Laitosmittaukset turbiinilaitoksen suorituskyvyn seurantaan ydinvoimalaitoksen vuosihuoltojen yhteydessä

Työssä kehitettiin höyryvoimalaitosprosessin tilan seurantaan laitosmittausrutiini, jolla tarkastellaan erityisesti turbiinilaitoksen suorituskykyä ennen ja jälkeen vuosihuoltojen. Laitosmittaukset on kehitetty Teollisuuden Voima Oyj:n Olkiluodon ydinvoimalaitosyksikköjen OL1 ja OL2 tarpeisiin. Mittauksilla saadaan tietoa vuosihuollon kokonaisvaikutuksista prosessiin eli muuttuiko mikään vuosihuollon aikana ja mitkä syyt johtivat muutokseen. Lisäksi säännöllisillä mittauksilla tavoitellaan pitkän aikavälin referenssitietoa prosessin tilasta. Esimerkkimittaukset tehtiin kevään 2008 vuosihuolloissa, R108 ja R208. Työssä on esitetty mittausten suorittaminen, tulosten laskenta ja tarkastelu sekä raportointi. Luotu mittausrutiini pohjautuu höyryturbiinien ja lämmönsiirtimien vastaanottokokeita käsitteleviin standardeihin sekä laitosten viimeisimpiin prosessimuutosten yhteydessä toteutettuihin suorituskykymittauksiin. Laitosmittauksista tehtiin vastaanottokokeita kevyemmät ja yksinkertaisemmat mittaustapahtumat, joilla saadaan kuitenkin riittävän luotettavaa tietoa. Tunnuslukuja, joita ei käytettävissä olevien mittatietojen avulla saatu suoraan selville tai laskettua massa- ja energiataseilla, määritettiin stationaarisen tilan mallinnusohjelmalla TEMPO:lla. Esimerkkimittaukset sujuivat hyvin ja saadut tulokset antoivat kaivattua lisätietoa vuosihuollon vaikutuksesta prosessiin. Generaattorin bruttoteho aleni OL1:llä ja pysyi ennallaan OL2:lla. OL1:n tehon aleneminen selittyi syöttöveden virtausmäärän vähenemisellä, johon vaikutti virtausmittalaitteen lähettimen vaihto. OL2:lla ei havaittu turbiiniprosessissa muutoksia, mutta lauhduttimien suorituskyky parani. Lauhduttimien suorituskyvyn paraneminen ilmeni asteisuuksien pienentymisenä, johon vaikuttivat puhdistaminen ja ilmavuotojen väheneminen.

Design and testing of an armature-reaction-compensated permanent magnet synchronous generator for island operation

At present, permanent magnet synchronous generators (PMSGs) are of great interest. Since they do not have electrical excitation losses, the highly efficient, lightweight and compact PMSGs equipped with damper windings work perfectly when connected to a network. However, in island operation, the generator (or parallel generators) alone is responsible for the building up of the network and maintaining its voltage and reactive power level. Thus, in island operation, a PMSG faces very tight constraints, which are difficult to meet, because the flux produced by the permanent magnets (PMs) is constant and the voltage of the generator cannot be controlled. Traditional electrically excited synchronous generators (EESGs) can easily meet these constraints, because the field winding current is controllable. The main drawback of the conventional EESG is the relatively high excitation loss. This doctoral thesis presents a study of an alternative solution termed as a hybrid excitation synchronous generator (HESG). HESGs are a special class of electrical machines, where the total rotor current linkage is produced by the simultaneous action of two different excitation sources: the electrical and permanent magnet (PM) excitation. An overview of the existing HESGs is given. Several HESGs are introduced and compared with the conventional EESG from technical and economic points of view. In the study, the armature-reaction-compensated permanent magnet synchronous generator with alternated current linkages (ARC-PMSG with ACL) showed a better performance than the other options. Therefore, this machine type is studied in more detail. An electromagnetic design and a thermal analysis are presented. To verify the operation principle and the electromagnetic design, a down-sized prototype of 69 kVA apparent power was built. The experimental results are demonstrated and compared with the predicted ones. A prerequisite for an ARC-PMSG with ACL is an even number of pole pairs (p = 2, 4, 6, …) in the machine. Naturally, the HESG technology is not limited to even-pole-pair machines. However, the analysis of machines with p = 3, 5, 7, … becomes more complicated, especially if analytical tools are used, and is outside the scope of this thesis. The contribution of this study is to propose a solution where an ARC-PMSG replaces an EESG in electrical power generation while meeting all the requirements set for generators given for instance by ship classification societies, particularly as regards island operation. The maximum power level when applying the technology studied here is mainly limited by the economy of the machine. The larger the machine is, the smaller is the efficiency benefit. However, it seems that machines up to ten megawatts of power could benefit from the technology. However, in low-power applications, for instance in the 500 kW range, the efficiency increase can be significant.

Soodakattilalaitosten energiantuotannon lisääminen

The aim of this thesis is to study different methods to increase the energy production of recovery boilers. This improvement is encouraged by the current energy policy and the rapid rise in energy prices, especially in electricity. In addition, the energy efficiency of the power plants is intended to be improved. There are several methods to increase the energy production. The methods taken into more accurate study are lower pressure steam for soot blowing and flue gas coolers. Energy balances are made for these two cases to check a plausible addition of power generation of turbo-generator of the steam turbine. Also, the viability issues are studied. Solvo Power Plant Simulation program is used for the energy balance research. Two case power plants are simulated to solve the balances. To solve the addition of power generation with the flue gas coolers, basic balance calculation is performed. The viabilities are also taken into account, especially the payback times of these alternatives. On the basis of the results, installing the system to the process is viable in both cases. By installing the lowest possible pressure steam system for the soot blowing, the advantages are the most significant. The investment costs are the highest but the payback time is less than 1,5 years and the profit in the next 20 years is the greatest. In the case of flue gas coolers, the results did not entirely agree with past studies. Nevertheless, installing the flue gas coolers into the process also seems to be significant and profitable.

Integration of Torrefaction with Steam Power Plant

Torrefaction is one of the pretreatment technologies to enhance the fuel characteristics of biomass. The efficient and continuous operation of a torrefaction reactor, in the commercial scale, demands a secure biomass supply, in addition to adequate source of heat. Biorefinery plants or biomass-fuelled steam power plants have the potential to integrate with the torrefaction reactor to exchange heat and mass, using available infrastructure and energy sources. The technical feasibility of this integration is examined in this study. A new model for the torrefaction process is introduced and verified by the available experimental data. The torrefaction model is then integrated in different steam power plants to simulate possible mass and energy exchange between the reactor and the plants. The performance of the integrated plant is investigated for different configurations and the results are compared.

Design of a 1 kW 150 rpm permanent-magnet synchronous generator for stand-alone wind-power applications

A program for calculating low-speed low-power synchronous machine is presented. A permanent-magnet synchronous generator for 1 kW 150 rpm is designed. Optimization of magnet’s and coil’s dimensions was made.

Wind Turbine Direct-Drive Permanent-Magnet Generator with Direct Liquid Cooling for Mass Reduction

Today’s electrical machine technology allows increasing the wind turbine output power by an order of magnitude from the technology that existed only ten years ago. However, it is sometimes argued that high-power direct-drive wind turbine generators will prove to be of limited practical importance because of their relatively large size and weight. The limited space for the generator in a wind turbine application together with the growing use of wind energy pose a challenge for the design engineers who are trying to increase torque without making the generator larger. When it comes to high torque density, the limiting factor in every electrical machine is heat, and if the electrical machine parts exceed their maximum allowable continuous operating temperature, even for a short time, they can suffer permanent damage. Therefore, highly efficient thermal design or cooling methods is needed. One of the promising solutions to enhance heat transfer performances of high-power, low-speed electrical machines is the direct cooling of the windings. This doctoral dissertation proposes a rotor-surface-magnet synchronous generator with a fractional slot nonoverlapping stator winding made of hollow conductors, through which liquid coolant can be passed directly during the application of current in order to increase the convective heat transfer capabilities and reduce the generator mass. This doctoral dissertation focuses on the electromagnetic design of a liquid-cooled direct-drive permanent-magnet synchronous generator (LC DD-PMSG) for a directdrive wind turbine application. The analytical calculation of the magnetic field distribution is carried out with the ambition of fast and accurate predicting of the main dimensions of the machine and especially the thickness of the permanent magnets; the generator electromagnetic parameters as well as the design optimization. The focus is on the generator design with a fractional slot non-overlapping winding placed into open stator slots. This is an a priori selection to guarantee easy manufacturing of the LC winding. A thermal analysis of the LC DD-PMSG based on a lumped parameter thermal model takes place with the ambition of evaluating the generator thermal performance. The thermal model was adapted to take into account the uneven copper loss distribution resulting from the skin effect as well as the effect of temperature on the copper winding resistance and the thermophysical properties of the coolant. The developed lumpedparameter thermal model and the analytical calculation of the magnetic field distribution can both be integrated with the presented algorithm to optimize an LC DD-PMSG design. Based on an instrumented small prototype with liquid-cooled tooth-coils, the following targets have been achieved: experimental determination of the performance of the direct liquid cooling of the stator winding and validating the temperatures predicted by an analytical thermal model; proving the feasibility of manufacturing the liquid-cooled tooth-coil winding; moreover, demonstration of the objectives of the project to potential customers.

Strong magnetic field pulse generator

High magnetic fields and extremely low temperatures are essential in the study of new semiconductor materials for example in the field of spintronics. Typical phenomenons that arise in such conditions are: Hall Effect, Anomalous Hall effect and Shubnikov de-Haas effect. In this thesis a device capable for such conditions was described. A strong magnetic field pulse generator situated in the laboratory of physics and the Lappeenranta University of Technology was studied. The device is introduced in three parts. First one is the pulsed field magnetic generator, which is responsible for generating the high magnetic field. Next one is the measurement systems, which are responsible for monitoring the sample and the system itself. The last part describes the cryostat system, which allows the extremely cold temperatures in the system.

Comparison of energy balances of steam explosion and torrefaction technologies

The present study introduce two pretreatment technologies which are torrefaction and steam explosion, and compare energy balance for both technologies to investigate and compare the use of these technologies to improve pelletization. In this research, torrefaction and steam explosion pretreatments were accomplished on the mixed small diameter wood (70%) with moisture content of 40 %, and logging residues (30%) with moisture content of 45 % at temperature 230 ̊C, and treatment duration 10 min. Competing methods were evaluated, and the results showed higher volumetric energy for steam explosion pellet than torrefied pellet.

Lightweight, liquid-cooled, direct-drive generator for highpower wind turbines: motivation, concept, and performance

Thesis: A liquid-cooled, direct-drive, permanent-magnet, synchronous generator with helical, double-layer, non-overlapping windings formed from a copper conductor with a coaxial internal coolant conduit offers an excellent combination of attributes to reliably provide economic wind power for the coming generation of wind turbines with power ratings between 5 and 20MW. A generator based on the liquid-cooled architecture proposed here will be reliable and cost effective. Its smaller size and mass will reduce build, transport, and installation costs. Summary: Converting wind energy into electricity and transmitting it to an electrical power grid to supply consumers is a relatively new and rapidly developing method of electricity generation. In the most recent decade, the increase in wind energy’s share of overall energy production has been remarkable. Thousands of land-based and offshore wind turbines have been commissioned around the globe, and thousands more are being planned. The technologies have evolved rapidly and are continuing to evolve, and wind turbine sizes and power ratings are continually increasing. Many of the newer wind turbine designs feature drivetrains based on Direct-Drive, Permanent-Magnet, Synchronous Generators (DD-PMSGs). Being low-speed high-torque machines, the diameters of air-cooled DD-PMSGs become very large to generate higher levels of power. The largest direct-drive wind turbine generator in operation today, rated just below 8MW, is 12m in diameter and approximately 220 tonne. To generate higher powers, traditional DD-PMSGs would need to become extraordinarily large. A 15MW air-cooled direct-drive generator would be of colossal size and tremendous mass and no longer economically viable. One alternative to increasing diameter is instead to increase torque density. In a permanent magnet machine, this is best done by increasing the linear current density of the stator windings. However, greater linear current density results in more Joule heating, and the additional heat cannot be removed practically using a traditional air-cooling approach. Direct liquid cooling is more effective, and when applied directly to the stator windings, higher linear current densities can be sustained leading to substantial increases in torque density. The higher torque density, in turn, makes possible significant reductions in DD-PMSG size. Over the past five years, a multidisciplinary team of researchers has applied a holistic approach to explore the application of liquid cooling to permanent-magnet wind turbine generator design. The approach has considered wind energy markets and the economics of wind power, system reliability, electromagnetic behaviors and design, thermal design and performance, mechanical architecture and behaviors, and the performance modeling of installed wind turbines. This dissertation is based on seven publications that chronicle the work. The primary outcomes are the proposal of a novel generator architecture, a multidisciplinary set of analyses to predict the behaviors, and experimentation to demonstrate some of the key principles and validate the analyses. The proposed generator concept is a direct-drive, surface-magnet, synchronous generator with fractional-slot, duplex-helical, double-layer, non-overlapping windings formed from a copper conductor with a coaxial internal coolant conduit to accommodate liquid coolant flow. The novel liquid-cooling architecture is referred to as LC DD-PMSG. The first of the seven publications summarized in this dissertation discusses the technological and economic benefits and limitations of DD-PMSGs as applied to wind energy. The second publication addresses the long-term reliability of the proposed LC DD-PMSG design. Publication 3 examines the machine’s electromagnetic design, and Publication 4 introduces an optimization tool developed to quickly define basic machine parameters. The static and harmonic behaviors of the stator and rotor wheel structures are the subject of Publication 5. And finally, Publications 6 and 7 examine steady-state and transient thermal behaviors. There have been a number of ancillary concrete outcomes associated with the work including the following. X Intellectual Property (IP) for direct liquid cooling of stator windings via an embedded coaxial coolant conduit, IP for a lightweight wheel structure for lowspeed, high-torque electrical machinery, and IP for numerous other details of the LC DD-PMSG design X Analytical demonstrations of the equivalent reliability of the LC DD-PMSG; validated electromagnetic, thermal, structural, and dynamic prediction models; and an analytical demonstration of the superior partial load efficiency and annual energy output of an LC DD-PMSG design X A set of LC DD-PMSG design guidelines and an analytical tool to establish optimal geometries quickly and early on X Proposed 8 MW LC DD-PMSG concepts for both inner and outer rotor configurations Furthermore, three technologies introduced could be relevant across a broader spectrum of applications. 1) The cost optimization methodology developed as part of this work could be further improved to produce a simple tool to establish base geometries for various electromagnetic machine types. 2) The layered sheet-steel element construction technology used for the LC DD-PMSG stator and rotor wheel structures has potential for a wide range of applications. And finally, 3) the direct liquid-cooling technology could be beneficial in higher speed electromotive applications such as vehicular electric drives.

Permanent magnet synchronous generator design solution for large directdrive wind turbines: Thermal behavior of the LC DD-PMSG

Wind is one of the most compelling forms of indirect solar energy. Available now, the conversion of wind power into electricity is and will continue to be an important element of energy self-sufficiency planning. This paper is one in a series intended to report on the development of a new type of generator for wind energy; a compact, high-power, direct-drive permanent magnet synchronous generator (DD-PMSG) that uses direct liquid cooling (LC) of the stator windings to manage Joule heating losses. The main param-eters of the subject LC DD-PMSG are 8 MW, 3.3 kV, and 11 Hz. The stator winding is cooled directly by deionized water, which flows through the continuous hollow conductor of each stator tooth-coil winding. The design of the machine is to a large degree subordinate to the use of these solid-copper tooth-coils. Both steady-state and timedependent temperature distributions for LC DD-PMSG were examined with calculations based on a lumpedparameter thermal model, which makes it possible to account for uneven heat loss distribution in the stator conductors and the conductor cooling system. Transient calculations reveal the copper winding temperature distribution for an example duty cycle during variable-speed wind turbine operation. The cooling performance of the liquid cooled tooth-coil design was predicted via finite element analysis. An instrumented cooling loop featuring a pair of LC tooth-coils embedded in a lamination stack was built and laboratory tested to verify the analytical model. Predicted and measured results were in agreement, confirming the predicted satisfactory operation of the LC DD-PMSG cooling technology approach as a whole.

Droplet Deposition in the Last Stage of Steam Turbine

During the expansion of steam in turbine, the steam crosses the saturation line and hence subsequent turbine stages run under wet condition. The stages under wet condition run with low efficiency as compared to stages running with supersaturated steam and the life of the last stage cascade is reduced due to erosion. After the steam crosses the saturation line it does not condense immediately but instead it becomes supersaturated which is a meta-stable state and reversion of equilibrium results in the formation of large number of small droplets in the range of 0.05 - 1 μm. Although these droplets are small enough to follow the stream lines of vapor however some of the fog droplets are deposited on the blade surface. After deposition they coagulate into films and rivulets which are then drawn towards the trailing edge of the blade due to viscous drag of the steam. These large droplets in the range of radius 100 μm are accelerated by steam until they impact on the next blade row causing erosion. The two phenomenon responsible for deposition are inertial impaction and turbulent-diffusion. This work shall discuss the deposition mechanism in steam turbine in detail and numerically model and validate with practical data.

Computational modelling of non-equilibrium condensing steam flows in low-pressure steam turbines

The steam turbines play a significant role in global power generation. Especially, research on low pressure (LP) steam turbine stages is of special importance for steam turbine man- ufactures, vendors, power plant owners and the scientific community due to their lower efficiency than the high pressure steam turbine stages. Because of condensation, the last stages of LP turbine experience irreversible thermodynamic losses, aerodynamic losses and erosion in turbine blades. Additionally, an LP steam turbine requires maintenance due to moisture generation, and therefore, it is also affecting on the turbine reliability. Therefore, the design of energy efficient LP steam turbines requires a comprehensive analysis of condensation phenomena and corresponding losses occurring in the steam tur- bine either by experiments or with numerical simulations. The aim of the present work is to apply computational fluid dynamics (CFD) to enhance the existing knowledge and understanding of condensing steam flows and loss mechanisms that occur due to the irre- versible heat and mass transfer during the condensation process in an LP steam turbine. Throughout this work, two commercial CFD codes were used to model non-equilibrium condensing steam flows. The Eulerian-Eulerian approach was utilised in which the mix- ture of vapour and liquid phases was solved by Reynolds-averaged Navier-Stokes equa- tions. The nucleation process was modelled with the classical nucleation theory, and two different droplet growth models were used to predict the droplet growth rate. The flow turbulence was solved by employing the standard k-ε and the shear stress transport k-ω turbulence models. Further, both models were modified and implemented in the CFD codes. The thermodynamic properties of vapour and liquid phases were evaluated with real gas models. In this thesis, various topics, namely the influence of real gas properties, turbulence mod- elling, unsteadiness and the blade trailing edge shape on wet-steam flows, are studied with different convergent-divergent nozzles, turbine stator cascade and 3D turbine stator-rotor stage. The simulated results of this study were evaluated and discussed together with the available experimental data in the literature. The grid independence study revealed that an adequate grid size is required to capture correct trends of condensation phenomena in LP turbine flows. The study shows that accurate real gas properties are important for the precise modelling of non-equilibrium condensing steam flows. The turbulence modelling revealed that the flow expansion and subsequently the rate of formation of liquid droplet nuclei and its growth process were affected by the turbulence modelling. The losses were rather sensitive to turbulence modelling as well. Based on the presented results, it could be observed that the correct computational prediction of wet-steam flows in the LP turbine requires the turbulence to be modelled accurately. The trailing edge shape of the LP turbine blades influenced the liquid droplet formulation, distribution and sizes, and loss generation. The study shows that the semicircular trailing edge shape predicted the smallest droplet sizes. The square trailing edge shape estimated greater losses. The analysis of steady and unsteady calculations of wet-steam flow exhibited that in unsteady simulations, the interaction of wakes in the rotor blade row affected the flow field. The flow unsteadiness influenced the nucleation and droplet growth processes due to the fluctuation in the Wilson point.

Sähkökoneen staattorikäämityksen kehittäminen

Tämä insinöörityö tehtiin ABB:n Pitäjänmäen konetehtaalle Tahtikoneet-tulosyksikölle. Työssä tutkittiin mahdollisuuksia valmistaa murtovakovyyhtejä kestomagneettituuligeneraattoreihin, joissa vakoluku on alle yhden. Työ tehtiin tutustumalla aluksi Pitäjänmäen konetehtaan käytössä oleviin vyyhden valmistus- ja käämintämenetelmiin. Lisäksi tutkittiin erilaisia mahdollisia murtovakovyyhden valmistusmenetelmiä, joista lupaavimpia myös kokeiltiin. Saatujen kokemusten pohjalta valittiin vyyhden valmistusmenetelmä, jonka mukaan valmistettiin koe-erä. Koe-erälle suoritettiin mittauksia, joilla varmistettiin niiden sähköinen kestävyys Työn tuloksena valitulla valmistusmenetelmällä valmistettiin vyyhdet prototyyppi tuuligeneraattorin.

Vaneri- ja kertopuutehtaiden kuivatuskoneiden lämmöntalteenottojen järjestelmäselvitys

Vanerin tai kertopuun valmistusprosessissaviilun kuivaukseen käytetään suurin osa koko valmistusprosessin primäärienergiasta. Viilunkuivauskoneessa viilun sisältämä vesi siirretään tyypillisesti prosessihöyryllä lämmitettyyn viilunkuivaajan kiertoilmaan höyrystämällä ja poistetaanviilunkuivaajasta poistoilman mukana. Viilunkuivaajan poistoilma on lämmintä jaerittäin suuren kosteuspitoisuutensa takia sisältää runsaasti energiaa. Tyypillisellä viilunkuivaajalla poistoilmaan sitoutunut lämpöteho vaihtelee prosessiolosuhteista riippuen välillä 2,7-5,7 MW. Diplomityössä tutkittiin viilunkuivaajan poistoilman sisältämän lämmön talteenottoa laitteistolla, johon kuuluu lämmöntalteenottopesuri, jossa poistoilmalla lämmitetään tuotantolaitoksen tukkipuun hautomon kiertovettä sekä ilma-ilma-lämmönsiirrin, jolla lämmitetään pesurista poistuvan ilman jäännöslämmöllä ulkoilmaa tehdassalin tuloilmakäyttöön. Työn tavoitteena oli kehittää lämmöntalteenottojärjestelmän suunnittelua, mitoitusta ja ajotapoja. Työssä analysoitiin teoreettisesti pesuria ja ilmalämmönsiirrintä, kehitettiin lämmöntalteenottopesurin simulointimenetelmä ja mitattiin toiminnassa olevia talteenottolaitteistoja. Tutkimuksessa todettiin lämmöntalteenottohyötysuhteen vaihtelevan lämmityskaudella välillä 50-70 %. Lämmöntalteenottolaitteiston pesurin veteen saatava teho riippuu ensisijaisesti viilunkuivaajan poistoilman lämpösisällöstä, joka on enimmäkseen kosteusriippuvainen ja ilmanvaihtoilmaan saatava teho ulkolämpö-tilan määräämästä tehontarpeesta. Pesurin vesijärjestelmän vaikutusmekanismit pesurin suorituskykyyn tunnistettiin ja niiden pohjalta annetaan suositukset mitoitukseen ja ajotapaan. Lämmöntalteenottolaitteiston lämpötehon tasapainottamiseen pesurin ja ilma-ilma-lämmönsiirtimen välillä mitoituksen avulla esitellään työkalut.