Steam turbines include a shell that functions to contain the high pressure, high temperature steam and to support the nozzles and casings that direct steam in the most efficient manner possible through rotating airfoils to produce maximum torque on the shaft. The shell includes support arms that extend outward from the shell. Shell arms rest on a support structure that is integral to a structure that also provides support for the turbine rotor, and which serves to house other turbine related components and instrumentation. This structure is often referred to as a “standard”. The elements of the stator portion of the steam turbine are coupled to the shell, thus, the stator portion of the steam turbine is supported by the shell arm support structure.
The rotor of the steam turbine is typically supported by bearings. The bearings are typically mounted within a bearing housing that is supported by a bearing support structure. The bearing support structure can be a part of the “standard” mentioned above. The bearing support structure, while it may be integral with the standard, is not integral with the shell arm support structure. The shell arm support structures and the bearing support structures are exposed to different environmental conditions during various stages of operation of the steam turbine. During transient operations, including but not necessarily limited to startup, load changes, shutdown, and cool downs while on turning gear, different portions of the steam turbine and the supporting elements experience changes in temperature. These changes in temperature may occur at different rates within the different parts of the steam turbine and its support structure, which leads to differential thermal growth of the steam turbine elements, and the support elements.
During startup operations, the bearings and the bearing support structure which supports the bearings and the rotor of the steam turbine tend to increase in temperature more quickly than the shell arm support structure. In part, this occurs because the bearings supporting the rotor rapidly heat up during startup because they are being driven by the changing oil temperature which they are in constant contact with, and the heat generated in the bearings is transferred to the bearing support structure. In contrast, the shell and the shell arm support structure, which are not in constant contact with the oil, tend to warm up more slowly.
Similarly, the bearings typically cool more rapidly upon shutdown because oil supply temperature is lowered as the steam turbine moves from full speed operation to operation at turning gear speeds. In contrast, the support structure beneath the shell arms generally cools very slowly because its temperature is driven more by shell temperature and conduction of that heat from the shell arms into the structure. Shell temperatures decay very slowly. And this can cause the bearing support structure to cool more quickly than the shell arm support structure upon shutdown.
When there are differences in the rate at which the temperature of the bearing support structure increases or decreases, as compared to the rate at which the temperature of the shell arm support structure increases or decreases, the temperature differences can lead to differences in the rate or amount of thermal expansion and contraction of these two elements. And differences in the rate or amount of thermal expansion or contraction as between the bearing support structure and the shell arm support structure can cause changes in the amount of radial clearance available between rotating and stationary parts.
In one aspect, the invention may be embodied in a system for controlling a clearance between a rotor and a stator of a steam turbine during transient operations, the system including a shell support structure configured to support a shell of a steam turbine, the shell support structure having a main body including a base and an upper support that is configured to support at least one shell arm of a shell of a steam turbine and an interior passageway that passes through an interior of the main body between an inlet and an outlet, wherein the interior passageway is configured to conduct a flow of a heating or cooling medium. The system also includes a condensate supply line that is coupled to the inlet of the interior passageway of the shell support structure, the condensate supply line supplying condensate that has been created from steam that has passed though a steam turbine that is supported by the shell support structure. The system further includes a control valve that selectively varies a low rate of the condensate through the interior passageway of the shell support structure.
In another aspect, the invention may be embodied in a method of controlling a clearance between a rotor and a stator of a steam turbine during transient operations. The method determining that a transient operation has begun, and selectively supplying a flow of a heating or a cooling medium to an interior passageway of a shell support structure of the steam turbine to cause controlled thermal growth or contraction of the shell support structure, thereby controlling a clearance between a rotor and a stator of the steam turbine
In another aspect, the invention may be embodied in a system for controlling a clearance between a rotor and a stator of a steam turbine during transient operations that includes means for determining that transient operations have begun, and means for selectively supplying a flow of a heating or a cooling medium to an interior passageway of a shell support structure of the steam turbine to cause controlled thermal growth or contraction of the shell support structure, thereby controlling a clearance between a rotor and a stator of the steam turbine.
A steam supply line 150 provides high pressure steam to drive the steam turbine. A low pressure steam line 160 carries away low pressure steam, or condensate, after the high pressure steam has passed though the steam turbine.
In any given embodiment, the steam turbine could be a high pressure steam turbine, an intermediate pressure steam turbine or a low pressure steam turbine. In some embodiments, both low pressure and intermediate pressure steam turbines may be located within a single shell structure. Likewise, both an intermediate and a high pressure steam turbine may be located within a single shell structure. Thus, the depiction provided in
As explained above, during startup operations the elements of the steam turbine and the shell and bearing support structures would all gradually increase in temperature. However, as also noted above, it is common for the bearings 130 of the steam turbine to rapidly increase in temperature. And as a result, the temperature of the bearing support structures 140 tends to rapidly increase during startup. In contrast, the shell 110 of the steam turbine, which is coupled to the stator of the steam turbine, tends to increase in temperature more slowly than the bearings 130. As a result, the temperature of the shell support structures 120 tends to increase more slowly than the temperature of the bearing support structures 140.
Increases in the temperatures of the bearing support structures 140 and the shell support structures 120 cause corresponding thermal expansion of these elements. But because the temperatures of the elements change at varying rates, the amount of thermal expansion that occurs also occurs at different rates.
The differences in the amounts of thermal expansion between the bearing support structures 140 and the shell support structures 120 can cause radial clearance problems for the steam turbine. Essentially, during the startup operation the rotor, which rests on the bearing support structures 140, will be lifted upward more rapidly than the stator, which is supported on the shell support structures 120. Thus, for a certain period of time, the centerline of the rotor is misaligned with the centerline of the stator.
One way to accommodate this problem is to ensure that all radial clearances between the elements of the rotor and the elements of the stator are large enough to ensure that even during the period of time when the thermal expansion mismatch between the bearing support structures and the shell support structures is greatest, elements of rotor will not rub against corresponding elements of the stator. Unfortunately, building such clearances into the steam turbine necessarily requires a sacrifice of some performance. Also, over time, as wear occurs, the clearances can decrease to the point where elements of the rotor begin to rub against elements of the stator during startup operations.
The same basic issues exist during shutdown/cool down operations.
As illustrated in
The medium that is supplied through the steam/condensate supply pipe 510 could be steam, or it could be condensate, or it could be a mixture of both. Also, in some embodiments, the steam in the steam/condensate supply pipe 510 may be provided from a source or sources other than from within the shell 110 of the turbine. Thus, in some embodiments, the steam/condensate supply pipe 510 may not originate within the shell 110, as depicted in
The system also includes a heating medium supply pipe 514 that leads to an inlet 518 on the shell support structure 120. A heating medium control valve 512 is provided on the heating medium supply pipe 514 to control a flow rate of the heating medium supplied though the supply pipe 514 to the inlet 518.
The embodiment illustrated in
Of course, in alternate embodiments, the interior passageway(s) located inside the shell support structures 120 and that extend between the inlet 518 and the outlet 540 could have a variety of other forms.
When a shell support structure 120 as illustrated in
A system as illustrated in
Although the embodiment illustrated in
In alternate embodiments, some other cooling medium could be used. If an alternate cooling medium from a coolant supply is used to cool the shell support structure 120, the cooling medium exiting the outlet 540 may be routed back to the coolant supply so that the cooling medium can be recirculated.
In some embodiments, a mixture of coolant from the coolant supply 520 and condensate from the steam/condensate supply pipe 510 could be introduced into the inlet 518 of the shell support structure 120. The control valves 512, 522 would be selectively opened and closed to selectively vary the mixture that is introduced into the inlet 518. This can provide great control over the temperature and flow rate of the medium that is flowing through the shell support structure 120 to carefully control the thermal expansion of the shell support structure 120.
Temperature sensors may be mounted on the shell arm supports and the bearing supports to help monitor the temperature of those elements.
During shutdown operations, the cooling medium from the coolant supply 520 could be used to cool the shell support structure 120. By selectively varying the flow rate of the cooling medium, using the cooling medium control valve 522, one can control the rate at which the shell support structure undergoes thermal contraction. Thus, rate of thermal contraction of the shell support structure 120 can be matched to the rate of thermal contraction of the bearing support structures 140 so that the clearances between the rotor and the stator are maintained during shutdown operations.
When a shell support structure 120 as illustrated in
The first steam/condensate supply line 622 and second steam/condensate supply line 632 are coupled to a control valve 640 that selectively mixes the steam/condensate and delivers the mixture into the steam/condensate supply pipe 510. As discussed above, condensate resulting from the steam/condensate in the steam/condensate supply pipe 510 is then selectively introduced into a shell support structure 120 to control the thermal expansion of the shell support structure 120. The control valve 640 can control the relative amounts of the two different steams/condensates to control the temperature of the steam/condensate in the steam/condensate supply pipe 510. Of course, separate control valves, one in each of lines 622 and 632, could be provided instead of a single control valve 640.
In some embodiments, the shell support thermal growth control unit 902 would selectively control the heating medium control valve 904 and the cooling medium control valve 906 based on predetermined profiles or schedules to selectively control the flow of heating medium or cooling medium through the internal passageways of the shell support structures 120. This would be done to match the thermal expansion and contraction of the shell support structures 120 to the thermal expansion and contraction of the bearing support structures 140. The predetermined profiles or schedules could be established by experimentation.
In alternate embodiments, the system may include one or more clearance sensors 908 that are operatively coupled to the shell support thermal growth control unit 902. The clearance sensors 908 could sense one or more clearances between elements of the rotor and elements of the stator. Alternatively, the clearance sensors 908 could detect a clearance in one or more bearings of the steam turbine. Signals indicative of the sensed clearance(s) would be provided to the shell support thermal growth control unit 902, and the sensor signals would be used to determine how to control the heating medium control valve 904 and the cooling medium control valve 906 to control the thermal expansion and contraction of the shell support structures 120.
In other embodiments, thermal growth sensors 910 could be provided on the bearing support structures 140 and also possibly on the shell support structures 120. Signals from the thermal growth sensors 910 would indicate the degree or amount of thermal growth of these elements, and/or possibly a rate of change in the thermal growth being experienced by these elements. This information would be used by the shell support thermal growth control unit 902 to control the heating medium control valve 904 and the cooling medium control valve 906 to control the thermal growth or contraction of the shell support structures 120.
In still other embodiments temperature sensors 912 could be provided on the bearing support structures 140 and also possibly on the shell support structures 120. Signals from the temperature sensors 912 would indicate the temperatures of these elements, and/or possibly a rate of change in the temperature being experienced by these elements. This information would be used by the shell support thermal growth control unit 902 to control the heating medium control valve 904 and the cooling medium control valve 906 to control the thermal growth or contraction of the shell support structures 120.
In embodiments where the steam output from two or more steam turbines is used to heat and/or cool a shell support structure 120, the shell support thermal growth control unit 902 could be coupled to a steam source control valve 905 to control the relative amounts of the steam being used from each of the steam sources. The steam source control valve 905 illustrated in
The method begins in step S1002, where the system begins providing a flow of a heating medium to the interior passageway of a shell support structures. Next, in step S1004, a shell support thermal growth control unit would detect one or more of a clearance in the steam turbine, a temperature differential between the shell support structures and the bearing support structures, and a thermal growth differential between the shell support structures and the bearing support structures. This information would be obtained from sensors, as described above.
Next, in step S1006, the flow rate of the heating medium would be selectively controlled, based on the information obtained in step S1004, to control the thermal expansion of the shell support structures so that it approximates the thermal expansion of the bearing support structures. Then, in step S1008, a check is performed to determine if steady state operations have been achieved. This would basically mean checking the information provided by the sensors to determine if the bearing support structures and/or the shell support structures have stopped changing their temperature or stopped expanding. If not, the method loops back to step S1004. If so, the method proceeds to step S1010, and the flow of heating medium into the shell support structures is stopped.
A similar process would be used to control the flow of a cooling fluid into the shell support structures during a shutdown operation to match the thermal contraction of the shell support structures to the thermal contraction of the bearing support structures.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements which are encompassed within the spirit and scope of the appended claims.