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Repair and Construction
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Order Number
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Title
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Author
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Date
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Cooling Tower Maintenance (TP-17B)
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J.R. DeMonbrun, Union Carbide Corporation
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1965
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Abstract:
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Design of Concrete Basins for Cooling Towers (TP-92A)
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A.G. Stepp, Monsanto Company
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1971
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Abstract:
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Cooling Tower Rebuilding (TP-125A)
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Robert Burger, Robert Burger Associates, Inc.
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1974
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Abstract:
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How to Repair a Cooling Tower (TP-173A)
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James L. Willa & David Hoffman Lilie-Hoffmann Cooling Towers, Inc.
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1977
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Abstract:
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Basic Cooling Tower Technology and Rebuilding for Profits (TP-184A)
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Robert Burger, Robert Burger Associates, Inc.
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1978
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Abstract:
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Custom Reconstruction of Southwestern Public Service Company Jones Station Unit - 1 Cooling Tower (TP-205A)
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Peter G. Botsonis, Southwestern Public Service Company
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1979
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Abstract:
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Considerations for the Structural Analysis and Design of Wood-Framed Cooling Towers (TP-220A)
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Robert I. Speight, P.E., Bac-Pritchard, Inc.
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1980
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Abstract:
The analysis and design of timber-framed cooling towers is the
process in which we must 1) summarize and coordinate applicable
coodes and standards, 2) identify and classify loads imposed on
the tower, 3) analyze the distributed effects of applied loads,
4) determine allowable loads, and 5) apply the design criteria
in a manner consistent with actual physical details of the tower
construction. When carried out in rigorous and practical manner,
this process will yield a structure having a good balance of
strength and economy.
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Cooling Tower - Money Making Machines (TP-242A)
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Robert Burger, Burger Assoc., Inc.
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1981
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Abstract:
The question regarding what can be done to a cooling tower to
decrease the sump temperature to improve plant performance is
reviewed. Examples are discussed.
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Preplanning for Cooling Tower Upgrading (TP-259A)
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C.J. McCann, Tower Performance Inc.
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1983
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Abstract:
Before proceeding with a thermal upgrade project determine the
present, or like new, thermal operating level of the tower
relative to the original design conditions. Then, with an
evaluation of the components and thermal potential the user can
establish the necessary steps to meet his cooling requirements.
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An Evaluation of Steel as a Cooling Tower Structural Material (TP-268A)
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David Hutton, P.E., Bac-Pritchard Inc.
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1983
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Abstract:
An objective evaluation of common structural materials used in
the construction of industrial cooling towers is made, based on
their physical properties. The result is that steel offers the
best overall combination of desirable properties, provided that
a solution to corrosion in the industrial environment can be
found. The theory of corrosion and accepted methods of corrosion
protection are examined. A recently developed protection system
utilizing a thermosetting hybrid polymer fusion-bonded to a
hot-dip galvanized steel substrate (patent pending) is reviewed,
with emphasis on how it was developed, and how its performance
has been proven through a variety of chemical and mechanical
tests. A conclusion is reached that steel with appropriate
corrosion protection should be the preferred structural material
for industrial cooling towers.
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Restoration and Repair of 30-Year Old Cooling Towers at the Paducah Gaseous Diffusion Plant, Phase I (TP-85-11)
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M.F. Shelton, Martin Marietta Energy Systems
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1985
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Abstract:
Major cooling tower repairs accomplished during 1983 and 1984:
1) Replacing the underground portion of 46 risers located at 6
cooling towers, 2) Deck replacement on 2 16-cell counterflow and
2 14-cell crossflow towers. 3) Fan motor feeder cable and
conduit replacement on 2 16-cell counterflow and 2 14-cell
crossflow towers. Deals with equipment condition, problems
encountered and types of replacement materials.
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Utility Crossflow Cooling Tower Thermal Repair & Upgrading (TP-85-21)
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Dennis R. Moran, CM Towers, Inc.
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1985
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Abstract:
The "new" crossflow cooling towers built for the power
generation field during the 1970's has undergone significant
problems with the fill/support systems. This report looks at
what has been the cause, as well as reviewing the updated
considerations for repairing from a thermal, materials of
construction and cost point of view.
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Replacement of Asbestos Cement Fills in Natural Draft Cooling Towers (TP-86-08)
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George A. Gay & David W. Stackhouse, Custodis-Ecodyne, Inc.
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1986
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Abstract:
Case studies will be presented based on experience with actual
fill replacements in crossflow and counterflow towers. The
contribution of water chemistry and cold weather operation to
deterioration of asbestos cement fill will be addressed.
Environmental considerations in handling and disposal of
asbestos materials will be discussed along with the appropriate
interface with regulatory agencies. Details of the design and
installation of the replacement plastic fill system will be
shown and their effect on the performance of the tower will be
described.
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Restoration, Testing and Repair of 30-Year Cooling Tower at the Paducah Gaseous Diffusion Plant Phase II (TP-87-16)
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M.F. Shelton, Martin Marietta Energy Systems, Inc.
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1987
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Abstract:
Four fan cells of a 30-year old, 14 cell crossflow, redwood
splash fill tower were selected to install and test PVC-V-Bar
fill. This paper deals with the demolition, installation and
unique method of collecting tower off water temperature data to
perform a CTI Performance Test. Because of cooling demand the
entire 14-cell fan cell tower had to remain in service during
the tests.
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Crossflow to Counterflow Cooling Tower Conversion (TP-89-03)
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Allen E. Feltzin, Airco Industrial Gases
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1989
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Abstract:
This paper describes the conversion of a 16,000 gpm single
crossflow wood splash tower to a film pack counterflow tower at
one of our air separation plants. Emphasis is placed on a
thermal benefits as compared to other retrofit options.
Performance test results are included.
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Modification of the Induce Draft Cooling Tower at Cross Generating Station - Cross, South Carolina (TP-89-09)
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R.W. Lemay & Vino Verma, Santee Cooper
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1989
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Abstract:
Research Cottrell constructed the concrete induced draft-cooling
tower at Cross Generating Station in 1984. The initial
performance test indicated a major tower deficiency. The
subsequent performance tests I '85-'87 indicated a drastic
degradation in performance. The tower was upgraded in April '88
during the scheduled plant outage of three weeks. The major
modification included replacing the existing fill (approx.
180,000 cubic feet), nozzle assemblies, drift eliminators and
adding a cross-flow section. A performance test of modified
tower is to be conducted in June-July. Results will be
discussed.
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Removal of Asbestos Paper Fill From Large Industrial Cooling Towers (TP-90-04)
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E.D. Mittendorf, Cascade Dept. Operations Division
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1990
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Abstract:
A total of 81 counterflow fan cells at the Paducah Plant contain
asbestos paper fill. Because of environmental and health
considerations and the deteriorated condition of the fill
itself, it was determined that we should remove and replace this
fill. This document deals with an approved method of removing
asbestos paper fill. Included will be a discussion of the proper
safety equipment and clothing, sampling techniques, plasticizing
the entire tower, obtaining negative air through High Efficiency
Particulate Air (HEPA) filters, removal of the asbestos, and
moving it to landfill. Final clean up, encapsulation of any
remaining fibers, and clearance sampling will also be discussed.
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On-Line Rebuild of Cooling Tower Serving a 500 MW Power Station (TP-91-06)
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Roger R. Burger, Grand River Dam Authority, H. Peter Fay, GEA Power Cooling Systems,
Inc.
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1991
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Abstract:
Upgrading and rebuilding of cooling towers during plant outages
is common practice in industry. Demolition and rebuilding of a
tower while keeping the plant on-line at full power presents
special challenges and solutions. This paper describes such a
rebuild program including the planning, specifying, and
execution involved in replacing an existing wood framed tower
with a concrete tower at the Grand River Dam Authority Power
Station.
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Refurbishing America's First Hyperbolic Cooling Tower (TP-91-15)
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Brian W. Deuvall, The Marley Cooling Tower Co., and Frank L. Michel & Dan H.
Drew, American Electric Power Service Corp.
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1991
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Abstract:
When completed in 1962, Kentucky Power Company's Big Sandy Unit
1 cooling tower was the first built in this country using
large-scale natural draft design with a concrete hyperbolic
shell. The decision to replace the internal components recently
after 26 years of operation offered the opportunity to utilize
current technology and materials. This tower's maintenance and
operations history, and general condition at time of rebuild
will be reviewed.
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Design Methodology and Recommended Maintenance for FRP Composite Structured Cooling Towers (TP-92-05)
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JessSeawell & Toby Daley, Ceramic Cooling Tower Co.
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1992
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Abstract:
High performance composite structures and components offer long
life, low maintenance, and corrosion-free, low fire hazard
options to the cooling tower owner. But to take full advantage
of this life expectancy the designer must be aware of certain
design parameters unique to composites that must be addressed.
Additionally, there are routine inspections and maintenance
procedures that should be incorporated to insure and prolong the
cooling tower structure integrity.
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Cross to Counter Flow Repack on Induced Draft Operating Cooling Tower
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Michel Monjoie, Hamon Thermal Engineers & Contractors
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1996
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Abstract:
The paper describes the repack experience of a cross flow cooling tower to a
counter flow one using film fill, the cooling tower remaining in operation. The
thermal capability, the winter operation and the pumping head has been improved.
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Design Considerations for a Fiberglass, Field Erected, Closed-Circuit Cooling Tower
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Christopher W. Carlson, P.E., Baltimore Aircoil Company
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1997
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Abstract:
What is believed to be the world's first fiberglass, field
erected, closed-circuit cooling tower has been recently
constructed. The paper contains a review of the major design
differences between closed-circuit cooling towers in which the
air and water streams flow essentially parallel and other more
conventional field erected cooling products. The structural
design considerations for dead, wind and vibrational loads as
well as those required for field erection are offered.
Guidelines for the selection of composite and non-composite
materials of construction are presented.
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PGDP Enhances Plant RCW Reliability
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Michael Talley, Teresa Gross, John Elrod, Lockheed Martin Utility Services
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1997
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Abstract:
The recirculating cooling water (RCW) system has served the
Paducah Gaseous Diffusion Plant (PGDP) since 1951. Over the
years, there have been changes to the system: cooling tower
additions, cooling tower replacements, pump upgrades and the
installation of a cathodic protection system. However, the basic
system of headers and piping remains the same as the original
construction. This paper will illustrate the problems
experienced in a 40+-year-old piping system and the methods used
to transform failing expansion joints, valves and piping ranging
from 12 and 60 inch diameter into a reliable operating facility.
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Advances in Oil Mist Lubrication for Cooling Towers
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Fred Paben, Lubrication Systems Company
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1998
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Abstract:
This paper reviews the operating principles and advances that
have been made in oil mist lubrication for electric motors and
purcing gearboxes. Oil mist systems provide the most effective
protection against water contamination, corrosion and premature
failures of cooling tower gearboxes. Users report a reduction up
to 90% of the lubrication related electric motor bearing
failures and 75% of the gearbox failures. This minimizes injury
risk by reducing field repair work. A case study of a cooling
tower installation in a refinery will be presented.
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Evaluation of Design Loads for FRP Composite Columns
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Dr. Robert L. Yuan, University of Texas
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1999
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Abstract:
This paper presents an evaluation of design loads for FRP
composite columns fabricated from a pultrusion process. An
experimental investigation was performance on the behavior of
three manufacturing products, including two column cross-section
configurations with various lengths. The objectives of the
research are to determine the ultimate load capacity of each
group and to compare with the published design information. All
full-scale columns were tested in a vertical position under
axial compressive loads. The test results and analysis have
provided a comprehensive evaluation of FRP Composite columns.
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Improved Ower Plant Performance With Evaporative Steam Condensing
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Dave Hutton, Baltimore Aircoil Company
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1999
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Abstract:
Combining an open cooling tower and a steam condenser into one
common unit is a proven technology with many advantages in power
generation applications, including reduced first cost, reduced
energy consumption, reduced maintenance, and simplified H2O
treatment. Performance of the steam turbine benefits from the
evaporative condenser's direct approach to wet bulb temp, and
operating reliability improves compared to cooling tower/surface
condenser. Case histories and comparisons will be presented.
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The Retrofit of a Big Cooling Tower at an Oil Refinery in Vienna in Combination with a Significant Noise Reduction
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Henk van der Spek, Ventilatoren Sirocco Howden
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1999
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Abstract:
At a big oil refinery in Vienna an 18 unit cooling tower has
been retrofitted with fan and drive equipment in combination
with a significant noise reduction. Public authorities only
allowed the necessary retrofitting of the cooling tower after 18
years of operation, if the dominating noise generation of the
towers would be effectively reduced. From an inventory study by
acoustic specialists it hs turned out that the cooling tower
fans were the dominating noise sources for the exposed urban
area, in spite of the presence of splashing water in the tower.
Two fans have been selected for qualification together with
quiet drive equipment. Finally a super low noise fan with
special shape could only be accepted. Beside the choice for the
fan, the low noise demands had an impact on the selection on all
other equipment like E-mothers and gearboxes. The correctness fo
the noise analyses was confirmed by control readings after the
retrofit job. The presentation will review problem inventory,
equipment selection procedure, technical impact of noise
requirements on all components and verification.
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Collapse of the Conesville 4B Seven Cell Mechanical Draft Cooling Tower
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Frank L. Michell, Walt Demjanenko & Joe Tseng, American Electric Power
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2000
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Abstract:
Early in the morning of July 12, 1998, one of the two seven cell
mechanical draft cooling towers serving American Electric
Power's (AEP) 780 MW Conesville Unit 4 suddenly collapsed into
the cold water basin. Investigation into the cause of the
catastrophic collapse and resulting methodology for evaluating
the structural integrity of similar towers on the AEP System
will be reviewed. Structural upgrades incorporated into the
replacement tower design will also be discussed.
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Safe Construction of Field Erected Cooling Towers
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Mike Bickerstaff, Ceramic Cooling Tower Corporation
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2000
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Abstract:
Field construction and repair of cooling towers often involves
safety, health and environment conditions for employees. This
fact has long been acknowledged by cooling tower construction
companies. There is, however a growing interest in employee
safety by the customers, which employ tower suppliers to
construct or repair towers in the field. This paper will discuss
potential hazards on a cooling tower jobsite, state procedures
to correct the potential hazards, and suggest methods to
incorporate safety, health and environmental procedures.
Finally, the paper will relate the additional benefits that a
customer would receive with a safe work environment.
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Concrete Basins, Materials Selection in Design and Repair.
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Thomas G. Toth, Psychrometrics Systems, Inc.
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2002
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Abstract:
This paper is meant to provide a basic introduction and general
understanding of the materials available for use in concrete
towers and basins, and issues to be accounted for in the design
to provide longevity. A basic introduction to the causes of
deteriorations in concrete will also be presented along with
some common repair methods and repair materials.
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Suitability of Preservative-Treated Radiata Pine for Cooling Tower Construction.
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R.N. Wakeling, D.R. Page and M.J. Collins, Cooling tower Fabricators
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2002
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Abstract:
For over 50 years, radiata pine has been the main construction
lumber used in New Zealand. This solely plantation-grown species
has unique properties that make it very amenable to preservative
treatment, unlike species such as Douglas fir, spruce or
hemlock. These properties have allowed it to be used
successfully in all manner of industrial applications in New
Zealand and Australia, including cooling tower construction.
Data is presented to illustrate the long-term durability and
serviceability of this species.
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Avoiding Cooling Tower Catastrophe.
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James L. Willa, Willa, Inc.
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2002
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Abstract:
The three major catastrophic events on cooling towers are
structural failure, fan failure, and icing damage, in that
order. This paper describes in detail the causative factors,
methods of detection prior to event, workable preventative
solutions, and solutions after the event, on all three types of
catastrophes. The author has been personally involved in these
type failures on multiple occasions over the past years.
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Collapse of Tuttle No. 2 Cooling Tower and Resulting Replacement/Repair Program.
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Stephen Tips, City Public Service
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2002
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Abstract:
Since the collapse of the W.B. Tuttle plant No. 2, 10-cell,
Marley cooling tower in 1998, City Public Service has
re-evaluated the condition of its six other old wooden towers
and developed a plan for insuring against further failures. Two
towers were replaced with new fiberglass towers, and another
replacement planned. Three 40-45 year-old creosote treated
redwood Marley towers are being repaired and reinforced. This
paper describes the failure, replacements, repairs,
reinforcement, and reasoning used in making difficult decisions
on major expenditures for aging towers on old peaking units with
uncertain futures.
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Crossflow to Counterflow Natural Draft Tower Conversion
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Dr. John Arntson, Jamie Bland and Mike Bickerstaff, Ceramic Cooling Tower Corporation and Merwin Jones, Mirant Mid-Atlantic LLC
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2003
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Abstract:
This paper describes the turnkey conversion of an existing
Marley Class 700 natural draft cooling tower at Mirant
Mid-Atlantic LLC's Chalk Point Generating Station in
Southern Maryland, USA from a crossflow configuration to a
counterflow configuration. The work involved demolition of the
severely degraded crossflow cooling heat exchange system and
installing an all new composite fiberglass support structure,
low-fouling PVC film fill, high efficient PVC drift eliminators
and optimized distribution system, within an 11 week planned
outage during the Winter of 2002.
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One Company's Legionella Standard
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J.W. Smith, Shell Global Solutions; Jerry Ransdell and Jim McLean, Shell Chemical Co.
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2003
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Abstract:
Following issuance of Legionella guidelines by CTI, Shell
Chemical Company (SCC) upgraded procedures for control of
Legionella in its water systems. A Standard was developed which
addresses all water systems. This paper will focus on SCC
standards and guidelines for cooling towers. The Standard is
more prescriptive than the CTI guideline and represents a
compilation of regulations and guidelines in the literature. It
requires a Health Risk Assessment (HRA) and development of a
plan to address risk areas, outlines minimum standards, and
provides examples of how to meet the standards. For towers,
Legionella testing is required and chlorine residual control
ranges are specified.
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Correcting Sedimentation Problems at American Electric Power's Conesville Plant River Intake
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Frank Michell, Pedro Amaya, and C. Dannemiller, American Electric Power, Dr. Robert Ettema, and Marian Muste, University of Iowa
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2003
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Abstract:
American Electric Power's Conesville Generating Station has
had a history of chronic problems with silt build-up at the
river intake structure. This paper will describe modifications
that were completed to the area in front of the intake and to
the upstream riverbank that successfully eliminated the
sedimentation accumulation problem. Analytical and hydraulic
model studies conducted during the design optimization process
and construction techniques utilized to minimize impact to the
operating generating station will also be reviewed.
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Update on the Impact of Water Immersion for Pultruded FRP
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Clint Smith, Strongwell
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2004
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Abstract:
The development of CTI Standard 137 generated some questions regarding
the performance of pultruded structural shapes in a water immersion
environment. No data existed for pultruded Fiberglass Reinforced
Plastic (FRP), but there was some concern regarding a reduction of
properties. Three pultruders who supply the Cooling Tower Industry
with structural shapes submitted samples for a water immersion
analysis that has been underway with periodic testing for over one
year. This paper gives an update of that study which is scheduled to
last two years in addition to other water exposure data on pultruded
FRP. This information will be useful for individuals designing cooling
towers.
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Complete Structural Rebuild of two Six Cell Crossflow Cooling Towers using all FRP Members
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Deano Sarantakos, Kentucky Utilities
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2005
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Abstract:
This paper will detail the demolition and rebuild of two Marley 6,000
series cooling towers using all FRP members. It will begin with the
inspection stage and include design, material, and mechanical options,
history of the tower's maintenance as well as other towers on
site, the company's purchasing procedures, pictures of demolition
and construction, and performance data.
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Large Scale Mechanical Equipment Replacement - Simple Steps for Success
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David M. Suptic, David M. Suptic P.E., LLC
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2006
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Abstract:
Faced with multiple gear reducer failures on two large cooling towers,
an international power generation facility replaced 28 sets of rear
reduction drives and supporting structure with new, upgraded
equipment. A description of the unique nature of this large scale
equipment replacement project provides the reader with several key
steps to insure success on construction products of a similar nature.
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Westar Energy Cooling Tower Rebuilds
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David Spacek, Westar Energy, Inc.
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2006
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Abstract:
The purpose of this paper is to detail the activities which took place
before and during the reconstruction of the (2) cooling towers of Unit
#3 during the months of October and November of 2005. The paper
identifies the activities and justification involved leading up to
this replacement as well as the procedures performed to actually
demolish and rebuild these (2) towers during a 5-week outage.
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Wind Load Rated Packaged Cooling Towers
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Daniel S. Kelly, EVAPCO
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2006
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Abstract:
Changes to national building codes and state building codes in
California and Florida have given rise to special requirements for
cooling towers to be able to withstand windload and seismic
forces.
This paper will review the state and national codes as they apply to
cooling towers with emphasis on what must be communicated to
specifying engineers, owners and building inspectors with the goal of
getting unit acceptance at the jobsite and also design of units that
meet the code.
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Etiwanda Cooling Towers, Repair or Replace
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Robert Fulkerson, Fulkerson & Associates, Inc
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2007
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Abstract:
This paper discusses the structural problems and structural failures
associated with the 43 year old cooling towers located at Reliant
Energies' Etiwanda Power Plant located in Rancho Cucamonga,
California. It describes the decision analysis procedure used to
determine if the cooling towers should be repaired or replaced with
new cooling towers. It also describes the necessary modifications
required to improve the soundness and reliability of the structure.
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Rehabilitation of Hyperbolic Cooling Towers at Electric Generating Station
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Kevin A. Michols, CTLGroup
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2007
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Abstract:
Two concrete cooling towers serving a generating station exhibited
concrete deterioration, steel corrosion, and water leakage. These
towers needed major repairs that could be done only during scheduled
outages.
Detailed structural analysis helped determine the maximum size,
relative location, and sequencing of repair areas to ensure stability
during repairs. Materials were chosen to withstand conditions within
the towers.
Structural engineers and construction material consultants took part
in condition evaluation, repair design and construction quality
assurance. Repair crews removed deteriorated concrete and used
specialty shotcrete materials for structural restoration. Durability
enhancements included a waterproofing coating on the interior. They
sealed tower surfaces and sealed cracks with epoxy. Meticulous QC
testing and inspection helped ensure the project's success. After
more than 15 years of continuous service, the repaired towers show no
evidence of on-going deterioration or structural distress.
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Living in a Material World
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Frank T. Morrison, Baltimore Aircoil Company
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2007
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Abstract:
The proper selection of materials of construction is critical to
ensuring long life, reduced maintenance, and operational reliability
for evaporative cooling equipment. These functional needs must be
balanced with the budgetary constraints on each project, both on a
first cost and operating cost basis. This paper examines the wide
range of materials currently available for components used in open and
closed circuit cooling towers as well as evaporative condensers.
Whether using galvanized steels, stainless steel, or FRP, we are
living in a material world where the right material choices can
provide long-term payoffs, but the wrong choices can be costly.
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Construction Productivity Guidelines for Field Erected Cooling Towers
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James Baker, Composite Cooling Solutions, L.P.
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2008
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Abstract:
Construction contacts on field erected cooling towers have two major types of cost: fixed and variable. Fixed costs are costs a contractor procures on a fixed price. Variable costs are items such as labor, supervision, equipment and job overhead. On many field erected cooling tower projects, the largest single area of cost overrun is in supervision and labor costs. This is not surprising, because supervision and labor are frequently the largest variable cost for a contractor. Within the past 20-years, there has been significant research in construction labor productivity which provides an increasing body of empirical data as to the effects of various factors on construction labor productivity within our industry.
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