(AN EXPERT COOLING TOWER PERFORMANCE PROGRAM)

COUNTER FLOW PROGRAM VERSION 2.O for SI UNITS © Copyright 1992 to 2010

BY

RICHARD J. DESJARDINS
DESJARDINS AND ASSOCIATES
38373 CHERRYWOOD DRIVE, MURRIETA, CA 92562 USA
TELEPHONE and FAX 951-600-1564
EMAIL: richard@rjdesjardins.com
Web site: www.rjdesjardins.com
 SUPPORT POLICY

DesJardins & Associates will provide program support regarding the operation of the program.  The support is 
limited to the program operation, itself, and it does not include interpretation of the program results, or guarantee of
the program results.

DesJardins & Associates is available for cooling tower consulting on a fee basis.  Please contact us for a current fee
schedule at telephone or FAX:  USA 951­600­1564, E­mail richard@rjdesjardins.com.

DISCLAIMER

THE RESULTS OF THIS PROGRAM ARE NOT GUARANTEED TO BE ACCURATE. SOME

MANUFACTURER'S DATA USED IN THIS PROGRAM MAY BE UNRELIABLE.

Where we have not been given direct access to manufacturer's data, we have used whatever resources we could 
find, and we have simulated the required information.  In some cases the algorithms used produce results that are 
not precisely equal to the manufacturer's data, however, the results will normally be well within reasonable 
tolerances.

2
 ART vs. SCIENCE

Designing a cooling tower is partially art and mostly science.  "Black Magic" should not exist.  

The art is picking the best box size and the right combination of fill, fan, and other components to give the most 
economical selection.  The most economical selection may be low first cost or low evaluated cost.  

The science is adequately measuring the test data, developing a theory that properly correlates the data and allows 
for application of the data in a manner which does not produce distorted results.  Practical review of the results 
should show the laws of physics still apply, i.e., similar fills should produce similar performance characteristics, 
and similar fans should have similar efficiencies.  There is no "Black Magic".

UNCERTAINTY

Air and water distribution are all important.  The best performance is going to occur when the distribution is even 
over the full area of the tower.  This is difficult to achieve.  Some water nozzles and distributors are better than 
others, and sometimes a manufacturer may claim performance capabilities based on testing with one type of nozzle 
apply to their nozzle when this is really not the case.  

Fan testing may have been done in ideal eased inlet cylinders with very close tip clearances.  Actual field 
installations seldom have extremely close tip clearances to allow for wind load deflections, thermal expansion of 
the fan blades or the cylinder, possible slight slumping of a cylinder over time, and construction assembly 
tolerances.  The shape of the cylinder being used may not be the same as the fan manufacturer used for this tests.  
Improper fan hub seal disks may be used.

Air distribution can be affected by high inlet velocities, louver spacing and angles, wind, partition location, 
obstructions and structural blockage, etc.

Static pressure losses for various components are the most difficult data to measure and predict.  You will most 
likely see significant variations in the pressure drop across individual components, but the total pressure drop will 
normally be quite consistent.  

These are just a few of the many considerations that create uncertainty.  The object is not to hedge:  it is to try the 
best possible to predict something close to reality.

If you have serious doubts about tower operation, the program gives you places to actively make changes.  You can
change the inlet height; increase or decrease the "blockage factor"; change the "recirculation allowance" which 
makes a direct change to the required L/G; add or delete static pressure to account for air inlet screens or different 
louver designs; or choose your own total fan efficiency if you don't like what the manufacturer's fan program 
predicts.

3
 PROGRAM PHILOSOPHY

In some cases performance test data from several sources has been considered in establishing the correlation line.  
In other cases, test data showed variations in performance based on type or size of distribution nozzle or orifice.  
The final analysis of the data usually resulted in a straightline function when plotted on a log­log graph of KaV/L 
vs. L/G. 

The establishment of the correlation line is based on the philosophy that it is the BEST one could expect given 
good air and water distribution: i.e, the manufacturer could always get to the distribution system to fix or change 
nozzle spacing or elevation, etc.  However, you are cautioned, that some distribution systems work better at non­
design condition flow rates than others.  Good examples are a high pressure design hollow cone nozzle in a counter 
flow tower that only gives a small stream of flow at a low flow rate, or operating with too little head in the hot 
water basin of a cross flow tower to get water to all portions of the basin.  The program does not predict 
performance under such conditions: it assumes you have good distribution.

Where adequate data on a given fill, drift eliminator or other component is not available, we have used what might 
be believable:  In any case, performance is "Predicted", it is not "Guaranteed"!  In most cases, we would expect to 
be within two percent (plus or minus), or 0.1oC., which ever is the greater.  We hope there are no variations from 
reality that exceed five percent, but it could exist.  We have several sets of actual test data which indicate the 
program predicted performance with less than 0.5% variation, however, this not always the case, and in some cases 
there is no field test data to back up information provided to us on laboratory tests or consolidated test results.

Data on some of the older fill types has been passed down from companies that no longer exist, or people no longer
in the industry:  It is the best available, so it was included.  If more up­to­date information is received, program up­
grades will be offered.

Manufacturers of fans and other components often do not guarantee performance in a particular installation:  if they
don't, how can we?  However, we do not think it should be necessary to include huge pads in performance unless 
you think there could be large amounts of "recirculation" do to the tower location, orientation, or normal weather 
conditions.

We have seen installations with as much as 2 o C to 5o C of "recirculation" at the inlets under some operating 
conditions.  If you expect this to happen in your installation during high wet bulb periods, it would be prudent to 
add to the tower size, either by raising the inlet wet bulb, or including a "recirculation factor" greater than 1.0.

4
 PROGRAM USER INTERFACE

This is a stand­alone program, but in some cases it uses spread sheet like formulas which can be changed on the 
screen.  Actually, it has a simplified spread sheet for the screen.  Data is taken from some cells on the screen, it is 
processed, and the results are written to the screen. The referenced cell numbers, like you would have in a common 
spread sheet, are shown in the lower left hand corner of the screen.  If you write in some cells, your changes will be
over written when the program is run.  This format was used to allow you flexibility. 

This format was used because it is much more difficult to program for everyone's tower than for a given 
manufacture's product or line of products.  It is amazing how many variations we have seen.  One manufacturer 
may have high air rates and low static pressure drops, while another will have just the opposite.  Yet, the final total 
fan horsepower will be the same.

As an example, with the format used, you can make adjustments to the static pressure for an air inlet screen and let 
the additional pressure drop vary with the air flow rate by including a formula in cell F7 that varies as a function of 
the velocity raised to a power.  Or, you could change the formula for the stack outlet diameter shown at cell D2 
which is normally based on a 7.5 degree stack flair.  Also, using the spread sheet format produces immediate 
changes in the tip speed given a change in the gear ratio or motor rpm.  You don't have to wait to run the program 
to see if you guessed right.

5
 WHAT MUST BE INCLUDED ON THE DISK

1) The main program: SICFLOW.EXE (counter flow). 

2)  SCMASTER.CFT (counter flow): (the start­up screens for the performance program.)  CAUTION: do 
NOT delete these files and do NOT "save" a screen in this file name.

3) CFLOWFIL.CFT: The fill data files.  They are ASCII type files because you might want to add more fills 
in the future, and you could do it with only our telephone advise.

4) SCFPRICE.CFT:  The master pricing estimator file.  CAUTION: do NOT delete this file and do NOT 
"save" a screen in this name.

ENTERING DATA
Most of what you need to enter is included in the first one and one­half columns of data.

When the program first starts it loads a SCMASTER screen which may be modified to fit your needs.

If you change the input of any cell, you must invoke one of the two possible run functions.

When entering data, press the <ENTER> key once to enter the new data, and once more to automatically go to the 
cell below.  If you are in the bottom cell it will "wrap" to the top, and if you are using arrows to get to the next 
column they also "wrap" both left and right.  The program does NOT support a mouse – it is actually quicker to use
without a mouse.

You can enter a formula starting with a + sign.  You edit a formula starting with the <ESC> key.  Formulas show in
the lower left hand corner of the page.

An attempt has been made to cover all the possible ways the program would fail to run.  For example, a check is 
made and warnings are included that prevent the program from failure because you entered a letter where a number 
or formula should exist, or it will not let you run with a fan diameter bigger than the cell width. I cannot protect 
against bad input such as entering 1000 instead of 100.  If the answer obviously looks wrong you should check your
input.

If you find a situation you believe should be covered with a fail safe addition to the program, please let us know, 
and will modify it and send you a new copy.

6
 RUNNING THE PROGRAM

The main program controls are accessed with the / [slash] key.  Press the highlighted letter to invoke an action.

    '/': [slashkey]: Pressing the slash key refreshes the screen and returns you the enter data mode.

    '/Q': Quit:  Stops the program.

    '/M': ForMat; Allows you to set the number of decimals in a cell.  Caution: it also lets you set the cell 
width, and it is possible to overwrite the cells to the right if you make the cell too wide.  
The default should be ten letters or numbers.  If you make a mistake, bring up the 
SCMASTER screen and start over.

    '/S': Save; You may save your customized screen under the file name SICF.CFT (counter flow) by 
simply pressing the [ENTER] key, or you may assign any eight letter name and it will be
saved under [YOURNAME.CFT].  Also, when the program runs, there is an automatic 
save of the screen as SICFX.CFT if the AUTOSAVE function described below is 'ON'.  
CAUTION: NEVER SAVE A FILE A 'MASTER' OR 'SCMASTER'!

    '/L': Load; You may load a saved file by typing just the name of the file without the .CFT file 
extension.  If you forget what you were going to load, load SCMASTER.

    '/E':  Estimator; Saves the performance screen to file "SICFX.CFT" on your current disk, clears the 

screen and loads file SCFPRICE.CFT, the "Price Estimator" screen.  The screen is NOT 
saved when you leave the Price Estimator unless you save it under another name.

    '/A': Auto; Toggles the auto save function on and off.  If you have entered data or made a "typing" 
error which we have not anticipated in the program warnings an error detection 
functions, you will be glad you saved the file.  It is also useful when you make a change,
have not yet run the program, and decide to return to what you just did.

    '/C': Clear; Clears the screen.  You could use it as a simple spread sheet.

    '/P': Print; Allows you to print the screen.  This function includes a simple one line editor.  The 
program asks you if you want to print a header at the top of the print­out.  You can add 
lines of text, one line at a time.  When you press the [ENTER] key, it asks if you want to
add another line.  It will do this until you indicate NO.  It will then print the screen, add 
the date, and time before asking if you also want to add notes at the bottom, as you did 
for the header at the top.

    '/F': Form Feed Form Feeds most printers from your key board.
     

    '/I ': Integrate; The full integration routine is run for the counter flow program.  You must use this 
routine if you have changed any of the data in the left hand column above the dashed 
line. (cells B1 ­ B10).

7
    '/T': Tower; If you have not changed anything above the dashed line in the left hand column of data, 
(cells B1­ B10) it is not necessary to re­run the integration routine.   You would use this 
if you have changed some other "Tower" component or size that did not affect the base 
L/G obtained from the integration routine.  Using "/T" does not save much time in the 
counter flow program in the non­CTI ("offset") mode. 

    '/H': Help; Help comments are provided at each cell on the screen.  They are also tabulated in the 
Manual with additional comments.  This is also where you can look at what fills, fans, or
eliminators are included and the proper entry designation to use them.

    '/D': Directory: Gets a directory given Path; example: C:\PATH\*.CFT will list all the files with a .CFT 
file extension in directory C:\PATH on your disk.  This function was included so you 
could look up the name of a file you saved, so you could load it.  Entering *.CFT, 
without a path, reads all the .CFT files on the current directory.

     THE FOLLOWING COMMANDS ARE NOT SHOWN ON THE COMMAND LINE:

    '/R': Recalculate: Recalculates the formulas in the screen. 

    '/O': Out File Q: Saves the current screen as a Quote and Comma delimited file under the file name 
CFLOWQ.PRN.  This file can be imported to a spread sheet program like Excel or Lotus
123 for further processing.  File CFLOWQ.PRN is overwritten each time this function is
invoked, so you may want to exit the program and change it's name for permanent 
storage.

     'W': Out File W: Saves the current screen as an ASCII file under the file name
CFLOWW.CFT.  This file can be imported to a word processor program like Word 
Perfect for further processing.  File CFLOWW.CFT is overwritten each time this 
function is invoked, so you may want to exit the program and change it's name for 
permanent storage.

8
 HELP SCREEN SUMMARY
CELLS B1-B5 AND B7-B8

ENTER TEMPERATURES IN DEGREE C.

Consult the fill manufacturer for maximum temperatures allowable for their products.
Normally, standard PVC fill and eliminators are limited to about 52 degrees C maximum hot
water temperature. CPVC, polypropylene, etc. may have higher limits.

The program will check to see if you have entered data correctly: example the cold water cannot
be less than the hot water, etc.

ENTER ALTITUDE, FILL HEIGHT AND INLET HEIGHT IN METERS

FOR REFERENCE:

PSIA = INCHES Hg * 14.696/29.921

ALTITUDE =(EXP((LN(PSIA/14.696))/5.2561)-1/(-6.8745E-6))

CHANGING ANYTHING ABOVE THE DASHED LINE REQUIRES RE-INTEGRATIO-

N, USE THE "/I" (SLASH i) COMMAND TO RUN THE INTEGRATION ROUTINE.

IF THE INTEGRATION ROUTINE HAS BEEN RUN, YOU CAN CHANGE THE
TOWER CONFIGURATION, FLOW RATE, FAN SIZE OR OTHER
CHARACTERISTICS BY USING THE "/T" (SLASH t) COMMAND SO YOU WILL
NOT HAVE TO WAIT FOR THE INTEGRATION ROUTINE TO RUN: SAVES THE
MOST TIME IN "OFFSET" MODE.

BEFORE THE PROGRAM RUNS, THE SCREEN IS SAVED TO FILE CFX.CFT, JUST
IN CASE SOMETHING GOES WRONG. YOU CAN TOGGLE THE SAVE FUNCTION
OFF AND ON WITH "/A" (SLASH a) FROM THE COMMAND LINE; IF
SOMETHING GOES WRONG, YOU CAN RECALL THE SCREEN USING "/L"
(SLASH L).

CELL B6 This help function lists the fills contained in file CFLOWFIL.CFT. Those fills included in the
counterflow program at the time of this release are listed below along with additional comments
about the fills and their test source.

Fill Test Manufacturer Sheet Nozzle

Type Source Spacing Type

Fill data included in the test data as published in CTI paper TP-88-05 by Robert Fulkerson may
be the best information published so far. In general it is in agreement with other data, however,
where there is reason to doubt it, slight modifications have been made. Since the fills listed for
the "Fulkerson" test appear to be the most used in the USA at the time of this publication, we
believe you should use this data as compared to other test data listed below by other sources.

MF19060 FULKERSON MUNTERS 19 MM MUNTERS

MF12060 FULKERSON MUNTERS 12 MM MUNTERS
ATPF FULKERSON ATP 1.63 IN MARLEY

Fill Test Manufacturer Sheet Nozzle

9
 Type Source Spacing Type

MC67F FULKERSON MARLEY 0.67 IN MARLEY

BF1900 FULKERSON BRENTWOOD 19 MM MUNTERS
BF1200 FULKERSON BRENTWOOD 12 MM MUNTERS

Test data from EPRI (EPRI GS-6370, Vol.1 &2) may not properly reflect what would be
obtained in regular applications. For example, the Marley MC67 fill appears to be greatly under
rated, as measured by the EPRI tests. This data should be used with caution. It is included for
reference and because in some cases it is the only source of testing available at this time. Note
that all these fills were tested with the Marley nozzle, and there is a great chance other nozzles
may not perform as well under some conditions.

MU19060 EPRI MUNTERS 0.73 IN MARLEY

MC67E EPRI MARLEY 0.64 IN MARLEY
BW1900 EPRI BRENTWOOD 0.73 IN MARLEY
MU12060 EPRI MUNTERS 0.45 IN MARLEY
TOSCHI EPRI TOSCHI 0.72 IN MARLEY
ATPE EPRI HAMON 1.63 IN MARLEY
COOLDROP EPRI HAMON 8.0 IN MARLEY
SHAPE10_1 EPRI ECODYNE 12.0 IN MARLEY
SHAPE10_2 EPRI ECODYNE 24.0 IN MARLEY

The testing by Ovard of the Brentwood and Munters fills included very few test points. Usually
nine to twelve test points per run. Considering the difference in nozzles, it appears to agree quite
well with the Fulkerson data.

MO19060 OVARD MUNTERS 19 MM CONE

MO12060 OVARD MUNTERS 12 MM CONE
BO1900 OVARD BRENTWOOD 19 MM CONE
BO1200 OVARD BRENTWOOD 12 MM CONE

The reliability of the following tests are unknown. They will be included in future releases for
lack of better data. Initial releases will be updated with this data as soon as it is reviewed.

Fluor10_1 FLUOR ECODYNE 24 INCH UNKNOWN

D_DECK PRITCHARD NONE 24 INCH UNKNOWN
CERAMIC UNKNOWN CERAMIC STACKED UNKNOWN

CELL B9

THIS PROGRAM RUNS IN TWO ALTERNATE MODES.

ENTER "CTI" AT CELL B9 AND IT DUPLICATES THE STANDARD CTI MERKEL

THEORY WHICH DOES NOT TAKE INTO ACCOUNT WATER EVAPORATION,
LEWIS NUMBER VARIATIONS, OR HOT WATER CORRECTION FACTORS. IT
ALSO USES STANDARD TCHEBYCHEFF QUADRATURE INTEGRATION.

You will find it may save time to make preliminary calculations with the "CTI" mode. When you arrive
at a probable best fit design, run the "offset" mode to see if hot water corrections are significant.

ENTER "OS" IN CELL B9 AND THE PROGRAM RUNS IN THE "OFFSET" MODE
AS DESCRIBED BY BAKER AND SHRYOCK IN "JOURNAL OF HEAT TRANSFER
AUG, 1961, PP 339-348, AND CTI PAPER TP92-01 BY RICHARD DESJARDINS.
THIS MODE ACCOUNTS FOR ALL MERKEL SIMPLIFICATIONS, AND WILL GIVE
MORE ACCURATE RESULTS, ESPECIALLY AT HIGH HOT WATER TEMPERA-

10
 TURES. IT USES A 10 POINT GAUSS INTEGRATION ROUTINE.

The "offset" system has built-in hot water correction factors inherent in the method of integration. The
theory is different. Do not mix data from the "offset" system and the "CTI" system.

CELL B10

THE SPECIFIC HEAT OF NORMAL COOLING WATER IS 1.0.

Contact DesJardins and Associates if you are calculating for sea water or oily water.

CELL B12

ENTER THE TOTAL FLOW RATE FOR ALL CELLS. Cubic meters per hour.

CELL B13

ENTER THE TOTAL NUMBER OF CELLS.

CELLS B14 AND B15

ENTER THE CELL WIDTH AND LENGTH IN MM.

CELL B16

FOR NORMAL WOOD TOWER CONSTRUCTION THE BLOCKAGE FACTOR SHO-

ULD BE APPROXIMATELY 1.05 ( i.e 5%) OF THE AIR AND WATER AREA IS
BLOCKED BY STRUCTURAL MEMBERS. THIS WAS THE BASIS OF THE TEST
DATA.

ELIMINATORS ARE CONSIDERED TO HAVE THE SAME BLOCKAGE AS THE

FILL. IF ELIMINATORS ARE PLACED BETWEEN THE DISTRIBUTION MANI-
FOLDS, THEN YOU SHOULD CONSIDER INCREASING THE ELIMINATOR
PRESSURE DROP BY THE SQUARE OF THE INVERSE RATIO OF THE REDUCED
AREA.

DO THIS AT CELL F7, "Extnl (hs)", BY ENTERING A FORMULA LIKE :

+ F4/0.9/0.9-F4

CELL B17
ELIMINATOR CHOICES

CELLULAR Generic Cellular Type

D15 Munters D15 Cellular Type
XCEL10 Marley 1.0" Spacing Cellular
XCEL15 Marley 1.5" Spacing Cellular
MCPS Munters CPS 4" thick Cellular
W2 Wood Blade 2.0" Spacing 2-Pass
W2.5 Wood Blade 2.5" Spacing 2-Pass
W2 ThermaTec Spectra "C"
W2.5 ThermaTec Spectra "A"
CDX150 Brentwood 1.5" Cellular
CDX080 Brentwood 0.8" Cellular
DE080 Brentwood 0.8" Wave
Form
DE120 Brentwood 1.20" Wave

11
Form
DE097 Brentwood 0.97" Wave
Form, 40% Exit
TU12C Marley 1.2” Spacing
Cellular
100 Brentwood CL100 Cellular Eliminators

CELLS B18 - B19

INDICATE "Y" OR "N" IF THERE ARE LOUVERS ON ONLY ONE SIDE OF A CELL
ALSO, ALSO INDICATE "Y" OR "N" IF THERE ARE LOUVERS ON THE WIDTH
AS WELL AS THE LENGTH OF A CELL.

PLEASE NOTE THAT TOWERS WITH MORE THAN TWO CELLS ARE COMPRO-
MISED BY THE PROGRAM AS THE INLET LOUVER LENGTH IS AVERAGED. TO
GET AN ACCURATE ASSESSMENT OF THE OPERATION OF THE MIDDLE
CELLS, IT IS NECESSARY TO MAKE A SEPARATE RUN OF THAT CELL USING
NO LOUVERS ON THE WIDTH. YOU MAY FIND THE INLET VELOCITY
INCREASES DRAMATICALLY FOR THE MIDDLE CELLS.

CELL B20

ENTER 0 FOR NO LOUVERS.

ENTER 100 IF LOUVERS ARE LIKE BRENTWOOD CL-100 CELLULAR LOUVERS
ENTER LOUVER SPACING IN MM.
IT IS SUGGESTED YOU LIMIT SPACING TO 250 TO 1000 MM.

CELL B21

USE THIS CELL TO EITHER ADD A PAD FOR RECIRCULATION AS A DECIMAL

PERCENT (LIKE 1.02), OR USE IT TO DETERMINE THE ANTICIPATED
PERCENTAGE CAPACITY: i.e. IF YOU ENTER A NUMBER LIKE 0.92 AND WHEN
THE PROGRAM RUNS IT RESULTS IN THE VENDORS QUOTED BHP, THEN IT IS
LIKELY THE BEST THE TOWER WILL DO IS 92 % CAPACITY.

IN EFFECT, THIS IS THE "MAGIC FACTOR": IT ADJUSTS THE L/G.

CELL D1

VELOCITY RECOVERY IS CALCULATED AT 75% OF THE DIFFERENCE

BETWEEN THE VELOCITY HEAD OF THE NET DISK AREA AND THE VELOCITY
HEAD AT THE STACK OUTLET FOR ALL HEIGHTS OVER 6 FEET. FOR HEIGHTS
LESS THAN 6 FEET, SPECIFY 6 FEET

PROPER PROPORTIONS FOR VELOCITY RECOVERY STACKS ARE:

FAN DIAMETER TOTAL STACK HEIGHT

14 FT (4267 MM) TO 20 FT. (6096 MM) 10 FT. (3048 MM)
20 FT (6096 MM) TO 24 FT. (7315 MM) 14 FT. (4267 MM)
24 FT (7315 MM) TO 32 FT. (9754 MM) 18 FT. (5486 MM)

NORMAL VELOCITY RECOVERY STACK FLARE IS APPROX. 7.5 DEGREES

12
CELL D2
HELPFUL HINT:

IF YOU ENTER THE FOLLOWING FORMULA IN CELL D2, THE STACK OUTLET
DIAMETER WILL BE AUTOMATICALLY CALCULATED FOR YOU BASED ON ANY
STACK HEIGHT OVER 1800 MM (SIX FEET) AND THE FAN DIAMETER EN-
TERED AT D3.

+((D1-1800)*0.26)+D3

IF YOU GET A WARNING THAT "STACK OUTLET DIAMETER CANNOT BE LESS

THAN FAN DIAMETER", SET THE STACK HEIGHT TO 1800 MM.

CELL D3

ENTER FAN DIAMETERS IN FEET.

ALTHOUGH THE ALGORITHMS INCLUDED FOR THE FANS MAY FUNCTION FOR
LARGER AND SMALLER FAN DIAMETERS, YOUR SELECTIONS SHOULD BE
LIMITED TO 1525 MM TO 10000 MM FANS TO OBTAIN REASONABLE ACCU-
RACY. SEE THE HELP SCREENS FOR FAN TYPE, HUB DIAMETER AND
NUMBER OF BLADES FOR ADDITIONAL INSTRUCTIONS AND LIMITATIONS.

CELL D4
HUB DIAMETERS SHOULD BE ENTERED IN MM, EXCEPT FOR MOORE

PROPER HUB DIAMETERS ARE AS FOLLOWS: (SEE HELP SCREEN AT D4

FOR MM VALUES). DATA SHOWN BELOW IS IN FEET.

MARLEY
HUB DIA. FAN DIA. HUB DIA. FAN DIA. HUB DIA. FAN DIA.
1 TO 4.5 1.5 5 TO 6 2 7 TO 8
2.5 9 TO 12 4 12 TO 18 6 20 TO 22
8 24 TO 32

HUDSON:
HUB DIA. FAN DIA. HUB DIA. FAN DIA. HUB DIA. FAN DIA.
2.5 5 TO 10 3.17 11 TO 12 3.83 13 TO 14
4.42 14 TO 20 6 22 TO 24 7 26 TO 28
8 30 TO 32

MOORE:

NOTE: MOORE FAN HUBS ARE ENTERED IN INCHES

HUB DIA. FAN DIA. HUB DIA. FAN DIA. HUB DIA. FAN DIA.
19 3 TO 7 27 4 TO 10 33 5 TO 12
40 6 TO 14 49 8 TO 18 60 9 TO 22
73 11 TO 24 90 14 TO 24

CELL D5

FAN CHOICES: ALL SELECTIONS ASSUME VERY GOOD CYLINDERS. CHECK

THE HELP LISTING UNDER HUB DIA. TO GET CORRECT HUB SIZE. CHECK

13
 THE HELP LISTING UNDER STACK HEIGHT FOR ASSISTANCE.

HUDSON: "H" FAN: 4 THROUGH 12 BLADES

TIP CLEARANCES ARE VERY TIGHT. USE 1.03 RECIRC ALLOWANCE
OR USE COLUMN "F" TO REDUCE EFFICIENCY ABOUT 3% FOR
NORMAL CYLINDERS

MARLEYH3: ALSO GOOD FOR KOPPERS OR ENELCO

LIMITED TO 8, 9, AND 12 BLADED FANS

(Many of the old Koppers and ENELCO fans, and some of the old Marley fans were
installed in old style fan stacks with wide tip clearances. you might consider decreasing the
fan efficiencies 3 to 4 percent to be more realistic. Do this at Cell F19)

MARLEYHP4: LIMITED TO 8 BLADES IN TALL STACK

MARLEYHP7: LIMITED TO 6 BLADES: LIKE HUDSON B BLADES

MARLEYH3TC; SHORT CONE CYLINDER, LOW EFFICIENCY FAN

(This data was included to demonstrate how poor the fan efficiencies might be if you use
lower cost fabrication. Many of these cylinders are used on small package and field erected
tower. They usually only 18" to 36" high, and by the nature of the truncated cone design,
the tip clearance is usually quite wide. Also, these cylinders usually have a fan guard, and
the pressure drop of the guard is seldom considered. Proceed with caution.)

MOORE: USES MOORE EQUATIONS AND COULD BE + OR - 3%.

ENTER HUB SEAL DIAMETER IN INCHES. ALLOWABLE HUB SIZE ENTRIES
ARE 19, 27, 33, 40, 73, AND 90

CAUTION: DO NOT USE FAN DATA WITH TOTAL EFFICIENCIES GREATER THAN
84 % FOR LARGE DIAMETER FANS, AND 78% FOR SMALLER FANS. VERY
SMALL FANS COULD HAVE EFFICIENCIES AS LOW AS 55% TO 68%
DEPENDING ON CYLINDER QUALITY

CELL D6

NORMAL BLADE COUNT AVAILABLE WITH VARIOUS FAN DIAMETERS;

HUDSON:
7 FT TO 14 FT DIAMETER = 4 TO 8 BLADES.
16 FT TO 20 FT DIAMETER = 4 TO 9 BLADES.
22 FT TO 33 FT DIAMETER = 6 TO 12 BLADES.

MARLEY:
5 FT TO 9 FT DIAMETER = 6 OR 8 BLADES.
10 FT TO 18 FT DIAMETER = 6, 8, OR 9 BLADES.
22 FT TO 33 FT DIAMETER = 8 OR 12 BLADES.

MOORE: HUB DIAMETER IS IN INCHES

HUB DIA. MAX NO. BLADES HUB DIA. MAX NO. BLADES
19 4 27 6
33 7 40 10
60 12 73 15
90 18

14
CELL D7 - D10

ENTER MOTOR RPM (LIKE 1750 OR 1260) IN CELL D7.

ADJUST THE GEAR RATIO TO CHANGE THE RPM AND TIP SPEED.

ENTER THE GEAR RATIO IN CELL D8. OBSERVE THE TIP SPEED IS
CALCULATED ON SCREEN.

THE FAN RPM IS CALCULATED IMMEDIATELY ON THE SCREEN. THE

FORMULA IN CELL D9 SHOULD BE:
" +D7/D8 ".

THE TIP SPEED IS CALCULATED IMMEDIATELY ON THE SCREEN. THE

FORMULA IN CELL D10 SHOULD BE:

" +3.1415927*D9*D3 ".

THE TIP SPEED NORMALLY SHOULD BE LIMITED TO ABOUT 61 M/S. FOR

QUITE OPERATION SELECT A GEAR RATIO TO GIVE TIP SPEEDS LESS THAN
50 M/S AND USE MORE FAN BLADES.

BE SURE TO CHECK WITH THE FAN MANUFACTURER FOR CRITICAL FAN

SPEEDS WHICH SHOULD BE AVOIDED AND THEIR MAXIMUM RECOMMENDED
TIP SPEEDS.

CELL D11

NORMALLY GEAR BOX EFFICIENCIES ARE APPROXIMATELY 95 PERCENT.

ACTUALLY, SPIRAL BEVEL GEARS HAVE EFFICIENCIES OF ABOUT 98% AND

THERE IS A "NO LOAD" LOSS DUE TO FRICTION AND OIL VISCOSITY AND OIL
PUMP LOSSES. "NO LOAD" LOSSES ALSO VARY WITH GEAR RATIO.

BKW = (FKW/0.98) + NLL

TO CUSTOMIZE YOUR SCREEN, YOU COULD ENTER THE NLL AT CELL F11.
THEN SET CELL F19 TO +G19, SET F21 TO +(F20/0.98)+D11 AND READ
THE BHP AT F21.

TYPICAL "NO LOAD" LOSSES WITH 30 WT OIL IN SUMMER CONDITIONS ARE:

MOTOR BKW NLL
4TO 12 0.15
12 TO 38 0.75
38 TO 56 1.9
56 TO 75 2.25
75 TO 112 3.0
112 TO 185 3.75
CAUTION: SOME MANUFACTURERS MAY RECOMMEND MUCH HEAVIER OILS.

CELL D12 -D14

THE M3/HR PER CELL, KG OF DRY AIR PER MINUTE PER SQUARE METER OF
NET FILL AREA, AND THE M3/HR PER SQUARE METER OF NET FILL AREA
ARE CALCULATED AUTOMATICALLY BY THE PROGRAM.

15
 ACCURACY OF PROGRAM RESULTS CAN BE GREATLY AFFECTED BY EXTREME
VARIATIONS IN AIR AND WATER RATES. FOR COUNTER FLOW TOWERS.
NORMAL WATER RATES FOR PRACTICAL APPLICATIONS WILL BE WITHIN 7.3
TO 28.3 M3/HR/M2. NORMAL AIR RATES WILL BE BETWEEN 595 AND 1305
KG DRY AIR/MIN/M2.

LIGHT WATER LOADINGS AND HIGH AIR RATES CAN CAUSE EXTREMELY
POOR DISTRIBUTION. HEAVY WATER LOADINGS AND HIGH AIR RATES CAN
CAUSE WHAT IS CALLED "PLUGGING" IN SMALL CELL FILM TYPE FILLS.
CONSULT THE FILL MANUFACTURER FOR RECOMMENDED LIMITS.
PLUGGING CAN SOMETIMES BE ELIMINATED BY USING "ALTERNATE TIPS
RECESSED" IN THE BOTTOM LAYER OF FILM FILLS.

OPERATION AT WATER RATES MUCH LESS THAN DESIGN WILL LIKELY

RESULT IN GREATLY REDUCED PERFORMANCE FOR MOST TYPES OF
NOZZLES SINCE NOT ALL THE FILL WILL GET WETTED.

CELL D15

L/G IS THE LIQUID TO GAS RATIO IN TERMS OF TOTAL KG OF WATER TO

TOTAL KG OF DRY AIR.

THE L/G SHOULD NORMALLY NOT BE LESS THAN 0.5 OR GREATER THAN 3.0
FOR NORMAL DESIGN CONDITIONS, EVEN THOUGH THE TOWER MIGHT
OPERATE AT CONDITIONS OTHER THAN DESIGN.

THE PROGRAM CALCULATES THE REQUIRED L/G AT THE INTERSECTION OF

THE BUILT IN TEST CORRELATION DATA SUPPLY LINE AND THE INTEGRATED
DEMAND LINE OF THE SPECIFIED DESIGN TEMPERATURES. IT THEN
CALCULATES THE REQUIRED KG OF AIR BASED ON THE TOTAL KG OF WATER
TO BE COOLED, USING THE L/G. ONCE THE KG OF AIR ARE KNOW, THE AIR
M3/S, PRESSURE DROPS AND FAN POWER CAN BE CALCULATED.

CELL D16

NTU IS THE NUMBER OF TRANSFER UNITS, OTHERWISE KNOWN AS KaV/L.

"K" IS THE TRANSFER COEFFICIENT; "a" IS THE TOTAL SURFACE OF ALL THE
WATER DROPS OR FILM SURFACE, "V" IS THE UNIT VOLUME OR HEIGHT IF
YOU CONSIDER ONLY ONE SQUARE FOOT OF TOWER, AND "L" IS THE WATER
LOADING.

THE NTU WILL BE QUITE DIFFERENT FOR THE "CTI" MODE AS COMPARED TO
THE "OFFSET" MODE. THIS IS OF NO CONCERN, HOWEVER, AS LONG AS
YOU REALIZE THE PROGRAM IS BEING CONSISTENT IN KEEPING THE DATA
AND THEORY WITHIN ITS OWN SYSTEM, AND YOU MUST, ALSO. DO NOT
MIX RESULTS FROM THE TWO MODES OF OPERATION.

ACTUALLY, THE NTU DOES NOT ENTER INTO WHAT YOU NEED TO KNOW.
GIVEN A SET OF DESIGN CONDITIONS, YOU ARE LOOKING FOR A REQUIRED
L/G, M3/S PER FAN, STATIC PRESSURE LOSS, AND RESULTING BKW PER FAN.

CELL D17 - D20

TYPICAL PRACTICAL VELOCITY LIMITS ARE LISTED BELOW. VARIOUS MANU-

FACTURES MAY ACCEPT HIGHER VALUES UNDER SOME CONDITIONS. IF
INLET VELOCITIES ARE TOO HIGH, THE AIR MAY BY-PASS A LARGE PORTION

16
 OF THE FILL. IF EXIT VELOCITIES ARE TOO LOW, THERE MAY BE EXCESSIVE
RECIRCULATION. IF ELIMINATOR VELOCITIES ARE TOO HIGH, DRIFT MAY BE
EXCESSIVE. HIGH FILL VELOCITIES ALONG WITH HIGH WATER RATES MAY
CAUSE PLUGGING IN SOME CLOSE SPACED FILM FILL PACKS.

MAXIMUM VELOCITY IN: 5.55 M/S

MINIMUM VELOCITY OUT: 6.1 M/S
MAXIMUM AVERAGE FILL VELOCITY: 3.175 M/S
MAXIMUM ELIMINATOR VELOCITY: 3.3 M/S

HIGHER VELOCITIES MAY BE USED AT HIGH ELEVATION, AS MASS FLOW IS

REDUCED.

For designs with high power evaluations, the most economical selection will usually have fill velocities
quite a bit less than 3 M/S. You might look for selections with about 2.5 M/S fill velocity as a starting
value.

CELL D21

THE "PRESSURE FACTOR" IS AN INDICATION OF WHETHER THE AIR WILL BE

WELL DISTRIBUTED UNDER THE FILL. IT IS THE RATIO OF THE INLET
VELOCITY PRESSURE LOSSES, TO THE PRESSURE LOSS ACROSS THE FILL,
SPRAY SYSTEM, UPPER PLENUM AND ELIMINATORS. IT SHOULD NOT BE
LESS THAN 5.0, AND 8.0 TO 10.0 WOULD BE BEST. IF IT IS VERY HIGH, IT
MIGHT BE LOGICAL TO REDUCE THE AIR INLET HEIGHT, IF THE INLET
VELOCITY IS WITHIN LIMITS.

CELLS F2 - F6
PRESSURE DROPS

THE PRESSURE DROP THROUGH THE INLET LOUVERS, FILL AND SPRAY,
DRIFT ELIMINATORS AND PLENUM ARE CALCULATED BY THE PROGRAM.
THEY ARE AUTOMATICALLY SUB-TOTALED IN CELL F6.

CELL F7

USE THIS SPACE TO ENTER EXTERNAL STATIC PRESSURE LOSSES, SUCH AS

SPECIAL FAN GUARDS, AIR INLET SCREENS, ETC.

STATIC PRESSURES LOSSES ARE THE MOST DIFFICULT INFORMATION TO

OBTAIN FROM FIELD MEASUREMENTS, AND YOU CAN EXPECT TO SEE SOME
SIGNIFICANT VARIATIONS, EVEN FOR THE SAME MEDIA, FROM DIFFERENT
MANUFACTURERS. THE BREAKDOWN OF THE COMPONENT PRESSURE
DROPS IS OFTEN DIFFERENT, BUT YOU WILL USUALLY FIND THE TOTAL LOSS
IS ABOUT THE SAME. YOU ALSO MIGHT FIND THE PRESSURE DROP IS UP
WHILE THE AIR FLOW RATE IS DOWN, OR VISA VERSA, RESULTING IN THE
SAME TOTAL FKW, WHEN COMPARING DATA FROM TWO DIFFERENT
VENDORS. THE BREAK-DOWN IS NOT IMPORTANT, JUST THE FINAL BKW.

YOU MAY USE THIS SPACE TO ADJUST STATIC PRESSURES WHEN YOU ARE
COMPARING INFORMATION FROM A VENDOR QUOTATION AND TO SEE IF
THE QUOTED FAN EFFICIENCIES ARE ACCURATE FOR THE DATA PROVIDED.
SIMPLY ENTER THE DIFFERENCE BETWEEN THE PROGRAM CALCULATED hs
AND THE QUOTED hs. THEN ENTER THE QUOTED FAN EFFICIENCY AT CELL
F19 AND COMPARE THE BHP AT CELL F21 TO THE QUOTED BHP.

17
CELLS F8 - F10
PRESSURE DROPS

THE SUB-TOTAL (hs) PRESSURE DROP IN CELL F8 IS THE TOTAL OF THE

PROGRAM CALCULATED PRESSURE DROPS AND ANY ADJUSTMENTS MADE
AT CELL F7.

THE VELOCITY RECOVERY SHOWN IN CELL F9 IS ONLY CALCULATED IF THE

FAN STACK IS TALLER THAN 1800 MM. IT IS CALCULATED FOR RECOVERY
OF 75 PERCENT OF THE DIFFERENCE BETWEEN THE FAN NET DISK AREA
VELOCITY HEAD AND THE STACK DISCHARGE VELOCITY HEAD TO OBTAIN
THIS MUCH. RECOVERY REQUIRES PROPER FAN CYLINDER PROPORTIONS AS
DESCRIBED IN "HELP" FOR CELL D1.

THE NET STATIC PRESSURE LOSS SHOWN IN CELL F10 IS THE TOTAL STATIC
PRESSURE FROM CELL F9 LESS THE RECOVERED VELOCITY PRESSURE LOSS.
THIS IS WHAT SHOULD BE USED TO ENTER MANUFACTURES FAN CURVES
THAT WERE NOT DEVELOPED FROM TALL STACK TESTS.

CELL F11

THE VELOCITY HEAD LOSS IS THE VELOCITY HEAD BASED ON THE FAN NET DISK
AREA.

CELL F12

THE TOTAL PRESSURE (ht) IS THE SUM OF THE NET STATIC PRESSURE (hs)
AND THE VELOCITY PRESSURE (hv).

CELL F13 AND G13

THE SPECIFIC VOLUME, M3 MIX PER KG OF DRY AIR, IS SHOWN AT CELL F13
FOR THE INLET AIR AND CELL G13 FOR THE OUTLET AIR. IT IS USED TO
GET “ACTUAL” M3/S FROM KG OR DRY AIR PER MINUTE.

CELL F14 AND G14

THE AIR DENSITY, KG OF MIX PER M3, IS SHOWN IN CELL F14 FOR THE
INLET AIR AND CELL G14 FOR THE OUTLET AIR. THE OUTLET DENSITY IS
USED TO ADJUST MANUFACTURERS FAN CURVES WHICH ARE USUALLY
DRAWN FOR STANDARD AIR.

CELL F15

CAUTION: THE OUTLET AIR TEMPERATURE, DEGREES F, IS CALCULATED ON

THE ASSUMPTION THE AIR IS SATURATED. THIS MAY NOT BE A PROPER
ASSUMPTION, HOWEVER, THE OUTLET TEMPERATURE WILL SELDOM BE
GREATER THAN 5 OR 6. DEGREES LESS THAN THE INLET HOT WATER
TEMPERATURE.

CELL F16

THE M3/HR EVAPORATED IS THE TOTAL FOR ALL CELLS. THE EVAPORATION
RATE WILL BE DIFFERENT AT NON DESIGN CONDITIONS.

CELL F17

18
 M3/S IS THE ACTUAL M3/S OF MOIST AIR PER MINUTE PER FAN, BASED ON
THE EXIT CONDITIONS OF AN INDUCED DRAFT TOWER.

MULTIPLY BY NUMBER OF CELLS TO GET TOTAL M3/S FOR THE TOTAL

TOWER.

CELLS F18 - F21

FAN OUTPUT INFORMATION

THE OUTPUTS FROM THE INTERNAL FAN ALGORITHMS ARE SHOWN IN THE
FAR RIGHT HAND COLUMN - CELLS G18-G21. YOU CANNOT CHANGE THEM.
IF YOU GET "ZERO" RESULTS, YOUR FAN SELECTION IS NOT WITHIN RANGE
OF THE AVAILABLE DATA FOR MANY POSSIBLE REASONS: TRY CHANGING
THE GEAR RATIO, NUMBER OF BLADES, OR FAN DIAMETER.

THE RESULTS SHOWN IN CELLS F18-F21 CAN BE MODIFIED BY YOU FOR

GOOD REASONS. DO THIS BY CHANGING THE TOTAL EFFICIENCY SHOWN IN
CELL F19. YOU MIGHT WANT TO MAKE A CHANGE TO COMPARE THE
MANUFACTURERS QUOTED EFFICIENCY TO THE COMPUTER OUTPUT, ADJUST
FOR A POOR FAN CYLINDER OR TIP CLEARANCE, OR BECAUSE YOU ARE NOT
USING A FAN BLADE SHAPE AS GOOD AS THE ONES LISTED FOR THE
PROGRAM.

"STATIC EFFICIENCY" CALCULATIONS SERVE LITTLE USEFUL PURPOSE.

"TOTAL EFFICIENCY" SHOULD NOT BE GREATER THAN 85%, AND IT MAY

BE CONSIDERABLY LESS .... TOTAL EFFICIENCY = ht*M3/HR/FAN KW/36,000.

"FKW" IS THE FAN INPUT POWER: AT THE FAN SHAFT.

"MOTOR KW" IS THE MOTOR OUTPUT POWER (DRIVER INPUT SHAFT).

INPUT KW = MOTOR KW/MOTOR EFFICIENCY/MOTOR POWER FACTOR
TO CONVERT FROM KW OT HORSEPOWER MULTIPL BY 0.746

CELLS G1 - G12

These cells are used to determin the proper height of the upper plenum based on a 45 degree line from the
width or length of the cell to the fan blade tip. It is recommended you use the highest value. You cannot
access these cells.

CELLS G18 - G21

These are the output values from the internal fan programs. You cannot access these cells. If you get
"zeros" for results, you have a problem with your fan selection. See the notes for Cells F18 - 21.

HELP FOR THE PRICING ESTIMATOR

CELLS B1 TO B9, WITH THE * , ARE WHERE YOU MODIFY THE PRICING ESTIMA-
TOR. OTHER CELLS GET INPUT FROM EITHER THE PERFORMANCE PROGRAM OR
FORMULAS. THE INFLATION INDEX IS AT CELL F17.

CELL B1:

19
 THE STARTUP SCREEN INSERTS THE BKW IN CELL B1. YOU SHOULD
CHANGE THIS TO A STANDARD AVAILABLE MOTOR SIZE.

CELL B2:

THE BASE FILL TYPE IS 0.75", 19 MM, PVC FILM FILL, 15 MIL THICK. THE
BASE FACTOR IS 1.0. FOR 12 MM FILL ENTER +19/12 THERE IS MORE
PLASTIC. MAKE A SIMILAR ADJUSTMENT FOR OTHER SPACINGS, THICKNESS
OR FILL DESIGNS OR TYPES. IN GENERAL THE PRICE IS RELATED TO KG OF
MATERIAL.

CELL B3:

BASE ELIMINATOR TYPE IS MUNTERS D15 PVC. ADJUST ACCORDINGLY.

CELL B4:

ENTER 2 FOR TR. REDWOOD, 1.5 FOR TR. FIR STRUCTURES. MODIFY FOR
OTHER STRUCTURE MATERIALS

CELL B5:

ENTER THE PRESENT WORTH VALUE OF POWER.

CELL B6:

YOU MAY WANT TO CHANGE CONCRETE PRICE BY MAKING THE FORMULA AT

F11 MORE COMPLICATED.

CELL B7:

THE BASE LABOR RATE IS FOR A STANDARD CARPENTER RATE. INCLUDING

FRINGE BENEFITS: ADJUST ACCORDINGLY.

CELL B8:

ENTER YOUR TAX RATE AS A DECIMAL % (Like 0.0725).

CELL B9:
ENTER THE NUMBER OF STAIRS.

BY THE VERY NATURE OF THE SIMPLIFIED FORMULAS OF THIS PRICING

ESTIMATOR, THE ACCURACY IS LIMITED. FEEL FREE TO MODIFY THE FORMULAS
BASED ON YOUR EXPERIENCE OR VENDOR QUOTES. SAVE YOUR MODIFIED FILE
UNDER A FILE NAME AND LOAD IT WHEN NEEDED.

PRESS <ESC> TO MODIFY FORMULAS. FORMULAS START WITH A + SIGN.

TAX IS NOT ADDED TO FREIGHT AND LABOR: ADJUST IF NECESSARY.

SPACE IS PROVIDED AT CELL F1 FOR YOU TO ADD AN EXTRA ITEM.

YOU CAN ENTER AN INFLATION INDEX AT CELL F17 (AS A %, NOT A DECIMAL, Like
4.25, or -10 ).

PRESS "/Q" TO EXIT TO PERFORMANCE PROGRAM.

20
CELL B13
AN UPPER PLENUM HEIGHT IS IS CALCULATED USING 45 DEGREE ANGLE
BETWEEN THE TOWER CASING AND THE FAN CYLINDER BASED ON THE
DIFFERENCE BETWEEN THE LENGTH OF THE CELL AND THE FAN DIAMETER.
CELL D2
THE PUMP HEAD IS CALCULATED BASED ON 2 FEET OF SPRAY HEIGHT AND
8 FT OF NOZZLE PRESSURE AND PIPE LOSSES.

CELL F13
THE PUMPING POWER COST IS FOR 85% PUMP & PUMP MOTOR EFFICIENCY.

21
Sample performance screen view.

Sample estimator screen view.

22