Air cooler pipe structure

Abstract

This invention relates to the field of air cooler piping layout technology, and in particular to an air cooler piping structure. It includes a main pipe with a main control valve, which connects to multiple first branch pipes. Each first branch pipe is connected to a second branch pipe via a flexible connection structure. Each second branch pipe is connected to an air cooler inside a generator wind tunnel. Each first branch pipe has a maintenance valve near the flexible connection structure, and both the maintenance valve and the flexible connection structure are located inside the generator wind tunnel. This invention allows for individual maintenance of a single faulty air cooler without shutting down the generator or closing the main valve, improving maintenance convenience and unit operation continuity. The flexible connection structure facilitates the replacement of flange seals and piping modifications, and provides sufficient installation leeway for replacing new air coolers, reducing the difficulty of disassembly and modification, and further enhancing the flexibility and practicality of piping maintenance.

Description

Technical Field

[0001] This invention relates to the field of air cooler piping layout technology, and in particular to an air cooler piping structure. Background Technology

[0002] An air cooler is a heat exchanger that uses air to cool a hot fluid. Air is used as the coolant and can be used as both a cooler and a condenser. An air cooler mainly consists of a tube bundle, a support frame, and a fan. The hot fluid flows inside the tubes, while air blows over the outside of the tube bundle. To improve heat transfer efficiency, fins are usually added to the outside of the tubes to increase the heat transfer area, enhance fluid turbulence, and reduce thermal resistance. Air coolers are widely used in the cooling systems of hydroelectric generator sets.

[0003] Traditional air cooler piping designs involve water entering through a main pipe, with water flowing through branch pipes into individual air coolers. The main pipe and main valve are exposed for easy on-site maintenance and operation; the branch pipes are embedded in concrete, penetrating from the turbine floor concrete into the generator wind tunnel and directly connecting to the air coolers. In actual operation, cooling water typically contains impurities such as calcium and magnesium ions and silt. When flowing through metal pipes, it easily forms carbonate scale. Simultaneously, silt can cause wear and thinning of the cooling pipe walls, leading to leaks over long-term operation, severely affecting heat exchange efficiency, and even causing generator short circuits.

[0004] Furthermore, traditional piping systems connect the main air cooler pipe, main valve, and branch pipes sequentially, with no individual valves or maintenance structures between the branch pipes and the air cooler. When an air cooler leaks or malfunctions, the entire unit must be shut down and the main water supply valve closed for repairs, disrupting continuous operation. Therefore, redesigning the air cooler piping system is of significant practical importance. Summary of the Invention

[0005] The purpose of this invention is to provide an air cooler piping structure that can solve the problems of traditional air cooler piping lacking a separate maintenance valve, requiring shutdown for maintenance, and being inconvenient to install and maintain.

[0006] This invention provides an air cooler piping structure, including a main pipe with a main control valve. The main pipe is connected to multiple first branch pipes, each of which is connected to a second branch pipe via a flexible connection structure. Each second branch pipe is connected to an air cooler inside a generator wind tunnel. Each first branch pipe has a maintenance valve at one end near the flexible connection structure. Both the maintenance valve and the flexible connection structure are located inside the generator wind tunnel.

[0007] Furthermore, a protective sleeve is provided outside the first branch pipe, the bottom of the protective sleeve is attached to the bottom wall of the generator wind tunnel, and a concrete sealing layer is poured between the protective sleeve and the first branch pipe.

[0008] Furthermore, the concrete sealing layer is made of fine aggregate concrete with added silicone waterproofing agent and polypropylene fiber, wherein the silicone waterproofing agent content is 0.8% to 1.2% of the mass of fine aggregate concrete, and the polypropylene fiber content is 0.05% to 0.1% of the mass of fine aggregate concrete.

[0009] Furthermore, a waterproof sealant is laid on top of the concrete sealing layer, and the waterproof sealant is in close contact with the surface of the protective sleeve and the first branch pipe.

[0010] Furthermore, the flexible connection structure includes a flexible hose, with a first connecting flange and a second connecting flange fixed at both axial ends of the flexible hose; a first fixed flange is provided at the end of the first branch pipe, and the first connecting flange is connected to the first fixed flange by a first bolt; a second fixed flange is provided at the end of the second branch pipe, and the second connecting flange is connected to the second fixed flange by a second bolt.

[0011] Furthermore, the maintenance valve is located between the first fixed flange and the first connecting flange; the first bolt passes through the first fixed flange, the bolt hole of the maintenance valve, the first connecting flange, and the lock nut in sequence.

[0012] Furthermore, sealing gaskets are provided between the first fixed flange and the maintenance valve, between the first connecting flange and the maintenance valve, and between the second connecting flange and the second fixed flange.

[0013] Furthermore, the maintenance valve is a manual valve or an electric valve.

[0014] Furthermore, the maintenance valve is a wafer-type butterfly valve.

[0015] Furthermore, a main pipeline pressure monitoring device is provided on the main pipeline, and a branch pipeline pressure monitoring device is provided on each of the first branch pipes. Both the main pipeline pressure monitoring device and the branch pipeline pressure monitoring device are connected to an electrical control cabinet or a remote controller.

[0016] In summary, compared with the prior art, the present invention has the following advantages: The technical solution of this invention involves installing maintenance valves on the branch pipes corresponding to each air cooler. When an air cooler experiences leakage, malfunction, or other abnormalities, maintenance can be performed on the faulty air cooler by individually closing the maintenance valve on the corresponding branch pipe, without needing to shut down the unit or close the main control valve. This effectively avoids the impact of maintenance work on the normal operation of the unit, significantly improving the convenience of maintenance and the continuity of unit operation. At the same time, the flexible connection structure not only facilitates the replacement of flange seals and pipeline modifications but also provides sufficient installation margin for the replacement of new air coolers, reducing the difficulty of disassembly and modification, and further enhancing the flexibility and practicality of pipeline maintenance. Attached Figure Description

[0017] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the pipeline structure in Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the connection between the first branch pipe and the second branch pipe in Embodiment 1 of the present invention; Figure 3 This is a schematic diagram of the pipeline structure in Embodiment 2 of the present invention.

[0019] Explanation of reference numerals in the attached drawings: 1-Main pipe; 101-Main pipe pressure monitoring device; 2-Main control valve; 3-First branch pipe; 301-First fixed flange; 302-Branch pipe pressure monitoring device; 4-Second branch pipe; 401-Second fixed flange; 5-Air cooler; 6-Maintenance valve; 7-Hose; 701-First connecting flange; 702-Second connecting flange; 8-First bolt; 9-Second bolt; 10-Protective sleeve; 11-Concrete sealing layer; 12-Generator wind tunnel bottom wall. Detailed Implementation

[0020] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0022] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0023] Example 1 An air cooler piping structure, such as Figure 1 and Figure 2 As shown, the system includes a main pipeline 1, on which a main control valve 2 is installed to control the on / off state of the entire pipeline system. The main pipeline 1 is connected to multiple first branch pipes 3 to achieve media diversion. Each first branch pipe 3 passes through the bottom wall 12 of the generator wind tunnel (i.e., the concrete of the turbine layer) and enters the interior of the generator wind tunnel. Each first branch pipe 3 is detachably connected to a second branch pipe 4 via a flexible connection structure. Each second branch pipe 4 is connected to an air cooler 5 inside the generator wind tunnel to ensure no leakage during media transportation and to guarantee the cooling efficiency of the air cooler 5.

[0024] Each first branch pipe 3 is equipped with a maintenance valve 6 near the flexible connection structure. The maintenance valve 6 is located inside the generator wind tunnel, with its operating end facing the wind tunnel maintenance passage for easy operation by maintenance personnel. The maintenance valve 6 is a wafer-type butterfly valve with a valve body made of corrosion-resistant alloy material, suitable for the corrosive environment of water media. The valve seat is made of high-temperature resistant and aging-resistant fluororubber material, which can adapt to the temperature changes of the medium in the pipeline. The butterfly valve's operating handle has a foldable structure, which can be folded and stored when not in use, reducing the space occupied inside the wind tunnel. The surface of the handle is equipped with anti-slip texture to improve the ease of operation. A sign is set next to the maintenance valve 6, which clearly marks the corresponding air cooler 5 number and valve operation instructions, so as to facilitate quick identification by maintenance personnel and avoid misoperation.

[0025] Each first branch pipe 3 is externally fitted with a protective sleeve 10, which is made of PVC. The bottom of the protective sleeve 10 is tightly fitted to the bottom wall 12 of the generator wind tunnel. A concrete sealing layer 11 is poured between the protective sleeve 10 and the first branch pipe 3 to isolate moisture inside the wind tunnel and protect the first branch pipe 3 from corrosion. The concrete sealing layer 11 is made of fine aggregate concrete as the base material, modified with organosilicon waterproofing agent and polypropylene fiber. This not only improves the waterproof and seepage-resistant performance of the concrete sealing layer 11, but also effectively inhibits the generation of concrete shrinkage cracks, enhancing the integrity and durability of the concrete sealing layer 11. The dosage of organosilicon waterproofing agent is 1.0% of the mass of fine aggregate concrete, and the dosage of polypropylene fiber is 0.08% of the mass of fine aggregate concrete.

[0026] Before pouring the concrete sealing layer 11, apply a layer of epoxy interface agent with a thickness of 0.4 mm to the contact area of ​​the outer wall of the first branch pipe 3, the inner wall of the protective sleeve 10, and the bottom wall 12 of the generator wind tunnel. After the interface agent dries, pour the concrete in layers with vibration, controlling the thickness of each layer to be 40 mm, to ensure that the concrete sealing layer 11 is dense and defect-free, and seamlessly adheres to the first branch pipe 3, the protective sleeve 10, and the bottom wall 12 of the generator wind tunnel. The top of the concrete sealing layer 11 is flush with the top of the protective sleeve 10, and a layer of polyurethane waterproof sealant with a thickness of 2.5 mm is laid on top of the concrete sealing layer 11, tightly adhering to the top of the concrete sealing layer 11, the top of the protective sleeve 10, and the outer wall of the first branch pipe 3, forming double waterproof protection and completely preventing water vapor infiltration.

[0027] The length of the protective sleeve 10 is not less than 30% of the length of the section of the first branch pipe 3 located inside the generator wind tunnel. The top of the sleeve is higher than the water level inside the generator wind tunnel, which further enhances the waterproof protection effect, effectively prevents water vapor inside the generator wind tunnel from seeping into the sleeve and corroding the first branch pipe 3, and significantly extends the service life of the branch pipe.

[0028] like Figure 2As shown, the flexible connection structure includes a corrosion-resistant flexible hose 7, with a first connecting flange 701 and a second connecting flange 702 fixed at both axial ends of the hose 7, respectively; the end of the first branch pipe 3 near the flexible connection structure is provided with a first fixed flange 301 that matches the first connecting flange 701, and is fastened by a first bolt 8; the end of the second branch pipe 4 near the flexible connection structure is provided with a second fixed flange 401 that matches the second connecting flange 702, and a high-temperature resistant sealing gasket is provided between the two, and is fastened by a second bolt 9.

[0029] The maintenance valve 6 is located between the first fixed flange 301 and the first connecting flange 701, with both ends sealing against the first fixed flange 301 and the first connecting flange 701 respectively. The first bolt 8 passes through the bolt holes of the first fixed flange 301, the maintenance valve 6, and the first connecting flange 701 in sequence, and is then fastened to the lock nut. A sealing washer is provided between the first bolt 8 and the bolt hole to prevent water medium from leaking from the bolt connection. The mating surfaces of the maintenance valve 6 with the first fixed flange 301 and the first connecting flange 701 are provided with sealing grooves, and sealing washeres are embedded in the sealing grooves to further improve the sealing performance and eliminate the risk of medium leakage.

[0030] The working principle of the air cooler piping structure provided in this embodiment is as follows: Cooling water flows through the main pipe 1, and the main control valve 2 controls the on / off state and total flow of the entire pipeline system. After entering the main pipe 1, the water is divided into multiple first branch pipes 3, passes through the maintenance valve 6 and the flexible connection structure, and finally enters the air cooler 5 through the second branch pipe 4, providing an independent cooling water path for each corresponding air cooler 5, so as to realize the parallel operation of multiple air coolers.

[0031] During generator operation, continuous vibration is generated. The first branch pipe 3 and the second branch pipe 4 are connected by a flexible hose 7, which can effectively absorb and buffer the vibration transmitted by the generator and pipeline, avoid weld cracking, flange loosening and pipeline fatigue damage caused by rigid connection, and ensure long-term stable operation of pipeline.

[0032] Each branch pipe 3 is equipped with a maintenance valve 6, located inside the generator wind tunnel, near the flexible connection structure. During normal operation, the maintenance valve 6 is fully open to ensure smooth water flow. When a certain air cooler 5 or its corresponding pipeline needs maintenance, only the maintenance valve 6 of that branch is closed to achieve single-branch isolation without closing the main control valve 2, thus not affecting the normal operation of other air coolers and the generator.

[0033] Example 2 The piping structure of an air cooler, such as Figure 3 As shown, the technical solution in this embodiment is basically the same as that in embodiment 1, except that a pressure monitoring device is provided in this embodiment.

[0034] A main pipeline pressure monitoring device 101 is installed on the main pipeline 1, and a branch pipeline pressure monitoring device 302 is installed on each first branch pipe 3; the two work together. The main pipeline pressure monitoring device 101 is installed on the outlet side of the main pipeline 1 near the main control valve 2. The branch pipeline pressure monitoring device 302 is installed on the first branch pipe 3, on the side away from the flexible connection structure of the maintenance valve 6. Both the main pipeline pressure monitoring device 101 and the branch pipeline pressure monitoring device 302 are connected to the electrical control cabinet or remote controller.

[0035] Each branch pipe pressure monitoring device 302 on the first branch pipe 3 is independently set with upper and lower pressure warning thresholds. The upper threshold is 85% of the branch pipe's design pressure, and the lower threshold is 60% of the branch pipe's normal operating pressure. The thresholds can be flexibly adjusted via the field control cabinet or remote terminal and are linked with the warning threshold of the main pipeline pressure monitoring device 101. When an overpressure or underpressure abnormality occurs in a certain first branch pipe 3, the controller immediately issues an audible and visual alarm and pushes an alarm message with the branch pipe number to the maintenance personnel. The maintenance personnel can close the maintenance valve 6 of the corresponding branch and troubleshoot the branch, such as branch pipe blockage, leakage, valve failure, etc., without closing the main control valve 2, thus avoiding affecting the normal operation of other air coolers 5 and generators.

[0036] The main pipeline pressure monitoring device 101 and the branch pipeline pressure monitoring device 302 can be pressure sensors, pressure transmitters, electrical contact pressure gauges or intelligent pressure instruments, which can collect pipeline pressure signals in real time and transmit the signals to the electrical control cabinet or remote controller to realize pressure monitoring, threshold early warning and abnormal alarm.

[0037] Based on Example 1, this embodiment adds a dual pressure monitoring device to realize real-time monitoring and abnormal early warning of pipeline pressure, further improve the safety of pipeline operation, adapt to the vibration and humid conditions of generator wind tunnel, and ensure the stable operation of generator cooling system.

[0038] The air cooler piping structure provided by this invention absorbs vibration through a flexible connection structure, improving connection reliability; achieves corrosion and waterproofing through protective sleeves and concrete sealing layers, extending the service life of branch pipes; improves maintenance convenience through the reasonable setting of inspection valves; and achieves abnormal early warning and accurate troubleshooting through dual pressure monitoring of the main pipeline and branch pipes. It is adapted to the vibration and humidity conditions of generator wind tunnels, effectively solving the shortcomings of existing technologies and ensuring the stable operation of the generator cooling system.

[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An air cooler piping structure, characterized in that, Includes a main pipe (1), on which a main control valve (2) is provided. The main pipe (1) is connected to multiple first branch pipes (3). Each first branch pipe (3) is connected to a second branch pipe (4) through a flexible connection structure. Each second branch pipe (4) is connected to an air cooler (5) inside the generator wind tunnel. Each first branch pipe (3) has a maintenance valve (6) at one end near the flexible connection structure. The maintenance valve (6) and the flexible connection structure are both located inside the generator wind tunnel.

2. The air cooler piping structure according to claim 1, characterized in that, The first branch pipe (3) is provided with a protective sleeve (10) on the outside. The bottom of the protective sleeve (10) is attached to the bottom wall of the generator wind tunnel. A concrete sealing layer (11) is poured between the protective sleeve (10) and the first branch pipe (3).

3. The air cooler piping structure according to claim 2, characterized in that, The concrete sealing layer (11) is made of fine stone concrete with added organosilicon waterproofing agent and polypropylene fiber, wherein the dosage of organosilicon waterproofing agent is 0.8% to 1.2% of the mass of fine stone concrete, and the dosage of polypropylene fiber is 0.05% to 0.1% of the mass of fine stone concrete.

4. The air cooler piping structure according to claim 2, characterized in that, A waterproof sealant is laid on top of the concrete sealing layer (11), and the waterproof sealant is in close contact with the surface of the protective sleeve (10) and the first branch pipe (3).

5. The air cooler piping structure according to claim 1, characterized in that, The flexible connection structure includes a flexible hose (7), with a first connecting flange (701) and a second connecting flange (702) fixed at both axial ends of the flexible hose (7); the end of the first branch pipe (3) is provided with a first fixed flange (301), and the first connecting flange (701) is connected to the first fixed flange (301) by a first bolt (8); the end of the second branch pipe (4) is provided with a second fixed flange (401), and the second connecting flange (702) is connected to the second fixed flange (401) by a second bolt (9).

6. The air cooler piping structure according to claim 5, characterized in that, The maintenance valve (6) is located between the first fixed flange (301) and the first connecting flange (701); the first bolt (8) passes through the bolt hole of the first fixed flange (301), the maintenance valve (6), the first connecting flange (701), and the lock nut in sequence.

7. The air cooler piping structure according to claim 6, characterized in that, Sealing gaskets are provided between the first fixed flange (301) and the maintenance valve (6), between the first connecting flange (701) and the maintenance valve (6), and between the second connecting flange (702) and the second fixed flange (401).

8. The air cooler piping structure according to claim 1, characterized in that, The maintenance valve (6) is a manual valve or an electric valve.

9. The air cooler piping structure according to claim 8, characterized in that, The maintenance valve (6) is a wafer-type butterfly valve.

10. The air cooler piping structure according to claim 1, characterized in that, The main pipeline (1) is equipped with a main pipeline pressure monitoring device (101), and each of the first branch pipes (3) is equipped with a branch pipeline pressure monitoring device (302). The main pipeline pressure monitoring device (101) and the branch pipeline pressure monitoring device (302) are both connected to the electrical control cabinet or remote controller.

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