Note: Descriptions are shown in the official language in which they were submitted.
IMPROVED HEAT EXCHANGER UNIT
BACKGROUND
Field of the Disclosure
100011 This disclosure generally relates to a heat exchanger unit with
characteristics of
improved: airflow, monitoring, noise reduction, cooling efficiency, and/or
structural integrity. In
embodiments, the disclosure relates to a heat exchanger unit used in
connection with equipment
found in an industrial setting. In particular embodiments, 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.
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 08z.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
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
CA 2971746 2017-06-23
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.
100051 A particular segment in the upstream area of oil and gas production
pertains to fracing.
Now common, 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.
100061 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.
100071 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.
100081 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.
100091 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 include
the engine 103 and the frac pump 113, as well as a radiator (or cooler, heat
exchanger, etc.) 100.
2
CA 2971746 2018-09-13
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 I', 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.
loom 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 are 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, F?, F3, etc.), the air becomes
progressively hot (e.g., cooling
in series, where Tout > T2 > Ti > Tamb). See Figure 1C. 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 may be
3
CA 2971746 2017-06-23
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.
100171 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 lE 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".
4
CA 2971746 2017-06-23
=
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.
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 A related area of relevance pertains to a blender unit that creates the
frac slurry, and
transfers to unit 105. Figure IF illustrates a blender unit 160 that may be
mobile, such as via
skid (or chassis, trailer, etc.) 161, and is known by one of skill in the art
for making a slurry of
particulate material, such as sand blended with fracturing fluid, proppant,
and so forth. The
blender unit 160 usually has one or more blending tubs 162, from which the
slurry is discharged
and transferred via a booster pump 164 to a frac pump (113, Figure 1B), which
then injects the
slurry into a well and into the producing zones.
100231 Material (e.g., sand) may be provided to the tubs 162 through one or
more screw augers
163. The augers 163 may be may be powered simultaneously or separately,
depending on the
required amount of particulate matter. The screw augers 163 and the booster
pump 164 may be
powered by a heat generating device 103b, either of which may be a diesel
engine or other
comparable driver.
100241 The blender unit 160 may have a main control system, which may be
located in a cab 166
of the trailer 161. The control system may, among other things, control the
auger speeds, booster
pump speed, engines, and other related equipment. A suitable computer may be
used to control
the operation of the system so that a desired slurry is achieved. As one of
skill would appreciate.
the heat generating device(s) 103b may be coupled with a respective
radiator(s) 100b so that
necessary cooling of service fluids is possible. Radiator 100b alas has the
inherent problems
described herein related to noise, orientation, size, integrity, fouling, and
so forth.
100251 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
(HOD) 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
CA 2971746 2017-06-23
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.
100261 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.
100271 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).
100281 It is routine to have (indeed, need) some type of heat exchange ability
in such settings.
As set forth in US S/N 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.
100291 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.
100301 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, whereby
the air and the service fluid can 'exchange heat' via the surface material of
the stacked fins
between the passageways (e.g., aluminum).
100311 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
6
CA 2971746 2017-06-23
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.
0031 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.
100341 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.
100351 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.
100361 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.
100371 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.
100381 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.
7
CA 2971746 2018-09-13
100381 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.
100391 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.
100401 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.
100411 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.
100421 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,
and is useable in a wide range of settings.
100431 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.
100441 There is a need in the art for a heat exchanger that can accommodate
spatial constraints,
and is fighter in weight. There is a need in the art for a heat exchanger that
has improved or
reduced sound emissions. "lhere 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.
8
CA 2971746 2017-06-23
SUMMARY
100451 Embodiments of the disclosure pertain to a heat exchanger unit that may
include a frame
comprising a top region, a bottom region, and a plurality of side regions.
There may be a first
cooler coupled with the frame proximate to a respective side region and with
its long axis
generally parallel to an axis. There may be a second cooler coupled with the
frame proximate to
the top region, which may have its long axis generally perpendicular to the
axis. In aspects, there
may be an inner airflow region within the heat exchanger unit. There may be a
first baffle
disposed within the inner airflow region. The first baffle may be positioned
or otherwise
oriented as having a first angle to the axis.
100461 Embodiments of the disclosure pertain to a blender skid for creating a
frac fluid mixture
that may include one or more of a blender; a first diesel engine; and a heat
exchanger unit
configured to cool at least one service fluid transferable between the heat
exchanger unit and the
first diesel engine.
100471 The heat exchanger unit may include a frame comprising a top region, a
bottom region,
and a plurality of side regions. There may be a first cooler coupled with the
frame proximate to a
respective side region. The first cooler may have its body or long axis
generally parallel to the
axis.
100481 The heat exchanger unit may include a second cooler coupled with the
frame. The
second cooler may have its body or long axis generally perpendicular to the
orientation of the
first cooler.
100491 In aspects, there may be an inner airflow region within the heat
exchanger unit. There
may be a first baffle disposed within the inner airflow region. The first
baffle may have a planar
reference at a first angle to the axis.
100501 Embodiments for the disclosure pertain to a method for monitoring a
heat exchanger unit
that may include the steps of operatively coupling the heat exchanger unit
with at least one diesel
engine. The heat exchanger unit may include a frame comprising a top region, a
bottom region,
and a plurality of side regions. There may be a first cooler coupled with the
frame proximate to a
respective side region and generally parallel to an axis. There may be a
second cooler coupled
with the frame proximate to the top region. The second cooler may be oriented
or otherwise
positioned with its body generally perpendicular to the axis. There may be an
inner airflow
9
CA 2971746 2017-06-23
region within the heat exchanger unit. There may be a first baffle disposed
within the inner
airflow region. The baffle (or a reference plane thereof) may be at a first
angle to the axis.
100511 The method may include associating a monitoring module with an airflow
side of at least
one of the first cooler and the second cooler
100521 The monitoring module may include one or more of 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; a logic circuit in operable communication with the at
least one sensor, and
further comprising: a microcontroller configured with computer instructions
for performing a
plurality of tasks.
100531 The tasks may include one or more of: 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 an indication based on a result of
the comparing the set
of data to the set of lookup data step.
100541 The method may include performing an action based on an indication from
the
monitoring module.
100551 Embodiments of the disclosure pertain to a heat exchanger unit that may
include a frame
comprising a top region, a bottom region, and a plurality of side regions.
There may be a first
cooler coupled with the frame proximate to a respective side region, with its
body or long axis
generally parallel to a reference axis. There may be a second cooler coupled
with the frame
proximate to the top region, with its long axis generally perpendicular to the
reference axis.
100561 The heat exchanger unit may include a first fan mounted to the frame
external to a first
side of the first cooler. There may be an inner airflow region within the heat
exchanger unit.
There may be a first baffle disposed within the inner airflow region. The
first baffle may have an
associated reference plane intersecting the reference axis at a first angle.
100571 Embodiments herein pertain to a monitored heat exchanger unit of the
present disclosure.
CA 2971746 2017-06-23
100581 These and other embodiments, features and advantages will be apparent
in the following
detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
100591 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:
100601 Figure IA shows an overview process diagram of a conventional land-
based fracturing
operation;
100611 Figure 1B shows a side view of a frac pump truck;
100621 Figure IC shows a close-up profile view of a horizontal heat exchanger
useable with the
frac pump truck of Figure 1B;
100631 Figure ID shows a simple schematic view of a heat exchanger used with a
heat
generation device in a general industrial setting;
100641 Figure IE shows a close-up side view of a typical temperature profile
when a tank is
welded to a radiator core;
100651 Figure IF shows an isometric view of a mobile blender unit;
100661 Figure 2A shows a side view of a heat exchanger unit coupled with a
heat generation
device according to embodiments of the disclosure;
100671 Figure 211 shows an isometric view of a -frame of the heat exchanger
unit according to
embodiments of the disclosure;
100681 Figure 2C shows a side cross-sectional view of an HX unit configured
with a plurality of
baffles according to embodiments of the disclosure;
100691 Figure 2D shows an isometric view of a set of a plurality of baffles
according to
embodiments of the disclosure;
100701 Figure 2E shows a close-up partial side view of a baffle coupled to a
vertical member
according to embodiments of the disclosure;
100711 Figure 3A shows an isometric view of a baffle according to embodiments
of the
disclosure;
11
CA 2971746 2017-06-23
100721 Figure 3B shows a lateral cross-sectional view of a baffle according to
embodiments of
the disclosure;
100731 Figure 4A shows an isometric partial view of a radiator core according
to embodiments
of the disclosure;
100741 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;
100751 Figure 4C shows a view of a tank welded to a core according to
embodiments of the
disclosure;
100761 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;
100771 Figure 5B shows a component breakout view of a flexible mount assembly
according to
embodiments of the disclosure;
100781 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;
100791 Figure 5D shows a component breakout view of another flexible mount
assembly
according to embodiments of the disclosure;
100801 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;
100811 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;
100821 Figure 6A shows a downward looking isometric view of a top region of a
heat exchanger
unit according to embodiments of the disclosure; and
100831 Figure 6B shows an isometric view of a fan mount according to
embodiments of the
disclosure;
100841 Figure 6A shows a downward looking isometric view of a top region of a
heat exchanger
unit according to embodiments of the disclosure;
100851 Figure 6B shows an isometric view of a fan mount according to
embodiments of the
disclosure;
12
CA 2971746 2017-06-23
100861 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;
100871 Figure 7B shows an isometric view of a frame of the heat exchanger unit
according to
embodiments of the disclosure;
100881 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;
100891 Figure 8A shows a logic circuit process flow diagram according to
embodiments of the
disclosure;
100901 Figure 811 shows a logic circuit decision tree operable as part of a
monitoring module
according to embodiments of the disclosure;
100911 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;
100921 Figure 9A shows a side view of a monitored heat exchanger system that
includes a
monitoring module, a heat exchanger unit with at least one topside mounted
cooler, and a heat
generating device coupled together according to embodiments of the disclosure;
100931 Figure 10A shows an isometric view of a heat exchanger unit with a top
mounted cooler
coupled in fluid communication with a heat generation device according to
embodiments of the
disclosure;
100941 Figure 10B shows a lateral cutaway view of the heat exchanger unit of
Figure 10A
according to embodiments of the disclosure;
100951 Figure 10C shows a breakout view of a sidewall according to embodiments
of the
disclosure;
100961 Figure 11 A shows a front isometric view of a heat exchanger unit with
two top mounted
coolers according to embodiments of the disclosure;
100971 Figure 1 IB shows a back isometric view of the heat exchanger unit of
Figure 1 1B
according to embodiments of the disclosure; and
100981 Figure 1 1C shows a blender skid having the heat exchanger unit of
Figures 1 1A-1 1B
according to embodiments of the disclosure.
13
CA 2971746 2017-06-23
DETAILED DESCRIPTION
100991 Herein disclosed are novel apparatuses, systems, and methods that
pertain to an improved
heat exchanger, details of which are described herein.
1001001 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.
1001011 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.
1001021 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.
Temis
1001031 The term "noise" as used herein can refer to a sound, including an
undesirous sound.
1001041 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
14
CA 2971746 2017-06-23
,
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
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.
1001051 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.
1001061 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.
1001071 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 (Hz) which is defined
as cycles per
second. The higher the frequency, the more high-pitched a sound is perceived.
1001081 The term "dominant acoustic frequency" can refer to a respective sound
that is most
discernable or noticeable to a human ear or instrument.
1001091 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.
101101 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.
1001111 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).
1001121 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.
CA 2971746 2017-06-23
,
1001131 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.
1001141 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.
1001151 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, fraccing,
and frac. A frac
operation can be land or water based.
1001161 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.
1001171 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.
I Ieat can also be exchanged to another fluid, such as air.
1001181 The term "cooling circuit" as used herein can refer to a cooler and
respective
components.
1001191 The term "core" as used herein can refer to part of a cooler, and can
include multiple
layers of fins or fin elements.
i001201 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.
1001211 The term "heat generating device" (or sometimes `FIGD') as used herein
can refer to an
operable device, machine, etc. that emits or otherwise generates heat during
its operation, such as
16
CA 2971746 2017-06-23
,
an engine, motor, a genset, or a pump (including the pump and/or respective
engine). The I ICiD
can be for an industrial or a residential setting.
1001221 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.
1001231 The term "baffle" as used herein can refer to a component used within
a heat exchanger
unit to help regulate or otherwise improve airflow therethrough. The baffle
can be one-piece in
nature or configured from a number of subcomponents connected together. There
can be a
plurality of baffles, including various 'sets' of baffles. The baffle(s) can
include noise absorbing
material.
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
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 (Mb), 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 "machining" ("machine", "machined", etc.) as used herein can
refer to re-
machining, cutting, drilling, abrading. cutting, drilling, forming, grinding,
shaping, etc. of a
target piece.
1001301 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
17
CA 2971746 2017-06-23
, .
have an effective mass, or a core end mass. The mass of the core end is less
than the mass of the
whole core.
1001311 The term "mounted" 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.
1001321 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.
1001331 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.
1001341 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.
1001351 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.
1001361 The term "voltage regulator" as used herein can refer to a device or
logic circuit that
maintains a constant voltage level.
1001371 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).
1001381 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).
18
CA 2971746 2017-06-23
1001391 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.
1001401 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.
1001411 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.
1001421 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.
1001431 The term "blender unit" as used herein can refer to one or more pieces
of equipment
arranged together for the purpose of forming a frac slurry. The blender unit
can have one or
more engines associated and operably engaged with a respective cooler. The
blender unit can,
but need not have to be, mobile.
1001441 Embodiments herein pertain to a heat exchanger unit that may include a
vertical axis; and
a frame. The -frame may include a top region, a bottom region. and a plurality
of side regions. A
first cooler may be coupled with the frame proximate to a respective side
region. The first cooler
may be mounted with its long axis generally may be parallel to the Vertical
axis.
1001451 The heat exchanger unit may include a second cooler coupled with the
frame. The
second cooler may be coupled proximate to the top region. The second cooler
may coupled and
oriented in a manner whereby its long axis may be generally perpendicular to
the vertical axis.
1001461 The heat exchanger unit may include an inner airflow region therein.
There may be a
first baffle disposed within the inner airflow region, and at a first angle to
the vertical axis.
1001471 The heat exchanger unit may include a third cooler. The third cooler
may be coupled
with the frame proximate to a respective side region. The third cooler may be
coupled adjacent
the first cooler. The third cooler may be coupled and oriented with its long
axis generally
parallel to the vertical axis. The heat exchanger unit may include a fourth
cooler.
19
CA 2971746 2017-06-23
1001481 The fourth cooler may be coupled proximate to the top region, and may
be adjacent the
second cooler. The fourth cooler may coupled and oriented in a manner whereby
its long axis
may be generally perpendicular to the vertical axis.
1001491 The heat exchanger unit may include a second airflow region
partitioned from the inner
airflow region. The second airflow region may be associated with the third
cooler and the fourth
cooler. There may be a second baffle disposed within the second airflow
region. The second
baffle may be coupled and oriented a second angle to the vertical axis. The
first angle and/or the
second angle may be in the range of about 30 degrees to about 60 degrees. The
first angle and
the second angle may be at least substantially the same.
1001501 Either of the first baffle and the second baffle may include a sound
absorbing material.
In aspects, the sound absorbing material may be mineral wool or other
comparable material.
1001511 The heat exchanger unit may include at least one fan configured to
operate and produce a
point source dominant acoustic frequency. Sound absorbing material may be
capable to reduce
the point source dominant acoustic frequency by at least 10 dB.
1001521 The heat exchanger unit may include a first fan mounted to the frame
external to a first
side of the first cooler. There may also be a second fan mounted to the frame
external to a first
side of the third cooler. Each of the first fan and the second fan may have an
axis of rotation
substantially perpendicular to the vertical axis.
1001531 One or more coolers of the exchanger unit may be configured to permit
airflow to pass
therethrough. In aspects, operation of the first fan and/or the second fan may
result in airflow
through one or more respective coolers and airflow regions, and out of an
outlet of the I-IX unit.
1001541 -I-he FIX unit may include a first sidewall; a second sidewall; a back
wall; and a bottom.
At least one of the first sidewall, the second sidewall, the back wall, and
the bottom may have a
sound absorbing material. At least one of the first sidewall, the second
sidewall, the back wall,
and the bottom may have a vinyl-based material. In aspects, At least one of
the first sidewall, the
second sidewall. the back wall, and the bottom may have an inner layer of
sound absorbing
material; and an exterior layer of a vinyl-based material.
1001551 The heat exchanger unit may include a monitoring module proximately
coupled to at
least one of the first cooler. the second cooler, the third cooler, and the
fourth cooler. The
monitoring module may include: a cover panel; an at least one sensor coupled
with the cover
panel; at least one controller housinL, coupled with the cover panel; and a
microcontroller
CA 2971746 2017-06-23
disposed within the controller housing and in operable communication with the
at least one
sensor.
[001561 At least one sensor of the module 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 and programmed with computer instructions for
processing the
system signal. In aspects, the system signal may pertain to an amount of
fouling.
1001571 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. At least
one of the
plurality of sensors may include a plurality of blades radially extending from
the respective
rotating member.
1001581 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.
1001591 Embodiments of the disclosure pertain to a blender skid for creating a
frac fluid mixture
that may include a blender (or tub); a heat generating device; and a heat
exchanger unit
configured to cool at least one service fluid transferable between the heat
exchanger unit and the
heat generating device.
1001601 The heat exchanger unit may include a vertical axis; and a frame
having a top region, a
bottom region, and a plurality of side regions. The unit may include a first
cooler coupled with
the frame proximate to a respective side region. The first cooler may be
mounted in a manner to
have its long axis generally parallel to the vertical axis. The unit may
include a second cooler
coupled with the frame.
1001611 In aspects, the second cooler may have its long axis generally
perpendicular to the long
axis of the first cooler. Accordingly, the second cooler may be coupled
proximate to the top
region. In other aspects, the second cooler may have its long axis generally
parallel to the long
axis of the first cooler. Accordingly, the second cooler may be coupled
proximate to one of the
plurality of side regions.
1001621 The heat exchanger unit may include an inner airflow region within the
heat exchanger
unit. There may be a first baffle disposed within the inner airflow region,
and at a first angle to
21
CA 2971746 2017-06-23
the vertical axis. The heat exchanger unit may include a second baffle
disposed therein. The
second baffle may be disposed and oriented at a second angle to the vertical
axis. The first angle
and the second angle may be in the range of 30 degrees to 60 degrees. In
aspects, either of the
first baffle and the second baffle may include or otherwise have a sound
absorbing material.
1001631 The heat exchanger unit of the skid may include a first sidewall; a
second sidewall; a
back wall; and a bottom.
1001641 At least one of the first sidewall, the second sidewall, the back
wall, and the bottom
further may include: an inner layer of sound absorbing material; and an
exterior layer of a vinyl-
based material.
1001651 Embodiments of the disclosure pertain to a method for monitoring a
heat exchanger unit
that may include one or more of coupling the heat exchanger unit with at least
heat generating
device; associating a monitoring module with an airflow side of at least one
cooler; performing
an action based on an indication of the monitoring module.
1001661 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 first cooler
coupled with the frame
proximate to a respective side region and generally parallel to the vertical
axis; a second cooler
coupled with the frame proximate to the top frame and generally perpendicular
to the vertical
axis; and an inner airflow region within the heat exchanger unit. There may be
a first baffle
disposed within the inner airflow region, and at a first angle to the vertical
axis.
1001671 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; a logic circuit in operable communication with the at least one
sensor; and a
microcontroller. The microcontroller may have computer instructions for
performing one or
more of a plurality of tasks that includes: 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
77
CA 2971746 2017-06-23
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.
1001681 "Me indication from the monitoring module 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
1001691 The monitoring module may further include one or all 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 thus have
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.
1001701 The heat exchanger unit of the method may include a third cooler; and
a fourth cooler.
1001711 Any coolers of the heat exchanger unit may have a respective core and
a respective tank.
The respective core(s) may have a core end having a core end mass. The
respective tank(s) may
have a tank end having a tank end mass. In aspects, any respective core end
mass may be greater
than any respective tank end mass.
1001721 The heat exchanger unit of the method may include a mount assembly for
coupling any
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. Any of the coolers of the heat exchanger unit may have a
mounting slot,
whereby the respective elongated fastening member may extend therethrough and
at least
partially into the frame.
1001731 The heat exchanger unit may have a second airflow region partitioned
from the inner
airflow region. The second airflow region may be associated with the third
cooler and the fourth
cooler. There may be a second baffle disposed within the second airflow
region, and at a second
angle to the vertical axis.
1001741 Other embodiments of the disclosure pertain to a heat exchanger unit
that may have a
vertical axis; a frame comprising a top region, a bottom region, and a
plurality of side regions; a
first cooler coupled with the frame proximate to a respective side region and
generally parallel to
the vertical axis; a second cooler coupled with the frame proximate to the top
region and
generally perpendicular to the vertical axis; a first fan mounted to the frame
external to a first
93
CA 2971746 2017-06-23
side of the first cooler; an inner airflow region within the heat exchanger
unit; and a first baffle
disposed within the inner airflow region, and at a first angle to the vertical
axis.
1001751 The heat exchanger unit may include a third cooler coupled with the
frame proximate to
the respective side region, and adjacent the first cooler. Thc heat exchanger
unit may include a
fourth cooler coupled with the frame proximate to the top frame, and adjacent
the second cooler.
1001761 The heat exchanger unit may include a second airflow region
partitioned from the inner
airflow region. The second airflow region may be associated with the third
cooler and the fourth
cooler.
1001771 The heat exchanger unit may have a second baffle disposed therein.
1001781 Any baffle of the heat exchanger unit may have or otherwise include a
sound absorbing
material. The sound absorbing material may be that for which is capable of
reducing noise
associated with a point source, such as noise from a fan. The sound absorbing
material may be
mineral wool.
1001791 The heat exchanger unit may include a second fan mounted to the frame
external to a first
side of the second cooler. Any fan of the heat exchanger unit may have an axis
of rotation
substantially perpendicular to the vertical axis.
1001801 The heat exchanger unit may include a monitoring module operably
associated therewith.
In aspects, the monitoring module may be proximately coupled to one of the
first cooler, the
second cooler, the third cooler, and the fourth cooler. 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.
1001811 The sensor of the module may include a rotating member configured to
generate a system
signal proportional to an amount of rotation of the rotating member. The
microcontroller may
have computer instructions for processing the system signal.
1001821 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 comprises may include a plurality of blades radially extending from
the respective
rotating member
1001831 The monitoring module may include any or all 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
74
CA 2971746 2017-06-23
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.
1001841 In aspects, the system signal may pertain to an amount of fouling.
1001851 In aspects, the heat exchanger unit may have a plurality of monitoring
modules operably
associated therewith.
1001861 Any cooler of the heat exchanger unit may have a respective core and a
respective tank,
which may further have a respective core end having a core end mass, and a
respective tank end
having a tank end mass. Although not necessary, the respective core end mass
may be greater
than the respective tank end mass.
1001871 Yet other embodiments 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 IIX 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.
1001881 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.
1001891 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.
1001901 Thc 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.
1001911 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.
CA 2971746 2017-06-23
1001921 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.
1001931 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.
1001941 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.
1001951 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.
1001961 The system may include the use of a mount assembly for coupling a
cooler to the frame
of the I IX 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.
1001971 Other embodiments of the disclosure pertain to a 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 therebetween.
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.
26
CA 2971746 2017-06-23
1001981 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.
1001991 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.
1002001 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.
1002011 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.
1002021 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.
1002031 Any respective cooler may include a weld between the tank end and the
core end that
may be a v-groove weld.
1002041 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.
1002051 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
7
CA 2971746 2017-06-23
more sensors may have a respective rotating member with a plurality of blades
extending
therefrom.
1002061 The module may include a logic circuit in operable communication with
the plurality of
sensors, and further comprising: a microcontroller and a data storage. 't he
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.
1002071 The microcontroller may be powered at least partially, directly or
indirectly, by at least
one of the plurality of sensors.
1002081 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.
1002091 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
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.
1002101 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 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
28
CA 2971746 2017-06-23
=
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.
1002111 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. 'Elms 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.
1002121 The monitoring module may be operable to provide the indication as it
pertains to an
amount of fouling on the airflow side.
1002131 The microcontroller may be powered at least partially by at least one
of the plurality of
sensors.
1002141 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.
1002151 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.
1002161 The sound absorbing material may be mineral wool.
1002171 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.
1002181 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.
1002191 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.
1002201 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.
1002211 The heat exchanger unit may have an airflow region therein.
29
CA 2971746 2017-06-23
1002221 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.
1002231 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.
1002241 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.
1002251 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.
1002261 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.
1002271 In aspects, the mount assembly may include a top plate, a bottom
plate, and a washer.
1002281 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.
1002291 The heat exchanger unit may include an axis, such as a vertical axis.
1002301 the heat exchanger unit may include an airflow region therein.
1002311 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.
1002321 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
CA 2971746 2017-06-23
vertical axis. Other baffles of other sets may likewise be configured with a
respective angle to an
applicable axis.
1002331 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.
1002341 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.
1002351 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.
1002361 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.
1002371
1002381 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.
1002391 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.
1002401 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.
1002411 Any mount assembly may include a top plate, a bottom plate, and/or a
washer.
1002421 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.
31
CA 2971746 2017-06-23
1002431 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.
1002441 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.
1002451 The method may include the step of operating the fan motor with a
pressurized hydraulic
fluid.
1002461 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.
1002471 The heat exchanger unit may include various sets of baffles, such as a
first set, second
set, third set, fourth set, etc.
1002481 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.
1002491 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.
1002501 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.
1002511 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.
1002521 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.
32
CA 2971746 2017-06-23
1002531 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.
1002541 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.
1002551 The method may include the step of using at least one baffle within
the heat exchanger
unit that has a sound absorbing material therein.
1002561 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.
1002571 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.
1002581 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.
1002591 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.
1002601 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.
1002611 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.
1002621 The heat exchanger unit and the heat generating device may be in fluid
communication.
33
CA 2971746 2017-06-23
1002631 There may be a plurality of heat exchanger units coupled with a
respective plurality of
heat generating devices.
1002641 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. In aspects, the
heat generating device
may be an engine of a blender unit. The engine may be associated with a screw
auger or blender
unit booster pump.
1002651 The system may include the frac pump in fluid communication with a
wellbore. The
system may include the booster pump in fluid communication with the frac pump.
The system
may include the blender unit in fluid communication with the frac pump skid.
1002661 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 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.
1002671 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.
1002681 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, h etc.) may include a support plate slot or groove 253.
1002691 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
34
CA 2971746 2017-06-23
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.
1002701 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.
1002711 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 FIX 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.
1002721 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 2 I
1 may be adjusted
to promote optimal and efficient cooling of the HX unit 200.
1002731 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 ran 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 11X
unit 200, repressurized. and recirculated back to the motor 212.
CA 2971746 2017-06-23
1002741 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 cfin
to about 200,000
cfm. 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.
100275] 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).
1002761 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 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.
100277] 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 I IX unit 200.
1002781 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.
36
CA 2971746 2017-06-23
1002791 The configuration of the shroud and aeroring may provide added ability
for further
streamlining airflow, which may beneficially reduce overall power
requirements.
1002801 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.
1002811 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).
1002821 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
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.
1002831 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 MX unit outlet 284 back to the HUD 203 at a cooler
temperature. While not
meant to be limited. 11GD 203 may be an engine, a gensct, a motor, a pump, or
other comparable
equipment that operates in a manner whereby a utility fluid is heated.
1002841 There may be one or more cores 206. A 'cooler' or 'cooling circuit'
may include one or
more cores 206. The EIX unit 200 may have between about I to about 8 cooling
circuits, which
each may be configured for cooling in parallel to each other.
1002851 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
37
CA 2971746 2017-06-23
bracket and a frame of a heat exchanger unit, respectively, in accordance with
embodiments
disclosed herein. are shown.
1002861 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.
1002871 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).
1002881 The OD of the outer rigid ring 1008, and ID's of bottom plate slot
1014a and core mount
slot 288 may be substantially equivalent, or to the point where ring 1008 may
fit (including with
tight tolerance fit) within one or both of the bottom plate slot 1014a and
core mount slot 288.
1002891 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.
1002901 the deformable ring 1010 may have a generally cylindrical shape. with
the ring slot
1010a. The ring slot 1010a may he concentric with respect to the ring 1010
(e.g., see Figure SF),
or may be eccentric. The clearance between the top plate 1006 and the bottom
plate 1014 may
38
CA 2971746 2017-06-23
accommodate movement of the mount 287, which may result from thermal expansion
or
contraction of the core 206.
1002911 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.
1002921 Referring now to Figures 5ll, 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.
1002931 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 1000a may include
various
components including, a bolt 1002a, a first washer 1004a, a top plate 1006a,
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.
1002941 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.
1002951 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.
39
CA 2971746 2017-06-23
1002961 Referring now to Figures 2C, 2ll, and 2E together, a side cross-
sectional view of an I IX
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.
1002971 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 retaliation, which is of
even greater
significance in the event the HX unit 200 is used in or proximate to a
residential setting.
1002981 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 FIX unit
200 may be thought of
as positionally relative to where ambient air and heated air are).
1002991 Although numerous components around or proximate to an lifill (203,
Figure 2A) may be a
source of noise, a fan 208 may produce a noise having dominant acoustic
frequency T with initial
amplitude A. To reduce noise emitted from the fan 208, the HX 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 11X 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.
1003001 Thus, instead of chaotic turbulence within the interior of the fIX
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.
1003011 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
CA 2971746 2017-06-23
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 FIX unit 200.
1003021 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.
1003031 One or more baffles 222 may be positioned approximately a quarter
wavelength Q1
below where the fan 208 is mounted. The quarter wavelength Q1 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.
1003041 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 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 Li,. As the baffles
222 may be at varied
angles a,, 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.
1003051 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
41
CA 2971746 2017-06-23
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.
1003061 The sets of baffles may each have a respective angle a, such as al for
the first set, a7 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.
1003071 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.
1003081 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.
1003091 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 221 b installed or mounted
thereon. The lower
part of the frame 202 may be configured in a manner to accommodate various
equipment, piping,
ducts, or other structure within the FIX 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.
42
CA 2971746 2017-06-23
1003101 The lower set of baffles 246 may include one or more asymmetrical
baffles 222, with one or
more of which that may be polygonal. 'Hie 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 HX unit 200 may include noise blocking material adhered
thereto.
1003111 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 221b) may include an extended baffle mount element 233 (or 233b)
oriented to or at a
predetermined angle 13. In this respect, when the respective baffle 222 is
coupled therewith, the
baffle angle a. may be substantially equal to the predetermined angle 13, as
shown by way of example
in Figure 2E.
1003121 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.
1003131 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 FIX unit 200.
1003141 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 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.
43
CA 2971746 2017-06-23
1003151 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.
1003161 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 dlls. 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 HX unit
200 is possible.
The reduced loudness may be in the range of about to 20 dB's to about 65 dB's.
1003171 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.
1003181 The FIX 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.
1003191 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,
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.,c,7., housing 245. Figure 2D).
44
CA 2971746 2017-06-23
1003201 In aspects, the I IX 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.
1003211 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.
1003221 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.
1003231 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.
1003241 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 3B.
1003251 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 mesh
237a connected to the first side 265a of the elongated member 239 and the
corresponding first side
4s
CA 2971746 2017-06-23
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.
1003261 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 I-IGD (e.g., 203, Figure 2A). The
material 262 may be a
'green' material made from recycled materials.
1003271 While the baffle 222 may be constructed and otherwise completed prior
to insertion of
the material 262, ease 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.
1003281 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).
1003291 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.
1003301 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.
46
CA 2971746 2017-06-23
A radiator core 206 for an 11X 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 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.
1003311 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.
1003321 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.
1003331 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.
1003341 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.
1003351 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
to about 15 fins per inch.
1003361 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 276.4 brazing
material may be placed between respective sheets 272 and bars 275. 276. The
brazing material may
be 4004 aluminum, or other comparable material.
1003371 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
47
CA 2971746 2017-06-23
cooled. The brazing may be controlled with time and temperature. The assembled
unit may be a
'core' 206.
1003381 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 mariner whereby a HOD utility fluid F may
flow 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.
1003391 With brief additional reference to Figure 2A, in operation, a utility
fluid F from HOD 203
may be transferred into the IIX 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.
1003401 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 11X unit
200, whereby the
heated air then may transition to a generally vertical direction and out as
exhaust 218.
1003411 The service fluid F101. having a temperature hotter than the airflow,
may be cooled (and
conversely, the airflow warms). Cooled service fluid I'
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
48
CA 2971746 2017-06-23
aspects, the tank outlet 284 may be in fluid communication with an inlet of a
subsequent cooling
circuit also connected with the frame 202.
1003421 Cooled utility fluid may be returned from the FIX unit 200 to a source
tank, or directly to the
fIGH 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.
1003431 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.
1003441 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 12000 F. These temps may leave the core 206 distorted, and promote flow and
leaching of the
braze alloy.
1003451 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.
1003461 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
vvelded to the core there is a natural barrier within the core (as a result of
its increased mass) that
49
CA 2971746 2017-06-23
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.
1003471 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.
1003481 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.
100349]
1003501 Referring now to Figures 10A and 10B together, an isometric view of a
heat exchanger
unit with a top mounted cooler, and coupled in fluid communication with a heat
generation device,
and a lateral cutaway view of the heat exchanger unit, respectively, in
accordance with
embodiments disclosed herein, are shown.
1003511 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 400 may be
like that in
many respects to heat exchanger unit 200, but as would be readily apparent
need not be the same,
and indeed as shown here may have a number of discernable differences. The
heat exchanger
unit 400 may include a solid integral frame (or skeletal frame) or may be a
frame 402 that
includes a number of elements arranged and coupled together, such as a
plurality of horizontal
elements 450 and a plurality of vertical elements 451.
1003521 Although the shape of the frame 402 need not be limited, Figures 10A
and 10B together
illustrates a generally rectangular prism shape (i.e., four side regions, a
top region, and a bottom
region) that results from the horizontal elements 450 and the vertical
elements 451 being
connected at various corners and/or generally perpendicular to one another,
and joined together
with various sheeting (or sidewall) 452. Other shapes of the frame 402 could
include cylindrical,
hexagonal, pyramidal, and so forth. As the shape of the frame 402 may vary, so
may the shape
of frame elements 450, 451.
1003531 The frame 402 may include additional frame support plates (including
interior and
exterior). sidewalls. sheeting. etc.. which may be suitable for further
coupling frame elements
together. as well as providing additional surface area or contact points for
which other
CA 2971746 2017-06-23
components may be coupled therewith. In aspects, one or more frame support
plates 454a may
have an angled inclination orientation (such as greater than 0 degrees to less
than 90 degrees
from either axis 426, 427), whereas one or more frame support plates 454b may
have a generally
horizontal orientation. One or more frame support plates (e.g., 454a) may
include a support plate
slot or groove, which may be useable for mounting the plate to the frame 402.
1003541 Members (or frame 402) 450, 451 include one or more core support mount
slots, whereby
a radiator core (or 'core') 406 may be coupled therewith. There may be a
plurality of such slots
configured and arranged in a manner whereby a plurality of cores 406 may be
coupled therewith.
One or more coolers (comprising a respective core 406) may be coupled to the
frame with
respective mount assemblies (e.g., 1000, 1000a Figures 5A-5E). There may be a
first cooler
404a and a second cooler 404b.
1003551 One or more cores 406 may be associated with and proximate to a
respective protective
grate (not shown here), which may be useful for protecting fins 473 of the
core 406.
1003561 The frame 402 may include yet other additional support or structural
elements, such as
one or more frame support bars, which may be coupled between various elements
450, 451, such
as in a horizontal, vertical, or diagonal manner. The support bar(s) may be
coupled to elements
in a known manner, such as rivet, weld, nut-and-bolt, etc.
1003571 The frame 402 may also include a plate 455, which may have a plate
opening. The plate
opening may be of a shape and size suitable for accommodating airflow
therethrough. The FIX
unit 400 may include a fan system 457. The fan system 457 may include related
subcomponents,
such as a fan 408 that may be understood to include a rotating member with a
plurality of fan
blades 411 extending therefrom. 'fhe fan system 457 may be operable by way of
a suitable
driver, such as a fan motor, which may be hydraulic, electrical, gas-powered,
etc. The fan motor
may receive power through various power cords, conduits, etc., as would be
apparent to one of
skill in the art. The fan 400 may operate in the range of about 200 rpm to
about 1200 rpm, and
may further operate in a manner to provide airflow in the range of about
10,000 cfm to about
200,000 cfm. The originating noise of the fan 408 may be the range of about 70
dB's to about
120 dB's. The frequency of noise from the fan 408 may be in the range of about
20 hz to about
20.000 hz.
1003581 The frame 402 may include a fan rock guard mount, which may be used
for the coupling
of a fan rock guard 447 thereto. The frame 402 may include a fan mount plate
449. The fan
51
CA 2971746 2017-06-23
system 447 can be operable to draw (or blow) in and direct the flow of air
416. The air 416 may
be drawn (or blown) through the sides of the IIX unit 400 (and respective
cores, which may then
be used to cool one or more utility fluids F) and out as heated exhaust 418.
The benefit of such a
configuration is the ability to provide cooling while saving space and/or
reducing noise. 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.
1003591 One of skill in the art would appreciate that airflow through the
cooler 404a may be
generally in a path parallel to horizontal axis 426. In an analogous manner,
the fan 408 may
have an axis of rotation generally parallel to horizontal axis 426. In
aspects, airflow through the
first cooler 404a may be generally parallel to the fan 408 axis of rotation.
In aspects, airflow
through the second cooler 404b may be generally perpendicular to the fan 408
axis of rotation.
Accordingly, airflow through the I4X unit 400 may be transitioned from
(approximately)
horizontal to vertical as the airflow moves through the unit 400 and out as
heated exhaust 418.
1003601 As such, by way of example, utility fluid F1 may be transferred from a
heat generating
device 403 at a hot temperature into an HX unit inlet 478, cooled with airflow
cooler 404a, and
transferred out of an HX unit outlet 484 back to the FIGD 403 at a cooler
temperature. While not
meant to be limited, EIGD 403 may be an engine (including diesel engine), a
genset, a motor, a
pump, or other comparable equipment that operates in a manner whereby a
utility fluid is heated.
1003611 There may be one or more cores 406. A respective 'cooler' or 'cooling
circuit' may
include one or more cores 406. The HX unit 400 may have between about 1 to
about 8 cooling
circuits, which each may be configured for cooling in parallel to each other.
1003621 Any cooler 404 a,b (or respective core) of the disclosure may be
mounted to the frame
402 with a flexible mount assembly 1000 as described herein (see, e.g.,
Figures 5A-5F and
supporting text). Although not shown here, the flexible mount assembly 1000
may be coupled to
the frame 402 (or also vertical member 451 and/or horizontal member 450) via a
nut plate or
threaded receptacle.
1003631 Airflow through an HX unit 400 may be turbulent and otherwise chaotic.
In addition, a
fan 408 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 408 (or HX unit 400).
In addition or the
alternative. the noise from the fan 408 may exceed a regulation, which is of
even greater
significance in the event the 11X unit 400 is used in or proximate to a
residential setting.
.5?
CA 2971746 2017-06-23
1003641 As shown, the FIX unit 400 may be configured with one or more baffles
422, which may
be arranged or otherwise installed on a pseudo-interior side 429 of the unit
400 (the "exterior"
429a and "interior" 429 of the FIX unit 400 may be thought of as positionally
relative to where
ambient air and heated air are). Ingress and egress may be provided via access
way 492. The
access way may be closed via door 493, which may be, for example, hingedly
mounted to the
frame. The door 493 may be shut and held shut via one or more securing members
(not viewable
here).
1003651 Although numerous components around or proximate to the FIGD 403 may
be a source of
noise, the fan 408 may produce a noise having dominant acoustic frequency
with initial
amplitude. To reduce noise emitted from the fan 408, the I IX unit 400 may be
configured with one
or more baffles 422 coupled to the frame 402 (such via frame member 454a). In
aspects, airflow
through FIX unit 400 may actually increase as a result of the presence of
baffle 422. This
synergistic effect is believed attributable to the baffle 422 (and position of
the baffles) helping to
streamline the airflow, rather than acting as a restriction. The baffle 422
may be like that
described herein (see, e.g., Figures 3A-3B and related text).
1003661 Thus, instead of chaotic turbulence within the interior of the HX unit
400, a baffle shape
and an angled orientation of the baffles 422 may result in smoothing out the
transition of the
airflow from generally horizontal to generally vertical, reducing the airflow
recirculation within
the interior of IIX unit 400, 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.
1003671 While the baffle 422 may be shown herein as having a generally planar
face, it will be
understood that baffle 422 may have other shapes, such as curved (thus anon-
planar face). The
positioning of any baffle 422 herein may depend on an angle at which the
respective baffle 422
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 the baffle face
intersects an axis). In
aspects, the angle a may be in the range of about 30 degrees to about 60
degrees. Dimensions of
the baffle 422 herein may be dependent upon variables, such as the size of the
FIX unit 400,
proximity of other baffles. 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 an exhaust
outlet, such that air may be more easily drawn through the I IX unit 400.
s;
CA 2971746 2017-06-23
1003681 The baffle(s) 422 may be designed. configured, and oriented
(positioned) to optimize a
reduction in amplitude of fan noise. One or more baffles 422 may be made to
include or be fitted
with a sound absorbing material (262. Figure 3B). The material may be mineral
wool or another
suitable material as described herein.
1003691 The baffle 422 may be non-isosceles trapezoidal in shape, may also be
configured in a
manner to accommodate various equipment piping, ducts, etc. While baffle shape
is not meant to
be limited, the baffle shape may be generally rectangular in nature.
1003701 There may be additional baffles 422, such as a second baffle, a third
baffle, and so forth.
The use of the second baffle may result in a second airflow region proximate
thereto.
1003711 While the number of baffles 422 (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.
1003721 At the same time, the sound absorbing material (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
408. 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 HX unit 400 configured with the
baffle 422 in
accordance with embodiments of the disclosure results in significantly reduced
noise whereby
person-to-person conversation in the proximate vicinity of the HX unit 400 may
be possible. The
reduced loudness may be in the range of about to 20 dB's to about 65 dB's.
1003731 Referring briefly to Figure 10C, a breakout cross-sectional view of a
sidewall of a heat
exchanger unit, in accordance with embodiments disclosed herein, is shown. The
I-IX unit 400 may
include one or more sidewalls 452 configured with various layers. For example,
the outer exterior
side may be a sheeting layer 490, which may be sheet metal. The interior side
of the sidewall 452
(i.e., the side exposed inward in interior 429, Figure 10B) may have a mesh
437. Between the mesh
437 and sheeting layer 490 may be one or more layers of additional material.
1003741 As shown, there may be a layer of sound absorbing material 462. The
sound absorbing
material may be mineral wool or other comparable material. There may be a
layer of material 491.
In aspects, the sound absorbing material 462 may be positioned between the
sheeting layer 490 and
the layer of material 491. The layer of material may be a vinyl-based
material. In aspects, the layer
54
CA 2971746 2017-06-23
of material 491 has physical properties and characteristics of being able to
reduce or otherwise
mitigate the passing of sound thereby.
1003751 Referring again to Figures 10A-10B, the coolers 404 a,b may be coupled
to the frame 404 in
accordance with embodiments disclosed herein, including directly, or
indirectly via mounting to the
frame 402. The coolers 404 a,b may include at least one core and a tank. The
core(s) 406 may
include one or more tanks (such as inlet tank 477 and outlet tank 480) welded
thereto. The inlet
tank 477 may be associated with the tank inlet 478. Similarly, the outlet tank
480 may be associated
with a tank outlet 484.
1003761 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.
1003771 Referring now to Figures 11A, 11B, and 11C together, a frontal
isometric view and a
backside isometric view of a heat exchanger unit with two top side mounted
coolers, and a
blender skid having the heat exchanger unit of Figures 11A-11B coupled with
two heat
generating devices, respectively, according to embodiments of the disclosure,
are shown.
1003781 The FIX unit 500 may be like that in many respects to heat exchanger
units 200, 400
described herein, but as would be readily apparent need not be the same, and
indeed may have a
number of discernable differences. The heat exchanger unit 500 may include a
solid integral
frame (or skeletal frame) or may be a frame 502 that includes a number of
elements arranged and
coupled together, such as a plurality of horizontal elements 550 and a
plurality of vertical
elements 551.
1003791 the frame may include a top region 543a, a bottom region 543b, and a
plurality of side
regions 542 a-d. There may be a first cooler (not viewable here) coupled with
the frame 502
proximate to a respective side region 542d. the first cooler may have a
respective long (or
longitudinal axis) that may be generally parallel to a vertical axis 527.
1003801 The 11X unit 500 may include a second cooler 504b coupled with the
frame 502
proximate to the top region 543a. The second cooler 504b may have its long
axis generally
perpendicular to the vertical axis 527. Although not viewable here, there may
be an inner
airflow region within the heat exchanger unit 500. In this respect, there may
be a first baffle
(e.g., 422. Figure 10B) disposed within the inner airflow region. and at a
first angle a to the
vertical axis 527.
CA 2971746 2017-06-23
1003811 The FIX unit 500 may include a third cooler (not viewable here)
coupled with the frame
502 proximate to the respective side region 542d, and adjacent the first
cooler. And the HX unit
500 may have a fourth cooler 504d coupled with the frame 502 proximate to the
top region 543a,
and adjacent the second cooler 504b.
1003821 The 11X unit may include an inner partition 552a that separates the
first airflow region
from a second airflow region associated with the third cooler and the fourth
cooler. The partition
552a may be formed by connecting two sidewalls together.
1003831 The second airflow region may include a second baffle (e.g., 422,
Figure 10B), which
may be configured or otherwise oriented at a second angle a to the vertical
axis 527. In aspects,
either or both of the first angle and the second angle may be in the range of
about 0 degrees to 90
degrees. In aspects, either or both of the first angle and the second angle
may be in the range of
about 30 to about 60 degrees. Although they need not be, the first angle and
the second angle
may be substantially the same (i.e., equal or nearly equal to each other).
1003841 The first baffle 522 and/or the second baffle may include a sound
absorbing material
disposed therein (see, e.g, Figures 3B). The FIX unit 500 may include a first
fan 508a and a
second fan 508b. Fither of the fans 508 a,b may be configured to operate and
produce a point
source dominant acoustic frequency. The sound absorbing material may be
capable to reduce the
point source dominant acoustic frequency by at least 10 dB.
1003851 The first fan 508a may be mounted to the frame 502 external to a first
side of the first
cooler. In a similar manner, the second fan 508b may be mounted to the frame
external to a first
side of the second cooler. The first fan 508a and the second fan 508b may each
have an axis of
rotation substantially perpendicular to the vertical axis 527.
1003861 In operation, the first cooler and/or the second cooler may be
configured to permit
airflow to pass therethrough. Related thereto, operation of the first fan 508a
and/or the second
fan 508b may result in airflow through each of the respective coolers and
airflow regions, and
out of the outlet.
1003871 The 1-IX unit may include a first sidewalk a second sidewalk a back
wall; and a bottom.
In aspects, at least one of the first sidewall, the second sidewall, the back
wall, and the bottom
further may include: an inner layer of sound absorbing material; and an
exterior layer of a vinyl-
based material. Any of the sidewall(s) may be like that as shown and described
for Figure 10C.
56
CA 2971746 2017-06-23
1003881 The FIX unit 500 may be configured and operable with a monitoring
module 1000 as
described herein. Ingress and egress may be provided via access way 592. The
access way 592
may be closed via door 593, which may be, for example, hingedly mounted to the
frame 502.
The door 593 may be shut and held shut via one or more securing members 594.
In aspects,
turning handle 595 may move the securing member 594 to a position, whereby the
door 593 may
be opened, and the inside of the FIX unit 500 may be accessed.
1003891 Figure 11C illustrates the HX unit 500 may be used and operable with a
blender unit 560
for creating a frac fluid mixture. One of skill in the art would appreciate
the blender unit 560
may be a stationary process, or provided with mobility via a trailer 561. The
blender unit 560
may include one or more blender tubs 562; one or more auger screws 563; and at
least one HOD
503a. The HOD 503a may be a diesel engine.
1003901 The FIX unit 500 may be configured to cool at least one service fluid
transferable
between the HX unit 500 and the first HOD 503a.
1003911 The second cooler 504b may be coupled with the frame 502 generally
perpendicular to
the orientation of the first cooler. In this respect, the second cooler 504b
may be coupled with
the frame 502 proximate to the top region 543a. In other aspects, the second
cooler 504b may be
coupled with the frame 502 generally parallel to the orientation of the first
cooler. In this
respect, the second cooler 504b may be coupled with the frame 502 proximate to
another side
region. The first cooler and/or the second cooler may be thought of has having
a long
(longitudinal) axis through itself, which may be used as a reference point
with respect to other
axis. The orientation reference is generally understood as being with respect
to a long axis
through the core.
1003921 The HX unit 500 may have a third cooler 504c coupled with the frame
502 proximate to
the respective side region, and adjacent the first cooler 504a. The HX unit
500 may include a
fourth cooler 504d coupled with the frame 502 proximate to the top region
543a, and adjacent
the second cooler 504b.
1003931 The I IX unit 500 may include a second airflow region partitioned from
the inner airflow
region. The second airflow region may be associated with the third cooler and
the fourth cooler.
There may be a second baffle disposed within the second airflow region, and at
a second angle to
the vertical axis. The second baffle may include a sound absorbing material.
In aspects. the
sound absorbing material may be mineral wool.
57
CA 2971746 2017-06-23
1003941 The angle of orientation of any baffle 522 of the IIX unit 500 may be
in the range of
about 30 to about 60 degrees. In embodiments, the first angle and the second
angle may be at
least substantially the same.
1003951 The FIX unit 500 may include a second fan 508b mounted to the frame
502 external to a
first side of the third cooler. The first fan 508a and the second fan 508b
each may each have an
axis of rotation substantially perpendicular to the vertical axis 527.
1003961 Any of the coolers of the HX unit 500 may be configured to permit
airflow to pass
therethrough. Operation of the first fan 508a and the second fan 508b may
result in airflow
(drawn or blown) through each of the respective coolers and airflow regions,
and out of the
outlet.
1003971 The IIX unit 500 may have at least one monitoring module 1000 of the
present disclosure
operably associated therewith.
1003981 Any of the first cooler, the second cooler, the third cooler, and the
fourth cooler may have
a respective core and a respective tank. The at least one of the respective
cores may have a core
end having a core end mass. The at least one of the respective tanks may have
a tank end having
a tank end mass. In aspects, the core end mass may be greater than the
respective tank end mass,
as provided for in embodiments herein. See, e.g., Figures 4A-4C.
1003991 The HX unit may include a mount assembly for couple any of the coolers
to the frame.
The mount assembly may be as described herein, and may thus 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. At least one of the plurality of coolers
may include a
mounting slot, whereby the elongated fastening member may extend through the
rigid inner ring
and at least partially into the frame. See, e.g., Figures .5A-5E.
1004001 One of skill in the art would appreciate the blender unit 560 may be
operable with other
'IX unit embodiments of the disclosure.
1004011 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
58
CA 2971746 2017-06-23
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).
1004021 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. To be sure, the monitoring module may be used with other heat
exchanger units,
including such as unit 200, 400, 500, etc. of the present disclosure.
1004031 The heat exchanger unit (or FIX 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 FIX unit 700 coupled with
a heat generation
device 703. As can be seen a hot service fluid film may circulate from the HOD
703 to the FIX
unit, be cooled via core 706 (also sometimes recognizes as a cooler or
radiator, or part thereof),
and recirculate as a cooled service fluid Fced back to the HOD 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 FIX unit 700 with the HOD 703 for
operable
transfer of one or more service fluids therefrom.
1004041 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 HX unit 700. As an example, the
monitoring module
1000 may be configured and used for measuring fouling associated with the core
706.
1004051 The module 1000 may be a modular assembly having various components
and
subcomponents associated and operable together, and like that described
herein. The module
1000 may be sized and optimized accordingly for operable coupling with any
type of radiator,
including that associated with the I-IX 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 I-IX unit 700 may have multiple
monitoring modules
1000 associated therewith.
59
CA 2971746 2017-06-23
1004061 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 he 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 IIX unit or radiator core.
1004071 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.
1004081 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
1011 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 I IX unit 700.
1004091 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
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.
CA 2971746 2017-06-23
1004101 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.
1004111 The sensor 1021 may be mounted to the cover panel 1007, and operated
in a manner to
sense airflow into the FIX 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.
1004121 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.
1004131 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
movement of air) will be
61
CA 2971746 2017-06-23
felt by the blade members 1023, and as a result of being connected to the
rotating member 1024,
induce rotation of the member 1024.
1004141 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).
1004151 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.
1004161 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 1016a).
1004171 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 therethrough. The openings 1017 a,b may
be sealed, such as
with silicone.
1004181 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., RGI3 I,FDs) 1032.
62
CA 2971746 2017-06-23
1004191 Referring now to Figures 7A, 711 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 HDMI output to a screen such as a TV or a
monitor_ as
well as wirelessly communicating to smart phones or computers via Wifi or
Bluetooth.
1004201 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.
1004211 Software herein may be able to read values from the SD card and create
a look-up table.
1004221 Referring now to Figures 8A and 8B 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.
1004231 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/0 devices (not shown), which may all be
operatively
communicatively coupled together, including such as circuitry, pins, and via a
local interface
(not shown).
1004241 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.
63
CA 2971746 2017-06-23
1004251 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-
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 I,iPo battery cell (1200mAh, 3.7V). The battery
1027a may be
charged by a battery charger 1027b. An example battery charger includes LiPo
Energy Shield.
1004261 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.
1004271 Microcontroller 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.
1004281 The microcontroller 1006 may be in communicative operability with Wi-
Fi module 1029.
An example Wi-Fi module includes ESP8266 or particle photon.
1004291 The microcontroller 1006 may be in communicative operability with GSM
module 1030.
An example GSM module includes Arduino GSM Shield V2 or Particle Elctron.
1004301 The microcontroller 1006 may be in communicative operability with CAN-
Bus module
1031. An example CAN-Bus module includes CAN-BUS shield with MCP2515 CAN bus
controller.
1004311 The microcontroller 1006 may be in communicative operability with LEDs
1032
1004321 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
64
CA 2971746 2017-06-23
forth. Moreover, the controller memory may incorporate electronic, magnetic,
optical, and/or
other types of storage media.
1004331 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),
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.
1004341 The OS may be configured for execution control of other computer
programs, and
provides scheduling, input-output, tile 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.
[004351 Software may include an executable program, script, object code,
source program, or any
other comparable set of instructions to be performed.
1004361 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++, Ci#, Pascal, BASIC, API calls, ASP
scripts,
FORTRAN, COBOL, Perk .NET, Ruby, and the like.
1004371 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.
1004381 In aspects, external computers (and respective programming) may be
communicably
operable with the logic circuit (and thus monitoring module 1000).
CA 2971746 2017-06-23
1004391 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)
1004401 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 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.
1004411 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).
1004421 Once the sampled data of task 1 has been accepted, it is checked with
a lookup-table
(FUT) 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 LIIT 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 FUT table through multiple iterations
(averaging), the
system turns the FUT flag true.
1004431 If the FU]' flag is true, the overall fouling is then calculated in
task 9. This 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
66
CA 2971746 2017-06-23
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.
1004441 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.
1004451 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
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.
1004461 The FIX unit 900 may include one or more cores 906 being associated
with respective
monitoring module(s) 1000. It should be apparent that while FIX 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.
1004471 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.
1004481 Although not shown in entire detail here, the 11X 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.
67
CA 2971746 2017-06-23
1004491 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.
1004501 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.
1004511 The configuration of the shroud and aeroring may provide added ability
for further
streamlining airflow, which may beneficially reduce overall power
requirements.
1004521 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 FIX 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.
1004531 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).
1004541 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.
1004551 As such, by way of example, utility fluid 171 may be transferred from
a heat generating
device 903 at a hot temperature into an 1-IX unit inlet 978, cooled with
airflow via core 906, and
transferred out of an
unit outlet 984 back to the fIGD 903 at a cooler temperature. While not
68
CA 2971746 2017-06-23
meant to be limited, I IGD 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.
1004561 There may be one or more cores 906. A 'cooler' or 'cooling circuit'
may include one or
more cores 906. The HX unit 900 may have between about 1 to about 8 cooling
circuits, which
each may be configured for cooling in parallel to each other.
1004571 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.
1004581 In operation, a utility fluid F from HOD 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.
1004591 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
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.
1004601 The service fluid F1.41õt, having a temperature hotter than the
airflow, may be cooled (and
conversely, the airflow warms). Cooled service fluid F 1-cold 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.
1004611 Cooled utility fluid may be returned from the FIX unit 900 to a source
tank, or directly to the
HOD 903. Thus, service fluid from the HOD 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.
1004621 Other coolers of the FIX unit 900 may be generally similar in nature.
and suitably
configured for the cooling of various service fluids from the HOD 903.
1004631
69
CA 2971746 2017-06-23
1004641 Referring now to Figure 9A, 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 900a may be part of an overall system
901a that may
be monitored. Monitored system 901a may include at least one monitoring module
1000, as
described herein.
1004651 While it need not be exactly the same, system 901a may be like that of
system 701 of
Figures 7A-7C, system 901, or other systems herein, and components thereof may
be duplicate
or analogous. Thus, only a brief discussion of system 901a 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 901a may include various additional
improvements
related to airflow, noise reduction, cooling efficiency, structural integrity,
and combinations
thereof.
1004661 The HX unit 900a may include one or more coolers being associated with
respective
monitoring module(s) 1000. It should be apparent that while HX unit 900a may
have a plurality
of sides (or side regions), and one or more sides may have respective coolers,
not every side (nor
cooler) need have a monitoring module 1000. Still, it may very 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 FIX unit 900a (or
system 901a) may be
monitored.
1004671 The fan system (e.g., 457, Figure 10A) can be operable to draw (or
blow) in and direct
the flow of air. The air may be drawn through the sides of the FIX unit 900a
(and respective
cores, which may then be used to cool one or more utility fluids F) and out as
heated exhaust.
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).
1004681 One of skill in the art would appreciate that airflow through the
cooler(s) may be
generally in a path parallel to a horizontal axis. In an analogous manner. the
fan (e.g., 508.
Figure 11A) may have an axis of rotation generally perpendicular to a vertical
axis.
CA 2971746 2017-06-23
Accordingly, airflow through the I IX unit 900a may be transitioned from
(approximately)
horizontal to vertical as the airflow moves through the coolers and out the
fan exhaust.
1004691 While not meant to be limited. HOD 903a 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.
1004701 There may be one or more cores. A 'cooler' or 'cooling circuit' may
include one or more
cores. The HX unit 900a may have between about 1 to about 8 cooling circuits,
which each may
be configured for cooling in parallel to each other.
1004711 The HX unit 900a may include various sound reduction or integrity
features like that as
described herein, such as various sound baffle configurations and/or flexible
mount assemblies.
1004721 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 and/or a blender
skid. The frac trailer may include a frac pump, a HOD, and a HX unit as
pertaining to the
disclosure. The blender skid may include a booster pump, at least one HOD, and
a FIX unit as
pertaining to the disclosure.
100473] 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. "I he 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.
1004741 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).
100475] The provider may provide services and equipment directly, or may use a
subcontractor.
1004761 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
71
CA 2971746 2017-06-23
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.
1004771 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.
1004781 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.
1004791 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.
1004801 Embodiments of the disclosure advantageously provide for an improved
heat exchanger unit
useable with a wide array of heat generating devices.
1004811 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
characteristic may be
fouling. The ability to accurately warn of fouling alleviates the need for
conventional and
cumbersome remediation methods.
7?
CA 2971746 2017-06-23
1004821 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 ftwther helps reduce sound emission and
improves overall
efficiency of the heat exchanger unit because of lowered power requirements.
1004831 The heat exchanger unit may advantageously provide for the ability to
simultaneously cool
multiple utility fluids in parallel.
1004841 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.
1004851 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.
1004861 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 defounable member may deform resulting to absorb the
expansion motion or
stress.
1004871 Advantages herein may provide for a more convenient and realizable
welding practice for
core and tank, and a more convenient and flexible mount assembly.
1004881 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 alternatives are
intended to be within
73
CA 2971746 2017-06-23
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.
1004901 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. Each and every claim is incorporated into the
specification as an
embodiment of the present disclosure. 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.
74
CA 2971746 2018-09-13
