He 2016
He 2016
Abstract: The layout of an air-cooled steam condenser (ACSC) has a great impact on a power plant’s operation. This is owed to the fact that
the performance of the condenser and subsequently of the whole power plant is strongly affected by meteorological conditions. Hence, it is of
great significance to determine the optimal design of wind angle that gives a higher performance for an air-cooled power plant. This study
applies an existing numerical model in order to investigate the wind angle’s impact on the performance of an air-cooled steam condenser, as
well as on the whole power plant. Moreover, the optimal design of wind angle is obtained based on the corresponding sensitivity analysis.
Finally, the benefit to the power plant’s performance at the optimal-design wind angle is calculated through the comparison with the actual
design values at a wind angle of β ¼ 22.5°. The obtained results show that the net power and thermal efficiency can be improved by am-
plitudes of 1.2 and 0.37%, respectively, at the wind angle of β ¼ 90°, which should be proposed as the design wind angle for air-cooled power
plants. DOI: 10.1061/(ASCE)EY.1943-7897.0000347. © 2016 American Society of Civil Engineers.
Author keywords: Air-cooled steam condenser; Design wind angle; Numerical model; Net power; Thermal efficiency.
Introduction arising from the types for the heat exchangers and arrangement
of the power plants were evaluated. Van Rooyen and Kroger
Air-cooled steam condensers have become widely popular to reject (2008) found the phenomenon of flow distortions and the corre-
waste heat from the turbine exhaust in arid regions (Moore et al. sponding low-pressure region under the windward fans, which con-
2014; Yang et al. 2014). Turbine exhaust condenses in the finned tributed to the performance reduction of the air-cooled steam
tube exchangers while ambient air flow outside takes away the rel- condenser as the wind speed increases. Mathematical models for
evant latent heat. In view of the physical properties of air fluid, it is flow and heat transfer of the air-side fluid in air-cooled condensers
impossible to absorb the tremendous heat load from the turbine ex- were established by Yang et al. (2011a, b), and the boundary con-
haust by natural convection in large-scale power plants, and forced- ditions by radiator type was first introduced to describe the finned
draft fans must be utilized to induce enough air to cool the turbine tube bundles. The volume flow rates as well as the inlet air temper-
exhaust. However, the power consumption of such equipped axial ature and heat rejection for different air-cooled steam condensers
fans should be considered in the forced-draft thermal system. were obtained. Hu et al. (2014) proposed a reduced-order model
Due to the influence from the inflow and outflow situations of based on proper orthogonal decomposition (POD) to rapidly and
the fans under uncertain wind conditions, the characteristics of the accurately predict the flow and heat-transfer characteristics of an
air-cooled steam condenser will be altered (Thiart 1990). As a re- air-cooled steam condenser under the influence of natural wind,
sult, the performance of the power plant will deteriorate during ad- and the velocity and temperature fields of four typical test cases
verse wind conditions, such as strong wind and high-temperature were estimated with a maximum relative errors of 1.75 and 0.19%,
conditions. It is significant to investigate the influence principles respectively, while the degree of freedom was reduced by 105 com-
from the wind conditions on the air-cooled steam condenser as well pared to calculations using computational fluid dynamics. User-
as the whole power plant. An air-cooled steam condenser was first defined functions based on steam properties were utilized to
numerically modeled by Van Staden (1995), and the impacts from simulate the condensation of the turbine exhaust in the finned tube
ambient conditions were investigated. Performance differences heat exchangers (He et al. 2013; He and Dai 2012), and a numerical
1
model close to the true status was established. Gao et al. (2009)
Nanjing Univ. of Aeronautics and Astronautics, Jiangsu Province simulated the effect from the wind conditions as well as the height
Key Laboratory of Aerospace Power System, No. 29 Yudao St., Qinhuai
of the air-cooled steam condenser on the relevant condenser per-
District, Nanjing 210016, China (corresponding author). E-mail: wfhe@
nuaa.edu.cn; [email protected] formance, modeling the simplified model with a cubic fluid zone
2
Professor, Nanjing Univ. of Aeronautics and Astronautics, Jiangsu regarded as the condenser cell. It was found that the condenser per-
Province Key Laboratory of Aerospace Power System, No. 29 Yudao St., formance decreases with an increase of wind speed and increases as
Qinhuai District, Nanjing 210016, China. E-mail: [email protected] the platform height is elevated. Owen (1992) developed an efficient
3
Nanjing Univ. of Aeronautics and Astronautics, Jiangsu Province Key and reliable method to evaluate the performance of an air-cooled
Laboratory of Aerospace Power System, No. 29 Yudao St., Qinhuai steam condenser under windy conditions, and the pressure jump
District, Nanjing 210016, China. E-mail: [email protected] fan model was attempted to minimize the computational expense
4
Professor, Nanjing Univ. of Aeronautics and Astronautics, Jiangsu of the performance evaluation. The accuracy of the numerical
Province Key Laboratory of Aerospace Power System, No. 29 Yudao St.,
model was validated through the test data obtained during the
Qinhuai District, Nanjing 210016, China. E-mail: [email protected]
Note. This manuscript was submitted on June 25, 2015; approved on
full-scale tests in an air-cooled steam condenser.
November 24, 2015; published online on February 18, 2016. Discussion All the literatures mentioned earlier discusses the coupling
period open until July 18, 2016; separate discussions must be submitted relation between the wind conditions and performance of the
for individual papers. This paper is part of the Journal of Energy Engi- air-cooled steam condenser (ACSC). In addition, effect of the
neering, © ASCE, ISSN 0733-9402. configuration of the ACSC was also the research focus (Yang et al.
Fig. 2. Boundary conditions of the numerical model for the air-cooled power plant: (a) skew wind; (b) front wind
2000 35
1000 20
800
15
600
400
10
200
0 5
TRL THA TMCR VWO CP TRL THA TMCR VWO CP
Fig. 3. Grid independence test and validation of the numerical model: (a) grid independence test; (b) validation with the corresponding design values
densities at such regions are achieved, and thus three sets of grids, the volumetric effectiveness of the fan array and the heat transfer
namely 4,120,000, 4,680,000, and 5,170,000, are gained. A grid performance of the finned tube exchangers are obtained for differ-
independence test is verified with a maximum deviation of the heat ent wind conditions. Based on the coupling effect between the wind
transfer rate of 2.1%, shown in Fig. 3(a). As a result, the middle conditions and condenser performance, new stable backpressures
grid consisting of 4,680,000 cells is used to ensure the accuracy of are iterated utilizing the stated user defined function (UDF) method
the simulation results and short the calculation period simultane- by He et al. (2013), and then the connection between the backpres-
ously. Furthermore, the stable back pressures of the air-cooled sure of the air-cooled steam condenser and other thermal parame-
steam condenser in the designed wind conditions, including the ters in the closed Ranking cycle is exploited to calculate the
current-design wind angle, β ¼ 22.5° and the wind speed, characteristics of the whole power plant. During the investigation,
vw ¼ 3 m=s, is validated through the five typical design cases, in- the parameters of the turbine exhaust in the TRL case in Table 1 are
cluding turbine rated load (TRL), turbine heat acceptance (THA), considered, while the ambient temperature is 306 K and the pres-
turbine maximum continues rate (TMCR), valve wide open sure is 101,325 Pa.
(VWO), and choking pressure (CP). It is found that the predicted
backpressures are almost consistent with the design values, as Performance of the Air-Cooled Steam Condenser
shown in Fig. 3(b), which verifies the precision of the numeri-
cal model. In the air-cooled steam condenser, the designed fan performance is
determined to calculated the face velocity through the finned tube
exchangers corresponding to the heat load of the turbine exhaust.
Results and Discussion For an axial fan, the fan performance is obtained for specific wind
conditions, and it will differ at off-design wind speeds and wind
Due to the great influence from wind conditions, the performance angles. The pressure rise and power of the axial fan in the air-
of the air-cooled steam condenser is numerically investigated, and cooled steam condenser with the volume flow rate through the rotor
140 Based on the adverse effect from the wind conditions, it is found
70
that a reduction of the volume flow rate for the fan array appears
130 with an increase in the wind speed. It is inferred that the correlation
65
120 angle. The maximum decrease in amplitude at a wind angle of 180°
is 15,264.6 m3 · s−1 from vm ¼ 2 m · s−1 to vm ¼ 10 m · s−1 . Fur-
110
60 thermore, the fan array performance rises gently until reaching its
Δ pf peak value at the wind angle of 90° for all the wind speeds, and then
100
drops sharply with an increase in the wind angle. It is also seen that
N
55 the decreased amplitude of the volume flow rate with the wind an-
90
gle is more obvious for high-wind-speed cases. Taking the case of
vm ¼ 10 m · s−1 for example, the flow rate difference reaches
80 50
300 350 400 450 500 550 600 650 6,637.4 m3 · s−1 from β ¼ 0° to β ¼ 180°, while the correspond-
Volume fan flow rate/m3·s-1
ing value at vm ¼ 2 m · s−1 is only 1,079.9 m3 · s−1.
Regardless of the performance difference for the axial fans, the
Fig. 4. Design performance of the axial forced-draft fan average volumetric effectiveness of the fan array is also calculated
and presented in Fig. 5(b). It is found that the average volumetric
effectiveness of the fan array is close to 1 at vm ¼ 2 m · s−1 for all
the wind angles, which illustrates the performance of the fan array
is presented in Fig. 4. In the current paper, the influence of wind as it approaches the design point, and the worst conditions appear
conditions on the performance of the total fan array is investigated. at vm ¼ 10 m · s−1 and β ¼ 180° with only 70% of the design
Volumetric effectiveness, which is defined as the ratio of the capacity.
calculated flow rate and the design value in Eq. (3), is applied With the existing turbine exhaust parameters at the TRL mode
to characterize the actual performance of the axial fan under differ- and wind conditions, the heat transfer rate of the finned tube ex-
ent wind conditions changers in the air-cooled steam condenser is obtained, which is
presented in Fig. 6(a). Obviously, the sensitivity of fan performance
V to the wind conditions will result in alternations to the heat transfer
e¼ ð3Þ
Vd capacity. Corresponding to the trend of the fan performance
with wind conditions, the maximum heat transfer rate appears at
where e = volumetric effectiveness; V = actual calculated fan flow β ¼ 90° for all the wind-speed cases, which is reduced from
rate; and V d = design flow rate of the axial fan in this paper, where 1,719.9 MW at vm ¼ 2 m · s−1 to 1,454.6 MW at vm ¼ 2 m · s−1 .
1.05
54000
1.00
52000
50000 0.95
Volumetric effectiveness/%
Volume flow rate/m3· s-1
48000
0.90
46000
0.85
44000
vm=2m/s
vm=2m/s
0.80
42000
vm=4m/s vm=4m/s
40000 vm=6m/s 0.75 vm=6m/s
vm=8m/s vm=8m/s
38000
0.70 vm=10m/s
vm=10m/s
36000
0 20 40 60 80 100 120 140 160 180 0 20 40 60 80 100 120 140 160 180
(a) Wind angle/° (b) Wind angle/°
Fig. 5. Performance of the fan array with wind angles at different wind speeds: (a) volume flow rate; (b) volumetric effectiveness
vm=8m/s
Back pressure/kPa
50 vm=10m/s
1500
1400 vm=2m/s 40
vm=4m/s
vm=6m/s
Downloaded from ascelibrary.org by University of California, San Diego on 03/03/16. Copyright ASCE. For personal use only; all rights reserved.
1300 30
vm=8m/s
vm=10m/s
1200 20
0 20 40 60 80 100 120 140 160 180 0 20 40 60 80 100 120 140 160 180
Fig. 6. Performance of the air-cooled steam condenser with wind angles at different wind speeds: (a) heat transfer rate; (b) backpressure
8800
where Qid = ideal heat rejection; ms = steam flow rate; h 0 = exhaust
8600
steam enthalpy; and h 0 0 = enthalpy of the saturated water. Accord-
ing to the parameters of the TRL case, the ideal heat rejection is 8400
calculated as 1,665.6 MW.
The running point with a significant difference between the ac- 8200
tual heat-transfer rate and the ideal heat rejection is virtual due to
8000
the heat imbalance for the air-cooled steam condenser, and then an
iterative method will be utilized to obtain the final operating mode 7800
with a stable backpressure (He et al. 2013), which is shown in 350 400 450 500 550 600 650 700
Fig. 6(b). It is found that the lowest backpressure for each wind Steam turbine power/MW
speed at β ¼ 90° results from the best heat-transfer status between
the ambient and turbine exhaust, and the backpressure value of Fig. 7. Heat rate of the power plant with turbine power at different
25.6 kPa is obtained at 2 m · s−1 while the highest backpressure backpressures (data from He et al. 2014, © ASCE)
with a value of 70.9 kPa emerges at vm ¼ 10 m · s−1 and β ¼ 180°
due to the poor heat-transfer environment. However, control action
is not taken into consideration during the numerical study. A higher
Based on the correlation between the exhaust heat load and
backpressure will contribute to the performance reduction, and the
turbine power at different backpressures as shown in Fig. 7
trip can detonate in serious cases. Generally speaking, a pressure
(He et al. 2014), the benefit output at different wind conditions
limit of 45 kPa is allowed in a 2 × 600-MW air-cooled power plant.
corresponding to stable backpressure is interpolated and presented
As a result, all the calculated cases with a backpressure more than
in Fig. 8(a). In comparison with the design output power of
the value of 45 kPa will be avoided.
1,200 MW, an excess value of 65.7 MW is observed at vm ¼ 2 m ·
s−1 and β ¼ 90°, while the worst value of 976.9 MW only fulfills
Performance of the Air-Cooled Power Plant the 81.4% of the design value. The fan array’s power is also pre-
sented in Fig. 8(b) according to the demonstration in Fig. 4. It is
In an air-cooled power plant, the superiority of water conservation found that a value of about 7,462 kW, which is close to the design
is acquired at the cost of tremendous power consumption for the fan fan power, is consumed by the axial fan array at vm ¼ 2 m · s−1 .
array, and the turbine output as well as the fan power should be However, under the effect of flow distortions at the fan inlets, es-
emphasized. The characteristics of the air-cooled steam condenser, pecially for the windward fans, the fan power is also reduced sig-
including the performance of the fan array and finned tube ex- nificantly, and the fan array has a power consumption of 6,419 kW
changers, are obtained considering the coupling effect from the at vm ¼ 10 m · s−1 and β ¼ 180° with a decreased amplitude of
wind conditions and the backpressure, which indicates that the per- 14% compared to the design value.
formance connection between the air-cooled steam condenser and Furthermore, the final net power of the air-cooled power plant is
the whole power plant is also achieved through the proposed iter- expressed as
ative method. It is necessary to calculate the power plant perfor-
mance, thus establishing the standard to judge the economy of the
whole thermal system. Pnet ¼ P − N=1000 ð6Þ
1250 7400
1200 7200
1150 7000
vm=8m/s
1000 6400 vm=10m/s
vm=10m/s
950 6200
0 20 40 60 80 100 120 140 160 180 0 20 40 60 80 100 120 140 160 180
Fig. 8. Performance of the air-cooled power plant with wind angles at different wind speeds: (a) plant power; (b) fan shaft power
42
of 1,258.3 MW.
Turbine exhaust in the air-cooled power plants condenses
in the finned tube exchangers when ambient air flows outside
41
and the thermal cycle in the power plant is completely closed. After
the illustration of turbine power distributions in different wind con-
40 vm=2m/s
ditions, the input heat from the steam generator can be calculated in
vm=4m/s combination with the relation between the steam turbine’s power
39 vm=6m/s and the relevant heat rate at different backpressures shown in Fig. 7;
vm=8m/s in addition, the total thermal efficiency of the closed Ranking cycle,
38 vm=10m/s which is listed in Fig. 9, can be calculated as the ratio of the benefit
power and the heat input in the steam generator.
37 With an increase in wind speed from vm ¼ 2 m · s−1 to
0 20 40 60 80 100 120 140 160 180 vm ¼ 10 m · s−1 , the thermal efficiency of the air-cooled power
Wind angle/° plant rises until the wind angle of β ¼ 90°, and then drops contin-
uously. The efficiency values at vm ¼ 2 m · s−1 implies that the
Fig. 9. Ranking cycle efficiency of the air-cooled power plant with
design thermal efficiency is close to 43%, and the optimal effi-
wind angles at different wind speeds
ciency corresponding to each wind speed is reduced from 43.2
1280 43.5
1260
43.0
Ranking cycle efficiency/%
1240
42.5
1220
Net plant power/MW
1200
42.0
1180
41.5
1160
β =22.5°
1140 β =22.5°
41.0 β =90 °
β =90°
1120
40.5
1100
1080 40.0
2 4 6 8 10 2 4 6 8 10
Fig. 10. Comparison of the power plant performance for the optimized wind angle and current design: (a) net power; (b) thermal efficiency
Conclusions
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