. The approach taken was to utilise the better regulation and plant wide optimisation capabilities of Advanced Process Control, especially Model Predictive Control (MPC) techniques. These have recently made their appearance in the pulp and paper industry but are better known in the oil and petrochemical industry where they have been used for nearly 30 years. The issue in the power and steam plant is to ensure that sufficient steam is available when the paper machines require it and yet not to have to waste too much steam when one or more of the machines suffers an outage. This is a problem for which MPC is well suited. It allows variables to be kept within declared constraint ranges, a feature which has been used, effectively, to increase the steam storage capacity of the existing plant. This has resulted in less steam being condensed when it is not required and in significant reductions in the need for supplementary firing. The incidence of steam being dump-condensed while also supplementary firing the Combined Heat & Power (CHP) plant has been reduced by 95% and the overall use of supplementary firing is less than 30% of what it was. In addition the plant runs more smoothly and requires less operator time. The yearly benefit provided by the control system is greater than £200,000, measured in terms of 2005 gas prices.

A dynamic model to predict the occurrence of skidding in wind-turbine bearings

Despite use of the best in current design practices, high-speed shaft (HSS) bearings, in a wind-turbine gearbox, continue to exhibit a high rate of premature failure. As HSS bearings operate under low loads and high speeds, these bearings are prone to skidding. However, most of the existing methods for analyzing skidding are quasi-static in nature and cannot be used to study dynamic operating conditions. This paper proposes a dynamic model, which includes gyroscopic and centrifugal effects, to study the skidding characteristics of angular-contact ball-bearings. Traction forces between rolling-elements and raceways are obtained using elastohydrodynamic (EHD) lubrication theory. Underlying gross-sliding mechanisms for pure axial loads, and combined radial and axial loads are also studied. The proposed model will enable engineers to improve bearing reliability at the design stage, by estimating the amount of skidding. © 2011 Published under licence by IOP Publishing Ltd.

Practical deployment of the brushless doubly-fed machine in a medium scale wind turbine

The Brushless Doubly-Fed Machine (BDFM) is a brushless electrical generator which allows variable speed operation with a power converter rated at only a fraction of the machine rating. This paper details an example implementation of the BDFM in a medium-scale wind turbine. Details of a simplified design procedure based on electrical and magnetic loadings are given along with the results of tests on the manufactured machine. These show that a BDFM of the scale works as expected but that the 4/8 BDFM chosen was slower and thus larger than the turbine's original induction machine. The implementation of the turbine system is discussed, including the vector-based control scheme that ensures the BDFM operates at a demanded speed and the Maximum Power Point Tracking (MPPT) scheme that selects the rotor speed that extracts the most power from the incident wind conditions.

Passive control of combustion instability in a low emissions aeroderivative gas turbine

This paper describes the conceptual ideas, the theoretical validation, the laboratory testing and the field trials of a recently patented fuel-air mixing device for use in high-pressure ratio, low emissions, gaseous-fueled gas turbines. By making the fuel-air mixing process insensitive to pressure fluctuations in the combustion chamber, it is possible to avoid the common problem of positive feedback between mixture strength and the unsteady combustion process. More specifically, a mixing duct has been designed such that fuel-air ratio fluctuations over a wide range of frequencies can be damped out by passive design means. By scaling the design in such a way that the range of damped frequencies covers the frequency spectrum of the acoustic modes in the combustor, the instability mechanism can be removed. After systematic development, this design philosophy was successfully applied to a 35:1 pressure ratio aeroderivative gas turbine yielding very low noise levels and very competitive NOx and CO measurements. The development of the new premixer is described from conceptual origins through analytic and CFD evaluation to laboratory testing and final field trials. Also included in this paper are comments about the practical issues of mixing, flashback resistance and autoignition.

Design methodology for composite structures: A small low air-speed wind turbine blade case study

A small low air-speed wind turbine blade case study is used to demonstrate the effectiveness of a materials and design selection methodology described by Monroy Aceves et al. (2008) [24] for composite structures. The blade structure comprises a shell of uniform thickness and a unidirectional reinforcement. The shell outer geometry is fixed by aerodynamic considerations. A wide range of lay-ups are considered for the shell and reinforcement. Structural analysis is undertaken using the finite element method. Results are incorporated into a database for analysis using material selection software. A graphical selection stage is used to identify the lightest blade meeting appropriate design constraints. The proposed solution satisfies the design requirements and improves on the prototype benchmark by reducing the mass by almost 50%. The flexibility of the selection software in allowing identification of trends in the results and modifications to the selection criteria is demonstrated. Introducing a safety factor of two on the material failure stresses increases the mass by only 11%. The case study demonstrates that the proposed design methodology is useful in preliminary design where a very wide range of cases should be considered using relatively simple analysis. © 2011 Elsevier Ltd.