INSTRUCTIONAL MANUAL FOR

EXPERIMENTAL WATER COOLING TOWER

OBJECTIVE:-

 Study of the heat & mass transfer in Water Cooling Tower for different
flow & thermodynamic conditions.

AIM:-

 To determine the overall heat transfer coefficient in a forced draft counter

current cooling tower.
 To measure Tower Characteristic parameter KV/L for various liquid and air flow
rates (L/G) in a counter-current Forced draft Cooling Tower.

INTRODUCTION:-

Water from condensers and heat exchangers is usually cooled by an air stream
in spray ponds or in cooling Towers using natural draft or forced flow of the air.
Mechanical draft towers are of the forced draft type, where the air is blown into the
tower by a fan at the bottom. The forced draft materially reduces the effectiveness of
the cooling.

THEORY:-

Water may be cooled by the air as its temperature is above the wet bulb
temperature of the entering air. Markel’s Theory is used which based on enthalpy
potential difference as the driving force.

For heat transfer operation: Each particle of water is assumed to be surrounded

by a film of air and the enthalpy difference between the film and the surrounding air
provides the driving force for the cooling process. Assume that liquid is warmer than
gas.
 For mass transfer operation: Each particle of water is assumed to be surrounded
by a film of air and the enthalpy difference between the film and the surrounding air
provides the driving force for the cooling process.

In the iterated from Markel’s equation can be written as:

Tower characteristic can be evaluated numerically by: -

hw1 = value of hw at temperature = T3 + 0.1 (T2 - T3)

hw2 = value of hw at temperature = T3 + 0.4 (T2 - T3)
hw3 = value of hw at temperature = T3 + 0.6 (T2 - T3)
hw4 = value of hw at temperature = T3 + 0.9 (T2 - T3)
ha1 = h1 + 0.1 (L/G) (T2 - T3)
ha2 = h1 + 0.4 (L/G) (T2 - T3)
ha3 = h1 + 0.6 (L/G) (T2 - T3)
ha4 = h1 + 0.9 (L/G) (T2 - T3)

And ∆hi = hwi – hai

The carrying of liquid with the gas stream is termed as Liquid Entrainment.
This may be to a high rate of air flow. This should be avoided to get better
performance. This can be avoided by following the Operational limit of the equipment.

Description of temp. Sensors are as follows:-

T1 = Water Bath temperature, OC.

T2 = Water Inlet temperature, OC.
T3 = Water Outlet temperature, OC.
T4 = Air Inlet dry bulb temperature, OC.
T5 = Air Inlet wet bulb temperature, OC.
T6 = Air Outlet dry bulb temperature, OC.
T7 = Air Outlet wet bulb temperature, OC.

DESCRIPTION:-

The apparatus is provided for the process of Forced draft counter current cooling of
hot water using air. The water to be cooled is heated in a heating tank using a
heater. It is then circulated; through a rota meter; to the top of the cooling tower
mounted over the heating tank. Cooled water is then re-circulated to the heating
tank. A blower is provided for the cooling air. A valve is provided in airline to regulate
the flow rate of air. There is an Orifice meter mounted with its taps connected to a
manometer to find the flow rate of air. A set of two temperature sensors is provided
at both inlet and outlet of air stream. These sensors gives Dry bulb & Wet bulb air
temperatures. The cooling tower is packed with Aluminium expanded wire mesh.

UTILITIES REQUIRED:-
  Water Supply & Drain
 Electrically supply: 1 phase, 220 V AC and 3 kW

TECHNICAL SPECIFICATION:-

Tower : Material Stainless Steel

Size – Cross Section 6”x6”, Height – 30”
Packing : Expanded wire mesh made of Aluminium
Air Flow Measurement : Orifice meter connected to U-tube manometer
Water Flow Measurement : Rota meter
Hot Water Tank : Material Stainless Steel, Double wall,
Insulated with ceramic wool
Hot water Circulation : Magnetic Pump made of Polypropylene to
Circulate Hot water. Maximum working
temperature is 85OC.
Heater : 1.5 kW
Temperature Sensors : 7 No.
Dry & Wet Bulb : RTD PT-100 type Sensors
Temp. Measurement
Control Panel Comprising Of:-
 Digital Temperature Controller : Range 0-200OC (for water tank)
 Digital Temperature Indicator : Range 0-200OC with multi-channel switch.
 With Standard make On/Off switch, Mains Indicator & Fuse etc.

A good quality painted rigid MS structure is provided to support all the parts.

EXPERIMENTAL PROCEDURE:-

1. Fill the heating tank with water, set the temperature with the help of D.T.C. and
switch on heater.
2. Switch on pump & blower after desired temperature achieved.
3. Set the flow rate of water.
4. Record the flow rate of water and manometer reading after steady state
achieved.
5. Record the temperatures.
6. Steps 3 to 5 may be repeated for different water & air flow rates within
operational range.
FORMULAE:

Head in terms of air m in air.

Flow rate of air m3/s

Mass flow rate of air kg/sec.

Flow rate of water kg/s

Liquid To Gas Ratio =

Cooling Co-efficient

From Enthalpy table, the enthalpy of entering air at a wet bulb temp T 2 (0F) is
h1= …………….. Btu/lb of air

0
Cooling Range, R = T2 - T 3 = C

0
Temperature approach = T5 - T 3 = C

Now tower characteristics

TEMPERATURE CONVERTION FORMULA

1. °C to °F = (°C × 9/5) + 32 = °F)

2. °F to °C = (°F - 32) x 5/9 = °C)
OBSERVATION & CALCULATIONS:-

DATE:


Diameter of Orifice, (d1) = 25mm

Diameter of pipe, (d2) = 50mm

Cross Section area of Orifice (a1) = 490.62*10-6m2

Cross Section area of Pipe (a2) = 1962.50*10-6m2

Coefficient of discharge Cd = 0.6

Density of Manometer Fluid (Water) w = 1000 kg/m3


Density of Air, a = 1.126 kg/m3

Height Of Packing = 0.75m

Rotameter Range (Qw) = 1 LPM (60 LPH)

g = 9.81 m/s2

OBSERVATION TABLE:-

S. No. T1 T2 T3 T4 T5 T6 R1(cm) R2(cm) QW (LPH)

1
2
3

Temperature & Enthalpy:-

T,0F hwi hai ∆hi = hwi - hai
T=T3 = h1 =
T=T3 + 0.1 (R) hw1 = ha1 = h1 + 0.1 (L/G)(R) =
T=T3 + 0.4 (R) hw2 = ha2 = h1 + 0.4 (L/G)(R) =
T=T3 + 0.6 (R) hw3 = ha3 = h1 + 0.6 (L/G)(R) =
T=T3 + 0.9 (R) hw4 = ha4 = h1 + 0.9 (L/G)(R) =

NOMENCLATURE:-

KaV/L = Tower characteristic or enthalpy transfer coefficient (lbm/hr-ft2)

Cd = Coefficient of discharge (Orifice)
d1 = Diameter of Orifice, mm
d2 = Diameter of pipe, mm
a1 = Cross Section area of Orifice, m2
a2 = Cross Section area of Pipe, m2
h1 = Enthalpy of entering air at a wet bulb temp T2 Btu/lb of air
∆hi = Enthalpy of air stream, kJ/kg
hai = Enthalpy of Saturation Temp. of Inlet water cooling, Btu/lb
hwi = Enthalpy of air – water vapour mixture at bulk temp, Btu/lb
L = Flow rate of water, kg/s
G = Mass flow rate of air, kg/s
Qa = Flow rate of air, m3/s
Qw = Water Flow rate of LPH
R = Orifice – Manometer reading (for air flow), m
g = Acceleration due to gravity, 9.81 m/s2
w = Density of Manometer Fluid (Water), kg/m3
a = Density of Air, kg/m3

PRECAUTIONS & MAINTENANCE INSTRUCTIONS:-

1. Heater should not be switched on before filling the water in heating tank.
2. Pump should not be switched on at low voltage.
3. Water in heating tank should be properly drained after experiment is over.

TROUBLESHOOTING:-

In case of any problem regarding operation of the apparatus; the apparatus should
be quickly switched off and electric supply should be cut off.

Electrical:

1. Electric Shock: It means that either earth wire inside the panel is loose or
there is no earth provided in the socket to switch the equipment is plugged. So,
make it sure that the equipment is earthed properly.
2. Display of ‘1’ on D.T.C./D.T.I.: It means sensors connections are loose.
Locate the point of loose connection and solder it properly.
3. No rise in temperature despite heater is ON: It means there is some loose
connection. Check out for the same and then either solder it or tight it,
whatever is applicable.

General:

Leakage: The point of leakage should be detected & the concerned part is tightened
properly. If the problem still persists then the part is removed & Teflon tape is
wrapped on the threads properly & the part is then refitted carefully.

REFERENCES:-

1. Perry, R.H., Chilton, C.H. (eds.): “The Chemical Engineers’ Handbook”, 5th
edition, pp 12/13-12/15, McGraw-Hill, NY, 1977.

2. Treybal, R.H.: “Mass Transfer Operations”, 3rd edition, pp. 259-261,

McGraw-Hill, NY, 1981.