Modular cooling tower structure, design, and method of assembly

Abstract

A method of designing a modular cooling tower cell which may utilize mechanicals from a preexisting cell and assembling the modular cell within a cooling field in-situ using a series of custom modules. After collecting a data set from a preexisting cooling tower cell and removing the preexisting tower, a build specification is generated, including calculating a cut list for vertical and horizontal members which will form the basis of the plurality of modules forming the cell. The members are fabricated and include a plurality of connection points which allow for sizing adjustments without affecting the connection points. The modules are then constructed using the data set from the preexisting tower to form a plurality of modules comprising a cell matrix based on the data set from the preexisting cooling tower cell.

1 . A method of assembling a crossflow cooling tower, comprising:
 removing a selected crossflow cooling tower cell, including removing vertical columns which form an original structure of said selected crossflow cooling tower cell;   providing a lifting device capable of supporting, balancing and lifting objects below the lifting device by lift members;   providing a first framework structure of a crossflow modular cooling tower cell, said first framework structure comprising:
 a framework structure and vertical members each having a top end, a bottom end, and an axis in the vertical direction: 
 first lifting elements on said vertical member top end; and 
 first receiving elements on said bottom end of said vertical members, wherein said first lifting elements are sized to be fitted with complementary first receiving elements of a second framework structure to secure said first framework structure to said second framework structure; 
   forming dry air inlets with said first framework structure on at least two opposing sides of said crossflow cooling tower cell, such that after installation, dry air flowing through said dry air inlets is directed within said first framework in a direction approximately perpendicular to said vertical members;   forming a plenum with said first framework structure for receiving and distributing said dry air flowing through said dry air inlets, said plenum extending vertically from approximately a bottom of said first framework structure to a top of said first framework structure, and having a top opening for air egress from said first framework structure;   inserting said first lifting elements within said lift members, thereby securing said first framework structure to said lift members;   lifting, using the lifting device, the first framework structure;   while lifted, moving the first framework to a position above a selected installation location;   lowering said first framework structure onto the selected installation location;   securing said first framework to said selected installation location; and   detaching said lift members from said first lifting elements.   
     
     
         2 . The method of  claim 1 , further comprising:
 providing said second framework structure of the crossflow cooling tower cell, said second framework structure having a top end, a bottom end, and second framework vertical members each having a top end, a bottom end, and an axis in the vertical direction, second lifting elements on said second framework structure vertical member top end, and second receiving elements on said bottom end of said second framework structure vertical member;   constructing said second framework structure to form a dry air inlet on at least two opposing sides of said crossflow cooling tower cell, such that after installation dry air flowing through said dry air inlets is directed within said second framework in a direction approximately perpendicular to said vertical members;   constructing said second framework structure to form a plenum for receiving and distributing said dry air flowing through said dry air inlets, said plenum extending vertically from approximately a bottom of said second framework structure to a top of said second framework structure, and having a top opening for air egress from said second framework structure;   inserting said lifting elements within said lift members, thereby securing said second framework structure to said lift members;   lifting, using the lifting device, the second framework structure;   while lifted, moving the second framework structure to a position above said first framework structure;   lowering said second framework onto said first framework structure, and subsequently aligning said first lifting elements of said first framework structure with said second receiving elements of said second framework structure;   inserting said first lifting elements of said first framework structure within said second receiving elements of said second framework structure, thereby securing said second framework structure to said first framework structure; and   detaching said lift members from said second lifting elements.   
     
     
         3 . The method of  claim 1 , wherein the method is performed while a second crossflow cooling tower cell remains operational in a crossflow cooling tower field including the selected installation location. 
     
     
         4 . The method of  claim 1 , wherein the method further comprises:
 providing a water distribution system for pumping process water to a hot liquid basin at an approximately top of said first or second framework structure.   
     
     
         5 . The method of  claim 4 , wherein said hot liquid basin includes holes or openings in a bottom surface for distributing said process water under gravity through said dry air. 
     
     
         6 . The method of  claim 1 , wherein said crossflow cooling tower includes mechanicals of said selected crossflow cooling tower. 
     
     
         7 . The method of  claim 1 , wherein said first framework structure includes angled longitudinal members forming an angled first framework structure. 
     
     
         8 . A method of designing a modular crossflow cooling tower cell, comprising:
 collecting at a first location a data set from a preexisting crossflow cooling tower cell, said data set including at least basin size data, cell size data, header pipe elevations, and deck elevations;   using said data set to generate a build specification for said modular crossflow cooling tower cell to replace said preexisting crossflow cooling tower cell, said modular crossflow cooling tower cell comprising a plurality of modules, dry air inlet formations on at least two opposing sides, and a plenum formation for receiving and distributing dry air flowing through said dry air inlet formations;   calculating a custom cut list for vertical and horizontal members which form the basis of said plurality of modules;   adjusting dimensional measurements of said vertical and horizontal members without affecting a predetermined bolt hole pattern along a length of each of said vertical and horizontal members, said predetermined bolt hole pattern comprising a plurality of connection points;   fabricating said vertical and horizontal members according to said custom cut list;   constructing at a second location the plurality of modules using said build specification such that the vertical and horizontal members are connected using said plurality of connection points to form each of the plurality of modules; and   moving said plurality of modules from said second location to said first location where said plurality of modules may be installed;   wherein said build specification allows the modular crossflow cooling tower cell to utilize mechanicals of said preexisting crossflow cooling tower cell after installation of said plurality of modules.   
     
     
         9 . The method of  claim 8  wherein each of said plurality of modules further includes a plurality of brace members such that said plurality of modules provides a truss-like structure in said modular crossflow cooling tower cell. 
     
     
         10 . The method of  claim 8  wherein said mechanicals of said preexisting crossflow cooling tower comprises a water distribution system having a hot liquid basin. 
     
     
         11 . The method of  claim 8  wherein said mechanicals of said preexisting crossflow cooling tower further comprise a motor, a gearbox, a fan stack, a fan assembly and hub, and/or combinations thereof. 
     
     
         12 . The method of  claim 8  wherein said mechanicals of said preexisting crossflow cooling tower cell further comprise inlet water piping and related pumps. 
     
     
         13 . The method of  claim 10  wherein said hot liquid basin includes holes or openings in a bottom surface for distributing process water under gravity through said dry air. 
     
     
         14 . The method of  claim 8 , wherein the step of adjusting dimensional measurements of said vertical and horizontal members further comprises expanding and/or contracting a dimension of at least one of said plurality of modules. 
     
     
         15 . A structure forming a portion of a modular crossflow cooling tower, comprising:
 a rectangular framework of the structure including vertical members each having a top end and a bottom end and an axis in the vertical direction;   a plenum formed within said rectangular framework of the structure designed to receive and distribute dry air through said rectangular framework structure, said plenum extending vertically from approximately a bottom of said rectangular framework to approximately a top of said rectangular framework;   a fitting element extending from at least one of said vertical members top end along said vertical axis; and   a receiving element on at least one of said bottom end of said vertical members;   wherein said fitting element is sized to be fitted with a complementary receiving member of a second structure to secure said rectangular framework to said second structure, and wherein said receiving element is sized to be fitted with a complementary fitting element of a third structure to secure said rectangular framework to said third structure.   
     
     
         16 . The structure of  claim 15 , wherein said fitting element may be received within a lift member on a lifting device and secured thereto such that said lifting device may raise, lower, move, or any combination thereof, said structure from an uninstalled position to an installed position. 
     
     
         17 . The structure of  claim 15 , wherein said rectangular framework of the structure further includes horizontal members secured to said vertical members to form the rectangular framework, said horizontal members and said vertical members further including a plurality of repeating bolt hole patterns comprising a plurality of connection points such that one or more dimensions of said rectangular framework may be constructed. 
     
     
         18 . The structure of  claim 15 , wherein said fitting element further includes an alignment block. 
     
     
         19 . The structure of  claim 15 , wherein said vertical members comprise a material selected from the group consisting of: fiberglass-reinforced polymer, hot-dipped galvanized steel, and stainless steel. 
     
     
         20 . The structure of  claim 15 , further including a plurality of brace members interposing said vertical members. 
     
     
         21 . The structure of  claim 20  wherein said plurality of brace members comprise fiberglass-reinforced polymer. 
     
     
         22 . The structure of  claim 15 , wherein said third structure comprises a foundation beam comprising an elongated member having a top surface and a bottom surface opposite said top surface, said top surface and said bottom surface extending along a length of the said foundation beam, said top surface including a complementary fitting element to secure said rectangular framework to said third structure. 
     
     
         23 . A method of installing a subassembly of a modular crossflow cooling tower cell comprising:
 providing at a first location a first framework structure of the modular crossflow cooling tower cell, said first framework structure including vertical members each having a top and a bottom end and an axis in the vertical direction, at least one fitting element on said vertical member top end along said vertical axis, and at least one receiving element on said bottom end of said vertical members;   constructing said first framework structure to form a dry air inlet on at least two opposing sides of said crossflow cooling tower cell, such that after installation, dry air flowing through said dry air inlets is directed within said first framework structure in a direction approximately perpendicular to said vertical members;   constructing said first framework structure to form a plenum for receiving and distributing said dry air flowing through said dry air inlets, said plenum extending vertically from approximately a bottom of said first framework structure to a top of said first framework structure, and having a top opening for air egress from said first framework structure;   installing, at the first location, media fill within said first framework structure plenum;   moving said first framework structure to a second location;   installing, at the second location, said first framework structure, such that said first framework structure forms said subassembly of said modular crossflow cooling tower cell;   wherein at least one fitting element is sized to be fitted with complementary receiving element of a second structure to secure said first framework structure to said second framework structure, and wherein at least one receiving element is sized to be fitted with complementary receiving lugs of a third structure to secure said first framework structure to said third structure.   
     
     
         24 . The method of  claim 23 , wherein the method further comprises:
 providing a water distribution system for pumping process water to a hot liquid basin at an approximate top of said framework.   
     
     
         25 . The method of  claim 24 , wherein said hot liquid basin includes holes or openings in a bottom surface of said hot liquid basin for distributing process water under gravity through said dry air.