Abstract: With respect to atmospheric steam generating humidifiers, the present disclosure resolves the problem of end-users not adjusting the drain interval of the humidifier by using an electronic controller to automatically choose an appropriate drain interval without requiring any user input. The electronic controller accomplishes this by receiving input data from a sensor that measures a water quality parameter, automatically determining a drain interval based on the received data, and sending an output control signal to a drain water control valve to execute a drain event in accordance with the drain interval. In some examples, the electronic controller utilizes a look-up table correlating the water quality parameter to a total dissolved solids or cycles of concentration value.

Abstract: A steam dispersion system includes a header defining a first end and a second end, a plurality of steam dispersion tubes extending upwardly from the header, a condensate drain outlet located at the first end, a hollow pipe positioned within the header, the pipe defining a length extending in a direction generally from the first end to the second end, the pipe defining a main humidification steam inlet located at the first end and a main steam outlet that is within the header. The hollow pipe is configured to receive steam flowing in from the main steam inlet toward the main steam outlet. The pipe may define a plurality of orifices along the length thereof for allowing steam flowing through the pipe to enter the header for distribution through the dispersion tubes. A steam re-direction structure directs steam flow leaving through the main steam outlet back toward the first end of the header.

Abstract: A steam dispersion apparatus includes a steam chamber communicating in an open-loop arrangement with a first steam source for supplying steam to the steam chamber. The steam chamber includes a steam dispersion location at which steam exits therefrom at generally atmospheric pressure. A heat exchanger communicates in a closed-loop arrangement with a second steam source for supplying steam to the heat exchanger at a pressure generally higher than atmospheric pressure. The heat exchanger is located at a location that is not directly exposed to the air to be humidified, the heat exchanger being in fluid communication with the steam chamber so as to contact condensate from the steam chamber. The heat exchanger converts condensate formed by the steam chamber back to steam when the condensate contacts the heat exchanger.

Abstract: A steam dispersion apparatus includes a steam chamber communicating in an open-loop arrangement with a first steam source for supplying steam to the steam chamber. The steam chamber includes a steam dispersion location at which steam exits therefrom at generally atmospheric pressure. A heat exchanger communicates in a closed-loop arrangement with a second steam source for supplying steam to the heat exchanger at a pressure generally higher than atmospheric pressure. The heat exchanger is located at a location that is not directly exposed to the air to be humidified, the heat exchanger being in fluid communication with the steam chamber so as to contact condensate from the steam chamber. The heat exchanger converts condensate formed by the steam chamber back to steam when the condensate contacts the heat exchanger.

Abstract: A staged dry out process and control system for an evaporative media cooling system having a plurality of media stages that are selectively activated and deactivated by a control system is disclosed. The staged dry out process ensures that wet media stages are appropriately dried with minimal disruption to the staging strategy implemented by the control system. In one aspect, the staged dry out process monitors deactivated media stages to determine if the media stages reach a dry state before being activated. In another aspect, the staged dry out process locks out a media stage that has been in a wet state beyond a predetermined maximum time limit until the media stage attains a dry state. With this strategy the cooling system can operate without being required to completely shut down for a drying process.

Abstract: A cycles of concentration (COC) control process and system for an evaporative media cooling system having a water storage tank in fluid communication with a drain valve and a refill valve is disclosed. In one step, the COC control process includes the step of executing a plurality of discrete refill events to maintain a level or volume of water within the storage tank. In another step, the COC control process includes the step of executing a discrete drain event, equaling the volume of a refill event, after a discrete refill event has been executed when necessary to maintain a target cycles of concentration value of the water within the storage tank. In one embodiment, a discrete drain event is executed when the number of refill events is greater than or equals a target cycles of concentration of the water in the storage tank.

Abstract: A staging control process for an evaporative media cooling system having a plurality of media stages is disclosed. In one step, a leaving air dry bulb temperature setpoint for air exiting the evaporative media cooling system is received or defined. In one aspect, an expected media exit dry bulb temperature is calculated for each media stage based on a dry bulb temperature and a wet bulb temperature of air entering the media cooling system and based on a measured or assigned condition of the media. In another aspect, an estimated combined leaving dry bulb temperature is calculated for different combinations of activated and deactivated media stages. Once the estimated leaving temperature is known, the method can then activate the media stage(s) associated with the combination that has an estimated combined leaving dry bulb temperature that is nearest to but less than the leaving air dry bulb temperature setpoint.

Abstract: A heat transfer system includes a steam chamber that communicates in an open-loop arrangement with a first steam source for supplying steam to the steam chamber, the steam chamber including a steam exit for supplying steam to air at atmospheric pressure. A heat transfer tube communicates in a closed-loop arrangement with a second steam source for supplying steam to an interior surface of the heat transfer tube, the heat transfer tube vaporizing condensate forming within the heat transfer system back to steam that is supplied to the air via the steam exit. The outer surface of the heat transfer tube is configured to contact the condensate and vaporize the condensate back into steam, wherein the heat transfer tube includes a plurality of pockets formed on the outer surface of the tube, each pocket including a pocket exit/entry portion having a smaller cross-sectional area than the cross-sectional area of the pocket at a root portion thereof adjacent the outer surface of the tube.

Abstract: An evaporative media system having multiple media stages each served by a separate pump is disclosed. In one aspect, the evaporative media system has a first media stage and a second media stage. A first pump is provided that is configured to deliver water from the first compartment of the water storage tank to the first media stage. Additionally, a second pump is provided that is configured to deliver water from the first compartment of the water storage tank to the second media stage. Additional media stages and pumps may be provided as well. The disclosed configuration eliminates the need for individual staging valves, provides a higher level of operational redundancy, reduces electrical consumption, and can be provided at a lower cost, as compared to many existing systems.

Abstract: A steam dispersion system includes a header defining a first end and a second end, a plurality of steam dispersion tubes extending upwardly from the header, a condensate drain outlet located at the first end, a hollow pipe positioned within the header, the pipe defining a length extending in a direction generally from the first end to the second end, the pipe defining a main humidification steam inlet located at the first end and a main steam outlet that is within the header. The hollow pipe is configured to receive steam flowing in from the main steam inlet toward the main steam outlet. The pipe may define a plurality of orifices along the length thereof for allowing steam flowing through the pipe to enter the header for distribution through the dispersion tubes. A steam re-direction structure directs steam flow leaving through the main steam outlet back toward the first end of the header.

Abstract: A heat transfer system includes a steam chamber that communicates in an open-loop arrangement with a first steam source for supplying steam to the steam chamber, the steam chamber including a steam exit for supplying steam to air at atmospheric pressure. A heat transfer tube communicates in a closed-loop arrangement with a second steam source for supplying steam to an interior surface of the heat transfer tube, the heat transfer tube vaporizing condensate forming within the heat transfer system back to steam that is supplied to the air via the steam exit. The outer surface of the heat transfer tube is configured to contact the condensate and vaporize the condensate back into steam, wherein the heat transfer tube includes a plurality of pockets formed on the outer surface of the tube, each pocket including a pocket exit/entry portion having a smaller cross-sectional area than the cross-sectional area of the pocket at a root portion thereof adjacent the outer surface of the tube.

Abstract: A steam dispersion apparatus includes a steam chamber communicating in an open-loop arrangement with a first steam source for supplying steam to the steam chamber. The steam chamber includes a steam dispersion location at which steam exits therefrom at generally atmospheric pressure. A heat exchanger communicates in a closed-loop arrangement with a second steam source for supplying steam to the heat exchanger at a pressure generally higher than atmospheric pressure. The heat exchanger is located at a location that is not directly exposed to the air to be humidified, the heat exchanger being in fluid communication with the steam chamber so as to contact condensate from the steam chamber. The heat exchanger converts condensate formed by the steam chamber back to steam when the condensate contacts the heat exchanger.

Abstract: A steam dispersion system is disclosed. The steam dispersion system includes a header and a mounting plate spaced from the header. A steam dispersion tube including a first end and a second end and an interior cavity defined between the first end and the second end is mounted between the mounting plate and the header. The steam dispersion tube defines a longitudinal axis. A biasing structure is mounted between the mounting plate and the header, wherein the biasing structure applies a biasing force on the steam dispersion tube along a direction parallel to the longitudinal axis of the steam dispersion tube when mounted between the header and the mounting plate.

Abstract: A steam dispersion apparatus includes a steam chamber communicating in an open-loop arrangement with a first steam source for supplying steam to the steam chamber. The steam chamber includes a steam dispersion location at which steam exits therefrom at generally atmospheric pressure. A heat exchanger communicates in a closed-loop arrangement with a second steam source for supplying steam to the heat exchanger at a pressure generally higher than atmospheric pressure. The heat exchanger is located at a location that is not directly exposed to the air to be humidified, the heat exchanger being in fluid communication with the steam chamber so as to contact condensate from the steam chamber. The heat exchanger converts condensate formed by the steam chamber back to steam when the condensate contacts the heat exchanger.

Abstract: A steam dispersion system is disclosed. The steam dispersion system includes a header and a mounting plate spaced from the header. A steam dispersion tube including a first end and a second end and an interior cavity defined between the first end and the second end is mounted between the mounting plate and the header. The steam dispersion tube defines a longitudinal axis. A biasing structure is mounted between the mounting plate and the header, wherein the biasing structure applies a biasing force on the steam dispersion tube along a direction parallel to the longitudinal axis of the steam dispersion tube when mounted between the header and the mounting plate.

Abstract: An evaporative cooler circulation and drain system including a fluid pump and a storage tank defining an interior volume for holding a fluid is disclosed. In one aspect, the system is operable between a circulation and drain-circulation operational modes. In the circulation mode, a drain valve is closed and the fluid pump is activated such that fluid is continuously circulated within the storage tank to discourage debris from settling by keeping debris in the tank in suspension. In the drain-circulation mode, the drain valve is opened and the fluid pump is activated such that fluid is both being continuously circulated within the interior volume of the storage tank and draining from the tank. In some embodiments, the system increases the drain flow rate by directing circulated fluid directly at a drain opening of the tank to flush debris through the drain piping and prevent plugging.

Abstract: A staging control process for an evaporative media cooling system having a plurality of media stages is disclosed. In one step, a leaving air dry bulb temperature setpoint for air exiting the evaporative media cooling system is received or defined. In one aspect, an expected media exit dry bulb temperature is calculated for each media stage based on a dry bulb temperature and a wet bulb temperature of air entering the media cooling system and based on a measured or assigned condition of the media. In another aspect, an estimated combined leaving dry bulb temperature is calculated for different combinations of activated and deactivated media stages. Once the estimated leaving temperature is known, the method can then activate the media stage(s) associated with the combination that has an estimated combined leaving dry bulb temperature that is nearest to but less than the leaving air dry bulb temperature setpoint.

Abstract: A staged dry out process and control system for an evaporative media cooling system having a plurality of media stages that are selectively activated and deactivated by a control system is disclosed. The staged dry out process ensures that wet media stages are appropriately dried with minimal disruption to the staging strategy implemented by the control system. In one aspect, the staged dry out process monitors deactivated media stages to determine if the media stages reach a dry state before being activated. In another aspect, the staged dry out process locks out a media stage that has been in a wet state beyond a predetermined maximum time limit until the media stage attains a dry state. With this strategy the cooling system can operate without being required to completely shut down for a drying process.

Abstract: An evaporative media system having multiple media stages each served by a separate pump is disclosed. In one aspect, the evaporative media system has a first media stage and a second media stage. A first pump is provided that is configured to deliver water from the first compartment of the water storage tank to the first media stage. Additionally, a second pump is provided that is configured to deliver water from the first compartment of the water storage tank to the second media stage. Additional media stages and pumps may be provided as well. The disclosed configuration eliminates the need for individual staging valves, provides a higher level of operational redundancy, reduces electrical consumption, and can be provided at a lower cost, as compared to many existing systems.

Abstract: A cycles of concentration (COC) control process and system for an evaporative media cooling system having a water storage tank in fluid communication with a drain valve and a refill valve is disclosed. In one step, the COC control process includes the step of executing a plurality of discrete refill events to maintain a level or volume of water within the storage tank. In another step, the COC control process includes the step of executing a discrete drain event, equaling the volume of a refill event, after a discrete refill event has been executed when necessary to maintain a target cycles of concentration value of the water within the storage tank. In one embodiment, a discrete drain event is executed when the number of refill events is greater than or equals a target cycles of concentration of the water in the storage tank.