Note: Descriptions are shown in the official language in which they were submitted.
MONITORED HEAT EXCHANGER SYSTEM AND RELATED
BACKGROUND
Field of the Disclosure
100011 This disclosure generally relates to a heat exchanger unit with
characteristics of
improved: airflow, noise reduction, cooling efficiency, and/or structural
integrity. In some
embodiments, the disclosure relates to a heat exchanger unit used in
connection with
equipment found in an industrial setting. Other aspects relate to a system for
monitoring
airflow through a heat exchanger unit, or fouling related thereto. In
particular embodiments,
a monitoring module is mounted externally to the heat exchanger unit of a
monitored system,
the system being usable to monitor fouling of the unit, and provide an
associated warning.
The heat exchanger unit may be used for cooling various utility fluids used
with a heat
generating device, such as an engine, a pump, or a genset. Other embodiments
pertain to a
method of monitoring fouling, a method for using a monitoring system, and a
method of
doing business.
Background of the Disclosure
100021 Whether its refrigeration, hot showers, air conditioning, and so on,
the function of
heating and cooling is prevalent in today's residential and industrial
settings. One area of
relevance is the oil and gas industry, including exploration, upstream, and
downstream
operations where the ability to heat and/or cool is critical. Upstream
operations can include
drilling, completion, and production, whereas downstream operations can
include refining
and other related hydrocarbon processing, all of which utilize a vast amount
of process
equipment including that which provide heat transfer. To be sure, the
background of the
disclosure is relevant elsewhere, but for brevity discussion is focused on
O&G.
100031 As the modern world continues to experience growth in population, it
similarly
continues to experience an increase in energy demand and consumption, and the
oil and gas
industry needs to respond accordingly. Although 'green' energy has experienced
a gain in
popularity, the dominant source of energy remains fossil fuels. Driven by
demand and high
prices for fossil fuels, the U.S. energy sector experienced a boom in the late
2000's and into
the early 2010's, contributing to expansion in exploration and production
across the country.
100041 Quite unexpectedly various global economic factors resulted in a rapid
turnaround in
demand and a decrease in profit margin that left many industry related
companies vying to
CA 2969703 2017-06-06
remain in business. This has resulted in consolidation and innovation, as the
reality of likely
never again seeing the record highs associated with the price of oil sets in.
To remain
competitive, companies have begun looking at how they can be successful and
profitable with
a margin based on an oil price in a range of about $30-$50 per barrel.
[00051 A particular segment in the upstream area of oil and gas production
pertains to
fracing. Now prevalent, fracing includes the use of a plug set in a wellbore
below or beyond
a respective target zone, followed by pumping or injecting high pressure frac
fluid into the
zone. The frac operation results in fractures or "cracks" in the formation
that allow valuable
hydrocarbons to be more readily extracted and produced by an operator, and may
be repeated
as desired or necessary until all target zones are fractured.
10061 The injection fluid, which may be mixed with chemicals, sand, acid,
etc., may be
pressurized and transported at high rate via one or more high pressure frac
pumps, typically
driven by diesel combustion engines.
[0007] Figures 1A and 1B together illustrate a conventional land-based
fracturing operation
and frac pump trailer unit. The operation 101 may include multiple frac pump
units 105.
Each unit 105 is typically operable with a pump 113 and engine 103 mounted or
otherwise
disposed thereon, and is capable of producing upwards of 15,000 psi. Suitable
units 105
include those manufactured or provided by NOV, Haliburton, Magnum,
Weatherford, and the
like.
[0008] The necessity of fracturing has progressively increased as production
rates on new
wells continue to decline. It is believed by some that at least 90 percent of
all future wells in
North America will require some degree of fracturing to increase production
results, with a
majority of these operations occurring in shale gas formations.
[0009] As demand continues to rise, producers have moved to unconventional
sources such
as the Barnett Shale, which for the first time resulted in wide reliance on
horizontal drilling,
leading to an increase on pumping pressures and operating times. Horizontal
drilling and its
associated multistage fracturing techniques are now the norm as shale
formations have
become the leading source of natural gas in North America. This harsher
pumping
environment demands stronger pumps capable of operating at extreme pressures
and
extended pumping intervals.
100101 The frac pump is now part of a pumping system (or skid unit, etc.) that
is typically
self-contained on a transportable system, such as a trailer unit 105. The
system components
2
CA 29 6 97 03 2 0 1 8-1 0-1 7
include the engine 103 and the frac pump 113, as well as a radiator (or
cooler, heat
exchanger, etc.) 100. Today's pumps are capable of producing 2500 BHP 1900
rpm while
operating in standard pressure pumping well service operations in ambient
conditions of
about 0 F to 125 F, and can provide upwards of 15,000 psi injection pressure
at a working
rate of 17 bpm. The frac pump 113 provides pressurized fluid into well(s) 191
via transfer
(injection) lines 190.
100111 But there are several drawbacks to this modern equipment. First, the
operational
requirements have driven the associated equipment to become massive in weight,
and single
trailer units sometimes exceed 80,000 lbs. Unfortunately the trailer unit 105
must comply
with federal, state, and local regulation, where a number of regulators are
starting to draw a
line on weight limitations. Permits for a job site will only be issued when
requirements are
met.
100121 Similarly, the operational requirements have driven the associated
equipment, such as
the diesel engine or radiator fan, to become huge point sources of noise
pollution. And again,
regulators arc starting to draw a line on noise. This is even more problematic
as job sites start
to encroach closer and closer to residential areas.
100131 Next, operational requirements have driven the associated equipment,
for example the
diesel engine, to become extreme generators of heat, thus requiring a larger
cooling system.
The typical radiator further adds significant weight to the trailer unit. And
as a result of
spatial constraints, the radiator 100 often lies horizontal on the bed of the
trailer unit 105, as
shown in Figure 1B. The problem with this arrangement is that as the radiator
fan 108 blows
in ambient air to cool various service fluids (F1, F2, F3, etc.), the air
becomes progressively
hot (e.g., cooling in series, where Toot > T2 > Ti > Tamb). See Figure IC.
This temperature
gradient results in ineffective cooling as the air is moved through the
radiator 100.
100141 The heat exchanger is typically used to cool by passing a hot service
fluid through the
heat exchanger along one path (or side), and passing a cooling medium through
the heat
exchanger along a second path (or side). In an air-cooled radiator, a fluid
may circulate
through the equipment and pass through the first side, and air may be drawn
through the
second side to cool the fluid before it returns to the equipment.
100151 Operational requirements have further attributed to extreme conditions
(e.g.,
temperature, pressure, vibration, etc.) that subject equipment to additional
failure modes, for
example, it has been found that leaks may occur at the joints of the
equipment.
100161 One type of heat exchanger is one that may be formed from a series of
header bars
and face bars, with plates connected between the bars to form flow paths. One
or more tanks
3
CA 2969703 2017-06-06
may be connected in fluid communication with either or both of a first and a
second path to
direct fluid flow through the respective path. In one example, in which plates
are brazed to
the header and face bars, and tanks welded to the ends of the heat exchangers,
it was found
that leaks were occurring adjacent to the header and face bars.
Kam It was found that when the header bars and face bars were small, the heat
affected
zone related to a weld between the core and the tank extended past the header
bars and face
bars and into the brazed joint between the plates and the respective bar(s).
When the weld
temperature (i.e., melting point of weld material) was greater than the
brazing temperature,
the brazing material would melt and flow away, such that the connection at
these points was
either opened, or weakened, and resulted in greater likelihood of failure
during operation.
100181 Figure 1E shows a close-up side view of part of a radiator core. A tank
177 is welded
to the core 106 at the core end 106a (i.e., the weld point). The tank 177 has
a tank end, which
has an effective tank end mass. The mass of the tank (and its end) 177 is
extensive (including
as depending on tank wall thickness Wt), and a significant amount of heat must
be applied in
order to reach the weld temperature Tw at the weld point. The temperature of
the melting
point of the weld material Tw (typically about 1200 F) is greater than the
melting point Tb
(typically about 960 F) of the brazing material between the parting sheets 172
and respective
bars 175 (e.g., header and face). As the tank end mass of the tank end (Mte)
is larger than a
core end mass of the core end (Mce), the presence of weld temperature at the
weld point
results in a heat profile P into the core 106 (which the profile P may be
parabolic).
100191 Heat at the weld point radiates along the easiest path. As the heat
profile of
temperature greater than Tb extends length 1, and is beyond the effective bar
brazing length
(or area A) 185 of the bar 175, the brazing material B (by having a melting
temperature Tb
less than weld temperature Tw) is heated and can freely flow or leach away
from the area A
between the bar 175 and the parting sheet 172. This results in the core 106
being susceptible
to failure because upon cooling the brazing is now incomplete.
100201 Another issue that reduces the structural integrity of the heat
exchanger unit is the
thermal expansion of a radiator core, particularly those made of aluminum.
Typically a core
is rigidly mounted without regard for how it might expand in application.
However, as the
core experiences expansion, it becomes prone to leaking. It was determined
that a cause of
the leaks was the impact of thermal expansion, with some large heat exchangers
expanding
by almost 1/2". As the cores are solidly brazed together and then hard mounted
(welded or
nut/bolt) to a frame, the stress from expansion caused cracking in some welds
due to
excessive load being applied to it.
4
CA 2969703 2017-06-06
100211 Thermal expansion occurs, for example, when the radiator core is
manufactured at
ambient temperature, but is generally exposed to temperatures well above
ambient during
use. As a result, the material of the core will expand. As the core is
normally rigidly
mounted to a support structure, which resisted thermal expansion, it is
believed that stresses
are induced in the heat exchanger, and that failures can occur in the welds as
a result.
100221 One or more of these concerns is just as valid to non-oilfield related
heat exchangers.
Figure ID illustrates a simple schematic overview of a heat generation device
(HGD) 103a
used in a general industrial operation or setting 101a. The operation or
setting 101a may be a
construction site, a building, a water treatment plant, a manufacturing
facility, or any other
setting whereby a heat exchanger 100a is used for heat transfer, such as to
cool (or heat) a
utility fluid F that is used with the HGD 103a. The operation of a fan 108
results in an
undesirable noise characterized by an acoustic frequency f with amplitude Al,
which his
readily discernable to an operator.
100231 In an analogous manner HGD's associated with a residential setting may
also have
similar concerns. In other aspects, it is becoming more and more common that
an industrial
setting or operation is adjacent or proximate to a residential setting.
100241 Common settings are nothing short of challenging in the sense that in
many instances
operations and processes (and related equipment) are exposed to environmental
conditions,
such as extreme heat, cold, wind, and dust (including natural amounts of
particulate, as well
as that caused by the operation of equipment and vehicles).
100251 It is routine to have (indeed, need) some type of heat exchange ability
in such settings.
As set forth in US S/1\1 15/477,097, an example operation in an industrial
setting may include
one or more frac pump units. Each unit is typically operable with a pump and
engine
mounted or otherwise disposed thereon, as well as a radiator (or analogously
referred to as
cooler, heat exchanger, etc.). As mentioned before, equipment like this must
be rugged and
durable in order to have long-term operational capacity and effectiveness.
100261 The radiator is configured for cooling one or more hot service fluids
associated with
the equipment of the frac pump unit, such as lube oil or jacket water. The
radiator typically
includes a 'core' of stacked fins, with one part of the core providing a flow
are for the service
fluid(s), while another part of the core is provides a proximate, albeit
separate, flow area for
ambient air. A fan is used to blow or pull air through the stacked fins, the
air being a low or
moderate enough temperature to cool the service fluid, which is then
recirculated in a loop.
100271 The stacked fins often have a configuration that is tantamount to an
extensive amount
of small air passageways proximate to (albeit separate from) service fluid
passageways,
CA 2969703 2017-06-06
whereby the air and the service fluid can 'exchange heat' via the surface
material of the
stacked fins between the passageways (e.g., aluminum).
[0028] Over time airborne dirt in and other particulate in the air will begin
to deposit on the
air intake side (and elsewhere), resulting in a fouled radiator. Fouling can
seriously
deteriorate the capacity of the surface of the fins to transfer heat under the
conditions for
which they were designed. Among other problems, the fouling layer has a low
thermal
conductivity which increases the resistance to heat transfer and reduces the
effectiveness of
heat exchangers. In addition, fouling reduces the cross-sectional area in the
passageways,
which causes an increase in pressure drop across a heat exchanger.
[0029] Radiator fouling affects both capital and operating costs of heat
exchangers (and
overall processes). Higher capital expenditures include that for excess
surface area (for heat
transfer), extra space, and transport and installation costs. Operating
expenditures include
that for energy losses due to the decrease in thermal efficiency, increases in
the pressure drop
through process equipment, and production losses during planned and unplanned
plant
shutdowns for fouling cleaning.
[0030] Moreover, government emissions regulations are forcing engine
manufacturers and
their customers to reduce emissions from reciprocating engines. Current
solutions involve
returning the exhaust through heat exchange, which elevates combustion
temperature and
puts significantly more heat into the cooling system. Tier 4 Final (US and CA)
Emission
regulations come into effect in 2017 & 2020 will force end users into
significant equipment
redesign industry wide.
[0031] In summary, fouling of heat transfer surfaces is one of the most
important problems in
heat transfer equipment. Some have described fouling as the major unresolved
problem in
heat transfer. Equipment operators world-wide are also trying to reduce
maintenance costs.
One of the highest maintenance costs any piece of equipment has is cooling
system
maintenance.
[0032] And yet despite these detriments, consideration of improved remediation
or
management techniques have been largely ignored and unchanged. Conventional
techniques
include mitigation (such as upstream filtering) and chemical treatment.
[0033] Mechanical cleaning is also used, but only during predetermined
periodic intervals,
namely during a planned shutdown or when an exchanger reaches a point of
failure and is no
longer operable. This approach relies on extensive cost and resource being
allocated toward
the antiquated philosophy of operational redundancy.
6
CA 2969703 2018-10-17
100341 There is a need in the art to overcome deficiencies and defects
identified herein.
There is a need in the art to reliably monitor fouling of a radiator. There is
a need in the art to
provide a real-time warning indication about fouling conditions of a radiator.
100351 There is a need in the art for a monitoring system that is durable for
use in outdoor
and other difficult environmental conditions. There is a need in the art for a
monitoring
system capable of high degree of sensing accuracy, yet impervious to or
otherwise able to
withstand external conditions.
100361 There is a need in the art for a method of doing business that includes
monitoring and
servicing of radiators, especially when the radiator reaches various stages of
fouling or
provides other indication requiring attention. There is a need in the art to
clean a fouled
radiator with little or no downtime.
100371 There is a need in the art for a monitoring module that can be
retrofitted to any
existing heat exchanger, including of great importance to a heat exchanger
that has one or
more sides (or surfaces) exposed to ambient air.
100381 There is a particular need in the art for a monitoring system that is
readily adaptable
and compatible to radiators associated with different pieces of heat
generating equipment,
such as an engine, a motor, a pump, or a genset useable in a wide range of
settings.
100391 There is a need in the art to overcome deficiencies and defects
identified herein.
There is a particular need in the art for a heat exchanger that is readily
adaptable and
compatible to different pieces of heat generating equipment, such as an
engine, a motor, a
pump, or a genset useable in a wide range of settings.
100401 There is a need in the art to be able to reduce pressure drop, whereby
airflow through
a heat exchanger can be streamlined and increased. There is a need to reduce
sound emission
from a heat exchanger so that it may satisfy regulatory limitations or be
suitable for use in or
proximate to a residential setting.
100411 There is a need in the art for a heat exchanger that can accommodate
spatial
constraints, and is lighter in weight. There is a need in the art for a heat
exchanger that has
improved or reduced sound emissions. There is a need in the art for a heat
exchanger that
improves cooling efficiency. There is a need in the art for a heat exchanger
with improved
structural integrity, including the ability to withstand or tolerate thermal
expansion and hot
welding temperatures.
7
CA 2969703 2017-06-06
SUMMARY
100421 Embodiments of the disclosure pertain to a monitored heat exchanger
system that may
include a heat exchanger unit in operable engagement with a heat generating
device. There
may be at least one service fluid being transferable therebetween. The heat
exchanger unit
may further have a frame; and at least one cooler coupled with the frame. The
at least one
cooler may have an airflow side and a service fluid side.
100431 The system may include the use of a monitoring module coupled to the
heat
exchanger unit. The monitoring module may include: a cover panel; an at least
one sensor
coupled with the cover panel; at least one controller housing coupled with the
cover panel;
and a microcontroller disposed within the controller housing and in operable
communication
with the at least one sensor. The at least one sensor may have a rotating
member configured
to generate a system signal proportional to an amount of rotation of the
rotating member.
The microcontroller may be provided with computer instructions for processing
the system
signal.
100441 In aspects, the monitoring module may include a plurality of sensors,
with each of the
plurality of sensors in operable communication with the microcontroller. At
least one of the
plurality of sensors or the microcontroller may be powered at least partially
by rotation of the
rotating member.
100451 The at least one sensor may include a plurality of blades radially
extending from the
rotating member. The system signal may pertain to an amount of fouling
associated with the
airflow side of the at least one cooler.
100461 The monitoring module may include any of: a solid data storage, a Wi-Fl
module, a
GSM module, and a CAN-Bus module being disposed within the controller housing
and in
operable communication with the microcontroller. The microcontroller may be
provided
with computer instructions for communicating with one or more of the solid
data storage, the
Wi-Fi module, the GSM module, and the CAN-Bus module.
100471 The at least one service fluid may include one of lube oil, hydraulic
fluid, fuel, charge
air, transmission fluid, jacket water, and engine cooler.
100481 The heat generation device may be a diesel engine. The heat exchanger
unit may
have about four sides. Any of the sides may have a respective cooler mounted
to the frame.
100491 Other embodiments of the disclosure pertain to a monitored heat
exchanger system
that may include a heat exchanger unit in operable engagement with a heat
generating device.
There may be at least one service fluid being transferable directly or
indirectly therebetween.
The heat exchanger unit may have: a frame; and at least one cooler coupled
with the frame.
8
CA 2969703 2017-06-06
The at least one cooler having an airflow side and a service fluid side
fluidly separated from
each other.
100501 There may be a monitoring module coupled to the heat exchanger unit.
The
monitoring module may include: a cover panel; an at least one sensor coupled
with the cover
panel, and being positioned proximate to the airflow side. The module may
include at least
one controller housing coupled with the cover panel. There may be a
microcontroller
disposed within the controller housing and in operable communication with the
at least one
sensor. The at least one sensor may include a rotating member configured to
generate a
system signal proportional to an amount of rotation of the rotating member.
The
microcontroller may be provided with computer instructions for processing the
system signal.
The amount of rotation may be dependent upon an amount of fouling in the
airflow side.
100511 The monitoring module may include the use of a plurality of sensors.
Any of the
plurality of sensors may be in operable communication with the
microcontroller. In aspects,
at least one of the plurality of sensors or the microcontroller may be powered
at least
partially, directly or indirectly, by rotation of the rotating member.
100521 The monitoring module may include one or more of a solid data storage,
a Wi-Fl
module, a GSM module, and a CAN-Bus module, any of which may be disposed
within the
controller housing and in operable communication with the microcontroller. The
microcontroller is provided with computer instructions for communicating with
one or more
of the solid data storage, the Wi-H module, the GSM module, and the CAN-Bus
module.
100531 The at least one service fluid may one of lube oil, hydraulic fluid,
fuel, charge air,
transmission fluid, jacket water, and engine cooler. In aspects, there may be
a plurality of
service fluids transferrable therebetween. The generation device may be a
diesel engine. The
heat exchanger unit may include about four sides. One or more sides may have a
respective
cooler mounted to the frame, and wherein each of the four sides is operably
associated with a
respective monitoring module.
100541 Embodiments of the disclosure pertain to a method for monitoring a heat
exchanger
unit that may include the steps of coupling the heat exchanger unit with a
heat generating
device; associating a monitoring module with an airflow side of the heat
exchanger unit;
operating the monitoring module whereby a microcontroller operably associated
therewith
performs various tasks, including providing an indication; and taking an
action based on the
indication.
100551 The monitoring module of the method may include an at least one sensor
proximate to
the airflow side. The at least one sensor may have a respective rotating
member. The module
9
CA 2969703 2017-06-06
may include a logic circuit in operable communication with the at least one
sensor. The logic
circuit may include the microcontroller.
100561 Tasks performable by the microcontroller include: acquiring a set of
data from the at
least one sensor; sampling the set of data over a predetermined period of
time, and computing
an average and a standard deviation; comparing the standard deviation with
predetermined
data stored on a data storage; determining whether the set of data is
acceptable within a
defined parameter; determining whether a first lookup table comprising a set
of lookup data
has been completed, and creating the first lookup table using an averaging
method if it has
not; comparing the set of data to the set of lookup data; and providing the
indication based on
a result of the comparing the set of data to the set of lookup data step.
100571 In aspects, the microcontroller may be powered at least partially,
directly or
indirectly, by at the at least one sensor. The indication may be communicated
to an end user
by way of at least one of a text message, an email, an audio signal, display,
a visual
indicator, and combinations thereof. In aspects, the indication may be related
to an amount of
fouling present within the heat exchanger unit, particularly the airflow side.
100581 The monitoring module may include a plurality of sensors. One or more
of the
plurality of sensors may be in operable communication with the
microcontroller. The
indication may pertain to an amount of fouling associated with the airflow
side of the heat
exchanger unit.
100591 The monitoring module may include one or more of a solid data storage,
a Wi-Fi
module, a GSM module, and a CAN-Bus module being disposed within the
controller
housing and in operable communication with the microcontroller. The
microcontroller may
be provided with computer instructions for communicating with one or more of
the solid data
storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
100601 Other embodiments of the disclosure pertain to a method of doing
business that may
include the steps of: entering into a transaction with a first recipient; per
terms of the
transaction, operably associating a monitoring module with a heat exchanger
unit, the
monitoring module being configured and operable to monitor a condition of the
heat
exchanger unit; providing information to the first recipient about an
indication received from
the monitoring module related to the condition; and performing an action on
the heat
exchanger unit upon based on the indication.
100611 The transaction may include terms pertaining to at least one of:
equipment purchase,
installation, software license, data sharing, cleaning service, and
combinations thereof.
100621 The condition may pertain to fouling of an airflow side of the heat
exchanger unit.
CA 2969703 2017-06-06
100631 The monitoring module of the method may include a plurality of sensors
mounted
proximate to the airflow side of the heat exchanger unit. One or more of the
sensors may
have a rotating member with a plurality of blades extending therefrom. The
module may
include a logic circuit in operable communication with the plurality of
sensors.
100641 The transaction may pertain to the logic circuit having a
microcontroller in operable
communication with the plurality of sensors. In aspects, the transaction may
tertian to use of
the microcontroller being programmed with and having computer instructions for
performing
the tasks of: acquiring a set of data from at least one of the plurality of
sensors; sampling the
set of data over a predetermined period of time, and computing an average and
a standard
deviation; comparing the standard deviation with predetermined data;
determining whether
the set of data is acceptable within a defined parameter; determining whether
a first lookup
table comprising a set of lookup data has been completed, and creating the
first lookup table
using an averaging method if it has not; comparing the set of data to the set
of lookup data:
and providing the indication based on a result of the comparing the set of
data to the set of
lookup data step.
100651 The transaction may include a one-time or ongoing fee associated with
the use and
operation of the monitoring module.
100661 The method of doing business may include the step of providing an
incentive to the
recipient when the transaction pertains to at least two of: equipment
purchase, installation,
software license, data sharing, and cleaning service. The incentive may be a
reduction in
cost.
100671 The monitoring module may include each of a solid data storage, a Wi-Fi
module, a
GSM module, and a CAN-Bus module being disposed within the controller housing
and in
operable communication with the microcontroller. Thus, the microcontroller may
be
provided with computer instructions for communicating with one or more of the
solid data
storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
100681 There may be an at least one service fluid transferable between the
heat exchanger
unit and a heat generation device coupled in fluid communication therewith.
The at least one
service fluid may be one of lube oil, hydraulic fluid, fuel, charge air,
transmission fluid,
jacket water, and engine cooler. the heat generation device may be a diesel
engine. The heat
exchanger unit may have about sides. One or more sides may have a cooler
proximately
mounted to the frame.
100691 These and other embodiments, features and advantages will be apparent
in the
following detailed description and drawings.
11
CA 2969703 2017-06-06
BRIEF DESCRIPTION OF THE DRAWINGS
100701 A full understanding of embodiments disclosed herein is obtained from
the detailed
description of the disclosure presented herein below, and the accompanying
drawings, which
are given by way of illustration only and are not intended to be limitative of
the present
embodiments, and wherein:
100711 Figure lA shows an overview process diagram of a conventional land-
based
fracturing operation;
100721 Figure IB shows a side view of a frac pump truck;
100731 Figure IC shows a close-up profile view of a horizontal heat exchanger
useable with
the frac pump truck of Figure 1B;
100741 Figure ID shows a simple schematic view of a heat exchanger used with a
heat
generation device in a general industrial setting;
100751 Figure lE shows a close-up side view of a typical temperature profile
when a tank is
welded to a radiator core;
100761 Figure 2A shows a side view of a heat exchanger unit coupled with a
heat generation
device according to embodiments of the disclosure;
100771 Figure 2B shows an isometric view of a frame of the heat exchanger unit
according to
embodiments of the disclosure;
100781 Figure 2C shows a side cross-sectional view of an HX unit configured
with a
plurality of baffles according to embodiments of the disclosure;
100791 Figure 2D shows an isometric view of a set of a plurality of baffles
according to
embodiments of the disclosure;
100801 Figure 2E shows a close-up partial side view of a baffle coupled to a
vertical member
according to embodiments of the disclosure;
100811 Figure 3A shows an isometric view of a baffle according to embodiments
of the
disclosure;
100821 Figure 3B shows a lateral cross-sectional view of a baffle according to
embodiments of
the disclosure;
100831 Figure 4A shows an isometric partial view of a radiator core according
to
embodiments of the disclosure;
100841 Figure 4B shows a partial close-up downward view of an end of a
radiator cooler
having a tank and a core according to embodiments of the disclosure:
100851 Figure 4C shows a view of a tank welded to a core according to
embodiments of the
disclosure;
12
CA 2969703 2017-06-06
100861 Figure 5A shows a close-up view of a radiator core mounted to a frame
of a heat
exchanger unit according to embodiments of the disclosure;
100871 Figure 5B shows a component breakout view of a flexible mount assembly
according
to embodiments of the disclosure;
100881 Figure 5C shows a partial side cross-sectional view of a flexible mount
assembly
used with a bracket and a frame of a heat exchanger unit assembly according to
embodiments
of the disclosure;
100891 Figure 5D shows a component breakout view of another flexible mount
assembly
according to embodiments of the disclosure:
100901 Figure 5E shows a partial side cross-sectional view of the flexible
mount assembly of
Figure 5D used with a core a heat exchanger unit according to embodiments of
the
disclosure;
100911 Figure 5F shows a close-up view of a flex mount assembly used for
coupling various
components of a heat exchanger unit according to embodiments of the
disclosure;
100921 Figure 6A shows a downward looking isometric view of a top region of a
heat
exchanger unit according to embodiments of the disclosure;
100931 Figure 6B shows an isometric view of a fan mount according to
embodiments of the
disclosure;
100941 Figure 7A shows an isometric view of a monitored heat exchanger system
that includes
a monitoring module, a heat exchanger unit, and a heat generation device
operably coupled
together according to embodiments of the disclosure;
100951 Figure 7B shows an isometric view of a frame of the heat exchanger unit
according to
embodiments of the disclosure;
100961 Figure 7C shows a component breakout view of a controller housing
usable with a
monitoring module, and having various internal components according to
embodiments of the
disclosure;
100971 Figure 8A shows a logic circuit process flow diagram according to
embodiments of the
disclosure;
100981 Figure 8B shows a logic circuit decision tree operable as part of a
monitoring module
according to embodiments of the disclosure; and
100991 Figure 9 shows a side view of a monitored heat exchanger system that
includes a
monitoring module, a four-sided heat exchanger, and a heat generating device
coupled
together according to embodiments of the disclosure.
13
CA 2969703 2017-06-06
DETAILED DESCRIPTION
1001001 Herein disclosed are novel apparatuses, systems, and methods that
pertain to an
improved heat exchanger, details of which are described herein.
1001011 Embodiments of the present disclosure are described in detail with
reference to the
accompanying Figures. In the following discussion and in the claims, the terms
"including"
and "comprising" are used in an open-ended fashion, such as to mean, for
example,
, "including, but not limited to...". While the disclosure may be described
with reference to
relevant apparatuses, systems, and methods, it should be understood that the
disclosure is not
limited to the specific embodiments shown or described. Rather, one skilled in
the art will ,
appreciate that a variety of configurations may be implemented in accordance
with
embodiments herein. -
1001021 Although not necessary, like elements in the various figures may be
denoted by like
reference numerals for consistency and ease of understanding. Numerous
specific details are
set forth in order to provide a more thorough understanding of the disclosure;
however, it will
be apparent to one of ordinary skill in the art that the embodiments disclosed
herein may be
practiced without these specific details. In other instances, well-known
features have not
been described in detail to avoid unnecessarily complicating the description.
Directional
terms, such as "above," "below," "upper," "lower," "front," "back," "right",
"left", "down",
etc., are used for convenience and to refer to general direction and/or
orientation, and are only
intended for illustrative purposes only, and not to limit the disclosure.
1001031 Connection(s), couplings, or other forms of contact between parts,
components, and
so forth may include conventional items, such as lubricant, additional sealing
materials, such
as a gasket between flanges, PTFE between threads, and the like. The make and
manufacture
of any particular component, subcomponent, etc., may be as would be apparent
to one of skill
in the art, such as molding, forming, press extrusion, machining, or additive
manufacturing.
Embodiments of the disclosure provide for one or more components to be new,
used, and/or
retrofitted to existing machines and systems.
Terms
1001041 The term "noise" as used herein can refer to a sound, including an
undesirous sound.
1001051 The term "sound" as used herein can refer to a vibration(s) that
travels through the air
or another medium, and can be detectable or discernable to the human ear or an
instrument.
Sound can be referred to as a pressure wave resulting in pressure variations.
A loud noise
usually has a larger pressure variation and a weak one has smaller pressure
variation. The
14
CA 2969703 2017-06-06
more readily referred to measurement of loudness of sound is a logarithmic
scale of Pascals,
the decibel (dB). Sound and noise can be interchangeable, or have comparable
meaning.
1001061 The term "noise absorbing material" as used herein can refer to a
material having a
physical characteristic of being able to reduce amplitude of a noise or sound.
That is, reduce
a pressure variation. 'Noise absorbing' can be interchangeable to noise
reduction, noise
absorbent, abatement by absorbing, and so forth. The material can be a fibrous
material, such
as mineral wool.
1001071 The term "noise barrier" can refer to a material or component capable
of stopping
noise from passing therethrough. In aspects, a noise barrier material can be
adhered (such as
glued) to a component. The noise barrier material can be vinyl.
1001081 The term "frequency" as used herein can refer to the rate at which a
vibration (of a
respective sound) occurs over a period of time. The number of pressure
variations per second
is called the frequency of sound, and is measured in Hertz (11z) which is
defined as cycles per
second. The higher the frequency, the more high-pitched a sound is perceived.
1001091 The term "dominant acoustic frequency" can refer to a respective sound
that is most
discernable or noticeable to a human ear or instrument.
1001101 The term "engine" as used herein can refer to a machine with moving
parts that
converts power into motion, such as rotary motion. The engine can be powered
by a source,
such as internal combustion.
1001111 The term "motor" as used herein can be analogous to engine. The motor
can be
powered by a source, such as electricity, pneumatic, or hydraulic.
(001121 The term "drive" (or drive shaft) as used herein can refer to a
mechanism that controls
or imparts rotation of a motor(s) or engine(s).
1001131 The term "pump" as used herein can refer to a mechanical device
suitable to use an
action such as suction or pressure to raise or move liquids, compress gases,
and so forth.
'Pump' can further refer to or include all necessary subcomponents operable
together, such as
impeller (or vanes, etc.), housing, drive shaft, bearings, etc. Although not
always the case,
'pump' can further include reference to a driver, such as an engine and drive
shaft. Types of
pumps include gas powered, hydraulic, pneumatic, and electrical.
1001141 The term "frac pump" as used herein can refer to a pump that is usable
with a frac
operation, including being able to provide high pressure injection of a slurry
into a wellbore.
The frac pump can be operable in connection with a motor or engine. In some
instances, and
for brevity, 'frac pump' can refer to the combination of a pump and a driver
together.
CA 2969703 2017-06-06
1001151 The term "frac truck" as used herein can refer to a truck (or truck
and trailer) useable
to transport various equipment related to a frac operation, such as a frac
pump and engine,
and a radiator.
1001161 The term "frac operation" as used herein can refer to fractionation of
a downhole well
that has already been drilled. 'Frac operation' can also be referred to and
interchangeable
with the terms fractionation, hydrofracturing, hydrofracking, fracking,
fracing, and frac. A
frac operation can be land or water based.
1001171 The term "radiator" can also be referred to or interchangeable with
the term 'heat
exchanger' or 'heat exchanger panel'. The radiator can be a heat exchanger
used to transfer
thermal energy from one medium to another for the purpose of cooling and/or
heating.
1001181 The term "cooler" as used herein can refer to a radiator made up of
tubes or other
structure surrounded by fins (or 'core') that can be configured to extract
heat from a fluid
moved through the cooler. The term can be interchangeable with 'heat exchanger
panel' or
comparable. Heat can also be exchanged to another fluid, such as air.
1001101 The term "cooling circuit" as used herein can refer to a cooler and
respective
components.
1001201 The term "core" as used herein can refer to part of a cooler, and can
include multiple
layers of fins or fin elements.
1001211 The term "heat exchanger unit" as used herein can refer to a device or
configuration
that uses multiple coolers along with other components, such as a fan, mounts,
tubing, frame,
and so on. The heat exchanger unit can be independent and standalone or can be
directly
mounted to a heat generating device. The heat exchanger unit can be operable
to pull (draw)
ambient air in through the coolers in order to cool one or more service
fluids. The heated air
is moved or blown out as a waste exhaust stream.
1001221 The term "heat generating device" (or sometimes `1-1GD') as used
herein can refer to
an operable device, machine, etc. that emits or otherwise generates heat
during its operation,
such as an engine, motor, a genset, or a frac pump (including the pump and/or
respective
engine). The EIGD can be for an industrial or a residential setting.
1001231 The term "genset" (or generator set) as used herein can refer to a
'diesel generator' or
the combination of a diesel engine (or comparable) and an electric generator.
The genset can
convert the mechanical energy to electrical energy.
1001241 The term "utility fluid" as used herein can refer to a fluid used in
connection with the
operation of a heat generating device, such as a lubricant or water. The
utility fluid can be for
16
CA 2969703 2017-06-06
heating, cooling, lubricating, or other type of utility. 'Utility fluid' can
also be referred to and
interchangeable with 'service fluid' or comparable.
1001251 The term "mesh" as used herein can refer to a material made of a
network of wire or
thread, or an interlaced/interconnected structure.
1001261 The term "brazed" as used herein can refer to the process of joining
two metals by
heating and melting a filler (alloy) that bonds the two pieces of metal and
joins them. The
filler may have a melting temperature below that of the two metal pieces.
1001271 The term "welded" as used herein can refer to a process that uses high
temperatures to
melt and join two metal parts, which are typically the same. Such a process
can refer to
different types of welding, including TIG weld, metal inert gas (M1G), arc,
electron beam,
laser, and stir friction.
1001281 The term "deformable" as used herein can refer to an ability for a
material to
experience a change in shape from an original shape, such as from a force, and
then
substantially return to the original shape.
1001291 The term "effective mass" as used herein can refer to the mass of part
of a component,
or partial mass of the component. For example, a core may have a core end, and
the core end
may have an effective mass, or a core end mass. The mass of the core end is
less than the
mass of the whole core.
1001301 The term "mounted" as used herein can refer to a connection between a
respective
component (or subcomponent) and another component (or another subcomponent),
which can
be fixed, movable, direct, indirect, and analogous to engaged, coupled,
disposed, etc., and can
be by screw, nut/bolt, weld, and so forth.
1001311 The term "sensor" as used herein can refer to a device that detects or
measures a
physical property and records, indicates, or otherwise responds to it. The
output of a sensor
can be an analog or digital signal.
1001321 The term "airflow sensor" as used herein can refer to a sensor used to
detect or
otherwise be able to measure (directly or indirectly) airflow.
1001331 The term "microprocessor" as used herein can refer to a logic chip or
a computer
processor on a microchip. The microprocessor may have most or all central
processing unit
(CPU) functions.
1001341 The term "microcontroller" as used herein can refer to a CPU with
additional function
or structure, such as RAM, ROM, and or peripherals like I/O all embedded on a
single chip.
1001351 The term "voltage regulator" as used herein can refer to a device or
logic circuit that
maintains a constant voltage level.
17
CA 2969703 2017-06-06
1001361 The term "computer readable medium" (CRM) as used herein can refer to
any type of
medium that can store programming for use by or in connection with an
instruction execution
system, apparatus, or device. The CRM may be, for example, a device,
apparatus, or system
based on electronic, magnetic, optical, electromagnetic, or semiconductor
function. By way
of further example, the CRM may include an electrical connection (electronic)
having one or
more wires, a portable computer diskette (magnetic or optical), a random
access memory
(RAM) (electronic), a read-only memory (ROM) (electronic), an erasable
programmable
read-only memory (EPROM, EEPROM, or Flash memory) (electronic), an optical
fiber
(optical), and a portable compact disc memory (CDROM, CD R/W) (optical).
1001371 The term "solid data storage" as used herein can refer to a CRM having
an array of
data, including one or more lookup tables (LUT).
1001381 The term "lookup table" (or LUT) as used herein can refer to a data
array that may
include predetermined or reference data useable for comparison. A LUT(s) can
be stored in
static program storage, including solid data storage.
1001391 The term "Wi-Fl module" as used herein can refer to a device or logic
circuit that
provides ability for a microcontroller to communicate data to a network, as
well as update
firmware and code inside the microcontroller.
1001401 The term "GSM module" as used herein can refer to a device or logic
circuit that
provides ability for a microcontroller to communicate data or signal to a
Global System for
Mobile communication (GSM). The microcontroller can thus initiate, for
example, the
sending of information in a SMS message.
1001411 The term "CAN-Bus module" as used herein can refer to a message-based
protocol
that allows a microcontroller to communicate with other devices, which can
include industrial
or large pieces of equipment associated with a respective microcontroller.
1001421 Embodiments herein pertain to a monitored heat exchanger system that
may include a
heat exchanger unit in operable engagement with a heat generating device, with
an at least
one service fluid being transferable therebetween. The I IX unit may include a
frame; and at
least one cooler coupled with the frame, the at least one cooler having an
airflow-in side and
a service fluid-in side.
1001431 The system may include a monitoring module coupled to the heat
exchanger unit.
The monitoring module may include a panel (or cover panel); an at least one
sensor coupled
with the cover panel; an at least one controller housing coupled with the
cover panel; and a
microcontroller disposed within the controller housing and in operable
communication with
the at least one sensor.
18
CA 2969703 2017-06-06
1001441 The at least one sensor may include a rotating member configured to
generate a
system signal proportional to an amount of rotation of the rotating member. In
aspects, the
microcontroller may be provided with computer instructions, and may be
otherwise operable,
for processing the system signal.
1001451 The monitoring module may include a plurality of sensors. One or more
of the
plurality of sensors may be in operable communication with the
microcontroller. In aspects,
at least one of the plurality of sensors or the microcontroller may be powered
at least
partially, directly or indirectly, by rotation of the rotating member.
1001461 The at least one sensor may include a plurality of blades extending
(such as generally
radially) from the rotating member. The system signal may pertain to or be
based on an
amount of fouling associated with the airflow side of the at least one cooler.
1001471 The monitoring module may include one or more of a solid data storage,
a Wi-Fi
module, a GSM module, and a CAN-Bus module. Each may be disposed within the
controller housing and may be in operable communication with the
microcontroller.
Accordingly, the the microcontroller may be provided with computer
instructions for
communicating with one or more of the solid data storage, the Wi-Fi module,
the GSM
module, and the CAN-Bus module.
1001481 The at least one service fluid comprises one of lube oil, hydraulic
fluid, fuel, charge
air, transmission fluid, jacket water, and engine cooler. The heat generation
device may be a
diesel engine. In aspects, the heat exchanger unit may have four respective
sides (and thus
cubical or rectangular prism shaped). Each side may have a respective cooler
mounted to the
frame.
1001491 The heat exchanger unit may include a vertical axis; a frame
comprising a top region,
a bottom region, and a plurality of side regions; a plurality of coolers, each
of the plurality of
coolers coupled with the frame proximate to a respective side region of the
plurality of side
regions. Each of the plurality of coolers may have an outer surface and an
inner surface.
There may be an airflow region within the heat exchanger unit.
1001501 The heat exchanger unit may include a first set of baffles disposed
therein. One or
more of the first set of baffles may be configured or otherwise oriented at a
first angle to the
vertical axis.
1001511 The heat exchanger unit may include a second set of baffles disposed
therein, each
baffle of the second set of baffles configured at a second angle to the
vertical axis. The heat
exchanger unit may include a third set of baffles, each baffle of the third
set of baffles
19
CA 2969703 2017-06-06
configured at a third angle to the vertical axis. In aspects, the heat
exchanger unit may
include a fourth set of panels.
1001521 The first sct of baffles, the second set of baffles, and the third set
of baffles may have
about three to about five baffles. One or more baffle of the first set of
baffles, the second set
of baffles, and/or the third set of baffles may include a sound absorbing
material.
1001531 One or more baffles may be generally isosceles trapezoidal in shape.
On or more
baffles may have mineral wool disposed therein. One or more baffles may be
configured
(positioned, mounted, oriented, etc.) at a respective angle in the range of
about 30 to about 60
degrees.
1001541 The heat exchanger unit may include a fan mount bar; a shroud coupled
to a top
surface; an aeroring; and a fan mounted to the fan mount bar. The fan may have
a motor and
a one or more fan blades, including in the range of about 8 to about 12. The
heat exchanger
unit may have an exhaust outlet.
1001551 The heat exchanger unit may have a plurality of coolers configured to
permit airflow
to pass therethrough. In aspects, operation of a fan may result in airflow
through each of the
plurality of coolers, into the airflow region, and out of the outlet. The
frame of the heat
exchanger unit may include a plurality of horizontal members and vertical
member
configured together in a manner that results in a generally cube-shaped frame.
1001561 The heat exchanger unit of the system may include other
configurations, such as a
frame comprising a top region, a bottom region, and plurality of side regions;
a plurality of
coolers, each of the plurality of coolers coupled with the frame proximate to
a respective side
region, and each of the plurality of coolers comprising a core welded with a
tank. Each core
further may include a core end having a core end mass. Each tank further may
include a tank
end having a tank end mass. In aspects, each core end mass may be greater than
each
respective tank end mass.
1001571 The heat exchanger system may include the HX unit having a frame with
a top region,
a bottom region, and an at least one side region. There may be at least one
cooler coupled
with the frame proximate to the at least one side region. The cooler may have
an outer
surface and an inner surface.
1001581 The system may include the use of a mount assembly for coupling a
cooler to the
frame of the HX unit. The mount assembly may include an elongated fastening
member; a
rigid outer ring; a rigid inner ring; and a deformable ring disposed between
the rigid outer
ring and the inner outer ring,
CA 2969703 2017-06-06
1001591 At least one cooler may include a mounting slot. In aspects, the
elongated fastening
member may extend through the rigid inner ring and at least partially into the
frame.
1001601 Other embodiments of the disclosure pertain to a monitored heat
exchanger system
that may include a heat exchanger unit in operable engagement (including fluid
communication) with a heat generating device. There may be an at least one
service fluid
transferable therebetvveen. The heat exchanger unit may include a frame; and
at least one
cooler coupled with the frame, the at least one cooler having an airflow side
and a service
fluid side fluidly separated from each other.
1001611 The monitored system may include a monitoring module coupled to the
heat
exchanger unit. The monitoring module may include a cover panel; an at least
one sensor
coupled with the cover panel; at least one controller housing proximate with
the cover panel;
and a microcontroller mountingly disposed within the controller housing and in
operable
communication with the at least one sensor.
1001621 The at least one sensor may include a rotating member configured to
generate a
system signal proportional to an amount of rotation of the rotating member.
The
microcontroller may be provided with computer instructions for processing the
system signal.
In aspects, an amount of rotation of the rotating member maybe dependent upon
an amount of
fouling in the airflow side.
1001631 The monitoring module may include a plurality of sensors. One or more
of the
plurality of sensors may be in operable communication with the
microcontroller. In aspects,
at least one of the plurality of sensors or the microcontroller may be powered
at least
partially, directly or indirectly, by rotation of the rotating member.
1001641 The monitoring module may include one or more of a solid data storage,
a Wi-Fl
module, a GSM module, and a CAN-Bus module. Any of which may be mountingly
disposed within the controller housing and may be in operable communication
with the
microcontroller. Accordingly, the microcontroller may be provided with
computer
instructions for communicating and otherwise operating with with one or more
of the solid
data storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
1001651 The at least one service fluid may be one of lube oil, hydraulic
fluid, fuel, charge air,
transmission fluid, jacket water, and engine cooler. The heat generation
device may be a
diesel engine. The heat exchanger unit may have a plurality of sides, such as
about three
sides to about five sides. In aspects, there may be four sides. Any of the
sides may have a
respective cooler mounted to the frame proximate thereto. Any of the sides may
have a
respective monitoring module operably associated therewith.
21
CA 2969703 2017-06-06
1001661 The heat exchanger unit of the monitored system may include a frame
having a top
region, a bottom region, and plurality of side regions; a plurality of
coolers, each of the
plurality of coolers coupled with the frame proximate to a respective side
region, and each of
the plurality of coolers comprising a core welded with a tank; and a first set
of baffles, each
baffle of the first set of baffles configured at a first angle to an axis.
1001671 In aspects, one or more cores may have a core end having a core end
mass. In
aspects, one or more tanks may have a tank end having a tank end mass. In
aspects, the core
end mass may be greater than the tank end mass of a respective core.
1001681 The heat exchanger unit may include a second set of baffles, each
baffle of the second
set of baffles configured at a second angle to the axis. Any of the baffles
may have a sound
absorbing material therein. The first angle and/or the second angle may be in
the range of
about 30 degrees to about 60 degrees. The sound absorbing material may be
mineral wool.
1001691 The heat exchanger unit of the system may include a frame comprising a
top region, a
bottom region, and one or more side regions. There may be one or more coolers
coupled with
the frame proximate to a respective side region. Any cooler may have a core
welded with a
tank. The unit may include a first set of baffles, any of which may be
configured at a first
angle to an axis. Any core may include a core end having a core end mass. Any
tank may
have a tank end having a tank end mass. For any respective core, the core end
mass may be
greater than each respective tank end mass.
1001701 The heat exchanger unit may include a mount assembly associated
therewith. The
mount assembly may be configured for coupling a respective cooler to the
frame. The mount
assembly may include an
elongated fastening member; a rigid outer ring; a rigid inner
ring; and a deformable ring disposed between the rigid outer ring and the
inner outer ring.
The respective cooler may include at least one mounting slot, whereby the
elongated
fastening member may extend through the rigid inner ring and at least
partially into the
frame.
[001711 The heat exchanger unit may include a vertical axis; an airflow region
within the heat
exchanger unit; and a first set of baffles, each of the first set of baffles
configured at an angle
to the vertical axis.
1001721 Any of the baffles may have a sound absorbing material, such as
mineral well,
disposed therein (or therewith). An orientation angle of the baffle within the
heat exchanger
unit may be in the range of about 30 to about 60 degrees.
1001731 The heat exchanger unit of the system may include a fan mount bar
extending
between one of the plurality of side regions and another of the plurality of
side regions; and a
22
CA 2969703 2017-06-06
fan mounted to the fan mount bar. The fan may include a motor and a plurality
of fan blades
in the range of about 8 to about 12. The fan may include a hydraulic motor.
The motor may
be powered by a pressurized hydraulic fluid pressurized to a range of about
2000 to about
6000 psi. The pressurized fluid may be cooled by the heat exchanger unit.
1001741 Any respective cooler may include a weld between the tank end and the
core end that
may be a v-groove weld.
1001751 The heat exchanger unit may include between about one set of baffles
to about four
sets of baffles, any of which may include the sound absorbing material, which
may include
mineral wool. Baffles of the sets may have various orientation angles,
including in the range
of about 30 degrees to about 60 degrees. Baffles of the sets may have various
shapes, any of
which may be generally isosceles trapezoidal in shape.
1001761 Embodiments of the disclosure pertain to a monitoring module for
monitoring
operation of a heat exchanger unit that may include a cover panel configured
for direct or
indirect coupling to the heat exchanger unit; one or more sensors coupled with
the cover
panel. Any of the one or more sensors may have a respective rotating member
with a
plurality of blades extending therefrom.
1001771 The module may include a logic circuit in operable communication with
the plurality
of sensors, and further comprising: a microcontroller and a data storage. The
microcontroller
may be configured with computer instructions for performing one or more of the
tasks of:
acquiring a set of data from at least one of the plurality of sensors;
sampling the set of data
over a predetermined period of time; computing an average and a standard
deviation of the
set of data; comparing the standard deviation with predetermined data;
determining whether
the set of data is acceptable within a defined parameter; determining whether
a first lookup
table comprising a set of lookup data has been completed, and creating the
first lookup table
using an averaging method if it has not; comparing the set of data to the set
of lookup data;
and providing an indication based on a result of the comparing the set of data
to the set of
lookup data step.
1001781 The microcontroller may be powered at least partially, directly or
indirectly, by at
least one of the plurality of sensors.
1001791 The indication may be communicated to an end user by way of at least
one of: a text
message, an email, an audio signal, a visual indicator, and combinations
thereof.
1001801 The logic circuit may include the microcontroller in operable
communication with
one or more of: a Wi-Fi module, a GSM module, and a CAN-Bus module.
Accordingly, the
23
CA 2969703 2017-06-06
microcontroller may be provided with computer instructions for communicating
with one or
more of: the Wi-Fi module, the GSM module, and the CAN-Bus module.
1001811 Other embodiments of the disclosure pertain to a monitoring module
that may include
a cover panel mountingly associated with an airflow side of the heat exchanger
unit; a
plurality of sensors coupled with the cover panel, each of the sensors having
a respective
rotating member with a plurality of blades extending therefrom; a logic
circuit in operable
communication with the plurality of sensors. The logic
circuit may include a a
microcontroller configured with computer instructions for performing one or
more of the
tasks of: acquiring a set of data from at least one of the plurality of
sensors; sampling the set
of data over a predetermined period of time of less than 120 seconds;
computing an average
and a standard deviation of the set of data; comparing the standard deviation
with
predetermined data stored in a data storage; determining whether the set of
data is acceptable
within a defined parameter; determining whether a first lookup table
comprising a set of
lookup data has been completed, and creating the first lookup table using an
averaging
method if it has not; comparing the set of data to the set of lookup data; and
providing an
indication based on a result of the comparing the set of data to the set of
lookup data step.
1001821 The logic circuit may include the microcontroller in operable
communication with
one or more of a Wi-Fi module, a GSM module, and a CAN-Bus module. Thus the
microcontroller may have computer instructions programmed therein for
communicating with
one or more of the Wi-Fi module, the GSM module, and the CAN-Bus module.
1001831 The monitoring module may be operable to provide the indication as it
pertains to an
amount of fouling on the airflow side.
1001841 The microcontroller may be powered at least partially by at least one
of the plurality
of sensors.
1001851 A method for monitoring a heat exchanger unit coupling the heat
exchanger unit with
a heat generating device; associating a monitoring module with an airflow side
of the heat
exchanger unit. The monitoring module may include a cover panel configured for
direct or
indirect coupling to the heat exchanger unit; an at least one sensor coupled
with the cover
panel, the at least one sensor having a respective rotating member with a
plurality of blades
extending therefrom.
1001861 The logic circuit may be in operable communication with the at least
one sensor. The
microcontroller may have computer instructions for performing one more of the
tasks of:
acquiring a set of data from the at least one sensor; sampling the set of data
over a
predetermined period of time; computing an average and a standard deviation;
comparing the
24
CA 2969703 2017-06-06
standard deviation with predetermined data stored on a data storage;
determining whether the
set or data is acceptable within a defined parameter; determining whether a
first lookup table
comprising a set of lookup data has been completed, and creating the first
lookup table using
an averaging method if it has not; comparing the set of data to the set of
lookup data;
providing an indication based on a result of the comparing the set of data to
the set of lookup
data step; and performing an action based on the indication.
1001871 In aspects, the microcontroller is powered at least partially by at
the at least one
sensor. The indication is communicated to an end user by way of at least one
of: a text
message, an email, an audio signal, display, a visual indicator, and
combinations thereof. The
indication may be related to an amount of fouling present within the airflow
side.
1001881 The monitoring module may include a plurality of sensors, any of which
may be in
operable communication with the microcontroller.
1001891 The method may include where the monitoring module may have one or
more of a
solid data storage, a Wi-Fi module, a GSM module, and a CAN-Bus module being
disposed
within the controller housing, one or more of which may be in operable
communication with
the microcontroller. Thus the microcontroller may be programmed with
respective computer
instructions for communicating therewith, as applicable.
1001901 The method may include the use of at least one service fluid
transferable between the
heat exchanger unit and the heat generation device. The service fluid may be
one of lube oil,
hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and
engine cooler. There
may be multiple service fluids transferable between the heat exchanger unit
and the heat
generation device.
1001911 In aspects, the generation device of the method may be a diesel
engine. The heat
exchanger unit may have four sides, each side having a respective cooler
mounted to the
frame.
1001921 The method may include the use of the heat exchanger unit having one
or more of a
vertical axis; a frame comprising a top region, a bottom region, and a
plurality of side
regions; a plurality of coolers, each of the plurality of coolers coupled with
the frame
proximate to a respective side region of the plurality of side regions, and
each of the plurality
of coolers having an outer surface and an inner surface; an airflow region
within the heat
exchanger unit; and a first set of baffles, each baffle of the first set of
baffles configured at a
first angle to the vertical axis.
1001931 The heat exchanger unit of the method may further have a second set of
baffles, one
or more of which may be configured at a second angle to the vertical axis.
There may be a
CA 2969703 2017-06-06
third set of baffles, one or more of which may be configured at a third angle
to the vertical
axis. There may be a fourth set of baffles. Any baffle of the fourth set of
baffles may be
configured at a fourth angle to the vertical axis. Any of the first, second,
third, and fourth
angles may be in the range of about 30 degrees to about 60 degrees. Any of the
sets of
baffles may have about four baffles. Any of the baffles may comprise a sound
absorbing
material associated therewith. Any of the baffles may be generally isosceles
trapezoidal in
shape
1001941 The heat exchanger unit of the method may further include one or more
of a fan
mount bar; a shroud coupled to a top surface; an aeroring; and a fan mounted
to the fan
mount bar. The fan may include a motor and a plurality of fan blades in the
range of about 8
to about 12. The unit may have an exhaust outlet.
1001951 The heat exchanger unit of the method may include one or more of a
frame
comprising a top region, a bottom region, and plurality of side regions; a
plurality of coolers,
each of the plurality of coolers coupled with the frame proximate to a
respective side region,
and each of the plurality of coolers comprising a core welded with a tank; and
a first set of
baffles, each baffle of the first set of baffles configured at a first angle
to an axis
1001961 Any cooler of the heat exchanger unit may have a core end mass. Any
cooler of the
heat exchanger unit may have a tank end mass. In aspects, the core end mass
may be greater
than the tank end mass of any of the respective coolers.
1001971 The method may include configuring the exchanger unit with a mount
assembly. The
mount assembly may include an elongated fastening member; a rigid outer ring;
a rigid inner
ring; a deformable ring disposed between the rigid outer ring and the inner
outer ring. At
least one of the plurality of coolers may include a mounting slot. In aspects,
the elongated
fastening member may extend through the rigid inner ring and at least
partially into the
frame.
1001981 The method may include the heat exchanger unit having an airflow
region therein.
The heat exchanger unit may include a fan mount bar extending between one of
the plurality
of side regions and another of the plurality of side regions. There may be a
fan mounted to
the fan mount bar, the fan further having a motor and a plurality of fan
blades in the range of
about 8 to about 12.
1001991 A respective cooler of the heat exchanger unit may have a weld between
the first tank
end and the core end that may be a v-groove weld.
1002001 Yet other embodiments of the disclosure pertain to a method for
monitoring a heat
exchanger unit that may include one or more steps of coupling the heat
exchanger unit in
26
CA 2969703 2017-06-06
fluid communication with a heat generating device; and associating a
monitoring module
with an airflow side of the heat exchanger unit
1002011 The monitoring module may include one or more of a cover panel coupled
to the heat
exchanger unit; a plurality of sensors, each having a respective rotating
member with a
plurality of blades extending therefrom; and a logic circuit in operable
communication with
the plurality of sensors. The logic circuit may include a microcontroller that
may be
programmable and programmed for performing various tasks that may include any
of :
acquiring a set of data from at least one of the plurality of sensors;
sampling the set of data
over a predetermined period of time; determining whether the set of data is
acceptable within
a defined parameter; determining whether a first lookup table comprising a set
of lookup data
has been completed; comparing the set of data to the set of lookup data;
providing an
indication based on a result of the comparing the set of data to the set of
lookup data step;
based on the indication, performing a cleaning action on the heat exchanger
unit.
1002021 The monitoring module may include one or more of a solid data storage,
a Wi-Fi
module, a GSM module, and a CAN-Bus module being disposed within the
controller
housing and in operable communication with the microcontroller. Accordingly
the
microcontroller may be provided with computer instructions for communicating
with one or
more of the solid data storage, the Wi-Fi module, the GSM module, and the CAN-
Bus
module.
1002031 The method may include an at least one service fluid transferable
between the heat
exchanger unit and the heat generation device. The service fluid may be one of
lubc oil,
hydraulic fluid, fuel, charge air, transmission fluid, jacket water, and
engine cooler.
1002041 In aspects, the heat generation device may be a diesel engine. The
heat exchanger
unit may include four sides, each side having a respective cooler mounted to
the frame.
1002051 The heat exchanger unit of the method may include a vertical axis; a
frame
comprising a top region, a bottom region, and a plurality of side regions; a
plurality of
coolers, each of the plurality of coolers coupled with the frame proximate to
a respective side
region of the plurality of side regions, and each of the plurality of coolers
having an outer
surface and an inner surface; an airflow region within the heat exchanger
unit; and a first set
of baffles, each baffle of the first set of baffles configured at a first
angle to the vertical axis.
1002061 The heat exchanger unit may further include a second set of baffles,
each baffle of the
second set of baffles configured at a second angle to the vertical axis. There
may be a third
set of baffles, each baffle of the third set of baffles configured at a third
angle to the vertical
axis. Any of the sets of baffles may have between about 1 to about 8 baffles.
In aspects, any
27
CA 2969703 2017-06-06
of the sets of baffles may have about four baffles. Any of the baffles may
include a sound
absorbing material.
1002071 The heat exchanger unit may include any of a fan mount bar; a shroud
coupled to a
top surface; an aeroring; and a fan mounted to the fan mount bar. The fan may
have a motor
and a plurality of fan blades in the range of about 8 to about 12. There may
be an exhaust
outlet.
1002081 Embodiments of the disclosure pertain to a business method (or a
method of doing
business) that may include one or more steps of: entering into a transaction
with a first
recipient; per terms of the transaction, providing a monitoring module for a
heat exchanger
unit; operably associating the monitoring module with the heat exchanger unit,
the
monitoring module being operable to monitor a fouling condition of the heat
exchanger unit;
receiving an indication from the monitoring module related to the fouling
condition; and
performing a cleaning action of the heat exchanger unit upon based on the
indication.
1002091 In aspects, the transaction may have one or more terms related to
equipment purchase,
installation, software license, data sharing, cleaning service, and
combinations thereof.
1002101 The business method may pertain to use of the monitoring module having
a plurality
of sensors mounted proximate to an airflow side of the heat exchanger unit,
one or more of
the sensors having a respective rotating member with a plurality of blades
extending
therefrom. There may be a logic circuit in operable communication with the
plurality of
sensors. The logic circuit may include a microcontroller and a data storage.
The
microcontroller may be configured with computer instructions for performing
one or more
tasks of: acquiring a set of data from at least one of the plurality of
sensors; sampling the set
of data over a predetermined period of time, and computing an average and a
standard
deviation; comparing the standard deviation with predetermined data;
determining whether
the set of data is acceptable within a defined parameter; determining whether
a first lookup
table comprising a set of lookup data has been completed, and creating the
first lookup table
using an averaging method if it has not; comparing the set of data to the set
of lookup data;
and providing the indication based on a result of the comparing the set of
data to the set of
lookup data step.
1002111 In aspects, the transaction may pertain to a one-time or ongoing fee
associated with
the use and operation of the monitoring module. The method may include
providing data
acquired by the monitoring module to the first recipient. The method may
include providing an
incentive to the recipient when the transaction pertains to at least two of:
equipment purchase,
installation, software license, data sharing, and cleaning service.
28
CA 2969703 2017-06-06
1002121 The method may include, per terms of the transaction. performing at
least one of:
coupling the heat exchanger unit in fluid communication with a heat generating
device, and
associating the monitoring module with an airflow side of the heat exchanger
unit.
1002131 The monitoring module of the method may have one or more of a solid
data storage, a
Wi-Fi module, a GSM module, and a CAN-Bus module being disposed within the
controller
housing and in operable communication with the microcontroller. The
microcontroller may
be provided with computer instructions for communicating with one or more of
the solid data
storage, the Wi-Fi module, the GSM module, and the CAN-Bus module.
1002141 There may be an least one service fluid if transferable between the
heat exchanger
unit and a heat generation device coupled in fluid communication therewith,
and wherein the
at least one service fluid comprises one of lube oil, hydraulic fluid, fuel,
charge air,
transmission fluid, jacket water, and engine cooler.
1002151 In aspects, the heat generation device may be a diesel engine. The
heat exchanger
unit may include four sides. One or more sides may have a respective cooler
mounted to the
frame.
1002161 The heat exchanger unit of the method may include a vertical axis; a
frame
comprising a top region, a bottom region, and a plurality of side regions; a
plurality of
coolers, each of the plurality of coolers coupled with the frame proximate to
a respective side
region of the plurality of side regions, and each of the plurality of coolers
having an outer
surface and an inner surface; an airflow region within the heat exchanger
unit; and a first set
of baffles, each baffle of the first set of baffles configured at a first
angle to the vertical axis.
1002171 The heat exchanger unit may further include a second set of baffles,
each baffle of the
second set of baffles configured at a second angle to the vertical axis; and a
third set of
baffles, each baffle of the third set of baffles configured at a third angle
to the vertical axis.
The first set of baffles, the second set of baffles, and the third set of
baffles may each have
about four baffles. Any of the baffles may include a sound absorbing material,
such as
mineral wool.
1002181 The heat exchanger unit of the method may include a fan mount bar; a
shroud coupled
to a top surface; an aeroring; and a fan mounted to the fan mount bar. The fan
may have a
motor and a plurality of fan blades in the range of about 8 to about 12, and
an exhaust outlet.
1002191 The heat exchanger unit may have at least one cooler having a core
welded with a
tank. The more may have a core end mass. The tank may have a tank end mass. In
aspects,
the core end mass may be greater than the tank end mass, of any respective
core.
29
CA 2969703 2017-06-06
1002201 The heat exchanger unit may include the use of one or more mount
assemblies. The
mount assembly may be configured for coupling at least one cooler to the
frame. The mount
assembly may include: an elongated fastening member; a rigid outer ring; a
rigid inner ring; a
deformable ring disposed between the rigid outer ring and the inner outer
ring. There may be
at least one cooler having a mounting slot. The elongated fastening member may
extend
through the rigid inner ring and at least partially into the frame.
1002211 Embodiments of the disclosure pertain to a heat exchanger unit that
may include a
frame. The frame may have one or more associated regions, such as a top
region, a bottom
region, and a plurality of side regions. The unit may include a plurality of
coolers. One or
more of the plurality of coolers may be coupled with the frame proximate to a
respective side
region. Any of the plurality of coolers may include an outer surface and an
inner surface.
The heat exchanger unit may include an airflow region therein. The exchanger
unit may
include one or more baffles, such as a first set of baffles. One or more
baffles of the first set
of baffles may be configured at an angle to a reference point, which may be a
vertical axis
(e.g., a vertical axis of the heat exchanger unit).
1002221 The heat exchanger unit may include a second set of baffles. One or
more baffles of
the second set of baffles configured at a respective second angle to the
vertical axis. In
aspects, there may be a third set of baffles. One or more baffles of the third
set of baffles
may be configured at a respective third angle to the vertical axis.
1002231 One or more of the first angle, second angle, and third angle may be
in the range of
about 30 to about 60 degrees. In aspects the first angle, the second angle,
and the third angle
may be substantially the same.
1002241 One or more of the first set of baffles, the second set of baffles,
and the third set of
baffles may have in the range of about three to about five baffles. Any of the
baffles of the
heat exchanger unit may be configured to have a sound absorbing material
associated
therewith.
1002251 The heat exchanger unit may include a fan. The fan may be operable in
a manner
whereby the fan produces a point source dominant acoustic frequency. Which is
to say
during operation the fan may generate the point source dominant acoustic
frequency. The
sound absorbing material within respective baffles of the heat exchanger unit
may be suitable
to reduce the point source dominant acoustic frequency by at least 10 dB.
1002261 One or more baffles of the heat exchanger unit may be generally
isosceles trapezoidal
in shape. In aspects, each of the first set of baffles are generally isosceles
trapezoidal in
shape.
CA 2969703 2017-06-06
1002271 The sound absorbing material may be mineral wool.
1002281 The heat exchanger unit may include a fan mount bar; a shroud coupled
to a top
surface; and an aeroring. The fan may be mounted to the fan mount bar. The fan
may
include a motor and a plurality of fan blades in the range of about 8 to about
12. The fan may
be associated with and/or proximate to a fan exhaust outlet.
1002291 At least one of the sets of baffles may be positioned a quarter
wavelength below the
fan. The quarter wavelength may be calculated based on the dominant acoustic
frequency
generated by the fan.
1002301 One or more coolers of the heat exchanger unit may be configured to
permit airflow
to pass therethrough. Operation of the fan may result in airflow through at
least one of the
plurality of coolers, into the airflow region, and out of the outlet.
1002311 The frame may include a plurality of horizontal members and vertical
member
configured together in a manner that results in a generally 'cube-shaped'
frame.
1002321 Other embodiments of the disclosure pertain to a heat exchanger unit
that may include
a vertical axis and a frame. The frame may include one or more regions, such
as a top region,
a bottom region, and a plurality of side regions.
1002331 The unit may further include a plurality of coolers. At least one of
the plurality of
coolers may be coupled with the frame proximate to a respective side region.
At least one of
the plurality of coolers may have an outer surface and an inner surface.
1002341 The heat exchanger unit may have an airflow region therein.
1002351 The heat exchanger unit may include a first set of baffles. One or
more baffles of the
first set of baffles configured at an angle to the vertical axis, and each of
the first set of
baffles comprising mineral wool.
1002361 The heat exchanger unit may include a second set of baffles, and may
also include a
third set of baffles. One or more baffles of the second set of baffles may be
configured (or
positioned, oriented, etc.) at a respective second angle to the vertical axis.
One or more
baffles of the third set of baffles may be configured at a respective third
angle to the vertical
axis.
1002371 In aspects, any of the respective first angle, second angle, and third
angle may be in
the range of about 30 to about 60 degrees. Any of the first angle, the second
angle, and the
third angle may be substantially the same to each other.
1002381 Either or all of the first set of baffles, the second set of baffles,
and the third set of
baffles may include about one to about five baffles.
31
CA 2969703 2017-06-06
1002391 One or more of the first, second and third set of baffles may be
positioned a quarter
wavelength below the fan. The quarter wavelength may be calculated based on a
dominant
acoustic frequency generated by the fan.
1002401 The fan may be operable with an axis of rotation. The axis of rotation
may be
substantially parallel to the vertical axis. Operation of fan may result in
airflow through one
or more of the plurality of coolers, into the airflow region, and out of the
top region.
1002411 The exchanger unit may include other components or features, such as a
tubular fan
mount bar; a shroud coupled to a top surface; and an aeroring. There may be a
fan mount
coupled to the tubular fan mount bar. There may be a fan coupled to the fan
mount. The fan
may be a hydraulic motor.
1002421 The hydraulic motor may be powered by a pressurized hydraulic fluid.
The hydraulic
fluid may be pressurized to a range of about 2000 to about 6000 psi. The
pressurized
hydraulic fluid may power the hydraulic motor by passing therethrough, and
thereafter the
hydraulic fluid may be cooled via one of the plurality of coolers.
1002431 The frame may include a plurality of horizontal members and vertical
member
configured together in a manner that results in a pre-determined frame shape,
such as a cube-
shaped frame.
1002441 Yet other embodiments of the disclosure pertain to a heat exchanger
unit that may
include a frame having one or more associated regions, such as a top region, a
bottom region,
and a plurality of side regions. The heat exchanger unit may have a plurality
of coolers
coupled with the frame. Various coolers of the plurality of coolers may be
coupled with the
frame proximate to a respective side region. The coolers may have an outer
surface and an
inner surface.
1002451 The heat exchanger unit may include one or more mount assemblies. A
respective
mount assembly (or sometimes 'flexible mount assembly') may be configured for
the
coupling of a corresponding cooler of the plurality of coolers to the frame.
1002461 The amount assembly may include an elongated fastening member; a rigid
outer ring;
a rigid inner ring; and a deformable ring disposed between the rigid outer
ring and the inner
outer ring.
1002471 In aspects, the mount assembly may include a top plate, a bottom
plate, and a washer.
1002481 Any of the plurality of coolers may include a mounting slot. The
elongated fastening
member may extends through the rigid inner ring. The elongated fastening
member may
extend at least partially into and/or engage the frame.
1002491 The heat exchanger unit may include an axis, such as a vertical axis.
32
CA 2969703 2017-06-06
1002501 The heat exchanger unit may include an airflow region therein.
1002511 The heat exchanger unit may include a first set of baffles. One or
more baffles of the
first set of baffles may be configured (positioned, oriented, etc.) at a
respective angle to the
vertical axis.
1002521 The heat exchanger unit may include other sets of baffles, such as a
second set of
baffles, third set of baffles, fourth set of baffles, fifth set of baffles,
etc. One or more baffles
of the second set of baffles may be configured at a respective second angle to
the vertical
axis. One or more baffles of the third set of baffles may be configured at a
respective third
angle to the vertical axis. Other baffles of other sets may likewise be
configured with a
respective angle to an applicable axis.
1002531 Any of the sets of baffles may have between about one to about ten
baffles. In
aspects, the first set of baffles, the second set of baffles, and the third
set of baffles may each
have about three to about five baffles.
1002541 Any of the baffles of the heat exchanger unit may have therewith or
otherwise be
configured with a sound absorbing material. In aspects, any of the baffles of
either of the
first set of baffles, the second set of baffles, and the third set of baffles
may include the sound
absorbing material. The sound absorbing material may be mineral wool.
1002551 Any of the baffles of the heat exchanger unit may formed with a
desired shape. For
example, one or more of the baffles of the first set of baffles may have a
generally isosceles
trapezoidal shape.
1002561 Any of the baffles of the heat exchanger unit may be configured with a
respective
angle to an axis. The angle may be in the range of about 30 degrees to about
60 degrees.
1002571 The heat exchanger unit may include other components or features, such
as a fan
mount bar. The fan mount bar may extend between one of the plurality of side
regions and
another of the plurality of side regions. There may be a fan mounted to the
fan mount bar.
The fan may include a fan motor and a plurality of fan blades. The fan motor
may be a
hydraulic motor. The plurality of fan blades may be in the range of about 5 to
about 15 fan
blades, including any number therebetween.
1002581 Any of the plurality of coolers may be configured to permit airflow to
pass
therethrough. In aspects, operation of a fan of the heat exchanger unit may
result in airflow
through any of the respective plurality of coolers, into the airflow region,
and out of an
exhaust outlet.
33
CA 2969703 2017-06-06
1002591 The frame may include a plurality of horizontal members and vertical
member
configured together in a manner that results in a predetermined frame shape,
such as a cube-
shaped frame.
1002601 The heat exchanger unit may include a cooler. The cooler may include a
first tank
end welded to a core end. The mass of the first tank end may be less than the
core end.
1002611 The first tank end and the core end may be welded together, such that
there may be a
weld between the first tank end and the core end. The weld may be a v-groove
weld.
1002621 Still other embodiments of the disclosure pertain to a heat exchanger
unit that may
include a frame comprising an at least one side region and an at least one
cooler coupled with
the frame proximate to the respective side region. The heat exchanger unit may
include a
mount assembly (or flexible amount assembly), which may be configured for
coupling
(including partially coupling) the at least one cooler to the frame,
1002631 The unit (or analogously the frame) may include an axis, such as a
vertical axis.
1002641 The mount assembly may include an elongated fastening member; a rigid
outer ring; a
rigid inner ring; and a deformable ring disposed between the rigid outer ring
and the inner
outer ring.
1002651 The mount assembly may include a top plate, a bottom plate, and a
washer.
1002661 The at least one cooler may include a mounting slot. In some aspects
as pertaining to
assembly and related coupling, the rigid outer ring, the rigid inner ring, and
the deformable
ring may be disposed within the mounting slot. In other aspects, the elongated
fastening
member may extend into and through the rigid inner ring. The elongated
fastening member
may extend at least partially into the frame.
1002671 The heat exchanger unit may include various baffles, including a first
set of baffles.
1002681 Any of the baffles of the first set of baffles may be configured or
otherwise positioned
(mounted, etc.) at a respective first angle to the vertical axis. One or more
baffles of the heat
exchanger unit may include or otherwise be configured with a sound absorbing
material.
1002691 The heat exchanger unit may include other sets of baffles, such as a
second set of
baffles, a third set of baffles, and a fourth set of baffles. Any baffles of
the second set of
baffles may be configured at a respective second angle to the vertical axis.
Any baffles of the
third set of baffles may be configured at a respective third angle to the
vertical axis.
1002701 Any of the angles of the baffles may be in the range of about 30 to
about 60 degrees.
In aspects, each of the first angle, the second angle, and the third angle may
be in the range of
about 30 to about 60 degrees.
34
CA 2969703 2017-06-06
1002711 The heat exchanger unit may include other components or features, such
as a tubular
fan mount bar; a shroud coupled to a top surface; and an aeroring. There may
be a fan mount
coupled to the tubular fan mount bar. There may be a fan coupled to the fan
mount. The fan
may include or otherwise be associated with a fan motor. The fan motor may be
a hydraulic
motor.
1002721 The fan motor may be powered or otherwise driven a fluid. The fluid
may be a
pressurized hydraulic fluid pressurized to a range of about 2000 to about 6000
psi.
1002731 Any of the sets of baffles may be positioned a quarter wavelength
below the fan. The
quarter wavelength may be calculated based on a dominant acoustic frequency
generated by
the fan.
1002741 The fan may have or be otherwise operable with an associated axis of
rotation. The
axis of rotation may be substantially parallel to the vertical axis. In
aspects, operation of the
fan may result in airflow through the at least one cooler.
1002751 The frame may include a plurality of horizontal members and vertical
member
configured together in a manner forms a desired shape of the frame. In
aspects, the shape of
the frame may be cube-shaped.
1002761 Any cooler of the unit may have a respective first tank end welded to
a core end. The
respective first tank end mass of the first tank may be less than a respective
core end mass of
the core end.
1002771 The weld between the first tank end and the core end may be a v-groove
weld.
1002781 And still other embodiments of the disclosure pertain to a heat
exchanger unit that
may include a frame having various regions, such as a top region, a bottom
region, and
plurality of side regions.
1002791 The heat exchanger unit may include one or more coolers. There may be
a plurality
of coolers, any of which may be coupled with the frame proximate to a
respective side region.
Any of the plurality of coolers may include a respective a core welded with a
tank.
1002801 In aspects, any respective core may further include a core end having
a core end mass.
Similarly, any respective tank may further include a tank end having a tank
end mass. Any,
including each and every, respective core end mass may be greater than each
respective tank
end mass.
1002811 The heat exchanger unit may include an airflow region therein.
1002821 The heat exchanger unit may include various sets of baffles, such as a
first set, second
set, third set, and fourth set.
CA 2969703 2017-06-06
1002831 Any of the baffles of the various sets of baffles may be configured
(positioned,
mounted, oriented, etc.) at a respective angle to an axis of the unit (or
frame). The axis may
be a vertical axis. In aspects, one or more baffles of the first set of
baffles may be configured
at a respective first angle to the vertical axis. One or more baffles of the
second set of baffles
may be configured at a respective second angle to the vertical axis. One or
more baffles of
the third set of baffles may be configured at a respective third angle to the
vertical axis. One
or more baffles of the fourth set of baffles may be configured at a respective
fourth angle to
the vertical axis.
1002841 Any of the respective first angle, second angle, third angle, and
fourth angle may be in
the range of about 30 to about 60 degrees.
1002851 Any of the baffles of the heat exchanger unit may include a material
capable of
effecting sound. The material may be a sound absorbing material.
1002861 Any of the baffles of the heat exchanger unit may have or be otherwise
formed to
include a particular baffle shape. In aspects, at least one baffle may have a
generally
isosceles trapezoidal shape. In other aspects, each baffle of the first set of
baffles may be
generally isosceles trapezoidal in shape.
1002871 Any of the baffles may include mineral wool.
1002881 Any of the various the sets of baffles of the heat exchanger unit may
be positioned a
quarter wavelength below a fan mounted to the outlet, the quarter wavelength
being
calculated based on a dominant acoustic frequency generated by a fan.
1002891 Any of the coolers of the heat exchanger unit may be configured to
permit airflow to
pass therethrough. In aspects, operation of the fan may results in airflow
through at least one
of the plurality of coolers, into the airflow region, and out of an exhaust.
1002901 The frame may include a plurality of horizontal members and vertical
members
configured and coupled together in a manner that forms a predetermined shape.
In aspects,
the shape may be a cube-shaped frame.
1002911 The heat exchanger unit may include one or more mount assemblies for
coupling an at
least one of the plurality of coolers to the frame.
1002921 Any respective mount assembly may include an elongated fastening
member; a rigid
outer ring; a rigid inner ring; and a deformable ring disposed between the
rigid outer ring and
the inner outer ring.
1002931 Any of the coolers of the exchanger unit may include a mounting slot.
In aspects, a
respective and corresponding mount assembly may include the elongated
fastening member
36
CA 2969703 2017-06-06
to extend into and through the rigid inner ring. The elongated fastening
member may extend
through the mounting slot, and at least partially into the frame.
1002941 Yet other embodiments of the disclosure pertain to a heat exchanger
unit may include
a frame comprising an at least one side region.
1002951 There may be a cooler coupled with the frame proximate to the at least
one side
region. The cooler may include a core welded with a tank.
1002961 The core may include a core end having a core end mass. The tank may
include a
tank end having a tank end mass. The core end mass may be greater than the
respective tank
end mass.
1002971 The heat exchanger unit may include a mount assembly, which may be
useful for
coupling, at least partially, the cooler to the frame. The mount assembly may
include an
elongated fastening member; a rigid outer ring; a rigid inner ring; and a
deformable ring
disposed between the rigid outer ring and the inner outer ring.
1002981 Any cooler of the heat exchanger unit may include a mounting slot. In
aspects, the
elongated fastening member of a respective mount assembly may extend, through
the rigid
inner ring, through the mounting slot, and at least partially into the frame.
1002991 Yet still other embodiments of the disclosure pertain to a heat
exchanger unit that may
include a frame having a top region, a bottom region, and a plurality of side
regions. The unit
may include at least one cooler. In aspects, there may be a plurality of
coolers. Any of the
plurality of coolers may be coupled with the frame proximate to a respective
side region.
Any of the plurality of coolers may include a respective core welded with a
tank.
1003001 The unit (or frame) may have an associated reference axis, such as a
vertical and/or
horizontal axis.
1003011 There may be an airflow region within the heat exchanger unit.
1003021 The heat exchanger unit may include a tubular fan mount bar coupled
between one of
the plurality of side regions, and another of the plurality of side regions.
1003031 There may be a fan mount coupled to the tubular fan mount bar.
1003041 There may be a fan coupled to the fan mount. In aspects, the fan may
have or
otherwise include a hydraulic motor. The hydraulic motor may be powered by
pressurized
hydraulic fluid pressurized to a range of about 2000 to about 6000 psi.
1003051 The fan may be operable to pull airflow through any of the plurality
of coolers and
into the airflow region. Any of the respective cores may have a core end mass.
Any of the
respective tanks may have a tank end mass. In aspects, any respective core end
mass may be
37
CA 2969703 2017-06-06
greater than each respective tank end mass. In aspects, any core may have a
first tank end
welded thereto, and a second tank end welded thereto.
1003061 The fan may have an associated axis of rotation. The axis of rotation
may be
substantially parallel to a reference axis, such as the vertical axis. The fan
may be operable in
a manner whereby operation thereof may result in airflow through at least one
cooler of the
unit.
1003071 The heat exchanger unit may include various sets of baffles, such as a
first set, second
set, third set, fourth set, etc.
1003081 Any baffle of any respective set of baffles may be coupled to the
frame. Any baffle of
any respective set of baffles may have a material capable of effecting sound
associated
therewith.
1003091 In aspects, any baffle of the first set of baffles may be coupled to
the frame at an
orientation of a respective first angle to the axis. Any baffle of the first
set of baffles may
include a sound absorbing material.
1003101 In aspects, any baffle of the second set of baffles may be coupled to
the frame at an
orientation of a respective second angle to the axis. Any baffle of the second
set of baffles
may include a sound absorbing material.
1003111 In aspects, any baffle of the third set of baffles may be coupled to
the frame at an
orientation of a respective third angle to the axis. Any baffle of the third
set of baffles may
include a sound absorbing material.
1003121 In aspects, any baffle of the fourth set of baffles may be coupled to
the frame at an
orientation of a respective fourth angle to the axis. Any baffle of the fourth
set of baffles may
include a sound absorbing material.
1003131 Any of the respective first angle, the second angle, the third angle,
and the fourth
angle may be in the range of about 30 to about 60 degrees.
1003141 Any respective set of baffles may be positioned a quarter wavelength
below the fan,
the quarter wavelength being calculated based on a dominant acoustic frequency
generated by
the fan during its operation.
1003151 The heat exchanger unit may include one or more mount assemblies. A
respective
mount assembly may be configured for the coupling of, at least partially, a
corresponding
cooler of the plurality of coolers to the frame. Any respective mount assembly
may include
various components, such as an elongated fastening member; a rigid outer ring;
a rigid inner
ring; a deformable ring disposed between the rigid outer ring and the inner
outer ring.
38
CA 2969703 2017-06-06
1003161 Any cooler may include or be associate with one or more mounting
slots. The
elongated fastening member of a respective mount assembly may be configured to
extend
into and through the rigid inner ring, through the respective mounting slot,
and/or at least
partially into the frame.
1003171 Any mount assembly may include a top plate, a bottom plate, and/or a
washer.
1003181 The frame of the heat exchanger unit may include one or more frame
members, such
as horizontal members and vertical members. In aspects, a plurality of
horizontal members
and vertical member coupled together in a manner that results in a desired
frame shape. The
desired frame shape may be a cube-shape.
1003191 Other embodiments of the disclosure pertain to a method of operating
or otherwise
using a heat exchanger unit of the present disclosure. The method may include
the steps of
assembling a heat exchanger unit that includes a plurality of horizontal
members and vertical
member coupled together in a manner that results in a desired frame shape. The
heat
exchanger unit may include one or more coolers. One or more coolers may be
associated
with one or more respective mount assemblies. The mount assemblies may be
configured or
otherwise suitable for the coupling, at least partially, of the respective
cooler to the frame.
1003201 The method may include the step of associating a fan (or fan system)
with the frame.
The fan may be driving by a motor, which may be a hydraulic motor.
1003211 The method may include the step of operating the fan motor with a
pressurized
hydraulic fluid.
1003221 The method may include using one or more coolers having a respective
core end
welded with a first tank end. The core end may have a core end mass. The first
tank end
may have a tank end mass. The core end mass may be greater than the tank end
mass.
1003231 The heat exchanger unit may include various sets of baffles, such as a
first set, second
set, third set, fourth set, etc.
1003241 Any baffle of any respective set of baffles may be coupled to the
frame. Any baffle of
any respective set of baffles may have a material capable of effecting sound
associated
therewith.
1003251 In aspects, any baffle of the first set of baffles may be coupled to
the frame at an
orientation of a respective first angle to the axis. Any baffle of the first
set of baffles may
include a sound absorbing material.
1003261 In aspects, any baffle of the second set of baffles may be coupled to
the frame at an
orientation of a respective second angle to the axis. Any baffle of the second
set of baffles
may include a sound absorbing material.
39
CA 2969703 2017-06-06
1003271 In aspects, any baffle of the third set of baffles may be coupled to
the frame at an
orientation of a respective third angle to the axis. Any baffle of the third
set of baffles may
include a sound absorbing material.
1003281 In aspects, any baffle of the fourth set of baffles may be coupled to
the frame at an
orientation of a respective fourth angle to the axis. Any baffle of the fourth
set of baffles may
include a sound absorbing material.
1003291 Any of the respective first angle, the second angle, the third angle,
and the fourth
angle may be in the range of about 30 to about 60 degrees.
1003301 Any respective set of baffles may be positioned a quarter wavelength
below the fan,
the quarter wavelength being calculated based on a dominant acoustic frequency
generated by
the fan during its operation.
1003311 The method may include the step of using at least one baffle within
the heat
exchanger unit that has a sound absorbing material therein.
1003321 The method may include the step of coupling the heat exchanger unit
with a heat
generating device. The heat exchanger unit and the heat generating device may
be in fluid
communication.
1003331 Other embodiments of the disclosure pertain to a system for cooling a
fluid that may
include a heat exchanger unit of the present disclosure coupled in fluid
communication with
at least one heat generating device. The heat exchanger unit may include a
plurality of
horizontal members and vertical member coupled together in a manner that
results in a
desired frame shape. The heat exchanger unit may include one or more coolers.
One or more
coolers may be associated with one or more respective mount assemblies. The
mount
assemblies may be configured or otherwise suitable for the coupling, at least
partially, of the
respective cooler to the frame.
1003341 The heat exchanger unit of the system may include a fan coupled with
the frame. The
fan may be operably associated with a motor, which may be a hydraulic motor.
The motor
may be operable via the use of a pressurized hydraulic fluid.
[003351 The heat exchanger unit of the system may include one or more coolers
having a
respective core end welded with a first tank end. The core end may have a core
end mass.
The first tank end may have a tank end mass. The core end mass may be greater
than the
tank end mass.
1003361 The heat exchanger unit of the system may include various sets of
baffles, such as a
first set, second set, third set, fourth set, etc.
CA 2969703 2017-06-06
1003371 Any baffle of any respective set of baffles may be coupled to the
frame. Any baffle of
any respective set of baffles may have a material capable of effecting sound
associated
therewith.
1003381 In aspects, any baffle of the first set of baffles may be coupled to
the frame at an
orientation of a respective first angle to the axis. Any baffle of the first
set of baffles may
include a sound absorbing material.
1003391 In aspects, any baffle of the second set of baffles may be coupled to
the frame at an
orientation of a respective second angle to the axis. Any baffle of the second
set of baffles
may include a sound absorbing material.
1003401 In aspects, any baffle of the third set of baffles may be coupled to
the frame at an
orientation of a respective third angle to the axis. Any baffle of the third
set of baffles may
include a sound absorbing material.
1003411 In aspects, any baffle of the fourth set of baffles may be coupled to
the frame at an
orientation of a respective fourth angle to the axis. Any baffle of the fourth
set of baffles may
include a sound absorbing material.
1003421 Any of the respective first angle, the second angle, the third angle,
and the fourth
angle may be in the range of about 30 to about 60 degrees.
1003431 Any respective set of baffles may be positioned a quarter wavelength
below the fan,
the quarter wavelength being calculated based on a dominant acoustic frequency
generated by
the fan during its operation.
1003441 The heat exchanger unit of the system may include at least one baffle
having a sound
absorbing material therein.
1003451 The system may include the heat exchanger unit coupled with at least
one heat
generating device.
1003461 The heat exchanger unit and the heat generating device may be in fluid
communication.
1003471 There may be a plurality of heat exchanger units coupled with a
respective plurality of
heat generating devices.
1003481 In aspects, the heat generating device may be an engine of a frac
pump. The frac
pump may be associated with a mobile frac pump skid or trailer.
1003491 The system may include the frac pump in fluid communication with a
wellbore.
1003501
1003511 Referring now to Figures 2A and 2B together, a side view of a heat
exchanger unit
coupled with a heat generation device, and an isometric view of a frame of the
heat exchanger
41
CA 2969703 2017-06-06
unit, respectively, in accordance with embodiments disclosed herein, are
shown.
Embodiments herein apply to a heat exchanger unit that may be an inclusive
assembly of a
number of components and subcomponents. The heat exchanger unit 200 may
include a solid
integral frame (or skeletal frame) or may be a frame 202 that includes a
number of elements
arranged and coupled together, such as a plurality of horizontal elements 250
and a plurality
of vertical elements 251.
1003521 Although the shape of the frame 202 need not be limited, Figure 2B
illustrates a
generally cubical shape (i.e., four side regions, a top region, and a bottom
region) that results
from the horizontal elements 250 and the vertical elements 251 being connected
at various
corners and generally perpendicular to one another. Other shapes of the frame
202 could
include cylindrical, hexagonal, pyramidal, and so forth. As the shape of the
frame 202 may
vary, so may the shape of frame elements 250, 251. It is within the scope of
the disclosure
that heat exchanger unit 200 may have a single side (or region), and thus a
single frame side.
1003531 The frame 202 may include additional frame support plates, which may
be suitable for
further coupling elements 250 and 251 together, as well as providing
additional surface area
or contact points for which other components may be coupled therewith. One or
more frame
support plates 252a may have a generally vertical orientation, whereas one or
more frame
support plates 252b may have a generally horizontal orientation. One or more
frame support
plates 252 (or 252a, b etc.) may include a support plate slot or groove 253.
1003541 The horizontal or vertical members 250, 251 may include one or more
core support
mount slots 282, whereby a radiator core (or 'core') 206 may be coupled to the
frame 202 via
therewith. There may be a plurality of such slots 282 configured and arranged
in a manner
(of respective members 250 or 251) whereby a plurality of cores 206 may be
coupled
therewith. One or more coolers (comprising a respective core 206) may be
coupled to the
frame with respective mount assemblies (e.g., 1000, 1000a Figures 5A-5E). One
or more
cores 206 may be associated with and proximate to a respective protective
grate 248, which
may be useful for protecting fins of the core 206.
1003551 The frame 202 may include yet other additional support or structural
elements, such
as one or more frame support bars 254. The support bar(s) 254 may be coupled
between
various elements 250, 251, such as in a horizontal, vertical, or diagonal
manner. The support
bars 254 may be arranged in a 'turnbuckle' configuration. The support bar(s)
254 may be
coupled to elements in a known manner, such as rivet, weld, nut-and-bolt, etc.
The bars 254
may be tubular in shape, which may help improve airflow and reduce pressure
drop
thereacross.
42
CA 2969703 2017-06-06
1003561 The frame 202 may also include a top plate 255, which may have a top
plate opening
256. The top plate opening 256 may be of a shape and size suitable for
accommodating
airflow therethrough. The HX unit 200 may include a fan system 257. The fan
system 257
may include related subcomponents, such as a fan 208 that may be understood to
include a
rotating member with a plurality of fan blades 211 extending therefrom. The
fan 208 may be
a Multi-Wing fan from Multi-Wing International or a Horton fan.
1003571 There may be in the range of about 4 to about 16 blades 210 attached
in a generally
symmetrical manner. The blades 211 may be oriented at a blade angle to the
horizontal axis
226 in the range of about 10 degrees to about 50 degrees. The angle of blades
211 may be
adjusted to promote optimal and efficient cooling of the HX unit 200.
1003581 The blades 211 may have an effective blade diameter in the range of
about 10 inches
to about 100 inches. The fan 208 may be operable by way of a suitable driver,
such as a fan
motor 212, which may be hydraulic, electrical, gas-powered, etc. The fan motor
212 may
receive power through various power cords, conduits (e.g., conduit and cabling
258), etc., as
would be apparent to one of skill in the art. The conduits 258 may be
configured for the
transfer of pressurized hydraulic fluid to and from the motor 212. As such,
pressurized
hydraulic fluid may be used to power the motor 212. The pressure of the
hydraulic fluid may
be in the range of about 2,000 psi to about 6,000 psi. Hydraulic fluid may
exit the motor 212,
and be cooled via the FIX unit 200, repressurized, and recirculated back to
the motor 212.
1003591 The fan 208 may operate in the range of about 200 rpm to about 1200
rpm. The fan
208 may operate in a manner to provide airflow in the range of about 10,000
cfm to about
200,000 cfin. The originating noise of the fan 208 may be the range of about
70 dB's to
about 120 dB's. The frequency of noise from the fan 208 may be in the range of
about 20 hz
to about 20,000 hz.
1003601 The frame 202 may include a fan rock guard mount 210, which may be
used for the
coupling of a fan rock guard 247 thereto. The frame 202 may include a fan
mount plate 249.
The fan mount plate 249 may include a generally planar surface for coupling
with respective
fan mounts of the fan 208. The fan mount plate 249 may be connected to a fan
mount bar
209. The mount bar 209 may be a rigid bar or beam that extends from one side
259a of the
HX unit 200 to another side 259b. The mount bar 209 may be generally
cylindrical or tubular
shaped, and may be integral to the frame 202 or coupled therewith. In aspects,
the bar 209
may be welded to the frame 202 (such as to horizontal members 250 a,b ¨see
Figure 6A),
1003611 The fan mount bar 209 may be suitable to provide a synergistic effect
of sufficient
strength for supporting the fan 208, as well as have smooth surfaces that
reduce noise as a
43
CA 2969703 2017-06-06
result of a decrease in a pressure variation from air flowing over surface
area of the bar 209.
The fan 208 may have a drive that extends downwardly through fan motor slot
249a.
1003621 The fan system 257 may include a fan shroud 213, which may be
generally annular.
The fan shroud 213 may be coupled to the frame 202 via connection with the top
plate 255.
The rock guard 247 may be coupled to the shroud 213. the shroud 213 may
include one or
more lateral openings 260 to accommodate the passing of the mount bar 209
therethrough.
The fan 208 may have a central rotational axis around the vertical axis 227.
The shroud 213
may be positioned with respect to the central rotational axis such that fan
blades 211 may be
extended within desired manufacturing tolerances whereby a clearance exists
between the fan
blades 211 and a shroud inner surface 213a. The shroud 213 may be a unitary
piece or the
combination of multiple pieces. The size of the shroud 213, including its
height and diameter
may be as desired to accommodate airflow through and out of the HX unit 200.
1003631 The shroud 213 may be proximate to an aeroring (223, Figure 2C). The
aeroring
(223) may be annular in nature, and have a ring cross-section that may have a
radius of
curvature. Thus, the aeroring (223) may have a rounded surface that may aid in
improving
airflow and reducing pressure in and around the fan system 257. Without the
aeroring (223),
eddies and other undesired airflow may occur in corners of the top of the
frame 202.
1003641 The configuration of the shroud and aeroring may provide added ability
for further
streamlining airflow, which may beneficially reduce overall power
requirements.
1003651 The fan system 257 can be operable to draw in and direct the flow of
air 216. The air
216 may be drawn through the sides of the HX unit 200 (and respective cores,
which may
then be used to cool one or more utility fluids F) and out as heated exhaust
218. The benefit
of such a configuration is the ability to provide cooling in parallel, versus
series. In a series
configuration (i.e., a typical horizontal orientation ¨ see Figure IC), the
airflow becomes
progressively hotter as it passes through each cooling circuit, resulting in a
loss in cooling
efficiency. This can be especially problematic where ambient air temperature
is usually
hotter, like Texas and Oklahoma.
1003661 Utility fluid F (or multiple F's) may include by way of example, lube
oil, jacket water,
turbo (such as for an engine), transmission fluid (such as for a pump), and
hydraulic fluid
(such as for fan drive 212).
1003671 One of skill in the art would appreciate that airflow through the core
206 may be
generally in a path parallel to horizontal axis 226. In an analogous manner,
the fan 208 may
have an axis of rotation generally parallel to vertical axis 227. In aspects,
airflow through the
core 206 may be generally perpendicular to the fan 208 axis of rotation.
Accordingly, airflow
44
CA 2969703 2017-06-06
through the HX unit 200 may be transitioned from (approximately) horizontal to
vertical as
the airflow moves through the core 206 and out the fan exhaust 218.
1003681 As such, by way of example, utility fluid F1 may be transferred from a
heat generating
device 203 at a hot temperature into an HX unit inlet 278, cooled with airflow
via core 206,
and transferred out of an HX unit outlet 284 back to the HGD 203 at a cooler
temperature.
While not meant to be limited, HGD 203 may be an engine, a genset, a motor, a
pump, or
other comparable equipment that operates in a manner whereby a utility fluid
is heated.
1003691 There may be one or more cores 206. A 'cooler' or 'cooling circuit'
may include one
or more cores 206. The FIX unit 200 may have between about 1 to about 8
cooling circuits,
which each may be configured for cooling in parallel to each other.
0003701 Referring now to Figures 5A, 5B, and 5C together, a close-up view of a
radiator core
mounted to a frame of a heat exchanger unit, a component breakout view of a
flexible mount
assembly, and a partial side cross-sectional view of a flexible mount assembly
used with a
bracket and a frame of a heat exchanger unit, respectively, in accordance with
embodiments
disclosed herein, are shown.
1003711 Any cooler 204 (or core 206) of the disclosure may be mounted to a
frame 202 with a
flexible mount assembly 1000. The flexible mount 1000 provides for the ability
to have one
or more degrees of movement between the core(s) 206 and the frame 202, such as
movement
that may be caused by thermal expansion of the core 206. As shown, the mount
assembly
1000 includes various components, including a bolt 1002 with elongated member
or shaft
1001, a first washer 1004, a top plate 1006, an outer rigid ring 1008, an
inner rigid (spacer)
ring 1012, and a deformable ring 1010, and a bottom (or back) plate 1014 (with
plate slot
1014a). Although not shown here, the flexible mount assembly 1000 may be
coupled to the
frame 202 (or also vertical member 251 and/or horizontal member 250) via a nut
plate or
threaded receptacle.
1003721 The core 206 may have various structure configured for coupling to the
frame 202.
For example, there may be one or more core mounts or core mount brackets 287,
which may
each have one or more core mount slots 288. The bracket 287 may be an integral
piece of the
core 206 formed at the time of manufacture, or may be connected therewith,
such as via a
welding process. In addition or alternative, there may be a bracket 287
coupled with a tank
277 of a cooler (204).
1003731 The OD of the outer rigid ring 1008, and 1D's of bottom plate slot
1014a and core
mount slot 288 may be substantially equivalent, or to the point where ring
1008 may fit
CA 2969703 2017-06-06
(including with tight tolerance fit) within one or both of the bottom plate
slot 1014a and core
mount slot 288.
1003741 Outer ring 1008 may have an ID configured or otherwise sized in a
manner whereby
the deformable ring 1010 may fit therein. Similarly the deformable ring 1010
may have an
ID (defined by the presence or ring slot 1010a) configured or otherwise sized
in a manner
whereby the inner rigid ring 1012 may fit therein. And each of the inner rigid
ring 1012, the
top plate 106, the washer 1004, and a core mount slot 282 may have a
respective slot or
orifice size configured to receive a bolt shaft 1002a, including with tight
tolerance fit. The
mount assembly 1000 may be matable with a mount slot 282a of a respective
member 250
and/or 251.
1003751 The deformable ring 1010 may have a generally cylindrical shape, with
the ring slot
1010a. The ring slot 1010a may be concentric with respect to the ring 1010
(e.g., see Figure
5E), or may be eccentric. The clearance between the top plate 1006 and the
bottom plate
1014 may accommodate movement of the mount 287, which may result from thermal
expansion or contraction of the core 206.
1003761 The deformable ring 1010 may be of such a material that the movement
in one or
more vectors may be accommodated (such as laterally and axially, and so
forth). As shown
in Figure 5C, the mount 287 may move back and forth along a path of the
directional arrow.
In aspects the deformable ring 1010 may be a rubbery material, such as
neoprene. The
deformable ring 1010 may have the characteristic of having an original shape,
being
deformed as a result of a force, and then returning (substantially or even
exactly) to the
original shape. The deformable ring 1010 may have excellent chemical stability
and maintain
flexibility over a wide temperature range. The force may be that which is
incurred as a result
of thermal expansion of the core 206, and thus movement of mount 287.
1003771 Referring now to Figures 5D, 5E, and 5F together, a component breakout
view of a
mount assembly, a side cross-sectional view of a mount assembly used with a
bracket and a
frame of a heat exchanger unit, and a close-up view of a radiator core mounted
to a frame of a
heat exchanger unit, respectively, in accordance with embodiments disclosed
herein, are
shown.
1003781 Any core 206 (or cooler) may be mounted to a frame 202 (or member(s)
250/251)
with a flex mount 1000a. The flex mount 1000a provides for the ability to have
one or more
degrees of movement between the core(s) (206) and the frame 202, such as
movement that
may be caused by thermal expansion of the core. As shown, the flex mount 1
000a may
include various components including a bolt 1002a, a first washer 1004a, a top
plate 1006a,
46
CA 2969703 2017-06-06
an outer rigid ring 1008a, an inner rigid (spacer) ring 1012a, and a
deformable ring 1010b,
and a bottom (or back) plate 1014b (with plate slot 1014c). Although not shown
here, the
flex mount 1000a may be coupled to the frame 202 (or members 250 and/or 251)
via a nut
plate or threaded receptacle. Alternatively, the flex mount 1000a may be
bolted or coupled
with the respective cooler 204.
1003791 The cooler (or core 206) may have one or more core mounts or core
mount brackets
287, which may each have one or more core mount slots 288.
1003801 As the flexible mount 1000a may be comparable to flexible mount 1000,
flexible
mount 1000a is only discussed in brevity. Of note, is the presence of one or
more clearance
regions 1018, which may promote or otherwise accommodate movement of the core
206 in
one more vectors, such as illustrated by way of example via the directional
arrows.
1003811 Referring now to Figures 2C, 2D, and 2E together, a side cross-
sectional view of an
HX unit configured with a plurality of baffles, an isometric view of a set of
a plurality of
baffles, and a close-up partial side view of a baffle coupled to a vertical
member, respectively,
in accordance with embodiments disclosed herein, are shown.
1003821 Airflow through an HX unit 200 may be turbulent and otherwise chaotic.
In addition,
a fan 208 may be so loud in noise emission that it may be impossible to have a
conversation
between operators in an area of proximity near the fan 208 (or HX unit 200).
In addition or
the alternative, the noise from the fan 208 may exceed a regulation, which is
of even greater
significance in the event the FIX unit 200 is used in or proximate to a
residential setting.
1003831 As illustrated by way of example in Figure 2C, the HX unit 200 may be
configured
with one or more baffles 222, which may be arranged or otherwise installed on
a pseudo-
interior side 229 of the unit 200 (the "exterior" 229a and "interior" 229 of
the HX unit 200
may be thought of as positionally relative to where ambient air and heated air
are).
1003841 Although numerous components around or proximate to an HOD (203,
Figure 2A) may
be a source of noise, a fan 208 may produce a noise having dominant acoustic
frequency '1 with
initial amplitude A,. To reduce noise emitted from the fan 208, the 1-IX unit
200 may be
configured with one or more baffles 222 coupled to a frame 202. It was
initially contemplated
that the use of baffles 222 could be problematic (restrictive) to airflow;
however, in field
testing it was unexpectedly discovered that airflow through HX unit 200 had
actually
increased as a result of the presence of baffles 222. This synergistic effect
is believed
attributable to the baffles 222 (and position of the baffles) helping to
streamline the airflow,
rather than acting as a restriction.
47
CA 2969703 2017-06-06
1003851 Thus, instead of chaotic turbulence within the interior of the HX unit
200, a baffle
shape and an angled orientation of the baffles 222 may result in smoothing out
the transition
of the airflow from generally horizontal to generally vertical, reducing the
airflow
recirculation within the interior of FIX unit 200, and thus reducing
restriction and increasing
airflow. The angled orientation may allow for a wider baffle width, which when
paired with
the proper baffle spacing and absorption material, may work to reduce
undesirous fan noise.
Spacing may be done in a manner to account for a quarter wave length (Q1 ¨ Q4)
of the fan
noise.
1003861 While the baffles 222 may be shown herein as having a generally planar
face 261, it
will be understood that baffles 222 may have other shapes, such as curved
(thus a non-planar
face). The positioning of any baffle 222 herein may depend on an angle at
which the
respective baffle 222 is mounted, and will generally be at an angle a between
0 degrees to 90
degrees relative to the vertical axis (i.e., an angle defined by where a plane
of face 261
intersects a vertical axis 227), as illustrated by way of example in Figure
2E. In aspects, the
angle a may be in the range of about 30 degrees to about 60 degrees.
Dimensions of baffles
222 herein may be dependent upon variables, such as the size of the HX unit
200, proximity
of other baffles 222, and the angle a of the baffle orientation, and may
change from those
depicted. The angle a of baffle orientation may help direct airflow into and
toward the
exhaust outlet 218a, such that air may be more easily drawn through the HX
unit 200.
1003871 The dominant acoustic frequency f of the fan 208 may depend on the
intended
operating speed of the fan 208 and/or number of fan blades 211. The baffle(s)
222 may be
designed, configured, and oriented (positioned) to optimize a reduction in
amplitude of fan
noise. One or more baffles 222 may be made to include or be fitted with a
sound absorbing
material 262. The material 262 may be mineral wool or another suitable
material. The sound
absorbing material 262 may be capable of reducing the level of at least the
dominant acoustic
frequency by 10 dB or more. In an analogous manner, the sound absorbing
material may
reduce the amplitude of the original fan noise.
1003881 One or more baffles 222 may be positioned approximately a quarter
wavelength Qi
below where the fan 208 is mounted. The quarter wavelength Qi may be
calculated based on
the dominant acoustic frequency f generated by the fan 208. By referring to a
quarter
wavelength distance, it will be understood that it may be a multiple of the
quarter wavelength,
i.e., at or close to the position at which the acoustic wavelength is at its
maximum.
1003891 In the instance of using a plurality of sets of baffles 222, it may be
desirous to arrange
baffles 222 in sets postionable at the quarter wavelength (e.g., Q1 to Q4) of
a different
48
CA 2969703 2017-06-06
acoustic frequency in order to target different frequencies for acoustic
damping. In this
respect, baffles 222 of respective sets may be oriented at various angles a,.
As the baffles 222
may be at varied angles (ix, the entire face of the respective baffle 222 may
not be at the same
quarter wavelength position, which allows for some variation in the position
of the baffles.
Generally speaking, a baffle midpoint 224 of the baffle 222 may be positioned
at the
respective quarter wavelength position, but this may depend on the acoustic
profile of the fan
208.
1003901 In aspects, there may be a first (or 'upper') set of baffles 263. One
or more of the first
set of baffles 263 may be configured in a manner whereby a first baffle plane
261 (respective to
a first baffle planar surface) intersects the vertical axis 227 of the frame
at an angle a. The angle
a may be in the range of about 30 degrees to about 60 degrees. In embodiments,
each baffle 222
of the first set of baffles 263 may be coupled to the frame 202 in a manner
whereby the
respective angle a of each of the first set of the baffles 263 is in the range
of about 30 degrees to
about 60 degrees. It is within the scope of the disclosure that the angle a of
each respective
baffle 222 of the first set of baffles 263 may be substantially similar;
however, the angle a of
each baffle 222 may also be varied with respect to the angles of the other
baffles.
1003911 The sets of baffles may each have a respective angle a, such as al for
the first set, a2 for
the second set, etc. In aspects, the angle of each may be substantially the
same, such as within
about 1 to about 5 degrees.
1003921 The baffles 222 may be pivotablly connected directly to the frame 202.
Alternatively,
the baffles 222 may be fixedly connected to the frame 202, such as with a nut-
bolt connection or
weld. In this respect, one or more baffle mount couplers 221 may be connected
to the frame 202
via coupling to multiple points of either or both of horizontal and vertical
members 250, 251. In
general, the vertical member 251 may have a plurality of baffle mount couplers
221 thereon. In
aspects, each vertical member 251 may have in the range of about three to
about five baffle
mount couplers 221. The baffle mount coupler 221 may have a hole or slot
configured to align
with a corresponding frame hole or slot, whereby a bolt or pin from the baffle
222 may be
inserted therethrough.
1003931 The HX unit 200 may be optimized for the greatest amount of sound
absorption by
taking into account variables such as the number of baffles 222, distance
between baffles 222
(or sets of baffles), baffle length, and density of sound absorbing material.
1003941 As shown in Figure 2D, a lower part (or bottom region) of the frame
202 may be defined
by a plurality of horizontal members 250 and/or horizontal support plates
252b. Various support
plates 252b may have one or more baffle mount couplers 221b installed or
mounted thereon.
49
CA 2969703 2017-06-06
The lower part of the frame 202 may be configured in a manner to accommodate
various
equipment, piping, ducts, or other structure within the HX unit 200, such as
housing 245.
Accordingly, baffles 222, such as baffles that are part of a lower set of
baffles 246, one or more
of which may be non-isosceles trapezoidal in shape, may also be configured in
a manner to
accommodate various equipment piping, ducts, etc.
1003951 The lower set of baffles 246 may include one or more asymmetrical
baffles 222, with
one or more of which that may be polygonal. The housing 245 may have one or
more baffle
mount couplers 221b installed or mounted thereon. Equipment and components in
the lower
part of the frame 202 may have a noise blocking material associated therewith.
In aspects, the
noise blocking material may be vinyl. The noise blocking material may be
adhered to a
respective surface. Other parts or components of FIX unit 200 may include
noise blocking
material adhered thereto.
1003961 The baffle mount coupler(s) 221 may be integral to respective vertical
member 251 (or
other mountable structure, such as horizontal support plate 252b), or may be
coupled therewith
via rigid and sturdy connection, such as a weld, rivet, or other suitable
manner. The baffle
mount coupler 221 (or 22 lb) may include an extended baffle mount element 233
(or 233b)
oriented to or at a predetermined angle f3. In this respect, when the
respective baffle 222 is
coupled therewith, the baffle angle a may be substantially equal to the
predetermined angle 3, as
shown by way of example in Figure 2E.
1003971 The first set of baffles 263 may include in the range of about three
to about five
baffles 222. The first set of baffles 263 may be arranged in a generally
symmetrical manner
to each other, such that a first baffle 222 is associated with a first side
region 242a, a second
baffle 222 is associated with the second side region 242b, and so on. The
configuration of
the set of baffles may result in a first airflow region 230. As would be
apparent to one of
skill in the art, the volume of airflow in the first region 230 may be greater
than at other
regions, and thus a larger region 230 (relatively) may be desirous. Figure 2C
illustrates the
sets of baffles may be configured in a manner whereby the positioning of
baffles form a
pseudo 'chevron' shape 220 (in cross-sectional) within the interior 229.
1003981 While baffle shape is not meant to be limited, and may vary amongst
respective baffles
of the first set of baffles 263, the baffle shape may be generally isosceles
trapezoidal in nature.
In this respect the baffles 222 of the first set 263 may have at least some
minimal clearance with
respect to each other upon installation and orientation within the HX unit
200.
1003991 There may be additional baffles 222, such as a second set of baffles
268, a third set of
baffles 269, and so forth. The configuration of the second set of baffles 268
may result in a
CA 2969703 2017-06-06
second airflow region proximate thereto, and similarly, the configuration of
the third set of
baffles 269 may result in a third airflow region proximate thereto.
1004001 While the number of baffles 222 (including sets of baffles) is not
meant to be limited,
there may be spatial and operational constraints and considerations. For
example, too many
baffles may result in inability for adequate airflow, and too few baffles may
have no effect on
negating unwanted noise.
1004011 At the same time, a sound absorbing material 262 (see also Figure 3B)
within the
baffle(s) may provide the synergistic effect of reducing decibels of the noise
attributable to
operation of the fan 208. A person standing next to a fan and radiator may not
be able to have
an audible conversation with another person standing relatively adjacent
thereto, as the loudness
may be in excess of 70 dBs. In contrast, beneficially the operation of the FIX
unit 200
configured with the baffles 222 in accordance with embodiments of the
disclosure results in
significantly reduced noise whereby person-to-person conversation in the
proximate vicinity of
the FIX unit 200 is possible. The reduced loudness may be in the range of
about to 20 dB's to
about 65 dB's.
1004021 Accordingly, the HX unit 200 may include the second set of baffles
268, each of the
second set of baffles configured at an angle a to the vertical axis 227. While
not meant to be
limited, the angle a of any of the baffles 222 may be in the range of about 0
degrees to about
90 degrees. In aspects, the angle a of any of the baffles 222 of the second
set of baffles 268
may be in the range of about 30 degrees to about 60 degrees. Each of the
second set of baffles
268 may be connected to the frame 202 in a manner comparable to that of the
first set 263.
As such, the second set of baffles 268 may be connected to respective baffle
mount couplers
221.
1004031 The HX unit 200 may include additional sets of baffles, such as a
third set of baffles,
fourth (or 'lower') set of baffles, and so forth. Each and every baffle of any
respective set of
baffles may be coupled to the frame 222 via the respective and corresponding
baffle mount
couplers. Each of the third set of baffles 269 may be configured with an
orientation at an angle
a to the vertical axis 237. That is, each respective baffle 222 of the third
set 269 may have a
plane 261 that intersects the vertical axis 237 at the angle a. The angle a
may be in the range of
about 30 to about 60 degrees.
1004041 It is within the scope of the disclosure that respective baffles of
any particular set of
baffles may be asymmetrical. Thus, as an example, one or more of the baffles
of the first set of
baffles may be generally isosceles trapezoidal in shape, while the remaining
baffles of the first
set are not (i.e., the remaining baffles are other quadrilateral in shape,
polygonoal,
51
CA 2969703 2017-06-06
hemispherical, and so on). The shape of the baffle may need to made to account
other internals
of the HX unit 200, such as piping, ducts, other subcomponents, etc. (e.g.,
housing 245, Figure
2D).
1004051 In aspects, the HX unit 200 may include four sets of baffles. One or
more, including all,
baffles 222 may have a respective plane 261 (associated to an effective planar
baffle face
surface). The respective plane 261 may intersect the vertical axis 227 at an
angle a in the range
of about 0 to about 90 degrees. In aspects, the respective angle a may be in
the range of about
30 to about 60 degrees.
1004061 The core(s) 206 may be coupled to the frame 202 in accordance with
embodiments
disclosed herein, including directly, or indirectly via mounting a cooler 204
to the frame 202.
The cooler 204 may include the core 206 and a tank. The core(s) 206 may
include one or more
tanks (such as inlet tank 277 and outlet tank 280) welded thereto. The inlet
tank 277 may be
associated with a tank inlet 278. Similarly, the outlet tank 280 may be
associated with a tank
outlet 284.
1004071 As shown in the drawings and as would be understood by one of skill in
the art, each set
of baffles may have a respective first baffle associated with a first side
region of the HX unit
200. As it follows, each set of baffles may have a respective second baffle
associated with a
second side region of the HX unit 200, a respective third baffle associated
with a third side
region, respective fourth baffle associated with a fourth side region, and so
on.
1004081 Referring now to Figures 3A and 3B together, an isometric view of a
baffle, and a lateral
cross-sectional view of a baffle, respectively, in accordance with embodiments
disclosed
herein, are shown. As illustrated by way of example, the baffle (including any
baffle of the
disclosure) 222 may include one or more rigid members 237. The rigid member
237 may be a
mesh. The mesh 237 may include various cross-linking or interconnected
structure that may
result in a plurality of orifices or openings 238. The orifices 238 may be in
the range of about
0.1 inches to about 2 inches in mesh size.
1004091 The baffle 222 may include a baffle frame 264. The baffle frame 264
may be a unitary
piece, or the combination of multiple subpieces. As shown, the baffle frame
264 may have a
generally elongated linear member 239, as well as a non-linear member 240 (as
a result of a
curve, plurality of linear segments, bend, etc.). While other shapes are
within the scope of the
disclosure, one or both of the elongated member 239 and the non-linear member
240 may have a
generally u-shape cross-sectional 241, as shown in Figure 313.
1004101 As such, each of the elongated member 239 and the non-linear member
240 may have a
first side 265 a,b, a middle 266 a,b, and a second side 267 a,b, respectively.
There may be a first
52
CA 2969703 2017-06-06
mesh 237a connected to the first side 265a of the elongated member 239 and the
corresponding
first side 265b of the non-linear member 240. In a similar manner, there may
be a second mesh
237b connected to the second side 267a of the elongated member 239 and
corresponding second
side 267b of the non-linear member 240.
1004111 The mesh 237 a,b may be connected to the members 239, 240 in a secured
or other fixed
manner, such as weld or other suitable form of attachment. As shown in Figure
3B, the baffle
222 may form an effective enclosure or have a resultant baffle chamber 236.
The baffle
chamber 236 may be filled with a material 262, which may be sound absorbing.
The material
262 may be mineral wool, such as a mineral wool product provided by Roxul,
Inc. (subsidiary
of Rockwool International). The material 262 may have other characteristics,
such as non-
combustible, high melting point, fire retardant, hypoallergenic, and
chemically inert, any of
which may be useful for the environment associated with a HGD (e.g., 203,
Figure 2A). The
material 262 may be a 'green' material made from recycled materials.
1004121 While the baffle 222 may be constructed and otherwise completed prior
to insertion of
the material 262, case of insertion of the material 262 may be achieved prior
to final
construction. For example, the first mesh 237a may be welded to the first side
265a of the
non-linear member 239, then the second mesh 237b may be welded to the second
side 267a
of the linear member 239, and then the material 262 may be inserted into
chamber 236. Once
the material 262 is inserted, each side 265b and 267b the non-linear member
240 may be
correspondingly welded with the first and second mesh.
1004131 One or more, including all, baffles 222 may include the material 262.
The presence of
the sound absorbing material may contribute to a reduction of the loudness of
the dominant
acoustic frequency of the fan by at least 10 dB. At least one of the sets of
baffles may be
positioned approximately a quarter wavelength below the fan mounted to the
outlet. The
quarter wavelength may be calculated based on the dominant acoustic frequency
(f) generated
by the fan (208).
1004141 One of ordinary skill in the art would appreciate that embodiments
herein provide for
an improved heat exchanger unit of the present disclosure that need not have
one or more
baffles therein.
1004151 Referring now to Figures 4A, 4B, and 4C together, an isometric partial
view of a
radiator core, a close-up downward view of a tank welded to a core, and an
isometric view or
a core end welded to a tank end, respectively, in accordance with embodiments
disclosed
herein, are shown. A radiator core 206 for an FIX Unit (e.g., 200) may include
a structure
formed from stacked layers 270 a, b, etc. of corrugated fin elements. Each
layer 270 may be
53
CA 2969703 2017-06-06
mounted or otherwise arranged in manner so that channels 271a formed by the
fins in one
layer 270a lie in transverse (or albeit sometimes parallel) relation to the
channels 271b
formed by the fins in adjacent layers 270b, whereby fluid flow passing through
the channels
may be in cross-flow or counterflow relation in alternate layers.
1004161 While only some layers of the core 206 are shown, various numbers of
finned layers
may be similarly stacked for completing the core 206, the number of layers
depending on the
particular application.
1004171 A parting sheet 272 may be placed between adjacent layers to maintain
separation
between alternate fluid flow paths, and an outer cover bracket(s) 281 may also
be used,
including for structural support. The cover bracket 281 may be similar to the
parting sheets
272, but of thicker stock for added strength. The cover brackets 281 may be
brazed to the
core 206 (or parts of core 206, such as sheets 272) on each respective side.
1004181 In aspects, the core 206 may be a structure in which a first fluid
passes through
alternate layers of the core in one direction and a second fluid passes
through the remaining
layers in a direction perpendicular to the first fluid.
1004191 The core 206 may include external fins 273, which may be associated
with each layer
where airflow passes therethrough. The core 206 may include internal fins 274,
which may be
associated with each layer where a HGD utility fluid F passes therethrough.
1004201 The fin elements of layers 270 a,b may be made of aluminum, or other
material
suitable for heat transfer, including copper, brass, steel, and composite. In
aspects, the fins
may be made of 3003 aluminum. Each layer 270 may have a fin density of about 4
to about
30 fins per inch. In aspects, layers 270 of the external and internal fins
273, 274 may have in
the range of about 10 to about 15 fins per inch.
1004211 In manufacture, the layers 270 of fins may be laid alternatingly
transverse to each other
between parting sheets 272, and fitted with respective header bars 275 and
face bars 276. A
brazing material may be placed between respective sheets 272 and bars 275,
276. The brazing
material may be 4004 aluminum, or other comparable material.
1004221 The layers are pressed and held together, and then placed into a
brazing oven (or heating
furnace, etc.). The brazing operation is finished by taking out the core from
the oven, and
then cooled. The brazing may be controlled with time and temperature. The
assembled unit
may be a 'core' 206.
1004231 The core 206 may be part of a cooler 204 (or cooling circuit). There
may be an inlet
tank 277 and an outlet tank (not shown here), which may be welded to a core
end 206a of the
core 206. 'the tank 277 may be welded in a manner whereby a HGD utility fluid
F may flow
54
CA 2969703 2017-06-06
therein, and into respective layers 270b of internal fins 274. Although not
shown here, the
inside of inlet tank 277 may be divided by one or more partition walls or
plates, for which
fluid may flow therein. The inlet tank may have one or more tank inlets 278.
The tank inlets
278 may be configured in a manner whereby a fluid may be transferred into the
tank 277 via
the inlets 278. Various piping, tubing, etc. may be connected to the tank
inlets 278, as may
be desired for a particular application, and as would be apparent to one of
skill in the art.
Fluid may be generally evenly distributed through the respective channels 271
as a result of
inherent resistance from the fin stack configuration.
1004241 With brief additional reference to Figure 2A, in operation, a utility
fluid F from HGD
203 may be transferred into the HX unit 200. The transfer may be direct or
indirect (such as
from a holding tank). Within the unit 200, the fluid may flow into a tank
chamber (not
shown) via inlet 278 of inlet tank 277. The fluid then distributes into the
various alternating
layers 270 b, etc. and respective channels 271b.
1004251 Similarly airflow 216 may be drawn into HX unit 200, and into the
various
perpendicular and alternating layers 270 a, etc. and respective channels 271a.
The HX unit
200 may be configured for passing atmospheric air through or in contact with
the core 206, so
as to reduce the temperature of the service fluid circulated through the core
206. In this
respect, a fan (or fan system) 208 may be rotatable about a fan axis so as to
draw in (or
suction, etc.) atmospheric air inwardly through channels 271a, resulting in
airflow through
the core 206. The fan 208 may operate in a manner whereby airflow may move in
a
generally horizontal direction from external of the core 206, through the core
206, and into
the interior of the HX unit 200, whereby the heated air then may transition to
a generally
vertical direction and out as exhaust 218.
1004261 The service fluid FIh0, having a temperature hotter than the airflow,
may be cooled (and
conversely, the airflow warms). Cooled service fluid Fi_coid leaves the
cooling circuit via a fluid
outlet 284. Various piping, tubing, etc. may be connected to the tank outlet
284, as may be
desired for a particular application, and as would be apparent to one of skill
in the art. In
some aspects, the tank outlet 284 may be in fluid communication with an inlet
of a
subsequent cooling circuit also connected with the frame 202.
1004271 Cooled utility fluid may be returned from the HX unit 200 to a source
tank, or directly to
the IIGD 203. Thus, service fluid from the heat generation unit 203 may be
circulated in a
cooling circuit in a systematic and continuous manner. As will be appreciated,
a suitable
circulating pump (not shown) may be provided to circulate the service fluid
through the core
cooler 204.
CA 2969703 2017-06-06
1004281 Header bars 275 and face bars 276 may be mounted adjacent to the sides
of fins 274
and 273, respectively, the bars being brazed between the extending ends of the
parting sheets
272. The face bars 276 may be coupled parallel to the channels 271b and serve
to block the
sides of the channels to prevent fluid leakage, add structural stability and
strength to the core
206, and provide a structure to which the tanks may be welded.
1004291 To direct the fluid flow into the channels, tanks may be welded to the
core 206 at the
fluid inlet side 206a, or the fluid outlet side, or commonly both sides. Since
the core 206
(including the fins), parting sheets, and bars are normally joined by brazing,
welding the
tanks directly to the core 206 may be of concern as the welding temperature
may be about or
in excess of 1200 F. These temps may leave the core 206 distorted, and
promote flow and
leaching of the braze alloy.
1004301 The bars 275, 276 may have a respective bar length 286, which may
include pointed
extension 283. Thus the bar 275 or 276 may have an effective brazing length
285.
Accordingly, at least some or all of the brazing material between the bar and
respective
parting sheet may heat, and even partially melt during a weld process;
however, the brazing
length 285 is sufficient enough to prohibit or deter flow of the brazing
material, and after
weld heat is removed, the braze resolidfies in place.
1004311 In essence, the bars 275 and 276 are part of a core end 206a, which
has an effective
core end mass Mce approximately defined by the mass within region Mce. Mce may
be
determined by mass within a volume (e.g., brazing length 285 x fin stack
height x core
width). In a similar respect the tank (277, 280) has a tank end 277a, which
has an effective
tank end mass Mte within region Mte. Mte may be defined by a volume of
material at the
tank end (e.g., tank wall thickness x tank length x tank width). The effective
core end mass
Mce may be greater than the effective tank end mass Mte. This may provide the
ability so
that whereby when the tank is welded to the core there is a natural barrier
within the core (as
a result of its increased mass) that prevents leaching or flowing of the
brazing material. And
where maybe some of the brazing material becomes molten or gooey, this portion
of material
may be held in situ by the part of the brazing material that remains solid.
1004321 The tank end 277a may be welded to the core end 206a. The weld 293 may
be any
desired weld suitable and known to one of skill in the art for welding a tank
to a core. In
embodiments, the weld 293 may be a v-groove weld. Weld material 294 may be
used to
accomplish the weld.
56
CA 2969703 2017-06-06
1004331 Other coolers 204 (e.g., 204 b, c, d, etc.) may be generally similar
in nature, and
suitably configured for the cooling of various service fluids from the heat
generation device
203.
1004341 Referring now to Figures 7A and 7B together, an isometric view of a
monitored heat
exchanger system that includes a monitoring module, a heat exchanger unit, and
a heat
generation device operably coupled together, and an isometric component
breakout of a
monitoring module associated with a heat exchanger unit, respectively, in
accordance with
embodiments disclosed herein, are shown. Embodiments herein apply to a heat
exchanger
unit that may be an inclusive assembly of a number of components,
subcomponents, which
may be further associated with operable systems, subsystems, assemblies,
modules, and so
forth that may overall be referred to as a system, such as heat exchanger
monitoring system
701 (or monitored heat exchanger system).
1004351 The heat exchanger unit 700 may be part of an overall system 701 that
may be
monitored. Monitored system 701 includes at least one monitoring module 1000,
as
described herein. While it need not be exactly the same, system 701 may
include various
features and components like that of other systems or units described herein,
and thus
components thereof may be duplicate or analogous
1004361 The heat exchanger unit (or HX unit) 700 may include a solid integral
frame (or
skeletal frame) or may be a frame 702 that includes a number of elements
arranged and
coupled together. The simplified diagram of Figure 7B illustrates the HX unit
700 coupled
with a heat generation device 703. As can be seen a hot service fluid Fhoi may
circulate from
the HGD 703 to the HX unit, be cooled via core 706 (also sometimes recognizes
as a cooler
or radiator, or part thereof), and recirculate as a cooled service fluid Fc001
back to the HGD
703. Other equipment including other piping, valves, nozzles, pumps, tanks,
etc. need not be
shown, as one of skill in the art would have an understanding of coupling the
HX unit 700
with the 11GD 703 for operable transfer of one or more service fluids
therefrom.
1004371 As shown system 701 may include the use of a monitoring module 1000.
The
monitoring module 1000 may be usable for monitoring one or more conditions,
properties,
characteristics, etc. associated with the operation of the FIX unit 700. As an
example, the
monitoring module 1000 may be configured and used for measuring fouling
associated with
the core 706.
1004381 The module 1000 may be a modular assembly having various components
and
subcomponents associated and operable together, and like that described
herein. The module
57
CA 2969703 2017-06-06
1000 may be sized and optimized accordingly for operable coupling with any
type of
radiator, including that associated with the FIX unit 700. One of skill in the
art would
appreciate the monitoring module 1000 could be retrofitted to equipment
already used in the
field. Just the same the monitoring module 1000 could come associated and
operably
engaged with newly fabricated equipment. In aspects, a single HX unit 700 may
have
multiple monitoring modules 1000 associated therewith.
1004391 The module 1000 may be coupled to the frame 702 on a respective side
of the FIX
unit 700 (including in place of a rock grate [not shown]). As shown, the
module 1000 may
include a mounting frame 1001. The mounting frame 1001 may be an integral
piece having a
first mounting frame side 1002, a second mounting frame side 1003, a mounting
frame top
1004, and a mounting frame bottom (not shown here). The mounting frame may
have a
cover panel or guard 1007, which may be integral or coupled therewith.
Analogous to the
mounting frame 1001, the cover panel 1007 may have a first cover panel side
1008, a second
cover panel side 1009, a cover panel top 1010a, and a cover panel bottom
1010b. Although
quadrilateral in the general sense, it is within the scope of the disclosure
that the mounting
frame 1001 and/or the cover panel 1007 may have different shapes, including as
might be
necessary to be mounted with a different shape HX unit or radiator core.
1004401 As shown in Figure 7A, the cover panel 1007 may have a plurality of
cover panel
apertures 1012 configured to coincide with a respective plurality of mounting
frame apertures
1014a. Likewise the mounting frame 1001 may have a plurality of other mounting
frame
apertures 1014b configured to coincide with a respective plurality of
apertures 782 of the
frame 702.
1004411 One of skill would appreciate the mounting frame 1001 may be connected
to the frame
702 via insertion of a plurality of connectors (fasteners, etc.) 1013 through
apertures 1014b and
782, which may be screws, nut/bolt, quick disconnect, etc. Similarly, the
cover panel may be
connected to the mounting frame 1001 via insertion of a plurality of cover
connecters 10H
through apertures 1012 and 1014a. The use of a separable mounting frame 1001
and cover
panel 1007 allows for simple connect and disconnect from each other, which may
make it easier
for tasks such as maintenance or cleaning. In this respect the panel 1007 may
be easily
attachable and removable from the HX unit 700.
1004421 There may be a dampener(s) 1018 disposed between various components.
For example,
there may be one or more dampeners 1018 disposed between the frame 702 and the
mounting
frame 1001. Analogously, there may be one or more dampeners 1018 disposed
between the
cover panel 1007 and the mounting frame 1001. The dampener(s) 1018 may be
suitable for
58
CA 2969703 2017-06-06
reducing vibration stemming from operation of the heat exchanger unit 700 that
may otherwise
be induced into or received by the monitoring module 1000. The dampener 1018
may be one or
more layers of a rubbery material, which may have one or more sides with an
adhesive thereon.
1004431 The cover panel 1007 may have a front side 1019 and a back side 1020.
From a
reference standpoint the front side 1019 may be that which tends to face
outward or away from
the HX unit 700. Or where the cover panel 1007 may be considered exposed or
external to the
surrounding environment. The back side 1020 of the cover panel 1007 may be
associated with
one or more sensors 1021. The monitoring module 1000 may have a number of
different types
of sensors associated therewith, including pressure, temperature, noise, etc.
Sensor 1021 may be
referred to as an airflow sensor, in that the operation of sensor 1021 may
help measure,
determine, or otherwise sense airflow 716 moving into (or out of) the HX unit
700. In aspects,
there may be about 1 to about 26 sensors 1021 associated with module 1000.
However, the
number of sensors 1021 is not meant to be limited, and may change depending on
desired
monitoring requirements for a given type of heat exchanger.
1004441 The sensor 1021 may be mounted to the cover panel 1007, and operated
in a manner to
sense airflow into the HX unit 700 as a result of suction. However, the sensor
1021 may just as
well be mounted and operated in a manner to sense airflow out of the HX unit
700 (as a result of
blowing). The sensor 1021 may be operated and setup to detect airflow through
the core 706
during a clean, unfouled state, which may then be used as a baseline. As the
HX unit 700 fouls,
airflow through the core 700 may be effected, and the electrical signal
generated by the sensor
1021 will have a measurable, detectable change in signal strength.
1004451 In some embodiments, the configuration (including its size, type
placement, etc.) and
operation of the sensor 1021 is believed of significance. For example, the
sensor 1021 may need
to be robust and durable, yet not of any (or as minimal as possible) effect on
the operation of the
HX unit 700. For example, a sensor that has an orifice may be just as prone to
fouling and
plugging, and ultimately failure and inability to measure airflow. Other
sensors that are large or
bulky may be cost prohibitive and/or attribute to unacceptable pressure drop
attributable to the
monitoring module.
1004461 As shown the sensor 1021 may have a rotating member 1024 (rotatable
around an axis)
with a plurality of blade members 1023 extending radially therefrom. The blade
members 1023
may be configured to induce movement of the rotating member 1024 (rotatable
about an axis)
much in the same way the blades of a windmill function. That is, upon movement
of air thereby,
at least a minor amount of force (the amount of force being dependent upon the
amount of
59
CA 2969703 2017-06-06
movement of air) will be felt by the blade members 1023, and as a result of
being connected to
the rotating member 1024, induce rotation of the member 1024.
1004471 The rotating member 1024 may be associated with one or more bearings,
whereby the
rotating member 1024 may be freely movable with respect to a sensor housing or
chassis 1025.
In aspects, the rotating member 1022 may have a shaft or rotor, and the
housing 1025 may be
configurable as a (pseudo) stator. The sensor 1021 may have various circuitry
and hardware
associated therewith, whereby rotation of the shaft may induce or generate an
electric current
(e.g., via inductive properties attributable to a rotor/stator configuration).
1004481 The sensor 1021 may thus be configured to generate an electric current
(or in the
analogous sense, a voltage) proportional to an amount of rotation. The
current, or really, a
signal, may then be communicated to a microcontroller (1006, Figure IC), which
may be part of
a logic circuit of the monitoring module 1000.
1004491 Referring briefly to Figure 7C, a component breakout view of a
controller housing
usable with a monitoring module, and having various internal components,
according to
embodiments of the disclosure, is shown. Equipment, such as hardware and
software, pertaining
to the logic circuit may be operably arranged within a controller housing 1016
(which may have
a controller housing top I016a).
1004501 The controller housing 1016 may be weatherproof and dustproof, and
this may have an
ability to protect internals from undesired environmental and harsh weather
conditions. The
housing 1016 may be mountable to housing mount 1015. The housing 1016 and
housing
mount 1015 may have corresponding openings 1017a, 1017b, respectively, for
accommodating the passing of wires and other circuitry thercthrough. The
openings 1017 a.b
may be sealed, such as with silicone.
1904511 The controller housing 1016 may be configured with suitable components
and hardware
for that accommodate or provide functionality of the monitoring system 201.
Such components
may include, for example, the microcontroller 1006 (in operable communication
and connected
with sensors 1021 via wiring, circuitry, and so forth), a regulator (such as a
voltage regulator)
(not shown here), a power supply or battery (or battery cell) 1027a, a charger
(e.g., battery
charger) (not shown here), solid data storage 1028, a Wi-Fi module 1029, a GSM
module 1030,
a CAN-Bus module 1031, and various indicators, such as audio or visual (e.g.,
ROB LEDs)
1032.
1004521 Referring now to Figures 7A, 7B, and 7C, together, the microcontroller
1006 may be
readily useable and compatible with various hardware, including switches,
LED's, and
sensors. The microcontroller 1006 may include HDM1 output to a screen such as
a TV or a
CA 2969703 2017-06-06
monitor, as well as wirelessly communicating to smart phones or computers via
Wifi or
Bluetooth.
1004531 A signal from the microcontroller 1006 may generate a signal
communicable as a
message or other form of warning, including by way of one or more of audio,
video/visual
(e.g., Green, Yellow, Red LEDs), email, SMS/text, CAN Bus, such as J1939.
Thus, the
module 1000 may include a LED response interface. In embodiments, LED lights
may be
configured to provide varied warnings based on monitoring and detection. For
example, and
with respect to certain percentage of fouling, the LED lights may flash green
(0-25% fouled),
yellow (25-75% fouled), or red (75-100% fouled). In a similar manner, a
warning may be
transmitted (e.g., text/SMS, push notification, email, J1939, etc.) based on a
percentage of
fouling.
1004541 Software herein may be able to read values from the SD card and create
a look-up
table.
1004551 Referring now to Figures 8A and 813 together, a logic circuit process
flow diagram and a
logic circuit decision tree operable as part of a monitoring module,
respectively, according to the
embodiments of the disclosure, are shown. As illustrated and previously
touched on, the
monitoring module 1000 may include various hardware and software operable
together as an
overall 'logic circuit' in which logic of the present disclosure may be
implemented.
1004561 The logic circuit may be programmable and compatible to various
computer devices
that include, for example, PCs, workstations, laptops, mobile devices, cell
phones, tablets,
PDAs, palm devices, servers, storages, and the like. Generally, in terms of
hardware and
related architecture, the logic circuit may include one or more
microcontrollers 1006,
memory or data storage 1028, and one or more I/O devices (not shown), which
may all be
operatively communicatively coupled together, including such as circuitry,
pins, and via a
local interface (not shown).
1004571 As would be apparent to one of skill in the art the local interface
may be understood
to include, for example, one or more buses or other wired or wireless
connections. The local
interface may have additional elements, such as controllers, buffers (caches),
drivers,
repeaters, and receivers, to enable communications. Further, the local
interface may include
address, control, and/or data connections to enable appropriate communications
among the
aforementioned components.
1004581 The logic circuit may receive power from a source, such as (upwards
of) a 5V
supplier. The power, which may be in the form of a voltage, may be regulated
by regulator
1026. An example voltage regulator includes AC DC Converters_ Recom Power
RAC03-
61
CA 2969703 2017-06-06
05SE/277 (85 ¨ 305 VAC TO V). Power from the regulator 1026 may be fed to a
power
supply or battery 1027a. The battery 1027a may be a LiPo battery cell
(1200mAh, 3.7V).
The battery 1027a may be charged by a battery charger 1027b. An example
battery charger
includes LiPo Energy Shield.
1004591 The microcontroller (or sometimes just 'controller') 1006 may be a
hardware device
configured for execution of software (programming, computer readable
instructions, etc.),
which may be stored (programed thereinto) in a controller memory. The
controller 1006 may
be any custom made or commercially available processor, a central processing
unit (CPU), a
digital signal processor (DSP), or an auxiliary processor among several
processors associated
therewith. As an example, the controller 1006 may be an Arduino MEGA 2560
microcontroller.
1004601 Mierocontroller 1006 may be powered via the battery1027a. In an
embodiment, the
microcontroller 1006 may be powered, directly or indirectly, via operation of
the sensor(s)
1021. With power initiation, such as at startup of the monitoring module
(1000), the
controller 1006 may be in communicative operability with the SD storage 1028.
An example
SD storage includes Yun Shield.
1004611 The microcontroller 1006 may be in communicative operability with Wi-
Fl module
1029. An example Wi-Fi module includes ESP8266 or particle photon.
1004621 The microcontroller 1006 may be in communicative operability with GSM
module
1030. An example GSM module includes Arduino GSM Shield V2 or Particle
Elctron.
1004631 The microcontroller 1006 may be in communicative operability with CAN-
Bus
module 1031. An example CAN-Bus module includes CAN-BUS shield with MCP25I5
CAN bus controller.
1004641 The microcontroller 1006 may be in communicative operability with LEDs
1032
1004651 The controller memory may include any one or combination of random
access
memory (RAM), dynamic random access memory (DRAM), static random access memory
(SRAM), ROM, erasable programmable read only memory (EPROM), electronically
erasable
programmable read only memory (EEPROM), programmable read only memory (PROM),
tape, compact disc read only memory (CD-ROM), disk, diskette, cartridge,
cassette or the
like, and so forth. Moreover, the controller memory may incorporate
electronic, magnetic,
optical, and/or other types of storage media.
1004661 Software in the controller memory may include one or more separate
programs, each
of which may include an ordered listing of executable instructions for
implementing logical
functions. Software in the controller memory may include a suitable operating
system (OS),
62
CA 2969703 2017-06-06
compiler, source code, and/or one or more applications in accordance with
embodiments
herein. Software may be an application ("app") that may include numerous
functional
components for implementing the features and operations of embodiments of the
disclosure.
1004671 The OS may be configured for execution control of other computer
programs, and
provides scheduling, input-output, file and data management, memory
management, and
communication control and related services. In aspects, the app may be
suitable for
implementation of embodiments herein to all commercially available operating
systems.
1004681 Software may include an executable program, script, object code,
source program, or
any other comparable set of instructions to be performed.
1004691 Software may be written as object oriented programming language, which
may have
classes of data and methods, or a procedure programming language, which has
routines,
subroutines, and/or functions. The programming language may include for
example Python,
HTML, XHTML, Java, ADA, XML, C, C++, C#, Pascal, BASIC, API calls, ASP
scripts,
FORTRAN, COBOL, Perl, .NET, Ruby, and the like.
1004701 The input/output (I/O) device(s) may include an input device such as,
for example, a
mobile device, a keyboard, a mouse, a touchscreen, a microphone, a camera, a
scanner, and
so forth. The I/O device(s) may include an output device such as, for example,
a display, a
printer, an email, a text message, and so forth. The I/O device may include
devices
configurable to communicate both inputs and outputs, such as a router, a
telephonic interface,
a modulator/demodulator or NIC (that may be suitable to access remote devices,
other files,
devices, systems, or a network), a radio frequency (RF) or other transceiver,
a bridge, and so
forth. The I/O devices may include one or more components for communicating
over various
networks, such as the Internet or intranet.
1004711 In aspects, external computers (and respective programming) may be
communicably
operable with the logic circuit (and thus monitoring module 1000).
1004721 In operation of the logic circuit, the microcontroller may: execute
software stored
within the memory; communicate data to and from the memory; and/or generally
control
operations of the logic circuit pursuant to the software.
In Operation (with logic)
1004731 The operation of the logic circuit may be further understood with an
explanation of
the tree diagram of Figure 8B. The tasks are numbered in above the task name.
Task 1 is to
acquire data from the sensors 1021. This may include sampling the data from
the sensors
1021 over a short time (e.g., 60 seconds) and taking an average and standard
deviation. Task
63
CA 2969703 2017-06-06
2 compares the standard deviation of the new data with a predetermined
acceptable limit
saved on a memory of the system. This allows sporadic or outlier data to be
excluded. This
consequently ensures that, for example, windy conditions will not be
interpreted as fouling,
and thus preventing false alarms.
1004741 If the sampled data is sporadic and not acceptable, a delay (task 5)
will be
implemented to retry (or loop) for data acquisition. Either the data will be
acceptable or will
remain sporadic. If the sporadic data is very consistent and the number of
sporadic data
occurrence exceeds a predefined value (task 3), the user is notified of an
error (task 4)
(typically an installation error).
1004751 Once the sampled data of task 1 has been accepted, it is checked with
a lookup-table
(LUT) flag (task 6), which is essentially a binary that allows for the
completion of the fouling
lookup-table. This flag indicates if the fouling lookup-table is already
generated and exists or
not (Initially and during installation, this flag is false, meaning that the
table is not yet
generated). If the LUT flag from task 6 is false, the programming uses an
averaging method
to create a fouling lookup-table containing the data output of the sensors
1021 in a clean
condition (tasks 7 and 8). After generating the LUT table through multiple
iterations
(averaging), the system turns the LUT flag true.
1004761 If the LUT flag is true, the overall fouling is then calculated in
task 9. ibis consists of
referencing acquired data from the sensors 1021 against the fouling lookup-
table which
represents a clean condition. If fouling is evident, a foul state is recorded
(task 10). In task
11, the fouled state is evaluated. If consecutive data has determined that the
radiator is in a
severe (as defined by the user) fouling condition, then the user will be
notified using one or
more of the defined warning methods (task 10), e.g., LED, email, J1939
message, etc. If the
foul count is not too high, a delay will occur (task 12), and the system will
continue to collect
data to proactively warn the user in case of any fouling.
1004771 Referring now to Figure 9, a side view of a monitored heat exchanger
system that
includes a monitoring module, a heat exchanger unit, and a heat generation
device, operably
coupled together, in accordance with embodiments disclosed herein, are shown.
Embodiments herein apply to a heat exchanger unit that may be an inclusive
assembly of a
number of components and subcomponents. The heat exchanger unit 900 may be
part of an
overall system 901 that may be monitored. Monitored system 901 may include at
least one
monitoring module 1000, as described herein.
1004781 While it need not be exactly the same, system 901 may be like that of
system 701 of
Figures 7A-7C (or other systems herein), and components thereof may be
duplicate or
64
CA 2969703 2017-06-06
analogous. Thus, only a brief discussion of system 701 is provided,
recognizing that
differences, if any, should be discernable by one of skill in the art.
Accordingly it would be
further understood that aspects of system 901 may include various additional
improvements
related to airflow, noise reduction, cooling efficiency, structural integrity,
and combinations
thereof.
1004791 The HX unit 900 may include one or more cores 906 being associated
with respective
monitoring module(s) 1000. It should be apparent that while HX unit 900 may
have a
plurality of sides (or side regions), each of the plurality of sides having
respective coolers, not
every side need have a monitoring module 1000. Still, it may every well be
that every cooler
is monitored via one or more modules 1000. Moreover, while the module 1000 may
be
particularly useful for monitoring fouling, other conditions of the HX unit
900 (or system
901) may be monitored.
1004801 One or more cores 906 may be associated with and proximate to a
respective
protective grate (not viewable), which may be useful for protecting fins of
the core 906. The
monitoring module 1000 may be installed in place of the grate.
1004811 Although not shown in entire detail here, the I IX unit 900 may
include a fan system.
Briefly, the fan system may include related subcomponents, such as a fan that
may be
understood to include a rotating member with a plurality of fan blades
extending therefrom.
The fan may be operable by way of a suitable driver, such as a fan motor,
which may be
hydraulic, electrical, gas-powered, etc. Conduits may be configured for the
transfer of
pressurized hydraulic fluid to and from the motor. As such, pressurized
hydraulic fluid may
be used to power the motor.
1004821 The fan system may include a fan shroud, which may be generally
annular. The fan
shroud may be coupled to the frame via connection with the top plate. The
shroud may
include one or more lateral openings 960 to accommodate the passing of the
mount bar 909
therethrough. The mount bar 909 may be a rigid bar or beam that extends from
one side 959a
of the HX unit 900 to another side 959b.
1004831 A fan rock guard 947 may be coupled to a shroud 913. The shroud 913
may be
proximate to an aeroring (not shown). The aeroring may be annular in nature,
and have a
ring cross-section that may have a radius of curvature. Thus, the aeroring may
have a
rounded surface that may aid in improving airflow and reducing pressure in and
around the
fan system. Without the aeroring, eddies and other undesired airflow may occur
in corners of
the top of the frame.
CA 2969703 2017-06-06
1004841 The configuration of the shroud and aeroring may provide added ability
for further
streamlining airflow, which may beneficially reduce overall power
requirements.
1004851 The fan system can be operable to draw in and direct the flow of air
916. The air 916
may be drawn through the sides of the HX unit 900 (and respective cores, which
may then be
used to cool one or more utility fluids F) and out as heated exhaust 918. The
benefit of such
a configuration is the ability to provide cooling in parallel, versus series.
In a series
configuration, the airflow becomes progressively hotter as it passes through
each cooling
circuit, resulting in a loss in cooling efficiency. This can be especially
problematic where
ambient air temperature is usually hotter, like Texas and Oklahoma.
1004861 Utility fluid F (or multiple F's) may include by way of example, lube
oil, jacket water,
turbo (such as for an engine), transmission fluid (such as for a pump), and
hydraulic fluid
(such as for the fan drive).
1004871 One of skill in the art would appreciate that airflow through the core
906 may be
generally in a path parallel to a horizontal axis. In an analogous manner, the
fan 908 may
have an axis of rotation generally parallel to a vertical axis. Accordingly,
airflow through the
HX unit 900 may be transitioned from (approximately) horizontal to vertical as
the airflow
moves through the core 906 and out the fan exhaust 918.
1004881 As such, by way of example, utility fluid F1 may be transferred from a
heat generating
device 903 at a hot temperature into an HX unit inlet 978, cooled with airflow
via core 906,
and transferred out of an HX unit outlet 984 back to the HGD 903 at a cooler
temperature.
While not meant to be limited, HGD 903 may be an engine, a genset, a motor, a
pump, or
other comparable equipment that operates in a manner whereby a utility fluid
is heated.
1004891 There may be one or more cores 906. A 'cooler' or 'cooling circuit'
may include one
or more cores 906. The FIX unit 900 may have between about 1 to about 8
cooling circuits,
which each may be configured for cooling in parallel to each other.
1004901 The HX unit 900 may include various sound reduction or integrity
features like that as
described herein, such as various sound baffle configurations and/or flexible
mount
assemblies.
1004911 In operation, a utility fluid F from HGD 903 may be transferred into
the HX unit 900.
The transfer may be direct or indirect (such as from a holding tank). Within
the unit 900, the
fluid may flow into a tank chamber (not shown) via inlet 978 of inlet tank.
The fluid then
distributes into the various alternating layers and respective channels of the
core 906.
1004921 Similarly airflow 916 may be drawn into HX unit 900, and into the
various
perpendicular and alternating layers and respective channels of the core 906.
The HX unit
66
CA 2969703 2017-06-06
900 may be configured for passing atmospheric air through or in contact with
the core 906, so
as to reduce the temperature of the service fluid circulated through the core
906. In this
respect, a fan (or fan system) may be rotatable about a fan axis so as to draw
in (or suction,
etc.) atmospheric air inwardly through channels (or fins 973), resulting in
airflow through the
core 906.
1004931 The service fluid Fi-hot, having a temperature hotter than the
airflow, may be cooled (and
conversely, the airflow warms). Cooled service fluid Fi_coid leaves the
cooling circuit via a fluid
outlet 984. Various piping, tubing, etc. may be connected to the tank outlet
984, as may be
desired for a particular application, and as would be apparent to one of skill
in the art. In
some aspects, the tank outlet 984 may be in fluid communication with an inlet
of a
subsequent cooling circuit also connected with the frame 902.
1004941 Cooled utility fluid may be returned from the HX unit 900 to a source
tank, or directly to
the HGD 903. Thus, service fluid from the I IGD 903 may be circulated in a
cooling circuit in
a systematic and continuous manner. As will be appreciated, a suitable
circulating pump (not
shown) may be provided to circulate the service fluid through the core cooler
306.
1004951 Other coolers of the IIX unit 900 may be generally similar in nature,
and suitably
configured for the cooling of various service fluids from the HGD 903.
1004961 Embodiments herein provide for a system (and related method of
operating or using the
system) using on or more components described herein. For example, such a
system may
include a wellbore and other wellbore and production equipment, as well as a
frac trailer. The
frac trailer may include a frac pump, a HGD, and a 1-IX unit as pertaining to
the disclosure.
1004971 Other embodiments herein provide for a method of doing business
related to a monitored
heat exchanger system. The method may include the steps of having a customer
relationship
between a provider and recipient (i.e., customer, client, etc.). The method
may include charging
a one-time or ongoing fee related to the monitored system. The provider may
install the
monitored heat exchanger system as a new standalone skid. Alternatively, the
provider may
retrofit existing equipment for operable communication with a monitoring
module as described
herein. Thus, in embodiments there may be a first transaction related to
equipment purchase or
use, followed by a second transaction related to installation.
1004981 Another part of transaction, or alternatively, a separate transaction,
may pertain to a
license for the use software (or programming) related to a logic circuit of
the monitoring
module, as the provider may own copyright in the respective software (or be an
exclusive
licensee).
1004991 The provider may provide services and equipment directly, or may use a
subcontractor.
67
CA 2969703 2017-06-06
1005001 Once a recipient has completed its applicable transaction, and the
system has been
associated with at least one monitoring module, the recipient may be provided
with the
capability to track and monitor one or more characteristics or properties
respective to an
individual heat exchanger unit performance. Reported information (or
parameters) may
include percentage of fouling, time between warnings, cleaning frequency,
etc). This
information may be groupable by location or region to see if one is performing
better than
another. The system may also indicate them how many units are in green, yellow
or red,
which may further help identify problem regions, operators etc.
1005011 The method may further include a field service component. That is, the
provider, or
affiliated field service business, may be able to offer (give, etc.) a
solution, whereby the
monitored system sends out an alarm of some variation, such as SMS/text,
email, etc. In this
respect the recipient has the option to address the alarm, or have the
provider tend to. In
other words, in the event the monitored system provides a warning about, for
example, a dirty
radiator, the recipient is prompted to find a remedy that can alleviate or
mitigate process
downtime.
1005021 The business method may thus include steps pertaining to receiving a
warning via the
monitoring module, and selecting a remediation option, such as cleaning with
dry ice or a
pressure washer or in their yard when the pump comes back in from the field.
In aspects,
these steps may be handled remotely and/or off the jobsite. Accordingly, the
recipient need
not even have to take any action, as the provider may handle all steps.
1005031 The business method may include providing an incentivized transaction
if the
monitoring module is used with a HX unit that is sold by the provider. The
monitoring
module may have components as described herein, and the HX unit may likewise
have
components of any HX unit described herein.
Advantages.
1005041 Embodiments of the disclosure advantageously provide for an improved
heat exchanger
unit useable with a wide array of heat generating devices.
1005051 Embodiments of the disclosure advantageously provide for new and
innovative systems,
hardware, software, and related methods, for monitoring a heat exchanger unit.
An associated
monitoring module may beneficially be retrofitted to existing equipment.
Sensors of the module
are configured for precision, and in conjunction with a microcontroller, are
able together to
accurately measure characteristics of a heat exchanger in real-time. In
particular, the
68
CA 2969703 2017-06-06
characteristic may be fouling. The ability to accurately warn of fouling
alleviates the need for
conventional and cumbersome remediation methods.
1005061 The heat exchanger unit of the disclosure may provide for the ability
to reduce sound
attributable to a point source, such as a fan. The fan may have a dominant
acoustic frequency
that may be reduced by at least 10 decibels. The heat exchanger unit may be
configured with a
particular baffle configuration that helps reduce sound. The baffles may be
configured to have
or contain a sound absorbing material. At the same time the baffle
configuration may help
drastically improve streamlined airflow, which further helps reduce sound
emission and
improves overall efficiency of the heat exchanger unit because of lowered
power requirements.
1005071 The heat exchanger unit may advantageously provide for the ability to
simultaneously
cool multiple utility fluids in parallel.
1005081 Advantages of the disclosure provide for a compact design with more
heat transfer area
in limited space, more heat transfer capability, reduced overall height by
arranging heat
exchanger cores at all four sides in general cube shape.
1005091 Embodiments of the disclosure advantageously provide for the ability
to improve
structural integrity of a heat exchanger unit. A radiator core of the unit may
have an increased
mass on a core end that may substantially prohibit or eliminate runoff of
brazing material during
a welding process.
10050:11 The heat exchanger unit may provide for the ability to provide an
'absorber' effect with
any thermal expansion. That is, one or more components may be coupled together
via the use of
a flex amount assembly, the assembly having a deformable member associated
therewith. As
thermal expansion occurs, the deformable member may deform resulting to absorb
the
expansion motion or stress.
1005111 Advantages herein may provide for a more convenient and realizable
welding practice
for core and tank, and a more convenient and flexible mount assembly.
1005121 While embodiments of the disclosure have been shown and described,
modifications
thereof can be made by one skilled in the art without departing from the
spirit and teachings
of the disclosure. The embodiments described herein are exemplary only, and
are not
intended to be limiting. Many variations and modifications of the disclosure
presented herein
are possible and are within the scope of the disclosure. Where numerical
ranges or
limitations are expressly stated, such express ranges or limitations should be
understood to
include iterative ranges or limitations of like magnitude falling within the
expressly stated
ranges or limitations. The use of the term "optionally" with respect to any
element of a claim
is intended to mean that the subject element is required, or alternatively, is
not required. Both
69
CA 2969703 2017-06-06
alternatives are intended to be within the scope of any claim. Use of broader
terms such as
comprises, includes, having, etc. should be understood to provide support for
narrower terms
such as consisting of, consisting essentially of, comprised substantially of,
and the like.
[00513] Accordingly, the scope of protection is not limited by the description
set out above
but is only limited by the claims which follow, that scope including all
equivalents of the
subject matter of the claims.
Thus, the claims are a further description and are an
addition to the preferred embodiments of the disclosure. The inclusion or
discussion of a
reference is not an admission that it is prior art to the present disclosure,
especially any
reference that may have a publication date after the priority date of this
application. The
disclosures of all patents, patent applications, and publications cited herein
are hereby
incorporated by reference, to the extent they provide background knowledge; or
exemplary,
procedural or other details supplementary to those set forth herein.
CA 2969703 2018-10-17
