Description
MODULAR CHILLED FLUID SYSTEM AND METHOD FOR PROVIDING CHILLED FLUID FOR COOLING
Technical Field
This invention relates generally to chilled fluid systems and, more particularly, to a modular cooling system for cooling air and fluid, having multiple refrigeration circuits and multiple stages for electrical data processing or control facilities. Though not limited thereto, the present invention is particularly useful in connection with large computer installations which require a continuous or near- continuous supply of conditioned air and chilled fluid for reliable operation.
Background Art
Individuals, businesses, and governments have grown increasingly dependent on the services and resources that are made available through the processing of computers and computerized control facilities. In spite of the explosive growth in the utilization of control circuits and personal computers in recent years, many computer applications continue to rely on the services provided by large computer mainframe installations. Such data processing facilities are often in continuous operation, twenty- four hours per day, three hundred and sixty- five days a year.
The computer equipment typically found in mainframe computer rooms generates vast amounts of heat and requires a limited temperature environment in
which to operate reliably. In addition, controlled humidity is required to prevent either damaging condensation or static charging of electrical components. Furthermore, mainframe computers have been designed in recent years to require cooling from both air and chilled water.
While the thousands of mainframe computer installations in continuous operation throughout the world attest to the fact that many data processing facilities have provided at least basic cooling, humidification, and ventilation operations, problems still exist. In fact, HVAC (heating/ventilation/air conditioning) systems have been designed and implemented for year-around operation, with energy conservation cycles to take advantage of lower ambient temperatures. Some of these systems are well known to be fully integrated systems that address the cooling, humidification, and ventilation requirements of electronic data processing and control equipment . However, such systems are designed and marketed in a finite number of configurations, such as in 5 , 10, 15, etc. ton capacities. Furthermore such systems are offered separately for chilling water or cooling air, each with their respective compressors, pumps, fan motors, condensers, and evaporators and each with a corresponding risk of component failure.
Because of the critical nature of the services and resources provided by mainframe data processing systems and because of the finite operating temperatures and humidity in which such equipment can operate reliably, HVAC systems supporting computer facilities have been designed with redundant
components in the form of backup compressors, pumps, and fan motors. However, such redundancy raises both the cost and size of such equipment. Furthermore, not all key components in such systems are duplicated, and a failure of any of these elements results in the HVAC system operating at reduced capacity or even being shut down to await parts and repair.
Additionally, compressors, pumps, and fan motors all generate heat while in operation. This is heat that adds to the cooling load wherever such cooling equipment is installed and must be accommodated by additional cooling capacity.
The present invention is directed to overcoming one or more of the problems set forth above.
Disclosure of the Invention
In one aspect of this invention, a modular chilled fluid supply system (100) for producing a supply of chilled fluid for cooling purposes is disclosed. The modular chilled fluid supply system (100) includes a module container and a conduit for transporting the chilled fluid within said module container and a pump in fluid connection with the conduit and a chilled fluid plant located within the module container, wherein the chilled fluid is pumped to at least one air handler and at least one fluid- cooled device, both of which are located external to the module container. In another aspect of the present invention, a method for producing a supply of chilled fluid for cooling purposes is disclosed. The method includes the steps of housing primary fluid chilling apparatus
of an evaporator, a condenser, and at least one compressor within a module container and chilling a fluid and pumping the chilled fluid through a conduit within the module container and pumping the chilled fluid to at least one air handler and at least one fluid-cooled device, both of which are located external to the module container.
Brief Description of the Drawings For a better understanding of the present invention, reference may be made to the accompanying drawings in which:
FIG. 1 is a schematic diagram of a modular chilled fluid system; and FIG. 2 is a schematic diagram of an alternative embodiment of the present invention, in which the condenser is located external to the module container.
Best Mode for Carrying Out the Invention
Referring now to the drawings and initially to FIG. 1, an external structure for a module container 10 for enclosing the components of a fluid chilling system on all sides, including a top and a bottom, is depicted. The entire chilled fluid system, comprising the container structure, the interior components, and quick-connect couplings as more thoroughly disclosed below will collectively be referred to as the "fluid chilling system" or "module", hereinafter depicted by numeral 100.
The aforementioned sides of module container 10 may traditionally include four sides of a
rectangular structure. However, the module container 10 could also be round or any other known design for enclosing a space for the housing of equipment. It is intended that the entire module 100, including container and internal components and connections is designed and constructed such that it can be moved intact from point of manufacture to an end site and from site to site regardless of location of the site. Such a feature permits complete replacement of the entire module 100 as a unit should any component fail, should the site no longer require the cooling provided by module 100, or should the site require a module 100 with more or less cooling capacity. As such, the module 100 may have external connections such as lifting brackets (not shown) to facilitate the moving and loading of module 100 by crane or other lifting means. Additionally, the module 100 may have wheels, rollers, or similar devices (not shown) operably connected to the bottom or sides of the modular container 10 to facilitate its mobility. By way of illustrative example, the modular container 10 may have nominal dimensions of five feet (5') deep by seven feet (7') high by sixteen feet (16') in length. However, the dimensions of the modular container 10 are a function of the size and number of components contained within and are not intended to be limited by the exemplary dimensions disclosed above. Given the size of module container 10, its containment components including top, bottom, and sides may also be described as ceiling, floor, and walls, respectively.
The primary operational component of module 100 is a compressor 12. Although two compressors 12 are shown, any number of compressors, including one, may be designed into a comparably-sized module container 10 to provide desired cooling capacity.
Compressors are typically utilized in water chilling and air conditioning systems in which a refrigerant is compressed and discharged to a condenser, routed through an expansion mechanism, passed through an exchanger to cool air or water, and then subsequently returned through a suction line to the compressor in a relatively continuous operation. Although the term refrigerant is used to describe the fluid within the compressor cycle, any fluid may be utilized that can absorb heat energy during evaporation and subsequently give up heat during a condensing step. While in operation in the present embodiment, the compressors 12 provide compressed refrigerant to condenser 14 through discharge pressure lines 16. Connected to the discharge pressure lines 16 are sensors 18 for detecting and reporting discharge pressure. Each of sensors 18 may be connected to a display panel (not shown) as more thoroughly disclosed below. While not shown in FIG. 1, the system is intended to include any of the sensory systems typically associated with compressors, electric motors, air conditioning systems, water chilling systems, and air handling equipment. Such sensory systems, by way of example and not limitation, detect such conditions as power on/off, start-up cycle, motor stopped, motor running, compressor pressure, high pressure conditions, low pressure conditions, air flow, water flow, pressure
differential, and malfunction. Also, connected to each line 16 is a pressure relief valve 20, which in turn is connected to a refrigerant relief header 22 directed to outside of module container 10 for eventual discharge of refrigerant to the atmosphere should an excess pressure condition arise and cause the opening of pressure relief valve 20.
Passing through condenser 14 is a separate fluid loop 24 connected to a heat exchanger or heat sink (not shown) located external to module container 10. The heat acquired by the compression of the refrigerant in compressor 12 and the evaporation of the refrigerant in evaporator 42 is transferred within condenser 14 to the fluid within fluid loop 24 of the external heat exchanger (not shown) and directed to the heat exchanger by supply line 26. The fluid is returned to condenser 14 by means of return line 28 for a continuous cooling operation. Preferably, the fluid in loop 24 for such a heat exchange process is a water or glycol-water solution. However, the fluid in loop 24 is not limited to a water or glycol-water solution and may be any pumpable fluid that is capable of accepting and releasing heat through heat exchange coils . Sensors 30 and 32 on supply line 26 and return line 28, respectively, detect and report the temperature of the fluid directed to and returning from the external heat exchanger. A high temperature reading by 32 may signal a malfunction in the external heat exchange system. The supply 26 and return 28 lines between condenser 14 and the external heat exchanger terminate at the wall of module 100 in
quick-connect couplings 34. These quick-connect couplings 34 comprise isolation valves, flexible links, and bleed lines to facilitate the modular features of the inventive system by permitting rapid and convenient connection and disconnection of module 100 from its surroundings by non-technical personnel, using non-specialized equipment. A centrifugal separator 36 is located in the return line 28 from the external heat exchanger for purposes of filtering the fluid. Connected to centrifugal separator 36 is a solids recovery vessel 38 for capturing any debris or material captured by centrifugal separator 36 and thereby keeping it relatively clean for continual, efficient operation. A sensor 40 is located on solids recovery vessel 38 to signal when solids recovery vessel 38 is full. The fluid in loop 24 is transported through condenser 14, supply line 26, the external heat exchanger (not shown) , and return line 28 by well known fluid pump means (not shown) . While the fluid in loop 24 is pumped in sufficiently close proximity to the refrigerant in lines 16 to absorb some of the heat of the refrigerant, loop 24 and lines 16 represent separate systems whose respective fluid volumes are not exchanged nor intermingled. The refrigerant is directed from condenser
14 to evaporator 42 by means of a pair of return lines 44, each with an integrated expansion valve 46, as is typically found in air conditioning and refrigeration systems. Evaporator 42 includes a heat exchange coil (not shown) for cooling the fluid in chilled fluid loop 48, thereby cooling the fluid in loop 48 for eventual output from module 100 to provide chilled
fluid to processing equipment and air handling equipment (not shown) located external to module container 10. The expanded refrigerant is then returned to compressor 12 through suction lines 50. Pressure sensors 52 are located on suction lines 50 in a manner similar to the sensors 18 on discharge lines 16, as disclosed previously. As discussed above regarding fluid loop 24, the fluid in loop 48 is preferably a water or glycol-water solution; but may be any pumpable fluid that is capable of accepting and releasing heat through heat exchange coils.
The system comprising the compressors 12, condenser 14, evaporator 42, expansion valves 46, and interconnecting pressure lines 16 and 50 is collectively termed a chilled fluid plant, is contained within the module container 10, and is responsible for providing the cooling for chilling the fluid supplied by module 100 to external equipment and air handling equipment (not shown) through fluid loop 48.
The aforementioned chilled fluid loop 48 actually comprises of a plurality of pipes and loops within module container 10, all of which are intended to provide a conduit by which a chilled fluid is delivered to external equipment, air handling equipment, or storage and returned from said external equipment or storage to evaporator 42 for cooling. Additionally, one loop of the chilled fluid loop is utilized within module container 10 to provide cooling for both the interior of module container 10 and for the space immediately proximate to module container 10, and thereby regulate the temperature within and
around the module container 10. This cooling of module container 10, provided by air handler 92, will be discussed in greater detail below.
A chilled fluid pump 54 maintains fluid pressure and flow within chilled fluid loop 48. The output of pump 54 is directed into evaporator 42 by means of input line 56, and the fluid is cooled as described above. The cooled fluid exiting evaporator 42 is directed by pump pressure through output line 58. Sensors 60 and 62 on input line 56 and output line 58, respectively, detect and report fluid temperature. Fluid flow sensor 64 on input line 56 detects and reports fluid flow out of pump 54 and, therefore, can detect and signal a malfunction in pump 54 or piping loop 48 should fluid flow drop below an acceptable level .
Chilled fluid exiting evaporator 42 in output line 58 is directed by pump pressure through line 66 to optional storage tank 68. Storage tank 68 may have internal baffles. Fluid exiting storage tank
68 is directed through line 70 and valve 72 to line 76. Lines 66 and 70 terminate at the wall of module 100 with a pair of quick-connect couplings 34. A sensor 74 is located on line 70 for detecting temperature of fluid exiting storage tank 68. By routing the chilled fluid through storage tank 68, the system provides a reserve of chilled fluid to be delivered to heat loads external to module 100 in the event the chilled fluid plant fails. Such a reserve provides time for repair or replacement of a malfunctioning component, for orderly shutting down of equipment relying upon the cooling provided by module
100, or for providing backup cooling to the external heat load from another source. An alarm mechanism (discussed below) associated with temperature sensor 62 could signal when the fluid exiting evaporator 42 rises above an acceptable level . Although only one storage tank 68 is depicted in FIG. 1, any number and size of storage tanks 68 could be connected in either parallel or series to provide a reserve of chilled fluid sufficient to support a plurality of processing equipment and air handlers located external to module container 10. The top of valve 72, to which line 58 is connected, is normally closed. However, in the event that no storage tank 68 is provided in the system or if the path to storage tank 68 is closed or restricted, the top of valve 72 is opened, routing chilled fluid from line 58 to line 76, and bypassing storage tank(s) 68.
Line 76 intersects with supply lines 78 and 80, with the chilled fluid being directed through both supply line 78 and supply line 80. Line 76 continues to the bottom of valve 82, but this connection is normally closed. The chilled fluid is directed through line 78 to an air handler (not shown) located external to module 100 for providing air conditioning to a space external to module container 10. The fluid returning from the air handler is directed through return line 86, through valve 82 and into line 88. Lines 78 and 86 terminate at the wall of module 100 with quick-connect couplings 34. Sensors 90 and 91 on supply line 78 and return line 86, respectively, detect and report water temperature. Valve 82 modulates as a function of the conditions in the space
served by the air handler (s) . If the space requires less cooling, then valve 82 permits some of the fluid in line 76 to pass through the valve to line 88, thereby reducing the flow of chilled fluid in lines 78 and 86.
The flow of chilled fluid in supply line 80 is directed through a fan heat exchange coil (not shown) in air handler 92 to provide for cooling the interior of module 100 as discussed above. A fan motor 94 draws air across the heat exchange coil, where the air is cooled, and directs the air back into module 100. A portion of this air is directed through duct 96 to the space immediately exterior to module 100 to provide cooling for the space adjacent to module 100. If module 100 is located outside, then duct 96 is either eliminated from module 100 or capped at the wall of module 100. A sensor 98 detects and reports air flow exiting air handler 92. A sensor 110 detects air pressure drop across a filter 112 for determining when to change the filter. The fluid exiting air handler 92 is directed through return line 114 and through valve 116 to line 118. Valve 116 modulates as a function of the conditions in module 100, including those conditions detected and reported by air temperature sensor 117. If the conditions call for less cooling, then valve 116 permits a variable amount of the fluid in line 80 to pass through valve 116 to line 118, thereby reducing the flow of chilled fluid passing through air handler 92. The chilled fluid in line 88 is directed through temperature control valve 120 to pump 122. The chilled fluid output from pump 122 is directed to
chilled fluid loop 124, consisting of a supply line 126 to and a return line 128 from fluid-chilled equipment (not shown) located external to module container 10. While the present invention is directed toward delivering chilled fluid to external computer equipment for purposes of delivering cooling capacity, the inventive system can be utilized to deliver chilled fluid to any resource located external to module container 10. Supply line 126 is also connected to the top of valve 130, but this connection is normally closed. Sensors 132 and 134 on supply line 126 and return line 128, respectively, detect and report water temperature. Pressure sensor 136 detects and reports any difference in pressure between supply line 126 and return line 128. Lines 126 and 128 terminate at the wall of module 100 with quick-connect couplings 34. The flow of chilled fluid in return line 128 is directed through valve 130 to line 138.
Fluid cooled computer equipment (not shown) typically includes solenoid valves (also not shown) for controlling the volume of chilled fluid directed past various computer equipment components. When such solenoid valves close, and if the computer equipment does not provide for bypass fluid circuits, the pressure in supply line 126 will rise as pump 122 continues to pump fluid. The resultant pressure differential will be detected by sensor 136, causing valve 130 to modulate, and some of the flow in line 126 will be directed through valve 130 to line 138 as a bypass. Should the flow in loop 124 be completely closed-off at the equipment (not shown) being cooled, the entire fluid flow in line 126 will be directed
through valve 130 to line 138. Fluid exiting valve 130 is directed through line 138 to line 140 and on to pump 54 to complete the cycle of fluid flow within module 100. Line 138 intersects with line 142 to temperature valve 120, but the connection of line 142 to valve 120 is normally closed.
Although only one pump 122, valve 130, and fluid loop 124 are shown, the present invention could support any number of such water chilling systems and thereby supply the particular cooling needs of multiple pieces of equipment requiring water chilling, such as computer equipment. Similarly, the invention could support multiple external air handlers (not shown) through additional combinations of valve 82 and chilled fluid loop 84.
A key feature of the chilled fluid supply system 100 represented by valve 120, pump 122, valve 130 and fluid loop 124 is the capability of independent temperature control of the fluid supplied through line 126 to the external equipment (not shown) being cooled. Such a feature is important because the temperature of fluid supplied to an air handler (such as through line 78) is typically cooler than fluid supplied to directly cool computer equipment (such as through line 126) . The fluid directed to valve 120 in line 88 has absorbed heat from both the external and the internal air handlers discussed above and therefore is transporting a fluid with a higher temperature than has exited evaporator 42 into line 58. Therefore, warmer fluid is supplied to pump 122 through temperature control valve 120. Additionally, line 138 is transporting fluid that has absorbed the
additional heat from the fluid-cooled equipment (not shown) external to module 100. Sensor 132 detects the temperature of the fluid being supplied through line 126 to the external equipment (not shown) . If the temperature of the fluid in line 126 is too cool, valve 120 will modulate, allowing more of the warmer fluid in line 138 to pass through line 142 into valve 120, until the temperature of the fluid in supply line 126 as detected by sensor 132 is at a pre-determined level. Similarly, should the temperature in supply line 126 become too warm, valve 120 will close-off the flow of fluid from line 142 and allow more of the relatively cooler fluid from line 88 through to pump 122 and ultimately to temperature sensor 132 and fluid loop 124. By such means, the equipment (not shown) serviced by chilled fluid loop 124 can receive chilled fluid at a temperature independently tailored for that equipment's particular environmental and cooling requirements An additional feature of the inventive system is the flexibility of using a higher pressure pump 122 to overcome a higher pressure differential required to propel the proper amount of chilled fluid through the intercooled computer equipment (not shown) located external to module 100.
Any excess flow in line 88 that cannot pass through valve 120 because of the modulation of valve 120 to accept fluid through line 142 will be directed to pump 54 through line 140. The entire flow of fluid in line 88 may be directed through line 140 to pump
54, thereby bypassing valve 120 and pump 122. Such a bypass permits the completion of chilled fluid loop 48
as directed by pump 54 should the bypass/recirculating feature of valve 120 be completely open or should pump 122 malfunction, blocking the flow of fluid through pump 122. The output of pump 54, in addition to supplying chilled fluid loop 48, directs a flow of water through line 144 to a chemical treatment tank (not shown) located outside module 100. This chemical treatment tank is supplied with various treatment products and inhibitors as is typical in the art of fluid and water circulation systems. The fluid passing through the chemical treatment tank is returned to fluid loop 48 of module 100 through return line 146. Any makeup fluid required for fluid loop 48 is provided through line 146 from a fluid source (not shown) external to module container 10. Lines 144 and 146 terminate at the wall of module 100 with quick- connect couplings 34.
An exhaust mechanism is included within module container 10 to ventilate module container 10 with air from space exterior to module 100. Air from outside module 100 is drawn through intake louver 148 by means of fan 150 and is expelled from module 100 through exhaust stack 152. Intake louver 148 may consist of a fixed-vane vent that permits the passage of air whenever fan 152 is operating. Sensor 158 detects and reports temperature of the air entering through intake louver 148, and sensor 154 detects and reports air flow exiting fan 152. A low reading by sensor 154 may active an alarm indicating a failure in fan 152. Although not shown in FIG. 1, the air drawn through intake louver 148 could derive from the space
immediately adjacent module 10. Alternatively, if module 100 is placed within a larger structure, the air could be drawn from a source outside the larger structure. The air exhausted through stack 152 is directed to the outside.
Leads from each of the aforementioned sensors may be directed to a control status panel (not shown) which may be located within module 100, external to module container 10, or both. The control status panel may be located at a site many miles from module container 10. The panel may merely display the temperature, flow, and pressure readings as detected by the various sensors . The panel may further indicate the operational status of each compressor, pump, and fan motor within the module container, such as displaying a green light for each component currently in operation. Additionally, the panel may contain lights and /or alarms that visually and/or audibly indicate an out-of-range condition as detected by the sensors and as compared against permissible range settings for each particular sensor. Upon detection of an out-of-range condition, the panel status light for the respective component may be changed from green to red, an audible alarm may be activated, and control circuitry may be activated to shut down the affected compressor, pump, or motor.
Turning now to FIG. 2, an alternate embodiment of the present invention is shown. In FIG. 2, condenser 14, supply line 26, and return line 28 as shown in FIG. 1, have been eliminated; and the heat acquired by the refrigerant is dissipated by means of a heat exchanger (not shown) located external to
module 100. Additionally, module 100 components associated with fluid loop 24 of FIG. 1 have been eliminated from module 100, including sensors 30 and 32, centrifugal separator 36, solids recovery vessel 38, and sensor 40. Quick-connect couplings 34 on fluid loop 24 are replaced with refrigerant quick- connect assemblies 156 on lines 16 and 44 as means for maintaining the modular quick-connection features of module 100. The refrigerant quick-connect assembly 156 includes shut-off valves 158, flexible connection 160, quick-connect coupling 162, and vent valve 164. For disconnection, shut-off valves 158 are closed, vent valve 164 is connected to a refrigerant receiver (not shown) and opened. After release of the refrigerant between two shut-off valves 158 to the refrigerant receiver, quick-connect coupling 162 is disconnected, thereby disconnecting module 100 from the external heat exchanger (not shown) . For reconnection, refrigerant line quick-connect coupling 162 is reconnected, the high pressure side shut-off valve 158 is opened to the refrigerant receiver (not shown) connected to vent valve 164 until refrigerant quick- connect assembly 156 is filled with refrigerant. Once refrigerant quick-connect assembly 156 is filled with refrigerant, vent valve 164 is closed, the refrigerant receiver is removed, and the low pressure side shut- off valve 158 is opened.
The system of FIG. 2 also provides chilled fluid to a plurality of possible external air handlers and fluid-cooled equipment (not shown) but does so without an internal condenser. The chilled fluid plant of FIG. 2 therefore is comprised of compressors
12, evaporator 42, expansion valves 46, refrigerant quick-connect assemblies 156, and interconnecting pressure lines 16, 44, and 50. By removing the condenser and components associated with fluid loop 24 from module 100, the modular chilled fluid system is correspondingly simpler and can be housed in a smaller module container 10 than the embodiment represented by FIG.l. The remaining components and operational features of the invention as illustrated in FIG. 2 are the same as those described above regarding FIG. 1.
Industrial Applicability
In view of the foregoing, the present invention is advantageously applicable to a modular chilled fluid plant for providing a supply of chilled fluid to remotely situated air handlers and fluid- cooled equipment. The components for cooling the fluid and for pumping the fluid to the remote air handlers and equipment are secured within a transportable module container such that the entire structure can be swapped out should any component fail or should the cooling requirements of the remote air handlers and equipment change. The components of the chilled fluid plant are also modular in that each component can be easily removed by non-technical personal and a replacement component easily and quickly plugged back in place so as to avoid or minimize any loss of cooling capacity. All connections of piping, ductwork, and power between the module container and its external environment are in the form of quick-connect couplings to facilitate the easy installation, removal, and replacement of the entire module. The modular plant is particularly useful in providing the chilled fluid required to air
condition a computer room facility and to directly cool computer equipment .
Other aspects, objects and advantages of the present invention can be obtained from a study of the drawings, the disclosure and the appended claims.