Ventilation of drainage system for frame engine evaporative cooler

An evaporative cooler for cooling air includes a cooling housing having an air inlet and an air outlet and an evaporation media, located within the cooling housing intermediate the air inlet and the air outlet for air flow there through and for receiving water to permit evaporation of at least some water. The evaporative cooler includes a drain pan located within the cooling housing and below the evaporation media to catch water which has not evaporated and falling from the evaporation media and a sump located within the cooling housing and below the drain pan for collecting water for use in supplying water to the evaporation media. The evaporative cooler includes a pipe connecting the drain pan to the sump for water movement from the drain pan to the sump and an air vent located within the cooling housing and connected to the pipe, the air vent being open to air within the cooling housing and above the drain pan to permit release of air from within the pipe.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to evaporative coolers, and specifically relates to a drainage arrangement for evaporative coolers.

2. Discussion of Prior Art

An evaporative cooler may be useful where high ambient temperatures and low relative humidity are common. Within an evaporative cooler, water is added to inlet air. Part of the water evaporates absorbing latent heat from the air. As a result, the air, which gives up sensible heat, cools and increases in density. In one specific example, an evaporative cooler may be a useful option for turbine inlet air. With the use of an optional evaporative cooler, adding the water to the turbine inlet air will provide a higher mass flow rate and pressure ratio for the turbine and will cause in an increase in turbine output and efficiency. For example, considering a dry-bulb temperature of 40° C. with 20% relative humidity, the output power may be increased by about 12% if an 80% effective evaporative cooler is used. Correspondingly, the heat rate decreases by about 4%. The benefit of an evaporative cooler system from an economic point of view is related to the potential average annual increase in output from the turbine. Of course, evaporative coolers may be used in other example environments.

In general, within an evaporative cooler a spray system wets media the medium and the water flows through the media (e.g., corrugated layers of fibrous material). Air flow intermixes with the flowing water at the media. The water flows down through the media by gravity and non-evaporated water is collected within a drain pan. In turn the drain pan is connected to a sump which collects water for recirculation/reuse to the media.

It is to be appreciated that the presence of water within the evaporative cooler makes the environment within the evaporative cooler somewhat adverse. The use of materials that are adversely affected by water should be avoided. One example material that is typically used within an evaporative cooler is stainless steel. One drawback of stainless steel is a relatively high cost of material. Continued efficient operation of the evaporative cooler is a typical desired expectation. As such there is a need for a successive generation of evaporative coolers that provide improvements.

BRIEF DESCRIPTION OF THE INVENTION

One aspect of the invention provides an evaporative cooler for cooling air. The evaporative cooler includes a cooling housing having an air inlet and an air outlet. The evaporative cooler includes an evaporation media, located within the cooling housing intermediate the air inlet and the air outlet for air flow there through and for receiving water to permit evaporation of at least some water. The evaporative cooler includes a drain pan located within the cooling housing and below the evaporation media to catch water which has not evaporated and falling from the evaporation media. The evaporative cooler includes a sump located within the cooling housing and below the drain pan for collecting water for use in supplying water to the evaporation media. The evaporative cooler includes a pipe connecting the drain pan to the sump for water movement from the drain pan to the sump. The evaporative cooler includes an air vent located within the cooling housing and connected to the pipe, the air vent being open to air within the cooling housing and above the drain pan to permit release of air from within the pipe.

DETAILED DESCRIPTION OF THE INVENTION

Example embodiments that incorporate one or more aspects of the invention are described and illustrated in the drawings. These illustrated examples are not intended to be a limitation on the invention. For example, one or more aspects of the invention can be utilized in other embodiments and even other types of devices. Moreover, certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. Still further, in the drawings, the same reference numerals are employed for designating the same elements.

An example embodiment of an evaporative cooler10that includes an aspect in accordance with the present invention is a schematic illustrated withinFIG. 1. In the shown example the evaporative cooler10is for use with a turbine12. However, it is to be appreciated that the present invention need not be limited to use with a turbine.

In general, the evaporative cooler10includes a cooling housing14that has an air inlet16and an air outlet18. The air outlet18is operatively connected to the turbine12as will be appreciated by the person of ordinary skill in the art. The turbine12is schematically shown and thus it is to be appreciated that the structure of the turbine may take any form and also that the configuration of the turbine is not a specific limitation upon the present invention.

Turning to the air inlet16of the evaporative cooler10, it is to be appreciated that at or near the air inlet one or more filtering devices22are positioned and operated to filter out unwanted materials from an air flow24moving into the inlet24and through the cooling housing14. Also, it is to be appreciated that the air flow24moving into the air inlet16via the filtering devices22is generally a warm air flow.

Located within the cooling housing14is at least one evaporation media30. With the evaporation media30being located within the cooling housing14, the evaporation media is located intermediate the air inlet16and the air outlet18. Within the shown example, three evaporation media30are provided and are individually identified via the use of alphabetic suffixes A-C. Hereinafter, the evaporation media30may be referred to generically or collective via the use of the reference number30, but may be referred to specifically via the use of the reference number30and the alphabetic suffixes A-C. The evaporation media30are arranged in a vertical array, with one media generally located above the other within the vertical array. Each evaporation media30may be made of any suitable material and may have any suitable construction. Typically, the media30is made of corrugated layers of fibrous materials. The corrugated layers provide channels through the media30. Accordingly, the flow of air can pass through the media30.

A water supply arrangement34is operatively connected and positioned to provide water to cause wetting of the media30. In the shown example, a supply pipe36extends and is operatively connected to at least one water distribution manifold38. The distribution manifold38distributes or sprays water40onto the evaporation media30. Thus, the media receives the water40from the manifold38and, as will be appreciated, at least some water evaporates. Within the shown example, three water distribution manifolds38are provided, with each manifold being positioned above a respective media. Each distribution manifold38is separately connected to the supply pipe36. The three distribution manifolds38are individually identified via the use of alphabetic suffixes A-C. Hereinafter, the distribution manifolds38may be referred to generically or collective via the use of the reference number38, but may be referred to specifically via the use of the reference number38and the alphabetic suffixes A-C.

A water supply reservoir/sump42is provided at a lower location of the cooling housing14. Hereinafter, this reservoir is referred to as a sump42. The location of the sump42is vertically beneath the vertical array of media30. A water pump46is operatively connected to the sump42and to the supply pipe36. The pump46operates to move the water40from the sump42, up the supply pipe36into the water distribution manifolds38. It is to be appreciated that the sump42may be connected to an exterior water replenishment supply and/or an exterior drain. Also, it is to be appreciated that the water supply arrangement34may include various water flow regulation/control devices (not shown, e.g., at the pump) and/or other structures for periodic maintenance and the like. The person of ordinary skill in the art will appreciate various examples of such additional devices/structures.

A drain pan50is associated with each of the upper two media30A,30B. The two drain pans50are individually identified via the use of alphabetic suffixes A and B. Hereinafter, the drain pans50may be referred to generically or collective via the use of the reference number50, but may be referred to specifically via the use of the reference number50and the alphabetic suffixes A and B. Each respective drain pan50A,50B is located within the cooling housing14and located below the respective media30A,30B. Each drain pan50is for catching water40that has not been evaporated at the media30and thus falls from the media into the drain pan. The drain pans50are located above the sump42.

A drain pipe arrangement54extends from the drain pans50to the sump42. Specifically, at least one vertical section56of the drain pipe arrangement54extends vertically and at each drain pan50one or more connection sections58are operatively connected between the respective drain pan50and the vertical section56. As such, the sump42, which is located below the drain pans50, is for collecting water including water from the drain pans.

FIG. 1shows just a single vertical section56of the drain pipe arrangement54andFIG. 2shows two vertical sections56(at opposite sides of the drain pans50). In the shown example, the connection sections58are connected at a series of locations along the drain pans50. However, it is to be appreciated that the configuration may be varied (e.g., different number/location of the connection sections). Hereinafter, the connection sections58may be referred to generically or collective via the use of the reference number58, but may be referred to specifically via the use of the reference number58and the alphabetic suffixes A and B. It is to be appreciated that the drain pipe arrangement54may be constructed of any combination of pipes secured together via any suitable means (e.g., flange-bolted, welded, etc.).

In operation, the water40is pumped from the sump42through the water supply arrangement34, including pumping the water40up the supply pipe36and out through the distribution manifolds38and onto the evaporation media30. The water40on the media30wets the media but also moves downward along the media under the influence of gravity. The air flow24moving through the evaporative cooler10moves through the channels in the media30. Water evaporates from the media30thus cooling the air and increasing the moisture content within the air. The cooled and moistened air flow24′ then proceeds toward the turbine12. It is to be appreciated that the evaporative cooler10may have various other structures involved in the function of the evaporative cooler. For example, one or more demisters may be located downstream of the media to remove water droplets from the cooled air.

As mentioned, water40that is not evaporated at the media30eventually falls into either a respective drain pan50or directly into the sump42. Water40that is collected within respective drain pan50proceeds down the drain pipe arrangement54and is delivered to the sump42.

It is to be appreciated that there is a certain amount of water40that is recirculated within the evaporative cooler10. Further, it is to be appreciated that it is beneficial to maintain the recirculation flow of the water40and not have water leave the evaporative cooler10in an unintended manner, have water collect within the evaporative cooler10in an unintended manner, or have water otherwise proceed in a manner that does not deliver the water40being recirculated to the sump42.

It is to be appreciated that flow of water40from one or more drain pans50to the drain pipe arrangement54may be somewhat intermittent. As such, it is possible for air to be introduced/present within the drain pipe arrangement54. In particular, it is possible for air to be introduced/present within vertical section56of the drain pipe arrangement54. Also, it is possible for such air within the drain pipe arrangement54to cause an air lock within a drain pipe arrangement. It is to be appreciated that air locks would pose some difficulty in maintaining the recirculation flow of the water40through the drain pipe arrangement54.

Also, it is to be appreciated that the environment within an evaporative cooler may be adverse to some materials. Certain types of metal are less desirable for use within an evaporative cooler due to the presence of water/moisture which can cause corrosion. As such, items made of metal, such as the pipes of a water supply arrangement and a drain pipe arrangement, may be made of stainless steel to help avoid corrosion. If fact, the use of stainless steel is common. It is to be appreciated that stainless steel is often considered to be an expensive material.

Returning to the issue of potential air locks within a drain pipe arrangement, it is possible to utilize oversized pipes within the drain pipe arrangement so that air locks are reduced. Specifically, oversized pipes would permit flow of both water and air simultaneously within a drain pipe arrangement. However, as mentioned, the material that is typically used within a drain pipe arrangement is stainless steel and thus an increased size of a stainless steel pipe would have an appreciable increase in cost.

In order to address the issues of air lock within the drain pipe and cost, the present invention provides at least one vent60within the drain pipe arrangement54to permit air flow to/from the drain pipe arrangement. The vent60provides at least one opening to permit air flow/release (escape). Within the shown example, the vent60is located at an upper extent of the vertical section56of the drain pipe arrangement54. As such, the vent60is operatively connected to the pipes (e.g., the vertical section56) of the drain pipe arrangement54. With the air vent60being open to air within the cooling housing14and above the highest drain pan50A, the air vent permits release of air from within the pipes of the drain pipe arrangement54. Also, with the a filtering device22located at the air inlet16of the cooling housing14such that air within the cooling housing is filtered, the vent60is open to the filtered air within the cooling housing. The vent60is not exposed to air outside of the cooling housing14.

The shown example provides the vent60at a location above the highest drain pan (i.e.,50A). This permits the vent60to be open to the atmosphere within the evaporative cooler10and yet prevents water40from flowing from the highest drain pan (i.e.,50A) directly into the vent60.FIG. 3shows one example of a configuration with the vent60located above the highest drain pan (i.e.,50A). It is to be appreciated that structure (e.g., a wall segment, not shown for clarity) may be present and the vent60may be attached to and/or supported by such structure. In the shown example, the vent has a flange62that may be affixed to such structure.

It is to be noted again that the vent60is open to the atmosphere within the evaporative cooler10. This atmosphere is filtered air. Thus, no contaminants from outside of the evaporative cooler10are introduced into the water40/drain pipe arrangement54/water supply arrangement34via passage through the vent60.