Proceedings of the National Conference on Recent Trends in Renewable Energy Technology (NACOEE 05) 09-10 December 2005

National Engineering College. K. R. Nagar, Kovilpatti-628 503. Tamil Nadu. pp-131-138

PERFORMANCE AND OPTIMISATION OF COOLING TOWER

REVEALS ENERGY SAVING OPPORTUNITY
Sharan.Shegedar 1, B.M.Shrigiri 2, S.M.Nagure3, M.B.Shetti 1, Chandrashekhar.R.Tamburimath 4
1

Department of Mechanical Engineering,College of Engineering, Ambajogai 431517

Department of Mechanical Engineering, Appa Institute of Engg & Technology, 585103
3
Department of Mechanical Engineering,T.B.G. Polytechnic, Ambajogai 431517.
4
Department of Mechanical Engineering, K.C.T College of Engg, Gulbarga 585103
E-mail: sharan_shegedar@yahoo.co.uk, sharan_shegedar@rediffmail.com

ABSTRACT
The present paper will outline the main aspect of energy saving opportunity in cooling tower by
studying its performance and optimization. Cooling tower is a specialized heat-exchanging device, which
dissipates low grade unusable heat to atmosphere. So far very less attention has been paid to cooling
tower. With a deeper insight study performance and optimization of cooling tower can increase the
efficiency of the entire power plant and reveals energy saving proposals.
To generate electricity in thermal power station fossil fuels are used. As the study shows that fossil
fuels are diminishing in nature and will be exhausted within hundred years, so efficient use of this low
grade energy is necessary to increase the efficiency of the plant. In this paper an attempt is made to
analyse the energy saving opportunities in cooling tower.
This paper has exhaustive data taken during operation of cross flow induced draft cooling tower unit-III at
Parli (V) thermal power station. As cooling tower performance depends on wet bulb temperature, range,
discharge, inlet water temperature, refrigerating effect and NTU. Cooling tower performance mainly
depends on wet bulb temperature and weather conditions. Considering the above parameters cooling
tower efficiency and performance were determined and there is enough scope for energy saving
opportunities by using sump thermostat and by replacing solid blades of induced draft fan with hollow
plastic blades.
1. INTRODUCTION
Cooling tower is an artificial device used to dispose of waste that from industrial processes and
from refrigeration or air conditioning systems, where it has been cheaper or more convenient to reject heat
to the atmosphere rather than to water in a near by River, Lake or Ocean.
In a fossil fire thermal power plant nearby 30 percent of the heat energy produced in the boiler is
rejected in condenser, large quantity of cooling water is required for condensing the exhaust Steam. There
are two basic types of cooling system. They are Direct cooling system (DCS) and closed loop
recirculatory cooling system (RCS).
In the closed loop recirculatory cooling system with the evaporative cooling tower, the hot water
that comes from the condenser is cooled in the tower by direct contact with ambient air and this cooled
water is recirculated through the condenser. Most of the heat transfer that occurs in the tower is due to
evaporation and it is estimated that about 2.5 to 3 percent of the circulating cooling water is required as
make up to compensate the loss due to evaporation, drift and blow down requirement. Water availability
for power generation is becoming continuously scare due no many other important uses of water like
drinking, irrigation and other industrial requirements and to the power plant.

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Performance and Optimisation of Cooling Tower Reveals Energy Saving Opportunity

This report covers the thermal performance of cooling tower of unit III of the Parli Thermal Power
Station and energy saving by using sump thermostats. The plant has installed one cross flow induced draft
cooling tower of 10 cells with a design flow of 31000 m3/h and 9.5 0C range. The plant has replaced all
the metallic aluminum blades of the cooling tower fans with fibre - reinforced blades the detailed
specifications of the cooling tower are given in appendix 1.
APPENDIX 1.Specifications of the Cooling Tower [1]

Design Date
Type and Design of Tower
Design Flow of water
Design Heat Load
Design wet bulb temperature
Hot water inlet temperature
Cold water outlet temperature
Cooling Range
Highest dry bulb temperature
Drift loss
Evaporation loss
Flow rate per cell
Fan Details
Make
No. of fans per cell
Type
Material of fan blades and hub
Dia. of fan
Number of blades per fan
Blade angle
Fan air flow rate per cell
Power consumption at motor inlet kW per
fan
Motor Details
Make
Rated output
Full load Speed

Induced Draft, R.C.C, one block, ten cells,

direct contact, double cross floor, packed
type manufactured by M/s Paharpur
Cooling Tower Pvt. Limited
31000 m3/hr
294. Mcal
25 0C
39.5 0C
30 0C
9.5 0C
44 0C
0.05% (15.5 m3/hr)
1.53% (474.3m3/hr)
3444m3/hr
Paharpur Marley HP 4 8
One
Axial Flow propeller
Fibre Reinforced plastic.
8.53m
8
Adjustable (22.50 to start)
21,46,000m3/hr
92.32 kW

Siemens
101 kW
1485 rpm

2. WORKING OF COOLING TOWER

A cooling tower (CT) is a specialized heat exchanger in which two fluids (air and water) are
brought in to direct contact with each other to affect the transfer of heat. In the " Spray-filled" tower as
shown in fig. 1 below is accomplished by spraying a flowing mass of water in to a rain like pattern
through which an upward moving mass flow of cool air is induced by the action of a fan [2].

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National Conference on Recent Trends in Renewable Energy Technology (NACOEE 05)

Fig 1. Cross flow induced draft fan.

Ignoring any negligible amount of sensible heat exchange that may occur through the walls of the
tower, the heat gained by the air must be equal to the heat lost by water.
A portion of the water absorbs heat to change from a liquid to vapour at constant pressure. This heat
of evaporation at atmospheric pressure is transferred from the water remaining in the liquid state into the
air stream.
However, because of the evaporation that takes place within the tower is less than that entering it
and a proper heat balance must account for this slight difference. Hence the rate of evaporation must be
equal to the rate of change in the humidity ratio (absolute humidity) of the air stream.
The below Fig 2 shows the temperature relationship between water and air as they pass through a
counter flow cooling tower. The curve indicates the drop in water temperature (point A to point B) and the
rise in the air wet bulb temperature (point C to point D) in their respective passages through the tower.
The temperature difference between the water entering (tw1) and leaving (tw2) the cooling tower (A minus
B) is the range (tw1- tw2). The range is determined by the heat load and water flow rate, not by the size of
the cooling tower.
The difference between the leaving water temperature and the entering air wet bulb temperature
(twb), B minus C is the approach (tw2-twb) of the cooling tower. The approach is the function of the cooling
tower capability, and a larger cooling tower produces a closer approach (colder leaving water) for given
heat load, flow rate and entering air condition. Thus the amount of heat transferred to the atmosphere by
the cooling tower is always equal to the heat load imposed on the tower, while the temperature level at
which the heat is transferred is determined by the thermal capability of cooling tower [3].
The entering air wet bulb temperature affects the thermal performance of cooling tower. Entering
air dry bulb temperature (tdb) and the relative humidity have an insignificant effect on thermal
performance, but they do affect the rate of water evaporation.
2.1 Terminology
The following terms are commonly used when referring to the performance of a cooling tower. [3]
Approach: It is the difference between the temperature of the cooling water leaving the tower and the wet
bulb temperature of the air entering to tower.
Range(R): Temperature difference between temperature of cooling water entering the tower and the temperature of
water leaving the cooling tower.
Blow down: Water discharged to the drain periodically in order to avoid build up of dissolved solids.
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Performance and Optimisation of Cooling Tower Reveals Energy Saving Opportunity

Fig 3. Temperature relationship between water and air passing through cooling tower.
Fill: The structure that forms the heat transfer surface within the tower cooling water from the condenser
or coil is distributed along the flow passage of the fill through the nozzles down to the water basin.
Make - up: Water added to the circulating water to compensate for the loss the water to evaporation drift
and blow down.
Capacity: Average rate of flow of water circulating in the system and being handled by the cooling tower
(m3/hr)
Drift: Loss of water in the form of air borne particles carried way by the exhaust air expressed as
percentage of circulating water flow rate.
Wet bulb temperature (twb): Temperature as indicated by a thermometer the bulb of which is kept moist
by wick over which air is circulated. This is theoretically, the lowest temperature to which water can be
cooled and it depends on the dry bulb temperature and relative humidity of the ambient air.
Dry bulb temperature (tdb): External out door temperatures as indicated by a dry bulb thermometer in 0C.

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National Conference on Recent Trends in Renewable Energy Technology (NACOEE 05)

Recirculation: Tendency for the hot air to be sucked along with the ambient (cold) air in to the tower this
takes place in mechanical draft cooling towers and this has an adverse effect on the tower performance if
spacing of cells and orientation of the tower with respect to prevailing winds are not proper.
3. ENERGY AUDIT OF COOLING TOWER
The energy audit of cooling tower is performed to assess the present level of approach and range
against their designed value and also to identify the areas of energy wastage. The instrumented energy
audit was carried out to know the various parameters such as, wet and dry bulb temperature, Cooling
water (CW) inlet and outlet temperature, water and air flow rate and electrical parameters of cooling tower
fan and motor.
4. EXPERIMENTATION
The first objective of study was to evaluate present heat removal load of cooling tower within the
working condition keeping in mind the draw back and plant problem. The second objective was to suggest
an optimum low cost solution to management towards energy saving.
By using the parameters of circulating water conditions such as inlet and outlet temperature of
cooling water, wet bulb temperature (WBT),dry bulb temperature (DBT), atmospheric pressure, water
flow rate, fan consumption and pump consumption, the performance and optimization of the cooling
tower is conducted. These readings are taken directly from the inlet and outlet of the cooling tower with
the help of measuring instruments such as dry bulb thermometer, wet bulb thermometer and hygrometer.
Unit load, fan consumption (voltage and current) and flow rate of cooling water are taken at unit control
board.The General observations made at cooling tower site are, Channeling of water due to choking of
distributor holes, algae and fungi formation on structural and the water flow rate is reduced to 27000
m3/hr.The observations are drawn by, taking constant flow rate of 27000m3/hr and with all 10 fans
working on 11th & 12th Aug 2004 on 13th Aug 2004 one fan is switched off. See the following Table 1.
Table1: Experimental observation of cooling tower unit III
Date

Time In
hrs

11-08-2004
12-08-2004
13-08-2004

2300
2300
2300

Load
In
MW
185
150
170

DBT In
0
C
tdb
25
24.5
24.6

WBT
In 0C
tWb
23
23
22.9

CW
Inlet In
0
C tW1
41
40
40.5

CW
Outlet In
0
C tW2
28.75
28
29.5

Humidity
in %
84
87
84

The following observations have been drawn for fan consumption for three consecutive at 2300hrs
see Table2.
Table 2: Experimental observation of fan consumption
11th
Aug
th

12
Aug
13th
Aug

Voltage V in Volts

415

415

415

415

415

415

415

415

415

415

Current I in Amps

120

110

105

105

110

100

90

100

90

105

Voltage V in Volts

415

415

415

415

415

415

415

415

415

415

Current I in Amps

120

110

105

105

110

100

90

100

90

105

Voltage V in Volts

415

415

415

415

415

415

415

415

415

415

Current I in Amps

120

110

105

105

110

--

90

100

90

105

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Performance and Optimisation of Cooling Tower Reveals Energy Saving Opportunity

4.1 CALCULATIONS AND RESULT SHEET

Cooling tower efficiency

t w1 t w 2
x100
t w1 t wb

Refrigerating effect (R.E)

mw Cp R/210

Where, mw is mass of cooling water kg/min, Cp is specific heat of water in KJ/Kg K.

L and G are water loading and gas loading in Kg/hr

From below Table3 and Fig 3.where, Ha enthalpy of air water mixture at wet bulb temperature
and Hw enthalpy of water [4].
Table 3: Calculation of test characteristic curve on 11-08-2003
Water

Air side

Enthalpy difference

Description

tw in
C

Hw in
kJ/kg

Description

Ha
kj/kg

Hw-Ha

1/(Hw-Ha)

tw2+(0.1xR)

29.97

125.75

Ha+(0.1xL/GxR)

87.92

37.83

0.0264

tw2+(0.4XR)

33.65

140.3

Ha+(0.4xL/GxR)

91.97

48.33

0.0207

tw2+(0.6XR)

36.1

151.24

Ha+(0.6xL/GxR)

94.67

56.57

0.0177

tw2+(0.9XR)

39.77

166.58

Ha+(0.9xL/GxR)

98.72

67.86

0.0147

Sum of 1/(Hw-Ha)
Tower demand (NTU) = sum of 1/(Hw - Ha) x

Range
4

0.0795
0.2435

Tower demand (NTU)

Log mean enthalpy difference Hm

KaV/L (NTU)
= R/ Hm= 0.238
Hence 0.238 is less than 0.2435 performance is acceptable [5].

Fan power consumption.

=
3 VIcos watts
= 3 x 415 x 0.85 x (120+110+105+105+110+100+90+100+90+105)

= 0.2435
=

= 632365.25 watts

136

67.86 37.83
= 51.391
67.86
ln

37.83

National Conference on Recent Trends in Renewable Energy Technology (NACOEE 05)

Figure 3. Test characteristic curve of

cooling tower on 11-08-2003

Enthalpy in kj/kg

Hw

Ha

180
160
140
120
100
80
60
40
20
0
29.97 31.97 33.97 35.97 37.97 39.97 41.97
Water temperature tw in C

5. RESULT AND DISCUSSION

On the basis of observations and calculations conducted on cooling tower, the following results are
obtained and shown in below Table 4.

Date
Designed
11-08-04
12-08-04
13-08-04

Table 4: Result sheet of cooling tower performance.

Range Approach
L/G
Kav/L
CT
R.E
C
C
Eff.
Tons
%
9.5
5
1.264928 0.223289 65.52 97862.82
12.25
5.25
1.1017
0.2435 62.36 100188.92
12
5
1.1017
0.2784 70.58 107665.71
11
6.6
1.22412 0.213128 62.5 98693.57

Power
KW
923.2
643.051
635.42
571.26

On the basis of results on 13-08-2003 at 1200hrs to 2400 hrs one fan is switched off. The cooling
tower performance is satisfactory during night hours. The NTU (diffusion units), Refrigerating Effect,
Cooling tower Efficiency, outlet temperature of cooling tower are nearly matching with the designed
values even though one fan is switched off. During this period the performance is satisfactory. So there is
scope for energy saving when wet bulb temperature is low
Comparing the results obtained on 12-08-2003 and 13-8-2003 at 2400hrs (the weather conditions
are almost same). Therefore here is enough opportunity for energy saving by switching off one or two
fans by using sump thermostats, when WBT fall below designed value. The energy saved is equal to Fan
consumption on 11-8-2003(10fans working) minus Fan consumption on 13-8-2003(9 fans working), i.e.
72.05KW. Approximate energy saved per annum when on fan is switched off for 6 hours, the energy
saved is 157789.5 KWH.
The cooling tower has 10 cells, fans in cell No. 1,2,3,4 are solid blades and the fans in cell No.5,
6,7,8,9 are hollow blade fans. Therefore the power consumption of fan in cells 1,2,3,4 is more than the
cells 5,6,7,8,9,10. The energy saving per annum by replacing hollow blades to cell No 1,2,3 and 4 is approximately
347894.64 KWH.

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Performance and Optimisation of Cooling Tower Reveals Energy Saving Opportunity

6. CONCLUSION
The field study established the scope of energy saving by stopping the cooling tower fan. Moreover,
there exits a potential for savings on fan and replacing solid blades with hollow blade fans.
7. REFFERENCES
[1] Performance guarantee provided by Paharpur Cooling Tower Pvt. Limited.
[2] Cooling tower performance: Basic Theory and Practice, Issue 1,
[3] www.marleyct.co/pdf_forms/CTll-1pdf
[4] Veeresh Angadi : Performance Analysis of Cooling Tower, C.P.R.I,

Trivendrum 1998-99.

[5] Cooling Tower Technical Site of Daeil Aqua Co, Ltd for cooling tower Engineers,
[6] Operators and Purchasers, 2000-2001.
[7] www.coolingtowertechnicalsite.com
[8] D.Q.Kern, Process Heat Transfer, TATA Mc Graw-Hill, 1997.

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