Cooling Tower Educational Standcairouniversity

Faculty of Engineering Cairo University Mechanical Power Departement
Cooling Tower Educational Stand

B.Sc. Graduation Project
2008
Cairo University Faculty of Engineering Mechanical power department B.Sc. Graduation Project 2008
Project Supervisors: Prof. Dr. Adel Khalil Prof. Dr. Hany Khater Dr. Galal Mostafa
Contents
Acknowledgement. Project description. Nomenclatures. Page
Chapter One: Introduction. 1. Objective. 2. Classification. 3. Components. 4. Water Treatment. Chapter Two: Literature review 1. Gunt. 2. Armfield. 3. P. A. Hilton. 4. Edibon. Chapter Three: Cooling Tower Design Calculation 1. Column. 2. Cooling tower performance 3. Tanks. i. Water tank. ii. Air tank. iii. Make up tank. iv. Drain tank. 4. Piping System and pump. 5. Blower and Butterfly Valve. 6. Water Injection Nozzle. 7. Stand. Chapter Four: Measuring devices and auxiliaries. 1. Temperature Measurements. 2. Humidity Measurements. 3. Flow Measurements. 4. Displays. 5. Data acquisition card. 6. Calibration. Chapter Five: Bill of Material and Cost. Chapter Six: Fabrication Procedure. 1. Welding. 2. Stand fabrication. 3. Painting and coating. 4. Pipes components and fittings. 5. The column. 6. Stand preparation. 7. Control panel. 8. Electronic and Electric devices installation. 9. Electric Connections. 10. Component assembly. II 1 1 2 6 7 8 8 10 12 14 16 20 21 21 23 23 24
25 29 30 31 32 32 34 34 37 38 46 48 51 51 55 56 57 59 61 62 62 63 64
Chapter Seven: Tests and Results. 1. Procedure 2. Results 3. Relations summery and conclusion -Appendices. -References
66 66 67 70 71 105
III
Acknowledgment
First, we would like to thank Allah the merciful and compassionate for making all this work possible and for granting us with the best professors, family, friends, and colleagues that many people would wish and dream of having. We would like to thank our supervisors
Prof. Dr. Adel Khalil Prof. Dr. Hany Khater Dr. Galal Mostafa.
We are greatly indebted to them for their valuable supervision, kind guidance, and great help and effort to make this project possible. Words cannot express our deep gratitude and sincere appreciation to them.
Group Members:
Eng. Basel Amr Gouda Eng. Hebatallah Abdel Moniem Mohamed Eng. Mohamed El Sayed Rizk. Eng. Al Hussain Mohamed Kamel Eng. Ismail Gamal El Din Ismail. Eng. Ahmed Samir Abdallah. . Special Thanks to: Eng. Somya Mohamed Abdel Rehim For Supplying us with materials and support Colleague Ahmed waheed For his effort
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- Project description
The students affiliating with the present project will be required to study, design and fabricate a Water Cooling Tower Educational Stand. The Water Cooling Tower educational stand will eventually form a part of the undergraduate students Heat Transfer Laboratory. Step 1 : Water cooling tower fabrication. In this step, the following will be accomplished: Study the different heat and mass transfer mechanisms. Cooling tower heat load estimation. Design calculations of the water cooling tower showing different geometrical parameters and dimensions. Material selection of the different components. Working drawing sheets for the different cooling tower components. Fabricating the different components and assembling the cooling tower. Step 2 : Water cooling tower educational stand erection In this step, the following will be accomplished: Selecting and preparing the types of the measuring sensors, devices and data acquisition system. Assembling the cooling tower together with, the storage tank with heaters, the make-up tank, the air blower and air chamber, the water circulating pump, water injection nozzle, the column, valves and hoses, and the different measuring devices on the stand. Finalizing all mechanical, electrical and electronic works needed for the stand. Step 3 : Performance test on the water cooling tower educational stand In this step, the following will be accomplished: Assuring the validity of all stand measuring devices. Studying the effect of different parameters on the cooling tower performance. Comparing the experimental results with those calculated.
V
-Nomenclatures
VI
VII
Chapter 1
Chapter One Introduction

1. Objective
Cooling towers (Fig. 1) are heat removal devices used to transfer process waste heat to the atmosphere. They may either use the evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature or rely solely on air to cool the working fluid to near the dry-bulb air temperature. The objective of cooling towers can be divided into two categories: HVAC An HVAC cooling tower is a subcategory rejecting heat from a chiller. Water-cooled chillers are normally more energy efficient than air-cooled chillers due to heat rejection to tower water at or near wet-bulb temperatures. Air-cooled chillers must reject heat at the dry-bulb temperature, and thus have a lower average reverse-Carnot cycle effectiveness. Large office buildings, hospitals, and schools typically use one or more cooling towers as part of their air conditioning systems. Generally, industrial cooling towers are much larger than HVAC towers. Industrial Industrial cooling towers can be used to remove heat from various sources such as machinery or heated process material. The primary use of large, industrial cooling towers is to remove the heat absorbed in the circulating cooling water systems used in power plants, petroleum refineries, petrochemical plants, natural gas processing plants, food processing plants, semiconductor plants, and other industrial facilities. The circulation rate of cooling water in a typical 700 MW coal-fired power plant with a cooling tower amounts to about 71,600 cubic metres an hour (315,000 U.S. gallons per minute) and the circulating water requires a supply water makeup rate of perhaps 5 percent (i.e., 3,600 cubic metres an hour).
Fig. (1.1) cooling tower 1 Cooling Tower Educational Stand B.Sc. Project 2008
Chapter 1
2. Classification
Cooling towers can be classified into different categories as follows: Heat transfer mode Wet cooling towers or simply cooling towers operate on the principle of evaporation. Dry coolers operate by heat transfer through a surface that separates the working fluid from ambient air, such as in a heat exchanger, utilizing convective heat transfer. Fluid coolers are hybrids that pass the working fluid through a tube bundle, upon which clean water is sprayed and a fan-induced draft applied. The resulting heat transfer performance is much closer to that of a wet cooling tower, with the advantage provided by a dry cooler of protecting the working fluid from environmental exposure. In a wet cooling tower, the warm water can be cooled to a temperature lower than the ambient air dry-bulb temperature, if the air is relatively dry. As ambient air is drawn past a flow of water, evaporation occurs. Evaporation results in saturated air conditions, lowering the temperature of the water to the wet bulb air temperature, which is lower than the ambient dry bulb air temperature, the difference determined by the humidity of the ambient air Air flow generation With respect to drawing air through the tower, there are three types of cooling towers: Natural draft, which utilizes buoyancy via a tall chimney. Warm, moist air naturally rises due to the density differential to the dry, cooler outside air. Warm moist air is less dense than drier air at the same pressure. This moist air buoyancy produces a current of air through the tower (Fig. 2).
Fig. (1.2) Natural draft cooling tower
2 Cooling Tower Educational Stand B.Sc. Project 2008
Chapter 1
Mechanical draft, which uses power driven fan to force or draw air through the tower. Induced draft: A mechanical draft tower with a fan at the discharge which pulls air through tower (Fig. 3). The fan induces hot moist air out the discharge. This produces low entering and high exiting air velocities, reducing the possibility of recirculation in which discharged air flows back into the air intake. This fan/fill arrangement is also known as draw-through.
Fig. (1.3) Induced draft fan cooling tower
Forced draft: A mechanical draft tower with a blower type fan at the intake (Fig. 4). The fan forces air into the tower, creating high entering and low exiting air velocities. The low exiting velocity is much more susceptible to recirculation. With the fan on the air intake, the fan is more susceptible to complications due to freezing conditions. Another disadvantage is that a forced draft design typically requires more motor horsepower than an equivalent induced draft design. The forced draft benefit is its ability to work with high static pressure. They can be installed in more confined spaces and even in some indoor situations. This fan/fill geometry is also known as blow-through.
Chapter 1
Fig. (1.4) Forced draft fan cooling tower Air-to-Water Flow -Cross flow: Is a design in which the air flow is directed perpendicular to the water flow (Fig 5). Air flow enters one or more vertical faces of the cooling tower to meet the fill material. Water flows (perpendicular to the air) through the fill by gravity. The air continues through the fill and thus past the water flow into an open plenum area. A distribution or hot water basin consisting of a deep pan with holes or nozzles in the bottom is utilized in a cross flow tower. Gravity distributes the water through the nozzles uniformly across the fill material. -Counter Flow: The air flow is directly opposite of the water flow (Fig 6). Air flow first enters an open area beneath the fill media and is then drawn up vertically. The water is sprayed through pressurized nozzles and flows downward through the fill, opposite to the air flow. Common to both designs: The interaction of the air and water flow allow a partial equalization and evaporation of water. The air, now saturated with water vapour, is discharged from the cooling tower. A collection or cold water basin is used to contain the water after its interaction with the air flow. Both cross flow and counter flow designs can be used in natural draft and mechanical draft cooling towers.
Chapter 1
Fig. (1.5) Cross Flow cooling tower
Fig (1.6) Counter Flow cooling tower
Chapter 1
3. Components:
Inlet water distributors: There are several types of water distributors, among them: 1. Gravity distributors: applied mainly for cross flow cooling towers and consist of vertical water riser that feed water into an open concrete basin, from which the water flows by gravity through orifices to the fill. 2. Spray distributors: used mainly with counter flow cooling towers and have cross pipe net with spray downward nozzles. 3. Rotary distributors: applied for cross flow cooling towers and consists of two slotted arms rotate about a central hub containing water supply pipe. The slots in the tow arms are directed downward but make small angle with the vertical direction to one side. The slots form a curtain angle and due to reaction force the arms rotate at a rotational speed of 25-to-30 rev/min. Drift eliminators: An assembly constructed of wood, plastic, cement board, or other material that serves to remove entrained moisture from the discharged air. Circulating Pump: The circulating pump transports the cooling water between the cooling tower and the condenser. The water is pumped from the cooling tower basin through to the condenser, where it is used as cooling medium. The water returns back for evaporative cooling in the cooling tower. Fan: A device for moving air in a mechanical draft tower. The fan design may be either an axial flow propeller or centrifugal blower. Also may be applied as induced draft or forced draft. Noticing that the induced type requires less power for same result. Fills: Is the heart of the cooling tower. The fill must provide good water-air contact area, high rates of heat and mass transfer and low air flow resistance. The fill also must be strong and deterioration resistant. The fill has mainly two forms Splash fill: breaks falling water into small drops. This Type is made of bars stacked in desks and may be narrow-edged, square bars, rough bars and grids. Different materials are used, such as redwood, high-impact polystyrene or polyethylene, Film fill: is made of vertical sheets that have a rough adsorbent surface and good wetness of water that allows water to fall as a film over the vertical surface. Film fill has different forms and materials; redwood battens, cellulose corrugated sheets, asbestos cement and waveform plastic. Water Basin: Is situated beneath the tower, collects and strains the water before pumped back to the circulating system. Large utility tower basins are generally made of concrete. Water leaves the basin via sloped canal at the bottom and through screens that prevent dust and foreign materials from entering the pump.
Chapter 1
4. Water Treatment
The large variety of alternative construction materials allows users to match unit construction to the water quality available for their systems, while helping to protect the tower from temporary upsets. Water treatment programs must be designed for three requirements: 1. Scale control; 2. Protection of system components against corrosion; and 3. Control of biological contaminants, such as Legionella pneumophilia, the bacterium that causes Legionnaires' disease. The first two requirements help to ensure energy efficiency and longevity of the cooling system, while the third ensures safe operation. Biological control is relatively easy to accomplish and is essential to the safe operation of the tower. Cooling towers can collect and concentrate airborne dirt and debris over time. To control this buildup, the cooling tower should be located so as to minimize contaminant induction and a proper blowdown rate should be maintained. Sidestream filters or separators have proven valuable in this regard by effectively removing dirt and debris from the tower water. These devices are coupled with a basinsweeping nozzle package, which is available either as original equipment in the tower or as a fieldinstalled aftermarket item. Cleaner tower water makes water treatment regimens more effective while keeping the cooling loop cleaner, saving energy, reducing maintenance, and improving reliability of the entire cooling system.
Chapter 2
Chapter Two Literature review

In this chapter we will introduce the specifications of the cooling tower educational stand that manufactured by different companies like Gunt, Armfield, P.A. Hilton, Edibon.
1. Gunt
Fig. (2-1) Gunt cooling tower educational stand. Column: Dimensions: 150x150x630 mm Pacing density: 110 m2/m3 Orifice diameter: 80 mm Approx. weight: 5 Kg Heaters: 3 stages 0.5-1-1.5 KW. Thermostat switches off at 50c. Fan: Radial fan: - Power consumption 0.25 KW. -max. Flow rate 13 m3/min.
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-max. Differential pressure 430 pa.
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Chapter 2 Pump: -Power consumption: -max. Head: 34 m. -max. Flow rate: 34 L/min. Instrumentation: -Temp. Sensors at air inlet &outlet. -Temp Sensors at water inlet& outlet. -Water flow rate sensor. -Humidity sensors at air inlet& outlet. Dimensions: Height: 1.228 m. Length: 1.11 m. Width: 0.46 m. Weight: approx. 90 Kg. Service required: Electrical: -230 v, 50/60 HZ, 1 phase. or -230 v, 60 HZ, 3 phases. Computer& Data acquisition: Data acquisition with lab view software, h-w diagram and Windows X-P. 0.7 KW.
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Chapter 2
2. Armfield
Fig. (2-2) Armfield cooling tower educational stand. Column: Dimensions:150x150x600 mm Pacing density:110 m2/m3 (10 plates) Heaters: Maximum working temperature 50c
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Chapter 2 Fan: Centrifugal fan: Maximum air flows: 0.06 Kg/s-1 Instrumentation: -thermocouple with digital read out. -Variable area flow meter with control valve. -Inclined manometer for orifice differential pressure measurement. Dimensions: Height: 1.2 m. Length: 0.95 m. Width: 0.6 m. Weight: approx. 130 Kg. Volume: 0.7 m3. Service required: Electrical: -220-240 v/1 ph/50 HZ. or -120 v/1 ph/60 HZ. Water: 2 L/hr distilled.
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Chapter 2
3. P. A. Hilton
Fig. (2-3) P.A.Hilton cooling tower educational stand Column: Dimensions: 150x150x60 mm Pacing density: 110 m2/m3 transparent P.V.C Orifice diameter: 80 mm Heaters: 0.5 &1 KW Instrumentation: -digital temp indicator with channel selector switch for all wet bulb, dry bulb & water temp variable area water temp flow meter & manometer air flow.
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Chapter 2 Dimensions: Height: 1.12 m. Length: 0.82 m. Width: 0.73m. Weight: approx. 56 Kg. Gross weight: app. 96 Kg. Volume: 0.76 m3. Service required: Electrical: -1.6 KW, 220-240 v, 1 ph, 50 HZ (with earth ground). or -1.6 KW, 110-220 v, 1 ph, 60 HZ (with earth ground). Water: demineralised or distilled approx 2 Kg/hr. Computer& Data acquisition: An optional Data Acquisition Upgrade HC892A comprising of an electronic data logger, menu driven software and all necessary transducers, allow all relevant parameters to be simultaneously displayed and recorded on a suitable PC.
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Chapter 2
4. Edibon
Fig. (2-4) Edibon cooling tower educational stand. Column: Dimensions: Total surface: 1.915 m2, Height of packaging: 650 mm. Pacing density: 58 m2/m3 (10 plates). Dimensions: Height: 1.4m. Length: 1 m. Width: 0.45 m. Weight: approx. 100 Kg. Service required: Electrical: -220V./50 Hz or 110 V. /60 Hz, directly from the mains.
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Chapter 2 Computer& Data acquisition: PCI Data acquisition board (National Instruments) to be placed in a computer slot. Bus PCI. Analog input: Number of channels= 16 single-ended or 8 differential. Resolution=16 bits, 1 in 65536. Sampling rate up to: 250 KS/s (Kilo samples per second). Input range (V)= 10V. Data transfers=DMA, interrupts, programmed I/0. Number of DMA channels=6. Analog output: Number of channels=2. Resolution=16 bits, 1 in 65536. Maximum output rate up to: 833 KS/s. Output range(V)= 10V. Data transfers=DMA, interrupts, programmed I/0. Digital Input/Output: Number of channels=24 inputs/outputs. D0 or DI Sample Clock frequency: 0 to 1 MHz. Timing: Counter/timers=2. Resolution: Counter/timers: 32 bits
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Chapter 3
Chapter Three Cooling Tower Design Calculation

1. Column
The column is divided into two parts as follows: -The column body The column body Fig. (3.1) is an important component of the cooling tower at which the water and air interface where heat and mass exchange occur. The column material was manufactured from transparent plastic to allow viewing of water through the system. It is oppened from endes to allow the water and air movement inside it, also to insert and renise fill from it eassly. Column dimension estimation: The inlet air conditions: Tai=35C=308 K. Pai=101.3 kPa. RHi=40%.
ai = Pai R Tai
Fig.(3.1) columnbody
Where: ai: Air inlet density,kg/m3. Pai: Air inlet pressure,kPa.
Tai: Air inlet temperature,K. R: universal constant,
Assume air flow rate to be
101.3 103 yields ai = ai = 1.15 kg/m3 287 308 V blower = 13 m3 /min m blower = V blower ai
From psychrometric chart at 35c dry bulb temperature and 40% relative humidity;the humidity ratio ai=0.01414 kg/kgda and wet bulb temperature wbtai=23.9C. m da = Cooling Tower Educational Stand m blower 1 + ai B.Sc. Project 2008
m blower =
yields 13 1.15 60
m blower = 0.24 kg/s
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Chapter 3 m da = 0.24 1 + 0.01414
The cooling tower characteristics (KaV/L) specifies the size of the tower necessary to achevie the maximum possible effectiveness. The cooling tower characteristics,as a whole, are function of cooling range, tower approach, ambient wet bulb temperature and fluid flow ratio.these cooling tower characteristics represents also at the same time the fill characteristics required for a spacified job.the fill characteristics should be equal to the fill performance, which is a function of fluid flow ratio for a given matrix. As the evaluation of the cooling tower characteristics is time consuming procudure, in practice this is avoided by using the charts available by the Cooling Tower institute in Houston. In these charts the tower characteristic are expressed in terms of the cooling range,tower approach, ambient wet bulb temperature and the flow ratio. Design conditions: Twi=50C. Two=45C. Wbtai=23.9C. Vw=2 l/min. w=1000 kg/m3.
Where: m da : Dray air mass flow rate, kg/s.
= 0.238 kg/s mda
w = Vw w = m Where:
V w : Water volumetric flow rate, m3/s. w : Water density, kg/m3. total water mass flow rate total air mass flow rate
m w = 0.0333 kg/s
2 103 1000 60
L=0.0333 kg/s. G=0.238 kg/s.
Where; L : Water loading, kg/m2 s. G : Air loading, kg/m2 s. Cooling Tower Educational Stand
L L 0.0333 = = = 0.14 G G 0.238
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Chapter 3 Note: The cross section area at which the air pass equal to that thwe water pass in counter flow cooling tower so =
G L G L
Approach= Two-Wbtai Approach=35-23.9 Approach=21.1C=38.16 F. Cooloing Range (CR)=Twi-Two=50-45 CR=5 C=9 F. From the characteristic curves Appendix (6) the required cooling range doesnt exist, Hence, make interpolation. From Appendix (6) at From Appendix (6) at From Appendix (6) at
KaV L L G L G L G
= 0.14 , Approach=38.16 F and CR=18 F=10 C =0.14, Approach=38.16 F and CR=26 F=14.4 C
= 0.14, Approach=38.16 F and CR=22 F=12.2C
KaV
By interpolation using Appendix (6) at CR=9 F=5 C. By using table (3.1) and assuming Height (Y)=3 ft=0.9144m we get; Constants C=0.5 m=0.09 n=0.91 Substituting in the following equation; K a = c (L)m (G)n K a =0.5 (0.0333)0.09 (0.238)0.91 K a =0.0997 (2) By substituiting (2) in (1) we get; KaV = 0.17 L = 0.17 (1)
L KaV L
L KaV
= 0.24
= 0.36
= 0.27
yields 0.0997 V = 0.17 V = 0.0568 m3 0.0333
A 0.25 0.25 m2 So; the column dimensions will be 250250 900 mm3.
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A=
0.0568 = 0.062 m2 0.9144
V=AY
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Chapter 3 -The column cap Its the upper component of the column. The spray nozzle, drift eliminator and the humidity and exit air tempreature sensors are located in the cap. Hence, the cap hieght mustnt be long and its cross section equal to that of the column body. The cap dimensions=250250200 mm3. Fig. (3.2) column cap. -The packing/fill and drift elimenator The packing(Fig. 3.3) used to increase the area of content between the air and water. The packing surface is corecated of P.V.C material. The fill spacing shown inFig. (3.4). The drift elimenator Fig.(3.5) is placed in the air exit way to decrease the water droplets carried by air.
Fig. (3.4) Fill spacing
Fig. (3.3) Packing
Fig. (3.5) Drift eliminator

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Chapter 3
2. Cooling tower performance

Water: Air in: Twi=50C Tai=35C Two=45C RHai=40% Wbtai=23.9C m w = 0.0333 kg/s m da = 0.238 kg/s Cpw=4.18 kJ/kg C
From psychrometric chart :
ai=0.01414 kg/kgda
hai=71.49 kJ/kg
Cooling range and approach obtained CR=Twi-Two=50-45=5C Approach= Two-Wbtai=35-23.9=21.1C Q CT = m w Cp,w CR
Where: Q CT : Cooling tower load. mw : Water flow rate. Cpw : specific heat at constant pressure
Q CT = 0.033 4.18 5 Q CT = m da (hao hai ) hao = 74.42 kJ/kg da Q CT = 0.7 kW
0.7 = 0.238 (hao 71.49) From psychrometric at hao = 74.42 kJ/kg da and RHao=100% ao=0.01877 kg/kgda Tao=23.9C m evap = m da (ao ai ) = = Twi Two Twi Wbtai
m evap = 0.238(0.01877 0.01414) m evap = 1.10194 103 kg/s
50 45 100 45 23.9 = 23.697%
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Chapter 3
3. Tanks
i. Water tank In the educational stand cooling tower the water tank considered as the heat load component (condenser), water is heated by an immersion heaters fitted from the back of tank. The heaters are metal tubes containing an insulated electric resistance heater which provide heat load about 1.5 kilowatts. The water return pipe contains twelve holes to provide good mixing of cold and hot water. The tank was attached with eye glass to determine the level of water in the tank. There is a baffle inside the tank to make good mixing of the hot water and cold water coming from the column. Tank capacity estimation = =
Where: Q: Heaters power, kW : Mass flow rate, kg/s CP: water specific heat, kJ/kg K T: Temperature difference, C : Water density, kg/m3 V: Water volume, m3 t: time need to heat the water, sec.
Q=1.5 kW = Cp=4.18 kJ/kg K t=25 min. = 50 25 = 25
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Chapter 3 Q =
1.5 = 1000
4.18 25 = 0.0215 3 25 60
The tank dimension = 250 250 450 mm3
V 0.25 0.25 0.35 m3
Fig. (3.1) Water tank main dimensions(dimensions in cm).
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Chapter 3 ii. Air Tank Air tank is designed to deliver the air from the blower also to hold the column and allow air to be introduced into the column. So its dimensions must be suitable for carrying the column and also not large to force air to accelerate in the column (i.e. velocity is inversely proportional with area). Design requirements: Air velocity inside the tank doesnt exceed 4m/s to reduce the friction losses inside the tank. Take in consideration that the drain tank dimensions (25*25). Air flow upward around drain to the column and the area must be sufficient to the velocity not exceed 4 m/s. The air tank must be higher than the water tank to give the chance to support the drain inside to let the water flow the drain to the water tank. When the water tank have the water at level 40 cm from the ground and the drain must have at least 7 cm to let air flow from the air tank to the column. Hence the air tank will be 50 cm height and then the area around the drain as flow Q = Av
Let the air tank dimensions to be 0.4 0.4 0.5 m. And at this condition. v=
Aaround
drain
A = .054167m2
13 =A4 60
+ Adrai n = 0.341 0.341
Acceptable velocity.
13 60 = 2.222 ms 0.42 0.352
iii. Make up tank Is used to supply the system by the water loosest due to evaporation, drift, and blow down. The makeup water is piped to the water tank and at the end of the pipe a float valve exists to keep water level in the water tank constant.
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Chapter 3 Assume that the makeup tank support the system with makeup water for 1.5 hour, so the tank capacity can be calculated as follows. evap = m Vmakeup t
yields
1.1662 103 =
So let the makeup tank dimensions to be 202020 cm3. iv. Drain tank
Vmakeup = 18.5 18.5 18.5 cm3
1000 Vmakeup 1.5 60 60
Vmakeup = 6.3 103 m3
A tank that located in the air chamber under the column to collect the cooled water from the column and return it back to the water tank. The tank is designed to be with inclined base to accelerate the water over it to return quickly to the water tank to be heated and recirculated. Assume that the recirculated water to be stored in the drain tank for 2.5 minute so the drain tank capacity can be calculated as follows.
0.0322 =
1000 Vdrain 2.5 60
m circulated =
yields
Vdrain = 0.005 m3
Vdrain t
The drain tank dimensions are shown in figure (3.2) the base inclination is to force the water to be discharged from the pipe.
Fig. (3.2) drain tank main dimensions(dimensions in cm).

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Chapter 3
4. Piping system and pump -piping system

Piping system conveys water between tanks to complete circulation. Piping system includes: Pipe Fittings - Three elbows. - One nibble. - Two boshes. - Two screwed union. - One T joint. Orifice plate with flanges. Valves - Check valve. - Gate valve. - Float valve.
Drain line :Design requirements: Water velocity doesnt exceed 0.07 m/sec Water flow rate 2lit/min
=(1/30)Kg/sec Hence when V=0.07m/sec & A=

Where is the water flow rate & A is the inner area of the pipe = 4.7619 104 = 0.0246
1000 0.07
(1/30)
= 4.7619 104 2
Then
The nearest standard diameter = 1 = 0.0254 =
V= 0.06578 m/sec
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Chapter 3 Losses W.R.T. the velocity : = + + = 2 2

.1
Where L is the pipe length & = Also
2 log
37 2
F = 0.26405
.0254
Design requirements:Orifice total area > pipe area. For holes exit velocity < in pipe velocity Let (1.25) * pipe area = holes area = (1.25) 0.02542 4
For the orifice with = 12
= 2.0634 103
= 8.2 102 Check the velocity through each hole
_ = 6.3348104 2

Which gives a velocity = =
= =
0.29 (0.06968)2 12 1 (0.0525)2 2 3 + 2.0634 10 + 2 9.81 2 = 6.1717 103

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2 2 ( )2 2 + + 2 2 2
= 0.0525 <
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Chapter 3 Losses in make up tank:. . = = 4.635 104 2
12 "
= 0.5
= 3.659 103 = 0.1 2 = 7.864 0.0254 1
1000
4 4.635 104
2 1 0.0254 4 2
= =
2 0.554 0.5 3.6592 106 = = 1.487 105 2 2 9.81 0.5 0.0254 0.12 (3.659 103 )2 = = 8.18855 108 2 9.81 = + = 1.4952 105
37 2 2 log
= 0.554
Pump discharge pipe head loss Total head losses
= + + + + + 2 = 2
2 log
0.26405 1.8 0.06572 = 4.1167 103 2 9.81 0.0254

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37
= 0.26405 , =
0.1 0.0254
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Chapter 3 2 2.5 0.06572 = = = 5.5 104 2 2 9.81 24 0.06572 = 5.28 103 2 9.81
2 , 2
Head losses across the nozzle by using of hand pump and measuring the pressure in the nozzle line we find that P=2 bar Using B.E.
2 2 1 2 2 1 + 1 + = + 2 + + 2 2
0.9(0.26287)2 = = 3.16975 103 2 9.81
8.2(0.0659)2 = = 1.8 103 2 9.81
1 = .0657
2 2 (1 2 ) 2 1 + (1 2 ) + = 2
2 = 18.83672 2 = 0.15 1 = 2.54
= (4.1167 + 0.55 + 5.28 + 1.8 + 3.16975) 103 + 1.763 = 1.77791645
= 1.763
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Chapter 3
-pump
Used to circulate the water through the system and also to overcome the losses in the pipes and valves. the suitable Pump specifications are: Power Max. Flow Min. Flow Max. delivery head Min. delivery head Power supply 0.5 HP. 2.16 m3/hr. 0.6 m3/hr. 32.5 m. 5 m. 230v, 50Hz.
4. Blower and Butter fly valve -Blower

The Blower has to overcome the system resistance, which is defined as the pressure loss, to move the air. The Blower output or work done by the Blower is the product of air flow and the pressure loss. Specifications: Power supplies 230 V-50 HZ. Power 100 W. Flow rate 740 m3/hr. Pressure 473 Pa.
Blower Size, mm Mass, Type of ventilator dimensions: Kg d D C A B L E VKMZ 160 200 344 240 25 25 350 40 6.6
Fig. (3.3) Blower main dimensions.
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Chapter 3 -Butterfly valve A butterfly valve figure (3.4) is from a family of valves called quarter-turn valves. The "butterfly" is a metal disc mounted on a rod. When the valve is closed, the disc is turned so that it completely blocks off the passageway. When the valve is fully open, the disc is rotated a quarter turn so that it allows an almost unrestricted passage of the process fluid. The valve may also be opened incrementally to regulate flow. The butter fly used was fabricated to suit the blower suction diameter.
Fig (3.4) butterfly valve
5. Water Injection Nozzles

Two spray nozzles attached to sprinkler pipe. The nozzle atomizes water to increase the heat exchange and mass transfer between air and water; also the nozzle must provide good water distribution over the column fill. Fig(3.5) spray nozzles
The nozzle spray shape is cone 30 angles with vertical.
Fig(3.6) testing angle of nozzle spray
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Chapter 3
6. Stand
The table which will carry all cooling tower components.
Air Tank Water Tank Fits and Tolerance Display and Screen Column Connection Pipe Stand
Length(cm) 40 25 10 100 25 10 200
Width(cm) 40 25 10 25 50
Height(cm) 50 45 150 182
Length= 175 Cm (Length of air tank) < Length of Stand Max Width = 40 Cm (width of air tank) < width of Stand Max Height = 150 Cm (height of column) < Height of Stand = + + + + + = 5 + 7 + 33.5 + 5 + 30 + 40 = 120.5 Max Weight for wheel=200Kg < Max Weight for wheel
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Chapter 4
Chapter 4 Measurement devices and data acquisition system

1. Temperature measurements
Three basic types of temperature measuring sensors Thermocouples Self Generating - Two metals joined together at a junction which generate a very small voltage (millivolts) which is a function of temperature. Voltage goes up as temperature goes up. Resistance Temperature Devices (RTDs) Resistive - Measuring the change of resistance in a piece of metal due to temperature. Resistance goes up as temperature goes up. Thermistors Resistive - Measuring the change in resistance in a semiconductor material due to temperature. Resistance goes down as temperature goes up. Other methods exist such as infrared detection and bimetallic strips
Characteristic Excitation Output Signal
Thermocouple Self-Generating millivolts
RTD External Required Typically volts for coarse measurements.. Can be millivolts for high accuracy Grounded, susceptible to lead wire resistance Increases with temperature -200 to +800 DegC for platinum Stability and linearity Expense, Slow Response Time, Low Sensitivity, Self Heating
Thermistor External Required Typically Volts Can be millivolts for high accuracy. Grounded, susceptible to lead wire resistance Decreases with temperature if NTC, Increases with PTC -100 to + 200 DegC
Ground/Noise/Error
Floating, susceptibility to noise Increase with temperature - 200 deg c to +1200 deg C depending on type Inexpensive and rugged Floating measurement requires careful attention
Signal
Range
Pros Cons
High Sensitivity Smaller Temperature Range, NonLinear, Self Heating
Table (4.1) Comparison Of Sensing Methods

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Chapter 4
Resistance Temperature Detectors (RTDs) a device used to relate change in resistance to change in temperature. Typically made from platinum, the controlling equation for an RTD is given by: = [1 + ( )]
RT is the resistance of the RTD at temperature T (measured in C) R0 is the resistance of the RTD at the reference temperature T0 (usually 0C) s the temperature coefficient of the RTD
PT100 Platinum wire-wound detectors comprise a pure platinum wire wound into a miniature spiral and located within axial holes in a high purity alumina rod. The freedom of movement of the platinum wire gives good long term stability. Specifications: Ro 100 Ohms Temperature range -200 to +800C
Fig. (4.1) Resistance Temperature curve for PT 100.
Table (4.2) Resistance VS temperature and tolerance for PT100

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Chapter 4
2. Humidity sensors
Is composed of a resistance where its ohm varies with the humidity of air.
General Description The EWHS 280 humidity sensor is a probe designed to be connected to a humidity measuring device. Output signal is a current signal (4...20 mA). Specifications Power input 9 28 Volt DC Measurement range 15 100 % Maximum Load 250 Ohm Accuracy +/- 5%
3. Flow Measurements
3.1 Pipe Flow rate Meters
Fig. (4.2) orifice plate Three of the most common devices used to measure the instantaneous flow rate in pipes are The orifice meter, the nozzle meter, and the Venturi meter. Each of these meters operates on the principle that a decrease in flow area in a pipe causes an increase in velocity that is accompanied by a decrease in pressure. Correlation of the pressure difference with the velocity provides a means of measuring the flowrate. In the absence of viscous effects and under the assumption of a horizontal pipe, application of both the Continuity and Bernoulli equations between points (1) and (2) shown in the following figure gave
Fig.(4.3) Typical pipe flow meter geometry

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Chapter 4
Qideal = A2 V2 = A2
2P
A typical orifice meter is constructed by inserting between two flanges of a pipe a flat plate with a hole. The pressure at point (2) within the vena contracta is less than that at point (1). Nonideal effects occur for two reasons. First, the vena contracta area, (A2), is less than the area of the hole, (A0), by an unknown amount. Thus, A2=KA0, where Cc is the contraction coefficient (Cc<1). Second, the swirling flow and turbulent motion near the orifice plate introduce a head loss that cannot be calculated theoretically. Thus, an orifice discharge coefficient, K, is used to take these effects into account. That is = = 0 2
Where 0 = 2 /4 is the area of the hole in the orifice plate. The value of C0 is a function of = / and the Reynolds number = / , where = /1 . Typical values of C0
Fig (4.4) Typical pipe flow meter geometry.
Fig (4.5) Typical orifice meter construction.
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Chapter 4 are given in Appendix.(3) Note that the value of K depends on the specific construction of the orifice meter (i.e., the placement of the pressure taps, whether the orifice plate edge is square or beveled, etc.). Very precise conditions governing the construction of standard orifice meters have been established to provide the greatest accuracy possible. Orifice Design Operating flow rate = 2 / = 3.333 105 3 / = 25.4 = 0.2 =
We assumed a small value in order to obtain a large pressure drop over the orifice giving a more clearer reading by the differential pressure transmitter. = ()2 = 5.0671 104 2 4 ( )2 = 2.02683 105 2 4 = 0.06578 /
= 0 =
988 1.645 0.00508 = = 15090.04 5.47 104
= 1.645 /
From chart (according to ASME standard) = 0.2 = 15090.04 Therefore = 0.605 =
= 0.605 2.0268 105

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= 5.5169976 10
7
Chapter 4
3.33 105 = 5.5169979 107 Theoretical reading = 0.53 psi Error 2 % Error = 5 * 0.02 = 0.1 Actual reading = 0.53 0.1 = 0.63 = 0.43 (for 2 l/min water) Error analysis =
0.53 0.1
= 3643.2 = 3.6432
= 18.8%
4- Displays
Microprocessor based and fully programmable process controllers for single setpoint applications; the output provides ON-OFF and analog output 4-20 mA
Fig.(4.6) Display connection diagram

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Chapter 4
5-Data Acquisition
Fig.(4.7) schematic diagram for DAQ card connection It is a basic A/D converter that allows a personal computer to control its actions, also computer acquires the values of the Analog or digital signals being processed. A data acquisition card plugs directly into a PC bus, like PCI, or USB.etc.
Analog Signal any value continuously within the range, continuous over time
Digital Signal Maps to one of eight discrete values at only has those values at discrete times that it was sampled and converted
Elements of an End to End Data Acquisition System

Transducer/Sensor May generate their own electrical signal (thermocouple or piezoelectric) or require external excitation (power) Converts one physical Quantity Under Measurement (QUM) into another Typical output is in volts to microvolts Data Acquisition Unit (DAU) Samples and holds Digitizes Multiplexes (combines with other measurements) Converts for transmission Transmits Typical output is in binary digits (bits) Recording, Storage and Display
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Chapter 4 Example Temperature Measurement fig. (4.8) Transducer/Sensor is Platinum Resistance Temperature Detector (RTD) Signal Conditioning is power supply for excitation (power) and resistor to complete the circuit Data Acquisition fig. (4.9)Unit is the NI 6008 It communicates over a Universal Serial Bus (USB) to the laptop computer The laptop Computer is running a LabVIEW Virtual Instrument (VI) Example is RTD Acq One Sample w loop and waveform chart.vi
Fig. (4.8) Example for temperature measurement Unit installation
Fig.(4.9) DAQ Unit installation
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Chapter 4 5.1 Data acquisition system software (LAB VIEW) LabVIEW (Laboratory Virtual Instrument Engineering Workbench) is a graphical programming language that uses icons instead of lines of text to create applications. In contrast to text-based programming languages, where instructions determine the order of program execution, LabVIEW uses dataflow programming, where the flow of data through the nodes on the block diagram determines the execution order of the VIs and functions. VIs, or virtual instruments, are LabVIEW programs that imitate physical instruments. In LabVIEW, you build a user interface by using a set of tools and objects. The user interface is known as the front panel. You then add code using graphical representations of functions to control the front panel objects. This graphical source code is also known as G code or block diagram code. The block diagram contains this code. In some ways, the block diagram resembles a flowchart
Fig. (4.10) Illustration for interface of LABVIEW.
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Chapter 4 5.2 Electronic connections In figure (4.11), the sensor sends signals to the display unit, in turn the display transmits an analog output signal 4 ~ 20 mA, a resistance is needed since the DAQ only accepts Voltage analog signal of range -10 ~ 10 Volt .
Preferring a range from 1 ~ 5 Volt a resistance is required to be put in parallel. Returning to Ohms law =
Also assuming minimum values for both V and I
Therefore the required resistance will be
1 = 4 103 = 250
Due to there is no standard resistance 250 , we selected the nearest available resistance 270 . By recalculating the voltage range, it varied to become 1.08 ~ 5.4 Volt. We programmed the display unit to transmit a minimum signal of 4 mA corresponding to 10 C, and a maximum signal of 20 mA corresponding to 70C.
Fig(4.11) wiring diagram for temperature measurements For the humidity sensor there was no display with analog output available in the market and the available sensor had one terminal wire, therefore we added a resistance in series with joining the resistance terminals with the sensors output wires and the display, creating a voltage variation across the resistance terminals transmitted to the DAQ. Figure (4.12 ) illustrates the previous operation.
Fig. (4.12) wiring diagram for Humidity measurements
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Chapter 4
Fig. (4.13) solving the analog output problem for the humidity sensors
Fig.(4.14) rear view of the temperature display showing ampere to volt conversion
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Chapter 4 5.3 Data Acquisition programming 1. For programming temperature values on LABVIEW, we programmed the DAQ card to translate the voltage signal to temperature values, having a linear relation between voltage and temperature = +
a,bconstants Initial conditions: I. V=1.08 Volt II. V=5.4 Volt
Ttemperature (C)
Vvoltage
at at
T=10C T=70C 10 = 1.08 + (1) (2)
By solving equations (1) and (2) a=13.8889 Therefore the final equation is
70 = 5.4 +
b= -5 = 13.8889 5
Fig.(4.15) snapshot from LABVIEW

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Chapter 4 2. For humidity sensor, its maximum load = 250 therefore the required resistance should be higher than 250 . In order to avoid producing high ampere causing damage to sensor. So the resistance added is 300. Determining the maximum and minimum voltages, and returning to Ohms law =
= = 3 103 300 = 0.9 3 300 = 18 10 = 5.4 Due to signal splitting there are some errors in the two signals, one for display and other for data acquisition card. So calibration must be done for both of them by an accurate device.
For programming humidity values on LABVIEW, we programmed the DAQ card to translate the voltage signal to temperature values, having a linear relation between voltage and temperature % = +
a,bconstants Initial conditions: III. V=0.9 Volt IV. V=5.4 Volt
RHRelative humidity (%)
Vvoltage
at RH=15% at RH=90% 15 = 0.9 + (1) (2)
By solving equations (1) and (2) a=16.66667 Therefore the final equation is
90 = 5.4 +
b= 0 % = 16.66667
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Chapter 4
Fig. (4.16) snapshot from LABVIEW illustrating variation of humidity signal with voltage.
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Chapter 4
6- Calibration
1. Humidity sensor 1.1. Inlet humidity sensor Humidity sensor without analog output 57 65 70 76 83 90 100 Humidity sensor with DAQ reading Hygrometer analog output 53 32.66 58.7 61 41.01 66.5 66 45.834 72 72 51.334 78.5 79 58.765 84.3 85 64.789 91.8 95 76.122 100 Fig.(4.17) inlet Humidity sensor calibration table
After updating the humidity sensor to give an output signal to the DAQ card there is a zero error = 4% so we calibrated the display to increase the displayed value about 4% to give the actual reading. Ex: Measured value = 50 % so the display will indicate 54% In the DAQ reading there is a zero error = -25%, therefore calibrated to increase the indicated value a 25% to give actual reading. 1.2. Outlet humidity sensor Humidity sensor without analog output 57 65 70 76 83 90 100 Humidity sensor with DAQ reading Hygrometer analog output 52 29.3453 58.7 60 39.014 67.2 65 44.134 73.3 71 50.334 77.9 72 56.765 83.1 85 62.789 92.4 95 74.724 100 Fig.(4.18) outlet Humidity sensor calibration table
For the displays the calculated error = -5%, while the DAQ reading has a zero error = -26.5 %.
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Chapter 4 2. Temperature sensor Thermocouple K-Type C 30 40 50 60 70 80 90 100 PT 100 class B sensor C DAQ Reading C 30.2 29.9 40.5 40.2 50.7 50.6 60.5 60.1 70.2 70.002 80.3 80.07 90.7 90.4 100 100.04 Fig.(4.19) PT 100 sensor calibration table
We see that the DAQ reading is less than the PT 100 sensor for about 0.3 C and this is more accurate than the sensor display because Sensor display has a sampling rate for about 10 samples per sec but the DAQ card has sampling rate 1000 samples per sec.
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Chapter 5
Chapter Five Bill of Materials and Cost

SERIAL NO. 1 1.1 1.2 1.3 1.4
1.5 1.6
Item no 100 101 103 105 109
Item name Stand Frame wheels Bords Al edges

Staneless steel Cutting cup set
Quan tity 1 1 4 2 1
1 1
Make or Buy make make buy buy buy

buy buy
Description & Specifications
Material steel steel
4 wheels carry up to 200 Kg 1.22x2.44 (m)

60x60 cm
price per each(LE) 790.5 54.55 55 350 30

158.4 71.5
total price (LE) 790.5 54.55 220 700 30 158.4 71.5 0 186.5 49.5 8 90 871.5 720 0 0 0 60 0 33
Formica Aluminum
st.st
2 2.1 2.2
2.3 2.4
200 203
Tanks Metal sheets Gaskets

Teflon Silicon
1 1
4 2
make make buy

buy buy
steel steel
186.5 49.5
2 45
3 4 4.1 5 5.1 5.2 5.3 5.4
300 400 401 406 500 501 502
Heaters Column Column body cap Metal connections Butter fly valve Drain valve Gate valve 3 1 1 1 6 1 1 1
buy make make make buy buy buy buy
0.5 KW,length= ,flange diameter= dimensions 25x25x113 cm dimensions 25x25x20 cm P.V.C P.V.C P.V.C
290.5 720 0 0
3'' D=3/4'', Oriffice Dia.=20mm

48
60 copper 33
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Chapter 5 5.5
5.6 5.7 5.8 5.9 5.11 5.11 5.7 5.8 5.11 5.12 5.13
6 7 7.1 7.2 7.3 7.4 8 8.1 8.1-1 8.1-2 8.1-3 8.2 8.2-2 8.2-3
Check valve Float valve Gelb Gelb Gelb screws+nuts screws+nuts nozzles Welding rods Sight glass Elbow Copper rod Copper rod Blower pumping system pump pipes Hose Nozzle Electronics Displays Temp display for air Temp display for water Humidity display+Sensors sensors Air temp sensor
1 1 3 2 1 20 1 2 2 1 1 1 1 1 1 1 1 1 6 2
buy buy buy buy buy buy buy make buy buy buy buy buy buy make buy buy buy make buy buy buy buy
1.25" 1.5" 0.5" no. of units=52
copper plastic iron iron iron st.st. copper copper
1" , 90 deg. 19mm Hexagonal 3mm dia. flow rate max.=740 (m^3/hr)
copper copper
26 15 26.125 3.3 20 4 98.35 60 27 122 4.4 45 7 710.7
26 15 78.375 6.6 20 80 98.35 120 54 122 4.4 45 7 710.7 0 230 35 56.35 120 0 0 1760 1760 4400 0 411.4
P=0.5 hp, Hmax=35 m, Qmax=35 L/min steel 1.5 m length PVC 6 m length, 10 Bar copper
230 35 56.35 120
880 880 2200
2 buy 2 2 buy buy PT 100

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platinum
205.7
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Chapter 5 8.2-4 8.2-5 8.4 8.5 8.5-1 8.5-2 8.5-3 8.5-4

8.5-4
8.5-5
8.5-6
8.5-7 8.5-8 8.6 8.7 8.8 8.8-1 8.8-2 8.8-2 9 9.1 9.2
Water temp sensor Orifice Meter Tempreature Controller Circuit components Main C.B Blower C.B Pump C.B Heaters C.B Displays C.B Diff. pressure sensor C.B Contactor Bridge Leds Resistors Switches Data acquisation card Cables Cables ducts Cable 6x0.22 wiring Computer LCD screen Desktop
buy 2 1 3 buy 7 1 1 1 1 1 1 1 1 13 50 5 2 1 1 1 1 1 buy buy buy buy 6mm dia buy buy buy Project Total Cost buy buy buy buy buy buy buy buy buy buy buy PT 100 buy buy PT 100
platinum stainless
205.7 1100 200.2
411.4 1100 600.6 0
16 12 12 12 12 12 46.2 5.5 1.1 0.1 11 1540
16 12 12 12 12 12 46.2 5.5 14.3 5 55 3080 0 15 58.75 45 0 1155 0 20871.375 L.E
6 Amperes
15 58.75 45 1155
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Chapter 6
Chapter Six Fabrication procedure

1. Welding
Water tank:
Fig. (6.1) Pipe with twelve nozzles attached to elbow both of 1 inch diameters, welded to the left side of the water tank
Fig. (6.2) Section of water tank showing inner baffle attached by welding, with hole of 1 inch for pump suction pipe (left side in picture)
Chapter 6
Fig. (6.3) Attaching the final side containing the positions through which the heaters will be inserted into tank.
Fig. (6.4) Top view of the tank after completing the welding process.
Chapter 6 Make up tank:
Fig. (6.5) the sides of the makeup tank being welded except the top cover for later internal painting.
Fig. (6.6) Make up tank after painting the internal with epoxy resin and completing welding, appearing in the figure an eye sight glass, four adjustable legs and a lid with air passage through its center.
Chapter 6 Air tank and its attached components:
Fig. (6.7) Air tank after complete welding, appearing (on the right) the exit pipe of drain, and (on the left) the opening through which the blower is attached as shown.
Fig. (6.8) Water drain basin, receives the water falling from the column and delivers it to the water tank, the basin is placed inside the air tank.
Fig. (6.9) butterfly handmade with various degrees of opening attached to the blower suction side, all attached to the left side of air tank.
Chapter 6
2. Stand fabrication
Fig. (6.10) The stands structure is constructed of bars welded together, with four wheels attached which is capable of carrying the stand holding components weight.
Fig. (6.11) wood boards after being cut to designed dimensions, and the exterior frames which will be attached to the edges to protect the wood.
Fig. (6.12) stand after installation of wooden boards.
Chapter 6
3. Painting and coating
Fig. (6.13) tanks after painting the first layer (all tanks needed to be coated inside and outside with a primary layer of epoxy to protect it from corrosion).
Fig (6.14) after the epoxy had dried, we painted a secondary layer of green paint. To enhance its color.
Chapter 6
4. Pipe components and fittings:

Referring to the designs of the pipe line, we cut the pipes with the required lengths (and screwing its ends), then connecting the elbows, screwed union, orifice meter, throttle and check valves.
Fig. (6.15) T joint, screwed union, elbow, nibbles.
Fig.(6.16) swing check valve.
Fig (6.18) Gate valve.
Fig. (6.17) Orifice plate, flanges and pipe.
Fig. (6.19) Float valve
Chapter 6
Fig. (6.20) T joint (one branch is attached by the bush showing in the figure, the other branch by the pipe discharge line and the main branch by the Hose.
Fig. (6.21) pump after fixation on the stand and attaching the suction and delivery pipes with their fittings.
Fig. (6.22) The pump delivery line after attaching the fittings and valves.
Chapter 6 5.
The Column
The column consists of two main parts; the lower part which holds the fills and the upper part (the cap) which holds the water distributers and drift eliminator. The column body (lower part): The body material is transparent PVC to provide clear view of the actions occurring inside the tower for the students, there are small holders attached on the inner surface of the column to hang the fill on. Also the column bottom is bending with 45 to affirm that all water falls into drain basin. The column appears in Figure (6.23). The fill (Fig 6.24) was cut to calculated size and required number of layers, and penetrated with two bars horizontally near the top and one at the bottom, to settle down on the holders inside the column. Also to confirm uniform distribution of fill layers, stainless strips were added to constrain the fill. Figure (6.25) show the final shape of column body.
Fig. (6.22) column body.
Fig. (6.24) The Fill.
Fig. (6.25) the column body after attaching the fill
Chapter 6 The column Cap (upper part): The column cap Fig. (6.26) was fabricated similar to the column body, also with adding two opposite holders to carry the eliminator, with adding two opposite holes to install the water spray line. The drift eliminator was also fabricated from the same material of the fill, penetrated with three bars to confirm alignment of layers Fig. (6.27). The water spray nozzles were attached to a hexagonal pipe of copper vertically, with an external connection to hose supplying income water from main pipe line, and then installed in the cap Fig. (6.28).
Fig. (6.26) The Cap.
Fig. (6.27) The drift eliminators attached to the cap.
Fig. (6.28) The hexagonal sprinkle attached to the cap.
Chapter 6 6.
Stand preparation
Mark the areas required to be cut on the stand to be opened for the following requirements: 1. Pump Suction and delivery pipes holes and drain pipes holes Fig. (6.29). 2. Digital displays openings Fig. (6.30). 3. LCD screen opening Fig (6.31). 4. Control panel switches and indication light holes Fig. (6.32).
Fig. (6.29) pipes holes.
Fig. (6.30) digital displays openings.
Fig. (6.32) Control panel holes. Fig. (6.31) LCD opening with circle holes around the opening circumference for ventilation.
Chapter 6
7. Control panel
Since the project is an educational cooling tower, it was preferred to show the switches on a schematic drawing of the cycle with apparent indication lights. A stainless steel sheet being drilled to pass the switches and indication lights Fig. (6.33), then the schematic drawing was attached to the stainless sheet, finally the switches and lights where installed, and fixed on the stand as shown in figure (6.34).
Fig. (6.33) preparing the stainless steel sheet.
Fig. (6.34) control panel final shape.
8. Electronic and Electric devices installation

After preparing the stand install the electronic devices (digital displays, pressure deffrance transmitter, temperature controller), the electric devices (LCD screen, PC) and control panel fig. (6.35).
Fig. (6.35) electric and electronic devices after installation.
Chapter 6
9. Electric connections
Before connecting any device to electricity, we classified them according to their operating voltage. All devices operate at 220 volt except for the differential pressure transmitter which works at 24 volt. Therefore we used one adapter to convert 220 volt to 24 volt. We designed the circuit loop by adding a main circuit breaker of maximum load of 40 Ampere at the beginning of the line. Then we branched the main line into five lines, each passing through a suitable circuit breaker each device: Pump, blower, displays and differential pressure transmitter required circuit breakers of 10 ampere. Heaters required a circuit breaker of 16 ampere. Finally we added a switch and indication light in series on the five sub-lines, appearing on the control panel.
(a)
(b)
(c) (d)
Fig. (6.36.a, b, c, d) electric connections.
Chapter 6
10. Components assembly

After preparing all cooling tower educational stand components as shown in previous sections, assembly the components together figures (6.37), (6.38), (6.39) and (6.40).
Fig. (6.37) assemble the air tank with water tank by means of screwed union and pipes.
Fig. (6.39) assemble water tank with makeup tank and insert the water tank sight glass. Fig. (6.38) assemble air tank with column.
Chapter 6
Fig. (6.40) the final shape of cooling tower educational stand.
Chapter 7
Chapter seven Tests and results

After installing the educational stand cooling tower take some readings .
Procedure:
1. Turn on the main switch then the main circuit breaker (orange key). 2. Turn the CPU and LCD on. 3. Turn the heaters and displays switches on and wait until reaching the required heating temperature; i.e. when the heaters disconnected by the temperature controller. 4. Turn the blower, differential pressure and pump switches on. 5. Adjust the pump (water) flow rate and blower (air) flow rate. 6. Wait until steady state the take the readings. 7. Repeat the procedure by changing water and air flow rates. 8. Turn off the CPU and all switches. 9. Tabulate the results and calculate the cooling tower performance parameters.
Results:
1- Fix the air flow rate and change water flow rate. 0 0 0 P (psi) 0.4 0.12 0.03 Two 28.1 27.1 27.1 Twi 41.3 41.4 41.6 Tai 28.1 28.5 28.6 Tao 28.8 28.4 28.1 RHo% 88 79 78 RHi% 57 57 57
2-Fix the water flow rate and changes the air flow rate. 0 30 60 P (psi) 0.22 0.22 0.22 Two 26.8 27.5 28.3 Twi 42.9 43.8 43.5 Tai 29.6 29 29.7 Tao 28.3 28.9 30.2 RHo% 79 79 82 RHi% 57 57 57
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Chapter 7
Relations:
To get the water mass flow rate using orifice equation = Where 2
= 1.9625 105 2 = 0.605
= 0.605 1.9625 105
2 10 14.7 1000
NOTE: There is no available measurement device installed for the air flow rate. So calibrations are made for the air flow rate using hot wire; as follows: 1. Divide the column exit cross section area into nine equal parts as shown in figure. 2. Measure the air velocity at the center of each grid. 3. Repeat the measuring at different butter fly angles of opening. 4. Then get the average velocity of the air and get the air volumetric flow rate. 5. Plot the relation between the butter fly opening ( ) and the air volumetric flow rate.
) = 5.5172 ( ) 107 (3 /sec
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Chapter 7 Air velocity gradient through the matrix over the column cross-section, with Average velocity and volumetric flow rate. 0.4 5.5 0.4 0.7 5.6 0.7 5.8 5.8 4.9 =0 v=3.31 m/s =0.206875 m3/sec =10 v=2.98 m/s = 0.18625 m3/sec =20 v=2.7 m/s =0.16875 m3/sec =30 v=2.5 m/s =0.15625 m3/sec =40 v=2.35 m/s =0.146875 m3/sec =50 v=2.26 m/s = 0.14125 m3/sec =60 v=2.01 m/s = 0.125625 m3/sec =70 v=1.644 m/s = 0.10275 m3/sec
0.4 4.2 0.5 1.5 5.3 0.6 5.2 5.1 4 0.4 3.8 0.4 0.7 5.1 0.7 5.1 5.1 3
0.4 3.4 0.4 0.6 4.5 0.5 4.8 4.7 2.9
0.5 3.2 0.4 0.7 4.1 0.7 4.5 4.4 2.7
0.4 3 0.4 0.7 3.9 0.7 4.4 4.1 2.8
0.4 2.5 0.4 0.7 3.5 0.7 4 3.5 2.4
0.8 2.2 0.3 2 2.4 0.4 2.8 3.5 0.4
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Chapter 7 Table between Air flow discharge (V*) versus butterfly opening angle ()
V* 0 10 20 30 40 50 60 70
0.20688 0.18625 0.16875 0.15625 0.14688 0.14125 0.12563
0.1027
0.25
0.2
air flow rate m^3/s
0.15
Air Flow chart 0.1 Linear (Air Flow chart)
0.05
0 0 10 20 30 40 50 60 70 80 Butterfly angle
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Chapter 7
Summery and conclusion 1. We designed the cooling tower with a cooling range 5C but in the actual running for the experiment the cooling range goes up to 15C and this is due to the high atomization happened for the water from the nozzle, which in turns increased the exposed surface area of the water to that of the air. 2. Differential Pressure transmitter reading is unstable at high flow rates, because the nozzles makes a back pressure on the downstream of the orifice plate which makes the downstream pressure nearly equal the upstream one. 3. While preparing the experiment we noticed that the water present in its upper part of tank is higher than the lower on due to almost negligible mixing of water when the pump is not operating.
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Appendix
Appendices
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Appendix
Appendix -1Physical Properties of Water
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Appendix
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Appendix
Appendix -2Orifice ASME Standards
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Appendix
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Appendix
Flow Coefficient Chart
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Appendix
Appendix -3Moody Chart
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Appendix -4Physical properties of Air
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Appendix
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Appendix
Appendix -5Piping minor head losses
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Entrance loss coefficient
Sudden contraction loss coefficient
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Sudden expansion loss coefficient
Conical diffuser loss coefficient
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Appendix
90 Bend loss coefficient
90 Mitered bend loss coefficient
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Loss coefficient for pipe fittings
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Appendix
Appendix -6Cooling Tower Design Charts
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Appendix
Table ( 1 ): Film tower fill performance correlation constants.

Fill Source Type Fill Size (Height X Depth in Feet) 5 5 7.5 7.5 7.5 7.5 7.5 X 2 X 3 X 2 X 3 X 4 X 3 X 4
Constants for Ka Equation Eq. (8-21)
Constants for DP Equation Eq. (8-25) A b E-09 E-09 E-09 E-09 E-09 E-09 E-09 E-12 E-12 E-12 E-12 E-09 E-09 E-09 E-09 0.433 0.210 0.428 0.371 0.358 0.739 0.622 0.305 0.175 0.148 0.148 0.272 0.209 0.257 0.240 d 1.665 1.849 1.705 1.757 1.665 1.682 1.701 2.545 2.944 3.103 3.019 2.065 2.180 2.120 2.070 8.16 14.10 7.31 7.09 17.10 0.20 0.54 44.10 4.15 1.32 2.29 1.01 0.67 0.76 1.28
Munters Crossflow XF12560/15
Ca 0.61 0.60 0.61 0.54 0.51 0.19 0.23 1.08 0.93 0.80 0.71 0.50 0.50 0.49 0.45
ma
a 0.23 0.20 0.20 0.22 0.23 0.54 0.51 0.25 0.14 0.12 0.13 0.16 0.09 0.04 0.08 0.77 0.80 0.80 0.78 0.77 0.46 0.49 0.75 0.86 0.88 0.87 0.84 0.91 0.96 0.92
Crossflow XF19060 (Height)
hunters Counterflow CF12060 Counterflow CF19060
1 2
3 4 2 3 4 5
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Appendix
Cooling Tower Performance Curves and Tower Fill Data

69 W E T BULB (F) 26 RANGE (F)
KaV/L
Figure (1), Counterflow tower charachteristic curves (wet-bulb temperature 69 F and cooling range 26 F),
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69 W E T B U L B (F) 22 RANGE (F)
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Appendix 69 W E T B U L B (F) 18 RANGE (F)
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Appendix -7Product Catalogues
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Appendix -8Electric Circuit
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Appendix -9Electric Loads
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Electric loads
Pump Blower Heaters Displays Differential pressure gauge Computer Voltage 220 220 220 220 24 220 Ampere
1.83 A
0.4545 A 6.9 A 0.021 A 0.003 A
We choose Switches can withstand over 10 A for safety, and circuit breakers over 20 A
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Appendix -10AutoCAD Drawings
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References
References:
ASME. Fluid Meters.6th Ed. ASME 1967 Lewitt. Hydraulics. Pullman. 1980 Clayton T. crowe, Elger. Engineering Fluid Mechanics. 8th Ed. Wiley. 2005 Okishi. Fundamentals of Fluid Mechanics. 4th Ed.Wiley www.CTI.org (Cooling Technology Institute) www.omega.com ASHRAE Magazine
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Faculty of Engineering Cairo University Mechanical Power Departement

Cooling Tower Educational Stand

Cooling Tower Educational Stand

Chapter One Introduction

Fig. (1.2) Natural draft cooling tower

2 Cooling Tower Educational Stand B.Sc. Project 2008

Fig. (1.3) Induced draft fan cooling tower

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4 Cooling Tower Educational Stand B.Sc. Project 2008

Fig. (1.5) Cross Flow cooling tower

Fig (1.6) Counter Flow cooling tower

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7 Cooling Tower Educational Stand B.Sc. Project 2008

Chapter Two Literature review

-max. Differential pressure 430 pa.

Cooling Tower Educational Stand

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Cooling Tower Educational Stand

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Cooling Tower Educational Stand

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Cooling Tower Educational Stand

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Cooling Tower Educational Stand

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Cooling Tower Educational Stand

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Cooling Tower Educational Stand

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Cooling Tower Educational Stand

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Chapter Three Cooling Tower Design Calculation

Where: ai: Air inlet density,kg/m3. Pai: Air inlet pressure,kPa.

Tai: Air inlet temperature,K. R: universal constant,

Assume air flow rate to be

m blower = 0.24 kg/s

Chapter 3 m da = 0.24 1 + 0.01414

Where: m da : Dray air mass flow rate, kg/s.

= 0.238 kg/s mda

L=0.0333 kg/s. G=0.238 kg/s.

L L 0.0333 = = = 0.14 G G 0.238

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= 0.14, Approach=38.16 F and CR=22 F=12.2C

yields 0.0997 V = 0.17 V = 0.0568 m3 0.0333

0.0568 = 0.062 m2 0.9144

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Fig. (3.4) Fill spacing

Fig. (3.3) Packing

Fig. (3.5) Drift eliminator

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2. Cooling tower performance

From psychrometric chart :

Cooling range and approach obtained CR=Twi-Two=50-45=5C Approach= Two-Wbtai=35-23.9=21.1C Q CT = m w Cp,w CR

Q CT = 0.033 4.18 5 Q CT = m da (hao hai ) hao = 74.42 kJ/kg da Q CT = 0.7 kW

m evap = 0.238(0.01877 0.01414) m evap = 1.10194 103 kg/s

50 45 100 45 23.9 = 23.697%

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Q=1.5 kW = Cp=4.18 kJ/kg K t=25 min. = 50 25 = 25

Cooling Tower Educational Stand