Abstract:
A method of planning and building a power plant are described. A method of building a power plant comprising positioning a first power plant module within the power plant via roll transfer technology wherein the first power plant module is encased within a first shipping structure; positioning a second power plant module within the power plant adjacent to the first power plant module via roll transfer technology wherein the second power plant module is encased within a second shipping structure; and electrically coupling the first power plant module with the second power plant module with a quick connector connection. A method of designing a power plant comprising determining an amount of power needed from the power plant; calculating a plurality of power generator modules needed to generate the amount of power; and symmetrically configuring the plurality of power generator modules within the power plant.

Description:
FIELD OF THE INVENTION  
         [0001]    The invention relates generally to the field of power plants, and more particularly the design, configuration, construction, and maintenance of power plants.  
         BACKGROUND OF THE INVENTION  
         [0002]    The proliferation of the use of electricity around the world has increased in the past years. The use of power plants to generate electricity has also increased world-wide. There is a need to construct more power plants which are closer to the consumer of electric power. By achieving a more distributed electric power generation system, power distribution delays and bottlenecks can be alleviated and avoided. However, designing and constructing a power plant has traditionally been costly and time consuming.  
           [0003]    There have also been many innovations relating to prefabrication of power plant segments thereby aiding in the construction of power plants. However, there is always a need for power plants which are easier to design and construct. The benefits of power plants which are easier to design and construct include a more reliable power plant with less down-time, more consistently designed power plant which can be duplicated, decreased construction costs, and faster construction period.  
           [0004]    As the demand and dependency on electricity has grown, the reliability of electric power generation becomes more important. Improvements to reliability may be achieved through refinements in the design of electric power plants. One benefit of increased reliability is less costly maintenance and less wasted downtime.  
           [0005]    The increase in the number of electric power plants world-wide underscores the importance of improvements in the design and construction of power plants.  
         SUMMARY OF THE INVENTION  
         [0006]    A method of planning and building a power plant are described. A method of building a power plant comprising positioning a first power plant module within the power plant via roll transfer technology wherein the first power plant module is encased within a first shipping structure; positioning a second power plant module within the power plant adjacent to the first power plant module via roll transfer technology wherein the second power plant module is encased within a second shipping structure; and electrically coupling the first power plant module with the second power plant module with a quick connector connection. A method of designing a power plant comprising determining an amount of power needed from the power plant; calculating a plurality of power generator modules needed to generate the amount of power; and symmetrically configuring the plurality of power generator modules within the power plant.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    For a better understanding of the present invention, together with other and further advantages and features thereof, reference is had to the following description taken in connection with the accompanying drawings in which:  
         [0008]    [0008]FIG. 1 illustrates a simplified block diagram of a power plant layout in accordance with one embodiment of the invention.  
         [0009]    [0009]FIG. 2 illustrates a block diagram of a power plant layout in accordance with one embodiment of the invention.  
         [0010]    [0010]FIG. 3 illustrates an exemplary direct converter in accordance with one embodiment of the invention.  
         [0011]    [0011]FIG. 4 illustrates an exemplary superconducting magnet in accordance with one embodiment of the invention.  
         [0012]    [0012]FIGS. 5A, 5B,  5 C, and  5 D illustrate an exemplary process of assembling modules of a power plant by use of roll transfer in accordance with one embodiment of the invention.  
         [0013]    [0013]FIG. 6 illustrates an exemplary process of manufacturing a converter module in accordance with one embodiment the invention.  
         [0014]    [0014]FIG. 7 illustrates an exemplary routing scheme in accordance with one embodiment of the invention.  
         [0015]    [0015]FIG. 8 is a flow diagram illustrating the modular nature of configuring a power plant to meet the current and future power demands  
         [0016]    [0016]FIG. 9 is a flow diagram illustrating general design and construction principles of a power plant.  
         [0017]    [0017]FIG. 10 is a flow diagram illustrating one embodiment of positioning a power plant module within a power plant.  
     
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0018]    In the following descriptions for the purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention. In other instances, well-known electrical structures or circuits are shown in block diagram form in order not to obscure the present invention unnecessarily.  
         [0019]    The invention describes both off-site pre-fabrication and on-site installation of electric power plants. The invention further describes a standardized system and method for building electric power plants. By standardizing the electric power plant assembly, power plant construction design and assembly times are reduced, damaged parts are minimized, operating personnel are minimized, and mean time between failure is maximized.  
         [0020]    The method of power plant prefabrication and installation illustrate the power plant being divided into modules. These modules are designed to be prefabricated within finite packaging limitations. These finite packaging limitations allow the modules to be shipped fully assembled while minimizing shipping costs.  
         [0021]    In one embodiment, the prefabrication of the modules occurs off-site at a factory production facility. Further, by dividing the power plant components into modules, the design and implementation of the power plant output capacity is scalable and is based upon the number of power generating modules, the size of the power plant facility, and the interface to the power grid.  
         [0022]    In one embodiment, the invention is optimized for a plasma electricity generation power plant. However in other embodiments, other types of fuel may be utilized by the power plant such as diesel, natural gas, oil, nuclear and the like.  
         [0023]    To efficiently maintain and operate a power plant, the invention utilizes multiple independent power units in one embodiment. Additionally, each independent power unit utilizes multiple power modules.  
         [0024]    [0024]FIG. 1 illustrates one embodiment of a power unit and power module layout. In other embodiments, various configurations may be utilized.  
         [0025]    In one embodiment, a power plant  100  has a capacity of 300 Mwe. In this embodiment, the power plant  100  utilizes three separate independent 100 Mwe units  110 ,  120 , and  130 . In one embodiment, each of the independent 100 Mwe units utilizes a two separate 50 Mwe module. For example, the independent unit  110  utilizes separate 50 Mwe modules  112  and  114 . Similarly, the independent unit  120  utilizes separate 50 Mwe modules  122  and  124 . Similarly, the independent unit  130  utilizes separate 50 Mwe modules  132  and  134 . By creating multiple power modules such as modules  112 ,  114 ,  122 ,  124 ,  132 , and  134 , the power plant  100  may continue producing power while individual modules are shut down for routine maintenance or in the event of a failure in a particular module.  
         [0026]    In other embodiments, each of the units  110 ,  120 . and  130  may have an infinite capacity to produce power. Similarly, in other embodiments, the modules  112 ,  114 ,  122 ,  124 ,  132 , and  134  may have an infinite capacity to produce power.  
         [0027]    In one embodiment, a helium cooling system is utilized to cool the modules  112 ,  114 ,  122 ,  124 ,  132 , and  134 . The helium system is capable of allowing one module to warm up for service while still cooling the remaining modules. Helium refrigeration compressors have an extended expected mean time between failure. In other embodiments, various other cooling systems may be utilized.  
         [0028]    [0028]FIG. 2 illustrates one embodiment of a simplified block diagram of a power plant  200 . The power plant  200  includes a power generation block  210 , a control room block  260 , and a connection to transmission lines block  270 . In one embodiment, the power generation block  210  includes vacuum pump modules  212  and  256 ; superconducting magnet modules  214 ,  216 ,  218 ,  220 ,  222 , and  224 ; direct converter modules  226 ,  228 ,  230 ,  232 ,  234 ,  236 ,  238 ,  240 ,  242 ,  244 ,  246 , and  248 ; ion accelerator and fuel preparation modules  258 ,  260 ,  262 ,  264 ,  266 , and  268 ; and helium refrigerator modules  250 ,  252 , and  254 .  
         [0029]    The superconducting magnet module  214  is coupled to the direct converter modules  226  and  230 , the ion accelerator and fuel preparation module  268 , and the helium refrigeration module  250 . The superconducting magnet module  216  is coupled to the direct converter modules  228  and  232 , the ion accelerator and fuel preparation module  266 , and the helium refrigeration module  250 . The superconducting magnet module  218  is coupled to the direct converter modules  234  and  236 , the ion accelerator and fuel preparation module  264 , and the helium refrigeration module  252 . The superconducting magnet module  220  is coupled to the direct converter modules  238  and  240 , the ion accelerator and fuel preparation module  262 , and the helium refrigeration module  252 . The superconducting magnet module  222  is coupled to the direct converter modules  242  and  244 , the ion accelerator and fuel preparation module  260 , and the helium refrigeration module  254 . The superconducting magnet module  224  is coupled to the direct converter modules  246  and  248 , the ion accelerator and fuel preparation module  258 , and the helium refrigeration module  254 .  
         [0030]    In another embodiment, the helium refrigerator modules  250 ,  252 , and  254  may be a different type of refrigeration unit.  
         [0031]    The direct converter modules  226 ,  228 ,  236 ,  238 ,  242 , and  246  are coupled to the vacuum roughing pump  212  via vacuum lines. The direct converter modules  230 ,  232 ,  234 ,  240 ,  244 , and  248  are coupled to the vacuum roughing pump  212  via vacuum lines.  
         [0032]    In one embodiment, each of the modules is sized to fit within a shipping container. The shipping container is dimensioned to be able to be shipped as freight on trains, ships, and trucks. In another embodiment, the shipping container forms a structure for the particular module when constructing the power plant  200 . In one embodiment, the container is utilized to form the structure of the power plant  200 . In another embodiment, a portion of the container is utilized to form the structure of the power plant  200 .  
         [0033]    The power generation block  210  is preferably 125 feet by 225 feet. In other embodiments, the power generation block  210  has various dimensions. In one embodiment, the design of the modules within the power generation block  210  are symmetric. The symmetrical design may aid with maintenance and ongoing power production.  
         [0034]    In one embodiment, the power plant  200  has a capacity of 300 Mwe. However in other embodiments, the power plant  200  can be scaled from 50 Mwe to over 500 Mwe. In one embodiment, the power plant  200  utilizes multiple power generation blocks. In one embodiment, the power plant  200  utilizes power generation blocks which have varying power generation capabilities by adding or deleting modules within the power generation block.  
         [0035]    The control room  262  and office space  260  preferably is 50 feet by 100 feet. A control room  262  is contained within and preferably measures 25 feet by 40 feet. In other embodiments, different dimensions are utilized for the control room  262  and the office space  260 .  
         [0036]    [0036]FIG. 3 illustrates an exemplary direct converter  300  in one embodiment. The direct converter  300  includes a vacuum chamber  310  which is configured to be housed within a structure  320 . In one embodiment, the structure  320  has a dimension of 8 feet by 8 feet by 40 feet. In another embodiment, the structure  320  may have different dimensions. In yet another embodiment, the structure  320  is constructed as part of a shipping container.  
         [0037]    In addition, the structure  320  includes mounting brackets for use during shipping and fixed operation. In one embodiment, the structure  320  is capable of housing the vacuum chamber  310  during shipping, construction, and operation of a power plant.  
         [0038]    [0038]FIG. 4 illustrates an exemplary superconducting magnet  400 . The superconducting magnet  400  includes a magnet  410  which is configured to be housed within a structure  420 . The structure  420  preferably has a dimension of 8 feet by 16 feet by 20 feet. The structure  420  preferably is constructed as part of a shipping container. In addition, the structure  420  includes mounting brackets for use during shipping and fixed operation. The structure  420  is capable of housing the magnet  410  during shipping, construction, and operation of a power plant. In other embodiments, the structure  420  may have various other dimensions.  
         [0039]    In one embodiment, the invention utilizes roll transfer technology to construct modular portions of the power plant such as the superconducting magnets, the direct converters, and the like in building power plants. By using roll transfer technology, lifting individual modules during construction is minimized. Transporting power plant modules by primarily sliding the modules horizontally as opposed to vertically lifting the modules is one principle behind the roll transfer technology. By minimizing vertically lifting power plant modules, the risk damaging individual modules is minimized. In one embodiment, if vertical lifting occurs, it is kept to a minimum in order to move the power plant module from one surface to another surface. However, the vertical lifting is not utilized for the purpose of transporting the power plant module over horizontal distances. Further, costly cranes or other lifting means are not needed thus decreasing the cost and time line of building power plants. Roll transfer technology may be applied to the power plant modules with rails, air pallets, ball bearings, and/or anti-friction materials.  
         [0040]    [0040]FIGS. 5A, 5B,  5 C, and  5 D illustrate a process in one embodiment of assembling modules of a power plant by use of roll transfer instead of lifting. FIGS. 5A, 5B,  5 C, and  5 D are shown for exemplary purposes only and are not to be construed as limiting the scope of the invention.  
         [0041]    [0041]FIG. 5A illustrates a converter module  510  being slided onto a platform  520  along a rail  505 . The converter module  510  includes a direct converter  512  and a plasma converter  515 . A superconducting magnet  530  is rolled along the rail  505  into position to couple with the converter module  510 .  
         [0042]    [0042]FIG. 5B illustrates a portion of the container over the converter module  510  being removed and supports  540  under the plasma converter  515  being placed.  
         [0043]    [0043]FIG. 5C illustrates a plurality of superconducting magnets  535  being rolled along the rail  505  into position surrounding the plasma converter  515 . Further, another converter module  550  is rolled along the rail  505  towards the converter module  510  with the plurality of superconducting magnets  535  located between the converter module  510  and the converter module  550 .  
         [0044]    [0044]FIG. 5D illustrates the converter module  510  being coupled with the converter module  550  with the plurality of superconducting magnets  535  located between the converter modules  510  and  550 .  
         [0045]    The rail  505  is utilized as one embodiment of roll transfer technology according to FIGS. 5A, 5B,  5 C, and  5 D. In other embodiments, different roll transfer technology may be utilized.  
         [0046]    [0046]FIG. 6 illustrates a process of manufacturing a converter module. In step  600 , the direct converters are manufactured and are positioned ready to transfer and load onto a structure without lifting. The direct converters are transferred by utilizing roll transfer technology as previously described. In step  610 , the plasma converters are manufactured and are positioned ready to transfer and load onto a structure without lifting. The plasma converters are transferred by utilizing roll transfer technology as previously described. In step  620 , the direct converters are loaded within the structure first followed by the plasma converters without lifting either the direct converters or the plasma converters. Similarly, the direct converters and plasma converters are transferred by utilizing roll transfer technology as previously described.  
         [0047]    Another aspect of power plant design, building, and operating is routing of control and power conductor cabling. In a preferred embodiment, the invention routes the control and power conductor cabling through sealed conduits without pigtails. Further, the control and power conductor cabling are mounted at an appropriate height for servicing and maintenance. Additionally, the cabling is routed through the converter modules and superconducting magnetic modules.  
         [0048]    [0048]FIG. 7 illustrates a wire routing scheme. A superconducting magnetic module  715  is electrically coupled between a converter module  710  and a converter module  720 . A power conductor cabling  730  is routed through the structure of the superconductor magnetic module  715  and the converter modules  710  and  720 . Preferably the height of the power conductor cabling  730  is approximately 3 feet high. Also, after the converter modules  710  and  720 , the power conductor cabling  730  is routed in the floor to prevent breakage. Although not shown in FIG. 7, the control cabling is preferably run on the opposite side of the superconductor magnetic module  715  and the converter modules  710  and  720 . In other embodiments, the power conductor cabling  730  may contain the control cabling as well. In another embodiment, the power conductor cabling  730  may be mounted at any height.  
         [0049]    Prior to electrically coupling the superconductor magnetic module  715  with the converter modules  710  and  720 , the power conductor cabling  730  was separately found routed through the superconductor magnetic module  715  and the converter modules  710  and  720 . In one embodiment, the superconductor magnetic module  715  and the converter modules  710  and  720  were configured to utilize a quick connector connection to electrically couple the superconductor magnetic module  715  with the converter modules  710  and  720 . The quick connector connection allows an electrically connection between superconductor magnetic module  715  and the converter modules  710  and  720  through the power conductor cabling  730  by aligning the superconductor magnetic module  715  and the converter modules  710  and  720 . The quick connector connection allows quick electrical connections through the power conductor cabling  730  without tedious wire customization or manual wire connections.  
         [0050]    The flow diagrams as depicted in FIGS. 8, 9, and  10  are merely one embodiment of the invention. Each functional block may be performed in a different sequence without departing from the spirit of the invention. Further, blocks may be deleted, added or combined without departing from the spirit of the invention.  
         [0051]    [0051]FIG. 8 is a flow diagram illustrating the modular nature of configuring a power plant to meet the current and future power demands. In Block  800 , a desired amount of power is determined during the planning process of the power plant. In Block  810 , a number of power generation modules needed for the power plant is determined. The number of power generation modules depends on the amount of power rated for each power generation module and the desired amount of power needed from the power plant. In Block  820 , a space provision is planned for future additional power generation required of the power plant. The power plant is constructed in Block  830 . In Block  840 , additional power generation modules are added to the power plant due to an increased power demand from the power plant.  
         [0052]    [0052]FIG. 9 is a flow diagram illustrating general design and construction principles of a power plant. In Block  900 , the power plant is designed with a symmetrical layout with respect to the power generation blocks, converter modules, vacuum pumps, and the like. The symmetrical layout of the modules within the power plant increases layout efficiency from the perspective of designing multiple power plants, fabrication of the power plant modules, and efficiency in servicing the power plant. In Block  910 , individual power plant modules are manufactured either on-site or off site. In Block  920 , the power plant modules are configured within the power plant and placed into position via roll transfer technology. As described previously, roll transfer technology may include any means of rolling, sliding, and/or transporting that does not require lifting the item. For example, roll transfer may include transporting an item via tracks, rails, ball bearings, air pallets, and the like.  
         [0053]    [0053]FIG. 10 is a flow diagram illustrating one embodiment of positioning a power plant module within a power plant. In Block  1000 , a converter module is positioned within the power plant via roll transfer technology. In Block  1010 , the shipping structure surrounding the converter module is partially removed. In Block  1020 , supports are placed under the portion of the converter module without the shipping structure. In Block  1030 , a magnet module is positioned to surround a portion of the converter module via roll transfer technology. In Block  1040 , another converter module is positioned adjacent to the magnet via roll transfer technology.  
         [0054]    The foregoing descriptions of specific embodiments of the invention have been presented for purposes of illustration and description.  
         [0055]    They are not intended to be exhaustive or to limit the invention to the precise embodiments disclosed, and naturally many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.