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9th International Conference on Compressors and their Systems IOP Publishing IOP Conf. Series: Materials Science and Engineering 90 (2015) 012062 doi:10.1088/1757-899X/90/1/012062 Thrust loads act in both directions, depending on the operating point, necessitating a double-sided thrust bearing design. To support heavier loads acting in one direction, the corresponding side of the thrust bearing was configured to be a hydrostatic bearing with higher capacity than the hydrodynamic bearing on the opposite face. 4.4 Material choices Using expertise within Spirax Sarco, material choices were made for the critical components in areas that would be exposed to steam. Of concern was the need to have impellers that would last for extended periods when exposed, not only to dry saturated steam but also to impact by water droplets from wet steam reaching the turbine or condensation taking place within the turbine. Some research gave assurance that titanium provides good erosion resistance in this environment. The light weight, high strength and reasonable machinability of titanium also made it a natural choice for this application. At the conclusion of an endurance running test, the impeller, in particular, was examined for signs of erosion. After 1000 hrs there was no visible damage or measurable weight loss. Other components in contact with the steam such as the volute and nozzles were made from 316 stainless steel and have been found to give excellent service 4.5 Over speed Avoidance System. It was necessary to design a system that would prevent the generator ‘running away’ in the event of grid loss or a failure of the inverter. Traditional low speed machines may be controlled by ‘governor’ systems that shut off the steam supply as the speed rises. In this case the low inertia of the machine giving rise to very high potential acceleration rates means that such a system would not act quickly enough. The system employed has a fast acting steam shut-off valve on the inlet to the turbine that is directly operated in the event of grid loss or other potential over speed event. This valve is pneumatically operated with a normally closed function so that in the event of loss of air pressure or power it will close. In the event of failure of this valve, the slower acting, inlet control valve was also designed to close automatically. A secondary system was designed to act with the steam valves: In the event of grid loss, other over speed event or inverter fault the generator windings are connected via a pair of fail-safe contactors to air-cooled resistors that are sized to absorb the output of the generator until the steam valves operate. These systems are designed to operate, even in the event of a failure of the central controller. Thorough testing has proved the efficacy of this system under a number of dual failure modes. 5. Performance testing A rig was constructed to test the microturbine package across a range of steam and environmental conditions. It was important to provide an installation that matches conditions with industrial steam users. The unit was installed in parallel with a pressure reducing valve, and the facility to vary running conditions and record test parameters as enabled. The test rig was supplied with a 30BarG steam supply reduced to test pressures in the range of 4 to 14 BarG. The supply of saturated steam was conditioned via a steam separator. Temperature and pressure measurements were used to confirm saturated conditions. A valve placed downstream of the microturbine provided the facility to control the load, mimicking a downstream application. A power meter was used to measure the net power output from the prototype package. An inline variable area steam flow meter was used to measure the steam mass flow rates passing into the microturbine. The unit was tested at a wide range of conditions, with varying upstream and downstream pressures resulting in a range of steam mass flow rates passing through the device. Power output was recorded at each set of conditions. The plot shown in Figure 8 illustrates the power output recorded over a range 9PDF Image | IOP Science The Development of a Small High Speed Steam Microturbine Generator System
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