Hydraulic turbine driven generator set

Abstract

This utility model discloses a hydraulic turbine-driven generator set, comprising: a hydraulic recovery turbine, including a housing with multiple stages of impellers inside, and a turbine inlet and outlet on the housing; a reduction gearbox, the input shaft of which is connected to the output shaft of the hydraulic recovery turbine, and the output shaft of the reduction gearbox is connected to the input shaft of the generator, the reduction gearbox being used to reduce the output speed of the hydraulic recovery turbine to the rated operating speed of the generator; a generator, used to receive the mechanical energy output from the reduction gearbox and convert it into electrical energy; and an overspeed protection device, including a control unit and a speed detection element, a turbine inlet valve being provided at the turbine inlet, the control unit being electrically connected to the turbine inlet valve and the speed detection element, the speed detection element being used to detect the output speed of the hydraulic recovery turbine. This application can achieve efficient recovery and utilization of fluid pressure energy, while ensuring the safety and stability of operation under high head and high speed conditions.

Description

Technical Field

[0001] This utility model relates to the field of energy recovery technology, and in particular to a hydraulic turbine-driven generator set. Background Technology

[0002] In industrial gas purification processes such as ammonia synthesis, coal-to-methanol production, and natural gas treatment, physical absorption solvents (such as low-temperature methanol washing solvents) are typically used to absorb acidic gases such as CO2 and H2S from the process gas under high pressure and low temperature conditions. The rich liquid solvent, which has dissolved a large amount of acidic gases, needs to be depressurized and then fed into a thermal regeneration tower for solvent regeneration and recycling. In this process, if the high-pressure energy carried by the rich liquid is directly released through a throttling valve, it will result in a large amount of energy waste.

[0003] To achieve energy recovery, a hydraulic turbine is used instead of a traditional throttle valve, which can convert the pressure energy of the rich liquid into mechanical energy, thereby driving a generator to generate electricity and achieving the goal of energy saving and consumption reduction. However, in this type of industrial scenario, the pressure difference between the inlet and outlet of the hydraulic turbine is usually 4-6 MPa, which is a high-lift condition, requiring a multi-stage turbine structure, and the operating speed is about 3000 rpm.

[0004] In actual operation, there exists a dangerous abnormal condition: when a sudden power outage occurs, the generator disconnects from the grid, and the hydraulic turbine instantly loses its load. Under the continuous drive of high-pressure, rich hydraulic fluid, the turbine speed can rapidly increase to more than 1.4-2 times the normal operating speed within seconds (i.e., runaway speed). If the unit is not specifically designed for this runaway condition, it is highly susceptible to mechanical failures such as bearing wear and rotor breakage, which can lead to equipment damage, safety accidents, and economic losses in severe cases.

[0005] Most existing hydraulic turbine generator sets are not designed for the high head and high speed characteristics of such industrial gas purification scenarios, lack effective overspeed protection mechanisms, and some units have unreasonable structural designs such as bearing support and speed detection, which cannot adapt to the high pressure and high speed operation requirements of scenarios such as ammonia synthesis and coal-to-methanol, and are difficult to meet the long-term stable operation and safety protection requirements of industrial gas purification processes.

[0006] Therefore, it is necessary to propose a hydraulic turbine-driven generator set to solve at least one of the above problems.

[0007] It should be noted that the above introduction to the technical background is only for the purpose of providing a clear and complete explanation of the technical solutions of this application and facilitating understanding by those skilled in the art. It should not be assumed that these technical solutions are known to those skilled in the art simply because they have been described in the background section of this application. Utility Model Content

[0008] In view of the shortcomings of the existing technology, this utility model provides a hydraulic turbine-driven generator set that can realize the efficient recovery and utilization of fluid pressure energy, while ensuring the safety and stability of operation under high head and high speed conditions.

[0009] The specific technical solution of this utility model embodiment is as follows:

[0010] A hydraulic turbine-driven generator set includes: a hydraulic recovery turbine, which is a horizontal structure including a housing with multiple stages of impellers inside. The housing has a turbine inlet and a turbine outlet, and the housing and the multiple stages of impellers cooperate to form a spiral guide channel for fluid flow; a reduction gearbox, the input shaft of which is connected to the output shaft of the hydraulic recovery turbine, and the output shaft of which is connected to the input shaft of the generator, the reduction gearbox being used to reduce the output speed of the hydraulic recovery turbine to the rated operating speed of the generator; a generator, which receives the mechanical energy output by the reduction gearbox and converts it into electrical energy; and an overspeed protection device, which includes a control unit and a speed detection element. The turbine inlet is provided with a turbine inlet valve, and the control unit is electrically connected to the turbine inlet valve and the speed detection element, the speed detection element being used to detect the output speed of the hydraulic recovery turbine.

[0011] Furthermore, the hydraulic turbine drive generator set also includes a lubrication system, which includes a lubrication station, an oil supply line, and a return line. The input end of the oil supply line is connected to the lubrication station, and the output end of the oil supply line is connected to the reduction gearbox. The input end of the return line is connected to the reduction gearbox, and the output end of the return line is connected to the lubrication station.

[0012] Furthermore, the hydraulic recovery turbine is equipped with a rotor shaft inside, and bearings are provided at both ends of the rotor shaft. The hydraulic recovery turbine has a preset runaway speed. When the runaway speed is within the limit speed of the roller bearing, the bearing is a roller bearing. When the runaway speed exceeds the limit speed of the roller bearing, the bearing is a hydrodynamic bearing.

[0013] Furthermore, the internal structure of the hydraulic recovery turbine is equipped with a rotor shaft, and hydrodynamic bearings are installed at both ends of the rotor shaft. The oil supply line and the oil return line are also connected to the hydrodynamic bearings. The lubrication station forms a bearing lubrication circulation line with the hydrodynamic bearings through the oil supply line and the oil return line.

[0014] Furthermore, the hydraulic recovery turbine has a rotor shaft in the middle, and multiple rotors are interference-fitted with the rotor shaft and fixed in stages. The multiple rotors are divided into two groups along the axial direction of the rotor shaft, namely the first rotor group and the second rotor group. The two groups of rotors are arranged in opposite symmetrical ways and are distributed back to back along the rotor shaft. The number of rotors in the two groups is equal or differs by one.

[0015] Furthermore, the spiral guide channel includes: a first spiral guide channel and a second spiral guide channel, wherein the first impeller assembly cooperates with the housing to form the first spiral guide channel, and the second impeller assembly cooperates with the housing to form the second spiral guide channel, wherein the spiral directions of the first spiral guide channel and the second spiral guide channel are opposite.

[0016] Furthermore, an intermediate bushing is provided between the first impeller assembly and the second impeller assembly.

[0017] Furthermore, the generator is an asynchronous generator.

[0018] Furthermore, the asynchronous generator is a 4-pole asynchronous generator.

[0019] Furthermore, the hydraulic turbine-driven generator set also includes a base, on which the hydraulic recovery turbine, the reduction gearbox, and the generator are sequentially mounted. The output shaft of the hydraulic recovery turbine is coaxially arranged with the input shaft of the reduction gearbox, and the output shaft of the reduction gearbox is coaxially arranged with the input shaft of the generator.

[0020] Furthermore, the hydraulic turbine drive generator set also includes: a liquid supply pipeline, the outlet end of which is connected to the turbine inlet, and the turbine inlet valve is disposed on the liquid supply pipeline; and a bypass pipeline, the inlet end of which is connected to the liquid supply pipeline and located upstream of the turbine inlet valve, and a bypass valve is disposed on the bypass pipeline, and the bypass valve is electrically connected to the control unit.

[0021] Furthermore, the hydraulic turbine-driven generator set also includes a drain pipe, one end of which is connected to the turbine outlet, and the other end of which is connected to the bypass pipe, with the connection point between the drain pipe and the bypass pipe located downstream of the bypass valve.

[0022] The speed detection device includes a first speed probe, a second speed probe, and a third speed probe. The first speed probe, the second speed probe, and the third speed probe are distributed circumferentially around the output shaft of the hydraulic recovery turbine. When at least two of the first speed probe, the second speed probe, and the third speed probe detect that the speed reaches the preset tripping speed, the turbine inlet valve closes and the bypass valve opens.

[0023] The technical solution of this utility model has the following significant beneficial effects:

[0024] The hydraulic turbine-driven generator set provided in this application replaces the traditional throttle valve with a hydraulic recovery turbine, converting the pressure energy and kinetic energy of high-pressure fluids (such as high-pressure rich liquid) in industrial processes into electrical energy. This avoids the energy waste caused by directly releasing the pressure energy of high-pressure fluids through throttling, improves the energy utilization efficiency of industrial production, and reduces production energy consumption and costs. It is suitable for the energy-saving requirements of industrial gas purification processes such as ammonia synthesis and coal-to-methanol. By setting an overspeed protection device linked to the turbine inlet valve, the turbine output speed is monitored in real time, which can quickly respond to abnormal speed and suppress runaway overspeed. This solves the technical pain point of sudden power failure in industrial scenarios, which can cause a sudden increase in turbine speed and easily lead to equipment damage or safety accidents, ensuring the safe operation of the unit under high head and high speed conditions. The coordinated design of the hydraulic recovery turbine, reduction gearbox, generator, and overspeed protection device realizes the stable conversion of fluid energy and mechanical energy into electrical energy. The speed adaptation function of the reduction gearbox helps the generator work at the rated speed, improving power generation efficiency and stability.

[0025] Specific embodiments of the present invention are disclosed in detail with reference to the following description and accompanying drawings, indicating how the principles of the present invention can be adopted. It should be understood that the embodiments of the present invention are not limited in scope. Features described and / or shown for one embodiment may be used in the same or similar manner in one or more other embodiments, combined with features in other embodiments, or substituted for features in other embodiments. Attached Figure Description

[0026] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely illustrative to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. Those skilled in the art, under the guidance of this invention, can select various possible shapes and proportions to implement this invention according to specific circumstances.

[0027] Figure 1This is a schematic diagram of the distribution principle of a hydraulic turbine-driven generator set provided in the embodiments of this application;

[0028] Figure 2 This is a partial front view of a hydraulic turbine-driven generator set provided in the embodiments of this application;

[0029] Figure 3 This is a partial top view of a hydraulic turbine-driven generator set provided in the embodiments of this application;

[0030] Figure 4 This is a cross-sectional view of a hydraulic recovery turbine of a hydraulic turbine-driven generator set provided in the embodiments of this application.

[0031] The reference numerals in the above figures are as follows:

[0032] 1. Hydraulic recovery turbine;

[0033] 11. Shell;

[0034] 12. Rotary wheel;

[0035] 13. Turbine inlet;

[0036] 14. Turbine outlet;

[0037] 15. Rotor shaft;

[0038] 16. Bearings;

[0039] 17. Intermediate bushing;

[0040] 181. First spiral guide channel;

[0041] 182. Second spiral guide channel;

[0042] 2. Reduction gearbox;

[0043] 3. Generator;

[0044] 41. Control unit;

[0045] 42. Rotational speed detection component;

[0046] 5. Turbine inlet valve;

[0047] 61. Lubrication oil station;

[0048] 62. Oil supply pipeline;

[0049] 63. Return oil pipeline;

[0050] 7. Base;

[0051] 81. Liquid supply pipeline;

[0052] 82. Bypass pipeline;

[0053] 83. Drainage pipeline;

[0054] 9. Bypass valve. Detailed Implementation

[0055] The details of this utility model can be more clearly understood by referring to the accompanying drawings and the description of specific embodiments. However, the specific embodiments of this utility model described herein are only for explaining the purpose of this utility model and should not be construed as limiting this utility model in any way. Under the teachings of this utility model, those skilled in the art can conceive of any possible modifications based on this utility model, and these should all be considered to fall within the scope of this utility model. It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or there may be an intervening element. The terms "mounted," "connected," and "connected" should be interpreted broadly, for example, it can be a mechanical connection or an electrical connection, or it can be a connection within two elements, which can be a direct connection or an indirect connection through an intermediate medium. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only embodiments.

[0056] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0057] This invention provides a hydraulic turbine-driven generator set that can achieve efficient recovery and utilization of fluid pressure energy, while ensuring safety and stability under high head and high speed conditions.

[0058] Please refer to the following for comprehensive information. Figures 1 to 4This application specification provides a hydraulic turbine-driven generator set, which may include: a hydraulic recovery turbine 1, the hydraulic recovery turbine 1 being a horizontal structure, including a housing 11, the housing 11 having multiple stages of impellers 12 inside, a turbine inlet 13 and a turbine outlet 14 on the housing 11, the housing 11 and the multiple stages of impellers 12 cooperating to form a spiral guide channel for fluid flow; and a reduction gearbox 2, the input shaft of the reduction gearbox 2 being connected to the output shaft of the hydraulic recovery turbine 1, and the output shaft of the reduction gearbox 2 being connected to... The generator 3 has an input shaft, and the reduction gearbox 2 is used to reduce the output speed of the hydraulic recovery turbine 1 to the rated operating speed of the generator 3; the generator 3 is used to receive the mechanical energy output by the reduction gearbox 2 and convert it into electrical energy; the overspeed protection device includes a control unit 41 and a speed detection element 42, the turbine inlet 13 is provided with a turbine inlet valve 5, the control unit 41 is electrically connected to the turbine inlet valve 5 and the speed detection element 42, and the speed detection element 42 is used to detect the turbine output speed of the hydraulic recovery turbine 1.

[0059] The hydraulic turbine-driven generator set provided in this application is used to realize the recovery and electrical energy conversion of industrial high-pressure fluid pressure energy, while ensuring the safe operation of the unit through overspeed protection. Its specific working principle is as follows:

[0060] High-pressure fluids in industrial production (such as high-pressure rich liquid in the synthesis of ammonia and coal-to-methanol processes) enter the turbine inlet 13 of the hydraulic recovery turbine 1 through a preset flow path, and flow through the spiral guide channel formed by the shell 11 and the multi-stage impeller 12. The pressure energy and kinetic energy of the fluid drive the multi-stage impeller 12 to rotate at high speed, converting the fluid energy into the mechanical energy of the output shaft of the hydraulic recovery turbine 1.

[0061] The output shaft of the hydraulic recovery turbine 1 is connected to the input shaft of the reduction gearbox 2. The reduction gearbox 2 reduces the high speed output of the turbine (suitable for high head conditions under pressure difference of 4-6MPa in industrial scenarios) to the rated operating speed of the generator 3. Then, the mechanical energy is transmitted to the input shaft of the generator 3 through the output shaft of the reduction gearbox 2. After receiving the mechanical energy, the generator 3 converts it into electrical energy, thus completing the energy recovery.

[0062] The overspeed protection device participates in the entire unit operation. The speed detection element 42 monitors the output shaft speed of the hydraulic recovery turbine 1 (i.e., the turbine output speed) in real time and transmits the speed signal to the control unit 41. The control unit 41 is electrically connected to the turbine inlet valve 5 and the speed detection element 42. When an abnormal increase in turbine speed is detected (such as runaway overspeed caused by a sudden power failure), the control unit 41 issues a command. For example, the flow rate of fluid entering the turbine can be adjusted by controlling the opening of the turbine inlet valve 5, thereby suppressing the continuous increase in speed and avoiding overspeed faults. For example, for units equipped with a bypass valve 9, the turbine inlet valve 5 can be closed and the bypass valve 9 opened, allowing high-pressure liquid to enter the downstream process through the bypass pipeline 82.

[0063] Overall, the hydraulic turbine-driven generator set provided in this application replaces the traditional throttle valve with a hydraulic recovery turbine 1, converting the pressure energy and kinetic energy of high-pressure fluids (such as high-pressure rich liquid) in industrial processes into electrical energy. This avoids the energy waste caused by directly releasing the pressure energy of high-pressure fluids through throttling, improves the energy utilization efficiency of industrial production, and reduces production energy consumption and production costs. It is suitable for the energy-saving requirements of industrial gas purification processes such as ammonia synthesis and coal-to-methanol. By setting an overspeed protection device linked to the turbine inlet valve 5, the turbine output speed is monitored in real time, which can quickly respond to abnormal speed and suppress runaway overspeed. This solves the technical pain point of sudden power failure in industrial scenarios, which can cause a sudden increase in turbine speed and easily lead to equipment damage or safety accidents, and ensures the safe operation of the unit under high head and high speed conditions. The coordinated design of the hydraulic recovery turbine 1, the reduction gearbox 2, the generator 3, and the overspeed protection device realizes the stable conversion of fluid energy and mechanical energy into electrical energy. The speed adaptation function of the reduction gearbox 2 helps the generator 3 to work at the rated speed, improving power generation efficiency and stability.

[0064] The present application will now be described in detail with reference to the accompanying drawings and embodiments.

[0065] like Figure 2 and Figure 3 As shown, the hydraulic turbine-driven generator set mainly includes a hydraulic recovery turbine 1, a reduction gearbox 2, and a generator 3 arranged in series. Furthermore, the hydraulic turbine-driven generator set may also include a base 7, on which the hydraulic recovery turbine 1, the reduction gearbox 2, and the generator 3 are sequentially mounted. The output shaft of the hydraulic recovery turbine 1 is coaxial with the input shaft of the reduction gearbox 2, and the output shaft of the reduction gearbox 2 is coaxial with the input shaft of the generator 3, ensuring the stability and efficiency of power transmission.

[0066] like Figure 4As shown, the hydraulic recovery turbine 1 adopts a horizontal structure, meaning that the rotor shaft 15 of the hydraulic recovery turbine 1 extends horizontally, adapting to the installation layout of industrial sites and the horizontal conveying requirements of high-pressure fluids. The hydraulic recovery turbine 1 includes a housing 11, which is an axially split volute design, for example, comprising a first housing and a second housing that are detachably connected in half, facilitating disassembly, assembly, maintenance, and repair of the unit, and meeting the maintenance requirements of long-term industrial operation. The housing 11 is provided with a turbine inlet 13 and a turbine outlet 14, wherein the turbine inlet 13 can be located on the first housing, and the turbine outlet 14 can be located on the second housing. The horizontal arrangement of the inlet and outlet facilitates the smooth inflow of high-pressure fluid and the smooth discharge of low-pressure fluid, reducing energy loss during fluid flow.

[0067] Furthermore, the hydraulic recovery turbine 1 is internally equipped with a rotor shaft 15. Multiple impellers 12 are interference-fitted with the rotor shaft 15 and fixed in stages. The impellers 12 are divided into two groups along the axial direction of the rotor shaft 15: a first impeller group and a second impeller group. The two groups of impellers 12 are arranged symmetrically in opposite directions, back-to-back along the rotor shaft 15. The number of impellers 12 in the two groups is equal or differs by one. The first impeller group cooperates with the housing 11 to form a first spiral guide channel 181, and the second impeller group cooperates with the housing 11 to form a second spiral guide channel 182. The spiral directions of the first spiral guide channel 181 and the second spiral guide channel 182 are opposite, causing the fluid to generate opposing forces when flowing through the two groups of impellers 12. This automatically balances the axial thrust of the impellers 12, reduces wear on the rotor shaft 15 and bearings 16, and improves the operational stability of the unit.

[0068] Furthermore, an intermediate bushing 17 is provided between the first and second impeller groups. The intermediate bushing 17 is fixedly connected to the rotor shaft 15. It can not only effectively separate the adjacent impellers 12 of the first and second impeller groups, avoiding mutual interference and collision when the impellers 12 rotate at high speed, but also reduce interstage fluid leakage and improve the energy conversion efficiency of the hydraulic recovery turbine 1. At the same time, the intermediate bushing 17 can act as a hydrodynamic bearing when the rotor (including the rotor shaft 15, all impellers 12 and other high-speed rotating components) is running at high speed, further improving the dynamic stability of the rotor when running at high speed, and adapting to the operating speed of the unit at about 3000 rpm and the operating requirements under runaway conditions.

[0069] After the high-pressure fluid (such as industrial rich liquid) enters the turbine, it flows through multiple rotors 12 in sequence. The fluid pressure drives the rotors 12 to rotate, converting the pressure energy of the fluid into the mechanical energy of the rotor rotation. After the fluid flows through each rotor 12, the pressure gradually decreases and finally it is discharged from the turbine outlet 14, completing the energy conversion.

[0070] Corresponding to the above structural design, the working principle of the hydraulic recovery turbine 1 is as follows: High-pressure fluid is transported to the turbine inlet 13 through the liquid supply pipeline 81, enters the hydraulic recovery turbine 1 through the turbine inlet 13 on the first housing, flows through the multi-stage impellers 12 (first impeller group, second impeller group), and drives the impellers 12 to rotate through the fluid pressure, converting the pressure energy of the fluid into the mechanical energy of the rotor shaft 15 rotation; after the fluid flows through each stage of impellers 12, the pressure gradually decreases, and finally it is discharged through the turbine outlet 14 on the second housing, and after merging with the bypass pipeline 82 through the drain pipeline 83, it enters the subsequent process flow to complete the energy conversion.

[0071] In this embodiment, the inlet and outlet pressure difference of the hydraulic recovery turbine 1 is suitable for the 4-6 MPa requirements of industrial gas purification scenarios such as ammonia synthesis and coal-to-methanol production. The operating speed is about 3000 rpm, which can match the energy recovery requirements of high-pressure rich liquid, realize the efficient recovery of fluid pressure energy, and achieve energy saving and consumption reduction.

[0072] The hydraulic recovery turbine 1 operates normally within 105% of its optimal efficiency, limiting runaway speed from the source and preventing excessive speed. Combined with an overspeed protection device, it further enhances the safety of the unit under runaway conditions and solves the overspeed hazard caused by sudden power failure in industrial scenarios.

[0073] Each stage of the hydraulic recovery turbine 1 adopts a double volute structure, which can effectively offset most of the hydraulic radial force generated during operation; the impeller 12 is divided into two groups, which are arranged back to back in opposite directions (equal in number or one stage apart), automatically balancing the axial thrust of the rotor, reducing the wear of the rotor shaft 15 and bearing 16, and extending the service life of the components.

[0074] An intermediate bushing 17 is installed between adjacent impellers 12 of the first and second impeller groups of the hydraulic recovery turbine 1. This not only reduces interstage leakage and improves energy conversion efficiency, but also serves as an auxiliary support for the hydrodynamic bearing, improving the dynamic stability of the rotor during high-speed operation and ensuring long-term stable operation of the unit.

[0075] The hydraulic recovery turbine 1 can flexibly configure the bearings 16 according to the runaway speed. If the runaway speed is within the limit speed of the roller bearing, the roller bearing is used; if the runaway speed exceeds the limit speed of the roller bearing, a hydrodynamic bearing can be used. The hydrodynamic bearing can be forcibly lubricated and cooled by an external lubrication system to ensure continuous operation under runaway conditions.

[0076] In one embodiment, the hydraulic turbine-driven generator set may further include a lubrication system, which includes a lubrication station 61, an oil supply line 62, and an oil return line 63. The input end of the oil supply line 62 is connected to the lubrication station 61, and the output end of the oil supply line 62 is connected to the reduction gearbox 2. The input end of the oil return line 63 is connected to the reduction gearbox 2, and the output end of the oil return line 63 is connected to the lubrication station 61.

[0077] Furthermore, the internal structure of the hydraulic recovery turbine 1 is provided with a rotor shaft 15, and hydrodynamic bearings are provided at both ends of the rotor shaft 15. The oil supply line 62 and the oil return line 63 are also connected to the hydrodynamic bearings. The lubrication station 61 forms a bearing lubrication circulation pipeline with the hydrodynamic bearings through the oil supply line 62 and the oil return line 63.

[0078] In this embodiment, the lubrication system serves as the core auxiliary protection system of the unit, capable of starting synchronously and working collaboratively with the unit's operation to form a closed-loop lubrication cycle. Specifically, the lubrication station 61, as the core for storing, filtering, and supplying lubricating oil, delivers clean lubricating oil, after filtration and cooling, through the oil supply pipeline 62 to the gear transmission pairs inside the reduction gearbox 2 and the hydrodynamic bearings at both ends of the rotor shaft 15 of the hydraulic recovery turbine 1. This provides lubrication to the gear meshing parts and lubrication and cooling to the mating parts between the hydrodynamic bearings and the rotor shaft 15. After completing the lubrication and cooling processes, the lubricating oil is collected through the return oil pipeline 63 and flows back to the lubrication station 61. After being filtered and cooled again, it enters the next lubrication cycle, achieving the reuse of lubricating oil. The lubrication station 61 is connected to the hydrodynamic bearings through the oil supply pipeline 62 and the return oil pipeline 63, forming a dedicated bearing lubrication circulation pipeline to ensure continuous and stable lubrication for the hydrodynamic bearings, adapting to the high-speed rotation requirements of the rotor shaft 15.

[0079] By setting up a lubrication system, continuous lubrication is provided to the gears of the reduction gearbox 2, the rotor shaft 15, and the hydrodynamic bearings. This effectively reduces frictional losses between components, avoids overheating, jamming, and wear caused by dry friction or insufficient lubrication, significantly extends the service life of the unit's core moving parts, reduces equipment maintenance costs and component replacement frequency, and meets the needs of long-term industrial operation. Specifically, for the unit's high-speed operation at around 3000 rpm, the lubricating oil effectively cools the moving parts, removes heat generated during operation, and prevents component failure due to overheating. Simultaneously, it provides stable support for the hydrodynamic bearings. Combined with the hydraulic balance design of the impeller 12, this further balances the axial and radial forces on the rotor, helping to ensure the stability of the rotor shaft 15 during high-speed rotation, preventing unit shutdown due to lubrication failure, and ensuring the continuity of industrial production processes.

[0080] Furthermore, in this embodiment, the closed-loop lubrication cycle design not only enables the reuse of lubricating oil, avoids lubricating oil waste, and reduces operating costs, but also allows for flexible adjustment of the oil supply pressure and flow rate through the lubrication station 61 according to changes in unit load, adapting to lubrication requirements under runaway conditions, thereby forming a complete lubrication protection system that can ensure stable operation of the unit under high speed, high load, and runaway conditions.

[0081] In one embodiment, the generator 3 is an asynchronous generator. Further, the asynchronous generator 3 is a 4-pole asynchronous generator.

[0082] In this embodiment, the generator 3 is an asynchronous generator (driven by a standard asynchronous motor in reverse at a speed higher than that of synchronous operation). It has a simple structure, no complex excitation system, low failure rate, and is suitable for the long-term continuous operation requirements of industry. Specifically, the generator 3 is driven to rotate and generate electricity by the turbine output speed reduced by the reduction gearbox 2. It receives the mechanical energy transmitted from the output shaft of the reduction gearbox 2, efficiently converts it into electrical energy, and then connects it to the power grid through matching grid-connected equipment, realizing the resource utilization of recovered energy and completing the entire energy recovery process.

[0083] Furthermore, the asynchronous generator 3 is a 4-pole asynchronous generator, with a rated operating speed of approximately 1510 rpm during grid-connected operation. This speed is compatible with the reduction gearbox 2's reduction ratio of approximately 1.98:1, ensuring speed matching and stable power generation, and avoiding energy loss or abnormal power generation due to speed mismatch. Simultaneously, this 4-pole asynchronous generator allows it to operate at 2-pole speed (approximately 3010 rpm) for short periods, fully meeting the requirements for following the hydraulic turbine's runaway operation. Even if the turbine speed suddenly increases due to abnormal situations such as power failure, the generator 3 will not be damaged due to excessive speed, effectively ensuring the overall safety of the unit under runaway conditions. This, combined with the unit's overspeed protection system and the runaway buffer function of the reduction gearbox 2, forms a complete runaway protection system.

[0084] In this embodiment, the reduction gearbox 2, as the core speed matching and protection auxiliary component of the hydraulic turbine-driven generator set, is installed between the hydraulic recovery turbine 1 and the generator 3 to ensure the smoothness and efficiency of power transmission. Its reduction ratio is set to approximately 1.98:1. This reduction ratio, after calculation, can match the operating speed of the hydraulic recovery turbine 1 (approximately 3000 rpm) and the grid-connected rated speed of the 4-pole asynchronous generator 3 (approximately 1510 rpm). This provides a basic guarantee for the efficient transmission of mechanical energy and the stable output of electrical energy, avoiding damage to the equipment caused by high speed directly transmitted to the generator 3. At the same time, it ensures that the generator 3 can operate at its rated speed, guaranteeing power generation efficiency and power quality, and avoiding energy loss or abnormal power generation caused by speed mismatch.

[0085] To address the runaway hazard caused by sudden power loss leading to turbine unload and rapid speed increase in industrial scenarios, the rotating components of the reduction gearbox 2 increase the total moment of inertia of the entire rotating system. This slows down the rate of speed increase after unit unload, providing sufficient response time for the overspeed protection device. This helps ensure that the interlocking system can promptly close the turbine inlet valve 5 and open the bypass valve 9, quickly suppressing the speed surge. Simultaneously, this buffering effect effectively reduces the water hammer impact effect on the upstream liquid supply pipeline 81 caused by sudden changes in fluid flow from the hydraulic turbine during runaway conditions, preventing pipeline vibration, leakage, or even damage. This protects the safety of the entire unit and pipeline system. In conjunction with the unit's overspeed protection device and the runaway adaptation design of the generator 3, it further improves the unit's runaway protection system.

[0086] In one embodiment, the hydraulic turbine-driven generator set further includes: a supply line 81, the outlet end of which is connected to the turbine inlet 13, and a turbine inlet valve 5 disposed on the supply line 81; and a bypass line 82, the inlet end of which is connected to the supply line 81 and located upstream of the turbine inlet valve 5, and a bypass valve 9 disposed on the bypass line 82, the bypass valve 9 being electrically connected to the control unit 41. Further, the hydraulic turbine-driven generator set also includes a drain line 83, one end of which is connected to the turbine outlet 14, and the other end of which is connected to the bypass line 82, with the connection point between the drain line 83 and the bypass line 82 located downstream of the bypass valve 9.

[0087] In this embodiment, the working principle of the hydraulic turbine-driven generator set equipped with the aforementioned supply pipeline 81, bypass pipeline 82, and drain pipeline 83 is as follows:

[0088] High-pressure fluids in industrial production (such as high-pressure rich liquid in the synthesis of ammonia and coal-to-methanol processes) are transported to the turbine inlet 13 of the hydraulic recovery turbine 1 through the liquid supply pipeline 81. The turbine inlet valve 5 is installed on the liquid supply pipeline 81 to control the flow and flow rate of the fluid entering the turbine. The high-pressure fluid flows through the spiral guide channel formed by the housing 11 and the multi-stage impeller 12. The pressure energy and kinetic energy of the fluid drive the multi-stage impeller 12 to rotate at high speed, converting the fluid energy into the mechanical energy of the output shaft of the hydraulic recovery turbine 1.

[0089] The output shaft of the hydraulic recovery turbine 1 is connected to the input shaft of the reduction gearbox 2. The reduction gearbox 2 reduces the high speed output of the turbine (suitable for high head conditions under pressure difference of 4-6MPa in industrial scenarios) to the rated operating speed of the generator 3. Then, the mechanical energy is transmitted to the input shaft of the generator 3 through the output shaft of the reduction gearbox 2. After receiving the mechanical energy, the generator 3 converts it into electrical energy, thus completing the energy recovery.

[0090] After energy conversion, the fluid is discharged from the turbine outlet 14 of the hydraulic recovery turbine 1 and transported to the bypass pipeline 82 via the drain pipeline 83. The connection between the drain pipeline 83 and the bypass pipeline 82 is located downstream of the bypass valve 9, so that the fluid discharged from the turbine outlet 14 and the fluid diverted by the bypass pipeline 82 merge and enter the subsequent process flow (such as the thermal regeneration tower), realizing the orderly circulation and discharge of the fluid and ensuring the continuity of the entire industrial process.

[0091] The overspeed protection device can participate in the entire operation of the unit. The speed detection element 42 detects the output shaft speed of the hydraulic recovery turbine 1 (i.e., the turbine output speed) in real time and transmits the speed signal to the control unit 41. The control unit 41 is electrically connected to the turbine inlet valve 5, the bypass valve 9 and the speed detection element 42 respectively. When an abnormal increase in turbine speed is detected (such as runaway overspeed caused by sudden power failure), the control unit 41 immediately issues a command to close the turbine inlet valve 5 on the liquid supply line 81 and simultaneously open the bypass valve 9 on the bypass line 82, so that the high-pressure fluid is directly diverted through the bypass line 82 and no longer enters the hydraulic recovery turbine 1, thereby quickly suppressing the continuous increase in speed and avoiding overspeed-induced failure.

[0092] By setting up a bypass pipeline 82 and a bypass valve 9, and linking them with the control unit 41 and the turbine inlet valve 5, a dual protection mechanism is formed. When the hydraulic recovery turbine 1 has an overspeed risk, it can cut off the fluid supply by closing the turbine inlet valve 5 and quickly divert the high-pressure fluid by opening the bypass valve 9. The dual action can suppress the speed increase more quickly and reliably, solve the technical pain point of sudden power failure in industrial scenarios that causes the turbine to run away and overspeed, which can easily lead to equipment damage or safety accidents, and ensure the safe operation of the unit under high head and high speed conditions.

[0093] In one embodiment, the speed detection element 42 includes a first speed probe, a second speed probe, and a third speed probe. The first speed probe, the second speed probe, and the third speed probe are distributed circumferentially around the output shaft of the hydraulic recovery turbine 1. When at least two of the first speed probe, the second speed probe, and the third speed probe detect that the speed reaches the preset tripping speed, the turbine inlet valve 5 is closed and the bypass valve 9 is opened.

[0094] In this embodiment, the speed detection device 42 may include a first speed probe, a second speed probe, and a third speed probe. The first speed probe, the second speed probe, and the third speed probe simultaneously detect the speed signal of the turbine drive end in real time and transmit the detection data to the control unit 41 respectively. When the control unit 41 determines whether the speed has reached the preset tripping speed, it does not rely on the signal of a single probe, but uses the speed detected by at least two of the first speed probe, the second speed probe, and the third speed probe reaching the tripping speed as the condition for triggering the interlocking action. That is, the control unit 41 controls the turbine inlet valve 5 to open and the bypass valve 9 to close.

[0095] By implementing a redundant design for the speed probe, it is possible to prevent the control unit 41 from malfunctioning or failing to operate when a single speed probe fails (such as signal distortion, damage, or false detection), thus ensuring the reliability of speed monitoring and interlocking protection and meeting the safety protection requirements under runaway conditions of the unit.

[0096] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from the others. Similar or identical parts between embodiments can be referred to interchangeably. The above embodiments are only for illustrating the technical concept and features of this utility model, and are intended to enable those skilled in the art to understand the content of this utility model and implement it accordingly. They should not be construed as limiting the scope of protection of this utility model. All equivalent changes or modifications made in accordance with the spirit and essence of this utility model should be included within the scope of protection of this utility model.

Claims

1. A hydraulic turbine-driven generator set, characterized in that, The hydraulic turbine-driven generator set includes: A hydraulic recovery turbine, wherein the hydraulic recovery turbine is a horizontal structure, including a housing, a multi-stage impeller inside the housing, a turbine inlet and a turbine outlet on the housing, and the housing and the multi-stage impeller cooperate to form a spiral guide channel for the flow of fluid; A reduction gearbox, the input shaft of which is connected to the output shaft of the hydraulic recovery turbine, and the output shaft of which is connected to the input shaft of the generator, the reduction gearbox being used to reduce the output speed of the hydraulic recovery turbine to the rated operating speed of the generator; A generator, which receives the mechanical energy output from the reduction gearbox and converts it into electrical energy; An overspeed protection device is provided, comprising a control unit and a speed detection element. A turbine inlet valve is provided at the turbine inlet. The control unit is electrically connected to the turbine inlet valve and the speed detection element. The speed detection element is used to detect the output speed of the hydraulic recovery turbine.

2. The hydraulic turbine-driven generator set as described in claim 1, characterized in that, The hydraulic turbine-driven generator set also includes a lubrication system, which includes a lubrication station, a supply line, and a return line. The input end of the supply line is connected to the lubrication station, and the output end of the supply line is connected to the reduction gearbox. The input end of the return line is connected to the reduction gearbox, and the output end of the return line is connected to the lubrication station.

3. The hydraulic turbine-driven generator set as described in claim 1, characterized in that, The hydraulic recovery turbine has a rotor shaft inside, and bearings are installed at both ends of the rotor shaft. The hydraulic recovery turbine has a preset runaway speed. When the runaway speed is within the limit speed of the roller bearing, the bearing is a roller bearing. When the runaway speed exceeds the limit speed of the roller bearing, the bearing is a hydrodynamic bearing.

4. The hydraulic turbine-driven generator set as described in claim 2, characterized in that, The hydraulic recovery turbine is equipped with a rotor shaft inside, and hydrodynamic bearings are installed at both ends of the rotor shaft. The oil supply line and the oil return line are also connected to the hydrodynamic bearings. The lubrication station forms a bearing lubrication circulation line with the hydrodynamic bearings through the oil supply line and the oil return line.

5. The hydraulic turbine-driven generator set as described in claim 1, characterized in that, The hydraulic recovery turbine has a rotor shaft in the middle. Multiple rotors are interference-fitted with the rotor shaft and fixed in stages. The multiple rotors are divided into two groups along the axial direction of the rotor shaft, namely the first rotor group and the second rotor group. The two groups of rotors are arranged in opposite symmetrical manner and are distributed back to back along the rotor shaft. The number of rotors in the two groups is equal or differs by one.

6. The hydraulic turbine-driven generator set as described in claim 5, characterized in that, The spiral guide channel includes a first spiral guide channel and a second spiral guide channel. The first rotating wheel assembly cooperates with the housing to form the first spiral guide channel, and the second rotating wheel assembly cooperates with the housing to form the second spiral guide channel. The spiral directions of the first spiral guide channel and the second spiral guide channel are opposite.

7. The hydraulic turbine-driven generator set as described in claim 5, characterized in that, An intermediate bushing is provided between the first impeller assembly and the second impeller assembly.

8. The hydraulic turbine-driven generator set as described in claim 1, characterized in that, The generator is an asynchronous generator.

9. The hydraulic turbine-driven generator set as described in claim 8, characterized in that, The asynchronous generator is a 4-pole asynchronous generator.

10. The hydraulic turbine-driven generator set as described in claim 1, characterized in that, The hydraulic turbine-driven generator set also includes a base, on which the hydraulic recovery turbine, the reduction gearbox, and the generator are sequentially mounted. The output shaft of the hydraulic recovery turbine is coaxial with the input shaft of the reduction gearbox, and the output shaft of the reduction gearbox is coaxial with the input shaft of the generator.

11. The hydraulic turbine-driven generator set as described in claim 1, characterized in that, The hydraulic turbine-driven generator set also includes: A liquid supply line, the outlet end of which is connected to the turbine inlet, and the turbine inlet valve is installed on the liquid supply line; A bypass line is provided, the inlet end of which is connected to the liquid supply line and located upstream of the turbine inlet valve. A bypass valve is provided on the bypass line, and the bypass valve is electrically connected to the control unit.

12. The hydraulic turbine-driven generator set as described in claim 11, characterized in that, The hydraulic turbine-driven generator set also includes a drain pipe, one end of which is connected to the turbine outlet and the other end of which is connected to the bypass pipe. The connection between the drain pipe and the bypass pipe is located downstream of the bypass valve.

13. The hydraulic turbine-driven generator set as described in claim 12, characterized in that, The speed detection device includes a first speed probe, a second speed probe, and a third speed probe. The first speed probe, the second speed probe, and the third speed probe are distributed circumferentially around the output shaft of the hydraulic recovery turbine. When at least two of the first speed probe, the second speed probe, and the third speed probe detect that the speed reaches the preset tripping speed, the turbine inlet valve closes and the bypass valve opens.

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