ABSTRACT

Water cooling tower experiment is a model of cooling tower that is being used in
industries processes. The purpose of this experiment is to study the performance at different
water flow rate and temperature of water cooling tower. Besides, this experiment was also
conducted to perform energy and mass balance on the cooling tower system. By changing the
parameter on the cooling tower, it will affect the cooling performance of the cooling tower. In
this experiment, the parameters that can be changed are temperature and water flow rate of
the cooling tower. In the first experiment, the water flow rate was constant and the heater
power were changes while in the second experiment, the water flow rate were changes and
the heater power was constant. The energy and mass balance equations were employed to
give an insight on the amount of energy transferred between phases under different
conditions.

INTRODUCTION

A cooling tower is a specialized heat exchanger in which air and water are brought
into direct contact with each other in order to reduce the water's temperature. As this occurs,
a small volume of water is evaporated, reducing the temperature of the water being circulated
through the tower.

Generally, in industry, water, which has been heated by an industrial process or in an

air-conditioning condenser, is pumped to the cooling tower through pipes. The water sprays
through nozzles onto banks of material called "fill," which slows the flow of water through
the cooling tower, and exposes as much water surface area as possible for maximum air-
water contact. As the water flows through the cooling tower, it is exposed to air, which is
being pulled through the tower by the electric motor-driven fan.

When the water and air meet, a small amount of water is evaporated, creating a
cooling action. The cooled water is then pumped back to the condenser or process equipment
where it absorbs heat. It will then be pumped back to the cooling tower to be cooled once
again.

Cooling towers are used in a variety of applications from the 400 foot tall towers at
nuclear power plants to small 4 foot cooling boxes used by neighborhood dry cleaners. The
most common use is in large building central cooling systems, but also used for refrigeration,
cold storage facilities, dry cleaning, medical equipment, manufacturing and industry.
Cooling towers are generally the most efficient means to remove large amounts of heat from
air and equipment.
 However in this experiment, the laboratory cooling tower used is a cooling tower unit
from a commercial air conditioning system in order to study the principles of cooling tower
operation. It is used along with a residential size water heater to simulate a cooling tower
used to provide cool water to an industrial process. The cooling tower process load is
provided by the water heater. The laboratory cooling tower allows for complete control of the
speed of the fan used in cooling the warm return water and the pump used to return the
cooled water to the water heater.

Experiment is conducted by firstly adjusting and controlling the heater from 0.5kW,
1.0kW and 1.5kW at constant water flow rate of 1.7 LPM. This Part 1 experiment is being
carried out to investigate the effect of different the power of heater toward cooling range of
cooling tower. Meanwhile, in the second experiment, water flow rate is varied from 0.8 LPM,
1.0 LPM, and 1.2 LPM at 1.0 kW heater. This Part 2 experiment is done to study the effect of
cooling range toward different water flow rate.

OBJECTIVE

To study the performance at difference ranges cooling load and inlet temperature of cooling
tower.

THEORY

As according to the First Law of Thermodynamic, which is the conservation of energy stated
that energy can neither be created nor destroyed. Energy just transform from one form to
another form. This law applied into this experiment. Energy that enters into the equipment
which is the cooling tower is in form of hot water and it will cold from temperature T1 to
temperature T2. The cooling process of hot water in this experiment was in the form of
forced convection 3 by which ambient air at T1 was blown over the hot water and exited the
cooling tower at temperature T2. Other energy contributions in the equipment such as heat
generation from friction of both air and water, energy losses from pipes, and others are
ignored. The main component of the energy balance is enthalpy which defined as;

H = U + PV

Where: H is enthalpy

U is internal energy

P is pressure

V is volume
Enthalpy can either be calculated from the equation above or can be referenced from the table
of data for the fluid being used. The enthalpy of the output cooled water can be calculated
from the energy balance;

Ʃ Δ H in = Ʃ Δ H out

The enthalpy of water enters and exit the cooling tower can be determined by using the
enthalpy of saturated liquid water in a steam table.

Δ H water = Δ H water out + Δ H water in

The change in enthalpy of air can be determined from either two methods. First, by treated air
as an ideal gas since the air is at low pressure, the enthalpy can be calculated from the
equation below;

Δ H = Cp ΔT

Where: Δ H is the change in enthalpy

ΔT is the change in temperature

Cp is the specific heat

Other method for determined the change in the enthalpy of air can be determined by using the
same way as used for water.

Δ H air = Δ H air out + Δ H air in

Since water enter the cooling tower and release heat, the change in enthalpy of water should
have negative value while enthalpy of air should have positive value as it absorb heat from
water. Theoretically, when the values of the enthalpy change of water and enthalpy change of
air add up together, it should get zero as the First Law of Thermodynamic stated;

Δ H water = Δ H air

Δ H water + Δ H air = 0
 APPARATUS

3
7
4
8

5
9
6
10

1. Orifice
2. Water distributor
3. Packing Column
4. Flow meter
5. Receiver Tank
6. Air Blower
7. Make-up tank
8. Differential Pressure Transmitter
9. Load Tank
10. Control Panel.
PROCEDURE

General start up:

1. Check the valves V1, V6 and V7 and ensure that the valvesV1 and V6 are close while
valve V7 partially open.
2. Fill the load tank with dionized water. Firstly, remove the makeup tank and pour the
deionized water through the opening at the top of the load tank. Replace the makeup
tank onto the load tank and lightly tight the nuts. Then, fill the tank with deionized
water up to the zero mark and the scale.
3. Add the deionized water to the wet bulb sensor reservoir to the fullest.
4. Connect all the appropriate tubing to the differential pressure sensor.
5. Install the appropriate cooling tower packing for the experiment.

Part 1: Heat as the manipulated variable

1. Set the temperature controller up to 45 ̊ c. Switch on the 1.0kW water heater and heat
the water up to 40 ̊ c.
2. Switch on the pump and slowly open the control valve V1 and set the flowrate to
1.7LPM.
3. Fully open the damper and switch on the fan.
4. After the water already went through the cooling tower, switch on the blower.
5. Run the experiment for 20minutes to ensure that float valve correctly adjusted the
level in the load tank. Refill the makeup tank as required.
6. Set the damper and flowrate to be constant.
7. Switch off the 1.0kW water heater to set power as 0kW.
8. After 10minutes leaving the unit to stabilized, record all the data required.
9. To measure the differential pressure across the orifice, valves V4 and V5 are open
while valves V3 and V6 are close.
10. To measure the differential pressure across the column, valves V3 and V6 are open
while valves V4 and V5 are close.
11. Repeat steps 1 until 10, set the water heater to 0.5kW and 1.5kW.

Part 2: Water flowrate as the manipulated variable

1. Set the temperature controller up to 45 ̊ c. Switch on the 1.0kW water heater and heat
the water up to 40 ̊ c.
2. Switch on the pump and slowly open the control valve V1 and set the flowrate to
0.8LPM.
 3. Fully open the damper and switch on the fan.
4. After the water already went through the cooling tower, switch on the blower.
5. Run the experiment for 20minutes to ensure that float valve correctly adjusted the
level in the load tank. Refill the makeup tank as required.
6. Set the damper and heater power to be constant.
7. Switch off the 1.0kW water heater to set power as 0kW.
8. After 10minutes leaving the unit to stabilized, record all the data required.
9. To measure the differential pressure across the orifice, valves V4 and V5 are open
while valves V3 and V6 are close.
10. To measure the differential pressure across the column, valves V3 and V6 are open
while valves V4 and V5 are close.
11. Repeat steps 1 until 10, set the water flowrate 1.0LPM and 1.2LPM.

RESULT

Part 1: Heat as the manipulated variable

Column: C Water Flowrate: 1.7 LPM Blower: Fully opened

Heater (KW) 0.5 1.0 1.5

Air inlet dry bulb, T1 (°C) 28.6 28.7 28.9
Air inlet wet bulb, T2 (°C) 29.6 29.3 29.5
Air outlet dry bulb, T3 (°C) 25.4 25.5 27.3
Air outlet wet bulb ,T4 (°C) 27.2 26.5 27.6
Water inlet temp, T5 (°C) 29.8 32.4 36.4
Water outlet temp, T6 (°C) 25.0 25.1 26.3
Heater power (W) 500 1000 1500
Dp orifice (Pa) 73 73 72
Dp column (Pa) 75 73 86
Part 2: Water flowrate as the manipulated variable

Column: C Heater: 1.0 kW Blower: Fully opened

Water flowrate(LPM) 0.8 1.0 1.2

Air inlet dry bulb, T1 (°C) 28.8 29.0 29.2
Air inlet wet bulb, T2 (°C) 29.7 29.3 29.4
Air outlet dry bulb, T3 (°C) 25.9 26.0 25.6
Air outlet wet bulb ,T4 (°C) 26.7 26.8 27.0
Water inlet temp, T5 (°C) 39.1 38.3 36.0
Water outlet temp, T6 (°C) 25.0 25.0 24.9
Heater power (W) 1000 1000 1000
Dp orifice (Pa) 75 74 73
Dp column (Pa) 63 65 68
CALCULATION

Part 1: Heat as the manipulated variable

Water flowrate constant: 1.7 LPM Variable: Heater

Change in temperature for each power supply, ΔT (cooling range)

= Water inlet temp, T5 – Water outlet temp, T6

For power = 0.5 kW;

ΔT = T5 – T6

= 29.8 – 25

= 4.8 °C

For power = 1.0 kW;

ΔT = T5 – T6

= 32.4 – 25.1

= 7.3 °C

For power = 1.5 kW;

ΔT = T5 – T6

= 36.4 – 26.3

= 10.1 °C
Part 2: Water flowrate as the manipulated variable

Density of water = 1000 kg/𝑚3

Cp = 4.186 kJ/kg.°C

1 LPM = 0.01667 kg/s

Heat load, Q = mCpΔT

For water flowrate = 0.8 LPM;

0.8 LPM = 0.0133 kg/s

ΔT = T5 – T6

= 39.1 – 25

= 14.1 °C

Q = mCpΔT

= (0.0133)(4.186)(14.1)

= 0.7850 kW

For water flowrate = 1.0 LPM;

1.0 LPM = 0.01667 kg/s

ΔT = T5 – T6

= 38.3 – 25

= 13.3 °C

Q = mCpΔT

= (0.1667)(4.186)(13.3)

= 0.9280 kW

For water flowrate = 1.2 LPM;

1.2 LPM = 0.0200 kg/s

ΔT = T5 – T6

= 36 – 24.9

= 11.1 °C
Q = mCpΔT

= (0.0200)(4.186)(11.1)

= 0.9292 kW

Water flowrate (LPM) Heat load, (kW) Cooling range, (°C)

0.8 0.7850 14.1
1.0 0.9280 13.3
1.2 0.9292 11.1
DISCUSSION

There are two part of experiment were conducted. The first one is experiment 1where
as the aims is to study the effect of various of the heater’s power with constant water flowrate
and blower speed, toward cooling range while in experiment 2, aims is to study the effect of
cooling range, which have constant the power of the heater and the blower speed, towards
different water flowrate. From this experiment, Column C is being used of the Water Cooling
Tower HE152 unit. The mechanism for this process of removing heat from water is by
evaporates a little amount of water that flow through the equipment. To understand the aims
of these experiments, there are some expressions that being used for this experiment which
are cooling range, wet bulb temperature, approach, heat load. Cooling range is defines as the
difference in temperature between hot water entering the tower and the cold water leaving the
tower. Next, wet bulb temperature is the lowest temperature that water can start to evaporate.
The third one is approach which is the difference between the temperature of the cold water
leaving the tower and the wet bulb temperature of the air. The last one is heat load which is
the amount of heat that is needs to be removed from the tower. In the experiment 1, constant
value of the blower speed which is fully opened, a constant value of water flowrate which is
0.7 LPM with three value of heat of the heater which are 0.5 kW, 1.0, kW and 1.5 kW are
being used which gives a cooling range of 4.8°C, 7.3°C and 10.1°C respectively. This results
show that when the heat provided towards the tower from the heater increase while the
blower speed and the water flowrate at constant, the cooling range will be increase.
Meanwhile in the experiment 2, a constant value of heat which is 1.0 kW, a constant blower
speed which is fully opened with three value of water flowrate which are 0.8 LPM, 1.0LPM
and 1.2 LPM is used. From the results we found out that the cooling range become decrease
as the water flowrate increase which are 14.1°C, 13.3°C, and 11.1°C respectively. The reason
of this happens because as the water flow faster, the time of the transfer of heat between two
medium become shorter and some of the heat does not have enough time to be in equilibrium.
So that is why the cooling range becomes lower. Heat load were calculated for each of the
flowrate and found out that the heat load value increase as the water flowrate decrease which
are 0.7850 kW, 0.9280 kW, 0.9292 kW. The reason of why heat load increase in value is
because as the cooling range become lower, the heat that is needs to be removed from the
cooling tower have to be higher. The results of both of the experiments shows a successful
results as it does prove with the theory and the logical thinking of what happen when heat
from the heater varies with a constant value of water flowrate and water flowrate varies with
a constant value of heat of the heater.
CONCLUSION

In this experiment, it is concluded that this experiment is successfully conducted

because the objective of this experiment had achieved. In the first part of this experiment
which is the water flow rate was constant and the heater power were changes, it can be
concluded that if the value of the heater power is increasing, the temperature of the cooling
range in the cooling tower will also increase. Besides, in the second experiment which is the
water flow rate were changes and the heater power was constant, it can be concluded that
when the water flow rate is increase, the energy in the form of heat transfer is decrease.

RECOMMENDATION

A few recommendations should be done to improve the accuracy and precision of result.
There are:

1. Alert to the time taken of every ten minutes running so that no error in recording the
result.
2. Since the result of cooling tower experiment are sensitive to the change in temperature,
therefore it is recommended to keep the tower insulated so that no lesser heat lost to
the surrounding.
3. A better water tank heater with temperature control is recommended in cooling tower
experiment as the results are dependent on temperature of water.
4. The humidity recording devices were not working properly. Recalibrated or replaced
so that more accurate and timely measurements of humidity can be made.
5. Pressure tubing for differential pressure measurement are always check and made sure
to be connected correctly and tightly to prevent leakage so that accurate differential
pressure measurement is obtained.
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APPENDIX

Cooling Tower Equipment

Blower
 Rotameter

Indicator