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  • The man in the middle is Will Nuckolls, head of EVAPCO’s Sound Engineering department…… and no, that is not Will’s boat propeller! The fan on the right is EVAPCO’s SUPER Low Sound Fan, which offers 9 to 15 dB(A) reduction. The SUPER Low Sound Fan is state of the art sound reducing technology that is unparalleled in the evaporative cooling industry. (click)
  • EVAPCO’s Thermal-Pak coils feature an elliptical design which assures maximum cooling capacity. This design provides a more aerodynamic shape, which lowers air side pressure drop while allowing more water to be loaded on the coil.
  • And here is a visual representation of how it works. (Animate!!) The warm process fluid circulates from the heat source to the coil of the closed circuit cooler. The fluid in the coil transfers its heat through the tube walls to the spray water by sensible heat transfer. Having gained heat from the coil, the spray water then falls at the rate of 12 gpm/ft2 of coil to the sump where it is circulated by the spray pump up to the spray nozzles. The warmed spray water is then distributed as a thin film over the fill surface at a rater of 6 gpm/ft2 of fill for maximum cooling efficiency. The fan system operates simultaneously, moving large volumes of air through the unit opposite the falling water. The air and water contact across the fill surface causing a small portion of the spray water to be evaporated. The evaporation process is a latent transfer of heat from the spray water to the air passing through the unit. The warm and saturated air is then discharged from the unit with final heat dissipation to the atmosphere. [Click]
  • Introducting the HEART of the New ESWA, Evapco’s new Sensi-Coil Technology. This amazing new technology is the results of months of hard work by the Evapco Product Development and Manufacturing Teams. [Click] Sensi-Coil Technology is available exclusively on the ESWA Closed Circuit cooler. [Click]
  • Sensi-Coil Technology includes reduced tube spacing which is perfect for sensible cooling. As shown in the diagrams, the Thermal-Pak Coil has extra spacing between the elliptical tubes to allow for airflow between the tube bundles. The Sensi-Coil has tighter tube spacing, which has been designed specifically for the flooded sensible cooling of the ESWA. Which is the reason that it is only available on this product. [Click]
  • As I had mentioned at the beginning…the ESW provides energy savings and low sound…How Low?... [Click] 30 to 50% less horsepower than other Induced draft coolers…and up to 80% less than forced draft models. [Click] The sound levels of the ESW are as good, or slightly better than standard forced draft coolers… Let’s go through an example of the potential savings… [Click]
  • As I had mentioned at the beginning…the ESW provides energy savings and low sound…How Low?... [Click] 30 to 50% less horsepower than other Induced draft coolers…and up to 80% less than forced draft models. [Click] The sound levels of the ESW are as good, or slightly better than standard forced draft coolers… Let’s go through an example of the potential savings… [Click]
  • As I had mentioned at the beginning…the ESW provides energy savings and low sound…How Low?... [Click] 30 to 50% less horsepower than other Induced draft coolers…and up to 80% less than forced draft models. [Click] The sound levels of the ESW are as good, or slightly better than standard forced draft coolers… Let’s go through an example of the potential savings… [Click]
  • As I had mentioned at the beginning…the ESW provides energy savings and low sound…How Low?... [Click] 30 to 50% less horsepower than other Induced draft coolers…and up to 80% less than forced draft models. [Click] The sound levels of the ESW are as good, or slightly better than standard forced draft coolers… Let’s go through an example of the potential savings… [Click]
  • And that is exactly what Evapco did. They designed a testing program to evaluate the performance of the Thermal-Pak coil with no air over the coil and at very high flow rates per square foot. [Click]
  • As I mentioned a few slides back, the ESW is designed with the functionality of a discharge hood as standard. Coil heat loss in the winter is minimized by the protective panels and because freezing air does not have free passage across the coil. The ESW avoids the maintenance expense and hassle associated with lubricating hundreds of pivot pins and linkage to prevent the dampers from seizing. [Click]
  • The ESW features the most accessible coil in the industry. When the protective panels are removed, a service mechanic has complete access to the coil and basin area. [Click]
  • The ESW features the most accessible coil in the industry. When the protective panels are removed, a service mechanic has complete access to the coil and basin area. [Click]
  • Presenter: The WDW is unique because it has a completely separate dry cooling section. There are no finned coils in the wet air stream. [click]
  • Presenter: Evapco chose the name Sage to represent both wisdom and sagebrush – the water conserving desert plant. The Sage Control System regulates: Fan Operation, Pump Operation, Switchover Point, Water Level, the Heater Package, and Interfaces with the Building Automation System. [click]
  • This is Stage 1, where the dry cell fan motor is on, and is cycling in VFD mode until the load requires this cell to be on full speed operation. Let’s look at this operation again. CLICK
  • Next is Stage 2, in this mode, the dry cell goes to line power and full speed operation. The wet cell fan motor is then switched on and cycles in VFD operation . The wet cell runs dry until the fan cycles up to 100% fan speed. At this point, the load dictates that wet operation is required. At the end of this stage, the fans in the dry and wet cells are operating at 100% fan speed in dry operation. Let’t look at this mode of operation. CLICK
  • Next we go to Stage 3, the wet/dry mode of operation, In stage 3, the dry cell is operating at 100%, and the pump is turned on in the wet cell. The wet cell fan that was running at 100% in the dry mode, now ramps down to approximately 30% fan speed operation. The fan drops in speed in the evaporative cell due to its large capacity gain with water on. The fan may even turn off on the wet cell. The fan will unload to maintain temperature and satisfy the leaving water set-point. Let’s look at this mode of operation again. CLICK
  • This is another stage of capacity control, Stage 4. This stage occurs when the dry bulb temperature exceeds the design inlet water temperature. In this case the dry bulb RTD senses the inlet dry air temperature and if it is greater than the entering water temperature into the dry coil, the dry cell fan cuts out so that we are not adding heat to the system. This situation would occur on a very hot, dry day, like in Denver, where there is no humidity, and the wet cell will do the entire load in wet operation. Here is the last stage of operation. CLICK
  • Presenter: Here is a sample of a graphical profile of water usage contrasting the WDW versus a Standard Induced Draft Cooler. The WDW water use numbers in m3 are in green. The standard induced draft cooler water use numbers are in blue. [click]

Evapco Evapco Presentation Transcript

  • EVAPCO, Inc. Taking Quality and Service to a Higher Level . . .
  • - Short History of Evapco - Product Overview - Open Cooling Towers - Features & Benefits - Closed Circuit Coolers EVAPCO, Inc.
    • Founded in 1976 - Baltimore, Maryland
      • 16 Facilities in 8 Countries
      • 160 Offices in 42 Countries
    • Employee Owned Company
      • Continuous Product Development Based on Innovation and Market Drivers
    EVAPCO, Inc.
  • EVAPCO WORLDWIDE World Headquarters/R&D Center Manufacturing Facilities Johannesburg, South Africa Cairo, Egypt Milan, Italy Kingsgrove, Australia Shanghai, China Madera, CA Bryan, TX Taneytown, MD Greenup, IL Sondrio, Italy Beijing, China Tongeren, Belgium Lake View, IA Ramseur, NC Lenexa, KS Lake Oswego, OR
  • EVAPCO , Inc . World Headquarters & Research Center
  • Evaporative Condensers and Closed Circuit Coolers
  • Open Cooling Towers
  • Extra-Pak TM Ice Coils – for Thermal Energy Systems
  • Recirculator Packages
  • MRP Recirculator Systems
    • Matrix Microprocessor Control
    • Bypass Flow Control
    • Dual Double Wall Canned Pump
  • Evaporators
  • Custom Coils
  • Critical Process Air Units
  • Field-Erected Cooling Towers
  • Pulse ~Pure TM Water Treatment
  • Induced Draft Counterflow Cooling Towers A dvanced T echnology
  • Induced Draft – Counterflow Hot Saturated Discharge Air Hot Water In Cold Water Out Cool Dry Entering Air (All Sides) Principle of Operation Fill Pack = Heat Transfer Media
  • Features & Benefits INDUCED DRAFT COUNTERFLOW PRODUCTS
  • Design Advantages & Signature Features
    • Most Efficient Heat Transfer
    • Optimal Layouts & Piping Arrangement
    • Advanced Materials of Construction
    • Superior Warranty, Guarantee and Certification
    • Easy Maintenance
    • Super Low Sound Technology
    AT Induced Draft Counterflow Cooling Towers
  • Optimal Fill Location Completely encased in steel Protected from direct exposure AT Induced Draft Counterflow Cooling Towers
    • EVAPAK ® Counterflow Fill:
    • Even Temperature Gradients through Fill Cross-section
    • Cools precisely to design temperature
    • Requires Less Air
    Design Advantages – Most Efficient Heat Transfer 95 °F Entering Water Temperature Entering Air at 78 °F Wet-Bulb Temperature 85 °F Net Outlet Water Temperature 93 °F 91 °F 88 °F 86 °F AT Induced Draft Counterflow Cooling Towers Water Temp Isotherms Cool Air Hot Water
    • EVAPAK ® Fill
      • Removable, bonded block construction
      • Low pressure drop
      • Bottom supported
      • Doubles as a working platform
    Signature Feature – High Efficiency Fill AT Induced Draft Counterflow Cooling Towers
  • Induced Draft – Crossflow (Competitors Product) Hot Saturated Discharge Air Hot Water In Cold Water Out Cool Dry Entering Air (Two Sides) Principle of Operation Hot Water In Cool Air Hot Water
    • Crossflow Fill:
    • Temperature Gradients Not Uniform Across Fill
    • Some Water Not Cooled to Design Temperature
    • Easily clogged, difficult to replace
    • Inefficient
    Comparison – Crossflow Heat Transfer 95° F Entering Water Temperature 94° F 92° F 90° F 88° F 85° F 82° F 80° F Entering Air at 78° F Wet-Bulb Temperature 85° F Net Outlet Water Temperature Water Temp Isotherms
    • EVAPCO Counterflow 20,000 CFM per 100 Tons (2.1 m 3 /s per 100 kw)
    • BRAND X Crossflow 30,000 CFM per 100 Tons (3.2 m 3 /s per 100 kw)
    • EVAPCO Induced Draft Products . . . Less Air
    Design Advantages – Most Efficient Heat Transfer AT Induced Draft Counterflow Cooling Towers
  • Design Advantages – Layout and Op. Weight AT Induced Draft Counterflow Cooling Towers Crossflow 35% LESS TOWER AREA Compared to Equivalent Capacity Crossflow Tower
  • Plan Area Net Free Area Crossflow More Tower Area + More Air = Larger Plan Area Design Advantages – Layout AT Induced Draft Counterflow Cooling Towers Less Tower Area + Less Air = Smaller Plan Area Net Free Area Counterflow Tower 360° Air Intake End Air Intake
    • Counterflow Fill:
    • Temperature Gradients 45°F - 32°F = 13°F Safety
    • Optimum Fill Location
    • Unique Inlet Louver Design
    Design Advantages – Winter Operation AT Induced Draft Counterflow Cooling Towers 65° F Entering Water Temperature Entering Air at 10° F Wet-Bulb Temperature 45° F Net Outlet Water Temperature 60°F 55°F 50°F 45°F Water Temp Isotherms
    • Crossflow Fill:
    • Temperature Gradients 34°F - 32°F = Greater Probability of Ice Formation
    • Ice Builds on Louvers & Fill
    • Prevailing Wind Problem
    Design Advantages – Winter Operation 65° F Entering Water Temperature 64° F 60° F 55° F 50° F 45° F 40° F 34° F Entering Air at 10° F Wet-Bulb Temperature 45° F Net Outlet Water Temperature Water Temp Isotherms
  • Design Advantages – Winter Operation
    • Exposed Crossflow Fill:
    • Ice Formation
    • Ice Builds on Louvers & Fill
    • Prevailing Wind Problem
    • Recirculation Problem
    • Air Inlet Louver Screens
      • Two Pass Inlet Louver
      • Basin Enclosed - Not exposed to Wind & Sun
      • Angled Cross section “Sight-tight” design (patent pending)
    Sunlight Splashout Debris Air Intake Signature Features – WST Inlet Louver Design AT Induced Draft Counterflow Cooling Towers
  • Signature Feature – Basin Area Access AT Induced Draft Counterflow Cooling Towers
    • Easily Removable Inlet Louvers for Full 360° Basin Access
    • Service Can Be Performed from Outside Unit
      • Float Valve Adjustment
      • Remove and Clean Strainers
      • Clean Pan Bottom
    • Drift Rate Less Than 0.001% of Recirculated Water Rate
    • Block Sunlight from shining directly in the cold water basin
    • Significantly Better Than Crossflow Drift Rate of 0.005%
    EVAPCO High Efficiency Drift Eliminators Signature Features – Most Efficient Drift Eliminators AT Induced Draft Counterflow Cooling Towers
    • Pressurized Water Distribution
    • Self Balancing – No Valves
    • Single Inlet Piping
    • No Hot Water Distribution Pans
    Design Advantages – Water Distribution System AT Induced Draft Counterflow Cooling Towers
  • Simplified Maintenance – Water Distribution System AT Induced Draft Counterflow Cooling Towers
    • No Service Necessary from the Fan Deck
    • Fill Provides Safe Work Area for Maintaining Water Distribution System
  • Simplified Maintenance – Water Distribution System AT Induced Draft Counterflow Cooling Towers
    • Removable Clean Out Plug for Water Distribution System
    • EvapJet Nozzles Prevent Clogging and Maximize Spray Area
    • G235 Galvanized Steel
    • PVC Distribution System
    • PVC Inlet Louvers
    • PVC Drift Eliminators
    • Stainless Steel Strainers
    EVAPCO Corrosion Protection System Signature Features – Materials of Construction AT Induced Draft Counterflow Cooling Towers
    • Stainless Steel Lower Section
    • Type 304 and Type 316 Stainless Steel
    • 100% Corrosion Resistant Model USS.
    Advanced Material Options Signature Features – Materials of Construction AT Induced Draft Counterflow Cooling Towers Stainless Steel
  • USS Induced Draft Counterflow Cooling Towers Worldwide Leader in Evaporative Cooling Products
    • Type 304 Stainless Steel Casing and Fan Deck
    • Type 316 Stainless Steel Water Touch Basin
    Standard Materials 316 SS 304 SS Signature Features – Materials of Construction MADE IN USA
  • USS Induced Draft Counterflow Cooling Towers Worldwide Leader in Evaporative Cooling Products Superior Corrosion Resistance through Molybdenum! MADE IN USA
  • Standard on all AT Models AT Induced Draft Counterflow Cooling Towers Warranty, Guarantee, and Certification Standard on AT with Stainless Steel Lower Section
  • AT Induced Draft Counterflow Cooling Towers Warranty, Guarantee, and Certification Standard on all AT Models
    • Externally Mounted Totally Enclosed Motor
    • Power-Band Adjustment Performed from Outside
    • Bearing Lubrication Lines Extended to Outside
    8.5 Ft. (2.5 m) Wide Models Simplified Maintenance – Mechanical Drive System AT Induced Draft Counterflow Cooling Towers
  • 10 ft. (3.0m), 12 ft. (3.7m) and 14 ft. (4.3m) Wide Models Simplified Maintenance – Mechanical Drive System AT Induced Draft Counterflow Cooling Towers
    • Easy Access Fan Belt Adjustment
    • Fan Bearing Lubrication from Outside the Unit
    Simplified Maintenance – Mechanical Drive System AT Induced Draft Counterflow Cooling Towers 10 ft. (3.0m), 12 ft. (3.7m) and 14 ft. (4.3m) Wide Models
    • 10 ft., 12 ft. and 14 ft. Wide Cells have Swing Out Motor Base for Easy Service
    Simplified Maintenance – Mechanical Drive System AT Induced Draft Counterflow Cooling Towers 10 ft. (3.0m), 12 ft. (3.7m) and 14 ft. (4.3m) Wide Models
    • Extruded Aluminum Fan
    • Aluminum Alloy Sheaves
    • Heavy Duty Pillow Block Bearings (Rated L10 Life of 75,000 - 135,000 Hrs)
    • Polished Steel Shaft
    • Corrosion Protected Bushings
    • Totally Enclosed Fan Motor
    Components Ideal for Severe Duty Application Simplified Maintenance – Mechanical Drive System AT Induced Draft Counterflow Cooling Towers
    • EVAPAK ® Fill Acts As Working Platform
    • Provides Safe Work Area for Maintaining Mechanical Equipment
    • No Fan Deck Handrails Required!
    The Most Accessible Mechanical System in the Industry Simplified Maintenance – Drive System Access AT Induced Draft Counterflow Cooling Towers
  • Simplified Maintenance – Optional Accessories AT Induced Draft Counterflow Cooling Towers
    • Sloped Ladders
  • Simplified Maintenance – Optional Accessories AT Induced Draft Counterflow Cooling Towers
    • Motor Davits
    • External Service Platforms
    • NEW Basin Level Platform
  • Simplified Maintenance –Basin Area Access AT Induced Draft Counterflow Cooling Towers
    • Clean Pan Sloped Basin Design
    • Stainless Steel Basin Strainers Standard
    Simplified Maintenance –Basin Area Access AT Induced Draft Counterflow Cooling Towers
  • A dvanced T echnology LOW SOUND SOLUTIONS SUPER Low Sound Fan
  • SUPER Low Sound Fan – 9 to 15 dB(A) Reduction! 9 to 15 dB(A) Reduction! A dvanced T echnology LOW SOUND SOLUTIONS
  • EVAPCO, Inc. Induced Draft Closed Circuit Coolers
  • ATW - INDUCED DRAFT COUNTERFLOW Hot Water In Hot Saturated Discharge Air Cool Dry Entering Air
  • CLOSED CIRCUIT COOLERS
    • Closed System
    • - Will not foul heat exchanger surfaces
    • - Will not contaminate process cooling equipment
    • - Reduced maintenance costs
    • Can Cool MANY Fluids
    • - Water
    • - Water and an ethylene or propylene glycol solution
    • - Oils or hydraulic fluids
    APPLICATION ADVANTAGES:
  • CLOSED CIRCUIT COOLERS
    • Higher Fluid Temperature Limitations
    • - Less likely to damage components
    • - Maximum fluid temperature of 170 o F
    • Dry Operation Option (except ESWA)
    • - Utilize bare coil
    • - Utilize coils with extended surface (spiral fins)
    APPLICATION ADVANTAGES (Cont.):
  • EXCLUSIVE THERMAL-PAK ® COIL Patent Granted 1988 No. 4,755,331
    • Lowers Air Pressure Drop
    • Increased Spray Water Flow
    • Maximize Tube Surface Area
    EVAPCO’S EXCLUSIVE THERMAL-PAK ® COIL Thermal-Pak Coil Benefits:
  • EXCLUSIVE THERMAL-PAK® COIL
    • Galvanized (standard)
    • Copper
    • 304 Stainless steel
    • 316 Stainless steel
    Coil Types:
  • ATW Enhanced Dry Performance
    • Cooling capacity in the event of water failure
    • Save on water usage
    • Cooling capacity with water off at lower ambient temperatures
    • Plume reduction
    Dry Cooling Benefits:
  • ATW – 3 Meter Wide Models New Ideal for Exact Replacement of Forced Draft
  • Containerized ATW New
  • Containerized ATW New Ships in Two Sections Fan Section and Basin Coil and Casing
  • Containerized ATW New Sections fit into a Shipping Container
  • ESWA CLOSED CIRCUIT COOLERS – Superior Design, Superior Unit
    • Contains both Fill and Coil
    • 184 Models
    • 5 Box Sizes
    • Capacity: 75 to 441 tons (225 to 1,323 gpm)
    ESWA Models:
  •  
    • Technology
    ESWA Sensi-Coil – Superior Design, Superior Unit
  • Thermal-Pak ® Coil Tube Spacing Sensi-Coil TM Tube Spacing Technology – Superior Design, Superior Unit Reduced Tube Spacing – Perfect for Sensible Cooling
    • Low Energy…
    • 30 to 50% less than other Induced draft
    Major Energy Savings Low Sound… better than standard Forced Draft 80% less than Forced Draft! – Superior Design, Superior Unit
  • Decreased Horsepower for the SAME tonnage Total Fan Energy (Hp) Based on 3gpm per ton, 95F/85F at 78F wetbulb. – Superior Design, Superior Unit Tons Evapco Forced Draft Evapco ATW Evapco ESWA 100 25 15 7.5 200 40 25 10 300 80 40 15 400 80 50 30
  • Based on 34% annual operation (3,000 fan hours per year) Electric rate = $0.09/KWHR Fan motor efficiency = 90% – Superior Design, Superior Unit
  • Based on 3gpm per ton, 95F/85F at 78F wetbulb. – Superior Design, Superior Unit Decreased Sound Levels from Top and Side Sound Level – Measured at 5 ft from the TOP (dBA) Tons Evapco Forced Draft Evapco ATW Evapco ESWA 200 81 89 77 300 85 92 79 400 82 89 77 500 85 92 79
  • Based on 3gpm per ton, 95F/85F at 78F wetbulb. – Superior Design, Superior Unit Decreased Sound Levels from Top and Side Sound Level – Measured at 5 ft from the AIR INLET (dBA) Tons Evapco Forced Draft Evapco ATW Evapco ESWA 200 80 84 73 300 87 87 76 400 84 84 73 500 87 87 76
    • No evaporation on coil – reduces scale
    – Superior Design, Superior Unit ESWA Features and Benefits
    • Totally enclosed coil protected from heat loss
    ESWA Features and Benefits – Superior Design, Superior Unit
    • Easy coil access
    The Most Accessible Coil in the Industry – Superior Design, Superior Unit ESWA Features and Benefits
    • NEW 14’x24’ Models
    – Superior Design, Superior Unit ESWA Features and Benefits New
  • EVAPCO, Inc. Water and Energy Conservation System
  • Complete Dry Cooler Section
  • Complete Wet Section Typical Induced Draft Cooler
  • The Control System:
    • Fan Operation
    • Pump Operation
    • Switchover Point
    • Water Level
    • Heater Package
    • Interfaces with Building Automation System
  • Stage 1 - Dry Mode Only
  • Stage 2 - Dry Mode Both Cells Running Dry
  • Stage 3 – Wet/Dry Mode
  • Stage 4 – Wet Mode Only
  • Profiles of the WDW versus an Induced Draft Cooler Water Usage m 3
  • Pulse ~Pure TM Water Treatment
    • Non-Chemical Water Treatment with Pulsed Electric Fields
  • Pulse ~Pure TM Water Treatment Corrosion Scale Biological
  • Pulse ~Pure TM Water Treatment
    • Scaling – Seed crystals.
    • Biological – Cell disruption and agglomeration.
    • Corrosion – pH in 8.3 to 9.0 range and no indiscriminate oxidizers added (chlorine or bromine).
  • Pulse ~Pure TM Water Treatment
    • Environmental – Pulse~ Pure can eliminate chemicals from the job site and conserve water.
    • Economical – Pulse~ Pure can save $$$ through water savings, water re-use, chemical avoidance, and increased system efficiency.
    • Effective – Pulse~ Pure will provide effective water treatment for evaporative equipment.
  • EVAPCO, INC. Taking Quality and Service to a Higher Level . . .