Copyright © Siemens AG 2006. All rights reserved. Design Team Calvin Stewart Carl Stewart Huy Lam Kirtan Patel Jessica Hanson

Copyright © Siemens AG 2006. All rights reserved.

SENIOR DESIGN PROJECT: SIEMENS LP FLOW GUIDE (SIE)

Design Team

Calvin Stewart

Carl Stewart

Huy Lam

Kirtan Patel

Jessica Hanson

PROJECT PURPOSE

Page 3 Feb - 5

Copyright © Siemens AG 2006. All rights reserved.Customer Order EngineeringSIE Design Team

EXISTENCE OF A NEED

A Diffuser is designed to minimize the pressure loss between the last row blades and the condenser.

This flow guide is hard bolted onto the inner casing and can not alter its geometry to suit different operating conditions.

To alleviate this problema design is needed that can Modify the profile of the flowguide to optimize its performance at various back pressures.

Page 4 Feb - 5


Design Requirements

Original Requirements

Simple Design

Able to increase and decrease the flow guide length, change profile,

and Rfg

Continuous adjustment over a year span

Backup system to prevent shutdown of the steam turbine

Repeatedly attach to the same axial and transverse position

Page 5 Feb - 5


Design Requirements

Modified Requirements

Only design top center section

Only a 2D design is required

Manufacturing process is not an issue

Cost is not an issue

FBD and Stress Calculations

Design for a safety factor of 2

Use hydro-actuators with compressed water (steam).

Detailed Design Analysis

Page 7 Feb - 5


2D Summer

The Blue Circle represents the geometry necessary during the summer for

optimized efficiency

Working Model was used as design optimization tool

Page 8 Feb - 5


2D Winter

The Orange Circle represents the geometry necessary during the winter for

optimized efficiency

Working Model was used to validate conformance to the shape change design requirements

Page 9 Feb - 5


2D Animated

Demonstration of Conformance to Design Requirements

Page 10 Feb - 5


Parametric Model

Member Relation

DP1 0.350

DP2 0.700

DP3 1.000

L1 1.000

L2 1.040

FLANGE 1.000

SLIDER 0.900

Rfg 2.4

Member Reduced Extendedθ1 6.000 6.000

θ2 35.156 20.109θ 3 62.360 34.991

φ 14.594 37.837

Page 11 Feb - 5


FBD

Factor of safety is 2. Therefore, the loads are doubled.

Assume massless rods/links.

Use 2- force members.

Page 12 Feb - 5


Stress

3 Kilopascal Pressure Conservative value maximum pressure seen on

outside diffuser surface area

Page 13 Feb - 5


Actuators

An Actuator is a mechanical device that can be use to move or control a mechanism or system.

Hydraulic actuator(6 per section)

Advantages/Disadvantages

Actuator # Actuator extended

Actuator reduced

Difference(stroke)

Actual Length

(max & min)

Actual Stroke

Primary Actuator(68) 0.869 0.419 0.45 .550(max)

.265(min) 0.285

Middle actuator(62) 1.916 1.166 0.75 1.212(max)

0.737(min) 0.474

Bottom actuator(47) 0.498 0.453(original) 0.045 0.315(max)

0.287(min) 0.0285

Page 14 Feb - 5


Actuators

Three Manufacturershttp://www.eckart-gmbh.de http://www.peninsularcylinders.com/ http://www.parker.com

Hydraulic rotary linear actuators use a pressurized, incompressible fluid and a patented method to convert rotary motion into linear extension.

http://www.eckart-gmbh.de/

http://www.peninsularcylinders.com/

http://www.parker.com/

Page 15 Feb - 5


Materials

Major ComponentsCarbon Steel Alloy Siemens Proprietary

Friction Reduction Layer (over Diffuser Plates)Fluoroelastomers are fluorinated synthetic polymers designed for harsh environments including aggressive chemical and high temperature applications.

Fluoroelastomers can perform up to 450 F to 500 F.

Fluoroelastomer are resistant to • oils• lubricants• fuels• high temperature steam

Page 16 Feb - 5


Pin Sub-Assembly

Individual Designs Design optimization and safety

Page 17 Feb - 5


Pin Sub-Assembly

Pin Parts Male Holder Female Holder Rod Bolts

Page 18 Feb - 5


Slider Sub-Assembly

Individual Designs Design optimization and safety

Page 19 Feb - 5


Slider Sub-Assembly

Slider Parts Cover Holder Base Holder Inset Ball Bearings

Page 20 Feb - 5


Final Assembly

Image of Assembly

Video rotating around Assembly

Page 21 Feb - 5


Documentation of Design Records

Page 22 Feb - 5


Drawings

Page 23 Feb - 5


Bill of Materials

A Bill of material is a list of parts going from assembly to sub-assembly to individual parts. The type of

BOM we will use is an indented one. With the finished product at the head.

Part Name Level Part Number Revision Quantity Make/BuyFlange 1 001-001 A 1 NoneDP1 2 002-001 A 1 MakeDP2 2 002-002 A 1 MakeDP3 2 002-003 A 1 MakeSlider 3 003-001 A 1 MakeL1 4 004-001 A 2 MakeL2 4 004-002 A 2 MakeA1 5 005-001 A 2 BuyA2 5 005-002 A 2 BuyA3 5 005-003 A 2 BuyPin1 6 006-001 A 2 MakePin2 6 006-002 A 4 MakeMaterial 7 007-001 A N/A Buy

Page 24 Feb - 5


Operation of Mechanism

In order for the system to function according to the requirements (over a yearly cycle) its important to have a feedback control system which will automatically adjust the mechanism based on recordable stimuli

Possible Sampling Sources Cooling Water

Thermocouple Back Pressure

Pressure coupleSample

Activate Actuators

Start FBC at Steady State

SCHEDULE & ASSIGNMENTS

Page 26 Feb - 5


GANTT CHARTGroup Tasks 8-Jan 15-Jan 22-Jan 29-Jan 5-Feb 12-Feb 19-Feb 26-Feb 4-Mar 11-Mar 18-Mar 25-Mar 1-Apr 8-Apr 15-Apr

Detailed Design Siemens Approval Report Sections Introductory Material Redefinition of Design Reqs X Bill of Materials Conclusion Material Research Projects X Actuator Study X Pinning Study X Slider Study X Brief on Fouroelastomers Calculations X Free Body Diagrams X MathCAD Code X Stress Calculations CAD X Pro Engineer Modeling X Pro Engineer Animation X Pro Engineer Drawings X Presentation of Detailed Design Written Detailed Design Report Manufacturing Determine Prototype Style Funding Proposal Building Testing Documentation Final Presentation Final Report

Page 27 Feb - 5


Individual Tasks

Individual Tasks 8-Jan 15-Jan 22-Jan 29-Jan 5-Feb 12-Feb Jessica Hanson X Free Body Diagrams X MathCAD Code Huy Lam Introductory Material X Actuator Study Kirtan Patel X Pro Engineer Modeling X Pro Engineer Animation X Pro Engineer Drawings Calvin Stewart Conclusion Material X Pinning Study X Slider Study X Stress Calculations Carl Stewart Redefinition of Design Reqs X Bill of Materials X Brief on Fouroelastomers

Jessica HansonReport Organizer and CAD Modeler

Huy Lam

Presentation Organizer and Mechanism Design Researcher

Kirtan Patel

Data Organizer, Materials Researcher, and CAD Modeler

Calvin Stewart

Team Organizer, Mechanism Design Researcher, and Finite Element Analyzer

Carl Stewart

Communicator, Materials Researcher, and CAD Modeler

Page 28 Feb - 5


CONTACT INFORMATION

Advisors

Jeffrey R. CheskiSteam Turbine EngineeringP11A12, COE Manager(407) 736-4743

Matt Johnston Steam Turbine EngineeringP11A13, Engineer

Lewis Gray Steam Turbine EngineeringP11A13, Fellow Engineer

Project Details

Calvin M Stewart, Steam Turbine EngineeringP11A12, COE Intern(407) 736-4289

Page 29 Feb - 5


QUESTIONS ?

Documents

Copyright © Siemens AG 2006. All rights reserved. Design Team Calvin Stewart Carl Stewart Huy Lam Kirtan Patel Jessica Hanson