Acoustic abatement system for air cooled heat exchanger

A system configured to thermally regulate heat dissipation of a power plant system (e.g. steam turbine, gas turbine compressor, intercooler or other fluidic thermal source, etc.) and acoustically attenuate operation of an air cooled heat exchanger via sound reflection, sound absorption, sound diffraction, and/or active noise cancellation is disclosed. In one embodiment, a system includes: a set of inner barriers; a base barrier disposed beneath the set of inner barriers; a set of outer barriers disposed about the base barrier and the set of inner barriers, the set of outer barriers including a top surface located above a bottom surface of the set of inner barriers; a heat exchanger fluidly connected to a power generation system and disposed within the set of inner barriers; and a set of fans disposed within the set of inner barriers and configured to form a flow of air through the set of inner barriers.

FIELD OF THE INVENTION

The subject matter disclosed herein relates to thermal regulation systems and, more particularly, to acoustic abatement systems for air cooled heat exchangers.

BACKGROUND OF THE INVENTION

Some systems, for example certain nuclear, fossil fuel, solar, simple-cycle and combined-cycle power plant systems, employ thermal regulation systems (e.g., heat exchangers, air cooled heat exchangers, etc.) in their design and operation. During operation these thermal regulation systems may cool portions of and/or fluids within the power plant systems (e.g., in turbines, between compressors) via a radiator system and a set of fin fan coolers. In these systems, a fluid (e.g., water, glycol, etc.) may be passed through a high temperature medium via a set of pipes which then circulate the fluid to the heat exchanger (e.g., a radiator system) where the set of fin fan coolers pass a large quantity of air by the fluid for convective cooling. As a result of the size of some power generation systems and the temperature extremes inherent therein, some thermal regulation systems must continuously pass a large amount of air (e.g., about 400 pounds to about 500 pounds per second) through the heat exchanger to meet operational demands. This large quantity of air movement may require a large set of fan coolers to draw the necessary amount of air from the environment to run over the heat exchanger to cool components of the power plant systems. However, these finned fan coolers may be susceptible to recirculation (e.g., intake of exhausted air) and the use of this set of fan coolers may result in inconsistent cooling fluid temperatures and noise pollution.

BRIEF DESCRIPTION OF THE INVENTION

Systems for acoustically attenuating operation of a thermal regulation system via sound reflection, sound absorption, sound diffraction, and/or active noise cancellation are disclosed. In one embodiment, a system includes: a set of inner barriers; a base barrier disposed beneath the set of inner barriers; a set of outer barriers disposed about the base barrier and the set of inner barriers, the set of outer barriers including a top surface located above a bottom surface of the set of inner barriers; a heat exchanger fluidly connected to a power generation system and disposed within the set of inner barriers; and a set of fans disposed within the set of inner barriers and configured to form a flow of air through the set of inner barriers.

A first aspect of the invention provides a system including: a set of inner barriers; a base barrier disposed beneath the set of inner barriers; a set of outer barriers disposed about the base barrier and the set of inner barriers, the set of outer barriers including a top surface located above a bottom surface of the set of inner barriers; a heat exchanger fluidly connected to a power generation system and disposed within the set of inner barriers; and a set of fans disposed within the set of inner barriers and configured to form a flow of air through the set of inner barriers.

A second aspect of the invention provides an acoustic abatement system for a thermal regulation system, the acoustic abatement system including: a set of inner barriers shaped to house a heat exchanger and a set of fans; a base barrier disposed beneath the set of inner barriers, the base barrier substantially separated from the set of inner barriers; and a set of outer barriers disposed about the base barrier and the set of inner barriers, the set of outer barriers oriented to enable a flow of air into the set of inner barriers and including a top surface located above a bottom surface of the set of inner barriers.

A third aspect of the invention provides a power generation system including: a gas turbine; at least one generator operably connected to the gas turbine; and a thermal regulation system operably connected to the gas turbine or the at least one generator, the thermal regulation system including: a set of inner barriers; a base barrier disposed beneath the set of inner barriers; a set of outer barriers disposed about the base barrier and the set of inner barriers, the set of outer barriers including a top surface located above a bottom surface of the set of inner barriers; a heat exchanger fluidly connected to the gas turbine or the at least one generator and disposed within the set of inner barriers; and a set of fans disposed within the set of inner barriers and configured to form a flow of air through the set of inner barriers.

It is noted that the drawings of the disclosure may not necessarily be to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure. It is understood that elements similarly numbered between the FIGURES may be substantially similar as described with reference to one another. Further, in embodiments shown and described with reference toFIGS. 1-6, like numbering may represent like elements. Redundant explanation of these elements has been omitted for clarity. Finally, it is understood that the components ofFIGS. 1-6and their accompanying descriptions may be applied to any embodiment described herein.

DETAILED DESCRIPTION OF THE INVENTION

As indicated herein, aspects of the invention provide for systems configured to reduce recirculation and acoustically attenuate operation of a thermal regulation system (e.g., a finned fan cooler, etc.) via sound reflection, sound absorption, sound diffraction, and/or active noise cancellation. These systems include a heat exchanger (e.g., a fin fanned air cooler) disposed with a set of fans proximate ground level (e.g., at a height about equivalent to ground level) above a chamber (e.g., a sunken chamber) and substantially surrounded by a set of barriers (e.g., walls). In an embodiment, the set of barriers may include an inner barrier and an outer barrier which are disposed proximate one another. The outer barrier may be disposed substantially below ground level, and the inner barrier may include a lower surface disposed below a topmost portion/surface of the outer barrier (e.g., causing portions of the inner barrier and the outer barrier to overlap) and may extend substantially above a height of the outer barrier.

Turning to the FIGURES, embodiments of a thermal regulation system configured to acoustically attenuate operation of the thermal regulation system by locating a heat exchanger proximate ground level and including a set of barrier walls about and/or beneath the heat exchanger and a set of fans are shown. Each of the components in the FIGURES may be connected via conduit, or other conventional means as is indicated inFIGS. 1-6. Specifically, referring toFIG. 1, a schematic view of a thermal regulation system100including a heat exchanger142located proximate ground level112below a set of fans140(e.g., fan blades, motors, etc.) and between a set of barriers is shown in accordance with an embodiment of the invention. Set of fans140are configured to flow a fluid (e.g., dry air, atmospheric air, ambient air, etc.) through heat exchanger142to thermally regulate a medium/fluid (e.g., glycol, water, etc.) being passed there through from a turbine, intercooler, etc. Set of fans140and heat exchanger142are disposed proximate ground level112and above a chamber150which is formed substantially below ground level112. Chamber150may be substantially defined by a set of outer barriers130and a base barrier134. In one embodiment, chamber150may be disposed (e.g., dug into) in a soil structure110(e.g., earth, ground, etc.). Soil structure110may include top soil, sand, gravel, etc. In an embodiment, a set of inner barriers120may be located substantially about set of fans140and heat exchanger142. Set of inner barriers120may be located between set of outer barriers130and above base barrier134. As can be seen inFIG. 1, the configuration of set of inner barriers120, set of outer barriers130, set of fans140, heat exchanger142, and chamber150are such that there is not a direct line/noise path from set of fans140and heat exchanger142to an object116(e.g., a person, a building, etc.) disposed on ground level112outside of thermal regulation system100. Set of inner barriers120and/or set of outer barriers130may enclose (e.g., surround) heat exchanger142and/or set of fans140. In one embodiment, set of inner barriers120and set of outer barriers130may include concentric uneven walls.

In an embodiment, set of fans140and/or heat exchanger142may be disposed substantially planar relative to ground level112. In one embodiment set of fans140and/or heat exchanger142may be disposed between about 1 meter below and about 1 meter above a plane of ground level112. Locating set of fans140and/or heat exchanger142proximate to ground level112may reduce acoustic proliferation and may further ease pumping of fluid through heat exchanger142. It is understood that active noise cancellation may include analysis of noise source waveforms and generation of a sound wave which may phase shift and/or invert the polarity of the original signal. Control and/or amplification of this sound wave may create a sound wave directly proportional to the amplitude of the original waveform which may create destructive interference, thereby effectively reducing the noise level of the noise source waveforms.

In an embodiment, set of inner barriers120and/or set of outer barriers130may include concrete. In one embodiment, set of inner barriers120may include concrete and set of outer barriers130may include metal (e.g., sheet metal lined with absorptive materials). In another embodiment, set of inner barriers120and/or set of outer barriers130may include porous concrete and/or a set of cinder blocks. The set of cinder blocks may include tunable sections which may be set to a blade-pass frequency for set of fans140. In another embodiment, set of inner barriers120and/or set of outer barriers130may include a set of patterned (e.g., cavities, sound-absorbing cavities, ridges, etc.) and/or hollow walls. An outside surface of set of inner barriers120and/or set of outer barriers130may be painted and/or sealed. It is understood that while descriptions are made to specific materials and compositions herein, these descriptions are merely examples and set of inner barriers120and/or set of outer barriers130may include any material now known or later developed. Further, any number and/or configuration of inner barriers120and outer barriers130may be used in accordance with the invention, the number and configuration of inner barriers120and outer barriers130may be tunable/adjustable to match blade-pass frequencies for set of fans140.

In an embodiment of the present invention, set of outer barriers130may include a first outer top surface132which is disposed at a distance A above ground level112. Distance A may be greater than a height of a normal noise receiver (e.g., human ear, office window, residential window, etc.). First outer top surface132may be patterned to inhibit mixing (e.g., recirculation) in thermal regulation system100. In one embodiment, set of inner barriers120may include a first inner top surface124which is located at a distance C above first outer top surface132of set of outer barriers130. Distance C may provide a path/elevation for exhaust182(shown inFIG. 3) to exit thermal regulation system100to the atmosphere and be discharged several feet in the air above the inlet.

Set of inner barriers120may further include a first bottom surface122which is located a distance B below first outer top surface132of set of outer barriers130. Distance B represents an overlap between set of outer barriers130and set of inner barriers120which prevents set of fans140and/or heat exchanger142from having a direct horizontal line of sight with an object116(e.g., a person, a building, etc.) disposed on ground level112outside of thermal regulation system100. In an embodiment, set of inner barriers120may be located at a distance D from set of outer barriers130and first bottom surface122may be located at a distance E above base barrier134. Distance D and/or distance E may be sized so as to allow full flow/draw of air (e.g., unimpeded, unimpinged, minimal pressure drop, etc.) into set of inner barriers120of thermal regulation system100by set of fans140. In one embodiment, chamber150and/or set of outer barriers130may extend about 3 to about 4 meters below ground level112. Inner barriers120, outer barriers130, and/or base barrier134may be tuned in respect to a specific heat exchanger142and/or set of fans140.

Turning toFIG. 2, a schematic view of thermal regulation system100located at a distance G above ground level112and including a set of barriers120and130is shown in accordance with an embodiment of the invention. As can be seen inFIG. 2, chamber150may be disposed at distance G above ground level, thereby increasing a magnitude of A and elevating set of fans140and heat exchanger142relative to ground level112and/or object116. In an embodiment, thermal regulation system100may include an active noise cancellation system186(shown in phantom) which is configured to destructively interfere with noise generated during operation of thermal regulation system100. It is understood that active noise cancellation system186may include any form of active noise cancellation now known or later developed including analysis of noise source waveforms and generation of a sound wave which may phase shift and/or invert the polarity of the original signal. Further, operation of active noise cancellation system186may include control and/or amplification of this sound wave which may create a sound wave directly proportional to the amplitude of the original waveform which may create destructive interference, thereby effectively reducing the noise level of the noise source waveforms.

Turning toFIG. 3, a schematic view of air flow through a thermal regulation system200including heat exchanger142located above set of fans140and disposed between a set of barriers is shown in accordance with an embodiment of the invention. In this embodiment, an air flow180may be drawn through a supply channel between set of inner barriers120and set of outer barriers130via set of fans140. Air flow180may be drawn in from all sides of thermal regulation system200and directed/drawn over/across heat exchanger142as a combined flow184by set of fans140and/or set of inner barriers120. Once combined flow is passed through heat exchanger142and absorbs thermal energy therefrom, combined flow184may be released/exhausted from thermal regulation system200as exhaust flow182. In an embodiment, combined flow184and/or exhaust flow182may have a velocity which is greater than a velocity of air flow180as a result of channeling through set of inner barriers120. It is understood that while specific embodiments and arrangements of components are described herein (e.g., heat exchanger142disposed above set of fans140, heat exchanger142disposed below set of fans140, etc.), these are merely examples and that any combination of components (e.g., heat exchanger142disposed between a set of fans140) may be used in accordance with embodiments of the invention.

Turning toFIG. 4, a schematic view of a first acoustic flow190(e.g., sound waves, noise, etc.) and a second acoustic flow192through thermal regulation system200during operation is shown in accordance with an embodiment of the invention. As can be seen inFIG. 4, arrangement/configuration of set of inner barriers120and set of outer barriers130as described herein may provide acoustic attenuation through sound reflection, sound absorption, sound diffraction, and/or active noise cancellation. In this embodiment, set of inner barriers120and set of outer barriers130may absorb and/or direct acoustic flows190and192substantially upward into the atmosphere for dissipation. Acoustic flows190and192may have a point of origin substantially proximate to the set of fans140(e.g., being primarily generated by fan blades) and heat exchanger142during operation, and may be diffracted via bending through chamber150, set of inner barriers120, set of outer barriers130, and base barrier134.

As can be seen inFIG. 4, acoustic flow190which is initially directed substantially downward may be reflected from base barrier134toward set of outer barriers130and/or set of inner barriers120which may channel acoustic flow upward to the atmosphere. In an embodiment, set of outer barriers130may include a surface138(e.g., a substantially vertical surface) which includes a set of acoustic absorbers/acoustically absorptive materials. In one embodiment, surface138may be modified to enhance acoustic attenuation. Porous concrete, acoustically absorptive concrete, or other rough, acoustically absorptive materials may be applied to surface138and/or base barrier134. In another embodiment, base barrier134may be partially covered with gravel. Acoustic flow192is initially directed upward and may be channeled by set of inner barriers120to the atmosphere. In an embodiment, set of inner barriers120and set of outer barriers130overlap (e.g., distance B shown inFIG. 1) so as to eliminate any direct path for acoustic flows190and192from set of fans140and heat exchanger142to an object116(e.g., a person, a building, etc.) disposed on ground level112outside of thermal regulation system200. In one embodiment, set of inner barriers120and/or set of outer barriers130may be shaped to direct acoustic flows190and192skyward.

Turning toFIG. 5, a schematic view of portions of a multi-shaft combined-cycle power plant500is shown. Combined-cycle power plant500may include, for example, a gas turbine580operably connected to a generator570. Generator570and gas turbine580may be mechanically coupled by a shaft515, which may transfer energy between a gas turbine580and generator570. Also shown inFIG. 5is a heat exchanger586operably connected to gas turbine580and a steam turbine592. Heat exchanger586may be fluidly connected to both gas turbine580and steam turbine592via conventional conduits (numbering omitted). Heat exchanger586may be a conventional heat recovery steam generator (HRSG), such as those used in conventional combined-cycle power systems. As is known in the art of power generation, HRSG586may use hot exhaust from gas turbine580, combined with a water supply, to create steam which is fed to steam turbine592. Steam turbine592may optionally be coupled to a second generator system570(via a second shaft515). Any of generator system570, gas turbine580, and steam turbine592may be operably connected to thermal regulation system100ofFIG. 1, or other embodiments described herein. It is understood that generators570and shafts515may be of any size or type known in the art and may differ depending upon their application or the system to which they are connected. Common numbering of the generators and shafts is for clarity and does not necessarily suggest these generators or shafts are identical. In another embodiment, shown inFIG. 6, a single-shaft combined-cycle power plant600may include a single generator570coupled to both gas turbine580and steam turbine592via a single shaft515. Single generator570, gas turbine580, and/or steam turbine592may be operably connected to thermal regulation system100ofFIG. 1or other embodiments described herein.

The configurations illustrated inFIGS. 5-6represent only examples of options for deploying thermal regulation system100in a multi-shaft combined-cycle power plant and a single-shaft combined-cycle power plant, respectively, and are not meant to limit the scope of the various embodiments of the present invention. For example, inFIGS. 5-6, it may be desirable to have a fluid connection between heat exchanger586and thermal regulation system100. Those skilled in the art will appreciate that other connections between components of the combined-cycle power plants shown inFIGS. 5-6and the thermal regulation system100are possible.

The thermal regulation system of the present disclosure is not limited to any one power generation system, combined-cycle power generation system, turbine or other system, and may be used with other power systems. For example, the various embodiments of the present invention may be suitable for use with other combined-cycle power generation systems than those illustrated inFIGS. 5-6and co-generation power plants. Additionally, the various embodiments of the present invention may be used with other systems not described herein that may benefit from the thermal regulation and acoustic abatement provided by the thermal regulation system described herein. For example, the various embodiments of the thermal regulation system described herein may be suitable for use with carbon recovery systems.