Housing assembly and method of assembling same

A method of assembling a housing assembly is provided. The method includes providing a housing that includes an access panel and a cavity defined therein, wherein the housing is sized to enclose at least one electrical system within the cavity. A portion of the housing is enclosed with a cover such that the access panel remains accessible and the cover is positioned against the portion of the housing. At least one gasket is coupled between the housing and the cover such that a seal is formed on the housing assembly that substantially prevents fluid from entering the housing assembly.

BACKGROUND OF THE INVENTION

The field of the invention relates generally to industrial systems and, more particularly, to housing assemblies for use with industrial systems.

At least some known industrial systems, such as power generation systems, include various electrical systems, such as, for example, turbine control equipment, generator controls, exciter controls, and/or static starter controls. Such electrical systems generally require protection against various factors, such as dust particles and water. More specifically, contaminants, such as dust particles and/or water, may cause damage to the electrical system if such contaminants contact the system. Moreover, continued operation with such contaminants within the electrical system may lead to a premature failure of the electrical system and/or the higher-level system which the electrical system, such as the control system controls. To prevent such failures, at least some electrical systems are housed within a structure, such as a housing or a cabinet. For example, many industrial control and electronic systems are mounted inside sheet metal cabinets that have an Industrial Protection (IP) rating of 20 or 21. Specifically, a cabinet with an IP20 rating is protected against touch by a finger, but is not protected against liquids, whereas a cabinet with an IP21 rating protected against touch by a finger and is also protected against condensation. Many power generation systems require additional protection and use cabinets with an IP54 rating that also protects against dust ingress and water spray from any direction.

Many power generation facilities may require an upgrade of their IP20 and/or IP21 cabinet to a cabinet that offers better protection, such as an IP54 cabinet. However, making such an upgrade is costly, tedious, and time consuming. More specifically, as part of an upgrade process, a facility may also be forced to modify their industrial control and power electronics equipment to enable such equipment to be properly mounted within the cabinet.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a method of assembling a housing assembly is provided. The method includes providing a housing that includes an access panel and a cavity defined therein, wherein the housing is sized to enclose at least one electrical system within the cavity. A portion of the housing is enclosed with a cover such that the access panel remains accessible and the cover is positioned against the portion of the housing. At least one gasket is coupled between the housing and the cover such that a seal is formed on the housing assembly that substantially prevents fluid from entering the housing assembly.

In another embodiment, a housing assembly is provided. The housing assembly includes a housing that includes an access panel and a cavity defined therein, wherein the housing is sized to enclose at least one electrical system within the cavity. Moreover, the housing assembly includes a cover that is configured to enclose a portion of the housing such that the access panel remains accessible and the cover is positioned against the portion of the housing. The housing assembly also includes at least one gasket that is coupled between the housing and the cover such that a seal is formed on the housing assembly that substantially prevents fluid from entering the housing assembly.

In yet another embodiment, an industrial system is provided. The industrial system includes at least one electrical system and at least one housing assembly configured to enclose the electrical system. The housing assembly includes a housing that includes an access panel and a cavity defined therein, wherein the housing is sized to enclose the electrical system within the cavity. Moreover, the housing assembly includes a cover that is configured to enclose a portion of the housing such that the access panel remains accessible and the cover is positioned against the portion of the housing. The housing assembly further includes at least one gasket that is coupled between the housing and the cover such that a seal is formed on the housing assembly that substantially prevents fluid from entering the housing assembly.

DETAILED DESCRIPTION OF THE INVENTION

The exemplary methods, apparatus, and systems described herein overcome at least some known disadvantages associated with at least some known housing or cabinet structures used to enclose electrical systems. The embodiments described herein provide a housing assembly that includes a housing that includes an access panel and a cavity defined therein. The housing is sized to enclose at least one electrical system within the cavity. Moreover, the housing assembly also includes a cover configured to enclose a portion of the housing such that the access panel remains accessible and the cover is positioned against the housing. At least one gasket extends between the housing and the cover to prevent fluid from entering therein. Moreover, the combination of a cover and the gaskets enables the electrical system to be substantially shielded from any fluid that may cause damage. As such, there is no need to purchase a cabinet with a higher IP rating and there is no need to modify the electrical system to enable it to be mounted within a new cabinet.

FIG. 1is a schematic illustration of an exemplary industrial system100. More specifically, in the exemplary embodiment, system100is a combined-cycle power generation system. Although the exemplary embodiment illustrates a combined-cycle power generation system, the present invention is not limited to combined-cycle power generation systems, and one of ordinary skill in the art will appreciate that the current invention may be used in connection with any type of industrial system.

In the exemplary embodiment, system100includes at least one gas turbine engine102and at least one steam turbine engine104that are rotatably coupled to a first electric power generator106and a second electric power generator108, respectively. System100also includes at least one heat recovery steam generator (HRSG)110coupled in flow communication with gas turbine engine102via an exhaust gas conduit111. It should be noted that, as used herein, the term “couple” is not limited to a direct mechanical, communication, and/or an electrical connection between components, but may also include an indirect mechanical, communication and/or electrical connection between multiple components.

Moreover, in the exemplary embodiment, steam turbine engine104is coupled in flow communication with HRSG110via multiple steam conduits112. Steam turbine engine104is also coupled in flow communication with a condenser122via a low pressure steam exhaust conduit124. In the exemplary embodiment, HRSG110includes a high pressure (HP) superheater section126, a reheater/intermediate pressure (RH/IP) section128, and a low pressure (LP) section130. Similarly, steam turbine engine104includes an HP section132, an IP section134, and a LP section136.

In the exemplary embodiment, system100includes a main stop valve (MSV)151and a main control valve (MCV)152that are each coupled in flow communication with one of conduits112upstream from HP section132. System100also includes an intermediate stop valve (ISV)153and an intermediate control valve (ICV)154that are each coupled in flow communication in a conduit112upstream from IP section134. System100also includes an HP bypass pressure control valve (HP bypass PCV)156that is coupled in flow communication with a conduit112and an IP bypass pressure control valve (IP bypass PCV)158that is coupled in flow communication with a conduit112.

Moreover, in the exemplary embodiment, gas turbine engine102includes, a compressor section160, a combustor section162coupled downstream from compressor section160, a turbine section163that is coupled downstream from combustor section162, and an exhaust section164. Turbine section163is coupled to compressor section160via a rotor shaft165. Turbine section163is also coupled to generator106.

Moreover, in the exemplary embodiment, system100includes at least one electrical system, such as an exciter167coupled to generator106and to turbine section163, a static starter168coupled to generator108, and a control system170coupled to HRSG110and coupled to MSV151, MCV152, ISV153, ICV, HP bypass PCV156, and IP bypass PCV158. In the exemplary embodiment, control system170regulates steam flow and pressure within system100by selectively opening and closing HP bypass PCV156, IP bypass PCV158, MSV151, MCV152, ISV153, and ICV154via features, such as, but not limited to, receiving permissive inputs, transmitting permissive outputs, and transmitting opening and closing commands. Alternatively, control system170may regulate any other parameters and/or features of system100. Moreover, in the exemplary embodiment, exciter167, static starter168, and control system170are each enclosed within a housing assembly180. While the exemplary embodiment illustrates housing assembly180enclosing exciter167, static starter168, and control system170, housing assembly180may enclose any other electrical system that is part of industrial system100.

During operation, air is channeled towards compressor section160wherein the air is compressed to a higher pressure and temperature prior to being discharged towards combustor section162. The compressed air is mixed with fuel and ignited to generate combustion gases that are channeled towards turbine section163. More specifically, fuel, for example, natural gas and/or fuel oil, is injected into the air flow, and the fuel-air mixture is ignited to generate high temperature combustion gases that are channeled towards turbine section163. Turbine section163converts the thermal energy from the gas stream to mechanical rotational energy, as the combustion gases impart rotational energy to turbine section163enabling gas turbine engine102to generate power used to drive generator106. Generator106then supplies electrical power to a power grid (not shown).

Moreover, in the exemplary embodiment, exhaust gases from gas turbine engine102are channeled to HRSG110, via exhaust gas conduit111. While the exhaust gases are being channeled to HRSG110or through HRSG110, housing assembly180facilitates shielding exciter167and control system170from any gases that may leak from conduit111or from any other fluids within system100.

When exhaust gases enter HRSG110, the exhaust gases enable steam to be generated. More specifically, in the exemplary embodiment, HP superheater section126of HRSG110generates steam. HP bypass PCV156is opened and MSV151is closed to enable steam flow to be channeled through conduits112to steam turbine engine104. Similarly, steam flow is channeled from RH/IP section128through conduits112and through IP bypass PCV158to steam turbine engine104. Control system170regulates steam flow and pressure within system100by selectively opening and closing features of HP bypass PCV156, IP bypass PCV158, MSV151, MCV152, ISV153, and/or ICV154via features that may include, without limitation, receiving permissive inputs, transmitting permissive outputs, and transmitting opening and closing commands. Housing180facilitates shielding control system170, exciter167, and static starter168from any steam and/or any other fluid that may leak from conduits112or from any part of system100.

Steam that is channeled to steam turbine engine104enables steam turbine engine104to rotate and generate power. More specifically, power generated by steam turbine engine104drives generator108such that electrical power is transmitted to the power grid.

FIG. 2illustrates an enlarged schematic perspective view of housing assembly180taken along area2(shown inFIG. 1).FIG. 3is a partially exploded view of housing assembly180. In the exemplary embodiment, housing assembly180includes a housing200, such as an existing housing, that defines a cavity201therein. In the exemplary embodiment, housing200is sized to enclose control system170(shown inFIG. 1) within cavity201. Moreover, in the exemplary embodiment, housing200has a substantially three-dimensional rectangular shape and is an IP21 cabinet. Alternatively, housing200may have any other shape and be any other type of cabinet that enables assembly180and/or industrial system100(shown inFIG. 1) to function as described herein.

Moreover, in the exemplary embodiment, housing200includes an access panel202. In the exemplary embodiment, access panel202may be a door that includes a handle or panel knob204that enables a user to selectively open and close access panel202. Moreover, in the exemplary embodiment, panel202may be locked to prevent unauthorized individuals from gaining access into housing200through panel202. Housing assembly180also includes a cover206that encloses a portion of housing200such that access panel202remains accessible and cover206is positioned against portion of housing200. Moreover, in the exemplary embodiment, cover206is fabricated from carbon steel. Alternatively, cover206may be fabricated from any other type of material that enables assembly180and/or system100to function as described herein.

Moreover, in the exemplary embodiment, housing200includes a top portion302that is coupled to access panel202. More specifically, access panel202is coupled to a first edge303of top portion302when access panel202is in a closed position. Moreover, housing200includes a first sidewall304and a second sidewall306. In the exemplary embodiment, each sidewall304and306is coupled to top portion302and access panel202. More specifically, sidewall304is coupled to a second edge308of top portion302, and sidewall306is coupled to a third edge310of top portion302. Moreover, in the exemplary embodiment, sidewall304is coupled to a first edge312of access panel202when access panel202is in a closed position, and sidewall306is coupled to a second edge314of access panel202via at least one hinge (not shown).

Housing200may also include a base portion370that is coupled to each sidewall304and306. More specifically, bottom edge (not shown) of sidewall306is coupled to a first edge (not shown) of base portion370and bottom edge372of sidewall304is coupled to second edge374of base portion370.

In the exemplary embodiment, housing200also includes a rear portion316that is coupled to a rear edge317of top portion302and to a rear edge376of base portion370, while first sidewall304is coupled to a first edge318of rear portion316and second sidewall306is coupled to a second edge320of rear portion316. Moreover, in the exemplary embodiment, access panel202, top portion302, first sidewall304, second sidewall306, and rear portion316are each substantially rectangular. Alternatively, access panel202, top portion302, first sidewall304, second sidewall306, and rear portion316may have any other shape that enables assembly180and/or system100to function as described herein.

In the exemplary embodiment, cover206includes a first portion324that is positioned against housing top portion302. Moreover, in the exemplary embodiment, a length326and a width328of first portion324are each slightly longer than a length330and a width332of housing top portion302such that when first portion324is positioned against housing top portion302, first portion324substantially conceals housing top portion302.

Cover206also includes a second portion334that is coupled to first portion324. More specifically, in the exemplary embodiment, second portion334is coupled to a rear edge336of first portion324. Moreover, in the exemplary embodiment, second portion334is positioned against housing rear portion316. Further, in the exemplary embodiment, a length340and a width342of second portion334are slightly longer than a length (not shown) and a width (not shown) of housing rear portion316such that when second portion334is positioned against housing rear portion316, second portion334substantially conceals housing rear portion316.

In the exemplary embodiment, cover206also includes at least one side portion, such as a first side portion346and a second side portion348that are each coupled to first portion324and second portion334. More specifically, in the exemplary embodiment, side portion346is coupled to a first edge350of first portion324and a first edge351of second portion334. Side portion348is coupled to a second edge352of first portion324and to a second edge353of second portion334. Moreover, in the exemplary embodiment, a length356and a width358for first side portion346are approximately equal to a length360and a width362for second side portion348.

Moreover, in the exemplary embodiment, first side portion346is positioned against first sidewall304and second side portion348is positioned against second sidewall306. Further, in the exemplary embodiment, length356and width358for first side portion346are each slightly longer than a length366and a width368for first side wall304, respectively, such that when first side portion346is positioned against first sidewall304, first side portion346substantially conceals first sidewall304. Similarly, length360and width362for second side portion348are each slightly longer than a length (not shown) and a width (not shown), respectively, of second sidewall306such that when second side portion348is positioned against second sidewall306, second side portion348substantially conceals second sidewall306. Moreover, in the exemplary embodiment, first portion324, second portion334, first side portion346, and second side portion348are each substantially rectangular. Alternatively, first portion324, second portion334, first side portion346, and second side portion348may have any other shape that enables assembly180and/or system100to function as described herein.

Moreover, in the exemplary embodiment, at least one gasket, such as a first gasket380and a second gasket382are each coupled between housing200and cover206to form a seal on housing assembly180that substantially prevents fluid from entering housing assembly180. More specifically, in the exemplary embodiment, first gasket380is coupled between housing200and cover such that first gasket380extends between access panel202and a front edge384of first portion324, and extends between access panel202and a front edge386of side portion346. In the exemplary embodiment, first gasket380also extends between a front edge388of side portion348. In the exemplary embodiment, second gasket382is coupled between housing200and cover206such that second gasket382extends between second portion334and side portions346and348. More specifically, in the exemplary embodiment second gasket382extends between second portion first edge351and a rear edge390of side portion346. Second gasket382also extends between second portion second edge353and a rear edge392of side portion348.

During operation, while exhaust gases are channeled from gas turbine engine102(shown inFIG. 1) to HRSG110(shown inFIG. 1) and while steam is channeled from HRSG110to steam turbine engine104(shown inFIG. 1), housing assembly180substantially shields control system170from any gases, steam, or any other fluids that may leak and/or be present within system100. Because cover206encloses a portion of housing200, and because gaskets380and382are between cover206and housing200, fluid is substantially prevented from entering housing assembly180and/or contaminating control system170. More specifically, in the exemplary embodiment, because cover first portion324is positioned against housing top portion302, housing top portion302is concealed such that fluid may not flow within housing top portion302. Similarly, because cover second portion334is positioned against housing rear portion316, housing rear portion316is substantially concealed such that fluid may not flow within housing rear portion316. Moreover, in the exemplary embodiment, first side portion346is positioned against sidewall304such that sidewall304is substantially concealed and fluid is prevented from flowing within sidewall304. Similarly, second side portion348is positioned against sidewall306such that sidewall306is substantially concealed and fluid is prevented from flowing within sidewall306.

Moreover, by having first gasket380extend between access panel202and cover206, a seal is formed between housing200and cover206such that fluid is prevented from entering housing assembly180. Similarly, by having second gasket382be coupled between housing200and cover206such that second gasket382extends between second portion334and side portions346and348, a seal is formed between second gasket382and second portion334and side portions346and348such that fluid is prevented from entering housing assembly180.

As compared to known industrial systems, the embodiments described herein facilitate protecting an electrical system without purchasing a cabinet with a higher IP rating and without a need to modify the electrical system such that the electrical system may be mounted within the cabinet. The embodiments described herein provide a housing assembly that includes a housing that includes an access panel and a cavity defined therein. The housing is sized to enclose at least one electrical system within the cavity. Moreover, the housing assembly also includes a cover configured to enclose a portion of the housing such that the access panel remains accessible. At least one gasket extends between the housing and the cover to prevent fluid from entering therein. Moreover, the combination of a cover and the gaskets facilitates shielding the electrical system from being exposed to any fluid that may cause damage.

Exemplary embodiments of the apparatus, system, and method are described above in detail. The apparatus, system, and method are not limited to the specific embodiments described herein, but rather, components of the system and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. For example, the apparatus may also be used in combination with other systems and methods, and is not limited to practice with only the system as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications.