StephenLowe ASHRAEHamptonRoadsChapterPastPresident AECOMDesign MechanicalEngineeringDiscipline Manager,VirginiaBeachDivision ProfessionalEngineer CommonwealthofVirginia, Virginia NCEES BSME UniversityofVirginia,2002 Sheetmetalfabricator,equipmentinstaller,refrigeration servicetechnicianduringhighschoolandcollege Consulting C l i E Engineer

ngineer i from f 2003 Present P

Overview
Introduction CoolingTowerBasics PrinciplesofOperation TypesofCoolingTowers CommonApplications DesignConsiderations SelectionCriteria OpenPipingandPumpingSystems WaterQuality TowerLocation AncillarySystems ConstructionIssues Constructability,QualityControlandStartup RatingandCertification Lessons L L Learned d Conclusion Resources QuestionsandDiscussion

CoolingTowerBasics
PrinciplesofOperation CoolingViaEvaporation dependsonWetBulb Temperature DesignDryBulbTemperaturescommonlyexceed95deg F:poordeltaTforcoolingprocesses Design D i W Wetb bulb lbmuch hless: l ~80deg d F UseaprocessthatdependsonWBtotakeadvantageof greaterdeltaT g Evaporativeeffectisachangeofstateandthusalarge transferofenergyoccursrelativetotherequiredmass flow

OpenCoolingTower

Cl dCi i Closed Circuit CoolingTower

CrossFlowArrangement

CounterFlowArrangement

CoolingTowerBasics
CommonApplications PowerPlantSteamCondensation ProcessCooling HVACHeatRejection

ChillerCondenserHeat WSHPLoopHeat

*Wewillbefocusingonopen,crossflowcoolingtowersfor j fortheremainderofthe chillercondenserheatrejection presentation.

To erApplication BasicHVACCoolingTower

DesignConsiderations
DesignConsiderations SelectionCriteria OpenPipingandPumpingSystems WaterQuality TowerLocation AncillarySystems

DesignConsiderations
SelectionCriteria Process(ChillerCondenser)TemperatureRequirements

HotWaterTemperature p (HWT) ):Temperature p ofwaterentering gthe tower ColdWaterTemperature(CWT):Temperatureofwaterleavingthe tower TowerRange:HWT CWT LowerCWTgenerallyresultsinhigherChillerEfficiency

FlowRateorCapacity AmbientConditions Evaporation(orEntering)DesignWetBulb(EWB) Approach:CWT EWB Lowerapproachgenerallyresultsinalargertower

DesignConditions

DesignConditions

NO

YES

DesignConditions
UseEvaporationDesignWBforselectionof

evaporativeequipment Use U of f0.4%, % 1%, % or2% %condition di i is i uptothe h d designer i basedonspecificapplicationanddesignfirmpractice A2degreeFmarginofsafetyisrecommendedto accountforrecirculation(ruleofthumb further analysis y isrequired q forthespecific p application) pp CondenserwaterdeltaTdependsonmanyfactors suchastheprocessthatiscooledandoptimizationof the h pumping i system

DesignConsiderations
OpenPipingandPumpingSystems Coolingtowerpumpingapplicationtroublesare

generally ll related l dtooneof fthe h following f ll i i issues:

IncorrectPumpHeadEstimation PumpCavitation AirIntroductiontoPumpSuction ImproperBypassConfiguration/Control

DesignConsiderations
OpenPipingandPumpingSystems PumpHeadEstimation

Determineactual lstaticl lift f height h h Determineimpactofsiphondraw:eitherbreakthesiphonor designtomaintainit. Determinefrictionhead Pipe Equipment(condenser, (condenser towerspraynozzle, nozzle etc etc.) ) Components(valves,strainers,etc.)

DesignConsiderations
OpenPipingandPumpingSystems Pumpheadestimationerrorscancause:

Unstable bl pumpoperation Unstablecondenserflowatthechiller Admissionofairintothep pump pinlet Energywasteduetoneedforextensivethrottling Manywastedhoursandheadachesfindingtheproblem!

DesignConsiderations
OpenPipingandPumpingSystems Pumpcavitation istheflashing(boiling)oftheworking fluid(water)intoavaporduetoexcessivelylowsuction pressureand di isoften ft confused f dwith ithair i introduction i t d ti i into t the th pumpsuction. NetPositiveSuctionHead(NPSH)isthemeasureofsuction pressure pressure. Therequired suctionpressureforaparticularpumpis indicatedNPSHR andispublishedasacurveonthepump selectionchart. Thesuctionpressureavailable tothepumpinaparticular systemisindicatedNPSHA andmustbecalculatedbythe engineer. IfNPSHA<NPSHR, NPSHR cavitation it ti will ill occur.

NPSHAExampleCalculation

DesignConsiderations
OpenPipingandPumpingSystems B&GCoolingTowerPumpingandPipingManualhas4 rules l concerning i the th pumpsuction ti piping: i i
1. 2. 3. 4.

LeavethesuctionLineAlone! Placethep pump pbelowtowerp panwaterlevel Avoidabovethepumpairtrapsinthesuctionline Avoidfinemesh,highpressuredropstrainersinthesuction line

DesignConsiderations
OpenPipingandPumpingSystems Airadmittancetothepumpinletistypicallycausedby:

Towerpanvortexing Towerpandraindown Incorrectbypass yp arrangement g

DesignConsiderations
OpenPipingandPumpingSystems Towerpanvortexing iscausedbyexcessivevelocityin th tower the t exit itpiping i i and dcanb becontrolled t ll dby: b

Donotexcessivelyoversizethepump Maintaining gtowerexitpipe p p sizeforaminimumof10pipe pp diameters Increasepandepth Provideavortexbreakerinthetowerpan Installtowerontheequator

DesignConsiderations
OpenPipingandPumpingSystems Towerpandraindowniscausedbyinsufficientwater d tht depth tofl flood dth thetower t exit itpiping i i and dcanb beavoided id d by:

Correctly ysizing gthemakeup pwaterline EvaporationRate Blowdown Rate Providingacheckvalvetokeepthepipingsystemfloodedon pumpshutdown Properlyisolatingtowercellsinmultiplecellinstallations

WRONG
Condenserandasignificant portionofthepipingsystemwill drainpacktopanonpump shutdown.Panmayfloodand chillercouldstartwithadry condenser.

CORRECT
Condenserwillremainflooded onpumpshutdown.Minimal systemvolumewilldraintopan onshutdown,thereforep pan shouldnotflood.

WRONG
Bypassconnectedtopump suction i piping i i cancauseair i introductiontopumpinletand unstablepumpoperation.

CORRECT
Bypassdischarging B di h i to t basin b i with ith balancingvalvesetequalto dischargenozzlepressuredrop willresultinconstantpump headandfloodedp pump psuction.

CORRECT
Separateoperatorsallowvalvestomaintain aconstanttotalflowasbothvalves modulate.

WRONG
Linkedvalveswillresultinunstableflow.

BypassConfigurationExample

DesignConsiderations
WaterQuality RemovalofSolids ChemicalTreatment

Consultachemicaltreatmentprofessionalforyourspecific application pp Minimizedrift Sitetowersawayfromairintakes Avoidpipingdesignsthatresultinstagnantwater Chemically ytreat

BiologicalContamination

DesignConsiderations
WaterQuality RemovalofSolids Whatsthatfloating ginthebasin???? Whateveritis,ithasagoodshotatendingupinsideyourchiller!!!!

DesignConsiderations
WaterQuality RemovalofSolids

Guywith hshovel h land db bucket k Inlinestrainers Sidestreamfilters Basinsweepingsystem

DesignConsiderations
TowerLocation Visibility Sound Drift

GettingtheproperRealEstate
Location,location,location CoolingTowersarehighlyvisibleduetophysicalsize

and dplume l Needampleclearancetominimizerecirculationand ensureproperperformance Lowfrequencysoundemittedfromlargefanstravels greatdistance Driftcanmarkwindowsandpaintjobs

DesignConsiderations
AncillarySystems FreezeProtection

TowerSumpBasin Electric SteamInjection Recirculation Piping

WaterTreatmentSystems ChemicalSystems SolidsFiltration ControlSystems Pneumaticoperators willrequirefreezeprotectioninsome climates Largevalvesrequirelotsof torque electricoperatorsmayneedto beindustrialgrade

ConstructionIssues
Constructability,Startup,QualityControl Thereislotsoflargepipingunderneaththetower,make sureyougetplentyofspaceforit Considerlayingoutallofthepipingbasedona manufacturersparticulartower Use U the h manufacturers f startupchecklist h kli onyoursite i visit Readtheinstallationandoperation p manualduring g design;therearelotsofoptionsthataffectthecostof thetower.Youneedtospecifythemifyourapplication needsthem.

ConstructionIssues
RatingsandCertification ManufacturersRatedPerformance CTICertification PerformanceBasedCommissioning

ConstructionIssues
LessonsLearned TowerBasinFreezeProtection

Directsteaminjectionispopular l inindustrial d land d l largescale l HVACapplications. Chemicalusedforboilerfeedwater mayreactwithcondenser waterchemicaltreatmentresultinginthereleaseofnoxious gases. Ahotwatercirculatorp pump pcoupled p toaheatsourcecanbe usedinstead.

ConstructionIssues
LessonsLearned VerticalLoopinSuctionPiping

Towermounted dongrade d adjacent d tomechanical h lroom Coldwaterpipeexitsbottomofbasinandpassesthrough mechanicalroomwall Pipeistherunupthewalltotheroofstructuretogetthepipe acrosstheroomtothepump Uponshutdown,thesystemequalizesandthepipingatthe rooflevelbecomesairlocked Thepumpwillrequiremanualpriminginordertostart

ConstructionIssues
LessonsLearned FloodingToweronPumpShutdown

Towerismountedongradeadjacenttomechanicalroom. room Thereisasignificantvolumeofwaterlocatedabovethetower basinduetoalonghorizontalrunofhotcondenserwaterpipe inthemechanicalroom. room Thedivertingvalveisinstalledinthehorizontalwiththe bypassconnectionfacingdown. Wheneverthepumpshutsdown, down allofthewaterinthe horizontalpiperunsthroughthedivertingvalveandbackto thebasin. Thebasinoverflowsinthep parking glotresulting ginan unsightlypuddleandwastedchemicaltreatment

ConstructionIssues
LessonsLearned Airintroducedtopumpsuctionviabypass

ConstructionIssues
LessonsLearned Airintroducedtopumpsuctionviabypass
AIRCANBEDRAWNINTO PUMPSUCTION

ConstructionIssues
LessonsLearned Airintroducedtopumpsuctionviatowerdischarge manifold if ld

ConstructionIssues
LessonsLearned Airintroducedtopumpsuctionviatowerdischarge manifold if ld

MUSTISOLATETOWER DISCHARGE

ConstructionIssues
LessonsLearned Floodinghotwaterpansonmanifolded towers

ConstructionIssues
LessonsLearned Floodinghotwaterpansonmanifolded towers

AUTOFLOWVALVE

ConstructionIssues
LessonsLearned Multipleconnectedtowersshouldhaveanequalization line. li Whenaddingorreplacingtowersconnectedthroughan equalization q line, ,design g thetowerandframing gto ensurethattheexistingoperatingwaterlevelis matchedwiththenewtower. If it i is i necessarytoprovide id vibration ib i i isolation l i for f the h tower,thepipingsystemmust beisolatedfromthe tower.

Resources
B&GCoolingTowerPumpingandPipingManual MarleyCoolingTowerCompany CoolingTower

Fundamentals F d l BaltimoreAirCoilProductandApplicationHandbook E Evapco E i Equipment Layout L M Manual l www.CTI.org ASHRAEHandbook H db k 2008 8HVACSystems S t and d Equipment,Chapter39

Questions?