Variable Flow

Variable Flow Over
Cooling Towers for Energy Savings

AHR Expo – Orlando, Florida
Gary Stauffer, Sales Engineer
© 2020 SPX Cooling Technologies, Inc. All Rights Reserved

Meet the Presenter
Gary Stauffer
Sales Engineer – West , SPX Cooling Technologies
• With SPX since 2005, has held roles including
Designer - Mechanical Components, Technical
Services Engineer, and Applications Engineer
• Previously worked as an Engineering Technician

in the aluminum casting industry
• Member of ASHRAE and ASME
Variable Flow Over Cooling Towers for Energy Savings

© 2020 SPX Cooling Technologies, Inc. All Rights Reserved April 25, 2020 2
In addition to boosting your knowledge,
today you will...
• Receive a Certificate of Completion*

• Receive a Thank You gift
• Have the opportunity to inquire about educational
programming at your facility or at SPX Cooling in
Overland Park, KS
*Be sure to get your badge scanned so we can mail your certificate!

Presentation Purpose & Overview
• Increase energy savings on new or existing tower

installations using variable flow over cooling towers
• Understand the differences between crossflow and
counterflow designs and how they impact variable flow

Variable Flow Fundamentals
© 2020 SPX Cooling Technologies, Inc. All Rights Reserved 5

Yesterday and Today
Yesterday…
• Controls were simple
• Energy was cheap
• Tower considered a ‘constant flow’ device: # towers operating = # chillers operating
Today…
• Life isn’t so simple
• Controls are much more capable
• Energy is NOT cheap
Are there opportunities to save energy by operating towers differently?

Foundation for Variable Flow
Less surface area requires more airflow (hp)

Trade size for horsepower
• Example: 500 ton selections (5200 GPM, 95°- 85°- 78°F)
Model HP ASHRAE
efficiency
(gpm/hp)
NC8405TAN 40 hp 49.5
NC8407QAN 20 hp 92.1
NC8409PAN 15 hp 128.3
Source: Selection Software

Another Reason to consider Variable Flow
ASHRAE 90.1-2019 Tower Flow Turndown Requirements[6]
6.5.5.4 Tower Flow Turndown. Open-circuit cooling towers used on water cooled chiller
systems that are configured with multiple- or variable-speed condenser water pumps shall
be designed so that all open-circuit cooling tower cells can be run in parallel with the
larger of:
a. the flow that is produced by the smallest pump at its minimum expected flow rate or
b. 50% of the design flow for the cell
Foundation for Variable Flow – Fan Speed
Tower Cooling Capacity varies directly with

fan speed
• 100% speed provides 100% performance
Tower Fan Energy varies with the cube of the

speed ratio
• 100% speed: 1.003 = 100.0% hp
• 75% speed: 0.753 = 42.2% hp
• 50% speed: 0.503 = 12.5% hp

Traditional Example – 3000 Ton Chiller Plant
4 @ 750 ton chillers and 4-cell tower

9000 GPM, 95-85-78 Select NC8411TAN4 @ 40 hp/fan
75% Load – 3 chillers and 3 towers running
End Results: 75% of the energy @ 75% load with

traditional approach
Variable Flow Example – 75% Load
3000 Ton Chiller Plant

Now @ 75% Load – 3 chillers and 4 towers running
End Results: 67.6/120 = 44% energy savings

versus traditional
Variable Flow Example – 50% Load
3000 Ton Chiller Plant

Now @ 50% Load – 2 chillers and 4 towers running
End Results: 20/80 = 75% energy savings

versus traditional
Implementing Variable Flow
in Crossflow Design

Crossflow Design – Water Distribution
1. Gravity flow water distribution basins

2. Lots of nozzles (~260 in a 400 ton
tower)
3. Nozzles are close together – easy to
distribute water over the fill
4. Min / Max water depth over nozzle
(2.5” min. – 5.4” max.)
Using Nozzle Cups in Crossflow Designs
Nozzle Cups Nozzle Cups at Low Flow

• Simple passive modification • Cups restrict water distribution to
standard nozzles only
Nozzle Cups at Intermediate Flow Nozzle Cups at Full Flow

• Some restriction to cupped nozzles • No restrictions
Full Flow Example:

• Water overflows nozzle cups
• Entire fill volume is active
• Nozzle cups have no effect
Low Flow Example:

• Reduced head in basin
• No water flows over cup
• All water is outboard
Benefits:
• Eliminates risk of scaling / icing
• Uniform air-side pressure drop
• Prevents air channeling
Crossflow Design – Center Inlets
Center Inlet Design:

• Distribution flume rotated 90°
• Water distributed along entire air travel of fill
Center Inlet Basin Dam:

• During full flow water floods entire basin
Center Inlet Basin Dam:

• During low flow water floods dammed area
only
Results:
• Effective air travel varies between two
extremes
• Low air rate through center
• Diminished performance
• Higher air rates through ends
• Higher risk of icing during winter operation or
free cooling
Crossflow Design – Integral Inlet Louvers
Same Day Same Facility
Integral Louvers Separate Louvers

Crossflow Design – Integral Inlet Louvers
Important: Make sure film fill has integral inlet louvers to minimize ice
formation
• Icing can damage fill and reduce performance
• Keep heat (water) close to louvers
air in
Integral Louvers Separate Louvers

Implementing Variable Flow
in Counterflow Design

Counterflow Design – Water Distribution
• Pressurized spray system

• Relatively few spray nozzles
(~60 in 400 ton tower)
• Nozzles much farther apart
• No modifications are available for
counterflow designs to enhance variable
flow performance
• Limited ability to run at low flow rates
• Less pressure at spray nozzle
Variable Flow in Counterflow Designs
100% Nozzle Flow 50% Nozzle Flow

• Adequate Distribution • Water Channeling
Variable Flow in Counterflow Designs
If you reduce flow too much (generally more

than 30%), you get uneven water loading:
• Lower air-side pressure drop in
fill sections with less water
• Air takes path of least resistance
• More air in drier sections
• Less air in wetter sections
Resulting in:
• Reduced thermal performance
• Risk of ice formation in fill
• Greater risk of fill scaling
Wrap Up

Key Take-Aways
1. Variable flow offers big energy / dollar savings potential

• Remember - Tower fan energy varies with the cube of the speed
ratio
2. Inherent design differences between cooling towers:
• Crossflow – can be easily modified for variable flow
• Counterflow – cannot be practically modified and opportunity for
variable flow in counterflow towers is significantly smaller than
with crossflow towers
Wrap-Up
Additional Information
• Marley Technical Report TR-14

“Variable Flow Over Cooling
Towers for Energy Savings”
• Nozzle Cups Cut sheet
• Variable Flow Over Cooling Towers
• VIDEO: Marley ST Nozzle and
Cup System
Wrap-Up
Thank You! Questions?
• Get your badge scanned to ensure
you receive Certificate of Completion
• See me or a Marley representative to
share feedback on the presentation
• Inquire about lunch & learns and
other educational programming that
would benefit your team
• Pick up your gift before you head out!

Variable Flow

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Variable Flow Over

Cooling Towers for Energy Savings

© 2020 SPX Cooling Technologies, Inc. All Rights Reserved

• Previously worked as an Engineering Technician

• Member of ASHRAE and ASME

Variable Flow Over Cooling Towers for Energy Savings

• Receive a Certificate of Completion*

Variable Flow Over Cooling Towers for Energy Savings

• Increase energy savings on new or existing tower

Variable Flow Over Cooling Towers for Energy Savings

© 2020 SPX Cooling Technologies, Inc. All Rights Reserved 5

Are there opportunities to save energy by operating towers differently?

Variable Flow Over Cooling Towers for Energy Savings

Less surface area requires more airflow (hp)

Variable Flow Fundamentals

ASHRAE 90.1-2019 Tower Flow Turndown Requirements[6]

Tower Cooling Capacity varies directly with

Tower Fan Energy varies with the cube of the

Variable Flow Fundamentals

4 @ 750 ton chillers and 4-cell tower

End Results: 75% of the energy @ 75% load with

4 @ 750 ton chillers and 4-cell tower

End Results: 67.6/120 = 44% energy savings

4 @ 750 ton chillers and 4-cell tower

End Results: 20/80 = 75% energy savings

© 2020 SPX Cooling Technologies, Inc. All Rights Reserved 13

1. Gravity flow water distribution basins

Nozzle Cups Nozzle Cups at Low Flow

Nozzle Cups at Intermediate Flow Nozzle Cups at Full Flow

Full Flow Example:

Low Flow Example:

Center Inlet Design:

Center Inlet Basin Dam:

Center Inlet Basin Dam:

Same Day Same Facility

Integral Louvers Separate Louvers

Integral Louvers Separate Louvers

© 2020 SPX Cooling Technologies, Inc. All Rights Reserved 24

• Pressurized spray system

100% Nozzle Flow 50% Nozzle Flow

If you reduce flow too much (generally more

© 2020 SPX Cooling Technologies, Inc. All Rights Reserved 28

1. Variable flow offers big energy / dollar savings potential

• Marley Technical Report TR-14

© 2020 SPX Cooling Technologies, Inc. All Rights Reserved 31

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