Active wind management system for air coolers

Abstract

A wind management system (100) for an air cooler system comprising a support structure (10) comprising at least four columns (11, 12, 13 14) which defines four sides, tube bundles (90) supported by the support structure (10) and circulating a fluid to be cooled and at least one fan (20) arranged above the tube bundles. The wind management system (100) comprises a shutter system comprising a plurality of shutters (30) arranged at least on a side of the support structure (10) and being configured to be movable between a fully opened configuration and a fully closed configuration, at least one actuator (40) mechanically coupled to the shutter system and configured to change the degree of opening of the plurality of shutters (30) and a control unit (50) electrically coupled to the at least one actuator (40) and configured to control the at least one actuator (40). The control unit (50) is configured to receive information about wind direction and wind speed to control the at least one actuator (40) based on said information so to set the plurality of shutters (30) which are on the downstream side(s) with respect to the wind direction in a closed configuration, possibly in a fully closed configuration, if the wind speed is greater than a minimum threshold and if the wind speed is less than a maximum threshold.

Description

TITLEActive wind management system for air coolersDESCRIPTIONTECHNICAL FIELD

[0001] The subject-matter disclosed herein relates to a wind management system for air coolers and method for controlling the wind management system.BACKGROUND ART

[0002] Air cooled heat exchangers (ACHEs) or condensers (ACCs) are essentially used for petrochemical plants, oil refining plants, power plants (e.g. geothermal plants) and other industrial plants.

[0003] ACHEs and ACCs performs an indirect thermal exchange: in general, set of ventilators cools the tube bundle, typically finned, so that the fluid which flows inside the tubes can be cooled. In particular, heat from the fluid is transferred to ambient air which can be moved by passive (induced or forced) motion through the ventilators; typically, axial fans are used and are installed so that the desired flow of air through the heat exchanger is from the bottom up. Axial fans are generally located above the tube bundles to induce ambient air across the bundles and the tube bundles are mounted on the top of a supporting structure so that air can flow vertically upward through the bundles. The axial fans may be also located below the tube bundle, to have a forced draft.

[0003] However, the efficiency of heat dissipation of such systems depends on various ambient conditions and specifically on wind speed and cross winds. Currently, high wind speeds create a blockage effect on the airflow circulatingthrough coolers, thereby reducing their effectiveness. To maintain the required thermal duty necessary to cool the fluid at the required temperature, the parasitic power of the fans will need to be increased, which will decrease the overall net power generated by the power plant, e.g. by a geothermal plant.

[0004] To partially overcome this problem, there are usually used passive devices to reduce (not to eliminate) the impact of the wind speed, such as windscreen placed around the outlet of the fans, static porous screens on the perimeter of the lower part of the air coolers and fixed cross plates placed at the inlet of the fans. These solutions however affect the performance of the system when there is no wind or the wind has a low speed and may add significant weight and cost to the supporting structure.

[0005] Another alternative solution to partially overcome this problem is the use of wind deflector to reduce (not to eliminate) the impact of the wind direction.

[0006] From document US 8,302,670 B2 is known an air guide for an aircooled condensing tower system which substantially extends downwardly and outwardly from at least a side wall of the condensing tower system in order to help direct the air flow and sometimes permit the same performance from the tower while using less fan energy than would be required for an identical tower without the air guides.

[0007] From document US 8,997,828 B2 is known a shield system comprising at least one arrangement for fixing, in use, at least one flexible sheet to an air cooler structure as an air inlet guide. The teaching of this document is to set the sheets in a fully closed configuration when the wind speed is relatively low (e.g. less than about 4.0 m / s), while to fully open the sheets when the wind speed is in a high range (e.g. over about 6.1 m / s).

[0008] From document US 9,587,842 B2 it is known a method for minimizingthe undesired effect of wind on the operation of a heat exchanger system providing a wind deflector constructed and arranged to divert wind flowing in any approximately horizontal direction below a fan to instead flow in a direction that is more vertically upward and toward the axis of the fan as compared to the approximately horizontal direction.SUMMARY

[0009] According to an aspect, the subject-matter disclosed herein relates to a wind management system for an air cooler system comprising a support structure comprising at least four columns defining four sides, tube bundles supported by the support structure and circulating a fluid to be cooled and at least one fan arranged above the tube bundles, the wind management system comprising: a shutter system comprising a plurality of shutters arranged at least on a side of the support structure, preferably on each side of the support structure, the plurality of shutters being configured to be movable between a fully opened configuration and a fully closed configuration, at least one actuator mechanically coupled to the shutter system and configured to change the degree of opening of the plurality of shutters, and a control unit electrically coupled to the at least one actuator and configured to control the at least one actuator.The control unit is configured to receive information about wind direction and wind speed to control the at least one actuator based on the received information so to set the plurality of shutters which are on the downstream side(s) with respect to the wind direction in a closed configuration, possibly in a fully closed configuration, if the wind speed is greater than a minimum threshold and if the wind speed is less than a maximum threshold.

[0010] According to another aspect, the subject-matter disclosed herein relates to a method for controlling a wind management system comprising acontrol unit, at least one actuator and a shutter system comprising a plurality of shutters arranged at least on a side of the support structure of an air cooler system, preferably on each side of the support structure, the method comprising the steps of:A. Receiving information about wind direction and wind speed by to the control unit;B. Control at least one actuator through the control unit so to set all the plurality of shutters in a fully opened configuration if the wind speed is less than a minimum threshold or if the wind speed is greater than a maximum threshold;C. Control at least one actuator through the control unit so to set the plurality of shutters which are on the downstream side(s) with respect to the wind direction in a closed configuration, possibly in a fully closed configuration, if the wind speed is greater than a minimum threshold and if the wind speed is less than a maximum threshold.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:Fig. 1 shows a simplified diagram of a cross-sectional view of an air cooler system provided with an innovative active wind management system according to the present disclosure,Fig. 2 shows a simplified diagram of a top view of the air cooler system of Fig. 1, andFig. 3 shows a flow chart of an embodiment of logic control of the activewind management system according to the present disclosure.DETAILED DESCRIPTION OF EMBODIMENTS

[0012] According to an aspect, the subject-matter disclosed herein relates to a system for increasing the net power generated by a plant with an air cooler system in particularly windy locations (for example an Organic Rankine Cycle plant) by avoiding the blockage effect to the air flow circulated through coolers due to high wind speed. The system provides for plurality of shutters arranged at least on a side of the support structure of the air cooler system, preferably on each side of the support structure, which are movable between an opened and a closed configuration depending on the wind direction and wind speed. The resulting effect is that the air flow passing through the structure of the air cooler system is conveyed toward the opening of the fans (which are arranged on the top of the supporting structure) alleviating their effort to induce air circulation. In other words, the system creates a positive pressure difference across the air cooler pipe bundle by harnessing the kinetic energy of the wind.

[0013] According to an aspect, the subject-matter disclosed herein relates to a method for controlling the opening and closing of the plurality of shutters arranged at least on a side of the support structure of an air cooler system, preferably on each side of the support structure, so to reduce the effort of the fans to induce air circulation in the air cooler system and increasing the net power of the plant, in particular by opening the upstream shutters and closing the downstream shutters with respect to thew wind direction.

[0014] Reference now will be made in detail to embodiments of the disclosure, examples of which are illustrated in the drawings. The examples and drawing figures are provided by way of explanation of the disclosure and should not be construed as a limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spiritof the disclosure. In the following description, similar reference numerals are used for the illustration of figures of the embodiments to indicate elements performing the same or similar functions. Moreover, for clarity of illustration, some references may be not repeated in all the figures.

[0015] Fig. 1 shows, for example and without limitations, a simplified diagram of a cross-sectional view of an air cooler system provided with an innovative active wind management system 100 (referred in the following as “system 100”) according to the present disclosure and Fig. 2 shows, for example and without limitations, a simplified diagram of a top view of the air cooler system of Fig. 1.

[0016] The air cooler system typically comprises a support structure 10 comprising at least four columns 11, 12, 13 and 14 - located in particular at the corners of the support structure 10 - which defines four sides of the support structure 10 (and therefore defining the perimeter of the support structure 10, see for example the top view of Fig. 2). In general, tube bundles 90 circulating a fluid to be cooled are supported by the support structure 10 and fan(s) are arranged above the tube bundles 90, so to induce an ambient air flow circulation across the tube bundles 90 and to allow the transferring of heat from the fluid circulating in the tube bundles to ambient air flow. In particular, the support structure 10 is placed on the ground and is configured to support the tube bundles 90 and the fan(s) at a certain distance from the ground.

[0017] The wind management system 100 comprises a shutter system comprising a plurality of shutters 30 arranged at least on a side of the support structure 10, preferably on each side of the support structure 10 (i.e. on each side of the perimeter of the support structure 10). For example, with nonlimiting reference to Fig. 1, there are shown two sides, in particular two opposite sides, of the support structure 10 provided with a first plurality of shutters 30-1 and a second plurality of shutters 30-2.

[0018] As already stated, that the plurality of shutters 30 may not be arranged on all the sides of the support structure 10. In particular, an anemometric campaign may be performed before installing the shutter system so to determine to determine the sides of the supporting structure that are most likely to be exposed downstream of the wind direction during the operating life of the system.

[0019] The plurality of shutters 30 of the system 100 are configured to be movable between a fully opened configuration and a fully closed configuration. In particular, as it will be better described in the following, the shutters of each plurality of shutters 30 may be movable along a horizontal axis or a vertical axis (for example, Fig. 1 shows a first plurality of shutters 30-1 and a second plurality of shutters 30-2 which are movable along a horizontal axis).

[0020] It is to be noted that, if the shutters are movable along a horizontal axis, each plurality of shutters 30 is mechanically coupled between two adjacent columns 11, 12, 13 and 14 of the support structure 10, in particular each plurality of shutters 30 extends between two adjacent columns 11, 12, 13 and 14 of the support structure 10. For example, with non-limiting reference to Fig. 1 and Fig. 2, the first plurality of shutters 30-1 extends between the two adjacent columns 11 and 12 and the second plurality of shutters 30-2 extends between the two adjacent columns 13 and 14.

[0021] Alternatively, if the shutters are movable along a vertical axis, each plurality of shutters 30 is mechanically coupled between the top of the support structure 10 and the ground, in particular each plurality of shutters 30 extends between extends between the top of the support structure 10 and the ground.

[0022] According to a possibility, the shutters of the plurality of shutters on the same side of the supporting structure 10 (for example the first plurality of shutters 30-1 or the second plurality of shutters 30-2) may be configured to bemovable together so that all the shutters arranged on the same side of the supporting structure 10 have the same opening / closing degree.

[0023] According to another possibility, the shutters of the plurality of shutters on the same side of the supporting structure 10 may have a different opening / closing degree, for example a different opening / closing configuration along a vertical direction (i.e. a different opening / closing degree from bottom to top) or a horizontal direction (i.e. a different opening / closing degree from left to right).

[0024] With non-limiting reference to Fig. 1, the system 100 further comprises at least one actuator 40 and a control unit 50. The control unit 50 is electrically coupled to the at least one actuator 40 and is configured to control it, while the at least one actuator 40 is mechanically coupled to the shutter system and is configured to change the degree of opening of the plurality of shutters 30.

[0025] It is to be noted that the system 100 may be provided with one actuator 40 for each plurality of shutters 30 arranged on one side of the support structure 10 or even of a plurality of actuators 40 for each plurality of shutters 30 arranged on one side of the support structure 10 (for example one actuator for each shutter of the plurality of shutters 30 or one actuator for each group of shutters of the plurality of shutters 30, where the group of shutters may comprise two or more shutters of the plurality of shutters 30).

[0026] With non-limiting reference to Fig. 1, the system 100 further comprises a control unit 50 electrically coupled to the at least one actuator 40 and configured to control the at least one actuator 40. The control unit 50 is configured to receive information about wind direction and wind speed to control the at least one actuator 40 based on said information so to set the plurality of shutters 30 which are on the downstream side(s) with respect to the wind direction in a closed configuration, possibly in a fully closedconfiguration, if the wind speed is greater than a minimum threshold, for example a minimum threshold in the range 1-4 m / s, and if the wind speed is less than a maximum threshold, for example a maximum threshold in the range 10-30 m / s.

[0027] For example and without limitations, Fig. 1 shows the second plurality of shutters 30-2, which are on the downstream side with respect to the wind direction (see the big black arrow on the left), in a closed configuration.

[0028] With non-limiting reference to Fig. 2, the support structure 10 has two main axis X and Y which defines four quadrants indicated with references I, II, III and IV. As already stated, depending on the wind direction information received by the control unit 50, the actuator(s) 40 controlled by the control unit 50 set the plurality of shutters 30 which are on the downstream side(s) of the wind direction in a closed configuration. For example, if the wind direction is the one shown by the big black arrow in Fig. 2, the actuator(s) 40 will set the plurality of shutters 30 which are at least partially arranged in the IV quadrant in a closed configuration (i.e. set the plurality of shutters which are on the side defined by columns 11 and 14 and the plurality of shutters which are on the side defined by columns 13 and 14 in a closed configuration).

[0029] It is to be noted that, as the wind direction may vary even in a short time, while it is not particularly efficient to modify continuously the opening / closing degree of the plurality of shutters 30, the control unit 50 may perform a calculation of the average wind direction over a given period of time, for example over few seconds (e.g. 5 or 10 seconds) or few minutes (e.g. 1 or 2 minutes).

[0030] As already stated, the system 100 may comprise a plurality of actuators 40, each actuator 40 being mechanically coupled to one or more shutter of each plurality of shutters 30. Advantageously, the control unit 50 isconfigured to control the plurality of actuators 40 so that each plurality of shutters 30 may have at least two shutters with a different degree of opening.

[0031] Advantageously, the control unit 50 is further configured to control the at least one actuator 40 so to set the plurality of shutters 30 which are on the upstream side(s) with respect to the wind direction in an open configuration if the wind speed is greater than the minimum threshold and if the wind speed is less than the maximum threshold.

[0032] With non-limiting reference to Fig. 2, if the wind direction is the one shown by the big black arrow in Fig. 2, the actuator(s) 40 will set the plurality of shutters 30 which are at least partially arranged in the II quadrant in an open configuration (i.e. set the plurality of shutters which are on the side defined by columns 11 and 12 and the plurality of shutters which are on the side defined by columns 12 and 13 in an open configuration).

[0033] Advantageously, the system 100 further comprises at least one wind sensor 60 electrically coupled to the control unit 50. The at least one wind sensor 60 may be configured to provide the information about wind direction and wind speed to the control unit 50.

[0034] With non-limiting reference to Fig. 1 and Fig. 2, the system 100 may further comprise secondary shutters 35 arranged on the top of the support structure 10. For example, Fig. 2 shows a couple of secondary shutters 35-1 and 35-2 arranged at two opposite side of the support structure 10, in particular the first secondary shutter 35-1 is arranged at the side defined by columns 11 and 12 and the second secondary shutter is arranged at the side defined by columns 13 and 14. Advantageously, the secondary shutters 35-1 and 35-2 are movable along a horizontal axis and are mechanically coupled to at least one actuator which is electrically coupled to the control unit 50, so that the control unit 50 may control the degree of opening of the secondary shutters 35 based on the information about wind direction and wind speed.

[0035] Advantageously, the at least one actuator 40 is configured to set all the plurality of shutters 30 in a fully opened configuration if the wind speed is less than the minimum threshold or if the wind speed is greater than the maximum threshold.

[0036] According to another aspect, the subject-matter disclosed herein provides for an air cooler system comprising the wind management system 100 of the present disclosure.

[0037] According to still another aspect, the subject-matter disclosed herein provides a method 200 for controlling a wind management system 100 comprising a control unit 50, at least one actuator 40 and a shutter system comprising a plurality of shutters 30 arranged at least on a side of the support structure 10 of an air cooler system, preferably on each side of the support structure 10, the method comprising the steps ofA. Receiving information about wind direction and wind speed by to the control unit 50;B. Control at least one actuator 40 through the control unit 50 so to set all the plurality of shutters 30 in a fully opened configuration if the wind speed is less than a minimum threshold or if the wind speed is greater than a maximum threshold;C. Control at least one actuator 40 through the control unit 50 so to set the plurality of shutters 30 which are on the downstream side(s) with respect to the wind direction in a closed configuration, possibly in a fully closed configuration, if the wind speed is greater than a minimum threshold, for example a minimum threshold in the range 1-4 m / s, and if the wind speed is less than a maximum threshold, for example a maximum threshold in the range 10-30 m / s.

[0038] With non-limiting reference to Fig. 3, it is shown a flow chart of an embodiment of logic control of the active wind management system 100 according to the present disclosure.

[0039] Advantageously, the control unit 50 may control a plurality of actuators, each actuator being mechanically coupled to one or more shutter of each plurality of shutters 30 arranged on the same side of the support structure 10 so that at least two shutters of each plurality of shutters 30 on the same side of the support structure 10 may have a different degree of opening, for example along a vertical direction (i.e. a different opening / closing degree from bottom to top) or a horizontal direction (i.e. a different opening / closing degree from left to right) as the plurality of shutters 30 may be movable along a horizontal axis or a vertical axis.

[0040] Advantageously, the method 200 further comprises the step D of control at least one actuator 40 through the control unit 50 so to set the plurality of shutters 30 which are on the upstream side(s) with respect to the wind direction in an open configuration if the wind speed is greater than the minimum threshold and if the wind speed is less than the maximum threshold.

[0041] According to a possibility, the closed configuration of step C and the open configuration of step D are settled also taking into account a difference between the target outlet temperature of the air cooler system and the actual one.

[0041] Advantageously, the information about wind direction and wind speed are provided by at least one wind sensor 60.

Claims

CLAIMS1. A wind management system (100) for an air cooler system comprising a support structure (10) comprising at least four columns (11, 12, 13 14) defining four sides, tube bundles (90) supported by the support structure (10) and circulating a fluid to be cooled and at least one fan (20) arranged above the tube bundles, the wind management system (100) comprising: a shutter system comprising a plurality of shutters (30) arranged at least on a side of the support structure (10), preferably on each side of the support structure (10), the plurality of shutters (30) being configured to be movable between a fully opened configuration and a fully closed configuration, at least one actuator (40) mechanically coupled to the shutter system and configured to change the degree of opening of the plurality of shutters (30), and a control unit (50) electrically coupled to the at least one actuator (40) and configured to control the at least one actuator (40), wherein the control unit (50) is configured to receive information about wind direction and wind speed to control the at least one actuator (40) based on said information so to set the plurality of shutters (30) which are on the downstream side(s) with respect to the wind direction in a closed configuration, possibly in a fully closed configuration, if the wind speed is greater than a minimum threshold and if the wind speed is less than a maximum threshold.

2. The wind management system (100) of claim 1, wherein the minimum threshold is in the range 1-4 m / s.

3. The wind management system (100) of claim 1, wherein the maximum threshold is in the range 10-30 m / s.

4. The wind management system (100) of claim 1, wherein the shutters of each plurality of shutters (30) are movable along a horizontal axis.

5. The wind management system (100) of claim 4, wherein each plurality of shutters (30) is mechanically coupled between two adjacent columns (11, 12, 13, 14) of the support structure (10).

6. The wind management system (100) of claim 5, wherein each plurality of shutters (30) extends between two adjacent columns (11, 12, 13, 14) of the support structure (10).

7. The wind management system (100) of claim 1, wherein the shutters of each plurality of shutters (30) are movable along a vertical axis.

8. The wind management system (100) of claim 7, wherein each plurality of shutters (30) is mechanically coupled between the top of the support structure (10) and the ground.

9. The wind management system (100) of claim 8, wherein each plurality of shutters (30) extends between the top of the support structure (10) and the ground.

10. The wind management system (100) of claim 1, wherein the control unit (50) is further configured to control the at least one actuator (40) so to set the plurality of shutters (30) which are on the upstream side(s) with respect to the wind direction in an open configuration if the wind speed is greater than a minimum threshold and if the wind speed is less than a maximum threshold.

11. The wind management system (100) of claim 10, wherein the control unit (50) is configured to control a plurality of actuators (40), each actuator (40) being mechanically coupled to one or more shutter of each plurality of shutters (30) so that each plurality of shutters (30) may have at least two shutters with a different degree of opening.

12. The wind management system (100) of claim 1, further comprising secondary shutters (35) arranged on the top of the support structure (10), in particular at two opposite side of the support structure (10), the secondary shutters (35) being movable along a horizontal axis andbeing mechanically coupled to at least one actuator which is electrically coupled to the control unit (50), the control unit (50) being configured to control the degree of opening of the secondary shutters (35) based on the information about wind direction and wind speed.

13. The wind management system (100) of claim 1, further comprising at least one wind sensor (60) electrically coupled to the control unit (50), the at least one wind sensor (60) being configured to provide the information about wind direction and wind speed to the control unit (50).

14. The wind management system (100) of claim 1, wherein the at least one actuator (40) is configured to set all the plurality of shutters (30) in a fully opened configuration if the wind speed is less than a minimum threshold or if the wind speed is greater than a maximum threshold.

15. An air cooler system comprising the wind management system (100) of claim 1.

16. Method (200) for controlling a wind management system (100) comprising a control unit (50), at least one actuator (40) and a shutter system comprising a plurality of shutters (30) arranged at least on a side of the support structure (10) of an air cooler system, preferably on each side of the support structure (10), the method comprising the steps ofA. Receiving information about wind direction and wind speed by to the control unit (50);B. Control at least one actuator (40) through the control unit (50) so to set all the plurality of shutters (30) in a fully opened configuration if the wind speed is less than a minimum threshold or if the wind speed is greater than a maximum threshold;C. Control at least one actuator (40) through the control unit (50) so to set the plurality of shutters (30) which are on the downstream side(s) with respect to the wind direction in a closed-15-configuration, possibly in a fully closed configuration, if the wind speed is greater than a minimum threshold and if the wind speed is less than a maximum threshold.

17. The method (200) of claim 16, further comprising the step of:D. Control at least one actuator (40) through the control unit (50) so to set the plurality of shutters (30) which are on the upstream side(s) with respect to the wind direction in an open configuration if the wind speed is greater than a minimum threshold and if the wind speed is less than a maximum threshold.

18. The method (200) of claim 17, wherein the control unit (50) may control a plurality of actuators, each actuator being mechanically coupled to one or more shutter of each plurality of shutters (30) so that at least two shutters of each plurality of shutters (30) may have a different degree of opening.

19. The method (200) of claim 17, wherein the closed configuration of step C and the open configuration of step D are settled also taking into account a difference between the target outlet temperature of the air cooler system and the actual one.

20. The method (200) of claim 16, wherein the information about wind direction and wind speed are provided by at least one wind sensor (60).-16-

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