This invention relates generally to rotary machines and more particularly, to diaphragm patch rings for use in a rotary machine.
At least some steam turbines have a defined steam path which includes, in serial-flow relationship, a steam inlet, a turbine, and a steam outlet. Many of these steam turbines include stationary nozzle segments that direct a flow of steam towards rotating buckets, or turbine blades, that are coupled to a rotatable member. The nozzle airfoil construction is typically called a diaphragm assembly. Each diaphragm assembly is usually referred to as a stage and most steam turbines have a configuration that includes a plurality of diaphragm assembly stages.
Steam leakage, either out of the steam path or into the steam path, from an area of higher pressure to an area of lower pressure may adversely affect an operating efficiency of the turbine. For example, steam-path leakage in the turbine between a rotating rotor shaft of the turbine and a circumferentially surrounding turbine casing may lower the efficiency of the turbine. Additionally, steam-path leakage between a shell and the portion of the casing extending between adjacent turbines may reduce the operating efficiency of the steam turbine and over time, may lead to increased fuel costs.
In addition to facilitating steam flow, to facilitate minimizing steam-path leakage as described above, at least some known steam turbines use a plurality of labyrinth seals that are integral to the diaphragm assemblies. The seals are typically ring segments that are inserted into circumferential grooves at the radially innermost section of the diaphragm assembly, often referred to as a bore. Some known labyrinth seals include longitudinally spaced rows of labyrinth seal teeth which are used to seal against pressure differentials that may be present in the steam turbine.
Some steam turbine maintenance activities periodically include reducing the associated rotor diameters for a variety of reasons that include accommodating new features such as longer buckets, enhancing rotor stability, and/or mitigating rotor thrust values. In some of these instances, it is desirable to retain and reuse the existing diaphragm assemblies. In the event that the aforementioned seals alone cannot be modified to accommodate the extended gap between the diaphragm assemblies and the rotor, the existing diaphragm may be modified such that the bore of the diaphragm assembly and associated seals can mate with the reduced rotor diameter. In those steam turbine configurations where sufficient radial space exists, welding a diaphragm extension to existing diaphragms may suffice. Furthermore, alternative methods of extension attachment may be considered, such as for example, coupling extensions to existing diaphragms with a dowel-type configuration. However, in some known steam turbines, sufficient space for the aforementioned welding and dowel configurations may not be present and a low-profile, self-supporting configuration may be a solution.
In one aspect, a method of assembling a rotary machine having a casing extending at least partially around a rotor is provided. The method includes providing a diaphragm patch ring. The method also includes assembling a diaphragm assembly by configuring a diaphragm bore portion to receive the diaphragm patch ring and forming a diaphragm patch member sub-assembly by coupling the diaphragm patch ring to the configured diaphragm bore portion. The method further includes positioning the diaphragm assembly in a gap formed by the casing and the rotor.
In another aspect, a diaphragm assembly for a steam turbine is provided. The assembly includes a substantially annular radially inner member configured to extend substantially circumferentially within the steam turbine. The assembly also includes a substantially annular diaphragm patch member sub-assembly configured to extend substantially circumferentially within the steam turbine. The sub-assembly includes a substantially annular diaphragm patch ring and the diaphragm patch member sub-assembly is coupled to the inner member.
In a further aspect, a rotary machine is provided. The machine includes at least one rotor and at least one stationary machine casing extending at least partly circumferentially around the rotor such that a clearance gap is defined between the rotor and the casing. The machine also includes at least one diaphragm assembly. The diaphragm assembly is positioned within the clearance gap defined between the rotor and the stationary machine casing. The diaphragm assembly includes a substantially annular radially inner member configured to extend substantially circumferentially within the rotary machine. The assembly also includes a substantially annular diaphragm patch member sub-assembly configured to extend substantially circumferentially within the rotary machine. The sub-assembly includes a substantially annular diaphragm patch ring. The diaphragm patch member sub-assembly is coupled to the inner member.
An annular section divider 134 extends radially inwardly from central section 118 towards a rotor shaft 140 that extends between HP section 102 and IP section 104. More specifically, divider 134 extends circumferentially around a portion of rotor shaft 140 between a first HP section inlet nozzle 136 and a first IP section inlet nozzle 138. Divider 134 is received in a channel 142 defined in a packing casing 144. More specifically, channel 142 is a C-shaped channel that extends radially into packing casing 144 and around an outer circumference of packing casing 144, such that a center opening of channel 142 faces radially outwardly.
During operation, high pressure steam inlet 120 receives high pressure/high temperature steam from a steam source, for example, a power boiler (not shown in
It should be noted that although
Steam enters section 104 via IP section steam inlet 122 and is transported through section 104 as illustrated by the arrows. Inlet nozzle 138 and diaphragm assemblies 152 facilitate directing steam flow to buckets 154. Diaphragm assemblies 152 also facilitate mitigation of steam flow losses from the primary steam flow path of nozzle-to-bucket-to-nozzle, etc. via an axial gap 156 formed between a radially innermost portion of diaphragm assemblies 160 and a rotor surface 158. Diaphragm assemblies 152 are discussed further below.
Assembly 152 also has a plurality of nozzles 166 that facilitate steam flow through engine 100 as discussed above. Assembly 152 further has a substantially annular inner member 160 that includes a radially innermost portion 168, referred to as a bore portion, or bore. Bore portion 168 forms a substantially annular groove 170 that extends substantially circumferentially within steam turbine engine 100 and is configured to receive a substantially arcuate seal ring segment 172. Nozzles 166 are spaced circumferentially between members 160 and 164 and each extends substantially radially between inner and outer members 160 and 164, respectively. Turbine rotor shaft 140 with centerline 162 and rotor surface 158, and gap 156 formed by segment 172 and rotor surface 158 are illustrated in
Diaphragm patch ring 206 may be formed by machining a cast member, a forged member, or a plate (none of which are shown in
A substantially annular seal ring groove 218 with a substantially annular radially outermost surface 220 is formed within patch ring 206. At least a portion of each of a plurality of open passages that will eventually form dowel passages 202 and bolt passages 204 are machined substantially radially into ring 206 extending from surface 210 to surface 220. Passages 202 and 204 are machined with dimensions and with spacing substantially similar to those for modified bore portion 178.
As discussed above, the method of forming diaphragm assembly 152 with two half sections applies to sub-assembly 200. Sub-assembly 200 is assembled by positioning a section of ring 206 against a section of modified bore portion 178 such that the mating surfaces 180 and 210 are in contact and passages 202 and 204 formed in bore 178 and ring 206 are in substantially radial alignment such that they may receive the associated fasteners of which bolt 224 is illustrated and dowels are not illustrated. In other words, groove 213 formed in ring 206 is rolled over tongue 186 formed in modified bore portion 178. The tongue and groove configuration formed by ring 206 and bore 178 serves to mitigate any potential axial displacement of ring 206 due to the aforementioned differential pressure acting axially on ring 206 as described above.
In the exemplary embodiment, the predetermined dimensions of tongue 186 and groove 213 are such that a contact friction fit between the two components is effected wherein the upstream portion of tongue 186 and protrusion 208 provide substantially most of the coupling force for coupling ring 206 to bore portion 178. In operation, as steam is admitted to steam turbine 100 and bore portion 178 and ring 206 expand as heated causing the coupling force between ring 206, bore portion 178 to increase. In this manner, a low-profile, self-supporting configuration for sub-assembly 200 is provided. When steam turbine 100 is removed from service and ring 206 and bore portion 178 are cooled, sufficient coupling force between ring 206 and bore portion 178 is maintained.
Bolts 224 are inserted into bolt passages 204 to fixedly couple ring 206 to bore portion 178. Dowels (not shown in
In the exemplary embodiment, bolts 224 and the dowels provide a coupling force to cooperate with the aforementioned friction fit force between protrusion 208 and tongue 186 to carry the load associated with sub-assembly 200. Alternatively, the predetermined dimensions of tongue 186 and groove 213 may be formed such that bolts 224 and the dowels merely provide captivation and alignment between ring 206 and bore portion 178 and the number of bolts 224 and dowels may be reduced or eliminated.
Further alternatively, passages 202 and the associated dowels may be eliminated for protrusions 208 and 212 and tongue 186 being keyed, notched or having lipped protrusions added to perform the function of mitigating circumferential displacement.
Also illustrated in
Assembly 250 further has machined bore portion 178 coupled to diaphragm patch ring 206 as discussed above. Seal ring segment 172 is inserted into seal ring groove 218. Rotor 226 with rotor surface 228 and axial centerline 162 are illustrated for perspective. Gap 230 is formed between surface 28 and seal ring segment 172.
The methods and apparatus for a fabricating a turbine diaphragm assembly described herein facilitates operation of a turbine system. More specifically, the turbine diaphragm assembly as described above facilitates a more robust turbine steam seal configuration. Such steam seal configuration also facilitates efficiency, reliability, and reduced maintenance costs and turbine system outages.
Exemplary embodiments of turbine diaphragm assemblies as associated with turbine systems are described above in detail. The methods, apparatus and systems are not limited to the specific embodiments described herein nor to the specific illustrated turbine diaphragm assembly.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.