Module (s 203) fundamentals of cooling tower أساسيات ومبدأ عمل أبراج التبريد- getco

Module (S-203)
‫أساسيات‬‫ومبدأ‬‫عمل‬‫أبراج‬‫التبري‬‫د‬
Fundamentals of Cooling Tower
Heating, Ventilation and Air Conditioning (HVAC) Systems

1) What Is A Cooling Tower
2) How Do Cooling Towers Work Explanation
3) Cooling Tower Working Principle
4) What Are Cooling Towers Used For
5) Cooling Tower Applications
6) Types Of Cooling Tower Systems
7) How are cooling towers relate to Atmospheric Vortex
Engines?
8) Installation Check List.
9) Assessment of Cooling Tower.
10)Performance of Cooling Towers.
11)Energy Efficiency & Reduce of Energy Wastage
Possibilities.
12)Cooling Tower Parts & Functions.
13)Schedule Cooling Tower Services in Gulf Area
Training Agenda: Cooling Towers ‫التدريب‬ ‫دليل‬:

1) What is a cooling tower?
Cooling towers are a special type of heat exchanger
that allows water and air to come in contact with each
other to lower the temperature of the hot water.
During the cooling tower working process, small
volumes of water evaporate, lowering the temperature
of the water that’s being circulated throughout the
cooling tower.
In a short summary, the purpose of a cooling tower is
to cool down water that gets heated up by industrial
equipment and processes. Water comes in the cooling
tower hot (from industrial process) and goes out of the
cooling tower cold (back into the industrial process).

Main Features of
Cooling Towers

2) How Do Cooling Towers Work
Explanation?
• The hot water is usually caused by air conditioning condensers or
other industrial processes. That water is pumped through pipes
directly into the cooling tower. Cooling tower nozzles are used to
spray the water onto to the “fill media”, which slows the water
flow down and exposes the maximum amount of water surface
area possible for the best air-water contact. The water is exposed
to air as it flows throughout the cooling tower. The air is being
pulled by an motor-driven electric “cooling tower fan”.
• When the air and water come together, a small volume of water
evaporates, creating an action of cooling. The colder water gets
pumped back to the process/equipment that absorbs heat or the
condenser. It repeats the loop over and over again to constantly
cool down the heated equipment or condensers. For more
knowledge and learning about cooling towers.

There are many different
types of cooling towers but
the cooling tower
working principles stay
pretty much the same. Most
cooling towers work based
on the principle of
“evaporative cooling“.

Main Features of Cooling Towers

10
• Frame and casing: support exterior
enclosures
• Fill: facilitate heat transfer by
maximizing water / air contact
• Splash fill
• Film fill
• Cold water basin: receives water at
bottom of tower
Components of a cooling tower ‫التبريد‬ ‫برج‬ ‫مكونات‬-

3) What is Cooling Tower Working
Principle? (Evaporative Power)
Water Molecular ‫الماء‬ ‫جزئ‬

Water Molecular
gathered to form
Water as Allah
make it easy for
us to use
‫الماء‬ ‫جزيئات‬
‫لتكون‬ ‫تتجمع‬
‫سخره‬ ‫كما‬ ‫الماء‬
‫لنس‬ ‫لنا‬ ‫المولى‬‫تفيد‬
‫منه‬

‫الماء‬ ‫جزيئات‬ ‫حاالت‬
Status of Water Molecular
‫تختلف‬ ‫الماء‬ ‫حاالت‬
‫بين‬ ‫الروابط‬ ‫بقوة‬
‫الجزيئات‬
Water Status
differ Molecular
according to Bonds
Strength
‫صلب‬‫سائل‬‫غاز‬
SolidLiquidGas

‫الماء‬ ‫جزيئات‬
‫بالحرارة‬ ‫بينها‬ ‫الروابط‬ ‫تفكك‬ ‫و‬
Water Molecular
Broken bonds as heated

‫الماء‬ ‫حاالت‬ ‫على‬ ‫وتأثيرها‬ ‫الحرارة‬ ‫وكميات‬ ‫أنواع‬
Type & Quantities of Water Heating
‫حرارة‬
‫تسخين‬
‫الثلج‬
‫التبخير‬ ‫حرارة‬
‫حرارة‬
‫ذوبان‬
‫الثلج‬
‫حرار‬
‫ة‬
‫تسخي‬‫ن‬
‫الماء‬
‫حرارة‬
‫تسخين‬
‫البخار‬

‫حرارة‬
‫تسخين‬
‫الثلج‬
‫التبخير‬ ‫حرارة‬
‫حرارة‬
‫الذوبان‬
‫حرارة‬
‫تسخين‬
‫الماء‬
‫حرارة‬
‫تسخين‬
‫البخار‬
Heat
Steam
Vaporizing WaterHeating
Water
Ice
Melt
Heating Ice
1 cal
/gm/’C
540 calories/gm100801 cal/gm/’C

‫حرارة‬
‫الثلج‬ ‫تسخين‬
‫التبخير‬ ‫حرارة‬‫الذوبان‬ ‫حرارة‬ ‫حرارة‬
‫الماء‬ ‫تسخين‬
‫حرارة‬
‫البخار‬ ‫تسخين‬
Heating
Steam
Water
Ice MeltingHeating Ice
_____ K.cal/gm
_______ BTU/lb

‫حرارة‬
‫الثلج‬ ‫تسخين‬
‫التبخير‬ ‫حرارة‬‫الذوبان‬ ‫حرارة‬ ‫حرارة‬
‫الماء‬ ‫تسخين‬
‫حرارة‬
‫البخار‬ ‫تسخين‬
Heating
Steam
Water
Ice MeltingHeating Ice
200 K.cal/gm540 K.cal/gm1008030
800 BTU/lb1080 BTU/lb200 BTU/lb160 BTU/lb60 BTU/lb

Can you guess: Why Ct are not
efficient in Humid Day?

4) What are cooling towers used for?
Air cooled chillers
are less efficient
than water cooled
chillers due to
rejection of heat
from tower water
near wet-bulb
temperatures.
An HVAC cooling tower is used for disposing or
rejecting heat from chillers.

5) Cooling Tower Applications
Traditional HVAC heating and cooling systems are
used in Mega Projects, such as:
• schools,
• large office buildings,
and hospital.
• On the other hand, Cooling towers are much
larger than traditional HVAC systems and are used
to remove heat from cooling tower water systems
in petroleum refineries, plants, natural gas
processing plants, petrochemical plants, and
other industrial processes and facilities.

6) Types Of Cooling Tower Systems
Cooling towers are usually designed for specific
purposes. Not all cooling towers work for all
applications or industrial processes. Here we help
you understand the various types of cooling towers,
there advantages/disadvantages and determine
which cooling tower type is right for your industrial
process. Check out the cooling tower list and parts
list that provides an overview of cooling tower types
to help you figure out which tower is right for your
industrial application and what replacement parts
you might need.

Types of Cooling Towers
‫أنواع‬‫أبراج‬‫التبريد‬
Mechanical Draft Cooling Towers ‫ميكانيكي‬ ‫برج‬-
Natural Draft Cooling Towers
‫برج‬‫الطبيعى‬ ‫بالتدفق‬ ‫تبريد‬
Induced Draft Cross Flow CT
‫عرضيا‬ ‫المسحوب‬ ‫بالهواء‬ ‫تبريد‬
Induced Draft Counter
Flow‫رأسيا‬ ‫المسحوب‬ ‫بالهواء‬ ‫برج‬
Forced Draft Cooling Towers
‫المدفوع‬ ‫بالهواء‬ ‫تبريد‬ ‫برج‬
Evaporative Condenser
‫بالهواء‬ ‫تبريد‬ ‫برج‬

26
• Hot air moves through
tower
• Fresh cool air is drawn
into the tower from
bottom
• No fan required
• Concrete tower <200 m
• Used for large heat duties
Natural Draft Cooling Towers‫الطبيعى‬ ‫بالتدفق‬ ‫تبريد‬ ‫برج‬

Cross flow
• Air drawn across
falling water
• Fill located
outside tower
Counter flow
• Air drawn up
through falling
water
• Fill located
inside tower

Natural Draft & Fan Assisted Natural Draft Cooling Towers

Forced Draft & Induced Draft Cooling
Towers Process
Cooling tower
fans are used on
induced draft
cooling towers to
pull air up
through the fill
media. On forced
draft cooling
towers, the air is
pushed/forced by
blowers at the
bottom of the air
inlet louver.

31
Mechanical Draft Cooling Towers ‫ميكانيكي‬ ‫برج‬-
• Large fans to force air
through circulated water
• Water falls over fill surfaces:
maximum heat transfer
• Cooling rates depend on
many parameters
• many parameters
• Large range of
capacities
• Can be grouped,
e.g. 8-cell tower

Mechanical Draft Cooling Towers ‫ميكانيكي‬ ‫تبريد‬ ‫برج‬
Three types
• Induced
draft cross
flow
• Forced draft
• Induced
draft
counter
flow

Fill Material
Air In
Air In
Drift Eliminators
Induced
Draft Fan
External Fan Drive Unit
Drift Air to
Atmosphere
Induced Draft Cross Flow CT‫عرضيا‬ ‫المسحوب‬ ‫بالهواء‬ ‫تبريد‬

Induced
Draft
Counter
Flow ‫برج‬
‫بالهواء‬
‫المسحوب‬
‫رأسيا‬

• Hot water
enters at the
top
• Air enters at
bottom and
exits at top
• Uses forced
and induced
draft fans
Induced Draft Cross Flow ‫رأسيا‬ ‫المسحوب‬ ‫بالهواء‬ ‫برج‬-

36
© UNEP 2006
• Two types
• Cross flow
• Counter flow
• Advantage: less
recirculation than
forced draft towers
• Disadvantage: fans
and motor drive
mechanism require
weather-proof
Induced Draft Cooling Towers ‫المسحوب‬ ‫بالهواء‬ ‫برج‬-

37
• 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
Forced Draft Cooling Towers‫المدفوع‬ ‫بالهواء‬ ‫تبريد‬ ‫برج‬
(GEO4VA)

Forced Draft Cooling Towers‫المدفوع‬ ‫بالهواء‬ ‫تبريد‬ ‫برج‬

• Water enters top and passes over fill
• Air enters on one side or opposite sides
• Induced draft fan draws air across fill

• Water
enters top
and
passes
over fill
• Air enters
on one
side or
opposite
sides
• Induced
draft fan
draws air
across fill

Crossflow Cooling Towers Flow Diagram
In crossflow cooling tower systems the water
vertically flows through the fill media while the air
horizontally flows across the falling water. That’s why
they call it “crossflow” because the air and water
cross paths or flows. Because of the crossing of flows,
the air doesn’t need to pass through the distribution
system. This permits the use of hot water flow via
gravity and distribution basins on the top of the
tower right above the fill media. The basins are a
standard of crossflow cooling towers and are applied
on all units.

Counterflow Cooling Tower Diagram
Difference between crossflow and counterflow
cooling towers: In counterflow cooling tower system
processes, the air vertically flows upwards, counter
to the water flow in the fill media. Due to the air
flowing vertically, it’s not possible to use the basin’s
gravity-flow like in crossflow towers. As a substitute,
these towers use pressurized spray systems, usually
pipe-type, to spray the water on top of the fill media.
The pipes and cooling tower nozzles are usually
spread farther apart so they will not restrict any air
flow.

Factory Assembled Cooling Towers
(FAP) Factory Assembled Product
These factory-assembled cooling tower systems come
somewhat disassembled and are shipped in a few
sections, ready for final assembly or field erection.
Although, small factory-assembled cooling towers can
be shipped intact. FAP cooling towers can be induced
draft, crossflow, forced draft or counterflow
depending on the application its need
for. TCIA cooling towers are widely used for light
industrial applications and HVAC.

Field-Erected-Towers (FEP) Field
Erected Product
Field-erected cooling towers are usually
constructed on the final destination site. The large
FEP is usually prefabricated, marked by piece and
shipped to the construction site for assembly.
The cooling tower manufacturer usually handles all
of the cooling tower construction process, final
assembly, and labor involved. These type of towers
can be counterflow or crossflow depending on the
application. For heavy industrial applications or
more power needed, field-erected cooling towers
can be built to your exact specifications, structure,
performance, plume abatement and drift.

7) How are cooling towers relate to
Atmospheric Vortex Engines?

How are cooling towers relate to
Atmospheric Vortex Engines?
• Cooling towers are normally required to transfer the heat from power
plants to other process and then to the atmosphere. By using the wasted
stream of heat that is intended for cooling towers to generate vortex
provides the idea of pulling out additional energy by refusing the heat to
the colder upper troposphere.
• There is always potential to used wasted heat as additional fuel for
atmospheric vortex engines whenever there is a cooling tower present or
if there a abundant heat source available.
• At the base of a natural waterspout, spray from warm sea water transfers
sensible and latent heat to the rising air column. An atmospheric vortex
engine simulates this natural heat transfer process using proven
technology adapted from the cooling tower industry.
• Although, there is a chance that you will need to make modifications to
the tangential air inlet ducts.
• These changes are required to make the air rise and create a spinning
motion. It would only take a couple of minor modifications to convert
cooling towers into atmospheric vortex engines.

What is Atmospheric Vortex Engines?
These changes are required to make the air rise and create a
spinning motion. It would only take a couple of minor
modifications to convert cooling towers into atmospheric
vortex engines.

The cooling tower installation checklist is a list of
questions to be asked to the builder or installer
by the quality inspector for the safety and
security. It is drafted by the government. The
cooling towers are generally installed at
refineries, manufacturing and industrial plants
where the average temperature is higher than
usual. The primary responsibility of these
cooling towers is to provide the proper
ventilation and cooling.

Some of the questions listed in the checklist are given below for your references:
Do you have an easy and safe access to the installer?
Is there any maintenance mechanism for the cooling towers? What are the
techniques of cool room cleaning?
Does it have an automatically controlled continuous water treatment system?
Are the materials for systems components compatible enough?
Are the surfaces of the cooling towers smooth?
Are the drift eliminators properly installed and maintained?
Is there any possibility of splash out?

ISO 9001 Compliant
Cooling Towers must be ISO 9001 compliant
organization which documents its quality
system using this tiered schema:
• A Quality Manual describes the overall
system and states the general policies and
distribution of authority;
• Procedures define in general terms how
the interdepartmental (cross-functional)
flow of work is controlled.
• Work Instructions define specifically how
work is performed, step by tedious step,
within an individual department.

COOLING TECHNOLOGY INSTITUTE
CTI CODE TOWER
Standard
Specifications
Thermoplastic
Materials Used for
Film Fill, Splash Fill,
Louvers And Drift
Eliminators
https://www.scribd.com/document/313663888/136-STD

How Cooling Towers Are Rated by CTI
The CTI rates all cooling towers based on the
following design conditions:
• 95°F/85°F @ 78°F wet bulb
• 10°F Range and 7°F Approach
• 3 GPM per Cooling Tower Ton
the Cooling Tower Institute (CTI)

• Drift eliminators: capture droplets in air
stream
• Air inlet: entry point of air
• Louvers: equalize air flow into the fill
and retain water within tower
• Nozzles: spray water to wet the fill
• Fans: deliver air flow in the tower

9) Assessment of cooling towers
• Wet bulb temperature of air
• Dry bulb temperature of air
• Cooling tower inlet water temperature
• Cooling tower outlet water temperature
• Exhaust air temperature
• Electrical readings of pump and fan motors
• Water flow rate
• Air flow rate

Assessment of Cooling Towers ‫التبريد‬ ‫أبراج‬ ‫تقييم‬-
Measured Parameters

Performance Parameters ‫معايير‬‫كفاءة‬‫األداء‬
1. Range
2. Approach
3. Effectiveness
4. Cooling capacity
5. Evaporation loss
6. Cycles of concentration
7. Blow down losses (Bleeding)
8. Liquid / Gas ratio

1. Range ‫المدي‬
Difference between cooling
water inlet and outlet
temperature:
Range (°C) =
CW inlet temp – CW outlet temp
High range =
good performance
Range
Approach
Hot Water Temperature (In)
Cold Water Temperature (Out)
Wet Bulb Temperature (Ambient)
(In) to the Tower
(Out) from the Tower

6
2. Approach ‫المقاربة‬
Difference between cooling tower
outlet cold water temperature and
ambient wet bulb temperature:
Approach (°C) =
CW outlet temp – Wet bulb temp
Low approach =
good performance
RangeApproach
(In) to the Tower

3. Effectiveness ‫الفعالية‬
Effectiveness in %
= Range / (Range +
Approach)
= 100 x (CW temp – CW out
temp) / (CW in temp – Wet
bulb temp)
High effectiveness =
good performance
RangeApproach
(In) to the Tower

4. Cooling Capacity ‫التبريد‬ ‫سعة‬
Heat rejected in kCal/hr
or tons of refrigeration
(TR)
= mass flow rate of water
X specific heat X
temperature difference
High cooling capacity =
good performance
RangeApproach
(In) to the Tower

5. Evaporation Loss ‫التبخير‬ ‫فقد‬
Water quantity (m3/hr)
evaporated for cooling duty
= theoretically, 1.8 m3 for
every 10,000,000 kCal heat
rejected
= 0.00085 x 1.8 x circulation
rate (m3/hr) x (T1-T2)
T1-T2 =
Temp. difference between inlet
and outlet water
RangeApproach
(In) to the Tower

6. Cycles of concentration (C.O.C.) ‫التركيز‬ ‫دورات‬
Ratio of dissolved solids in circulating water to
the dissolved solids in make up water
Depend on cycles of concentration and
the evaporation losses
Blow Down =
Evaporation Loss / (C.O.C. – 1)
7. Cycles of concentration (C.O.C.) ‫التركيز‬ ‫دورات‬

8. Liquid Gas (L/G) Ratio‫بالهواء‬ ‫مقارنة‬ ‫الماء‬ ‫تدفق‬ ‫معدل‬
Ratio between water and air mass flow rates
Heat removed from the water must be equal to
the heat absorbed by the surrounding air
L(T1 – T2) = G(h2 – h1)
L/G = (h2 – h1) / (T1 – T2)
T1 = hot water temp (oC)
T2 = cold water temp (oC)
Enthalpy of air water vapor mixture at inlet wet bulb temp (h1)
and outlet wet bulb temp (h2)

‫التبريد‬ ‫أبراج‬ ‫كفاءة‬
10
Performance of
Cooling Towers

Performance of Cooling Towers
Calculate range, approach, L/G (Liquid to gas) ratio and
effectiveness for design and operating conditions for each tower
1. C.T. Range = Water inlet temperature – Water
outlet temp.
2. C.T. Approach = Water outlet temperature – Wet
bulb temp.
3. Effectiveness % =
Range x 100
( range + approach )
Fan actual airflow (Nm3) / cell =
Fan rated airflow (Nm3) / h x ( Fan input kW actual )
( Fan input rated )
1/3
1/3
4.
5. Air mass flow / cell = flow x density of air

5. Evaporation losses =
CW flow (m3/ h) x CT range in 0C
675
6. Makeup water consumption =
Evaporation losses
(COC – 1)
➢ The above readings may be taken on daily basis for three
days on different atmospheric conditions say during mid
summer, winter & monsoon period. Once in the mid day and
once in the mid night time and a record duly maintained.
➢ Collect unit load (MW), frequency, and condenser vacuum
condition while taking the cooling tower measurement

• Power consumption of CT fans
Exploration of Energy Conservation Possibilities:
❖Condenser
• Possibility of Improvement in condenser vacuum
• Turbine heat rate Reduction possibilities
• Improving the effectiveness of condenser and TTD
• Cooling water flow adequacy and flow optimization
• Air ingress
• Increasing the TTD of the condenser
• Fouling of tubes

The lower the condenser water temperature (that which is circulating
to the cooling towers) is, the less work the compressor has to do.
‫المكثف‬ ‫ماء‬ ‫حرارة‬ ‫درجة‬ ‫انخفضت‬ ‫كلما‬(‫يتم‬ ‫التي‬‫تدويرها‬‫التبريد‬ ‫أبراج‬ ‫على‬)،‫انخ‬‫فض‬
‫به‬ ‫القيام‬ ‫الضاغط‬ ‫على‬ ‫يتعين‬ ‫الذي‬ ‫العمل‬.

11) Energy Efficiency & Reduce of Energy
Wastage Possibilities.
Optimized Operation Energy Wastage Operation

Energy Efficiency Opportunities Energy Efficiency
Opportunities: Water Pump & Pumping
• Improvement of systems and drives
• Use of energy efficient pumps
• Correcting inaccuracies of the Pump sizing /
Trimming of impellers
• Use of high efficiency motors
• Integration of variable speed drives into
pumps: The integration of adjustable speed
drives (VFD) into compressors could lead to
energy efficiency improvements, depending
on load characteristics

Opportunities: Cooling Tower Performance
• Measuring and tracking system performance
• Heat dissipation (kCal/hour)
• Circulated flow rate (m3/hr)
• Improvements in condenser performance
• Improvement in cooling tower performance
• Efficiently designed fill media reduces pumping costs
• Fan efficiency depends on blade profile
• Replace metallic fans with FBR blades (20-30% savings)
• Use blades with aerodynamic profile (85-92% fan efficiency)

Opportunities: Water Condition
• Measuring water use and energy consumption is essential
in determining whether changes in maintenance practices
or investment in equipment could be cost effective
• In this case it is advised to monitor the water flow rate and
condenser parameters, cooling tower parameters
periodically i.e. at least once in a three months and energy
consumption on daily basis. This will help in identifying the
- Deviations in water flow rates
- Heat duty of condenser and cooling towers
- Measures to up keep the performance
• Increase cycles of concentration (COC) by cooling
water treatment helps reduce make up water
• Replace Drift Eliminators to lower loss from 0.02% to
less than: 0.003%

Opportunities: System Effect Factors
• Equipment cannot perform at its optimum capacity if
fans, pumps, and blowers have poor inlet and outlet
conditions
• Correction of system effect factors (SEFs) can have a
significant effect on performance and energy savings
• Elimination of cavitation: Flow, pressure, and efficiency
are reduced in pumps operating under cavitation.
Performance can be restored to manufacturer’s
specifications through modifications. This usually
involves inlet alterations and may involve elevation of a
supply tank

Opportunities: Service & Cleaning
• Internal Running Clearances: The internal running
clearances between rotating and non-rotating elements
strongly influence the turbo machine's ability to meet rated
performance. Proper set-up reduces the amount of leakage
(re-circulation) from the discharge to the suction side of the
impeller
• Reducing work load of pumping: Reducing of obstructions
in the suction / delivery pipes thereby reduction in
frictional losses. This includes removal of unnecessary
valves of the system due to changes. Even system and
layout changes may help in this including increased pipe
diameter. Replacement of components deteriorated due to
wear and tear during operation, modifications in piping
system

Opportunities: Demand Control System
• Controlling the flow rate by speed variation
• Pumps in parallel to meet varying demand
• Eliminating flow control valve
• Eliminating by-pass control
• Start/stop control of pump
• Monitor the CT performance to decide when to
start/stop second CT.
• Monitor hardness to increase cycling and reduce
bleeding (Chemical Dosing Controller).

12)
‫برج‬ ‫مكونات‬
‫و‬ ‫التبريد‬
‫القطع‬ ‫وظيفة‬
Cooling
Tower
Parts &
Functions

Cooling Tower Parts & Products
Cooling Tower Fill Media
What is cooling tower fill media? Fill media is
by far one of the most important cooling
tower parts. It could be considered the
middle man of the entire process. Many of
today’s cooling towers use efficient plastic
film fills or fill media that maximize the
surface area for evaporative cooling
processes. Water gets distributed onto the
fill, which spreads into thin film. This process
increases the water-air interface and allows
extra heat to evaporate at a fast pace. The
major factors in choosing fill media are TSS
levels or Total Suspended Solids, intended
treatment, water make-up and
contamination potential. The 2 basic types of
fill media are film type fill media (spreads the
water out into a thin layer) and splash type
fill media (breaks the water up). There is also
fill media for specific types of towers such
as crossflow fill media and counterflow fill
media.

Cooling Tower Parts & Products
Cooling Tower Drift Eliminators
What are cooling tower drift
eliminators used for? Cooling tower
drift eliminators and heavy duty
drift eliminators are parts of a
cooling tower that are designed to
remove droplets of water from the
air and minimize loss of process
water. Drift eliminators cause the
droplets and air to change direction
suddenly. This process causes the
water to become separated from
the air and put back into the
cooling tower.

Cooling Tower Nozzles
What are cooling tower nozzles used for?
Cooling tower nozzles are most frequently
used in crossflow cooling towers because they
use gravity-flow distribution basins. With these
types of systems, the water supply is raised to
the distribution basins above the fill media and
then flows down over the fill (by way of
gravity) through the cooling tower nozzles in
the basin floor.

Cooling Tower Fans
What are cooling tower fans used for? Cooling tower fans are used to force or
push large amounts of air throughout the cooling tower. They must be built to
withstand the corrosive effects in which the environment that they operate.
These fans are usually loud but there are certain types of low-sound cooling
tower fans. Cooling tower fans are used in crossflow, counterflow,
induced/forced draft cooling towers. Natural draft cooling towers don’t need
fans because they use the natural air flow and different processes that cool the
water.

Cooling Tower Fans: Belt Driven
Fan Deck & Fan Cylinder
The deck of the fan is a supporting platform for
cylinders of the fan, which also makes an access way
to the fan and water distribution system.

Gear Box:
The different types of gear boxes include A series single reduction
gear boxes, A series double reductions gear boxes, single reduction
gear boxes and double reduction gear boxes.

Drive Shafts
What are cooling tower Cooling tower drive shafts used for? Drive
shafts transmit power from the motor’s output shaft into the gear
reducer’s input shaft. Drive shafts must also be corrosion resistant due
to the harmful environment it which they operate. The drive shaft is the
connecting link between the electric motor and the input shaft of the
gearbox.

Automatic Water Level Controls
Water Level Controls or float
switches are manufactured to
control water levels automatically.
This helps ensure there is always the
correct amount of water inside your
storage tank. The level controls are
typically used to automatically fill
water and stop the fill once it
reaches the adequate height. These
controls can also be installed with
LED sensors that will let you know
when your levels are getting too low
or too high, called high and low level
alarms. “Automatic water level
controllers switch the motor
on whenever the water level drops
below a certain level and shuts the
motor off when the water rises well
above a fixed level.” Water Level
Controls

Piping For Water
Distribution:
Piping, for water
distribution in a cooling
tower, is buried
underground and should be
supported in-ground to
prevent thrust loading in
the cooling tower because
of self weight and water
pressure in the pipe.
Distribution
Valves:
Distribution Valves
regulate the flow of hot
water to evenly
distribute it in cells. The
body of the valve in a
distribution valve is
made withstand
corrosive environments.

Air Inlet Louvers
• What are air inlet used for? Air inlet
louvers or air intake louvers
prohibit the sun light from entering
the basin, which prohibits algae
growth and lowers chemical costs.
These louvers also lower the
amount of splash-out, which lowers
the volume of water and chemical
use. Also, you will experience easier
basin removal and access. The air
inlet louvers in counterflow towers
can sometimes become scaly if they
are not correctly maintained and
cleaned. Scaled louvers lessen the
amount air flow which lowers the
efficiency of the unit.

Ball Float Valve
Electronic Float Valves
What are electronic float valves used for?
Electronic Float Valves are design for cooling tower
functionality, brass float valves and electronic
water level systems have little maintenance with an
extended life. Typically, there are electronic float
valve kits available which include the float arm,
float valve and float in kits to fit specific
applications.

Cooling Tower Sealants & Coatings
Interior cooling tower coatings, or cooling tower sealants,
help prevent corroding, leaking or rusting inside a cooling
tower, while exterior coatings protect the outside of the
cooling tower from corrosion and rust. Protecting all sides of
your cooling tower helps prevent future problems and costly
repairs.

Cooling Tower Basin Heaters
What are cooling tower basin heaters used
for? Cooling Tower Basin heaters prevent
the cold water basin from freezing up
during the winter weather conditions and
can be used on Evapco, BAC, Marley and
other industrial manufacturers’ products.
BAC basin heaters are CSA and UL rated.
They have strong long lasting copper
heating elements to ensure a long-life. The
MPT connection is simple to fit into any
cold water basin for closed circuit fluid
coolers, cooling towers, and evaporative
condensers.

cooling tower water drift eliminator
Cooling tower drift eliminator are used to
control water loss from a cooling tower
by limiting the amount of circulating
water droplets that are emitted with the
exhaust air of the tower. Since drift
droplets contain the same chemical and
particulate matter of the circulating
water from which they originate, they
can cause numerous detrimental effects
on surrounding equipment and the
environment. The cooling tower industry
uses drift rate to compare drift
eliminator performance, a relationship
that correlates droplet capture efficiency
to the water circulation rate in a tower.
drift eliminators are specifically designed
to achieve maximum drift removal
efficiency in both crossflow and
counterflow tower applications with
various product options available to
minimize pressure drop, drift loss, cost,
or a combination of all three.

What is a Drift Eliminator?
To put it simply, a drift eliminator is designed to capture large
water droplets caught in the air stream, and prevent the droplets
and mist from escaping the cooling tower. Another example of
drift eliminators, they are baffles in a cooling tower through
which air passes before exiting the tower, the purpose of which is
to remove entrained water droplets from the exhaust air.

Cooling Tower Drift Eliminators
Cooling tower drift eliminators and heavy duty/dura drift eliminators are
designed to remove droplets of water from the air and minimize loss of
process water. Drift eliminators cause the droplets and air to change direction
suddenly. This process causes the water to become separated from the air and
put back into the cooling tower. Drift eliminators limit the amount of
circulating water emitting from the tower’s exhaust.

REDUCE WATER LOSS AND EMISSIONS
In all different types of cooling
towers drift eliminators are used
to reduce the loss of water and
emissions. Above the water
distribution and the cooling fills, a
layer of drift eliminators is
installed for this purpose. It
catches the water drops which are
carried away with the air flow and
redirects them into the cooling
water circuit.

13) Schedule Cooling Tower Services in
Gulf Area ‫الصيانة‬‫فى‬‫الخليج‬‫العربي‬

CT Risking Health in the Real (Dirty) World

CHECK-LIST TO AVOID
LEGIONELLA OUTBREAKS
The following critical cooling tower
components must be cleaned on a regular
basis (at least annually, but preferably every
six months) to protect the public from
Legionella bacteria. As part of our
Performance Clean, technicians must work
according to a checklist to inspect every
component, clean, disinfect and reassemble
correctly – including difficult to access areas:

CHECK-LIST TO AVOID
1. Drift eliminators. Drift eliminators
help to stop the spread of the
Legionella bacteria. ‘NO DRIFT
MEANS NO LEGIONELLA’ leaving a
cooling tower to infect the public. Drift
eliminators MUST be inspected, kept
clean and not damaged. Removal to
clean is best practice.

CHECK-LIST TO AVOID
2. Water distribution nozzles. Water nozzles
and associated pipes/trays MUST be clean and
free of debris so that treated cooling tower water
can make full contact with all internal
components. “YOU CANNOT KILL BACTERIA
WITH CHEMICALS, if the chemicals are not in
contact with the bacteria,” says Coolclean
Managing Director Darren Driscoll. “If the water
is not being distributed evenly across the fill pack,
the coils, and the casing, then water treatment
cannot be fully effective. The bacteria will live and
breed where chemicals do not contact.”

CHECK-LIST TO AVOID
3. Fill pack and coils. These are the
heat exchange components. To cool
effectively, fill pack and coils MUST be
kept as clean as possible. It is critical that
water runs over the surfaces freely
without interference from dirt, scale and
bacteria. Dirt in cooling tower fill pack
is a breeding ground for bacteria.

CHECK-LIST TO AVOID
4. Air intake louvers. These components
stop water splash-out onto surfaces outside
the cooling tower. Reducing water splash-
out protects the environment. Updating air
intake louvers to modern louvers with
sunlight block out is a major improvement to
assist the water treatment program as
sunlight promotes bacteria and algae
growth.

CHECK-LIST TO AVOID
5. Other items to be cleaned.
Casing, basin, fans and motor drives, hot
water boxes, strainers, pumps, ball float
valves, chemical dosing lines, the outside
casing and the area surrounding a
cooling tower.

5. Utilize the Benefits of Chemicals
‫المؤكسدات‬
Oxidizers
‫ألجايسيد‬
Algaecide
‫بيولوجي‬ ‫مبيد‬
Biocide
‫مانع‬‫التكلس‬
Scale Inhibitor
‫الحموضة‬ ‫درجة‬ ‫منظم‬
pH Regulator
‫التآكل‬ ‫مانع‬
Corrosion
Inhibitor

Takeaways - ‫مختصرات‬
the lower the condenser water temperature (that which
is circulating to the cooling towers) is, the less work the
compressor has to do.
for every pound of water we are able to evaporate in the
cooling tower, we absorb another 1000 BTUs from BLD.
it’s harder to evaporate water into air that’s already
wet. (I.e. The higher the wet bulb, the harder a cooling
tower has to work to evaporate enough water to maintain
set points.)
A refrigeration ton is equal to 12,000 BTU/hr. A cooling
tower ton is 15,000 BTU/hour. The extra 3000 BTUHs is
carried over from the refrigeration cycle. (12,000 BTU/hr
(Refrigeration Ton) + 3000 BTU/hr (Compressor Heat)).

Challenges - ‫تحديات‬
Conserving Cooling Tower Water: most cooling towers will
operate fine at up to 4 or 6 cycles of concentration, How to
increase cycles is a Challenge?
Operating CT at High Humidity Days: since design of CT is at
WBT 78’F (25.5’C), How to keep evaporating water at higher
WBT is a Challenge?
Cooling Tower Clearances: air around the cooling tower was
already too saturated with moisture to effectively evaporate
water. This led to another problem: elevated condenser
water temperatures., Maintaining the minimum clearances is
a Challenge?
CT & Condenser Piping: Larger facilities often have
multiple cooling towers serving multiple chillers,
enabling them to more closely match demand, Keep
the pumping flexibility is a Challenge?

By Eng. Juma Yousef Juma‫يوسف‬ ‫جمعة‬
jumayjuma@gmail.com+962-7-9074-6811

Module (s 203) fundamentals of cooling tower أساسيات ومبدأ عمل أبراج التبريد- getco

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