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    Cooling Tower Project Report: Drift Air To Atmospher e

    Uploaded by

    Dinesh Verma
    This document provides a report on a cooling tower project at a fertilizer plant. The project involved replacing aging packing, drift eliminators, nozzles, and other components to improve performance. Work was completed over 142 days by local laborers and some supervision from CNCEC. Key activities included removing old materials, fabricating and installing new packing, drift eliminators, nozzles, and protection layers. Performance is expected to improve with lower drift loss, better temperature control, and increased reliability. Lessons learned include the ability of local workers to complete much of the work.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd

    Cooling Tower Project Report: Drift Air To Atmospher e

    Uploaded by

    Dinesh Verma
    92 views24 pages
    This document provides a report on a cooling tower project at a fertilizer plant. The project involved replacing aging packing, drift eliminators, nozzles, and other components to improve performance. Work was completed over 142 days by local laborers and some supervision from CNCEC. Key activities included removing old materials, fabricating and installing new packing, drift eliminators, nozzles, and protection layers. Performance is expected to improve with lower drift loss, better temperature control, and increased reliability. Lessons learned include the ability of local workers to complete much of the work.

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    This document provides a report on a cooling tower project at a fertilizer plant. The project involved replacing aging packing, drift eliminators, nozzles, and other components to improve performance. Work was completed over 142 days by local laborers and some supervision from CNCEC. Key activities included removing old materials, fabricating and installing new packing, drift eliminators, nozzles, and protection layers. Performance is expected to improve with lower drift loss, better temperature control, and increased reliability. Lessons learned include the ability of local workers to complete much of the work.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    92 views24 pages

    Cooling Tower Project Report: Drift Air To Atmospher e

    Uploaded by

    Dinesh Verma
    This document provides a report on a cooling tower project at a fertilizer plant. The project involved replacing aging packing, drift eliminators, nozzles, and other components to improve performance. Work was completed over 142 days by local laborers and some supervision from CNCEC. Key activities included removing old materials, fabricating and installing new packing, drift eliminators, nozzles, and protection layers. Performance is expected to improve with lower drift loss, better temperature control, and increased reliability. Lessons learned include the ability of local workers to complete much of the work.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 24

    Cooling Tower Project Report

    Drift Air to
    Atmospher
    e
    External Fan Drive Unit

    Induced
    Draft Fan

    Prepared by
    Ashik Ahmed
    Section Manager
    Technical Services
    Working in a Multinational
    Fertilizer Company
    Tel.: +880 31 618972~4; Ext.:
    2237 (Office)
    Email : [email protected],
    [email protected],
    Mobile: +880 1730059920

    Drift
    Eliminators

    Fill Material

    Air In
    Air In

    Reason For The Project

    SPIG Engineers visited our plant on 27~28th October,2010 &


    evaluated the performance of cooling tower. The observation
    shows the following tings:-

    Suggestion from the SPIG

    SPIG Engineers suggested the following modifica


    Immediately replace the existing packing with new type.
    Install the recent design drift eliminators- which
    will reduce water losses.
    Install dynamic Ecojet type nozzles for better distributor.
    Install Gear Box Vibration Monitoring system.

    Note: SPIG informed that Existing Packing Materials are no


    Producing now a days as they are producing improved typ

    26th BTCM

    Minutes of 26th BTCM - Justification for CT works.pdf

    On 26th BTCM , the Project / SPIG offer has been approved


    to the following reasons:-

    The working life of Cooling tower Packing's, drift eliminato


    & distributor nozzles have already expired.
    Normal working life of these items are 7~10 years.

    Cooling Tower
    Drift Air to
    Atmospher
    e
    External Fan Drive Unit

    Induced
    Draft Fan

    Drift
    Eliminators
    Spray from Ecojet
    Nozzles

    Hot Water from Heat


    Exchangers

    Fill Material

    Air In
    Air In

    Cool Water To

    Cool Water Collected in Cooling Tower

    Total Cost

    SAP.jpg

    The Cooling tower improvement project has booked $2,51


    Till 10.12.12.
    ITEM

    COST (USD)

    Material

    $ 2,423,998

    Inspection

    $ 13,893

    Installation &
    Commissioning

    $ 75,679

    Total

    $ 2,514,186
    (Planned Budget was $ 3,000,000)

    SPIG Supervisor with one Technician will come to KAFCO Plant Site to
    conduct Performance Test probably on January, 2012.
    So, there is some travelling cost still left.

    Schedule of Cooling Tower Cell I


    Cooling Tower Cell -I.mpp Microsoft Office Project - Cash Flow.pdf Microsoft Office Project - Network Diagram.pdf

    HAZARD IDENTIFICATION AND RISK ASSESSMENT (HIRA)


    K-IMS-PRJDEV- HIRA.pdf

    Work Sequence of Cooling Tower


    SR
    I

    Activity

    Description

    Film Filling
    (Packing)
    Fabrication

    As the weather condition


    was good, the packing
    fabrication work had
    completed smoothly.
    The required no of packings
    for Each cell (600 Pcs) had
    completed on 9 days . Here
    9 local skilled labors had
    completed the job & they
    fabricated 70 pcs/D

    OLD Packing
    The filling actually installed
    was film X12,made of slightly
    sloped waves and corrugated
    surfaces, self spacing, which
    mixing the external and
    internal layer of water.

    Problem
    The old packings were
    totally clogged with an
    heavy increase of the
    weight of each panel. The
    new film filling y20 is more
    resistant and stronger. The
    thickness of previous X20
    was 180 micron while the
    thickness of Y20 film is
    220micron.

    Image

    IMAGE

    Work Sequence of Cooling Tower


    SR

    II

    Activity Description
    Scaffoldin South side scaffolding
    works is the Most
    g works
    important because the
    packing removal start
    from south side.
    We completed the south
    side scaffolding on first 2
    days then start old
    packing removal. This
    reduce the project working
    time to 12 Days.

    Lesson Learned
    We have marked
    the Scaffolding
    Pipes for making
    future cell
    scaffolding easy

    All the pipes of north &


    south side cell scaffoldings
    are marked from west to
    east side from 1 to 18
    numbers.
    It had eased the cells
    Scaffolding works thus
    anyone can easily install
    the pipes.

    Image

    Work Sequence of Cooling Tower


    SR
    IV

    Activity

    Description

    Removal The whole amount of


    of old
    old packings, drift
    packings eliminators, nozzles,
    debris, etc are
    removed easily on 5
    days.

    Lesson Learned
    Previously we
    were removing
    old materials by
    CNCEC personnel.
    It was very costly
    as well as a very
    lengthy process.
    (~ 7 Days)

    Now by the local


    manpower ,we can remove
    the materials easily.
    We requires more safety on
    the last layer removal only.
    So, it takes 5 days
    maximum.

    Image

    Work Sequence of Cooling Tower


    SR
    V

    Activity
    Shifting
    of old
    packings

    Description
    The whole amount of
    old packings, drift
    eliminators, nozzles,
    debris, etc are shifted
    easily from the site by
    Tractor.
    **01 Tractor can load
    98 Pcs of old
    packings (Approx).**

    Lesson Learned
    Previously we
    were shifting
    old materials
    by local hired
    dump truck. It
    was very
    costly as well
    as a very
    lengthy
    process.(~ 7

    Now by the new tractor


    procured by Admin Dept ,we
    can shift the materials easily.
    We requires 29 tractors to
    shift 1 Cell materials.
    (24 for Packing's,03 for drift
    eliminators & 2 for Debris).
    So, it takes 5 days
    maximum.

    Image

    Work Sequence of Cooling Tower


    SR
    VI

    VII

    Activity

    Description

    Drift
    Eliminator
    Fabricatio
    n

    Only 02 people can


    fabricate 80 pcs of
    drift eliminators per
    day.
    So it takes 3 days
    maximum to produce
    all required quantity
    (248 Pcs) for each
    cell.

    Installing
    new
    nozzle
    holders

    All the 324 Nozzle


    holders are installed
    by 3 workers within 3
    days maximum.

    Image

    Work Sequence of Cooling Tower


    SR

    Activity

    Description

    VIII

    Installatio Packing installation


    n of new
    has done on both side
    Packing
    at the same time.

    IX

    Mobilizing
    Drift
    Eliminator
    s to cell
    through
    100T
    crane

    All the required drift


    eliminators had
    mobilized to the cellG through the gaps of
    the fan by
    100 T crane.
    It had taken 02 days.

    Image

    Work Sequence of Cooling Tower


    SR

    Activity

    Description

    Installing
    new
    nozzles,
    protection
    layers

    After installing the


    packing's, 04 workers
    had installed the 324
    pcs nozzles within a day.

    OLD Nozzles
    Problem

    New Nozzle

    The old nozzles


    design was like that
    it cant spray the hot
    water properly.

    The new nozzles are Ecojet type.


    This nozzle has large square
    water distribution area uniformly.
    It has Self cleaning surface by
    means of rotating impeller & Anti
    clogging.

    Image

    Image
    OLD

    NEW

    Work Sequence of Cooling Tower


    SR Activity
    XI Installing

    Description

    Image

    248 Drift
    new Drift
    eliminators are
    Eliminators installed easily by
    a day. Only point
    here is small flat
    side will be on
    down side
    (*See Image*)

    Old Drift Eliminator


    The old wave type
    drift eliminators are
    not
    in good conditions.
    The PVC is loosing
    his
    mechanical
    properties making
    this
    component fragile.

    New Drift Eliminator


    The H-Moon drift
    eliminators that have
    drift loss of 0.001% of
    the total water flow.
    That means it is 100
    times better of the old
    drift eliminators.

    Image
    OLD

    NEW

    Work Sequence of Cooling Tower


    SR
    XII

    Activity

    Description

    Installing
    new
    protection
    layer

    253 pcs
    Protection Layers
    are installed
    easily by a day.

    Old Protection
    Layer
    Previously we dont
    have any protection
    layers to protect the
    fillings.

    New Protection Layers


    The new protection STAR 20
    type is a kind of SPLASH type.
    It resists to the working
    temperatures, keeping
    unchanged the no-clogging
    characteristics. The wide
    dimension of vertical channels
    allows the pollutants to be
    easily washed through.

    Image

    Image

    Work Sequence of Cooling Tower


    SR

    Activity

    Description

    XIII

    Repairing
    of the
    broken
    concrete
    pipe
    supports

    The civil department


    has had repaired
    broken supports by
    Lock fix P Hardener.
    (Maker : FOSROC)

    XIV

    Installatio Carbon shaft was


    n of new
    installed on Cell-B.
    Carbon
    Shaft
    It got very light
    weight & single shaft.
    So no need of bearing
    housing & greasing.
    This shaft is given at
    free of cost from SPIG
    for our judgment.

    Image

    SR
    XV

    Activity

    Description

    Installing
    new
    vibration
    system.

    10 pcs TA 18S
    vibration probes
    are installed on
    the gear boxes.

    Old System

    New System

    Previously
    we dont
    have proper
    vibration
    measuring
    system.

    New vibration probes are


    installed in the gear boxes. Now
    we can able to monitor gear
    box vibration level locally by
    RMCM team.
    For better analysis we may
    have to install minimum
    another probe on the gear box.
    For transmitting vibration signal
    to CCR, Instrument department
    can arrange 24V DC power
    routing to the site as well DCS
    input to the panel by ABB.

    The
    vibration
    switch sense
    only the
    vibration of
    GB lube oil
    pipe.

    Image

    Image

    Cell No

    Cell Working Time


    Improvement
    Man Days
    Consumed (CNCEC)

    Cell - A

    20

    Cell B

    16

    Cell C

    15

    Cell D

    15

    Cell - E

    15

    Cell F

    14

    Cell G

    12

    Cell H

    12

    Cell I

    12

    Cell J

    11

    Total

    142 Days for 10 Cells

    Item

    Design & Expected Operating


    Parameter
    Original
    design

    Expected
    after
    Renovation

    Circulating Water Flow, M 3/


    H

    27,440

    22,000

    Hot (Inlet) Water Temp., C

    43

    Cold (Outlet) Water Temp.,


    C

    33

    32

    Wet bulb Temp., C - Design


    Entering

    29

    29

    Drift Loss of circulating


    water, %

    0.1

    0.001

    44.24

    Performance Test
    Performance test will be carried out on
    January,2013 by SPIG.
    A performance test by our company could be
    carried before that & compare with previous test
    result.
    Expected Benefits as per SPIG offer:
    As Cooling Tower internals replaced with
    modified and higher efficiency state-of-the-art
    materials, better performance and higher
    reliability will be achieved.

    Expected Cooling Water Range and Approach


    will be 12oC & 3oC instead of existing 10oC & 4oC
    respectively.

    Achievement & Learning's


    We had worked for more than 142 days for 10 Cells operation .
    The work was completed by mostly 25 Bangladeshi workers & 4 CNCEC
    personnel. We dont reported any NEAR MISS OR LTA. It is a huge achievement.

    The local daily labors showed that they are quite capable to compete with the CNCEC
    guys on normal jobs.(Not critical like Comperssors,HP vessel,Welding,etc).
    So for future works we will try to reduce CNCEC guys if that
    could be done by local manpower

    For any cell operation please at first open the inlet butterfly valve at least 30
    then start the fan. Otherwise the protection layers got scattered during
    no load operation.

    We give a big thank to Operation, Ware House,Administration,HSE, Civil &


    Mechanical Maintenance departments for their huge support during the working.
    period We hope they will continue their great support on the future project works also.

    Any Question Please?

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