Topic : Cooling Towers

C.T MODEL : 85454 – 5.0 – 08 B

NBEIL 150 MW CFPP
MAKE : PAHARPUR

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 Topics
 Introduction
 Definitions
 Operating Conditions
 Basic Components
 Technical Details
 Water Cooling Systems
 Types
 Maintenance Schedule
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 Trouble shooting
 Introduction
 Boxed shaped collection of multilayered RCC
structure i.e under class 800

 Air flow breaks up water as it falls

 Design ensures good contact between water and

air

 Used to remove heat from water

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Definitions

 Wet bulb temperature: Lowest temperature that can be

obtained by evaporating water into the air at constant
pressure.

 Name comes 4 from the technique of putting a wet cloth

over the bulb of a mercury thermometer and then blowing
air over the cloth until the water evaporates. Since
evaporation takes up heat, the thermometer will cool to a
lower temperature than a thermometer with a dry bulb at
the same time and place. Wet bulb temperatures can be
used along with the dry bulb temperature to calculate dew
point or relative humidity.
 Key Definitions
 Wet-bulb temperature = air temperature measured by a
wet-bulb thermometer
– simulates effect of evaporative cooling

 Dry-bulb temperature = air temperature measured by a

dry-bulb thermometer

 Approach = difference in wet-bulb temperatures between

inlet and outlet called “the approach to the tower”

 Latent heat = heat associated with change in state of

matter (e.g., liquid to gas phase)
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 Performance Parameters
Factors which affect cooling tower performance
 Range
 Approach
 Effectiveness
 Cooling capacity
 Evaporation loss
 Cycles of concentration
 Blow down losses
 Liquid / Gas ratio 6
 Assessment of cooling tower

1. Range
Difference between cooling water inlet and
outlet temperature:

Range (°C) = CW inlet temp – CW outlet temp

High range = good performance

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 Assessment of cooling tower

2. Approach

Difference between cooling tower outlet cold

water temperature and ambient wet bulb
temperature:

Approach (°C) =
CW outlet temp – Wet bulb temp

Low approach = good performance

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 Assessment of cooling tower

3. Effectiveness

Effectiveness in %

= Range / (Range + Approach)

= 100 x (CW temp – CW out temp) / (CW in

temp – Wet bulb temp)

High effectiveness = good performance

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Assessment of cooling tower

4. Cooling Capacity
Heat rejected in kCal/hr or
tons of refrigeration (TR)

= mass flow rate of water X

specific heat X temperature
difference

High cooling capacity = good

performance
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Assessment of cooling tower

5. Evaporation Loss

Water quantity (m3/hr) evaporated

for cooling duty

= theoretically, 1.8 m3 for every

10,000,000 kCal heat rejected

= 0.00085 x 1.8 x circulation rate

(m3/hr) x (T1-T2)

T1-T2 = Temp. difference between

inlet and outlet water 11
Assessment of cooling tower

6. Cycles of concentration (C.O.C.)

Ratio of dissolved solids in circulating
water to the dissolved solids in make up
water

7. Cycles of concentration (C.O.C.)

Depend on cycles of concentration
and the evaporation losses

Blow Down =
12
Evaporation Loss / (C.O.C. – 1)
 Assessment of cooling tower
8. Liquid Gas (L/G) Ratio
Ratio between water and air mass flow rates

Heat removed from the water must be equal to

the heat absorbed by the surrounding air

L(T1 – T2) = G(h2 – h1)

L/G = (h2 – h1) / (T1 – T2)

T1 = hot water temp (oC)

T2 = cold water temp (oC)
Enthalpy of air water vapor mixture at inlet wet bulb temp (h1)
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and outlet wet bulb temp (h2)
Operating Conditions

 10-20% of heat (sensible heat) removed

from contact between water and air

 80-90% of heat removed following

evaporation

 Evaporation is most critical factor affecting

tower efficiency!

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Operating Conditions

 Factors which affect cooling tower

performance:
– relative humidity
– temperature Let’s discuss these!
– wind velocity
– tower design
– water contamination
– equipment problems (pump failure)

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:

Factors affecting tower performance

 Humidity is the amount of water vapor in the air

 Humidity is described in different ways

– "relative humidity," which is the term used most often
in weather information meant for the public
– Relative humidity is the amount of water vapor in the
air compared with the amount of vapor needed to make
the air saturated at the air's current temperature

 Dew point temperature gives a much better estimate of the

amount of moisture actually present in the air

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Factors affecting tower performance

 Absolute humidity: Mass of water vapor in a

given volume of air( i.e., density of water
vapor in a given parcel, usually expressed in
grams per cubic meter)

 Dewpoint: Temperature air would have to

be cooled to in order for saturation to occur
(Assumes there is no change in air pressure
or moisture content of the air).
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Factors affecting tower performance
 Relative humidity: The amount of water
vapor actually in the air divided by the
amount of water vapor the air can hold.
Relative humidity is expressed as a
percentage and can be computed in a
variety of ways.
 One way is to divide the actual vapor
pressure by the saturation vapor pressure
and then multiply by 100 to convert to a
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percent.
Components of cooling tower

•Fans
•Gear Boxes
•Motors
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 Technical Detail
S.No Description Unit Data
1 Cooling tower Model 85454-5.0-08B
(Back to Back)
2 Number of Cells Nos 8
3 Cooling Water Flow m3/hr 28000
4 Hot Water Inlet Temperature Deg Centigrade 43
5 Re-Cooled Water Deg Centigrade 33
Temperature
6 Approach Deg Centigrade 5
7 Cooling Range Deg Centigrade 10
8 Water Flow (L) Kg/M2 – Hr 13599.6
9 Air Flow (G) Kg/M2 – Hr 7576.4
10 Ratio L/G – Cooling Factor % 1.795
11 Evaporation Loss m3/hr 404 20
 Technical Detail
S.No Description Unit Data
12 Material of fill PVC film
13 Shape of fill Corrugated
14 Manner of Jointing Glue
15 Type of Drift eliminator PVC Full wave
16 Type and Material of HP-4-8:GRP
Construction of fan
17 Diameter of fan M 8.53
18 Clearance between Tip and mm 20
Diffuser
19 Reduction Gear Type Sr 32.2
20 Reduction Gear make Paharpur
21 Service factor 4.4
22 Reducing Gear Ratio 12.93:1 21
 Basic Components
 Water distribution system = includes header which
distributes (spray nozzles) water from top of tower over
splash bars and the material is PVC

 Fan = induced draft towers use fans to push or pull air &
make

 Water basin = collects water at bottom of tower prior to

discharge
 Gear Reducer = 32.2 Series which is a high strength
special alloy steel

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 Basic Components
 fill = material inside a tower which redirects air flow and
water

 column = wooden or metal post which supports tower

 stack = hyperbolic towers and chimney towers have huge

stacks located at top

 make-up water = water which is added due to evaporation

and blowdown

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Parallel vs. Series Flow

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Classification of CTs

 By direction of air flow

– crossflow (airflow is horizontal )
– counterflow (airflow is vertical) designs

 By how the air flow is produced

– naturally (hyperbolic or chimney towers)
– mechanically (forced draft or induced draft)

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Induced Draft, Cross Flow CT

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Atmospheric Cooling Tower (Natural Draft)

 Use natural forces (wind)

to move air through CT

 Air flows in through the

sides, and out the top

 Drift eliminators on the

top

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Hyperbolic Cooling Tower

 Also called chimney CT

 Often seen at power plants

 Very high flowrates

 Air flows up, creating a

draft

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Forced Draft Cooling Tower

 Fans used to create a draft

 Air forced in the bottom,

and flows out the top

 Typically solid sides

 Some recirculation of air

possible, harming
efficiency

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Induced Draft Cooling Towers

 Fans located at the top of

the CT

 Lifts air out of the CT,

preventing recirculation

 Probably the most

common type used in
chemical plants and
refineries

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Troubleshooting

 Water dissolves many things (especially hot

water!)

 Water is cooled and results in deposits in

tower

 Solids concentrate in cooling tower basin

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 Troubleshooting
SNO TROUBLE CAUSE REMEDY
1 Gear reducer Gear reducer If new, see noise in one week of
bearings bearings operation. Oil drain, flush and refill
gear reducer according to service
manual. If still noisy, replace.
Gears Correct tooth engagement. Replace
badly worn gears. Replace gears with
imperfect tooth spacing or form.

2 Unusual Fan Drive Loose bolts and cap Tighten all bolts and cap screws on all
Vibration screws mechanical equipment and supports

Unbalanced drive Make sure motor & gear reducer shaft

shaft or worn are in proper alignment & “match
couplings marks” properly matched. Repair or
replace worn-out couplings. Rebalance
drive shaft by adding or removing
weights from balancing cap screws by
seeing manual. 32
 Troubleshooting
SNO TROUBLE CAUSE REMEDY
2 Unusual Fan Drive Fan Be sure blades are properly
Vibration positioned in correct sockets, check
match numbers. Make certain all
blades are as far from center of fan
as safety devices permit. All blades
must be pitched the same as per
manual. Clean off deposit build up
on blades.
Worn gear Check fan and pinion shaft endplay.
reducer Replace bearings as necessary.
bearings
Unbalanced Disconnect load and operate motor.
motor If motor still vibrates, rebalance
rotor.
Bent gear Check fan and pinion shaft with dial
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reducer shaft indicator.Replace if necessary
 Troubleshooting
SNO TROUBLE CAUSE REMEDY
3 Fan Noise Loose fan hub cover Tighten hub cover fasteners.

Blade rubbing inside Adjust blade tip clearance.

of stack
Loose bolts in blade Check and tighten if necessary.
clamps
4 Unusual Motor running single Stop motor and attempt to start
Motor Noise phase it.Motor will not start if single
phased. Check wiring, controls and
motor.
Motor leads Check motor connections against
connected wiring diagram on motor.
incorrectly
Ball bearings Check lubrication & replace bad
bearings and use correct bearings. 34
 Troubleshooting
SNO TROUBLE CAUSE REMEDY
4 Unusual Rotor unbalance Rebalance
Motor Noise
Cooling fan hitting Reinstall or replace fan.
guard
5 Motor runs Over load Check fan blade pitch & see
hot fan service manual. Check
fan drive from damaged
bearings.
Bearings over Remove grease reliefs & run
greased motor up to speed to purge
excessive grease.
Wrong lubrication in Change to proper lubricant
bearings & see manual
Bearings damaged Replace bearings
Incorrect blade pitch See fan service manual. 35
 Troubleshooting
SNO TROUBLE CAUSE REMEDY
6 Scale formation Dissolved solids Blow down or Bleed- off

Chemical Treatment i.e. sulphuric

acid (to prevent scale & corrosion)
& chlorine (to control slime &
algae and free residual levels
should not exceed one parts per
million).
7 Nozzles clogging Suspended solids Cleaning should be done according
like stones from to schedule
RCC duct
8 Fills, Nozzles clogging Cleaning should be done& re
Distribution fixing of the fills according to
system damaging schedule
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 Troubleshooting
SNO TROUBLE CAUSE REMEDY

9 DP at cooling Damage Fills, Cleaning & removing of

tower & condenser damage nozzles, waste
waste bags
collecting
10 Evaporation i.e Distribution system, Proper maintenance
thermal efficiency fills, drift according to schedule
decreases eliminators, blade
angle i.e. air flow &
water flow
11 Air flow variations Thermal efficiency Blade angle should be
according to of cooling tower will change (max 19 degrees)
seasons decrease (i.e Delta T according to motor rating
will decrease)

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 Maintenance schedule
Description of Work Daily Weekly Mon Quart Half- Yearly As
thly erly Yearly Required
1
INSPECTION OF OIL LEVEL IN CT FANS √
2 SOUND AND VIBRATIONS OBSERVATIONS √
3 INSPECTION OF WATER DISTRIBUTION SYSTEM √
INSPECTION OF COUPLING BUSHES AND
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TIGHTENING BOLTS √
5
RISER VALVES CLEANING AND GREASING √
6 INSPECTION OF RCC DUCT, FILLS, DRIFT
ELIMINATORS, NOZZLES AND DISTRIBUTION
PIPES FOR CLOGGING √
7
GREASING OF MOTORS √
8 CHECK ALIGNMENT OF GEARBOX WITH MOTOR
AND FAN √
9
CT SUMP CLEANING √
10 PAINTING OF FANS, GEARBOX, SHAFTS AND 38
MOTOR √
 Maintenance schedule
Description of Work Daily Weekly Mon Quart Half- Yearly As
thly erly Yearly Required

11 SCREEN MESHES CLEANING AND PAINTING √

12 COMPLETE CHANGE OF SP 320 OIL √
13 CHECK FAN BLADE TIP CLEARENCE √
14 CHECK WATER LEVEL IN SUMP √
CHECK FOR LEAKAGE OF WATER FROM
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BASIN,VALVES,CONECTION PIPE LINES &
DISTRIBUTION SYSTEM √
16 CHECKING OF GEAR BOX TEETH ,VENT SHOULD
BE OPEN & OIL SEALS √
17 INSPECTION OF HOIST √
18 OVER HAULING √

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 Problems Faced by Operators
 Scale formation -
suspended solids form
deposits

 Corrosion -
electrochemical reactions
with metal surfaces

 Fouling - due to silt,

debris, algae

 Dissolved solids formation

which can rectified by
blow down 40
Problems Faced by Operators
 Nozzles clogging
 Screen meshes jamming cause DP
across cooling tower & intake channel
 Fills damaging due to high pressure &
clogging of nozzle by stones & other
material.

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 Water Composition Control
 Suspended solids levels checked by operators (< 10
Neflowmeter turbidity unit)

 Measured values compared to make-up water

concentrations (COC)

 Problem controlled by “blow down” (i.e., old water

replaced with new)

 Note: 1 ppm = 1 mg/litre.

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Water Composition Control (Solutions)

 Scale formation
– remove scale forming solids with softening agents
( Softening agents like phosphate base chemical 9272)
– prevent scale forming materials by addition of
chemicals
– Bio dispersant 9079
– Chlorine (oxidising biocides) kill micro organisms
– Non oxidising biocides (i.e sulphates) 9087,7106 is
used.

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Water Composition Control (Solutions)

 Corrosion
– add chemical inhibitors (adds thin film to metal)
( 9024)
 Sulphuric acid
– PH controlling

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Water Testing (by Operators)

 pH of water (7.7 to 7.9 )

 total dissolved solids (TDS) < 2000 µs/cm
 Sump level because for blow down
 chlorine concentration (< 0.2 ppm)
 screen checks
 Temperature, water & air flow distribution

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Sling Psychrometer

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Cooling tower Blade Failures

Caused due to
misalignment

It will not occur

when daily
vibrations &
sounds readings
noting according
to schedule
Here Blade tip
distance is also
important
Cooling tower Gear teeth Failures
High viscosity
oil should be
used
Backlash is the
major criteria i.e
the play,is
clearence or
motion in
between teeth
allow for
lubrication 48
END LECTURE!

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