Patent Publication Number: US-9404688-B2

Title: Cooling tower nozzle and methods of assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. provisional patent application Ser. No. 61/865,305, filed Aug. 13, 2013, which is herein incorporated by reference in its entirety. 
    
    
     FIELD 
     Embodiments of the present invention generally relate to nozzles for use in cooling towers. 
     BACKGROUND 
     Cooling towers are used for cooling a liquid, for example water, used in a manufacturing plant, such as a power generation station, to cool equipment being operated within the facility. Normally, a cooling tower includes a region where liquid falling through the region can contact air passing through the region. By contact of the air and liquid, a portion of the liquid evaporates, thereby cooling the remaining liquid. In order to effect intimate contact between the liquid to be cooled and the air in the cooling tower and thereby increase the amount of cooling, nozzles are typically used to distribute the liquid into droplets prior to contacting the air. 
     Some nozzles use a splash plate disposed opposite a nozzle orifice to enhance distribution of the liquid to be cooled. The splash plate is a separate component that snaps on to a support arm in position opposite the nozzle orifice. However, the inventors have noticed that due to the force of the liquid impinging upon the splash plate, the splash plate often becomes partially or wholly disconnected from the support arm, thereby greatly negatively impacting cooling efficiency. 
     Thus, the inventors have provided improved cooling tower nozzles. 
     SUMMARY 
     Cooling tower nozzle assemblies and methods of assembly are provided herein. Embodiments of the present invention relate to cooling tower nozzles used, for example, in counterflow cooling towers. Embodiments of the present invention include cooling tower nozzles having a nozzle body and a splash plate that is more securely coupled to the nozzle body to prevent or minimize detachment or misalignment of the splash plate. Embodiments of the present invention may also include features that facilitate ease of assembly while providing enhanced coupling between the splash plate and the nozzle body. 
     In some embodiments, a cooling tower nozzle assembly includes a body having an opening extending through the body from a first end to a second end; a support arm extending from the body and comprising a disk disposed on a first portion of the support arm opposite the first end of the body; a splash plate coupled to the disk, the splash plate having a bottom surface including a plurality of legs extending away from the bottom surface, wherein the plurality of legs have radially inwardly facing portions spaced a first distance from a central axis of the splash plate and aligned with the disk, and wherein the plurality of legs include features to interconnect to the disk; and a screw disposed through the splash plate to couple the splash plate to the support arm. 
     In some embodiments, a cooling tower nozzle assembly includes a body having an opening extending through the body; a nozzle insert disposed in the opening at a first end of the body, the nozzle insert including a nozzle orifice; a support arm extending from the body, the support arm comprising a disk disposed on a portion of the support arm opposite the nozzle orifice; and a splash plate coupled to the support arm. The splash plate may include a bottom surface including a plurality of legs extending away from the bottom surface, the legs comprising radially inwardly facing portions spaced a first distance from a central axis of the splash plate, wherein the radially inwardly facing portions of the legs comprise a radial recess having a first radius and a first height, wherein the disk has a second radius and a second height, and wherein the second radius is less than the first radius and the second height is less than the first height such that the disk is retained within the recess; and a portion extending from the bottom surface sized to abut a top surface of the disk. The disk may include a plurality of first portions having a radius to allow at least the radially inwardly facing portions of the plurality of legs to pass through the plurality of first portions without interference; a plurality of second portions extending radially outward from the plurality of first portions beyond the first radius; and a plurality of third portions having a radius less than the first radius and greater than the first distance. 
     In some embodiments, a method of assembling a cooling tower nozzle assembly includes providing a body having an opening extending through the body and a support arm extending from the body to support a disk in a position opposite the opening of the body; providing a splash plate having a bottom surface including a plurality of legs extending away from the bottom surface, wherein the legs have radially inwardly facing portions spaced a first distance from a central axis of the splash plate and a plurality of radial recesses formed in the radially inwardly facing portions of the legs, wherein the plurality of radial recesses having a first radius; aligning the plurality of legs with a plurality of first portions of the disk that have a radius that is less than the first distance; bringing the splash plate and the disk together such that the plurality of legs pass through the plurality of first portions until the radial recesses are aligned with the disk; rotating the splash plate with respect to the disk to engage a plurality of second portions of the disk with the plurality of legs, wherein each of the plurality of second portions have a radius that is greater than the first radius; and continuing to rotate the splash plate with respect to the disk such that respective third portions of the disk are disposed within radial recesses of the plurality of legs, wherein the third portions each have a radius that is less than the first radius and greater than the first distance. 
     Other and further embodiments of the present invention are described below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present invention, briefly summarized above and discussed in greater detail below, can be understood by reference to the illustrative embodiments of the invention depicted in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. 
         FIG. 1  is a side view of a cooling tower nozzle assembly in accordance with some embodiments of the present invention. 
         FIG. 2  is a side cross-sectional view of a portion of a cooling tower nozzle assembly in accordance with some embodiments of the present invention. 
         FIG. 2A  is a side cross-sectional view of a portion of a cooling tower nozzle assembly in accordance with some embodiments of the present invention. 
         FIG. 3  is a bottom view of a cooling tower nozzle assembly in accordance with some embodiments of the present invention. 
     
    
    
     To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. The figures are not drawn to scale and may be simplified for clarity. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation. 
     DETAILED DESCRIPTION 
     Embodiments of the present invention provide cooling tower nozzles used, for example, in counterflow cooling towers. The nozzle is designed to provide a non-clogging nozzle with large overlapping spray pattern and increased efficiency. Properly functioning cooling tower nozzles advantageously provide for optimum efficiency in a cooling tower. Nozzles that are not functioning properly can drastically reduce cooling tower efficiency, which can result in a loss of megawatts to the power grid and a great waste of efficiency, water, electricity, and fuel. 
     The main problem with some conventional nozzle designs is that the splash plate detaches from the nozzle body. When the splash plate detaches from the nozzle body it defeats the primary functionality of the nozzle. The liquid needs to leave the nozzle orifice and hit the splash plate to properly distribute to efficiently cool the liquid. Embodiments of the present invention retain the splash plate more securely to the nozzle body to prevent or minimize detachment or misalignment of the splash plate. 
       FIG. 1  is a side view of a cooling tower nozzle assembly  100  in accordance with some embodiments of the present invention. The cooling tower nozzle assembly  100  generally includes a body  102  having an opening  104  extending through the body  102  from a first end  116  to a second end  114  and a nozzle insert  106  disposed at the first end  116  of the opening  104 . The second end  114  of the opening  104  is adapted to be coupled to a source (not shown) of liquid to be cooled. The nozzle insert  106  includes a nozzle orifice  108  to facilitate spraying the liquid as it passes through the opening  104  of the body  102  and the nozzle insert  106 . Alternatively, the nozzle orifice  108  may be provided by the opening  104  without the nozzle insert  106 . The support arm  110  extends from the body  102  and is part of, or coupled to, the body  102  to support a splash plate  112  in a position opposite the nozzle orifice  108  and aligned with an axis  118  of the opening  104 . The splash plate  112  is a separate component that is securely coupled to the support arm  110 . The splash plate  112  functions to disperse the stream of liquid provided through the nozzle orifice  108  to enhance the efficiency of cooling of the liquid. 
     The splash plate  112  may be coupled to the support arm  110  in one or more of a variety of ways. For example, as depicted in  FIG. 2 , the splash plate  112  includes a top surface  202  and an opposing bottom surface  204  having a plurality of legs  206  extending away from the bottom surface  204 . A plurality of features  208  are provided in the legs  206  to facilitate interconnection with the support arm  110 . For example, the support arm  110  may include a disk  210  configured to interface with the features  208 . The disk  210  may be disposed on a first portion  120  of the support arm  110  opposite the first end  116  of the body  102 . The features  208  may include a groove or radial recess  209  formed in a radially inwardly facing portion of at least some of the legs  206 . The radial recess  209  has a first radius R1 measured from a central axis  232  (which may be collinear with the axis  118 ) and a first height T1. The disk  210  has a second radius R2 measured from the central axis  232  and a second height T2 sized to be press fit and retained within the radial recess  209  of the legs  206 . The second height T2 may be chosen to be less than the first height T1 such that the disk fits within the radial recess  209 . The second height T2 may be chosen to be less than, but close to, the first height T1 such that the disk fits snugly within the radial recess  209  to minimize play between the disk  210  and the splash plate  112 . In some embodiments, the second radius R2 may be slightly greater than the first radius R1 such that the disk is retained within the radial recess  209  by force of the plurality of legs  206 . In some embodiments, the second radius R2 may be less than the first radius R1. In some embodiments, as depicted in  FIG. 2A , the disk  210  may include a slanted outer wall  222  to facilitate placing the disk  210  in position within the radial recesses  209  of the legs  206 . 
     In some embodiments, a portion  214  of the splash plate  112  extends from the bottom surface  204  to advantageously provide a bearing surface  224  to support the splash plate  112  against forces of liquid impinging upon the top surface  202  of the splash plate  112  during use. The bearing surface  224  may abut and be supported by a top surface  220  of the disk  210 . In some embodiments, the portion  214  extends into a corresponding recess  216  formed in the disk  210  such that the bearing surface  224  abuts and is supported by a surface  230  of the recess  216 . In some embodiments, a centrally located opening  226  may be provided at least partially through the portion  214 . 
     In some embodiments, a threaded fastener, for example, a screw  212 , may be provided through an opening, passage  228 , in the support arm  110  that extends through the thickness, (for example first thickness T1) of the disk  210  to fasten the support arm  110  to the portion  214  of the splash plate  112 . The screw  212  may extend into and engage a wall of the opening  226 . In some embodiments, the screw  212  may be a self-tapping screw. In some embodiments, a washer  218  may be provided between the head of the screw  212  and the support arm  110  to distribute the load developed by securing the splash plate  112  to the support arm  110  with the screw  212 . 
     In some embodiments, the portion  214  of the splash plate  112  may advantageously provide extra material for the threads of the screw  212  to bite into to more securely couple the splash plate  112  to the support arm  110  (as compared to fastening the splash plate  112  without the portion  214 ). In some embodiments, the portion  214  of the splash plate  112  may abut a top surface  220  of the disk  210  when the splash plate  112  is secured to the support arm  110  with the screw  212 . 
     In some embodiments, the portion  214  of the splash plate  112  may extend into the corresponding recess  216  formed in the disk  210  to provide additional surface area for the threads of the screw  212  to more securely retain the splash plate  112  and withstand forces of liquid impinging upon the top surface  202  of the splash plate  112  during use. In addition, providing the splash plate  112  with a portion  214  that extends into the recess in the disk  210  further advantageously facilitates guidance and alignment of the components during assembly. 
     in some embodiments, the screw may facilitate securing the splash plate  112  to the support arm  110  as described above without other securing elements, such as the legs  206  and the plurality of features  208 . The screw may also be used with the legs  206  and the plurality of features  208 , or with other securing elements or features. 
     In some embodiments, as shown in  FIG. 3 , the disk  210  may include one or more features to facilitate ease of installation or assembly of the splash plate  112  to the support arm  110  while providing a more secure coupling (e.g., lock and fit) between the splash plate  112  and the support arm  110 . For example, the disk  210  in  FIG. 3  has a plurality features  302  where each feature  302  includes a first portion  304  spaced from a central axis  232  a radial distance  310  and sized to allow the legs  206  of the splash plate  112  to pass through the first portion  304  without interference during assembly. A second portion  306  of the feature  302  extends radially outward from the first portion  304  (and from the central axis  232  a radial distance  312 ) at least beyond the radial distance R1 of the corresponding radial recess  209  of the feature  208  of the legs  206 . A third portion  308  of the feature  302  extends radially outward from the central axis  232  of the disk a radial distance  314 , which is less than the radial distance  312 , to provide additional clearance between the feature  208  of the legs  206  and the disk  210 . 
     To assemble the splash plate  112  to the support arm  110  the legs  206  may first be aligned with the first portion  304  of the features  302  of the disk  210 , and the support arm  110  and splash plate  112  may be brought together with the legs  206  passing through the first portions  304  until the features  208  of the legs  206  are aligned with the disk  210 . The splash plate  112  may then easily be rotated to engage the second portions  306  with the legs  206  and to pass the second portions  306  through the features  208  so that the third portions  308  are disposed in the features  208 . In this position, the legs  206  are aligned with the third portions  308  and the second portion  306  serves to hold the splash plate  112  in place and prevent rotation back to the assembly/disassembly position (e.g., where the legs  206  of the splash plate  112  are aligned with the first portions  304 ). As forces applied by the liquid impinging upon the splash plate  112  are predominantly normal to the top surface  202  of the splash plate  112 , minimal rotational forces are developed on the splash plate  112 . Thus, minimal forces exist during use that would cause the splash plate  112  to rotate beyond the second portion  306  to the first portion  304  where the splash plate  112  could easily be removed from the support arm  110 . In addition, in some embodiments, the third portions  308  are sized to be spaced apart from the extreme edges of the features  208  of the legs  206 , thereby advantageously allowing the splash plate  112  to be retained within the feature  208  with minimal forces on the legs  206  that could undesirably lead to failure of the legs  206  and decoupling of the splash plate  112 . 
     The foregoing embodiments may be combined or provided separately. For example the splash plate may be coupled to the support arm using just the screw. In some embodiments, the splash plate may include a portion extending from the back surface of the splash plate to provide additional splash plate material for the screw to mate with. In some embodiments, the portion extending from the back surface of the splash plate may be provided in combination with a corresponding recess in the disk that mates with the extending portion to provide additional material for the screw to bite into as well as to guide and align the mating of the splash plate and the support arm. In some embodiments the rotating locking design shown in  FIG. 3  may be used alone or in combination with the screw and/or the collar as shown in  FIG. 2 . 
     While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.