Note: Descriptions are shown in the official language in which they were submitted.
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ADVANCED LARGE SCALE FIELD-ERECTED AIR COOLED INDUSTRIAL STEAM
CONDENSER
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[001] The present invention relates to large scale field erected air cooled
industrial steam
condensers.
DESCRIPTION OF THE BACKGROUND
[002] The typical large scale field erected air cooled industrial steam
condenser is constructed of
heat exchange bundles arranged in an A-frame arrangement above a large fan,
with one A-frame
per fan. Each tube bundle typically contains 35-45 vertically oriented
flattened finned tubes, each
tube approximately 11 meters in length by 200 mm in height, with semi-circular
leading and
trailing edges, and 18-22 mm external width. Each A-frame typically contains
five to seven tube
bundles per side.
[003] The typical A-Frame ACC described above also includes both 1' stage or
"primary"
condenser bundles (sometimes referred to as K-bundles for Kondensor) and 2'
stage or
"secondary" condenser bundles (sometimes referred to as D-bundles for
Dephlegmator). About
80% to 90% of the heat exchanger bundles are 1' stage or primary condenser.
The steam enters
the top of the primary condenser bundles and the condensate and some steam
leave the bottom. In
the 1" stage the steam and condensate travel down the heat exchanger bundles
and this process is
commonly referred to as the co-current condensing stage. The first stage
configuration is thermally
efficient; however, it does not provide a means for removing non-condensable
gases. To sweep
the non-condensable gases through the 1" stage bundles, 10% to 20% of the heat
exchanger
bundles are configured as 2' stage or secondary condensers, typically
interspersed among the
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primary condensers, which draw vapor from the lower condensate manifold. In
this arrangement,
steam and non-condensable gases travel through the 1st stage condensers as
they are drawn into
the bottom of the secondary condenser. As the mixture of gases travels up
through the secondary
condenser, the remainder of the steam condenses, concentrating the non-
condensable gases at the
top while the condensate drains to the bottom. This process is commonly
referred to as the counter-
current condensing stage. The tops of the secondary condensers are attached to
a vacuum manifold
which removes the non-condensable gases from the system.
[004] Variations to the standard prior art ACC arrangement have been
disclosed, for example in
US 2015/0204611 and US 2015/0330709. These applications show the same finned
tubes, but
drastically shortened and then arranged in a series of small A-frames,
typically five to six A-frames
per fan. Part of the logic is to reduce the steam-side pressure drop, which
has a small effect on
overall capacity at summer condition, but greater effect at a winter
condition. Another part of the
logic is to weld the top steam manifold duct to each of the bundles at the
factory and ship them
together, thus saving expensive field welding labor. The net effect of this
arrangement, with the
steam manifold attached at the factory and shipped with the tube bundles, is a
reduction of the tube
length to accommodate the manifold in a shipping container.
[005] Additional variations to the prior art ACC arrangements are disclosed,
for example in US
2017/0363357 and US 2017/0363358. These applications disclose a new tube
construction for use
in ACCs having a cross-sectional height of lOmm or less. US 2017/0363357 also
discloses a new
ACC arrangement having heat exchanger bundles in which the primary condenser
bundles are
arranged horizontally along the longitudinal axis of the bundles and the
secondary bundles are
arranged parallel to the transverse axis. US 2017/0363358 discloses an ACC
arrangement in which
all of the tube bundles are secondary bundles.
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SUMMARY OF THE INVENTION
[006] The invention presented herein is a new and improved design for large
scale field-erected
air cooled industrial steam condensers for power plants and the like which
provides significant
improvements and advantages over the ACCs of the prior art.
[007] According to one embodiment of the present invention, heat exchanger
panels are
constructed with an integral secondary condenser section positioned in the
center of the heat
exchanger panel, flanked by primary condenser sections which may or may not be
identical to
one-another. A bottom bonnet runs along the bottom length of the heat
exchanger panel,
connected to the bottom side of the bottom tube sheet, for delivering steam to
the bottom end of
the primary condenser tubes. In this arrangement, the 1st stage of condensing
occurs in counter-
current operation. The tops of the tubes are connected to a top tube sheet,
which in turn is
connected on its top side to a top bonnet. Uncondensed steam and non-
condensables flow into
the top bonnet from the primary condenser tubes and flow toward the center of
the heat
exchanger panel where they enter the top of the secondary condenser section
tubes. In this
arrangement the 2nd stage of condensing occurs in co-current operation. Non-
condensables and
condensate flow out the bottom of the secondary tubes into an internal
secondary chamber
located inside the bottom bonnet. Non-condensables and condensate are drawn
from the bottom
bonnet secondary chamber via outlet nozzle, and condensate is drawn off and
sent to join the
water collected from the primary condenser sections.
[008] According to an alternate embodiment, the heat exchanger panels may be
constructed as
single stage condenser heat exchange panels, in which all the tubes of the
heat exchanger panels
receive steam from and deliver condensate to the bottom bonnet, and non-
condensables are
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drawn off via the top bonnet. More specifically, a bottom bonnet runs along
the bottom length of
the heat exchanger panel as with the multiple stage embodiment, connected to
the bottom side of
the bottom tube sheet, but in the single stage embodiment, the bottom bonnet
delivers steam to
the bottom end of all the tubes in the heat exchanger panel. As with the
multiple stage
embodiment, the tops of all of the tubes are connected to a top tube sheet,
which in turn is
connected on its top side to a top bonnet. Uncondensed steam and non-
condensables flow into
the top bonnet from all of the tubes in the heat exchanger panel and are drawn
away from the top
bonnet for further processing. Condensate flows out the bottom of all of the
tubes into the bottom
bonnet, and into the steam distribution manifold.
[009] According to various embodiments of the invention, each heat exchanger
panel may be
independently loaded into and supported in the heat exchange section
framework. According to
one embodiment, adjacent panels may be inclined relative to vertical in
opposite directions in an
arrangement resembling an A-frame or V-frame type of arrangement, although
there is
preferably no relation or interaction between adjacent panels. According to
another embodiment,
each heat exchange panel may be oriented vertically, with an optional air
deflection or seal
positioned at an angle between each adjacent panel. According to a further
embodiment, all of
the heat exchange panels may be inclined at an angle relative to vertical, all
in the same
direction. According to yet another embodiment, all of the heat exchange
panels on one side of a
heat exchange section may be inclined relative to vertical in one direction,
and all of the heat
exchange panels on the other side of the heat exchange section may be inclined
relative to
vertical in an opposite direction.
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[0010] According to some embodiments of the invention, each cell or module of
the ACC has a
plenum section module with a single fan large fan creating an air flow over
all of the heat
exchange panels in the same module.
[0011] According to other embodiments of the invention, the plenum section
module may
include a plurality of longitudinal fan deck plates arranged over the fan deck
framework, each
fan deck plate having a plurality of fans. According to various aspects of
this embodiment, the
fan deck plates may be aligned so that their longitudinal axis is parallel to
or perpendicular to the
longitudinal axes of the heat exchange panels in the same ACC module.
[0012] According to a further embodiment of the invention, a lower steam
distribution manifold
runs under a plurality of ACC cells/modules in a row, and the heat exchange
panels of each cell
or module of the ACC is fed by a single riser which delivers its steam to a
dedicated upper steam
distribution manifold, preferably comprising a large horizontal cylinder
closed at both ends,
suspended from below the heat exchange section support framework,
perpendicular to the
longitudinal axis of the heat exchanger panels, and beneath the center point
of each heat
exchanger panel. The upper steam distribution manifold feeds steam to the
bottom bonnet of
each heat exchanger panel at a single location at the center point of the each
panel.
[0013] According to a further embodiment of the invention, the heat exchange
module frame and
the heat exchanger panels for each cell are pre-assembled at ground level. The
heat exchange
module frame is then supported on an assembly fixture just high enough to
suspend the upper
steam distribution manifold from the underside of the heat exchange module
frame. Separately,
the plenum section, which includes the fan deck and fan set for a
corresponding heat exchange
module, is likewise assembled at ground level. Sequentially or simultaneously,
the
understructure for the corresponding heat exchange module may be assembled in
its final
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location. The heat exchange module, with the upper steam distribution manifold
suspended
therefrom, may then be lifted in its entirety and placed on top of the
understructure, followed by
similar lifting and placement of the completed plenum section sub-assembly.
[0014] According to an alternate embodiment of the invention, the plurality of
upper steam
distribution manifolds for a plurality of cells are combined into a single
elevated steam manifold
that is suspended from and runs the length of a plurality of condenser
modules. According to
this embodiment, the lower steam manifold and riser is eliminated, and the
elevated steam
manifold is fed directly from the turbine exhaust duct which itself is
elevated to the level of the
elevated steam manifold. The elevated steam manifold feeds steam to the bottom
bonnet of each
heat exchanger panel at a single location at the center point of the panel.
[0015] This new ACC design may be used with tubes having prior art cross-
section
configuration and area (for example, 200mm x 18-22mm). Alternatively, this new
ACC design
may be used with tubes having the design described in US 2017/0363357 and US
2017/0363358
(200mm x lOmm or less), the disclosures of which are hereby incorporated
herein in their
entirety.
[0016] According to a further alternative embodiment, the new ACC design of
the present
invention may be used with 100 mm by 5mm to 7mm tubes having offset fins.
[0017] According to a further embodiment, the new ACC design of the present
invention may be
used with 200mm by 5mm to 7mm tubes or 200mm by 17-20 mm tubes, the tubes
preferably
having "Arrowhead"-type fins arranged at 5-12 fins per inch (fpi), preferably
at 9-12 fpi, and
most preferably at 9.8 fins per inch.
[0018] According to a further embodiment, the new ACC design of the present
invention may be
used with 120mm by 5mm to 7mm tubes having "Arrowhead"-type fins arranged at
9.8 fins per
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inch. According to an even further embodiment, the new ACC design of the
present invention
may be used with 140mm by 5mm to 7mm tubes having "Arrowhead"-type fins
arranged at 9.8
fins per inch. While the 120mm and 140mm configurations do not produce quite
the same
increase in capacity as the 200mm configuration, both the 120mm and 140 mm
configurations
have reduced materials and weight compared to the 200mm design.
[0019] For a disclosure of the structure of Arrowhead-type fins discussed
above, the disclosure
of U.S. Application Serial No. 15/425,454, filed February 6, 2017 is
incorporated herein in its
entirety.
[0020] According to yet another embodiment, the new ACC design of the present
invention may
be used with tubes having "louvered" fins, which perform approximately as well
as offset fins,
and are more readily available and easier to manufacture.
[0021] The description of fin type and dimension herein is not intended to
limit the invention.
The tubes of the invention described herein may be used with fins of any type
without departing
from the scope of the invention.
[0022] Accordingly, there is provided according to the invention, a large
scale field erected air
cooled industrial steam condenser connected to an industrial steam producing
facility, having a
single or plurality of condenser streets, each condenser street comprising a
row of condenser
modules, each condenser module comprising a plenum section having a single fan
or multiple
fans drawing air through a plurality of heat exchanger panels supported in a
heat exchanger
section, and each heat exchanger panel having a longitudinal axis and a
transverse axis
perpendicular to its longitudinal axis, each heat exchanger panel having a
plurality of tubes, a top
bonnet connected to and in fluid communication with a top end of each tube, a
bottom bonnet
connected to and in fluid communication with a bottom end of at least a subset
of said tubes, said
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bottom bonnet having a single steam inlet; each condenser street including a
steam distribution
manifold suspended from the heat exchanger section and arranged along an axis
that is
perpendicular to a longitudinal axis of said heat exchanger panels at a
midpoint of said heat
exchanger panels and extending a length of said condenser street beneath a
plurality of heat
exchanger panels, said steam distribution manifold including a cylinder having
first and second
ends, the cylinder closed at a second end distal from the first end, the
cylinder having at its top
surface a plurality of connections, each connection adapted to connect to a
corresponding single
steam inlet.
[0023] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser wherein each heat exchanger
panel comprises a
single condenser stage in which all tubes in the heat exchanger panel receive
steam from a
bottom end of said tubes.
[0024] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, in which the top bonnet is
configured to receive
non-condensable gasses, and optionally uncondensed steam, from said condenser
tubes, and does
not provide steam to said tubes.
[0025] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein each heat exchanger
panel comprises a
secondary condenser section, a primary condenser section and a top bonnet
connected to and in
fluid communication with a top end of each tube in said secondary condenser
section and said
primary condenser sections, a primary bottom bonnet connected to and in fluid
communication
with a bottom end of each tube in said primary condenser sections, an internal
secondary
chamber inside the bottom bonnet connected to and in fluid communication with
a bottom end of
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each tube in said secondary condenser section, said secondary bottom bonnet
connected to a top
side of said primary bottom bonnet, each said primary bottom bonnet having a
single stem inlet.
[0026] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser wherein each heat exchanger
panel comprises two
primary condenser sections flanking said secondary section.
[0027] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein the secondary condenser
section is
centrally located along said heat exchange panel and flanked at each end by
primary condenser
sections.
[0028] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said steam distribution
manifold cylinder
is attached at a first end to a turbine exhaust duct.
[0029] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said steam distribution
manifold is closed
at both ends, and having at a bottom surface a single connection to a steam
riser.
[0030] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein each said heat
exchanger panel is
independently suspended from a frame of the heat exchanger section by a
plurality of flexible
hanging supports.
[0031] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein all of the heat
exchange panels in a single
heat exchanger section are oriented in the same direction.
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[0032] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein all of the heat
exchange panels in a single
heat exchanger section are oriented vertically.
[0033] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein all of the heat
exchange panels in a single
heat exchanger section are oriented in the same direction, at the same angle
relative to vertical.
[0034] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein all of the heat
exchange panels on one
side of a single heat exchanger section are inclined relative to vertical in
one direction, and all of
the heat exchange panels on the other side of the single heat exchanger
section are inclined
relative to vertical in an opposite direction.
[0035] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, said plenum section comprising
a single fan
resting on fan deck framework and drawing air over all of said heat exchange
panels in said heat
exchanger section.
[0036] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, said plenum section comprising
a plurality of fan
deck plates resting on fan deck framework, said fan deck plates each
comprising a plurality of
fans.
[0037] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein in each fan draws air
across no more than
two heat exchange panels.
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[0038] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said flexible hanging
supports each
comprise a central rod connected at each end to a connection sleeve, and
wherein one connection
sleeve of each flexible hanging support is connected to said heat exchanger
section frame and a
second connection sleeve of each flexible hanging support is connected to a
tube sheet of said
heat exchanger panel.
[0039] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said plurality of tubes
in said heat
exchanger panels have a length of 2.0m to 2.8m, a cross-sectional height of
120 mm and a cross-
sectional width of 4-10 mm.
[0040] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said tubes have a cross-
sectional width of
5.2-7 mm.
[0041] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said tubes have a cross-
sectional width of
6.0 mm.
[0042] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said plurality of tubes
in said heat
exchanger panels have fins attached to flat sides of said tubes, said fins
having a height of 9 to
lOmm, and spaced at 5 to 12 fins per inch.
[0043] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, wherein said plurality of tubes
in said heat
exchanger panels have fins attached to flat sides of said tubes, said fins
having a height of 18 mm
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to 20 mm spanning a space between adjacent tubes and contacting adjacent
tubes, said fins
spaced at 5 to 12 fins per inch.
[0044] There is further provided according to an embodiment of the invention,
a method of
assembling a large scale field erected air cooled condenser including the
steps assembling a heat
exchange section at ground level, including a heat exchange section frame and
said heat
exchanger panels; supporting said heat exchange section at a height from
ground sufficient only
to suspend a steam distribution manifold section directly beneath and adjacent
said heat
exchanger panels, assembling a plenum section with fan deck and fan assembly
at ground level;
raising said assembled heat exchange section and said steam distribution
manifold section and
placing it atop a corresponding understructure; attaching adjacent steam
distribution manifold
sections to one-another; and raising said assembled plenum section and placing
it atop said heat
exchange section.
[0045] There is further provided according to an embodiment of the invention,
a large scale field
erected air cooled industrial steam condenser, optionally connected to an
industrial steam
producing facility, including: a single or plurality of condenser streets,
each condenser street
comprising a row of condenser modules, each condenser module comprising a
plenum section
having single fan or multiple fans drawing air through a plurality of heat
exchanger panels
supported in a heat exchange section, and each heat exchanger panel having a
longitudinal axis
and a transverse axis perpendicular to its longitudinal axis, each heat
exchanger panel comprising
a plurality of condenser tubes and a top bonnet connected to and in fluid
communication with a
top end of each said plurality of condenser tubes, a bottom bonnet connected
to and in fluid
communication with a bottom end of each said plurality of condenser tubes,
each said bottom
bonnet having a single steam inlet; each said condenser street having a single
steam distribution
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manifold suspended from and directly adjacent to a bottom side of said heat
exchanger section
arranged along an axis that is perpendicular to a longitudinal axis of said
heat exchanger panels
at a midpoint of said heat exchanger panels and extending a length of said
condenser street, said
steam distribution manifold comprising a cylinder attached at a first end to a
turbine exhaust
duct, and closed at a second end distal from said first end, said cylinder
having at its top surface
a plurality of connections adapted to connect to said bottom bonnet inlets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] Figure 1 is a perspective view representation of the heat exchange
portion of a prior art
large scale field erected air cooled industrial steam condenser.
[0047] Figure 2 is a partially exploded close up view of the heat exchange
portion of a prior art
large scale field erected air cooled industrial steam condenser, showing the
orientation of the
tubes relative to the steam distribution manifold.
[0048] Figure 3 is a side view of a two stage heat exchanger panel according
to an embodiment
of the invention.
[0049] Figure 4 is a top view of the heat exchanger panel shown in Figure 3.
[0050] Figure 5 is a bottom view of the heat exchanger panel shown in Figure
3.
[0051] Figure 6 is a cross-sectional view of the heat exchanger panel shown in
Figure 3, along
line C-C.
[0052] Figure 7 is a cross-sectional view of the heat exchanger panel shown in
Figure 3, along
line D-D.
[0053] Figure 8 is a cross-sectional view of the heat exchanger panel shown in
Figure 3, along
line E-E.
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[0054] Figure 9 is a side elevation view of a two stage heat exchanger panel
and upper steam
distribution manifold according to an alternate embodiment of the invention.
[0055] Figure 10A is a Section view along line A-A of Figure 9.
[0056] Figure 10B is alternative embodiment to the embodiment shown in Figure
10A.
[0057] Figure 11 is a cross-sectional view of a bottom bonnet of the type
shown in Figure 9 with
a flat shield plate according to an embodiment of the invention.
[0058] Figure 12 is a cross-sectional view of a bottom bonnet of the type
shown in Figure 9 with
a bended shield plate according to an embodiment of the invention.
[0059] Figure 13A is a side view of a large scale field erected air cooled
industrial steam
condenser according to an embodiment of the invention with new steam delivery
and distribution
configuration.
[0060] Figure 13B is a plan view of a large scale field erected air cooled
industrial steam
condenser shown in Figure 13A.
[0061] Figure 14 is a closeup side view of one cell of the large scale field
erected air cooled
industrial steam condenser shown in Figures 13A and 13B.
[0062] Figure 15 is a further closeup side view of one cell of the large scale
field erected air
cooled industrial steam condenser shown in Figures 13A, 13B and 14.
[0063] Figure 16 is an elevation view of the upper steam distribution manifold
and its
connections to the heat exchanger panels, including optional condensate piping
from the
secondary bottom bonnet (in the case of a two stage condenser panel) according
to an
embodiment of the invention.
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[0064] Figure 17 is a further closeup side view of one cell of the large scale
field erected air
cooled industrial steam condenser shown in Figures 13-15, showing an end view
of two pairs of
heat exchanger panels.
[0065] Figure 18A is a set of engineering drawings showing a hanger rod
according to an
embodiment of the invention in a cold position.
[0066] Figure 18B is a set of engineering drawings showing the hanger rod of
Figure 18A in a
hot position.
[0067] Figure 19A is a set of engineering drawings showing a hanger rod
according to a
different embodiment of the invention in a cold position.
[0068] Figure 19B is a set of engineering drawings showing the hanger rod of
Figure 19A in a
hot position.
[0069] Figure 20A shows a top perspective view of a single pre-assembled
condenser module
including the upper steam distribution manifold suspended therefrom.
[0070] Figure 20B shows a bottom perspective view of a single pre-assembled
condenser
module including the upper steam distribution manifold suspended therefrom.
[0071] Figure 21A shows a top perspective view of a fan deck and fan (plenum)
subassembly for
a single cell corresponding to the condenser module shown in Figures 20A and
20B.
[0072] Figure 21B shows a bottom perspective view of a fan deck and fan
(plenum) subassembly
for a single cell corresponding to the condenser module shown in Figure 20A
and 20B.
[0073] Figure 22 shows a perspective view of a tower frame for a single cell
corresponding to
the condenser module shown in Figure 20A and 20B.
[0074] Figure 23 shows the placement of the pre-assembled condenser module of
Figures 20A
and 20B lifted onto the tower frame of Figure 22.
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[0075] Figure 24 shows the placement of the fan deck and fan (plenum) sub-
assembly of
Figures 21A and 21B installed atop the tower section and condenser modules in
Figure 23.
[0076] Figure 25 is side view of a large scale field erected air cooled
industrial steam condenser
according to an alternate embodiment of the invention having elevated steam
distribution
manifolds directly connected to the turbine steam duct.
[0077] Figure 26 is side view of a large scale field erected air cooled
industrial steam condenser
according to a second alternate embodiment of the invention having elevated
steam distribution
manifolds directly connected to the turbine steam duct.
[0078] Figure 27 is an end view of the embodiment shown in Figure 26.
[0079] Figure 28 is an elevation view of an alternate embodiment of the
invention in which all of
the heat exchange panels in a heat exchange module are oriented vertically,
with an air deflection
seal situated between each adjacent pair of panels.
[0080] Figure 29 is an elevation view of another embodiment of the invention
in which all of the
heat exchange panels on one side of a heat exchange module are inclined
relative to vertical in
one direction, and all of the heat exchange panels on the other side of the
heat exchange module
are inclined relative to vertical in the opposite direction.
[0081] Figure 30 is a representation of a fan deck plate according to an
embodiment of the
invention in which each plenum section module supports a plurality of fan deck
plates, each fan
deck plate supporting a plurality of fans.
[0082] Figure 31 is a representation of an embodiment of the invention in
which the fan deck
includes a plurality of fan deck plates supported on the fan deck structure
above the heat
exchange module, where each fan deck plate includes a plurality of fans, and
the fan deck plates
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are arranged so that their longitudinal axis is perpendicular to the
longitudinal axis of the heat
exchange panels.
[0083] Figure 32 is a representation of another embodiment of the invention in
which the fan
deck includes a plurality of fan deck plates supported on the fan deck
structure above the heat
exchange module, where each fan deck plate includes a plurality of fans, and
the fan deck plates
are arranged so that their longitudinal axis is perpendicular to the
longitudinal axis of the heat
exchange panels.
[0084] Figure 33 shows examples of the type of fans that may be used in the
fan deck plate
embodiment of the invention.
[0085] Figure 34 is a side elevation view of a single stage heat exchanger
panel and upper steam
distribution manifold according to an alternate embodiment of the invention.
[0086] Figure 35 is a plan view of a large scale field erected air cooled
industrial steam
condenser according to an alternate embodiment of the invention having an
elevated steam
distribution manifolds connected to a ground level turbine exhaust duct via
end risers.
[0087] Figure 36 is an elevation view of the embodiment of Figure 35, along
section A-A.
[0088] Figure 37 is an elevation view of the embodiment of Figure 35, along
section B-B.
[0089] Features in the attached drawings are numbered with the following
reference numerals:
2 heat exchanger panel 12 top bonnet
4 primary condenser section 14 bottom tube sheet
6 secondary condenser section 15 lifting/support angle
7 tubes 16 bottom bonnet
8 condenser bundles 18 stem inlet/condensate
outlet
top tube sheet 20 shield plate
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21 perforations 50 hangers
22 scalloped edge 54 hanger rod
24 secondary bottom bonnet 56 hanger sleeve
26 nozzle (for secondary bottom bonnet) 58 hanger fixed discs or knobs
27 ACC condenser module (cell) 60 hanger recesses
28 upper steam manifold 62 understructure module
29 Y-shaped nozzle 64 plenum section module
30 riser (LSM to USM) 66 elevated steam distribution
manifold
31 turbine exhaust duct 68 elevated turbine exhaust
duct
32 lower steam distribution manifold 70 air deflection seal
34 street/row of ACC cells 72 fan deck plate
36 frame (of heat exchange section) 74 small fan
37 heat exchange module 76 ground level turbine
exhaust duct
40 deflector shield 78 end riser (GLTED to ESDM)
42 condensate piping
DETAILED DESCRIPTION
[0090] Referring Figures 3-8, the heat exchanger panel 2 according to a first
embodiment of the
present invention includes two primary condenser sections 4 flanking an
integrated and centrally
located secondary condenser section 6. Each heat exchanger panel 2 consists of
a plurality of
separate condenser bundles 8, with a first subset of condenser bundles 8
making up the centrally
located secondary section 6, and a second subset of different condenser
bundles 8 making up
each flanking primary section 4. The dimensions and constructions of the tubes
7 of the primary
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and secondary sections are preferably identical. At their top, all of the
tubes 7 of both the
primary and secondary sections 4, 6 are joined to a top tube sheet 10, on
which sits a hollow top
bonnet 12 which runs the length of the top of the heat exchanger panel 2. The
bottom of all of
the tubes 7 of the primary and secondary sections 4, 6 are connected to a
bottom tube sheet 14,
which forms the top of a bottom bonnet 16. The bottom bonnet 16 likewise runs
the length of
the heat exchanger panel 2. The bottom bonnet 16 is in direct fluid
communication with the
tubes 7 of the primary section 4 but not with the tubes of the secondary
section 6. The bottom
bonnet 16 is fitted at the center point of its length with a single steam
inlet/condensate outlet 18
which receives all the steam for the heat exchanger panel 2 and which serves
as the outlet for
condensate collected from the primary sections 4. The bottom of the bottom
bonnet 16 is
preferably angled downward at an angle of between 1 degree and 5 degrees,
preferably about 3
degrees with respect to the horizontal from both ends of the bonnet 16 toward
the steam
inlet/condensate outlet 18 at the middle of the heat exchanger panel 2.
According to a preferred
embodiment and referring to Figs 9-12, the bottom bonnet 16 may include a
shield plate 20 to
partition condensate flow from the steam flow. The shield 20 may have
perforations 21 and/or
have a scalloped edge 22 or have other openings or configuration to allow
condensate falling on
top of the shield 20 to enter the space beneath the shield and to flow beneath
the shield toward
the inlet/outlet 18. When viewed from the end of the bottom bonnet 16, the
shield plate 20 is
secured at a near-horizontal angle (between horizontal and 12 degrees from
horizontal in the
crosswise direction) so as to maximize the cross-section provided by the
bottom bonnet 16 to the
flow of steam. The shield plate 20 may be flat as shown in Fig. 11 or bended
as shown in Fig.
12. The top tube sheet 10 and bottom tube sheet 14 may be fitted with
lifting/support angles 15
for lifting and/or supporting the heat exchangers 2.
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[0091] An internal secondary chamber, or secondary bottom bonnet 24, is fitted
inside the
bottom bonnet 16 in direct fluid connection with only the tubes 7 of the
secondary section 6 and
extends the length of the secondary section 6, but preferably not beyond. This
secondary bottom
bonnet 24 is fitted with a nozzle 26 to withdraw non-condensables and
condensate.
[0092] According to an alternate, single stage condenser, embodiment shown in
Fig. 34, there is
no secondary section or secondary bottom bonnet, and the bottom bonnet 16 is
in direct fluid
communication with all of the tubes in the heat exchange panel 2. According to
this
embodiment, bottom bonnet 16 runs along the bottom length of the heat
exchanger panel 2
connected to the bottom side of the bottom tube sheet 14. Bottom bonnet 16
delivers steam to
the bottom end of all the tubes of condenser bundles 8 in the heat exchanger
panel 2. The tops of
all of the tubes are connected to a top tube sheet 10, which in turn is
connected on its top side to
a top bonnet 12. Uncondensed steam and non-condensables flow into the top
bonnet 12 from all
of the tubes 7 in the heat exchange panel 2 and are drawn away from the top
bonnet 12 for
further processing. Condensate flows out the bottom of all of the tubes 7 into
the bottom bonnet
16, and into the steam distribution manifold.
[0093] The steam inlet/condensate outlet 18 for the heat exchanger panel 2 and
the steam
inlet/condensate outlets 18 for all of the heat exchanger panels in the same
ACC cell/module 27
are connected to a large cylinder or upper steam distribution manifold 28
suspended beneath the
heat exchanger panels 2 and which runs perpendicular to the longitudinal axis
of the heat
exchanger panels 2 at their midpoint. See, e.g., Figs. 13-15, 20A and 20B. The
upper steam
distribution manifold 28 extends across the width of the cell/module 27 and is
closed at both
ends. At its bottom center, the upper steam distribution manifold 28 is
connected to a single riser
30 which is connected at its bottom to the lower steam distribution manifold
32. Where the top
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surface of the upper steam distribution manifold 28 passes below the center
point of each heat
exchanger panel 2, the upper steam distribution manifold 28 is fitted with a Y-
shaped nozzle 29
which connects to the steam inlet/condensate outlets 18 at the bottom of each
adjacent pair of
heat exchanger panels 2.
[0094] According to this construction, each cell 27 of the ACC receives steam
from a single riser
30. The single riser 30 feeds steam to a single upper steam distribution
manifold 28 suspended
directly beneath the center point of each heat exchanger panel 2, and the
upper steam distribution
manifold 28 feeds steam to each of the heat exchanger panels 2 in a cell 27via
a single steam
inlet/condensate outlet 18.
[0095] Therefore, the steam from an industrial process travels along the
turbine exhaust duct 31
at or near ground level, or at any elevation(s) suited to the site layout.
When the steam duct 31
approaches the ACC of the invention, it splits into a plurality of sub-ducts
(lower steam
distribution manifolds 32), one for each street (row of cells) 34 of the ACC.
Each lower steam
distribution manifold 32 travels beneath its respective street of cells 34,
and it extends a single
riser 30 upwards at the center point of each cell 27. See, e.g., Fig. 13A and
13B. The single riser
30 connects to the bottom of the upper steam distribution manifold 28
suspended from the frame
36 of the condenser module 37, Figs. 13-15. The upper steam distribution
manifold 28 delivers
steam through a plurality of Y-shaped nozzles 29 to the pair of bonnet
inlets/outlets 18 of each
adjacent pair of heat exchanger panels 2, Figs. 15-17. The steam travels along
the bottom bonnet
16 and up through the tubes 7 of the primary sections 4, condensing as air
passes across the
finned tubes 7 of the primary condenser sections 4. The condensed water
travels down the same
tubes 7 of the primary section 4 counter-current to the steam, collects in the
bottom bonnet 16
and eventually drains back through the upper steam distribution manifold 28
and lower steam
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distribution manifold 32 and turbine exhaust duct 31 to a condensate
collection tank (not shown).
According to a preferred embodiment, the connection between the bottom bonnet
16 and the
upper steam distribution manifold 28 may be fitted with a deflector shield 40
to separate the
draining/falling condensate from the incoming steam.
[0096] The uncondensed steam and non-condensables are collected in the top
bonnet 12 and are
drawn to the center of the heat exchanger panel 2 where they travel down the
tubes 7 of the
secondary section 6 co-current with the condensate formed therein. Non-
condensables are drawn
into the secondary bottom bonnet 24 located inside the bottom bonnet 16 and
out through an
outlet nozzle 26. Additional condensed water formed in the secondary section 6
collects in the
secondary bottom bonnet 24 and travels through the outlet nozzle 26 as well
and then travels
through condensate piping 42 to the upper steam distribution manifold 28 to
join the water
collected from the primary condenser sections 4.
[0097] According to another feature of the invention, the heat exchanger
panels 2 are suspended
from framework 36 of the condenser module 37 by a plurality of flexible
hangers 50 which allow
for expansion and contraction of the heat exchanger panels 2 based on heat
load and weather.
Figure 17 shows how the hangers 50 are connected to the frame 36 of the
condenser module 37,
and Figures 18A, 18B, 19A and 19B shows the details of two embodiments of the
hangers.
According to each embodiment, the hanger 50 is constructed to allow the heat
exchanger panel 2
to expand or contract while providing support for their weight. Four hangers
50 are used for
each heat exchanger panel 2. According to one embodiment, the hanger 50 is
constructed of a
rod 54 with sleeves 56 at each end. The sleeves 56 are fitted over the rod 54
and are prevented
from coming off of the respective ends by fixed discs or knobs 58 at each end
of the rod 54
which fit into correspondingly shaped recesses 60 on the inside surface of the
respective sleeves,
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but which recesses do not extend to the end of the sleeve. One end of the
hanger 50 is connected
to the frame 36 of the condenser module 37 and the other end of the hanger is
attached to an
lifting/support angle 15 or other attachment point on the top tube sheet 10 or
bottom tube sheet
14. The sleeves 56 are preferably adjustable to allow for the setting of
correct hanger length
during construction. Once set, movement of the heat exchanger panels 2 is
accommodated by the
ball joints at the top and bottom of the hangers 50 and the angular
displacement of the hangers
50.
[0098] The heat exchange panels 2 may each be independently loaded into and
supported in heat
exchange module framework 36. The heat exchange panels 2 may be supported in
the heat
exchange module framework 36 according to any of a variety of configurations.
Figures 13-17,
23-27 show the heat exchange panels 2 independently supported in the heat
exchange module
framework 36 with adjacent heat exchange panels 2 inclined relative to
vertical in opposite
directions. Figure 28 shows an alternate embodiment in which each heat
exchange panel 2 is
independently supported in the heat exchange module with each heat exchange
panel oriented
vertically, and an optional air deflection seal 70 positioned at an incline
between a bottom of one
heat exchange panel 2 and a top of an adjacent heat exchange panel 2. Figure
29 shows a further
alternate embodiment in which each heat exchange panel 2 on one side of the
heat exchange
module is inclined relative to vertical in one direction, and each heat
exchange panel 2 on the
other side of the heat exchange module is inclined relative to vertical in the
opposite direction,
with an optional air deflection seal 70 vertically positioned between each
pair of adjacent
exchange panels 2.
[0099] According to an alternate embodiment of the invention, shown in Figures
25-27, instead
of the plurality of upper steam distribution manifolds 28, lower steam
manifold 32 and risers 30,
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the air cooled condenser of the invention may instead have a plurality of
elevated steam
distribution manifolds 66 connected directly to an elevated turbine steam duct
68 in which each
elevated steam distribution manifold runs the length and feeds the heat
exchange panels of a
plurality of heat exchange modules along a street/row 34 of condenser cells
27. The elevated
steam distribution manifolds 66 may be suspended from the heat exchange module
frame in the
same way that the upper steam distribution manifolds 28 are suspended from the
heat exchange
module frame. Likewise, the elevated steam distribution manifolds 66 run
perpendicular to the
longitudinal axis of the heat exchange panels and is connected to the heat
exchange panels at
their center points through a plurality of Y-shaped nozzles to the pair of
bonnet inlets/outlets of
each adjacent pair of heat exchanger panels. According to this embodiment, the
lower steam
manifold 32 and riser 30 is eliminated, and the elevated steam manifold is fed
directly from the
turbine exhaust duct which itself is elevated to the level of the elevated
steam manifold.
[00100] According to a further alternate embodiment of the invention,
shown in Figures
35-37, the plurality of elevated steam distribution manifolds 66 may be
connected to a ground
level turbine exhaust duct 76 via end risers 78.
[00101] According to preferred embodiments of the invention, the ACCs of
the invention
are constructed in a modular fashion. According to various embodiments,
understructure 62,
condenser modules 37 and plenum sections 64 may be assembled separately and
simultaneously
on the ground. According to one embodiment, the heat exchange module frame may
be lifted on
a stick built understructure just high enough to suspend the upper steam
distribution manifold 28
from the underside of the heat exchange module framework. The heat exchanger
panels 2 are
then lowered into and attached to the frame 36 of the condenser module 37 and
to the upper
steam distribution manifold 28, preferably at or just above ground level, see
Figs. 20A and 20B.
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Once completed, the assembled condenser module 37 with attached upper steam
distribution
manifold 28 may be lifted and placed on top of the corresponding completed
understructure 62
(Figs. 22 and 23).
[00102] The plenum section 64 for each ACC module 27, including the plenum
section
frame, fan deck supported on the plenum section frame, fan(s) and fan
shroud(s), may be
assembled at ground level with a single large fan, as shown, e.g., in Figs.
13A, 13B, 14, 15, 21,
21B, and 24-29), or it may be assembled (also at ground level) with a
plurality of elongated fan
deck plates 72, each supporting a plurality of smaller fans 74 in a row, as
shown in Figs. 30-32.
The fan deck plates 72 are each preferably sized to fit into a standard
shipping container.
Accordingly, the fans 74 may be attached to the fan deck plates 72 at the
factory and shipped to
the final assembly location. An example of fan 74 is shown in Figure 33.
According to various
embodiments, the fan motors may be NEMA standard or electronically commutated.
According
to preferred aspects of the multiple fan deck plate embodiment, each fan draws
air across no
more than two heat exchange panels, fan replacement is significantly
simplified, and the loss of
one or even several fans does not make a significant difference in
performance.
[00103] The completed corresponding plenum section 64 (Figs. 21A and 21B
or Figures
31 and 32) is subsequently lifted to rest on the top of the condenser module
37 (Fig. 24).
Alternatively, plenum section framework (absent any fans or fan deck plates)
may be lifted atop
the condenser module 37, and the fan deck plates 72 may be lifted atop the
framework of the
plenum section 64 after the plenum section framework has been rested on top of
the condenser
module 37. While the assembly described herein is described as being performed
at grade, the
assembly of the various modules may be performed at their final position if
planning and
construction schemes allow.
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[00104] . Every feature and alternative embodiment herein is intended and
contemplated
to work with and be used in combination of every other feature and embodiment
described
herein with the exception of embodiments with which it is incompatible. That
is, each heat
exchange module arrangement described herein (e.g., single stage, multiple
stage), and each heat
exchange panel arrangement described herein, (e.g., all vertical, all tilted
one way, each tilted in
an alternate direction), and each tube type and each fin type described
herein, each steam
manifold arrangement described herein, and each fan arrangement (single fan,
multiple fan), is
intended to be used in various ACC assemblies with every combination of
embodiments with
which they are compatible, and the inventors do not consider their inventions
to be limited to the
exemplary combinations of embodiments that are reflected in the specification
and figures for
purpose of exposition.
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