Heat Exchanger Sensor Grid Through Tube Restraints
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Solution Overview
Problem
Current heat exchanger systems in combined cycle power plants (CCPPs) face inefficiencies due to limited sensor access, as sensors can only be mounted on outermost rows of heat exchange tubes, preventing comprehensive measurement of operational parameters within inner rows, which hampers understanding and control of the heat exchange process.
Innovation Solution
A heat exchanger design that includes a sensor grid with sensor leads extending through tube restraints, allowing sensors to be installed during manufacturing rather than in the field, enabling access to both outermost and inner sets of heat exchange tubes for comprehensive data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sensors are mounted on outermost rows of heat exchange tubes in the field, then installation is feasible using scaffolding or high-lift equipment, but sensors cannot access inner rows of heat exchange tubes, limiting measurement capability
Solution Approach 1:
The patent applies preliminary action by pre-installing sensors and routing sensor leads through tube restraints during heat exchanger manufacturing, before the heat exchanger is assembled and installed in the field. This allows sensors to be positioned in inner rows of heat exchange tubes that would otherwise be inaccessible, eliminating the need for scaffolding or high-lift equipment during sensor installation while enabling comprehensive data collection from all tube rows.
2Loss of information
If sensors are installed during manufacturing with leads extending through tube restraints, then comprehensive data collection from all heat exchange tube rows is enabled, but device complexity increases due to integrated sensor grid and restraint modifications
Solution Approach 1:
The patent merges the sensor grid system with the tube restraint structure by integrating sensor leads directly through the tube restraints during manufacturing. This combination eliminates the need for separate sensor installation processes and scaffolding equipment, reducing overall system complexity despite the integrated design. The sensor leads are routed through openings in the tube restraints, creating a unified structure that simplifies both installation and maintenance.
3Measurement precision
If manual sensor installation with scaffolding or high-lift equipment is used, then outermost row sensors can be mounted, but installation time and equipment requirements increase, and inner row measurement is impossible
Solution Approach 1:
The patent applies preliminary action by completing sensor installation during heat exchanger manufacturing before field installation. This eliminates the time-consuming process of setting up scaffolding or high-lift equipment and allows comprehensive sensor placement in both outermost and inner rows of heat exchange tubes, enabling complete operational parameter measurement without time loss.
Data Source
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AI summary
A heat exchanger (108) includes a sensor grid (180) with sensor leads (184) extending through tube restraints (190) for heat exchange tubes (146) in the heat exchanger (108). The tube restraint (190) includes a body (192) having a plurality of tube openings (194) defined therein with each tube opening (194) receiving one of the set of heat exchange tubes (146) therethrough. The body (192) also includes a sensor lead opening (200) defined therein to receive a sensor lead (184) therethrough. Each tube opening (194) has a larger dimension than the sensor lead opening (200). The sensor grid (180) is installed during manufacture rather than in the field, allowing the sensor grid (180) to be on outermost and inner sets (176) of heat exchange tubes (146) in the heat exchanger (108).