Air-cooled condenser apparatus and method
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Solution Overview
Problem
Existing air-cooled condenser apparatuses using delta-type heat exchanger modules require significant site-specific design and engineering, leading to high labor and time costs due to extensive field welding and adaptation needs for varying steam flow capacities.
Innovation Solution
The design and method involve manufacturing compact, self-supporting delta-type heat exchanger units with standardized components, including tubes, manifolds, and fans, which can be easily assembled into modules and transported, reducing on-site work and allowing for modular expansion or reduction based on capacity needs, using a standardized support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If delta-type heat exchanger modules are assembled on-site with long tubes (9-12m), then the steam condensation capacity is sufficient, but the field welding work and installation time become excessive
Solution Approach 1:
The patent divides the long tube assembly into multiple shorter tube sections (e.g., three sections of 3-4m each) that can be pre-assembled into complete delta-type heat exchanger modules in the factory. These modular sections are then transported and installed on-site, eliminating the need for extensive field welding of single long tubes while maintaining the required steam condensation capacity through the modular configuration.
Solution Approach 2:
The patent performs preliminary assembly of tube sections into complete delta-type heat exchanger modules in the factory before transportation. This pre-assembly includes connecting the tube sections, attaching condenser panels, and configuring the modular structure, so that only simple assembly operations are required on-site, significantly reducing installation time and field welding requirements.
2Adaptability or versatility
If delta-type heat exchanger modules are customized for each installation, then the steam flow capacity requirements are met, but the design and engineering work increases significantly
Solution Approach 1:
The patent develops universal, standardized delta-type heat exchanger modules with fixed geometric configurations (e.g., equilateral triangles with 60° angles) that can be used across different installations. These modular units can be replicated and combined in various quantities to meet different steam flow capacity requirements, eliminating the need for custom design and engineering work for each installation while maintaining adaptability to various capacity needs.
3Productivity
If standardized modular units are used, then the installation cost and time are reduced, but the capacity must be adjusted by adding or removing modules
Solution Approach 1:
The patent designs the standardized modular delta-type heat exchanger units with dynamic scalability, where the system capacity can be adjusted by simply adding or removing complete modular units. Each module is self-contained with standardized connection interfaces, allowing flexible configuration changes without requiring re-engineering. The modular design enables the system to adapt to varying steam flow capacities while maintaining installation efficiency through repeated use of the same standardized components.
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 approach significantly reduces project costs and time by minimizing site-specific engineering and field welding, enabling efficient and cost-effective installation and adaptation to various steam condensation capacities without the need for extensive re-engineering.
Implementation Method 1
a series of fans FAN(k) aligned along an axis parallel with the Y axis and configured to generate an air flow through each delta-type heat exchanger unit of the series HEXU(j)
Implementation Method 2
an air-cooled condenser apparatus for condensing a steam flow exiting a steam turbine
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
The present invention relates to an air-cooled condenser apparatus for condensing a steam flow exiting a turbine from for example a power plant. The air-cooled condenser apparatus comprises a series of condenser modules, each module having a series of compact delta-type heat exchanger units and a series of fans. The air-cooled condenser apparatus further comprises a series of independent frame structures FRS(m) wherein the number of frame structures has a lower limit depending on the number of modules. The invention further relates to a method for manufacturing an air-cooled condenser apparatus comprising steps of manufacturing the delta-type heat exchanger units in the factory, placing the units in a container for transportation and erecting the air-cooled condenser apparatus at a site of installation.