Air-Cooled Condenser Deflection Limiter Beams
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Solution Overview
Problem
Current air-cooled condensers require significant structural support and are prone to thermal expansion issues, while nuclear fuel storage racks face seismic challenges, and shell and tube heat exchangers experience differential thermal expansion problems, leading to reliability concerns and complex cooling needs for radioactive waste casks.
Innovation Solution
The air-cooled condenser design features self-supporting inclined tube bundles with hinged coupling and slideable condensate headers to manage thermal expansion, a seismic-resistant fuel rack system with embedment plates to restrain lateral movement, and improved heat exchanger designs with axial flow baffles and curved tube bundles to mitigate thermal stresses, along with a passive cooling system using a sublimating medium for radioactive waste casks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional structural support systems are used for air-cooled condensers, then structural stability is maintained, but device complexity and construction time increase significantly
Solution Approach 1:
The condenser structure is divided into modular A-frame units, each capable of independent support. The tube bundles are segmented into discrete assemblies that can be independently positioned and supported, reducing the complexity of the overall structural support system while maintaining stability.
Solution Approach 2:
The support system incorporates dynamic elements that allow for thermal expansion and contraction of the tube bundles. The structure can adapt its configuration in response to thermal loading, maintaining stability without requiring overly rigid and complex fixed support systems.
2Stability of the object's composition
If tube bundles are fully supported by structural A-frames, then structural stability is improved, but thermal expansion capabilities are restricted causing differential thermal expansion cracks
Solution Approach 1:
The support system is designed with dynamic characteristics that permit controlled movement of the tube bundles during thermal cycling. This allows the structure to accommodate thermal expansion and contraction without developing damaging stresses, while maintaining overall structural stability through the A-frame configuration.
Solution Approach 2:
The support system allows for changes in geometric parameters of the tube bundles in response to thermal loading. The A-frame structure can adjust its configuration to accommodate thermal expansion, preventing differential thermal expansion cracks while maintaining structural integrity.
3Stability of the object's composition
If extensive structural support is provided for tube bundles, then structural stability is maintained, but erection time and human effort increase significantly
Solution Approach 1:
The condenser is divided into modular A-frame units with self-supporting tube bundle assemblies. These modules can be pre-assembled and then quickly erected on-site, significantly reducing construction time while maintaining structural stability through the inherent rigidity of the A-frame configuration.
Solution Approach 2:
The tube bundles are designed to be self-supporting within the A-frame structure, eliminating the need for extensive external structural support systems. The structure supports itself through its geometric configuration, reducing both erection time and the amount of structural material required.
4Stability of the object's composition
If rigid structural support is used, then structural stability is improved, but adaptability to thermal expansion and contraction is reduced
Solution Approach 1:
The A-frame support structure incorporates dynamic characteristics that allow it to adapt its configuration in response to thermal loading. The structure can flex and adjust to accommodate thermal expansion and contraction of the tube bundles while maintaining overall structural stability through its geometric rigidity.
Solution Approach 2:
The support system allows for changes in geometric parameters of the A-frame structure in response to thermal conditions. This enables the structure to adapt to thermal expansion and contraction while maintaining structural stability, combining rigidity with thermal flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
These solutions reduce the need for extensive structural support, enhance seismic resistance, improve heat exchanger reliability, and provide efficient, passive cooling for radioactive waste casks, addressing thermal expansion and seismic challenges effectively.
Implementation Method 1
a passive cooling system using a sublimating medium for radioactive waste casks
Implementation Method 2
The heat transfer function of the ACC means that the tube bundles and piping headers of the structure undergoes significant thermal expansion and contraction under the ACC's normal operating conditions
Data Source
AI summary
An air-cooled condenser system for steam condensing applications in a power plant Rankine cycle includes an air cooled condenser having a plurality of interconnected modular cooling cells. Each cell comprises a frame-supported fan, inlet steam headers, outlet condensate headers, and tube bundle assemblies having extending between the headers. The tube bundle assemblies may be arranged in a V-shaped tube structure. A plurality of deflection limiter beams are arranged coplanar with the tube bundles. Top ends of each deflection limiter beam are slideably inserted in an associated floating end cap affixed to an upper tubesheet which moves vertically relative to the beams via thermal expansion/contraction concomitantly with the tubes. The deflection limiter beams provides guided restraint system for expansion/contraction of the tube bundles which prevents out of plane tube bowing.