Heating, Ventilating, Air-Conditioning & Refrigeration Technology

SECTION 10
CHILLED WATER AIRCONDITIONING SYSTEMS UNIT 49 COOLING TOWERS AND PUMPS

UNIT OBJECTIVES
After studying this unit, the reader should be able to Describe the function of the cooling tower in a chilled water
system Identify the relationship between the wet-bulb temperature of the ambient air and the temperature of the water leaving the tower Describe three types of cooling towers Describe various fan and drive types used on cooling towers Describe the function of the fill in a cooling tower Explain the purpose of makeup water and blowdown

COOLING TOWER FUNCTION

Water is moved by a pump from the condenser to the cooling tower and back to the condenser Tower must reject more heat than the chiller absorbs The compressor adds approximately 25% additional heat Design temperature of water leaving the tower is 85 The tower can cool the water down to within 7 of the wet-bulb temperature of the ambient air (approach) Cools the water by evaporation
As air is passed over the water, some of it evaporates This evaporating water cools the remaining water

Hot water in (95F)

Fan motor

Air in 95F dry bulb, 78F wet bulb

Air out

Cooled water out (85F)

95F water

85F water

Load

Condenser
Pump Evaporator Pump

45F

55F

TYPES OF COOLING TOWERS

Natural draft towers rely on prevailing winds Operate with an approach temperature of about 10 Forced/induced draft towers use a fan to move air through the tower
Fans can be gear-driven or belt-driven

Closed-loop hybrid tower

Dry/wet mode, adiabatic mode, and dry mode

Warm water from condenser

Spray nozzles
Prevailing winds

Slats on all four sides of the tower

Float

Valve

Make-up water

Water to pump

DRY/WET MODE
Fluid to be cooled is fed first to the dry finned coil Fluid then fed to the prime surface coil Fluid then leaves tower Water in the tower flows over the prime surface coil and wet deck surface Air is drawn through the prime surface coil and wet deck surface

ADIABATIC MODE
Condenser water is cooled by evaporating the tower water No heat is added or removed during from the process Fluid to be cooled passes only through finned coil Spray water is used to help cool the air passing through the tower Plume is the saturated discharge air

DRY MODE
Fluid to be cooled passes through the finned coil and the primed surface coil No spray water is used No plume results Fluid is cooled by air passing over the coil

FIRE PROTECTION
The off season can create a fire hazard Tower components may be flammable A tower wetting system may be required Some towers are kept wet whenever the temperature is above freezing

FILL MATERIAL
Designed to slow the flow of trickling water through the tower Splash method
Uses wood slats, PVC pipe, or FRP plastic Tower has framework to support slats at the correct angle

Film or wetted surface

Fill is usually plastic or fiberglass The water is spread out over the fill as air is passed over it

FLOW PATTERNS
Crossflow
Air enters from the side and is discharged from the top or the other side

Counterflow
Air enters from the bottom and is exhausted at the top The water flows down as the air moves up

Water that is blown out of the tower is called drift Eliminators reduce the amount of drift

TOWER MATERIALS
Must withstand the environment Must withstand fan and drive mechanism vibrations Usually made of galvanized steel, fiberglass, or FRP Larger towers may have a concrete base The sides of the tower can be made of wood, fiberglass, corrugated FRP

FAN SECTION
Belt-driven fan
Primarily found on smaller towers

Gear box transmissions

Motors are usually mounted at a 90 degree angle to the fan May be designed to reduced the fan speed Motor, gear box, and bearings must be accessible for servicing

TOWER ACCESS
Tower fill must be accessible for cleaning or replacement Sludge needs to be cleaned from the tower basin Garbage, bird features, and other pollutants accumulate in the sump There is a strainer to prevent garbage from entering the pump and water circuit Stairs or ladders provide access to fans and drive mechanisms on tall towers

TOWER SUMP
Area where tower water collects Sump water must not freeze May be installed underground Should be accessible for cleaning Is usually equipped with a strainer to protect the pump

Warm water from condenser

Spray nozzles
Prevailing winds

Slats on all four sides of the tower

Float

Valve

Make-up water Water to pump

Thermostatically controlled heater

MAKE-UP WATER
Water continuously evaporates from the system Fresh water must be supplied to the system as needed Float valve

Solenoid controlled valve

Electrodes

As the water level drops, the valve will open and add supply water Solenoid valve operation controlled by a float switch Used to sense the water level

Float and Valve

Float ball Water level

Make up water

Float valve

Strainer

To pump

Float Switch and Solenoid

Solenoid Float switch Float ball Water level

Make up water

Strainer

To pump

Electronic Water Level Control

Control Sensors

Solenoid

Strainer

To pump

BLOWDOWN
Process of bleeding off a portion of the system water This water is replaced with fresh water Designed to reduce the amount of solid materials in the water Blowdown reduces head pressure and approach temperature Must be done correctly

BALANCING THE WATER FLOW FOR A TOWER

Water flow to each of tower cell must be equal Distribution pans
Receives water returning from the condenser Have calibrated holes to distribute water Holes must be clean

Balancing valves must be adjusted properly

WATER PUMPS
Responsible for moving water through the condenser and cooling tower circuit Usually a centrifugal pump Close coupled pump
Impeller is mounted to the motor shaft Used in small applications Shaft seal prevents water leakage

WATER PUMPS
Base mounted pump
Motor and pump are connected by a flexible coupling Can have a single- or double-sided impeller Motor and pump are mounted on a base Base is usually cemented to the floor Motor and pump are factor aligned

WATER PUMPS
Pump must have a shaft seal Most pumps are made from cast iron Most centrifugal pump impellers are made of bronze The eye of the impeller must be under water during startup If the pump is located higher than the sump, the pump must be filled with water before starting Whirlpool action in the pump is called vortexing

WATER PUMPS
Strainers are located between the sump and pump Tower bypass valve
Helps to maintain correct water pressure during start-up and low-ambient conditions Water from the pump outlet is recirculated to the pump inlet

Pumps can have sleeve bearing or ball bearings Pumps and shafts must be properly aligned

SUMMARY
Heat laden water from the condenser is cooled in the tower so the water can be reused Tower must reject more heat than the chiller absorbs The tower can cool the water down to within 7 of the wet-bulb temperature of the ambient air (approach) Natural draft towers rely on prevailing winds Forced/induced draft towers use a fan to move air through the tower Closed-loop hybrid tower Tower components may be flammable

SUMMARY
Fill material is designed to slow the flow of trickling water through the tower Airflow pattern can be counterflow or crossflow Tower materials must withstand the environment The fan section often has a gear box transmission Tower fill, sump and strainer must be accessible Fresh water must be supplied to the system as water evaporates Blowdown is the process of bleeding off a portion of the system water Water flow to each of tower cell must be equal