densing medium includes both the heat
absorbed in the evaporator and the heat of
14
Condensers and
Cooling Towers
14-1. Condensers. Like the evaporator, the
condenser is a heat transfer surface. Heat
from the hot refrigerant vapor passes through
the walls of the condenser to the condensing
medium. As the result of losing heat to the
condensing medium, the refrigerant vapor is
first cooled to saturation and then condensed
into the liquid state.
Although brine or direct expansion refrig
erants arc so_mctimes used as condensing
mediums in low temperature applications, in
the great majority of cases the condensing
medium employed· is either air or water, or a
combination of both.
Condensers arc of three general types:
(I) air-cooled, (2) water-cooled, and (3)
evapo rative. Air-cooled condensers employ
air as the condensing medium, whereas water-
cooled condensers utili7.C water to condense
the refrigerant. In both the .air-cooled and
water cooled condensers, the heat given off by
the condensing refrigerant increases the
temperature of the air or water used as the
condensing medium.
Evaporative condensers employ both air and
water. Although there is some increase in
the temperature of the air p;wing through the
condenser, the cooling of the refrigerant in the
condenser results initially from the evaporation
of the water from the surface of the
condenser. The function of the air is to
increase the rate of evaporation by carrying
away the water vapor which results from the
evaporating process.
14-2. The Condenser Load. Since the heat
compres sion, the heat load on the condenser
always exceeds that on the evaporator by an
amount equal to the heat of compression.
Since the work (heat) of compression per unit
of refrig erating capacity depends upon the
compression ratio, the heat load on the
condenser per unit of evapo tor load varies
with the operating conditions of the system.
The quantity of heat. liberated at the con
denser per minute per ton of evaporator
capacity at various suction and condensing
temperatures can be estimated from Charts 14-
1,. 14-2, and 14-3. Chart 14-1 applies to R-
12 systems, whereas Charts 14-2 and 14-3
apply to R-22 and R-717 (ammonia) systems,
respec tively. The values given are based on a
simple saturated cycle.
Example 14-1. An R-12 system, operating
at a 15° F suction temperature, has a condens
ing temperature of 100° F. Determine the
load on the condenser in Btu per minute per
ton.
Solution. In Chart 14-1, locate the 15° F
suction temperature line at the base of the
graph. Follow the line until it intersects the
100° F condensing temperature curve. The
value on the left-hand index corresponding to
this point is approximately 245 Btu per
minute per ton.
It is evident that for any given set of
operating conditions there is a fixed
relationship between the condenser load and
the evaporator load. For instance, for the R-12
system described in Example 14-1, the
relationship between the condenser load and
the evaporator load is such that 245 Btu are
liberated at the condenser for each 200 Btu
taken in at the evaporator.
Once the relationship between the
condenser load and the evaporator load has
been estab lished for any given set of operating
conditions, the total condenser load
corresponding to ariy given total evaporator
load can be easily computed. The following
equation may be used:
q.
Q. = Q. X - (14-1)
q .
given up by the refrigerant vapor to the con-
where Q. -= the condenser load in Btu/hr Btu/min/ton (from Fig. 14-15)
Q. -= the evaporator load in Btu/hr q. -= the evaporator load in
q. -= the condenser load in Btu/min/ton (always 200 Btu)
l-44

NOTE: Q. may also be in Btu/min or in
tons, in which case Qc will be in Btu/min or in
tons, respectively.
Example 14-2. For the system described in
Example 14-1, determine the load on the con
denser if the load on the evaporator is 35,000
Btu/hr.
Solution. Applying
Equation 14-1, the = 35,000 X
load on the condenser, 245/200
Qc
= 42,875 Btu/hr
It is important to notice that any increase or
decrease in the load on the evaporator
(system) will result in a proportional increase
or decrease in the load on the condenser.
14-3. Condenser Capacity. Since heat trans
fer through the condenser walls is
byconduction, condenser capacity is a function
of the funda mental heat transfer equation:
Q=AxUxD (14-2)
where Q = the condenser capacity (Btu/hr)
A = the surface area of the condenser
(sq ft)
U = the transfer coefficient of the con
denser walls (Btu/hr/sq ft/° F)
D = the log mean temperature difference where T1 = the temperature of the; air or water
between the condensing
refrigerant and the condensing
medium
Examination of the factors in Equation 14-2 (T2 - Ti) == the temperature rise (AT) experi
will show that for any fixed value of U
the capacity of the condenser depends on the
surface area of the condenser and on the
temperature difference between the
condensing refrigerant and the condensing
medium. It is evident also that for any one
condenser of specific size and design, wherein
the surface area and the U factor are both fixed
at the time of manufacture, the capacity of the
condenser depends only on the temperature
differential between the refrigerant and the
any given condenser load (Q,), Equation 14-2
condensing medium. Therefore, for any one
contains only two variables, M and AT, the
specific condenser, the capacity of the
value of each being inversely proportional
condenser is increased or decreased only by
to the value of the other, viz:
increasing or
decreasing the temperature differential.
Further more, if it is assumed that the average
tempera ture of the condensing medium is
constant, it follows that an increase or a
decrease in the capacity of the condenser is
brought about only
by an increase or a decrease, respectively, in
CONDENSERS AND COOLING TOWERS 2-45
Since the condenser capacity must always
be equal to the condenser load, it is evident
from the foregoing that, for any given
condensing load, the larger the surface area of
the condenser, the smaller will be the required
temperature differential and the lower will be
the condensing temperature. Too, since the
load on the condenser is always proportional
to the load on the evaporator (system), any
increase or decrease
in the load on the evaporator will be reflected by
an increase or a decrease, respectively, in the
condensing temperature.
14-,4, Quantity and Temperature Rise of
Condensing Medium. In both the air-cooled
and water-cooled condensers, all the heat
given off by the condensing refrigerant
increases the temperature of the condensing
medium. There fore, in accordance with
Equation 2-8, the temperature rise experienced
by the condensing medium in passing through
the condenser is directly proportional to the
condenser load and inversely proportional to
the quantity and specific heat of the
condensing medium, viz:
Q,
(Ta - T1) =M x C (14-3)
entering the condenser (T,)
T2 = the temperature of the air or water
leaving the condenser (T1)
enced in the condenser
Q, = the load on the condenser in Btu
per hour
M = the weight of air or water
circulated
through the condenser in pounds
per hour
C = the specific heat at constant
pressure of the air or water
Assuming that C has a constant value, for
Q. (14-4)
M=CxAT
AT= (14-5)
C xM
the
condensing temperature. Therefore, for any given condenser load, if
the temperature rise of the condensing medium
246 PRINCIPLES OF REFRIGERATION

is known, the quantity of condensing medium convert from pounds per minute to cubic feet
circulated through the condenser in pounds per minute, viz:
per hour can be determined by applying M(lb/hr) x v(cu ft/lb)
Equation 14-4. Likewise, if the quantity cfm =- .
circulated is known, the temperature rise 60 m m
through the con denser can be computed by Assuming the specific volume of the air to be
applying Equation 14-5. the specific volume of standard air (13.34 cu
Average specific heat values for air and ft/ lb), incorporation of these conversion
water are 0.24 Btu/lb and 1 Btu/lb, factors into Equation 14-7 results in the
respectively. By substituting the appropriate following:
value for C, Equations 14-4 and 14-5 can be . Q, x 13.34 cu ft/lb
written to apply specifically to either water or cfm ... 0.24 x 60 x b.T
air, viz: or, combining constants (13.34/0.24 x 60 =

for water M=- Q, 1/1.08),

(14-6) Q, )
b.T
cfm = 1.08x b.T (14-11
.
a. T = Q, (14-7) Example 14-3. If the load on a water
M cooled condenser is 150,000 Btu/hr and the
M= Q, (14-8) temperature rise of the water in the condenser
and for air
0.24 X b.T is 10° F. What is the quantity of water cir
Q, culated in gpm?
(14-9)
= 0.24
-
b.T xM Solution. Applying Equation 150,000
14-10, the water quantity in 500 X 10
Since general practice is to express air and gpm
water quantities in cubic feet per minute (cfm) =- 30 gpm
and in gallons per minute (gpm), respectively, Example 14-4. The)oad on a water-cooled
it is usually desirable to compute condensing condenser is 90,000 Btu7hr. If the quantity of
medium quantities in these units rather than in water circulated through the condenser is IS
pounds per hour. gallons per minute, determine the temperature
To ,convert pounds of water per hour into rise of the water 41 the condenser.
gallons per minute, divide by 60 min to Solution. Rearranging and
reduce pounds per hour to pounds per minute, 90,000
applying Equation 14-10, b.T = 500 X 15
and then divide by 8.33 lb per gallon to
convert pounds per minute to gallons per =- 12° F
minute, viz:
M(lb/hr) Example 14-5. Thirty-six gallons of water
gpm = - - - - - - per minute are circulated through a water
60 min x 8. 33
- cooled condenser. If the temperature rise of
l b / g al the water in the condenser is 12° F, compute
If these conversion factors are incorporated the load on the condenser in Btu/hr.
into Equation 14-6, the water quantity can be Solution. Rearrang
computed directly in gpm. The following
equa
tion results: ingand applying Equa = 500 X b.T X gpm
Q, tion 14-10, the load = 500 X 12 X 36
gpm ""' 60 X 8.33 X b.T on Q,the condenser, = 216,000 Btu/hr
or, combining constants (60 x 8.33 - 500), Example 14-6. The load on an air-cooled
condenser is 121,500 Btu/hr. If the desired
(14-10) temperature rise of the air in the condenser is
gpm- 500 >< b.T 25° F, determine the air quantity in cfm which
To reduce pounds of air per hour to cubic must be circulated over the condenser.
Solution. Apflying Equa
feet per minute, divide pounds per hour by 60 min to determine pounds per m inute and
then tion 14-11, the air quantity in
cfm ... 1.08
121,500
X 25
multiply by the specific volume of the air to - 4500cfm
 CONDENSERS AND COOLING TOWERS 247

I
Condensing temperature
t
1100·
!
Mean effective l
Flt• 14-1. Water temperature temperature J Leaving waier temperature 92°-.Water out
difference ,· - ----------
(13.84")

,
rise through condenser. _t -.- Average water temperature L86.1 •
I , .
Temper ture
nse m
1 condenser

i
1
Water in Entenng water temperature 1a•

I,..•--- Flow through condenser---.!•'

Example 14-7. Three thousand cfm of air

are circulated over an air-cooled condenser. If greater the flow rate of the condensing
the load on the condenser is 64,800 Btu/hr, medium the lower will be the condensing
compute the temperature rise of the air temperature. 14-5. Condenser Appllcatlon.
passing over the condenser. As a general rule, for any given condenser
load, the size of the condenser and the
quantity of condensing
Solution. Rearranging and medium circulated will depend upon the
applying Equation 14-11, b.T 64,800
=---
1.08 X 3000
entering temperature of the condensing
medium and upon the desired condensing
-
= 20°F temperature. A careful analysis of the data in
Sections 14-3
For any given condenser and condenser medium. There fore, for any given
loading, the condensing temperature of the condenser loading, the
refrigerant in the condenser will depend only
upon the average temperature of the con
densing medium flowing through the condenser.
The lower the average temperature of the con
densing medium the lower is the condensing
temperature. For example, assume that the
size and loading of a condenser are such that
the required mean temperature differential
between the refrigerant and the condensing
medium is IS° F. If the average temperature
of the condensing medium is 90° F, the
condensing
temperature will be 105° F (90 + IS), whereas
if
the average temperature of the condensing
medium is 85° F, the condensing temperature
will be 100° F (85 + IS).
The average temperature of the condensing
medium flowing through the condenser
depends upon both the initial temperature of
the condensing medium entering the condenser
and the temperature rise experienced in the
con denser. Since the temperature rise of the
condensing medium decreases as the flow rate
increases, the greater the quantity of
condensing medium circulated the lower is the
average temperature of the condensing
 CONDENSERS AND COOLING TOWERS 248
and 14-4 will show that the condensing
tempera ture of the refrigerant in the
condenser is a function of three variables: (I)
the entering temperature of the condensing
medium, (2) the temperature rise in
thecondenser, and (3) the temperature
difference between the refrigerant and the
condensing medium. This relationship is
illustrated in Fig. 14-1.
Recalling that the temperature rise in the
condenser varies inversely with the flow rate
of the condensing medium and that the
tempera ture differential between the
refrigerant and the condensing medium varies
inversely with the size (surface area) of the
condenser,• it is evident that:
I . For any given condensing surface and
flow rate, the condensing temperature will
increase or decrease as the entering
temperature of the condensing medium
increases or de creases.
2. For any given entering temperature, the
larger the condensing surface and the higher
the flow rate, the lower will be the
condensing temperature.
3. For any given entering temperature, the
• Assuming the transfer coefficient to be con
stant.
2'48 PRINCIPLES OF REFRIGERATION
amount of condensing surface required for a
given condensing temperature decreases as the
flow rate of the condensing medium increases.
With regard to the latter statement, this
means in effect that the same condensing
temperature can be maintained with either a ·
small condensing surface and a high flow rate
or a large condensing surface and a low flow
rate. However, it should be recogni7.ed that
the flow rate of the condensing medium is
fixed within certain limits by the size and
design of the condenser. If the flow rate
through the condenser is too low, flow will be
streamlined rather than turbulent and a low
transfer coeffi cient will.result. On the other
hand, if the flow rate is too high, the pressure
drop through the condenser becomes
excessive, with the result that the power
required to circulate the con densing medium
also becomes excessive.
Since the design entering temperature of the
condensing medium is usually fixed by condi
tions beyond the control of the system
designer, it follows that the size and design of
the con denser and the flow rate of the
condensing medium are determined almost
entirely by the design condensing temperature.
Although low condensing temperatures are
desirable in that they result in high compressor
efficiency and low horsepower requirements
for the compressor, this does not necessarily
mean that the use of a large condensing
surface and a high flow rate in order to
provide a low con densing temperature will
always result in the most practical and
economical installation. Other factors which
must be taken into account and which tend to
limit the size of the condenser and/or the
quantity of condensing medium circulated
are initial cost, available space, and the power
requirements of the fan, blower., or pump
circulating the condensing medium. Too,
where water is used as the condensing
medium and the water leaving the condenser
is wasted to the sewer (see Section 14-9), the
availability and cost of the water must also be
considered. The limitations imposed on
condenser size by the factors of initial cost
and available space are self-evident. As for
the power requirements of the fan, blower,
or pump circulating the condensing medium,
it has already been stated that the power
required to circulate the con densing medium
increases as the flow rate
CONDENSERS AND COOLING TOWERS 249
increases. If the flow rate is increased beyond
a certain point, the increase in the power
required to circulate the condensing medium
will more than offset the reduction in the
power require ments of the compressor
accruing from the increased flow rate.
Therefore, the quantity of condensing medium
which can be economically circulated is
limited by the power requirements of the fan,
blower, or pump.
Obviously, the optimum flow rate for the
condensing medium is the one which will
result in the lowest over-all operating costs for
the system. This will vary somewhat with the
conditions of the individual installation, being
influenced by the type of application, the size
and type of condenser used, fouling rates, and
the design conditions for the region, along
with such practical considerations as the cost
and availability of water, utility costs, local
codes and restrictions, etc. For example, since
good system efficiency prescribes lower
condensing temperatures for low temperature
applications than for high temperature
applications, it follows that for the same
condenser load the optimum condensing
medium flow rate will usually be higher for a
low temperature appli cation than for a high
temperature application. Too, where the
entering temperature of the condensing
medium is relatively high, larger condensing
surfaces and higher flow rates are required
to provide reasonable condensing
temperatures than where the entering tempera
ture of the condensing medium is lower.
14-6. Air-Cooled Condensers. The circula
tion of air over an air-cooled condenser may
be either by natural convection or by action
of a fan or blower. Where air circulation is
by natural convection, the air quantity
circulated over the condenser is low and a
relatively large condensing surface is
required. Because of their limited capacity
natural convection con densers arc used only
on small applications, principally domestic
refrigerators and freez.ers. Natural convection
condensers employed on domestic
refrigerators are usually either plate surface
or finned tubing. When finned tubing is used,
the fins are widely spaced so that little or no
resistance is offered to the free circulation of
air. Too, wide fin spacing reduces the
possibility of the condenser being fouled with
dirt and lint.
The plate-type condenser is mounted on the
 CONDENSERS AND COOLING TOWERS 249
back of the refrigerator in such a way that an limitation in physical size, chassis-mounted
air flue is formed to increase air circulation.
condensers of the type shown in Fig. 6-12 are
Finned tube condensers are mounted either on
rarely found in capacities larger than 2 tons.•
the back of the refrigerator or at an angle
Another disadvantage of the chassis-mounted
underneath the refrigerator. Regardless of
air-cooled condenser is their susceptibility to
condenser type or location, it is essential that
fouling. Since most condensing units are
the refrigerator be so located that air is
mounted on the floor, the condenser air tends
permitted to circulate freely through the
to sweep across the floor so that dirt, lint, and
condenser at al} times. Too, warm locations,
other foreign materials are picked up from the
such as one adjacent to an oven, should be
floor and carried to the surface of the
avoided when ever possible.
condenser, thereby "clogging" the condenser
A number of domestic free7.er
and restricting
manufacturers uti1ilize the outer shel1 of the
the air flow.
freezer (outside wal1 surface) as a condensing
Too, on "open-type" air-cooled condensing
surface. This is accomplished by bonding
units the condenser fan is usually mounted on
bare tubing to the inside surface of the outer
the shaft of the compressor driver (Fig. 6-12).
sheU so that the entire outer shell becomes a
Natural1y this limits both the size and the
plate-type heat transfer surface. The use of
location of the fan so that the quantity of air
these "wrap around" condensers permits a
circulated over the condenser is always less
considerable reduction in the size of the
than that which would produce maximum
freezer (6 to 8 in. on both length and width),
efficiency at fu]] load conditions. Notice also
not only because it eliminates the space
that, because of the fan location, the distri
ordinarily required for the condenser but also
bution of the air over the condenser surface is
because it allows the use of
very uneven, being much greater on the end of
3 to 4 in. of insulation in the walls where
the condenser directly in front of the fan.
normal1y 6 to 8 in. is required in order to
Remote air-cooled condensers are used in •
prevent moisture from condensing on the
sizes from 1 ton up to 100 tons or more and
outside surface of the freezer. The slightly
may be mounted either indoors or outdoors.
higher operating costs which accrue as a result
When located indoors, provisions must be
of reducing the amount of wan insulation is
made for an adequate supply of outside air to
more than offset by the savings in space that
the condenser (Fig. 14-2). If the condenser is
this practice makes possible.
installed in a warm location, such as in an attic
Air-cooled condensers employing fans or
or boiler room, ducts should be used to carry
blowers to provide "forced-air" circulation can
the air into the condenser and back to the
be divided into two groups according to the
outside. Because of the large quantity of air
location of the condenser: (1) chassis-mounted
required, only the smaller sizes are mounted
and (2) remote.
indoors.
A chassis-mounted air-cooled condenser is
When located outdoors, the air-cooled con
one that is mounted on a common chassis with
denser may be mounted on the ground, on the
the compressor and compressor driver so that
roof, or on the side of a wall, with roof
it is an integral part of the air-cooled "con
locations being the most popular. Typical wall
densing unit" (Fig. 6-12). Although chassis
and roof installations are shown in Figures 14-
mounting of the air-cooled condenser makes
3 and 14-4, respectively. In all cases, the
possible a very compact, completely self
condenser should be so oriented that the
contained condensing unit which is ideally
prevailing winds for the area in the
suited for use on smal1 commercial fixtures,
summertime will aid rather than retard the
this arrangement has certain inherent
action of the fan. In the event that such
disadvan tages which make chassis-mounting
orientation is not possible, wind deflectors
impractical in larger applications.
should be installed on the discharge side of the
The principal disadvantage of chassis
mounted air-cooled condensers is that the condenser (Fig. 14-5).
physical size of the condenser is limited to • This is the approximate condenser
the dimensions of the chassis. Because of the capacity required on a 3 hp, commercial, air-
cooled '-.m densing. Approximately 25% of the
motor horse power is required to drive the fan.
Naturally, this reduces the horsepower available to
the compressor.

Ceilin Purge
g valve
D
D
D v:-
D Fl1. 10-2, Indoor installation of
Locate receiver below unicon outlet
One significant outgrowth of the remote air
cooled condenser has been the development of
a new type of air-cooled condensing unit which
is designed specifically for remote installation.
The air-cooled condensing unit illustrated in
Fig. 14-6 is typical of these newer designs. This
Fl1. 14-3. Remote air-cooled condensen Installed
on ouuide wall. (Courtesy Kramer Trenton
Company.)
CONDENSERS AND COOLING TOWERS 250
Air
flo
air-cooled condenser. (Cour
tesy Kramer Trenton Com
pany.)
type is rapidly gaining in popularity and is now
available in almost any desired capacity.
14-7. Air Quantity and Velocity. For an
air-cooled condenser there is a definite relation
ship between the size (face area) of the con
denser and the quantity of air circulated in that
the velocity of the air through the condenser is
critical within certain limits. Good design pre
scribes the minimum air velocity that will pro
duce turbulent flow anda high transfer
coefficient. Increasing the air velocity beyond
this point causes an excessive pressure drop
through the condenser and results in an
unnecessary increase in the power requirements
of the fan or blower circulating the air.
The velocity of the air passing through an air
cooled condenser is a function of the free face
area of the condenser and the quantity of air
circulated. The relationship is given in the
following equation:
. . Air quantity (cfm)
Air velocity (fpm) =F reef ace area( sqf
)t
The free faoe area of the condenser is the
area of the free air spaces between the tubes
and fins. The actual free area per unit of face
area varies with the design of the condenser,
being depend ent upon the size, number, and
arrangement of the tubes and fins.

Fis. 14-4. Remote air-cooled condensers mounted on roof. (Courtesy Dunham-Bush, Inc.)
Normally, air velocities over air-cooled
con densers are between 500 and 1000 fpm.
How ever, because of the many variables
involved, the optimum air velocity for a given
condenser design is best determined by
experiment. For this reason, most air-cooled
condensers come from the factory already
equipped with fans or blowers so that the air
quantity and velocity over the condenser are
fixed by the manu facturer. In all cases, to
realize peak perform ance from an air-
cooled condenser, the
Fl1. 14-5. Remote air-cooled
condensers equipped with
wind deflectors. (Courtesy
Kramer Trenton Company.)
CONDENSERS AND COOLING TOWERS 2SI
manufacturer's recommendations as to the air
quantities should be carefully followed.
14-8. Rating and Selection of Air-Cooled
Condensen. Capacity ratings for air-cooled
condensers are usually given in Btu/hr for
various operating conditions. It has already
been shown that since the surface area and the
value of U are fixed at the time of
manufacture, the capacity of any one
condenser depends only on the mean
temperature difference between the air and
the condensing refrigerant. Since
 CONDENSERS AND COOLING TOWERS 2SI

Fl1, 14-6, Air-cooled condensln& unit designed for remote Installation. Notice generous size of condenser.
(Courtesy Kramer Trenton Company.)

most air-cooled condensers come equipped In order to select a condenser from the
with fans or blowers, the quantity of air rating tables, the following design data must be
circulated over the condenser is also fixed so known:
that the average temperature of the air passing (1) The design suction and condensing tem
over the condenser depends only on the dry peratures
bulb tem perature of the entering air and the (2) The compressor capacity in Btu/hr
load on the condenser. Obviously, then, in (3) The design outdoor dry bulb temperature
such cases, the capacity of thecondenser is (use values in Table 10-6A. Round off
directly proportional to the temperature to next highest multiple of 5)
difference between the dry bulb temperature of
the entering air and the condensing Example 14-8. From Table R-13, select
temperature. This temperature differential is an air-cooled condenser for a compressor
having a capacity of 75,000 Btu/hr if the
often referred to as the "tempera ture split" in design evaporating and condensing
order to distinguish it from the mean effective temperatures arc 20° F and 110° F,
temperature differential.• respectively, and the outdoor design dry bulb
Table R-13 is a typical manufacturer's for the region is 90° F.
rating table for air-cooled condensers. The Solution. From Table
basic ratings given in Table R-I 3A arc based R-13B, the correction
on 90° F fac- tor for 20° F suction
tem
ambient air temperature, 120° F condensing perature = 0.95
temperature, and 40° F evaporating tempera From Table R-12C,
ture. For other design conditions multiply the the correction factor for
basic rating from Table R-13A by the con- densing
temperature of 110° F
correction factors for variation in evaporating and entering air = 0.665
temperatures (Table R-13B) and for variation temperature of 90° F
in entering air and condensing temperatures Required capacity of 75,000
(Table R-13C). condenser at basic rating =.,.....,,..,,.........,..,c,c
0.95 X 0.665
• The temperature split is always proportional conditions = 118,700 Btu/hr
to the METD.

From Table R-13A, select condenser Model
#BDlOOO which has a capacity of 120,000
Btu/hr at the basic rating conditions.
Experience has shown that as a general rule
selecting an air-cooled condenser on the basis
of a condensing temperature of 110° F will
result in the most economical condenser size.
Hence, the actual size of the condenser
selected will depend upon the outdoor design
dry bulb temperature for the region in
question. The higher the dry bulb
temperature, the larger the condenser required.
For example, for a con densing temperature of
110° F, if the dry bulb temperature is 85° F,
the condenser can be selected for a 25° F
temperature split, whereas if the dry bulb
temperature is 90° F, the con denser must be
selected for a 20° F temperature split, which
will require a larger size.
14-9. Water-Cooled Condenser Systems.
Systems employing water-cooled condensers
can be divided into two general categories: (I)
waste-water systems and (2) recirculated
water systems. In waste-water systems the
water supply for the condenser is usually
taken from the city main and wasted to the
sewer after passing through the condenser
(Fig. 14-7). In recirculated water systems the
water leaving the condenser is piped to a water
cooling tower where its temperature is
reduced to the entering temperature, after
which the water is recircu lated through the
condenser (Fig. 14-8).
Naturally, where the condenser water is
wasted to the sewer, the availability and cost
of the water are important factors in
determining the quantity of water circulated
per unit of con denser load. As a general rule,
an economical balance between water and
power costs pre scribes a water flow rate of
approximately 1.5 gal per minute per ton of
capacity.
The high cost of water, along with limited
sewer facilities and recurring water shortages
in many regions, bas tended to limit waste-
water systems to very small sizes. Too, many
cities have placed severe restrictions on waste-
water systems, particularly where the water
supply is taken from the city main and wasted
to the sewer.
When the condenser water is recirculated
the power required to circulate the water
through the water system must be taken into
account in determining the water flow rate.
Experience has
CONDENSERS ANO COOLING TOWERS 2S3
shown that, in general, a water flow rate of
between 2.5 and 3 gal per minute per ton
usually provides the most economical balance
between compressor horsepower and pump
horsepower. In some instances, the water
supply for a waste-water system is taken from
a well or from some nearby body of water,
such as a river, lake, pond, etc., in which case
both the cost of the water and the pumping
horsepower must be considered in
determining the optimum water
flow rate.
To a large extent, the quantity of water cir
culated through the condenser determines the
design of the water circuit in the condenser.
Since heat transfer is a function of time, it
follows that where low water quantities
necessi tate a high temperature rise in the
condenser, the water must remain in contact
with the con densing refrigerant for a longer
period than when the water flow rate is high
and the tem perature rise required is smaller.
Hence, where the water flow rate is low, the
number of water circuits through the
condenser are few and the circuits are long so
that the water will remain in the condenser for
enough time to permit the required amount of
heat to be absorbed. On the other hand, when
the flow rate is high and the temperature rise
low, more circuits are used and the circuits are
shorter in order to reduce the pressure drop to
a minimum. This is illu strated in Figs. 14-9a
and 14-9b. In Fig. 14-9a, the two water circuits
through the condenser are connected in series
for a low flow rate and a high temperature rise.
The water enters through opening A and
leaves through opening C. Opening B is
capped. In Fig. 14-9b, the two water circuits
are connected in parallel for a high flow rate
and a low temperature rise. The water enters
through opening B and leaves through
openings A and C.
In designing the condenser water circuit
particular attention must be given to the water
Waterreaulatingn
warm water out ,-+
to sewer
-
Cold water in
from city ll1lin
Liquid to control
Fl1. 14-7. Waste water system.

"Bleed­
off" line
Hot gas in
"By­
L C_on_d_e_ns_e_r....J--='-
liquid out tilo---"""'pass"
Pump
velocity and pressure drop through the con
denser. In all cases the minimum permissible
velocity is that which will produce turbulent
flow and a high transfer coefficient. Since
pressure drop is a function of velocity, the
pressure drop through the condenser increases
as the water velocity increases. For this reason,
the maximum permissible velocity in any one
case is usually determined by the allowable
pressure drop.• For waste-water systems, where
C Water
out
A Water in
(aJ
C Water
Water in
out
A Water in
(b)
Fl1. 14-9. (a) Water circuit connected for series
flow. (b) Water circuit connected for parallel flow.
• Exoessive velocity will usually cause erosion of
the water tubes, particularly at points where the
water changes direction. The maximum velocity
recommended by Air Conditioning and Refrigeration
Institute (ARI) is 8 fps.
CONDENSERS AND COOLING TOWERS 25S
Cooling
tower
"Make-up"
water
Fl1. 14-8. Re circulating water
system.
the water is forced through the condenser by
city main pressure, the pressure drop through
the condenser is not critical as long as it is
within the limits of turbulent flow and the avail
able city main pressure. In such cases, high
velocities are recommended in order to talcc
advantage of the higher transfer coefficient. On
the other hand, when the water is circulated by
action of a pump, -a high pressure drop through
the condenser will increase the pumping head
and the power required to circulate the water.
Therefore, for recirculating water systems, the
optimum water velocity is one which will pro
vide the most economical balance between a
high transfer coefficient and a low pumping
head.
In Figs. J4-9a and ,J4-9b, it is of interest to
notice that for the same flow rate the velocity
and pressure drop through the circuit arrange
ment in Fig..14-9a arc approximately four times
as great as that through the circuit arrangement
in Fig. 14-9b. Too, because of the higher velo
city, the transfer coefficient is somewhat higher
for the condensing surface in Fig. 14-9a and less
condensing surface is required for the same heat
transfer capacity.
14-10. Fouling Rates. Another factor which
must be considered in selecting a water-cooled
condenser is fouling of the tube surface on the
water side. The fouling is caused primarily by
mineral solids which precipitate out of the water
and adhere to the tube surface. The scale thus
formed on the tube not only reduces the water
side transfer coefficient, but it also tends to

restrict the water- tube and reduce the quantity
of water circulated, both of which will cause
serious increases in the condensing pressure.
In general, the rate of tube fouling is in
fluenced by: (I) the quality of the water used·
with regard to the amount of impurities con
tained therein, (2) the condensing temperature,
_and (3) the frequency of tube cleaning with
relation to the total operating time.
Most manufacturers of water-cooled con
densers give condenser ratings for clean tubes
and for four stages of tube fouling in
accordance with the scale factors given in
Table 14-1 for various types of water. These
scale factors are an index ·of the reduction in
the tube transfer coefficient resulting from the
scale deposit. In selecting a water-cooled
condenser, a minimum
Refrigerant
vapor in
Fig. 14-10. Double - tube
water-cooled condenser.
scale factor of 0.0005 should always be used.
Under no circumstances should a condenser
be selected on the basis of clean tubes.
However, when the condensing temperature is
low (leaving water temperature less than 100°
F) and the condenser tubes are to be cleaned
frequently, the fouling factor from Table 14-1
may be reduced to the next lowest value. The
use of scale factors will be illustrated later in
the chapter.
1-4-11. Water-Cooled Condensers. Water
cooled condensers are of three basic types:
(1) double-tube, (2) shell-and-coil, and (3)
shell and-tube.
As its name implies, the double-tube con
denser consists of two tubes so arranged that
one is inside of the other (Fig. 14-10). Water
is piped through the inner tube while the
refrig erant flows in the opposite direction in
the space between the inner and outer tubes.
With
CONDENSERS AND COOLING TOWERS 25S
this arrangement, some air-cooling of the
refrig erant is provided in addition to the
water cooling. Counterftowing of the fluids in
any type of heat exchanger is always desirable
since it results in the greatest mean
temperature difference between the fluids and,
therefore, the highest rate of heat transfer.
Several types of double-tube condensers are
shown in Figs. 14-11 and 14-12. The type
shown in Fig. 14-11 can be cleaned mechan
ically by removing the end-plates (inset). The
type shown in Fig. 14-12 is cleaned by circu
lating approved chemicals through the water
tubes (see Section 14-23).
Equipped with water-regulating valves
(Sec· tion 14-20), double-tube condensers
make ex cellent "booster" •condensers for
use with
- Water)
Condensed
refrigerant out
chassis-mounted air-cooled condensers during
periods of peak loading. Since the water valve
can be adjusted to open and allow water to
flow through the condenser only when the
con densing pressure rises to some
predetermined level, the amount of water used
is relatively small in comparison to the
savings in power afforded by the increased
compressor effi ciency.
The shell-and-coil condenser is made up of
one or more bare-tube or finned-tube coils
enclosed in a welded steel shell (Fig. 14-9).
The condensing water circulates through the
coils while the refrigerant is contained in the
shell surrounding the coils. Hot refrigerant
vapor enters at the top of the shell and
condenses as it comes in contact with the
water coils. The con densed liquid drains off
the coils into the bottom of the shell, which
often serves also as _the receiver tank. Care
should be taken not to

Fl1r- 1<4-11, Double-pipe a)l:ldensers with mechanlally cleanable t1.1bci. (CootttS)' Hatuead and MttcheU.)
o n::harge the system with refrigerant since
an exCC:Ssive aocumulation of liquid in the
con. denser will k:nd to cover too much of the:
con• deru;ing i;urfa{;e. and cause an increa:ie in
lhe discharge temperature and pressure.
Most shell-and-wil. condenstn1 s:re equ,ipped
with a split water circuit. The two parts of
the circuit are connected in series for waste-
water sy tcm:s (Fig. 14-9b) and in parallel for
rcc:ircu
]ati ng systems (Fig. l4-9a). As a general
rule, me11.:.and-coil condensers arc used ooly
for small installation:s; up to approximatt:ly 10 ton
capacity,
SheH-and--t:oi1 condensers are cleaned by
cir cufotir1g an approved chcmkaJ through
the water coil .
TI1c sbeU-and.tubc condenser consists. of a
cy1indrical stct:l she:H in which 11. numbec or
straight tubes are arranged in parallet and held
in place at lhe ends by ube sheel.3. Construc
tion is almost identical ta that of the flooded
type shell-and-tube liquid chiller, The con·
denslng water is circulated through the tubes,
which may be ehher steel or copper, bare or
elltended surface. The rerrigerant is contained
in the steeJ hell between. ll1c tube sheets. Water
circulates in lh..: ilr1Ilular spaces hi:\ween the
tube sheets and lhe md-platcs, the end-plates
being baffled to act as manifolds to guide the
wa Ltt now lhrough lhe tubes. The arrangemcnl of
the cnd-plale baffiing determines the number
of passes the water makes through the
condenser
CON DENSE:RS AND COOLING TOWE 257
R.5
from one end to the olher before leaving the
condcnr..er. The number of passes may he all
few as two or- as many a, twenty.
For any given totaJ riumber of tubes., the
number of tu'boe:J per pass varie<i inversely
with lM number of passes. For example.
assuming that a condenser has a total of forty
tubes, jf lherti are two passes, the nwnbi!:r of
tub:s per pa js twenty. whereas if there are
four '
lhe number of Lubes per pass fa ten.
It fa important to notice that for the same
total number of tubes and the samt:; water
quantity. the velocity of the water and the
pressure drop through thecondenser wiU be four
times as great for a four.pass condenser u for
a two-pass condenser. Because of the high r
\'clo city the transfer coefficient will be higher
far lhe
four-pass condenser and n smaller CQndens.ing
surface will be required for a gt,..en heat transfer
capacity. However, 011 the other hand,
because of the Jiigh pressure drop, the p=r
required to circulate the water- will be greater.
Hence. for a wa!lti:-water system, the four pasi.
condenser fa probably the best selection,
whereas for a reel rcula ling sys[.Cm, lhe two-
pass condenser .is probably lhe beuer of the
two.•
Sfu::U.and-tube condensers an: avaifable io
capacities ranging from 2 tons up to severa1
• This example i intended only lo illusttiu.e
Ute: priqclple:s of design and sboL1ld not be
cons.trued to mean that rour•p;i.ss condensc111 a!(!
undesirable for rcufating sysreru.

R11, 14-ll. Typical dm,1hle-pip1!! c.afld 11 r r11lg ndot15.
tlon. (Courtesy Edwanh En n l!,dn:i:; Corpor;a.t[oP.)
hundred tons or more. Shen dia.mctcrS range:
from appro:<lmatcly 4 in. up to 60 in., wlierea.s
tube length varies from approximately 3 ft lo 20
rt. The .n1.1.mber and the dfametcr of lhe tubes
depend on the diameter of the shelt Tube
d iameterr, of i in. through 2 in, arc: common,
whereas the number of tubes in the condenser
var!es from as few a$six or eight to a.ii many as a
thousand or more. The end-plales of the conT
denser arc remo,,.abie to pi:rmEt mochanica I
cleaning of the .vate:r tubes,.
Slngle-pass1 vertical hell-and·tube condenstrn
are sometimes employed on large ammonia:
instaHat.ions. The: construction of th vertical
shell-and-tube condc:ns.cr is similar io that of
the vertical :s.hell-a.11d-tube chiHer illustrared In
Fig. l144. The rtical condenser is equipped
with a water box at the top to distribute the
water to the lubes and a drain al the bottom t.o
cany thi:: water away. Each tube is equipped at
the top with adaslributor fitttng whtch imparts a
rotating molion to lhe water to as.sure adequate
.1:etti ng of the tube. The hot refrigertmt vapor
usually enters at the s.lde of the shell near the
middle of the condenser and the Ji.quid leaves
the con denser at the side of the shell nei:;r the
bottom. The height of vertical hell-and4ube
ndenser
ninges rrom 12 ft to lll rt. The lubes are
mechanically cleanable.
14-rl. Ratl ng and Sel e.cUon of W ;ater-•
Cooled Conden5"ers.* The ratings shown in
• The mi!.terial iri thi $Cettrm i rfr1ted dir«Uy
rrom the manufacturer's callllog, lne 0111}' alter
atk1[1 belri the table: de:lgn.iltion . Courte:iy or
Acme lndustrfes, Jnc.
CON DENSE:RS AND COOLING TOWE 257
R.5
MTramoone ront'lgt.1!'11,tlo11-. (b} Helix: conf1gura
Table R 14 are based on d(:nsing tempera•
turcs: of 10r and ]O G F, 20 and w·w:iter
rtse
and 0.0005 scale factor which js the minimum
recommended in ARr standards.
Where olher cond ctlon e;,;,isL, the following
procedure should be followed jn selecting the
proper condenser.
Condemcrs must not be .selected for less than
0.5 gpm per rube below which streamline
instead of turbulent water ftow OCCt.Jrs. ARl
standards indicate that lhe water velocity should
not exceed 8 fps whk:h is 5.75 gpm per tube for
Aerni: STF and SR F condensers,
It is necessary to ha.ve the following info;ma
tion to select a proper condenser :
l. Total tons {iow :side).
2. Eraporalor temperature.
3. Condensing temperature.
4. \Yater temperature "in."
S. Water temperature "out," or gpm avail-
able.
6. Type of water or- rcqutred scale factor.
Thi:n prncct:d as. follows :
}, Determine the corrected tons to b.e used in
selecting the proper conden..-;er by reference to
Fig. 2, Table R-14. The factor obtained for the
desired evaporator temperature and condensing
temperature is mnltiplial by thi:: actuaJ tons to
obtain corrected tons.
1. Determine the water tempe..rnture rise and
gpm per ton. Knowing cilhi:r fac-lor. the other
may be obtaint:tl by reference lo Fig. J, Table
R-14. Use correcled tons to determine the lotal
gpm rcqulred.
 CONDENSERS AND COOLING TOWERS 159
2. Determine the temperature differences Refrigeration load 30 tons
between the condensing temperature and the Condensing temperature 100° F
"water in" and "water out" temperatures and Suction temperature 30° F
find the METD by referring to Table 11-1. Water available 2 gpm/ton
3. Make preliminary selection of condenser river water reasonably clean at 78oF
shell diameter by reference to Table R-14, Maximum tube length 12ft
basing the selection on the corrected tons found Maximum water pressure drop 7.5 psi
in step 1. Find the number of tubes per pass and
Solution
then by referring to step 2, find the gpm per I. From Fig. 2, the correction factor for
tube. 30° F suction temperature and 100° F con
4. Select the desired scale factor by reference densing temperature is 1.013.
to Table 14-1 which suggests scale factors for Corrected tons 30 x 1.013 = 30.4 tons
various types of water. The most commonly 2. From Fig. 3, for 2 gpm/ton the water
temperature rise is found to be 14.4°.
used. factor is 0.0005 and it should be borne in Total gpm 30.4 x 2 = 60.8
mind when selecting a factor that a determina Water "out" temperature 78 plus 14.4
tion is being made of the frequency of cleaning = 92.4° F
which will be required. 3. GTD 100 - 78 = 22°
5. Referring to Fig. l, Table R-14, determine LTD 100 - 92.4 = 7.6°
the rate of heat transfer "U" for the gpm per From Table 11-1, METD = 13.55° F
tube in step 4 and the scale factor in step 5. 4. Refer to Table R-14. Use of four passes
6. Calculate the surface required by use of will usually give an economical selection for
the following formula. 75° F water in and 95° F water out which
approximates the required water conditions.
Square feet of surface Note that a 10! shell will probably be needed.
Corrected tons x 14,400 This shell has sixty tubes.
U x METD Total gpm x number of passes
gpmpertube Number of tubes in condenser
7. Select a condenser having at least the 60.8 X 4
required surface from Table R-14. Be sure to 60
use the shell diameter determined in the pre = 4.05 gpm per tube
liminary selection of step 4. 5. Referring to Table 14-1, for clean river
8. Make final checks on selection. water and over 3 fpm velocity, the suggested
a. Using the gpm per tube from step 4 and scale factor is 0.001.
the nominal tube length shown in Table R-14 6. From Fig. 1, the U factor for 4.05 gpm per
for the model selected in step 8, refer to Fig. tube and 0.001 scale factor is 121.5 Btu per hour
4 of Table R-14 to obtain water pressure drop per square foot of extended surface per °F
through condenser. METD.
b. Obtain nominal operating charge from 7. Square feet required
the last column of Table R-14. This is the Corrected tons x 14,400
maximum weight of liquid refrigerant which U factor x METD
can be allowed in the shell during the operat 30.4 X 14,400
ing period covering some of the lower tubes. = 121.5 X 13.55 = 266 sq ft
Larger shell diameters or separate receivers 8. Referring to Table R-14, a Model STF-
may be used where greater storage capacity is 1010 has 289 sq ft external tube surface and
needed during operation. should be selected. When installed the water
c. Determine the pump down capacity connection should be made for four-pass
from Table R-14. Ifless than the total weight operation.
of refrigerant to be used in the system and 9. (a). For water pressure drop, refer to Fig.
provision for complete pump-down are re 4 and note that the pressure drop for 4.05 gpm
per tube in an STF-1010 condenser connected
quired, an additional receiver should be used.
for four passes is 7.1 psi. (b). Table R-14 shows
Example 14-9. Select an R-12 condenser a nominal operating charge of 38 lb of R-12,
to meet the following conditions: which will normally be sufficient for a 30-ton

installation. However, if more operating
storage is needed, a separate receiver may be
chosen, or alternately a different condenser
selection may be made if more economical.
(c). Table R-14 also shows pump-down
capacity which is 252 lb of R-12. Usually
.this will be sufficient, but if greater pump-
down capacity is required, a separate receiver
tank must be used.
l.._13. Slmpllfled Ratlnp. Simplified ratings,
based on the horsepower of the compressor
driver, are available for most air-cooled and
water-cooled condensers, particularly in smaller
sizes. Since the power required by the com
pressor varies with both the evaporator load
and the compression ratio, it prov.ides a
reasonable index of the condenser load at
all operating conditions. Table R-15, which
applies to double tube condensers of the type
shown in Fig. 14-12, is a typical simplified
condenser rating table. l.._14. Coolln1
Towen. Cooling towers are essentially water
conservation or recovery de vices. Warm
water from the condenser is pumped over
the top of the cooling tower from where it
falls or is sprayed down to the tower basin.
The temperature of the water is reduced as it
gives up heat to the air circulating through the
tower.
Although there is some sensible heat
transfer from the water to the air, the cooling
effect in a cooling tower results almost
entirely from the evaporation of a portion of
the water as the water falls through the tower.
The heat to vaporize the portion of water that
evaporates is drawn from the remaining mass
of the water so that the temperature of the
mass is reduced. The vapor resulting from the
evaporating pro cess is carried away by the
air circulating through the tower. Since both
the temperature and the moisture content of
the air are increased as the air passes through
the tower, it is evident that the effectiveness of
the cooling tower depends to a large degree on
the wet bulb tem perature of the entering air.
The lower the wet bulb temperature of the
entering air, the more effective is the cooling
tower.
The efficiency of a cooling tower is
influenced by all the factors governing the rate
at which the water will evaporate into the air
(see Section 4-8). Some of the factors which
determine cooling tower efficiency are: (I) the
mean difference in vapor pressure between the
air and the water in the tower, (2) the
amount of
CONDENSERS AND COOLING TOWERS 159
exposed water surface and the length (time) of
exposure, (3) the velocity of the air passing
through the tower, and (4) the direction of the
air flow with relation to the exposed water
surface (parallel, transverse, or counter).
For anx given water temperature entering
the tower, the vapor pressure difference is
essentially a function of the wet bulb
temperature of the entering air. In general, the
lower the entering wet bulb temperature, the
greater the vapor pressure differential and the
greater the tower capacity.
The exposed water surface includes: (1) the
surface of the water in the tower basin, (2) all
wetted surfaces in the tower, and (3) the com
bined surface of the water droplets falling
through the tower.
Theoretically, the lowest temperature to
which the water can be cooled in a cooling
tower is the wet bulb temperature of the
entering air, in which case the water vapor in
the leaving air will be saturated. In actual
practice, it is not possible to cool the water to
the wet bulb tem perature of the air. In most
cases, the tem perature of the water leaving
the tower will be 1° to 10° F above the wet
bulb temperature of the entering air. Too, the
air leaving the tower will always be somewhat
less than saturated.
The temperature difference between the
tem perature of the water leaving the tower
and the wet bulb temperature of the entering
air is called the tower "approach." As a
general rule, all other conditions being equal;
the greater the quantity of water circulated
over the tower the closer the leaving water
temperature approaches the wet bulb
temperature of the air. However, the quantity
of water which can be economicaJiy circulated
over the tower is somewhat limited by the
power requirements of the pump.
The temperature reduction experienced by the
water in passing through the tower (the differ
ence between the entering and leaving water
temperatures) is called the "range" of the
tower. Naturally, to maintain equilibrium in
the con denser water system, the tower
"range" must always be equal to the
temperature rise of the water in the
condenser.•
The load on a cooling tower can be approxi
mated by measuring the water flow rate over
the
• Except where a condenser by-pass is used. See
Section 14-17.

tower and the entering and leaving water tem
peratures. The following equation is applied:
Tower load(Btu/min) = flow rate(gpm)
x 8.33 x (entering water temperature
- leaving water temperature) (14-12)
Example 14-10. Determine the approxi
mate load on a cooling tower if the entering and
leaving water temperatures are 96° F and 88° F,
respectively, and the flow rate of the water over
the tower is 30 gpm.
Solution. Applying
14-12, the tower load
(Btu/min) =- 30 X 8.33
X (96 - 88)
= 2000 Btu/min
Since the load on the tower is equal to the
load on the condenser, the approximate refrig
erating capacity of the system can be computed
by dividing the tower load by the condenser load
in Btu/min/ton corresponding to the operating
conditions of the system.
Example 14-11. Compute the refrigerating
capacity of an R-13 system operating on the
cooling tower of E'.xample 14-10, if the
evaporat ing and condensing temperatures are
20° F and 110° F, respectively.
Solution. From Fig. 14-1,
the load on the condenser
"" 247 Btu/min/ton
The approximately refrig
erating capacity of the
system
Tower load (Btu/min)
"",=- = - - -= -- c -- - e -
C --ot,u
d (B n-/d-m-,en- -- : -- , -
i n s/tero lno) a
= 2000
247
= 8.1 tons
Since the heat absorbed per pound of water
evaporated is approximately 1000 Btu, assuming
a condenser load of 250 Btu/min/ton, the
quantity of water evaporated per ton of refrig
eration (evaporator) is approximately 0.25 lb
per minute or 2 gal per hour.
In addition to the water lost by evaporation,
water is lost from the cooling tower by "drift"
and by "bleed-off." A small amount of water in
the form of small droplets .is entrained and
carried away by the air passing through the
tower. Water lost in this manner is called the
drift loss. The amount of drift loss from a tower
CONDENSERS AND COOLING TOWERS 159
depends on the design of the tower and the wind
velocity.
"Bleed-off" is the continuous or intermittent
wasting of a certain percentage of the circulated
water in order to avoid a build-up in the con
centration of dissolved mineral solids and other
impurities in the condenser water. Without
bleed-off the concentration of dissolved mineral
solids in the condenser will build up quite
rapidly as a result of the evaporation taking
place in the cooling tower. Since the scaling rate
is propor tional to the quality of the water, as the
concen tration of mineral solids in the water
increases the scaling rate also increases.
The amount of bleed-off required to maintain
the concentration of dissolved mineral solids at
a reasonable level depends upon the cooling
range, the water flow rate, and the initial water
conditions. Suggested bleed-off rates for various
cooling ranges are given in Table 14-2. To
determine the quantity of water loss by bleed
off, multiply the water flow rate over the tower
by the factor obtained from Table 14-2.
Example 14-12. Determine the quantity of
water lost by bleed-off if the water flow rate
over the tower is 30 gpm and the range is 10° F.
Solution. From
Table 14-1, the percent
bleed-off required = 0.33%
The quantity of
water lost by bleed-off = 30 gpm X 0.0033
= 0.099gpm
The bleed-off line should be located in the hot
water return line near the top of the tower so
that water is wasted only when the pump is
running (Fig. 14-8).
Make-up water, to replace that lost by
evapo ration, drift, and bleed-off, is piped to
the tower basin through a float valve which
tends to maintain a constant water level in the
basin.
14-15. Coolln1 Tower Design. According to
the method of air circulation, cooling towers are
classified as either natural draft or mechanical
draft. When air circulation through the tower
is by natural convection, the tower is called a
natural draft or atmospheric tower. When air
circulation through the tower is by action of a
fan or blower, the tower is called a mechanical
draft tower. Mechanical draft towers may be
further classified as either induced draft or
forced draft, depending on whether the fan or

Hot water
in
Make-up water
from city
main
Fl1. 14-13. Natural draft-cooling tower.
blower draws the air through the tower or
forces (blows) it through. A schematic
diagram of a spray-type natural draft tower is
shown in Fig. 14-13. Schematic diagrams of
induced draft and forced draft towers are
shown in Figs. 14-14 and 14-15, respectively.
In the spray-type atmospheric tower, the
warm water from the condenser is pumped to
the top of the tower where it is sprayed down
through the tower through a series of spray
nozzles. Since the amount of exposed water
surface depends primarily on the spray
pattern, a good spray pattern is essential to
high effi ciency. The type of spray pattern
obtained depends on the design of the nozzles.
For most nozzle designs, a water pressure
drop of 7 to IO lb per square inch will produce
a suitable spray pattern.
Some natural draft towers contain decking or
filling (usually of redwood) to increase the
Water in-+-
Fl1. 14-14. Small Induced
draft-cooling tower.
Air in
-water outi--- -- -Ba-s-in------------------i
CONDENSERS AND COOLING TOWERS 261
amount of wetted surface in the tower and to
break up the water into droplets and slow its
fall to the bottom of the tower. Atmospheric
towers containing decking are called "splash
deck." Often, in splash-deck towers, no spray
nozzles are used and the water is broken up
into droplets by the "splash-impact" method.
The quantity and velocity of the air passing
through a natural draft cooling tower depend
on the wind velocity. Hence, the capacity of a
natural draft tower varies with the wind
velocity, as does the amount of"drift"
experienced. Too, natural draft towers must
always be located out of-doors in places where
the wind can blow freely through the tower.
In commercial appli cations, roof installations
are common.
Since air circulation through mechanical
draft towers is by action of a fan or blower,
small mechanical draft towers can be installed
indoors as well as out-of-doors, provided that
an adequate amount of outside air is ducted
into and out of the indoor location. Too, since
larger air quantities and higher velocities can
be used, the capacity of a mechanical draft
tower per unit of physical size is considerably
greater than that of the natural draft tower. In
addition, most mechanical draft towers contain
some sort of decking or fill to improve further
the effi ciency. Spray eliminators must be
used in mechanical draft towers to prevent
excessive drift losses.
14-16. Cooling Tower Rating and Selection.
Table R-16 contains rating data for the spray
type, natural draft cooling tower illustrated in
Fig. 14-13 and is a typical cooling tower
rating table. Notice that the tower ratings are
given in tons, based on a heat transfer capacity
of 250
--- = ---------- --------
-----
= - - - - - -
- - -
-
==-=-:--- == ->"<:a-:;.;:.,,.-=3 Air out
---------- Decking $' _
: :: .-. = -- = ;;>,". = 20:
= = f == ==
 CONDENSERS AND COOLING TOWERS 262
Air out

\tttttttt!(1 Spray
SSS%%SSSS<,ss<-,ss<H,SSSSSSSSSSSSS%SSSSSS eliminators

Fl1. 14-15. Forced draft•

cooling tower.

Water in

Water
out

Btu/min/ton. Nominal tower ratings are based Example 14-14. It is desired to cool 90 gpm
on a 3 mi per hour wind velocity, and 80° F from 96° F to 86° F when the design wet bulb is
design wet bulb temperature, and a water flow 78° F. Select the proper tower from Table
rate over the tower of 4 gpm per ton. Tower R-16.
performance at conditions other than those
listed in the table can be determined by using
Solution
the rating correction chart that accompanies the Tower range = 96 - 86 = 10°
table. Tower approach = 86 - 78 = 8°
To select the proper tower from the rating
table, the following data must be known: From rating correc-
tion chart, range-ap
I. Desired tower capacity in tons (compressor proach factor = I.I
capacity) From wet bulb cor
2. Design wet bulb temperature rection chart, wet bulb
factor = 1.04
3. Desired leaving water temperature (con
denser entering water temperature or tower
Nominal gpm = 90 x 1.1 x 1.04
approach)
= 103 gpm
From Table R-16, for 103 gpm nominal,
or select tower, Model #SA-68.
I. Desired flow rate over the tower (gpm)
2. Design wet bulb temperature Example 14-15. It is required to cool water
3. Desired entering and leaving water tem for 30 tons at 5 gpm/ton to a 5° F approach of
peratures (tower cooling range and tower an 80° F wet bulb. Select the proper tower from
approach) Table R-16.
Example 14-13. From Table R-16, select a
cooling tower to meet the following conditions: Solution
I. Required tower capacity = 20 tons Total gpm required
2. Design wet bulb for 30 tons at 5 gpm/
temperature = 78° F ton = 30 X 5 = 150 gpm
3. Desired leaving water From rating cor
temperature = 86° F tion chart, rating cor
rection factor for 5
Solution. From Table R-16, select tower, gpm/ton and 5° ap
Model #CSA-66, which has a capacity of 20.7 proach = 1.15
tons at the desired conditions when the flow
rate over the tower is 3 gpm per ton. Hence, for From wet bulb
20-tons capacity, a total of 60 gpm (20 x 3) correction chart, wet
must be circulated over the tower. As shown in bulb correction factor = 1.0
the table, the entering water temperature will be Nominal gpm = 150 X 1.15 X 1.0
approximately 96° F. = 172.6gpm
 CONDENSERS AND COOLING TOWERS 263

From Table R-16, for 172.6 gpm nominal,

select tower Model #SA-612. Tower gpm x tower range x 500
14-17. Condenser By-Pass. For any· given -= condenser gpm x condenser rise x 500
tower range and approach, the entering and Eliminating the constant,
leaving water temperatures will depend only Tower gpm x tower range
on the wet bulb temperature of the air. Hence, = condenser gpm x condenser rise (14-13)
in regions (particularly coastal areas) where
the outdoor wet bulb temperature is relatively Example 14-16. A compressor on a refrig
high, a closer approach to the wet buJb erating system has a capacity of 25 tons. The
temperature is required in order to maintain a design wet bulb temperature is 80° F. The
reasonable con densing temperature with an desired condenser water entering temperature is
economical con denser size than in areas 87° F and the desired temperature rise through
the condenser is 10° F. Select a cooling tower
where the wet-buJb temperature is lower. It from Table R-16 and determine:
has already been shown that, in general, the
greater the quantity of water circulated over I. The total gpm circulated over the tower
the tower per unit of capacity the closer the 2. The temperature of the water entering the
tower
leaving water temperature will approach the 3. The tower cooling range
wet bulb temperature. Therefore, in regions 4. The temperature of the water leaving the
having a high wet bulb temperature, it is condenser
usually desirable to circulate a greater quantity 5. The gpm circulated through the condenser
of water over the tower than can be 6. The gpm circulated through the by-pass
economically circuJated through the
condenser because of the excessive pumping Solution. From Table R-16, tower, Model
head encoun tered. This can be accomplished #SA-58 has a capacity of 25 tons at an 80° F
by installing a condenser by-pass line as wet bulb temperature and a 7° approach. This
capacity is based on a water flow rate of 4
shown in Fig. 14-8. Through the use of a gpm/ton and on a cooling range of 7.5°
condenser by-pass, a certain, predetermined (94.5 - 87).
portion of the water circulated over the tower Total gpm over the tower
is permitted to by-pass the condenser, thereby for 25 tons
reducing the over-all pumping head. = 25 tons x 4 gpm/ton
The advantage of the condenser by-pass is = 100 gpm
that it makes possible the maintenance of From Table R-16, the
reasonable condensing temperatures with mod tower entering water tem-
erate condenser and tower sius without greatly perature
increasing the pumping head. The quantity of =94.5°F
water flowing through the by-pass is regulated Tower range
by the hand valve in the by-pass line. Once - 94.5 - 87 = 7.5°
the hand valve has been adjusted for the proper Water temperature leaving
flow rate through the by-pass, the handle condenser
should be removed from the valve so that the = 87 + JO = 97° F
valve adjust ment cannot be changed Rearranging and applying
indiscriminately. An excessive amount of Equation 14-13, condenser
water flowing through the by-pass will not gpm
Tower gpm x tower range
only tend to starve the con denser and raise
.. Condenser rise
the condensing pressure, but it may also 100 X 7.5
cause the pump motor to become -=--.-0-
overloaded, thereby rendering the entire system
= 75gpm
inoperative. The desired flow rate through the
by-pass is determined by ubtracting the flow Gpm circulated through·
rate through the condenser from the flow rate by-pass
-= Tower gpm - condenser gpm
over the tower. This will be illustrated -= 100 - 75
presently. Since the cooling tower capacity = 25 gpm
must of necessity be equal to the condenser
capacity at
the design conditions, it follows that:
 CONDENSERS AND COOLING TOWERS 264
264 :PRINCIPLES OF RffA.1GERATlON

of the condenser into Ole air, the wurce of the

Fa
vaporizing beat being the condensing
n
refrigerant ln the condenser coil.
The cooling produced is .approximately lOOO
Elirninil>t,;m;
.Blu per pound or water evaporal.cd. AIi the
ITnII beat gt\len up by the refrigerant in the cond
mer eventually leaves the condenser as cilher
- $pr.a
fl0:!:?18 .-1---ot--tne sensible heat or fatent :he.it (moist\lre) in the
Re!riger;mt discharge ait. Since both the temperature
Yapor ln and moii ture content of ibe air' arc
increased as the air passes through the
R@ftlgerant condenser-, the effect.iveness of lhc condenser
liqu-ii:l out depends. in part, oo the wet bulb t mperatu of
the cnteringair-. The lower the wet bulb
Air temperature of the ent:ering ai,; the more
in effective is lhe evaporative condenser.
To facilitate cleaning and !iC!ilc rcmovaJ, the
condensio.g coil i llsually made up of bat"e
rather than finned tubing. The amount of con
Pump :s.1..rrfacc usc-d per ton of capacity varies with the

Fl1. I•U 6. Schematlc di,gram or enpc,ntlvi:- n manufacturer and depends to a large extent on
den i-. the llm.ount of air and water circulated.
Generally. the capacity of the evaporative
condenser increases as the quantity or air cir
l◄-18, Evaporative Cond nsen. An evapo· cuhHcd thrnugh the condenser i.ncR:ases. As a
rative coodenser is esscnlill.lily a watet constr practical matter. the maximum quantity of air
vation device and is, in effect, a condenser and
a cooling tower combined into a .singie unit, A
diagram of a typical evaporntive condenser i.s
shown in Fig. l 4-16.
As pnwiously stated, both air and water are
emplo)·ed in the. evaporative condenser. The
waler, pumped from the st1mp up to the spray
header, sprajiS down over the refrigetant coils
and returns. to the sump. The air is dr.twn in
rrom the outside at the bottom of lhe condcm.cr
by action of the blower and fa dlschargcd back
to t.he outside at the top of the condenser. In
some cases. both pump and btower are, driven
by the same motor. In others, s.eparatc motors
nre u$ed. The eliminators installed irt the air
stream above the spray header arc to prevent
entrained water rrom being carried over intQ
tbe blower. An alternate arran ment, with the
blower located on the entering air side of the
condenser, j5 shown in Fig. 14--17.
Although the actual Ut<.rmody.namlc proT
cesses taking place in lhc evaporative con-
denser 11re somewhat complex., the fundalll.Cntal Fig. 14-17. Cuu.wa:, vlew or "l>rl-hn'' ewa rad
process is that or evaporative cooling. Wat« is conderinr. Fun.nel-thaped o"' rflow dr'1In providM
1-u(t:1niatlt blel!d--ofl'. tCo rte,i;y Ref •,i= •tlon. En.gl
evapo ratedfron1 thespmy and from the wetted
l'l t1edng, Inc·. A proprlt1tary dt1sT&ri of Rt1frilll!
surface
ratfo11 Engln.eerl ng, Inc.)
 CONDENSERS AND COOLING TOWERS 16S
which can be circulated through the condenser
is limited by the horsepower requirements of 6-ton evaporator load (Refrigerant-12)
the fan and by the maximum air velocity that 20° evaporator temperature
can be permitted through the eliminators 78° entering wet bulb temperature
without the carry over of water particles. I05° F condensing temperature
The quantity of water circulated over the Solution. Since the rating table is in terms of
condenser should be sufficient to keep the evaporator load at 40° F, it is necessary to
tube surface thoroughly wetted in order to correct for other evaporator temperatures by
using a correction factor from R-l7B as
obtain follows: Tons x evaporator correction factor
maximum efficiency from the tube surface and
to
minimize the rate of scale formation. However, -= Rating table tons
a water flow rate in excess of the amount Therefore, 6 x 1.05 6.3 tons.
=
required for adequate wetting of the tubes will • McQuay Products.
only increase the power requirements of the
pump without materially increasing the con
denser capacity.
Assuming a condenser load of lS,000 Btu
per hour per ton, the water lost by evaporation
is approximately I5 lb (2 gal) per hour per ton
(15,000/1000). In addition to the water lost by
evaporation, a certain amount of water is lost
by drift and by bleed-off. The amount of
water lost by drift and by bleed-off is
approximately
1.5 to 2.5 gal per hour per ton, depending
upon the design of the condenser and the
quality of water used. Hence, total water
consumption for an evaporative condenser is
between 3 and 4 gal per hour per ton.
Some evaporative condensers are available
equipped with desuperheating coils, which are
usually installed in the leaving air stream. The
hot gas leaving the compressor passes first
through the desuperheating coils where its
tem perature is reduced before it enters the
con densing coils. The desuperheating coils
tend to increase the over-all capacity of the
condenser and reduce the scaling rate by
lowering the temperature of the wetted tubes.
Too, often the receiver tank is located in the
sump of the evaporative condenser in order to
iricrcase the amount of liquid subcooling.
14-19. Rating and Selection of Evaporative
Condensers. Table .R-17 is a typical evapo
rative condenser rating table. Notice that the
ratings are based on the temperature
difference between the condensing
temperature and the design wet bulb
temperature. The following sample selection
is reprinted directly from the manufacturer's
catalog data:•
Example 14-17. Select an evaporative con
denser for the following conditions:
 Referring to Table R-l7A, the E-135F has a
capacity of only 5.6 tons at 78° F entering
wet bulb and 105° F condensing temperature.
It does, however, have the required capacity of
6.3 tons at between 105° F and 110° F
condensing temperature.
The compressor ratings should then be
checked to see if the compressor originally
selected has the required capacity at between
105° F and 110° F condensing temperature.
If not, it will be necessary to select the next
larger size evaporative condenser or
compressor to do the job.
The next larger size evaporative condenser,
the E-270F, has a capacity of I1.2 tons at the
given conditions; however, the required
capa city of 6.3 tons will be obtained at a
condensing temperature between 90 and 95°
F. The com pressor selection should then be
made for these conditions.
14-20. Water Regulating Valves. The water
flow rate through a water-cooled condenser on
a waste water system is automatically
controlled by a water regulating valve (Fig.
14-18). The valve is installed on the water
line at the inlet of the condenser and is
actuated by the compressor discharge (Fig.
I4-7). When the compressor is in operation,
the valve acts to modulate the flow of water
through the condenser in response to changes
in the condensing pressure. An increase in
the condensing pressure tends to collapse the
bellows further and open the valve wider
against the tension of the range spring,
thereby increasing the water flow rate
through the condenser. Likewise, as the
condensing pressure decreases, the valve
moves toward the closed position so that the
flow rate through the condenser is reduced
accordingly. Although the regulating valve
tends to maintain the con densing pressure
constant within reasonable limits, the
condensing pressure will usually be
considerably higher during periods of peak
loading than during those of light loading.
2" PRlNCIPLES OF IU;fRIGERATION

.fl1, 14-IA. Typlt;il thre:ii.i:l.i:.:1- yp,e w1tet t g1.r!atin,11 ,,,.,J,,.e, bqjl!f sh.es 11.re 11:ll le wlth fbflge co11nectl0ns.
(a) CrosM ctianal vrew howlng· prh,clp .1 parts. { ) E:xtctltir vi(!_w, (Courtesy Pen.n Contrab, Tnt.}

When the compressor cydes off, the wati::r

valvc n::mains op-en and water rontinues lo flow
through the condenser until the p:resiiure in the
condenser is reduced to a certain predctennrned
minimum, t which tin1e the \/.t1ve doses off
completely and shuts o!T the waler flow. When
lhe compressor cycles on agLi.in, Lhe v,.-:Hcr
valve remains close<! until th1: prt:".SSurc in the
oon& denser puilds up to the vahie openlrig
pressure, at which time the val.,,e opens and
permits water to flow th rough the condenser. The
Op<:ni ng pressure of the val,..c is
approximately 7 p:ii
abo.,,e the shut-off pr ssun:.
The water valve is set for the des.ired shut-off
pressure by adj u:sting the tension or the range
spring. The minimum operating pres ure for
the ,,.n1ve, lh t i:'l-, thi:: shut-off pressure, mml be
set high cr,ough so lhat the valve will not remain
open and rmil water to flow lhtough chc con
denser when the co mprcssor lS on thi:: off cycle.
Since the saturation temperature of the rcfrig-
erant in the condcn.-.er can never be lower tha:n
the ambient temperalure at the condenser, lbc
shut-off p,ofnt oft.he water ..-al\'e should be set
at a saturation pressure i:orrcsponding to the
maxi mum ambccn t tempMahm:: in the
summertime at the condenser location. Too,
the shut-off pN::ssure of the valV€ must be
Mgh enough so that the minimum
0011densrr1g temperature in the winter1ime is
sufficientty high to provtck a pressure
diffi.:n::ntial acros the refrigerant con lrol large
c110ugh to assure its proper opera.lion. The
capacity of water regulating valves varie
whh the size of the valve and the pressure drop
acros the ,..al,..e orifict, The avaBable pressure
drop across the valve orifice is determined by
subtracting the pressure drop through the con•
dense:r =d wat r piping from the tots.l pn=.,;. urc
drop aval!a ble at the water main.
Water regulating val s are usuaBy S€1ected
from flow charts (Table R-18). ln order to
sckct the proper valve from the fiow chart, the

following data must be known: (1) the desired
water quantity in gpm; (2) the maximum
ambient temperature in the summertime; (3)
the desired condensing temperature; and (4)
the available water pressure drop across the
valve.
The following selection procedure and sample
selection are reprinted directly from the litera
ture of the manufacturer:•
I. Draw horizontal line across upper half of
Flow Chart (Table R-18) through the required
flow rate.
2. Determine refrigerant condensing pressure
rise above valve opening pqint.
a. Valve closing point (to assure closure
under all conditions) must be the refrigerant
condensing pressure equivalent to the highest
ambient air temperature expected at time of
maximum load. Read this in psig from "Satu
rated Vapor Table" for refrigerant selected.
b. Read from the same table the operating
condensing pressure corresponding to selected
condensing temperature.
c. Valve opening point will be about 7 psi
above closing point.
d. Subtract opening pressure from operat
ing pressure. This gives the condensing
pressure rise.
3. Draw horizontal line across lower half of
Flow Chart through this value.
4. Determine the water pressure drop through
the valve-this is the pressure actually available
to force the water through the valve.
a. Determine the minimum water pressure
available from city mains or other source.
b. From condensing unit manufacturer's
tables read pressure drop through condenser
corresponding to required flow.
c. Add to this estimated or calculated drop
through piping, etc., between water valve and
condenser, and from condenser to drain (or
sump of cooling tower).
d. Subtract total condenser and piping drop
from available water pressure. This is the
available pressure drop through the valve.
Example_14-18. The required flow for an
R-12 system is found to be 27 gpm. Condensing
pressure is 125 psig and the maximum ambient
temperature estimated at 86° F. City water
• By permission of Penn Controls, Inc., Goshen,
Indiana.
CONDENSERS AND COOLING TOWERS 267
pressure is 40 psig and manufacturer's table
gives drop through condenser and accompany
ing piping and valves as 15 psi. Drop through
installed piping approximately 4 psi. Select
proper siu of water regulating valve from Table
R-18.
Solution
1. Draw a line through 27 gpm-see dotted
line, upper half of Flow Chart (Table R-18).
2. Closing point of valve is pressure of R-12
corresponding to 86° F ambient = 93 psig.
3. Opening point of valve is 93 + 7 =- 100
psig.
4. Condens_ing pressure rise = 125 - 100 =
25 psi.
5. Draw line through 25 psi-see dotted line,
lower half of Flow Chart.
6. Available water pressure drop through
valve = 40 - 19 = 21 psi.
7. Interpolate just over the 20 psi curve
circle on lower half of Flow Chart.
8. Draw vertical line upward from this point
to flow line-circle on Flow Chart marks this
intersection.
9. This intersection falls between curves for
l in. and l ¼ in. valves. The J¼ in. valve is re•
quired.
14-21. Condenser Controls. For reasons of
economy, the condensing medium is
circulated through the condenser only when
the com• pressor is operating. Hence, mmon
practice is to cycle the condenser fan and/or
pump on and off with the compressor. This is
usually accomplished by electrically
interlocking the fan and/or pump circuit with
the compressor driver circuit. Method of
interlocking electrical circuits are discussed in
Chapter 21.
Whereas high pressure controls are always
desirable as safety devices on any type of
system, they are absolutely essential on all
equipment employing water as the condensing
medium in order to protect the equipment
against damage from high condensing pressures
and tempera tures in the event that the water
supply becomes restricted or is shut-off
completely. The high pressure control has
already been discussed in Section 13-13.
If a refrigerating system is to function pro
perly and efficiently, the condensing
temperature must be maintained within certain
limits. As previously described, high
condensing tempera• tures cause losses in
compressor capacity and efficiency, excessive
power consumption, and,
268 PRINCIPLES OF REFltlGERATION CONDENSERS AND COOLING TOWERS 268

in some cases, overloading of the compressor
driver and/or serious damage to the
compressor itself.
An abnormally low condensing
temperature, on the other hand, will cause an
insufficient pressure differential across the
refrigerant con trol (condensing pressure to
vaporizing pres sure), which reduces the
capacity of the control and results in starving
of the evaporator and general unbalancing of
the system.
As a general rule, low condensing tempera
tures result from either one or both of two
principal causes: (I) low ambient temperatures
and (2) light refrigerating loads. Naturally, the
problem of low condensing temperatures is
more acute in the wintertime when the
ambient temperature and the refrigerating load
are both apt to be low.
To maintain the condensing temperature at
a sufficiently high level, it is necessary to
make some provision for reducing or
controlling the
capacity of the condenser during periods when
the ambient temperature is low and/or the
refrig erating load is light. Although the
methods employed to control the capacity of
the con denser vary somewhat with the type of
con denser used, all involve reducing either
the quantity of condensing medium circulated
or the amount of effective condensing surface.
Condenser capacity control devices are
usually actuated by pressure or temperature
controls which respond to condensing
pressure or temperature.
With regard to air-cooled condensers, the
condensing temperature is maintained within
the desired limits by varying the air quantity
through the condenser or by causing a portion
of the condenser to become filled with liquid
so as to reduce the amount of effective
condensing surface.
The air quantity through the condenser is
varied by cycling the fan or blower or by the
use

Fl1. 14-19. Winterstat control

p_L
Air- ... ti)
of air-cooled condensers. (o)
cooled b l:
. J:. Loop Winterstat may be used
condense
C.:
. ,1--- .... 0--+1:2
wherever 3 feet of head room
r :::,
Is available above the top of
g the condenser. This type is
{!. the simplest and lowest In
(a) t cost.
(b) No-loop Wlnterstat Is
ConstJint employed where head room
inlet pressure is not available above con
throttling valve denser. Valves O and W are
supplied as an integral unit and
must be mounted at the level
Air-cooled
condenser of the liquid outlet of the
condenser. (The Winterstat is
a proprietary desian of the
r---------- Kramer Trenton Company and
is manufactured under the
1 I To liquid following patent numbers:
receiver 2,56-4,310; 2,761,287: and
2,869,330.)
From From
condenser discharge
outlet L----- J line
To receiver
(b}
 CONDENSERS AND COOLING TOWERS 269

Fl1. 14-20. Pressure stabilizer.

(A proprietary design of
Dunham-Bush, Inc.) (Courtesy
Dunham-Bush, Inc.)

of dampers placed in the air stream. , Because

is controlled by the regulating valve installed
it tends to .:ause large fluctuations in the con
between the condenser and the receiver. This
densing temperature, cycling of the fan cannot
valve is set at the desired operating pressure,
be recommended as a means of controlling
and throttles from the open position to the
the capacity of air-cooled condensers.
closed position as the condensing pressure
Modulating dampers installed in the air stream
drops. The throttling action backs up the
provide satisfactory control of the air quantity
liquid in the con denser, thus reducing the
in many cases, although some difficulty is
amount of effective condensing surface. The
experienced with dampers when the condenser
subcooled liquid coming from the condenser
is exposed to high wind velocities.
is forced through the heat exchanger portion
A more satisfactory method of controlling
of the pressure stabilizer and receives enough
the capacity of air-cooled condensers is to
heat from the hot gas to satisfactorily establish
vary the amount of effective condensing
the balanced pressure temperature relationship
surface by causing the liquid refrigerant to
in the receiver. This assures satisfactory
back up into the lower portion of the condenser
condensing pressure and a solid column of
whenever the condensing pressure drops
liquid at the refrigerant control.
below the desired minimum. To accomplish
TIie pressure stabilizer is designed with a
this, one design of capacity control employs a
pre determined pressure drop to insure against
modulating valve installed in a by-pass line
liquid refrigerant reheating during warm
between the inlet and outlet of the condenser
weather operations. During high ambient air
(Fig. 14-19). As the receiver pressure falls,
tempera tures, where thecondensing
the modulating valve opens and allows high-
temperature isabove the setting of the
pressure vapor from the compressor discharge
regulating valve, the liquid flows through the
to flow through the by pass line, thereby
valve, which is fully open, and thereby by-
restricting the flow of liquid refrigerant from
passes the heat exchanger section (Fig. 14-
the condenser and causing the liquid to back
21a). In Fig. 14-2lb, as the ambient
up into the lower portion of the unit. The
temperature drops to 50° F the condensing
amount of discharge vapor by-passed, and
tem perature drops below the setting of the
thecefore the amount of liquid refrigerant
regulat ing valve. The valve then modulates
retained in the lower portion of the condenser,
toward the closed position, and this action
is automatically controlled by the modulating
limits the flow of liquid through the regulating
valve and depends upon the receiver tank
valve. Consequently, the liquid backs up in
pressure.
the con
Another device used to restrict the amount denser until the condensing surface is reduced
of effective condensing surface is called a
approximately 60%, The liquid which is
"pressure stabilizer" (Fig. 14-20). The
forced to pass through the heat exchanger
following descrip tion of the operation of the section is then heated up to the saturation
pressure stabilizer is reprinted directly from temperature. When the ambient temperature
the manufacturer's engineering data.• drops to 0° F (Fig. 14-2lc), the regulating
The pressure stabilizer is a heat transfer valve throttles to hold 120 psi in the
surface which transfers the heat from the hot condenser. The liquid logs in the condenser
gas discharge of the compressor to the so that approximately l0% of the surface is
subcooled liquid leaving thecondenser. This utilized to condense the hot gas. With regard
heat exchange to evaporative condensers, capa city control is
best obtained through regulation of the air
• Courtesy Dunham-Bush, Inc. quantity through the condenser, which can be
accomplished either by cycling the blower
 CONDENSERS AND COOLING TOWERS 270
270 PllllNCIPLES OF REFRIGERATION

Cycling of the pump as a means of controlling

136
psi
50° Amb., R-
12
102• Cond. temp.
Fl1, 14-21. Air-cooled condenser controt employing
pressure stabilizer. (Courtesy Dunham-Bush, Inc.)
or by installing dampers in the air stream. Of
the two methods, the latter is usually the most
satisfactory, especially where modulating dam
pers are used and the air quantity can be varied
through a wide range.
the capacity of an evaporative condenser cannot
be recommended. Each time the pump cycles
off a thin film of scale is formed on the con
denser tubes. Consequently, frequent cycJing of
the condenser pump greatly increases the scaling
rate, which reduces the efficiency of the con
denser and greatly increases maintenance costs.
With reference to water-cooled condensers,
recall that for a given load and condensing
surface, the condensing temperature varies with
the quantity and temperature of the water
entering the condenser. Where waste water is
used, the modulating action of the water
regulating valve controls the water flow rate
through the condenser and maintains the con
densing temperature above the desired minimum
so that low condensing temperatures are not
usually a problem with waste water systems. On
the other hand, since the flow rate of the water
through the condenser on a recirculating water
system is maintained constant, the condensing
temperature decreases as the temperature of the
water leaving the tower decreases. Therefore,
when the ambient air temperature is low, the
condensing temperature will also be low unless
some means is provided for restricting the flow
rate through the condenser or for increasing the
temperature of the water leaving the tower.
One method of controlling the condensing
temperature in a recirculating water system is to
install a water-regulating valve in the water line
at the inlet to the condenser. The modulating
action of the water valve will restrict the water
flow rate through the condenser in response to a
drop in the condensing pressure. When a water
regulating valve is used in a recirculating water
system, the pressure drop through the valve
must be taken into account in computing the
total pumping head.•
Where mechanical draft cooling towers are
used, the condensing temperature can be main
tained at the desired level through regulation of
the tower leaving water temperature. As in the
case of the evaporative condenser, this can be
accomplished by cycling the tower fan or by
installing dampers in the air stream.
• Except in those cases where they have a specific
function, water-regulating valves should never
be used in recirculating water systems, since they
tend to restrict the water flow and increase the
pumping head unnecessarily.
 CONDENSERS AND COOLING. TOWERS 271
14-22. Winter Operation. When the com
pressor and/or condenser are solocated that
they are exposed to low ambient
temperatures,·the pressure in these parts may
fall considerably below that in the evaporator
during the com pressor· off-cycle. In such
cases, the liquid refrigerant, which otherwise
would remain in the evaporator, very often
tends to migrate to the area of lower pressure
in the compressor and condenser. With no
liquid refrigerant in the
evaporator, an increase in evaporator tempera
ture is not reflected by a corresponding increase
in the evaporator pressure, and, where the sys
tem is controlled by a low pressure motor
control, the rise in evaporator pressure may
not be sufficient to actuate the control and
cycle the system on in response to an increase Pump
in the evaporator temperature.
Corrective measures are several. One is to Fl1, 14-23. Evaporative condenser equipped with
install a thermostatic motor control in series modulating dampers for capacity control. Protected
with the low pressure control. The thermostat auxiliary pump Is designed to prevent freezing during
winter operation. (Courtesy Refrigeration Engineer
is adjusted to cycle the system on and off, ing Inc.)
whereas the low pressure control serves only as
a safety device. Another, and usually more
prac tical, solution is to isolate the condenser denser during the off-cycle. 1be (R) valve,
during the off-cycle. One method of isolating which closes on drop of pressure at the valve
the con denser during the off-cycle is inlet, closes when the compressor stops, pre
illustrated in Fig. 14-22. The check valve (C) venting the flow of refrigerant from the evapo
in the condenser liquid line prevents the rator, through the compressor valves and
refrigerant from boiling off in the receiv_er discharge line, into the condenser. With the
and backflowing to the con- condenser isolated, the evaporator pressure
can build up and start the compressor
regardless of the ambient temperature at the
condenser.
Air- Modulating valve Another and rather obvious problem con
cooled (open on rise of cerning the opera•fon of evaporative
condense inlet pressure)
r condensers and cooling towers in the
wintertime is the danger of freezing when the
Check valve equipment is exposed to freezing
temperatures. In general, the measures
employed to prevent freezing are similar to
those used to prevent low condensing
temperatures, that is, controJling the air
quantity ough the tower by the use of
dampers or by
Modulating by-pass From cycling the fan. In addition, an auxiliary sump
valve-open of drop discharge
in outlet pressure must be installed in a warm location and the
piping arranged so that the water drains by
Fl1, 14-ll. Sure-start Wlnterstat provides normal gravity into the auxiliary sump and does not
head and receiver pressures when the compressor
remain in the tower or condenser sump (Figs.
starts by allowing the compressor to Impose lu full
discharge pressure on the liquid through the open
14-23 and 14-24).
(W) valve. When the receiver pressure Is up to 14-23. Condenser and Tower Maintenance.
normal, the (R) valve opens and allows the discharge As a general rule, air-cooled condensers
gas to flow to the condenser. (Courtesy Kramer require little maintenance other than regular
Trenton Company.) lubrication of the fan and motor bearings.
However, the
272 PRINCIPLES OF REFRIGERATION CONDENSERS AND COOLING. TOWERS 272

tubes by applying an approved inhibited acid

r
compound, many of which are available in
either liquid or powder form. After the tower
Tower or condenser sump has been drained, deaned,
static and filled with fresh water, the cJeaning com
head pound can be added directly to the sump
water. The pump is then started and the
cleaner is circulated through the system until
the system is clean, at which time the sump is
again drained, flushed, and filled with cJean
Additio
static head.._
nal
water before the system is placed in normal
L . , tank
Indo
or
operation.
It should be pointed out that dcsca1ing com
pounds have an acid base and should not be
allowed to contact grass, shrubs, or painted
surfaces. Therefore, it is usually advisable to
remove the cooling tower spray nozzles, if
any, in order to minimize the danger of
damaging shrubs or painted surfaces with drift
from the tower.
Conden When rapid descaJing of the condenser tubes
ser is required, an inhibited solution {18%) of
muriatic acid may be used. However, muriatic
acid should be used only on the condenser
Fl1. 14-24. Protected Indoor tank. tubes. The system pump should not be used to
circu late the acid. A small pump having an
acid resistant impeller (brass or nylon) may be
fan blades and condensing surface should be used for this purpose (see Fig. 14-25). After
inspected occasionally for the accumulation of the condenser is clean, it should be flushed
dust and other foreign materials. These parts with clean water or with an acid neutrali7.er as
should be kept clean in order to obtain high recommended by the manufacturer.
efficiency from the condenser. Corrosion is usually greatest in areas near
Any type of condenser employing water is salt water or in industrial areas where relative
subject to scaling of the condenser tubes,
corro sion, and the growth of algae and
bacterial slime on all wetted surfaces. The
latter is con trolled by frequent cleaning of the
infected parts and by the use of various
algaccides which arc available commercially.
As previously stated, the scaling rate
depends primarily upon the condensing
temperature and the quality of water used.
The scaling rate will be relatively low where
the condenser leaving water temperature is
below 100° F. Too, the importance of
providing for the recommended amount of
.bleed-off'cannot be ovcremphasiud with
regard to keeping the scaling rate at a
minimum. In addition, a number of chemical
companies have products which when added
to the sump water considerably reduce the
scaling rate.
Scale can be removed from the condenser Fl1. 14-25. Apparatus for descalin1 condenser.
large concentrations of sulfur and other indus trial fumes are found in the atmosphere. Corro sion damage is
minimi7.Cd by regular cleaning and painting of the affected parts and by application of protective coatings of
various types.
PROBLEMS

1. An R-12 system is operating at an evaporator temperature of 0° F and a condensing tempera ture of 100° F.
From Chart 14-1, determine the heat load on the condenser in Btu per minute per ton of refrigeration. Ans. 251
Btu/min/ton
2. An R-22 system operating with a 40° F evaporator and a I l0° F condenser has an evaporator load of IO tons.
Determine the heat load on the condenser in Btu/hr.
Ans. 141,000Btu/hr
3. The heat rejected to a water-cooled con denser is 120,000 Btu/hr. How many square feet of effective tube
surface must this condenser have if the U factor of the condenser is I 00 Btu/hr/sq ft/° F and the METD is 5° F at
the desired gpm? Ans. 240 sq ft
4. The heat load on the evaporator of an air conditioning system is 60,000 Btu/hr. If the coefficient of
performance of the system is 4 : 1, what is the heat load on the condenser in Btu/hr?
Ans. 75,000 Btu/hr
5. An R-12 waste water system operating at a 40° F suction temperature and a 105° F con densing temperature
has an evaporator load of 5 tons. If the condenser is selected for a 12° F water temperature rise, how many gpm
must be circulated through the condenser?
Ans. 11.5 gpm
6. Seventy-two gallons of water per minute are circulated through a water-cooled condenser. If the temperature
rise of the water in the con denser is 14° F, what is the heat load on the condenser? Ans. 504,000 Btu/hr
7. An R-12 air conditioning system operating with an evaporator temperature of 40° F and a condensing
temperature of 120° F has an evaporator load of 60,000 Btu/hr. 4500 cfm of air arc circulated over the
condenser. If the temperature of the air entering the condenser is 90° F, compute: (a) the leaving air temperature
and (b) the METD.
Ans. (a) 104.6° F (b) 21.89° F
8. If the air-cooled condenser in Problem 7 has a free face area of 5.5 sq ft, what is the velocity of the air through
the condenser?
Ans. 818 fpm
9. From Table R-12, select an air-cooled con denser for a compressor having a capacity of 42,000 Btu/hr if the
design suction and discharge temperatures are 40° F and 130° F, respectively, and the outdoor design dry bulb
temperature for the region is 95° F.
10. Select a shell-and-tube water-cooled con denser for an R-12 system to meet the following conditions:
Refrigeration load and eva-
porator 60 tons
Evaporator temperature 40° F
Condensing temperature 110° F
Water quantity 2.5 gpm/ton Untreated cooling tower water enters con-
denser at 85° F.
11. Rework Problem 10 using a condensing temperature of 120° F.
12. A cooling tower and a water-cooled con denser (with by-pass) are operating with a condenser load of
240,000 Btu/hr. Forty-eight gpm are circulated through the condenser and 32 gpm are by-passed. The ambient
wet bulb temperature is 78° F and the tower approach is 7° F. Determine:
(a) The temperature of the water entering the condenser. Ans. 85° F
(b) The temperature of the water leaving the condenser. Ans. 95° F
(c) The temperature of the water entering the cooling tower. Ans. 91° F
(d) The tower range. Ans. 6° F
13. A compressor on a Refrigerant-12 system has a capacity of 50 tons. The design wet bulb temperature is 78°
F. The desired condenser water entering temperature is 85° F and the desired temperature rise through the
condenser is 12° F. Select a cooling tower from Table R-15 and determine:
(a) The total gpm circulated over the tower
(b) The temperature of the water entering the tower
(c) The temperature of the water leaving the
condenser
(d) The tower range
(e) The gpm circulated through the condenser (/) The gpm by-passed
14. Select an evaporative condenser for the following conditions:
Refrigcrant-12 system
Evaporator load-10 tons Evaporator temperature-40° F
Wet bulb temperature of entering air-78° F Condensing temperature-105° F