Apparatus and Method for Connecting Air Cooled Condenser Heat Exchanger Coils to Steam Distribution Manifold

Abstract

An air cooled condenser, and methods of manufacturing and field assembly of air cooled condensers in which one half of the primary heat exchanger coils are shop fitted with a length of steel configured to quickly and easily mate, during field assembly, with an opposing primary heat exchanger coil of standard configuration, thereby reducing material, shipping, and handling costs, improving positioning and orientation of HECs during assembly, and reducing the requirement for expensive field welding.

Claims

1. An air cooled condenser comprising: a steam distribution manifold; at least two heat exchanger coils arranged in an A-frame configuration in fluid communication with said steam distribution manifold, each of said heat exchanger coils fitted with a tube sheet, wherein the tube sheets of less than all of said heat exchanger coils have been modified prior to arrival at the assembly location to be connected to a tube sheet of an opposing heat exchanger coil in said A-frame configuration along a single field welded seam.

2. An air cooled condenser according to claim 1, wherein up to one half of said heat exchanger coils have been modified prior to arrival at the assembly location to be connected to a tube sheet of an opposing heat exchanger coil in said A-frame configuration along a single field welded seam.

3. An air cooled condenser according to claim 2, wherein said opposing heat exchanger coils have a flat and unmodified tube sheet.

4. An air cooled condenser according to claim 1, wherein said modification comprises an extended and bent tube sheet configured to mate with an edge of a tube sheet of an opposing heat exchanger coil in a flush or nearly flush interface.

5. An air cooled condenser according to claim 1, wherein said modification comprises a length of steel that has been shop welded to an edge of said modified tube sheet.

6. An air cooled condenser according to claim 5, wherein said length of steel is flat.

7. An air cooled condenser according to claim 5, wherein said length of steel is L-shaped.

8. An air cooled condenser according to claim 5, wherein said length of steel is an inverted U-shape.

9. An air cooled condenser according to claim 5, wherein said length of steel is an inverted V-shape.

10. A heat exchanger coil for an air cooled condenser, comprising: a heat exchanger coil fitted with a modified tube sheet, wherein said modification permits the connection of said heat exchanger coil to an opposing heat exchanger coil in an A-frame of an air cooled condenser along a single field welded seam.

11. A heat exchanger coil according to claim 10, wherein said modification comprises an extended and bent tube sheet configured to mate with an edge of a tube sheet of an opposing heat exchanger coil in a flush or nearly flush interface.

12. A heat exchanger coil according to claim 10, wherein said modification comprises a length of steel that has been shop welded to an edge of said modified tube sheet.

13. A heat exchanger coil according to claim 12, wherein said length of steel is flat.

14. A heat exchanger coil according to claim 12, wherein said length of steel is L-shaped.

15. A heat exchanger coil according to claim 12, wherein said length of steel is an inverted U-shape.

16. A heat exchanger coil according to claim 12, wherein said length of steel is an inverted V-shape

17. A method of assembling an air cooled condenser including a steam distribution manifold supported on an A-frame arrangement of heat exchanger coils, comprising: positioning a first heat exchanger coil in a final or near-final assembly location and orientation; positioning a second heat exchanger coil in a final or near-final assembly location and orientation opposite said first heat exchanger coil, wherein one of said first and second heat exchanger coils has a factory modified tube sheet configured to permit the connection of said heat exchanger coil to an opposing heat exchanger coil in an A-frame of an air cooled condenser along a single field welded seam; field welding said first heat exchanger coil to said second heat exchanger coil along a single field welded seam.

18. A method according to claim 17, wherein said modification comprises an extended and bent tube sheet configured to mate with an edge of a tube sheet of an opposing heat exchanger coil in a flush or nearly flush interface.

19. A method according to claim 17, wherein said modification comprises a length of steel that has been shop welded to an edge of said modified tube sheet.

20. A method according to claim 19, wherein said length of steel is flat.

21. A method according to claim 19, wherein said length of steel is L-shaped.

22. A method according to claim 19, wherein said length of steel is an inverted U-shape.

23. A method according to claim 19, wherein said length of steel is an inverted V-shape

Description

DESCRIPTION OF THE DRAWINGS

[0019] The subsequent description of the preferred embodiments of the present invention refers to the attached drawings, wherein:

[0020] FIG. 1 is a perspective view of an air cooled condenser having a generally standard arrangement.

[0021] FIG. 2 is a perspective view of the heat exchanger A-frame portion of a prior art air cooled condenser in which the tube sheets of the heat exchanger coils are connected by a closure plate.

[0022] FIG. 3 is an end view schematic of a prior art heat exchanger A-frame portion of a prior art air cooled condenser of the type shown in FIG. 2, including exploded views of the connections between the closure plate and the heat exchanger tube sheets and between the steam distribution manifold skirt and the tube sheet.

[0023] FIG. 4 is an end view computer model rendering of the heat exchanger A-frame portion of a prior art air cooled condenser shown in FIG. 3.

[0024] FIG. 5 is an underside view computer model rendering of the heat exchanger A-frame portion of a prior art air cooled condenser shown in FIG. 3.

[0025] FIG. 6A is an end view of an embodiment of the invention in which an angle is show welded to the tube sheet of one heat exchanger and in which the ACC A-frame is site assembled, in part, by field welding the tube sheet of a second, standard configuration, heat exchanger is field welded to the angle of the first heat exchanger.

[0026] FIG. 6B is an exploded end view of the embodiment shown in FIG. 6A, but also including the SDM skirts which are preferably field welded to the heat exchanger tube sheets.

[0027] FIG. 6C is a perspective view of the embodiment of the invention shown in FIG. 6A.

[0028] FIG. 6D is an underside perspective view of the embodiment of the invention shown in FIG. 6A.

[0029] FIG. 7 is an end view computer model rendering of the embodiment of the invention shown in FIG. 6B.

[0030] FIG. 8 is an underside view computer model rendering of the embodiment of the invention shown in FIG. 6B.

[0031] FIG. 9A is an end view of an embodiment of the invention in which the tube sheet of one heat exchanger coil is extended and bent, and in which during site assembly of the ACC A-frame, the tube sheet of a second, standard configuration, heat exchanger is field welded to the extended and bent tube sheet of the first heat exchanger coil.

[0032] FIG. 9B is a perspective view of the embodiment of the invention shown in FIG. 9A.

[0033] FIG. 9C is an underside perspective view of the embodiment of the invention shown in FIG. 9A.

[0034] FIG. 10A is an end view of an embodiment of the invention in which an inverted V-shaped length of steel is shown welded to the tube sheet of one heat exchanger and in during site assembly of the ACC A-frame, the tube sheet of a second, standard configuration, heat exchanger is field welded to the inverted V-shaped length of steel that was shop welded to the first heat exchanger.

[0035] FIG. 10B is a perspective view of the embodiment of the invention shown in FIG. 10A.

[0036] FIG. 10C is an underside perspective view of the embodiment of the invention shown in FIG. 10A.

[0037] FIG. 11A is an end view of an embodiment of the invention in which an inverted U-shaped length of steel is shown welded to the tube sheet of one heat exchanger and in during site assembly of the ACC A-frame, the tube sheet of a second, standard configuration, heat exchanger is field welded to the inverted U-shaped length of steel that was shop welded to the first heat exchanger.

[0038] FIG. 11B is a perspective view of the embodiment of the invention shown in FIG. 11A.

[0039] FIG. 11C is an underside perspective view of the embodiment of the invention shown in FIG. 11A.

[0040] FIG. 12A is an end view of an embodiment of the invention in which a flat length of steel is shown shop welded to an angled or beveled edge of the tube sheet of one heat exchanger and in which, during site assembly of the ACC A-frame, the tube sheet of a second, standard configuration, heat exchanger is field welded to the flat length of steel that was shop welded to the first heat exchanger.

[0041] FIG. 12B is a perspective view of the embodiment of the invention shown in FIG. 12A.

[0042] FIG. 12C is an underside perspective view of the embodiment of the invention shown in FIG. 12A.

DETAILED DESCRIPTION OF THE INVENTION

[0043] In the following description, numerous details are set forth to provide a more thorough explanation of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form, rather than in detail, in order to avoid obscuring the present invention.

[0044] FIG. 1, which is a perspective view of an air cooled condenser having a generally standard arrangement, will first be described to provide context for the present invention. Modern air cooled condensers (ACCs) 10 are generally field assembled in an A-frame arrangement 2 of heat exchanger coils 4, topped by a steam distribution manifold 6. Steam generated by a power plant or other industrial facility passes through a riser duct and into a steam distribution manifold 6. From the steam distribution manifold 6, the steam passes into the heat exchanger coils 4 via the heat exchanger tube sheets 12. As the steam travels down the heat exchanger coils, it cools, and the resulting condensate is collected in the condensate collection manifolds at the bottom of heat exchanger coils 4. According to current and standard manufacturing and assembly procedures, two identical or nearly identical heat exchanger coils 4, including tube sheets 12, are raised into nearly their final position at the final assembly location, and closure plate(s) 8 is/are field welded to the tube sheets 12 of both heat exchanger coils 4. See FIGS. 2-5. SDM skirts 14 are field welded to the opposite sides of the tube sheets 12. According to this process, both sides of the closure plate is field welded the entire length, or nearly the entire length of the ACC, also referred to as “the street.”

[0045] FIGS. 6A through 6D, 7 and 8 show a first embodiment of the invention in which the closure plate 8 is replaced with an angle 16, that is, an L-shaped piece of steel. During the factory manufacture process, angle 16 is shop welded to the tube sheets 12a of one half of the heat exchange coils. According to a preferred embodiment, the end of tube sheets 12a may be angled or beveled to fit flush or nearly flush against a face of the angle 16. The preferred locations of the shop welds are shown in FIGS. 6A and 6B.

[0046] For assembly of an ACC according to this first embodiment of the invention, one half of the primary heat exchanger coils that are shipped to the assembly location include the shop welded angle, and the other one half of the primary heat exchanger coils have a generally standard configuration. During assembly of the heat exchanger A-frame 2 at the assembly location, one modified heat exchanger coil bearing the shop welded angle is positioned opposite a generally standard configuration heat exchanger coil, and the inner edge of the tube sheet 12 of the standard configuration heat exchanger coil is field welded to the face of the angle 16 that is opposite the face that is welded to tube sheet 12a of the modified heat exchanger coil.

[0047] FIGS. 9A through 9C show a second embodiment of the invention in which one half of the primary heat exchanger coils are fitted with an extended and bent tube sheet 18, and the other half of the primary heat exchanger coils may have the standard configuration. The length of the extension and angle of the bend is configured to generally allow for a flush connection between the top face of the bend and the edge of the tube sheet of the heat exchanger coil to which it will be welded during site assembly.

[0048] For assembly of an ACC according to this embodiment of the invention, one half of the primary heat exchanger coils that are shipped to the assembly location include the extended and bent tube sheet, and the other one half of the primary heat exchanger coils have a generally standard configuration. During assembly of the heat exchanger A-frame 2 at the assembly location, one modified heat exchanger coil bearing the extended and bent tube sheet 18 is positioned opposite a generally standard configuration heat exchanger coil, and the inner edge of the tube sheet 12 of the standard configuration heat exchanger coil is field welded to the top face of the extended and bent portion of tube sheet 18.

[0049] FIGS. 10A through 10C show a third embodiment of the invention in which the closure plate 8 is replaced with an inverted V-shaped length of steel 20 that is shop welded at the factory to the tube sheets 12a of one half of the primary heat exchange coils. According to a preferred embodiment, the end of tube sheets 12a need not be angled or beveled to fit flush or nearly flush against a face of the V-shaped length of steel 20.

[0050] For assembly of an ACC according to this third embodiment of the invention, one half of the primary heat exchanger coils that are shipped to the assembly location include the shop welded inverted V-shaped length of steel 20, and the other one half of the primary heat exchanger coils have a generally standard configuration. During assembly of the heat exchanger A-frame 2 at the assembly location, one modified heat exchanger coil bearing the shop welded V-shaped length of steel 20 is positioned opposite a generally standard configuration heat exchanger coil, and the inner edge of the tube sheet 12 of the standard configuration heat exchanger coil is field welded to the face of the V-shaped length of steel 20 that is opposite the face that is welded to tube sheet 12a of the modified heat exchanger coil.

[0051] FIGS. 11A through 11C show a fourth embodiment of the invention in which the closure plate 8 is replaced with an inverted U-shaped length of steel 22 that is shop welded at the factory to the tube sheets 12a of one half of the heat exchange coils. According to a preferred embodiment, the end of tube sheets 12a need not be angled or beveled to fit flush or nearly flush against a face of the U-shaped length of steel 22.

[0052] For assembly of an ACC according to this fourth embodiment of the invention, one half of the primary heat exchanger coils that are shipped to the assembly location include the shop welded inverted U-shaped length of steel 22, and the other one half of the primary heat exchanger coils have a generally standard configuration. During assembly of the heat exchanger A-frame 2 at the assembly location, one modified heat exchanger coil bearing the shop welded U-shaped length of steel 22 is positioned opposite a generally standard configuration heat exchanger coil, and the inner edge of the tube sheet 12 of the standard configuration heat exchanger coil is field welded to the face of the U-shaped length of steel 22 that is opposite the face that is welded to tube sheet 12a of the modified heat exchanger coil.

[0053] FIGS. 12A through 12C show a fifth embodiment of the invention in which the closure plate 8 is replaced with a flat length of steel 24 that is shop welded at the factory to the tube sheets 12a of one half of the primary heat exchanger coils. According to a preferred embodiment, the end of tube sheets 12a may be angled or beveled to fit flush or nearly flush against a face of the flat length of steel 24. The angle at which the flat length of steel 24 is welded to the end of tube sheet 12a may be configured to generally allow for a flush connection between the face of the flat length of steel that is opposite the shop weld and the edge and the edge of the tube sheet 12 of the heat exchanger coil to which it will be welded during site assembly.

[0054] For assembly of an ACC according to this fifth embodiment of the invention, one half of the primary heat exchanger coils that are shipped to the assembly location include the shop welded flat length of steel 24, and the other one half of the primary heat exchanger coils have a generally standard configuration. During assembly of the heat exchanger A-frame 2 at the assembly location, one modified heat exchanger coil bearing the shop welded flat length of steel 24 is positioned opposite a generally standard configuration heat exchanger coil, and the inner edge of the tube sheet 12 of the standard configuration heat exchanger coil is field welded to the face of the flat length of steel 24 that is opposite the face that is welded to tube sheet 12a of the modified heat exchanger coil.

[0055] It will be appreciated that other manufacturing (shop) modifications to one half of the heat exchange coils of an ACC which permit easy field fit and reduce field welding during assembly are within the scope of this invention and well within the skill of ordinary practitioners, given the disclosure of the invention herein.