Injection Cooler Modular Flange Assembly for Steam Cooling
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Solution Overview
Problem
Existing injection coolers for superheated steam in power generation systems face challenges such as limited service life due to high stress on seals and guide elements, complex maintenance, and uneven cooling water distribution, leading to high operating costs and maintenance intervals.
Innovation Solution
The design features a modular injection cooler with a control element and injection cylinder separated by coolant supply lines connected via flange plates, allowing for easy assembly and replacement, and a core insert with separate feed channels for each injection nozzle, reducing the need for pipes within the injection cylinder and enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lifting movement is used to control the injection nozzles, then the cooling water distribution can be controlled, but the seals and guide elements are subjected to very high stress limiting service life
Solution Approach 1:
The invention transitions from a linear lifting movement to a rotational movement of the control spindle. This dynamic change allows the control cross-sections to be opened and closed in a rotational manner, reducing the stress on seals and guide elements while maintaining control functionality. The rotational movement enables the control elements to operate more smoothly under high pressure conditions.
Solution Approach 2:
The invention changes the movement dimension from linear (axial lifting) to rotational (angular rotation). This dimensional transformation allows the control mechanism to operate with reduced mechanical stress, as the rotational path distributes the load more evenly across the seal and guide element surfaces compared to the concentrated stress of linear lifting.
2Ease of operation
If injection nozzles are arranged in longitudinal direction with lifting control, then control is possible, but water distribution is uneven and cooling efficiency is reduced
Solution Approach 1:
The invention introduces asymmetry in the control mechanism by using a偏心 (eccentric) control spindle arrangement. This asymmetric design causes the control cross-sections to open and close in a non-uniform manner, which optimizes the water distribution pattern across the injection nozzles. The asymmetric geometry allows for better control of water flow to each nozzle, improving overall cooling efficiency.
Solution Approach 2:
The rotational movement of the control spindle creates dynamic opening and closing of the control cross-sections. This dynamic operation allows for more uniform water distribution compared to the static or linear control methods, as the rotational motion naturally distributes the water flow more evenly across multiple nozzles in sequence.
3Reliability
If control element is placed outside steam line, then moving parts are protected from extreme loads, but complex water lines and assembly are required
Solution Approach 1:
The invention divides the injection cooler into distinct segments: the injection cylinder with nozzles remains in the steam line, while the control element is positioned outside. This segmentation allows the control mechanism to be protected from extreme thermal and pressure conditions, improving reliability. The separate control element can be connected through simplified connections rather than complex internal water lines.
4Ease of operation
If lifting movement is used for control, then nozzle release is possible, but assembly and maintenance is complex and time-consuming
Solution Approach 1:
The rotational movement mechanism is simpler to assemble and maintain compared to the lifting mechanism. The control spindle can be rotated into position without requiring complex guide elements and seal arrangements, reducing the time and complexity of both assembly and maintenance operations while maintaining the ability to release nozzles as needed.
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 extends the service life of the injection cooler, simplifies maintenance, reduces assembly errors and costs, and ensures optimal cooling water distribution with improved durability and reduced pressure loss in the steam line.
Implementation Method 1
The injected water is atomized due to the differential pressure between the water and the steam in the steam pipe
Implementation Method 2
It evaporates and superheats while the vapor itself cools
Implementation Method 3
The injected water is atomized due to the differential pressure between the water and the steam in the steam pipe
Implementation Method 4
the control spindle or the piston rod no longer carries out a lifting movement, but rather a pivoting movement
Implementation Method 5
a piston rod which is axially guided in a hollow cylindrical cooling water line arranged between a water inlet opening and the injection nozzles
Data Source
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AI summary
In an injection cooler (10) for cooling superheated steam carried in a pipe (20), comprising an injection cylinder (30) arranged at least partially in the pipe (20) and equipped with several injection nozzles (32), a control element (50) that can be connected to a coolant supply via a connection (52), wherein a valve arrangement (60) is provided in the control element (50) with which the coolant supply to the injection nozzles (32) in the injection cylinder (30) can be regulated, and coolant supply lines (70) that are provided between the injection cylinder (30) and the control element (50), wherein a separate coolant supply line (70) is provided for each injection nozzle (32), the invention provides that the ends (71) of the coolant supply lines (70) associated with the injection cylinder (30) are attached to a common first flange plate (73) which is mounted on a receiving surface (36) on the The injection cylinder (30) can be fixed,and that the ends (72) of the coolant supply lines (70) associated with the control element (50) are attached to a common second flange plate (74), which can be fixed to a receiving surface (56) of the control element (50), wherein the coolant supply lines (70) and the flange plates (73, 74) form an assembly (B) that can be mounted between the injection cooler (30) and the control element (50). The injection cylinder (30) has a housing (31) in which a core insert (40) is provided, wherein a separate supply channel (44) is formed in the core insert (40) for each injection nozzle (32), which is fluid-connected to the respective associated injection nozzle (32).