Dog-Bone Connector for Steam Turbine Condenser Alignment
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Solution Overview
Problem
Existing steam turbine systems face vertical misalignment issues due to tolerance stack-up and weld shrinkage when coupling a condenser to a steam turbine, requiring extensive leveling and delaying additional foundation work, which prolongs the installation process.
Innovation Solution
A connection system comprising a dog-bone connector and two clamps that allow for adjustable retention cavities to accommodate misalignment, enabling the condenser to be positioned beneath the turbine without final welding, thus allowing independent assembly and adjustment of the turbine system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to couple the condenser to the steam turbine, then a strong permanent connection is achieved, but vertical misalignment occurs due to tolerance stack-up and weld shrinkage, requiring time-consuming leveling operations
Solution Approach 1:
The connection system is divided into separate modular components: a condenser coupling assembly, a turbine coupling assembly, and an adjustable positioning assembly. This segmentation allows each component to be manufactured independently with standard tolerances, avoiding the tolerance stack-up problem that plagues traditional welded connections while enabling time-efficient assembly through modular coupling.
Solution Approach 2:
The positioning assembly incorporates adjustable and repositionable components that allow the condenser coupling assembly to be dynamically positioned relative to the turbine coupling assembly. This dynamic adjustment capability eliminates the need for time-consuming leveling operations after welding, as misalignment can be corrected during assembly rather than requiring post-weld adjustments.
2Manufacturing precision
If the condenser is jacked up and levelled to enable final welding, then proper alignment is achieved, but additional foundation work must be delayed until after welding and leveling are complete
Solution Approach 1:
The positioning assembly is designed to establish proper alignment and positioning of the condenser coupling assembly relative to the turbine coupling assembly before final assembly operations. This preliminary positioning action ensures that alignment precision is achieved during the assembly process itself, rather than requiring post-assembly leveling operations that would delay foundation work.
Solution Approach 2:
The adjustable positioning assembly acts as an intermediary mechanism between the condenser coupling assembly and the turbine coupling assembly. It mediates the alignment process by providing adjustable positioning capabilities that accommodate tolerance variations, enabling proper alignment to be achieved without time-consuming jack-and-level operations that would delay subsequent foundation work.
3Reliability
If final welding is performed from inside the joint, then a permanent connection is achieved, but the process is complex and time-consuming
Solution Approach 1:
The connection system segments the coupling process into modular assemblies that can be joined through simpler connection methods. By dividing the system into a condenser coupling assembly and a turbine coupling assembly with an intermediate positioning assembly, the need for complex internal welding operations is eliminated, reducing assembly complexity while maintaining connection reliability through the modular design.
Data Source
AI summary
A connection system for coupling a steam turbine to a condenser is provided. The connection system includes a dog-bone connector, a first clamp, and a second clamp. The dog-bone connector includes a first end, a second end opposite the first end with respect to the third direction, and a body extending therebetween. The first clamp includes a first portion, a second portion coupled to the first portion, and a first retention cavity defined therebetween. The first clamp is configured to couple to one of the steam turbine and the condenser such that the first portion is movable relative to the second portion along the third direction. The second clamp is configured to couple to the other of the steam turbine and the condenser and includes a third portion, a fourth portion coupled to the third portion, and a second retention cavity defined therebetween.