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Cooling Tower Educational Stand 2008: Faculty of Engineering Cairo University Mechanical Power Departement
Cooling Tower Educational Stand 2008: Faculty of Engineering Cairo University Mechanical Power Departement
Cairo University
Mechanical Power Departement
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
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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
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:
- 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).
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).
2
Cooling Tower Educational Stand
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.
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.
3
Cooling Tower Educational Stand
Chapter 1
4
Cooling Tower Educational Stand
Chapter 1
5
Cooling Tower Educational Stand
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.
6
Cooling Tower Educational Stand
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.
7
Cooling Tower Educational Stand
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
Chapter 2
Pump:
-Power consumption:
0.7 KW.
-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.
Chapter 2
2. Armfield
10
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.
11
Chapter 2
3. P. A. Hilton
12
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.
13
Chapter 2
4. Edibon
14
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
15
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%.
Fig.(3.1) columnbody
Where:
ai: Air inlet density,kg/m3.
Pai: Air inlet pressure,kPa.
ai =
Pai
R Tai
m blower =
V blower = 13 m3 /min
m blower = V blower ai
yields
13
1.15
60
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
16
Chapter 3
m da =
0.24
1 + 0.01414
= 0.238 kg/s
mda
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.
m w = Vw w =
Where:
2 103
1000
60
m w = 0.0333 kg/s
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
17
Chapter 3
Note:
The cross section area at which the air pass equal to that thwe water pass in counter flow
L
cooling tower so =
G
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
G
L
G
L
G
= 0.17 (1)
= 0.24
L
KaV
KaV
L
KaV
L
= 0.27
= 0.36
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
yields
0.0997 V
= 0.17 V = 0.0568 m3
0.0333
A=
V=AY
0.0568
= 0.062 m2
0.9144
A 0.25 0.25 m2
So; the column dimensions will be 250250 900 mm3.
18
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.
Chapter 3
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
ai=0.01414 kg/kgda
hai=71.49 kJ/kg
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 = 0.7 kW
Q CT = m da (hao hai )
Twi Two
Twi Wbtai
50 45
100
45 23.9
= 23.697%
20
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:
: Water density, kg/m3
V: Water volume, m3
t: time need to heat the water, sec.
Q: Heaters power, kW
: Mass flow rate, kg/s
CP: water specific heat, kJ/kg K
T: Temperature difference, C
Q=1.5 kW
=
= 50 25 = 25
Cp=4.18 kJ/kg K
t=25 min.
21
Chapter 3
1.5 = 1000
Q =
4.18 25 = 0.0215 3
25 60
22
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
13
=A4
60
Aaround
A = .054167m2
drain
Acceptable velocity.
v=
13
60
= 2.222 ms
0.42 0.352
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.
1.1662 103 =
m evap =
1000 Vmakeup
1.5 60 60
Vmakeup
t
yields
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 =
m circulated =
1000 Vdrain
2.5 60
yields
Vdrain
t
Vdrain = 0.005 m3
The drain tank dimensions are shown in figure (3.2) the base inclination is to force the water to
be discharged from the pipe.
Chapter 3
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.
(1/30)
10000.07
Where is the water flow rate & A is the inner area of the pipe
= 4.7619 104 2
Then
V= 0.06578 m/sec
25
Chapter 3
Losses W.R.T. the velocity :
= + +
37 2
2 log
Also
2
2
.1
.0254
F = 0.26405
= 2.0634 103
= (1.25) 0.02542
4
_ = 6.3348104 2
= 8.2 102
=
=
= 0.0525 <
2 2 ( )2 2
+
+
2 2
2
0.29 (0.06968)2
12 1 (0.0525)2 2
3
+ 2.0634 10 +
2 9.81
2
= 6.1717 103
26
Chapter 3
Losses in make up tank:.
.
=
= 4.635 104 2
12 "
4 4.635 104
1000
= 3.659 103
= 0.5
=
=
2
1
0.0254
4 2
0.1 2
= 7.864
0.0254
1
37 2
2 log
= 0.554
= + + + + +
2 log
37
2
=
2
= 0.26405 , =
0.1
0.0254
Chapter 3
2 2.5 0.06572
=
=
= 5.5 104
2
2 9.81
2
,
2
24 0.06572
= 5.28 103
2 9.81
8.2(0.0659)2
=
= 1.8 103
2 9.81
0.9(0.26287)2
=
= 3.16975 103
2 9.81
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.
12
2
22
1
+ 1 +
=
+ 2 +
+
2
2
1 = .0657
(1 2 )
12 22
+ (1 2 ) +
=
2
2 = 18.83672
1 = 2.54
2 = 0.15
= 1.763
28
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.
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
29
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.
30
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
Width(cm)
40
25
Height(cm)
50
45
10
10
100
25
10
25
-
150
-
200
50
182
31
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
Thermocouple
RTD
Thermistor
Excitation
Self-Generating
External Required
External Required
Output Signal
millivolts
Ground/Noise/Error
Floating,
susceptibility to noise
Grounded, susceptible
to lead wire resistance
Grounded,
susceptible to lead
wire resistance
Signal
Increase with
temperature
Increases with
temperature
Decreases with
temperature if NTC,
Increases with PTC
Range
Pros
Inexpensive and
rugged
High Sensitivity
Cons
Floating measurement
requires careful
attention
Expense, Slow
Response Time, Low
Sensitivity, Self
Heating
Smaller
Temperature Range,
NonLinear, Self
Heating
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 + ( )]
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
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
2
= = 0
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
35
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.
=
0 =
= 0.06578 /
= 1.645 /
988 1.645 0.00508
=
= 15090.04
5.47 104
2
988
= 5.5169976 10
Chapter 4
= 3643.2
= 3.6432
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 =
0.1
0.53
= 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
Chapter 4
5-Data Acquisition
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
38
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
39
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
40
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 .
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.
41
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
42
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
at
at
Ttemperature (C)
Vvoltage
T=10C
T=70C
10 = 1.08 +
70 = 5.4 +
(1)
(2)
a=13.8889
b= -5
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
= 18 103 300
= 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
Vvoltage
at RH=15%
at RH=90%
15 = 0.9 +
90 = 5.4 +
(1)
(2)
a=16.66667
b= 0
44
Chapter 4
Fig. (4.16) snapshot from LABVIEW illustrating variation of humidity signal with voltage.
45
Chapter 4
6- Calibration
1. Humidity sensor
1.1. Inlet humidity sensor
Humidity sensor without
analog output
57
65
70
76
83
90
100
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
For the displays the calculated error = -5%, while the DAQ reading has a zero error = -26.5 %.
46
Chapter 4
2. Temperature sensor
Thermocouple K-Type C
30
40
50
60
70
80
90
100
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.
47
Chapter 5
Chapter Five
Bill of Materials and Cost
SERIAL
NO.
1
1.1
1.2
Item
no
100
101
103
1.3
1.4
105
109
1.5
1.6
2
2.1
2.2
200
203
2.3
2.4
3
4
4.1
5
5.1
5.2
5.3
5.4
300
400
401
406
500
501
502
Item name
Stand
Frame
Quan
tity
1
1
Make or
Buy
make
make
buy
wheels
Bords
Al edges
4
2
1
buy
buy
Staneless steel
Cutting cup set
1
1
buy
buy
Tanks
Metal sheets
Gaskets
1
1
make
make
buy
Teflon
Silicon
4
2
buy
buy
buy
Heaters
Column
Column body
cap
Metal
connections
Butter fly valve
Drain valve
Gate valve
3
1
1
1
6
1
1
1
make
make
make
buy
buy
buy
buy
Description &
Specifications
Material
price per
each(LE)
790.5
54.55
55
total price
(LE)
790.5
54.55
220
Formica
Aluminum
350
30
st.st
158.4
71.5
700
30
158.4
71.5
0
186.5
49.5
8
90
871.5
steel
steel
4 wheels carry up to 200
Kg
1.22x2.44 (m)
60x60 cm
steel
steel
186.5
49.5
2
45
0.5 KW,length=
,flange diameter=
dimensions 25x25x113 cm
dimensions 25x25x20 cm
290.5
P.V.C
P.V.C
P.V.C
3''
D=3/4'', Oriffice
Dia.=20mm
copper
720
0
0
720
0
0
0
60
60
0
33
33
48
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
1
1
3
2
1
20
1
2
2
1
1
1
1
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
1
1
1
6
buy
buy
buy
buy
buy
buy
buy
make
buy
buy
buy
buy
buy
buy
make
buy
buy
buy
make
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
880
0
230
35
56.35
120
0
0
1760
buy
880
1760
buy
2200
4400
205.7
0
411.4
230
35
56.35
120
2
2
2
2
buy
buy
PT 100
platinum
49
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
platinum
205.7
411.4
stainless
1100
200.2
1100
600.6
PT 100
buy
buy
PT 100
buy
7
1
1
1
1
1
1
1
1
13
50
5
buy
buy
buy
buy
buy
buy
16
12
12
12
12
12
16
12
12
12
12
12
buy
buy
buy
46.2
5.5
1.1
0.1
11
1540
46.2
5.5
14.3
5
55
3080
6 Amperes
buy
buy
2
1
1
1
1
1
buy
buy
buy
buy
6mm dia
buy
buy
buy
Project Total Cost
15
58.75
45
1155
0
15
58.75
45
0
1155
0
20871.375
L.E
50
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)
51
Cooling Tower Educational Stand
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.
52
Cooling Tower Educational Stand
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.
53
Cooling Tower Educational Stand
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.
54
Cooling Tower Educational Stand
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.
55
Cooling Tower Educational Stand
Chapter 6
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.
56
Cooling Tower Educational Stand
Chapter 6
57
Cooling Tower Educational Stand
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.
58
Cooling Tower Educational Stand
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.
59
Cooling Tower Educational Stand
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).
60
Cooling Tower Educational Stand
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).
61
Cooling Tower Educational Stand
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).
62
Cooling Tower Educational Stand
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)
63
Cooling Tower Educational Stand
Chapter 6
Fig. (6.37) assemble the air tank with water tank by means of screwed union and pipes.
64
Cooling Tower Educational Stand
Chapter 6
65
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
Tao
28.3
28.9
30.2
RHo%
79
79
82
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
66
Chapter 7
Relations:
To get the water mass flow rate using orifice equation
2
=
Where
= 1.9625 105 2
= 0.605
2 10 14.7
1000
) = 5.5172 () 107
(3 /sec
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.
67
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
0.4 3
0.4
0.7 3.9 0.7
4.4 4.1 2.8
=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
68
Chapter 7
Table between Air flow discharge (V*) versus butterfly opening angle ()
V*
10
20
30
40
50
60
70
0.1027
0.25
0.2
0.15
0.05
0
0
10
20
30
40
50
60
70
80
Butterfly angle
69
Chapter 7
70
Appendix
Appendices
71
Appendix
72
Appendix
73
Appendix
74
Appendix
75
Appendix
76
Appendix
77
Appendix
78
Appendix
79
Appendix
80
Appendix
81
Appendix
82
Appendix
83
Appendix
84
Appendix
85
Appendix
86
Appendix
Fill
Source
Type
Munters Crossflow
XF12560/15
Crossflow
XF19060
(Height)
hunters Counterflow
CF12060
Counterflow
CF19060
X 2
X 3
X 2
X 3
X 4
X 3
X 4
Ca
0.61
0.60
0.61
0.54
0.51
1
2
3
4
2
3
4
5
ma
0.19
0.23
0.23
0.20
0.20
0.22
0.23
0.54
0.51
0.77
0.80
0.80
0.78
0.77
0.46
0.49
8.16
14.10
7.31
7.09
17.10
0.20
0.54
E-09
E-09
E-09
E-09
E-09
E-09
E-09
0.433
0.210
0.428
0.371
0.358
0.739
0.622
1.665
1.849
1.705
1.757
1.665
1.682
1.701
1.08
0.93
0.80
0.71
0.50
0.50
0.49
0.45
0.25
0.14
0.12
0.13
0.16
0.09
0.04
0.08
0.75
0.86
0.88
0.87
0.84
0.91
0.96
0.92
44.10
4.15
1.32
2.29
1.01
0.67
0.76
1.28
E-12
E-12
E-12
E-12
E-09
E-09
E-09
E-09
0.305
0.175
0.148
0.148
0.272
0.209
0.257
0.240
2.545
2.944
3.103
3.019
2.065
2.180
2.120
2.070
87
Appendix
KaV/L
Figure (1), Counterflow tower charachteristic curves (wet-bulb temperature 69 F and cooling
range 26 F),
88
Appendix
69 W E T B U L B (F)
22 RANGE (F)
Figure (2), Counterflow tower charachteristic curves (wet-bulb temperature 69 F and cooling
range 22 F),
89
Appendix
69 W E T B U L B (F)
18 RANGE (F)
Figure (3), Counterflow tower charachteristic curves (wet-bulb temperature 69 F and cooling
range 18 F),
90
Appendix
91
Appendix
92
Appendix
93
Appendix
94
Appendix
95
Appendix
96
Appendix
97
Appendix
98
Appendix
99
Appendix
100
Appendix
101
Appendix
102
Appendix
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
103
Appendix
104
References
References:
105