good cooling tower practise
DESCRIPTION
this articles explain everything realted to the cooling tower from the design point of view and aslo mention all good cooling tower prectiseTRANSCRIPT
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GoodGood coolingcooling towertower practisespractises
Georges Hoeterickx Georges Hoeterickx Evapco Evapco EuropeEurope
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GoodGood coolingcooling towertower practisespractises Design Design considerationsconsiderations
ApproachApproach
: : DifferenceDifference
betweenbetween
coolingcooling
towertower
outletoutlet
temp. temp.
and design entering and design entering wbwb
temp.temp.
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Design Design considerationsconsiderations CoolingCooling towertower sizesize versus versus approachapproach
0
1
2
3
4
5
6
3 4 5 6 7 8 9 10 11 12
Coo
ling
Tow
er S
ize
Approach ° F
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Design Design considerationsconsiderations Minimum Minimum approachapproach
CTI CTI CertificationCertification
underunder
STDSTD--201201CertificationCertification
is is limitedlimited
to to thermalthermal
operatingoperating
conditionsconditions…….. and a .. and a coolingcooling
approachapproach
of of 2.82.8°°C (5C (5°°F) F) oror
greatergreater……..
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GoodGood coolingcooling towertower practisespractises CoolingCooling towertower rangerange
RangeRange
::DifferenceDifference
betweenbetween
coolingcooling
towertower
inletinlet
and and
coolingcooling
towertower
outletoutlet
temperaturetemperature. .
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Design Design considerationsconsiderations CoolingCooling towertower sizesize versus range versus range
0
0,2
0,4
0,6
0,8
1
1,2
80% 90% 100% 110% 120% 130% 140% 150%
Range
C.T
. Siz
e
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GoodGood coolingcooling towertower practisespractises Design Design considerationsconsiderations
AvoidAvoid
recirculationrecirculation
: : Bypass of warm discharge air Bypass of warm discharge air intointo
the the coolingcooling
towertower
air air inletinlet
willwill
causecause
capacitycapacity
losseslosses. .
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Design Design considerationsconsiderations AvoidAvoid recirculationrecirculation
Top of Top of coolingcooling towertower shouldshould bebe at least level at least level withwith enclosureenclosure..
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Design Design considerationsconsiderations AvoidAvoid recirculationrecirculation
Fan discharge Fan discharge velocityvelocity : min. 1200 : min. 1200 fpmfpm(6 m/sec).(6 m/sec).DownwardDownward velocityvelocity : max. 600 : max. 600 fpmfpm(3 m/sec).(3 m/sec).
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Design Design considerationsconsiderations AvoidAvoid recirculationrecirculation
Limit Limit downwarddownward velocityvelocity -- twotwo sideside air air inletinlet unitsunits
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Design Design considerationsconsiderations AvoidAvoid recirculationrecirculation
Limit Limit downwarddownward velocityvelocity -- single air single air inletinlet unitsunits
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GoodGood coolingcooling towertower practisespractises Design Design considerationsconsiderations
UseUse
of of VFDVFD’’ss
forfor
fan motorsfan motors
: : AllowAllow
to to controlcontrol
air air flowflow
throughthrough
the the coolingcooling
towertower
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Design Design considerationsconsiderations VFDVFD’’ss forfor fan motors fan motors
Energy Energy savingsaving
? ?
CondenserCondenser water temp 1water temp 1°°FFChillerChiller
efficiency 3%efficiency 3%
CoolingCooling towertower kW = ~ 5 %kW = ~ 5 %ChillerChiller
kW. kW.
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Design Design considerationsconsiderations VFDVFD’’ss forfor fan motorsfan motors
Water Water consumptionconsumption : : Air Air flowflow
Water Water consumptionconsumption
PlumePlume formationformation ::Air Air flowflow
PlumePlume
formationformation
tendencytendency
NoiseNoise controlcontrol @ @ nightnightFan @ half speed : Fan @ half speed : ––
9 9 dBAdBA
fan fan noisenoise
(60% (60% capacitycapacity) )
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Design Design considerationsconsiderations VFDVFD’’ss forfor fan motorsfan motors
Min. RPM Min. RPM forfor geargear(motor speed (motor speed ≥≥
450 RPM)450 RPM)
GearGear withwith mechanicalmechanical oiloil pump pump forfor proper proper lubricationlubrication
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Design Design considerationsconsiderations CoolingCooling towertower basinsbasins
CommonCommon
basinbasin
+ + EasierEasier
basinbasin
and and coolingcooling
towertower
constructionconstruction..+ No + No needneed
forfor
equalizingequalizing
connectionconnection--
Maintenance Maintenance ––
sumpsump
cleaningcleaning
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GoodGood coolingcooling towertower practisespractises Design Design considerationsconsiderations
CoolingCooling
TowerTower
BasinBasin
: : HoldHold
circulatingcirculating
water of the water of the towertower. .
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Design Design considerationsconsiderations CoolingCooling TowerTower BasinBasin
IndividualIndividual
BasinBasin
per per CellCell
+ + EasierEasier
forfor
maintancemaintance
(water)(water)--
NeedNeed
equalizingequalizing
betweenbetween
basinsbasins..--
More More costlycostly
constructionconstruction
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Design Design considerationsconsiderations CoolingCooling TowerTower BasinBasin
Sound mats to Sound mats to reducereduce
water water noisenoiseNoiseNoise reductionreduction functionfunctionnumbernumber of of layerslayersdistancedistance mats mats –– water in water in basinbasin !!
Sound mats Sound mats willwill obstructobstruct basinbasin accessaccess : : maintenancemaintenance !!
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GoodGood coolingcooling towertower practisespractises
ObtainObtain
the the specifiedspecified
and correct and correct qualityquality
level !level !
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ObtainObtain the the specifiedspecified qualityquality CostCost distribution distribution mainmain items items
Fan
Gear & Motor
Fill
Structure
Louvers
DE
Water Dis.
Fan Stack
Other
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GoodGood coolingcooling towertower practisespractises ObtainObtain the the specifiedspecified qualityquality
TypicalTypical
requirementsrequirements: :
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ObtainObtain the the specifiedspecified qualityquality FRP FRP structurestructure
ReputableReputable manufacturersmanufacturers have have theirtheircomponentscomponents thirdthird party party testedtested perperASTM E 84 ASTM E 84 forfor
strengthstrength
valuesvalues
and and
flamabilityflamability
AskAsk ifif these these evidencesevidences are part of contract are part of contract submittalssubmittals ! !
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ObtainObtain the the specifiedspecified qualityquality FRP FRP structurestructure
ThreeThree
factors factors influenceinfluence
lifelife
expectancyexpectancy
::
CreepCreep : long term : long term deformationdeformation of a of a membermemberunderunder loadload
ShearShear : FRP : FRP strongstrong in in oneone directiondirection
UV UV degradationdegradation
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ObtainObtain the the specifiedspecified qualityquality FRP FRP structurestructure : : creepcreep
Design Design structurestructure loadsloads primarilyprimarily taken taken bybyfiber fiber –– unidirectionalunidirectional
LoadsLoads byby resinresin to to bebe maintainedmaintained lowlow
Correct design Correct design assuresassures long long lifelife timetime
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ObtainObtain the the specifiedspecified qualityquality FRP FRP structurestructure : : shearshear
LoadsLoads in in planeplane of of laminatelaminate byby resinresin
AvoidAvoid water water migrationmigration byby proper proper sealingsealingall holesall holes
InspectInspect onon regularregular basisbasis
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ObtainObtain the the specifiedspecified qualityquality FRP FRP structurestructure
UV UV protectionprotection
UV UV degradationdegradation and and moisturemoisture penetrationpenetrationwillwill have have influenceinfluence lifelife time of time of anan FRP FRP coolingcooling towertower
The UV The UV raysrays willwill causecause the the decompositiondecomposition of of the the polymerspolymers holding the holding the fibrefibre glassglass togethertogether
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FRP FRP structurestructure UV UV protectionprotection
SurfaceSurface veil veil materialmaterial of non of non wovenwoven polyester polyester fabricfabric to prevent fiber blow outto prevent fiber blow out
SurfaceSurface veil veil createscreates a a resinresin richrich surfacesurface areaareato provide to provide enhancedenhanced UV UV protectionprotection
OneOne milmil thicknessthickness of of surfacesurface veil =veil =2 2 ––
3 3 yearsyears
lifelife
timetime
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STRUCTURAL RESIN 55-25%GLASS 45-75%WOVEN ROVEN ANDCONTINUOUS GLASS250 MILS OR MORE
CORROSION BARRIERRESIN 60-70 %GLASS 30-40%MAT OR CLOTH40-60 MILS
EXTERNAL LINERRESIN RICH 80-90%GLASS 10-20%
15-20 MILSSURFACING VEIL TYPE C10-20 MIL THICKNESS
FRP FRP structurestructure UV UV protectionprotection
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FRP FRP structurestructure UV UV protectionprotection
0
10
20
3040
50
60
70
80
5 10 15 20 25 30Years
Midde East Climate European Climate
UsefulUseful
lifelife
of UV of UV projectedprojected
componentscomponents
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FRP FRP structurestructure UV UV protectionprotection
HowHow
to to verifyverify
UV UV protectionprotection
qualityquality
? ?
Have samples of different Have samples of different weightweight veil veil materialmaterial forfor comparisoncomparison..VariationVariation in the in the visibilityvisibility of the of the ContiniousContiniousFilament Mat. Filament Mat.
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ObtainObtain the the requiredrequired qualityquality FRP FRP structurestructure
Fire Fire retardancyretardancy
Fire Fire resistanceresistance
and and damagedamage
controlcontrol
of the of the FRP FRP structurestructure. .
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FRP FRP structurestructure Fire Fire retardancyretardancy
Design Design withwith high high qualityquality, heat , heat resistantresistant / / firefireretardantretardant resinresin systemssystems, , ClassClass 1 type1 type
SpecifySpecify selfself extinguishingextinguishing
High High glassglass content = minimum content = minimum burnburn raterate
AdditionAddition AntimonyAntimony Trioxide Trioxide improvesimproves firefireretardingretarding
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ObtainObtain the the requiredrequired qualityquality FRP FRP structurestructure
Major part of the Major part of the coolingcooling towertower costcostMost Most criticalcritical item item forfor the the coolingcooling towertower lifelifetime !time !
HowHow
to to obtainobtain
the the requiredrequired
qualityquality
? ?
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ObtainObtain the the requiredrequired qualityquality FRP FRP structurestructure
1. 1. DemandDemand
coolingcooling
towertower
suppliersupplier
namesnames
the FRP the FRP sourcesource
and and askask
deliverydelivery
certificatescertificates
fromfrom
the the
FRP FRP manufacturermanufacturer..
2. Reserve the right to 2. Reserve the right to inspectinspect
beforebefore
deliverydelivery
to to verifyverify
QualityQuality
ProcessProcess
Map is Map is compliedcomplied
withwith. .
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ObtainObtain the best the best qualityquality Fans Fans
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ObtainObtain the best the best qualityquality FansFans
Fans are Fans are selectedselected forfor a a givengiven airflowairflow and and static static pressurepressure
Fan design parameters : Fan design parameters : diameter diameter ––
speed speed ––
nbrnbr
and and shapeshape
of of bladesblades
––
bladeblade
widthwidth
Fan design parameters Fan design parameters influenceinfluence ::costcost
––
power power consumptionconsumption
––
noisenoise
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CoolingCooling towertower fans fans NoiseNoise definitiondefinition
SpecifySpecify
sound sound pressurepressurein dB(A) in dB(A) measuredmeasured
1,5 meter 1,5 meter
aboveabove
fan discharge fan discharge (per CTI (per CTI stdstd
ATC ATC ––
128)128)
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CoolingCooling towertower fansfans NoiseNoise
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CoolingCooling towertower fansfans ComparisonComparison -- 2000 ton 2000 ton towertower -- 196 m196 m³³/ sec @ 160 Pa / sec @ 160 Pa pressurepressure drop drop
FanFandia dia
NbrNbrBladesBlades RpmRpm
TipTipspeed speed
SoundSoundPowerPower
Fan Fan shaftshaftPower Power Fan Fan
ftft m/secm/sec dB(A)dB(A) kW kW US $ US $
1414 66 270.8270.8 60.560.5 100.3100.3 59.359.3 21002100
1616 77 193.9193.9 49.549.5 95.695.6 53.253.2 36003600
1818 55 186.8186.8 54.254.2 9999 4646 1350013500
18 *18 * 44 137137 4040 86.386.3 54.954.9 4500045000
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CoolingCooling towertower fansfans Fan power Fan power vsvs costcost –– 2000 ton 2000 ton towertower –– 196 m196 m³³/sec @ 160 Pa /sec @ 160 Pa pressurepressure dropdrop
Fan dia Fan dia TowerTower priceprice Fan Power Fan Power
ftft %% kWkW
1414 -- --
1616 + 1, 25 %+ 1, 25 % -- 11 % 11 %
1818 +8 % +8 % -- 22 % 22 %
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CoolingCooling towertower fansfans ComparisonComparison -- 5000 ton 5000 ton towertower -- 375 m375 m³³/ sec @ 160 Pa / sec @ 160 Pa pressurepressure dropdrop
FanFandia dia
NbrNbrBladesBlades RpmRpm Tip speed Tip speed
SoundSoundPowerPower
Fan Fan shaftshaftPower Power Fan Fan
ftft m/secm/sec dB(A)dB(A) kW kW US $ US $
2222 66 226226 44.244.2 106.3106.3 106.3106.3 95009500
2626 99 104.8104.8 43.543.5 97.997.9 87.187.1 2600026000
2626 66 89.789.7 37.237.2 90.690.6 104.2104.2 6000060000
2828 66 82.682.6 36.936.9 9090 102.3102.3 6500065000
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CoolingCooling towertower fansfans Fan power Fan power –– noisenoise vsvs costcost -- 5000 ton 5000 ton towertower –– 375 m375 m³³/ sec @ 160 Pa / sec @ 160 Pa pressurepressure dropdrop
FanFandia dia
TowerTowerpriceprice Power Power
SoundSoundPower Power
ftft %% kWkW dB (A)dB (A)
2222 106.3106.3
2626 + 7 %+ 7 % -- 18 % 18 % 97.997.9
2626 20%20% --2%2% 90.690.6
2828 + 22% + 22% --4%4% 9090
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ObtainObtain the the requiredrequired qualityquality Fan Fan stacksstacks
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Fan Fan stacksstacks MaterialMaterial
HeightHeight : 6 : 6 –– 8 8 –– 10 ft 10 ft -- ……
MaterialMaterial : : ClassClass 1 1 –– flameflame spread rating 25spread rating 25((ClassClass
II and II and ClassClass
III = III = CheaperCheaper
!)!)
UV UV resistanceresistance ((gelcoatgelcoat 20 20 milmil).).
Access door Access door oror removableremovable panel panel
AssemblyAssembly hardware SST hardware SST
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Fan Fan stacksstacks
MakeMake suresure fan deck fan deck floorfloor opening matches opening matches fan fan cylindercylinder
SmoothSmooth air air inletinlet
Fan tip Fan tip clearanceclearance : 0,5% fan dia: 0,5% fan dia
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ObtainObtain the the requiredrequired qualityquality Air Air inletinlet louverslouvers
Water stays in… Sunlight stays out!
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Air Air inletinlet louverslouvers Single pass Single pass louverslouvers
WaterdropletsWaterdroplets tendtend to to splashsplash out out whenwhen fans fans are are shutshut offoff. .
SunlightSunlight stillstill enters the enters the coolingcooling towertower basinbasin !!
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Air Air inletinlet louverslouvers TwoTwo pass air pass air inletinlet louverslouvers
MinimiseMinimise splashoutsplashout
Direct Direct sunlightsunlight is is blockedblocked fromfrom the water the water insideinside the the towertower and and reducingreducing the the potentialpotentialforfor algaealgae formationformation ! !
Minimum Minimum pressurepressure drop drop
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Air Air inletinlet louverslouvers TwoTwo pass air pass air inletinlet louverslouvers
TypicalTypical
twotwo
pass air pass air inletinlet
louverslouvers
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ObtainObtain the the requiredrequired qualityquality Drift Drift eliminatorseliminators
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ObtainObtain the the requiredrequired qualityquality Drift Drift eliminatorseliminators
Drift Drift ratesrates : 0,01 to : 0,01 to 0,00050,0005 % of % of towertower flowflowraterate
Drift Drift raterate functionfunction of type DE, air of type DE, air velocityvelocity, , water water loadingloading and spray and spray nozzlenozzle typestypes
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Drift Drift eliminatorseliminators QualityQuality
Drift Drift raterate
dependendsdependends
onon: :
WaterloadingWaterloadingAir Air velocityvelocitySpray Spray nozzlenozzle arrangement arrangement
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Drift Drift eliminatorseliminators Efficiency Efficiency confirmationconfirmation
AskAsk youryour coolingcooling towertower suppliersupplier namesnamesmanufacturermanufacturer of DEof DE
DemandDemand independent test independent test certificationscertificationsaccordingaccording toto acceptedaccepted standardsstandards
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Air passes Air passes throughthrough
areaarea
withwith
minimum minimum resistanceresistance
Air bypass Air bypass reducesreduces coolingcooling effecteffectWater loss Water loss becausebecause of of higherhigher air air velocityvelocity
Drift Drift eliminatorseliminators ExecutionExecution onon sitesite
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Drift Drift losseslosses Design Design considerationsconsiderations : air : air sealsseals
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GoodGood coolingcooling towertower practisespractises Design Design considerationsconsiderations
Mechanical Mechanical equipmentequipmentFillFillWater distributionWater distribution
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GoodGood coolingcooling towertower practisespractises
ObtainObtain
the the specifiedspecified
and correct and correct qualityquality
level !level !
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ThankThank
youyou
Georges HoeterickxGeorges Hoeterickx