CONDENSER SUBCOOLER COMPONENT OF A VAPOR COMPRESSION SYSTEM

Abstract

In certain embodiments, a condenser includes a shell having a longitudinal axis, a first tube bundle disposed within the shell, and a subcooler component disposed within the shell beneath the first tube bundle. The subcooler component includes a rectilinear housing, a plurality of rectilinear grid support assemblies disposed within the rectilinear housing and spaced lengthwise along the axis of the shell, and a second tube bundle disposed within the rectilinear housing, wherein tubes of the second tube bundle are held in place within rectilinear grid channels of the rectilinear grid support assemblies.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of U.S. Provisional Application Ser. No. 62/611,751, entitled “CONDENSER SUBCOOLER COMPONENT OF A VAPOR COMPRESSION SYSTEM,” filed Dec. 29, 2017, which is hereby incorporated by reference in its entirety for all purposes.

BACKGROUND

The present disclosure generally relates to heat exchangers in vapor compression systems. The present disclosure relates more specifically to a condenser for a vapor compression system having a subcooler component that includes a rectilinear housing and rectilinear grid supports.

In some condensers, one or more tube bundles may be positioned in a shell or housing and used to circulate a fluid that can exchange heat with refrigerant vapor entering the shell. The transfer or exchange of heat between the refrigerant vapor and the fluid can cause the refrigerant vapor to condense or change phase to a liquid. Before the refrigerant liquid leaves the condenser, the refrigerant liquid may be further cooled, i.e., subcooled, by a second tube bundle that can be positioned as a subcooler component. The subcooler component can control the flow of the refrigerant liquid over the second tube bundle, which also circulates a fluid, to further exchange or transfer heat with the refrigerant liquid.

This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present techniques, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

SUMMARY

Certain embodiments commensurate in scope with the present disclosure are summarized below. These embodiments are not intended to limit the scope of the disclosure, but rather these embodiments are intended only to provide a brief summary of possible forms of present embodiments. Indeed, present embodiments may encompass a variety of forms that may be similar to or different from the embodiments set forth below.

In one embodiment, a condenser includes a shell having a longitudinal axis, a first tube bundle disposed within the shell, and a subcooler component disposed within the shell beneath the first tube bundle. The subcooler component includes a rectilinear housing, a plurality of rectilinear grid support assemblies disposed within the rectilinear housing and spaced lengthwise along the axis of the shell, and a second tube bundle disposed within the rectilinear housing, wherein tubes of the second tube bundle are held in place within rectilinear grid channels of the rectilinear grid support assemblies.

In another embodiment, a condenser subcooler component includes a rectilinear housing, a plurality of rectilinear grid support assemblies disposed within the rectilinear housing and spaced lengthwise along a longitudinal axis of the rectilinear housing, and a tube bundle disposed within the rectilinear housing, wherein tubes of the tube bundle are held in place within rectilinear grid channels of the rectilinear grid support assemblies.

In another embodiment, a condenser subcooler component includes a rectilinear housing and a plurality of rectilinear grid support assemblies disposed within the rectilinear housing and spaced lengthwise along a longitudinal axis of the rectilinear housing. Each of the plurality of rectilinear grid support assemblies includes a plurality of rectilinear grid support sections. The condenser subcooler component also includes a tube bundle disposed within the rectilinear housing, wherein tubes of the tube bundle are held in place within rectilinear grid channels of the rectilinear grid support assemblies.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 illustrates a heating, ventilation and air conditioning system, in accordance with embodiments of the present disclosure;

FIG. 2 illustrates a vapor compression system, in accordance with embodiments of the present disclosure;

FIG. 3 is a diagram of a heating, ventilation and air conditioning system, in accordance with embodiments of the present disclosure;

FIG. 4 illustrates a cross sectional view of a vapor compression system, in accordance with embodiments of the present disclosure;

FIG. 5 illustrates a cross-sectional view of a condenser, in accordance with embodiments of the present disclosure;

FIG. 6 illustrates a partial cut-away perspective view of a condenser, in accordance with embodiments of the present disclosure;

FIG. 7 illustrates a perspective view of a subcooler component of a condenser, in accordance with embodiments of the present disclosure;

FIG. 8 illustrates a cross-sectional view of a rectilinear housing of the subcooler component, in accordance with embodiments of the present disclosure;

FIGS. 9 and 10 illustrate embodiments of rectilinear grid support sections of the subcooler component, in accordance with embodiments of the present disclosure;

FIG. 11 illustrates a cross-sectional view of an embodiment of an end rectilinear grid support of the subcooler component, in accordance with embodiments of the present disclosure; and

FIG. 12 illustrates a chamber sight glass and a vertical liquid probe of the subcooler component of a condenser, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

Embodiments of the present disclosure are directed towards a condenser that includes a subcooler component having a rectilinear housing and rectilinear grid supports configured to support tubes of a subcooler tube bundle disposed within the rectilinear housing of the subcooler component. The rectilinear nature of the housing and the grid supports enables the subcooler component to be manufactured relatively inexpensively. For example, in certain embodiments, the rectilinear housing may comprise a subcooler box formed as a single rectilinear extruded piece, or may be relatively easily formed of sheet metal folded into a rectilinear shape. In addition, in certain embodiments, the rectilinear grid supports may be constructed as multiple rectilinear grid support sections that may collectively form a rectilinear grid support assembly, which also simplifies the construction of the grid supports.

Turning now to the drawings, FIG. 1 illustrates a heating, ventilation and air conditioning (HVAC) system 10 in a building 12 in a typical commercial setting. The HVAC system 10 may include a vapor compression system 14 that may supply a chilled liquid to cool the building 12 and a cooling tower 16 that may provide a process fluid to the vapor compression system 14 by conduits 18. In certain embodiments, the HVAC system 10 may also include a boiler 20 to supply a heated liquid to heat the building 12, and an air distribution system that circulates air through the building 12. The air distribution system may include an air return duct 22, an air supply duct 24, and an air handler 26. The air handler 26 may include a heat exchanger connected to the boiler 20 and the vapor compression system 14 by conduits 28. The heat exchanger in the air handler 26 may receive heated liquid from the boiler 20 and/or chilled liquid from the vapor compression system 14, depending on the mode of operation of the HVAC system 10. In certain embodiments, the HVAC system 10 may include a separate air handler on each floor of the building 12, but it will be appreciated that the components may be shared between or among floors.

FIGS. 2-4 illustrate a vapor compression system 14 that may be used in HVAC system 10 of FIG. 1. In certain embodiments, the vapor compression system 14 may circulate a refrigerant through a circuit starting with a compressor 30 and including a condenser 32, one or more expansion valves 34, and an evaporator 36. In addition, the vapor compression system 14 may also include a control panel 38 that, in certain embodiments, may include an analog to digital (A/D) converter 40, a processor 42, memory 44, an interface board 46, and a user interface 48. Some examples of fluids that may be used as refrigerants in the vapor compression system 14 are hydrofluorocarbon (HFC) based refrigerants, for example, R-410A, R-407, R-134a, hydrofluoro olefin (HFO), “natural” refrigerants like ammonia (NH3), R-717, carbon dioxide (CO2), R-744, or hydrocarbon based refrigerants, or any other suitable type of refrigerant.

As illustrated in FIG. 3, in certain embodiments, a motor 50 may be used to drive or operate the compressor 30. The motor 50 may be powered by a variable speed drive 52 or may be powered directly from an alternating current (AC) or direct current (DC) power source. The motor 50 may be any suitable motor type that may be powered by a VSD or directly from an AC or DC power source, for example, a switched reluctance motor, an induction motor, or an electronically commutated permanent magnet motor. In alternate embodiments, other drive mechanisms, such as steam or gas turbines or engines and associated components, may be used to drive the compressor 30.

In certain embodiments, the variable speed drive 52 receives AC power having a particular fixed line voltage and fixed line frequency from an AC power source, and provides AC power to the motor 50 at a desired voltage and desired frequency, both of which may be varied to satisfy particular requirements. In certain embodiments, the variable speed drive 52 may provide a variable magnitude output voltage and variable frequency to the motor 50 to permit effective operation of the motor 50 in response to particular load conditions. In certain embodiments, the control panel 38 may provide control signals to the variable speed drive 52 to operate the variable speed drive 52 and the motor 50 at appropriate operational settings for the particular sensor readings received by the control panel 38. For example, the control panel 38 may provide control signals to the variable speed drive 52 to adjust the output voltage and output frequency provided by the variable speed drive 52 in response to changing conditions in the vapor compression system 14. In other words, the control panel 38 may provide instructions to increase or decrease the output voltage and output frequency provided by the variable speed drive 52 in response to increasing or decreasing load conditions on the compressor 30.

In certain embodiments, the compressor 30 compresses a refrigerant vapor and delivers the vapor to the condenser 32 through a discharge passage 54. In certain embodiments, the compressor 30 may be a centrifugal compressor having one or more compression stages. However, in other embodiments, the compressor 30 may be any suitable compressor type including screw compressor, reciprocating compressor, rotary compressor, swing link compressor, scroll compressor, or turbine compressor. The refrigerant vapor delivered by the compressor 30 to the condenser 32 transfers heat to a fluid, for example, water or any other suitable liquid. The refrigerant vapor condenses to a refrigerant liquid in the condenser 32 as a result of the heat transfer with the fluid. In certain embodiments, the condenser 32 includes a supply line 56 and a return line 58 for circulating fluid between the condenser 32 and a cooling tower 16, for example, where the fluid from the condenser 32 is cooled by exchanging heat with another fluid, such as air. The fluid may then be returned to the condenser 32 through the return line 58, where the fluid is heated by exchanging heat with the refrigerant in the condenser 32. The heated fluid may then be removed from the condenser 32 though the supply line 56, and provided to the cooling tower 16 to complete the cycle.

In the embodiment illustrated in FIG. 3, the condenser 32 is water cooled and includes a tube bundle 60 connected to the cooling tower 16. In certain embodiments, the tube bundle 60 in the condenser 32 may include a plurality of tubes and a plurality of tube bundles. In addition, as illustrated in FIG. 4, in certain embodiments, the condenser 32 may include a subcooler component 62, which is used to cool the liquid refrigerant to a temperature below the saturation temperature of the refrigerant (i.e., to subcool the liquid refrigerant) before the liquid refrigerant is directed to the evaporator 36. As described in greater detail herein, in certain embodiments, the subcooler component 62 includes a rectilinear housing and rectilinear grid supports configured to support tubes of a subcooler tube bundle disposed within the rectilinear housing of the subcooler component 62, thereby enabling the subcooler component 62 to be manufactured relatively inexpensively.

In certain embodiments, once subcooled by the subcooler component 62, the liquid refrigerant from the condenser 32 flows through the expansion valve 34 to the evaporator 36. In certain embodiments, a hot gas bypass valve (HGBV) 64 may be connected in a separate line extending from the compressor discharge to the compressor suction. The liquid refrigerant delivered to the evaporator 36 absorbs heat from another fluid, which may or may not be the same type of fluid used for the condenser 32, and undergoes a phase change to a refrigerant vapor.

In the embodiment illustrated in FIG. 3, the evaporator 36 includes a tube bundle 66 having a supply line 68 and a return line 70 connected to a cooling load 72. The supply line 68 and the return line 70 may be in fluid communication with the air handler 26 via the conduits 28 that circulate the process fluid through the HVAC system 10. In certain embodiments, a process fluid, for example, water, ethylene glycol, calcium chloride brine, sodium chloride brine, or any other suitable liquid, enters the evaporator 36 via the return line 70 and exits the evaporator 36 via the supply line 68. The evaporator 36 lowers the temperature of the process fluid in the tubes. In certain embodiments, the tube bundle 66 in the evaporator 36 may include a plurality of tubes and a plurality of tube bundles. The vapor refrigerant exits the evaporator 36 and returns to the compressor 30 by a suction line 74 to complete the circuit or cycle.

In the embodiment illustrated in FIG. 4, the compressor 30 may include pre-rotation vanes 76, which may be used at the inlet to the compressor 30, and may be fixed into a predetermined position or may have a position that is adjustable. In certain embodiments, the vapor compression system 14 may use one or more of each of the variable speed drive 52, the motor 50, the compressor 30, the condenser 32, the expansion device or expansion valve 34 and/or the evaporator 36 in one or more refrigerant circuits.

A cross sectional view of an embodiment of the condenser 32 is illustrated in FIG. 5. As illustrated in FIG. 5, in certain embodiments, the condenser 32 includes a shell 78 having a generally cylindrical geometry and including headers 80 positioned at opposing axial ends of shell 78. In certain embodiments, the headers 80 distribute fluid to a first tube bundle 82 and a second tube bundle 84 (of the subcooler component 62) as illustrated by the arrows 86. The flow path of the fluid through the condenser 32 is also illustrated by arrows 86. In certain embodiments, the condenser 32 further includes an inlet 88 for receiving refrigerant vapor, as indicated by arrow 90, and an outlet 92 for discharging refrigerant liquid, as indicated by arrow 94. In certain embodiments, the inlet 88 and the outlet 92 are located at approximately the axial midpoint of the condenser 32. However, in other embodiments, the location of the inlet 88 and the outlet 92 may vary in position along the shell 78.

In certain embodiments, the first tube bundle 82 includes tubes 96 circulating a process fluid that exchanges heat with refrigerant vapor entering the condenser 32, causing the refrigerant vapor to condense or change state to a refrigerant liquid. In certain embodiments, the first tube bundle 82 may have one or more passes of process fluid through the first tube bundle 82. In the embodiment illustrated in FIG. 5, the first tube bundle 82 may have two passes of process fluid through the first tube bundle 82. In certain embodiments, the second tube bundle 84 of the subcooler component 62 may have a single pass of process fluid through the second tube bundle 84. The process fluid from the single pass through the second tube bundle 84 may be combined with the process fluid from the first pass through the first tube bundle 82 for the second pass through the first tube bundle 82.

In certain embodiments, before the refrigerant liquid leaves the condenser 32 through the outlet 92, the refrigerant liquid may be further cooled to a temperature below the saturation temperature of the refrigerant (i.e., subcooled) by the tubes 98 located in the subcooler component 62 of the condenser 32, which may completely contain or enclose the second tube bundle 84. The subcooler component 62 controls the flow of the refrigerant liquid over and around the tubes 98 of the second tube bundle 84. In certain embodiments, the condenser 32 includes tube supports 100 for the supporting tubes 96. Similarly, as described in greater detail herein, the subcooler component 62 may include corresponding structures (e.g., rectilinear grid support assemblies) for supporting the tubes 98 while also enabling axial flow of refrigerant along the tubes 98.

As also illustrated in FIG. 5, in certain embodiments, the subcooler component 62 is submerged in a liquid reservoir 102 that extends along the full length of the condenser 32. The liquid reservoir 102 has a liquid surface 104 above the subcooler component 62. The liquid reservoir 102 forms a liquid seal that prevents refrigerant vapor from entering the subcooler component 62. In other embodiments, the liquid surface 104 may be lower than a top surface 106 of the subcooler component 62. In other embodiments, the liquid surface 104 may be located relative to the subcooler component 62 so as to prevent the flow of any refrigerant vapor into the subcooler component 62, or in other words, the liquid surface 104 may be located above any inlet to the subcooler component 62.

FIG. 6 illustrates a partial cut-away perspective view of the condenser 32 with the first tube bundle 82 and the headers 80 removed for illustration purposes. The flow of condensed refrigerant is illustrated by arrows 108. The condensed refrigerant collects and forms the liquid reservoir 102. The refrigerant liquid then enters the subcooler component 62 through inlets 110 as indicated by arrows 112. The second tube bundle 84 provides additional cooling to the refrigerant liquid. The refrigerant liquid enters the subcooler component 62 and contacts and flows over and around the tubes 98 of the second tube bundle 84 within the subcooler component 62. In certain embodiments, the tubes 98 of the second tube bundle 84 within the subcooler component 62 may circulate the same or a different fluid as the tubes 96 of the first tube bundle 82 to exchange heat to further cool (i.e., subcool) the refrigerant liquid.

As illustrated in FIGS. 4 and 6, in certain embodiments, the subcooler component 62 includes two or more outer channels 114 and a central channel 116 between the outer channels 114. In certain embodiments, the outer channels 114 include bottom walls 118 with inlets 110 in the bottom walls 118. In certain embodiments, the subcooler component 62 may also include two or more intermediate channels between the central channel 116 and the outer channels 114. In certain embodiments, the liquid refrigerant collected in the liquid reservoir 102 may enter the subcooler component 62 through the inlets 110 and flow over and around the tubes 98 in the outer channels 114 towards header plates of the header 80, as illustrated by the arrows 120 in FIG. 6, providing a first pass for the refrigerant liquid. In certain embodiments, the inlets 110 may be located approximately at the axial midpoint of the condenser 32. In other embodiments, the inlets 110 may be located at any location along the bottom walls 118, e.g., at the ends of the bottom walls 118. In the embodiment illustrated in FIG. 6, each outer channel 114 includes a single inlet 110. However, in other embodiments, each outer channel 114 may be provided with more than one inlet 110. In certain embodiments, the liquid reservoir 102 forms a liquid seal at the inlets 110 to substantially prevent refrigerant vapor from entering the subcooler component 62.

FIG. 7 illustrates a perspective view of an embodiment of the subcooler component 62 with certain features, such as the tubes 98 of the second tube bundle 84, removed for illustration purposes. In the embodiment illustrated in FIG. 7, the subcooler component 62 includes a rectilinear housing 122 that forms a subcooler box within which the components of the subcooler component 62 may be housed. In certain embodiments, the rectilinear housing 122 may be formed as a single piece, such as a single rectilinear extruded piece (i.e., a single extruded piece that includes a rectilinear cross-sectional profile, for example, as viewed along a central longitudinal axis 124 of the subcooler component 62). However, in other embodiments, instead of being extruded, the rectilinear housing 122 may be formed by one or more pieces of sheet metal folded into the rectilinear shape illustrated in FIG. 7, or into other comparable rectilinear shapes. Furthermore, in other embodiments, the rectilinear housing 122 may be comprised of multiple rectilinear housing sections that collectively form the rectilinear housing 122. Regardless of the manufacturing process used, the rectilinear housing 122 may be formed into a rectilinear shape that includes only generally rectilinear walls 126 having rectilinear transitions (e.g., generally right angle transitions between the various sections of the rectilinear walls 126).

A cross sectional view of an embodiment of the rectilinear housing 122 of the subcooler component 62 is illustrated in FIG. 8. As illustrated in FIG. 8, the cross-sectional profile of the rectilinear housing 122 includes only generally rectilinear transitions 128 between the various wall sections 130 of the rectilinear walls 126 of the rectilinear housing 122, which are substantially linear (e.g., only deviating from being linear, as measured from opposite ends, by at most less than 3 degrees, less than 2 degrees, less than 1 degree, or even less) as one of ordinary skill in the art would understand.

As used herein, the terms “generally rectilinear”, “substantially rectilinear”, and so forth, are intended to refer to physical features of the various components of the subcooler component 62 that have adjacent lines, walls, surfaces, and so forth, that are rectilinear (i.e., perpendicular) with respect to each other within manufacturing tolerances and deviations that one of ordinary skill in the art would understand. For example, the “generally rectilinear”, “substantially rectilinear”, and so forth, may be interpreted as defining adjacent lines, walls, surfaces, and so forth, that are rectilinear (i.e., perpendicular) with respect to each other whereby transitions points between the adjacent lines, walls, surfaces, and so forth, form substantially right angles such that the adjacent lines, walls, surfaces, and so forth, form angles between them that are 90 degrees+/−3 degrees, are 90 degrees+/−2 degrees, are 90 degrees+/−1 degree, are 90 degrees+/−0.5 degree, or are even closer to 90 degrees.

Returning now to FIG. 7, in certain embodiments, a plurality of rectilinear grid support assemblies 132 may be disposed within the rectilinear housing 122 and spaced lengthwise along the central longitudinal axis 124 of the rectilinear housing 122. In the illustrated embodiment, three rectilinear grid support assemblies 132 are used. However, it will be appreciated that any number of rectilinear grid support assemblies 132 may be used in the subcooler component 62. As illustrated in FIG. 7, in certain embodiments, each of the rectilinear grid support assemblies 132 may include at least three rectilinear grid support sections, for example, at least two smaller outer rectilinear grid support sections 134 (i.e., disposed within two or more outer channels 114 defined by the rectilinear housing 122 and that support the tubes 98 of the second tube bundle 84 corresponding to the two or more outer channels 114) disposed on opposite sides of one larger central rectilinear grid support section 136 (i.e., disposed within a central channel 116 defined by the rectilinear housing 122 and that supports the tubes 98 of the second tube bundle 84 corresponding to the central channel 116).

As illustrated in FIGS. 9 and 10, each of the rectilinear grid support sections 134, 136 (e.g., outer rectilinear grid support sections 134, as illustrated) include a plurality of rectilinear grid support channels 138 formed between rectilinear support members 140 of the respective rectilinear grid support section 134, 136, which are used to support (e.g., hold in place) the tubes 98 of the second tube bundle 84 of the subcooler component 62. As illustrated in FIGS. 9 and 10, the cross-sectional profiles of the rectilinear grid support sections 134, 136 include only generally rectilinear transitions 142 between the various rectilinear support members 140 of the rectilinear grid support sections 134, 136, which are substantially linear (e.g., only deviating from being linear, as measured from opposite ends, by at most less than 3 degrees, less than 2 degrees, less than 1 degree, or even less) as one of ordinary skill in the art would understand, thereby forming a rectilinear grid that supports the tubes 98 of the second tube bundle 84 of the subcooler component 62.

As discussed above with respect to the rectilinear housing 122 of the subcooler component 62, as used herein, the terms “generally rectilinear”, “substantially rectilinear”, and so forth, are intended to refer to physical features of the various components of the subcooler component 62 that have adjacent lines, walls, surfaces, and so forth, that are rectilinear (i.e., perpendicular) with respect to each other within manufacturing tolerances and deviations that one of ordinary skill in the art would understand. For example, the “generally rectilinear”, “substantially rectilinear”, and so forth, may be interpreted as defining adjacent lines, walls, surfaces, and so forth, that are rectilinear (i.e., perpendicular) with respect to each other whereby transitions points between the adjacent lines, walls, surfaces, and so forth, form substantially right angles such that the adjacent lines, walls, surfaces, and so forth, form angles between them that are 90 degrees+/−3 degrees, are 90 degrees+/−2 degrees, are 90 degrees+/−1 degree, are 90 degrees+/−0.5 degree, or are even closer to 90 degrees.

Returning now to FIG. 7, in certain embodiments, the subcooler component 62 may also include one or more rectilinear grid supports 144 disposed at axial ends 146 of the rectilinear housing 122. As illustrated in FIG. 11, the end rectilinear grid supports 144 may also include rectilinear grid support channels 148 formed between rectilinear support members 150 of the end rectilinear grid supports 144, which are used to support (e.g., hold in place) the tubes 98 of the second tube bundle 84 disposed within the subcooler component 62. In certain embodiments, the end rectilinear grid supports 144 may also be split into separate rectilinear grid support sections, similar to the rectilinear grid support sections 134, 136 of the rectilinear grid support assemblies 132. However, in other embodiments, the end rectilinear grid supports 144 and/or the rectilinear grid support assemblies 132 may be formed as single piece supports.

Similar to the rectilinear grid support sections 134, 136, the cross-sectional profiles of the end rectilinear grid supports 144 include only generally rectilinear transitions 152 between the various rectilinear support members 150 of the end rectilinear grid supports 144, which are substantially linear (e.g., only deviating from being linear, as measured from opposite ends, by at most less than 3 degrees, less than 2 degrees, less than 1 degree, or even less) as one of ordinary skill in the art would understand.

As discussed above with respect to the rectilinear housing 122 of the subcooler component 62 and the rectilinear grid support sections 134, 136, as used herein, the terms “generally rectilinear”, “substantially rectilinear”, and so forth, are intended to refer to physical features of the various components of the subcooler component 62 that have adjacent lines, walls, surfaces, and so forth, that are rectilinear (i.e., perpendicular) with respect to each other within manufacturing tolerances and deviations that one of ordinary skill in the art would understand. For example, the “generally rectilinear”, “substantially rectilinear”, and so forth, may be interpreted as defining adjacent lines, walls, surfaces, and so forth, that are rectilinear (i.e., perpendicular) with respect to each other whereby transitions points between the adjacent lines, walls, surfaces, and so forth, form substantially right angles such that the adjacent lines, walls, surfaces, and so forth, form angles between them that are 90 degrees+/−3 degrees, are 90 degrees+/−2 degrees, are 90 degrees+/−1 degree, are 90 degrees+/−0.5 degree, or are even closer to 90 degrees.

As illustrated in FIG. 12, in certain embodiments, the condenser 32 may also include a chamber sight glass 154 and a vertical liquid probe 156, which may enable monitoring of the operation of the subcooler component 62.

It is important to note that the construction and arrangement of the present application as shown in the various embodiments is illustrative only. Although only a few embodiments have been described in detail in this application, those who review this application will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described in the application. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present application. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the embodiments without departing from the scope of the present application. Accordingly, the present application is not limited to a particular embodiment, but extends to various modifications that nevertheless fall within the scope of the appended claims.

Furthermore, in an effort to provide a concise description of the embodiments, all features of an actual implementation may not have been described (i.e., those unrelated to the presently contemplated best mode of carrying out the invention, or those unrelated to enabling the claimed invention). It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

Claims

1. A condenser, comprising:

a shell having a longitudinal axis;

a first tube bundle disposed within the shell;

a subcooler component disposed within the shell beneath the first tube bundle, the subcooler component comprising: a rectilinear housing; a plurality of rectilinear grid support assemblies disposed within the rectilinear housing and spaced lengthwise along the longitudinal axis of the shell; and a second tube bundle disposed within the rectilinear housing, wherein tubes of the second tube bundle are held in place within rectilinear grid channels of the rectilinear grid support assemblies.

2. The condenser of claim 1, wherein the rectilinear housing is a single rectilinear extruded piece.

3. The condenser of claim 1, wherein the rectilinear housing is formed of sheet metal folded into a rectilinear shape.

4. The condenser of claim 1, wherein each of the plurality of rectilinear grid support assemblies comprises a plurality of rectilinear grid support sections.

5. The condenser of claim 1, wherein each of the plurality of rectilinear grid support assemblies comprises one central rectilinear grid support section and at least two side rectilinear grid support sections disposed on opposite sides of the central rectilinear grid support section.

6. The condenser of claim 5, wherein the side rectilinear grid support sections are each smaller than the central rectilinear grid support section.

7. The condenser of claim 1, wherein the subcooler component comprises one or more rectilinear grid supports disposed at axial ends of the subcooler component, wherein each of the one or more rectilinear grid supports comprises a plurality of rectilinear grid support channels configured to support the tubes of the second tube bundle.

8. A condenser subcooler component, comprising:

a rectilinear housing;

a plurality of rectilinear grid support assemblies disposed within the rectilinear housing and spaced lengthwise along a longitudinal axis of the rectilinear housing; and

a tube bundle disposed within the rectilinear housing, wherein tubes of the tube bundle are held in place within rectilinear grid channels of the rectilinear grid support assemblies.

9. The condenser subcooler component of claim 8, wherein the rectilinear housing is a single rectilinear extruded piece.

10. The condenser subcooler component of claim 8, wherein the rectilinear housing is formed of sheet metal folded into a rectilinear shape.

11. The condenser subcooler component of claim 8, wherein each of the plurality of rectilinear grid support assemblies comprises a plurality of rectilinear grid support sections.

12. The condenser subcooler component of claim 8, wherein each of the plurality of rectilinear grid support assemblies comprises one central rectilinear grid support section and at least two side rectilinear grid support sections disposed on opposite sides of the central rectilinear grid support section.

13. The condenser subcooler component of claim 8, wherein the side rectilinear grid support sections are each smaller than the central rectilinear grid support section.

14. The condenser subcooler component of claim 13, comprising one or more rectilinear grid supports disposed at axial ends of the condenser subcooler component, wherein each of the one or more rectilinear grid supports comprises a plurality of rectilinear grid support channels configured to support the tubes of the tube bundle.

15. A condenser subcooler component, comprising:

a rectilinear housing;

a plurality of rectilinear grid support assemblies disposed within the rectilinear housing and spaced lengthwise along a longitudinal axis of the rectilinear housing, wherein each of the plurality of rectilinear grid support assemblies comprises a plurality of rectilinear grid support sections; and

a tube bundle disposed within the rectilinear housing, wherein tubes of the tube bundle are held in place within rectilinear grid channels of the rectilinear grid support assemblies.

16. The condenser subcooler component of claim 15, wherein the rectilinear housing is a single rectilinear extruded piece.

17. The condenser subcooler component of claim 15, wherein the rectilinear housing is formed of sheet metal folded into a rectilinear shape.

18. The condenser subcooler component of claim 15, wherein each of the plurality of rectilinear grid support assemblies comprises one central rectilinear grid support section and at least two side rectilinear grid support sections disposed on opposite sides of the central rectilinear grid support section.

19. The condenser subcooler component of claim 15, wherein the side rectilinear grid support sections are each smaller than the central rectilinear grid support section.

20. The condenser subcooler component of claim 19, comprising one or more rectilinear grid supports disposed at axial ends of the condenser subcooler component, wherein each of the one or more rectilinear grid supports comprises a plurality of rectilinear grid support channels configured to support the tubes of the tube bundle.