Turbulence enhancer for keel cooler

Abstract

A keel cooler assembly comprising a liquid coolant tube including a plurality of turbulence enhancers for improving the heat transfer of the liquid coolant without substantially increasing pressure drop of the liquid coolant. In one embodiment, the turbulence enhancers generate turbulent wakes in the liquid coolant for disrupting laminar boundary layers for improving heat transfer. In another embodiment, the turbulence enhancers generate and propagate turbulent vortexes in the liquid coolant to enhance mixing of the bulk liquid coolant for improving heat transfer. In other embodiments, turbulators, including inserts or impediments, are provided having various configurations and being arranged in predetermined patterns for enhancing turbulence of the liquid coolant for improving keel cooler heat transfer efficiency without substantially increasing pressure drop.

Claims

1. A keel cooler assembly for use on a marine vessel, said keel cooler assembly exchanging heat with an internal liquid coolant flowing through the keel cooler assembly, said keel cooler assembly comprising: a header comprising an upper wall, an end wall, a bottom wall, opposing sidewalls, and an inclined surface operatively connecting said upper wall, said bottom wall and said opposing sidewalls; at least one liquid coolant tube extending in a longitudinal direction from said header, said at least one liquid coolant tube comprising: at least one inlet for ingress of the liquid coolant; at least one outlet for egress of the liquid coolant; an elongated body portion extending between said at least one inlet and said at least one outlet, said elongated body portion including an interior surface forming an internal channel for allowing flow of the liquid coolant in a longitudinal direction along a length of said elongated body portion, said elongated body portion being configured as a rectangular parallelepiped comprising opposing upper and lower walls, and opposing first and second sidewalls transverse to said opposing upper and lower walls, said first and second sidewalls operatively connecting said upper and lower walls for forming said internal channel, wherein said elongated body portion includes at least one open end portion being received by at least one spacing in said inclined surface of said header, said at least one open end portion having a rectangular cross-sectional configuration defining said at least one inlet; a means for enhancing the turbulence of the liquid coolant flowing through said elongated body portion of said at least one liquid coolant tube for improving heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one coolant tube lacking said means for enhancing turbulence; wherein said means for enhancing turbulence comprises a plurality of turbulence enhancers extending inwardly into said internal channel from at least one of said upper wall, said lower wall, said first side wall and said second side wall, said plurality of turbulence enhancers being arranged in a predetermined pattern; wherein said turbulence enhancers are selected from the group consisting of: inserts attached to and extending inwardly into said internal channel from at least one of said upper wall, said lower wall, said first sidewall and said second sidewall; configurations of at least one of said upper wall, said lower wall, said first sidewall and said second sidewall; and impediments to liquid coolant flowing through said at least two liquid coolant tubes; and wherein said predetermined pattern comprises a plurality of adjacent longitudinal rows of said turbulence enhancers, said plurality of adjacent longitudinal rows of said turbulence enhancers including a first longitudinal spacing (X.sub.L) between respective longitudinally adjacent turbulence enhancers located in the same longitudinal row, and a second transverse spacing (X.sub.H) between respective transversely adjacent turbulence enhancers located in adjacent longitudinal rows; wherein adjacent ones of said longitudinal rows being offset from each other.

2. The keel cooler assembly of claim 1 wherein said respective longitudinal rows of turbulence enhancers located in the same longitudinal row of turbulence enhancers are transversely offset in an alternating staggered configuration from said turbulence enhancers in each adjacent row of turbulence enhancers.

3. The keel cooler assembly of claim 2 wherein a spacing ratio () of said first longitudinal spacing (X.sub.L) to said second transverse spacing (X.sub.H) is greater than about 3.5 for generating and propagating turbulent vortexes in the coolant for enhancing coolant mixing and improving heat transfer without substantially increasing pressure drop of the coolant.

4. The keel cooler assembly of claim 2 wherein a spacing ratio () of said first longitudinal spacing (X.sub.L) to said second transverse spacing (X.sub.H) is in the range between about 1.0 and 7.0 for generating turbulent wakes in the coolant for enhancing eddying motion and improving heat transfer without substantially increasing pressure drop of the coolant.

5. A keel cooler assembly for use on a marine vessel, said keel cooler assembly exchanging heat with an internal liquid coolant flowing through the keel cooler assembly, said keel cooler assembly comprising: a header; at least one liquid coolant tube extending in a longitudinal direction from said header, said coolant tube comprising; an elongated body portion comprising an interior surface forming an internal channel for allowing flow of the liquid coolant in a longitudinal direction along a length of said elongated body portion; and a plurality of turbulators extending inwardly into said internal channel from said elongated body portion interior surface and being configured to interact with the liquid coolant for enhancing the turbulence of the liquid coolant for improving heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators, said plurality of turbulators being located in longitudinal rows with adjacent rows being offset from each other; wherein said at least one liquid coolant tube is configured as a rectangular parallelepiped, said at least one liquid coolant tube comprising opposing upper and lower walls, and opposing first and second sidewalls transverse to said opposing upper and lower walls, said first and second sidewalls operatively connecting said upper and lower walls for forming said internal channel; wherein each of said plurality of turbulators comprises an elongated body portion extending between at least one of (i) said opposing first and second sidewalls and (ii) said opposing upper and lower walls, said respective turbulator elongated body portions having opposing end portions being operatively connected to each of said respective opposing walls; wherein said respective turbulator elongated body portions are configured as at least one of: a solid cylinder having a round cross section for enhancing the turbulence of the liquid coolant for improving heat transfer without substantially increasing pressure drop above an identical at least one liquid coolant tube lacking said turbulators; a hollow cylinder having a round cross section for enhancing turbulence of the liquid coolant without substantially increasing pressure drop above an identical at least one liquid coolant tube lacking said turbulators, said hollow cylinder having round openings on said opposing end portions with an interior channel formed therebetween for allowing flow of ambient liquid through said turbulator interior channel for increasing heat transfer of the liquid coolant flowing through said liquid coolant tube and around said turbulator elongated body portion; and a solid bar having a wing-shaped cross section for directing turbulent wakes of the liquid coolant in a predetermined direction for enhancing the turbulence of the liquid coolant increasing heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators.

6. A keel cooler assembly for use on a marine vessel, said keel cooler assembly exchanging heat with an internal liquid coolant flowing through the keel cooler assembly, said keel cooler assembly comprising: a header; at least one liquid coolant tube extending in a longitudinal direction from said header, said liquid coolant tube comprising; an elongated body portion comprising an interior surface forming an internal channel for allowing flow of the liquid coolant in a longitudinal direction along a length of said elongated body portion; and a plurality of turbulators extending inwardly into said internal channel from said elongated body portion interior surface and being configured to interact with the liquid coolant for enhancing the turbulence of the liquid coolant for improving heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators; wherein said at least one liquid coolant tube is configured as a rectangular parallelepiped, said at least one liquid coolant tube comprising opposing upper and lower walls, and opposing first and second sidewalls transverse to said opposing upper and lower walls, said first and second sidewalls operatively connecting said upper and lower walls for forming said internal channel; wherein said plurality of turbulators are arranged in a predetermined pattern, said predetermined pattern comprising a plurality of adjacent longitudinal rows of said turbulators, said plurality of adjacent longitudinal rows of said turbulators including a first longitudinal spacing (X.sub.L) between respective longitudinally adjacent turbulators located in the same longitudinal row, and a second transverse spacing (X.sub.H) between respective transversely adjacent turbulators located in adjacent longitudinal rows, adjacent ones of said longitudinal rows being offset from each other.

7. The keel cooler assembly of claim 6 wherein said respective longitudinally adjacent turbulators located in the same longitudinal rows are transversely offset in an alternating staggered configuration.

8. The keel cooler assembly of claim 7 wherein a spacing ratio () of said first longitudinal spacing (X.sub.L) to said second transverse spacing (X.sub.H) is in the range between about 1.0 and 7.0 for generating turbulent wakes in the liquid coolant for enhancing eddying motion and improving heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators.

9. The keel cooler assembly of claim 7 wherein a spacing ratio () of said first longitudinal spacing (X.sub.L) to said second transverse spacing (X.sub.H) is greater than about 3.5 for generating and propagating turbulent vortexes in the liquid coolant for enhancing liquid coolant mixing and improving heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators.

10. The keel cooler assembly of claim 9 wherein each of said plurality of turbulators comprises opposing turbulator end portions and an elongated body portion extending between said opposing turbulator end portions, said respective turbulator elongated body portions extending between said opposing first and second sidewalls, said opposing turbulator end portions being operatively connected to each of said respective sidewalls, wherein: said respective turbulator elongated body portions are arranged orthogonally to each of said opposing first and second sidewalls; and wherein said respective turbulator elongated body portions are configured as at least one of the group consisting of: a solid cylinder having a round cross section for enhancing the turbulence of the liquid coolant for improving heat transfer without substantially increasing pressure drop above an identical at least one liquid coolant tube lacking said turbulators; a hollow cylinder having a round cross section, said hollow cylinder having round openings on said opposing end portions with an interior channel formed therebetween for allowing flow of ambient liquid through said turbulator interior channel for increasing heat transfer of the coolant flowing through said liquid coolant tube and for enhancing the turbulence of the turbulent walls without substantially increasing pressure drop of the liquid coolant around said turbulator elongated body portion above an identical at least one coolant tube lacking said turbulators; and a solid bar having a wing-shaped cross section for directing turbulent wakes of the liquid coolant in a predetermined direction for enhancing the turbulence of the turbulent walls increasing heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators.

11. The keel cooler assembly of claim 10 wherein said turbulator elongated body portion being configured as a solid bar having a wing-shaped cross section comprises a leading head portion, an intermediate portion having a concave surface, and a trailing tail portion to collectively form a wing-shaped turbulator; said respective wing-shaped turbulators collectively forming a plurality of turbulators, said plurality of turbulators being arranged in an alternating pattern, wherein said concave surface of respective longitudinally adjacent wing-shaped turbulators in the same longitudinal row face generally opposite directions.

12. The keel cooler assembly of claim 11 wherein said respective wing-shaped turbulators are rotatably arranged in a predetermined pattern for effecting said concave surface to generally face at least one of (i) an upstream bulk liquid coolant flow and (ii) a downstream bulk liquid coolant flow.

13. A liquid coolant tube for use in a keel cooler, said liquid coolant tube exchanging heat with an internal liquid coolant flowing through the liquid coolant tube, said liquid coolant tube extending in a longitudinal direction from a header, the header including an upper wall, an end wall, a bottom wall, opposing sidewalls, and an inclined surface operatively connecting said upper wall, bottom wall and sidewalls, said liquid coolant tube comprising: an elongated body portion comprising: an interior surface forming an internal channel for allowing flow of the liquid coolant in a longitudinal direction along a length of said elongated body portion; opposing upper and lower walls, and opposing first and second sidewalls transverse to said opposing upper and lower walls, said first and second sidewalls operatively connecting said upper and lower walls for forming said internal channel; said elongated body portion having a rectangular cross-sectional configuration; and a plurality of turbulators extending inwardly into said internal channel from said elongated body portion interior surface and being configured to interact with the liquid coolant for enhancing the turbulence of the liquid coolant without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators; wherein each of said plurality of turbulators comprises an elongated body portion extending between at least one of (i) said opposing first and second sidewalls and (ii) said opposing upper and lower walls, said respective turbulator elongated body portions having opposing end portions being operatively connected to each of said respective opposing walls; wherein said plurality of turbulators are arranged in a predetermined pattern, said predetermined pattern comprising a plurality of adjacent longitudinal rows of said turbulators, said plurality of adjacent longitudinal rows of said turbulators including a first longitudinal spacing (X.sub.L) between respective longitudinally adjacent turbulators located in the same longitudinal row, and a second transverse spacing (X.sub.H) between respective transversely adjacent turbulators located in adjacent longitudinal rows, said adjacent longitudinal rows being offset from each other.

14. The liquid coolant tube of claim 13, wherein said respective longitudinally adjacent turbulators located in the same longitudinal rows are transversely offset in an alternating staggered configuration.

15. The liquid coolant tube of claim 14, wherein said respective turbulator elongated body portions are configured as at least one of: a solid cylinder having a round cross section for enhancing the turbulence of the liquid coolant for improving heat transfer without substantially increasing pressure drop above an identical at least one liquid coolant tube lacking said turbulators; a hollow cylinder having a round cross section, said hollow cylinder having round openings on said opposing end portions with an interior channel formed therebetween for allowing flow of ambient liquid through said turbulator interior channel for increasing heat transfer of the liquid coolant flowing through said liquid coolant tube; and a solid bar having a wing-shaped cross section for directing turbulent wakes of the liquid coolant in a predetermined direction for increasing heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators.

16. The liquid coolant tube of claim 15, wherein a spacing ratio () of said first longitudinal spacing (X.sub.L) to said second transverse spacing (X.sub.H) is in the range between about 1.0 and 7.0 for generating turbulent wakes in the liquid coolant for enhancing eddying motion and improving heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators.

17. The liquid coolant tube of claim 15, wherein a spacing ratio () of said first longitudinal spacing (X.sub.L) to said second transverse spacing (X.sub.H) is greater than about 3.5 for generating and propagating turbulent vortexes in the liquid coolant for enhancing liquid coolant mixing and improving heat transfer without substantially increasing pressure drop of the liquid coolant above an identical at least one liquid coolant tube lacking said turbulators.

18. The liquid coolant tube of claim 15 wherein said turbulator elongated body portion being configured as a solid bar having a wing-shaped cross section comprises a leading head portion, an intermediate portion having a concave surface, and a trailing tail portion to collectively form a wing-shaped turbulator; said wing-shaped turbulator being arranged in an alternating pattern, wherein said concave surface of respective longitudinally adjacent turbulators in the same longitudinal row face generally opposite directions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention may take physical form in certain parts and arrangement of parts, the preferred embodiments of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:

(2) FIG. 1 is a schematic view of a keel cooler on a vessel in the water according to the prior art.

(3) FIG. 2 is a perspective view of a keel cooler, including a partially cut-away view of the header and a cut-away view of coolant tubes with a rectangular cross section according to the prior art.

(4) FIG. 3 is a cross-sectional view of a portion of a keel cooler according to the prior art, showing a header and part of the coolant tubes.

(5) FIG. 4 is a perspective view of a portion of a keel cooler according to a preferred embodiment of the invention, including a partially cut-away view of square header and a cut-away view of coolant tubes with turbulence enhancers.

(6) FIG. 5A is a perspective, cross-sectional view of a portion of a coolant tube showing a plurality of solid cylindrical turbulators arranged in a staggered pattern inside of coolant tube according to a preferred embodiment of the invention. FIG. 5B is a cross-sectional view thereof, and further including a schematic of coolant fluid flow and turbulent wake (W) region.

(7) FIG. 6 is a chart showing experimental results of heat transfer coefficient versus volumetric flow rate for various preferred embodiments of the invention that were tested and compared against the prior art.

(8) FIG. 7 is a chart showing experimental results of pressure loss versus volumetric flow rate for various preferred embodiments of the invention that were tested and compared against the prior art.

(9) FIG. 8A is a schematic cross-sectional view of a coolant tube and turbulators in a spaced pattern showing coolant flow paths, boundary layers, and turbulent wakes. FIG. 8B is a schematic cross-sectional view of a coolant tube and turbulators in a spaced pattern showing coolant flow paths, boundary layers, and turbulent vortexes.

(10) FIG. 9A is a perspective, cross-sectional view of a portion of a coolant tube showing a plurality of hollow cylindrical turbulators arranged in a staggered pattern inside of coolant tube according to a preferred embodiment of the invention. FIG. 9B is a cross-sectional view thereof, and further including a schematic of coolant fluid flow and turbulent wake (W) region.

(11) FIG. 10A is a perspective, cross-sectional view of a portion of a coolant tube showing a plurality of wing-shaped turbulators arranged in a staggered pattern inside of coolant tube according to a preferred embodiment of the invention. FIG. 10B is a cross-sectional view thereof, and further including a schematic of coolant fluid flow and turbulent wake (W) region.

(12) FIG. 11 is a perspective view of a portion of a keel cooler according to a preferred embodiment of the invention, including a partially cut-away view of beveled header and a cut-away view of coolant tubes with turbulence enhancers.

(13) FIG. 12 is a perspective view of a portion of a keel cooler according to a preferred embodiment of the invention, including a partially cut-away view of square header with an angled wall, and a cut-away view of coolant tubes with turbulence enhancers.

(14) FIG. 13 is a perspective view of a portion of a keel cooler according to a preferred embodiment of the invention, including a partially cut-away view of square header with a fluid flow diverter, and a cut-away view of coolant tubes with turbulence enhancers.

(15) FIG. 14 is a perspective view of a portion of a keel cooler according to a preferred embodiment of the invention, including a partially cut-away view of square header with arrow-shaped orifice, and a cut-away view of coolant tubes with turbulence enhancers.

(16) FIG. 15 is a perspective view of a two-pass keel cooler according to a preferred embodiment of the invention, including a cut-away view of coolant tubes with turbulence enhancers.

(17) FIG. 16 is a perspective view of a multiple-systems-combined keel cooler having two single-pass portions according to a preferred embodiment of the invention, including a cut-away view of coolant tubes with turbulence enhancers.

(18) FIG. 17 is a perspective view of a keel cooler having a single-pass portion and a double-pass portion according to a preferred embodiment of the invention, including a cut-away view of coolant tubes with turbulence enhancers.

(19) FIG. 18 is a perspective view of a keel cooler having two double-pass portions according to a preferred embodiment of the invention, including a cut-away view of coolant tubes with turbulence enhancers.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(20) The fundamental components of a keel cooler system for a water-going or marine vessel are shown in FIG. 1. The system includes a heat source 1, a keel cooler 3, a pipe 5 for conveying the hot coolant from heat source 1 to keel cooler 3, and a pipe 7 for conveying cooled coolant from keel cooler 3 to heat source 1. As shown in FIG. 1, keel cooler 3 is located in the ambient water below the water line (i.e. below the aerated water line where foam and bubbles occur), and heat from the hot coolant is transferred through the walls of keel cooler 3 and expelled into the cooler ambient water. Heat source 1 could be an engine, a generator, or other heat source for the vessel. Keel cooler 3 could be a one-piece keel cooler, however, the present invention is not limited to one-piece keel cooler systems and may include demountable keel cooler systems having detachable parts (such as spiral coolant tubes), or even channel steel heat exchanger systems that are welded to the hull to form an enclosed channel in which the coolant is ported through the hull and flows through the channel.

(21) In the discussion above and to follow, the terms upper, inner, downward, end, etc. refer to the keel cooler, coolant tubes, or header as viewed in a horizontal position as shown in FIG. 2. This is done realizing that these units, such as when used on water going vessels, can be mounted on the side of the vessel, or inclined on the fore or aft end of the hull, or spaced from the hull, or mounted in various other positions.

(22) Turning to FIG. 2, a keel cooler 10 according to the prior art is shown. Keel cooler 10 includes a pair of headers 30 at opposite ends of a set of parallel, rectangular coolant tubes 50 (also known as heat conduction or coolant flow tubes). Coolant tubes 50 include interior or inner coolant tubes 51 and exterior or outer coolant tubes 60. As shown in FIG. 2, headers 30 may have a generally prismatic construction, including an upper wall or roof 34, an end wall or back wall 36, and a bottom wall or floor 32. Header end walls 36 are perpendicular to the parallel planes in which the upper and lower surfaces of coolant tubes 50 are located. In some keel coolers, end wall 36 and floor 32 are formed at right angles, as shown in FIG. 2. However, as discussed below, other configurations of header are possible.

(23) Keel cooler 10 is connected to the hull of a vessel through which a pair of nozzles 20 extend. Nozzles 20 have nipples 21 at the ends and cylindrical connectors 22 with threads 23. Nozzles 20 discharge coolant into and out of keel cooler 10. Large gaskets 26 each have one side against headers 30 respectively, and the other side engages the hull of the vessel. Rubber washers 25B are disposed on the inside of the hull when keel cooler 10 is installed on a vessel, and metal washers 25A sit on rubber washers 25B. Nuts 24 which typically are made from metal compatible with the nozzle 20, screw down on sets of threads 23 on connectors 22 to tighten the gaskets 26 and rubber washers 25B against the hull to hold keel cooler 10 in place and seal the hull penetrations from leaks. The gaskets 26 are provided for three essential purposes. First, they insulate the header to prevent galvanic corrosion. Second, they eliminate infiltration of ambient water into the vessel. Third, they permit heat transfer in the space between the keel cooler tubes and the vessel by creating a distance of separation between the keel cooler and the vessel hull, allowing ambient water to flow through that space. Gaskets 26 are generally made from a polymeric substance. In typical situations, gaskets 26 are between one-quarter inch and three-quarter inches thick.

(24) The plumbing from the vessel is attached by means of hoses to nipple 21 and connector 22. A cofferdam or sea chest (part of the vessel) at each end (not shown) contains both the portions of the nozzle 20 and nut 24 directly inside the hull. Sea chests are provided to prevent the flow of ambient water into the vessel should the keel cooler be severely damaged or torn away, where ambient water would otherwise flow with little restriction into the vessel at the penetration location. The keel cooler described above shows nozzles for transferring heat transfer fluid into or out of the keel cooler. However, there are other means for transferring fluid into or out of the keel cooler. For example, in flange mounted keel coolers, there are one or more conduits such as pipes extending from the hull and from the keel cooler having end flanges for connection together to establish a heat transfer fluid flow path. Normally, a gasket is interposed between the flanges. There may be other means for connecting the keel cooler to the coolant plumbing system in the vessel. This invention is independent of the type of connection used to join the keel cooler to the coolant plumbing system.

(25) Turning to FIG. 3, which shows a portion of keel cooler 10 in cross section, nozzle 20 is shown connected to header 30. Nozzle 20 has nipple 21, and connector 22 has threads, as described above. Nipple 21 of nozzle 20 is normally brazed or welded inside of connector 22 which extends inside the hull. A flange 28 surrounds an inside orifice 27 through which nozzle 20 extends and is provided for helping support nozzle 20 in a perpendicular position on header 30. Flange 28 engages a reinforcement plate 29 on the underside of upper wall 34. In this manner, nozzle 20 can either be an inlet conduit for receiving hot coolant from the engine whose flow is indicated by the arrow C in FIG. 3, but also could be an outlet conduit for receiving cooled coolant from header 30 for circulation back to the heat source.

(26) Referring to FIGS. 2-3, header 30 further includes an inclined surface or wall 41 composed of a series of fingers 42, which are inclined with respect to coolant tubes 50, and define spaces to receive end portions or cooling ports 44 of inner coolant tubes 51. End portions or ports 44 of inner coolant tubes 51 extend through inclined surface 41 and are brazed or welded to fingers 42 to form a continuous surface. Each exterior sidewall of header 30 is comprised of an outer rectangular coolant tube 60 that extends into header 30. FIGS. 2-3 show both sides of outer coolant tube 60, including an outermost sidewall 61, and an interior sidewall 63. A circular orifice 31 is shown extending through interior sidewall 63 of outer coolant tube 60, and is provided for carrying coolant flowing through outer coolant tube 60 into or out of header 30. Header 30 may also have a drainage orifice 33 for receiving a correspondingly threaded and removable plug for emptying the contents of keel cooler 10.

(27) Because keel coolers are sometimes used in corrosive salt-water environments, keel coolers are typically made from 90-10 copper-nickel alloy, or some other material having a large amount of copper. This makes the keel cooler a relatively expensive article to manufacture and an object of the present invention to reduce the size of keel cooler would be advantageous for reducing overall material and manufacturing costs.

(28) Turning to FIG. 4, a preferred embodiment of the present invention is shown. The embodiment includes a keel cooler 100 having at least one coolant tube 150 extending in a longitudinal direction from a header 130. Header 130 may be the same header 30 as described earlier according to the prior art, and includes an upper wall 134, an end wall 136, and a bottom wall 132. A nozzle 120 having a nipple 121 and a connector 122 with threads 123, may be the same as those described earlier and are attached to header 130. A gasket 126, similar to and for the same purpose as gasket 26, is disposed on top of upper wall 134. A drainage orifice 133 may also be provided for emptying the contents of keel cooler 100.

(29) Also as shown in the embodiment of FIG. 4, keel cooler 100 includes coolant tubes 150 (also known as coolant flow or heat transfer fluid flow tubes, since in some instances the fluid may be heated instead of cooled). Coolant tubes 150 include interior or inner coolant tubes 151 and exterior or outer coolant tubes 160. Coolant tubes 150 may have a generally rectangular parallelepiped construction, including an elongated body portion between opposing end portions, each portion of which comprises a top wall, a bottom wall, and opposing sidewalls. Coolant tube 150 includes an interior surface 158 forming an internal channel through which the coolant flows. As shown in FIG. 4, inner coolant tubes 151 join header 130 through an inclined surface (not shown), which is composed of fingers 142 inclined with respect to inner coolant tubes 151 and which define spaces to receive open end portions or ports (i.e., inlets/outlets) 144 of inner coolant tubes 151. Open end portions 144 of inner coolant tubes 151 are shown as having a rectangular cross section and are angled to correspond with the angle of inclined surface and/or fingers 142. Outer coolant tubes 160 have outermost sidewalls 161, part of which are also the sidewalls of header 130. Outer coolant tubes 160 also have an interior sidewall 163 with an orifice 131, which is provided as a coolant flow port (i.e., inlet/outlet) for coolant flowing between the chamber of header 130 and outer coolant tubes 160. A header chamber is defined by upper wall 134, end wall 136, bottom wall 132, interior sidewalls 163, and any of inclined surface (not shown), fingers 142 and/or inner coolant tube end portions 144.

(30) Also as shown in FIG. 4, coolant tubes 150 comprise a turbulence enhancer 170 or plurality of turbulence enhancers 170 arranged inside of coolant tubes 150 (including inner coolant tubes 151 and/or outer coolant tubes 160). As defined herein, a turbulence enhancer is a device or plurality of devices arranged inside of a coolant tube that provides a means for promoting or enhancing turbulence of the coolant flowing through a coolant tube for improving heat transfer without substantially increasing the pressure drop of the coolant to a level that detracts from the overall usefulness of the keel cooler.

(31) Turbulence enhancers are an important aspect of the present invention and provide a number of important advantages to the keel cooler. As mentioned previously, whether fluid flow will result in turbulent flow is primarily determined by the Reynolds number, which is in part dependent on the velocity of the cooling fluid. In general, at a given fluid viscosity, a fluid flowing at a low velocity will provide laminar flow, and as the velocity of the fluid is increased, the fluid can become more turbulent. In a laminar flow regime, the coolant in contact with surfaces will have its velocity reduced by viscous drag, which forms an insulating boundary layer that can reduce heat transfer. However, as the fluid becomes more turbulent, the static and insulative boundary layer becomes unstable due to the fluid inertial forces overpowering the fluid viscous forces. This can cause the fluid to form turbulent eddies where the boundary layer breaks away from the wall, therefore disrupting or destroying the thermally insulative layer to improve heat transfer. Enhancing turbulence at a given fluid velocity or flow rate in order to disrupt, thin-down, or destroy the boundary layer is one way in which an embodiment of the present invention improves heat transfer.

(32) Turbulence enhancers according to an embodiment of the present invention can achieve the foregoing means through the provision of inserts or impediments extending inwardly from a coolant tube interior surface into the coolant. As described herein, inserts may include separate parts and impediments may be integral with a coolant tube. A tremendous variety of inserts for turbulence enhancer are available. Among the factors regarding the inserts are the shape of the inserts, the placement of the inserts within the keel cooler tube, the pattern of inserts along the keel cooler tube, and the size of the respective inserts. An aspect of turbulence enhancers according to the invention is the provision of inserts having various configurations, such as cylindrical inserts with round, ellipsoid, or oval cross sections; hollow inserts, such as inserts with interior channels; inserts in the shape of a rectangular parallelepiped, such as with square or rectangular cross sections; pyramidal inserts, such as with triangular cross sections; flat bars; bars having a wing-shaped configuration; inserts with polygonal configurations; combinations of different configurations; or any variety of inserts having irregular cross sections. Inserts could be attached to the keel cooler walls in a number of ways depending in part on the nature of the insert and the type of wall involved. The inserts could be welded to the walls, the walls themselves could have a configuration which could convert part of them into impediments to cause heat transfer, having the inserts extend across the walls, and protrude through the walls where they could be welded or brazed in place so as to prevent any coolant leakage, and the like. The inserts could even extend in the longitudinal direction of the respective coolant tubes with appropriate supports.

(33) Another aspect of turbulence enhancers is the provision of impediments to coolant flowing through the keel cooler tubes. Such impediments could be, amongst others, pins of various configurations, impediments sloped as chevrons, vane configurations having tear drop-shaped cross sections, impediments with or without orifices, impediments having undulating shapes, impediments having star-shaped cross sections, and the like. It should be understood that there are many factors which determine the best type of insert or impediment to increase heat transfer while not substantially increasing the pressure drop to a level that detracts from the overall performance and usefulness of the keel cooler. Some of these factors are the size and shape of the keel cooler tubes, the viscosity of the coolant, the temperature differential between the coolant and ambient water, and the like. In addition, the foregoing inserts or impediments could face in different directions inside the keel cooler tube, depending on the nature of the coolant, the shape and size of the keel cooler tube, the pressure of the coolant, amongst other factors. In preferred embodiments, inserts or impediments could be disposed in the bulk coolant for effecting turbulence enhancement.

(34) An object of the present invention is that turbulence enhancers do not cause a substantial increase in pressure drop of the coolant to a level that detracts from the overall usefulness of the keel cooler. An acceptable pressure drop level may, of course, depend on the design considerations and pumping capacity of the particular marine engine or heat source to which keel cooler is plumbed. However, for many marine applications, a substantial increase in pressure drop may be defined as no greater than about a 10-percent increase over the pressure drop of a standard, or baseline, coolant tube configuration that lacks turbulence enhancers, such as those prior art coolant tubes having a generally rectangular cross section as shown in FIGS. 2-3. Preferably, the increase in pressure drop will be no greater than about 7-percent more than the baseline or standard tube configuration, and more preferably there will be no increase in pressure drop, and even more preferably there will be a reduction in pressure drop when incorporating turbulence enhancers according to the present invention.

(35) Another aspect of turbulence enhancers according to an embodiment of the invention includes the arrangement of turbulence enhancers inside of the coolant tube, which includes the spacing between respective turbulence enhancers and the pattern and placement of turbulence enhancers within the coolant tube. Such patterns could be, amongst others, symmetrical or asymmetrical; parallelogram patterns, such as rectangular, square or diamond; triangular patterns; polygonal patterns; spiral, undulating and/or sinuous patterns; irregular or random patterns; and the like.

(36) According to an embodiment of the invention, the arrangement of turbulence enhancers can affect the flow characteristics and pressure drop of the coolant in a manner that can be explained by the well-known Moody diagram (which is incorporated herein by reference in its entirety). According to the Moody diagram, for a given relative roughness factor of the surfaces over which the coolant flows, the friction factor will decrease as the Reynolds number increases (increasing turbulence), up to a limit defined by wholly turbulent flow. The friction factor can be defined as a resistance to flow, such that a reduction in friction factor will generally result in minimizing or reducing substantial pressure drop. Thus, turbulence enhancers according to a preferred embodiment of the invention provides a means for enhancing turbulence in order to minimize or reduce friction factor (and pressure drop). More particularly, one manner in which turbulence enhancers can achieve these means is through the arrangement of a plurality of turbulence enhancers in a narrow configuration for effecting a constriction of coolant flow in the areas between adjacently arranged turbulence enhancers. Constricting the coolant flow in this manner causes the coolant velocity to reach a maximum where there is a minimum cross-sectional spacing between adjacent turbulence enhancers, particularly where coolant flow is normal to the spacing between transversely adjacent turbulence enhancers. The increased velocity increases the Reynolds number of the coolant flowing between turbulence enhancers, and according to the Moody diagram, this reduces the friction factor to minimize or reduce the amount of pressure drop. However, turbulence enhancers should not be so narrowly arranged as to restrict coolant flow and increase pressure drop.

(37) Turbulence enhancer structures and/or the arrangement of turbulence enhancers according to an embodiment of the invention can also minimize or reduce substantial pressure drop of the coolant by providing a means for enhancing turbulence through generating turbulent wakes in the coolant, which can also improve heat transfer. Turbulence enhancers can provide a means for generating these turbulent wakes through the provisions of inserts and/or impediments, as described above. In a preferred embodiment, turbulence enhancers extend from the coolant tube interior wall(s) into the bulk coolant to effect the development of turbulent wakes in the bulk coolant flow. When the coolant flows around a turbulence enhancer, the fluid flow is distorted and a boundary layer may be formed on the turbulence enhancer body in the same way as the boundary layer is formed at the coolant tube interior wall. As the coolant approaches the vertical boundaries of the turbulence enhancer body, fluid separation can develop leading to highly distorted fluid chunks, which may begin to rotate if they travel far enough downstream. At increased velocities (higher Reynolds numbers), the inertia of the fluid particles passing over a turbulence enhancer body can overcome the fluid viscosity, and the highly distorted fluid particles can separate to form a turbulent wake region extending downstream from the turbulence enhancer body. The turbulent wake region thus formed can interact with boundary layers that have developed on downstream turbulence enhancer bodies and coolant tube walls. Since the boundary layers can be a source of high resistance due to frictional shear, the enhanced eddying motion and increased Reynolds number of the turbulent wake region that acts to disrupt, thin-down, or destroy the boundary layers on downstream surfaces can lead to a reduced friction factor according to the Moody diagram, as described above. Moreover, disruption of the boundary layer in this manner destroys the thermal insulation, which increases heat transfer.

(38) If coolant flow in the turbulent wake region becomes highly unsteady, large eddies or vortexes can be shed downstream from the turbulence enhancer body. This may require sufficient spacing in the arrangement between respective turbulence enhancers to allow turbulent vortexes to develop. Development of turbulent vortexes in the coolant can also increase Reynolds number and thus reduce friction factor on coolant tube walls and downstream turbulence enhancers, as described above. Therefore, yet another aspect of the turbulence enhancer structure and/or the arrangement of turbulence enhancers according to an embodiment of the present invention is to provide a means for enhancing turbulence by generating turbulent vortexes in the coolant for improving heat transfer without substantially increasing the pressure drop of the coolant. As used herein, the term vortex is defined as a region within a fluid where the flow is mostly a spinning or swirling motion about an imaginary axis, straight or curved. Therefore, the characteristic swirling motion of a turbulent vortex formed by turbulence enhancers can provide an effective means for mixing the bulk coolant and increasing eddying motion. Since, eddies can transport large quantities of thermal energy as they are mixed with the fluid, increasing eddying motion through turbulent vortex mixing can increase heat transfer by disrupting the boundary layer insulation and by taking large amounts of cooler fluid from the coolant tube wall region and distributing it into the hot bulk fluid regions.

(39) It should be understood that aspects of turbulence enhancers according to preferred embodiments of the invention could provide benefits even where the coolant tube interior walls are smooth between respective turbulence enhancers. The smoothness of the coolant tube interior surface can be defined according to the relative roughness factor of the Moody diagram, such that a smooth tube according to an embodiment of the invention has a relative roughness factor between 9.7410.sup.5 and 1.97810.sup.4, and more preferably between 9.710.sup.5 and 1.210.sup.4. In certain embodiments, it may be preferable to have smooth coolant tube interior walls, since an increase in the relative roughness factor can restrict flow and increase friction factor (according to the Moody diagram), which could substantially increase pressure drop. It is believed that known prior art keel coolers having a plurality of roughness elements in the form of small protrusions or bumps on the coolant tube interior walls demonstrates this adverse phenomena, as it is known to suffer from substantial pressure drop.

(40) It should also be understood that aspects of turbulence enhancers according to preferred embodiments of the invention can provide improvements regardless of whether the bulk coolant flow is laminar or turbulent. In other words, regardless of whether the flow rate is low and provides laminar flow, or whether the flow rate is increased to promote more turbulence, turbulence enhancers according to preferred embodiments of the invention can still improve heat transfer without a substantial increase in pressure drop. For example, where the bulk coolant flow is generally laminar, the insulative boundary layer at the coolant tube interior wall may be thicker (compared to when flow is more turbulent), however, turbulence enhancers according to preferred embodiments can still effectively cool the hot bulk fluid by providing a means for enhancing naturally occurring eddying motions through the generation of turbulent wakes and/or turbulent vortexes that effectively mix the coolant. Even as the coolant velocity increases to become more turbulent, turbulence enhancers that generate turbulent wakes and/or turbulent vortexes still enhance eddying motion and improve heat transfer. Therefore, it should be understood that an object of turbulence enhancers is to increase heat transfer independently of coolant velocity or flow rate.

(41) It should also be understood that the corresponding structures, materials, acts, and equivalents of all means plus function elements of turbulence enhancers in the claims below are intended to include any structure, material, or acts for performing the functions in combination with other claimed elements as specifically claimed. Thus, for example, although turbulence enhancers have been described through the provision of inserts or impediments, and through other aspects such as spacing and patterns, other structures and arrangements may be provided. Accordingly, any specific embodiments pertaining to the structure or arrangement of turbulence enhancers through the provision of turbulators, including previously described inserts and impediments, should be understood to be non-limiting embodiments of the present invention.

(42) Turning now to FIGS. 5A-5B, a coolant tube 150 comprising turbulators 175 according to a preferred embodiment of the invention is shown. Turbulators may be inserts or impediments, as described above, which are arranged inside of coolant tube. As described herein, a turbulator according to an embodiment of the present invention can be a device or plurality of devices arranged inside of a coolant tube that promotes or enhances turbulence of the coolant flowing through coolant tube for enhancing heat transfer without substantially increasing the pressure drop of the coolant to a level that detracts from the overall usefulness of the keel cooler. The turbulator configurations and/or the arrangement of turbulators according to an embodiment of the invention can also enhance turbulence by generating turbulent wakes and/or turbulent vortexes for improving heat transfer without substantially increasing pressure drop, as those attributes were also described above and are further described below.

(43) FIGS. 5A-5B show an embodiment of coolant tube 150 having a rectangular parallelepiped construction, including an elongated body portion having an exterior surface 157 and an interior surface 158 between opposing coolant tube end portions (not shown). Coolant tube interior surface 158 forms an internal channel through which coolant flows. Coolant tube 150 is shown as having opposing sidewalls 152, a top wall 155, and a bottom wall 152 that opposes top wall 153. In a preferred embodiment, coolant tube 150 has a rectangular cross section for allowing a set of parallel coolant tubes 150 to be spaced relatively close to each other for increasing the effective heat transfer area of the keel cooler. Coolant tube 150 may include inner coolant tube and outer coolant tube (not shown), which may have the same general features of inner coolant tube 151 and outer coolant tube 160, respectively described above.

(44) As shown in the embodiment of FIGS. 5A-5B, coolant tube 150 comprises a plurality of turbulators 175. As shown, turbulators 175 can have an elongated body portion that extends from coolant tube interior surface 158 into the bulk coolant flow path. In a preferred embodiment, turbulators 175 extend between opposing sidewalls 152, however, turbulators 175 could also extend between opposing top wall 155 and bottom wall 153, or could even extend between sidewall 152 and either top wall 155 or bottom wall 153, or in some instances may only extend part-way across the interior. As shown in the embodiment of FIG. 5A, the elongated body portion of respective turbulators 175 is substantially parallel to bottom wall 153 and top wall 155. Turbulators 175 may have an elongated body portion or bar portion with a longitudinal axis that is perpendicular or normal to the direction of bulk coolant flow (C). Turbulators 175 may be perpendicular or orthogonal to opposing sidewalls 152, but could also be perpendicular to opposing top wall 155 and bottom wall 153. However, in other embodiments, turbulators 175 may be angled into or away from the direction of coolant flow, or may be oriented in varying directions.

(45) In the embodiment shown in FIGS. 5A-5B, turbulators 175 are configured as solid cylinders having round cross sections. However, other cross-sectional configurations could include: round, ellipsoid, oval, rectangular, square, triangular, wing-shaped, airfoil-shaped, polygonal, irregular, and the like. Turbulators 175 are arranged in a predetermined pattern, which may be an offset or staggered turbulator pattern 177 as shown in FIGS. 5A-5B, but could also have turbulators 175 aligned in straight rows, or could be in any type of symmetrical or asymmetrical pattern. As shown in FIG. 5B, staggered turbulator pattern 177 includes a plurality of longitudinal rows (e.g., R1, R2) in the direction of coolant flow (C). Within each row, respective longitudinally adjacent turbulators 175 are spaced by a distance (X.sub.L); and between adjacent rows, transversely adjacent turbulators 175 are spaced by a distance (X.sub.H). In staggered turbulator pattern 177 of FIG. 5B, respective longitudinally adjacent turbulators in the same row are transversely offset in an alternating staggered manner. According to an object of the present invention, an equation was developed for defining a turbulator pattern spacing ratio (), the equation defined as X.sub.L=*X.sub.H. In preferred embodiments of the invention, respectively adjacent turbulators 175 may be spaced evenly with a spacing ratio of =1, or the spacing may be uneven with a spacing ratio where 1<<1.

(46) A series of experiments were conducted to evaluate the effect of turbulator 175 according to several embodiments of the present invention. The experimental apparatus comprised a 32 inch long segment of a keel cooler coolant tube disposed inside of a chamber that flowed external cooling water over the exterior surface of the coolant tube segment. The coolant tube flowed internal coolant (the coolant being water) through its interior channel. Although keel cooler coolants typically comprise a glycol mixture, the viscosity and characteristics of water were sufficiently similar for the purposes of experimental comparison. Thermocouples were placed throughout the apparatus to measure the coolant tube shell (exterior wall) temperature, the coolant inlet temperature and coolant outlet temperature. Based on the thermocouple readings, the logarithmic mean temperature difference (LMTD) was calculated. Based on the calculated LMTD, measured flow rate and fluid specific heat, the overall heat transfer coefficient was calculated for various internal and external flow rates. Pressure transducers located at the inlet and outlet ports measured pressure drop of the coolant across the coolant tube segment. In each experiment, the coolant tube material and dimensions remained constant. The test was conducted over a range of flow rates with a coolant inlet temperature of 98 F. and an ambient shell temperature of 75 F. The coolant tube segment in each series of experiments was substantially the same, having a rectangular cross section measuring 0.375 inches wide by 2.375 inches in height. The coolant tube segment was made of a 90-10 copper-nickel alloy and had a wall thickness of about 0.062 inches. The surface roughness or relative roughness factor of the coolant tube interior walls was substantially equivalent for each setup, and ranged from about 63 to 125 micro-inches.

(47) Three configurations were tested in the experimental apparatus. The first configuration was a coolant tube lacking turbulators, which represented the baseline condition (hereinafter, the baseline configuration). The second configuration comprised turbulators 175 according to the embodiment depicted in FIGS. 5A-5B and having staggered turbulator pattern 177 with an even spacing ratio (=1) (hereinafter, the narrow turbulator configuration). The third configuration also comprised turbulators 175 arranged in a staggered turbulator pattern 177 according to the embodiment depicted in FIGS. 5A-5B, which maintained the same transverse spacing (X.sub.H) as the second configuration, but widened the longitudinal spacing (X.sub.L) compared to the second configuration, such that =4 (hereinafter, the wide turbulator configuration). For the second and third configurations, turbulators were inserted into the coolant tube segment by drilling holes through coolant tube sidewalls, inserting turbulators into the holes and brazing turbulators in place. For these experiments, turbulators had a solid round cross section and were about 0.100 inches in diameter; and turbulator pattern had a transverse spacing (X.sub.H) of about 0.765 inches between respectively adjacent turbulators.

(48) The effect of turbulators and turbulator pattern spacing ratio () on heat transfer coefficient versus flow rate is shown in the graph of FIG. 6. Each series of results in FIG. 6 represents the average of three experiments. The results indicate that turbulators according to embodiments of the present invention improve heat transfer coefficient over the baseline configuration over the entire range of flow rates tested. In particular, the narrow turbulator configuration (=1) had a 4-percent increase in heat transfer coefficient over the baseline configuration, and the wide turbulator configuration (=4) had a 10-percent increase in heat transfer coefficient over the baseline configuration. It is believed based on these experiments that other configurations may yield larger increases in heat transfer.

(49) The effect of turbulators and turbulator pattern spacing ratio () on pressure drop versus flow rate is shown in the graph of FIG. 7. The results of FIG. 7 represent the average of the same three experiments for each series shown in FIG. 6. The results indicate that turbulators according to embodiments of the present invention do not increase pressure drop over the baseline configuration. In particular, the wide turbulator configuration (=4) had an equivalent pressure drop to the baseline configuration, and the narrow turbulator configuration (=1) demonstrated an unexpected reduction in pressure drop compared to the baseline condition. These results were so surprising that the instrumentation, including pressure transducers, were recalibrated twice. Although not shown in FIGS. 6-7, the testing was also conducted at inlet temperatures of 118 F. and 130 F. for all three configurations and the results showed the same trends.

(50) It is believed that the narrow turbulator configuration (=1) yields larger Reynolds numbers (increased turbulence) because of the closer spacing of respective turbulators constricting the fluid to effect an increase in fluid velocity, as previously explained. The spacing in this configuration is not so narrow as to restrict fluid flow and cause a substantial increase in the resistance to flow or pressure drop. As shown in the schematic of FIG. 8A, the reason for the lower pressure drop according to this narrow configuration is believed to be best explained by the turbulent wake region (W) that develops behind upstream turbulators (e.g., C1), and which then interacts with the boundary layer (B) of downstream turbulators (e.g., C3). As previously explained, increasing the eddying motion through turbulent wakes can disrupt downstream boundary layers which are a source of frictional shear, therefore, increasing turbulence results in a reduction of friction factor (according to the Moody diagram) and minimizes pressure drop. On the other hand, as shown in the schematic of FIG. 8B, the wider turbulator configuration (=4) is believed to have enough longitudinal spacing (X.sub.L) between respective turbulators to allow the turbulent wakes (W) that are generated from upstream turbulators (C1) to shed away and form a vortex or vortexes (V), which enhances the mixing action of the fluid and further improves heat transfer. The turbulent wakes (W) and/or vortex (V) are also believed to enhance turbulence and act to disrupt the boundary layer (B) on downstream turbulators (C3) in a similar manner that that does not substantially increase pressure drop.

(51) In order to visually verify the development of turbulent wakes (W) and/or turbulent vortexes (V) according to the above experimental results, a replica of the coolant tube segment and turbulator configuration could be made with a clear material, such as polycarbonate. Each of the same turbulator configurations could be tested, whereby coolant (e.g., water) could be flowed at the same flow rates and a dye could be injected into the flow stream for visual identification of the flow characteristics. Where the fluid would display rapid fluctuations in the dyed flow stream in an extended wake region downstream from the turbulator body, a turbulent wake region would be considered developed. Where the dyed fluid would display a swirling vortex motion, a turbulent vortex would be considered developed. Such testing is easy to conduct and is commonly utilized for characterizing fluid flow. These tests could even precede the above-mentioned heat transfer experiments as an adequate screening tool.

(52) In certain preferred and non-limiting embodiments of the invention, turbulators may be arranged in a staggered turbulator pattern wherein the spacing ratio () is preferably in the range between about 0.75 to 9, and more preferably in the range between about 1 to 7. In some preferred embodiments, it may be beneficial to improve heat transfer as much as possible without a substantial increase in pressure drop, which may correspond to a wide turbulator configuration wherein the spacing ratio () is preferably greater than about 3.5, and more preferably in the range between about 3.5 and 9. In still other preferred embodiments, it may be beneficial to minimize or reduce the pressure drop according to a narrow turbulator configuration wherein the spacing ratio () is preferably in the range between about 0.75 to 3.5, and more preferably in the range between about 1 to 3. As shown in the embodiment of FIGS. 5A-5B, turbulator 175 may be a solid cylinder or bar that extends between coolant tube sidewalls 152, wherein turbulator 175 is configured with a round cross section having a diameter between 0.030 inches and 0.250 inches, and more preferably between 0.075 inches to 0.125 inches, and even more preferably 0.090 inches to 0.110 inches. In certain preferred embodiments, coolant tube may have a rectangular cross section with typical cross-sectional dimensions of 1.375 in.0.218 in., 1.562 in.0.375 in., or 2.375 in.0.375 in. for increasing the effective area of the keel cooler.

(53) It should be understood that turbulators according to preferred embodiments of the present invention may have different geometric configurations and/or different turbulator patterns within a coolant tube for enhancing turbulence to improve heat transfer without substantially increasing pressure drop. In another preferred embodiment of the invention, shown in FIGS. 9A-9B, turbulator 181 comprises an elongated body portion or bar portion configured as a hollow cylindrical tube having a round cross section. Turbulator 181 further comprises round-shaped openings on opposing end portions that form a turbulator interior channel 182 therebetween. The purpose of turbulator interior channel 182 is to allow ambient external water (A) to flow through turbulator interior channel 182 in order to decrease turbulator 181 wall temperature and promote heat transfer with the internal coolant (C). As with the embodiment of FIGS. 5A-5B, coolant tube 150 of FIGS. 9A-9B may have a rectangular parallelepiped construction, including an elongated body portion having an exterior surface 157 and an interior surface 158 between end portions (not shown) that forms an internal channel through which coolant flows. Coolant tube 150 in FIGS. 9A-9B includes a plurality of turbulators 181 that extend from coolant tube interior surface 158 into the bulk coolant flow, and which can be arranged in similar manners to turbulators described above. Turbulators 181 may extend between opposing sidewalls 152, however, turbulators 181 could also extend between opposing top wall 155 and bottom wall 153. As shown, the elongated body portion of turbulators 181 may be substantially parallel to bottom wall 153 and top wall 155. Turbulators 181 may have an elongated body portion with a longitudinal axis that is perpendicular or orthogonal to opposing sidewalls 152, which may also be normal to the direction of bulk coolant flow (C) as shown. In the embodiment of FIGS. 9A-9B, turbulators 181 are arranged in a predetermined staggered pattern 183, which can be the same as the foregoing staggered pattern 177, including a longitudinal spacing (X.sub.L) between longitudinally adjacent turbulators 181, and a transverse spacing (X.sub.H) between transversely adjacent turbulators 181. Turbulators 181 according to certain embodiments may be arranged with the same preferred ranges of turbulator spacing ratio () and may have the same preferred ranges of turbulator diameter as defined with respect to the embodiment of FIGS. 5A-5B. In order to maximize the effect of heat transfer through turbulator 181 and into the ambient water flowing through turbulator interior channel 182, turbulator 181 may preferably have a wall thickness between about 0.035 inches and 0.125 inches, or more preferably between about 0.040 inches and 0.080 inches.

(54) Turning to FIGS. 10A-10B, another embodiment of a turbulator 191 is shown being arranged in a predetermined pattern as a plurality of turbulators 191 inside of coolant tube 150. Coolant tube 150 may be the same as previously described coolant tubes, including elongated body portion having interior surface 158, exterior surface 157, top wall 155, bottom wall 153, and opposing sidewalls 152. As shown, turbulator 191 includes an elongated body portion 195 configured as a bar that extends from coolant tube interior surface 158 into the bulk coolant flow (C), and which can be arranged in similar manners to turbulators described above. As shown in the cross-sectional view of FIG. 10B, turbulator 191 includes a leading head portion 196, an intermediate portion 197 having a concave surface, and a trailing tail portion 198. The purpose of wing-shaped turbulator 191 is to direct the flow of turbulent wakes (W) and/or turbulent vortexes toward downstream turbulators 191 or coolant tube interior surfaces 158 in order to disrupt the boundary layer in those regions to further improve heat transfer and minimize or reduce substantial pressure drop. As shown in the embodiment of FIGS. 10A-10B, turbulators 191 are arranged in a predetermined staggered pattern 193, which can be similar to the foregoing staggered patterns, including a longitudinal spacing (X.sub.L) between longitudinally adjacent turbulators 191, and a transverse spacing (X.sub.H) between transversely adjacent turbulators 191. The longitudinal (X.sub.L) and transverse (X.sub.H) spacing may be measured from the leading edge of turbulator 191, as shown. Accordingly, turbulators 191 in certain preferred embodiments may have the same ranges for turbulator spacing ratio () as described with respect to the embodiment of FIGS. 5A-5B. In addition, as shown in FIG. 10B, turbulators 191 may be arranged in an alternating pattern along respective longitudinal rows (e.g., R1, R2), wherein the concave surface of turbulator intermediate portion 197 faces a first wall (e.g., top wall 155) in a first series (C1), and faces an opposing second wall (e.g., bottom wall 153) in a second series (C2) longitudinally spaced from the first series (C1), and returns to facing the first wall (e.g., top wall 155) in a third series (C3) longitudinally spaced from the second series (C2), and so on. Further still, turbulator 191 can be rotated about its central axis in a predetermined arrangement within coolant tube 150 wherein the concave surface of intermediate portion 197 faces more of an upstream flow, or can be oriented to face more of a downstream flow depending on how turbulent wakes and/or turbulent vortexes are to be directed toward downstream areas.

(55) It should be understood according to objects of the present invention that turbulence enhancers or turbulators, including the provisions of inserts and/or impediments, may be incorporated into the coolant tubes of different types of keel coolers. For example, a keel cooler 200 according to an embodiment of the invention is shown in FIG. 11. Keel cooler 200 is the same as a keel cooler described in U.S. Pat. No. 6,575,227 (by the present assignee and incorporated herein by reference in its entirety), except for the incorporation of turbulence enhancers 270 according to the present invention. As shown in FIG. 11, keel cooler 200 includes a header 230, which is similar to header 130 as described earlier according to the invention. Header 230 includes an upper wall 234, an end wall 236 preferably transverse to upper wall 234, and a beveled bottom wall 237 beginning at end wall 236 and terminating at a generally flat bottom wall 232. A nozzle 220 having nipple 221 and connector 222 with threads 223, may be the same as those described earlier and are attached to header 230. A gasket 226, similar to and for the same purpose as gasket 126, is disposed on top of upper wall 234.

(56) Still referring to FIG. 11, keel cooler 200 according to an embodiment of the invention includes coolant tubes 250, each having a generally rectangular parallelepiped construction, and which may be the same as previously described coolant tubes. Coolant tubes 250 include interior or inner coolant tubes 251 and exterior or outer coolant tubes 260. As shown in FIG. 11, and similar to those described earlier, inner coolant tubes 251 join header 230 through inclined surface (not shown), which is composed of fingers 242 inclined with respect to inner coolant tubes 251 and which define spaces to receive open end portions or ports 244 of inner coolant tubes 251. Outer coolant tubes 260 have outermost sidewalls 261, part of which are also the sidewalls of header 230. Outer coolant tubes also have an interior sidewall 263 with an orifice 231, which is provided as a coolant flow port for coolant flowing between the chamber of header 230 and outer coolant tubes 260.

(57) Also as shown in FIG. 11 and according to a preferred embodiment of the invention, coolant tubes 250 (including inner coolant tubes 251 and/or outer coolant tubes 260) include a plurality of turbulence enhancers 270. Turbulence enhancers 270 provide the same means for enhancing turbulence of the coolant to improve heat transfer without substantially increasing pressure drop of the coolant as those turbulence enhancers described above. Accordingly, turbulence enhancers 270 may have the same structural configurations, arrangements, and/or attributes according to previously described embodiments of turbulence enhancers, and are similarly not limited to the particular structures described. Certain non-limiting embodiments of turbulence enhancers 270 may take physical form in the geometric turbulator configurations, turbulator patterns, spacing ratio () ranges, and turbulator size ranges described above with reference to the embodiments shown in FIGS. 5A-5B and FIGS. 9A-10B. Keel cooler 200 with header 230, having improved flow rate and flow distribution of the coolant into coolant tubes 250, could result in a very effective keel cooler for transferring heat without substantial pressure drop when incorporating turbulence enhancers 270. Such a keel cooler could significantly reduce the footprint of the keel cooler, as well as the costs associated with the keel cooler.

(58) Another embodiment of a keel cooler 300 according to the invention is shown in FIG. 12. Keel cooler 300 is the same as a keel cooler described in U.S. Pat. No. 6,896,037 (having the same assignee as the present application and being incorporated herein by reference in its entirety), except for the incorporation of turbulence enhancers 370 according to the present invention. Referring to FIG. 12, coolant tubes 350 (including inner coolant tubes 351 and/or outer coolant tubes 360) include a plurality of turbulence enhancers 370. Turbulence enhancers 370 provide the same means for enhancing turbulence of the coolant to improve heat transfer without substantially increasing pressure drop of the coolant as those turbulence enhancers described above. As such, turbulence enhancers 370 may have the same configurations, arrangements, and attributes of previous turbulence enhancers and are also not so limited to the specific structures disclosed. Certain non-limiting embodiments of turbulence enhancers 370 may take physical form in the geometric turbulator configurations, turbulator patterns, spacing ratio () ranges, and turbulator size ranges described above with reference to embodiments of FIGS. 5A-5B and FIGS. 9A-10B. Also as shown in FIG. 12, keel cooler 300 includes a header 330, including an upper wall 334, an angled wall 337 being integral (or attached by any other appropriate means such as welding) at its upper end with the upper portion of an end wall 336, which in turn is transverse to (and preferably perpendicular to) upper wall 334 and a bottom wall 332. Angled wall 337 may be integral with bottom wall 332 at its lower end, or also attached thereto by appropriate means, such as by welding. In other words, angled wall 337 is the hypotenuse of the triangular cross section formed by end wall 336, angled wall 337 and bottom wall 332. Coolant tubes 351 join header 330 through inclined surface (not shown), which is composed of fingers 342 inclined with respect to inner coolant tubes 351 and which define spaces to receive open end portions or ports 344 of inner coolant tubes 351. Outer coolant tubes 360 have outermost sidewalls 361, part of which are also the sidewalls of header 330. Outer coolant tubes also have interior sidewall 363 (with orifice 331), similar to the foregoing embodiments. A nozzle 320 having nipple 321 and connector 322 may be the same as those described earlier and are attached to header 330. A gasket 326, similar to and for the same purpose as gasket 126, is disposed on top of upper wall 334.

(59) FIG. 13 shows yet another embodiment of a keel cooler 400 according to the invention. Keel cooler 400 is also described in U.S. Pat. No. 6,896,037, except for the incorporation of turbulence enhancers 470 according to the present invention. Referring to FIG. 13, coolant tubes 450 (including inner coolant tubes 451 and/or outer coolant tubes 460) comprise a plurality of turbulence enhancers 470, which provide the same means for enhancing turbulence of the coolant to improve heat transfer without substantially increasing pressure drop of the coolant as those turbulence enhancers previously described. Accordingly, turbulence enhancers 470 may have the same configurations, arrangements, and attributes of previous turbulence enhancers, but are not so limited to the specific structures disclosed. Certain non-limiting embodiments of turbulence enhancers 470 may take physical form in the geometric turbulator configurations, turbulator patterns, spacing ratio () ranges, and turbulator size ranges described above with reference to the embodiments of FIGS. 5A-5B and FIGS. 9A-10B. Also as shown in the embodiment of FIG. 13, keel cooler 400 includes a header 430, including an upper wall 434, a flow diverter or baffle 437, a bottom wall 432, and an end wall 436. End wall 436 is attached transverse to (and preferably perpendicular to) upper wall 434 and bottom wall 432 so that header 430 is essentially rectangular or square shaped. Flow diverter 437 comprises a first angled side or panel 438 and a second angled side or panel 439, both of which extend downwardly at a predetermined angle from an apex 440. Extending downwardly from apex 440 at an angle greater than 0 from the plane perpendicular to end wall 436 and less than 90 from that same plane is a spine 441 which ends at the plane of bottom wall 432 (if there is a bottom wall 432; otherwise spine 441 would end at a plane parallel to the lower horizontal walls of inner coolant tubes 451) and at or near the open ends 444 of a plurality of parallel coolant tubes 450. Also as with the previous embodiments, coolant tubes 451 join header 430 through inclined surface (not shown), which is composed of fingers 442 inclined with respect to inner coolant tubes 451 and which define spaces to receive open end portions 444 of inner coolant tubes 451. Outer coolant tubes 460 have outermost sidewalls 461, part of which are also the sidewalls of header 430. Outer coolant tubes 460 also have interior sidewall 463 with orifice 431, which is provided as a coolant flow port. A nozzle 420 having nipple 421 and connector 422, may be the same as those described earlier and are attached to the header 430.

(60) Turning to FIG. 14, another embodiment of a keel cooler 500 according to the invention is shown. Keel cooler 500 is the same as the embodiment of keel cooler 100 shown in FIG. 4, except for the shape of orifice 531. As shown in the embodiment of FIG. 14, orifice 531 may have an arrow-shaped configuration, or may have any other polygonal configuration adapted to the shape of header chamber, such as those orifice configurations described in U.S. Pat. No. 7,055,576 (incorporated herein by reference in its entirety). As shown in FIG. 14, keel cooler 500 includes a header 530 (similar to header 130), including an upper wall 534, an end wall 536, and a bottom wall 532. A nozzle 520 having nipple 521 and connector 522, may also be the same. Coolant tubes 551 join header 530 through inclined surface (not shown), which is composed of fingers 542 inclined with respect to interior coolant tubes 551 and which define spaces to receive open end portions 544 of inner coolant tubes 551. Outer coolant tubes 560 have outermost sidewalls 561, part of which are also the sidewalls of header 530. Outer coolant tubes 560 also have interior sidewall 563 with an orifice 531 provided as a coolant port. Coolant tubes 550 (including inner coolant tubes 551 and/or outer coolant tubes 560) include a plurality of turbulence enhancers 570, which provide the same means for enhancing turbulence of the coolant to improve heat transfer without substantially increasing pressure drop as previously described turbulence enhancers, and may include certain configurations, arrangements and attributes as described, but without being limited thereto. Certain non-limiting embodiments of turbulence enhancers 570 may also take physical form in the geometric turbulator configurations, turbulator patterns, and ranges thereof, as described with reference to embodiments of FIGS. 5A-5B and FIGS. 9A-10B.

(61) It should also be understood that the importance and function of turbulence enhancers or turbulators according to the present invention may have advantages in other keel cooler systems as well. Referring to FIG. 15, a two-pass keel cooler 600 according to an embodiment of the invention is shown. Keel cooler 600 is also described in U.S. Pat. No. 6,575,227, except for the incorporation of turbulence enhancers 670, 670 according to the present invention. As shown, keel cooler 600 has two sets of coolant flow tubes 650, 650, a header 630 and an opposite header 630. Header 630 has an inlet nozzle 620 and an outlet nozzle 620, which extend through a gasket 626. Gasket(s) 626 is located on top of upper wall 634 of header 630. The other header 630 has no nozzles, but rather has one or two stud bolt assemblies 627, 627 for connecting the portion of the keel cooler which includes header 630 to the hull of the vessel. The hot coolant from the engine or generator of the vessel enters nozzle 620 as shown by arrow C, and the cooled coolant returns to the engine from header 630 through outlet nozzle 620 shown by the arrow D. Inner coolant tubes 651, 651 are like inner coolant tubes 251 in FIG. 11. Outer coolant tubes 660, 660 are like outer coolant tubes 260 in FIG. 11, such that orifices (not shown) corresponding to orifice 231 directs coolant into outer coolant tube 660 and from outer coolant tube 660. In addition, a coolant tube 655 serves as a separator tube for delivering inlet coolant from header 630 to header 630, and it has an orifice (not shown) for receiving coolant for separator tube 655 under high pressure from a part of header 630. Similarly, a coolant tube 655 which is the return separator tube for carrying coolant from header 630, also has an orifice 631 in header 630.

(62) An embodiment of two-pass keel cooler 600 shown in FIG. 15 has one set of coolant tubes 650 (including inner coolant tubes 651 and outer coolant tube 660) for carrying hot coolant from header 630 to header 630, where the direction of coolant flow is turned 180 by header 630, and the coolant enters a second set of coolant tubes 650 (including inner coolant tubes 651 and outer coolant tube 660) for returning the partially cooled coolant back to header 630, and subsequently through nozzle 620 to the engine or other heat source of the vessel. According to an object of the present invention, turbulence enhancers 670, 670, shown in the embodiment of FIG. 15, could improve the heat transfer of such two-pass keel coolers 600 without substantially increasing pressure drop. As with other embodiments, turbulence enhancers 670, 670 provide the same means for enhancing turbulence to improve heat transfer without substantial pressure drop, including certain configurations and arrangements, but not being limited thereto. Certain non-limiting embodiments of turbulence enhancers 670, 670 may also take physical form in the geometric turbulator configurations, turbulator patterns, and ranges thereof, as described with reference to embodiments of FIGS. 5A-5B and FIGS. 9A-10B. Keel cooler 600 shown in FIG. 15 has 8 coolant tubes. However, the two-pass system would be appropriate for any even number of tubes, especially for those with more than two tubes. There are presently keel coolers having as many as 24 tubes, but it is possible according to the present invention for the number of tubes to be increased even further. These can also be keel coolers with more than two passes. If the number of passes is even, both nozzles are located in the same header. If the number of passes is an odd number, there is one nozzle located in each header.

(63) Another embodiment of the present invention is shown in FIG. 16, which shows a multiple-systems-combined keel cooler 700 which has not been practically possible with some prior one-piece keel coolers. Multiple-systems-combined keel cooler 700 can be used for cooling two or more heat sources, such as two relatively small engines or an after cooler and a gear box in a single vessel. Although the embodiment shown in FIG. 16 shows two keel cooler systems, there could be additional ones as well, depending on the situation. Thus, FIG. 16 shows an embodiment of multiple-systems-combined (two single-pass) keel cooler 700, including two identical headers 730 and 730 having inlet nozzles 720, 720, respectively, and outlet nozzles 722, 722 respectively. Both nozzles in respective headers 730 and 730 could be reversed with respect to the direction of flow in them, or one could be an inlet and the other could be an outlet nozzle for the respective headers. The direction of the coolant flow through the nozzles is shown respectively by arrows E, F, G and H. Keel cooler 700 has beveled closed end portions 737, 737 as discussed in an earlier embodiment.

(64) Further as shown in the embodiment of FIG. 16, a set of coolant tubes 751 for conducting coolant between nozzles 720 and 722 commence with outer tube 760 and terminate with separator tube 753, and a set of tubes 751 extending between nozzles 720 and 722, commencing with outer coolant tube 760 and terminating with separator tube 753. Outer coolant tubes 760, 760 have orifices (not shown) at their respective inner walls which are similar in size and position to those shown in the previously described embodiments of the invention. The walls of coolant tubes 753 and 753 which are adjacent to each other are solid, and extend between the end walls of headers 730 and 730. These walls thus form system separators, which prevent the flow of coolant across these walls, so that the tubes 751 form, in effect, one keel cooler, and tubes 751 form, in effect, a second keel cooler (along with their respective headers). Keel cooler 700 includes turbulence enhancers 770, 770, which provide the same means for enhancing turbulence to improve heat transfer without substantially increasing pressure drop according to previous embodiments. Turbulence enhancers 770, 770 can include certain geometric turbulator configurations and turbulator patterns, as described above, including the ranges thereof, but without being specifically limited thereto. It should be understood that this type of keel cooler can be more economical than having two separate keel coolers, since there is a savings by only requiring two headers, rather than four.

(65) Multiple keel coolers can be combined in various combinations. For example, there can be two or more one-pass systems as shown in FIG. 16. However, there can also be one or more single-pass systems and one or more double-pass systems in combination as shown in the embodiment of FIG. 17. In FIG. 17, an embodiment of keel cooler 800 is depicted having a single-pass keel cooler portion 802, and a double-pass keel cooler portion 804, each portion having turbulence enhancers 870, 870 as previously described according to embodiments of the present invention. Keel cooler portion 802 functions as that described with reference to the embodiment of FIG. 11, and keel cooler portion 804 functions as that described with reference to the embodiment of FIG. 15. FIG. 17 shows a double-pass system for one heat exchanger, and additional double-pass systems could be added as well.

(66) FIG. 18 shows an embodiment of keel cooler 900 having two double-pass keel cooler portions 902, 904, which can be identical or have different capacities, and each portion having turbulence enhancers 970, 970 according to preferred embodiments of the invention. Each portion functions as described above with respect to the embodiment of FIG. 15. Multiple-coolers-combined is a powerful feature not found in prior one-piece keel coolers. The modification of the special separator/tube design improves heat transfer and flow distribution while minimizing pressure drop concerns, and the incorporation of turbulence enhancers could lead to a very effective keel cooler system.

(67) The invention has been described in detail with particular reference to the preferred embodiments thereof, with variations and modifications which may occur to those skilled in the art to which the invention pertains.