1. Field of the Invention
The present invention relates to systems for moving fluids among a plurality of fluid flow pathways. More particularly, the present invention relates to devices for fluid flow diversion in industrial processes, including in power generating systems, but is not limited thereto. Still more particular, the present invention relates to the mechanisms for causing movement of such diversion devices.
2. Description of the Prior Art
Effective fluid flow transfer is an important aspect of many industrial processes. In the power generation industry in particular, the effective transfer of significant volumes of fluids impacts power generation productivity and the environment. Devices designed to ensure that such fluids move from one portion of the power generation plant to another when desired aid in maximizing productivity and minimizing adverse environmental impact. However, as power generation facilities and systems increase in size, the task of fluid diversion devices becomes increasingly harder.
It is well known in the power generation industry that boilers are employed to produce steam at high temperature and pressure. That steam is used to move turbines coupled to generators. Combustible fuels are used in combustion containers such as gas turbines (for oil, gas or other fluid fuels), or boiler combustion chambers fired by solid-fuel combustibles such as coal, wood, or other solid fuels to produce the heat necessary to generate the steam. Products of that fuel combustion exit the boiler at high temperatures and can include a variety of hazardous byproducts, dependent upon the type of fuel. The high-temperature combustion or exhaust gases exiting the combustion container may be exhausted to the atmosphere through a cooling stack, transferred to a secondary energy recovery system, or both in alternation under a schedule or as conditions warrant.
Although it is easy to state that the exhaust gases can be transferred from the combustion container to an exhaust stack or to secondary recovery, the process itself is not trivial. The ducts used to contain the exhaust gas and through which the exhaust gas passes from one portion of the system to the next are very large. Some may have dimensions on the order of 15 feet, 20 feet, and 30 feet or more. The entry and exit ports of the individual components and to which the ducts are attached are necessarily similarly sized. The means for regulating the flow of the exhaust gas through those ports from one system component to another must also be similarly sized. Such means are ordinarily referred to as diverters or dampers. Dampers are designed either to allow fluids to pass through a port or to block fluids from entering a port. For example, a damper may be used to block exhaust gas entering the exhaust stack while allowing it to pass through to the energy recovery means, or to block the exhaust gas from entering the energy recovery means and allowing it to enter the exhaust stack.
The most common types of dampers used in large-scale industrial processes are guillotine dampers, louver dampers, and flap dampers. The guillotine damper is a blade that is lowered or raised into or out of the fluid path. When raised out of the path, they provide little in the way of an obstruction, resulting in little pressure drop. When lowered to block the fluid path, they block fluid passage effectively. However, guillotine dampers require extensive space and a substantial support arrangement to allow sufficient blade travel and structural integrity. Further, the actuation systems associated with guillotine dampers are relatively complex and expensive. Moreover, because it is completely out of the fluid path when raised, it goes through significant thermal cycling that can result in damper warpage. Importantly, if fluid is to be diverted among three ports, such as with the exit from the turbine to either the exhaust stack or the energy recovery, it is necessary to employ at least two guillotine dampers, one each for at least two of the ports. Guillotine dampers are therefore not suitable in all circumstances.
Louver dampers are positioned within the duct and therefore do not require extra room to employ. Moreover, because they are positioned in the fluid path, they experience less thermal cycling than do guillotine dampers. On the other hand, because they do remain in the fluid path at all times, they produce substantial pressure drops that reduce operational efficiency. Further, they are potentially subject to significant contaminant impingement and fouling. The actuation mechanisms for louver dampers are complex and, in order to reduce excess leakage, supplemental cushion air may be required. Importantly, if fluid is to be diverted among three ports, such as with the exit from the turbine to either the exhaust stack or the energy recovery, it is necessary to employ at least two louver dampers, one each for at least two of the ports. Louver dampers are therefore not suitable in all circumstances.
Flap dampers incorporate advantages of guillotine and louver dampers without similar limitations. First, the blocking element of the flap damper, the flap, can be moved completely out of the fluid path, minimizing pressure drops, and can also substantially completely block a port when in the blocking position. Second, flap dampers do not require as much operational space to employ as is required for guillotine dampers. Third, the actuation means for flap dampers tend to be less complex than for guillotine and louver dampers. Finally, a single flap damper may be used to divert fluid among three ports. Therefore, a single flap damper may be employed to replace two guillotine dampers or two louver dampers, thereby reducing costs and maintenance requirements.
Flap dampers include a flap with sealing edges for positioning within a housing frame. The flap includes a first side that comes in contact with the fluid to be diverted, and a second side that remains outside of the fluid path. Typically, for very large flap dampers, a pair of pivot arms is attached to the second side of the flap. The pivot arms are connected to an actuation system that causes the movement of the pivot arms and thus, the movement of the flap between a first position and a second position. The type of actuation system employed to cause movement of the pivot arms is dependent upon the size of the flap. For relatively small flaps, electromechanical (EM) actuators are employed. For larger flaps, hydraulic actuators are used. The EM actuators include wormgears coupled to the actuation system, and a single speed motor for rotating the wormgear. The hydraulic actuators include one or a pair of hydraulic cylinders coupled to the actuation system. An example of an effective flap damper is the IsoFlap™ damper provided by Bachmann Industries of Auburn, Me. The Bachmann flap damper includes a toggle drive system coupled to the flap.
There are advantages and disadvantages associated with each of the existing EM and hydraulic actuators presently in use with flap dampers. The EM actuators operate at a single speed and must be operated very slowly due to necessarily high reduction ratios. They are therefore unsuitable in situations where relatively rapid opening or closing is required. In addition, existing EM actuators are not sufficiently strong to be used in large-scale applications, including in modern power generation systems. The hydraulic actuators have sufficient strength for use in large systems; however, they are very complex and expensive to install and maintain. It is therefore preferable to use EM actuators whenever possible.
What is needed is a flap damper actuation system capable of causing movement of dampers of any size. What is also needed is such a damper actuation system of minimal complexity and limited maintenance requirement. Further, what is needed is a damper actuation system that may be operated at variable speed selectable as a function of the fluid diversion conditions required.
The present invention is a flap damper actuation system capable of causing movement of dampers of any size to cause the diversion of a fluid. The damper actuation system is of minimal complexity and may be operated at variable speed selectable as a function of the fluid diversion conditions required.
The damper actuation system is preferably used with a toggle drive arrangement such as is provided with the Bachmann Industries IsoFlap™ damper. The toggle drive includes a toggle tube affixed to the damper flap and coupled to the actuation system. Upon activation of the actuation system, the toggle tube is rotated from a first position to a second position, pivoting the damper flap from a first diversion position to a second diversion position. It is to be understood that the actuation system of the present invention may be employed with other types of structural means for joining the actuator and the damper flap together. However, the toggle tube is a lightweight device having minimal thermal impact while providing suitable structural integrity. The damper actuation system includes a ball screw assembly in combination with a crank arm and a variable frequency drive system to provide an electromechanical device capable of moving damper flaps that have heretofore only been moved by hydraulic actuators.
In one aspect of the invention, a system is provided for causing the movement of the moving component of a fluid flow diverter, the system including a drive frame assembly connectable to the diverter, a crank arm assembly connectable to the diverter's actuation system, a ball screw assembly connected to the drive frame assembly and including a ball screw connected to the crank arm assembly, the ball screw assembly configured to cause pivotal movement of the crank arm assembly, and a drive motor connected to the ball screw assembly to cause rotational movement of the ball screw. The ball screw assembly further includes a rotatable rod attached to the drive motor, which is preferably a variable speed motor. The ball screw attached around the rotatable rod such that as the drive motor rotates the rotatable rod, the ball screw moves linearly along the rotatable rod. The system also may include a drive lockout assembly connected between the drive motor and the ball screw assembly to regulate movement of the ball screw.
In another aspect of the invention with a flap damper diverter having a toggle tube attachment device to enable the flap, the system includes the drive frame assembly, crank arm assembly, and ball screw assembly as described above. The drive frame assembly includes a first frame plate and a second frame plate, the first frame plate and the second frame plate each including a toggle tube port for retaining the toggle tube therein. For such a diverter, the drive frame assembly further includes a pivot pin rotatably affixed to the first drive frame plate and the second drive frame plate, the pivot pin further rotatably connected to the ball screw assembly. Also, the crank arm assembly preferably includes a first crank arm plate, a second crank arm plate and a toggle tube bushing, wherein the toggle tube bushing retains the toggle tube therein, the first crank arm plate and the second crank arm plate each including at a first end thereof a bushing port for retaining therein the toggle tube bushing, and wherein the first crank arm plate and the second crank arm plate each includes at a second end thereof attachment pins for attaching the first crank arm plate and the second crank arm plate to the ball screw. Yet further, the ball screw assembly includes a rotatable rod attached to the drive motor, the ball screw attached around the rotatable rod such that as the drive motor rotates the rotatable rod, the ball screw moves linearly along the rotatable rod, and a support plate for rotatably retaining the rotatable rod thereon, and wherein the support plate includes at a first end thereof a stanchion with two ports for retaining therein the pivot pin of the drive frame assembly.
The details of one or more examples related to the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the appended claims.
An actuation system 10 of the present invention is illustrated in the accompanying drawings. The actuation system 10 preferably forms part of a fluid flow diverter 100, such as the fluid flow diverter 100 shown in
The diverter system 100 serves the purpose of enabling the switch of fluid flow from the turbine 200 to the HRSG 300 or to the exhaust stack 400. As illustrated in
As the primary components of the power generation system increase in size and are designed to operate with tighter functional requirements, the demands on the diverter system 100 have increased. As previously indicated, it is desired to have larger damper flaps 101 that may be controlled to move over a range of movement rates. It is also of interest to be cost effective. For cost effectiveness, the actuation system 10 of the present invention is an electromechanical system rather than a hydraulic system. However, unlike electromechanical actuation systems of the past, the actuation system 10 is capable of moving very large damper flaps over a selectable range of movement rates. This is achieved using a ball screw movement element and a variable drive motor for movement of the ball screw. With continuing reference to
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The combination of the drive frame assembly 20, the crank arm assembly 35, the ball screw assembly 45, and the drive motor 70 provide an electromechanical system for actuation of a flap damper of any size at a selectable range of movement rates. It is to be understood that while the actuation system 10 may be sized and configured to deploy a single system 10 to actuate a damper flap such as damper flap 101, it is to be understood that two actuation systems may be deployed, one at each end of the toggle tube 102. One may act as a redundant system or they may be operated in combination, provided they are appropriately synchronized. It is also to be understood that the actuation system 10 may be modified at the drive frame assembly 20 to accommodate other forms of connections to the diverter flap 101. Further, the drive assembly 20 may be directly coupled to the damper flap 101 by way of its pivot shaft without a toggle link of the type described in regard to the preferred embodiment of the invention. It is further to be understood that the actuation system 10 may be employed with other forms of fluid diversion arrangements including, but not limited to, water and other liquid movement systems, chemical process systems, and any form of gas flow systems, including over a wide range of temperature conditions. The materials used to fabricate the various components of the actuation system 10 may be selected as a function of the particular operation within which it is deployed. However, non-corrosive, high temperature metals, such as stainless steel, may be preferred in environments such as power generation systems.
While the present invention has been described with particular reference to certain embodiments of the separation system, it is to be understood that it includes all reasonable equivalents thereof as defined by the following appended claims.