Presentation

On

Design, Operation & Maintenance of Cooling Towers AT Power Management Institute

Date: 29 July 2008 By S. Ramasundar & Mahesh Kumar

Paharpur Cooling Towers Ltd. Kolkata

Road Map
Brief History Of Paharpur Cooling Towers Ltd Ltd. . PCT Association With NTPC Latest Development In Design Of Cooling Towers Tips for Better Performance of Cooling Towers Problems in Cooling Towers and Their Impact on Tower Performance Inspection and Maintenance Schedule of Cooling Towers Preferred Cooling Water Condition Limits A Case Study On Maintenance Problem at NTPC Kaniha Annual Maintenance Contracts for Cooling Tower Maintenance Brief Note on Treated Timber Cooling Towers Towers. .

Brief History of Paharpur Cooling Towers

Paharpur Cooling Towers Ltd Ltd. . - An ISO 9001 Company Core competency in turnkey contracts for supply of cooling towers Treated timber (Cross/ counter flow) RCC (Cross/ counter flow) Natural draft (Hyperbolic) GRP Pultruded section

First Cooling Tower of 7 cells (Treated Timber) constructed in 1959 at Rourkela Steel Plant Plant; ; This Cooling Tower is still in operation operation. .
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Total Nos of Towers Constructed Till Date Including Jobs in Hand

Treated Timber Cross Flow Total no of Cooling Towers (1709)* RCC Treated Timber C Counter t Fl Flow RCC Natural Draft Pultruted FRP RCC * Includes jobs in hand as on 12/06/2008

586 522 93 479 18 11

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PCT Association With NTPC

S. N. 1 2 3 4 5 6 7 8 9 10 11 12 13 Location Anta Auraiya Badarpur Bahr Dadri Faridabad Gandhar Jamshedpur Kahalgaon Order No. 8787-2-917 8888 -2-902A 7979-2-291 Model 1512 1512-11(15'AT) 8364283642-3.5 3.5-18B 1512 1512-09 N of No f towers 1 2 1 6 2 1 1 1 4 3 4 8 2 6 + + + + + + + 0404-2I2I-0030A 0404 -2I 2I-0030G 0202-2I2I-0029 0404-2I2I-0025D 0707-2I2I-0085 0404-2I2I-0043 9595-2-958A 86642 86642-6.0 6.0-10 8303083030 -6.06 0-03 6.0 86642 86642-6.0 6.0-10 82430 82430-6.0 6.0-03 6516 6516-0-12 86642 86642-6.0 6.0-09 8644886448-4.0 4.0-09
5

Order No.

Model

No N of f towers

0505-2I2I-0118 A 86641 86641-18V18V-12 9090-2-910A 9898-2I2I-0016 92 92-2-926 0202-2I2I-0045 8888-2-909A 8364283642-4.0 4.0-18B 84242 84242-4.0 4.0-18B 84848 84848-4.0 4.0-20B 1409 1409-02(18'AT) 1512X1512X-10 15141514-08

+ +

0505-2I2I-0118 G 0707-2I2I-0082 B

83636 83636-18V18V-03 ND Tower

1 1

6 1 4 1 1 1 4

Ramagundam 81 81-2-091A Sipat Talcher Unchar

04 04-2I2I-0025A 86642 86642-6.0 6.0-10 0000-2I2I-0003 9696-2-905A 8585-2-903A 86042 86042-5.0 5.0-10 8364283642-4.0 4.0-18B 15141514-09

14 Vindhyachal 29 June 2008

Latest Development In Design Of Cooling Towers

Pultruded FRO Cooling Towers Concrete towers (Cross flow/ counter flow) with GRP Fan cylinder SS channels for Bottom support in counter flow towers replaced with a. b. RCC post and FRP channels RCC post and RCC beams

Three pass PVC eliminators instead of two pass PVC / ACB eliminators eliminators. . Drift loss in three pass PVC eliminator is 0.005 005% % as compared to 0.05 05% % for two pass eliminators. eliminators. Reduced drift loss means less makeup water water. . PCT has also developed high temperature resistant fill material for engineering plastics for splah and film type fill which can withstand temperature upto 1000C. FRP Gratings in cooling towers in place of MS HDG gratings. gratings.
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Latest Development In Design Of Cooling Towers

Carbon fiber drive shaft a. b. c. Advantages: a. b b. c. d. Light weight easy to handle Hi h strength Higher t th to t weight i ht ratio ti Highly corrosion resistant and hence longer life. increased bearing g life of motor/ g gear box because of reduced weight. Combination of Splash type and Film type fill in cross flow towers Bigger fans up to 11 meter diameter
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Tube all glass Tube all carbon Tube Hybrid (50% Glass fiber + 50% Carbon fiber)

Tips for Better Performance of Cooling Towers

Water level in all the distribution decks of cross flow towers and water flow in all cells of counter flow towers should be equal and uniform. uniform After adjusting flow the lock handle of flow control valve in cross flow towers should be in locked position. If this is not done, this will lead to damage of stem guide and FC valve cannot be operated. Distribution deck should be clean with all nozzles in position. Excess water circulation leads to over flow from louver side in cross flow towers there by causing fill damage.

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Tips for Better Performance of Cooling Towers

For better performance of gear box oil to be used in the gear box should be as per manufacturer manufacturers s specification only. only Specification of oil should not be changed without concurrence of the manufacturer of gear box. New gear box is supplied with some oil in the gear box when despatched. Before installation this oil must be drained out and the gear box flushed twice with flushing oil before new oil is filled in. Flushing oil once used should be discarded. In case of gear box in use, the insides of gear box should be cleaned once with flushing oil before changing oil. Operation and maintenance practices as mentioned in the manuals should be followed strictly.
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Problems in Cooling Towers and Their Impact on Tower Performance

Contaminated water clogging of V bars reduced splashing affects thermal performance and can lead to collapse of fill. Contaminated water clogging of Fill packs reduced surface area affects thermal performance and can lead to collapse of support and fills. Clogging of eliminators restricts air flow affecting tower performance Clogged nozzles unequal distribution of water affects thermal performance. N l Cl Nozzles Clean b but t caps removed d unequal l di distribution t ib ti of f water t affects ff t thermal performance Algae g formation on fill reduces splashing p g affects thermal p performance Replacement of originally supplied fans with hollow blade fans leads to thermal performance problems.

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10

Problems in Cooling Towers and Their Impact on Tower Performance

Excess oil in gear boxes /Oil seal leak - Common problem problem oil leakage mixes with water can affect thermal performance. Incorrect fitting of NBM inserts vibration in drive shafts. NBM inserts are pressure fitted and hence to be lubricated with soap solution only. y GREASE / OIL SHOULD NOT BE USED AS LUBRICANT. Fan pitch angle setting Unequal pitch angle - leads to vibration Center line of fan / gear box not matching with the centre line of fan cylinder unequal tip clearance. Track variations of fan blade not within limits leads to vibration in fan.
29 June 2008

Problem with water quality proper water treatment measures required.

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Inspection & Maintenance Schedule (General recommendations)

Gear Reducer G

Structure S

1 2 3 4 5 6 7 8 9 11

Inspect for clogging Check for unusual noise Inspect keys, keyways and set screws Make sure vents are open Lubricate Check oil seals Check operating oil levels Check static oil level Check oil for water and sludge Check fan blade tip clearance S R M D M M S D D D S S S D S S

M M

10 Change oil, at least 12 Check water level 13 Check for leakage

D D W S S S

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12

Davits, Derrick ks

Suction screen n

DS & Guards

Eliminators

Float valve

C W basin HW Dist.

(More frequent inspection and Maintenance may be desirable)

Fan Motor

Valves mbers Structural Mem Casing fan Cylinder Stairs, Doors,

Fill

Inspection & Maintenance Schedule (General recommendations)

er Gear Reduce

DS & Guards

Structure

Fan Motor

14 Inspect for general condition 15 Tighten loose bolts 16 Clean 17 Repaint 18 Rebalance 19 Completely open and close 20 Inspect for proper spray formation 21 Inspect / repair for safe use 22 Inspect and repair before each use 23 Inspect Structure for any deterioration Q

S S S S S S R R R R R R R R

S Y S Y S Y S S R R R S R R R R R R

S S Y S S S Y R S R

S M Y Y Y R

D - daily; W - weekly; M - monthly; Q - quarterly; S - semi-annually; Y - yearly; R - as required

Note: In the case of concrete cooling towers, inspect the concrete members for cracks and exposed rebars annually and repaint all originally painted surfaces as required
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Davits, Derricks

Suction scre een

Eliminators

Float valve

C W basin HW Dist.

(More frequent inspection and M i t Maintenance may b be d desirable) i bl )

Valves Structural Members Casing fan Cylinder Stairs, Doors s,

Fill

Preferred Cooling Water Condition Limits

pH Temperature : 6.5 to 8.5 : 1250 F

Langelier Separation Index : 0.0 to 1.0 M-Alkalinity Silica Iron Sulphides Manganese Ammonia Free Chlorine Organic Solvents TDS : 100 to 500 ppm as CaCO3 : 150 ppm as SiO2 : 3 ppm max. : More than 1 ppm can be corrosive to copper , Iron, steel and G. steel : 0.1 ppm max. : 50 ppm max if copper alloys present : Wood structure: 1 ppm (Shock) Or 0.4 ppm (Continuously) : Attack plastics and promote bio-growth. <50ppm may be acceptable. : > 5000 ppm affect ff t thermal th l performance f & detrimental d t i t l to t wood d in i alternately wet/dry zones such as fan deck and louver face.
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Preferred Cooling Water Condition Limits

Individual Ions:
Cations: Ca Mg Na

Maximum

: : :

800ppm as CaCO3 Depends on pH and Silica level No Limit

-

Anions: Chlorides Sulphates Nitrates Carbonates/ Bicarbonates

: : : :

750 pppm as NaCl (455 ppm as Cl ) 800 as CaCO3 s 300 ppm as NO3 (Bacteria Nutrient) 300 ppm as CaCO3 max for Wood

Biological / Bacteria Bacteria counts listed below relate to maintaining fill thermal efficiency only Biocidal Treatment is required for all cooling tower installations
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Preferred Cooling Water Condition Limits

Total Suspended Solids
Fill Type MC67 Splash fill Aerobic bacteria Std. Plate Count 10,000CFU/ml 1000000CFU/ml target level TSS <25ppm preferred* No specific limit Sulphides 0.5 ppm Not Applicable

* Higher i h TSS can b be considered id d on a case-by-case b b basis. i Consult l PCT Engineering i i

Miscellaneous Solids and Nutrients

F film For fil fill avoid id fibrous, fib oily, il greasy, fatty f tt or tarry t material t i l which hi h can plug l fill and d avoid id nutrients t i t such h as glycols, alcohols and sugars which promote bacterial growth. For splash fill, oil and grease levels greater than 10 ppm can adversely affect thermal performance.

Special Note: In general, do not use film fill in steel plants, Pulp & Paper Mills Food Processing Operations or
similar applications unless leaks and contamination by airborne or waterborne particulates oil or fibers are extremely unlikely. If film fill is used, biological growth control must be stringent an diligent.
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A Case Study on Maintenance Problem at NTPC - Kaniha

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17

Annual Maintenance Contracts for Cooling Tower Maintenance

Paharpur is having AMC with a. NTPC Talcher c. WBPDCL Kolaghat e. NTPC Sipat Si t (Under (U d negotiation) ti ti ) g. DPL - Durgapur Advantages g of AMC: Maximum cell availability Correct fitment of original spare parts Easy availability of original spare parts as per rate contract (Local manufacturers supply does not conform to OEM quality criteria.) b. d. f f. NTPC Tanda WBPDCL Bakreswar DVC Durgapur D

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Why Treated Timber Cooling Towers

Cost of RCC Cooling g Tower is much more than timber cooing g tower. Susceptible to corrosion & Prone to attack by chemicals. Repair of structure is very costly and time taking. taking Treated timber cooling tower ideally suited for fertilizer and chemical plants and for salt water duty. Erection time very much less compared to RCC tower. Each part of timber cooling tower is easily accessible and hence easy to repair and maintain the tower.

27 June 2008

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Timber Used In Cooling Towers & Treatment of Timber

Preservatives Options:
- CCA - ACC - ACA : Cromated Copper Arsenate : Acid Copper Chrome : Ammoniated Copper Arsenate

Paharpur Carries out Treatment at Kandla factory as per CTI STD 112 for US Species and as per IS 401 for rest of the species
Note:
27 June 2008

CCA is the best Preservative treatment. Also specified in CTI -STD 112
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Class 400 / F400:

Counter Flow Industrial Cooling Tower

Structure : Fill :

Treated Wood / Pultruted GRP Film / Splash type

Models

4AB - X - Y / F4AB - X - Y

Model Code

Particulars

4 F4

Structure: Treated Wood Structure: St t Pultruted P lt t d GRP

Breadth of Cell: No of bays each of 6 ft Length of Cell: No of bays each of 6 ft Height of Fill No. of Cells
21

Model Specifications:

A B X Y

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Class 500 :

Cross flow Industrial Cooling Tower

Structure : Fill : Treated Wood Splash type PVC

Models

5 A B - XV - Y

Model Code A B

Particulars Splash Fill Height ( A x 3 ft) Length of Cell: = No of bays X 4 ft Air Travel ( X + 8 ft) V Bar Fill No. of Cells
22

Model Specifications:

X V Y

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Class 600 :

Cross flow Industrial Cooling Tower

Structure : Fill Models : :

Treated Wood Splash type PVC 6AB - X - Y

Model Code A B

Particulars Height of Fill ( A x 3 ft) L Length th of fC Cell: ll 1 1=20, 20 2 2=24, 24 3 3=28, 28 4 4=32, 32 15 15=36, 36 16=40, 17=44 Air Travel : -3 = 16 ( With 1-03/8 in 6 ) slope -4 = 18 ( With 2 in 6 ) slope -5 5 = 20 20 ( With 2 2 in 6 6 ) slope

Model Specifications: p f
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X Y No. of Cells

23

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