U.S. patent application number 11/765423 was filed with the patent office on 2008-06-05 for method, system, and apparatus for modular central plant.
Invention is credited to Kenneth M. Liles, Stephen C. Mullins, Gary G. Niver, Michael E. Stanfield.
Application Number | 20080127662 11/765423 |
Document ID | / |
Family ID | 38834090 |
Filed Date | 2008-06-05 |
United States Patent
Application |
20080127662 |
Kind Code |
A1 |
Stanfield; Michael E. ; et
al. |
June 5, 2008 |
Method, System, and Apparatus for Modular Central Plant
Abstract
There is provided a system and method for a modular central
plant. In one implementation, the inventive system includes a
chiller unit and cooling tower that are designed to be modularly
assembled, transported, and interconnected, thereby decreasing
system cost and assembly time, increasing system maintainability,
and improving scalability for increasing capacity at a future date.
The removable wall panels and roof of an embodiment of the present
invention aid in maintainability by providing enhanced access to
critical system components such as the chiller assembly. The
modular architecture of the present invention allows for speedy
delivery and installation, and with only external electrical and
water connections needed, the system can become rapidly
operational.
Inventors: |
Stanfield; Michael E.;
(Gilbert, AZ) ; Liles; Kenneth M.; (Chandler,
AZ) ; Mullins; Stephen C.; (Phoenix, AZ) ;
Niver; Gary G.; (Maricopa, AZ) |
Correspondence
Address: |
SQUIRE SANDERS & DEMPSEY LLP
TWO RENAISSANCE SQUARE, 40 NORTH CENTRAL AVENUE, SUITE 2700
PHOENIX
AZ
85004-4498
US
|
Family ID: |
38834090 |
Appl. No.: |
11/765423 |
Filed: |
June 19, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60805213 |
Jun 19, 2006 |
|
|
|
Current U.S.
Class: |
62/175 ;
261/75 |
Current CPC
Class: |
F25D 19/04 20130101;
F24F 3/06 20130101; F25B 2400/21 20130101; F24F 2221/36 20130101;
F25D 23/00 20130101; F28F 2025/005 20130101 |
Class at
Publication: |
62/175 ;
261/75 |
International
Class: |
F28C 1/00 20060101
F28C001/00; F25B 7/00 20060101 F25B007/00 |
Claims
1. A modular central plant system comprising: a plurality of
prefabricated chiller modules having substantially similar exterior
dimensions, each of said plurality of chiller modules including a
human-accessible environmental shelter respectively enclosing at
least part of each of the plurality of chiller modules; and means
for sealably joining said plurality of environmental shelters to
define a unified enclosed interior volume wherein: each of said
plurality of prefabricated chiller modules includes a plurality of
fluid-bearing pipes so disposed as to allow substantially direct
inter-module interconnection between respective fluid bearing pipes
from each of said plurality of chiller modules when respective
exterior mating surfaces of each of said plurality of chiller
modules are approximated and brought within substantial aligned
proximity of each other.
2. The modular central plant system as defined in claim 1, further
comprising means for electrically interconnecting each of said of
prefabricated chiller modules.
3. The modular central plant system as defined in claim 2, wherein
the electrical connection means further comprises pin and sleeve
connectors.
4. The modular central plant system as defined in claim 1, further
comprising a relocatable water treatment skid.
5. The modular central plant system as defined in claim 1, wherein
each of said plurality of prefabricated chiller modules further
comprises a supporting frame including a hook-and-roller
interconnection interface.
6. The modular central plant system as defined in claim 1, wherein
each of said plurality of prefabricated chiller modules further
includes a fastenably removable and replaceable roof.
7. The modular central plant system as defined in claim 1, wherein
each of said plurality of prefabricated chiller modules further
includes fastenably removable and replaceable wall panels.
8. The modular central plant system as defined in claim 1, wherein
each of said plurality of prefabricated chiller modules further
comprises an personnel access interlock, whereupon actuating the
personnel access interlock to an open position thereof: an
electrically operated door is translated from a closed position to
an open position thereof; an electrically operated air exchange fan
is energized; and at least one light fixture is energized.
9. The modular central plant system as defined in claim 1 further
comprising a plurality of cooling towers, each of said plurality of
cooling towers respectively interconnected to each of said
plurality of prefabricated chiller modules, wherein each of said
plurality of cooling towers is respectively substantially aligned
with each of said plurality of prefabricated chiller modules.
10. A method for constructing a modular central plant comprising:
providing a plurality of prefabricated chiller modules wherein each
of said plurality of prefabricated chiller modules has at least one
open side defining access to an interior space therein; aligning in
substantial parallel respective central axes of said plurality of
prefabricated chiller modules, wherein at least one open side of
each of said plurality of prefabricated chiller modules is made
substantially adjacent to at least one open side of another
prefabricated chiller module of the plurality of prefabricated
chiller modules; approximating a plurality of respective mechanical
interfaces of said plurality of prefabricated chiller modules and
thereafter respectively interconnecting said plurality of
mechanical interfaces; and interconnecting piping headers between
each of the fastened plurality of prefabricated chiller
modules.
11. The method for constructing a modular central plant as
disclosed in claim 10, further comprising electrically
interconnecting the plurality of prefabricated chiller modules
using pin and sleeve connectors.
12. The method for constructing a modular central plant as
disclosed in claim 10, further comprising fastenably connecting
vertical structural members of adjacent prefabricated chiller
modules of the plurality of prefabricated chiller modules.
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the full benefit and priority of
U.S. Provisional Application Ser. No. 60/805,213, filed on Jun. 19,
2006, the disclosure of which is fully incorporated by reference
herein for all purposes.
TECHNICAL FIELD
[0002] The present invention relates generally to the cooling and
heating equipment industry, and more specifically to methods,
systems, and apparatus for modular central plants for providing
heated and chilled water for building climate control.
BACKGROUND
[0003] To provide for efficient building climate control,
particularly in larger buildings, chilled or heated water is
typically furnished to building air handling systems from a central
plant. These central plants typically incorporate one or more
chiller/boiler units and cooling towers, and comprise sophisticated
combinations of electrical and mechanical control systems,
mechanical piping and fluid processing, pumps, fans, shelters, and
engineered structural elements. Also, in almost all cases, central
plants are designed from scratch for each building application, and
although many commercially available components are utilized,
installation requires substantial mechanical construction, field
assembly, and system integration effort at the building site. As a
result, the cost to design, deliver, and install a central plant is
a major factor in the overall expense of building construction, and
often impacts the schedule for building construction
completion.
[0004] As a further shortcoming of prior art custom-designed
central plants, nonstandard components and layouts are often
utilized to best fit unique installation requirements. In the long
run, however, selection of nonstandard components only serves to
further drive up cost and delays building completion schedules.
Further, the schedule and cost constraints commonly imposed on
central plant installation often results in the omission of
features that reduce overall system maintenance and operational
costs. As a result, building owners using prior art central plant
designs are faced with suboptimal long-term operational
expenses.
[0005] As a further limitation of prior art central plants,
capacity expansion to accommodate increased chilled or heated water
demand requires expensive redesign and retrofit. Future capacity is
generally not considered in designing and installing prior art
central plants, and the case-by-case reengineering of each plant
for additional load is a major detriment to building owners.
[0006] It would be an advance in the art to address the
aforementioned problems in the prior art and to provide for a
method, system, and apparatus for a central plant that is more cost
effective to design, requires less time and expense to install,
accommodates expansion, and provides superior maintenance for long
term cost-effective operation.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to improve various
problems associated with the prior art. In one implementation, the
inventive system includes a chiller unit and cooling tower that are
designed to be modularly assembled, transported, and
interconnected, thereby decreasing system cost and assembly time,
increasing system maintainability, and improving scalability for
increasing capacity at a future date. The removable wall panels and
roof of the present invention aid in maintainability by providing
enhanced access to critical system components such as the chiller
assembly. The modular nature of the present invention allows for
speedy delivery and installation, and with only electrical and
water connections the system can become rapidly operational. The
structural design of the inventive system allows for installation
on either a grade or on support posts for roof installation,
thereby substantially reducing the structural preparation work that
is necessary to install a central plant system on site. Further, by
interconnecting multiple modular components of the present
invention, central plant capacity can be quickly scaled up without
substantial engineering to provide optimal central plant support
for buildings of any size.
[0008] Additional embodiments include a modular central plant
system comprising: a plurality of prefabricated chiller modules
having substantially similar exterior dimensions, each of said
plurality of chiller modules including a human-accessible
environmental shelter respectively enclosing at least part of each
of the plurality of chiller modules; and a means for sealably
joining said plurality of environmental shelters to define a
unified enclosed interior volume wherein: each of said plurality of
prefabricated chiller modules includes a plurality of fluid-bearing
pipes so disposed as to allow substantially direct inter-module
interconnection between respective fluid bearing pipes from each of
said plurality of chiller modules when respective exterior mating
surfaces of each of said plurality of chiller modules are
approximated and brought within substantial aligned proximity of
each other.
[0009] Still referring to the previous embodiment, the modular
central plant system further comprises a plurality of cooling
towers, each of said plurality of cooling towers is respectively
interconnected to each of said plurality of prefabricated chiller
modules, wherein each of said plurality of cooling towers is
respectively substantially aligned with each of said plurality of
prefabricated chiller modules.
[0010] As described herein, the capacity that is desired to
accommodate particular building requirements by be achieved by
scalably adding modular chiller-water tower components until the
prescribed ratings are reached. Embodiments address the method of
interconnecting modular components. One exemplary method for
constructing a modular central plant comprises: providing a
plurality of prefabricated chiller modules wherein each of said
plurality of prefabricated chiller modules has at least one open
side defining access to an interior space therein; aligning in
substantial parallel respective central axes of said plurality of
prefabricated chiller modules, wherein at least one open side of
each of said plurality of prefabricated chiller modules is made
substantially adjacent to at least one open side of another
prefabricated chiller module of the plurality of prefabricated
chiller modules; approximating a plurality of respective mechanical
interfaces of said plurality of prefabricated chiller modules and
thereafter respectively interconnecting said plurality of
mechanical interfaces; and interconnecting piping headers between
each of the fastened plurality of prefabricated chiller
modules.
[0011] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed. The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate several
embodiments of the invention and together with the description,
serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of an integrated
modular chiller-tower unit with removable wall panels and roof
attached, with chiller module connected to a cooling tower;
[0013] FIG. 2 is an illustrative embodiment of one aspect of the
present invention showing a plan view of an integrated modular
chiller-tower unit with removable wall panels and roof attached,
with chiller module connected to a cooling tower;
[0014] FIG. 3 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of a chiller module
with removable wall panels removed and roof removed to show an
internal view of an embodiment of a modular chiller unit;
[0015] FIG. 4 is an illustrative embodiment of one aspect of the
present invention showing a top plan view of a chiller module with
removable wall panels removed and roof removed to show an internal
view of an embodiment of a modular chiller unit;
[0016] FIG. 5 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of another
integrated modular chiller-tower unit with removable wall panels
and roof attached, with chiller module connected to a dual cooling
tower;
[0017] FIG. 6 is an illustrative embodiment of one aspect of the
present invention showing a plan view of another integrated modular
chiller-tower unit with removable wall panels and roof attached,
with chiller module connected to a dual cooling tower;
[0018] FIG. 7 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of the chiller
module of FIGS. 5-6 with removable wall panels removed and roof
removed to show an internal view of an embodiment of a modular
chiller unit;
[0019] FIG. 8 is an illustrative embodiment of one aspect of the
present invention showing a top plan view of a chiller module of
FIGS. 5-6 with removable wall panels removed and roof removed to
show an internal view of an embodiment of a modular chiller
unit;
[0020] FIG. 9 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of another
integrated modular chiller-tower unit with removable wall panels
and roof attached, with chiller module connected to a dual cooling
tower;
[0021] FIG. 10 is an illustrative embodiment of one aspect of the
present invention showing a plan view of another integrated modular
chiller-tower unit with removable wall panels and roof attached,
with chiller module connected to a dual cooling tower;
[0022] FIG. 11 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of the chiller
module of FIGS. 9-10 with removable wall panels removed and roof
removed to show an internal view of an embodiment of a modular
chiller unit;
[0023] FIG. 12 is an illustrative embodiment of one aspect of the
present invention showing a top plan view of a chiller module of
FIGS. 9-10 with removable wall panels removed and roof removed to
show an internal view of an embodiment of a modular chiller
unit;
[0024] FIG. 13 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of another
integrated modular chiller-tower unit with removable wall panels
and roof attached, with chiller module connected to a cooling
tower;
[0025] FIG. 14 is an illustrative embodiment of one aspect of the
present invention showing a plan view of another integrated modular
chiller-tower unit with removable wall panels and roof attached,
with chiller module connected to a cooling tower;
[0026] FIG. 15 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of the chiller
module of FIGS. 13-14 with removable wall panels removed and roof
removed to show an internal view of an embodiment of a modular
chiller unit;
[0027] FIG. 16 is an illustrative embodiment of one aspect of the
present invention showing a top plan view of a chiller module of
FIGS. 13-14 with removable wall panels removed and roof removed to
show an internal view of an embodiment of a modular chiller
unit;
[0028] FIG. 17 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of another
integrated modular chiller-tower unit with removable wall panels
and roof attached, with chiller module connected to a cooling
tower;
[0029] FIG. 18 is an illustrative embodiment of one aspect of the
present invention showing a plan view of another integrated modular
chiller-tower unit with removable wall panels and roof attached,
with chiller module connected to a cooling tower;
[0030] FIG. 19 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of the chiller
module of FIGS. 17-18 with removable wall panels removed and roof
removed to show an internal view of an embodiment of a modular
chiller unit;
[0031] FIG. 20 is an illustrative embodiment of one aspect of the
present invention showing a top plan view of a chiller module of
FIGS. 17-18 with removable wall panels removed and roof removed to
show an internal view of an embodiment of a modular chiller
unit;
[0032] FIG. 21 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of another
integrated modular chiller-tower unit with removable wall panels
and roof attached, with chiller module connected to a dual cooling
tower;
[0033] FIG. 22 is an illustrative embodiment of one aspect of the
present invention showing a plan view of another integrated modular
chiller-tower unit with removable wall panels and roof attached,
with chiller module connected to a dual cooling tower;
[0034] FIG. 23 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of the chiller
module of FIGS. 21-22 with removable wall panels removed and roof
removed to show an internal view of an embodiment of a modular
chiller unit;
[0035] FIG. 24 is an illustrative embodiment of one aspect of the
present invention showing a top plan view of a chiller module of
FIGS. 21-22 with removable wall panels removed and roof removed to
show an internal view of an embodiment of a modular chiller
unit;
[0036] FIG. 25 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of two modularly
connected modular chiller-tower units with removable wall panels
and roof attached, with each chiller module of connected to a
cooling tower;
[0037] FIG. 26 is an illustrative embodiment of one aspect of the
present invention showing a plan view of two modularly connected
modular chiller-tower units with removable wall panels and roof
attached, with chiller each module connected to a cooling
tower;
[0038] FIG. 27 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of an alternate
configuration of two modularly connected modular chiller-tower
units with removable wall panels and roof attached, with each
chiller module of connected to a cooling tower;
[0039] FIG. 28 is an illustrative embodiment of one aspect of the
present invention showing a plan view of an alternate configuration
of two modularly connected modular chiller-tower units with
removable wall panels and roof attached, with chiller each module
connected to a cooling tower;
[0040] FIG. 29 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of three modularly
connected modular chiller-tower units with removable wall panels
and roof attached, with each chiller module of connected to a
cooling tower;
[0041] FIG. 30 is an illustrative embodiment of one aspect of the
present invention showing a plan view of three modularly connected
modular chiller-tower units with removable wall panels and roof
attached, with chiller each module connected to a cooling
tower;
[0042] FIG. 31 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of four modularly
connected modular chiller-tower units with removable wall panels
and roof attached, with each chiller module of connected to a
cooling tower;
[0043] FIG. 32 is an illustrative embodiment of one aspect of the
present invention showing a plan view of four modularly connected
modular chiller-tower units with removable wall panels and roof
attached, with chiller each module connected to a cooling
tower;
[0044] FIG. 33 is an illustrative embodiment of one aspect of the
present invention showing a side elevation view of five modularly
connected modular chiller-tower units with removable wall panels
and roof attached, with each chiller module of connected to a
cooling tower;
[0045] FIG. 34 is an illustrative embodiment of one aspect of the
present invention showing a plan view of five modularly connected
modular chiller-tower units with removable wall panels and roof
attached, with chiller each module connected to a cooling
tower;
[0046] FIG. 35 is an illustrative embodiment of one aspect of the
present invention showing a modular chiller-tower unit with an
attached boiler module;
[0047] FIG. 36 is an illustrative embodiment of one aspect of the
present invention showing a modular chiller-tower unit with an
attached secondary pump package;
[0048] FIG. 37 is an illustrative embodiment of one aspect of the
present invention showing a partial view of a hook-and-lift lug
mechanical interface between chiller module units;
[0049] FIGS. 38-41 are illustrative embodiment of one aspect of the
present invention showing various aspects of a hook-and-lift lug
mechanical interface chiller module units;
[0050] FIG. 42 is an illustrative embodiment of one aspect of the
present invention showing a schematic of water treatment controls
used in conjunction with chiller module units of the present
invention;
[0051] FIG. 43 is an illustrative embodiment of one aspect of the
present invention showing a block diagram of access and ventilation
controls as related to chiller module units of the present
invention;
[0052] FIG. 43 is an illustrative embodiment of one aspect of the
present invention showing a air eliminator as related to chiller
module units of the present invention; and
[0053] FIGS. 45-47 are various illustrative embodiments of aspects
of the present invention related to cooling tower units of the
present invention.
DETAILED DESCRIPTION
[0054] Referring to FIGS. 1 and 2, an exemplary integrated
chiller-tower module 100 is shown in elevation view and plan view,
respectively. In one embodiment, the integrated chiller-tower
module 100 comprises a modular chiller unit 105 interconnected to a
cooling tower 110. An optional additional cooling tower 115 may
also be provided. FIGS. 3 and 4 show respective elevation and plan
views of the chiller module 105, with removable roof panels and
side panels removed to illustrate internal components and placement
of piping at connection interfaces at the sides of the chiller
module. Commercially available components may be utilized in the
present invention to further improve cost efficiency and
performance.
[0055] The modular chiller-tower units, once assembled at the
jobsite and connected to building services, are fully
self-contained and capable of independent operation. In one
embodiment of the present invention, no additional controls or
building automation systems are needed to bring the modular units
into operational status. While prior art systems required
substantial on-site preparation activity to assemble and integrate
chiller units and cooling towers, in the present invention, the
cooling tower assembly includes all required support steel,
controls, electrical and piping.
[0056] The modular chiller units are designed to be easily
mechanically interconnected in a manner as shown in figures such as
FIGS. 37-41. Embodiments of the present invention include a hook
and roller lifting lug assembly as shown in FIG. 37. The hook and
roller lifting lug assembly is used to accommodate the modular
design goals of the present system. In one embodiment, referring to
FIGS. 37-41, the assembly incorporates a steel plate lifting lug
extending from the equipment base rail with a hook on the end and a
horizontal surface sloping slightly upward from the hook to its
attachment point on the equipment base rail, and a bronze bushing
secured with a structural bolt and nut between two steel plates
attached to a mating equipment base rail. When multiple modules are
connected together, the low point of the sloped horizontal surface
of the lifting lug on the module being lowered into place rests on
top of the brass bushing of the lifting lug on the module already
in place, the hook prevents the modules from separating during
installation, the low point of the sloped horizontal surface of the
lifting lug and the rolling action of the bronze bushing it rests
on keeps the weight of the module being set in place off of the
ground and allows easy movement of the modules when they are
connected together, and the hook and roller assembly ensures proper
alignment of the modules during installation.
[0057] Piping layouts in both the chiller modules and cooling
towers are designed to allow integrated chiller-cooling tower
modules to be "stacked" side by side in series, whereby cooling
capacity is increased as additional modules are interconnected to
the modular central plant system. For example, chilled water return
and supply lines that ultimately connect to the building being
serviced by the modular central unit plant system (shown as, for
instance, CHWR and CHWS pipes, respectively, on FIG. 4, run
orthogonally to the major axis of the cooling module units (the
major axis would be the longer dimension, i.e. left to right on
FIG. 4) which allows straightforward series connection of pipes
once chiller modules are located side by side, and intermediary
side panels are removed to allow access.
[0058] With this internal piping arrangement, a standard modular
central plant design can accommodate a wide range of capacities.
For example, by proper choice of components, a single compact
modular package can be easily scaled from 100 ton to 600 ton
capacity. By interconnecting additional modules, capacity can be
scaled up to the thousands of tons of capacity. As shown in FIGS.
35 and 35, standardized boiler and pumping options can be added on
to the modular chiller modules to enhance flexibility of
application without requiring substantial custom design.
[0059] The modules of the present modular central plant system are
designed to be easily truck mounted and transported so as to
minimize on-site assembly efforts. As an exemplary embodiment, in
one configuration, one chilling module is loaded per truck
inclusive of all items needed for a completely operational system
with the exception of the cooling towers, which may be sent
directly from the cooling tower manufacturer to the job site. The
design of the present invention allows for components to be
strategically placed and nested on a trailer and/or ship as
required for delivery to the end user.
[0060] As shown in FIG. 42, the present invention provides for an
integrated chemical treatment system as part of the modular unit
design. This obviates the need for addition of a separate chemical
treatment system at time of installation (or later) and decreases
the latency in bringing a central plant into fully operational
status. In one embodiment, chemical treatment controls can be
accessed from inside or outside the standard modular unit, easing
maintenance of the chemical treatment system.
[0061] Embodiments of the present invention include complete
chemical treatment controls and distribution system for both the
condenser water "open loop" and the chilled water "closed loop"
systems. The chemical treatment system is easily expandable to
accommodate expansions arising from the present modular design. The
chemical treatment system is designed to sufficiently monitor and
distribute chemicals to the individual modules as required to
assure the water quality of both the "open and closed loops" to
predetermined standards.
[0062] One embodiment comprises an all inclusive Chemical Treatment
Skid that includes all necessary equipment as required to maintain
a prescribed water quality. This includes, for example, the main
water treatment controller, water sampling coupons, flow
meter/water sampling meter, closed loop pot feeder, motorized bleed
valve, chemical storage tanks and chemical metering pumps. This
Skid contains with all its components monitor and control the water
quality of the condenser water (CW) system "open loop". The
programmable water treatment controller uses a remote water quality
sensor to monitor the CW loop. When the water quality drops below
the prescribed parameters, the controller energizes the chemical
pumps and injects biocides and inhibitor chemicals as required to
maintain a certain level of quality. The controller also monitors
the amount of total dissolved solids in the water (TDS) when the
TDS is above the prescribed parameters the controller opens a
motorized dump valve. This valve allows dirty water to drain/bleed
from the system until enough make up water (fresh water) has mixed
with the CW loop water to bring the TDS down top acceptable limits.
Once these limits have been reached the motorized valve closes
allowing the cycle to reset and begin again.
[0063] This skid also on contains a pot feeder that is tied to the
chilled water (CHW) system "closed loop". This pot feeder is used
as a means to manually feed chemicals into the CHW system as
required to inhibit rust and the growth of biologicals.
[0064] One aspect of embodiments of the present invention is the
use of a modular header system that allows for easy and simple
expansion to the base water treatment system as additional modules
are added. Each module then independently inter-connects this
chemical treatment header to their individual CW distribution
piping "open loop." This connection incorporates two special
devices, the first, is a one way check valve on the CW supply line
that allows water to flow only from the module into the chemical
treatment header, not from the header to the module. The second is
a motorized valve that is interlocked with the module's CW pump.
When the pump is on the valve is open and when that pump is off the
valve is closed. This configuration isolates the CW return pipe
from the chemical treatment header similar to the check valve at
the supply line, allowing the water to flow back into the
individual modules CW system when only when it is in operation.
[0065] The combination of using these two valves and the header
system allow only water from the modules in operation to supply
water to the Chemical Treatment Skid. This way, only the equipment
that is operating can get its water monitored, can get its required
chemicals and is allowed to bleed/replenish water. In certain
embodiments, systems that are offline stay isolated from the
Chemical Treatment System entirely.
[0066] With this modular approach, whether only one module is
running or if any combination of modules are running, the disclosed
header and inter-connect system along with the described Chemical
Treatment Skid maintain the prescribed water quality standard at
least equivalently to those systems that utilize alternative prior
approaches to water treatment.
[0067] Prior art central plants often are difficult to maintain
because of impaired access to key components of the system such as
chillers or pumps. While these prior art systems provide some
protection from the elements through custom enclosures, they do so
at the expense of maintainability. The present invention addresses
these limitations, in part, by providing customer-removable side
panels and roof elements while making such panels and roof
elements, when installed, resistant to wind, precipitation, and
dust. In one embodiment, neoprene gaskets are utilized at
mechanical interfaces to provide environmental seals. The roof of a
modular unit assembly is completely and easily removable (such as
by crane or winch) for complete access to internal components and
equipment. Further, individual wall panels are removable as needed
for select accessibility. In one embodiment of the present
invention, the layout and design of the internal modular elements
provides maintenance access to all internal components once panels
are removed, even when modules are interconnected in parallel or in
series (see, e.g., FIG. 34). Also, to further reduce maintenance
costs, structural steel, exposed piping and wall panels may be
galvanized or pre-finished aluminum so no routine painting is
required. A laptop computer may be interfaced to a port on the
interior or exterior of the modular unit to program and control the
modular unit's components and/or to monitor status of internal
component operation. Those of skill in the art also recognize that
such interfaces could be accomplished through wireless means such
as WiFi or Bluetooth RF protocols.
[0068] In one embodiment main access into the modular unit of the
present invention is provided through a large overhead door located
at one end of the module. This door allows for equipment and
personnel to easily enter and exit module to perform routine
maintenance on internal equipment. As shown in a block diagram in
FIG. 43, to enhance safety, when the door control is engaged to
open the door, internal lighting and ventilation is automatically
activated to promote occupant safety. In one embodiment, from the
time the door is activated until it is sufficiently opened to grant
ingress, one or more activated ventilation fans have displaced such
a volume of air that any gaseous toxins present in the enclosure
may be removed or sufficiently diluted to human-safe levels.
[0069] Chiller modules of the present invention are designed as an
unoccupied enclosure to house the components necessary to produce
chilled or heating hot water. Access to this enclosure is generally
to be used for the maintenance and replacement, and therefore
embodiments include controls and safeguards to protect the
personnel who enter chiller modules equipment for maintenance.
[0070] In some embodiments, the enclosure is equipped with specific
access controls and interlocks. Ventilation fans and lighting to
turn on when maintenance personnel energize entry door with key
operated switch by rotating it to the open (occupied mode). In
various embodiments, when the door is in the closed position
(unoccupied mode) all lighting, ventilation and convenience power
shut off. The door can only be closed and/or opened from the
outside of the equipment enclosure.
[0071] In certain example embodiments, via exemplary design and
sizes of the present chiller module enclosures enclosure, the afore
mentioned equipment door opening size and location of the equipment
module (for example, 20 feet from building egress opening) are as
such that they fall under the ASHRAE 15-1994 "Natural Ventilation"
clause which does not require any mechanical ventilation, yet
enhanced safety embodiments of the invention provide for a fan that
is sized at the ASHRAE prescribed "Alarm Ventilation Rate." The
exemplary 20 feet from egress opening of building also falls
outside of the International Building Code Section 1103.2 occupancy
classification.
[0072] Embodiments include controls for system function as well as
chemical treatment monitoring and controls. The system can be
interfaced with and controlled from a single point located outside
the enclosure via a handheld interface device or by a wired or
wireless interface with a building automation system. Optionally,
embodiments of enclosed spaces of the present design include air
conditioners to ensure the proper operation of the internal
components (for example, between 95 degrees cooling and 40 degrees
heating).
[0073] Turning to FIG. 44, embodiments of the chiller module of the
present system also include an air elimination system to remove air
from pipes, and that incorporates an assembly on the suction side
of the primary chilled water pump. In one embodiment this device,
comprises a fabricated tee with a sloping top and an outlet for an
automatic air vent, and is used to create turbulence with in the
chilled water system at the highest point inside the chiller
module. The turbulence at this tee causes air entrained in the
chilled water system "closed loop" to separate from the water and
migrate up to the top of the sloped cap. Air that accumulates to
the sloped cap is bled from the system through an automatic air
vent.
[0074] Additional embodiments of cooling tower aspects of the
present invention may be found in FIGS. 45-47. Embodiments include
a hot water box connection that enables high-profile cooling towers
to be placed on trucks and still clear height requirements, pin and
sleeve electrical connections to allow for straightforward but
electrically secure connections between the cooling towers and the
remainder of the modular system components, a condenser water pipe
rack system, basin filtration system, and plugged pipe connections
on every cooling tower.
[0075] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
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