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• Ramp up the pressure limit to its normal value (currently 280 psia). At some level the mode will switch from pressure control to superheat control. • Increase (and control) hot air enthalpy flux to bring the system to full load (maximum pressure and temperature at the evaporator exit). In the process of testing for reliability, however, four new major problems emerged. • First, the lack of sufficient NPSH caused the centrifugal pump to cavitate frequently. Sudden change in ambient temperature or sudden increase in the condenser fan speed starved the receiver of refrigerant and subsequently also cavitated the pump. To make things worse, the horizontal shape of the pump’s characteristic curve gave the controller a challenge to keep the unit running. • Second, small pieces of hardened metals such as weld slag, copper and aluminum shavings, bombarded the rotor and nozzle during operation and caused it to fail mechanically. Once the debris reached the area between the rotor and the nozzle, it had no means to exit and therefore, repeatedly damaged both the nozzle and the rotor. • Third, the match between the natural frequencies of the rotor blades and the second harmonics of the pressure field created by the number of stators, rotor blade number, and the angular velocity of the rotor combinations, caused the rotor to break up. Each one of these problems were thoroughly analyzed, their root cause were well identified and finally solved and retested on the Generation 2 ORC. • The solution for the pump problem was to use a regenerative pump instead of a centrifugal pump. Although the efficiency of this pump is slightly inferior, its robust operation under cavitating condition and its low NPSH requirement made it an ideal solution to the problem at hand. Even more attractive is the shape of the characteristic curve of the regenerative pump. The monotonically negative slope made system operation very stable. • The FOD problem was challenging. . At first it was believed that debris could be filtered out during the commissioning process. However, it was determined that the debris could be introduced during field service operation. Therefore a commissioning filter became permanent. • A more thorough calculation identified the high cycle fatigue failure problem at the high end of the frequency range. Prior Carrier experience for the turbomachinery used as a compressor did not require this process. The problem was solved by detuning the impeller’s natural frequency in a redesign process. These solutions were all implemented on the Generation 2 ORC which was successfully tested for over 1000 hours. 70PDF Image | ADVANCED MICROTURBINE SYSTEMS Final Report for Tasks 1 Through 4 and Task 6
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