Heat Exchanger Tube Bundle Maintenance via Segmentation
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Solution Overview
Problem
In heat exchangers of thermal power plants, maintenance of heat transfer bundles is hindered by wear and corrosion from combustion fly ashes, leading to frequent unplanned stops, increased costs, and prolonged maintenance periods due to the need to lift and inspect large modules, which also poses risks during outdoor storage and repair.
Innovation Solution
A heat exchanger design featuring back rails and bottom rails allows for the independent removal and replacement of specific heat transfer tube bundles, reducing the need to lift entire modules and minimizing the maintenance period by enabling targeted repairs and inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large-scaled module bundles are used in heat exchangers, then heat exchange efficiency is improved, but maintenance complexity and time consumption increase significantly
Solution Approach 1:
The heat transfer bundle is divided into multiple independent heat transfer tube bundles arranged in parallel. Each bundle can be independently removed and maintained through separate access openings, eliminating the need to dismantle entire large-scale modules while preserving overall heat exchange capacity.
Solution Approach 2:
Specific heat transfer tube bundles can be individually extracted from the heat exchanger through dedicated openings without removing other bundles. This allows targeted maintenance of only the affected bundles, significantly reducing maintenance time and complexity compared to removing entire large-scale modules.
2Reliability
If entire heat transfer bundles are removed for inspection, then comprehensive maintenance is achieved, but operational downtime and costs increase
Solution Approach 1:
Only the specific heat transfer tube bundles requiring inspection or maintenance are extracted through dedicated openings. Healthy bundles remain in place, allowing the system to maintain operational reliability while minimizing downtime and maintenance costs.
Solution Approach 2:
Different regions of the heat exchanger (different bundle openings) have different functional states - some bundles are removed for maintenance while others remain operational. This localized approach maintains overall system reliability while enabling necessary maintenance activities.
3Ease of operation
If robust bundles are temporarily placed in open space during maintenance, then maintenance access is enabled, but damage risks from weather exposure increase
Solution Approach 1:
Heat transfer tube bundles are extracted through side openings rather than requiring complete module removal. This allows bundles to be maintained in controlled environments or accessed more easily without prolonged exposure to outdoor weather conditions, reducing damage risks.
Solution Approach 2:
The side openings act as intermediary access points that allow bundles to be partially or fully removed without requiring complete disassembly. This intermediate access state enables maintenance while minimizing the time bundles are exposed to harmful weather conditions.
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
This design shortens maintenance and inspection periods, reduces costs, and minimizes the risk of damage and safety hazards by allowing for efficient and targeted maintenance of specific heat transfer tube bundles, thereby improving operational efficiency and reducing downtime.
Implementation Method 1
the heat recovery unit and the reheating unit are connected to a cool and hot water circulating line to perform a heat exchange with a flue gas through a circulating pump using water as a medium
Implementation Method 2
the temperature of the flue gas temperature-dropped by SO 2 absorbent and the like in the treatment process of the wet desulfurization equipment is raised by the heat exchange with heat medium water passing through an interior of a pipe disposed in the reheating unit
Data Source
Figure 1-1~1-2
Figure 2-1
Figure 2-2
AI summary
A heat exchanger is provided with a heat transfer tube bundle housing duct 20 for housing heat transfer tube bundles, openings 26 provided on a sidewall of the heat transfer tube bundle housing duct 20, for freely inserting and removing the heat transfer tube bundles, and rails provided in a direction perpendicular to an inflowing direction of a flue gas G within the heat transfer tube bundle housing duct 20, for freely moving the heat transfer tube bundles. Since the heat exchanger can draw out only a specific heat transfer tube bundle, it is possible to reduce a maintenance period, thereby minimizing a regular inspection period.