Clutchless Synchronous Condensing Coupling for Gas Turbine Retrofit
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Solution Overview
Problem
Existing power generation systems with gas turbine engines and synchronous generators require costly clutch assemblies for operation, which increase servicing and downtime, and are difficult to retrofit without significant changes to the system's footprint.
Innovation Solution
A clutchless synchronous condensing coupling system that couples the turbine shaft of a gas turbine system to the generator shaft of a synchronous generator, allowing operation in both active and reactive power modes without a clutch assembly, while maintaining the existing system footprint through adjustable components and a sump evacuation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a clutch assembly is installed in an existing power generation system, then selective engagement and disengagement between generator and gas turbine can be achieved, but servicing costs, replacement parts costs, and downtime increase
Solution Approach 1:
The patent removes the clutch assembly entirely from the power generation system. Instead of using a clutch for selective engagement and disengagement, the system relies on the inherent ability of the synchronous generator to operate in different modes (generator mode, motor mode, synchronous condenser mode) without requiring mechanical coupling changes. This extraction of the clutch component directly eliminates the associated maintenance costs, replacement parts costs, and downtime while maintaining operational flexibility.
2Reliability
If a clutch assembly is removed to reduce maintenance costs, then servicing and replacement parts costs decrease, but the ability to operate in various modes may be compromised
Solution Approach 1:
The synchronous generator is designed to perform multiple functions without requiring a clutch assembly. The generator can operate in generator mode (producing active power), motor mode (absorbing active power), and synchronous condenser mode (providing reactive power) by controlling the excitation and prime mover input. This multi-functionality of the single machine eliminates the need for clutch-based mode switching while maintaining full operational versatility.
3Reliability
If the system is retrofitted to operate without a clutch assembly, then maintenance costs and downtime are reduced, but substantial changes to the pre-existing footprint may be required
Solution Approach 1:
The retrofit approach segments the modification into manageable components: removing the clutch assembly, installing a coupling device to connect the prime mover shaft to the generator shaft, and updating control software. The coupling device is designed to fit within the existing spatial footprint, requiring minimal structural modifications to the foundation and mounting arrangements. This segmented approach makes the retrofit process more manageable and less intrusive than a complete system redesign.
4Adaptability or versatility
If a coupling device is installed to connect turbine shaft to generator shaft, then torque transfer for clutchless operation is enabled, but the coupling device must accommodate misalignment and operational flexibility
Solution Approach 1:
A flexible coupling device serves as an intermediary between the prime mover shaft and the generator shaft. This coupling accommodates misalignment in radial, axial, and angular directions while transmitting torque. The flexible nature of the coupling allows for operational flexibility without requiring precise alignment, simplifying the installation and reducing the complexity of foundation requirements while maintaining full torque transfer capability for both generator and motor modes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient retrofitting of power generation systems to operate in multiple modes without a clutch assembly, reducing downtime and maintenance costs by allowing torque transfer between shafts and maintaining system stability through adjustable couplings and lubrication systems.
Implementation Method 1
The clutchless synchronous condensing coupling is configured to transfer torque from the second shaft to the generator shaft to drive the synchronous generator in the active power mode
Implementation Method 2
The clutchless synchronous condensing coupling is configured to transfer torque from the generator shaft to the second shaft when the synchronous generator is operating as a synchronous condenser in the reactive power mode
Implementation Method 3
The sump evacuation system is configured to flow a lubricant to the plurality of bearings
Data Source
AI summary
A system includes a clutchless synchronous condensing coupling configured to couple a turbine shaft of a gas turbine system to a generator shaft of a synchronous generator of a power generation system. The clutchless synchronous condensing coupling includes a first coupling portion configured to couple to the turbine shaft, and a second coupling portion configured to couple to the generator shaft. The clutchless synchronous condensing coupling is configured to allow the power generation system to operate in an active power mode and a reactive power mode without a clutch assembly.