Induced Draft Cooling Tower

INDUCED DRAFT COOLING TOWER

PROJECT REPORT

ON

‘INDUCED DRAFT COOLING TOWER’

B.S.PATEL POLYTECHNIC,KHERVA

PROJECT GROUP: (1) Patel Kaushal 126440319030

(2) Patel Utkarsh 126440319031

(3) Patel Ravi 126440319032

(4) Patel Vishal 126440319038

(5) Patel Pasavin 126440319042

INTRNAL GUIDE- Mr.A.M.Patel H.O.D:-Mr.K.P.Patel

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CERTIFICATE

This is to certify that Mr.Patel Kaushal A. having Enrolment No

: 126440319030 has completed Part-I UDP Project work having title Induced Draft Cooling

Tower.

He has undergone the process of shodh yatra, literature survey and problem

definition. He is supposed to carry out the residue UDP Part-II work on same problem

during Semester-V for the final fulfillment of the UDP work which is prerequisite to

complete Diploma Engineering.

Guide – Mr.Alpesh M.Patel H.O.D:-Mr.K.P.Patel

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CERTIFICATE

This is to certify that Mr.Patel Utkarsh R. Having Enrolment No


Tower.





Guide – Mr.A.M.Patel H.O.D:-Mr.K.P.Patel

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CERTIFICATE

This is to certify that Mr.Patel Ravi S. having Enrolment No : 126440319032

has completed Part-I UDP Project work having title Induced Draft Cooling Tower .






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CERTIFICATE

This is to certify that Mr.Patel Vishal P. having Enrolment No


Tower .






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CERTIFICATE

This is to certify that Mr.Patel Pasavin H. having Enrolment No


Tower .






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INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM

STUDENT PARTICULARS-1

FIRST NAME KAUSHAL

LAST NAME PATEL

MOBILE NO. 1 8154887042 2 9924972429

EMAIL [email protected]

ENROLLMENT NO:-126440319030

COLLEGE NAME B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.

ADDRESS

AT:SHER

TA:MANDAL

DIST:AHEMEDABAD

BRANCH MECHANICAL ENGINEERING

SEMESTER 5th SEM. YEAR 2014-2015

TEAM NAME G-6

SIGNATURE OF STUDENT

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mailto:[email protected]




FIRST NAME UTKARSH

LAST NAME PATEL

MOBILE NO. 1. 9998385986 2. 7600083413



COLLEGE NAME

B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.

ADDRESS

AT:KIMBUVA

TA:PATAN

DIST:PATAN

BRANCH


TEAM NAME G-6


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FIRST NAME RAVI

LAST NAME PATEL

MOBILE NO. 1. 7874697626 2.



COLLEGE NAME


ADDRESS

AT:MOTAP

TA:BECHARAJI

DIST:MEHSANA



TEAM NAME G-6


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FIRST NAME VISHAL

LAST NAME PATEL

MOBILE NO. 1. 9924392268 2. 9033335659



COLLEGE NAME B.S.PATEL POLYTECNIC, GANPAT UNIVERSITY.

ADDRESS

35-YOGESHWAR PARK SOCIETY,

WONDERPOINT,CTM,

AMRAIVADI,AHMEDABAD



TEAM NAME G-6


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FIRST NAME PASAVIN

LAST NAME PATEL

MOBILE NO. 1. 9537149323 2. 8734830193



COLLEGE NAME


ADDRESS

AT: MANDRISANA

TA:DETROJ

DIST: AHMEDABAD



TEAM NAME G-6


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ACKNOWLEDGEMENT

We are feeling pleasure introducing our project “INDUCED DRAFT COOLING TOWER”

result of our new radical ideas to significant windup our studies during in course “DIPLOMA

IN MECHANICAL ENGG.” B.S.Patel Polytechnic,Kherva,Mehsana. Suggestion to improve

quality of product are always well come many hands have given their active support &

contributed for design& development of “INDUCED DRAFT COOLING TOWER”

We would like to thank our Prof.A.M.Patel, we would also like to thank our respected

principal B.S.Patel &our head of the department Prof. K.P.Patel.

And special thank to Prof. A.M.Patel (Induced draft cooling Tower designer) for their kind

co-operation & excellent help in making of project.

Your Truly :-

Kaushal

Utkarsh

Ravi

Vishal

Pasavin

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INDEX

Sr. No. Topics Name Page No.

01 SUMMERY 14

02 SELECTION OF PROJECT 15

03 MARKET SURVEY 16

04 INTRODUCTION 17

05 DEFINITION OF A PROJECT 18

06 AIM OF PROJECT 19

07 BASIC ELEMENTS OF PROJECT 20

08 WORKING PRINCIPLE 21

09 CLASSIFICATION OF COOLING TOWER 22

10 PARTS OF COOLING TOWER 23

11 MECHANICAL &THERMAL DESIGN PARAMETERS

OF COOLING TOWER

26

12 DESIGN CALCULATION 27

13 PROCEDURE FOR THE EXPERIMENT 28

14 PLANNING OF PROJECT WORK 29

15 REQUIRED MACHINE TOOLS & EQUIPMENTS 30

16 OPERATION PROCESS CHART & FLOW PROCESS

CHART

31

17 COSTING & CALCULATION 35

18 ADVANTAGES & DISADVATAGES 37

19 CONCLUSIONS 38

20 REFERENCES 39

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SUMMARY

We can see many projects in our work shop like furnace, speed reduction gear box, Rolling

mill, Thermal Power Plant, Glass cutter machine etc. But finally we decided to select the

Induced draft cooling tower. As a project.

For that first we collected all the required material like MS sheet, PVC pipes, Fins, Wire

mesh, exhaust fan, Stand, Nut and bolts and some other material for cooling tower.

After this all and after some operations like cutting, bending, welding and fitting. Finally we

assembled the parts of our project with final testing.

In this project of Induced draft cooling tower, we are clever students is participate are as

follow.

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SELECTION OF PROJECT

Before selecting a project, survey has to be done regarding demand & market value of the

product feasibility of the available resources & facilities.

RESOURCES OF PROJECT

Resources of project, which are very useful for doing project work are given below :

• Tool room

• Machine shop

• Fabrication Industries

• Discussion with project guide

• Market survey

• Industrial support

LITERATURE SURVEY

We have survey following literature or books for selection of project.

• Thermal engineering

• Powerplant engineering

• www.coolingtower.com

• www.induceddraftcoolingtower.com

• Autocad 2014& application.

Selection of Projection

• Resource utilized • Entrepreneurship

• Liberty • Discuss with student group

• Market survey. • Discuss with project in charge

• Magazine

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MARKET SURVEY

Before you launch the product you need to check your self-market product for the product

selected by you

A comprehension market study in must be specific advantages of such study are as under.

• It makes it possible for you to estimate scale & utilization of installed capacity with

reference to proposed enterprise.

• You can judge weather the proposed capacity is one the higher or lower size.

• It enables you to evaluated the viability of an enterprise by arcing at a years

estimate of seals.

• It provides a preliminary input for the marketing strategy & process formulation or

the enterprise (A market program is set of decision required in respect of various

markets related to issues it influences the market.)

Market survey is usually focused on gross market demand present & future. It typically

highlights the gap between expected market demand & supply in respect offer given

product. Such a gap could be positive & therefore favorably. The gap could also negative.

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INTRODUCTION

Over heating of machine elements is common problem in industry. It is caused due

to continuous operation of machine and atmospheric conditions of the surroundings.

Operation cannot be stopped or in other words the machine cannot be given time to be

cooled down and therefore there has to be provision for cooling. Water is the best cooling

medium as it is cheap and available in abundance. However it has to be noted that

continuous flow of fresh water to the machine is not advisable as it creates great waste.

Cooling tower is used to fulfil the purpose of cooling with minimum usage of fresh

water. It circulates fresh water for cooling to the machine and uses least make up water

that is lost due to evaporation. Apart from industry cooled water is needed for, for example,

air conditioners, or power generation. A cooling tower is the equipment used to reduce the

temperature of a water stream by extracting heat from water and emitting it to the

atmosphere. Cooling towers make use of evaporation whereby some of the water is

evaporated into a moving air stream and subsequently discharged into the atmosphere. As

a result, the remainder of the water is cooled down significantly as shown in the figure.

Cooling towers are able to lower the water temperatures more than devices that use only

air to reject heat, like the radiator in a car, and are therefore more cost-effective and energy

efficient.

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DEFINITIONS

WHAT IS A COOLING TOWER?

A cooling tower is a heat rejection device, which extracts waste heat to the

atmosphere though the cooling of a water stream to a lower temperature. Common

applications for cooling towers are providing cooled water for air-conditioning,

manufacturing and electric power generation. The generic term "cooling tower" is used to

describe both direct (open circuit) and indirect (closed circuit) heat rejection equipment. A

direct, or open-circuit cooling tower is an enclosed structure with internal means to

distribute the warm water fed to it over a labyrinth-like packing or "fill." The fill may consist

of multiple, mainly vertical, wetted surfaces upon which a thin film of water spreads. An

indirect, or closed circuit cooling tower involves no direct contact of the air and the fluid,

usually water or a glycol mixture, being cooled. In a counter-flow cooling tower air travels

upward through the fill or tube bundles, opposite to the downward motion of the water. In a

cross-flow cooling tower air moves horizontally through the fill as the water moves

downward. Cooling towers are also characterized by the means by which air is moved.

Because evaporation consists of pure water, the concentration of dissolved minerals and

other solids in circulating water will tend to increase unless some means of dissolved-solids

control, such as blow-down, is provided. Some water is also lost by droplets being carried

out with the exhaust air (drift)

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AIM OF PROJECT

• To developed attitude of inquiry

• To work as leader & as a member if a team

• To measure physical phenomenon.

• To developed problem solving ability.

• To developed ability of report writing.

• To developed planning & disciplinary studies

• To give students an opportunities to learn of to keep good record.

• To present students an excising and demanding challenges.

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BASIC ELEMENTS OF PROJECT

1. Operation :

These are to carried out in particular sequence to order it would still better, if the

method of performing each operation may also be established. It may be kept in mind that

for carrying out each. Actually there is always an expenditure of resources may be in terms

of coast, time etc.

2. Resources :

For the purpose of carrying out the activities, the resources meet are in term of

manpower, material, machines, money & time. The competitions of any activity or for that

matter the future project can not be said to be over values required resources are made

available at the appropriate time. In other word man has to be prepared co-ordination these

resources.

3. Conditions :

The activities are carries out under specified conditions of restrictions which we

have a direct bearing on the competition of the involving the factor.

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WORKING PRINCIPLE OF INDUCED DRAFT COOLING TOWER

Cooling tower is essentially a heat and mass transfer device. It removes

heat from the water and loses a fraction of water during heat transfer to the air. When air is

blown from downwards it came in contact with upcoming water the enthalpy of which is

higher and at the time of contact this air causes evaporation of water droplet. It is known

that in order to get evaporated water requires to gain certain amount of latent heat. It does

so from nearby droplet and evaporates into vapour form. Due to removal of sensible heat,

remaining water droplets loses temperature and cools down. Due to higher surface area in

packing heat transfer rate increases and water is further cooled to the require temperature.

Air moving upward takes away certain amount of water content in (vapour form) with it

which is not desirable. In order to recover lost water drift eliminators are provided.

Upcoming air loses their velocity and causes certain amount of vapour to be converted into

water. The water falls downward and collected in the basin.

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CLASSIFICATION OF COOLING TOWER

Classification of cooling tower

Natural Draft Mechanical Draft Cooling Tower Cooling Tower Spray Packed Hyperbolic Forced Induced Type Type Draft Draft Draft

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PARTS OF INDUCED DRAFT COOLING TOWER

FILLS :

Our honey combed PVC fills are high performance heavy duty, law weight, excellent

resistance to corrosion. These offer a striking balance between maximum heat transfer

surface area vis-à-vis minimum restriction to air flow.

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INDUCED DRAFT COOLING TOWER FAN :

The Axial flow fan consists of cast Aluminum or FRP variable pitch aerofoil blades fitted on a M.S. hot dip galvanized hub with S.S. 304 "U" bolts & nuts. The balanced fan assembly is mounted directly on the shaft of weather proof, flanged motor.

WATER DISTRIBUTION These spray water to wet the fill. Uniform water distribution at the top of the fill is

essential to achieve proper wetting of the entire fill surface. Nozzles can either be fixed and

spray in a round or square patterns, or they can be part of a rotating assembly as found in

some circular cross-section towers.

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DRIFT ELIMINATORS:

These capture water droplets entrapped in the air stream that otherwise would be

lost to the atmosphere.

Air inlet:

This is the point of entry for the air entering a tower. The inlet may take up an entire

side of a tower (cross-flow design) or be located low on the side or the bottom of the tower

(counter-flow design).

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MECHANICAL AND THERMAL DESIGN PARAMETERS FOR COOLING TOWER

power consumption by 7.5 tr cooling tower

In order to initiate cooling tower design the following parameters have been considered,

Technical Parameter Quantity Volume of circulating water (L) 3.8 m3/h Inlet temperature of water (T1) 38 0C Outlet temperature of water (T2) 32 0C Wet bulb temperature (WBT) 290C Height of the cooling tower (H) 1.2 m Inlet temperature of air (Ta1) 200C Outlet temperature of air (Ta2) 270C Design relative humidity (ɸ) 80% Allowable losses through Evaporation 1.44%

Thermal parameters Quantity Enthalpy of air at inlet temperature (Ha1) 50 KJ/Kg Enthalpy of air at outlet temperature (Ha2) 73 KJ/Kg Specific Humidity of air at inlet temperature (W1)

0.0118 Kg/Kg of air

Specific humidity of air at outlet temperature (W2)

0.018 Kg/Kg of air

Specific Volume of air at inlet temperature (Va1)

0.842 m3/Kg

Specific volume of air at outlet temperature (Va2)

0.875 m3/Kg

Enthalpy of water at inlet temperature (Hw1) 159.10 KJ/Kg Enthalpy of water at outlet temperature (Hw2)

134 KJ/Kg

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DESIGN CALCULATION

• Cooling tower approach (cta)

CTA = T2 – WBT = 32 – 29 = 3 0C

• Cooling tower range (ctr) CTR = T1 – T2 = 38 – 32 = 6 0C

• Mass of water circulated in cooling tower

Mw1 = Volume of circulating water x Mass density of water Mw1 = 3.8 x 1000 Mw1 = 3800 Kg / hr

• Heat loss by water (HL)

HL = Mw1 x Cpw x (T1 – T2) HL = 3800 x 4.186 x (38 - 32) HL = 99440.8 KJ / hr

• Volume of air required (G)

G = (HL x Gs1) / [(Ha2 – Ha1) - (W2 – W1) x Cpw x T2]

G = (99440.8 x 0.842) / [(73 - 50) – (0.018 – 0.0118) x 4.186 x 32] G = 3776.69 m3 / hr

• Mass of air required (Ma) Ma = Volume of air required / Specific volume of air at inlet temperature Ma = G / Gs1 Ma = 4485 Kg / hr

Based on above data power calculation can be calculated as follows,

Fan power = Air Volume (in ACFM) X Total Pressure in inch / 6356

=2223X0.6434/6356

=0.25 HP

=0.25 X 746 watts

=186.5 watts

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PROCEDURE FOR THE EXPERIMENT

Initially tower performance will be determined by considering anonymous range and later

on it will be compared with the experimental one.

Range considered for the cooling tower is 38-32=6 c; where 38 is inlet temperature and 32

is outlet temperature.

Following equation is used to determine cooling tower efficiency which is known as the

merkel equation.

KaV/L = [(T1 – T2) / 4] x {(1 /Δ h1) + (1 / Δ h2) + (1 / Δ h3) + (1 / Δ h4)}

Where,

K = Mass transfer co-efficient (Kg / hr m2); V = Active cooling volume (m3); T1 = water temperature entering the cooling tower, 0C; T2 = water temperature leaving the cooling tower, 0C; hw = enthalpy of saturated air at water temperature, kJ/(kg of dry air); ha = enthalpy of air, kJ/(kg of dry air); a = total area of wetted surface includes the surface area of water drops as well as wetted slats or other fill material, m2; L = water mass flow rate, kg/s; Now, Δ h1 = Value of Hw - Ha at T2 + 0.1 (T1 – T2) Δ h2 = Value of Hw - Ha at T2 + 0.4 (T1 – T2) Δ h3 = Value of Hw - Ha at T1 - 0.4 (T1 – T2) Δ h4 = Value of Hw - Ha at T1 - 0.1 (T1 – T2) Calculation gives the following value for cooling tower performance KaV / L = 0.1540 EFFICIENCY OF COOLING TOWER N = (T1 – T2) / (T1 – WBT) N = (38 - 32) / (38 - 29) N = 66.67 % EFFECTIVENESS OF COOLING TOWER P = (T1 – T2) / (T1 – Ta1) P = (38 - 32) / (38 - 20) P=0.33

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PLANNING OF PROJECT WORK

In the planning we have to select a project for our team has continue for give members for

this we added our past memory with a view of final a project that we must write to us.

We visited in many industries, visited library, read various books pertaining to

technical side made tentative collection of these all the project. Among these all the project

we compared the feasibility of project and reached at the decision to manufacture “Induce

draft cooling tower”. Because at the fact that it was available in our college workshop and

second during manufacture of this stall it should be easy for us to read and study the

thoughts to prevail difficulties.

In the planning stage we have also to analyze and study the different components

and part by dismantling the “Induce draft Cooling tower” and model list.

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REQUIRED MACHINE TOOLS & EQUIPMENTS

The tools & equipment, which are needed for project Induced draft cooling tower.

We must required different machines for different operations like.

• Sheet cutting machine (Hand shearing machine)

• Sheet banding machine

• Welding machine

• Drilling machine

• Hand grinder

And also some equipments like

• Measuring tape (500 mm)

• Venier caliper (200 mm)

• Marker (Standard quality)

• Hand hacksaw (300 mm)

• Drill bit (3 mm to 15 mm)

• Right (single) point cutting tool.

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FLOW PROCESS CHART

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COSTING

• There are three elements of any products are :

• Material

• Labor

• Expenses

• Material : • Direct material :

Material which is processed for final product but it is a part of the product is direct

material cost is this material is called direct from market.

• In – direct material :

Material which does not forms part of the final product but it is a must be for

processing direct material is called in-direct material e.g. – Cotton waste, oil, etc.

• Labor : • Direct labor :

The worked who actually performed the work on the directly material rather

mechanically of by machine is called direct labor.

• In-direct labor :

It supervised the activity of the direct labor.

Expenses :

• Direct Expenses :

The expenses, which can be directly changed on the particular product, are called

expenses.

• In – Direct Expenses :

The expenses that can not be directly or confidently changed on particular

products are called in-direct expenses.

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CALCULATION

Prime cost

• Direct material + Direct labour

= 6000 + 1,495

= 7,495 Rs.

• Overhead cost :

15% Prime Cost

= 1,124.25 Rs.

• Production cost :

= 7,495 + 1,124.25

= 8,619.25 Rs.

• Net Desired Profit

15% of production cost

= 1,292.88 Rs.

• Selling Price :

Production + Profit

= 8,619.25 + 1,292.88

= 9,912.13 Rs.

• Selling price of Cooling Tower is 9,912.13 Rs.

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ADVANTAGES AND DISADVANTAGE

Advantages:-

The main advantage is that coldest water comes in contact with the direct air & warmest

water comes in contact with most humid air.

• The re-circulation is seldom a problem with this tower as outlet a discharge the

heated & humidity away from air enters below the tower.

• The size of 20 in diameter can be used.

• Claims are made that the ID fan tower has the advantage of tower first cool, requires

less space, and is capable of cooling through a wide range.

• The first cost is lower due to the reduction in pump capacity required & smallest

length of water pipes. The power consumption per kg. of water cooled is less

compared with FD fan system

Disadvantages:-

• The static pressure loss is higher as restricted are at base tends to above off the

flow of high velocity air. This requires higher HPmotor to drive the fan compared with

forced draft handling equipment.

• The air velocities through the packing are contently distributed & it has very little

movement near the walls & center of the tower.

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CONCLUSIONS

The described study allows site-specific scenario calculations for the possible

development of water temperatures and the related impacts on the power plant cooling

system: these are e.g. cooling water temperature, heat discharge to the river or additional

operation costs due to high temperatures and low water levels. Therefore, the model will

provide a basis for site-specific adaptation measures.

Temperature inversions reduce a particular natural draft wetcooling tower heat

rejection by approximately 20% in winter and by approximately 8% in summer. The

reduction in tower performance due to the adversely affected pressure differential (draft

equation) on the outside of the tower, during temperature inversions, accounts for

approximately 20% of the total loss and the increased effective inlet temperature (transfer

process) for approximately 80% of the reduction in tower performance.

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REFERENCES

Thermal Design Of Cooling Tower.pdf, Authors: Ronak Shah & Trupti Rathod, LDRP

institute of Technology and Research, Gandhinagar, India

Cooling Tower Design.pdf, Karachi

Workshop Exercise - Cooling Tower.pdf, www.energyefficiencyasia.org , UNEP

(Asia)

Cooling Tower Basics And Common Misconceptions.pdf, Jalal Engineering, [email protected] Karachi

Cooling Tower, Bureau of Energy Efficiency (India)

Cooling Tower Thermal Design Manual, page 6-21, Technical site of Daeil Aquaco.

LTD, USA

http://www.engineeringtoolbox.com/fans-efficiency-power-consumption-d_197.html

For experiment outlet temperature will be measured using thermometer and cooling tower performance will be found using above mentioned equation.

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Induced Draft Cooling Tower