Modular piping manifold system for heat exchangers

1. An air-cooled heat exchanger connectable between an upstream fluid source and a downstream fluid destination by a plurality of external pipes having connection ends arranged in one or more external pipe connection configurations, the air-cooled heat exchanger comprising:

a plenum;

a plurality of boxed headers;

a cooling tubes assembly extending through the plenum;

a plurality of intermediate pipes connected to each of the plurality of boxed headers;

a modular manifold, wherein the modular manifold comprises:

a tray;

a first flanged pipe elbow connected to one of the plurality of intermediate pipes, wherein the first flanged pipe elbow is supported by a first elbow support that is supported by the tray;

a second flanged pipe elbow connected between one of the plurality of intermediate pipes, wherein the second flanged pipe elbow is supported by a second elbow support that is supported by the tray; and

wherein the first flanged pipe elbow and the second flanged pipe elbow are oriented in the tray in a configuration that matches the connection configuration of a corresponding one of the plurality of external pipes and along a common centerline of an open end of each of the first and second flanged pipe elbows.

2. The air-cooled heat exchanger of claim 1 , further comprising a plurality of modular manifolds.

3. The air-cooled heat exchanger of claim 1 , wherein the first elbow support of the modular manifold further comprises:

a first box bracket configured to be secured within the tray;

a first upper saddle connected to the first box bracket, wherein the first upper saddle is configured to support an upper end of the first flanged pipe elbow; and

a first lower saddle connected to the first box bracket, wherein the first lower saddle is configured to support a lower end of the first flanged pipe elbow.

4. The air-cooled heat exchanger of claim 3 , wherein the first elbow support of the modular manifold further comprises a first cover connected to the first box bracket over the first flanged pipe elbow.

5. The air-cooled heat exchanger of claim 3 , wherein the second elbow support of the modular manifold further comprises:

a second box bracket configured to be secured within the tray;

a second upper saddle connected to the second box bracket, wherein the second upper saddle is configured to support an upper end of the second flanged pipe elbow; and

a second lower saddle connected to the second box bracket, wherein the second lower saddle is configured to support a lower end of the second flanged pipe elbow.

6. The air-cooled heat exchanger of claim 5 , wherein the second elbow support of the modular manifold further comprises a second cover connected to the second box bracket.

7. The air-cooled heat exchanger of claim 6 , wherein each of the first and second flanged pipe elbows is welded to the each of the corresponding first and second box brackets and wherein the first and second box brackets are welded to the tray.

8. The air-cooled heat exchanger of claim 1 , wherein the tray is secured to the plenum.

9. The air-cooled heat exchanger of claim 1 , further comprising a plurality of custom-routed lines connected between one or more of the plurality of boxed headers and corresponding ones of the plurality of external pipes which are fabricated and placed after the exchanger is in place.

10. An air-cooled heat exchanger connectable between an upstream fluid source and a downstream fluid destination by a plurality of external pipes having connection ends arranged in one or more external pipe connection configurations, the air-cooled heat exchanger comprising:

a cooling tubes assembly that includes a plurality of headers;

a plurality of intermediate pipes connected to the plurality of headers; and

a modular manifold system that connects the plurality of intermediate pipes to the plurality of external pipes, wherein the modular manifold system comprises:

a plurality of pipe elbows, wherein each of the plurality of pipe elbows is connected to a corresponding one of the plurality of intermediate pipes;

a plurality of elbow supports, each elbow support supporting a pipe elbow; and

one or more trays, wherein each of the plurality of pipe elbows and elbow supports is retained within the one or more trays in a configuration that matches the one or more external pipe connection configurations and along a common centerline of an open end of each of the plurality of pipe elbows.

11. The air-cooled heat exchanger of claim 10 , wherein the elbow supports of the modular manifold system further comprises a plurality of box brackets configured to be secured within the one or more trays, wherein each of the plurality of box brackets is configured to receive a corresponding one of the plurality of pipe elbows.

12. The air-cooled heat exchanger of claim 11 , wherein the elbow supports of the modular manifold system further comprises a plurality of upper saddles, wherein each of the plurality of upper saddles is connected to a corresponding one of the plurality of box brackets and wherein each of the plurality of upper saddles is sized to receive a corresponding one of the plurality of pipe elbows.

13. The air-cooled heat exchanger of claim 11 , wherein the elbow supports of the modular manifold system further comprises a plurality of lower saddles, wherein each of the plurality of lower saddles is connected to a corresponding one of the plurality of box brackets and wherein each of the plurality of lower saddles is sized to receive a corresponding one of the plurality of pipe elbows.

14. The air-cooled heat exchanger of claim 13 , wherein the elbow supports of the modular manifold system further comprises a plurality of covers, wherein each of the plurality of covers is connected to a corresponding one or more of the plurality box brackets.

15. The air-cooled heat exchanger of claim 10 , wherein at least three of the plurality of pipe elbows are retained within the one or more trays in a horizontal linear arrangement.

16. The air-cooled heat exchanger of claim 10 , wherein at least three of the plurality of pipe elbows are retained within the one or more trays in a vertical linear arrangement.

17. The air-cooled heat exchanger of claim 10 , wherein at least three of the plurality of pipe elbows are retained within the one or more trays in a stacked arrangement.

18. The air-cooled heat exchanger of claim 10 , wherein at least three of the plurality of pipe elbows are retained within the one or more trays in a linear arrangement.

19. An air-cooled heat exchanger connectable between an upstream fluid source and a downstream fluid destination by a plurality of external pipes having connection ends arranged in one or more external pipe connection configurations, the air-cooled heat exchanger comprising:

a plenum;

a cooling tubes assembly that includes a plurality of headers;

a fan assembly configured to move air through the plenum and the cooling tubes assembly;

a plurality of intermediate pipes connected to the plurality of headers; and

a modular manifold system that connects the plurality of intermediate pipes to the plurality of external pipes, wherein the modular manifold system comprises:

a plurality of pipe elbows, wherein each of the plurality of pipe elbows is connected to a corresponding one of the plurality of intermediate pipes;

a plurality of elbow supports, each elbow support supporting a pipe elbow; and

one or more trays connected to the plenum, wherein each of the plurality of pipe elbows and elbow supports is retained within the one or more trays in a configuration that matches the one or more external pipe connection configurations and along a common centerline of an open end of each of the plurality of pipe elbows.

20. The air-cooled heat exchanger of claim 19 , wherein a first number of the plurality of pipe elbows is retained within a corresponding one of the one or more trays in a configuration selected from the group consisting of horizontal linear, vertical linear and stacked configurations.