7.

COOLING TOWER

Syllabus
Cooling Tower: Types and performance evaluation, Efficient system operation, Flow control
strategies and energy saving opportunities, Assessment of cooling towers

7.1 Introduction
Cooling towers are a very important part of many chemical plants. The primary task of a cooling
tower is to reject heat into the atmosphere. They represent a relatively inexpensive and
dependable means of removing low-grade heat from cooling water. 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. Typical closed loop cooling tower system is shown in Figure 7.1.

Cooling Tower Types

Cooling towers fall into two main categories: Natural draft and Mechanical draft.

Natural draft towers use very large concrete chimneys to introduce air through the media. Due to
the large size of these towers, they are generally used for water flow rates above 45,000 m 3/hr.
These types of towers are used only by utility power stations.

Mechanical draft towers utilize large fans to force or suck air through circulated water. The water
falls downward over fill surfaces, which help increase the contact time between the water and the
air - this helps maximise heat transfer between the two. Cooling rates of Mechanical draft towers
depend upon their fan diameter and speed of operation. Since, the mechanical draft cooling
towers are much more widely used, the focus is on them in this chapter.

Figure 7.1 Cooling Water System

Mechanical draft towers
Mechanical draft towers are available in the following airflow arrangements:
1. Counter flows induced draft.
2. Counter flow forced draft.
3. Cross flow induced draft.

In the counter flow induced draft design, hot water enters at the top, while the air is introduced at
the bottom and exits at the top. Both forced and induced draft fans are used.
In cross flow induced draft towers, the water enters at the top and passes over the fill. The air,
however, is introduced at the side either on one side (single-flow tower) or opposite sides
(double-flow tower). An induced draft fan draws the air across the wetted fill and expels it
through the top of the structure.
The Figure 7.2 illustrates various cooling tower types. Mechanical draft towers are available in
a large range of capacities. Normal capacities range from approximately 10 tons, 2.5 m 3/hr flow
to several thousand tons and m3/hr. Towers can be either factory built or field erected – for
example concrete towers are only field erected.
Many towers are constructed so that they can be grouped together to achieve the desired
capacity. Thus, many cooling towers are assemblies of two or more individual cooling towers or
“cells.” The number of cells they have, e.g., a eight-cell tower, often refers to such towers.
Multiple-cell towers can be lineal, square, or round depending upon the shape of the individual
cells and whether the air inlets are located on the sides or bottoms of the cells.

Components of Cooling Tower

The basic components of an evaporative tower are: Frame and casing, fill, cold water basin, drift
eliminators, air inlet, louvers, nozzles and fans.

Frame and casing: Most towers have structural frames that support the exterior enclosures
(casings), motors, fans, and other components. With some smaller designs, such as some glass
fiber units, the casing may essentially be the frame.

Fill: Most towers employ fills (made of plastic or wood) to facilitate heat transfer by maximising
water and air contact. Fill can either be splash or film type.

With splash fill, water falls over successive layers of horizontal splash bars, continuously
breaking into smaller droplets, while also wetting the fill surface. Plastic splash fill promotes
better heat transfer than the wood splash fill.

Film fill consists of thin, closely spaced plastic surfaces over which the water spreads, forming a
thin film in contact with the air. These surfaces may be flat, corrugated, honeycombed, or other
patterns. The film type of fill is the more efficient and provides same heat transfer in a smaller
volume than the splash fill.

Cold water basin: The cold water basin, located at or near the bottom of the tower, receives the
cooled water that flows down through the tower and fill. The basin usually has a sump or low
point for the cold water discharge connection. In many tower designs, the cold water basin is
beneath the entire fill.
In
channeled to a perimeter trough that functions as the cold water basin. Propeller fans are mounted
beneath the fill to blow the air up through the tower. With this design, the tower is mounted on
legs, providing easy access to the fans and their motors.

Figure 7.2 Cooling Tower Types

Drift eliminators: These capture water droplets entrapped in the air stream that otherwise would
be lost to the atmosphere.

Air inlet: This is the point of entry for the air entering a tower. The inlet may take up an entire
side of a tower—cross flow design— or be located low on the side or the bottom of counter flow
designs.

Louvers: Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize
air flow into the fill and retain the water within the tower. Many counter flow tower designs do
not require louvers.

Nozzles: These provide the water sprays to wet the fill. Uniform water distribution at the top of
the fill is essential to achieve proper wetting of the entire fill surface. Nozzles can either be fixed
in place and have either round or square spray patterns or can be part of a rotating assembly as
found in some circular cross-section towers.

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. Depending upon their size, propeller fans can either be fixed or variable pitch.

A fan having non-automatic adjustable pitch blades permits the same fan to be used over a wide
range of kW with the fan adjusted to deliver the desired air flow at the lowest power
consumption.

Automatic variable pitch blades can vary air flow in response to changing load conditions.

Tower Materials

In the early days of cooling tower manufacture, towers were constructed primarily of wood.
Wooden components included the frame, casing, louvers, fill, and often the cold water basin. If
the basin was not of wood, it likely was of concrete.
Today, tower manufacturers fabricate towers and tower components from a variety of
materials. Often several materials are used to enhance corrosion resistance, reduce maintenance,
and promote reliability and long service life. Galvanized steel, various grades of stainless steel,
glass fiber, and concrete are widely used in tower construction as well as aluminum and various
types of plastics for some components.
Wood towers are still available, but they have glass fiber rather than wood panels (casing) over
the wood framework. The inlet air louvers may be glass fiber, the fill may be plastic, and the cold
water basin may be steel.
Larger towers sometimes are made of concrete. Many towers—casings and basins—are
constructed of galvanized steel or, where a corrosive atmosphere is a problem, stainless steel.
Sometimes a galvanized tower has a stainless steel basin. Glass fiber is also widely used for
cooling tower casings and basins, giving long life and protection from the harmful effects of
many chemicals.
Plastics are widely used for fill, including PVC, polypropylene, and other polymers. Treated
wood splash fill is still specified for wood towers, but plastic splash fill is also widely used when
water conditions mandate the use of splash fill. Film fill, because it offers greater heat transfer
efficiency, is the fill of choice for applications where the circulating water is generally free of
debris that could plug the fill passageways.
Plastics also find wide use as nozzle materials. Many nozzles are being made of PVC, ABS,
polypropylene, and glass-filled nylon. Aluminum, glass fiber, and hot-dipped galvanized steel are
commonly used fan materials. Centrifugal fans are often fabricated from galvanized steel.
Propeller fans are fabricated from galvanized, aluminum, or molded glass fiber reinforced plastic.

7.2 Cooling Tower Performance

The important parameters, from the point of determining the performance of cooling towers, are:

i) “Range” is the difference between the cooling tower water inlet and outlet temperature. (See
Figure 7.3).
ii) “Approach” is the difference between the cooling tower outlet cold water temperature and
ambient wet bulb temperature. Although, both range and approach should be monitored,
the `Approach’ is a better indicator of cooling tower performance. (see Figure 7.3).
iii) Cooling tower effectiveness (in percentage) is the ratio of range, to the ideal range, i.e.,
difference between cooling water inlet temperature and ambient wet bulb temperature, or
in other words it is = Range / (Range + Approach).
iv) Cooling capacity is the heat rejected in kCal/hr or TR, given as product of mass flow rate of
water, specific heat and temperature difference.
v) Evaporation loss is the water quantity evaporated for cooling duty and, theoretically, for every
10,00,000 kCal heat rejected, evaporation quantity works out to 1.8 m 3. An empirical
relation used often is:

Evaporation Loss (m3/hr) = 0.00085 x 1.8 x circulation rate (m 3/hr) x (T1-T2)

T1-T2 = Temp. difference between inlet and outlet water.

Source: Perry’s Chemical Engineers Handbook (Page: 12-17)

Figure 7.3 Range and Approach

vi) Cycles of concentration (C.O.C) is the ratio of dissolved solids in circulating water to the
dissolved solids in make up water.

vii) Blow down losses depend upon cycles of concentration and the evaporation losses and is
given by relation:

Blow Down = Evaporation Loss / (C.O.C. – 1)

viii) Liquid/Gas (L/G) ratio, of a cooling tower is the ratio between the water and the air mass
flow rates. Against design values, seasonal variations require adjustment and tuning of
water and air flow rates to get the best cooling tower effectiveness through measures like
water box loading changes, blade angle adjustments.

Thermodynamics also dictate that the heat removed from the water must be equal to the
heat absorbed by the surrounding air:

where: L/G = liquid to gas mass flow ratio (kg/kg) T 1 = hot water temperature

(0C) T2 = cold water temperature (0C) h2 = enthalpy of air-water vapor mixture

at exhaust wet-bulb temperature
(same units as above) h 1 = enthalpy of air-water vapor mixture at inlet wet-
bulb temperature (same
units as above)

Factors Affecting Cooling Tower Performance

Capacity

Heat dissipation (in kCal/hour) and circulated flow rate (m 3/hr) are not sufficient to understand
cooling tower performance. Other factors, which we will see, must be stated along with flow rate
m3/hr. For example, a cooling tower sized to cool 4540 m 3/hr through a 13.9oC range might be
larger than a cooling tower to cool 4540 m3/hr through 19.5oC range.

Range

Range is determined not by the cooling tower, but by the process it is serving. The range at the
exchanger is determined entirely by the heat load and the water circulation rate through the
exchanger and on to the cooling water.

Range oC = Heat Load in kcals/hour / Water Circulation Rate in LPH

Thus, Range is a function of the heat load and the flow circulated through the system.
Cooling towers are usually specified to cool a certain flow rate from one temperature to another
temperature at a certain wet bulb temperature. For example, the cooling tower might be specified
to cool 4540 m3/hr from 48.9oC to 32.2oC at 26.7oC wet bulb temperature.

Cold Water Temperature 32.2oC – Wet Bulb Temperature (26.7oC) = Approach (5.5oC)
As a generalization, the closer the approach to the wet bulb, the more expensive the cooling tower
due to increased size. Usually a 2.8 oC approach to the design wet bulb is the coldest water
temperature that cooling tower manufacturers will guarantee. If flow rate, range, approach and
wet bulb had to be ranked in the order of their importance in sizing a tower, approach would be
first with flow rate closely following the range and wet bulb would be of lesser importance.

Heat Load
The heat load imposed on a cooling tower is determined by the process being served. The degree
of cooling required is controlled by the desired operating temperature level of the process. In
most cases, a low operating temperature is desirable to increase process efficiency or to improve
the quality or quantity of the product. In some applications (e.g. internal combustion engines),
however, high operating temperatures are desirable. The size and cost of the cooling tower is
proportional to the heat load. If heat load calculations are low undersized equipment will be
purchased. If the calculated load is high, oversize and more costly, equipment will result.
Process heat loads may vary considerably depending upon the process involved. Determination
of accurate process heat loads can become very complex but proper consideration can produce
satisfactory results. On the other hand, air conditioning and refrigeration heat loads can be
determined with greater accuracy.
Information is available for the heat rejection requirements of various types of power
equipment. A sample list is as follows:

* Air Compressor
- Single-stage - 129 kCal/kW/hr
- Single-stage with after cooler - 862 kCal/kW/hr
- Two-stage with intercooler - 518 kCal/kW/hr
- Two-stage with intercooler and after cooler - 862 kCal/kW/hr
* Refrigeration, Compression - 63 kCal/min/TR
* Refrigeration, Absorption - 127 kCal/min/TR
* Steam Turbine Condenser - 555 kCal/kg of
steam
* Diesel Engine, Four-Cycle, Supercharged - 880 kCal/kW/hr
* Natural Gas Engine, Four-cycle - 1523 kCal/kW/hr
(18 kg/cm2 compression)
Wet Bulb Temperature

Wet bulb temperature is an important factor in performance of evaporative water cooling

equipment. It is a controlling factor from the aspect of minimum cold water temperature to which
water can be cooled by the evaporative method. Thus, the wet bulb temperature of the air entering
the cooling tower determines operating temperature levels throughout the plant, process, or
system. Theoretically, a cooling tower will cool water to the entering wet bulb temperature, when
operating without a heat load. However, a thermal potential is required to reject heat, so it is not
possible to cool water to the entering air wet bulb temperature, when a heat load is applied. The
approach obtained is a function of thermal conditions and tower capability.

Initial selection of towers with respect to design wet bulb temperature must be made on the basis
of conditions existing at the tower site. The temperature selected is generally close to the average
maximum wet bulb for the summer months. An important aspect of wet bulb selection is, whether
it is specified as ambient or inlet. The ambient wet bulb is the temperature, which exists generally
in the cooling tower area, whereas inlet wet bulb is the wet bulb temperature of the air entering
the tower. The later can be, and often is, affected by discharge vapours being recirculated into the
tower. Recirculation raises the effective wet bulb temperature of the air entering the tower with
corresponding increase in the cold water temperature. Since there is no initial knowledge or
control over the recirculation factor, the ambient wet bulb should be specified. The cooling tower
supplier is required to furnish a tower of sufficient capability to absorb the effects of the increased
wet bulb temperature peculiar to his own equipment.

It is very important to have the cold water temperature low enough to exchange heat or to
condense vapours at the optimum temperature level. By evaluating the cost and size of heat
exchangers versus the cost and size of the cooling tower, the quantity and temperature of the
cooling tower water can be selected to get the maximum economy for the particular process.

The Table 7.1 illustrates the effect of approach on the size and cost of a cooling tower. The towers
included were sized to cool 4540 m 3/hr through a 16.67oC range at a 26.7oC design wet bulb.
The overall width of all towers is 21.65 meters; the overall height, 15.25 meters, and the pump
head, 10.6 m approximately.

Table 7.1 APPROACH Vs. COOLING TOWER SIZE (4540 m3/hr; 16.67oC Range 26.7oC Wet Bulb;
10.7 m Pump Head)
Approach oC 2.77 3.33 3.88 4.44 5.0 5.55

Hot Water oC 46.11 46.66 47.22 47.77 48.3 48.88

Cold Water oC 29.44 30 30.55 31.11 31.66 32.22

No. of Cells 4 4 3 3 3 3
Length of 10.98 8.54 10.98 9.76 8.54 8.54
Cells Mts.
Overall Length 43.9 34.15 32.93 29.27 25.61 25.61
Mts.
No. of Fans 4 4 3 3 3 3
Fan Diameter 7.32 7.32 7.32 7.32 7.32 6.71
Mts.
Approach and Flow

Suppose a cooling tower is installed that is 21.65 m wide × 36.9 m long × 15.24m high, has three
7.32 m diameter fans and each powered by 25 kW motors. The cooling tower cools from 3632
m3/hr water from 46.1oC to 29.4oC at 26.7oC WBT dissipating 60.69 million kCal/hr. The Table
7.2 shows what would happen with additional flow but with the range remaining constant at
16.67oC. The heat dissipated varies from 60.69 million kCal/hr to 271.3 million kCal/hr.
Table 7.2 Flow vs. Approach for a Given Tower (Tower is 21.65 m × 36.9 M; Three
7.32 M Fans; Three 25 kW Motors; 16.7 C Range with 26.7oC Wet Bulb)
o

Approach
For meeting the increased 3heat load, few modifications Cold
wouldWater
be neededHot Water the water
to increase Million
FlowHowever,
flow through the tower. m /hr at higher capacities,
oC oC would increase.
the approach oC kCal/hr

Range, Flow and Heat3632 Load 2.78 29.40 46.11 60.691

4086 3.33 29.95 46.67 68.318
Range is a direct function of the quantity of water circulated and the heat load. Increasing the
4563heat load does require
range as a result of added 3.89 an increase30.51 47.22
in the tower size. 76.25
If the cold water
temperature is not changed
5039 and the range 4.45is increased with higher hot water
31.07 temperature, the
47.78 84.05
driving force between the wet bulb temperature of the air entering the tower and the hot water
5516
temperature is increased, 5.00
the higher level heat is economical 31.62
to dissipate. 48.33 92.17
6060.9 5.56 32.18 48.89 101.28
If the hot water temperature is left constant and the range is increased by specifying a lower cold
7150.5 6.67 33.29 50.00 119.48
water temperature, the tower size would have to be increased considerably. Not only would the
range be increased, but8736
the lower cold water8.33 35.00
temperature would lower 51.67 145.63
11590 11.1 37.80 54.45 191.64
13620 13.9 40.56 57.22 226.91
16276 16.7 43.33 60.00 271.32
the approach. The resulting change in both range and approach would require a much larger
cooling tower.
Approach & Wet Bulb Temperature
The design wet bulb temperature is determined by the geographical location. Usually the design
wet bulb temperature selected is not exceeded over 5 percent of the time in that area. Wet bulb
temperature is a factor in cooling tower selection; the higher the wet bulb temperature, the
smaller the tower required to give a specified approach to the wet bulb at a constant range and
flow rate.
A 4540 m3/hr cooling tower selected for a 16.67 oC range and a 4.45oC approach to 21.11oC
wet bulb would be larger than a 4540 m 3/hr tower selected for a 16.67 oC range and a 4.45oC
approach to a 26.67oC wet bulb. Air at the higher wet bulb temperature is capable of picking up
more heat. Assume that the wet bulb temperature of the air is increased by approximately
11.1oC. As air removes heat from the water in the tower, each kg of air entering the tower at
21.1oC wet bulb would contain 18.86 kCals and if it were to leave the tower at 32.2 oC wet bulb it
would contain 24.17 kCal per kg of air.
In the second case, each kg of air entering the tower at 26.67oC wet bulb would contain 24.17
kCals and were to leave at 37.8oC wet bulb it would contain 39.67 kCal per kg of air.
In going from 21.1oC to 32.2oC, 12.1 kCal per kg of air is picked up, while 15.5 kCal/kg of air
is picked up in going from 26.67oC to 37.8oC.

Fill Media Effects

In a cooling tower, hot water is distributed above fill media which flows down and is cooled due
to evaporation with the intermixing air. Air draft is achieved with use of fans. Thus some power is
consumed in pumping the water to a height above the fill and also by fans creating the draft.
An energy efficient or low power consuming cooling tower is to have efficient designs of fill
media with appropriate water distribution, drift eliminator, fan, gearbox and motor. Power savings
in a cooling tower, with use of efficient fill design, is directly reflected as savings in fan power
consumption and pumping head requirement.

Function of Fill media in a Cooling Tower

Heat exchange between air and water is influenced by surface area of heat exchange, time of heat
exchange (interaction) and turbulence in water effecting thoroughness of intermixing. Fill media
in a cooling tower is responsible to achieve all of above.

Splash and Film Fill Media: As the name indicates, splash fill media generates the required heat
exchange area by splashing action of water over fill media and hence breaking into smaller water
droplets. Thus, surface of heat exchange is the surface area of the water droplets, which is in
contact with air.
Film Fill and its Advantages

In a film fill, water forms a thin film on either side of fill sheets. Thus area of heat exchange is
the surface area of the fill sheets, which is in contact with air.
Typical comparison between various fill media is shown in Table 7.3.

Tablerequirements
Due to fewer 7.3 Typical Comparisons Between Various
of air and pumping Fill Media
head, there is a tremendous saving in power with
the invention of film fill.
Splash Fill Film Fill Low Clog Film Fill
Recently, low-clog film fills with higher flute sizes have been developed to handle high turbid
waters. For sea water,
Possible low clog film fills
L/G Ratio 1.1 –are
1.5 considered as1.5the best choice in terms
– 2.0 of power
1.4 – 1.8
saving and performance compared to conventional splash type fills.
Effective Heat 30 – 45 m2/m3 150 m2/m3 85 – 100 m2/m3
ChoosingExchange
a Cooling Tower
Area
The counter-flow
Fill Height and cross flows 5are
Required – 10two mbasic designs
1.2 –of1.5cooling
m towers
1.5based
– 1.8 mon the
fundamentals of heat exchange. It is well known that counter flow heat exchange is more
effective as compared
Pumping Headto cross flow or parallel
9 – 12 mflow heat exchange.
5–8m 6–9m
Cross-flow cooling towers are provided with splash fill of concrete, wood or perforated PVC.
Requirement
Counter-flow cooling towers are provided with both film fill and splash fill.
TypicalQuantity of Air of Cross flow Spash
comparison HighFill, Counter Flow
MuchTower
low with Film FillLowand Splash
Required
fill is shown in Table 7.4. The power consumption is least in Counter Flow Film Fill followed by
Counter Flow Splash Fill and Cross-Flow Splash Fill.
Table 7.4 Typical Comparison of Cross flow splash fill, Counter Flow Tower
with Film Fill and Splash Fill

Number of Towers : 2

Water Flow : 16000 m3/hr.

Hot Water Temperature : 41.5oC

Cold Water Temperature : 32.5oC

Design Wet Bulb Temperature : 27.6oC

C
7.3 Efficient System Operation o
o
Cooling Water Treatment l
i
Cooling water treatment is mandatory for any cooling tower whether with splash fill or with n
film type fill for controlling suspended solids, algae growth, etc. g
With increasing costs of water, efforts to increase Cycles of Concentration (COC), by
Cooling Water Treatment would help to reduce make up water requirements significantly. In T
large industries, power plants, COC improvement
Counter Flow Filmis oftenCounter
considered
Flowas a key area for water
Cross-Flow Splash o
conservation. Fill Splash Fill Fill w
Fill Height, Meter 1.5 5.2 11.0 e
Drift Loss in the Cooling Towers r
Plant Area per Cell 14.4 × 14.4 14.4 × 14.4 12.64 × 5.49
It is very Number
difficult ofto Cells
ignoreper
drift problem6 in cooling towers. 6Now-a-days most of 5the end F
Tower
user specification calls for 0.02% drift loss. a
With technological
Power at development
Motor and processing
253 of PVC, manufacturers
310 have brought
330 large n
change inTerminal/Tower,
the drift eliminator
kW shapes and the possibility of making efficient designs of drift s
eliminators that Pumping
Static enable end user to specify
Head, 7.2 the drift loss requirement
10.9 to as low as 0.003 –
12.05
0.001%.
The purpose of a cooling tower fan is to move a specified quantity of air through the system,
overcoming the system resistance which is defined as the pressure loss. The product of air
flow and the pressure loss is air power developed/work done by the fan; this may be also
termed as fan output and input kW depends on fan efficiency.
The fan efficiency in turn is greatly dependent on the profile of the blade. An aerodynamic
profile with optimum twist, taper and higher coefficient of lift to coefficient of drop ratio can
provide the fan total efficiency as high as 85-92 %. However, this efficiency is drastically
affected by the factors such as tip clearance, obstacles to airflow and inlet shape, etc.
As the metallic fans are manufactured by adopting either extrusion or casting process it is
always difficult to generate the ideal aerodynamic profiles. The FRP blades are normally
hand moulded which facilitates the generation of optimum aerodynamic profile to meet
specific duty condition more efficiently. Cases reported where replacement of metallic or
Glass fibre reinforced plastic fan blades have been replaced by efficient hollow FRP blades,
with resultant fan energy savings of the order of 20-30% and with simple pay back period of
6 to 7 months.
Also, due to lightweight, FRP fans need low starting torque resulting in use of lower HP
motors. The lightweight of the fans also increases the life of the gear box, motor and bearing
is and allows for easy handling and maintenance.
Performance Assessment of Cooling Towers
In operational performance assessment, the typical measurements and observations involved
are:
• Cooling tower design data and curves to be referred to as the basis.
• Intake air WBT and DBT at each cell at ground level using a whirling pyschrometer.

• Exhaust air WBT and DBT at each cell using a whirling psychrometer.

• CW inlet temperature at risers or top of tower, using accurate mercury in glass or a digital
thermometer.

• CW outlet temperature at full bottom, using accurate mercury in glass or a digital

thermometer.

• Process data on heat exchangers, loads on line or power plant control room readings, as
relevant.

• CW flow measurements, either direct or inferred from pump motor kW and pump head and
flow characteristics.

• CT fan motor amps, volts, kW and blade angle settings

• TDS of cooling water.

• Rated cycles of concentration at the site conditions.

• Observations on nozzle flows, drift eliminators, condition of fills, splash bars, etc.
 3
The findings of one typical trial pertainingCT
to the Cooling Towers of a Thermal Power1565
water Plantm3 /hr
x
*
200 MW is given below: = (1565000 kg/hr)
Flow/Cell, m3/hr
Observations (Rated 1875 m3/hr)
* CT Fan air Flow, = 989544 m3/hr
Analysis
m3/hr (Avg.) (Rated 997200
Comments m3/hr)
• Cooling water
* flow per cell is much lower, almost
CT Fan by 16.5%,= need to investigate CW
air Flow pumpkg/hr
1068708
and system performance for improvements.
kg/hr (Avg.) Increasing CW flow through cell was
identified as a key result area for@improving performance
Density of 1.08 of cooling towers.
• Flow stratification in 3 cooling tower cells 3
kg/midentified.
* identified in 6 cooling tower
• Algae growth L/G cells.
Ratio of C.T. = 1.46
kg/kg (Rated 1.74 kg/kg)
• Cooling tower fans are of GRP type drawing 36.2 kW average. Replacement by efficient
* CT Range = (44 – 37.6) = 6.4oC
hollow FRP fan blades is recommended.
* CT Approach = (37.6 – 29.3) =
7.4 Flow Control Strategies 8.3oC
Control of tower
* air flow can be done by%varying methods: starting
CT Effectiveness = and stopping (On-off) of
fans, use of two- or three-speed fan motors, use of automatically adjustable pitch fans, use of
* Unit Load 1 & 3 of == 398 MW
variable speed fans. the Station
=
On-off fan operation of single speed fans provides the least effective 43.53 fans
control. Two-speed
provide better* control with further improvement
Mains Frequency
shown with =three speed fans. Automatic
49.3
* Rated % CT = 100 * (43 – 33) /
adjustable pitch
* fans and variable-speedEffectiveness
fans can
Inlet provide
Cooling even=closer control of tower
Water (43 cold-
27.5) 43oC)
44–(Rated
water temperature. In multi-cell towers, fans in adjacent
o cells may be running at different
Temperature C
speeds or some may be on and others off depending upon the=tower load and required 64.5%
water
temperature. **Depending upon the method Outlet
of
Coolingair Cooling
volume =
control
Duty = selected, control 37.6 (Rated 333oC)
strategies
can be determined to minimise fan energy Water Temperature
while achieving 1565 * 6.4 * 10
Handled/Cell in the desired control of the Cold
water temperature. o C
kCal
* Air
(i.e., Wet
Flow Bulb
* == o
Temperature near 10016 * 103 27.5 C)
29.3 (Rated
Temperature kCal/hr (Rated
Cell oC
Difference in
kCal/hr) 18750 * 103
* Air Dry Bulb = 40.8oC
kCal/hr)
* Evaporation = 0.00085 x 1.8 x
Losses in m3/hr circulation rate
(m3/hr) x (T1-T2)

= 0.00085 x 1.8 x
1565 x (44-37.6)
= 15.32 m3/hr per
cell
* Percentage = [15.32/1565]*100
Evaporation Loss
= 0.97%
* Blow down = Evaporation losses
requirement for / (COC–1)
site COC of 2.7
= 15.32/(2.7–1) per
cell i.e., 9.01
m3/hr
* Make up water = Evaporation Loss
requirement/cell in + Blow down Loss
7.5 Energy Saving Opportunities in Cooling Towers
− Follow manufacturer’s recommended clearances around cooling towers and
relocate or modify structures that interfere with the air intake or exhaust.
− Optimise 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.

− On old counter-flow cooling towers, replace old spray type nozzles with new
square spray ABS practically non-clogging nozzles.

− Replace splash bars with self-extinguishing PVC cellular film fill.

− Install new nozzles to obtain a more uniform water pattern

− Periodically clean plugged cooling tower distribution nozzles.

− Balance flow to cooling tower hot water basins.

− Cover hot water basins to minimise algae growth that contributes to fouling.

− Optimise blow down flow rate, as per COC limit.

− Replace slat type drift eliminators with low pressure drop, self extinguishing, PVC
cellular units.

− Restrict flows through large loads to design values.

− Segregate high heat loads like furnaces, air compressors, DG sets, and isolate
cooling towers for sensitive applications like A/C plants, condensers of captive
power plant etc. A 1oC cooling water temperature increase may increase A/C
compressor kW by 2.7%. A 1oC drop in cooling water temperature can give a
heat rate saving of 5 kCal/kWh in a thermal power plant.

− Monitor L/G ratio, CW flow rates w.r.t. design as well as seasonal variations. It
would help to increase water load during summer and times when approach is
high and increase air flow during monsoon times and when approach is narrow.

− Monitor approach, effectiveness and cooling capacity for continuous optimisation

efforts, as per seasonal variations as well as load side variations.

− Consider COC improvement measures for water savings.

− Consider energy efficient FRP blade adoption for fan energy savings.

− Consider possible improvements on CW pumps w.r.t. efficiency improvement.

− Control cooling tower fans based on leaving water temperatures especially in case
of small units.
− Optimise process CW flow requirements, to save on pumping energy, cooling load,
evaporation losses (directly proportional to circulation rate) and blow down
losses.
 Some typical problems and their trouble shooting for cooling towers are given in Table 7.5.

Table 7.5 Typical Problems and Trouble Shooting for Cooling Towers

Problem / Difficulty
Possible Causes
Remedies/Rectifying Action
1.Excessive absorbed current / electrical load
Voltage Reduction

Check the voltage

2a. Incorrect angle of axial fan blades

Adjust the blade angle

2b. Loose belts on centrifugal fans (or speed reducers)

Check belt tightness

3. Overloading owing to excessive air flow-fill has minimum water loading per m2 of tower section
Regulate the water flow by means of the valve

4. Low ambient air temperature

The motor is cooled proportionately and hence delivers more than name plate power
1. Drift/carry-over of water outside the unit
Uneven operation of spray nozzles
Adjust the nozzle orientation and eliminate any dirt

2. Blockage of the fill pack

Eliminate any dirt in the top of the fill

3. Defective or displaced droplet eliminators

Replace or realign the eliminators

4. Excessive circulating water flow (possibly owing to too high pumping head)
Adjust the water flow-rate by means of the regulating valves. Check for absence of damage to the fill
Loss of water from basins/pans
1. Float-valve not at correct level
Adjust the make-up valve

2. Lack of equalising connections

Equalise the basins of towers operating in parallel
Lack of cooling and hence increase in temperatures owing to increased temperature range
1. Water flow below the design valve
Regulated the flow by means of the valves

2. Irregular airflow or lack of air

Check the direction of rotation of the fans and/or belt tension (broken belt possible)
 QUESTIONS
1.
What do you understand by the following terms in respect of cooling towers? a)
Approach, b) Cooling Duty c) Range d) Cooling Tower Effectiveness
2.
Explain with a sketch the different types of cooling towers.
3.
What do you mean by the term of Cycles of Concentration and how it is related to
cooling tower blow down?
4.
Explain the term L/G ratio?
5.
CT Observations at an industrial site were * CW Flow : 5000 m3/hr * CW in
Temperature : 42oC * CW Out Temperature : 36oC * Wet Bulb Temperature : 29oC
What is the Effectiveness ofREFERENCES
the cooling tower?
6.
1. ASHRAEWhat is the function of fill media in a cooling tower?
Handbook
7.
2. NPC Case Studies
List the factors affecting cooling tower performance.
8.
List the energy conservation opportunities in a cooling tower system.
9.
Explain the difference between evaporation loss and drift loss?
10.
What is the Blow-down Loss, if the Cycles of Concentration (COC) is 3.0?