CFDOFAIRFLOWINHYDROPOWERGENERATORS
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1 CFDOFAIRFLOWINHYDROPOWERGENERATORS Pirooz Moradnia Göteborg-Sweden Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 1/3
2 Problem Definition Half of the electricity generation in Sweden from hydroelectric power generation Modifications to the existing units significant contributions to the total energy production Increasedpoweroutput moreheattoberemoved Two large sources of energy losses in the generators: thermal and ventilation losses - The electric resistance in the generator coils heattoberemoved -Aircoolingoftherotorandthestator ventilation losses Thestatorshouldbecooledbyairflowingthroughthestatorairchannels Focus of the present work: axially cooled generators Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
3 Generator Rotor-Therotatingpart: Magnetic poles with coils Drivenbytheturbine Stator- The stationary part: Windings Cooling channels The electric current is induced in the stator windings by the relative motion of the rotor poles Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 3/3
4 Case study Generator at Uppsala University(SVANTE) Previously an electric motor axialrowsofstatorcoolingchannels 1coolingchannelsineachrow 1rotorpoles Rotational speed: 5 rpm Innerradiusofthestator: 3.5cm Outerradiusofthestator: 3.7cm Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
5 Geometry in OpenFOAM A 1/1 sector in the tangential direction Symmetri-plane in the middle channelrows 9channelsineachrow 1pole Low-Re Launder-Sharma turbulence model No inlet and outlet boundaries noprescribedmassflow Air recirculating in an extra space computed mass flow Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 5/3
6 Stator cooling channels Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
7 Cases Frozen rotor concept: MRFSimpleFOAM(MRF = Multiple Reference Frames) u I t + ( u R u I ) + Ω u I = (p/ρ) + ν ( u I ) Low-Re Launder-Sharma turbulence model u I = k t + (Uk) D k,eff k = G ( ε + D) ε t + (U ε) D ε,eff ε = C ε1 G ε k C ε εf k + E Mesh generated with blockmesh(parameterized m script) Atotalof1cases:7rotordesigns,eachwith abasestator, C# abaffledstator, C#S abaffledstatorandfanbladesontherotor, C#F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 7/3
8 Poleandstatordesigninalltestcases Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
9 Volume Flow Distributions 1 x 1 1 C1 C1S C1F 1 x 1 1 C CS CF 1 x 1 1 C3 C3S C3F 1 x 1 1 C CS CF 1 x 1 1 C5 C5S C5F 1 x 1 1 C CS CF 1 x 1 1 C7 C7S C7F Volume flow, Upper row [m 3 /s] Channel # Channel # Channel # Channel # Channel # Channel # Channel # 1 x 1 1 C1 C1S C1F 1 x 1 1 C CS CF 1 x 1 1 C3 C3S C3F 1 x 1 1 C CS CF 1 x 1 1 C5 C5S C5F 1 x 1 1 C CS CF 1 x 1 1 C7 C7S C7F Volume flow, Lower row [m 3 /s] Channel # Channel # Channel # Channel # Channel # Channel # Channel # Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 9/3
10 Remarsk About Volume Flow Distributions Volume flows: smallest in cases without stator baffles, C# largestincaseswithbothstatorbafflesandfanblades, C#F C1 negativevolumeflows airsuckedinthechannelsfromoutsidethestator Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 1/3
11 Case Specifications and Rotor Axial Power Case Pole remarks Rotoraxialpower(W) (Ė = Ėpress + Ėvisc) name design Base Case Stator Baffle Fan Blade Ė press Ė visc Ė press Ė visc Ė press Ė visc C C Reduced areas C3 Pole supports C Rounded pole front C5 Rounded pole edges C More rounded pole edges C7 Halfplannedtopfront Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 11/3
12 Rotor axial Power vs volume flow E(C p ) Rotor Effekt(W) E(C ν ) E(CS p ) E(CS ) ν E(CF p ) E(CF ν ) Q(C1),(m 3 /s).1. Q(C),(m 3 /s).1. Q(C3),(m 3 /s).1. Q(C),(m 3 /s).1. Q(C5),(m 3 /s).1. Q(C),(m 3 /s).1. Q(C7),(m 3 /s) Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 1/3
13 The rotor power divided into: viscouspart, Ė visc pressurepart, Ė press Ėpress >> Ėvisc Remarks About Rotor Axial Power C# requiring more axial power than C#S(larger volume flows) The stator baffles reduce the losses Thehighestrotoraxialpowerrequiredby C#F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 13/3
14 Recirculation Zones in the Upper Stator Channels Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 1/3
15 Recirculation Zones in the Lower Stator Channels Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 15/3
16 Remarks About Recirculation Zones in the Stator Channels The shaded areas show the recirculation zones in the stator channels Cases without fan blades: a large recirculation zone at the downstream of the stator windings airsuckedinfromonesideofthestatorwindingsandpushedoutfromtheotherside Caseswithfanblades: considerably smaller recirculation zones airsuckedinthefrombothsides,causedbythelargepressurebuild-up Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 1/3
17 UnitVectorsoftheFlowBetweenthePoles, ( V / V ) Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 17/3
18 Remarks About Unit Vectors of the Flow Between the Poles Thin red curves showing the regions with -axial velocity Regions of upward velocities near the stator inner wall impossible to use boundary conditions at the inlet not desirable Stator baffles: separationjustundertheedgeofthebaffle purely downward velocities at the inlet to the machine Fan blades: strong pressure build up driving the flow more downwards reducing the regions with upward velocities minimizing separation region under the stator baffle Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 1/3
19 Contour Lines of Axial Velocity.mm Above the Pole Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 19/3
20 Remarks About Axial Velocity Above the Pole Theaxialvelocitiesshownintheboundarylayerregionjustabovethepoles Positive sign upward velocities not desirable UpwardvelocityregionsintheairgapbetweenTherotorandthestator Stator baffle weaker upward velocities near the rotor pole(larger pressure build-up) Fanblades reducing the upward velocities even more(even larger pressure build-up) higher volume flows Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
21 Contour Lines of Radial Velocity.mm Above the Pole Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 1/3
22 Remarks About Radial Velocity Above the Pole Theradialvelocitiesshownintheboundarylayerregionjustabovethepole Negativeradialvelocitiesinthegapbetweentherotorandthestator recirculation area between the poles Caseswithfanblades recirculation area between the fan blades Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
23 Contour Lines of tangential Velocity.mm Above the Pole Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 3/3
24 Remarks About Tangential Velocity Above the Pole Tangential velocities shown in the boundary layer region just above the pole Negative sign clockwise rotation in the picture Stator baffle increased tangential velocitiez Fanblades largest tangential velocities Rounding the pole edges larger tangential velocities above the rotor Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
25 ContourLinesof( p stat p stat,ref ρ )ontopfofthepole Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 5/3
26 ContourLinesof( p stat p stat,ref ρ )onthefrontsideofthepole Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
27 ContourLinesof( p stat p stat,ref ρ )onthepolepressureside Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 7/3
28 ContourLinesof( p stat p stat,ref ρ )onthepolesuctionside Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics /3
29 ContourLinesof( p stat p stat,ref ρ ) Inside the Stator Pole design 1-7 C# C1 C C3 C C5 C C7 C#S C1S CS C3S CS C5S CS C7S C#F C1F CF C3F CF C5F CF C7F Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 9/3
30 Remarks About Pressure Distributions Thequantities p stat, p stat,ref and ρreferingtothestaticpressureineachcell,staticpressure in a reference cell, and density Thecontourlinesplottedwithrespecttothereferencevaluesinareferencecell(same position in all cases) Lower( p stat p stat,ref )neartherotorbody ρ lower static pressure stronger suction near the rotor body Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 3/3
31 Conclusions Complex flow non-uniform separation recirculation Stator baffles increasing volume flow eliminating outward flow at the inlet reducing losses Rotorfanbladesandstatorbaffles increasing volume flow minimizing recirculation in the channels high rotor axial power required Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 31/3
32 Parallel projects Incompressible RAS turbulence models in OpenFOAM-1.5.x models investigated implementations compared to the original models results verified in a backward-facing step case and compared to the experimental results ledtothechoiceoflaunder-sharma k εmodel Laminar couette flow velocity and pressure distributions compared to the analytical resutls Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 3/3
33 Future Work Measurements at Uppsala University Modifications to the geometry BuildingarigatCHALMERS Running unsteady simulations with mesh motion Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 33/3
34 Thank you! Pirooz Moradnia, Chalmers/ Applied Mechanics/ Fluid Dynamics 3/3
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