TABLE OF CONTENTS PAGES

ACKNOWLEDGMENT.....................................................................................................2
Background and justification...............................................................................................3
Objective..............................................................................................................................3
Tasks to be done:.................................................................................................................4
Abstract................................................................................................................................5
Chapter one..........................................................................................................................6
1.1 Introduction................................................................................................................6
1.2 Working principle of evaporative cooler...................................................................7
1.3 Advantages of Dry Cooler over Refrigerated Air Conditioner.................................8
1.4 Benefits of dry cooler................................................................................................9
Chapter two........................................................................................................................11
2.1 Analysis for dry cooler dimension determination...................................................11
2.2 Determination of flow rate......................................................................................11
2.2.1 Mass flow rate of moist air...............................................................................11
2.2.2 Volume flow rate of moist air...........................................................................12
2.2.3 Mass flow rate of water....................................................................................13
Chapter three......................................................................................................................18
3.1 Determination of the Heat Transfer Area................................................................18
3.1.1 Determination of dimension of wetted media or pad.......................................18
Chapter four.......................................................................................................................21
4.1 Determination of reservoir capacity........................................................................21
Chapter five.......................................................................................................................23
5. Manufacturing process...............................................................................................23
5.1 MANUFACTURING..........................................................................................23
Pad.............................................................................................................................23
Reservoir....................................................................................................................23
Guide or (the sliding mechanism) on the reservoir...................................................23
Guide (the sliding mechanism) and water trough on the top cover...........................23
Front cover.................................................................................................................24
Plates..........................................................................................................................24
Chapter six.........................................................................................................................25
6. Design of Components of Dry Cooler.......................................................................25
6.1 Fan Selection.......................................................................................................25
6.1.1 Centrifugal fans................................................................................................25
6.1.2 Axial flow fans.................................................................................................25
Fan total pressure = System total pressure loss.................................................................26
6.1.3 Fan Air Power...................................................................................................27
6.2 Pump Selection........................................................................................................29
6.2.1 Types of pump..................................................................................................30
6.2.2 Principle of Operation of centrifugal pump......................................................30
6.2.3 Pressure drop due to friction.............................................................................32
Diameter of Pipe........................................................................................................32
6.2.4 Pressure drop in fittings....................................................................................34
6.2.5 Pump power......................................................................................................35
Chapter seven.....................................................................................................................37
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7. Cost analysis..............................................................................................................37
Assembly procedure..........................................................................................................39
LIMITATION....................................................................................................................39
Recommendation...............................................................................................................40
Conclusion.........................................................................................................................41
BIBLOGRAPHY...............................................................................................................42

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ACKNOWLEDGMENT

First and for most, we would like to express our sincere thanks to our foreman advisor
Ato Ftwi Yohannes, whose charity for us to being and to complete this work. His genuine
advice, diligent follow UP, certain changes and re-arrangement, constructive review and
deep interest in every state of our work has been a source of our encouragement.
Equaly, we would like to extend our heart felt gratitude to our advisor Ato teklay
W/abzig, for his ever lasting support and endless advice there after.
Our deepest tanks & appreciation also goes to all workshop assistant for their great deed,
encouragement and sharing of ideas.
Last but not least, I am greatly indebted to DIF the department of Mechanical
Engineering for their support in materials and financially. By which with out their
financial and material support this project will not completely manufactured on time.

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Background and justification

Dry cooling is one of the most ancient and one of the most energy-efficient methods of
cooling a home. It long has been regarded as environmentally "safe," since the process
typically uses no ozone-depleting chemicals. In dry climates, evaporative cooling, even
the relatively inefficient "swamp box" household cooler, can be used to inexpensively
cool large homes

The most common form of residential evaporative cooling uses a vertical pad of cellulose
fiber, a system for delivering water to the top of 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.

Most of our country people who live around hot and dry climate will not use ventilation
and refrigeration system for their home to feel comfort. This is due to the cost of this
refrigeration system. So the problem they are suffering will be reduced by supplying less
cost, simple and easily available products. That is dry cooler.

Evaporative cooling has the following advantages over a refrigerated system:

 Generally lower Initial purchase costs than refrigerated systems.
 Lower running costs than refrigerated systems
 Lower energy usage
 Less greenhouse gas production
 No CFC's or HFC's (i.e. no ozone depletion)

Objective
The objective of this project is:

 Making design analysis for manufacturing a dry cooler or evaporative cooler

 Manufacturing of dry cooler

 Testing for its effect

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Tasks to be done:
 Collecting data
 Understanding the previous work
 Calculating the flow rate of air and water
 Making design analysis for manufacturing, which includes;
 Calculating the flow rate of air
 Calculating the flow rate of water
 Determination of the heat transfer area, the so called pad
 Selection of pump
 Selection of fan

 Manufacturing of dry cooler

 Testing for its effectiveness

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Abstract
This project is about the design and manufacturing of dry cooler, which is to cool a home
in hot and dry climates. In the project there are different tasks to be done. The design
starts with obtaining or collecting the average the local weather data of most hot and dry
area of Tigray region, the location and orientation of the room to be cooled is assumed to
be of most houses, the material of the wall of the room, window are of great importance
in calculating the cooling load. in addition to this the direction of the door and window is
important.
After having the above data the amount of heat to be removed from the room which is
called the cooling load is calculated. Calculation of the cooling load is based on internal
heat gains, external heat gains and infiltration air. Internal heat gain includes heat gain
due to occupants and light. External heat gain is the heat gain by conduction through the
walls, roof, window and door and solar heat gain through glass.
Having the total heat gain (cooling load) the flow rate of air and water is determined.
From the flow rate and considering the energy balance the total heat transfer area is
calculated. By which this area is used to determine the dimension of the pad.
Finally after the fan which is used to push air through the wetted pad and then into the
room and the pump which is used to pump the cooling water is selected. The design
suitable for manufacturing is going to take place which includes considering of clearance,
fitting and surface finish. Then with all dimension required for manufacturing is on hand
the object is going to be manufactured. The manufacturing process included the
dimensioning of sheet metal, cutting into dimension, bending, welding and riveting.
Finally, assembling of each parts of the dry cooler.

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Chapter one
1.1 Introduction
Wet the back of your hand—then blow on it. Your skin surface feels cooler. That’s
evaporative cooling or dry cooler.

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.
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.
On dry days-which are almost every day in a desert-a swamp cooler (dry cooler) works
fine. It makes the house feel like a muggy swamp-but that’s only when the late summer
rains come and the cooler is less efficient. . In high humidity areas, they don’t work at all
because the water does not evaporate appreciably and thus the air is not cooled.
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 turbulence, wetness, and speed of air movement), the evaporability
of the water (both temperature and hardness of the water affect this), and the ability of the
building to “vent” warmer exhaust air back to the atmosphere.
According the US Department of Energy, the difference between the inside air

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temperature and the cooled air can be expected to be in the range of 15 to 20 degrees, but
the difference can be as high as 40 degrees in certain conditions. As an added bonus,
evaporative coolers provide incremental cooling effect; since the constant air movement
caused by the cooler’s fan actually makes a room’s temperature feel even cooler.
You can demonstrate the working principle of dry cooler to yourself by putting on a wet
T-shirt and standing in front of a fan. If you live in a dry climate where humidity is low,
you will feel an immediate cooling, even chilling effect. If you live where humidity is
high, you will simply feel damp. Cooling by evaporation works very efficiently in dry
areas, but isn’t worth spit in the tropics, or any other humid climate. Unlike 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 air flow to
distribute the cool air through the home and expel warm, moist air through window
openings.
Evaporative coolers work best when the air they are pulling in is dry. As the humidity in
the outside air increases, the effectiveness of evaporative cooling goes down. In reality,
evaporative coolers work best only in certain areas such as the southwest or where the
climate is arid and the air is dry. In areas with higher humidity, evaporative coolers aren't
really an option since they'd actually be adding moisture to the air and there would be no
cooling effect. Thus we do not use evaporative cooler every where.
Another drawback to evaporative coolers is they use a substantial amount of water (up to
15 gallons per day) to provide their cooling effect. In dry areas, this consumption can put
a real strain on water supplies.
In spite of the fact that evaporative coolers may not be a cooling option for all of us, there
is no doubt that they do provide energy savings and reduce the risk of damage to the
environment. So even if we all can't use an evaporative cooler, we all do benefit from the
energy conservation and environmental protection they provide.

1.2 Working principle of evaporative cooler

While evaporative coolers have moved beyond the “hang a cloth in the window” stage,
the principle remains the same. Nowadays an evaporative cooler usually consists of a
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large box containing a fan surrounded by a wet pad, mounted on the roof or side of a
house. A pump circulates water to keep the pad wet and the fan blows air through the
pad. The damp (but cooler) air is blown into the house driving the hotter inside air out
through open windows or vents.

That is, first the water in the reservoir is pumped into the pad. Then the motor of the fan
powers a fan to pushes air coming through the wetted pad into the room. When the
entering airs is hot and dry some of the water evaporates on the wetted pad and hence the
air becomes cooled and humidified. Finally, the cooled and humidified air is pushed into
the home.

1.3 Advantages of Dry Cooler over Refrigerated Air

Conditioner
There are a number of economic and environmental benefits to using an evaporative
cooler. For example:
 Evaporative coolers use substantially less electricity than an air conditioner for
the same sized house (some estimates are as much as 75 percent less).
 Evaporative coolers use simple technology and as a result are much cheaper to
buy, install and maintain. Plus, they operate on regular household current so they
don’t require a dedicated circuit.
 In dry climates, adding moisture to the air can help keep both furniture and fabrics
from drying out.
 The moist pads in the cooler act as air filters, helping keep dust and pollen out of
the house while providing a constant supply of fresh air into the home.
 Evaporative coolers are even available in small sized window and portable units
that can be used to cool an individual room.
 Generally lower Initial purchase costs than refrigerated systems.
 Lower running costs than refrigerated systems
 Lower energy usage, Power consumption is limited to the fan and water pump
where as in refrigerated air conditioning there are compressors, blowers and
pumps which are higher in cost.

 Less greenhouse gas production

 No CFC’s or HFC’s (i.e. no ozone depletion)
 Less expensive to install than air conditioning equipment.

 Most cooler maintenance and repairs can be accomplished by the homeowner

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 Requires less expensive operational cost. Using one-third the energy of

refrigerated air-conditioning.
 Dry Coolers bring (circulates) fresh, cooled, outside air into the home.

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

 Most dry Cooler replacement parts (pads, grills, etc.) are nominal in cost when
compared to air-conditioning system replacement parts.
 Dry cooler use significantly less energy, so it conserves electricity

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

 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.

1.4 Benefits of dry cooler

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

 Operation is a fraction of conventional air conditioning and mechanical

refrigeration systems. Maintenance costs are minimal requiring simpler
procedures and lower skilled maintenance people.

 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.

 Increases Comfort condition for human.

 Health Benefit: evaporative cooling is 100% fresh air cooling. This means that
all the air being cooled is brought into the room from outside with out addition of
any chemical.

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 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 two
2.1 Analysis for dry cooler dimension determination
Out side design condition
 dry- bulb temperature =28.40c
 wet-bulb temperature =14.20c
 relative humidity 64%
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%
From cooling load calculation, which is based on cooling and humidifying
the dormitory in Mekelle University, the following are already calculated.
Total sensible heat (qs) = 3291.228W
Total latent heat (ql) = -1423.54W
Total heat removed = qs + ql = 1867.688

2.2 Determination of flow rate

2.2.1 Mass flow rate of moist air
The mass flow rate of moist air required to cool the total load is calculated
from
qs=maCpa (Tr-Ts)
Where: qs= sensible heat gain, W or J/s
ma = mass flow rate of moist air, Kg/s
Cpa = specific heat capacity of moist air, J/Kg.K
Tr, Ts= supply air and room air temperatures respectively

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Since the objective is to cool and humidify the temperature of wetted

surface, the temperature of water Should be less than out side dry bulb
temperature and greater than the wet bulb temperature of out side air.

Assumption
 The temperature of the air at the outlet of wetted surface is assumed to be
16oC since evaporative media should cool the air in the range of (10-20)oC
 Temperature rise due to the supply fan power estimated to be 1oC, Thus
supply air
temperature to the room will be;
Ts=16oC+1oC=17oC
 The temperature of air at the outlet of wetted surface is equal to the
temperature of circulated water
Hence, the values that are used to calculate the mass flow rate of air are;
qs=3291.228W=3291.228J/s
Tr=24oC+273=297K
Ts=17oC+273=290K
Cpa=1.0246kJ/Kg.K

Thus mass flow rate of air is:

ma = qs/Cpa(Tr-Ts)
= 3291.228/51.0246*103J/Kg.K (297-290)
= 0.4589Kg/s or 27.534Kg/min

2.2.2 Volume flow rate of moist air

The volumetric flow rate of moist air is determined from the mass flow
rate of moist air:
Va =ma/ρa

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Where:Va=volume flow rate of moist air, m3/s

ma= mass flow rate of moist air, Kg/s
ρa= density of moist air,kg/m3
But the density of air is
ρa = Pa/RaTa
Where: Pa = the pressure of outside dry air 80KPa
Ra = gas constant of dry air = 0.287KJ/KgK
Ta = temperature of dry air = 28.40c = 301.4K

Thus, ρa = 80/0.287*301.4
= 0.9261 Kg/m3

Therefore the volumetric flow rate is

V = 0.4589kg/s
0.9261 Kg/m3
= 0.4955m3/s or 495.5 l/s

2.2.3 Mass flow rate of water

Before determining the mass flow rate of water, water vapor evaporated
mass flow rate is determined from mass balance of water vapor

Where: state 1 outside state

state 2 supply state

Since adiabatic saturation analysis as a steady flow process which no heat

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or work interaction, the kinetic and potential energy changes can be

negligible.

Mass balance for dry air mass flow rate

ma1=ma2=ma= constant

Where: ma1= out side mass flow rate of dry air

ma2 = supply mass flow rate of dry air
ma = mass flow rate of dry air
Mass flow rate of vapor in the air increased by an amount equal to the rate
of evaporation mf.
mw1 + mf=mw2
Where: mw1= out side mass flow rate of dry air
mw2= supply mass flow rate of dry air
mf= rate of evaporation (make up water required)
Or mawo+ mf=maws
mf =ma(ws – wo)
But mass of dry air (ma) can be determined from the following relation of
supply air:
Mair = m dry air +m water vapor
ws = ma + maws
ma = ms
(1+ws)
Where: ms= ma= mass flow rate of supply air
But, humidity of supply air (Ws) is determined from latent heat as follows:
ql = ma hfg ( Wr-Ws)
Where: ql = total latent heat of the room = -1.42354KJ/Kg
ma = mass flow rate of supply air = .4589Kg/s
Wr = specific humidity of room air,it calculated
Wr=0.622ǾPg
P-ǾPg
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Ǿ=80%

Pg= Psat at 240c= 3.003 kPa by interpolation Temp (0c)

pressure (kPa)
20……………2.339
24…………… Psat
=?
25……………3.169
Psat
=3.003kpa
Wr = 0.622*0.8*3.003
80-0.8*3.003
= 0.01926 Kg h2o vapor/Kg dry air

hfg = latent heat of evaporation at supply state, by interpolation

Temp ( Oc ) Enthalpy (oc)
hf hg
16………………...........67.13……….2530.9
17……………………. hf 17…………hg 17=?
18…………….............75.5………… 2534.5

hf17 =71.315kj/kg
hg17 =2532.7kj/kg
hfg =hg2-hf2=2461.385 KJ/Kg dry air

Rearranging the above formula;

Ws = Wi-(ql/ma hfg)
= 0.01926-(-1.42354/0.4589*2461.18)
= 0.02052 Kg h2o vapor /Kg dry air
Thus, mass of dry air
ma = ms
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(1+ws)
= 0.4589
1+0.02052
= 0.4497kg/s
Specific humidity of out side air WO
WO=0.622ǾPg
P-ǾPg

Ǿ=64%
Pg= Psat at 28.40c= 3.8706 kPa by interpolation Temp (0c)
pressure (kPa)
28……………3.778
28.4…………… Psat
=?
30……………4.241
Psat =3.8706
kpa

=0.01988 Kg h2o vapor /Kg dry air

Therefore, from water vapor balance evaporated mass flow rate is

=0.4497(0.02052 – 0.01988)
mf= 0.000287808Kg/s

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Thus volume flow rate of evaporated water is

Where: mass flow rate of evaporated water

density of water at 17oC and by interpolating

between 10oC and
20oC and is equal to 998.657Kg/m3

or
The volume flow rate of water is selected from the recommended water
flow rate for aspen fiber which is 6L/min’m
Thus volume flow rate is 7.2lit/min or 0.12l/s or 1.2*10-
4
m3/s

Table 1. Recommended water flow rates and sump capacities for vertically-mounted
cooling pad materials.
Minimum water flow Minimum sump
Pad type and thickness rate capacity
per unit length of pad per unit pad area
  gpm/ft L/min'm gal/ft2 L/m2
Aspen fiber  
2 to 4 in (50 to 100 mm) 0.3 4 0.5 20
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Aspen fiber, desert conditions  

2 to 4 in (50 to 100 mm) 0.4 5 0.5 20
Corrugated cellulose  
4 in (100 mm) 0.5 6 0.8 30
Aspen fiber  
6 in (150 mm) 0.8 10 1.0 40

Chapter three
3.1 Determination of the Heat Transfer Area
3.1.1 Determination of dimension of wetted media or pad
The dimension is determined from the concept of enthalpy potential.

[6]
Where:

=total heat removed

= forced convection of air

= total heat transfer area

= enthalpy of saturated air at the wetted surface temperature

= enthalpy of air in the free stream

= specific capacity of moist air ,1.0246KJ/kg

Generally, enthalpy at different states can be determined by

h = CpT + whg

Thus, enthalpy of outside air is

ho= Cp To + wo hg

Where: Cp= specific heat of dry air at constant pressure, it ranges from
1.006 at 0oc
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to 1.009 at 500c in kJ/kg. oc. Cp=1.0075 kJ/kg at 28.4 oC

To= outside temperature = 28.4oC
hg= enthalpy of saturated stream at temperature of air vapor
mixture,
wo= Specific humidity of out side air

Therefore, ho = CpTo + wohg

= 1.0075*28.4 + 0.01988*2553.44
ho = 79.304KJ/Kg.k

Similarly, hi = Cp Tr + wr hgr

Where: hi= enthalpy of saturated air at the wetted surface temperature

Cp= specific heat of dry air at constant pressure, Cp=1.007kJ/kg.oc
Ti= temperature at outlet of wetted surface, 17oC
Wi= Ws, specific humidity at outlet of wetted surface,i .e supply air
specific
humidity.
hgr= enthalpy at supply temperature at T=17oC ,by interpolating
and is equal to

hgi =2534.5KJ/Kg.K
Thus, substituting the above values enthalpy at supply is
h i= 1.007*17 + 0.0203*2532.7
hi=68.5328KJ/Kg.K
Now, recalling equation

= -1869.688W*1.0246KJ/Kg.K
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200 (68.5328 – 79.3754)

A= 0.8834m2

The dry cooler is rectangular with three of the sides the air enter in to the
pad and the other side in which acts as a duct for supply of air to the room
by the fan.
Hence, the area of the pad is equal in the three sides. This area is used to
determine the area of the area of the pad at each side.

A = A1 +
A2 + A3
There fore, A1 =A3=H*W=L*L/2=L2/2
A2=L*H=L*L= L2
There fore, A = A1 + A2 + A3
0.8834m2 =2 A1+ A2
=2(L2/2) + L2
0.8834 m2 =2 L2
L2=0.4417 m2

L=0.6646m OR 664.6mm
There fore, L=660mm=H

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Thus, the wetted media is with two sides and the other
side .

Chapter four
4.1 Determination of reservoir capacity

It is determined by considering the space occupied by the sitting (guide)

for the pad. That is at 30mm below the upper reservoir and space occupied
by pump.
Thus,
L = 660 + 40 + 40 + 50 + 50 + 10 = 850mm
W = 330 + 40 + 40 = 410mm
H = h + 30 + 5
Where h is the height at which the water can be filled.
Therefore,
Capacity = 850mm*410*h
But by assuming the water is replaced every two days, it can be
determined from makeup water required or water evaporated at each
second. this means,
Vf = 2.88*10-7m3/s
= 2.88*10-4lit/s
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Assuming that the dry cooler is works 12 hours a day. Hence for two days
the dry is cooler is woks for 24 hour.
Now, the amount of water required to be substituted in two days is;
= Vf*24hrs*3600s
= 2.88*10-4lit/s*24*3600s
= 24.9 lit
Now, we can determine the level of water that can be filled.
24.9 lit = 850mm*410mm*h
2409 lit =348500mm3*h
24.9 lit = (0.3485 lit)*h
h = 71.449mm
Say h = 75mm
Now, since the height of the guide is 30mm and giving a clearance of
15mm, the total height of the reservoir H will be;
H = h + 35 = 75mm + 35mm
H = 120mm
Therefore, the capacity of the reservoir will be;
Capacity = 85mm*850mm*410mm
= 2.96225*107mm3
= 2.96225*10-2m3 or 29.6225 lit

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Chapter five
5. Manufacturing process
5.1 MANUFACTURING
With the dimension obtain from analysis of the design the following are going to be
ready with the following manufacturing processes to several parts to satisfy the main
target of the project.

Pad
Pad is the main part of the dry cooler which real cools the incoming outside air. It is
made from grass or cellulose. They are three in number of each of them 50mm thickness.
The two that are on opposite sides are equal and each of them is 660mmX330mm.the pad
on the third side is 660mmX660mm.

Reservoir
Reservoir is the container or tank that is used to accumulate water that is going to be
pumped up to wet the pad. It is made by welding 1mm thickness steel sheet metal of
dimension 850mmX120mm.

Guide or (the sliding mechanism) on the reservoir

Is the guide or the sliding mechanism on the reservoir used from the simple removal and
assemble of the pad for maintenance and changing of the parts of the dry cooler, mainly
the pad. It is made by bending and then riveting on the three sides of the reservoir from
1mm thickness steel sheet metal of which two of them 330mmX125mm the third one is
of dimension 660mmX125mm.

Guide (the sliding mechanism) and water trough on the top cover
The guide or the sliding mechanism on the top cover is equal and used for the same
purpose as the guide on the reservoir. But it has additional part the so called water trough
which is used for the temporary storage of water that is slowly drop on the pad through
the priced hole to continuously wet the pad. They are three in number. They are made
from 1mm thickness steel sheet metal by bending and then riveting on the top cover.
Each of the two is of dimension 330mmX185mm and the third is 660mmX185mm.
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Front cover
Front cover is one part that the fan is mounted on it. It is made from 1mm thickness steel
sheet metal by pricing a hole equal to the circumference of the fan blade. And its
dimension is 850mmX740mm sheet metal.

Plates
They are used for preventing of the side flow of water on the water trough.
They are all equal and made of 1mm steel sheet metal of dimension
54mmX32mm.

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Chapter six
6. Design of Components of Dry Cooler
6.1 Fan Selection
Fans are necessary to distribute air through equipment and through ductwork to spaces
that are to be air conditioned. Hence, fan is defined as a rotary, bladed machine
maintaining a continuous of air. Continuous flow of air 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.
Fans may be classified into two main types, centrifugal fans and axial flow fans, which
differ in the direction of air flow through the fan. In centrifugal fan, air is pulled along the
fan shaft and the blown radially away from the shaft .the air is usually collected by a
scroll casing and concentrated in one direction. In an axial flow fan, air is pulled along
the fan shaft and then blown along in the same direction.

6.1.1 Centrifugal fans

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.
Centrifugal fans may be sub classified into forward curved, radial, backward curved,
and backward inclined types, which differ in the shape of their impeller blades. In
addition, backward curved blades with a double-thickness blade are called airfoil blades.

6.1.2 Axial flow fans

Axial flow fans have flow within the wheel that is substantially parallel to the shaft and
operate within cylindrical ring-type housing.
Axial fan may be sub classified into propeller, tube axial, and vaneaxial types. The
propeller fan is like a window fan, consisting of a propeller-type wheel mounted on a ring
or plate. The tubeaxial fan has a vaned wheel mounted in a cylinder. The vaneaxial fan is
similar to the tubeaxial type, except that it also has guide vanes behind the fan blades
which improve the direction of airflow through the fan.

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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.

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.

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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

6.1.3 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

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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.

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6.2 Pump Selection

A pump is a device that circulates liquid through piping systems. A pump provides the
pressure necessary to overcome the resistance to flow of a liquid in a piping system.
Before selecting a pump that will fit our needs, four thing s, the so called the pump

characteristics must be determined:

1) The total head or pressure against which it must operate
2) The desired flow rate,
3) The suction lift, and
4) Characteristics of the fluid.
The total head, suction lift and flow rate are dependent upon the piping system and the
pump’s characteristics. The piping system and the pump interact to determine the
operating point of the pump – flow rate and pressure. The pump cannot independently
control these parameters. As the flow rate is increased the work to move each unit of
water or total dynamic head the pump must produce increases. A pump will typically
have reduced capacity as the pressure or head it is pumping against increases. The
operating point of the system occurs when the two curves cross. In order to obtain a
pumping system that will meet your requirements, and meet them in an efficient manner,
you must match the pump to the piping system and required flow rate.
A cost analysis of pumping will consider initial cost of capital investment, annual fixed
cost and operating cost. All three costs are somewhat dependent on each other. The type
of pumping equipment, size of pipelines, size of pumps and type of water supply affect
not only the initial cost but also the fixed cost as well as the operating cost. For example,
piping systems using large pipes may cost more but could allow the use of smaller
horsepower pumps which cost less, require smaller power sources and cost less to operate
than a piping system with small diameter pipe. The lowest priced system is not always
the best buy, especially if the lower price means less efficient pumps.
To get the most efficient pump, an analysis should be made of all pumping requirements.
Key points to consider are:
 net positive suction head (NPSH)
 priming
 flexibility
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 corrosion
 useful life
 maintenance
 quantity pumped
 pumping head
 power source
 economics.

The NPSH is the amount of energy in the water at the pump’s inlet. The required NPSH
is a characteristic of the pump and depends on pump design, size and operating
conditions. The required NPSH is determined by the pump manufacturer. The available
NPSH must equal or exceed the required NPSH. The available NPSH is a characteristic
of the piping system.

6.2.1 Types of pump

Pumps can be classified into two groups according to the way they develop the pressure
necessary to overcome the resistance to flow of a liquid in a piping system.; 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, second type, is the type most widely used in circulating water in
HVAC system. Three types of centrifugal pumps are often used in water systems in
HVAC&R systems: double suction horizontal split-case, frame-mounted end suction, and
vertical in-line pumps. Double-suction horizontal split-case centrifugal pumps are the
most widely used pumps in large central hydronic air conditioning systems . The
centrifugal pump is generally used in both hydronic and cooling tower water system.

6.2.2 Principle of Operation of centrifugal pump

Centrifugal pumps are the most widely used pumps for transporting chilled water, hot
water, and Condenser water in HVAC&R systems because of their high efficiency and
reliable operation.
The centrifugal pump increases the pressure of the water by first increasing its velocity,
and then converting that velocity energy to pressure energy. That is, Centrifugal pumps
accelerate liquid and convert the velocity of the liquid to static head. A typical centrifugal

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pump consists of an impeller rotating inside a spiral casing, a shaft, mechanical seals and
bearings on both ends of the shaft, suction inlets, and a discharge outlet.
The impeller can be single-stage or multistage. The vanes of the impeller are usually
backward curved.
When a fluid is flowing through a pipe, the fluid experiences some resistance due to
which some of the energy of fluid is lost.

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6.2.3 Pressure drop due to friction

The loss of head in pipes due to friction is calculated from Darcy-Weisbach equation,
which is given by

[1]

Where: 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

But where: V = velocity of water

d = diameter of pipe
= kinematics viscosity

For water the kinematics viscosity is

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 2 Dimensions of steel pipe [2]

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

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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

[2]

Taking nominal size of 15mm (ID =15.80mm)

The velocity of water is calculated from the volume flow rate of water.

Where d is the diameter of the pipe = 15.80 mm

Therefore, the Reynolds number is

Since, Re is in between 4000 and106 i.e. 4000 < Re < 106

The coefficient of friction is

L=1540mm=1.540m
Hence, pressure drop due to friction will be

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6.2.4 Pressure drop in fittings

Pipe fittings and valves also introduce losses in head; these losses are usually allowed for
by use of a resistance coefficient k, which number of velocity heads is lost because of
valve or fittings. Thus,

Where:

2.1 Pressure drop in elbow

From table:
Pipe diameter mm is 15 mm for 900c elbow

K=30ft
Where: ft=0.023 for ½ inch nominal size
K=30*0.027
=0.81
Thus, Lf=kv /2g
2

=0.81*(0.61204)2
2*9.81
= 0.015465m
Lf=15.465mm
Since there are three elbows
Lf = 15.465mm*3= 46.395mm
K=fL/D
L=KD
F
=0.81*0.5
0.027
=3 inch
Since three elbows
L’= 3l= 3*15in= 45in
L’= 1.143m
The total equivalent length

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Actual length of pipe 1.54m

Three elbows 1.143m
Total 2.683m
Thus the lost head for the complete pipe run is then given by
Lf=lelf’
= (2.683m)*1.4*10-2
=0.037562m
Lf= 37.562mm

The total head loss is given by

H=hf+z+hs9+lf+lft
=59.3+760+0+37.562+46.395
=903.257mm

6.2.5 Pump power

Pump input or brake horsepower (BHP) is the actual horsepower delivered to the pump
Shaft.

Where Q- capacity in gallons per minute = 1.5838gpm

Ht- total differential head, ft = 2.9634ft
Sp.gr.- specific gravity of the liquid = 1 for water
Eff.- pump efficiency, % = 85%

Now,

Pump output or hydraulic or water horsepower (WHP) is the liquid horsepower delivered
by the pump. These two terms are defined by the following formulas.

Where Q-capacity in gallons per minute = 1.5838gpm

Ht-total differential head, ft = 2.9634ft
Sp.gr.-specific gravity of the liquid = 1 for water

Now,

The constant 3960 is obtained by dividing the number or foot-pounds for one horsepower
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(33,000) by the weight of one gallon of water (8.33 pounds).

BHP can also be read from the pump curves at any flow rate. Pump curves are based on a
specific gravity of 1.0. Other liquids’ specific gravity must be considered.
The brake horsepower or input to a pump is greater than the hydraulic horsepower or
output due to the mechanical and hydraulic losses incurred in the pump.
Therefore the pump efficiency is the ratio of these two values.
=85%

Therefore the selected pump is a centrifugal pump having the following specification
Capacity = 0.12lit/s
Head loss = 903.257mm
Power
BHP=0.001394gpmft
WHP=0.001185gpmft

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Chapter seven
7. Cost analysis
The material require for manufacturing of dry cooler are;
Steel sheet metal of thickness 1mm
Galvanized grill
Cellulose pad
Fan and pump
Bolt, rivet and electrode
Their respective expanses (cost) is listed below

No Material Quantity Dimension Cost(Birr)

1 Steel sheet metal 1mX2.5M of 1mm 300
thickness
2 Galvanized grill 1mX3m 90

3 Cellulose pad Packed up to 50mm No const. since it is

thickX1200mm made from grass.
4 Fan One centrifugal fan 450
of 5W power
5 pump One centrifugal pump 450
6 Bolt 4M,8M 10
7 Rivet 60 5
8 Electrode 10 5
Total 1310

As it can be seen from the total expanse for manufacturing of dry cooler, it seems to
be cost. But this total cost (1310) is calculated for manufacture of a unit product. That
is all cost of the material is highly increased. And the scraps of the left material are
also used to some extent if the manufacturing is made for mass production.
So if the manufacturing is made for mass production;
Total manufacturing cost is reduced
The scraps of the material is re used
Material is used effectively
Hence the estimated manufacturing cost of dry cooler for a mass production is listed in
the table below.
No Material Quantity Dimension Cost (Birr)
1 Steel sheet metal 1mX2M of 180
1mm thickness
2 Galvanized grill 1mX2m 60

3 Cellulose pad Packed up to No const. since

50mm it is made from
thickX1200mm grass
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4 Fan One centrifugal 200

fan of 5W
power
5 pump One centrifugal 250
pump
6 Bolt 4M,8M 7
7 Rivet 60 3
8 Electrode 10 4
Total 705

As can be seen from the estimated cost made if the equipment is going to be
manufactured by mass production the manufacturing cost is reduced up to 50% of a unit
manufacturing cost.

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Assembly procedure
To work effectively and efficiently the properly assembly of the manufactured equipment
is one requirement. So the procedure for assembly is;
1. the reservoir is force fit into the angle Iron at the bottom
2. pump is fitted by bolt at the middle of reservoir
3. front cover is mounted on the angle Iron by bolt
4. fan is fitted on the front cover by bolt
5. top cover is made force fit on to the angle Iron at the top
6. grill and pad assembly is assembled at their respective bottom and upper slide
guide
7. finally, pump and fan power cable is connected to electric socket
then the dry cooler starts it work. COOLING!

LIMITATION
Limitations that we encounter while working on this project is;
no gating workshop material on time
unavailability of required material on the market (pump and fan)
Shortage of time. Since we have worked on both design for manufacturing
and manufacturing of dry cooler. No diploma student assistant.

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Recommendation
This product is highly efficient only in the area the weather condition is hot and dry.
Since, it works on the principle of increasing the humidity of air by evaporating some
amount of water by the air to cool the home. And all the design calculation made is based
on the information obtained from the local weather data of this area, hot and dry area.
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, its orientation and its relations with the adjacent rooms is
important.
The cooling load calculation is done based on the above data by considering16hrs stay in
the dormitory and that the occupants are seated and doing light work (writing).and we
take this value directly from the previous design work to determine the flow rate of air
and water.
Having the flow rate of air the selection of fan is made. That pushes the air through the
cooling media, the so called pad and into the room.
With the flow rate of water and calculating the total head loss in pipe and pipe fitting
pump that is used to pump the water up is selected.
The diameter of the pipe is taken from standard table as explained in the pump selection.
In The manufacturing process all the sheet metal used is of equal thickness and is must be
galvanized sheet metal or painted with anti rest ink. This is due to all the parts of the dry
cooler has a direct contact with the circulating water.
The pump that is used to pump the water up and the fan that is used to push air into the
room also must be sealed for the same reason.
The water in the reservoir has to be changed or replaced every three days.
The equipment has to work on the optimal time. The time at which the weather condition
is assumed to be high, to save electric and water cost.

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Conclusion
The increase of the local weather temperature as result of the global warming is now a
day is the hot issues throughout the world. And that is the major cause of the human
discomfort.
The problem that most of our country people who live around hot and dry climate are
suffering will be reduced by supplying less cost (with fair cost), simple and easily
available products. That is dry cooler.
The determination of the air and water flow rate is done by taking the cooling load value
obtained by the previous design work.
The temperature of the water to be recirculated is determined in a such away that for
cooling and humidification to take the temperature of water is should be less than the dry
bulb temperature of the out door air and greater than the wet bulb temperature of the out
door air.
Evaporative coolers work best when the air they are pulling in is dry. As the humidity in
the outside air increases, the effectiveness of evaporative cooling goes down. In reality,
evaporative coolers work best only in certain areas such as the southwest and north or
where the climate is arid (hot) and the air is dry. In areas with higher humidity,
evaporative coolers aren't really an option since they'd actually be adding moisture to the
air and there would be no cooling effect. Thus we do not use evaporative cooler every
where.
In spite of the fact that evaporative coolers may not be a cooling option for all of us, there
is no doubt that they do provide energy savings and reduce the risk of damage to the
environment. So even if we all can't use an evaporative cooler, we all do benefit from the
energy conservation and environmental protection they provide.
As the initial purchase cost of the dry cooler is of that most of the people can afford, it
will be highly needed equipment on the market.

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BIBLOGRAPHY
1. ASRAE HANDBOOK 1981 FUNDAMENTAL
2. Professor S.Dasai.” Modern refrigeration and air conditioning for Engineers”
3. Dr.R.Bansal.”fliud Mechanics Hydraulic Machine”
4. C.P Arora.”Refrigeration and Air Conditioning” second edition
5. Faye C.Mc question, Jerald D.Parker, Jeffrey D.splitler.”HEATING
VENTILATION, and AIR CONDITIONIG”
6. Wilbert F.soecker/Jerald W.jones, “refrigeration and air conditioning” second
edition

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