Good Cooling Tower Practise

Good cooling tower practises
Georges Hoeterickx
Evapco Europe

Design considerations
Approach :
Difference between cooling tower outlet temp.
and design entering wb temp.
Cooling tower size versus approach
Cooling Tower Size
6
5
4
3
2
1
0
3
Approach F
10
11
12
Minimum approach
CTI Certification under STD-201

Certification is limited to thermal operating
conditions.. and a cooling approach of
2.8C (5F) or greater.

Cooling tower range
Range :
Difference between cooling tower inlet and
cooling tower outlet temperature.
Cooling tower size versus range
C.T. Size
1,2
1
0,8
0,6
0,4
0,2
0
80%
90%
100%
110%
Range
120%
130%
140%
150%

Avoid recirculation :
Bypass of warm discharge air into the cooling
tower air inlet will cause capacity losses.
Avoid recirculation
Top of cooling tower should be at least level

with enclosure.
Avoid recirculation
Fan discharge velocity : min. 1200 fpm
(6 m/sec).
Downward velocity : max. 600 fpm
(3 m/sec).
Avoid recirculation
Limit downward velocity - two side air inlet units
Avoid recirculation
Limit downward velocity - single air inlet units

Use of VFDs for fan motors :

Allow to control air flow through the cooling
tower
VFDs for fan motors
Energy saving ?
Condenser water temp 1F

Chiller efficiency 3%
Cooling tower kW = ~ 5 %
Chiller kW.
VFDs for fan motors
Water consumption :
Air flow
Water consumption
Plume formation :
Air flow
Plume formation tendency
Noise control @ night
Fan @ half speed : 9 dBA fan noise

(60% capacity)
VFDs for fan motors
Min. RPM for gear
(motor speed 450 RPM)

Gear with mechanical oil pump for proper
lubrication
Cooling tower basins
Common basin
+ Easier basin and cooling tower construction.

+ No need for equalizing connection
- Maintenance sump cleaning

Cooling Tower Basin :

Hold circulating water of the tower.
Cooling Tower Basin
Individual Basin per Cell
+ Easier for maintance (water)

- Need equalizing between basins.
- More costly construction
Cooling Tower Basin
Sound mats to reduce water noise

Noise reduction function
number of layers
distance mats water in basin !
Sound mats will obstruct basin access :
maintenance !

Obtain the specified and correct
quality level !
Obtain the specified quality

Cost distribution main items
Fan
Gear & Motor
Fill
Structure
Louvers
DE
Water Dis.
Fan Stack
Other

Typical requirements:

FRP structure
Reputable manufacturers have their
components third party tested per

ASTM E 84 for strength values and
flamability
Ask if these evidences are part of contract
submittals !

FRP structure
Three factors influence life expectancy :

Creep : long term deformation of a member
under load
Shear : FRP strong in one direction

UV degradation

FRP structure : creep
Design structure loads primarily taken by
fiber unidirectional
Loads by resin to be maintained low
Correct design assures long life time

FRP structure : shear
Loads in plane of laminate by resin

Avoid water migration by proper sealing
all holes
Inspect on regular basis

FRP structure
UV protection
UV degradation and moisture penetration
will have influence life time of an FRP

cooling tower
The UV rays will cause the decomposition of
the polymers holding the fibre glass together
FRP structure
UV protection
Surface veil material of non woven polyester
fabric to prevent fiber blow out
Surface veil creates a resin rich surface area
to provide enhanced UV protection
One mil thickness of surface veil =
2 3 years life time
FRP structure
UV protection
STRUCTURAL
RESIN 55-25%
GLASS 45-75%
WOVEN ROVEN AND
CONTINUOUS GLASS
250 MILS OR MORE
CORROSION BARRIER
RESIN 60-70 %
GLASS 30-40%
MAT OR CLOTH
40-60 MILS
EXTERNAL LINER
RESIN RICH 80-90%
GLASS 10-20%
15-20 MILS
SURFACING VEIL TYPE C
10-20 MIL THICKNESS
FRP structure
UV protection
Useful life of UV projected components

80
70
60
50
Midde East Climate
European Climate
40
30
20
10
0
5
10
15
20
25
30
Years
FRP structure
UV protection
How to verify UV protection quality ?

Have samples of different weight veil
material for comparison.

Variation in the visibility of the Continious
Filament Mat.
Obtain the required quality

FRP structure
Fire retardancy
Fire resistance and damage control of the
FRP structure.
FRP structure
Fire retardancy
Design with high quality, heat resistant / fire
retardant resin systems, Class 1 type
Specify self extinguishing

High glass content = minimum burn rate
Addition Antimony Trioxide improves fire
retarding

FRP structure
Major part of the cooling tower cost
Most critical item for the cooling tower life
time !
How to obtain the required quality ?

FRP structure
1. Demand cooling tower supplier names the FRP

source and ask delivery certificates from the
FRP manufacturer.
2. Reserve the right to inspect before delivery to
verify Quality Process Map is complied with.
Obtain the best quality

Fans
Obtain the best quality

Fans
Fans are selected for a given airflow and
static pressure
Fan design parameters :
diameter speed nbr and shape of blades

blade width
Fan design parameters influence :
cost power consumption noise
Cooling tower fans

Noise definition
Specify sound pressure

in dB(A) measured 1,5 meter
above fan discharge
(per CTI std ATC 128)
Cooling tower fans

Noise
Cooling tower fans

Comparison - 2000 ton tower - 196 m/ sec @ 160 Pa pressure drop
Fan
dia
Nbr
Blades
Rpm
ft
Tip
speed
Sound
Power
Fan shaft
Power
Fan
m/sec
dB(A)
kW
US $
14
270.8
60.5
100.3
59.3
2100
16
193.9
49.5
95.6
53.2
3600
18
186.8
54.2
99
46
13500
18 *
137
40
86.3
54.9
45000
Cooling tower fans

Fan power vs cost 2000 ton tower 196 m/sec @ 160 Pa pressure
drop
Fan dia
Tower price
Fan Power
ft
kW
14
16
+ 1, 25 %
- 11 %
18
+8 %
- 22 %
Cooling tower fans

Comparison - 5000 ton tower - 375 m/ sec @
Fan
dia
Nbr
Blades
Rpm
ft
160 Pa pressure drop
Tip speed
Sound
Power
Fan shaft
Power
Fan
m/sec
dB(A)
kW
US $
22
226
44.2
106.3
106.3
9500
26
104.8
43.5
97.9
87.1
26000
26
89.7
37.2
90.6
104.2
60000
28
82.6
36.9
90
102.3
65000
Cooling tower fans

Fan power noise vs cost - 5000 ton tower
375 m/ sec @ 160 Pa pressure drop
Fan
dia
Tower
price
Power
Sound
Power
ft
kW
dB (A)
22
106.3
26
+7%
- 18 %
97.9
26
20%
-2%
90.6
28
+ 22%
-4%
90

Fan stacks
Fan stacks
Material
Height : 6 8 10 ft -
Material : Class 1 flame spread rating 25
(Class II and Class III = Cheaper !)

UV resistance (gelcoat 20 mil).
Access door or removable panel
Assembly hardware SST
Fan stacks
Make sure fan deck floor opening matches
fan cylinder
Smooth air inlet
Fan tip clearance : 0,5% fan dia

Air inlet louvers
Water stays in
Sunlight stays out!
Air inlet louvers

Single pass louvers
Waterdroplets tend to splash out when fans
are shut off.

Sunlight still enters the cooling tower basin !
Air inlet louvers

Two pass air inlet louvers
Minimise splashout
Direct sunlight is blocked from the water
inside the tower and reducing the potential

for algae formation !
Minimum pressure drop
Air inlet louvers

Two pass air inlet louvers
Typical two pass air inlet louvers

Drift eliminators

Drift eliminators
Drift rates : 0,01 to 0,0005 % of tower flow
rate
Drift rate function of type DE, air velocity,
water loading and spray nozzle types
Drift eliminators
Quality
Drift rate dependends on:
Waterloading
Air velocity
Spray nozzle arrangement
Drift eliminators
Efficiency confirmation
Ask your cooling tower supplier names
manufacturer of DE
Demand independent test certifications
according to accepted standards
Drift eliminators
Execution on site
Air passes through area with minimum resistance

Air bypass reduces cooling effect
Water loss because of higher air velocity
Drift losses
Design considerations : air seals

Mechanical equipment
Fill
Water distribution

Obtain the specified and correct
quality level !
Thank you
Georges Hoeterickx

Good Cooling Tower Practise

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Good cooling tower practises