Base frame for a turbine system and turbine system comprising such a base frame

Abstract

The invention relates to a base frame (1) for a turbine system (2). The base frame (1) is manufactured at least partially in a lightweight construction, wherein the lightweight construction is formed by a honeycomb structure (3). The invention further relates to a turbine system (2) which comprises such a base frame (1) and on which at least one steam turbine (7) and a generator (8) are mounted.

Description

[0001] 2025PF00102

[0002] Description

[0003] Base frame for a turbine plant as well as turbine plant with such a base frame

[0004] The present invention relates to a basic frame for a turbine system, in particular a steam turbine system according to the preamble of independent claim 1 and a turbine system according to the preamble of independent claim 9.

[0005] A generic base frame is known, for example, from US 6230481 Bl. The base frame significantly facilitates the transport of the turbine system, as the turbine, generator, and any other components can be transported to the installation site fully assembled and aligned with each other.

[0006] The transport route for the base frame or the fully installed turbine system depends largely on the weight of the base frame or the system being transported. If the weight exceeds 80 tons, transport must be by ship. This presents considerable logistical challenges, as the transport route and the associated processes are more extensive and complex. In contrast, if the total weight is less than 80 tons, transport by truck is possible, which is generally less complex but still requires careful planning.

[0007] The choice of transport route directly influences transport costs and the transport route itself, which in turn affects transport time and thus the overall project lead time. Longer transport times can lead to delays in the project and increase overall costs. These temporal and financial aspects must be carefully considered to ensure project efficiency. 2025PF00102

[0008] A lightweight base frame is therefore desirable; however, it is important to remember that the base frame is a structural component and must fulfill a variety of functions. It must provide sufficient rigidity to safely absorb loads such as the turbine weight and the vibrations caused by operation. Insufficient rigidity could lead to structural damage and failures, resulting in high repair costs and downtime. The base frame must be manufactured with precision to ensure correct turbine mounting and accurate alignment of the rotational axes of all components. Misalignment can lead to uneven wear, increased vibration, and reduced efficiency. The turbine and its components can expand due to the high temperatures encountered during operation.The base frame must therefore be designed to compensate for thermal expansion without affecting the structure or alignment of the turbine. Furthermore, the base frame should be designed to allow easy access to all parts of the turbine system for inspection, maintenance, and repairs.

[0009] Previous approaches to reducing the weight of the base frame have mostly focused on using lighter materials and special construction methods. Optimizing the design and using lighter materials can reduce the weight of the steam generator housing. One solution involves using glass fiber reinforced plastic (GFRP) to improve the flexibility and efficiency of the base frame. However, the desire remains to further reduce the frame's weight without compromising its functional requirements.

[0010] The object of the present invention is therefore to provide a new basic frame which significantly 2025PF00102

[0011] 3

[0012] Weight reduction combined with improved rigidity is made possible. Furthermore, it is an object of the invention to provide a steam turbine plant with such a base frame.

[0013] The problem is solved with regard to the basic frame by the features of independent claim 1 and with regard to the steam turbine system by the features of independent claim 9.

[0014] Further advantages and embodiments of the invention, which can be used individually or in combination with each other, are the subject of the dependent claims.

[0015] The base frame according to the invention for a turbine system, in particular a steam turbine system (which is also referred to as a turbine package), is characterized in that the base frame is at least partially manufactured using lightweight construction, wherein the lightweight construction is formed by a honeycomb structure. Honeycomb structures are extremely lightweight and at the same time very stable. They enable high strength and stiffness, thereby allowing a significant reduction in the overall weight of the base frame.

[0016] One embodiment of the basic frame according to the invention is characterized by the fact that the honeycomb structure, i.e., the honeycomb core, is formed with thin facing sheets in a sandwich construction. To further improve the lightweight potential of honeycomb structures, they are designed as sandwich constructions. Here, the honeycomb structure is provided with thin, rigid facing sheets. The resulting composite material exhibits significantly better mechanical properties than the sum of its individual components. Honeycomb structures are particularly well suited as core material because, due to their excellent internal supports, they possess a high degree of strength.

[0017] 4

[0018] It exhibits compressibility while maintaining low weight.

[0019] A further embodiment of the invention provides that the base frame is at least partially manufactured using additive manufacturing. Additive manufacturing, often also referred to as 3D printing, is a manufacturing process in which material is applied layer by layer to create a three-dimensional object. Additive manufacturing is characterized by significantly greater design freedom, which makes it possible to variably adapt the size and / or shape of the honeycomb structure to the required mechanical properties and weight reduction targets. In particular, it is possible to adapt the honeycomb core to the component load. The size and fill level (honeycomb size relative to wall thickness) can be easily modified and optimized. Additive manufacturing enables the production of mesoscopic honeycomb structures, thus allowing the honeycomb structure to be adapted to any freeform surface of the base frame.This enables a design where bending stresses can be avoided, or at least drastically reduced. Careful analysis and simulation of the loads can help find the optimal balance between weight and stiffness. A mesoscopic honeycomb structure is understood to be a honeycomb structure with a geometric dimension that lies between the microscopic and macroscopic dimensions, in which massive material areas in the component can be replaced by complex material structures such as honeycombs, thus reducing mass.

[0020] A particularly advantageous embodiment of the invention provides that channels are formed in the base frame for receiving cables, wires, or other components. This reduces assembly effort and increases ease of servicing. 2025PF00102

[0021] 5

[0022] A further embodiment of the invention provides that all or individual cavities (honeycomb core) of the honeycomb structure are filled with a suitable material to improve thermal and / or acoustic insulation or to reduce the transmission of vibration.

[0023] In addition to their mechanical advantages, honeycomb structures also offer thermal and acoustic insulation properties. The standard hollow honeycomb core already provides good insulation against heat transfer and sound. To further improve these properties and adapt them to specific requirements, the honeycomb cores can be filled with a suitable material to enhance thermal and / or acoustic insulation or to reduce vibration transmission. The choice of filling material depends on the intended application. Foam, particularly aluminum-based foam, has proven especially advantageous as a filling material, as it exhibits not only good thermal and acoustic insulation properties but also a very low specific gravity.

[0024] A further embodiment of the invention provides that the base frame has a modular design. The modular design of the frame can increase the flexibility and efficiency of transport. A modular base frame makes it possible to disassemble the turbine system into transport-friendly units that are lighter and easier to handle. The modules are then assembled at the installation site. This reduces transport costs and simplifies logistics.

[0025] The turbine system according to the invention, comprising a previously described and claimed base frame, is characterized in that the turbine system includes at least one steam turbine and one generator. Preferably, the turbine system includes further components, such as a gearbox and / or an oil system with an integrated oil sump. The turbine system is particularly preferably a fully piped, wired, ready-to-operate, and pre-assembled unit. 2025PF00102

[0026] 6

[0027] trained. This allows it to be transported and set up at its destination without much effort.

[0028] Further embodiments and advantages of the invention are explained below using the exemplary embodiments.

[0029] It shows:

[0030] Fig. 1: The basic structure of a turbine system according to the invention

[0031] Fig. 2: A detailed view of a honeycomb structure of a lightweight base frame according to the invention.

[0032] Fig. 3 : A basic frame according to the invention which is manufactured using additive manufacturing.

[0033] The exemplary embodiments merely show a simplified schematic setup, in which essentially only the components essential to the invention are depicted. Identical or functionally equivalent components are identified by the same reference numerals across all figures.

[0034] Fig. 1 shows the basic structure of a turbine system 2 according to the invention. The turbine system comprises a base frame 1 on which a steam turbine 7 and a generator 8 are installed. A gearbox 9 is arranged between the steam turbine 7 and the generator 8. The steam turbine 7, the gearbox 9, and the generator 8 are connected to each other via a (split) common shaft 11. An oil supply 10 is integrated into the base frame 1. This oil supply includes an oil tank, which supplies the components, such as the bearings, with oil via lines 12 also integrated into the base frame 1. The oil supply 10 includes all necessary components, such as an oil pump and oil cooler, which are not explicitly shown in Fig. 1. Likewise, the live steam supply and the exhaust steam housing are not shown in Fig. 1.

[0035] The exhaust housing can also be mounted on the base frame 12025PF00102

[0036] 7

[0037] The exhaust steam housing can be installed or set up separately. Since the exhaust steam housing is usually a simple sheet metal construction, it is generally assembled and set up separately at the installation site. Similarly, in the case of a condensing turbine, a condenser can be provided which can be set up separately or installed on the base frame 1. The base frame 1 includes supports 13, with which the base frame can be fastened to a foundation.

[0038] To ensure a base frame 1 that is as light as possible yet sufficiently rigid and capable of safely absorbing loads such as the turbine weight and the vibrations caused by operation, the base frame 1 has a honeycomb structure 3. The entire base frame or only individual areas can be designed as a honeycomb structure 3.

[0039] To fully exploit the lightweight potential, the honeycomb structure 3, in the exemplary embodiment, is designed as a sandwich construction, meaning the honeycomb core is arranged between two thin outer layers. The resulting composite material exhibits significantly better mechanical properties than the sum of its individual components. Honeycomb structures are particularly well-suited as core materials because, due to their excellent internal supports, they offer high compressibility combined with low weight.

[0040] Fig. 2 shows a detailed view of a honeycomb structure 3 of the lightweight base frame 1. The top layer is not shown in Fig. 2, so the honeycomb structure 3 is visible. The honeycomb structure 3 consists of a multitude of adjacent hexagonal cells 14. The properties of the honeycomb structure 3 are determined, besides by the material used, essentially by the cell size S and the fill level (cell size S relative to wall thickness s) of the cell 14. A smaller cell size S and / or a 2025PF00102

[0041] 8

[0042] A thicker wall thickness (s) generally increases strength, whereas a larger honeycomb size (S) and / or a thinner wall thickness (s) exhibits higher elasticity and can therefore absorb vibrations better. By selectively choosing the honeycomb size (S), wall thickness (s), and fill level, the properties of the honeycomb structure can be individually tailored to specific requirements. Individual areas of the base frame can be customized in this way.

[0043] A particularly simple way to customize the base frame 1 is to manufacture it, at least partially, using additive manufacturing. The design freedom offered by additive manufacturing processes makes it possible to adapt the honeycomb core 15 to both the component geometry and the loads within the structure. The production of mesoscopic honeycomb structures 3 using additive manufacturing offers particular potential. Additive manufacturing allows the honeycomb structure 3 to be adapted to any freeform surface of the base frame 1. This enables a design in which bending stresses can be avoided, or at least drastically reduced. The orientation of the honeycomb structure is therefore not uniform within the base frame 1, but rather depends on the local force application.A careful analysis and simulation of the loads can help to find the optimal balance between weight and stiffness and the locally optimal orientation of the honeycomb structure.

[0044] The honeycomb core 15 is generally hollow or filled with air. This already provides good insulation against heat transfer and sound. To further improve these properties and adapt them to specific requirements, the honeycomb cores 15 can be filled to improve thermal and / or acoustic insulation or to reduce vibration transmission. The choice of filling material 16 depends on the intended application. A foam, in particular a 2025PF00102, has proven to be a suitable filling material.

[0045] 9

[0046] Aluminum-based foam has proven particularly advantageous, as it has a very low specific weight in addition to good thermal and acoustic insulation properties.

[0047] Fig. 3 shows a second embodiment of a base frame 1 according to the invention, which is manufactured using additive manufacturing. The base frame is again designed to accommodate the essential components of the turbine system. Here, the base frame 1 is designed as a modular base frame 1 and consists of two sub-frames 1', 1' which can be transported individually and assembled at the installation site. For example, the steam turbine and gearbox can be pre-assembled on the first sub-frame 1', and the generator on the second sub-frame. This reduces the weight and size of each unit, potentially allowing transport by truck.

[0048] The additive manufacturing of the base frame 1 enables virtually unlimited design freedom. For example, the frame can incorporate integrated bearing points 16, which can be designed to distribute bearing forces evenly throughout the base frame 1. The orientation, size, and fill level of the honeycomb structure can be individually and locally adjusted so that the base frame 1 meets all requirements for strength and stiffness and can withstand the vibrations without structural failure. Additive manufacturing is so flexible that an optimal frame can be produced for every specific application.

[0049] Additive manufacturing allows for the particularly simple formation of channels 17 within the base frame, which serve to accommodate cables, wires, or other components, thereby reducing assembly effort and significantly improving serviceability. Also the 2025PF00102

[0050] 10

[0051] Integration of the oil supply 10 can be easily achieved using additive manufacturing.

Claims

2025PF00102 11 Patent claims 1. Base frame ( 1 ) for a turbine plant (2 ) , characterized by the fact that the basic frame ( 1 ) is at least partially manufactured in a lightweight construction, the lightweight construction being formed by a honeycomb structure (3 ).

2. Base frame ( 1 ) according to claim 1, characterized by the fact that the honeycomb structure (3) is formed with thin cover layers in sandwich construction .

3. Base frame ( 1 ) according to claim 1 or 2, characterized by the fact that the basic frame ( 1 ) is at least partially manufactured by additive manufacturing .

4. Base frame ( 1 ) according to claim 3, characterized in that the honeycomb size S and / or the fill level is variable and adaptable to the required mechanical properties and weight reduction targets.

5. Base frame ( 1 ) according to claim 3 or 4, characterized in that channels (4) are formed within the honeycomb structure (3) which serve to accommodate cables, wires or other components.

6. Base frame ( 1 ) according to one of the preceding claims, characterized in that all or individual honeycomb cores (5) of the honeycomb structure (3) are filled with a suitable filling material to improve thermal and / or acoustic insulation or to reduce the transmission of vibration.

7. Base frame ( 1 ) according to claim 6, characterized by the fact that 2025PF00102 12 a foam ( 6 ) , in particular an aluminium-based foam , is used as a filling material .

8. Base frame ( 1 ) according to one of the preceding claims , characterized in that the basic frame ( 1 ) has a modular design .

9. Turbine system ( 2 ) comprising a base frame ( 1 ) according to one of the preceding claims, wherein the turbine system ( 2 ) comprises at least one steam turbine ( 7 ) and a generator ( 8 ).

10. Turbine system ( 2 ) according to claim 9 , characterized by the fact that the turbine system ( 2 ) includes further components such as gearbox ( 9 ) and / or oil system ( 10 ).

11. Turbine system ( 2 ) according to claim 10 , characterized by the fact that the turbine system ( 2 ) is a fully piped, wired, operationally ready and pre-assembled unit.

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