APPARATUS AND METHOD FOR MITIGATING THERMAL
EXCURSIONS IN AIR CORE REACTORS DUE TO WIND EFFECTS
This application claims benefit of the 24 July 2012 filing date of United States
provisional Application No. 61/674,971 and the 19 April 2013 filing date of United States
provisional Application No. 61/813,807.
FIELD OF THE INVENTION
The present invention relates to dry type air core reactors of the type used in
utility and power applications and, more particularly, to a reactor design and method
which facilitates cooling of winding layers within the reactors.
BACKGROUND OF THE INVENTION
Air core reactors are inductive devices used in high voltage power transmission,
distribution and industrial applications. Configurations and designs include devices
which have a number of applications, including filtering out harmonics, shunt devices
which compensate for introduction of capacitive reactive power, and devices which limit
short circuit currents. Air core reactors are formed with a series of concentrically
positioned, spaced-apart winding layers, referred to as packages, in a cylindrical
configuration. The winding layers are positioned between upper and lower current
carrying members, sometimes referred to as spider units. The spider units comprise a
series of arms radiating along a plane and away from a central position in a star
configuration.
Among other functions, the spider units may serve as line terminals for
connecting power lines and for connecting the winding layers in an electrically parallel
configuration. The reactors are normally installed with the spider units in a horizontal
orientation with respect to an underlying horizontal ground plane so that the major axis
of the cylindrical configuration extends vertically upward from the ground plane. For a
single reactor, or for the lower-most reactor in a stacked configuration of two or more
reactors, the winding layers are supported above the ground by the lower spider unit
and a series of insulators and structural leg members which extend from the lower
spider unit to the ground.
The useful life of these reactors can be adversely affected by heat generated in
and about the winding layers. With air core reactors typically placed in outdoor
environments, conventional designs allow for some cooling by movement of air
convection currents between the spaced-apart winding layers. These reactors have
openings along the upper and lower spider units, allowing air currents to rise from the
underlying ground plane, move along the direction of a central axis and pass above the
upper spider unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in the following description in view of the drawings that
show:
Figure 1A is an elevation view of an air core reactor incorporating an air deflector
according to an embodiment of the invention;
Figures 1B and 1C are partial cut-away views illustrating numerous features of
the reactor shown in Figure 1A, including upper and lower spider units;
Figure 2A is a plan view of a lower spider unit of the reactor shown in Figures 1;
Figure 2B is a partial schematic cross-sectional view of the reactor shown in
Figures 1, taken along line 2B shown in Figure 2A;
Figure 2C is another partial schematic cross-sectional view of the reactor shown
in Figure 1, taken along line 2C shown in Figure 2A;
Figure 2D is another partial schematic view of the reactor 10, taken along line 2D
shown in Figure 2A;
Figure 2E is a perspective view of a circular baffle wall and a base plate of a
wind deflector each having twelve sections;
Figure 2F is a plan view of the base plate shown in Figure 2E;
Figure 2G is an unrolled view of a circular shaped vertical baffle wall shown in
Figure 2C, illustrating a series of slots formed along an upper edge thereof;
Figure 3A is a partial perspective view of the reactor illustrating components of
multiple plena formed with the base plate shown in Figures 2;
Figure 3B is a plan view of a series of twelve plena each formed with a base
plate segment and arranged 360° about a central axis.
Figure 3C is a plan view which illustrates an arrangement of six plena according
to an alternate embodiment of the invention;
Figure 4A is a partial schematic view of the reactor 10 taken along line 2B shown
in Figure 2A, illustrating an alternate embodiment of a baffle plate shown in Figure 2B;
Figure 4B is another partial schematic view of the reactor 10 taken along line 2C
shown in Figure 2A, illustrating an alternate embodiment of a baffle plate shown in
Figure 2C;
Figures 5A, 5B and 5C are perspective views of a series of plenum units which
are monolithic constructs for modular assembly of a wind deflector according to the
invention;
Figure 5D is a partial perspective view of the wind deflector assembled with the
modular plenum units of Figures 5A, 5B and 5C; and
Figure 5E is a partial view of a reactor incorporating the wind deflector shown in
Figure 5D.
DETAILED DESCRIPTION OF THE INVENTION
With conventional designs of air core reactors allowing for passive cooling by
movement of air convection currents between the spaced-apart winding layers, it might
be expected that by allowing air currents to rise from the underlying ground plane, such
movement of air through gaps between winding layers could facilitate cooling of the
winding layers under wind conditions as well. However, measurements performed
under controlled conditions indicate that under mild wind conditions, e.g., on the order
of 6 Km/hr, winding temperatures increase significantly. In fact, under such wind
conditions, measurable temperature elevations can occur in all winding layers relative to
conditions in which there is no wind. The most significant temperature differentials,
relative to no-wind conditions, were observed in winding layers positioned between the
inner-most and outer-most windings of the reactor. Accordingly, a wind diverter
assembly, referred to in this description as a deflector, is provided for incorporation into
a reactor to direct wind through cooling duct spaces, or gaps, between and along the
winding layers. Tests indicate that with a deflector according to the invention,
temperatures in the reactor windings can be reduced to levels observed without the
presence of wind conditions. The magnitude of such temperature excursions can be
substantially reduced, thereby limiting long term, adverse effects of thermal energy in
the winding layers. Tests also indicate that temperatures in the reactor windings can be
reduced below levels observed without the presence of wind.
Figure 1A is an elevation view of an air core, dry type reactor 10, according to an
embodiment of the invention. Figures 1B and 1C are partial cut-away views of the
reactor 10 illustrating components typical of air core reactors. The reactor comprises a
series of cylindrically shaped, spaced-apart winding layers 12 concentrically positioned
about a central axis, A, of symmetry. The winding layers typically have a thickness
range, as measured in the radial direction, on the order of 0.5 to 3 cm and may vary in
thickness. Although the reactor 10 may comprise fewer or substantially more winding
layers than shown in Figures 1 (e.g., ranging from fewer than three layers to twenty or
more layers), for simplicity of illustration, Figures 1B and 1C illustrate only three such
winding layers, while Figures 2 illustrate the reactor 10 having an arbitrary and larger
number of winding layers 12. The reactor 10 as illustrated in Figure 1C includes an
innermost winding layer 12a, an intermediate winding layer 12b and an outermost
winding layer 12c. The reactor is shown in a common orientation, positioned above a
horizontal ground plane, G, with the central axis, A, extending vertically above the
ground plane. The reactor 10 includes a hollow reactor cavity 13 extending radially
inward from the winding layer 12a toward the axis, A. The cavity 13 and winding layers
12 are positioned between an upper spider unit 14 and a lower spider unit 16. The
spider units have horizontal orientations with respect to the underlying ground plane, G.
The layers 12 of winding are separated from one another by spacers 18 which
are shown to have a vertical orientation extending in a direction parallel to the axis, A. A
series of the spacers 18 is each positioned between each pair of adjacent winding
layers. The spacers 18 in each series are circumferentially spaced apart about the axis,
A, to provide winding layer air gaps 20 between adjacent pairs of the layers 12. In other
embodiments (not illustrated), the reactor may include an outer sheathing or a rigid
support structure to which, for example, an electrostatic shield may be attached. See
US 201 1/0043320 which is incorporated herein by reference. For such embodiments,
further spacers may be provided to facilitate separation of the sheathing or a rigid
support structure from the outermost layer of winding to also provide an air gap 20.
Each winding layer air gap 20 permits a current of air to flow upward along a surface of
the winding layer. The exemplary thickness of the winding layer air gaps 20, as
measured between the winding layers 12 is typically in the range of 1 to 3 cm as
measured in a radial direction outward from the axis, A, and the gap thickness may vary
among gaps 20.
The spider units 14, 16 each comprise a series of arms 24 radiating along a
plane and away from the axis, A, in a star configuration. The upper and lower spider
units 14, 16 in an embodiment of the reactor 10 shown in Figure 1A each have twelve
spider arms 24. For simplicity of illustrating general features of the reactor 10, in Figure
1B only four spider arms 24 (designated 24a, 24d, 24g and 24j in Figure 1B) are shown
in each of the upper and lower spider units 14, 16 of the reactor 10. The number of
arms in the spider units may range from fewer than four to more than twelve arms 24.
Among other functions, the spider arms of the units 14, 16 serve as line terminals
(not illustrated) for effecting power connections to and between the winding layers 12,
e.g., in an electrically parallel configuration. As shown in Figures 1B and 1C, the four
exemplary arms 24a, 24d, 24g and 24j of the spider units 14, 16 extend outward from a
central hub 26. For purposes of illustrating exemplary features of the invention, the
arms 24a, 24d, 24g and 24j of the spider units 14, 16 are shown rotationally spaced
ninety degrees apart about a central hub 26 and the axis, A. A lifting eye nut 28 may be
affixed to the hub 26 of the upper spider unit 14 to facilitate transport and placement of
the reactor 10. In other embodiments, the reactor may be lifted from the arms 24. For a
single reactor, and for at least the lower-most reactor 10 when arranged in a stacked
configuration of reactors, the winding layers 12 are supported above the ground by a
combination of spider arms 24 of the lower unit 16 and a series of structural leg
members 34. In the illustrated embodiment four of the arms 24 of the lower spider unit
16 are supported directly by leg members 34 which each extend from a spider arm 24
to the ground. In this embodiment, other spider arms 24 are not directly supported by
the leg members but are supported through the spider unit 16 in combination with
support provided by the leg 34 members to other arms. In other reactor designs each of
the arms of the lower spider unit may be directly coupled to a different leg member for
direct support. The leg members 34 of the reactor 10 each include an insulator 32. The
number of structural leg members supporting the reactor 10 can vary from fewer than
four to more than twelve.
With reference to Figures 1, 2 and 3, the reactor 10 includes a wind deflector 40
comprising a base plate 44 mounted beneath the lower spider unit 16. The following
description is specific to a twelve arm configuration of the lower spider unit 16 shown in
the plan view of Figure 2A, but it is exemplary of more general designs for deflectors 40
located beneath lower spider units and without regard to a lower spider unit having a
specific number of arms 24.
With the lower spider unit 16 having twelve arms 24 as shown in Figure 2A, the
illustrated arms 24 are numbered, clockwise and consecutively 24a - 24i. Pairs of
adjacent arms 24 define twelve, thirty degree sectors, S,, of the spider unit 16,
numbered S through S12, clockwise around the axis, A. For a reactor 10 with a lower
spider unit having n arms 24 equally spaced apart, adjacent pairs of the arms 24 of the
lower spider unit define n sectors, S,, each subtending 360/n degrees.
With reference to Figures 1B and 2A, Figure 2B is a partial schematic view of the
reactor 10 taken along line 2B, illustrating a portion of the base plate 44. The view of
Figure 2B is taken in front of a plane P which passes through the axis, A, and along a
surface 24s of one side of arm 24b of the lower spider unit 16. The wind deflector base
plate 44 is positioned below the arm 24a. Figure 2C is another partial schematic view of
the reactor 10 taken along line 2C, illustrating another portion of the base plate 44 and a
leg member 34. The view of Figure 2C is taken in front of a plane P2 which passes
through the axis, A, and along a surface 24s of one side of arm 24a of the lower spider
unit 16. Figure 2D is another partial schematic view of the reactor 10, taken along line
2D, illustrating still another portion of the base plate 44. The view of Figure 2D is taken
along a plane P 3 which passes through the axis, A, and between two adjacent arms 24b
and 24c of the lower spider unit 16. Figure 2D provides a view in front of the surface
24s of a side of the arm 24b.
With the reactor 10 being of a generic design for which the number of winding
layers 12 may vary, a series of k concentric winding layers 12 is indicated in Figures 2B
- 2D, positioned above the lower spider unit 16 and outward from the cavity 13. The
innermost layer is designated layer 12-i and the outermost layer is designated layer 12k.
An inner surface 42 of the inner-most winding layer 12-i faces the central axis, A . Figure
2E is a perspective view of the base plate 44 of the exemplary wind deflector 40. Figure
2F is a plan view of the base plate 44, which is shown as divided into twelve segments
44 - 44 each vertically aligned with respect to one of the sectors S through S of
the lower spider unit 16. That is, sector Sj overlies base plate segment 44j . As shown in
Figure 2F, the base plate 44 includes a series of cut outs 45 through which the leg
members 34 each extend from one of the spider arms to the ground.
In the embodiment of Figures 1 - 3, the wind deflector base plate 44 is a single
body having an upper deflecting surface 46 configured in the shape of a regular cone
with the base of the cone facing the underlying ground plane, G. However, instead of
forming the base plate 44 with the entire shape of a regular cone (i.e., instead of the
upper end of the cone shape converging to a point), the end of the cone shape which
would otherwise converge to a point is truncated to provide a frustoconical structure
having an interior opening 48 at an upper end 47 of the base plate 44. With the interior
opening 48 formed in the base plate 44, air is able to pass (e.g., via a rising convection
current) from the ground plane, through the interior opening 48, into the central cavity
13 and then out through the upper spider unit 14. The exemplary interior opening 48 in
the base plate 44 may, as illustrated with a conical shaped structure, be of circular
shape and concentric with both the axis, A, and the winding layers 12. The exemplary
opening 48 has a diameter which extends substantially, but not entirely, across a lower
region of the cavity 13. As shown in Figures 2, a circular shaped vertical baffle wall 54
extends upward from the upper deflecting surface 46 of the base plate 44, near the
opening 48, and through the lower spider unit 16. The circular shaped vertical baffle
wall 54 may be integrally formed with the base plate 44. The wall 54 has an inner
surface 54i facing the axis, A, and an opposing outer surface 54o facing radially
outward with respect to the axis, A. The circular vertical wall 54 passes between
adjacent pairs of arms 24, e.g., between arms 24a and 24b. The interior of the circular
shaped vertical wall 54 receives air passing from the ground plane and through the
opening 48 as the air continues to rise upward and into the central cavity 13.
With further reference to Figures 2, the vertical wall 54 extends from the base
plate 44 into the central cavity 13. As shown for the arm 24b in Figure 2B, the wall 54
extends above the arms 24, but this is not necessary.
In the exemplary embodiment, a circular interior edge 44e of the base plate 44 is
defined by the opening 48. The base plate 44 extends toward the arms 24 and the
interior edge 44e may contact the arms 24. As shown in the unrolled view of Figure 2G,
the exemplary wall 54 includes a series of slots 56 each extending upward from a lower
edge strip 58 to form wall segments 54s between the slots. The slots 56 also extend
upward from the base plate upper surface 46 so that individual slots 56 fit about
individual arms 24 of the lower unit 16 and slotted upper edges 54e of the wall 54
extend above the spider unit 16 and into the cavity 13. Each slot, numbered clockwise
and consecutively 56a - 56 , extends vertically along opposing vertical sides 60 of a
corresponding one of the arms 24a - 24 i (e.g., slot 56a extends along and above the
opposing sides 60 of the spider arm 24a; and slot 56b extends along and above the
opposing sides 60 of the spider arm 24b, etc.).
The circular shaped wall 54 is positioned to act in concert with a series of vertical
baffle plates 62 to divert movement of wind impinging on the base plate upper surface
46 in an upward direction along and between the winding layers 12. The baffle plates 62
are of two configurations 62a and 62b. The plates 62a, as shown in Figure 2B, provide
a seal along spider arms which are not directly supported by the leg members 34. The
plates 62b, as shown in Figure 2C, provide a seal along spider arms which are directly
supported by the leg members 34. See, also, Figure 3A. Each vertical baffle plate 62a
or 62b has an inner vertical sealing edge 62i positioned against the circular shaped
vertical wall 54 and an outer vertical edge 66.
Collectively, the vertical wall 54, the vertical baffle plates 62a, 62b and the upper
deflecting surface 46 of the baseplate 44 create a baffle structure which guides
movement of wind impinging on the upper surface 46, from any horizontal direction, in
an upward direction. As shown for one baffle plate 62a and one baffle plate 62b in the
elevation view of Figures 2B and 2C, the plates 62 each extend vertically from a sealing
joint 63 on the upper surface 46 of the base plate 44 in an upward direction. See, also,
Figure 3A which illustrates an arrangement in which the plates 62 each terminate along
one of the vertical sides 60 of an arm 24 of the lower spider unit 16. The illustrated
baffle plates 62 are flat plates which extend radially outward from the circular shaped
vertical wall 54. The illustrated plates 62 are generally in the shape of a right triangle
but, as illustrated in the example embodiment, may be trapezoidal in shape, with the
inner vertical sealing edge 62i being a fourth side of the plate and positioned against the
outside surface 54o of the wall 54. An upper edge 64 of the plate 62 extends along a
horizontal direction, terminating on a side 60 of a spider arm 24. The outer vertical side
edge 66 extends upward from near the outer periphery 69 of the deflector base plate 44
to near the edge 25 of a spider arm 24 at a radially outward end of the spider arm. The
circular shaped wall 54 extends upward from about the base plate interior opening 48
and into the cavity 13. In other embodiments, the circular shaped wall 54 may be
integrally formed with the base plate 44, in which case the wall may not include the
lower edge strip 58.
In the illustrated embodiment of Figures 2, the vertical wall 54 extends from the
base plate 44 into the central cavity 13. As shown in Figures 2B and 2C, the wall 54
may extend above the arms 24, in which case a portion 54p of the circular shaped
vertical wall 54 may extend a short distance (e.g., 2.5 to 10 cm or more) upward into the
cavity 13. With this arrangement, the outside diameter of the circular shaped wall 54
may be dimensioned to provide an optional baffle air gap 68 between the outer surface
54o of the circular shaped wall 54 and the inner surface 42 of the winding layer 12 . By
so extending the circular shaped wall 54 to provide the wall portion 54p and the optional
gap 68 along part of the inner surface 42 of the inner-most winding layer 12 upward
movement of wind from the upper surface 46 can be guided, between the outer surface
54o of the circular shaped wall and the inner surface 42 of the inner-most winding layer
12 to facilitate cooling of the inner-most winding layer.
Together, the base plate 44 and the circular shaped vertical wall 54 are
positioned to inhibit wind from moving entirely under and past the winding layers 12,
while also permitting rising air, e.g., due to convection currents, to pass through the
base plate interior 48 and through the cavity 13. Because the segments 54s of circular
shaped baffle wall 54 extend through the lower spider unit arms 24, the wall 54 may be
formed with the afore-described slots 56 that fit around opposing sides of individual
spider arms. However, in other embodiments, the wall 54 may be formed in discrete arc
segments extending between pairs of adjacent spider arms 24, in which case each
segment may be attached to each in a pair of adjacent spider arms 20.
The deflecting surface 46 is illustrated as having a constant slope upward from
the outer periphery 69 of the deflector base plate 44 toward the interior opening 48, but
other contours may be suitable. The lower edge 70 of each baffle plate 62 conforms
with the contour and slope along the base deflecting surface 46 (i.e., with respect to the
horizontal ground plane) so that the plate 62 serves as a sealing wall which extends
radially outward and against the deflecting surface 46 along the joint 63, i.e., from a
point at the interface of the outer surface 54o of the baffle wall 54 and the vertical
sealing edge 62i to an overlying spider arm 24. The combination of the circular shaped
wall 54 and each pair of adjacent baffle plates 62 creates a plenum 72. The wind
deflector 40 comprises a series of such plena 72a through 72 as more fully shown in the
perspective view of Figure 3A. Each plenum 72 is formed with or on a segment 44, of
the base plate 44 and arranged 360° about the axis, A. See, also, the partial schematic
view from above of the deflector 44 in Figure 3B. The view of Figure 3B is taken along a
plane parallel to and below the lower horizontal surfaces 6 1 of the lower spider unit
arms 24.
In the illustrated embodiment each plenum 72 comprises a pair of baffle plates
62 and, as shown in Figures 3, there are 24 baffle plates (e.g., 62a or 62b) in the wind
deflector. A baffle plate 62 is positioned along each side 24s of each spider arm 24. In
other embodiments each plenum 72 may comprise a discrete portion of the base plate
44, e.g., one of the twelve segments 44-i - 44 2 , and adjoining plena may share baffle
plates 62 such that there are 12 baffle plates instead of 24 baffle plates in the
exemplary wind deflector. See Figures 5.
As illustrated in Figure 2D, each plenum 72 has an intake opening 74 for
receiving wind and an outlet 76. The intake opening 74 of each plenum 72 is defined by
the lower edge 67 of the outermost winding 12k, the outer periphery 69 of the deflector
base plate 44 and the outer side edges 66 of the two adjacent plenum baffle plates 62.
The outlet 76 is between the upper edges 64 of adjacent baffle plates 62 and between
the circular shaped baffle wall 54 and the lower edge 67 of the outermost winding 12k.
The outlet 76 is open to the lower spider unit 16 (i.e., in fluid communication with the
lower spider unit) so that wind exiting the outlet can pass through the lower spider unit,
i.e., between adjacent spider arms 24, to enter the gaps 20 between the winding layers
12. In this arrangement, with each plenum including both the circular shaped baffle wall
54, positioned on the base plate symmetrically about the axis, A, and a base plate
segment 44,, each plenum is, essentially, an open chamber having an air intake
opening 74 and an air outlet 76.
With the wind deflector 40 comprising the series of plena 72 positioned
completely about the axis, A, the deflector can receive wind from any direction into the
opening 74 in one or more plena 72 and divert the wind so that the air travels in an
upward direction through the winding layer air gaps 20 as well as through the baffle air
gap 68 so that the moving air can provide heat transfer along inner and outer surfaces
of each winding layer 12,.
Numerous variations in the design and shape of the baffle plates 62 are
contemplated to provide flexibility in reactor design, accommodate tie down restraints
and avoid interference with mechanical or electrical connections. Figures 4A and 4B
illustrate variants of the baffle plates 62a and 62b shown in Figures 2B and 2C. Figure
4A is a partial schematic view of the reactor 10, like that of Figure 2B, taken along line
2B shown in Figure 2A and in front of the plane R i, along a side surface 24s of arm 24b
of the lower spider unit 16. Figure 4B is another partial schematic view of the reactor 10,
like that of Figure 2C, taken along line 2C shown in Figure 2A. The view of Figure 4B is
taken in front of a plane P2 and along the side surface 24s of the arm 24a of the lower
spider unit 16. Figure 4A illustrates a variant of the baffle plate 62a and Figure 4B
illustrates a variant of the baffle plate 62b. Each of the baffle plates 62a and 62b as
shown in Figures 4A and 4B incorporates a cutout 64c along the upper edge 64 to
accommodate a series of tie down straps 77 that extend from several of the winding
layers 12. The straps 77 may be formed as fiberglass resin composite materials bonded
to the winding layers which are typically coated with a fiberglass resin composite
material. The straps 77 each extend from a winding layer 12, under the spider arms 24,
and back to a winding layer 12. The straps 77 may each be fit within a recess 78 along
the lower horizontal surfaces 6 1 of a spider arm. Notwithstanding variations in the baffle
plates 62 illustrated in the figures, including provision of additional sides, the illustrated
plates 62 are generally triangular in shape with variations along edges, e.g., to
accommodate straps, electrical connections, etc. In lieu of forming cutouts the upper
edges of the baffle plates can include tabs or other appendages which are positioned
against the surfaces 24s of sides of the arms 24. It is to be understood that the
numerous variants in baffle plate design and in design of plenum units are
interchangeable among the numerous embodiments. It is also to be recognized that the
illustrated tie down straps and placement of these straps is exemplary of a variety of
configurations and that other tie down configurations are contemplated. Generally, the
baffle plates 62 may be shaped accordingly to provide clearances and openings for
mechanical and electrical components.
Those skilled in the art will readily recognize that there are numerous designs
and fabrication methods according to which a deflector may be designed and
incorporated into the reactor 10 to divert the direction of the wind to flow between the
gaps 20. In the disclosed embodiments, an opening 80 formed by the series of discrete
plenum outlets 76, extends completely, i.e., 360 degrees, around the deflector 40. The
opening 80 is partitioned by the series of plenum baffle plates 62, each extending
upward in a vertical direction from the deflector 40 to one of the arms 20 of the lower
spider unit 16. Numerous other arrangements of plena can effect the same function or a
similar function as that described for the embodiments shown in Figures 1 - 3. For
example, each plenum 72 may be formed as a complete and discrete unit comprising (i)
a segment 44, of the base plate 44, (ii) a wall segment 54s and (iii) a pair of baffle plates
66, similar to one of the arrangements shown in Figure 3A. Providing each plenum as a
modular unit facilitates field retrofits of existing reactors to incorporate wind deflectors.
In other embodiments, the modular plenum units may be designed to be spaced
apart from one another about the axis, A. Differing designs of modular plenum units are
contemplated to suit a variety of reactors which vary in reactor size and to provide
variations in cooling performance. One specific example is illustrated in Figures 5. More
generally, a single design of modular plenum units may be adapted for installation in
reactors which vary in size or vary in the number of spider arms with use of brackets or
spacers and the like. Such applications of standardized plenum units for different spider
arm sizes can facilitate rapid, lower cost installation of wind deflectors providing
acceptable levels of cooling to winding layers.
When implementing other embodiments with a modular plenum design, the
number of plena may remain the same as described for the deflector 40 shown in
Figure 3A, but with each plenum subtending a smaller angle, or there may be fewer
plena. In either case, the resulting configuration may have spaces between plena or
between plena and adjacent spider arms. The plena need not be uniformly spaced
apart. The plan view of Figure 3C illustrates implementation of uniform spacing between
plena with such modularity in a wind defector comprising six plena. In lieu of providing a
base plate 40 as one monolithic unit as shown in Figure 2D, six in the series of twelve
base plate segments 44, (e.g., 44-i, 443, 445, 44 , 449, 44 ) are provided as discrete
units while the other six base plate segments (e.g., 442, 44 , 446, 448, 44i 0, 44i 2) are
omitted. Each of the discrete base plate units which are retained forms a portion of one
plenum 72. With spaces positioned between adjacent plena, air can flow through such
spaces and into the reactor cavity 13.
In the embodiment of Figures 5, a series of modular plenum units are provided to
install a wind deflector 90 functionally equivalent to the wind deflector 40 shown in
Figures 1. As shown in Figures 5A, 5B and 5C, three plenum units 92a, 92b and 92c
are monolithic constructs each comprising one of the base plate segments 44i, one
vertical baffle wall 62 and one segment 54s of the circular shaped vertical wall 54. Each
plenum unit comprises a base member 44,, a vertical plate 62 and a vertical wall
member 54s corresponding to one of the wall segments of the circular wall 54. The
base member 44,, the vertical plate 62 and the vertical wall member 54s are attached to
one another to form a single unit. By way of example, they may be integrally formed as
one unit (e.g., as a fiberglass composite structure) or they may be assembled into a
single structure with fasteners. Each plenum unit base member is sized to fit beneath
the lower spider unit, and between a pair of other plenum unit base members. When
each base member is positioned with the deflecting surface 46 facing away from the
ground plane, G, the vertical plate and the vertical wall member are positioned to
extend upward and away from the ground plane and the base member to serve as
baffles members for deflecting wind. When a series of the plenum units is installed in
the reactor, as shown in figures 5D and 5E, the combination of each plenum unit with a
vertical plate of an adjoining plenum unit, provides a plenum capable of deflecting wind
entering the plenum unit in an upward direction to pass through the air gaps 20 between
winding layers 12. In other embodiments, not all of the plenum units 92 need have a
segment 54s corresponding to the circular shaped vertical wall 54 attached to the base
member 44i. For example, in an assembled system comprising a series of plenum units
there may be an alternating arrangement of spaced apart vertical wall segments.
Consistent with the shape of the deflector base plate 44 shown in Figures 1 and
2, when the combination of the vertical plate 62 and the base member 44, of each
plenum unit 90 is installed (e.g., when the plates 62 of all of the plenum units 90 are
installed against the sides 24s of the arms 24), the plenum units each define a base
plate slope (a positive gradient toward the axis, A) while the vertical wall member 54s
occupies a substantially vertical orientation.
It is to be understood that for a custom application the particular number of
different plenum units and the design of each plenum unit may result from specific
features of the reactor design (e.g., the number of arms 24 on the lower spider unit, and
the number of leg members 34). Other modular designs may utilize only one design of a
plenum unit 92 for all of the units used to create a wind deflector. Figure 5D is a partial
view of the of the wind deflector 90 illustrating assembly of the modular plenum units
92a, 92b and 92c to form a functional equivalent of the wind deflector 90. Figure 5E is a
partial view of the reactor 10 illustrating assembly of the wind deflector 90 therein. With
the modular units 90 it is possible to install the wind deflector without removal of the
reactor from the leg members 34. The modular units 90 can be fastened directly to the
arms 24 of the lower spider unit 16. In Figures 5 and other embodiments it is to be
understood that the baffle plates 62, although illustrated as similar in shape to those
shown in Figure 3A, may be of varied shapes, including those illustrated in Figures 2, 3
and 4. Similarly, the circular shaped vertical baffle wall 54, and associated baffle wall
segments 54s are not limited to the particular designs illustrated.
For a reactor having lower spider unit arms extending radially 167.5 cm (67 in)
from the axis, A, and the inner surface 42 of the winding layer 12-i positioned 118 cm
(46.5 in) from the axis, the deflector 40 may have the following approximate
dimensions:
- radius of deflector base plate interior opening 48 and circular shaped vertical
wall 54: 116 cm (46 in),
- radius of outer periphery 69 of deflector base plate 44: 167.5 cm (67 in),
- baffle plate length along upper edge 64: 52 cm (20.5 in),
- baffle plate height along side edge 66 up to bottom surface of arm 24: 20 cm
(8 in),
- slope of deflector base plate from horizontal: 22°.
The slope of the deflector base plate 44 along the lower edge 70 of each vertical
baffle plate 62 may range from zero to sixty degrees or more. Reference to the base
plate having a positive slope, e.g., 22°, corresponds to height of the base plate
increasing as the distance to the axis, A, decreases.
Functionally, deflectors according to the invention act like air scoops which direct
the flow of wind impinging upon the surface 46 so that the air moves upward along the
cone-like deflector base plate 44. The surrounding walls, e.g., the circular shaped
vertical wall 54 and a pair of adjacent plates 62, further constrain movement of the wind
so that the moving air is diverted primarily in an upward, vertical direction, to pass
through the air gaps 20 and through the upper spider unit 14. Functionally, the deflector
40 captures wind which would otherwise pass under the reactor and which would not
otherwise pass through the gaps 20 to assure that at least a portion of the wind is
directed to pass through the gaps 20.
Having observed that, under even mild wind levels, undesirable temperature
elevations can occur in reactor windings, particularly in those reactor winding layers
between the inner-most and outer-most winding layers, there has been disclosed a
deflector and a method which limit the temperature excursions of hot spots which
become prevalent under wind conditions. By directing wind, which would otherwise
pass under a reactor, upward and into air gaps between and around the winding layers,
the otherwise large temperature excursions are mitigated. For example, during wind
tests it was observed that when the temperature of the winding layer is measured at the
point along the reactor circumference facing the direction from which the wind is
traveling, the temperature excursions attributable to presence of the wind were reduced
to about the temperatures observed with no wind present and, in some portions of
winding layers, in specific segments 44,, the temperatures were reduced to below the
temperatures observed with no wind present.
One set of measurements indicated, for one particular winding layer, an
excursion under wind conditions of approximately 30 degrees C above the no wind
condition was actually reversed to 30 degrees C below the no wind condition with
installation of a deflector according to the invention. Generally, incorporation of the
deflector 40 into a reactor design can provide reductions in temperature excursions in
coil winding layers under wind conditions. Because the magnitude of such temperature
excursions can be substantially reduced, use of the deflector may be especially
beneficial in those reactors subject to steady winds for long durations of time. The
deflector can extend the lifetime of the reactors with enhanced cooling provided by the
wind.
Advantageously, the disclosed design does not require any forced flow of air for
cooling purposes but, instead, provides benefits when wind conditions arise. Further,
with the deflector base plate 44 and the circular shaped vertical baffle wall 54 providing
an opening into the reactor cavity 13, the design permits natural air circulation through
the gaps 20 and along the inner surface 42 of the inner-most winding layer 12 . The
deflector 40 provides cooling benefits which reduce thermal excursions under wind
conditions while sustaining the benefits associated with circulation of air through the
reactor in the absence of winds.
While various embodiments of the present invention have been shown and
described herein, it will be apparent that such embodiments are provided by way of
example only. For example, while the disclosed embodiments describe a deflector
located below a reactor cavity 13, the invention is not so limited. Wind deflection may
force air currents between winding layers in upward or downward directions, and a
deflector could be mounted above a reactor cavity, above the winding layers or above
an upper spider unit. Numerous other variations, changes and substitutions may be
made without departing from the invention concepts disclosed herein. Accordingly, it is
intended that the invention be limited only by the spirit and scope of the claims which
now follow.
CLAIMS
The claimed invention is:
1. An air core, dry type, power reactor of the type having multiple
concentrically positioned winding layers extending along a central axis and above arms
of a spider unit when the reactor is horizontally positioned with respect to a horizontal
ground plane, the winding layers arranged in spaced-apart relation providing air gaps
between the winding layers allowing air to flow along the winding layers, comprising:
a deflector positioned to receive air from wind blowing toward the reactor and to
guide the air in a vertical direction from the deflector and through the gaps.
2. The reactor of claim 1 wherein the deflector is positioned between the
winding layers and the ground plane.
3. The reactor of claim 1 wherein the deflector comprises a plenum including
a base plate and a plurality of vertical walls extending upward from the base plate, an
intake opening to the plenum for receiving the air and an outlet from the plenum through
which received air is directed upward toward the gaps.
4. The reactor of claim 1 wherein the deflector comprises a series of plena
integrally formed with the base plate, each of the plena extending away from the central
axis, wherein:
the series of plena is positioned around the axis; and
each of the plena is defined by a plurality of vertical walls extending upward from
the base plate, an intake opening for receiving the air and an outlet through which
received air is directed upward toward the gaps.
5. The reactor of claim 4 wherein the base plate includes a cutout through
which a leg member of the reactor extends.
6. The reactor of claim 4, wherein at least one vertical wall defines a portion
of each of two adjacent plena.
7. The reactor of claim 4, wherein each plenum comprises two vertical walls
unique to that plenum.
8. The reactor of claim 4 wherein the deflector includes a base plate
comprising a plurality of separate portions.
9. The reactor of claim 4 wherein the deflector comprises a single base plate
having an outer periphery which extends about the central axis and an inclined surface
which rises from the outer periphery toward the central axis.
10. The reactor of claim 3 wherein the base plate is frustoconical in shape.
11. The reactor of claim 3 wherein the reactor comprises an air cavity
between the central axis and an inner-most one of the winding layers, and the base
plate comprises a central opening through which air may travel from below the reactor
into the cavity.
12. The reactor of claim 11, further including a vertical plate extending about
the central opening, above the first spider unit and into the air cavity along an inner
surface of the inner-most winding layer.
13. A deflector for diverting wind in an air core, dry type reactor, the reactor
positioned above a horizontal ground plane during operation, the reactor including a first
spider unit having a series of arms radiating outward from a central axis in directions
parallel to the ground plane, and multiple cylindri cally shaped spaced-apart winding
layers concentrically positioned about the central axis and extending above the first
spider unit, there being a plurality of air gaps between the winding layers through which
air may flow from beneath the first spider unit, through the air gaps and upward with
respect to the ground plane, the deflector comprising:
a base, having an outer periphery, positioned between the first spider unit and
the ground plane so that, when wind blows in directions parallel to the ground plane, air
impinges on an upper surface of the base;
a series of plena formed on the base and arranged about the central axis, each
comprising at least one vertical plate, each vertical plate having an outer edge near the
outer periphery of the base and an upper edge, each vertical plate extending inward,
from the outer edge toward the central axis, and each vertical plate also extending
upward with the upper edge positioned along the spider arm, a combination of the base
and the outer edges of adjacent vertical plates defining a plenum intake opening
beneath the first spider unit for receiving the wind, the plena each also including an
outlet between the upper edges of the two vertical plates, wherein the outlet is in fluid
communication with an opening in the first spider unit.
14. The deflector of claim 13 further comprising a circular shaped baffle wall
positioned on the base about the central axis and extending upward from the base,
each of the vertical plates extending toward the circular shaped baffle wall, a
combination of the circular shaped baffle wall, two of the vertical plates and a portion of
the base plate between the two vertical plates defining a plenum chamber with the
outlet positioned along the circular shaped baffle wall.
15. The deflector of claim 13 wherein the base includes a cutout for receiving
therethrough a leg member of the reactor when the deflector is positioned to divert the
wind.
16. A method for modifying an air core, dry type, power reactor comprising
positioning a plenum to divert wind traveling under winding coils of the reactor into gaps
between the winding coils.
17. A plenum unit for diverting wind in an air core reactor, comprising a base
member having an upper surface suitable for deflecting wind, a baffle plate attached to
the base member and a wall member attached to the base member, the baffle plate and
the wall member each having a vertical orientation extending upward and away from a
horizontal ground plane when the base member upper surface faces away from the
ground plane after installation in the reactor, the plenum unit suitable to function with
another plenum unit, having a second baffle plate attached to a second base member,
when both plenum units are installed in the reactor to divert the wind upward and away
from the ground plane and through air gaps between winding layers in the reactor.
18. The plenum unit of claim 17 wherein the baffle plate of the claimed
plenum is a first baffle plate, the plenum further comprising an additional baffle plate
attached to the base member in spaced apart relation to the first baffle plate so that,
when the plenum unit is installed in the reactor, a combination comprising the first baffle
plate, the additional baffle plate and the base member provide for the diversion of the
wind upward and through the air gaps.
19. A system comprising the plenum unit of claim 17 and the second plenum
unit, the second plenum unit comprising the second baffle plate attached to the second
base member and a second wall member attached to the base member, the baffle plate
and the wall member each having a vertical orientation extending upward and away
from a horizontal ground plane when the base member upper surface faces away from
the ground plane after installation in the reactor, wherein each wall member includes a
surface facing away from a central axis of the reactor, and wherein:
when both plenum units are installed in the reactor a combination comprising the
base member and baffle plate and wall member of one plenum and the baffle plate of
the other plenum unit provide a path for diverting wind traveling toward the reactor
upward and through the air gaps between the reactor winding layers.
20. The system of claim 19 further including a plurality of additional plenum
units each comprising base member and baffle plate and wall member wherein, when
all of the plenum units are installed in the reactor, wind coming toward the reactor from
any direction is diverted through the air gaps.
2 1. The plenum unit of claim 17 wherein the base member includes a cutout
for receiving therethrough a leg member of the reactor when the deflector is positioned
to divert wind in the air core reactor.