Neural network control of a gas turbine

In this paper we explore the practical use of neural networks for controlling complex non-linear systems. The system used to demonstrate this approach is a simulation of a gas turbine engine typical of those used to power commercial aircraft. The novelty of the work lies in the requirement for multiple controllers which are used to maintain system variables in safe operating regions as well as governing the engine thrust.

Creep crack growth in cast steam turbine casing steels

The creep rupture properties of cast ½Cr½Mo¼V and 1Cr1Mo¼V alloy steel used in the manufacture of power station steam generating plant. have been investigated. The effects of constraint and geometry on the creep rupture properties are also considered. The validity of various criteria controlling macroscopic creep crack growth in cast CrMoV alloys has been examined. It is found that neither the stress intensity factor nor reference stress correlate satisfactorily the creep crack growth rates at the test temperature of 550°C. Certain minimum displacements must be achieved for crack initiation and propagation. It is found that this displacement as measured by crack opening displacement or crack aspect ratio, is the same in both compact tension and centre-cracked panel geometries, is invariant with crack length and decreases with increasing constraint. The effect of constraint on creep crack growth rate in the two geometries is less conclusive. A new model describing creep crack growth in cast CrMoV alloy steels has been developed. The model is based on the results from a numerical finite element creep analysis of the relaxation and redistribution of stress ahead of an incubating creep crack . It is found that macroscopic creep crack growth in a material undergoing either plane stress or plane strain deformation can be described by a fracture stress which is based on the Von Mises equivalent stress. It has been shown that this model is capable of rationalising all of the experimental crack velocity data from the cast CrMoV alloys. The resultant degree of data correlation is far superior to that obtained when using the stress intensity factor or reference stress. A cumulative damage creep fracture model based upon the results from the numerical analysis has been developed. It is found that the model is capable of predicting the behaviour of propagating creep cracks in cast CrMoV alloys from smooth bar creep rupture data.

The application of robotics to the turbine blade encapsulation process

A survey of the existing state-of-the-art of turbine blade manufacture highlights two operations that have not been automated namely that of loading of a turbine blade into an encapsulation die, and that of removing a machined blade from the encapsulation block. The automation of blade decapsulation has not been pursued. In order to develop a system to automate the loading of an encapsulation die a prototype mechanical handling robot has been designed together with a computer controlled encapsulation die. The robot has been designed as a mechanical handling robot of cylindrical geometry, suitable for use in a circular work cell. It is the prototype for a production model to be called `The Cybermate'. The prototype robot is mechanically complete but due to unforeseen circumstances the robot control system is not available (the development of the control system did not form a part of this project), hence it has not been possible to fully test and assess the robot mechanical design. Robot loading of the encapsulation die has thus been simulated. The research work with regard to the encapsulation die has focused on the development of computer controlled, hydraulically actuated, location pins. Such pins compensate for the inherent positional inaccuracy of the loading robot and reproduce the dexterity of the human operator. Each pin comprises a miniature hydraulic cylinder, controlled by a standard bidirectional flow control valve. The precision positional control is obtained through pulsing of the valves under software control, with positional feedback from an 8-bit transducer. A test-rig comprising one hydraulic location pin together with an opposing spring loaded pin has demonstrated that such a pin arrangement can be controlled with a repeatability of +/-.00045'. In addition this test-rig has demonstrated that such a pin arrangement can be used to gauge and compensate for the dimensional error of the component held between the pins, by offsetting the pin datum positions to allow for the component error. A gauging repeatability of +/- 0.00015' was demonstrated. This work has led to the design and manufacture of an encapsulation die comprising ten such pins and the associated computer software. All aspects of the control software except blade gauging and positional data storage have been demonstrated. Work is now required to achieve the accuracy of control demonstrated by the single pin test-rig, with each of the ten pins in the encapsulation die. This would allow trials of the complete loading cycle to take place.

A finite-element method for the solution of turbine-generation end-zone fields

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Exploration of a simple, low cost, micro gas turbine recuperator solution for a domestic combined heat and power unit

For micro gas turbines (MGT) of around 1 kW or less, a commercially suitable recuperator must be used to produce a thermal efficiency suitable for use in UK Domestic Combined Heat and Power (DCHP). This paper uses computational fluid dynamics (CFD) to investigate a recuperator design based on a helically coiled pipe-in-pipe heat exchanger which utilises industry standard stock materials and manufacturing techniques. A suitable mesh strategy was established by geometrically modelling separate boundary layer volumes to satisfy y + near wall conditions. A higher mesh density was then used to resolve the core flow. A coiled pipe-in-pipe recuperator solution for a 1 kW MGT DCHP unit was established within the volume envelope suitable for a domestic wall-hung boiler. Using a low MGT pressure ratio (necessitated by using a turbocharger oil cooled journal bearing platform) meant unit size was larger than anticipated. Raising MGT pressure ratio from 2.15 to 2.5 could significantly reduce recuperator volume. Dimensional reasoning confirmed the existence of optimum pipe diameter combinations for minimum pressure drop. Maximum heat exchanger effectiveness was achieved using an optimum or minimum pressure drop pipe combination with large pipe length as opposed to a large pressure drop pipe combination with shorter pipe length. © 2011 Elsevier Ltd. All rights reserved.

On the role of surface roughness in the aerodynamic performance and energy conversion of horizontal wind turbine blades:a review

Summary: Renewable energy is one of the main pillars of sustainable development, especially in developing economies. Increasing energy demand and the limitation of fossil fuel reserves make the use of renewable energy essential for sustainable development. Wind energy is considered to be one of the most important resources of renewable energy. In North African countries, such as Egypt, wind energy has an enormous potential; however, it faces quite a number of technical challenges related to the performance of wind turbines in the Saharan environment. Seasonal sand storms affect the performance of wind turbines in many ways, one of which is increasing the wind turbine aerodynamic resistance through the increase of blade surface roughness. The power loss because of blade surface deterioration is significant in wind turbines. The surface roughness of wind turbine blades deteriorates because of several environmental conditions such as ice or sand. This paper is the first review on the topic of surface roughness effects on the performance of horizontal-axis wind turbines. The review covers the numerical simulation and experimental studies as well as discussing the present research trends to develop a roadmap for better understanding and improvement of wind turbine performance in deleterious environments.