Patent ID: 12227964

DESCRIPTION OF THE EMBODIMENT(S)

In describing the embodiment of the present invention, reference will be made herein toFIGS.1-32of the drawings in which like numerals refer to like features of the invention.

The present invention incorporates a method of manufacture and installation for one or more cooling tower cells within a cooling tower field. The effectiveness and efficiency of a cooling tower field is often dependent upon the integrity of the structural frame members and mechanicals within one or more cells. Prior art methods of cooling tower replacement require the entire replacement of a cooling tower field2000a,2000b,2000c, since the use of preexisting distributions systems cannot be reused upon replacement of one or more cells within a field. The present invention is not so restricted and may utilize mechanicals of an original system including inlet piping and pumps, fan stack, fan assembly and hub, torque tube, gear box, motor and other related mechanical equipment. This not only reduces installation costs and materials but ensures the continued reliability of the system as a whole.

In contrast to prior art replacement of cooling towers, which utilize existing vertical member-construction foundation columns1001for replacement of one or more cells (seeFIG.1), the modular cooling towers of the present invention remove the entire preexisting lower column framework1001which is bolted to the existing concrete basin floor, leaving only the original basin footing1. After removal of the lower column framework, the modular cooling tower of the present invention employs heavy duty foundation beams5in-situ across the water-filled basin1000, the method of which will be discussed in detail below. After spanning the basin foundation1with the foundation beams5, a series of custom modules are utilized to erect layers of the cooling tower cell to be constructed and installed. In one or more embodiments, these modules may include as little as two layers, although the number of module layers are for exemplary purposes only.

With reference to theFIGS.2-3, and10-14, the method and structure of the present invention is described with respect to a preferred embodiment of a modular cooling tower, as an example, without limitation, of a field-erected, relocatable structure to be manufactured and constructed at a manufacture location and then moved to a site location, where the final assembly and construction is completed on-site. Advantageous to the present invention, the manufacture/construction of the modules of the cooling tower cell can be ongoing while the site location is being prepared or while a previous cooling tower at the site location is being disassembled and removed, further limiting the construction time needed. The method includes the construction of a multi-portion structure where a portion is constructed at the manufacture location and then moved to the site location, which would then be field-erected directly at the site location. Thus, the modular construction allows for construction of critical components of the cooling tower at different locations, one such location being at the site of construction, and the other(s) at off-site facilities.

Turning now toFIGS.22A and22B, an exemplary modular cooling tower cell of the present invention is depicted having three sections: a basin section100, a structural framework section200, and a stack section300. The basin section100includes a liquid basin foundation1which is the original liquid basin of the cooling tower cell which was deconstructed, and foundation beams5spanning the foundation1and providing a structural base for the remainder of the modular cooling tower cell.

The structural framework section200ofFIGS.22A and22Bis formed of multiple layers of framework modules, including an airflow module layer110comprised of one or more empty modules20of the present invention which sit atop foundation beams5and are described in further detail below, a media fill module layer210adjacent airflow module layer110, distribution module layer220between fill media module layer210and the topmost drift eliminator module layer230. Atop and adjacent structural framework section200is stack section300. Unlike modular cooling tower cells of the prior art, the cell of the present invention is composed of layers formed from a plurality of laterally adjacent interlocking and dynamic modules20which are capable of varying construction dimensions allowing for use of the existing stack section of the cell being replaced, including the fan stack, fan assembly and hub, torque tube, gear box, motor, and other related mechanical equipment forming stack section300. While the preferred embodiment depicts a modular cooling tower cell having four module layers, other configurations are not meant to be precluded. The cell may include more than a single empty module layer to facilitate air-flow throughout the cell, and similarly non-vertical arrangements and orientations for the cell mechanicals may be utilized to accommodate cooling tower cells of crossflow or other designs.

The embodiments of the cooling tower cell of the present invention allow for manufacture and assembly of cell modules before shipping to a construction site for installation. Unlike the methods of conventional cooling tower cell assembly, the modules of the present invention may be fabricated using specific, pre-determined dimensions which may vary on a project-by-project basis to allow for the custom cell design which reproduces the former cell's dimensions to remove the need to completely replace water inlet distribution systems and related pumps of the former cell. Thus, the design of the present invention may be adapted to any size or shape to accommodate replacement of one or more cooling tower cells of varying basin sizes, cell structure, and key elevations within the cooling tower cell which accommodate for structural components, such as fill, header pipe, or decking. These variations may be performed prior to modules arriving to site. The salient features of the cooling tower cell manufacture of the present invention allow accommodation of existing cell mechanicals within the replaced cell reducing labor expenses and material requirements.

Turning now toFIG.16A, an exemplary constructed module20is shown. Each module consists of a framework of vertical and horizontal members which form a matrix or grid-like construction of the module. The exemplary module framework depicted inFIG.16Aincludes three (3) vertical members22spaced uniformly across matrix width W and five (5) vertical members22spaced uniformly across matrix length L, forming a 3×5 matrix module framework20. Vertical members22are typically made of a tubular fiberglass-reinforced polymer, hot-dipped galvanized steel, stainless steel or the like, where the tubes preferably have a square cross-section, though tubes of other shapes and material are not to be precluded. It should be further understood, a salient feature of the present invention is to provide module matrices which may be expanded or contracted to any size necessary to meet design requirements, and therefore may vary in matrix patterns or dimensions including length, width, and height. The vertical members22are releasably attachable to other modules or structures forming the modular cooling tower cell via male and female connectors located at the ends of each member. Preferably, the extended vertical members22of the module20will have a mating connector24at each end to mate with a corresponding connector23of either a vertically adjacent module framework structure and/or a spreader platform as discussed further below. As depicted in the figures, female lugs23and male lugs24are the preferred embodiments for adjoining the heavy structural components.

Enclosing the module20matrix along the length L are a plurality of longitudinal members21which may be secured to the vertical member22along the height H of the vertical member via fasteners, welding, or any other connection means known in the art. Connecting the module20framework along the matrix width are a plurality of transverse members29, and may be similarly secured to via fasteners, welding, or other means to the vertical members22, longitudinal members21, or both. To ensure the stability of the module framework, the present invention utilizes brace members26spanning between intersections within the matrix created by one or more horizontal members, i.e., longitudinal members21or transverse members29, and vertical members22of the module framework20, an example of which is depicted inFIGS.15A and15B, showing brace members26spanning adjacent and between two intersections i1, i2within the module framework20. The brace members26of the present invention may be secured adjacent any intersection of the matrix interior or exterior to provide necessary rigidity to the module framework which would allow for the module20to be properly shipped from a manufacturing or first location to a construction site or second location where it can be installed to form a cooling tower cell. The design of the module framework structures of the present invention allows for brace members which need only span a single column bay to provide sufficient rigidity to the cooling tower cell, unlike conventional framework structures of the prior art which span multiple column bays of the structure.

As seen inFIG.26, a detailed view of a section of module20is shown incorporating the bracing structure within a module structure. As depicted, any of the horizontal or vertical members may include a plurality of through holes spanning along the length of the member in repeated patterns. Though not intended to be limiting, the exemplary through hole configuration ofFIG.26Aincorporates four openings allowing for a cross pattern, having two holes82aalong the length of the horizontal member22, and two holes82bspanning the width of the horizontal member located at the midpoint of holes82a, or at an approximate location thereto. In some embodiments, the through hole construction may be incorporated throughout vertical members22or even transverse members29. During construction of the module20, the repeating pattern of the through holes82allows implementation of the modular nature of the present invention's module framework structure, allowing sizing variations to the dimensions of the horizontal and vertical members while facilitating a plurality of connection points. While the horizontal and vertical members may be interlocked to one another in one or more of the through holes82, not all of through holes82will be utilized during the construction of the module20. Similarly, a portion of the cross pattern may be utilized, as shown, at the outermost vertical members of module20, where only three through holes are utilized. Thus, the construction of the module20may be customizable, resizing according to the in-situ dimensions of the cooling tower cell that is to be replaced. In this manner, consistent and flexible hole patterns82throughout the entire module structure allows for efficient automation and robotic fabrication, and the modular design philosophy of the present invention may modularize any existing cooling tower cell of any dimension within the physical limits of the structural framework members. This is advantageous to the construction of the cooling tower cell, allowing the modular cooling tower of the present invention to replicate existing dimensions of a single cooling tower cell which is to be replaced in a cooling tower cell bank, thereby allowing utilization of the replaced cells inlet piping and pumps to achieve related pump head pressures of the original structure. By incorporating the hole pattern across the modules which compose the entire cell, the manufacturing process is greatly simplified, requiring minimal tools. Furthermore, the hole pattern82increases symmetry of the modules20, which reduces fabrication complexity because the vertical or horizontal members forming the modules20may work in any orientation. Thus, the modular cooling towers of the present invention further utilize topology and connection design in tandem with a flexible design and engineering system that is capable of expanding and contracting to any project specific structural and mechanical dimensions. While the module20topology forming a 3×5×2 (W×L×H) vertical and horizontal framework matrix is just one example arrangement, these are for exemplary purposes only, and other module topologies are not meant to be precluded. Any number of framework arrangements are possible, including: 2×3×2, 2×5×2, 2×7×2, 2×3×3, etc. Preferably, any topology within the arrangements of (2 or 3) W×(2, 3, 5, or 7) L×(2 or 3) H, thereby forming 16 different combinations, is possible with the hole pattern82. Thus, the combination of any of these 16 modules topologies, along with hole pattern82provide the salient features of the present invention to accomplish the design, manufacture, and installation capable to form any custom cooling tower dimensions.

Unlike the brace configuration of prior art modules, particularly with respect to those of U.S. Pat. No. 9,739,069 issued to Jiang et al. on Aug. 22, 2017, titled, “METHOD OF ASSEMBLING COOLING TOWERS”, the bracing configuration of the modules of the present invention do not form triangular structures, rather trapezium structures which are preferentially right trapezoids formed from the connection of the bracing members26spanning adjacent intersections i1, i2constructed from the vertical and horizontal members forming the module. Generally, the vertical members21of the module form the altitude portion of the trapezium, with brace26forming the leg and horizontal member21,29forming the longest base portion. The length of the horizontal member between the vertical member22and one through hole82aform the second, shorter base of the trapezium connection of the module20. The trapezium structure of the present invention creates a truss-like structure throughout the modules20which make up the final cooling tower cell, and provide the entire cooling tower cell with an integral structure that is specifically designed to withstand wind and seismic loads to the final cell after complete installation. It should be understood by a person of skill in the art that the interior angles a1, a2forming the trapezium may vary depending on the dimensions of the vertical and horizontal members as well as the brace members, as an object of the present invention is to provide dynamic, adjustable modules which may be designed to replace one or more cooling tower cells within a field.

Turning toFIGS.17-19, an embodiment of a manufactured framework module20′ is depicted with a partial water distribution system201installed thereon prior to shipment of the module. In this embodiment, the module includes a header segment202, to which is attached a plurality of feed tubes203equipped with spray nozzles204for distribution of hot liquid in a fully installed modular cooling tower cell. During installation of multiple modules20′ forming distribution module layer220of the cell, each module20′ header segment202may be installed to a header segment of one or more adjacent modules via a header flange205, enabling fluid communication with the existing fluid inlet piping to form the water distribution system of the cooling tower cell. Unlike the modular cooling towers of the prior art, the water distribution system201of the present invention may be connected with existing inlet piping and pumps, maintaining the same related pump head pressures which are used in the cooling tower field2000. In a related aspect, the invention may include installation of the fill media within a module layer prior to shipment or the installation of the drift eliminators.

An embodiment of the present invention makes use of modular male and female lugs to secure and install the modular cooling tower cell. The male lugs are of generally square construction, though other geometries for the lugs are not meant to be precluded. Each of the male lugs include a series of holes or openings and may be on one or more faces of the male lugs, such that a bolt may be received within the openings. The male lugs of the present invention are intended to be received within female lugs during construction. These female lugs are of a slightly large yet complementary structure, to enable the male lugs to be received. The female lugs additionally include complementary openings so that upon receipt of the male lug within the female lug, a bolt or other fastening component may be received within the male/female holes, securing the members thereto. In some embodiments, the mating connector24of the module20may include an alignment block124, which may be integral with the mating connector24or of a separate construction which may be inserted within and detachable from the mating connector24. As depicted inFIG.29, alignment block124is of chamfered or tapered construction which aids the alignment of the male-female connection of the lug connections described herein. Alignment block124may be placed on any mating connector24on the vertical members22that comprise the module20, or may even be placed within the mating connection of the column splices6,6′ on the foundation beams5. The alignment block124is advantageous in facilitating the mating connection between the male and female lugs of the present invention, providing necessary tolerances during installation which ensures proper alignment throughout the cooling tower cell.

With reference to theFIGS.2-3, and10-14, the method and structure of the present invention is described with respect to a preferred embodiment of a modular cooling tower, as an example, without limitation, of a field-erected, relocatable structure to be manufactured and constructed initially at a first location and then moved to a second location, where the final assembly and construction is completed on site. The manufacture and construction of the modules of the cooling tower cell at the first location can be ongoing while the modular cooling tower cell construction at the second location is being readied or while a previous cooling tower at the site location is being disassembled and removed, further limiting the construction time needed. As shown inFIGS.3and10-13, the cooling tower structure of the exemplary embodiment includes bottom horizontal footing beams5for supporting the modular cooling tower cell, including framework module structures20,30forming the cooling tower airflow module layer110of the mechanical section200, as well as the remaining mechanical section200that is removably replaceable on top of the airflow module layer110, and below stack section300. The method includes the construction of a portion of a multi-portion structure where a portion is manufactured and constructed at the first location according to the specified module dimensions which would allow for construction of a cooling tower cell that may incorporate existing mechanicals after installation. Once manufactured and constructed, the modules which form the custom dimensions of the cooling tower cell are then moved to the second location, which in the prior art, would have been field-erected directly at the second location, unlike the implementation of the method of the present invention.

The modular construction of the present invention allows for construction of critical components of the cooling tower at different locations, one such location being at the site, and the other(s) at off-site facilities. The method further allows for modules of specified dimensions such that the cooling tower cell replaced may utilize existing inlet water piping and pumps of the former cooling tower cell which is to be replaced. With the assistance of a digital computer, which may include computer aided design (CAD) software and a database of modular cooling tower solutions, a data set unique to the cooling tower cell to be replaced may be generated which includes every parameter and dimension of the design elements forming the basis of the modules and other structures forming the modular cooling tower cell. These can include basin size data, cell size data, key elevations such as fill, header pipe, deck, etc. Utilizing the data set, manufacture of the modules may be customized on a job-by-job basis while allowing for the changing of parameters to expand or contract any dimension of the module to be built so that large scale changes which may occur at a second project or mid installation of a single project may be accomplished without further complicating the fabrication process of the modules or any other structures forming the modular cooling tower cells of the present invention.

The modular cooling towers of the prior art are lacking in that they cannot expand or contract dimensions of their modules to supply a cooling tower cell which would allow for the usage of a former cooling tower cells inlet piping and pumps. The present invention overcomes these deficiencies, allowing for an implemented design component which allows a cooling tower cell owner to replace a single cell, or even a plurality of cells in a bank, while simultaneously maintaining critical and expensive mechanical equipment of the preexisting cell after the installation of the modular cooling tower of the present invention. The design implementation allows for construction of modules which would accommodate any header pipe height of an existing cooling tower cell or bank across a plurality of installation sites. The plurality of designs is accomplished, in particular, using the consistent and single hole pattern82throughout the entire module structure. The single hole pattern82throughout the vertical and horizontal members of the module structure facilitates a plurality of connection points between brace member26and the rest of the module structure which facilitates rotation about the single hole pattern82, almost acting as a pivot point during the design process, allowing for alteration of the connective angles a1and a2throughout a module structure without refabricating the hole design. The single hole pattern82therefore implements efficient automation and robotic fabrication when used with a design algorithm that is capable of expanding and/or contracting the dimensions of the framework members which create the module without the need to recreating a preexisting cell's dimensions at a modular scale. Unlike the modular cooling towers of the prior art, the hole pattern throughout the module structures of the modular cooling towers of the present invention allow for dynamic changes to the dimensions of the framework members which comprise the modules without changing any design considerations during assembly of the modules. Thus, design algorithm of the present invention allows for the design, fabrication, and assembly of modules forming a modular cooling tower cell which can be resized to any dimension without the need to significantly alter installation methodology to ensure the modular cooling tower cell of the present invention may accommodate the inlet water piping and associated pumps of the cooling tower cell which is being replaced. The design modality of the present invention ensures that a modular cooling tower cell may be constructed of any dimension which would allow the utilization of the former (replaced) cell's inlet piping and pumps.

After a cooling tower cell, which is in need of replacement, is selected and the data set has been generated, the method of fabrication of the present invention uses an algorithm to generate a module matrix of relevant dimensions which will form the structure of the modular cooling tower cell of the present invention. By way of example, the algorithm of the present invention may determine a preexisting cell having dimensions corresponding to a length L1, width W1and Height H1. Included in the data set for the preexisting cell are a measured fill media height FH, main header height MH, drift eliminator layer DE, and a deck height DH. Utilizing the design algorithm of the present invention, a modular cell may be designed for construction in accordance with the example cell plan depicted inFIGS.31and32. As depicted, the cell plan may call for a modular cooling cell composed of twelve (12) modules of a 2×3×2 framework matrix, though the configuration depicted is for exemplary purposes only, and other module configurations may be utilized to compose the preexisting cell which is in need of replacement. As depicted, the algorithm will establish a design for modules which may encompass the width W1(formed using module width dimensions Wa-Wh), length L1(formed using module length dimensions La-Ld), and the height H1. In determining the module configuration encompassing H1, the design algorithm first accounts for the height Hfof the foundation beams5and determines key elevation dimensions taken from the data set which would allow for utilization of the inlet water piping and pumps of the preexisting cell (i.e., media height FH, main header height MH, drift eliminator layer DE, and a deck height DH). Using these key elevations, the algorithm of the present invention determines the height dimensions necessary for each module layer110,210,220, and230, which when taken in combination with foundation beam height Hf(as depicted Ha-He), creates the overall height H1. Each project designed by the algorithm of the present invention may generate a complete specification for the specific project, including 3D models, construction drawings, assembly drawings, fabrication drawings, engineering calculations, bill of materials, framework member cut lists, material cost estimates, etc. Thus, the design algorithm of the present invention is capable of constructing a manufacture plan utilizing the single hole pattern82on the framework members of the module which can alter the dimensions of the framework members without changing the hole pattern82connective points which allows for a modular recreation of an original cell. The modular cooling tower cell of the present invention may therefore create a stable structure which can reuse the inlet water piping and related pumps of the preexisting cell, dramatically reducing labor cost, material cost, and overall time for installation.

The construction method of the embodiments shown for the present invention need not use any specialized equipment to lift and move the structure to a position of installation for the cooling tower cell. However, in one embodiment of the present invention the method is efficiently and effectively carried out in part using a lift device connected by cables55, for example four cables, to spreader platform50that is capable of supporting, balancing, and lifting a structure by lift members40. As depicted inFIGS.6,7the connection between lift member40and a module structure20is shown. Lift member40is shown of a female lug construction, though other configurations, including male lug configurations are not precluded. In the depicted embodiment, lift member40has a bottom (female) receiving aperture40b, that receives the vertically extending portion of male connector24. Lift member40includes through-holes or apertures42, typically on opposed surfaces of the lift member, and potentially a second set of through-holes/apertures41on a transverse face of the lift member (see also FIG.9A). Lift member40further includes a top portion having an eyelet43which may be secured to lift member40by, for example, welding or any other means of attachment which would be known by a person of skill in the art. Lifting member40is secured to a spreader platform50, which is described in further detail below. Lift member40is designed to be secured to a corresponding male lug, for example lugs24of a module structure20being moved into a second position, by way of through-holes41,42on the lug. Lift member40is secured to the module20framework using carrier bolts or other similar fasteners known in the art through apertures27on the framework structure connectors. In a similar fashion, the lift member40receiving aperture40bcan receive the column splices6of the foundation beam5and secure thereto so that beams5may be lifted using spreading platform50to place the foundation beams across the bottom, water constraining basin foundation1.

FIG.5shows the spreader platform50being used to position a framework structure in accordance with the method of installation, which is described further below. The structure to be lifted and moved is connected to spreader platform50by a plurality of lift cables55, which may include shackles and clevis pins, evenly spaced lengthwise and widthwise along beams of spreader platform50to distribute the weight and to support and balance the framework structure to be lifted. The lift cables55connecting spreader platform50to the lifting component may be any number of cables to sufficiently support the spreader platform50. In connecting the shackles on the lift cables55to the spreader platform50, platform eyelets56are evenly spaced lengthwise and widthwise along beams of the spreader platform50to connect the lift cables55to the lifting device. The platform eyelets56may be attached to the upper surface of the beams of the spreader platform50through any means, such as through welding or by attaching the eyelets56through fasteners.

As best shown inFIGS.4,6and9B, the lift members40connected to the spreader platform50are illustriously presented. For each lift member40, securing members including a metal cable47is attached at its upper end to a support structure, such as a U-shaped retainer (pin shackle)45a, held by a pin46ain a framework structure lift eyelet52secured, preferably by welding or by other type of fastening, such as bolts and nuts, to a lift beam51, as depicted inFIG.6. The lift beams51are supported by at least two carrier beams53of the spreader platform50to be described in more detail below. The lower end of the metal cable is connected to a second support structure and pin45b,46bin a manner similar to the upper end of the cable to the lift member eyelet43. As shown inFIG.6A, the second support structure and pin45b,46bare releasably attachable to lift member40. In this manner, structures utilizing the male/female connections lugs of the present invention can be lifted, properly placed, and secured via one or more lift members40.

Usage of the lifting lug during construction of the cooling tower cell of the present invention can be seen as depicted inFIGS.6and7. Module20is shown attachable to lifting lug for the purpose of lifting and relocating module20via a spreader platform50(described below). On an upper surface20aof the module, male lugs24are shown which may be integral with or attached to the vertical members22of the module20. The male lugs24extend vertically upwards along the vertical axis of the vertical members22, presenting an attachment mechanism for insertion within corresponding female lugs, which may be for example, a female lug23of a second module structure during assembly. Female lug23may be located opposite male lug24on each vertical member22of a module structure20. While the module male lugs24, foundation beam column splices6, and female lifting lug are depicted as being square in horizontal cross-section, other cross-sectional shapes are permitted, and tubular male lugs are also not meant to be precluded. In the exemplary embodiment, the lower lugs of a module20are female lugs23, but the male and female designations may be interchangeable in this design. That is, in some embodiments, the upper framework structure may contain female lugs, or any combination male and female lugs, and vice versa for the lower portion of the framework. In an exemplary embodiment, the male and female lugs have apertures therethrough to receive attachment bolts; however, other connection schemes are not precluded. The design envisions a male/female connection that can support lifting the framework structures and be easily detachable. In the embodiment ofFIG.7, each male lug24is shown with two apertures or openings27, but may include any number of apertures or openings through the outside surface of the lug.

The spreader platform of one or more embodiments of the present invention is shown best inFIGS.4,5, and6. The spreader platform comprises at least two transversely spaced longitudinal carrier beams53, each preferably in the form of an I-beam having an I-shaped cross-section transverse to a longitudinal direction A along the beam. The carrier beams53are preferably made of steel and are of such a size and composition to safely support the weight of the remainder of the spreader platform and any structure supported by the spreader platform, although other strong, relatively stiff materials, are not precluded.

On the top surface of the carrier beams are at least a pair of platform connectors, such as eyelets56, spaced to evenly balance the load and adapted to be connected to lifting cables of a lifting device. The platform eyelets56are preferably welded to the carrier beams53, though they may similarly be attached through bolts and nuts, or other similar materials known in the industry. Shackles and clevis pins are utilized to connect the platform eyelets56to the cables55, which are in turn connected to the lifting device. The spreader platform50also includes a plurality of longitudinally spaced transverse lift beams51spaced along the length of and generally perpendicular to and supported by the carrier beams53. The transverse lift beams are of a similar construction to the carrier beams53. The carrier beams53may be further supported by one or more brace beams54, spaced along the length of and generally perpendicular to the carrier beams53, such that the brace beams54support the load to be lifted by spreader platform50, and also provides structural stability and integrity, allowing large loads to be lifted by the spreader platform50without exhibiting undue torque forces that could otherwise twist the platform. In one aspect of the invention depicted atFIG.20, transverse lift beams51may include a coupling assembly59, having a plurality of apertures58, to account for the range of acceptable module dimensions in the database of solutions, for receiving the U-shaped retainer45aof the securing members to change the position in which lift member40is secured to a structure to be lifted, further preventing twisting or swaying of the spreader platform or structure lifted during installation of the cooling tower cell of the present invention. The design structure of the spreader platform50is parameterized to expand or contract to any dimension of the module within the database of solutions.

After deconstruction of an existing cooling tower cell, while other cooling tower cells within the field or bank remain in place, horizontal foundation beams5are placed to form the footing support for the modular cooling tower cell during installation. The placement of these beams provides for a complete footing of one modular tower cell while maintaining (and not deconstructing) the adjacent cooling tower cell(s) within the field. As shown inFIGS.3and24, installation of the modular cooling tower is depicted with foundation beams5which extend across the basin foundation1, forming the base floor of a singular modular cooling tower cell, and may be of any heavy-duty material, such as steel, or any other material commonly used within the art. The top face of foundation beam5includes a plurality of male lugs or column splices6along the length of the beam, which project in a direction opposite the footing anchors4, located at opposing ends of each foundation beam5, which supports the beam across the basin footing1. These footing anchors4are designed to anchor and level the steel beam on the edges of the basin foundation1so that the entire construction of the beam may be elevated above the live liquid-filled basin during construction of the cooling tower. In this manner, the construction of the cooling tower cell may be performed in-situ, i.e., while the rest of the cooling tower field remains in place and may optionally continue to be operational, eliminating the need to terminate the operation of other live cooling towers within a cooling tower field. While the foundation beams depicted inFIG.24include a single row of male lug projections or column splices6along the beam length, in one or more embodiments, the foundation beams may include a double spliced column splice projection pattern6′ spanning the foundation beam5′ length, as shown inFIG.25. Utilizing the double splice column splice projection pattern6′ allows for multiple module framework structures20to be placed on a single beam (seeFIG.23). After placing beams5across the basin foundation1, anchors4located at opposing ends of each beam are secured to maintain the edge of the basin1. As depicted inFIGS.28A to28C, proper alignment along the foundation beam is achieved by utilizing anchor fasteners94along the anchor4such that they extend through an interior portion of the basin1, and may be adjusted during the initial installation to ensure foundation beam5is plumb, level, and square to the basin1as well as other foundation beams. A grout95is then subsequently added between the anchor4bottom surface and topmost surface of the basin1, thereby fixing the foundation beam to the basin1and providing sufficient bearing capacity to support the cooling tower loads. The beams5are preferably fabricated from material having sufficient strength to support the weight of the modular cooling tower, such as steel.

To move foundation beams5into position across the basin1, the lift members40of the spreader platform50are secured to one or more foundation beams5by securing each of the lift members40to column splices6of the foundation beam5so that foundation beam5may be lifted by the spreader platform50and moved over the basin footing structure1. As shown inFIG.4, the lifting device has moved the spreader platform50and attached foundation beams5to a position over the basin footing so that they may be secured to the edges of the basin1as described above, forming a platform for securing one or more modules20thereto (see alsoFIG.23), which will form the lower airflow module layer110of the modular cooling tower cell. The foundation beams5are secured over the live basin filled with cooled liquid1000, and may be placed adjacent a currently operational cooling tower cell2000.

FIGS.8and9Bdepict the foundation beam5attachment to the lift member40. In a similar manner to lifting operations of the module framework structures20described in detail below, a male/female attachment structure is presented for elevating the foundation beams5and placing them in position across the basin footing1. In the disclosed embodiment, male lugs or column splices6are shown fastened to foundation beam5. The column splice6may be fastened by weld or other attachment means provided the attachment strength is sufficient to bear the portioned weight of the modules after attachment to foundation beams5and provides adequate construction flexibility for in field adjustments and erection tolerances. In one or more embodiments depicted inFIGS.30A and30B, the column splices6,6′ may include a shim plate405,405′ attached or otherwise secured thereto for enabling adjustment of the column splices6,6′ along the longitudinal axis of the foundation beam or perpendicular thereto for facilitating connection between a female lug connector23,40band the column splices6,6′ during installation of the modular cooling tower of the present invention. Lift member40has a female bottom receiving end40bfor accepting column splice6, and each connector portion has aligned apertures42with the openings7on column splice6for accepting a bolting segment therethrough. While the lug structure is exemplary, it is not intended to be limiting, and other configurations of attachment are not meant to be precluded. In at least one embodiment, the foundation beams may include cavities for receiving the lug. In other embodiments, the foundation beam may be attached via metal anchors and tethers. Once the foundation beams are in their final position, the column splices6are detached from the lift members40so that the spreader bar may be subsequently utilized to move one or more additional foundation beams5to their final position.

The fabrication and assembly of this new footing platform, formed by the securing of foundation beams5to the basin footing alleviates the need to deconstruct multiple cooling tower cells in order to replace the newly added single cooling tower module, and allows for the construction to occur in-situ, or during operation of the remainder of the cooling tower field.

FIGS.5,10, and11depict the method of forming the lower airflow module layer110of the modular cooling tower cell of the present invention. Once foundation beams5are in their final position, the spreader platform of one or more embodiments of the present invention may begin to move the modules20forming the airflow module layer110into their final positions. Once framework module structure20is in position to be lifted by the spreader platform50, lift members40are secured to the corresponding male lugs24on the module upper surface portion20a. The lifting device then moves the spreader platform50, which holds secured via lift members40the module structure20which will form the upper layer of basin section100of the cell. The module20is moved into a position above foundations beams where it can be subsequently lowered such that the female lugs23on the opposing end of the module20bare fit within the column splices6on the foundation beams5, and are subsequently secured to one another by use of one or more fasteners. The lift members40are removed from the male lugs24, and the spreader platform50will be moved again to position a subsequent piece of framework20onto the foundation beams until the airflow module layer110of the cooling tower cell is completed.

After completion of the airflow module layer110and basin section100, the remaining structural framework section200may be constructed in a manner similar to placement of the airflow module layer110. Spreader platform50and lift members40are secured to the module forming subsequent layers of structural framework section200(e.g., fill media module layer210, distribution module layer220, and/or drift eliminator layer230) via complementary male/female lug interconnection of the module lugs24and lift members40, and the lifting device subsequently raises and moves the second module30into the position above the first module20. As shown inFIGS.13A and13B, the second module30has been lowered into place above the first module structure20, and the female lugs23on the bottom end30bof the second framework structure30are fit within the male lugs24on the first framework structure20. After interconnecting the male and female lugs, the apertures27of the male lugs24on the first, lower module20correspond to the apertures37on female lug23of the upper, second module30. Thus, the connection of the upper framework structure30to the lower framework structure20may then be secured to one another through carrier bolts, or other similar securing devices known in the art. After attachment, lift members40are detached from the second structure30, so that the remaining modules which form the structural framework layer200may be installed. The method of construction of the modular cooling tower described herein allows for increased productivity by allowing the modules20forming the airflow module layer110, fill media module layer210, distribution module layer220, and/or drift eliminator layer230to be fabricated and assembled at a manufacture location prior to assembly of the cooling tower on a field site. Once completed and shipped to the field site, the male/female lug configuration allows for entire module framework portions to be assembled in an expedited manner, and also allows for the cooling tower field2000and liquid basin1000to be operational during the construction period.

The modules20forming any module layer may be secured to adjacent modules via fasteners such as a carriage bolt or threaded rod to prevent racking during construction and improve the rigidity of the structure. In one embodiment, adjacent modules may be secured together via a strut block, as depicted inFIG.27. Strut block90may be placed between adjacent modules20which form a cooling tower cell layer to provide linear support and allows for thermal expansion and contraction between modules during operation of the cooling tower cell. Strut block90provides for an exact spacer to secure adjacent modules.

After completion of the cell basin section100and structural framework section200, the stack section300may be completed, and the water distribution system201of the modular cell can be connected to the inlet piping of the former cooling cell. The mechanicals may include equipment such as the fan stack, fan assembly and hub, torque tube, gear box, motor and other related mechanical equipment, and may be equipment recycled from the former cooling tower cell, if desired. The customizable dimensions of the modular cooling tower of the present invention thus allow retrofitting existing mechanicals. Due to the modular construction of the cooling tower described herein and utilization of former cooling tower cell mechanicals, the time needed to construct a fully operational cooling tower cell is significantly decreased, which minimizes downtime within the cooling tower field. After the mechanicals have been installed, the exterior of the cooling tower structural framework section200is wrapped with siding61, which may be of sheet metal construction or fiberglass siding to further improve the insulation of the cooling tower during operation to improve efficiency. After completion of siding61, other miscellaneous components such as structural safety components are added to the cooling tower. Once fully constructed, the cooling tower may be finally connected to the prior cooling tower field2000, as depicted inFIG.2.

The method of construction and manufacture of the present invention is an improvement over prior methods of installation. The method of the present invention allows manufacture and assembly work on the replacement tower to be ongoing at the manufacture site while the site is being readied at the second location. Unlike prior art construction of cooling towers, the present invention can replace a single cooling tower in-situ in as little as six (6) weeks. Much of this time (about four weeks) is factory assembly time for the modular cooling towers of the present invention, requiring as little as two (2) weeks to complete site assembly. Similarly, the spreader platform and lift members of the present invention allow for assembly of a modular, custom created cooling tower cell which may be replaced in-situ during operation of an existing cooling tower field. Once the foundation beams are installed, the lift members may be removed from the modular construction, thereby allowing a quick and secure means to install (and stack) further modular construction pieces. Due to the modular construction, the present invention can be retrofit with existing mechanicals, allowing alignment with a previous pump system, eliminating the need to replace existing systems. The modular bolt holes throughout the entire lug structure allow for efficient automation and robotic fabrication, and the modular design philosophy of the present invention may modularize any existing cooling tower cell of any dimension. Thus, the present invention allows in-situ construction achieved with the elimination of basin anchored, vertical columns, which normally operate in a live water basin. The modular cooling tower of the present invention further improves thermal performance, site safety, quality and achieves reduced field construction.

While the present invention has been particularly described, in conjunction with one or more specific embodiments, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.