CHAPTER 1

Introduction
The first step in design of air-conditioning system is the specification of the outdoor and
indoor design condition. The indoor design condition is specified based on comfort
condition for human beings and process requirements of industrial operation. The outdoor
conditions are obtained from weather data of the locality.

After the specification of outdoor and indoor design conditions, the second step will be
data collection about:

1. The building purpose, structure geographic location altitude, orientation, shape,

size and height relationship with adjacent buildings and light, etc.

2. The building materials and thickness of walls, roofs, ceilings, floor and their
relative positions in the structure.

Completing the data collections we will proceed with load calculation from which
cooling loads are determined

These loads are due to sensible and latent heat gains.

The amount of load dictates the supply air condition and its quality. The supply air
condition in turn dictates the system and equipments to be used.

The system used in this design is evaporative cooling. When hot and dry outdoor air is
pushed through a wetted surface with a fan there is a drop in the temperature of the as
some heat is taken from it to evaporate water.

Due to the evaporation of the water into the moving air the humidity of the air after
passing through the cooling media increase.

The temperature of the recirculated water remains constant in this cooling process.

Water is pumped by a pump which is buried in the water reservoir.

The pump which is used for this particular design is selected by using the flow rate of
water and by calculating the total head loss in the pipe. Similarly for the selection of fan
the flow rate of air and the pressure drops are used.

1
 CHAPTER 2
Basics of Dry Cooler
2.1 Introduction
Dry cooler is air-conditioning equipment used for cooling and humidifying home in dry
and hot climate.

An alternative to air conditioning, dry cooler uses evaporation, rather than chemical
coolant, to lower the temperature of air. For this reason it is sometimes called evaporative
cooler.

It is a large box-like frame containing a big fan and walled in by water-wetted pads or
cloth. The fan pushes the hot and dry outside air through the dripping pads which are
continuously soaked by a water pump. The air is then cooled and humidified as it
evaporates some water molecules from the pad. The fan then blows the water-cooled air
through the house.

Evaporative coolers have a low first cost, use a lot less electricity than conventional air
conditioners, and do not use refrigerants such as chlorofluorocarbons (CFCs).

Unlike air conditioned rooms, windows or ceiling vents need to be open when an
evaporative cooling system is operating. The large volume of fresh air added to the home
replaces a significant amount of air that exits from the home.

The most common form of residential evaporative cooling uses a wetted pad, a pump to
deliver water to the pad, and a fan to draw air through the porous pad as the water runs
down the medium and is absorbed. As dry air moves over the wet pad, water evaporates,
and the air gives up its heat. The air moving from the wet pad into the home is cooler
than the outdoor air.

The drop in temperature depends on how much water the air can absorb (a function of the
relative humidity), how evenly the pad media is wetted, and how long the air is exposed
to the pad (a factor of wetness, and speed of air movement), the evaporability of the water
(temperature of the water affect this).

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Evaporative cooler is used to lower the temperature of air by using latent heat of
evaporation, changing water to vapor. Warm dry air is changed to cool moist air. Heat in
the air is used to evaporate water.

2.2 How Dry Cooler or Evaporative Cooler Work

First one motor pumps water into the pad. Then another motor powers a fan that pushes
air through the wetted pad. When the entering air is hot and dry some of the water
evaporates into it and hence the cooled and humidified. Finally, the cooler air is pushed
through the wetted pad and into the home.

2.3 Advantages of Dry Cooler over Refrigerated Air Conditioner

1. Less expensive to install.

2. Less expensive to operate

Power consumption is limited to the fan and water pump where as in refrigerated

air conditioning there is compressors, blowers and pumps which are higher in

cost.

3. Circulates fresh air

4. Refrigerated air conditioner recirculates old air and eventually reduces the
humidity which will result in uncomfortable and unhealthy in desert climate

5. Dry cooler use significantly less energy, so it conserves electricity

6. Dry cooler not only cools air, but the atmosphere is more pleasant.

7. unlike refrigerated air conditioning, where people are accustomed to closing all
doors and windows to keep the cool air in an evaporative cooler requires
adequate ventilation and airflow to distribute the cool air through the home and
expel warm, moist air through the window openings.

2.4 Benefits of dry cooler

1. Economy: there is no compressor, condenser, chiller coils, cooling towers or
heavily insulated pi ping used in dry coolers. The cost of acquisition and

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2. operation is a fraction of conventional air conditioning and mechanical
refrigeration systems. Maintenance costs are minimal requiring simpler
procedures and lower skilled maintenance people.

3. effective: dry coolers has been used for thousands of years in various forms for
comfort cooling and is still in common use around the world because of its
simplicity, low cost and effectiveness.

4. Increased Comfort

5. Health Benefit: evaporative cooling is 100% fresh air cooling. This means that
all the air being cooled is brought in from outside

6. Improved Efficiency of other Equipment: evaporative cooling is commonly

used to pre-cool the air passing over heat exchangers, motors and many other
types of mechanical equipment.

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 CHAPTER 3
Given Data for Design of Dry Cooler
The following data is obtained from the meteorology office of Mekelle
 Latitude =130 20’
 Altitude =2367m
 Outside dry- bulb temperature =28.40c
 Outside wet-bulb temperature =14.20c
 Outside relative humidity 64%
The design is done to cool a dormitory in Mekelle University

Orientation of the room

The room is on the second floor. There are two unconditioned rooms on the adjacent two
sides (north and south).In addition there are one unconditioned room from below and one
from below. The west side is some part window and some part wall and on the east is a
corridor

Number of students in the room = 6

Appliances: 4 fluorescent lamps in the room

Window direction: west

Door direction: east

Dimensions of the room

Height = 3m

Length = 5.4m

Width = 3.5m

Area of the door = 1.68m2

Inside design condition for comfort

The following inside design conditions are assumed based on the design requirements of
the room to be conditioned.
 Inside dry-bulb temperature =240c
 Inside relative humidity =80%

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 CHAPTER 4
Space Cooling Load
Space cooling load is the rate at which heat must be removed from the space to maintain
room air at constant value. It is determined based on the orientation of the room, material
characteristics of the wall and the window, occupants, light and infiltration air.

4.1 Cooling load calculation

The dry cooler is designed for a dormitory of six (6) students.

Orientation of the room

The room is on the second floor. There are two unconditioned rooms on the adjacent two
sides (north and south).In addition there are one unconditioned room from below and one
from below. The west side is some part window and some part wall and on the east a
corridor.

Based on the above orientation of the room and the material property of the wall and the
glass the cooling load gained by the room is calculated.

4.2 External Heat Gain

4.2.1 Cooling Load Due to Conduction Heat Gain through the Walls
(north & south sides)
Due to the temperature difference between the room air and the external environment and
the fact that the external is at higher temperature than the room air heat will transfer from
the outside to inside by conduction.

Material of the wall:

The wall is made of a concrete block, rectangular core sand and gravel aggregate with
cement plaster sand aggregate in both sides.
R1
i .e.

R2

R3

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From table the resistances of the wall materials are obtained.
R1 =0.01m2K/W =R3
R2 =0.18m2K/W
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 23 table 3A ]
Therefore the total resistance RT of the wall is
RT = R1+R2+R3
= 0.01+ 0.18 + 0.01
= 0.2m2K/W
The coefficient of heat transfer U for the wall is:
U = 1/RT
= 1/0.2
=5W/m2K
Therefore the heat transfer through the wall due to conduction is
Qw = UAT
From a measurement taken in the dormitory, the area of the wall can be calculated as;
A = 5.4m*3m
= 16.2m2
Therefore the heat transfer through the wall is
Qw = 5*16.2*(28.4 -24)
=356 4W
Similarly for the wall on the other side
Qw= UAT
Since the two walls are of the same material and equal areas
Qw=356.4W

4.2.2. Conduction Heat Transfer through the Wall Facing the East
Material: the same as the other walls
R1 = 0.01m2K/W = R3
R2 = 0.18m2K/W
RT = 0.2m2K/W
U =5W/m2K
Assumption: the temperature in the corridor is the same as that of the outdoor air.

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Therefore;
Qw = UAT where the area of the wall is A =3.5*3-Adoor
= 3.5*3-.8*2.1
=10.5-1.68
=8.82m2
Qw = 5*8.82*(28.4-24)
= 194.04W

4.2.3. Conduction Heat Transfer through the Door

Material of the door: Wood (1.5in)
For wood type material (1.5) from table we have the resistance of the door is
R = 0.33m2K/W
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 23 table 3A]
The overall coefficient of heat transfer, U is
U = 1/R
= 3.03W/m2K
Qd = UAT where A = is the area of the door
A=1.68m2
Qd = 3.03*1.68*4.4
= 22.4W

4.2.4. Heat Transfer through the Roof and the Floor

Since there is no direct irradiation on the roof and the floor the heat transfer to the
conditioned space through the roof and the floor is only through conduction.
Material: 4in light weight concrete type
From table R =1.34m2K/W
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL, Chapter 23 table 3A]
The coefficient of heat transfer U is
U =1/R
= 0.75W/m2K
The conduction heat transfer through the roof is
QR = UAT where A = area of the floor

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 =3.5*5.4m2
=18.9m2
QR = 0.75*18.9*(28.4-24)
= 62.37W
Similarly, the conduction heat transfer through the floor is
QF =UAT
But the floor for the second floor is a roof for the first floor; hence they are made of the
same material and are of equal area.
Therefore the conduction heat transfer through the floor is
QF = 62.37w

4.2.5. Heat Gain through the West facing Wall

This side is a combination of wall and glass, there is a direct irradiation of sunlight
Wall

Glass

Door

Wall

Area of the wall:

Awall = 0.4*3.5 +1*2.7
= 4.1m2
Area of glass:
Aglass =A-Awall where A = 3*3.5 = 10.5m2
Aglass = 10.5-4.1
= 6.4m2

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4.2.5.1. Solar heat Gain through Glass
When the sun’s ray strikes a pane of glass, a small amount of energy is reflected, glass
absorbs some energy with consequent rise in temperature, but greater part of the energy
striking the surface passes through the glass.
The solar heat gain inside the conditioned space through glass is given by
Qglass = Radiation transmitted + Inward Flow of Absorbed + Conduction Heat Gain
Through Glass Solar Radiation
= Solar Heat Gain + Conduction Heat Gain
 Considering first the solar heat gain i.e. heat gain due to radiation and convection,
Q = A*SC*SHGF*CLF
Where: A= total area of glass
SC=shading coefficient
SHGF = maximum solar heat gain factor
CLF = cooling load factor
From table;
For a clear glass with an inside translucent shading SC =0.37
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 27 table 35]
The cooling load factor for glass with an interior shading and west facing fenestration is
CLF = 0.72
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 26 table 14]
The maximum solar heat gain factor is obtained for the appropriate latitude, month and
surface orientation
For this particular purpose, we have
Latitude = 13.330
Month = March
Then from table, we have for west facing glass
For 12 and month of March, SHGF = 757
For 16 and month of March, SHGF = 745
For 13.3 and month of March, SHGF =?
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 26 table 11]
By interpolation, we have for 13.3 and month of March,

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 SHGF = 753.01
Therefore the solar heat gain through glass is equal to
Q = A*SC*SHGF*CLF
= 6.4*0.37*753.01*0.72
= 1283.85W
= 1.284kW
 Now considering the conduction heat gain through glass
The cooling load due to conduction is given by
Q = UACLTDc where U = the coefficient of heat transfer for the material of the
glass
A= total area of glass
CLTDc = corrected cooling load temperature difference
From table:
Assuming solar time of 9hrs CLTD = 1
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 26 table 10]
This value of CLTD from table is calculated for an inside air temperature of 25.5 0c
outdoor maximum temperature of 350c and outdoor daily range of 11.60c
If the condition differs from those explained above the CLTD should be corrected.
Rule for correcting CLTD
The rule says that for room air temperature less than 25.5 0c add the difference between
25.50c and room air temperature, if greater than25.50c, subtract the difference.
For this particular case, room temperature is equal to 240c which is less than 25.50c
Therefore adding the difference i.e. 25.5-24= 1.50c to CLTD we have
CLTDc = 1+1.5
= 2.5
Therefore the cooling load due to conduction is
Q = UACLTDc but A = 6.4m2
U= 6.246W/m2K
Q = 6.246*6.4*2.5
= 99.968W

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4.2.5.2 Solar Heat Gain due to Conduction through Wall
Since there is a direct solar radiation on this side of the wall the cooling load gain through
this wall is considered differently from the other walls.
The cooling load due to conduction through this wall is given by
Q = UA*CLTDc
The material of this wall is the same as that for the other walls.
Therefore U = 5W/m2k
The area of the wall is calculated to be A = 4.1m2
The corrected cooling load temperature difference is obtained as follows
CLTDc = (CLTD+LM)*k+ (25.5-TR) + (To-29.
Where CLTD=cooling load temperature difference and is obtained from table
LM=latitude and month correction
K= color adjustment factor
(25.5-TR) = indoor design temperature correction, TR = 240c
(To-29.4) = outdoor design temperature correction where To is the average
out design temperature on design day, To =22.95
From table, for heavy weight concrete wall + finish of 12in the wall construction is
Group A
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 26 table 6]
For Group A wall, we have the CLTD from table is
CLTD = 12 (using solar time of 9hrs)
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 26 table 7]
Latitude and month correction (LM)
For the month of march and latitude of 13.33, we have by interpolation,
8 ……………………. -0.5
13.33 ……………………. LM
16 …………………….-0.5
[Source: ASHRAE HANDBOOK 1981 FUNDAMENTAL Chapter 26 table 9]
Therefore by interpolation
LM = -0.5

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The color adjustment factor k is
K = 0.5 (permanently light colored wall)
Therefore;
CLTDc = (12 + (-0.5))*0.5+ (25.5-24) + (22.95-29.4) = 0.8 ; and
Q= UA*CLTDc
= 5*4.1*0.8
= 16.4W

4.3 Infiltration Air

Outside air may get into the air conditioning space in several ways.
1. As ventilation air, properly brought into the room
2. By normal infiltration through walls, doors and windows
3. By infiltration through doors
4. By infiltration to replace air exhausted to the outside air

4.3.1 Calculation of the quantity of air infiltrated

There are two methods for calculating the quantity of air infiltrated
 Air change method and
 Crack method
For this particular case the air change method is used
It is based upon the average number of air changes/hr expected in the air conditioning
space.
Infiltration, Qi = [H*L*W*G]/60 (m/min)
Where: H=height of the room
L =length of the room
W= width of the room
G = number of air changes per hour
From measurement; H =3m
W =3.5m
L = 5.4m
From table, the value air changes per hour for two side exposed room is G = 1.5air
changes per hour

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[Source: Modern Refrigeration and Air Conditioning for Engineers.prof. p.s. Dasai]
Qi = [3*5.4*3.5*1.5]/60
= 1.4175m3/min

4.3.1.1 Door Infiltration

In addition to the above infiltration, door infiltration must be considered.
It is calculated using the following equation
Door infiltration (m/min) = [Door opening per hour*factor from table]/60
Assumption: -Neglect wall infiltration
-public building
For public buildings door openings/occupants/hr =3
For swinging door, the factor read from table is equal to 3.0
[Source: Modern Refrigeration and Air Conditioning for Engineers.prof. p.s. Dasai]
Therefore for 6 occupants = 3*6 = 18door openings/hr
Door infiltration = 18*3/60
= 0.9m3/min
As there are two doors, door infiltration = 1.8m/min
Total infiltration air = Infiltration due to air change + Door infiltration
= 1.4175 + 1.8
= 3.2175m3/min

4.3.1.2 Load due to Outside Air

The load due to the outside air will be both sensible as well as latent, and can be
calculated as follows:
OASH = 20.43*Qm (To-Ti) W, and
OALH = 50*Qm (Wo-Wi) W
Where: OASH =outside air sensible heat
OALH = outside air latent heat
Qm = volumetric flow of outside air entering the building
To= outside design condition
Ti = room design condition
Wo = specific humidity gms/kg outside air

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 Wi = specific humidity gms/kg inside air
OASH = 20.43*Qm(To-Ti) where Qm = 3.2175m/min
To = 28.4
Ti = 24
Putting the values in the above equation
OASH = 289.23W
OALH = 50*Qm (Wo-Wi)
Wo and Wi are read from psychometric chart
Wo: Using ODBT of 28.40c and OWBT of 14.20c
Wo = 0.0041kg moisture/kg dry air
= 4.1gms/kg dry air
Wi: Using IDBT of 240c and IRH of 80%
Wi = 0.015kg moisture/kg dry air
= 15gms/kg dry air
Therefore the outside air latent heat gain
OALH = 50*3.2175(4.1-15)
= -1753.54W
4.4 Internal Heat Gains
The heat gain components that contribute to internal heat gains are:
Light and
People (occupants)

4.4.1 Internal heat gain due to Light

Light generates sensible heat by the conversion of the electric power input into heat.
The cooling load due to heat gain from lighting is
ql = W*Ful*Fsa
Where; ql = heat gain W
W = total light wattage
Ful = light use factor
Fsa = light special allowance factor
The total light wattage: for a single fluorescent lamp the wattage is 36W.Sinse there are
four (4) lamps in the room the total light wattage is 4*36W = 144W

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The light use factor, Ful = Actual wattage in use/Installed wattage
= 1 for residential applications, stores etc
= 0.5 for work shop
So take Ful = 1 (residential application)
Light allowance factor, Fsa = 1.2 for tube light
= 1.0 for incandensate lamp
Since it is a tube light in this particular case, Fsa = 1.2
[Source: Modern Refrigeration and Air Conditioning for Engineers.prof. p.s. Dasai]
Therefore the cooling load due to light is
ql = 144*1*1.2
= 172.8W

4.4.2 Internal Heat Gain due to Occupants

Occupants give out both sensible and latent heat
Sensible: qs = # of occupants*Sens. H.G*CLF
Latent: ql = # of occupants* Lat. H.G
Where Sens. H.G = sensible heat gain
Lat. H.G =latent heat gain
CLF =cooling load factor for people
Assumption: - the occupants in the dormitory are seated and doing a light work (writing)
-the occupants stay in the room for 16hrs

From table; Sens.H.G = 65W

Lat. H.G = 55W
CLF = 0.96
[Source: Modern Refrigeration and Air Conditioning for Engineers.prof. p.s. Dasai]
Therefore;
The sensible heat gain is
qs = # of occupants*Sens.H.G*CLF
= 6*65*.96
= 374.4W
Similarly the latent heat gain is

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 ql = # of people*Lat H.G
= 6*55
= 330W
Therefore the total heat gain due to occupant is
Qt = qs + ql
= 704.4W
Total heat gain of the room

Room heat gain components Heat Gain

Sensible(W) Latent(W)
Wall (conduction) 923.24 ----
Door (conduction) 23.4 ----
Roof (conduction) 62.37 ----
Floor (conduction) 62.37 ----
Glass (radiation + convection) 1283.85 ----
Glass (conduction) 99.968 ----
Light 172.8 ----
Occupants 374.4 330
Infiltration 289.23 -1753.54

Total heat

TOTAL SENSIBLE HEAT (W) 3291.228

TOTAL LATENT (W) -1423.54

Total heat gain = total sensible heat + total latent heat

= 3291.228+ (-1423.54)
= 1869.688W

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 CHAPTER 5
Determination of the Flow Rates

5.1 The Mass Flow Rate of Air

The mass flow rate of air required to cool the total load is determined by
qs = maCpa(Tin-Tx)
Where: qs = total sensible heat of the room, W
Cpa = specific heat of moist air = 1.0246KJ/KgK
Tin = design indoor condition temperature, oc
Tx = air temperature at the outlet of the wetted surface,0c
For cooling and humidification to take place the surface temperature of water should be
less than the dry bulb temperature of the air and greater than the wet bulb temperature of
air.
Assumption
 The temperature of the air at the outlet of the wetted surface is equal to the
temperature of the circulating water.
 The surface temperature of the water T s is in between 14.20c and 28.40c, hence
assume Ts = 180c = Tx
Therefore the mass flow rate of air is
ma = qs/Cpa(Tin-Tx)
= 3.291228KJ/Kg/1.0246KJ/KgK (24-18)
= 0.53554Kg/s
= 32.124Kg/min

5.2 Volumetric Flow Rate of Air

The volumetric flow rate of air can be obtained from the mass flow rate.
Qa = ma/ρa where Qa = volumetric flow rate of air
ρa = density of air
ma = mass flow rate of air 0.5354Kg/s
But the density of air is
= Pa/RaTa where Pa = the pressure of outside dry air = Patm = 101.1KPa
Ra = gas constant of dry air = 0.287KJ/KgK

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 Ta = temperature of dry air = 28.40c = 301.4K
ρa = 101.1/0.287*301.4
ρa = 1.1688Kg/m3
Therefore the volumetric flow rate is
Qa = 0.5354/1.1688
= 0.4584m3/s
= 458.4l/s

Supply Air Humidity

The specific humidity of the supply air can be found from the latent heat balance.
ql = maCpw (Win-Ws)
Where ql = total latent heat of the room = -1.42354KJ/Kg
ma = mass flow rate of air = .5354Kg/s
Wi = specific humidity of room air = 0.015Kg/Kg dry air
Ws = specific humidity of supply air
Cpw = latent heat of evaporation = 2450KJ/Kg dry air
Rearranging the above formula;
Ws = Wi-(ql/maCpw)
= 0.015-(-1.42354/0.5354*2450)
= 0.0161Kg/Kg dry air

5.3 Determination of the flow rate of water

The mass flow rate of water can be obtained from the specific humidity balance and
enthalpy balance.
That is
Ws = Wo+mw/ma *Wo = Wo(1+mw/ma) and
h2 = h1+ mw/ma
Where Wo=specific humidity of outside air = 0.0041Kg/kg dry air
Ws= specific humidity of the air leaving the wetted surface = 0.0161Kg/Kg dry air
h2 = enthalpy of the air leaving the wetted surface
h1 = enthalpy of outside air
hw = enthalpy of liquid water

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From psychometric chart at 28.40c and relative humidity of 64% h1 = 69Kj/Kg
hw is read from table of saturated water at 180c
T = 150c ………….. h= 62.99KJ/Kg
T = 180c ……………hw =?
T = 200c ………… h = 83.96KJ/Kg
By interpolation, hw = 75.57KJ/Kg
Therefore;
Ws = Wo+ mw/ma *Wo
mw = (Ws-Wo)*ma/Wo
= (0.0161-0.0041)*0.5354/0.0041
= 1.5659Kg/s

5.4 Volumetric Flow Rate of Water

The volumetric flow rate of water is
Qw = mw/ρw where ρw = density of water
By interpolation the density of water at T = 180c is found to be pw = 998.58Kg/m3
Qw = 1.5659/998.58
= 1.568*10-3m3/s

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 CHAPTER 6
Determination of the Heat Transfer Area
Assumption
 The dry cooler is rectangular
 The dimensions of the dry cooler is such that H =L and W = 1/2H = 1/2L

The total heat removed from the air at the wetted surface is given by
Q = ma (h2-h1)
And from the principle of enthalpy potential, another expression for Q is
Q = hcA(hs-h1) /Cpm
Where hc = convection coefficient, KW/m2K
A = total heat transfer area
hs = enthalpy of water = 75.57KJ/Kg (at 180c)
h1 = enthalpy of the outdoor air = 69KJ/Kg
W
h2 = enthalpy of the leaving the wetted surface = 69.91Kj/kg
Cpm = specific heat of moist air = 1.0246KJ/KgK
For forced convection of air we have from table
hc = 10 to 100W/m2K
[Source: Refrigeration and air conditioning C P Arora]
Taking hc = 50W/m2K = 0.05KW/m2K
ma(h2-h1) = hcA(hs-h1)/Cpm

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 = 0.5354(69.91-69) = 0.05A (75.57-69)/1.0246
= 0.4872 = 0.321A
A = 1.5178m2
The total area of the heat transfer is
A = A1 + A2 + A3, but A1 = A3
= 2A1+A2 
= 2*H2/2 + H2
1.5178m2 = 2H2
H = 870mm = L and W =435mm
Note: the side on which the fan is mounted is covered by a sheet metal taken from
standards
Having these dimensions the capacity of the water reservoir can be determined by
assuming that its height is 100mm.
Capacity of water reservoir = 870*435*100
=37.845*106 mm3

Determination of the diameter of the hole through which water

drop
Again by considering the volumetric flow rate of water
Qw = nAV = n*πd2*V/4 where n = # of hole
d = diameter of the hole
V = velocity of water

But the velocity of water can be calculated by considering the volumetric flow rate of
water on the total area.
Qw = AV where A = total area of heat transfer
V = 1.568*10-3/1.5178
= 1.0331*10-3m/s
Assumption
The number of hole is determined such that the gap between the holes is 5mm.
Since the total length on which the hole should be made is 435+870+435= 1740mm
# of hole = 1740/5

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 = 348
The diameter of the hole will be
d = 74.5mm

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 CHAPTER 7
Cooling efficiency of the dry cooler
To find the cooling efficiency of the dry cooler first the following terms should be
defined.
Dry Bulb Temperature: the ambient (surrounding air) temperature taken with a
thermometer.
Wet Bulb Temperature: the lowest temperature level of the air that can be reached by
evaporatively cooling the air.
Wet Bulb Depression: the difference between the dry bulb and wet bulb temperatures.
Cooling Efficiency: the percent of the temperature drop across the media compared to
the Wet Bulb Depression.
Therefore the cooling efficiency is calculated as follows.
Cooling Efficiency = ( actual temperature drop across the cooling media) / (Wet Bulb
Depression)
= (28.4 – 18)/(28.4-14.4)
= 0.7324
= 73.24%
Note:
The cooling efficiency could have been 100% if the dry bulb temperature of the air after
passing through the cooling media is dropped to the wet bulb temperature of the hot and
dry outside air. But in reality this cannot happen as the dry cooler is not 100% efficient.

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 CHAPTER 8
Design of Components of Dry Cooler
8.1 fan selection
A fan is defined as a rotary, bladed machine maintaining a continuous of air.
Continuous because the air flows steadily into, through and out of the fan.
A fan has a rotating impeller invariably carrying blades of some kind. These blades exert
force on the air and thereby maintaining the flow and raising the total pressure of the air.
Most commercial fan used in HVAC work may be placed in one of the two general types
based upon construction and air flow patterns.
These types are:
1. Centrifugal or axial flow fan and
2. Axial flow fan
Centrifugal fans have flow within the rotating wheel or rotar that is substantially radial to
the shaft, with the rotar operating in scroll type casing.
Axial flow fans have flow within the wheel that is substantially parallel to the shaft and
operate within cylindrical ring-type housing.
Whenever a system has a duct-work, centrifugal fan have to be used as the static pressure
drop is considerable.
But when there is no duct-work axial flow fans can be used. Nevertheless, in window –
type and packaged units simple drum-type centrifugal are used, where as most exhaust
fans are of the axial type, as they occupy less space, and can handle large volumes.
The centrifugal fans have the advantage of quite and efficient operation at high pressures.
Axial flow fans are suited for handling large air volumes and can be used where noise-
level considerations are not important.
The volume flow rate of air delivered and the pressure created by the fan are called
performance characteristics.
The choice of the best type of fan to be used for a given application depends on the fan
performance characteristics.
Propeller fans cannot create a high pressure, and are thus used where there is little or no
ductwork. They are low in cost, and typical applications are as wall-or window-installed
exhaust fans.

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Centrifugal fans are the most commonly used type of fan in ducted air conditioning
system.
To select a fan it is necessary to know the capacity and total pressure requirement of the
system, nature of its load (variable or steady), and noise constraints must also be
considered.
It is usual for manufacturers to catalogue fan performance in terms of fan static pressure
and it is customary to select fans on this basis, thus

Fan total pressure = System total pressure loss

= Fan static pressure + Fan velocity pressure
The assumption is often made that the fan velocity pressure is very nearly system
discharge velocity pressure. The discharge velocity is neglected and the resulting total
taken as the required fan static pressure.
Since there is no ductwork, the pressure losses are that only on the cooling apparatus,
filter, and the fan intake and fan outlet.
The pressure losses in different apparatus are tabulated in the following table.
Item Pressure loss, Pa
1. Air intake or fan entry 1.23 to 24.5
2. air heaters or coolers 24.5 to 85.8
3. Air washer 49.1 to 85.8
4. Air filter 49.1 to 98.0
5. Outlet 12.3 to 24.5
6. Miscellaneous, screens, grills etc 24.5 to 49.0

[Source: Refrigeration and Air Conditioning For Engineers Prof. P.S. Dasai]
Therefore;
Static pressure consists of pressure losses:
1. At intake or entry to the fan = 10Pa
2. On the air cooler = 35Pa
3. On the air filter = 65Pa
4. At the fan outlet = 15Pa
Then the static pressure is equal to Ps = 10+35+65+15 = 125Pa

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8.1.1 Fan Drives
Belt drives are used extensively for fans in building ventilation and air conditioning work
for the following reasons;
1. Higher speed motor may be used resulting in lower cost.
2. An incorrect calculation of total resistance of air capacity of the system will
require only changing of pulley provide and of course that the motor has ample
capacity.

8.1.2 Fan Air Power

The power output of a fan is expressed in terms of air power.
It represents the power output by the fan.
It is the power required to move a given volume of air against a given pressure.
Based on static and total pressure, fan air powers are
(a) Fan static air power (b) Fan total air power
Static air power = Q*Ps/60,000 KW
Total air power = Q*Pt/60,000 KW
Where Q = air volume flow rate m3/min = 27.504m3/min
Ps = static pressure Pa
Pt = total pressure Pa
Since the velocity pressure is neglected the static air power is equal to the fan total air
power.
Total air power = 27.504*125/60000
= 0.0573KW = 57.3W
Therefore a propeller fan with a capacity of 27.504m3/min and total air power of 57.3W
is used.

8.2 Pump Selection

A pump is a device that circulates liquid through piping systems. The centrifugal pump is
the type most widely used in circulating water in HVAC system.
A pump provides the pressure necessary to overcome the resistance to flow of a liquid in
a piping system.

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Pumps can be classified into two groups according to the way they develop this pressure;
either by positive displacement or centrifugal force.
In the first group are included reciprocating, gear, vane, screw, and rotary pumps. They
are used in specialized cases in HVAC work.
The centrifugal pump is generally used in both hydronic and cooling tower water system.

8.2.1 Principle of Operation and Pump Characteristics

The centrifugal pump increases the pressure of the water by first increasing its velocity,
and then converting that velocity energy to pressure energy.
The items of major importance in the performance of a pump are the pressure (head) it
will develop, the flow rate it will deliver, the horse power required to drive the pump, and
its efficiency. These are called the pump characteristics.
The characteristics are usually presented in the form of curves or tables; these are used to
select the correct pump for an application.
When a fluid is flowing through a pipe, the fluid experiences some resistance due to
which some of the energy of fluid is lost.

8.2.2 Loss of Energy (or Head) due to Friction

The loss of head (or energy) in pipes due to friction is calculated from Darcy-Weisbach
equation, which is given by
hf = 4.f.L.V2/d*2g where hf = loss of head due to friction
f = coefficient of friction which is a function
of Reynolds number
= 16/Re for Re<2000
= 0.079/Re1/4 for Re varying from 4000 to 106
L = length of pipe
V = velocity of flow
d = diameter of pipe
[Source: Fluid Mechanics and Hydraulic Machines Dr. R.K. Bansal]
But Re = V*d/ where V = velocity of water
d = diameter of pipe
 = kinematic viscosity
For water the kinematic viscosity is 0.01*10-4 m2/s

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8.2.3 Diameter of Pipe
Standard size of steel pipe used in refrigeration and air conditioning system is shown in
table 7.2of Refrigeration and Air Conditioning book. Of the thicknesses shown schedule
40 pipe thickness is the most common.
Table 7-2 Dimensions of steel pipe
ID, mm
Nominal size, mm OD, mm Schedule 40 Schedule 80
15 21.34 15.80 13.88
20 26.67 20.93 18.85
25 33.40 26.64 24.30
35 42.16 35.04 32.46
40 48.26 40.90 38.10
50 60.33 52.51 49.25
60 73.03 62.65 59.01
75 88.90 77.92 73.66
100 114.3 102.3 97.18
125 141.3 128.2 122.2
150 168.3 154.1 146.4
200 219.1 202.7 193.7
250 273.0 254.5 242.9
300 323.9 303.3 289.0
[Source: Refrigeration and Air Conditioning WILBERT F. STOECKER/JEROLD W.
JONES]

Taking nominal size of 40mm (ID = 40.90mm)

The velocity of water is calculated from the volume flow rate of water.
Qw = AV = pid2*V/4 where d is the diameter of the pipe = 40.90mm
V = 4*1.568*10-3/pi*(40.90*10-3)2
= 1.1935m/s
The Reynolds number is
Re = V*d/
= 1.1935*40.90*10-3/0.01*10-4
= 48814.15
Re is in between 4000 and106 i.e. 4000 < Re < 106
Therefore the coefficient of friction f is
f = 0.079/ (48814.15)1/4

- 29 -
 = 0.005315
Then the loss of head due to friction is
hf = 4.f.L.V2/d*2g
The length of the pipe can be obtained by considering the height of the heat transfer area
and that of the water reservoir (sump water).
The height of the transfer area is calculated to be H = 0.87m = 870mm.
It was assumed that the height of the water reservoir is 100mm, and the pump is at the
center of the reservoir (i. e 50mm from the bottom) the length of the pipe is L =
920mm=0.92m = z
Therefore
hf = 4*0.005315*0.92*(1.1035)2/0.0409*2*9.81
= 0.03472m
= 34.72mm
The total head loss is
H = hf + z + hs
Since the pump is submerged in the water reservoir the head due to suction can be
neglected.
H = hf + z
= 0.03472 + 0.92
= 0.95472m
= 954.72mm
Therefore a centrifugal pump having a capacity of 1.5659kg/s and a total head loss of
954.72mm is used.

- 30 -
 CHAPTER 9

3-Dimentional Drawing of Dry Cooler

- 31 -
 Fig 3-Dimentional drawing imported from AUTOCAD

Note:
Fan is as per the selection
Pump is as per the selection
Pipe as per the selection
Cooling pad as per the design
Sheet metal to cover the side on which the fan is mounted as per the selection
Overall dimensions

height = 920mm

- 32 -
 
length = 870mm

width = 435mm

total area of heat transfer = A = 1.5178m2
Fan Capacity
 Capacity = 27.504m3/min
 fan total air power = 57.3W
Pump Capacity:
 Capacity = 1.5659kg/s
 total head loss = 954.72mm
Water capacity of the reservoir = 37.845*106 mm3
Cooling pad: wool type cloth with higher water absorbing capacity

33
Recommendation and Limitations
In the design of dry cooler or evaporative cooler there are some informations which are
very important that make the design complete.
The local weather data are needed in order to fix the comfortable indoor condition for
human beings.
In addition to this some information about the building like the material from which it is
made, it orientation and its relations with the adjacent rooms is important.
To determine the capacity of the dry cooler, i.e. the amount of the outdoor air intering
into the room, and its temperature and humidity after passing through the cooling media,
it is necessary to calculate the cooling load.
The cooling load calculation is done by considering 16hrs stay in the dormitory and that
the occupants are seated and doing light work (writing).
Finally after determining the cooling load the flow rates of air and water is determined.
Having the flow rate of the selection of fan that pushes the air through the cooling media
and into the room is made.
With the flow rate of water and calculating the total head loss in the pipe the selection of
pump is made.
The diameter of the pipe is taken from standard table as explained in the pump selection.
There are many limitations encountered in this project. The first limitation is shortage of
time due to which only the design part is done. But the actual project was design and
manufacturing of dry cooler. Hence the manufacturing part is not done in this project.
Secondly the design concentrates only on the air condition and heat transfer parts. But to
make the design complete appropriate design of the mechanical parts like the belt drive,
shaft for the fan, pump and fan should be done.

34
Conclusion

I calculated the cooling load of the room so that it will help in the design of the dry cooler
Calculation of the cooling load helps to find the amount of the outdoor air to be used and
its temperature and humidity after passing through the cooling media.
This is done by using the sensible heat and the latent heat.
The temperature of the water to be recirculated is determined in such a way that for
cooling and humidification the temperature of water should be less than the dry bulb
temperature of the outdoor air and greater than the wet bulb temperature of the outdoor
air.
But to increase the efficiency of the dry cooler the temperature of the water should be
equal to the wet bulb temperature of the outdoor air. In doing so the efficience of the dry
cooler will become 100%, but as the dry cooler is not 100% efficient the temperature of
the water should be greater than the wet bulb temperature of the outdoor air.

35
BIBLOGRAPHY
1. ASHRAE HANDBOOK 1981 FUNDAMENTAL
2. Prof. P. S. Dasai. “Modern refrigeration and Air Conditioning for Engineers”
3. Dr. R. K. Bansal. “Fluid Mechanics Hydraulic Machine”
4. C P Arora. “Refrigeration and Air Conditioning” second edition
5. Faye C. Mc Quiston, Jerald D. Parker, Jeffrey D. Splitler. “HEATING
VENTILATING, and AIR CONDITIONING”
6. Wilbert F. Soecker/Jerald W. Jones, “Refrigeration and Air Conditioning” second
edition

36