jeevan joy, spig

KUWAIT DISTRICT COOLING SUMMIT 25-26 JANUARY 2011

11

Application of Field Erected Cooling Towers in District Cooling

KUWAIT DISTRICT COOLING SUMMIT 25-26 JANUARY 2011 2

INDEX

What is a field erected cooling tower?

Types of Induced Draft Cooling Towers

Material of Construction

MOC-Type Comparison

FRP material properties and suitability in Field Erected Cooling Towers

FRP Cooling Tower Construction

Design Aspects

Case Study


33

What is a Field Erected Cooling Tower

Customized design to suit project specific requirement like space, noise and NO plume.

Engineered to meet stringent codes pertaining to Seismic, Wind and Maintenance loads.

Ideally suited for handling large flow rates per cell with aggressive water.

Typical applications: Power Plants, Refinery, Petrochemical Plants and Large Tonnage District Cooling Plants


FIELD ERECTED COOLING FIELD ERECTED COOLING TOWERSTOWERS


INDUCED DRAFT CROSS FLOW COOLING TOWERS


66

INDUCED DRAFT CROSS FLOW


INDUCED DRAFTCOUNTER FLOW COOLING TOWERS


INDUCED DRAFT COUNTER FLOW


99

MATERIAL OF CONSTRUCTION

TIMBER COOLING TOWERS


1010


STEEL COOLING TOWERS


1111


REINFORCED CONCRETE COOLING TOWERS


1212

FAILURES OCCURING IN RCC COOLING TOWERS


1313


Fiber Reinforced Polyester ( FRP ) COOLING TOWERS


MATERIAL COMPARISON

WOOD STEEL CONCRETE FRP

Corrosion resistance medium low medium highest

Strenght to weight ratio low high very high highest

Expansion and Contraction medium medium medium low

Thermal conductivity low high medium low

Maintenance high high medium low

Possibility of Wet Dry operation low high high excellent

Installation Time short long very long very short

Basin Load medium high very high lightest

Fire resistance low low medium highest

Need for preservating treatment/coating high high high low

Cost of maintenance and operation high high medium lowest


1515

FRP MATERIAL PROPERTIES

Life Cycle Cost: Exceptionally low.

Resistance to aggressive water. Accepts all types of aggressive water. Sea water, TSE, Brackish water and

geothermal water

Corrosion resistance: Exceptional resistance to corrosion due to inert nature of the material

Weather resistance: Not affected by UV, sunlight, sandstorm and rains.

Fatigue Properties: Excellent fatigue properties due to high glass content.


1616

FRP MATERIAL PROPERTIES

Impact Strength: The high impact strength and rigidity allow major deformation without fractures.

Fire Resistance: Due to high fire resistance, there is no need

for costly fire protection system .

Deposition rate : Very low deposition and scale formation

rate.

Bilological attack: Inert to biological attack, and micro

organisms.


FRP Structure Pultrusion Technology


1818

FRP COOLING TOWER CONSTRUCTION

The complete structure, columns and beams for the Cooling Tower structure are realised with pultruded profiles in fiber reinforced polyester.


FRP COOLING TOWER CONSTRUCTION

One FRP main header distributes water in lateral uPVC pipes


Design Aspects

INTERACTION BETWEEN CT and SURROUNDING ENVIRONMENT

COOLING TOWER is NOT LOCATED in a FREE FIELD


IDEAL CONDITION IDEAL CONDITION

FREE FIELD ISOLATED BODY NO WIND

Warm Air andVisible PlumeAre DispersedIn The Atmosphere


REAL CONDITIONREAL CONDITION

Large Vortices Are Generated

Small Part of Warm Air is Mixed with Large Amount of Fresh Air

Negligible changes in Inlet air Properties


STANDARD CONDITIONSTANDARD CONDITION

WHAT HAPPENS WHEN BUILDINGS OBSTRUCTIONS TREES HILLSARE PRESENT

Fresh Air Feeding is reduced

Warm Air Vortices are destroyed

Larger amount of Warm Air is re-sucked in


STANDARD CONDITIONSTANDARD CONDITION

WHAT HAPPENS WITH More CTs Wind

Feeding is reduced

Warm Air is Deflected …

And sucked in both the CTs

Wakes & Vortices


RECIRCULATION – INTERFERENCERECIRCULATION – INTERFERENCE

PLUME DISPERSIONPLUME DISPERSION

3 METHODS

ANALYTICAL EXPERIMENTAL COMPUTATIONAL

NAVIER-STOKES

Equations

Simplified Rules

Free Filed

SCALE MODEL

WIND TUNNEL

SOPHISTICATED EQUIPMENT

DEDICATED SW

POWERFUL HD

EXPERTS


RECIRCULATION & INTERFERENCERECIRCULATION & INTERFERENCE

EXPERIMENTAL - 1EXPERIMENTAL - 1

Wind Tunnel

Scaled Model

Warm Air Generator

Plume Generator

Sophisticated Measuring Equipment

Simplifications



COMPUTATIONAL - 1COMPUTATIONAL - 1

Detailed Model

Material Properties

Boundary Conditions

All air ParametersAre calculated



COMPUTATIONAL - 2 COMPUTATIONAL - 2


VFD CONTROLVFD CONTROL

Cooling Towers are usually designed for the worst conditions – Peak Summer Conditions.

In Winter conditions the CT is over performing.

The use of a variable Motor speed system can regulate the fan speed and consequently the airflow optimizing the cooling performance.

Fan speed optimization allows: consistent saving in absorbed power. Absorbed power is proportional to the cube of the fan speed so by reducing the fan speed at 50% means reducing the consumption by 12.5%

Drift reduction due to lower air velocity.

Visible plume reduction due to the lower concentration of water in the discharged air.


SUMMARYSUMMARY

In the CT Design, it is fundamental to consider the mutual interaction between the CT and the surrounding environment.

Surrounding environment can modify the free air circulation generating or intensifying recirculation, interference and plume formation phenomena.

The CT can modify the surrounding environment introducing moisture, fog and chemicals in the air.

Experimental methods can quantitatively estimate the recirculation and the interference but can only qualitatively estimate plume generation and dispersion.

Numerical methods can quantitatively estimate the recirculation, interference, plume generation and dispersion.


3131

SEA WATER COOLING TOWERS Using sea water in cooling towers is technically

and economically feasible. Sea water CT can satisfy the cooling needs of

petrochemical industries. No significant O&M complications with seawater

CT is reported Seawater CT economics are favorable as

compared with the once-through system

CTI Journal, Vol 24, No 2


3232

SEA WATER COOLING TOWER APPLICATION

Using seawater in cooling towers is technically and economically feasible.

Seawater CT can sattisfy the cooling needs of petrochemical industries.

No significant O&M complications with seawater CT is reported

Seawater CT economics are favorable as compared with the once-through system

CTI Journal, Vol 24, No 2


DUBAI FESTIVAL CITY50,000 TR- DISTRICT COOLING10 CELLS – CONCRETE COOLING TOWERS


CASE HISTORYEMIRATES AIRBUS A380 HANGAR DUBAI AIRPORT U.A.E- CUC

Make up - Treated Sewage Effluent


CASE HISTORY BAHRAIN CITY CENTRE7 CELLS – FRP COOLING TOWERS

HVAC


3636

CASE HISTORYBAHRAIN BAY UTILITIES FRP COOLING TOWERS

2 Seawater Cooling Towers

45,000 TR District Cooling Plant for Bahrain Bay


CASE HISTORYPETRORABIGH REFINING COMPANY; KSATOTAL WATER FLOW- 210,000 m3/hr48 Cells – FRP COOLING TOWERS


3838

CASE HISTORYSAHARA AL-WAHA; JUBAIL; KSAFRP COOLING TOWERS

Sea Water Cooling Tower- Petrochemical


3939

CASE HISTORYEMIRATES ALUMINIUM (EMAL) ABU DHABI

Largest Seawater Cooling Tower – UAE

Power Plant


4040

CASE HISTORYMESAIEED POWER COMPANY QATAR

3 Sea water Cooling Towers

33 Cells

Power Plant


Headquarters

SPIG S.p.A.

P.zza S. Graziano 31

28041 Arona – NO – ITALY

Ph. + 39 0322 245401

SPIG Middle East

LOB 7 Office No 7F09 Opp. Jebel

Ali Post Office, Jebel Ali Free Zone

Dubai – U.A.E. Ph.+9714 8817202 www.spig-int.com

Speaker Eng. Jeevan Joy

jeevan joy, spig

Technology

rcc cooling towers

cooling performance

cooling tower structure

vfd control cooling

wind warm air

weight ratio low high

high highest expansion

high impact strength