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Offshore Hydrokinetic Energy Conversion for Onshore Power Generation

Design comparisons have been performed for a number of different tidal energy systems, including a fully submerged, horizontal-axis electro-turbine system, similar to Verdant Tidal Turbines in New York's East River, a platform-based Marine Current Turbine, now operating in Northern Ireland's Strangford Narrows, and the Rotech Lunar Energy system, to be installed off the South Korean Coast. A fourth type of tidal energy system studied is a novel JPL/Caltech hydraulic energy transfer system that uses submerged turbine blades which are mechanically attached to adjacent high-pressure pumps, instead of to adjacent electrical turbines. The generated highpressure water streams are combined and transferred to an onshore hydroelectric plant by means of a closed-cycle pipeline. The hydraulic energy transfer system was found to be cost competitive, and it allows all electronics to be placed onshore, thus greatly reducing maintenance costs and corrosion problems. It also eliminates the expenses of conditioning and transferring multiple offshore power lines and of building offshore platforms embedded in the sea floor.

hydraulic↗

Mechanical Extraction of Power From Ocean Currents and Tides

A proposed scheme for generating electric power from rivers and from ocean currents, tides, and waves is intended to offer economic and environmental advantages over prior such schemes, some of which are at various stages of implementation, others of which have not yet advanced beyond the concept stage. This scheme would be less environmentally objectionable than are prior schemes that involve the use of dams to block rivers and tidal flows. This scheme would also not entail the high maintenance costs of other proposed schemes that call for submerged electric generators and cables, which would be subject to degradation by marine growth and corrosion. A basic power-generation system according to the scheme now proposed would not include any submerged electrical equipment. The submerged portion of the system would include an all-mechanical turbine/pump unit that would superficially resemble a large land-based wind turbine (see figure). The turbine axis would turn slowly as it captured energy from the local river flow, ocean current, tidal flow, or flow from an ocean-wave device. The turbine axis would drive a pump through a gearbox to generate an enclosed flow of water, hydraulic fluid, or other suitable fluid at a relatively high pressure [typically approx.500 psi (approx.3.4 MPa)]. The pressurized fluid could be piped to an onshore or offshore facility, above the ocean surface, where it would be used to drive a turbine that, in turn, would drive an electric generator. The fluid could be recirculated between the submerged unit and the power-generation facility in a closed flow system; alternatively, if the fluid were seawater, it could be taken in from the ocean at the submerged turbine/pump unit and discharged back into the ocean from the power-generation facility. Another alternative would be to use the pressurized flow to charge an elevated reservoir or other pumped-storage facility, from whence fluid could later be released to drive a turbine/generator unit at a time of high power demand. Multiple submerged turbine/pump units could be positioned across a channel to extract more power than could be extracted by a single unit. In that case, the pressurized flows in their output pipes would be combined, via check valves, into a wider pipe that would deliver the combined flow to a power-generating or pumped-storage facility.

Jones, Jack↗

Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved, lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbocharging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗

Process for Making Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved. lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbo-charging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗

History of Space Shuttle Main Engine Turbopump Bearing Testing at the Marshall Space Flight Center

The Space Shuttle is propelled into orbit by two solid rocket motors and three liquid fed main engines. After the solid motors fall away, the shuttle engines continue to run for a total time of 8 minutes. These engines are fed propellants by low and high pressure turbopumps. A critical part of the turbopump is the main shaft that supports the drive turbine and the pump inducer and impeller. Rolling element bearings hold the shaft in place during rotation. If the bearings were to fail, the shaft would move, allowing components to rub in a liquid oxygen or hydrogen environment, which could have catastrophic results. These bearings are required to spin at very high speeds, support radial and axial loads, and have high wear resistance without the benefit of a conventional means of lubrication. The Rocketdyne built Shuttle turbopumps demonstrated their capability to perform during launches; however, the seven hour life requirement was not being met. One of the limiting factors was the bearings. In the late 1970's, an engineering team was formed at the Marshall Space Flight Center (MSFC), to develop a test rig and plan for testing the Shuttle s main engine high pressure oxygen turbopump (HPOTP) bearings. The goals of the program were to better understand the operation of bearings in a cryogenic environment and to further develop and refine existing computer models used to predict the operational limits of these bearings. In 1982, testing began in a rig named the Bearing and Seal Material Tester or BSMT as it was commonly called. The first testing investigated the thermal margin and thermal runaway limits of the HPOTP bearings. The test rig was later used to explore potential bearing improvements in the area of increased race curvatures, new cage materials for better lubrication, new wear resistant rolling element materials, and other ideas to improve wear life. The most notable improvements during this tester s time was the incorporation of silicon nitride balls and bronze filled polytetrafluoroethylene (PTFE) cage inserts into the bearings and the anchoring of the SHABERTH bearing model and SINDA thermal computer model for cryogenic bearing analysis. In the mid 1990's, Pratt and Whitney (P&W) won the contract to deliver new high pressure turbopumps for the Shuttle s engines. P&W used two new bearing materials for the rings, Cronidur 30 and AISI 9310 steel and testing was needed on these new materials. A test rig had been designed and delivered to MSFC for testing hydrostatic bearings but with the need by Pratt to validate their bearings, the rig was reconfigured for testing of two ball bearings or a ball bearing and a roller bearing. The P&W bearings are larger than the Rocketdyne bearings and could not be installed in the BSMT. This new test rig was called the LH2 test rig and began operation in 1995. The LH2 test rig accumulated 75,000 seconds of run time in hydrogen. This test rig was valuable in two areas: validating the use of silicon nitride balls and rollers in Alternate Turbopump Development (ATD) bearings, which Pratt eventually used, and in proving the robustness of the balls and rollers after river marks appeared on the surface of the rolling elements. Individual test reports have been presented at conferences and symposiums throughout the years. This paper is a comprehensive report of all the bearing testing done at Marshall. It represents thousands of hours of dedication and labor in all engineering and technical fields that made this program a success.

Gibson, Howard↗