GPP SEAL SYSTEM MAINTENANCE, REPLACEMENT AND SEISMIC ISOLATION
20240200524 ยท 2024-06-20
Inventors
Cpc classification
F03G3/094
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05B2240/57
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03B11/006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03B13/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F03B11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03B13/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A sealing system for a Gravity Power Plant having a shaft (104) with a shaft wall (105) and a piston (102) incorporates a seal assembly support base (202) anchored into the shaft wall and surrounding the piston. A seal mount has a radial flange (210) to anchor the seal mount to the support base (202) and a vertical flange (212) extending from an inner circumference of the radial flange. A seal assembly (206) circumferentially contacting the piston, has a plurality of circumferentially spaced clamp assemblies (227) to engage the seal assembly to the vertical flange, the clamp assemblies having an open position releasing the seal assembly from the vertical flange and a closed position constraining the seal assembly on the vertical flange. For seismic isolation of the seal assembly the radial flange is supported on a lower bearing (406) supported on a top surface of the seal assembly support base proximate an inner surface. The radial flange (410) extends inward from the inner surface with the vertical flange spaced from the inner surface by a radial relief (428) within a gap between the seal assembly support base and the piston. An upper bearing is supported in engagement with a top surface (411) of the radial flange (410) of the seal mount (404).
Claims
1. A sealing system for a Gravity Power Plant having a shaft (104) with a shaft wall (105) and a piston (102), the sealing system comprising: a seal assembly support base (202) anchored into the shaft wall and surrounding the piston; a seal mount having a radial flange (210) adapted to anchor the seal mount to the support base (202) and a vertical flange (212) extending from an inner circumference of the radial flange; and, a seal assembly (206) having at least one seal group (226) circumferentially contacting the piston, the seal assembly incorporating a plurality of circumferentially spaced clamp assemblies (227) configured to engage the seal assembly to the vertical flange, the clamp assemblies having an open position releasing the seal assembly from the vertical flange and a closed position constraining the seal assembly on the vertical flange.
2. The sealing system as defined in claim 1 wherein the seal assembly further comprises: a seal carrier (220) terminating at a top end with a plurality of circumferentially spaced bosses (222) wherein the plurality of clamp assemblies are circumferentially aligned with a respective one of the bosses and each clamp assembly incorporates a clamp (228) configured to engage a rim (214) of the vertical flange.
3. The sealing system as defined in claim 2 wherein each clamp is bolted to the seal carrier with a shoulder bolt (230) having a threaded barrel (234) passing through a threaded bore 236 in the respective one of the bosses, an end flange attached to an inner end of the bolt preventing removal from the boss.
4. The sealing system as defined in claim 2 wherein the at least one seal group comprises a plurality of seal groups and further comprising a plurality of guide rings (224) mounted concentrically in the seal carrier (220) with one of the plurality of seal groups (226) supported between vertically adjacent guide rings on a support ring (248).
5. The sealing system as defined in claim 4 wherein each of the plurality of seal groups comprises: a seal (240) attached to the support ring; and contact pads (246) attached to the support ring.
6. The sealing system as defined in claim 1 wherein, with the plurality of clamp assemblies in the open position, the seal assembly is movable vertically along an axis of the piston and removed from the seal mount.
7. The sealing system as defined in claim 6 further comprising a hoist and carriage system (300) configured to grip the unlocked seal assembly and hoist the seal assembly from the seal mount to a water surface in the shaft.
8. The sealing system as defined in claim 7 wherein the hoist and carriage system comprises: a plurality of hoist assemblies (302) circumferentially spaced about an upper rim (304) of the shaft; a plurality of carriages (310) configured for longitudinal translation in the shaft, each carriage associated with one of the plurality of hoist assemblies and including grippers (312) that are adjustable on a lower frame element 314 for radial alignment with the seal assembly (206) for grabbing the seal assembly.
9. The sealing system as defined in claim 8 wherein each hoist assembly (302) includes a cable drum (306) with one or more cables (308) that attach to the associated one of the carriages.
10. The sealing system as defined in claim 9 wherein the one or more cables run over a sheave or pulley block (309) and then downwardly to attach to the associated one of the carriages.
11. The sealing system as defined in claim 1 wherein the seal assembly support base has an inner surface (424) with an inner radius (420), providing a gap (422) between the inner surface and a surface (103) of the piston (102), and wherein the radial flange (410) is supported with low friction engagement with respect to the support base and extends inward from the inner surface of the seal assembly support base with the vertical flange spaced from the inner surface by a radial relief (428) within the gap.
12. The sealing system as defined in claim 11 wherein the radial flange is supported on a lower bearing 406 supported on a top surface (407) of the seal assembly support base proximate the inner surface, with an upper bearing supported in engagement with a top surface (411) of the radial flange (410) of the seal mount (404).
13. The sealing system as defined in claim 12 wherein the lower bearing comprises a bearing plate (406) with a very low coefficient of friction and extends in a ring all the way around the assembly support base upper surface (408) encircling the piston (102).
14. The sealing system as defined in claim 13 wherein the upper bearing comprises a plurality of upper bearing plates (408) mounted on a plurality of heavy braces (414) strongly anchored to the shaft wall (105), each of the upper bearing plates (408) substantially the same width as the heavy brace normal to the piston circumference.
15. The sealing system as defined in claim 14 wherein the bearing plate and plurality of upper bearing plates are polytetrafluoroethylene (PTFE),
16. The sealing system as defined in claim 13 further comprising a seal (426) installed below the lower bearing plate (406) at a top inner edge (427) of the seal assembly support base to prevent water intrusion.
17. A removal and replacement system for seal assemblies in a Gravity Power Plant, the system comprising: a hoist and carriage system (300) configured to grip an unlocked seal assembly and hoist the seal assembly from a seal mount to a water surface in a shaft (104).
18. The removal and replacement system as defined in claim 17 wherein the hoist and carriage system comprises: a plurality of hoist assemblies (302) circumferentially spaced about an upper rim (304) of the shaft; a plurality of carriages (310) configured for longitudinal translation in the shaft, each carriage associated with one of the plurality of hoist assemblies and including grippers (312) that are adjustable on a lower frame element (314) for radial alignment with the seal assembly (206) for grabbing the seal assembly.
19. A method for removal of a seal assembly in a sealing system as defined in claim 8, the method comprising: placing the clamp assemblies in an open position; lowering the plurality of carriages to place the grippers in contact with the seal assembly; gripping the seal assembly with the grippers; raising the plurality of carriages.
20. A Gravity Power Plant energy storage system having a shaft (104) with a shaft wall (105) and a piston (102), with a sealing system providing seismic isolation comprising: a seal assembly support base (402) anchored into the shaft wall and surrounding the piston, the seal assembly support base having an inner surface (424) with an inner radius (420), providing a gap (422) between an inner surface (424) of the support base (402) and a surface (103) the piston (102); a seal mount (404) circumferentially surrounding the piston (102) supported in low friction engagement with respect to the seal assembly support base; a seal assembly (206) supported on the seal mount circumferentially contacting the piston, spaced from the inner surface by a radial relief (428) within the gap wherein the seal mount will slide with respect to the seal assembly support base within the radial relief preventing the seal assembly support base from impacting the seal assembly or piston.
21. The Gravity Power Plant energy storage system as defined in claim 20 wherein the seal mount has a radial flange (410) engaged to the support base (402) and a vertical flange (412) extending from an inner circumference of the radial flange, the radial flange supported on a lower bearing (406) supported on a top surface of the seal assembly support base proximate the inner surface, an upper bearing supported in engagement with a top surface (411) of the radial flange (410) of the seal mount (404).
22. The Gravity Power Plant energy storage system as defined in claim 21 wherein the lower bearing comprises a bearing plate (406) with a very low coefficient of friction and extends in a ring all the way around the assembly support base upper surface (408) encircling the piston (102).
23. The Gravity Power Plant energy storage system as defined in claim 22 wherein the upper bearing comprises a plurality of upper bearing plates (408) mounted on a plurality of heavy braces (414) strongly anchored to the shaft wall (105), each of the upper bearing plates (408) substantially the same width as the heavy brace normal to the piston circumference.
24. The Gravity Power Plant energy storage system as defined in claim 23 wherein the bearing plate and plurality of upper bearing plates are polytetrafluoroethylene (PTFE),
25. The Gravity Power Plant energy storage system as defined in claim 22 further comprising a seal (426) installed below the lower bearing plate (406) at a top inner edge (428) of the seal assembly support base to prevent water intrusion.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0033] The following detailed description is of the best presently contemplated mode for the implementations disclosed herein. This description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention.
[0034]
[0035] A pump-turbine 120 is disposed in the upper cross passage 116, such that fluid flowing through the passage 110 turns the pump-turbine 120. The pump-turbine 120 separates the upper cross passage 116 into first portion 122 extending from the pump-turbine 120 to the upper chamber 106 and a second portion 123 extending from the pump-turbine 120 to the vertical passage 112. The pump-turbine 120 is a rotational device that is configured to operate as a pump when rotating in a first direction and as a turbine when rotating in a second, opposite direction. The pump-turbine 120 is mechanically coupled to an electric motor/generator 124, such as via a driveshaft 126. The pump-turbine 120 may be coupled to the driveshaft 126 via an intermediate member, such as a clutch or a torque converter to allow the pump-turbine 120 to be mechanically decoupled from the electric motor/generator 124. One or more of the pump-turbine 120, the electric motor/generator 124, and the driveshaft 126 may be housed in a facility such as a powerhouse 128 that extends underground from the surface.
[0036] The motor/generator 124 is connected to an external source and destination for electric power, such as the electric power grid. Energy to be stored in the energy storage system 100 is used to drive the electric motor/generator 124, rotating the pump-turbine 120 through the interconnection of the motor/generator 124, the driveshaft 126, and the pump-turbine 120. The pump-turbine 120 forces fluid through the passage 110 from the upper chamber 106 to the lower chamber 108, creating a higher pressure in the lower chamber 108 underneath the piston 102. The pressure differential lifts the piston 102 upwards, toward the top of the shaft 104, storing energy in the form of gravitational potential energy. The stored energy may be output from the energy storage system 100 by allowing the piston 102 to descend in the shaft 104. The weight of the piston forces fluid through the passage 110 from the lower chamber 108 to the upper chamber 106. The fluid flows through the pump-turbine 120, rotating the pump-turbine 120. The motor/generator 124 is driven through the interconnection of the motor/generator 124, the driveshaft 126, and the pump-turbine 120 to produce electric power. The electric power may be supplied, for example to the electric power grid.
[0037] The relatively large size and vertical movement of the piston 102 and the relatively small drag losses because of the relatively modest speed of the piston 102 allows for substantial energy to be stored in the energy storage system 100. According to one exemplary embodiment, the shaft has a diameter of approximately 30 meters and a depth of approximately 500 meters and the piston has a height of approximately 250 meters and a volume of approximately 174,000 cubic meters. The piston 102 may be formed substantially from concrete, which has a negative buoyancy in water of approximately 1500 kg per cubic meter, providing a downward force of approximately 14700 Newtons. The energy (work) released by lowering one cubic meter of concrete through 1000 meters of elevation in water is:
For a concrete piston with a volume of approximately 174,000 cubic meters moving through an elevation change of 250 meters, the resulting storage capacity exceeds 160 megawatt-hours
[0038] A sealing system 130 is provided surrounding the piston 102 and disposed in an annular space 101 between the piston 102 and the wall of the shaft 104. The sealing system 130 is configured to prevent the flow of fluid around the piston 102 between the upper chamber 106 and the lower chamber 108. A wall 105 of the shaft 104, an outer surface 103 of the piston 102 and the sealing system 130 are configured to prevent high pressure or particulates in the fluid from causing damage to the shaft 104, the piston 102, or the seal assembly 130 and to maximize the operational lifetime of the energy storage system 100.
[0039] In the disclosed implementation, seal elements in sealing system 130 press against the outer surface 103 of piston 102, which moves up and down past sealing system 130. In other implementations the sealing system 130 may be attached to piston 102 and press against the shaft wall 105. The seal elements in sealing system 130 will eventually wear down and require replacement, but because they may be up to 500 meters or more below the surface of the water inside shaft 104 such replacement can be difficult and could even require that all the water in upper shaft chamber 106 be pumped out to allow direct access to the sealing system.
[0040] In the implementation disclosed in
[0041]
[0042] In
[0043] As seen in
[0044] As seen in
[0045] Each seal group 226 includes a seal 240 and contact pads 246 attached to the support ring 248. The seal 240 is formed of a resilient material, such as a synthetic polymer (e.g., polyurethane, polybutadiene, etc.), that is capable of being compressed against the piston 102 and conforming to the outer surface 103 to create a seal against the passage of working fluid between the seal assembly 206 and the piston 102. In exemplary implementations, the seal 240 may be formed (e.g., machined, molded, extruded, etc.) in segments that can be field welded or bonded into a continuous ring. The contact pads 246 are formed of a strong, low friction material such as ultra-high molecular weight polyethylene or Vesconite that resist compression. The contact pads 246 are disposed above and/or below the seal 240, are bolted or otherwise attached to the seal support ring 248 and are configured to prevent contact between the guide rings and surface 103 of the piston 102. The seal 240 and the contact pads 246 are configured to have a low coefficient of friction when sliding on a steel surface, such as the surface 103 of the piston 102. If the seal assembly 206 encounters a raised discontinuity (e.g., ridge, bump, swell, etc.) in the surface 103 of the piston 102, the relatively hard contact pads 246 are configured to displace the seal carrier 220 locally outward in the area of the discontinuity, protecting the relatively soft seal 240 from a shearing action.
[0046] In operation, the seal 240 expands inward in a radial direction due to the pressure of the working fluid in the lower chamber 108 below the seal assembly 206, tightly filling the gap between the seal carrier 220 and the piston 102 to prevent fluid from leaking past.
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[0049] In
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[0051] The configuration of the support base 202, seal mount 204 and seal assembly 206 allow for ease of installation and removal of the seal assembly for maintenance.
[0052] The hoists and carriages are deployed around the upper rim 304 of the shaft 104 as seen in the top plan view of FIG. 11with four carriages 310. Other implementations may utilize fewer or more carriages circumferentially spaced about the rim, depending on the needs of particular installations. As shown, each carriage is hoisted by two hoist cables 308, but in some embodiments one cable may suffice and in others more than two cables may be preferred. A motor 316, typically electrically powered although other types may be substituted, drives the cable drum 306. The carriages 310 may be interconnected with a frame 316 to fix relative placement of the carriages.
[0053] In operation as seen in
[0054] The carriages 310 are positioned in proximity to the support base 202 and the top of the piston as seen in
[0055] The hoist assemblies 302 are then employed to lift the carriages 310 and seal assembly 206 away from the seal mount 204 and piston 102 as seen in
[0056] Once the carriages 310 have been fully retracted and the seal assembly hoisted all the way to the surface, above the water level 303 of the shaft 104, as seen in
[0057] The previously mentioned figures and designs illustrate embodiments of the GPP and the seal system that provide for ease of maintenance and repair. A further implementation, described in detail below with respect to
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[0059] As seen in
[0060] As seen in
[0061] As seen in
[0062] The plurality of brace/upper bearing plate pairs around the piston circumference are shown in
[0063] The seal assembly 206 as disclosed in the previous implementation is attached to the vertical flange 412 of the seal mount 404.
[0064] The seal assembly installed on the seal mount is shown in
[0065] The radial flange 410 of the seal mount 404 is held between the upper bearing and the lower bearing. In the event of an earthquake the seal assembly support base, heavy brace, and shaft wall will all move laterally with the surrounding ground by a varying amount, depending on the magnitude of the earthquake. The piston will tend to remain stationary due to inertia and the buoyant forces in the water column in the shaft 104. The seal mount will slide between the upper and lower bearings with the increased radial relief 428 in the seal mount 404 preventing the seal assembly support base from impacting the seal assembly or piston in all but the very largest earthquakes, thereby preventing damage to the system.
[0066] Having now described various implementations of the disclosure in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific disclosure herein. Such modifications are within the scope and intent of the present disclosure as defined in the following claims. Within the specification and the claims, the terms comprising, incorporate, incorporates or incorporating, include, includes or including, has, have or having, and contain, contains or containing are intended to be open recitations and additional or equivalent elements may be present. The term substantially as used within the specification and claims means that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those skilled in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide. As used herein the terms top, bottom, upper. lower, inner, outer are employed to describe relative positioning and other than for the specific implementations disclosed may be substituted with appropriate descriptors such as first and second, top and bottom or right and left depending on orientation of actual implementation.