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Cooling Tower Failure Report at Indogulf
Cooling Tower Failure Report at Indogulf
Introduction
Ammonia Cooling Tower is an Induced Draft cross flow type supplied by
M/s Paharour Cooling Towers, having 2 hot return water distribution
decks, one on each side.
Both the decks have got six cells and one induced draft fan is installed in
the centre at the top of the Tower for each pair of cells.
Total Length of C.T. 80.67 Mtrs.
Height at Distribution Deck 13.63 Mtrs.
Height at fan Deck 14.43 Mtrs.
Total 24600 M3/Hr. Cooling Water is supplied to Ammonia Plant through
3 Nos. C.W. Pumps each having a capacity of 8200 M3/Hr.
Hot Cooling Water from Ammonia Plant after exchanging heat returns
through a common header and rises to the top of distribution deck
through 2 separate risers of 52 dia. for each deck.
From the risers, hot cooling water enters the distribution decks through
distribution headers having diameters reducing from 48 in first cell to
20 in last cell.
AMMONIA COOLING TOWER - INTRODUCTION
Damages Observed
Southern half of Ammonia Cooling Tower collapsed in the night of 23 rd
April. Tower components were lying on ground outside and inside the
tower.
Part of southern portion of Ammonia CT which was still erect, was found
leaning towards east because of damage to some cross members holding
the same
North side distribution deck and header was intact.
Fan deck was intact and all the fans were found running without any
indication of abnormality as observed from ground level.
52 dia. South side riser was bent towards east side and bulged at the
bottom.
3 FRP line for Chlorine dosing was completely damaged.
Return header had fallen & found to be broken in two pieces. The
damaged pieces were found to be severely deformed.
Part of the return header had fallen on the RCC Column inside the basin
damaging five RCC Columns.
31
AMMONIA COOLING TOWER FAILURE
Event
At around 23:45 hrs on 23rdApril 2002, entire south side wooden structure
of Ammonia Cooling Tower covering the six cells, collapsed along with
return header. Fans, structure to support the fans and other side of the
cooling tower, were intact. Since heavy loss of water was taking place, it
was not possible to maintain water level in the cooling tower sump.
Ammonia & Urea plants had to be stopped immediately.
AMMONIA COOLING TOWER FAILURE
AMMONIA COOLING TOWER FAILURE
AMMONIA COOLING TOWER FAILURE
AMMONIA COOLING TOWER FAILURE
AMMONIA COOLING TOWER FAILURE
AMMONIA COOLING TOWER FAILURE
AMMONIA COOLING TOWER FAILURE
AMMONIA COOLING TOWER REPAIR
Analysis
None of the exchangers in Ammonia plant were found leaking. Hence,
possibility of explosion is ruled out.
As the plant was running consistently without any change in the
parameters, possibility of water hammering is also ruled out.
Though we have observed thinning of pipe, the thickness was intact in the
upper parts. As the pipe has sufficient thickness in more than 50%
cross-section, sudden shearing of pipe can not take place. Hence,
possibility of breakdown due to sudden shearing of pipe is also ruled out.
Sudden failure of main supporting wooden columns appears to be the
most probable reason of failure. This might have resulted in breaking of
distribution header leading to collapse of particular tower cell due to
hydraulic loading and mechanical impact. This will result in failure of
other cells as well.
M/s. PCT has taken wood samples for analysis. We are also sending
damaged wood to some independent laboratory for analysis to assess the
strength of failed material.
COOLING TOWER - MAINTENANCE PRACTICES
Maintenance Practices
Sl. No. Existing Proposed
Fortnightly vibration measurement Vibration measurement of fans on
1
of all the fans weekly basis.
Annual Preventive maintenance of Shall Continue
2
fans, gearbox, motor.
Annual Inspection & repair of Shall Continue
3 cooling tower timber structure by
PCT personnel.
Need based patch repair of Bottom half shall also be taken care
distribution headers, mostly in of by providing patch from inside.
4
upper half. Need based replacement of
distribution headers shall also be
Need based painting of Shall Continue.
5
distribution header
Vibration measurement of return
6
water headers on weekly basis.
AMMONIA COOLING TOWER REPAIR