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 : ashik.rofy@gmail.com,
ashik_rofy@yahoo.com,
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?