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Presentation on cooling tower
The document provides details of a cooling tower renovation project at a fertilizer plant. Key points: - The existing cooling tower packing, drift eliminators, and nozzles needed replacement as their working life had expired after 7-10 years. - Modifications included installing new packing, drift eliminators, dynamic Ecojet nozzles, and a vibration monitoring system. - The project was completed on time and under budget using mostly local labor. It is expected to improve cooling tower performance and reliability. - Lessons learned include using local labor for most tasks and marking scaffolding pipes to streamline future work. The renovation reduced circulating water temperature ranges and approach.
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Presentation on cooling tower
- 1. Cooling Tower ProjectReport Drift Air to Atmosphere 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
- 2. Reason For TheProject SPIG Engineers visited our plant on 27~28th October,2010 & evaluated the performance of cooling tower. The observation shows the following tings:-
- 3. Suggestion from theSPIG SPIG 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.
- 4. 26th BTCM Minutes of26th 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.
- 5. Cooling Tower Drift Airto Atmosphere External Fan Drive Unit Induced Draft Fan Drift Eliminators Hot Water from Heat Exchangers Spray from Ecojet Nozzles Fill Material Air In Air In Cool Water To Pumps Cool Water Collected in Cooling Tower Basin
- 6. Total Cost SAP.jpg The Coolingtower 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.
- 7. Schedule of CoolingTower Cell –I Cooling Tower Cell -I.mpp Microsoft Office Project - Cash Flow.pdf Microsoft Office Project - Network Diagram.pdf
- 8. HAZARD IDENTIFICATION ANDRISK ASSESSMENT (HIRA) K-IMS-PRJDEV- HIRA.pdf
- 9. Work Sequence ofCooling 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 packing’s 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 Problem 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. The old packing’s 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
- 10. Work Sequence ofCooling Tower SR II Activity Description 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 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
- 11. Work Sequence ofCooling Tower SR IV Activity Description Removal of The whole amount of old old packing’s, drift packing’s 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
- 12. Work Sequence ofCooling Tower SR V Activity Shifting of old packing’s Description 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 Learned Previously 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. Image
- 13. Work Sequence ofCooling Tower SR Activity Description VI Drift Only 02 people can Eliminator fabricate 80 pcs of drift Fabrication eliminators per day. So it takes 3 days maximum to produce all required quantity (248 Pcs) for each cell. VII Installing All the 324 Nozzle new nozzle holders are installed by 3 holders workers within 3 days maximum. Image
- 14. Work Sequence ofCooling Tower SR Activity Description VIII Installation Packing installation has of new done on both side at the Packing 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 by 100 T crane. It had taken 02 days. Image
- 15. Work Sequence ofCooling Tower SR Activity Description X Installing new nozzles, protection layers After installing the packing's, 04 workers had installed the 324 pcs nozzles within a day. OLD Nozzles Problem The old nozzles design was like that it cant spray the hot water properly. Image New Nozzle 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 OLD NEW
- 16. Work Sequence ofCooling Tower SR Activity Description XI Installing new Drift Eliminators Image 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 The old wave type drift eliminators are not in good conditions. The PVC is loosing his mechanical properties making this component fragile. 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
- 17. Work Sequence ofCooling Tower SR Activity Description XII Installing new protection layer 253 pcs Protection Layers are installed easily by a day. Old Protection Layer New Protection Layers 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. Image Image
- 18. Work Sequence ofCooling Tower SR XIII Activity DeScRiption Repairing of the broken concrete pipe supports The civil department has had repaired broken supports by Lock fix P Hardener. (Maker : FOSROC) XIV Installation Carbon shaft was 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
- 19. SR Activity Description XV Installing new vibration system. 10 pcs TA18S vibration probes are installed on the gear boxes. Old System Previously we don’t have proper vibration measuring system. The vibration switch sense only the vibration of GB lube oil pipe. New 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. Image Image
- 20. Cell Working TimeImprovement 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
- 21. Design & ExpectedOperating Parameter Item Circulating Water Flow, M 3/ H Original design Expected after Renovation 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
- 22. Performance Test Performance testwill 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.
- 23. Achievement & Learning's Wehad 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.
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