Design and implementation of the ESEO spacecraft simulator

The thesis work is developed under the European Student Earth Orbiter (ESEO) project supported by the European Space Agency (ESA) in order to help prepare a well-qualified space-engineering workforce for Europe's future. In the following chapters we are going to analyse how to simulate some ESEO subsystem. First of all, the Thermal Subsystem that evaluates the temperature evolution of on-board instruments. For this purpose, simulating also the orbital and attitude dynamics of the spacecraft, it is necessary in order to evaluate external environmental fluxes. The Power Subsystem will be the following step and it models the ability of a spacecraft to produce and store electrical energy. Finally, we will integrate in our software a block capable of simulating the communication link between the satellite and the Ground Station (GS). This last step is designed and validated during the thesis preparation.

Structural verification of the ESEO spacecraft: from launch loads analysis to composite panels verification

The present thesis work was performed in the frame of ESEO (European Student Earth Orbiter) project. The activities that are described in this document were carried out in the Microsatellites and Space Micro systems Lab led by Professor Paolo Tortora and in ALMASpace company facilities. The thesis deals with ESEO structural analysis, at system and unit level, and verification: after determining the design limit loads to be applied to the spacecraft as an envelope of different launchers load profiles, a finite element structural analysis was performed on the model of the satellite in order to ensure the capability to withstand the loads encountered during the launch; all the analyses were performed according to ESA standards and using the software MSC NASTRAN SIMXPERT. Amplification factors were derived and used to determine loads to be considered at unit level. In particular structural analyses were carried out on the GPS unit, the payload developed for ESEO by students of University of Bologna and results were used in the preparation of GPS payload design definition file. As for the verification phase a study on the panels and inserts to be used in the spacecraft was performed: different designs were created exploiting methods to optimize weight and mechanical behavior. The configurations have been analyzed and results compared to select the final design.

Design of a GNSS receiver for the ESEO mission

This thesis was carried out inside the ESA's ESEO mission and focus in the design of one of the secondary payloads carried on board the spacecraft: a GNSS receiver for orbit determination. The purpose of this project is to test the technology of the orbit determination in real time applications by using commercial components. The architecture of the receiver includes a custom part, the navigation computer, and a commercial part, the front-end, from Novatel, with COCOM limitation removed, and a GNSS antenna. This choice is motivated by the goal of demonstrating the correct operations in orbit, enabling a widespread use of this technology while lowering the cost and time of the device’s assembly. The commercial front-end performs GNSS signal acquisition, tracking and data demodulation and provides raw GNSS data to the custom computer. This computer processes this raw observables, that will be both transferred to the On-Board Computer and then transmitted to Earth and provided as input to the recursive estimation filter on-board, in order to obtain an accurate positioning of the spacecraft, using the dynamic model. The main purpose of this thesis, is the detailed design and development of the mentioned GNSS receiver up to the ESEO project Critical Design Review, including requirements definition, hardware design and breadboard preliminary test phase design.

Whole ship energy optimization: the case study of a chemical tanker

La presente dissertazione investiga la possibilità di ottimizzare l’uso di energia a bordo di una nave per trasporto di prodotti chimici e petrolchimici. Il software sviluppato per questo studio può essere adattato a qualsiasi tipo di nave. Tale foglio di calcolo fornisce la metodologia per stimare vantaggi e miglioramenti energetici, con accuratezza direttamente proporzionale ai dati disponibili sulla configurazione del sistema energetico e sui dispositivi installati a bordo. Lo studio si basa su differenti fasi che permettono la semplificazione del lavoro; nell’introduzione sono indicati i dati necessari per svolgere un’accurata analisi ed è presentata la metodologia adottata. Inizialmente è fornita una spiegazione sul layout dell’impianto, sulle sue caratteristiche e sui principali dispositivi installati a bordo. Vengono dunque trattati separatamente i principali carichi, meccanico, elettrico e termico. In seguito si procede con una selezione delle principali fasi operative della nave: è seguito tale approccio in modo da comprendere meglio la ripartizione della richiesta di potenza a bordo della nave e il suo sfruttamento. Successivamente è svolto un controllo sul dimensionamento del sistema elettrico: ciò aiuta a comprendere se la potenza stimata dai progettisti sia assimilabile a quella effettivamente richiesta sulla nave. Si ottengono in seguito curve di carico meccanico, elettrico e termico in funzione del tempo per tutte le fasi operative considerate: tramite l’uso del software Visual Basic Application (VBA) vengono creati i profili di carico che possono essere gestiti nella successiva fase di ottimizzazione. L’ottimizzazione rappresenta il cuore di questo studio; i profili di potenza ottenuti dalla precedente fase sono gestiti in modo da conseguire un sistema che sia in grado di fornire potenza alla nave nel miglior modo possibile da un punto di vista energetico. Il sistema energetico della nave è modellato e ottimizzato mantenendo lo status quo dei dispositivi di bordo, per i quali sono considerate le configurazioni di “Load following”, “two shifts” e “minimal”. Una successiva investigazione riguarda l’installazione a bordo di un sistema di accumulo di energia termica, così da migliorare lo sfruttamento dell’energia disponibile. Infine, nella conclusione, sono messi a confronto i reali consumi della nave con i risultati ottenuti con e senza l’introduzione del sistema di accumulo termico. Attraverso la configurazione “minimal” è possibile risparmiare circa l’1,49% dell’energia totale consumata durante un anno di attività; tale risparmio è completamente gratuito poiché può essere raggiunto seguendo alcune semplici regole nella gestione dell’energia a bordo. L’introduzione di un sistema di accumulo termico incrementa il risparmio totale fino al 4,67% con un serbatoio in grado di accumulare 110000 kWh di energia termica; tuttavia, in questo caso, è necessario sostenere il costo di installazione del serbatoio. Vengono quindi dibattuti aspetti economici e ambientali in modo da spiegare e rendere chiari i vantaggi che si possono ottenere con l’applicazione di questo studio, in termini di denaro e riduzione di emissioni in atmosfera.

Space charge and dielectric response measurements to assess insulation aging of low-voltage cables used in nuclear power plants

The current design life of nuclear power plant (NPP) could potentially be extended to 80 years. During this extended plant life, all safety and operationally relevant Instrumentation & Control (I&C) systems are required to meet their designed performance requirements to ensure safe and reliable operation of the NPP, both during normal operation and subsequent to design base events. This in turn requires an adequate and documented qualification and aging management program. It is known that electrical insulation of I&C cables used in safety related circuits can degrade during their life, due to the aging effect of environmental stresses, such as temperature, radiation, vibration, etc., particularly if located in the containment area of the NPP. Thus several condition monitoring techniques are required to assess the state of the insulation. Such techniques can be used to establish a residual lifetime, based on the relationship between condition indicators and ageing stresses, hence, to support a preventive and effective maintenance program. The object of this thesis is to investigate potential electrical aging indicators (diagnostic markers) testing various I&C cable insulations subjected to an accelerated multi-stress (thermal and radiation) aging.

Design of an indirectly fired gas turbine integrated with an organic rankine cycle unit for combined heat and power production

In the last years, the European countries have paid increasing attention to renewable sources and greenhouse emissions. The Council of the European Union and the European Parliament have established ambitious targets for the next years. In this scenario, biomass plays a prominent role since its life cycle produces a zero net carbon dioxide emission. Additionally, biomass can ensure plant operation continuity thanks to its availability and storage ability. Several conventional systems running on biomass are available at the moment. Most of them are performant either in the large-scale or in the small power range. The absence of an efficient system on the small-middle scale inspired this thesis project. The object is an innovative plant based on a wet indirectly fired gas turbine (WIFGT) integrated with an organic Rankine cycle (ORC) unit for combined heat and power production. The WIFGT is a performant system in the small-middle power range; the ORC cycle is capable of giving value to low-temperature heat sources. Their integration is investigated in this thesis with the aim of carrying out a preliminary design of the components. The targeted plant output is around 200 kW in order not to need a wide cultivation area and to avoid biomass shipping. Existing in-house simulation tools are used: They are adapted to this purpose. Firstly the WIFGT + ORC model is built; Zero-dimensional models of heat exchangers, compressor, turbines, furnace, dryer and pump are used. Different fluids are selected but toluene and benzene turn out to be the most suitable. In the indirectly fired gas turbine a pressure ratio around 4 leads to the highest efficiency. From the thermodynamic analysis the system shows an electric efficiency of 38%, outdoing other conventional plants in the same power range. The combined plant is designed to recover thermal energy: Water is used as coolant in the condenser. It is heated from 60°C up to 90°C, ensuring the possibility of space heating. Mono-dimensional models are used to design the heat exchange equipment. Different types of heat exchangers are chosen depending on the working temperature. A finned-plate heat exchanger is selected for the WIFGT heat transfer equipment due to the high temperature, oxidizing and corrosive environment. A once-through boiler with finned tubes is chosen to vaporize the organic fluid in the ORC. A plate heat exchanger is chosen for the condenser and recuperator. A quasi-monodimensional model for single-stage axial turbine is implemented to design both the WIFGT and the ORC turbine. The system simulation after the components design shows an electric efficiency around 34% with a decrease by 10% compared to the zero-dimensional analysis. The work exhibits the system potentiality compared to the existing plants from both technical and economic point of view.