Cooling Tower Lecturer
Cooling Tower Lecturer
Cooling Tower Lecturer
1
Topics
Introduction
Definitions
Operating Conditions
Basic Components
Technical Details
Water Cooling Systems
Types
Maintenance Schedule
2
Trouble shooting
Introduction
Boxed shaped collection of multilayered RCC
structure i.e under class 800
3
Definitions
1. Range
Difference between cooling water inlet and
outlet temperature:
7
Assessment of cooling tower
2. Approach
Approach (°C) =
CW outlet temp – Wet bulb temp
8
Assessment of cooling tower
3. Effectiveness
Effectiveness in %
9
Assessment of cooling tower
4. Cooling Capacity
Heat rejected in kCal/hr or
tons of refrigeration (TR)
5. Evaporation Loss
Blow Down =
12
Evaporation Loss / (C.O.C. – 1)
Assessment of cooling tower
8. Liquid Gas (L/G) Ratio
Ratio between water and air mass flow rates
14
Operating Conditions
15
:
16
Factors affecting tower performance
•Fans
•Gear Boxes
•Motors
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Technical Detail
S.No Description Unit Data
1 Cooling tower Model 85454-5.0-08B
(Back to Back)
2 Number of Cells Nos 8
3 Cooling Water Flow m3/hr 28000
4 Hot Water Inlet Temperature Deg Centigrade 43
5 Re-Cooled Water Deg Centigrade 33
Temperature
6 Approach Deg Centigrade 5
7 Cooling Range Deg Centigrade 10
8 Water Flow (L) Kg/M2 – Hr 13599.6
9 Air Flow (G) Kg/M2 – Hr 7576.4
10 Ratio L/G – Cooling Factor % 1.795
11 Evaporation Loss m3/hr 404 20
Technical Detail
S.No Description Unit Data
12 Material of fill PVC film
13 Shape of fill Corrugated
14 Manner of Jointing Glue
15 Type of Drift eliminator PVC Full wave
16 Type and Material of HP-4-8:GRP
Construction of fan
17 Diameter of fan M 8.53
18 Clearance between Tip and mm 20
Diffuser
19 Reduction Gear Type Sr 32.2
20 Reduction Gear make Paharpur
21 Service factor 4.4
22 Reducing Gear Ratio 12.93:1 21
Basic Components
Water distribution system = includes header which
distributes (spray nozzles) water from top of tower over
splash bars and the material is PVC
Fan = induced draft towers use fans to push or pull air &
make
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Basic Components
fill = material inside a tower which redirects air flow and
water
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Parallel vs. Series Flow
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Classification of CTs
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Induced Draft, Cross Flow CT
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Atmospheric Cooling Tower (Natural Draft)
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Hyperbolic Cooling Tower
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Forced Draft Cooling Tower
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Induced Draft Cooling Towers
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Troubleshooting
31
Troubleshooting
SNO TROUBLE CAUSE REMEDY
1 Gear reducer Gear reducer If new, see noise in one week of
bearings bearings operation. Oil drain, flush and refill
gear reducer according to service
manual. If still noisy, replace.
Gears Correct tooth engagement. Replace
badly worn gears. Replace gears with
imperfect tooth spacing or form.
2 Unusual Fan Drive Loose bolts and cap Tighten all bolts and cap screws on all
Vibration screws mechanical equipment and supports
37
Maintenance schedule
Description of Work Daily Weekly Mon Quart Half- Yearly As
thly erly Yearly Required
1
INSPECTION OF OIL LEVEL IN CT FANS √
2 SOUND AND VIBRATIONS OBSERVATIONS √
3 INSPECTION OF WATER DISTRIBUTION SYSTEM √
INSPECTION OF COUPLING BUSHES AND
4
TIGHTENING BOLTS √
5
RISER VALVES CLEANING AND GREASING √
6 INSPECTION OF RCC DUCT, FILLS, DRIFT
ELIMINATORS, NOZZLES AND DISTRIBUTION
PIPES FOR CLOGGING √
7
GREASING OF MOTORS √
8 CHECK ALIGNMENT OF GEARBOX WITH MOTOR
AND FAN √
9
CT SUMP CLEANING √
10 PAINTING OF FANS, GEARBOX, SHAFTS AND 38
MOTOR √
Maintenance schedule
Description of Work Daily Weekly Mon Quart Half- Yearly As
thly erly Yearly Required
39
Problems Faced by Operators
Scale formation -
suspended solids form
deposits
Corrosion -
electrochemical reactions
with metal surfaces
41
Water Composition Control
Suspended solids levels checked by operators (< 10
Neflowmeter turbidity unit)
42
Water Composition Control (Solutions)
Scale formation
– remove scale forming solids with softening agents
( Softening agents like phosphate base chemical 9272)
– prevent scale forming materials by addition of
chemicals
– Bio dispersant 9079
– Chlorine (oxidising biocides) kill micro organisms
– Non oxidising biocides (i.e sulphates) 9087,7106 is
used.
43
Water Composition Control (Solutions)
Corrosion
– add chemical inhibitors (adds thin film to metal)
( 9024)
Sulphuric acid
– PH controlling
44
Water Testing (by Operators)
45
Sling Psychrometer
46
Cooling tower Blade Failures
Caused due to
misalignment
49