Heat exchange system adapted to selectively operate in wet and/or or dry mode

Abstract

A heat exchange system adapted to selectively operate in wet mode, dry mode, or both wet and dry mode comprises a plurality of layers of tube arrays arranged in a folded serpentine or stacked relationship such that fluid passes through each layer in a generally lateral manner, through a layer transition portion that conveys fluid to a lower layer of tube arrays existing at a lower elevation, one or more spray nozzles are located above an array of tubing and adapted to spray fluid onto the one or more arrays of tubing located below, and at least one fluid router is configured to convey process fluid only into the arrays of tubing in dry mode, only to the spray nozzles in wet mode, or to both into the arrays of tubing and to the spray nozzles.

1 . A heat exchange system adapted to selectively operate in wet or dry mode comprises:
 an inlet pass array of tubing that extends from an inlet manifold end tank for a predetermined length to a transition end;   a return for communicating fluid from the transition end of the inlet pass array of tubing to a second pass array of tubing;   the second pass array of tubing extends from the return at a first end for a predetermined length to a second end;   the second pass array exists below the inlet pass array and defines a first partial envelopment that exists between the inlet pass array, the return, and the second pass array;   a second return for communicating fluid from the second end of the second pass array of tubing to a third pass array of tubing;   the third pass array of tubing extends from the second return at a lead end for a predetermined length to a trailing end;   the third pass array exists below the second pass array and defines a second partial envelopment that exists between the second pass array, the second return, and the third pass array;   one or more subsequent pass arrays of tubing exist below and are in fluid communication with an above pass, of the one or more subsequent pass arrays a final pass array of tubing communicates fluid to an outlet;   one or more spray nozzles located in a partial envelopment above an array of tubing and adapted to spray fluid onto one or more arrays of tubing; and   at least one of the following fluid routers:   (a.) an inlet side fluid router located upstream of the inlet manifold end tank and adapted to selectively route fluid (i.) [in dry mode] to the inlet manifold end tank wherein the fluid passes into the arrays of tubing to the outlet and/or (ii.) [in wet mode] to the one or more spray nozzles,   (b.) an outlet side fluid router located downstream of the outlet and adapted to selectively route fluid from the outlet to the one or more spray nozzles and/or to a sump, and   (c.) a fluid router for directing fluid to the inlet manifold end tank wherein the fluid passes into the arrays of tubing to an outlet and/or (ii.) [in wet mode] to the one or more spray nozzles;   wherein air is drawn over a plurality of tubes comprising the one or more arrays of tubing and air is drawn through one or more partial envelopments while fluid is cooled as the fluid is selectively routed through the inside of the one or more arrays of tubing from the inlet manifold end tank to the outlet and/or fluid is selectively routed to the one or more spray nozzles onto the one or more arrays of tubing.   
     
     
         2 . The heat exchange system of  claim 1 , further including high surface area media contained within the one or more partial envelopments for providing evaporative surface area when air and liquid are exposed over the media structure to cool fluid sprayed onto the one or more arrays of tubing and/or the media. 
     
     
         3 . The heat exchange system of  claim 2 , one or more of the inlet pass array, the second pass array, the third pass array, and the one or more subsequent pass arrays are of a slab type configuration definable by tube sheet manifolds existing on each end, said tube sheet manifolds provide for transition of the flow of fluid between a common supply conduit to a plurality of tube conduits that form a pass array. 
     
     
         4 . The heat exchange system of  claim 2 , the one or more arrays of tubing are of a continuous coil configuration defined such that each tube of the plurality of tubes comprising the one or more arrays of tubing extends continuously from the inlet manifold end tank, forming the one or more returns, to the outlet. 
     
     
         5 . The heat exchange system of  claim 2 , the inlet manifold end tank comprising at least one wall forming a conduit to transition fluid flow between a common conduit and a plurality of tubes that form the inlet pass array, a debris filter existing between the common conduit and the plurality of tube conduits that form the inlet pass array for trapping debris in fluid conveyed into the end tank from the common conduit, and
 an access panel formed into the at least one wall; and the inlet pass array of tubing is elevated at the transition end relative to the inlet manifold end tank for automatic cleaning of the debris filter by enabling reversal flush of fluid by gravity flow from the inlet pass array through the debris filter to the common conduit when a fluid router closes supply fluid flow to the common conduit and opens the common conduit to a drain.   
     
     
         6 . The heat exchange system of  claim 5 , the inlet manifold end tank further including:
 a debris filter existing between the common conduit and the plurality of tube conduits that form the inlet pass array for trapping debris in fluid conveyed into the end tank from the common conduit, and   an access panel formed into the at least one wall.   
     
     
         7 . The heat exchange system of  claim 6 , the inlet pass array of tubing is elevated at the transition end relative to the inlet manifold end tank for automatic cleaning of the debris filter by enabling reversal flush of fluid by gravity flow from the inlet pass array through the debris filter to the common conduit when a fluid router closes supply fluid flow to the common conduit and opens the common conduit to a drain. 
     
     
         8 . The heat exchange system of  claim 2 , the inlet pass array of tubing is located above the one or more spray nozzles for aiding in the elimination of mist rising above the one or more spray nozzles by heating said mist as it rises past the inlet pass array of tubing. 
     
     
         9 . The heat exchange system of  claim 2 , the inlet pass array of tubing is located above the one or more spray nozzles for aiding in the elimination of mist rising above the one or more spray nozzles by heating said mist as it rises past the inlet pass array of tubing, and one or more arrays of tubing are located above the one or more spray nozzles for aiding in the elimination of mist rising above the one or more spray nozzles by heating said mist as it rises past the inlet pass array of tubing. 
     
     
         10 . A heat exchanger comprises:
 a plurality of layers of tube arrays arranged in a stacked relationship such that fluid passes through each layer in a generally lateral manner, through a layer transition portion that conveys fluid to a lower layer of tube arrays existing at a lower elevation, a partial envelopment exists between two layers of the tube arrays and a layer transition portion;   at least one partial envelopment existing above at least one of the plurality of layers and containing one or more nozzles for spraying liquid onto one or more layers of tube arrays and/or into one or more other partial envelopments;   at least one partial envelopment existing below at least one of the plurality of layers and containing a high surface area media structure for providing evaporative surface area when air and liquid are exposed onto the media structure to cool fluid sprayed onto the one or more arrays of tubing and/or the media; and   a fluid router adapted to direct fluid into each tube of the plurality of layers and/or to the one or more nozzles;   wherein process fluid is cooled by routing the fluid into the plurality of layers of tube arrays and/or routing the fluid to the one or more spray nozzles, and drawing air over a plurality of tube surfaces forming the plurality of layers.   
     
     
         11 . The heat exchanger of  claim 10 , further including high surface area media contained within one or more of the partial envelopments for providing evaporative surface area when air and liquid are exposed onto the media structure to cool fluid sprayed onto the one or more arrays of tubing and/or the media. 
     
     
         12 . The heat exchange system of  claim 10 , one or more of the plurality of layers are of a slab type configuration definable by tube sheet manifolds existing on each end, said tube sheet manifolds provide for transition of the flow of fluid between a common supply conduit to a plurality of tube conduits that form a pass array; and/or the one or more of the plurality of layers of tube arrays are of a continuous coil configuration defined such each tube of an array of tubes that form the plurality of layers extends continuously from an inlet, forming the layer transition portion and/or one or more additional layer transition portions, to the outlet. 
     
     
         13 . The heat exchange system of  claim 11 , the one or more of the plurality of layers of tube arrays are of a continuous coil configuration defined such each tube of an array of tubes that form the plurality of layers extends continuously from an inlet, forming the layer transition portion and/or one or more additional layer transition portions, to the outlet. 
     
     
         14 . The heat exchange system of  claim 10 , the inlet including an inlet manifold end tank comprising at least one wall forming a conduit to transition fluid flow between a common conduit and a plurality of tubes that form the inlet pass array, a debris filter existing between the common conduit and the plurality of tubes that form the inlet pass array for trapping debris in fluid conveyed into the end tank from the common conduit, and the inlet pass array of tubing is elevated at a transition end relative to the inlet manifold end tank for automatic cleaning of the debris filter by enabling reversal flush of fluid by gravity flow in a direction from the transition end to the inlet manifold end tank through the debris filter to the common conduit when a fluid router closes supply fluid flow to the common conduit and opens the common conduit to a drain. 
     
     
         15 . The heat exchange system of  claim 14 , the inlet manifold end tank further including:
 a debris filter existing between the common conduit and the plurality of tubes that form the inlet pass array for trapping debris in fluid conveyed into the end tank from the common conduit, and   an access panel formed into the at least one wall.   
     
     
         16 . The heat exchange system of  claim 15 , the inlet pass array of tubing is elevated at a transition end relative to the inlet manifold end tank for automatic cleaning of the debris filter by enabling reversal flush of fluid by gravity flow in a direction from the transition end to the inlet manifold end tank through the debris filter to the common conduit when a fluid router closes supply fluid flow to the common conduit and opens the common conduit to a drain. 
     
     
         17 . The heat exchange system of  claim 10 , one or more arrays of tubing are located above the one or more spray nozzles for aiding in the elimination of mist rising above the one or more spray nozzles by heating said mist as it rises past the inlet pass array of tubing. 
     
     
         18 . A method of cooling a fluid comprises the following steps:
 providing a heat exchange system capable of selective operation in wet mode or dry mode, said heat exchange system comprising a plurality of layers of tube arrays arranged in a stacked and/or serpentine relationship such that fluid passes through each layer in a generally lateral manner, through a layer transition portion that conveys fluid to, a lower layer of tube arrays existing at a lower elevation to an outlet—at least one partial envelopment existing above at least one of the plurality of layers and containing one or more nozzles for spraying liquid onto one or more layers of tube arrays and/or into one or more other partial envelopments formed between two layers of the plurality of layers,   drawing air over a plurality of tubes forming one or more of the plurality of layers of tube arrays and drawing air through one or more partial envelopments, and   directing fluid to a fluid router that functions to pass fluid (a) into the plurality of tubes forming the plurality of layers of tube arrays to an outlet, and/or (b) to the one or more nozzles.   
     
     
         19 . The method of  claim 18 , the step of “directing fluid to a fluid router” includes conveying fluid from a process fluid source into the plurality of tubes forming the plurality of layers to an outlet, wherein at least one outlet router located at the outlet selectively passes the fluid from the outlet to the one or more nozzles, or passes the fluid from the outlet to a sump. 
     
     
         20 . The method of  claim 18 , the step of “directing fluid to a fluid router” includes:
 providing an inlet side fluid router located upstream of the plurality of layers of tube arrays, said inlet side fluid router having a process fluid source port for receiving process fluid conveyed from a source, a tubing port for communicating process fluid to the plurality of layers of tube arrays, a spray port for communicating process fluid to the one or more nozzles, and a movable or rotatable valve body for selectively enabling fluid communication (a) from the source port to the tubing port, (b) from the source port to the spray port, or (c) from the source port to the tubing port and the spray port, and 
 conveying fluid from a process fluid source to the source port of the inlet side fluid router. 
 
     
     
         21 . The method of  claim 18 , the step of “directing fluid to a fluid router” further includes:
 providing an inlet side fluid router located upstream of the plurality of layers of tube arrays, said inlet side fluid router having tube shaped housing adapted to receive a valve body, the tube shaped housing having: 
 (i) a process fluid source port for receiving process fluid conveyed from a source, 
 (ii) a tubing port for communicating process fluid to the plurality of layers of tube arrays, 
 (iii) a spray port for communicating process fluid to the one or more nozzles, and 
 (iv) a signal pressure port for communicating a signal pressure from a signal fluid source to the valve body, 
 the valve body having: 
 (i) a signal pressure reading surface opposing a process fluid pressure reading surface to enable sliding of the valve body within the tube shaped housing from a first position to a second position depending upon the presence of the signal pressure exerted at the signal pressure port relative to a process fluid pressure exerted at the process fluid source port, 
 (ii) a first bore or pathway that communicates process fluid from the process fluid source port to the spray port when the valve body is in the first position, and 
 (iii) a second bore or pathway that communicates process fluid from the process fluid source port to the tubing port when the valve body is in the second position; and 
 conveying fluid from a heated process fluid source to the source port of the inlet side fluid router. 
 
     
     
         22 . The method of  claim 21 :
 the step of “providing an inlet side fluid router” further includes providing an inlet manifold end tank connected to an inlet pass array of tubing of the plurality of layers of tube arrays, the inlet manifold end tank comprising:   (i) at least one wall forming a conduit to transition fluid flow between a common conduit and a plurality of tubes that form the inlet pass array, and   (ii) a debris filter existing between the common conduit and the plurality of tubes that form the inlet pass array for trapping debris in fluid conveyed into the end tank from the common conduit, and   the inlet pass array of tubing is elevated at a transition end relative to the inlet manifold end tank for automatic cleaning of the debris filter by enabling reversal flush of fluid by gravity flow;   the step of “directing fluid to a fluid router” further includes the tube shaped housing having a drain outlet port for communicating backwash process fluid to a drain, and the valve body having a third bore or pathway that communicates backwash process fluid from the tubing port to the drain outlet port when the valve body is in the first position, allowing the flush of any debris from the debris filter to the drain.   
     
     
         23 . A heat exchange system capable of selective operation in wet mode or dry mode, said heat exchange system comprising:
 a plurality of layers of tube arrays arranged in a stacked and/or serpentine relationship such that fluid passes through each layer in a generally lateral manner, through a layer transition portion that conveys fluid to, a lower layer of tube arrays existing at a lower elevation to an outlet—at least one partial envelopment existing above at least one of the plurality of layers and containing one or more nozzles for spraying liquid onto one or more layers of tube arrays and/or into one or more other partial envelopments formed between two layers of the plurality of layers;   an inlet manifold end tank connected to an inlet pass array of tubing of the plurality of layers of tube arrays, the inlet manifold end tank comprising:   (i) at least one wall forming a conduit to transition fluid flow between a common conduit and a plurality of tubes that form the inlet pass array, and   (ii) a debris filter existing between the common conduit and the plurality of tubes that form the inlet pass array for trapping debris in fluid conveyed into the end tank from the common conduit, and   the inlet pass array of tubing is elevated at a transition end relative to the inlet manifold end tank for automatic cleaning of the debris filter by enabling reversal flush of fluid by gravity flow; and   an inlet side fluid router located upstream of the plurality of layers of tube arrays, said inlet side fluid router having tube shaped housing adapted to receive a valve body, the tube shaped housing having:   (i) a process fluid source port for receiving process fluid conveyed from a source,   (ii) a tubing port for communicating process fluid to the plurality of layers of tube arrays via the common conduit of the inlet manifold end tank,   (iii) a spray port for communicating process fluid to the one or more nozzles, and   (iv) a signal pressure port for communicating a signal pressure from a signal fluid source to the valve body,   (v) a drain outlet port for communicating backwash process fluid to a drain via the common conduit of the inlet manifold end tank,   the valve body having:   (i) a signal pressure reading surface opposing a process fluid pressure reading surface to enable sliding of the valve body within the tube shaped housing from a first position to a second position depending upon the presence of the signal pressure exerted at the signal pressure port relative to a process fluid pressure exerted at the process fluid source port,   (ii) a first bore or pathway that communicates process fluid from the process fluid source port to the spray port when the valve body is in the first position,   (iii) a second bore or pathway that communicates process fluid from the process fluid source port to the tubing port when the valve body is in the second position, and   (iv) a third bore or pathway that communicates backwash process fluid from the tubing port to the drain outlet port when the valve body is in the first position, allowing the flush of any debris from the debris filter to the drain,   (v) a signal pressure bleedoff bore or pathway that communicates signal fluid from the a signal pressure reading surface to the first bore and/or the second bore to enable the valve body to return to the second position when the signal pressure is shut off,   wherein process fluid is pumped from a process fluid heat source to the process fluid source port of the inlet side fluid router, a signal fluid source controlled by a remotely located operator valve is in communication with the signal pressure port of the inlet side fluid router,   when the operator valve is closed, the valve body of the inlet side fluid router travels to the second position allowing the communication of process fluid from the process fluid source port to the tubing port enabling dry mode operation, and   when the operator valve is opened, the valve body of the inlet side fluid router travels to the first position allowing the communication of process fluid to the nozzles and for allowing communication of backwash process fluid to a drain via the common conduit of the inlet manifold end tank, enabling wet mode operation.