A CFD and experimental investigation into a non-intrusive method for measuring cooling air mass flow rate through a synchronous generator

This paper presents a detailed methodology for a non-intrusive measurement of cooling air mass flow rate that enables an overall machine evaluation. This approach enables the simultaneous measurement of air mass flow with shaft torque at differing operating points, while minimising the change in air flow introduced by the measurement system. The impact of geometric parameters in the designed system are investigated using a detailed 180° CFD model. Special attention was paid to minimising their influence on pressure drop, mass flow rate through the machine and measurement uncertainty. Based on the results of this investigation, the system was designed and manufactured and the experimentally measured data was used to validate the CFD predictions. For the as optimal identified configuration, the flow rate is predicted to decrease by 2.2 % relative to unrestricted operation. The achieved measurement uncertainty is ±2.6 % at synchronous speed