THEORY

The theory behind the operation of the cooling tower is the First Law of
Thermodynamics, which is the conservation of energy. In simpler terms, the energy that
enters the system must exit the system, energy can neither be created nor destroyed,
and only transformed from one form to another.
Energy that enters the cooling tower is in the form of hot water. This hot water
was cooled from temperature T1 to a temperature of T2. The cooling of the hot water
was in the form of forced convection by which ambient air at T1 was blown over the hot
water and exited the cooling tower at some temperature T 2. Both the entrance and exit
temperatures of the air and water were recorded. Once this data is recorded, an energy
balance can be conducted on the system.
An energy balance is a form of bookkeeping that accounts for the energy
entering and leaving the system. The main component of the energy balance is
enthalpy which is defined as:
H = U + PV
Where H is enthalpy, U is internal energy, P is pressure, and V is volume.The combined
terms U+PV is enthalpy, which means to heat. Enthalpy can be calculated or referenced
from tables of data for the fluid being used. In the Engineering 435 laboratory, the fluids
used by the cooling tower are air and water, whose enthalpy values can be obtained
from a thermodynamics textbook. For example: Since both the initial and final
temperatures of the input hot water and the output cool water were measured, the
temperature Tin can be referenced and the enthalpy (BTU/lbm, or KJ/kg) can be
recorded. The enthalpy of the output cooled water can be similarly referenced and an
energy balance can be conducted for the water.
The equation below displays the general method to conduct an energy balance:
in =

out

where H = H in - H out. A similar method is employed for conducting the energy balance
for air entering and leaving the system.
The change in enthalpy for air can be determined form either of two methods. Since the
air is at low pressure, it can be treated as an ideal gas and the enthalpy change can be
calculated through the use of the following equation:
H = Cp

T (3)

where H is the change in enthalpy, T is the change in temperature, and C p is the

specific heat with respect to constant pressure.

The basic layout of the laboratory cooling tower system is shown below in Figure 1.

Figure 1 Cooling Tower System Schematic

Water from the water heater, which is denoted cooling water return (CWR), flows
through a hose to the cooling tower, where it is then carried by another hose to the top
of the cylindrical cooling tower. From here it is collected by a rotating sparger which
sprays the water over the area of the tower. The water then flows down the tower over a
series of baffles made from a cardboard style material. Ambient air is blown through a
duct perpendicular to the flow of water by the fan. This air interacts with the water
resulting in a net transfer of heat from the water to the air by the vaporization of some of
the water. The cooled water then flows into the reservoir which provides any make-up
water required to replenish that lost to evaporation. The reservoir is connected by a
hose to the water supply inside the laboratory. The level of the reservoir is kept constant
by a float valve which controls the flow of the make-up water from the water supply line.
From the reservoir, the water flows to the pump that returns the cooled water, now
denoted as cooling water supply (CWR), to the water heater via a hose. For more
detailed information on the setup of the cooling tower, refer to the setup/shutdown in
Appendix A. Also included in Appendix A is a procedure regarding safe operation of the
pump and fan motors and a procedure describing how to handle a mercury spill due to
breakage of thermometers.
Data collection for the tower is provided by a data link from the tower to a Macintosh
computer running Labview data collection software. Data collected by the software
includes the flow rate of the water through the system; the percent of total electrical load
of the fan (0-60 Hz), used to control the fan speed; the percent of total electrical load of

the pump (0-60 Hz), used to control the pump speed; the humidity and temperature of
the air entering the fan; the humidity and temperature of the air leaving the fan; the
temperature of the cooling water supply and the temperature of the cooling water return.
The water going into the cooling tower loses energy. The enthalpy of the water
going into the tower can be determined by using the enthalpy of saturated liquid water in
a steam table. The enthalpy of the water coming out of the tower can be determined in
the same way. The data in steam tables are usually not given for every temperature so
linear interpolation must be performed to determine the enthalpy at the desired
temperature. Then the enthalpy of the water is multiplied by the mass flow rate. A basis
of an operation of 1 minute was chosen to make the calculation easier. The change in
enthalpy for the water is determined by

The change in energy of the air can be determined using the same methodology as was
used for water. The enthalpy change is shown as

However, the determination of the enthalpy of air is more complicated than the
determination of the enthalpy values of the water stream. An important tool that is used
for this is the psychrometric chart. On the psychrometric chart, the enthalpy of the air
stream can be determined by using the wet bulb and the dry bulb temperature of the air
stream. The enthalpy is given with the units of BTU per pound of dry air. By using the
output stream, the volumetric flow per mass flow of dry air can be determined. This is a
conversion factor that is used to convert volumetric flow of air to pounds of dry air.
Now that the mass flow rate of dry air is known, the enthalpy values of the in and out
streams can be determined. The change in enthalpy of the water should have a
negative value, and the change in enthalpy of the air should have a positive value.
Theoretically, when the two values are added together, the result should be zero. This
can be shown by the first law of thermodynamics where

and

APPARATUS

1. Water cooling tower

2. Deionised water.

Load tank
Make up tank
Pump
Fan damper
Blower
Valves

PROCEDURE

General start-up procedure.

1.

Valve V1 to V6 are ensured to be closed while valve V7 is partially closed.

2.

The load tank is filled with deionised water.

3.

The make-up tank is filled with deionised water up to zero mark on the scale.

4.

Deionised water is added to the wet bulb sensor reservoir to the fullest.

5.

The appropriate cooling tower is installed for the experiment.

6.

All appropriate tubing to the differential pressure sensor is connected.

7.
The temperature set point of temperature controller is set to 45C. The 1.0 kW
water heaters is switched on and the water is heated up to approximately 40C.
8.
The pump is switched on and the control valve V1 is slowly opened. The water
flow rate is set to 2.0 LPM. A steady operation where the water is distributed and flowing
uniformly through the packing is obtained.
9.
The fan damper is fully opened and the fan is switched on. Check that the
differential pressure sensor is giving the reading :
a.
To measure the differential pressure across the orifice, open valve V4 and V5 ;
close valve V3 and V6.
b.
To measure the differential pressure across the column, open valve V3 and V6 ;
close valve V4 and V5.
10.
The unit is being let to run for 20 minutes for the float valve to correctly adjust the
level in the load tank. Refill the make-up tank as required.
11.

The unit is now ready to use.

Experiment 1.
1.

The heater is switched on and set to 0.5 kW.

2.

Pump and blower is then been switched on.

3.

The blower damper is fully opened.

4.

The water flow rate is set to 2 LPM.

5.

The water cooling tower is being let to operate for 10 minutes.

6.

The reading is taken when the float valve is correctly adjusted.

7.

Step 1-6 is being repeated with 1.0 kW and 1.5 kW heating load.

Experiment 2.
1.

The heater is switched on and set to 0.5 kW.

2.

The blower damper is fully opened.

3.

Set the water flow rate to 2 LPM.

4.

The unit is being let to run for 10 minutes.

5.

The reading is taken after steady operation achieved.

6.

Step 1-5 is being repeated with half opened blower damper.