Cooling Tower Project Report

Prepared by
Ashik Ahmed
Section Manager
Technical Services
Working in a Multinational
Drift Air to Fertilizer Company
Atmospher Tel.: +880 31 618972~4; Ext.:
2237 (Office)
e Email : ashik.rofy@gmail.com,
Induced
ashik_rofy@yahoo.com,
External Fan Drive Unit Mobile: +880 1730059920
Draft Fan

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

Hot Water from Heat Drift

Exchangers Eliminators
Spray from Ecojet
Nozzles
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 & $ 75,679

Commissioning
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 Activity
I Film Filling
(Packing)
Fabrication
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.
Description Image
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
Problem IMAGE
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.
 Work Sequence of Cooling Tower
SR Activity Description Image
Scaffoldin South side scaffolding
II g works works is the Most
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 All the pipes of north &
the Scaffolding south side cell scaffoldings
Pipes for making are marked from west to
future cell east side from 1 to 18
scaffolding easy numbers.
It had eased the cells
Scaffolding works thus
anyone can easily install
the pipes.
 Work Sequence of Cooling Tower
SR Activity Description Image
IV 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 Now by the local
were removing manpower ,we can remove
old materials by the materials easily.
CNCEC personnel. We requires more safety on
It was very costly the last layer removal only.
as well as a very
lengthy process. So, it takes 5 days
(~ 7 Days) maximum.
 Work Sequence of Cooling Tower
SR Activity Description Image
V Shifting The whole amount of
of old old packings, drift
packings 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 Now by the new tractor
were shifting procured by Admin Dept ,we
old materials can shift the materials easily.
by local hired We requires 29 tractors to
dump truck. It shift 1 Cell materials.
was very (24 for Packing's,03 for drift
costly as well eliminators & 2 for Debris).
as a very
lengthy So, it takes 5 days
process.(~ 7 maximum.
 Work Sequence of Cooling Tower
SR Activity Description Image
VI Drift Only 02 people can
Eliminator fabricate 80 pcs of
Fabricatio drift eliminators per
n day.
So it takes 3 days
maximum to produce
all required quantity
(248 Pcs) for each
cell.

VII Installing All the 324 Nozzle

new holders are installed
nozzle by 3 workers within 3
holders days maximum.
 Work Sequence of Cooling Tower
SR Activity Description Image
VIII Installatio Packing installation
n of new has done on both side
Packing at the same time.

IX Mobilizing All the required drift

Drift eliminators had
Eliminator mobilized to the cell-
s to cell G through the gaps of
through the fan by
100T 100 T crane.
crane
It had taken 02 days.
 Work Sequence of Cooling Tower
SR Activity Description Image
X Installing After installing the
new packing's, 04 workers
nozzles, had installed the 324
protection pcs nozzles within a day.
layers

OLD Nozzles
Problem
New Nozzle Image
The old nozzles The new nozzles are Ecojet type. OLD NEW
design was like that
it cant spray the hot This nozzle has large square
water properly. water distribution area uniformly.

It has Self cleaning surface by

means of rotating impeller & Anti
clogging.
 Work Sequence of Cooling Tower
SR Activity Description Image
XI Installing 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 New Drift Eliminator Image
The old wave type The H-Moon drift
drift eliminators are eliminators that have OLD NEW
not drift loss of 0.001% of
in good conditions. the total water flow.
The PVC is loosing That means it is 100
his times better of the old
mechanical drift eliminators.
properties making
this
component fragile.
 Work Sequence of Cooling Tower
SR Activity Description Image
XII Installing 253 pcs
new Protection Layers
protection are installed
layer easily by a day.

Old Protection New Protection Layers Image

Layer
Previously we dont The new protection STAR 20
have any protection type is a kind of SPLASH type.
layers to protect the It resists to the working
fillings. temperatures, keeping
unchanged the no-clogging
characteristics. The wide
dimension of vertical channels
allows the pollutants to be
easily washed through.
 Work Sequence of Cooling Tower
SR Activity Description Image
XIII Repairing The civil department
of the has had repaired
broken broken supports by
concrete Lock fix P Hardener.
pipe (Maker : FOSROC)
supports

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.
SR Activity Description Image
XV Installing 10 pcs TA 18S
new vibration probes
vibration are installed on
system. the gear boxes.

Old System New System Image

Previously New vibration probes are
we dont installed in the gear boxes. Now
have proper we can able to monitor gear
vibration box vibration level locally by
measuring RMCM team.
system. For better analysis we may
have to install minimum
The another probe on the gear box.
vibration For transmitting vibration signal
switch sense to CCR, Instrument department
only the can arrange 24V DC power
vibration of routing to the site as well DCS
GB lube oil input to the panel by ABB.
pipe.
 Cell Working Time
Cell No
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

 Design & Expected Operating
Parameter
Item Original Expected
design after
Renovation
Circulating Water Flow, M 3/ 27,440 22,000
H
Hot (Inlet) Water Temp., C 43 44.24

Cold (Outlet) Water Temp., 33 32

C

Wet bulb Temp., C - Design 29 29

Entering

Drift Loss of circulating 0.1 0.001

water, %
 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?