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Cooling Towers

For smooth functioning of any process industry a lot of heat has to be discharged into the atmosphere,to dissipate this excess heat cooling towers are required.

A cooling Tower is a device that uses the combination of heat & mass transfer to cool water.

BIL offers following services

BIL is a single source for cooling tower, spare parts, repair and maintenance.

BIL offer following advantages:

  • Skilled Manpower
  • Association with Leading Consultants in India & Abroad
  • Rich Experience of 30 Years in India & Abroad
  • Turnkey Systems
  • Strong Financial capabilities
  • Customized Cooling Tower
  • Modern & Advance Equipments
  • Provide best quality products & services
  • Guaranteed Performance

Construction of Concrete Cooling Tower:
To take advantage of our core competency in high rise construction, civil expertise & our experienced team of highly skilled man power, we have diversified in the construction of cooling towers.
BIL Offers:

  • Construction of concrete Cooling Tower.

BIL Strength & Sales Turnover
We have a well-organized & highly skilled sales, marketing, engineering & project management teams at our offices in Delhi, Mumbai & Dubai as well as on the sites in India & abroad. The total number of employees exceeds five hundred. 
We have state of art manufacturing & fabrication facilities in Navi Mumbai (India) for equipments and mechanical items.

 

 

 

 

 

 

 

Design, Engineering, Manufacturing & construction of:

  • Induced draft concrete cooling tower (IDCT) with film or splash fill

In mechanical draft Cooling Tower the fan is placed at the discharge point, which pulls air through tower.
Working Principle: Hot water is distributed evenly by nozzles over the fill media & air is pulled over thefill area with the help of a fan placed over it. This process results in exposing hot water to air stream thus cooling it by following two phenomena:

  • Evaporation (75%) approx
  • Sensible cooling (25%) approx

The cold water is accumulated at sump & again used for recirculation.
During evaporation there is a lot of water loss which goes out of cooling tower & gets discharged into the atmosphere as hot moist water vapor. In order to prevent evaporation loss, drift eliminators are used.
Material of Construction (MOC) for Induced draft cooling towers can be -Treated Wood Stainless Steel/ Pultruded FRP (Each having its own advantage & disadvantages)
Depending upon the air flow direction (Perpendicular /Parallel to water) IDCT can be classified as follows:

  • Counter flow
  • Cross Flow
    • BIL has its own experienced team of design, engineering & execution
    • BIL hasformedconsortium with several consultants for designing.
    • BIL designs cooling towers as per customerís specifications & requirement.
    • BIL offers cooling tower with optimum capital investment & running cost.
    • BIL always stickto quality & timely completion of projects.

  • Induced draft concrete cooling tower (IDCT) with film or splash fill
  • Initially wood was used as material of construction (MOC) for cooling tower.Later due toenvironmental concern and non-availability of good quality wood, RCC has been frequently used in Cooling Towers however it also has following limitations:

    • Longer construction time period
    • Susceptive to corrosion & other environmental impacts like biological growth
    • High initial cost for small cooling tower
    • Not suitable for sea water application

    Pultruded FRP is an excellent alternative material.

    • Advantages of Pultruded FRP as material of construction (MOC) for Cooling Tower are as following:
    • Light Weight
    • Remarkable strength
    • Easy erection
    • Free from biological attack
    • Chemically & Electrically inert
    • Corrosion free
    • Flame retardant& hence can be used in Refinery, Petrochemicals
    • Longer life span than wood
    • Suitable for sea water application
    • Low initial cost
    • BIL has its own expert team for erection of Pultruded FRP towers
    • BIL has tie ups with manufacturers of Pultruded FRP sections

Circulating Water Treatment
Circulating water contains water from many sources. The circulating water carries heat from the process which needs to be discharged along with its heat and accumulated impurities. But circulating water can’t be discharged all the time because of limited availability of water as a source. To reuse the same water again a Cooling Tower is required which removes the extra heat and accumulated impurities of the water. However using same water again & again creates following problems in the system:

  • Growth of Algae & fouling in system
  • Corrosion of various components like Pipes, Valves & other metallic components used in Cooling Tower
  • The dissolved chemicals form a hard layer of scalein the system
  • Microbiological Contamination
  • Chocking of nozzle & fills due to high Total Suspended Solids (TSS)

Circulating Water Treatment is very essential to keep impurities within limit. It consists mainly of:

  • Side Stream Filtration (to remove suspended solids)
  •  Chlorination System (to prevent biological growth)
  • Chemical Dosing System (to remove dissolved solids, corrosion/sc ale inhibition etc)

Side Stream Filter:
A small portion (usually 2-5%) of circulating water is taken and filtered using vessel containing filter media such assand and gravel.
It is used to reduceTSS (Total Suspended Solids) and Turbidity of circulating water.
It is used for prevention of fouling of heat transfer surface
Chlorinator System:
A small amount of chlorine is dosed in circulating water system either by tonner or by acid –hypochlorite ClO2 dosing.
 It is used for controlling biological growth like algae.
Chemical Dosing System:
Small amount of chemical is dosed in circulating water system.
Depending upon the type of chemical used it is further classified into following:

  • H2SO4 Dosing System:

A small amount of acid is dosed in circulating water system.
It is used to control scale build-up by lowering the PH of water and converting calcium bicarbonate scale to a more soluble calcium sulphate form.
Since H2SO4 is an aggressive acid that cancorrode metal,must be carefully dosed into the system and must be used in conjunction with an appropriate corrosion inhibitor.

  • Biocide Dosing System

Chemicals like Quarternary Ammonium compound based formulation and Carbamate / Isothiazolene / Bisphane based formulation containing active ingredients are used in the dosing system
Dosing of chemicals is done in cold water sump. It removes biological fouling agents

  • Polymeric Dispersant Dosing System

Dosing of low molecular weight dispersant (<5000) preferably Poly Acrylic Sulphonic Acid based Copolymer (PA-SA) or Acrylic Acid HydroxyAllyl Oxy Propane Sulphonate based dispersant (AAHAPS) is done.
It is used as a scale inhibitor and scale dispersant for circulating cooling water system

Timber to FRP Conversion:

Timber has been used as a construction material for Cooling Tower in past because of its easy availability.
However there are disadvantage of using wood as cooling tower construction material.

  • Lesser availability of good quality of timber & using inferior quality of timber may lead to sudden collapse of Cooling tower affecting plant performance.
  • Timber is susceptible to decay due to biological attack, internal decay, temperature&moisture.
  • To prevent it from decay wood is needed to be treated which is a costly& environmentally unsafe.

On the other hand Pultruded FRP has many advantages over timber.

  • Pultruded FRP has a remarkable strength
  • Free from biological attack
  • No chemical treatment is required
  • Chemically inert and can be used for sea water application
  • Electrically inert and can be used in electrical environment
  • Life span of Pultruded FRP is much more than timber
  • Corrosion free
  • Flame retardant

Why conversion of wooden cooling tower into Pultruded FRP tower?

  • Lesser availability of good quality of timber & using inferior quality of timber may lead to sudden collapse of cooling tower.
  • Timber is susceptible for decay & biological attack whereas PultrudedFRP is an inert material
  • Pultruded FRP cooling tower require less erection time & can be erected during annual shut down of the plant
  • Pultruded cooling tower require less maintenance
  • The lifespan of Pultruded FRP profiles are around 15 years

Annual Maintenance Contract:
Cooling towers are basically heat rejection devices, which are used to dissipate unusable waste heat in the environment.
Failure of cooling tower can result in shutting down of the whole plant so prime focus should be given to its maintenance. Although maintenance is looked by plant personnel /maintenance department but it is generally found that some of the defects are overlooked.

BIL understands that cooling tower maintenance is a very vital task &thus offers Annual Maintenance Contract (AMC) facility. This facility consists of:

  • Deployment of trained personnel looking after the cooling tower throughout the year
  • Rectify routine problems on the weekly, monthly basis while systemic problems are kept reserved for annual shutdown maintenance
  • Completely revamping the system which includes complete inspection, detection of problems and complete remedy during the time of complete shutdown.

Some of the services provided by BIL under AMC are:

S.No

Components

BIL offering under AMC

1

Fill

Inspect broken/clogged portion, remove it & install new one

2

Nozzle

Inspect& clean chocked nozzle &reinstallation

3

Fan

Inspect  - Pitch, Vibration &Tip clearance and take corrective action

4

Gear Box

Oil level, backlash, zero error etc

5

Drive Shaft

Misalignment, vibration, condition of flexible coupling

Benefits of our AMC:

  • Best service & support at much lower cost
  • Providing support for in house maintenance as well
  • It is hassle free as you don’t need to search for repair & maintenance team and spares every time
  • The spares as well as service come at a discounted rate as and when required
  • The total maintenance cost for one year become quite low in AMC contract
  • AMC may include certain spare parts to be replaced free of cost

Preventive Maintenance:

BIL understands that cooling tower is a vital part of any process &is usually neglected from maintenance point of viewwhich may results in unplanned shut down.
To prevent unplanned shut down & expenditure, BIL offers preventive maintenance facility apart from annual maintenance contract which includes:

  1. Systematicinspectionof each component of Cooling Tower as well as structure
  2. Detecting the problems which can harm cooling tower in future either before they occur or before they develop into major defects & take corrective action.
  3. BIL also train your maintenance personals to take care preventive maintenance. 

Preventive maintenance increases life of the equipments &reduces running cost of the plant.

 

Structural Upgradation:

Cooling Tower has to stand against various forces & loads. On the other hand it is susceptible for environmental attack, ageing, vibration& corrosion which over the period of time results in wear& tear,deterioration&at times making the cooling tower unsafe for use. Negligence in this regardcan affect load bearing capacity of foundations, columns and beams degradation and even failure of tower.
BIL is into civil construction for last three decades &have an experienced team which  thoroughly inspect the cooling tower from foundation to fan stack & provide cost effective solution & saves huge amount of capital investment for new cooling tower.


Inspection:

Usually inspection & maintenance are performed on day to day basis by maintenance department but certain flaws &weaknesses are overlooked.
To take decision for increasing tower’s capability,upgrading the tower for expansion and increasing water load it is very essential to inspect:

  1. The rotating mechanical equipment
  2. Water distribution system
  3. Tower internals
  4. Structure of cooling tower. 

BIL has in-house team of cooling tower experts who thoroughly inspect cooling tower, recognize potential problems & provide optimum possible solutions.
For inspection requirement please provide following information or click here:


General Information
Company Name
Contact Person
Mobile
Landline
Email
Address

Technical Information:
Cooling Tower  Location
Cooling Tower  Manufacturer
Type of Tower
Material of Construction (MOC)
Type of fill used              
Number of cells              
Fan Dia/Blades/RPM
Motor KW/RPM             
Gear reduction Ratio

Design Parameters

Hot Water Temperature
Cold Water Temperature
Wet Bulb Temperature
Total Flow to Tower

Current Parameters

Hot Water Temperature
Cold Water Temperature
Wet Bulb Temperature
Total Flow to Tower
Cell Size
Air Inlet height
Fill Height
Fan Stack Height
Fan deck height from basin curb
G.A Drawing  (Option for Attachment)

 

 

 

Residual Life Assessment:

Residual Life Assessment plays a vital role in decision making forrunning,repairing&replacement of cooling towerso to avoid breakdown/unnecessary capital investment or unplanned shutdown.
Prior to renovation, modernization or replacement of cooling tower, it is desirable to conduct Residual Life Assessment study of:

  1. Structural strength
  2. Design thermal condition & performing thermal condition
  3. Condition of fill, Nozzles & other components

Based on our in hand experience & Cooling Tower condition, suitable methods are chosen for inspection.
Residual Life Assessment of different components results in significant improvement of Cooling Tower life and performance.

 

Cooling Tower Spares:

BIL offers all spares within committed delivery period for all types of Cooling Towers:

Range :

  • Cooling Tower Fan
  • Cooling Tower Fan Stack
  • PVC fills
  • Drift Eliminator
  • Spray nozzles
  • Cooling tower motor
  • Gear Reducer
  • Drive Shaft
  • Sluice Gate

 

Overhauling & Refurbishment:

BIL has an in-house team of experienced Cooling Tower experts who analyse the condition of cooling tower Structural/Mechanical Equipment, its performance, and scope for repairing&also completeoverhauling of the cooling tower, by executing one or more combinations of the following services.

  • Replacement or cleaning of fills
  • Replacement or cleaning of drift eliminators
  • Repair/Refurbishment of water distribution systems
  • Repairs/modifications of pipes, valves, side stream filter
  • Servicing and testing of fans, fan shafts, motors drives and bearings
  • Repainting of Cooling Tower

BIL offers overhauling &refurbishment facility for any make &material of construction (MOC).

 

Root Cause Analysis:

“Root Cause Analysis”  is carried out to ascertain reason responsible for various parameter like non performance of Cooling Tower or other problem of Cooling Tower, due to which whole plant suffer.
 BILusingitsvast experience:

  1. Analyses Cooling Tower
  2. Prepares detailed investigation report
  3. Identifies problems accurately
  4. Develops cost effective action plan.

 

 

 

Thermal Upgradation:

In many cases it has been experienced that the basic structure of an existing cooling tower remains in sound condition, but internal componentdeteriorate or no longer meets the thermal requirements. This deterioration occurs due to poor maintenance, increased heat load or some accidental damage.  In such cases, BIL inspects the cooling tower & give optimized solution to increase the thermal capability of tower. Thermal up-gradation analysis can examine any combination of a multitude of upgrading options such as:

  • Change in water flow, airflow or heat load
  • Louver removal/replacement
  • Fill replacement and orientation
  • Fan and fan driver upgrade
  • Nozzle up-gradation
  • Airflow static pressure drop reduction
  • Replacement of standard fan cylinder with Velocity Recovery diffuser

BILoffersthermal up-gradation of cooling towers which in comparison to new Cooling Tower is a more economic option.
BIL also offersadditional cell to meet the additional cooling requirement.