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.

Thus, having described the invention, what is claimed is: 
     
         1 . A method of assembling in-situ a modular cooling tower cell for use in a cooling tower field, comprising:
 (a) removing a first single cooling tower cell in a cooling tower field having a plurality of cooling tower cells, including removing vertical columns which form an original structure of said first single cooling tower cell, exposing said cooling tower cell basin footing of said first single cooling tower cell;   (b) providing a first framework structure of said modular cooling tower cell, said first framework structure including an adjustable rectangular framework with horizontal members and vertical members, said vertical members each having a top and a bottom end and an axis in the vertical direction, said vertical and horizontal members having dimensional measurements and a predetermined bolt hole pattern consistent along a length of each of said vertical and horizontal members, said predetermined bolt hole pattern including a plurality of connection points;   (c) lifting said first framework structure of said modular cooling tower cell, and positioning said first framework structure above a selected installation location;   (d) lowering said first framework structure onto the selected installation location;   (e) adjusting dimensions of said first framework in-situ during assembly without altering locations of said plurality of connection points and/or locations of said bolt hole pattern on said vertical or horizontal members; and   (f) securing said first framework structure to said selected installation location and/or to an adjacent cooling tower cell within said cooling tower field.   
     
     
         2 . The method of  claim 1  wherein said step (f) of securing said first framework structure to said selected installation location includes securing said first framework structure to at least one foundation beam of said cooling tower cell basin footing and/or an adjacent cooling tower cell. 
     
     
         3 . The method of  claim 1 , wherein said vertical members include fitting lug projections extending from said vertical member top end along said vertical axis, and receiving lugs on said bottom end of said vertical members, and wherein said receiving lugs are sized to be fitted with securing members. 
     
     
         4 . The method of  claim 1 , including performing said method while at least one cooling tower cell remains operational in said cooling tower field. 
     
     
         5 . The method of  claim 1 , wherein said first framework structure includes angled longitudinal members. 
     
     
         6 . The method of  claim 1 , wherein said first framework structure of said modular cooling tower cell further includes a plurality of brace members such that said first framework structure provides a truss-like structure. 
     
     
         7 . The method of  claim 1  wherein said cooling tower is a crossflow cooling tower, and said first framework structure forms a crossflow cooling tower cell for said crossflow cooling tower. 
     
     
         8 . The method of  claim 7 , including 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 structure in a direction approximately perpendicular to said vertical members. 
     
     
         9 . The method of  claim 8 , including 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. 
     
     
         10 . The method of  claim 1  including:
 (g) providing a second framework structure of the modular cooling tower cell, said second framework structure including a second adjustable rectangular framework with second horizontal members and second vertical members, said second vertical members each having a top and a bottom end and an axis in the vertical direction, said second vertical and horizontal members having dimensional measurements and a second predetermined bolt hole pattern consistent along a length of each of said second vertical and horizontal members, said second predetermined bolt hole pattern including a plurality of second connection points. 
 
     
     
         11 . The method of  claim 10  including:
 (h) lifting said second framework structure of said modular cooling tower cell, and positioning said second framework structure above a selected second installation location; 
 (i) lowering said second framework structure onto the selected second installation location; 
 (j) adjusting dimensions of said second framework in-situ during assembly without altering said plurality of connection points and/or locations of said bolt hole pattern on said vertical or horizontal members; and 
 (k) securing said second framework structure to a second selected installation location and/or said first framework structure and/or to an adjacent cooling tower cell within said cooling tower field. 
 
     
     
         12 . The method of  claim 11  wherein said step (k) of securing said second framework structure to said second selected installation location includes securing said second framework structure to at least a second foundation beam of said cooling tower cell basin footing and/or said first framework structure. 
     
     
         13 . The method of  claim 12  wherein said step (k) of securing said second framework structure to said first framework structure includes stacking and securing said second framework structure on top of said first framework structure. 
     
     
         14 . The method of  claim 11  wherein said cooling tower is a crossflow cooling tower, and said second framework structure forms a crossflow cooling tower cell for said crossflow cooling tower. 
     
     
         15 . The method of  claim 14 , including forming dry air inlets with said second 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 second framework structure in a direction approximately perpendicular to said vertical members. 
     
     
         16 . The method of  claim 15 , including forming a second plenum with said second framework structure for receiving and distributing said dry air flowing through said dry air inlets, said second 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 second first framework structure. 
     
     
         17 . The method of  claim 1 , wherein adjusting dimensions of said first framework in-situ during assembly includes expanding and/or contracting said first framework in at least one vertical or horizontal direction to align connecting elements of said first framework such that connecting elements of said first framework align with complementary connecting elements of said selected installation location and/or said adjacent cooling tower cell within said cooling tower field. 
     
     
         18 . The method of  claim 17 , wherein adjusting dimensions of said first framework in-situ during assembly includes expanding and/or contracting said first framework in at least one vertical or horizontal direction such that said first framework aligns with an inlet pipe elevation of said adjacent cooling tower cell. 
     
     
         19 . The method of  claim 17  wherein adjusting dimensions of said first framework in-situ during assembly includes expanding and/or contracting said first framework in at least one vertical or horizontal direction to accommodate geological changes of earth at the selected installation location. 
     
     
         20 . An adjustable structure forming a portion of a modular cooling tower cell for installation within a cooling tower field, said adjustable structure comprising an adjustable framework with horizontal members and vertical members, said vertical members each having a top and a bottom end and an axis in the vertical direction, said vertical and horizontal members having dimensional measurements and a predetermined bolt hole patterns consistent along a length of each of said vertical and horizontal members, said predetermined bolt hole patterns including a plurality of connection points, said adjustable framework having modifiable dimensions for in-situ assembly and replacement of a single cooling tower cell within said cooling tower field, such that adjusting dimensions of said adjustable framework in-situ during assembly is performed without altering said plurality of connection points and/or locations of said bolt hole pattern on said vertical or horizontal members. 
     
     
         21 . The adjustable structure of  claim 20  including:
 a fitting element extending from at least one of said vertical members top end along said 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 element of a second structure or a second cell of a modular cooling tower in said cooling tower field to secure said adjustable framework to said second structure. 
 
     
     
         22 . The adjustable structure of  claim 20 , wherein said adjustable structure forms a portion of a crossflow modular cooling tower cell. 
     
     
         23 . The adjustable structure of  claim 22  including a plenum formed within said adjustable framework designed to receive and distribute dry air through said adjustable structure, said plenum extending vertically from approximately a bottom of said adjustable framework to approximately a top of said adjustable framework.