Cooling Tower Seminar Cooling Tower Depot – Keeping You Cool Worldwide
Brandon Rees Regional Sales Manager
Cooling Tower Plinko
Presentation Overview Cooling Tower Basics
Types of Cooling Towers
Structure Types
Film Fill Material Water Quality
Drift & Drift Eliminators
Plume Abatement
Cooli ng Tow er Depot’s
Cooling Tower Basics
Said the Texan way
Cooling Tower Terminology DESIGN CONDITIONS: Defined as the hot water
temperature (HWT), cold water temperature (CWT), gallons per minute (GPM), wet-bulb temperature (WBT) and elevation
THERMAL CAPACITY: The amount of water (GPM) that a cooling tower will cool at a specified rate, at a specified approach and defined wet-bulb temperature
Cooling Tower Design Point
95ºF
85ºF Approach
78ºF Heat L oad (BTU/hr) = Flow (GPM) X Rang e( ºF) X 500 Flow (GPM) = Heat Lo ad (BTU /hr) ÷ Rang e( ºF) ÷ 500
Types of Cooling Towers Mech ani cal D raft Cool in g Towers Three Types:
•Forced
Draft
•Induced
Draft Crossflow
•Induced
Draft Counterflow
Induced Draft Cooling Towers Crossflow - Counterflow Crossflow Counterflow
Common Tower Components Counterflow - Crossflow Counterflow Crossflow Fan Assembly Right Angle Gearbox Drive Shaft Electric Motor Fill Media Drift Eliminators Structure (FRP, Wood & Concrete) FRP Fan Stacks & Casing
Crossflow Features Crossflow Features •Shape: Characteristic “V” shape. •Distribution System: Gravity fed hot water basin. •Louvers: Extend from the cold water basin curb up to the hot water basin. •Fill Media: Typically, splash type fill material. •Drift Eliminators: Positioned on the inside of the fill area.
Crossflow Cooling Tower Fan Stack
Header
Mechanical Components
Nozzle s
Distributio n System
Fill Media Drift Eliminator s
Louver s
Cold Water B asin Structur e
Crossflow Tower-Airflow Crossflow
Hot H2O
Air
Hot H2O
Air
The crossflow tower - named because of the orientation of the incoming air to the falling water is at 90°.
Crossflow Advantages Crossflow Advantages •Open Distribution basin provides easy inspection & cleaning of nozzles. •Only one riser pipe at end of tower reduces additional external piping. •Ability to tolerate poor water quality.
Crossflow Disadvantages Crossflow Disadvantages •Capital Cost: Generally more expensive •Distribution System: Exposure to direct sunlight promotes growth of algae. •Nozzles: Prone to plugging. •Winter Operation: More Difficult to control icing. •Recirculation: Higher profile and fully open longitudinal walls. •Operating Cost: Higher pumping head.
Counterflow Tower-Airflow
Hot H2O Air
The counterflow tower is named because of the orientation of the incoming cool ambient air and falling hot water is 180°.
Counterflow Features Counterflow Features •Distribution System: Open, low pressure down spray system. •Louvers: Optional. •Fill Material: Typically, cellular film fill. •Drift Eliminators: Positioned above the distribution system.
Counterflow Advantages Counterflow Advantages •Capital Cost: Substantially lower. •Operating Cost: Lower in pumping head •Nozzles: Less likely to plug. •Recirculation: Less likely to occur. occur. Lower Lower profile profile and smaller air inlets. •Winter Operation: Less susceptible to icing. Lower profile, smaller air inlets and enclosed fill area.
Counterflow Disadvantages Counterflow Disadvantages •Distribution System: Difficult to inspect and clean. •Potential Fouling: High TSS, oils and greases can foul high efficiency fill. (Low fouling fills are available) •Riser piping: Individual riser for each cell, more external piping required.
Sometimes more piping is a GOOD THING!!
Not a Cooling Tower Depot Tower!
Structural Design
3 Main Types of Structures
Stainless or Galvanized Steel
Concrete Cooling Towers
Wood Cooling Towers
Fiberglass Cooling Towers
Splash Fill Material
Fill Detail
V-Bar Splash Fill
OptiBar Splash Fill
Splash Grids Installed
Damaged Counterflow Splash Broken clips and damaged grid in basin
Reduced tower performance
Splash Grids - Counterflow CTD Splash and Unique Clip-in System
Film Fill Materials
Cross-Flute Design Film Fill
Cross-Flutes High Efficiency
ACCU-PAC® CF1900(MA) 19 mm pitch (48 ft2/ft3) (157.6m²/m³)
Vertical-Flute Design Film Fill
Vertical-Flutes Anti-Fouling ACCU-PAC® VF19Plus 19 mm pitch (48 ft2/ft3) (157.6m²/m³)
Offset Flute Design Film Fill
Offset-Flutes High Efficiency Anti-Fouling ACCU-PAC® OF21MA 21 mm pitch (45 ft2/ft3) (147.6m²/m³)
Mechanically Assembled (MA) Fill
Special tabs are molded into the individual fill sheet
Pairs of sheets have their tabs crimped together by machines made for that purpose
The pairs are edge bonded together to make a full width pack
MA Film Fill
Vacuum Forming Process The forming process thins the material. Some manufacturers who supply “15 mil” are supplying 15 mil “before forming”: 12 mil
7 mil
10 mil
15 mil
Before Forming
After Forming
Question? 1.) How many calories are in 1 egg with a yoke? 2.) How many calories are in 1 egg white?
Answer 1.) There are roughly 78 calories in 1 large egg with a yoke. 2.) There are roughly 17 calories in 1 egg white. You can have 4 egg whites and still be under the calories of 1 egg with a yoke.
Cooling Tower Basics
Water Quality
Water Quality & Fill Selection
Total Suspended Solids (TSS)
Make-up from Sources (Uncontaminated or
Contaminated?)
Biocide Water Treatment Program in use Number of Cycles of Concentration Presence of Airborne Dust
Presence of Oil or Grease in Circulating Water
Bacteria Count: Number of colonies
Fill Selection Guidelines WATER QUALITY & CHEMICAL TREATMENT
CF-1900
OF-21ma
VF-19Plu s
TSS (ppm): good bio
<100
<200
<500
poor bio Bio&ScaleC ontrol
Oil&Grease(ppm)
Fibers
<25 Good
None
None
<50 Good
<1
<200 Good
<5
None
None
A Recipe for Fouled Fill •Total Suspended Solids >50 ppm •High Bacteria Counts high Mineral Concentrations with Alkaline pH Swings •Low Oxidizing Biocide Residual •Cross Cross--Contamination from Oil
Use High Efficiency 1900 Series Fill When: •TSS < 50 PPM (with good bio & scale control) •Make Make--up from uncontaminated sources •Biocide water treatment program in use •Low cycles of concentration •Airborne dust is minimal •No oil or grease in circulating water
Use Anti Use AntiFouling Fills when: •TSS > 50 PPM but < 500 PPM. •MakeMake-up from natural waters •High cycles of concentration •Airborne dust is prevalent •High Bacteria Counts •Oil & Grease <25 PPM
Use Splash Fills when: •TSS > 500 PPM •Make Make--up from surface waters •Little or no biological or scale control •Fibers in process water •Oil or Grease are present in the circulating water
Drift Eliminators
Herringbone Drift Eliminators
Why Eliminate Drift?
Reduces water loss
Reduces fan blade leading edge erosion
Reduces equipment corrosion
Reduces nuisance on surroundings
Reduces bacterial dispersion (Legionella)
Factors That Affect Drift AIR VELOCITY: Limit average air velocity to no more than 700 ft/min & peaks
DROPLET SIZE: Limit nozzle pressure to no more than 2.5 psi
SEALS: Around all columns & braces.
Use “Dri-Seals”
WORKMANSHIP OF PANEL INSTALLATION
Proper DE Installation
Drift Eliminator Functionality Blade & cellular designs work
by inertial impaction The inertia of the heavy
droplets cause them to impact the walls of the drift eliminators Cellular types work better since they have more surface for droplet impaction
Collected droplets form a water film and drain
Break-Through Velocity Each DE design has it’s own breakthrough velocity
The velocity where the water film is stripped-off the DE surfaces and are re-entrained into the air stream
Breakthrough Velocity
Drift Eliminator Model D15 (Munters) CF-150MAx
Breakthrough Velocity* (ft/min) 800 900
(Brentwood)
CDX-80 (Brentwood)
Over 1000
TU-12 (Marley)
800
Opti-Cell(Tower
700
Components)
*Based on Brentwood Industries testing
Modern Cellular Designs 2nd Generation Cellular Designs
CF-150MAx
Good performance - Drift rates to 0.001%
CDX-80
Best performance Drift rates to 0.0005%
Who Knows What a Haiku is?
A Haiku is…
A form of Japanese poetry, which consists of 3 lines in a 5-7-5 syllable pattern.
A Cooling Tower Haiku
Water flowing strong Wind and water intertwine Cool water flows free
Cooling Tower Basics
Plume Abatement
Plume Abatement
Plume Abated Tower
Plume Abated Tower
Now that’s a Cool Tower!
Coil Dampers
Questions? Comments?
Br andon Rees Regi on al Manager
[email protected] Find us on Li nkedIn www.coolingtowerdepot.co m
