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Cooling Towers
INTRODUCTION COOLING TOWER PSYCHROMETRICS
The purpose of this section is to provide a basic under- Psychrometry is the study of cooling by evaporation. Maxi-
standing of the design and operation of a cooling tower. A cool- mum evaporation takes place when water, in the form of tiny
ing tower allows water to be cooled by ambient air through droplets, is exposed to the maximum air flow for the longest
evaporation. possible time. The process of evaporation through removal of
FIG. 11-1
Nomenclature
11-1
FIG. 11-1 (Cont’d)
Blowdown: Water discharged from the system to control Louvers: Blade or passage type assemblies installed at the
concentrations of salt or other impurities in the circulating air inlet face of a cooling tower to control water splashout
water. and/or promote uniform air flow through the fill. In the
Capacity: The amount of water that a cooling tower will cool case of film-type crossflow fill, they may be integrally
through a specified range, at a specified approach and wet- molded to the fill sheets.
bulb temperature. Makeup: Water added to the circulating water system to
Cell: Smallest tower subdivision which can function as an replace water lost by evaporation, drift, windage, blow-
independent unit with regard to air and water flow; it is down, and leakage.
bounded by either exterior walls or partition walls. Each Natural Draft: Refers to the movement of air through a
cell may have one or more fans and one or more distribu- cooling tower purely by natural means. Typically, by the
tion systems. driving force of a density differential.
Circulation Rate: Actual water flow rate through a given Net Effect Volume: That portion of the total structural
tower. volume within which the circulating water is in intimate
Fan Cylinder: Cylindrical or venturi-shaped structure in contact with the flowing air.
which a propeller fan operates. Sometimes referred to as a Performance Factor: Variable used in determining per-
fan “stack” on larger towers. formance characteristics in cooling towers.
Fan Deck: Surface enclosing the top of an induced draft Psychrometer: An instrument incorporating both a dry-
cooling tower, exclusive of the distribution basins on a bulb and a wet-bulb thermometer, by which simultaneous
crossflow tower. dry-bulb and wet-bulb temperature readings can be taken.
Fan Pitch: The angle which the blades of a propeller fan Range: Difference between the hot water temperature and
make with the plane of rotation, measured at a prescribed the cold water temperature.
point on each blade.
Recirculation: Describes a condition in which a portion of
Fill: That portion of a cooling tower which constitutes its the tower’s discharge air re-enters the air inlets along with
primary heat transfer surface. Sometimes referred to as the fresh air. Its effect is an elevation of the average enter-
“packing.” ing wet-bulb temperatures compared to the ambient.
Forced Draft: Refers to the movement of air under pressure Water Rate: Mass flow of water per square foot of fill plan
through a cooling tower. Fans of forced draft towers are area of the cooling tower per hour.
located at the air inlets to “force” air through the tower.
Wet-Bulb Temperature: the temperature of the entering
Hot Water Temperature: Temperature of circulating water or ambient air adjacent to the cooling tower as measured
entering the cooling tower’s distribution system. with a wet-bulb thermometer.
Induced Draft: Refers to the movement of air through a
Wet-Bulb Thermometer: A thermometer whose bulb is en-
cooling tower by means of an induced partial vacuum. Fans
cased within a wetted wick.
of induced draft towers are located at the air discharges to
“draw” air through the tower. Windage: Water lost from the tower because of the effects of
wind.
Liquid-to-Gas Ratio: A ratio of the total mass flows of
water and dry air in a cooling tower. (See Air Rate and Wind Load: The load imposed upon a structure by a wind
Water Rate) blowing against its surface.
latent heat allows the water to be cooled below the ambient Types of Cooling Systems
dry-bulb temperature. The dry air enters the cooling tower
and begins to gain moisture and enthalpy in an effort to Cooling water is circulated through equipment to absorb
reach equilibrium with the water. The water may be cooled and carry away heat. The basic cooling systems are shown in
15°F or more while the air mass dry-bulb temperature may Fig. 11-4. The open recirculating system is the most common
increase only slightly. A psychrometric chart (Fig. 11-2) may for industrial plants.
be used to illustrate the relationships between wet- and
dry-bulb temperatures. All nomenclature is indicated in The open recirculating system routes cooled water through
Fig. 11-1. the heat-exchange equipment. Effluent warm water then is
cooled by contact with air in a cooling tower. The cooling effect
Wet-bulb Temperature is produced by evaporation of a portion of the circulating
water, and this evaporation causes the dissolved solids in the
The basis for thermal design of an evaporative type cooling water to become concentrated. Water lost by evaporation must
tower is the wet-bulb temperature of the air entering the be replaced by makeup water. But water lost through entrain-
tower. Water cannot be cooled below the wet-bulb temperature ment of droplets in the circulating air (windage or drift) tends
by evaporation. The air entering the tower at a temperature to limit the degree of concentration since the entrained drop-
of 75°F and 100% relative humidity has a 75°F "wet-bulb" tem- lets also contain dissolved solids. Windage loss varies with the
perature. The wet-bulb temperature is usually measured us- type of tower.
ing a sling psychrometer. Wet bulb and dry bulb data for
various locations around the world are shown in Figs. 11-3a
and 11-3b.
11-2
FIG. 11-2
Psychrometric Chart
11-3
FIG. 11-3a
Dry Bulb/Wet Bulb Temperature Data 2
11-4
FIG. 11-3a (Cont’d)
Dry Bulb/Wet Bulb Temperature Data2
11-5
FIG. 11-3a (Cont’d)
Dry Bulb/Wet Bulb Temperature Data 2
The dry bulb and wet bulb temperatures represent values which have been equalled or exceeded by 5% of the total hours during the months of June through September in the northern
hemisphere and the months December through March in the southern hemisphere.
The data for Canadian stations are based on the month of July only.
11-6
FIG. 11-3b
Dry Bulb/Wet Bulb Temperature Data2
11-7
FIG. 11-3b (Cont’d)
Dry Bulb/Wet Bulb Temperature Data2
The dry bulb and wet bulb temperatures represent values which have been equalled or exceeded by 5% of the total hours during the months of June through September in the northern
hemisphere and the months December through March in the southern hemisphere.
The data for Canadian stations are based on the month of July only.
11-8
FIG. 11-4
Cooling System Characteristics
Typical windage losses, expressed as percentages of the total Drift and condensed water can cause corrosion problems with
system water circulation rate, for different evaporative equip- downwind equipment.
ment are as follows:
PERFORMANCE CHARACTERISTICS
Spray ponds 1.0 to 5.0%
Atmospheric-draft towers 0.3 to 1.0% The performance characteristics of various types of tow-
ers will vary with height, fill configuration, and flow ar-
Mechanical-draft towers 0.1 to 0.3% rangement — crossflow or counterflow; however, these
factors have been taken into consideration in preparation
of the Performance Characteristic Nomograph Fig. 11-5.
Tower Location When accurate characteristics of a specific tower are re-
quired, the cooling tower manufacturer should be con-
Local heat sources upwind of the cooling tower can elevate
sulted.
the wet-bulb temperature of the air entering the tower. Inter-
ference occurs when a portion of the saturated air upwind of Performance tests on a cooling tower should be done in ac-
the tower contaminates the ambient air of a downwind tower. cordance with the Cooling Tower Institute (CTI) Acceptance
11-9
Example 11-1 — Effect of Varying WB Temperature on Cold
Water Temperature (CWT).
What is new CWT when WB changes from 75° to 60° with
Performance factor
gpm and range remaining constant?
F
Enter Nomograph at 85° CWT, go horizontally to 75° WB,
e
ng
then vertically down to 60° WB, read new CWT of 76°.
Ra
Cold water temperature F
F
e
tur
ra
85
pe
76
tem
74
lb
76
bu
et
60
W
20
Performance factor
F
30 nge
Ra
stant?
Enter Nomograph at 85° CWT, go horizontally to 75° WB,
F vertically to 20° R, horizontally to 30° R, vertically downward
e
ur to 75° WB, read new CWT 87.5°.
rat
87.5 pe
m
85 te
lb 76
bu
et 74
Performance factor
W
4.65
20
F
g e
R an
3.1
Cold water temperature F
90.5
1000 gpm to 1500 gpm (50% change in heat load at constant
tem
76 4
bu
11-10
Example 11-4 — Effect of Varying WB Temperature, Range,
24 and Water Circulating Rate on Cold Water Temperature.
Performance factor
26
20
What is new CWT when the WB changes from 75° to 60°, R
3.87
changes from 20° to 25°, gpm changes from 1000 to 1250 (25%
change in heat load.) Enter Nomograph at 85° CWT, go hori-
F 3.1 zontally to 75° WB, vertically to 20° R, horizontally read
g e
an PF 3.1 then multiply (3.1) (1250/1000) = 3.87 (new PF). Enter
R Nomograph at PF = 3.87, go horizontally to 25° R, vertically
down to 60° WB, read 82° new CWT.
Cold water temperature F
F
ure
rat
pe
tem
85 76
ulb
82
Performance factor
tb
74
20 4
We
60 2
26 3.6
°F
ge
an
R
Example 11-5 — Effect of Varying Fan HP Input on Cold
Water Temperature.
Cold water temperature F
the ratio of water rate to air rate, therefore the change in air
mpe
74
Performance Factor. PF correction factor = (25 HP/20 HP)1/3 =
t bu
Test Code and the American Society of Mechanical Engineers a new CWT of 82° when circulating 1250 gpm at 25° R and
(ASME) test code. 60°WB. If motor HP is increased from 20 to 25 under these
conditions with PF correction factor = 1.077 (as shown in Ex-
Examples ample 11-5), GPM could be increased from 1250 to (1250)
The use of the Nomograph is illustrated by the following (1.077) = 1346 gpm.
examples covering typical changes in operating conditions. Example 11-7 — Calculate the concentrations and blowdown
Assume a cooling tower is operating at known conditions of: rate for the following cooling tower:
Circulation Rate = 10,000 gpm
Flow = 1000 gpm
Hot Water = 105°F Water Temperature Drop Through Tower = 20°F
Cold Water = 85°F Type of Tower = Mechanical Induced Draft
Wet Bulb = 75°F Blowdown Rate = 20 gpm, or 0.2% of circulation rate
Therefore:
This is commonly referred to as 105-85-75 or 20° Range Evaporation Loss = 2% (1% for each 10° temperature drop)
(105° – 85°) and 10° Approach (85° – 75°).
(all rates are based on a percent of circulation rate)
Example 11-6 — The correction factor shown in Example 11-5
could also be used to increase gpm instead of decreasing CWT, Windage Loss = 0.3% (maximum for mechanical draft tower,
as was done in Example 11-5. In Example 11-4, we developed p. 11-2)
11-11
FIG. 11-5
Performance Characteristic Nomograph
11-12
Number of E+B FIG. 11-6
=
Concentrations (cycles) B Mechanical Forced Draft Counterflow Tower
2.0 + (0.2 + 0.3)
= = 5.0
(0.2 + 0.3) Air
Water Out
If the resultant concentrations are excessive and a desired con- Sprays
centration of 4.0 is required, what must the blowdown rate be?
Air
E In
B =
Cycles − 1
2.0
= = 0.67%
4.0 − 1
The windage component of B is 0.3%, therefore the blowdown
rate required would be 0.67 – 0.3 = 0.37% or
(10,000 gpm) (0.0037) = 37 gpm
Watet
TYPES OF COOLING TOWERS Outlet
11-13
FIG. 11-8 FIG. 11-10
Mechanical Draft Coil Shed Tower Hyperbolic Natural Draft Tower
Air
Air Outlet
Outlet
Fan Water
Gear Inlet
Drive
Hot
Coils
Water
Inlet
Air
Inlet
Water
Outlet
Water Outlet
11-14
FIG. 11-11
Properties of Saturated Air1
Humidity Humidity
Ratio Volume Enthalpy Ratio Volume Enthalpy
3
Temp. lbw/lba ft /lb dry air Btu/lb dry air Temp. lbw/lba ft3/lb dry air Btu/lb dry air
°F Ws va vas vs ha has hs °F Ws va vas vs ha has hs
–80 0.0000049 9.553 0.000 9.553 –19.221 0.005 –19.215 66 0.013750 13.248 0.292 13.540 15.856 14.983 30.840
–78 0.0000057 9.604 0.000 9.604 –18.740 0.006 –18.734 68 0.014758 13.299 0.315 13.613 16.337 16.094 32.431
–76 0.0000067 9.655 0.000 9.655 –18.259 0.007 –18.252 70 0.015832 13.349 0.339 13.688 16.818 17.279 34.097
–74 0.0000078 9.705 0.000 9.705 –17.778 0.008 –17.770 72 0.016976 13.400 0.365 13.764 17.299 18.543 35.841
–72 0.0000090 9.756 0.000 9.756 –17.298 0.010 –17.288 74 0.018194 13.450 0.392 13.843 17.779 19.889 37.668
–70 0.0000104 9.807 0.000 9.807 –16.817 0.011 –16.806 76 0.019491 13.501 0.422 13.923 18.260 21.323 39.583
–68 0.0000120 9.857 0.000 9.858 –16.336 0.013 –16.324 78 0.020871 13.551 0.453 14.005 18.741 22.851 41.592
–66 0.0000139 9.908 0.000 9.908 –15.856 0.015 –15.841 80 0.022340 13.602 0.487 14.089 19.222 24.479 43.701
–64 0.0000160 9.959 0.000 9.959 –15.375 0.017 –15.359 82 0.023902 13.653 0.523 14.175 19.702 26.211 45.913
–62 0.0000184 10.009 0.000 10.010 –14.895 0.019 –14.876 84 0.025563 13.703 0.561 14.264 20.183 28.055 48.238
–60 0.0000212 10.060 0.000 10.060 –14.414 0.022 –14.392 86 0.027329 13.754 0.602 14.356 20.664 30.017 50.681
–58 0.0000243 10.111 0.000 10.111 –13.933 0.025 –13.908 88 0.029208 13.804 0.646 14.450 21.145 32.105 53.250
–56 0.0000279 10.161 0.000 10.162 –13.453 0.029 –13.424 90 0.031203 13.855 0.692 14.547 21.626 34.325 55.951
–54 0.0000319 10.212 0.001 10.213 –12.972 0.033 –12.939 92 0.033323 13.905 0.742 14.647 22.107 36.687 58.794
–52 0.0000365 10.263 0.001 10.263 –12.492 0.038 –12.454 94 0.035577 13.956 0.795 14.751 22.588 39.199 61.787
–50 0.0000416 10.313 0.001 10.314 –12.011 0.043 –11.968 96 0.037972 14.006 0.852 14.858 23.069 41.871 64.940
–48 0.0000475 10.364 0.001 10.365 –11.531 0.050 –11.481 98 0.040516 14.057 0.912 14.969 23.550 44.711 68.260
–46 0.0000541 10.415 0.001 10.416 –11.050 0.056 –10.994 100 0.043219 14.107 0.976 15.084 24.031 47.730 71.761
–44 0.0000615 10.465 0.001 10.466 –10.570 0.064 –10.505 102 0.046090 14.158 1.045 15.203 24.512 50.940 75.452
–42 0.0000699 10.516 0.001 10.517 –10.089 0.073 –10.016 104 0.049140 14.208 1.118 15.326 24.993 54.354 79.346
–40 0.0000793 10.567 0.001 10.568 –9.609 0.083 –9.526 106 0.052383 14.259 1.196 15.455 25.474 57.986 83.460
–38 0.0000898 10.617 0.002 10.619 –9.128 0.094 –9.034 108 0.055826 14.309 1.279 15.588 25.955 61.844 87.799
–36 0.0001017 10.668 0.002 10.670 –8.648 0.106 –8.541 110 0.059486 14.360 1.367 15.727 26.436 65.950 92.386
–34 0.0001150 10.719 0.002 10.721 –8.167 0.120 –8.047 112 0.063378 14.411 1.462 15.872 26.917 70.319 97.237
–32 0.0001298 10.769 0.002 10.772 –7.687 0.136 –7.551 114 0.067512 14.461 1.562 16.023 27.398 74.964 102.362
–30 0.0001465 10.820 0.003 10.822 –7.206 0.154 –7.053 116 0.071908 14.512 1.670 16.181 27.879 79.906 107.786
–28 0.0001650 10.871 0.003 10.873 –6.726 0.173 –6.553 118 0.076586 14.562 1.784 16.346 28.361 85.169 113.530
–26 0.0001858 10.921 0.003 10.924 –6.245 0.195 –6.051 120 0.081560 14.613 1.906 16.519 28.842 90.770 119.612
–24 0.0002088 10.972 0.004 10.976 –5.765 0.220 –5.545 122 0.086860 14.663 2.037 16.700 29.323 96.742 126.065
–22 0.0002346 11.022 0.004 11.027 –5.284 0.247 –5.038 124 0.092500 14.714 2.176 16.890 29.805 103.102 132.907
–20 0.0002632 11.073 0.005 11.078 –4.804 0.277 –4.527 126 0.098504 14.764 2.325 17.090 30.286 109.877 140.163
–18 0.0002950 11.124 0.005 11.129 –4.324 0.311 –4.013 128 0.104910 14.815 2.485 17.299 30.767 117.111 147.878
–16 0.0003303 11.174 0.006 11.180 –3.843 0.348 –3.495 130 0.111738 14.865 2.655 17.520 31.249 124.828 156.076
–14 0.0003694 11.225 0.007 11.232 –3.363 0.390 –2.973 132 0.119023 14.916 2.837 17.753 31.730 133.066 164.796
–12 0.0004128 11.276 0.007 11.283 –2.882 0.436 –2.447 134 0.126804 14.966 3.033 17.999 32.212 141.873 174.084
–10 0.0004608 11.326 0.008 11.335 –2.402 0.487 –1.915 136 0.135124 15.017 3.242 18.259 32.693 151.294 183.987
–8 0.0005139 11.377 0.009 11.386 –1.922 0.543 –1.378 138 0.144019 15.067 3.467 18.534 33.175 161.374 194.548
–6 0.0005726 11.427 0.010 11.438 –1.441 0.606 –0.835 140 0.153538 15.118 3.708 18.825 33.656 172.168 205.824
–4 0.0006373 11.478 0.012 11.490 –0.961 0.675 –0.286 142 0.163748 15.168 3.967 19.135 34.138 183.754 217.892
–2 0.0007088 11.529 0.013 11.542 –0.480 0.751 0.271 144 0.174694 15.219 4.245 19.464 34.620 196.183 230.802
0 0.0007875 11.579 0.015 11.594 0.0 0.835 0.835 146 0.186460 15.269 4.545 19.815 35.101 209.550 244.651
2 0.0008742 11.630 0.016 11.646 0.480 0.928 1.408 148 0.199110 15.320 4.869 20.189 35.583 233.932 259.514
4 0.0009695 11.680 0.018 11.699 0.961 1.030 1.991 150 0.212730 15.370 5.218 20.589 36.064 239.426 275.490
6 0.0010743 11.731 0.020 11.751 1.441 1.143 2.584 152 0.227429 15.421 5.596 21.017 36.546 256.158 292.705
8 0.0011895 11.782 0.022 11.804 1.922 1.266 3.188 154 0.243309 15.471 6.005 21.477 37.028 274.245 311.273
10 0.0013158 11.832 0.025 11.857 2.402 1.402 3.804 156 0.260512 15.522 6.450 21.972 37.510 293.849 331.359
12 0.0014544 11.883 0.028 11.910 2.882 1.550 4.433 158 0.279166 15.572 6.933 22.505 37.992 315.120 353.112
14 0.0016062 11.933 0.031 11.964 3.363 1.714 5.077 160 0.29945 15.623 7.459 23.082 38.474 338.263 376.737
16 0.0017724 11.984 0.034 12.018 3.843 1.892 5.736 162 0.32156 15.673 8.034 23.707 38.956 363.501 402.457
18 0.0019543 12.035 0.038 12.072 4.324 2.088 6.412 164 0.34572 15.724 8.664 24.388 39.438 391.095 430.533
20 0.0021531 12.085 0.042 12.127 4.804 2.303 7.107 166 0.37220 15.774 9.355 25.129 39.920 421.352 461.271
22 0.0023703 12.136 0.046 12.182 5.285 2.537 7.822 168 0.40131 15.825 10.117 25.942 40.402 454.630 495.032
24 0.0026073 12.186 0.051 12.237 5.765 2.793 8.558 170 0.43343 15.875 10.959 26.834 40.884 491.372 532.256
26 0.0028660 12.237 0.056 12.293 6.246 3.073 9.318 172 0.46905 15.926 11.894 27.820 41.366 532.138 573.504
28 0.0031480 12.287 0.062 12.349 6.726 3.378 10.104 174 0.50867 15.976 12.937 28.913 41.848 577.489 619.337
30 0.0034552 12.338 0.068 12.406 7.206 3.711 10.917 176 0.55294 16.027 14.103 30.130 42.331 628.197 670.528
32 0.003790 12.389 0.075 12.464 7.687 4.073 11.760 178 0.60274 16.078 15.418 31.496 42.813 685.260 728.073
34 0.004109 12.439 0.082 12.521 8.167 4.420 12.587 180 0.65911 16.128 16.909 33.037 43.295 749.871 793.166
36 0.004452 12.490 0.089 12.579 8.648 4.793 13.441 182 0.72331 16.178 18.609 34.787 43.778 823.487 867.265
38 0.004820 12.540 0.097 12.637 9.128 5.194 14.322 184 0.79703 16.229 20.564 36.793 44.260 908.061 952.321
40 0.005216 12.591 0.105 12.696 9.609 5.624 15.233 186 0.88251 16.280 22.834 39.113 44.742 1006.149 1050.892
42 0.005640 12.641 0.114 12.756 10.089 6.086 16.175 188 0.98272 16.330 25.498 41.828 45.225 1121.174 1166.399
44 0.006094 12.692 0.124 12.816 10.570 6.582 17.152 190 1.10154 16.381 28.661 45.042 45.707 1257.614 1303.321
46 0.006581 12.743 0.134 12.877 11.050 7.114 18.164 192 1.24471 16.431 32.477 48.908 46.190 1422.047 1468.238
48 0.007103 12.793 0.146 12.939 11.531 7.684 19.215 194 1.42029 16.481 37.161 53.642 46.673 1623.758 1670.430
50 0.007661 12.844 0.158 13.001 12.012 8.295 20.306 196 1.64070 16.532 43.046 59.578 47.155 1877.032 1924.188
52 0.008259 12.894 0.171 13.065 12.492 8.949 21.441 198 1.92472 16.583 50.636 67.218 47.638 2203.464 2251.102
54 0.008897 12.945 0.185 13.129 12.973 9.648 22.621 200 2.30454 16.633 60.793 77.426 48.121 2640.084 2688.205
56 0.009580 12.995 0.200 13.195 13.453 10.397 23.850 Reprinted by permission of the American Society of Heating, Refrigerating and Air-Condi-
58 0.010309 13.046 0.216 13.262 13.934 11.197 25.131 tioning Engineers, Atlanta, GA, from the 1993 ASHRAE Handbook—Fundamentals.
60 0.011087 13.096 0.233 13.329 14.415 12.052 26.467
62 0.011919 13.147 0.251 13.398 14.895 12.966 27.862
64 0.012805 13.198 0.271 13.468 15.376 13.942 29.318
11-15