Modular Delta-Type Air-Cooled Condenser to Reduce Field Welding Time
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Solution Overview
Problem
Existing air-cooled condenser apparatuses for power plants require significant time and labor for field welding and site-specific design, leading to high costs and inefficiencies due to the need for large, custom heat exchanger modules adapted for each installation.
Innovation Solution
The design and method involve manufacturing compact, self-supporting delta-type heat exchanger units with standardized components, including tubes and manifolds, which can be pre-assembled in a factory and transported in standard containers, reducing on-site assembly time and eliminating the need for extensive site-specific engineering by using a modular system with adjustable condensation capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If large, custom heat exchanger modules are used to handle steam condensation, then the condensation capacity is sufficient, but the field welding time and labor requirements increase significantly
Solution Approach 1:
The heat exchanger module is divided into multiple standardized tube bundles that can be pre-assembled and pre-tested in the factory. Each tube bundle is a separate, interchangeable unit that can be quickly installed and connected on-site, eliminating the need for extensive field welding of large custom modules.
Solution Approach 2:
The tube bundles are pre-assembled, pre-welded, and pre-tested in the factory before shipment. This preliminary fabrication and testing eliminates or minimizes field welding operations, allowing for rapid on-site installation by simply connecting the pre-prepared bundles to the support structure.
2Adaptability or versatility
If large, custom heat exchanger modules are designed for each installation, then the steam flow capacity requirements are met, but the design and engineering work increases for each new installation
Solution Approach 1:
A universal support structure design is created that can accommodate different numbers and configurations of standardized tube bundles. This modular approach allows the same basic support structure to serve multiple installations with varying steam flow requirements by simply adding or removing tube bundles, eliminating the need for custom design work for each installation.
Solution Approach 2:
The system allows adaptation to different steam flow capacities by changing the number of tube bundles installed rather than redesigning the entire heat exchanger. The standardized tube bundles can be added or removed to match specific capacity requirements, maintaining design simplicity while providing flexibility.
3Strength
If each tube of the panel is connected to the top duct by field welding, then the connection is secure, but the time and labor consuming field welding increases
Solution Approach 1:
All welding operations between tubes and ducts are performed in the factory during tube bundle assembly. The tube bundles arrive at the installation site as complete, pre-welded units, eliminating the need for time-consuming field welding operations while maintaining the same connection strength and quality.
Solution Approach 2:
The field welding process is replaced with mechanical connection methods such as flanged connections or bolted joints for connecting tube bundles to the support structure and top duct. This substitution eliminates the need for welding equipment and skilled welders on-site while maintaining secure connections.
4Strength
If site-specific support structures are engineered and assembled for each installation, then the structural requirements are met, but the assembly time and complexity increase
Solution Approach 1:
A universal, standardized support structure design is developed that can accommodate various configurations of tube bundles through modular components. This allows the same support structure to be used across multiple installations with different capacity requirements, significantly reducing engineering and assembly time while maintaining the necessary structural strength.
Solution Approach 2:
The support structure is divided into modular, pre-fabricated components that can be easily assembled on-site using simple mechanical connections. This segmentation allows for rapid assembly by trained personnel without requiring complex engineering calculations or specialized skills, while still providing the necessary structural support.
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 allowing for rapid, cost-efficient installation and adaptation to varying steam flow capacities without extensive re-engineering, while minimizing the number of fans and components needed, thus enhancing modularity and reducing the risk of damage from overcapacity.
Implementation Method 1
heat exchangers which generally comprise a number of tubes arranged in parallel so as to form a condenser panel
Implementation Method 2
the steam gives off heat and is eventually condensed and collected
Implementation Method 3
A-type or delta-type heat exchanger modules comprise a fan either located below the two condenser panels or located above the two condenser panels in order to either generate respectively a forced air draft or an induced air draft through the two panels
Data Source
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.