DESIGN OF COOLING TOWER

DESIGN CONDITIONS:
Cooling Tower Type COUNTER FLOW INDUCED DRAFT
Water Temperature
Leaving C 25
Entering C 30
Air Condition
Leaving WB C DB C 98 , 38
Entering RH DB C % 65 , 26
Make-up Water
Temperature C 26
Barometric Pressure kPa 325 . 101

Note:
(1) The practical cooling range
2 1
t t is C 7 . 16 6 . 5 (Morse, 1990)
p 122

(2) For cooling towers the rating conditions are C 35 entering water, C 4 . 29
leaving water, and C 9 . 23 wet bulb of the outdoor air (Wang, 2001)
p 10.50

(3) In most cases, the temperature of the water leaving the tower will be F to 10 7
above wet bulb temperature of the entering air (Dossat, 1978)
p 333


Calculation Procedure:
Amount of water to be handled by the cooling tower, m
cw





( ) ( )
( )
sec 74 . 13
sec
78 . 10 96 . 2
kg m
kg
m
m m m
cw
cw
condenser cw compressor cw cw
=
+ =
+ =


Air Properties Using Psychometrics Chart

At RH and C % 65 26

air dry of kg
moisture of kg
HR
kg
KJ
h
0136 . 0
;
61
4 4
= =
At RH and C % 98 32

air dry of kg
moisture of kg
HR
kg
KJ
h
0297 . 0
;
108
5 5
= =



Mass of Air,
, a
m
Energy Balance on the cooling tower
( ) ( )
3 4 2 1
4 3 2 1
&
h h m t Cp m t t Cp m
m m m m m m
a mw w mw cw cw
a cw
= +
= = = =

( ) ( )
mw w
cw cw a
mw
t Cp
t t Cp m h h m
m
2 1 3 4

=
( ) ( )
( )
1 . 642 . 2 43174 . 0
26 187 . 4
25 30 187 . 4
sec
74 . 13 61 108
0
0
0
0
eq m m
C
C kg
KJ
C
C kg
KJ
kg
kg
KJ
m
m
a mw
a
mw
=

|
.
|

\
|
|
.
|

\
|

=


Mass Balance
Mass entering = Mass leaving

2 . 0161 . 0
) 0136 . 0 0297 . 0 ( ) . . (
. .
3 4
4 3
eq m m
m R H R H m m
R H m m R H m m m
a mw
a a mw
a w a w mw
=
= =
+ = + +


Substituting eq.1 to eq.2
642 . 2 43174 . 0 0161 . 0 =
a a
m m

a a
m m 0161 . 0 4317 . 0 642 . 2 =

sec
36 . 6
kg
m
a
=

Mass of Make-up water,
5 w
m
From Equation 2

water of
kg kg
m
m m
w
a w
sec
1023 . 0
sec
36 . 6 0161 . 0
0161 . 0
5
5
=
|
.
|

\
|
=
=

Volume flow rate of air,
a
V

( ) ( ) KPa KPa Psat RH Ps
KPa Psat RH and C At
18595 . 2 363 . 3 65 . 0
363 . 3 , % 65 26
= = =
=

MRT PV =
( )
( )
( )
3
0
0
18595 . 2 325 . 101
273 26
2871 . 0
sec
36 . 6
m
KN
or KPa
K
K kg
KJ
kg
P P
T R m
V
S B
a a a
a

+
|
.
|

\
|
|
.
|

\
|
=

=
sec
507 . 5
3
m
V
a
=
Where: R.H= relative humidity

vapor water of pressure partial P
C at pressure saturation P
V
Sat
=
= 26


Volume flow rate of air,
w
V

From Refrigeration Engineering by Mc Intire P. 495. cross-sectional area of
induced draft fan is found by allowing gpm/ft 3.0
2

t =
2
30 25+

= 27.5 C @ 27.5 C
3
512 . 996
m
kg
w
=


Therefore,

Volume flow rate (
w
v ) =
3
512 . 996
sec
74 . 13
m
kg
kg
M
w
w
=


=
min 1
sec 60
003785 . 0
1
sec
0138 . 0
3
3
x
m
gal
x
m

= 218.57 gpm
Cooling tower range, C.T.R.
C.T.R. = C t t
o
5
2 1
=
Cooling tower approach, C.T.A.
At 26 C
o
and 65% RH ; C t
o
wb
75 . 18 =
C.T.A. = C t t
o
wb
25 . 6 75 . 18 25
1
= =


Cooling tower efficiency, C.T.E.
C.T.R. =
% 100
75 . 18 30
25 30
% 100
1
2 1
x x
t t
t t
wb

= 44.4 %

















PIPING SYSTEM FOR COOLING TOWER

Design Condition:
Mass flow rate cooling water
Compressor sec 96 . 2 kg
Condenser sec 78 . 10 kg

water
v = 996.512 kg/
3
m ;
f
v v = @ C t
o
ave
5 . 27 =
Water Velocity, v = 1.83 m/sec (range: 1.5 to 2.1m/sec)

Solving for the total amount of cooling water,
Tcw
Q
sec / 10 97 . 2
/ 512 . 996
sec / 96 . 2
3 3
3
m x
m kg
kg
Q
compressor

= =
sec / 10 82 . 10
/ 512 . 996
sec / 78 . 10
3 3
3
m x
m kg
kg
Q
condenser

= =

condenser compressor Tcw
Q Q Q + =
sec / ) 10 82 . 10 10 97 . 2 (
3 3 3
m x x Q
Tcw

+ =
sec / 01379 . 0
3
m Q
Tcw
=




PIPE SIZE FOR THE SUPPLY AND RETURN PIPES

From cooling tower pool to tee-run
v D Q
Tcw
2
4
t
=
|
.
|

\
|
=
sec
83 . 1
4 sec
01379 . 0
2
3
m
D
m t

D = 0.0979 m = 97.9 mm

USE: 100 mm NPS schedule 40 (from Table 7-2 Dimensions of steel pipe by
Wilbert F. Stoeker, P 136)
OD = 114.3 mm ID = 102.3 mm

From tee-run to condenser inlet
v D Q
condenser
2
4
t
=
|
.
|

\
|
=

sec
83 . 1
4 sec
10 82 . 10
2
3
3
m
D
m
x
t

D = 0.08676 m = 86.76 mm

USE: 100 mm NPS schedule 40 (from Table 7-2 Dimensions of steel pipe by
Wilbert F. Stoeker, P 136)
OD = 114.3 mm ID = 102.3 mm
From tee-run to compressor inlet
v D Q
compressor
2
4
t
=
|
.
|

\
|
=

sec
83 . 1
4 sec
10 97 . 2
2
3
3
m
D
m
x
t

D = 0.04545 m = 45.45 mm

USE: 50 mm NPS schedule 40 (from M.E.T.C. Steel Pipe Dimensions, P 114.)
OD = 73.03 mm ID = 62.65 mm













COOLING WATER PUMP
Design Data:

Type Centrifugal
Capacity, Q
P
0.01379 m
3
/sec
Average water temperature, t
ave
27.5
0
C
Water density, 996.4129 kg/m
3
Main pipe 100 mm NPS
Capacity, Q
T
0.01379 m
3
/sec
Condenser pipe 100 mm NPS


Capacity, Q
cond
0.01082 m
3
/sec
Compressor pipe 50 mm NPS
Capacity, Q
comp
0.00297 m
3
/sec
Static head, h
S
2 m



Friction Heads, h
f

( ) ( ) ( ) ( ) ( ) ( ) k p L factor correction e Temperatur drop essure length equivalent Total h
e f
A = = Pr

For the main line, 100 mm NPS, Schedule 40, from cooling tower to Tee of
condenser

Straight Pipe ------------------------------------------------------------ 6.42 m
2 90
0
elbow ------------------------------------------------------------ 6 m

1 Standard tee ------------------------------------------------------------ 4.16 m
1 Gate valve ------------------------------------------------------------ 0.52 m
1 Check valve ------------------------------------------------------------ 9.15 m

__________
Total length 26.25 m

For the condenser line, 100 mm NPS, Schedule 40, from condenser tee to
condenser inlet
Straight Pipe ------------------------------------------------------------ 2.23 m
1 Standard tee ------------------------------------------------------------ 5.18 m
1 gate valve (open) --------------------------------------------------- 0.52 m
1 90
0
elbow ------------------------------------------------------------ 3.0 m

____________
Total length 10.93 m

For the condenser tubes, 25 mm NPS, Schedule 40
Straight Pipe ------------------------------------------------------ 279 m
3 Close return bend --------------------------------------------- 49.41 m
____________
Total length 328.41 m

For the compressor line, 50 mm NPS, Schedule 40, from condenser tee to
compressor tee

Straight Pipe ------------------------------------------------------------ 3.8 m
1 Standard tee ------------------------------------------------------------ 0.9 m
1 gate valve (open) --------------------------------------------------- 0.09 m
1 90
0
elbow ------------------------------------------------------------ 0.6 m


____________
Total length 5.39 m

From Compressor Tee to compressor inlet, 50 mm NPS, Schedule 40
Straight Pipe ------------------------------------------------------------ 3.0 m
1 Standard tee ------------------------------------------------------------ 0.9 m
1 gate valve (open) --------------------------------------------------- 0.09 m

____________
Total length 3.99 m

For the compressor jacket water line, assume equivalent length of 2 m inside
the compressor cooling water system.

From Figure 7 6, Pressure drop for water flowing in schedule 40 steel pipes,
Refrigeration and Air-conditioning by Stoecker & J ones, page 138.


For 100 mm pipe & 7.89 L/sec, p = 220 Pa / m
For 100 mm pipe & 7.65 L/sec, p = 370 Pa / m
For 50 mm pipe & 2.97 L/sec, p = 400 Pa / m
For 25 mm pipe & 0.24 L/sec, p = 1300 Pa / m

From Figure 7 7, Multiplying factors for pressure drops to correct for
temperature, Refrigeration and Air-conditioning by Stoecker & J ones, page 139.


For t
ave
of 27.5
0
C & 1.52 m/sec water velocity, k = 0.98
Therefore the friction heads h
f
, are equal to,
O H of m
kPa
O H of m
x kPa Pa x
m
Pa
x m h
f 2
2
1
5756 . 0 1017 . 0 6595 . 5 5 . 659 , 5 98 . 0
220
25 . 26 = = = =

O H of m
kPa
O H of m
x kPa Pa x
m
Pa
x m h
f 2
2
2
403 . 0 1017 . 0 963 . 3 218 . 963 , 3 98 . 0
370
93 . 10 = = = =

O H of m
kPa
O H of m
x kPa Pa x
m
Pa
x m h
f 2
2
3
55 . 42 1017 . 0 39 . 418 4 . 394 , 418 98 . 0
1300
41 . 328 = = = =

O H of m
kPa
O H of m
x kPa Pa x
m
Pa
x m h
f 2
2
4
2148 . 0 1017 . 0 112 . 2 88 . 2112 98 . 0
400
39 . 5 = = = =

O H of m
kPa
O H of m
x kPa Pa x
m
Pa
x m h
f 2
2
5
159 . 0 1017 . 0 564 . 1 08 . 1564 98 . 0
400
99 . 3 = = = =

O H of m
kPa
O H of m
x kPa Pa x
m
Pa
x m h
f 2
2
6
3 . 0 1017 . 0 98 . 2 2989 98 . 0
1525
2 = = = =


Also the total friction head h
fT
,

is equal to,
O H of m h h h h h h h
f f f f f f S f 2 6 5 4 3 2 1
2 . 44 3 . 0 159 . 0 2148 . 0 55 . 42 403 . 0 5756 . 0 = + + + + + = + + + + + =

Total friction head, h
fT
Assuming the supply line equal to the discharge line,
( )
S f T f
h h 2 =

Therefore,

( ) O H of m O H of m h
T f 2 2
4 . 88 2 . 44 2 = =


Total Pumping Head, H
T

O H of m h h H
S fT T 2
4 . 90 2 4 . 88 = + = + =



Water Horsepower, W
hp

( )( )( )
hp
hp kW
m m kN m H Q
W
T water P
hp
4 . 16
746 . 0
4 . 90 81 . 9 sec 01379 . 0
746 . 0
3 3
= = =



Motor Power, P
m
p
hp
m
m
hp
p
W
P
P
W
q
q = = ;
Using 75 % pump efficiency,
hp
hp
P
m
86 . 21
75 . 0
4 . 16
= =
For standard motor sizes, use 25 hp electric motor for the cooling water pump.