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Cooling
Tower Thermal Upgrade Projects
2003 Update
Contacting :
John
Cooper and Associates, P. A.
Background:
Two 200' OD round Zurn Towers with twelve 32' OD fans and 400 HP motors. In
August 1992 tower 1 tested at 92% and tower 2 tested at 89%. Florida Power Corporation
desired to increase circulation. flow by 10% and increase capability by 10%.
1993-Status:
Project has been successfully completed. Initially, exit air temperature and
velocity mapping were prepared for isolate water distribution problems. Following the
mapping a computer model of the water distribution system was completed along with the
development of the Upgrade Design Modification Package. In July 1993, after all upgrade
design modifications were implemented, the No. 1 Anclote cooling tower was retested.
Capability was and flumes did not overflow at higher flow because of
resized nozzle orifice sizes.
2003 Update:
In February of 1999 JC&A
inspected the Anclote Plant cooling towers and noted evidence of fill fouling in
both towers. In late September and early August of 1999 JC&A prepared updated
exit air temperature and velocity mappings in order to determine the extent of
fill fouling in the towers. In November of 2001 JC&A completed a formal “Study
Phase Report” to evaluate the cost-effectiveness and impact on thermal
performance of replacing the cooling towers’ high efficiency PVC fill with
low-fouling PVC fill. The following year JC&A prepared the bid specification
document for replacing the fill systems of both towers with low-fouling fill. In
October of 2001 JC&A completed the technical evaluations of the proposals for
replacing the fill. As of this writing, in July 2003, the fill replacement has
been completed in one cooling tower with the second tower’s fill replacement
scheduled for late 2003.
Background:
One 447 ft. tall Research Cottrell natural draft cooling tower tested at 94% of
design capability in September 1987.
Status:
Project has been successfully completed. Prepared "Pre-" and
"Post-" Upgrade exit air temperature and velocity mappings, computer hydraulic
analysis of the water distribution system and developed the Upgrade Design Modification
Package. In April 1994, after all upgrade design modifications were implemented, the ANO
cooling tower tested at of design capability.
2003 Update:
In August of 1995 JC&A
completed a formal study to evaluate the impact of replacing the ANO cooling
tower’s asbestos cement fill system with various PVC fill designs on the Mw
output of the power plant. In December of 1998 JC&A completed a second study to
evaluate the performance of the existing fill system design, and several
alternate fill designs, at 107.5% uprate conditions. Also in December of 1998,
JC&A conducted a two-day cooling tower seminar at ANO.
Background:
Two of the four Research Cottrell natural draft cooling towers at this plant
suffered significant performance losses because of severe fill degradation and fouling.
Status:
Exit air temperature and velocity mappings of Unit 3 & 4 cooling towers were
prepared in December 1992 in order to evaluate the extent of fill and water distribution
system problems in the 21 year old cooling towers. Georgia Power opted to replace the
entire fill system in both cooling towers in 1995-1996.
- Brandon Shores Unit 2 – Baltimore
Gas & Electric Company
Background:
One circular concrete counterflow
salt-water Zurn cooling tower with eighteen 40 ft. diameter fans that came on
line in 1991. The cooling tower’s high efficiency PVC fill system experienced
significant fouling after only a few years in service.
Status:
JC&A prepared a “Pre-Upgrade”
mapping of the cooling tower in February 1998 in order to assess the extent of
fill fouling. In August 1999 JC&A wrote the bid specification document for
replacement of the fill with low-fouling PVC fill and renovation of the fans and
gearbox support structures. In December 1999 JC&A prepared technical evaluations
of bidder’s Proposals. After the fill replacement and tower renovation work was
completed, testing showed the tower performance to be 82% of design. Exit air
temperature mappings prepared by JC&A in May 2002 revealed that the cooling
tower’s original water distribution system design does not provide adequate
water coverage over the newly installed vertical fluted low-fouling fill.
Background:
Three Research Cottrell natural draft cooling towers with deficiencies ranging
from 2 - 3 degrees F.
Status:
Exit air temperature and velocity mappings of all three Bruce Mansfield cooling
towers were performed in August - September of 1993. Significant water distribution
problems were found in all three cooling towers. Ohio Edison requested the development of
an upgrade modification for Units 1 & 2 in October 1996. Design work was completed in
October 1996. Upgrade design modifications were incorporated into the Unit 1 tower in
November 1996 and Unit 2 in October 1998.
2003 Update:
In October of
1997 JC&A prepared a “Post-Upgrade” exit air mapping of the Unit 1 cooling
tower. The mapping revealed the existence of significant nozzle pluggage in the
tower. In September of 1998 JC&A provided “Pre-Upgrade” thermal performance
capability testing services for the Unit 2 and Unit 3 cooling towers. Power
Generation Technologies, a CTI-licensed testing agency, provided manpower and
equipment as subcontractor to JC&A in this effort. Results of the testing
indicated that the Unit 2 tower was performing at 85% capability and the Unit 3
tower was performimg at 72% capability. In June of 2001 JC&A completed a Thermal
Performance Upgrade Design Modification Package for the Unit 3 cooling tower.
Implementation of the design modification of the Unit 3 cooling tower is
scheduled for the fall of 2003.
Background:
The tallest cooling tower in the western hemisphere at 553 ft. This Research
Cottrell natural draft cooling tower has been about 2 - 3 degrees deficient since plant
start-up in 1984.
Status:
Project successfully completed. In June 1992 exit air temperature and velocity
mappings of the Callaway cooling tower were made. Significant air and water distribution
problems were identified. A computer hydraulic analysis of the water distribution system
was made along with the development of an Upgrade Design Modification Package. After
implementation of all design modifications in October - November 1993, Union Electric
reported a 3 degree F reduction in cooling tower cold water temperature.
This Upgrade effort and results
were published and presented at EPRI’s 1994 Cooling Tower Conference in St.
Petersburg, Florida.
2003 Update:
In November 1995 JC&A
completed a formal Phase 1 Study to evaluate the thermal performance
efficiencies and cost-effectiveness of various fill replacement and fill
augmentation options for the Callaway hyperbolic cooling tower. In the summer of
2000 JC&A prepared a bid specification document for upgrade modification of the
cooling tower’s fill system. In March 2001 JC&A developed design modifications
to the hyperbolic cooling tower’s nozzle arrays in order to accommodate parallel
operation with a helper mechanical draft tower. In May 2001 JC&A prepared the
bid specification document for a state-of-the-art fiberglass helper mechanical
draft cooling tower featuring low-fouling PVC fill and high efficiency, low
pressure drop drift eliminators. At this writing, in October 2003, construction
of the helper tower at the Callaway Plant has been postponed.
Background:
Two 25 year old 374 foot diameter crossflow
natural draft cooling towers whose annulus-shaped precast concrete fill and
water distribution system support structure have been badly damaged by excessive
ice loading, exposure to numerous freeze-thaw cycles, and excessive chloride
penetration associated with continuous exposure to aggressive brackish
circulating water.
Status:
In April 2000 JC&A was retained as
consultant to develop cost effective strategies for resolving the Chalk Point
cooling tower problems. In order to assess the thermal performance efficiencies
of the cooling towers, JC&A performed thermal performance testing in June 2000
with Power Generation Technologies as subcontractor. Following the testing, JC&A
computed the Mw losses associated with the cooling tower deficiencies and
recommended conversion of the crossflow cooling towers to a counterflow
configuration. In June 2001 JC&A prepared the Bid Specification Documents for
the demolition of the existing fill and fill support structure and conversion of
the Unit 3 cooling tower to a counterflow design utilizing pultruded fiberglass
structure, low-fouling PVC fill, and high efficiency, low pressure drop PVC
drift eliminators. The conversion of the Unit 3 cooling tower was successfully
completed in 2002.
Crystal
River Units 4 and 5 –
Florida Power Corporation
Background:
Two counterflow hyperbolic towers
originally designed by John Cooper in the late 1970’s while employed as Chief
Thermal Engineer with Zurn Industries. These twin salt water towers were
originally designed with high efficiency cross-corrugated PVC fill modules and
have a long history of fill fouling problems.
Status:
In December 1996 JC&A contracted with Florida
Power to conduct an engineering study to evaluate options for fill replacement
in the cooling towers. In August 1998 JC&A performed exit air temperature and
velocity mappings to isolate sources of thermal performance deficiency in both
cooling towers. In September 1998 JC&A developed design modifications to improve
water distribution at the cooling tower perimeter and adjacent to the water
distribution flumes. In June 2000, after the design modifications were
implemented, JC&A performed “Post-Upgrade” mappings of both cooling towers. In
March 2002 JC&A conducted an in depth engineering study to evaluate the cost
benefits associated with replacing the cooling towers’ high efficiency fill with
low-fouling fill and replacement of all lateral distribution pipes and drift
eliminators. After all fill, lateral pipes, and drift eliminators were replaced
in the Unit 5 cooling tower in 2002, JC&A performed a benchmark exit air mapping
on the Unit 5 cooling tower (July 2002).
Background:
Two 18-cell counterflow induced-draft
fiberglass cooling towers that have served Exelon Nuclear's Dresden Nuclear
Power Station, Units 2 and 3, since June of 2000. Each of the two "once through"
cooling towers is comprised of 9 pair of 54 ft. x 54 ft. back-to-back cells
designed to reduce the temperature of 315,200 gpm of fresh water extracted from
the Dresden Station's "hot canal", which transports cooling water from the power
station to a cooling lake. In July of 2001, the six foot deep high efficiency
cross-corrugated PVC fill systems of the hot canal cooling towers became so
badly fouled with silt that the FRP fill support structure and casing wall of
Cell No. 1-C were damaged by the heavy silt-laden fill modules.
Status:
In August 2001 JC&A was
retained by Exelon to provide consulting services in support of their efforts to
resolve the hot canal cooling tower problem. JC&A provided engineering analysis
and design services in order to assess the impact of replacing the cooling
towers’ high efficiency fill with low-fouling PVC fill. In September 2001 JC&A
wrote a bid specification document that covered removal and replacement of
damaged FRP cooling tower structural members, installation of low-fouling fill,
installation of trash screens to pump intake structures, and installation of
electronic fill fouling monitoring systems. In October 2001 JC&A provided
thermal analysis and design services for a new Extended Power Uprate cooling
tower for the Dresden Station. In January 2002 JC&A performed technical
evaluations of proposals for renovation of the damaged hot canal cooling towers.
In April 2002 JC&A served as expert witness in a legal matter relating to the
damaged hot canal cooling towers. In May 2002 JC&A prepared bid specification
documents for a new state-of-the-art fiberglass EPU cooling tower. The new
6-cell EPU cooling tower was constructed in 2003.
- Grand Gulf Nuclear Station
- Entergy Operations, Inc.
Background:
One counterflow hyperbolic
cooling tower originally designed by John Cooper in the 1970’s while employed as
Chief Thermal Engineer with Zurn Industries.
Status:
From 1992 through 1999 JC&A
provided consulting and inspection services relating to the maintenance of the
cooling tower’s high efficiency fill system. In 1992 JC&A conducted a five-day
onsite cooling tower workshop and seminar. In 2000 JC&A was awarded two
engineering analysis and design contracts relating to the development of
preliminary designs for a helper cooling tower installed in parallel with the
existing hyperbolic cooling tower. The helper mechanical draft tower was
constructed in 2002, reducing the temperature of the return water to the
condenser by about 8 degrees Fahrenheit.
Background:
One Hamon/Research Cottrell natural draft
cooling tower designed circa 1983. The cooling tower fill system is comprised of
Hamon Coolfilm PVC fill modules that have experienced wholescale failure of glue
joints resulting in individual PVC sheets that are folded and leaning over. A
layer of Brentwood CF-1200 fill is installed on top of the Coolfilm modules at
the cooling tower perimeter. Thermal performance testing in 1987 indicated
performance at 89% capability.
Status:
In November 1999 JC&A was awarded a contract
to develop a Thermal Performance Upgrade Design Modification Package.
Development of the design modifications to the cooling tower water distribution
system was completed in December 1999. All upgrade design modifications were
implemented in 2000. Thermal performance testing of the cooling tower is planned
for the fall of 2003.
Background:
Three Research Cottrell counterflow natural
draft cooling towers originally designed with asbestos cement fill and drift
eliminators. The Unit 1 and 2 cooling towers were repacked with high efficiency
PVC fill in the 1980’s. The Unit 3 cooling tower was repacked with low-fouling
PVC fill in 1993.
Status:
In June 1999 JC&A performed an exit air
temperature and velocity mapping of the Unit 1 cooling tower in order to assess
the extent of fill fouling. After determining that fill fouling was widespread,
the Owner decided to replace the fill in the Unit 1 and 2 cooling towers with
low-fouling PVC fill. In August 1999 JC&A wrote the bid specification document
for replacing the fill in the cooling towers with low-fouling fill. In December
1999 JC&A prepared technical evaluations of the bidders’ proposals. In July 2000
JC&A performed an exit air mapping of the Unit 3 cooling tower, revealing
significant water distribution problems over boundary areas of the fill system.
In February 2001 JC&A developed a Thermal Performance Upgrade Design
Modification Package for the Unit 3 cooling tower.
Background:
One large Research Cottrell natural draft cooling tower that uses brackish water
from the Delaware River. This tower has been about 2 - 3 degrees deficient since plant
start-up.
Status:
Very significant
water distribution problems were revealed in exit air temperature and velocity
mappings of the Hope Creek cooling tower prepared by JC&A in July 1993. In
January 1994 PSE&G contracted with JC&A to develop a "partial fix", involving
the design of stainless steel flow diverters for installation in the concrete
water distribution flumes. Flume flow diverters were installed in the flumes in
1994. In 1995 JC&A prepared an engineering study to evaluate the feasibility of
piece-meal replacement of the asbestos cement fill system of the cooling tower.
In October 1999 updated exit air temperature and velocity mappings were prepared
by JC&A. In October 2000 JC&A developed a Thermal Performance Upgrade Design
Modification Package to eliminate water distribution problems revealed in the
mappings. In March through June 2002 JC&A provided engineering services to
develop budgetary pricing and thermal analyses to evaluate the cost
effectiveness of replacing perimeter bays of asbestos cement fill sheets with
low-fouling PVC fill bottom supported on new pultruded fiberglass fill joists.
JC&A prepared the bid specification document for replacing 50% of the perimeter
fill with low-fouling PVC fill in July 2002. In August 2002 JC&A prepared the
bid specification document for implementation of the Upgrade Design Modification
Package developed in October 2000. In November 2002 JC&A prepared technical
evaluations of the bidders’ proposals. The perimeter bay fill replacement work
and upgrade design modifications were implemented in May 2003.
Background:
Two Research Cottrell natural draft cooling towers that have been about 2 degrees
deficient since startup. Unit 1 tower tested at 84.5 % in 1993.
Status:
Significant water
distribution problems were found in the exit air temperature and velocity
mappings of the Independence Station cooling towers prepared by JC&A in 1991. In
1993, JC&A prepared a detailed engineering Upgrade Design Modification Package
for the cooling towers. After design modifications were implemented in Spring
1995, the towers tested at 95 %, with the shortfall attributed to nozzle fallout
problems. Nozzles were strapped to the pipes in 1997. Updated exit air mappings
of both cooling towers were prepared by JC&A in December 1999.
Background:
One 532 ft. tall Zurn natural draft cooling tower, featuring a 4’ deep
Munters CF-19060 PVC fill system. With a circulation. Water flow rate that was 18% above
design point flow, the tower capability, in July 1994, was determined to be about 93.5%
in July 1994..
Status:
Exit air
temperature and velocity mappings of the Nine Mile Point Nuclear Unit 2 cooling
tower prepared by JC&A in 1994 revealed significant water distribution problems
related to excessively high water flow. In the fall of 1994, JC&A developed
design modifications to the cooling tower water distribution in order to correct
the problems seen in the mappings. All modifications to the cooling tower water
distribution system were implemented in April 1995. Formal thermal performance
testing of Nine Mile Point 2 cooling tower carried out in July 1995 showed no
change in thermal performance efficiency due to numerous plugged nozzles.
Perry Nuclear Power Plant - Cleveland Electric Illuminating Company
Background:
In order to increase
plant Mw output, Cleveland Electric requested that John Cooper & Associates
develop a cost-effective strategy for upgrading the thermal performance of
Perry’s very large Research Cottrell natural draft cooling tower.
Status:
Exit air velocity and
temperature mappings, prepared by JC&A in March of 1998, revealed the existence
of significant cold air intrusion through the drift eliminators in perimeter
areas where the depth of the fill system is minimal. JC&A completed the Upgrade
Design Modification package, which involved doubling of the number of spray
nozzles at the cooling tower perimeter, in October 1998. All upgrade design
modifications were implemented into the Perry cooling tower in April 1999.
Pleasants Power Station - Allegheny Power
Background:
Allegheny Power solicited the services of John Cooper & Associates, P.A. in
November of 1997 to develop an Upgrade Design Modification Package for two Research
Cottrell natural draft cooling towers at the Pleasants Station near Parkersburg, West
Virginia.
Status:
Exit air mappings prepared in November 1997 revealed very significant water
distribution problems near the cooling tower perimeter and next to the water distribution
flumes. The Upgrade Design Modification Package was completed in February of 1998.
Implementation of the upgrade design modifications to the water distribution system of the
Pleasants Unit 1 cooling tower was completed in October of 1998.
Background:
Four Research Cottrell
natural draft cooling towers with longstanding thermal performance deficiencies.
Status:
Exit air mappings of all
four cooling towers prepared by JC&A in May 1998 revealed significant water
distribution problems over boundary areas of the fill systems of the cooling
towers. In October 1999 JC&A developed a Thermal Performance Upgrade Design
Modification Package for the cooling towers. In September 2003 implementation of
the design modifications is in progress.
Background:
Two 20+ year old Marley counterflow
natural draft cooling towers with high efficiency PVC fill. In 1990, SECI
experienced a substantial loss in cooling tower performance due to plugging of
the corrugated passageways of the fill with organic growth and matter, resulting
in Unit 1 and Unit 2 cold water temperatures that were 14oF and 21oF
above design, respectively. In 2002, after treatment with sodium hypochlorite,
cold water temperatures were 2-3oF above design.
Status:
In September 2002 JC&A was
awarded a contract to prepare the bid specification document for replacement of
the fill, drift eliminators and spray nozzles of both cooling towers. In
February 2003 JC&A prepared detailed thermal analyses in order to evaluate the
thermal performance claims of the bidders. Cooling tower renovation work began
in the fall months of 2003.
Background:
Two Research Cottrell natural draft cooling tower with long-standing 2 degrees F
thermal performance deficiencies.
Status:
Exit air temperature and velocity mappings of the Susquehanna Unit 1 cooling
tower in October 1994 showed serious water distribution problems in the vicinity of the
cooling tower perimeter and near the water distribution flumes. A detailed Upgrade Design
Modification to the cooling tower was requested. All upgrade modifications to the cooling
tower were implemented in May-June 1995 for Unit 2. PP&L reported cold water
temperature reduction of 2.5 degrees F in the summer of 1996. Upgrade modifications to
Unit 1 were implemented in September of 1996.
Background:
Two large Research
Cottrell natural draft cooling towers. In June 1995, Unit 1 cooling tower tested
at 90% and Unit 2 cooling tower tested at 86% after extensive upgrade design
modifications were made to the fill and water distribution system by Research
Cottrell. Riser standpipe water levels were observed to be unusually high under
normal operating conditions.
Status:
Exit air
temperature and velocity mappings of both cooling towers prepared by JC&A in
July 1995 revealed very low fill water loading in the interior of the cooling
towers. A detailed Thermal Performance Upgrade Design Modification Package was
completed by JC&A in November 1995. Implementation of the upgrade design
modifications into the Unit 2 cooling tower in the fall of 1997 failed to
improve tower performance. Additional modifications to the Unit 2 cooling tower
nozzle arrangements, developed by JC&A and implemented in the summer of 1998,
also failed to elevate tower performance to desired levels. Updated exit air
mappings of the Unit 2 cooling tower prepared by JC&A in September 1999
confirmed that water distribution to the interior regions of the fill system
continued to be insufficient. A third design modification to the cooling tower
nozzle arrangements, developed by JC&A in October 1999 and implemented by
Georgia Power in 2000, also failed to correct the observed water distribution
problems in the interior of the Unit 2 cooling tower. In 2000 Georgia Power
discovered that the two interior precast concrete water distribution flumes were
improperly installed in the cooling towers, extending by approximately 18 inches
into the flow stream of the riser pipes and obstructing flow to the lateral
pipes that feed water to the cooling tower interior. In 2003 Georgia Power is
considering options for correcting the hydraulic problems caused by the
improperly installed flume sections.
Background:
One Research
Cottrell natural draft cooling tower put into service in May 1996. Formal
thermal performance testing in June 1996 revealed that the cooling tower was
operating at 88% of design capability.
Status:
JC&A prepared exit
air temperature and velocity mappings of the Watts Bar cooling tower July 1996
in order to determine the source of the performance deficiency. A Thermal
Performance Upgrade Design Modification Package was developed by JC&A for TVA in
August 1996. All modifications to the cooling tower were implemented in an
eighteen day period in October 1996. CTI capability testing of the Watts Bar
cooling tower after the upgrade showed the tower to be operating at 106% of
design capability, a reduction in cold water temperature of 3 - 4 degrees
Fahrenheit. TVA estimates that the upgrade yields a gain in generation of 44,000
Mw-hrs per year or about 6 Mw additional system capacity. The Watts Bar cooling
tower upgrade project was documented in a technical publication presented at
EPRI’s 1997 Cooling Tower Technology Conference in St. Petersburg, Florida.
Background:
Two Research Cottrell natural draft cooling towers, historically 1.5 - 2.0
degrees F deficient.
Status:
Exit air temperature and velocity mappings prepared in April 1992 revealed
significant water distribution problems in both cooling towers. In 1993 a detailed
engineering Upgrade Design Modification Package was developed. . All modifications to the
cooling tower were implemented in the Spring of 1995. Thermal performance testing of the
White Bluff Unit 1 cooling tower carried out in September 1995 showed a capability of
97.5%.
2003 Update:
In November 2000 JC&A developed a
conceptual design for perimeter test bays of low fouling PVC fill modules bottom
supported on pultruded fiberglass fill joists for the Unit 1 cooling tower. The
test bays, including four different low fouling fill designs were installed in
2001. In January 2002, JC&A provided thermal analysis services in order to
evaluate the performance of the White Bluff cooling towers with the existing
asbestos cement fill sheets in perimeter bays replaced with various low fouling
PVC fill designs. In February 2002 JC&A prepared a bid specification document
for replacement of the asbestos cement fill sheets in all perimeter fill bays
with low fouling PVC fill modules supported by FRP beams. In April 2002 JC&A
provided field engineering and quality control services during the replacement
of the perimeter fill in the Unit 1 cooling tower. In June 2002 JC&A prepared
temperature and velocity mappings of the Unit 1 cooling tower in order to assess
the effect of the new fill on cooling tower performance. In March 2003 JC&A
provided field engineering and quality control services during the replacement
of the perimeter fill in the Unit 2 cooling tower. In May 2003 JC&A prepared
exit air mappings of the Unit 2 cooling tower. In August 2003, in order to
assess the effectiveness of 12 foot diameter TurboDraft fans at the cooling
tower air inlet, JC&A prepare exit air temperature mappings of the Unit 1
cooling tower with and without TurboDraft fans in service.
.
Background:
One Research Cottrell natural draft cooling tower with a thermal performance
deficiency of approximately 2 degree F.
Status:
Exit air
temperature and velocity mappings of Zimmer cooling tower prepared by JC&A in
December 1995 revealed significant air/water mal-distribution. In
August-September 1995, JC&A prepared a Thermal Performance Upgrade Design
Modification Package for the Zimmer Station cooling tower. In October 1995, the
upgrade modifications were partially implemented. In November 1995 JC&A prepared
updated exit air mappings of the cooling tower.
2003 Update:
In May 2000 JC&A
provided field engineering and quality control services while upgrade
modifications were implemented into the cooling tower. In February 2002 JC&A
prepared a bid specification document for replacement of asbestos cement fill
sheets in perimeter fill bays with new low fouling PVC fill modules bottom
supported on pultruded fiberglass beams. In April 2003 JC&A provided field
engineering and quality control services during replacement of fill in perimeter
fill bays. Completion of implementation of the Upgrade Design Modification
Package and perimeter fill replacement work is planned for future unit outages.
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