Abstract: In one aspect, a cooling tower system is provided that includes an evaporative heat exchanger, a sensor configured to detect a parameter of evaporative liquid distributed onto the evaporative heat exchanger, and an evaporative liquid treatment system. The cooling tower system further includes a controller having a normal operating mode wherein the controller operates the evaporative liquid treatment system to treat the evaporative liquid upon a determination of inadequate evaporative liquid quality based at least in part on the parameter of the evaporative liquid. The controller has a failsafe operating mode wherein the controller changes operation of the cooling tower upon a determination that the operation of the evaporative liquid treatment system is unable to remedy the inadequate evaporative liquid quality.

Abstract: In one aspect, a heat exchanger system is provided that includes a cooling system and a sensor configured to detect a variable of the cooling system. The heat exchanger system includes processor circuitry configured to provide the variable and a plurality of potential operating parameters of the cooling system to a machine learning model representative of the cooling system to estimate at least one of energy consumption, water usage, and chemical usage for the potential operating parameters. The processor circuitry is further configured to determine, based at least in part on the estimated at least one of energy consumption, water usage, and chemical consumption, for the potential operating parameters, an optimal operating parameter of the cooling system to satisfy a target optimization criterion.

Abstract: In one aspect, a fan array fault response control system is provided for a cooling tower. The fan array fault response control system includes a fan interface configured to be in communication with a plurality of fans of the cooling tower and a processor operably coupled to the fan interface. The processor is configured to detect at least one non-operational fan of the plurality of fans. The processor configured to effect, in response to detecting the at least one non-operational fan, a reduced fan speed of at least one operational fan of the plurality of fans.

Abstract: An improved indirect heat exchanger including a plurality of coil circuits, with each coil circuit comprised of an indirect heat exchange section tube run or plate. Each tube run or plate has at least one change in its geometric shape or may have a progressive change in its geometric shape proceeding from the inlet to the outlet of the circuit. The change in geometric shape along the circuit length allows simultaneously balancing of the external airflow, internal heat transfer coefficients, internal fluid side pressure drop, cross sectional area and heat transfer surface area to optimize heat transfer.

Abstract: In one aspect, a tubular membrane assembly is provided for a heat exchanger. The tubular membrane assembly includes a header having a header body, a tubular membrane, and a fitting connecting the tubular membrane to the header body. The fitting is configured to form a fluid tight connection between the fitting and the tubular membrane. The tubular membrane assembly further includes potting of the header keeping the tubular membrane connected to the fitting.

Abstract: In one aspect, a heat exchange apparatus is provided that includes an evaporative heat exchanger assembly including an evaporative heat exchanger and an evaporative liquid distribution assembly configured to distribute evaporative liquid onto the evaporative heat exchanger. The heat exchange apparatus includes a plume abatement assembly downstream of the evaporative heat exchanger. The plume abatement assembly includes at least one heating element configured to increase the temperature of the airflow from the evaporative heat exchanger before the airflow leaves the heat exchange apparatus. The plume abatement assembly has an operative configuration wherein the airflow travels through the at least one heating element to permit the at least one heating element to raise the temperature of the airflow and a bypass configuration wherein less of the airflow travels through the at least one heating element of the plume abatement assembly.

Abstract: Improved water management systems which deflect or collect evaporative liquid exiting counterflow heat exchangers and improve airflow distribution are provided. Such heat exchangers include open cooling towers, closed circuit cooling towers, and evaporative condensers. The improved water management systems eliminate water splash out and the noise associated with water splashing. Further, when the fan assemblies are located below the evaporative heat exchanger, the improved water management systems keep the fans dry and prevent freezing in subzero climates.

Abstract: An improved water management system with improved airflow distribution for counterflow evaporative heat exchangers is provided. Such heat exchangers include open cooling towers, closed circuit cooling towers, and evaporative condensers. The improved water management system eliminates water splash out and the noise associated with water splashing. Further when the fan assemblies are located below the evaporative heat exchanger, the improved water management system keeps the fans dry and prevents freezing in subzero climates.

Abstract: An improved heat exchange apparatus is provided with an indirect evaporative heat exchange section consisting of a series of serpentine tubes which are kept uniformly spaced in the return bend section. Providing uniform return bend spacing on the return bend ends allow for ease of circuit assembly (stacking), ease of coil pull-down, ease of manufacturing, reduction in production cost, produces a higher quality hot dip galvanizing process and is a more robust design that tolerates manufacturing variability issues such as variable tube circuit length and variable return bend angles. Uniform return bend spacing also reduces scaling relative to prior art designs which had wet/dry areas resulting from shadowed tubes which were non-uniformly spaced, provides for better inspection and access to the tubes in the return bend area, maintains uniform air passage around tubes, promotes better tube wetting of the return bend area and ultimately promotes higher quality and higher performing heat exchanger coils.

Abstract: An indirect heat exchanger has two airflow paths and an airflow generator to draw air through the airflow paths. A fluid conduit passes through the heat exchanger such that a cooling region is positioned within each of the flow paths. A dispenser is positioned to dispense evaporative liquid on one of the cooling regions. The dispenser operates in a wet mode and a dry mode. A controller regulates airflow through the first flow path and the second flow path, and also controls the operation of the dispenser. In this way, the controller may operate the airflow paths independently such that the airflow through a flow path operating in the dry mode is greater than that of the flow path operating in the wet mode.

Abstract: An improved heat exchange apparatus is provided with an indirect evaporative heat exchange section enclosed in a housing and a direct evaporative heat exchange section both of which are located within the same apparatus. An internal fluid stream is passed through the internal passageways of the indirect heat exchange section. An evaporative liquid is passed across the outside of the external passageways of the indirect heat exchange section to exchange heat indirectly with the internal fluid stream. The evaporative liquid that exits the indirect evaporative heat exchange section housing then passes onto and through the direct heat exchange section. The evaporative liquid exiting the direct heat exchange section is collected in a sump and then pumped upwardly to be distributed again through the indirect heat exchange section housing. The indirect heat exchange section may be comprised of a plate type heat exchanger or a circuit tube type heat exchanger located within a housing.

Abstract: A cooling tower is provided having a heat exchange section, and a fan for moving air through the heat exchange section. A water distribution assembly provides water onto and through the heat exchange section. An air inlet section is provided through which air is drawn into the cooling tower and the heat exchange section. The air inlet section has outside edges and corners. A wall assembly is provided in the air inlet section, with the wall assembly extending from the corners of the air inlet section inwardly. The water passing through the heat exchange section enters the air inlet section, and exits to a sump beneath the air inlet section. The air inlet section is comprised of a structure having outside edges and corners, and the wall assembly is comprised of a plurality of wall panel sections. Each wall panel section has an outer edge at a corner of the air inlet section, and each wall panel section extends inwardly from the corner of the air inlet section.

Abstract: Improved water management systems which deflect or collect evaporative liquid exiting counterflow heat exchangers and improve airflow distribution are provided. Such heat exchangers include open cooling towers, closed circuit cooling towers, and evaporative condensers. The improved water management systems eliminate water splash out and the noise associated with water splashing. Further, when the fan assemblies are located below the evaporative heat exchanger, the improved water management systems keep the fans dry and prevent freezing in subzero climates.

Abstract: An improved water management system with improved airflow distribution for counterflow evaporative heat exchangers is provided. Such heat exchangers include open cooling towers, closed circuit cooling towers, and evaporative condensers. The improved water management system eliminates water splash out and the noise associated with water splashing. Further when the fan assemblies are located below the evaporative heat exchanger, the improved water management system keeps the fans dry and prevents freezing in subzero climates.

Abstract: A cassette for use in cassette-type heat exchanger has an inlet and an outlet, and include an upper plate and a lower plate. The upper and lower plates are sealed together around an edge area of the cassette, thereby forming a flow path within the cassette between the inlet and outlet. The plates are formed with a stamped pattern that increases the surface area of the plates as compared to a flat plate surface. The pattern includes a series of weld points whereby the upper and lower plate are welded or bonded together at a point location.

Abstract: An improved indirect heat exchanger is provided which is comprised of a plurality of coil circuits, with each coil circuit comprised of an indirect heat exchange section tube run or plate. Each tube run or plate has at least one change in its geometric shape or may have a progressive change in its geometric shape proceeding from the inlet to the outlet of the circuit. The change in geometric shape along the circuit length allows simultaneously balancing of the external airflow, internal heat transfer coefficients, internal fluid side pressure drop, cross sectional area and heat transfer surface area to optimize heat transfer.

Abstract: An improved indirect heat exchanger is provided which is comprised of a plurality of coil circuits, with each coil circuit comprised of an indirect heat exchange section tube run or plate. Each tube run or plate has at least one change in its geometric shape or may have a progressive change in its geometric shape proceeding from the inlet to the outlet of the circuit. The change in geometric shape along the circuit length allows simultaneously balancing of the external airflow, internal heat transfer coefficients, internal fluid side pressure drop, cross sectional area and heat transfer surface area to optimize heat transfer.

Abstract: A cooling tower is provided having a heat exchange section. A water collection basin located above the heat exchange section. The water collection basin has a plurality of openings that allow water to be distributed downwardly onto the heat exchange section. The water collection basin openings each have a diameter of from 0.2 inch to 0.6 inch.

Abstract: An indirect heat exchanger has two airflow paths and an airflow generator to draw air through the airflow paths. A fluid conduit passes through the heat exchanger such that a cooling region is positioned within each of the flow paths. A dispenser is positioned to dispense evaporative liquid on one of the cooling regions. The dispenser operates in a wet mode and a dry mode. A controller regulates airflow through the first flow path and the second flow path, and also controls the operation of the dispenser. In this way, the controller may operate the airflow paths independently such that the airflow through a flow path operating in the dry mode is greater than that of the flow path operating in the wet mode.