Generator Temperature Control for Thrust Bearing and Vibration Stability
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Solution Overview
Problem
Power train assemblies in power-generating plants experience significant thrust bearing load and vibration issues due to generator shaft thermal expansion and contraction, leading to increased wear and unpredictable operation, particularly in combined cycle modes with gas and steam turbines.
Innovation Solution
An apparatus and method involving a temperature sensor and controller to monitor and adjust the delivery of cooling fluid through a heat exchange circuit, calculating target temperatures based on thrust bearing and vibration parameters to maintain consistent generator shaft temperature and reduce thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the generator shaft is exposed to cooling medium for heat dissipation, then the generator temperature is reduced, but the shaft undergoes significant thermal expansion and contraction leading to increased thrust bearing load and wear
Solution Approach 1:
The patent changes the temperature parameter of the cooling fluid dynamically using a heat exchange circuit. By adjusting the temperature of the cooling fluid (rather than using constant temperature cooling), the system reduces thermal gradients and minimizes shaft expansion/contraction while still achieving effective heat dissipation from the generator.
Solution Approach 2:
The patent implements a feedback control system where temperature sensors monitor the generator shaft temperature and thrust bearing conditions, and the controller adjusts the heat exchange circuit accordingly. This closed-loop feedback enables the system to maintain optimal temperature conditions that prevent excessive thermal expansion while ensuring adequate cooling, thereby protecting thrust bearing reliability.
2Stability of the object's composition
If the cooling fluid temperature is kept constant for stable operation, then the generator cooling is consistent, but the thrust bearing load increases due to shaft thermal expansion
Solution Approach 1:
The patent dynamically changes the cooling fluid temperature parameter through the heat exchange circuit to optimize both cooling consistency and thrust bearing load. By controlling the cooling fluid temperature to match the shaft's thermal conditions, the system maintains stable operation while minimizing thermal expansion forces on the thrust bearings.
Solution Approach 2:
The patent transitions from static constant-temperature cooling to dynamic temperature-adjusted cooling. The heat exchange circuit and control system enable the cooling fluid temperature to adapt dynamically to changing operational conditions, achieving both cooling consistency and reduced thrust bearing load through responsive temperature management.
3Power
If the generator shaft length is increased for higher power output, then the power generation capacity is improved, but the axial expansion and contraction becomes more significant affecting power train vibrations
Solution Approach 1:
The patent uses parameter changes in the cooling fluid temperature to control the shaft's thermal expansion characteristics. By adjusting the cooling fluid temperature through the heat exchange circuit, the system minimizes thermal gradients along the shaft, reducing differential expansion and the resulting vibrations that would otherwise be exacerbated by the shaft's increased length.
Solution Approach 2:
The feedback control system monitors vibration levels and shaft temperature, adjusting the heat exchange circuit to maintain optimal thermal conditions. This feedback mechanism compensates for the increased thermal mass and expansion potential of longer shafts, reducing vibrations by actively managing temperature distribution along the shaft length.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively manages thermal expansion and contraction, reducing thrust bearing load and vibration, enhancing mechanical performance and operational consistency of power train assemblies.
Implementation Method 1
a heat exchange circuit for adjusting a temperature of the cooling fluid
Implementation Method 2
Generator shafts exposed to generator cooling medium and having a relatively long length may undergo, e.g., an approximately ten to twenty Celsius degree daily temperature swing producing an axial length change of approximately one to three millimeters or more
Data Source
AI summary
The disclosure provides an apparatus including a temperature sensor configured to monitor a temperature of a generator component of a power train assembly. The power train assembly includes a power train component in thermal communication with a cooling fluid and mounted on a same shaft as the generator component. A controller is coupled to the temperature sensor and a heat exchange circuit for adjusting a temperature of the cooling fluid. The controller calculates a target temperature for the generator component based on a target thrust bearing parameter or a target vibration parameter for the power train assembly and adjusts a delivery of the cooling fluid to the power train component based on a difference between the monitored temperature and the target temperature.