COOLING TOWER

Presented By
Anis Abbas
ME-1
 Overview
• Cooling Tower
• Cooling Tower Principle and
categorization
• Types and classifications of
Cooling Towers
• Major Components of Cooling
Tower
• Cooling Tower Maintenance
and troubleshooting
 Heat Transfer Methods
• Wet cooling towers or simply
cooling towers operate on the
principle of evaporation.
• Dry coolers operate by
heat transfer through a surface
that separates the working fluid
from ambient air, such as in a
heat exchanger, utilizing
convective heat transfer.
• Fluid coolers are hybrids that
pass the working fluid through a
tube bundle, upon which clean
water is sprayed and a fan-
induced draft applied.
 Cooling Tower
• A cooling tower is a heat rejection
device, which extracts waste heat to
the atmosphere though the cooling
of a water stream to a lower
temperature.
• Cooling towers may either use the
evaporation of water to remove
process heat and cool the working
fluid to near the
wet-bulb air temperature or rely
solely on air to cool the working fluid
to near the dry-bulb air temperature.
 Cooling Tower
• They represent a relatively inexpensive and
dependable means of removing low-grade heat
from cooling water.
 Cooling Tower Principle
• Cooling towers are a
very important part of
many chemical
plants.  They
represent a relatively
inexpensive and
dependable means of
removing low grade
heat from cooling
water.
 Cooling Tower Principle
• The make-up water source is used to replenish
water lost to evaporation. Hot water from heat
exchangers is sent to the cooling tower. The
water exits the cooling tower and is sent back
to the exchangers or to other units for further
cooling.
Categorization by air-to-water flow
• Crossflow
Crossflow is a design
in which the air flow
is directed
perpendicular to the
water flow. Air flow
enters one or more
vertical faces of the
cooling tower to meet
the fill material.
 Categorization by air-to-water flow
• Counterflow
In a counterflow
design the air flow is
directly opposite to
the water flow. Air
flow first enters an
open area beneath
the fill media and is
then drawn up
vertically.
 Types of Cooling Towers
1) Natural Draft
Cooling Towers
• Hot air moves
through tower
• Fresh cool air is
drawn into the tower
from bottom
 Types of Cooling Towers
1) Natural Draft
Cooling Towers
• No fan required
• Concrete tower
<200 m
• Used for large
heat duties
• Air drawn across • Air drawn up
Types of Cooling Towers
falling water
• Fill located
through falling
water
outside tower • Fill located
1) Natural Draft Cooling Towers inside tower

Cross flow Counter flow

 Types of Cooling Towers
2) Mechanical Draft Cooling
Towers
• Large fans to force air through
circulated water
• Water falls over fill surfaces
maximum heat transfer
• Cooling rates depend on many
parameters
• Large range of capacities
• Can be grouped, e.g. 8-cell
tower
 Types of Cooling Towers
2) Mechanical Draft Cooling Towers
Three types
• Forced draft
• Induced draft cross flow
• Induced draft counter flow
 Types of Cooling Towers
Forced Draft Cooling Towers
• Air blown through tower by
centrifugal fan at air inlet
• Advantages: suited for high
air resistance & fans are
relatively quiet
• Disadvantages: recirculation
due to high air-entry and low
air-exit velocities
 Types of Cooling Towers
Induced Draft Counter Flow CT
• Hot water enters at the top
• Air enters at bottom and exits at top
• Uses forced and induced draft fans
 Types of Cooling Towers
Induced Draft Cross Flow CT
• Water enters top and passes over fill
• Air enters on one side or opposite sides
• Induced draft fan draws air across fill
Types of Cooling Towers
 Classification of Cooling Tower
1) Open (Direct) Cooling
Towers
• Open cooling towers
expose the condenser
water coming from the
chiller plant directly to the
atmosphere. This warm
water is sprayed over a fill
in the cooling tower to
increase the contact area,
and air passes through the
fill.
 Classification of Cooling Tower
2) Closed (Indirect)
Cooling Towers
• A closed cooling tower
circulates warm water
from the chiller plant
through tubes located in
the tower. In a closed
tower, the cooling water
does not come in contact
with the outside air.
 Cooling Tower Treatment
The three potential problems associated with
cooling water are:
• Corrosion
• Scale/deposits
• Microbiological activity
Corrosion will shorten the life of the equipment.
Scale/deposits will decrease heat transfer and
increase energy usage. Microbiological activity
will cause system blockages and potential health
hazards.
 Major Components
• Water Distribution
Hot water from the chilled-water
system is delivered to the top of the
cooling tower by the condenser pump
through distribution piping.
• Heat Transfer Medium (Fill)
Cooling towers use evaporation to
release waste heat from an HVAC
system. In an open tower, hot water
from the condenser is slowed down
and spread out over the fill. Some of
the hot water is evaporated in the fill
area which cools the water.
 Major Components
• Drift Eliminator
As air moves through the fill, small
droplets of cooling water become
entrained and can exit the cooling
tower as carry-over or drift. Devices
called drift eliminators remove carry-
over water droplets.
• Frame and casing
Most towers have structural frames
that support the exterior enclosures
(casings), motors, fans, and other
components.
 Major Components
• Cold-water basin
The cold-water basin is located at
or near the bottom of the tower,
and it receives the cooled water
that flows down through the tower
and fill.
• Nozzles
These spray water to wet the fill.
Uniform water distribution at the
top of the fill is essential to
achieve proper wetting of the
entire fill surface.
 Major Components
• Fans
Both axial (propeller
type) and centrifugal
fans are used in
towers. Generally,
propeller fans are
used in induced
draft towers and
both propeller and
centrifugal fans are
found in forced draft
towers.
 Types of Cooling tower fan
• Metallic blades, which are
manufactured by extrusion or
casting processes and therefore it
is difficult to produce ideal
aerodynamic profiles
• Fiber reinforced plastic (FRP)
blades are normally hand molded
which makes it easier to produce
an optimum aerodynamic profile.
FRP fans are light, low starting
torque, long lives of the gear box,
motor and bearing is increased.
 Steps to Cooling Tower Efficiency
• Follow manufacturer’s recommended clearances
around cooling towers and relocate or modify
structures that interfere with the air intake or
exhaust.
• Optimize cooling tower fan blade angle on a
seasonal and/or load basis.
• Correct excessive and/or uneven fan blade tip
clearance and poor fan balance.
• Check cooling water pumps regularly to
maximize their efficiency.
 Steps to Cooling Tower Efficiency
• In old counter-flow cooling towers, replace old
spray type nozzles with new square spray
nozzles that do not clog. Install nozzles that
spray in a more uniform water pattern.
• Balance flow to cooling tower hot water basins.
• Optimize the blow down flow rate.
• Consider energy efficient fiber reinforced plastic
blade adoption for fan energy savings.
 Hazards
• Cooling towers which are constructed in whole
or in part of combustible materials can support
propagating internal fires.
• Cooling-tower water must be regularly treated,
generally with chemicals, to prevent the growth
of harmful bacteria, minimize corrosion, and
inhibit the buildup of scale (mineral deposits) on
the fill.
Cooling Tower Maintenance
Cooling Tower Maintenance
Cooling Tower Maintenance
Cooling Tower Maintenance
Cooling Tower Maintenance
Troubleshooting
Troubleshooting