Presentation on cooling tower

Cooling Tower Project Report Prepared byAshik AhmedSection ManagerTechnical ServicesWorking in a Multinational Fertilizer CompanyTel.: +880 31 618972~4; Ext.: 2237 (Office)Email : [email protected],[email protected],Mobile: +880 1730059920

Fill Material

Air In

Air In

Drift Eliminators

Induced Draft Fan

External Fan Drive Unit

Drift Air to Atmospher

e

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 SPIGSPIG Engineers suggested the following modifications:-

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 not Producing now a days as they are producing improved type.

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

On 26th BTCM , the Project / SPIG offer has been approved due to the following reasons:-

The working life of Cooling tower Packing's, drift eliminators & distributor nozzles have already expired.

Normal working life of these items are 7~10 years.

Hot Water from Heat Exchangers

Spray from Ecojet Nozzles

Fill Material

Air In

Air In

Drift Eliminators

Cool Water Collected in Cooling Tower Basin

Induced Draft Fan

External Fan Drive Unit

Drift Air to Atmospher

e

Cool Water To Pumps

Cooling Tower Cooling Tower

Total Cost SAP.jpg

The Cooling tower improvement project has booked $2,514,186 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

SR Activity Description ImageII Film FillingFilm Filling

(Packing)(Packing) FabricationFabrication

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

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

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

Work Sequence of Cooling Tower

SR Activity Description Image

II Scaffolding works

South side scaffolding 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 LearnedWe 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 cellsScaffolding works thus anyone can easily install the pipes.



IV Removal of old packing’s

The whole amount of old packing’s, drift eliminators, nozzles, debris, etc are removed easily on 5 days.

Lesson LearnedPreviously 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.


SR Activity Description ImageV Shifting

of old packing’s

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

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

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.



VI Drift EliminatorFabrication

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.

VII Installing new nozzle holders

All the 324 Nozzle holders are installed by 3 workers within 3 days maximum.



VIII Installation of new Packing

Packing installation has done on both side at the same time.

IX Mobilizing Drift Eliminators to cell through 100T crane

All the required drift eliminators had mobilized to the cell-G through the gaps of the fan by100 T crane.

It had taken 02 days.


SR Activity Description ImageX 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 Image

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.


NEWOLD

SR Activity Description ImageXI Installing

new Drift Eliminators

248 Drift eliminators are 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 drift eliminators are notin good conditions. The PVC is loosing hismechanical properties making thiscomponent fragile.

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


OLD NEW

SR Activity Description ImageXII Installing

new protection layer

253 pcs Protection Layers are installed easily by a day.

Old Protection Layer

New Protection Layers Image

Previously we don’t have any protection layers to protect the fillings.

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.



XIII Repairing of the broken concrete pipe supports

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

XIV Installation of new Carbon Shaft

Carbon shaft was installed on Cell-B.

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.



XV Installing new vibration system.

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

Old System New System Image

Previously we don’t have proper vibration measuring system.

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

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.

Cell Working Time Improvement

Cell No 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 design

Expected after

RenovationCirculating Water Flow, M 3/ H

27,440 22,000

Hot (Inlet) Water Temp., °C 43 44.24

Cold (Outlet) Water Temp., °C

33 32

Wet bulb Temp., °C - Design Entering

29 29

Drift Loss of circulating water, %

0.1 0.001

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.

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 don’t 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.

Achievement & Learning's

Any Question Please?

Presentation on cooling tower

Education

Transcript of Presentation on cooling tower