U.S. patent application number 11/240116 was filed with the patent office on 2007-05-03 for modular industrial equipment facility.
This patent application is currently assigned to Ohio Transmission Corporation. Invention is credited to Gary Nelson, Steve Schoeny.
Application Number | 20070094946 11/240116 |
Document ID | / |
Family ID | 37906685 |
Filed Date | 2007-05-03 |
United States Patent
Application |
20070094946 |
Kind Code |
A1 |
Schoeny; Steve ; et
al. |
May 3, 2007 |
Modular industrial equipment facility
Abstract
A modular industrial equipment facility is provided. This
facility includes a plurality of pre-assembled, portable modules
that may further include a plurality of internal modules, and a
plurality of terminal modules for connecting to the plurality of
internal modules, wherein each module may be configured to operate
either in combination with or independent of the other modules.
These modules are typically intended for use with heavy, industrial
grade equipment. The internal modules and terminal modules may be
arranged to form a single, integrated structure that has the
appearance of a permanent, non-modular building. This invention may
also include a computerized monitoring and control system that may
further include a local component that monitors and controls the
operation of equipment that may be housed in the various modules;
and a remote monitoring and control component that is capable of
monitoring and controlling the operation of the equipment in the
various modules. Pre-installed ductwork and computerized air
handling allow the facility to be expanded or contracted without
significant structural modifications.
Inventors: |
Schoeny; Steve; (Maineville,
OH) ; Nelson; Gary; (Chillicothe, OH) |
Correspondence
Address: |
CALFEE HALTER & GRISWOLD, LLP
800 SUPERIOR AVENUE
SUITE 1400
CLEVELAND
OH
44114
US
|
Assignee: |
Ohio Transmission
Corporation
Columbus
OH
|
Family ID: |
37906685 |
Appl. No.: |
11/240116 |
Filed: |
September 30, 2005 |
Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
E04H 5/02 20130101 |
Class at
Publication: |
052/079.1 |
International
Class: |
E04H 1/00 20060101
E04H001/00 |
Claims
1) An industrial system, comprising: (a) a plant or factory for
performing an industrial process; and (b) a modular industrial
equipment facility connected to the plant or factory, wherein the
modular equipment facility further comprises: (i) a plurality of
internal modules, wherein each of the internal modules further
comprises at least one substantially non-weight bearing external
wall; (ii) a plurality of terminal modules for use with the
plurality of internal modules, wherein each of the terminal modules
further comprises at least two external substantially non-weight
bearing walls; and (iii) wherein the internal modules and terminal
modules are arranged to form an integrated structure.
2) The industrial system of claim 1, further comprising a
computerized monitoring and control system in communication with
the modular equipment facility, wherein the monitoring and control
system further comprises: a local component within the facility and
a remote component separate from the facility and in communication
with the local component.
3) The industrial system of claim 2, wherein the local component is
located in one of the internal modules or in one of the terminal
modules, and further comprises computer hardware and software for
operating the equipment facility.
4) The industrial system of claim 1, wherein the plant or factory
is an automotive manufacturing facility.
5) The industrial system of claim 1, wherein the modular equipment
facility is an air compressor facility, and wherein the air
compressor facility is substantially automated and provides a
substantially continuous supply of compressed air to the plant or
factory.
6) The industrial system of claim 1, wherein each of the internal
modules further comprises an air compressor/dryer, and wherein each
internal module is configured to operate the air compressor/dryer
either in combination with or independent of the other air
compressors.
7) The industrial system of claim 1, wherein each of the modules
further comprises pre-wired electrical lines and connections.
8) The industrial system of claim 1, wherein each of the internal
modules further comprises air-handling components, and wherein the
air-handling components further comprise: filters; fans; dampers;
and air ducts.
9) The industrial system of claim 1, wherein at least two of the
plurality of terminal modules each further comprise at least one
vent for providing ventilation to the interior of the modular
industrial equipment facility.
10) The industrial system of claim 1, wherein each of the internal
modules and each of the terminal modules is adapted to be crane
lifted.
11) The industrial system of claim 1, wherein the modular
industrial equipment facility may be modified by adding modules or
removing modules.
12) An industrial equipment facility, comprising: (a) a plurality
of preassembled, portable equipment modules, wherein the plurality
of preassembled, portable equipment modules further comprises: (i)
a plurality of internal equipment modules, wherein each of the
internal equipment modules further comprises at least one
substantially non-weight bearing external wall; and (ii) a
plurality of terminal modules for use with the plurality of
internal equipment modules, wherein each of the terminal equipment
modules further comprises at least two external substantially
non-weight bearing walls; and (b) wherein the plurality of
preassembled, portable equipment modules are arranged to form a
single, integrated structure.
13) The industrial equipment facility of claim 12, further
comprising a computerized monitoring and control system in
communication with the equipment facility, wherein the monitoring
and control system further comprises: a component located within
the facility and a component located remotely from the facility,
wherein the remotely located component is in communication with the
control component located within the facility.
14) The industrial equipment facility of claim 13, wherein the
local control component is located in one of the internal modules
or in one of the terminal modules, and further comprises computer
hardware and software for operating the equipment facility.
15) The industrial equipment facility of claim 12, wherein each of
the internal equipment modules further comprises an air
compressor/dryer unit, and wherein each air compressor/dryer unit
operates either in combination with or independent of the other air
compressor/dryer units.
16) The industrial equipment facility of claim 12, wherein each of
the modules further comprises pre-wired electrical lines and
connections for connecting to the other modules.
17) The industrial equipment facility of claim 12, wherein each of
the internal modules further comprises air-handling components, and
wherein the air-handling components further comprise: filters;
fans; dampers; and air ducts.
18) The industrial equipment facility of claim 12, wherein at least
two of the plurality of terminal equipment modules each further
comprises at least one vent for providing ventilation to the
interior of the industrial equipment facility.
19) The industrial equipment facility of claim 12, wherein each of
the internal equipment modules and each of the terminal equipment
modules are adapted to be crane lifted.
20) The industrial equipment facility of claim 12, wherein the
industrial equipment facility may be modified by adding equipment
modules or removing equipment modules.
21) An industrial equipment facility, comprising: (a) a plurality
of individual equipment modules; wherein the equipment modules are
arranged to form an integrated structure; (b) an industrial air
compressor/dryer installed in at least two of the individual
equipment modules, wherein each air compressor/dryer draws cooling
air and compressor intake air from the environment outside of the
industrial equipment facility; (c) a plurality of air-handling
components connected to or in communication with each of the at
least two industrial air compressor/dryers; wherein the plurality
of air-handling components further comprises: coolers, dampers,
fans, air ducts, and temperature sensors; (d) a computerized
monitoring and control system in communication with the
air-handling components in each equipment module and each air
compressor/dryer for monitoring and controlling the operation of
each air compressor/dryer; and (e) wherein the computerized
monitoring and control system operates each air compressor/dryer
unit in combination with or independent of the other air
compressor/dryers.
22) The industrial equipment facility of claim 21, further
comprising electric switchgear connected to the at least two
industrial air compressor/dryers; and a source of electric power
connected to the electric switchgear.
23) The industrial equipment facility of claim 21, wherein the
computerized monitoring and control system further comprises a
component located within the facility and a component located
remotely from the facility, wherein the remotely located component
is in communication with the component located within the
facility.
24) The industrial equipment facility of claim 22, wherein the
communication between the component located within the facility and
the component located remotely from the facility is wireless.
25) A method for constructing, installing and operating an
industrial equipment facility, comprising: (a) fabricating a
plurality of internal equipment modules, wherein each of the
internal modules further comprises at least one substantially non
weight-bearing external wall; (b) fabricating a plurality of
terminal equipment modules, wherein each of the terminal modules
further comprises at least two substantially non weight-bearing
external walls; (c) placing industrial equipment within some or all
of the internal modules and the terminal modules; (d) transporting
the internal modules and the terminal modules to a predetermined
site; (e) arranging the internal modules and terminal modules at
the predetermined site to form an integrated structure; and (f)
connecting the industrial equipment within the equipment modules to
a computerized monitoring and control system, wherein the
computerized system further comprises: a component located within
the facility and a component located remotely from the facility,
wherein the remotely located component is in communication with the
component located within the facility.
26) The method of claim 25, further comprising the step of
installing 110 V or single phase electric lines and connections
into each equipment module prior to transporting the module.
27) The method of claim 25, further comprising the step of
installing air-handling components in the internal modules, wherein
the air-handling components further comprise: filters; fans;
dampers; and air ducts.
28) The method of claim 25, wherein the industrial equipment
further comprises air compressor/dryers and electrical
switchgear.
29) The method of claim 25, wherein the remote component further
comprises a remote access device.
30) The method of claim 25, wherein the control system further
comprises at least one camera installed within the industrial
equipment facility for visually monitoring the industrial
equipment.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates in general to a facility for use with
industrial equipment, and in particular to a modular equipment
facility for use with heavy industrial equipment such as, for
example, air compressor/dryer units.
[0002] In certain circumstances, the use of prefabricated, modular
buildings for purposes such as constructing electrical facilities
and residential housing may be an acceptable alternative to more
traditional on-site construction methods. The use of individual
building modules or units may save time and may reduce the overall
complexity associated with some construction projects. However,
many modular buildings or structures, although often highly
functional, are unacceptable for certain applications because they
include multiple modules or units that are connected to one another
in a manner that creates a structure or structures that appear to
be incomplete, i.e., unfinished, or non-permanent. For example,
many modular facilities used for industrial applications include a
series of trailers that are connected together or that are simply
placed near one another at an equipment site. Facilities of this
nature are often undesirable because they are deemed unacceptable
by labor unions or because they negatively impact the appearance of
the physical environment in which they are located. Thus, there is
a need for a modular structure that can be used as an industrial
equipment facility and that when complete, has the appearance of a
finished, unified, non-modular structure.
[0003] Certain industrial factories and plants utilize large-scale
equipment facilities that operate on a substantially continuous
basis so that manufacturing or production can proceed without
interruption. However, many industrial equipment facilities,
including those that are modular in nature, do not include adequate
backup systems or system redundancies that provide for
substantially continuous operation in the event that one or more
individual components within the system fails. In the absence of
adequate safeguards or redundancies, manufacturing operations may
be interrupted or may cease if a partial system failure occurs.
Furthermore, if manufacturing or production output must be
increased or decreased, a rapid expansion or contraction of the
equipment facility servicing the factory or plant may become
necessary. Existing modular facilities are not typically expandable
or reconfigurable without reconstruction of the entire facility.
Reconstructing an entire facility to accommodate additional heavy
equipment significantly reduces or basically eliminates most of the
advantages realized by using a modular structure or system in the
first place. Thus, there is a need for a modular industrial
equipment facility that provides certain redundancies that assure
substantially continuous operation in the event of a partial system
failure and that can be reconfigured, i.e., expanded or
re-arranged, without significant reconstruction of the entire
facility.
SUMMARY OF THE INVENTION
[0004] Deficiencies in and of the prior art are overcome by the
present invention, the exemplary embodiment of which provides a
modular facility suitable for housing a variety of industrial
equipment or devices such as, for example, high-output air
compressor/dryers. In accordance with one aspect of the present
invention, an industrial system is provided. This system includes a
plant for performing one or more industrial processes and a modular
industrial equipment facility connected to the plant. The modular
equipment facility further includes a plurality of individual
modules which may be situated on the end portions of the facility
or which may be situated on the inside portion of the facility.
Each of the inside or "internal" modules further comprises at least
one non-weight bearing external wall and each of the end or
"terminal" modules further comprises at least two non-weight
bearing external walls. The internal modules and terminal modules
may be arranged in a variety of geometric configurations to form a
single, integrated structure that has the appearance of a unified,
non-modular building.
[0005] In accordance with another aspect of the present invention,
a modular industrial equipment facility is provided. An exemplary
embodiment of this facility includes a plurality of pre-assembled,
portable modules suitable for use with heavy industrial equipment
such as air compressor/dryers or other equipment. The modules may
be situated, i.e., placed, on the end portions of the facility or
they may be situated on the inside portion of the facility. Each of
the inside or "internal" modules further comprises at least one
non-weight bearing external wall and each of the end or "terminal"
modules further comprises at least two non-weight bearing external
walls. The internal modules and terminal modules may be arranged in
a variety of geometric configurations to form a single, integrated
structure that has the appearance of a unified, non-modular
building. Each of the modules (referred to herein as "equipment
modules") modules is typically configured to operate independent of
the other equipment modules in the event of a partial system
failure. In this embodiment, the terminal modules are typically
used to house switchgear, computers, or other electrical equipment
while the internal modules are typically used to house air
compressor/dryer units. The construction and configuration of both
the individual equipment modules and the facility itself creates an
industrial facility in which each air compressor/dryer unit
operates independent of the other air compressor/dryers in terms of
environmental control, i.e., compressor cooling, but that is still
fully integrated into the larger facility in terms of compressor
air output. The internal environment of the facility itself does
not significantly affect or limit the number of air
compressor/dryer units that may be added to or removed from the
system. Therefore, the output of the industrial equipment facility
of this invention may be increased or reduced without the need to
significantly reconstruct the entire facility to change internal
airflow characteristics. This invention also includes a
computerized control system that further includes a local component
and a remote component. The local component is typically placed
within the equipment facility and provides means by which to both
monitor and control the operation of the equipment located within
the facility. The remote component is typically placed at a
location separate from the main equipment facility and also
provides means by which to both monitor and control the operation
of the equipment located within the facility.
[0006] In yet another aspect of this invention, a method for
manufacturing, installing and operating a modular industrial
equipment facility is provided. This method includes the general
steps of: (i) fabricating a plurality of equipment modules for use
with heavy industrial equipment such as air compressor/dryer units,
wherein the equipment modules further include end or "terminal"
modules each having at least two external non-weight bearing walls
and inside or "internal" modules each having at least one external
non-weight bearing wall; (ii) installing equipment in the equipment
modules; (iii) transporting the equipment modules to a
predetermined construction site; (iv) arranging the equipment
modules to form a single, integrated structure, wherein the single,
integrated structure has the appearance of a unified, non-modular
building; and (v) connecting the equipment modules to a
computerized control system, wherein the control system further
comprises a local component and a remote component for monitoring
and controlling the operation of the equipment installed in the
modules.
[0007] Additional features and aspects of the present invention
will become apparent to those of ordinary skill in the art upon
reading and understanding the following detailed description of the
exemplary embodiments. As will be appreciated, further embodiments
of the invention are possible without departing from the scope and
spirit of the invention. For example, the invention may be used to
house and operate industrial equipment other than air
compressor/dryer units. Accordingly, the drawings and associated
descriptions are to be regarded as illustrative and not restrictive
in nature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated into and
form a part of the specification, schematically illustrate one or
more embodiments of the invention and, together with the general
description given above and detailed description of the exemplary
embodiments given below, serve to explain the principles of the
invention.
[0009] FIG. 1 is a generalized schematic representation of the
industrial system of the present invention showing the factory or
plant, the modular industrial equipment facility, the remote
monitoring and control component, and the transformers and power
source utilized by the equipment facility.
[0010] FIG. 2 is a side view of one of the equipment modules of the
exemplary embodiment showing the ductwork and air compressor/dryer
unit contained within the module.
[0011] FIG. 3 is a side view of one of the equipment modules of the
exemplary embodiment showing various electrical components
contained within the module.
[0012] FIG. 4 is a perspective view of an exemplary embodiment of
the industrial equipment facility of the present invention under
construction showing one of the equipment modules being lowered
into position by a crane.
[0013] FIG. 5 is a perspective view of an exemplary embodiment of
the assembled industrial equipment facility of the present
invention showing the final placement of the internal modules and
the terminal modules relative to one another.
[0014] FIG. 6 is a cross-sectional side view of an exemplary
embodiment of the industrial equipment facility of the present
invention showing the placement of air compressor/dryers and
associated ductwork within the interior of two equipment modules
that are facing one another.
[0015] FIG. 7 is a side view of the exterior of an exemplary
embodiment of the industrial equipment facility of the present
invention showing the placement of the internal modules and
terminal modules relative to one another.
[0016] FIG. 8 is a schematic representation of the computerized
local and remote components of an exemplary embodiment of the
industrial equipment facility of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] This invention relates to a reconfigurable modular
industrial equipment facility for use with a factory, manufacturing
plant or other industrial system or operation. An exemplary
embodiment of this facility includes a plurality of pre-fabricated,
portable equipment modules that are typically transported to and
arranged at a predetermined location. These equipment modules
further include: a plurality of internal equipment modules (i.e.,
for placement on the interior or middle portion of the structure),
wherein each internal module is configured to operate independently
of or in combination with the other internal modules in the event
of a partial system failure; and a plurality of terminal modules
(i.e., for placement on the end portions of the structure) for use
in combination with the plurality of internal modules. When final
construction/assembly of the facility of the present invention is
complete, the internal modules and terminal modules form a single,
integrated structure that has the appearance of a unified,
non-modular building. This invention also includes a computerized
control system that further comprises a local electronic/digital
component that monitors and controls the operation of the various
equipment modules and a remote electronic/digital component that is
also capable or monitoring and controlling the operation of the
equipment modules. This control system facilitates the
substantially continuous operation of the industrial equipment
facility of this invention. This invention is useful for use with
large, heavy duty air compressor/dryers or other equipment, and
includes a variety of computer-controlled dampers that allow each
air compressor/dryer to operate in a substantially self-contained
environment that is largely independent of the internal environment
and airflow of the building housing the air compressor/dryers
and/or other equipment.
Industrial System and Modular Equipment Facility
[0018] With reference now to the Figures, FIG. 1 provides a
schematic representation of an exemplary industrial system 10.
Industrial system 10 typically includes an industrial plant 20,
such as an automotive plant, which receives pressurized air from a
modular industrial equipment facility 30 for operating equipment
utilized in the plant. Modular industrial equipment facility 30 may
be arranged in any of a variety of geometric configurations, i.e.,
floor plans, and includes a plurality of equipment modules that
further include internal modules 32 and terminal modules 60. In the
exemplary embodiment shown in FIG. 1, there are twelve internal
modules 32 (six per side and facing one another), ten of which
house an air compressor/dryer unit 50 (designated as C1-C10 in FIG.
1) and, optionally, other equipment. Other embodiments of this
invention include a greater or lesser number of equipment modules
and in some embodiments, at least one of the equipment modules is
free of equipment and is used as a "service" module for accessing
the equipment in the other modules. The air compressor/dryers 50
direct compressed air into a plurality of air outlets 56, which are
connected to compressed air header 58, which supplies compressed
air to plant 20. In FIG. 1, one of the two internal modules 32 that
does not house an air compressor/dryer 50 houses the computer
hardware and software included in local component 90, which
monitors and controls the equipment located in facility 30. Local
component 90 is in electrical/digital communication with remote
component 100, which is also capable of monitoring and controlling
the equipment located in facility 30. Control components 90 and 100
are typically in direct or indirect electrical/digital
communication with each of the equipment modules. This
communication may be wireless. In the exemplary embodiment of FIG.
1, there are also four terminal modules 60. Two of these modules 60
are empty, although as shown in the Figure, compressor/dryer units
C11 and C12 may be added to equipment facility 30 as needed. The
other two terminal modules 60 shown in FIG. 1 house electric
switchgear 80, which is connected to transformers T1-T4, which are
connected to external power source 105 for providing electric power
to industrial equipment facility 30.
[0019] Numerous other arrangements of the equipment modules of
facility 30 are possible, and it should be noted that FIG. 1
illustrates only one such configuration. In the configuration shown
in FIG. 1, the construction and arrangement of the individual
equipment modules creates space on the interior of the building
that may be used by maintenance workers to access the individual
air compressor/dryers 50 and other equipment. Supports 66 provide
structural support to each end module and supports 38 provide
structural support to each internal module 32 making internal
weight bearing walls unnecessary. The dashed lines in FIG. 1
represent the physical boundaries of each individual module--there
are no internal walls present in this embodiment, thereby
permitting relatively unrestricted movement within industrial
equipment facility 30.
Construction of Equipment Modules
[0020] In the exemplary embodiment shown in the Figures, equipment
modules 32 and 60 have been constructed for use with large,
industrial capacity air compressor/air dryer units. Each equipment
module is designed to be structurally stable independent of
surrounding structures or modules and to accommodate very heavy
equipment, if desired. In the exemplary embodiment shown in the
Figures, each equipment module housing an air compressor/dryer unit
weighs about 45,000 pounds. FIG. 2 provides a side view of an
internal module 32, and illustrates the placement of an air
compressor/air dryer unit 50 within the module. FIG. 2 also shows
the various dampers, ductwork, and other equipment that is
typically pre-installed within the module prior to transporting the
module to a construction site. As shown in FIG. 2, the enclosure
portion of internal module 32 includes at least one exterior wall
34, floor 36, supports 38, roof 40, and aperture 42. Equipment
modules 32 and 60 are typically steel framed and supported over an
I-beam framed, reinforced concrete base. Although not shown in the
Figures, each equipment module 32 and 60 may be equipped with a
monorail four-inch I-beam crane, trolley, and a half-ton hoist for
facilitating lifting, placement, or replacement of equipment within
the module.
[0021] The construction specifications of each equipment module may
vary based on the site at which facility 30 is being constructed
and/or on the equipment being housed and operated in each module.
However, in an exemplary embodiment, the exterior walls of each
equipment module are sided with 26-gauge "Span-Line 36" (Metal
Sales Manufacturing Corp.). The exterior walls are metal studded
with galvanized metal interior wall panels. The roofing consists of
an EPDM membrane roof (60 mil, Firestone) on 3-inch rigid
insulation over metal decking, and the insulation is 3.5-inch
fiberglass insulation with a R13 rating. The metal deck is
3''.times.18' gauge type 3N galvanized steel. The roof slopes
0.25'' per 12'' from a height of 11 ft, 6 inches. The equipment
modules 32 and 60 may also include one or more doors 70. Industrial
equipment facility 30 is typically built to meet Zone 1
requirements as defined in the Uniform Building Code of the
International Conference of Building Officials. Despite the
specific application or equipment used, equipment facility 30 is
typically built to be compliant with all relevant local building
codes and standards for, but not limited to, building design and
construction, steelwork and structural work, pressurized piping and
vessels, and electrical wiring. Seismological factors are also
typically considered in the construction of both the equipment
modules and the facility itself. As will be appreciated by the
skilled artisan, other materials may be used for the construction
the equipment modules of the present invention.
[0022] Again with reference to FIG. 2, each internal equipment
module 32 (or terminal module 60 if used to house an air
compressor/dryer 50) is equipped with an air handling system that
includes ductwork, dampers and computerized controls such that a
high volume (e.g., 22,000 CFM) of compressor cooling air may be
utilized by each air compressor/dryer 50 regardless of the volume
of available air contained within the structure of equipment
facility 30. Although the specifications of each equipment module
may vary, in an exemplary embodiment, the air handling system
includes: (a) a Total Filtration (28VB10WX06H V) bank inlet filter
housing and filter bank 44; (b) two Ruskin CDTI-50 low temperature
intake air control dampers 48a with 110 volt 90 degree actuators;
(c) two 15 HP Atlas Copco cooling fans 43; (d) a Modicon PLC 53;
(e) an Atlas Copco compressor/dryer cooling system 51, which
includes an intercooler, an after-cooler, an oil cooler, and a
dryer regeneration cooler; (f) discharge air ducts 52a and 52b; (g)
two Ruskin CDTI-50 low temperature recirculation control dampers
48b with 110 volt 90 degree actuators; (h) a recirculation air duct
46; (i) a Ruskin CDTI-50 low temperature discharge control damper
48c with 110 volt 90 degree actuator; (j) a Ruskin CDTI-50 low
temperature discharge control damper 48d with 24 volt modulating
actuator; (k) an outside (ambient) air temperature sensor 41; and
(l) an internal compressor cooling temperature sensor 45 (see FIG.
2).
[0023] With reference to FIGS. 1 and 3, an exemplary embodiment of
this invention includes a variety of industrial grade electrical
components that provide power to equipment facility 30 and to the
equipment operating therein. In general, the electrical system
includes a main power source, a series of transformers, switchgear,
power distribution panels, and a series of electrical feeds and
lines. More specifically (see FIG. 1), an exemplary embodiment of
this invention includes a 13,800 V main switch house 106, which is
connected to four transformers 105, which are connected to
double-ended 480-volt GE AKD switchgear 80. In this example,
switchgear 80 includes two 4000-amp main breakers; four 800-amp
individual compressor and/or building power breakers 86, and one
4000-amp tie breaker. Each set of switchgear 80 includes one
800-amp breaker pre-wired to a GE distribution panel 81 for
powering certain auxiliary equipment, such as space heaters, which
may be installed in facility 30, and the single phase 480V/220-110
V single-phase transformer 83. Transformer 83 is pre-wired to a
single-phase panel board 82. A 600-amp safety disconnect switch 87
may also be included for each air compressor/dryer 50. Each
equipment module 32 and 60 may include pre-installed light
switches, duplex receptacles, interior lighting, fluorescent lamps,
and electrical wiring. To minimize on-site wiring requirements,
"pig tails" or other devices for interconnecting lighting and
outlet circuits between modular sections may be provided.
[0024] FIG. 4 shows modular industrial equipment facility 30 during
the assembly process. In this Figure, one of the internal modules
32 is being lowered into place by crane 120. FIGS. 5-7 depict the
assembled version of modular industrial equipment facility 30. As
is evident from FIG. 5, the fully constructed and assembled
facility has the appearance of a single, unified, permanent,
non-modular structure. As previously discussed, the internal
modules 32 typically include a metal frame, a concrete floor 36, a
plurality of supports 38, and a roof 40. A single, non-weight
bearing exterior wall or panel 34 is attached to the side of
internal module 32 that faces the outside environment when
industrial equipment facility 30 is assembled. Each terminal module
60 also includes a metal frame, a floor 64, a plurality of supports
66, and a roof 68. Two non-weight bearing exterior panels or walls
62 are attached to the sides of terminal module 60 that face the
outside environment when industrial equipment facility 30 is
assembled. Terminal modules 60 may be used for housing air
compressor/dryers 50 by removing one of the wall panels 62, cutting
an aperture 42 into the panel 62, and re-attaching the cut panel to
the module. Additionally, the roof portion of each equipment module
(terminal and internal) typically includes protruding "curbs" that
may be used to accommodate discharge air ducts 52a and 52b.
[0025] With reference to FIG. 5, an air intake 72 is included at
each end of equipment facility 30 for providing ventilation and
cooling air to the interior of the assembled facility. In an
exemplary embodiment, each air intake 72 includes a
thermostatically controlled motorized damper and a 4'.times.4'
Total Filtration "v-bank" filter system. In the exemplary
embodiment, an individually thermostatically controlled one-quarter
HP exhaust fan is installed in discharge duct 52a above each air
compressor/dryer 50 to discharge any excess compressor/motor/piping
radiant heat. Relatively cool outside air is then drawn into
equipment facility 30 by operation of the air intakes 72.
[0026] FIG. 6 provides a cross-sectional side view of two of the
internal modules 32 as arranged in an exemplary embodiment of the
final, assembled version of industrial equipment facility 30. As
previously indicated, each individual module is typically
constructed at a first location and then transported to a second
location, in some cases fully loaded with equipment. As discussed,
each individual equipment module is constructed to include some, or
for certain applications, all of the necessary electrical
connections and other connectors that allow that module to be
easily connected to the other modules that are included in the
completed and functional equipment facility. In an exemplary
embodiment, each internal module houses an Atlas Copco ZT275FF air
compressor/dryer that is equipped with an air dryer having
preinstalled interconnecting piping that includes 3-way bypass
piping. In the exemplary embodiment, each equipment module that
houses an air compressor/dryer unit includes a 4-inch Victaulic
air-piping riser 56 connected to a 10-inch, Schedule 40 air header
58 with flanges on each end for quick and easy interconnection with
the other equipment modules. Additionally, prior to shipping, the
condensate drain discharges of each air compressor/dryer 50 are
connected by way of tubing to a 3-inch PVC manifold pipe 59,
10-feet in length (see FIG. 6), which is installed over each air
compressor/dryer 50 and permits easy interconnection with the
condensate drain discharges of the other equipment modules.
[0027] The overall size of the final structure may be changed, or
the geometric configuration altered, by removing individual modules
or groups of modules, by adding modules, or by rearranging the
modules already in use. Advantageously, the significant weight of
each module allows the final facility to be assembled in most cases
without actually connecting, to any significant degree in terms of
structure, the individual modules to one another. Thus,
essentially, the final facility is a group of freestanding
equipment modules that have been placed close to one another. Once
the facility is assembled, a roofing material may be used to seal
seams between the roof portions 40 and 68 to prevent the elements,
especially water, from entering the industrial equipment facility
30. Metal siding filler pieces may also be used to cover seams
between the exterior wall panels 34.
Equipment Facility Control System (Hardware and Software)
[0028] With reference to FIGS. 1 and 8, the industrial equipment
located in facility 30 is monitored and controlled by a
computerized system that includes an on-site local component 90 and
a separate remote component 100. This computerized system allows
the equipment in facility 30 to operate in a substantially
autonomous or automated manner and typically very little human
intervention is involved once the facility is brought on-line. The
hardware and software included in this computerized system allows
the equipment in each of the individual modules to function both in
combination with and independent of the equipment in the other
modules, and helps assure that the failure of equipment in one or
more modules does not negatively impact the operation and output of
the entire system. As shown in FIG. 8, an exemplary embodiment of
local component 90 includes custom computer software for monitoring
and controlling the equipment in the modules, a wireless
router/switch 91, a system control computer 92, a power monitor
damper control computer 93, a security camera computer 94, an
ION.RTM. meter bank 95 for measuring power usage, and a bank of
security cameras 96. Local component 90 is in electronic/digital
communication with remote component 100. Remote component 100
typically includes custom computer software for monitoring and
controlling the equipment in the modules, a remote access software
component 101, a data connection 102, a remote access device or
service (e.g., cell phone, Internet, or other means) 103, and a
remote server 104. The ManagAIR.RTM. system (available from Ohio
Transmission Corporation; Columbus, Ohio) is an example of a
software-based system that may be used for local component 90, and
the MonitAIR.RTM. system (also available from Ohio Transmission
Corporation; Columbus, Ohio) is an example of a software-based
system that may be used for remote component 100. These systems may
be used to generate and send alarms and various reports by way of
e-mail or other electronic/digital communications means. Both of
these systems are useful for monitoring and controlling the
operation of a compressed air facility. However, as will be
appreciated by those skilled in the art, other custom or
customizable software-based systems may be used with the present
invention.
[0029] In an exemplary embodiment, each air compressor/dryer 50
contains a wireless communication device that provides at least two
communications ports. A first port is used to connect to the
compressor/dryer's Elektronikon (Atlas Copco) control system and
power metering equipment located in the compressor/dryer
disconnect. A second data port is used for connection to a Modicon
programmable logic controller (PLC) that is added to each air
compressor/dryer 50. In general terms, programmable logic
controllers are known computerized devices typically used for
automating industrial processes. These devices are
microprocessor-based and include either modular or integral
input/ouput circuitry that monitors the status of field connected
sensor inputs and controls attached devices (motor starters,
solenoids, actuators, pilot lights/displays, speed drives, valves,
etc.) according to a user-created program stored in battery-backed
memory. The functionality of a PLC may include typical relay
control, sophisticated motion control, process control, distributed
control, and complex networking. The PLCs used with the present
invention automate the process of regulating each air
compressor/dryer's cooling air temperature in response to changes
in ambient conditions and/or compressor heat loads. In this
embodiment, the ManagAIR.RTM. system requests data from all the air
compressor/dryers at predetermined intervals. These data include
information such as current operational status; operating
parameters such as pressures, temperatures and vibration levels;
power information, warning and alarm status for each parameter, as
well as service information. The ManagAIR.RTM. system analyzes this
information and performs various operations based on these results.
By communicating with the PLC used with each air compressor/dryer
50, the ManagAIR.RTM. system may be used to: (i) log data for
trending and diagnostics; (ii) start or stop machines based on
demand; (iii) load and unload machines based on demand; (iv) adjust
compressor sequence; (v) analyze data for predictive intervention;
(vi) calculate energy efficiency; (vii) provide alarms by way of
alphanumeric page; and (viii) provide e-mail and/or facsimile
communications.
[0030] In addition to power monitoring equipment, which is
typically provided for each air compressor/dryer 50, in an
exemplary embodiment, four ION power-metering devices are located
in switchgear 80. These devices are connected by an Ethernet cable
to router 91. A second complete computer system running ION Windows
based software monitors all information from the ION power metering
equipment. Also installed on this computer is software designed to
monitor and control the Modicon PLCs located in each air
compressor/dryer 50. Communications between this computer and the
PLCs are typically carried out over an encrypted wireless Ethernet
connection. This computer also serves as a backup to the computer
running the ManagAIR.RTM. software or other software.
[0031] In the exemplary embodiment, a third computer is also
located at the facility site for the purpose of video surveillance.
This surveillance system is a digital video recorder (DVR) system
that includes a Windows-based computer that incorporates
specialized video hardware and software. Attached to the computer
is a plurality of cameras 96 located inside and outside of the
building. Outdoor fixed cameras and indoor pan and tilt cameras are
connected to the computer with standard video/power wiring. A
portable wireless camera is also located inside industrial
equipment facility 30. The DVR system is equipped to record all
motion detected by the cameras for the purpose of security. The
system also allows visual inspections of the site to be performed
remotely by way of the Internet or other remote means.
Equipment Facility Operation (Module Micro-environment)
[0032] Due to the unique modular construction of industrial
equipment facility 30, the operation of the equipment housed in
each module, i.e., each air compressor/dryer 50, is not
significantly limited by the volume of air that can be drawn into
the integrated structure itself. Because each air compressor/dryer
50 draws compressor cooling air and compressor intake air from the
environment outside the facility and not from inside the facility,
the operation of each individual air compressor/dryer 50 does not
restrict or negatively impact the operation of the other air
compressor/dryers 50, nor does it limit number of air
compressor/dryers that may be included in facility 30. The air
handling on the interior of facility 30 is used to dissipate
radiant heat and is not used as a source of compressor cooling air
or compressor intake air. Consequently, additional equipment
modules and air compressor/dryers may be added to or removed from
industrial equipment facility 30 without necessitating
reconstruction of the entire building.
[0033] With reference to the exemplary embodiment of the present
invention shown in FIGS. 2 and 6, each internal module 32 (or
terminal module 60 if an air compressor/dryer 50 has been installed
therein) includes an aperture 42 in exterior wall 34. Inlet filter
housing and filter bank 44 are connected to aperture 42, and air
from the outside environment is drawn into each air
compressor/dryer 50 through aperture 42. Air that is used by the
components of air compressor/dryer cooling system 51, i.e., the
intercooler, after cooler, oil cooler, and dryer regeneration
cooler, is drawn into air compressor/dryer 50 though filter housing
and filter bank 44 by compressor cooling fans 43. Compressor intake
air is also drawn into the air compressor portion of
compressor/dyer unit 50 through aperture 42, but bypasses the
filter bank and enters compressor air intake hose 110, which is
attached to roof 36 by support brackets 112. Compressor intake hose
110 is attached to the air compressor portion of compressor/dyer
unit 50 at housing 111.
[0034] Each equipment module that contains an air compressor/dryer
50 includes a computerized system that operates dampers 48a-48d to
control the intake, exhaust and recirculation of the cooling air
utilized by the air compressor/dryer. This computerized system
allows cooling air to be re-circulated to the extent necessary
(based on temperature) to maintain the proper operating environment
for the various coolers, and consequently, for each air
compressor/dryer 50. Cooling air is not drawn into the air
compressor/dryers from the inside of the building that houses the
air compressor/dryers; thus, the internal environment and internal
air handling capacity of industrial equipment facility 30 does not
limit the number of air compressor/dryers that may be included in
or added to any particular facility. The exemplary embodiment of
the present invention does typically include at least one filtered
vent 72 on each end of the industrial equipment facility 30 for
supplying cooling air to disperse the radiant heat generated by the
air compressor/dryers; however, the primary source of cooling air
is the environment external to industrial equipment facility
30.
[0035] Regarding cooling air intake, exhaust and recirculation,
Modicon PLC 53 monitors external temperature sensor 41, mixed
temperature sensor 45, and the operating status of each air
compressor/dryer 50 through an auxiliary motor starter contactor
and controls the relative positions of the system's dampers and
fans. When the temperature outside industrial equipment facility 30
is at or above 50.degree. F., and an air compressor/dryer 50 is
operating: Modicon PLC 53 opens the inlet control dampers 48a,
closes the recirculation dampers 48b, and opens the discharge
control dampers 48c and 48d. When the air compressor/dryer 50
begins running, 22,000 CFM of cooling air is drawn into the air
compressor/dryer through the inlet filter housing and filter bank
44. This air is then directed through the inlet air control dampers
48a into the air compressor/dryer's enclosure, up through the air
compressor/dryer coolers 51 (which heats the cooling air), out of
the air compressor/dryer enclosure into the discharge duct 52a, out
through the two Modicon PLC-controlled discharge dampers 48c and
48d, and finally through discharge gooseneck duct 52b to the
outside environment. The recirculation control dampers 48b remain
closed during this operational mode. This procedure allows for a
"once through" cooling air circuit which is preferable when air
temperatures are relatively warm (i.e., above 50.degree. F).
[0036] If external air temperature sensor 41, which is connected to
or in communication with Modicon PLC 53, measures an outside
temperature below 50.degree. F., 22,000 CFM of cooling air is drawn
into the air compressor/dryer through the inlet filter housing and
filter bank 44. This air is then directed through the inlet air
control dampers 48a (opened by Modicon PLC 53) into the air
compressor/dryer enclosure, up through the air compressor/dryer
coolers 51 (which heats up the cooling air), out of the air
compressor/dryer enclosure, and into discharge duct 52a. At this
point Modicon PLC 53, which is measuring the mixed cooling air
temperature with temperature sensor 45, opens the recirculation
damper 48b to allow warm air to recirculate and mix with the cold
outside air in the inlet filter housing and filter bank 44. The
Modicon PLC 53 will also turn off one of the two cooling fans 43
and close one of the two intake control dampers 48a to reduce the
cooling airflow and save energy. If the mixed cooling air
temperature drops below 45.degree. F., the Modicon PLC 53 closes
the discharge control damper 48c and begins to modulate the
discharge control damper 48d to maintain a mixed cooling air
temperature between 45.degree. F. and 55.degree. F.; thereby
preventing freeze-ups and/or air compressor/dryer malfinction. If
compressor/dryer 50 is sensed as not operating (i.e., is not on),
the Modicon PLC 53 closes the inlet control dampers 48a and the
discharge control dampers 48c and 48d. A heater inside of air
compressor/dryer enclosure is then turned on to prevent air
compressor/dryer coolers 51 from being "cold soaked" by cold
outside air and ready for startup. In the exemplary embodiment, the
Modicon PLC 53 used with each air compressor/dryer 50 is connected
by way of an encrypted wireless connection to software running on
the backup PC. This software allows for remote adjustment of
temperature set points in each Modicon PLC 53 as well as full
manual control and override capabilities.
[0037] Advantages of the present invention include, but are not
limited to, the following: (i) the operation or malfunction of one
compressor/dryer unit does not affect any of the other compressor
dryer units, thereby substantially improving overall system
reliability; (ii) pre-installing the ventilation and recirculation
subsystem greatly accelerates the overall on-site system
installation and also allows for prototyping and testing the
system's operation prior to on-site installation and startup,
thereby ensuring proper performance; (iii) starting or stopping any
individual unit in the system does not adversely affect operation
of the entire the system; (iv) adding or removing equipment modules
requires little or no building redesign or modification, thereby
reducing costs and complications associated with changing the size
and/or capacity of a system (i.e., adding or removing
compressor/dryer units) after the initial installation; (v) the
number of air-cooled compressor units or other industrial equipment
installed in a single building/facility can be substantially
greater than current facilities, thereby allowing for much larger
system capacities with less complicated and more flexible
ventilation systems; (vi) significant energy savings is realized
due to the recovery of the hot discharge air in winter and due to
the shutting off of one of the 15 HP fans under certain operating
conditions; and (vii) remote adjustments of the ventilation system
are possible, as is full manual control when needed. Additionally,
the facility has the appearance of an actual, integrated structure
or building and not a trailer or series of trailers and can be
expanded or contracted by adding or removing individual modules to
or from the existing structure without reconstructing the entire
facility.
[0038] While the present invention has been illustrated by the
description of exemplary embodiments thereof, and while the
embodiments have been described in certain detail, it is not the
intention of the Applicant to restrict or in any way limit the
scope of the appended claims to such detail. Additional advantages
and modifications will readily appear to those skilled in the art.
Therefore, the invention in its broader aspects is not limited to
any of the specific details, representative devices and methods,
and/or illustrative examples shown and described. Accordingly,
departures may be made from such details without departing from the
spirit or scope of the applicant's general inventive concept.
* * * * *