COOLING TOWERS

A cooling tower is a specialized heat exchanger in which air and water are brought into direct contact with each
other in order to reduce the water’s temperature. As this occurs, a small volume of water is evaporated,
reducing the temperature of the water being circulated through the tower.
Water, which has been heated by an industrial process or in an air-conditioning condenser, is pumped to the
cooling tower through pipes. The water sprays through nozzles onto banks of material called “fill,” which slows
the flow of water through the cooling tower, and exposes as much water surface area as possible for maximum
air-water contact. As the water flows through the cooling tower, it is exposed to air, which is being pulled
through the tower by the electric motor-driven fan.
TYPES OF COOLING TOWERS
Cooling towers can be classified into two main types based on how air is drawn through the tower.
NATURAL DRAFT COOLING TOWER
Natural draft cooling tower is made from concrete in a hyperbolic shape which are enabled to obtain air flow
through chimney effect. This type of towers is mostly used in power stations. Hot water from the system is
cooled through direct contact with fresh air. This increases the temperature and humidity of the air in the
tower. Warm and moist air is less dense, which causes it to moves out of the tower into the atmosphere and
draw in denser fresh air. The difference between the warm air inside the tower and the cooler air outside
creates the perfect air flow.
MECHANICAL DRAFT COOLING TOWERS
Mechanical draft cooling buildings are widely utilized in structures that rely on power-driven buffs to remove or
push the atmosphere via the building. In other words, propeller lovers or centrifugal fanatics distribute the
atmosphere mechanically inside the building. They are typically discovered beyond the structure. Automated
draft towers arrive with a close plan and are influential and variably flexible to the individual operating and
climatic requirements. Similarly, they are the excellent answer for industrial applications such as authority
manufacturers, chemical and petrochemical manufacturers, steel manufacturers, perspective detachment
manufacturers, and the automotive endeavor, lumber, and document manufacturers as pleasingly as in
philosophy movement/ refrigeration techniques. The two numerous typical styles of automated breeze towers
are rendered breeze and pushed draft.

CROSSFLOW COOLING TOWERS

Crossflow are used to remove heat from water used in water-cooled applications. The heat is rejected to the
atmospheric air that is passed through the system fill in a crossflow or counterflow method. A small percentage
of the hot water from the system evaporates, cooling the remaining water which falls into the cold-water basin
which is then pumped from the cold water basin to the system to absorb more heat in a continuous process.

COUNTERFLOW COOLING TOWERS

The counterflow cooling tower is a type of cooling tower design that offers the maximum thermal performance
for its area of occupation. The fill media is horizontally installed beneath the hot water distribution basin, and
the cooling process is carried out as the air passes through the fill absorbing the heat from the water flowing
down the fill. The direction of the process water stream is opposite the airflow; hence, the name for the design.
The fan is usually located above the water distribution nozzles that pulls the air through the fill media (Induced
draft). It could also be installed at the air inlet section to push in the air inside the tower (forced draft). The
cooled process water would drain from the fill down to the cold water basin at the bottom of the tower.

HYPERBOLIC COOLING TOWERS

Hyperbolic cooling towers are a type of natural draft cooling tower that is diaracterized by its hyperbolic shape.
Hyperbolic cooling towers are very fall and can be seen from miles away. The hyperbolic shape helps to improve
the airflow the through the tower, which makes if more efficient. Hyperbolic cooling towers are typically used in
large application, such as power plant and refineries.

APPLICATIONS OF COOLING TOWERS

Cooling towers are used in a wide range of industrial and commercial applications including:

• Power plants

• Petrochemical plants

• Refineries

• Air conditioning systems

• Manufacturing plants

• Food processing plant

 DETERMINING REFRIGERANT LEAKAGE

1. Visual Inspection

If you find somewhere in the system with oil traces, probably that is the leakage point. This inspection method
can’t position precisely because the leakage point is usually very tiny and many parts of the refrigeration system
are barely visible. Unless it’s a big leakage point due to sudden break and the leaking liquid is coloured.

2. Bubble Water or Soapy Water Detection

Fill the cooling system with 10-20kg / cM2 pressure nitrogen, and then smear various parts of the system with
soapy water. The Bubbling is the leakage point. This is the most common approach for repair workers. But due
to human’s limited arms and visual acuity, you cannot very easily find the leakage points.

3. Nitrogen Water Detection

Fill the system with 10-20kg / cm2 pressure nitrogen, and soap it in the water. The bubbling is the point of
leakage. One obvious drawback of this method is that the water for leak detection can easily enter the system.
This will lead to corrosion of the materials in the system. At the same time, the high-pressure gas may cause
more damage to the system. And the labour intensity during the leak detection is also great.

4. Fluorescent Leak Detection

It applies the principle that fluorescent leak detector will emit a bright yellow-green under the UV / blue light
leak detector. It could be used as detection for fluid leakage in various types of systems. What you need to do is
just to add the fluorescent agent to the system according to a certain proportion. And after the system operates
for 20 minutes, wear special glasses and shine the outside of the system with the leakage light detector. The
leakage points will be yellow fluorescent.

5. Gas Pressure Detection

By using the pressure difference between interior and exterior of the system, the sensor will enlarge this
difference and express the test results in methods like digital, voice or electronic signal. This test way is also only
“qualitative” to know whether the system leaks and cannot accurately find the leakage points.

6. Halogen Lamp Detection

By holding lighted-up halogen lamp close to the system, the flame colour will turn into purple-blue when there
is a leak. This method is dangerous not only with the flame but also the combination of flame and refrigerant
will produce harmful gases, in addition, it is not easy to accurately locate the leak. So this method is almost out
of use now.

7. Electronic Leak Detector

This method has rapidly occupied the market thanks to its reliable and accurate functioning. By moving the
probe against the possible leakage places, the device will give an alert when there is a leakage. The electronic
leak detector is the most simple, quick and scientific leak detection method.

CHARGING A REFRIGERANT SYSTEM

Refrigerant charging is the process of adding refrigerant to a refrigerant system. Refrigerant should only be
performed by a qualified charging technician. To change a refrigerant system, the technician will first connect a
refrigerant charging manifold to the system. The technician will then use a vacuum pump to evacuate the
system of any air. Once the system is evacuated, the technician will add refrigerant to the system until the
desired pressure is reached.