Cooling Tower – A case study & Life Cycle Analysis

Cooling tower – A case study & Life Cycle Analysis
Recently visited the very large facilities of one of the biggest foundry unit near Pune.
The Unit is made with future expansions in mind and is ready for defense related production.
They are our very old clients and we have 3 no of Money Earning Jet Cooling Towers
1) 150 m3/hr cooling tower is dedicated to Air compressors
2) 400 m3/hr cooling tower is for Induction hardening machines (2500 KW load)
3) 800 m3/hr cooling tower is for Multi Applications

All the towers have been working trouble free since last 7 years.

The case study is mainly related to 800 m3/hr cooling tower as it is a unique tower.
Capacity: 800 m3/hr
Applications: Heat treatment and Equipment cooling division
Heat treatment comprises of: Polymer quenching and oil quenching
Equipment cooling is used for a) Hammer b) Press c) Reducer Roll d) Bend Shop

The Pumps: Since each application is having independent operation; there are separate dedicated pumps.
Pump set I: 350 m3/hr x 2 nos (55 m head) for Oil Quenching
Pump set II: 350 m3/hr x 2nos (55 m head) for Polymer Quenching
Pump set III: 108 m3/hr x 2 nose (55 m head) for Equipment cooling

The Jet cooling tower has 17 Spray Headers at the top.
a) 2 no are connected to 108 m3/hr pump with independent operation
b) 7 no are connected to 350 m3/hr pump of polymer quenching circuit
c) 8 no are connected to 350 m3/hr pump of oil quenching circuit
This makes 3 independent cells within one cooling tower structure.
The project team of the client had jointly worked with us during 2007 so that
a) Huge saving in civil cost could be achieved as the earlier idea of having 3 separate cooling towers for 3 different applications was modified
b) Piping cost could be reduced as the earlier idea of having 3 separate cooling towers required more elaborate pipelines
c) Cooling tower cost came down by half as compared to 3 different cooling towers.

Over the years, the actual money earning has been huge……………….

Year After Year Power & Money Saving Calculations
With Armec Jet Fan-Less Fill-Less Cooling Tower
Please look at the following, to understand the savings that have been achieved on account of estimated electricity cost in India. Along with this, the other considerable savings would have been also achieved in the form of manpower cost and maintenance-repair-revamping cost.
Note: Power rates and working hours estimated could vary from area to area and from industry to industry. Hence the calculations are approximate.
Power unit rate for Rs.
2007 to 2009 5.50
2010 to 2012 7.00
2013 to 2015 8.50

Working days in a year Working hours for continuous operation
365 [12month] 24

Energy Cost =
Rate of per Unit for Motor Kw x Working Hours x Working Days x Years

Example:
Fan Motor of 1 Kw Power working continuously for 365 Days (o/o 365 days) @ the rate of Rs.5.50 per Unit,
• Your Yearly Energy Cost for 3 years from 2007 to 2009 = 1 x 5.5 x 24 x 365 = Rs. 48,180/-
• Your Yearly Energy Cost for 3 years from 2010 to 2012 = 1 x 7.00 x 24 x 365 =
Rs. 61,320/-
• Your Yearly Energy Cost for 3 years from 2013 to 2015 = 1 x 8.50 x 24 x 365 =
Rs. 74,460/-

Along with savings from power cost, there were savings on account of maintenance, man power, changing of spares etc. Additionally a lot of time has been saved due to no break down.
Armec Jet Cooling Tower’s Cost Saving Factors:
Money saving due to user friendly technology –
Usually the running cost of a conventional system is very high because the attributes like:
I. Moving Parts’ Mechanism:
a) Fan Assembly Maintenance
b) Gear Boxes Maintenance
c) Lubrication Requirements
d) Vibration Stability
II. Probable Break Down Of:
a) Fan Assembly
b) Gear Drive
c) Electric Motor – Leading To Production Loss
III. Fills Packing Material:
a) Replacement
b) Regular Cleaning
IV. Lower Efficiency Cost Due To:
a) Reduction In Water Flow
b) Improper Passage For Water
c) Improper Passage For Air
V. Man – Hours for Maintenance:
a) For Fan Assembly
b) For Moving Part Mechanism
c) For Fills Cleaning And Replacement
d) For Providing Constant Water Sealing At Bottom
VI. Standby Spare Parts
a) Standby Spare Parts Are Must
Money saving during expansion /re-shifting of cooling towers –
As Jet Cooling Towers are having easy & modular construction, they can be added /subtracted /re-shifted easily with minimum cost involvement. In Jet Tower one saves a considerable amount on all the aspects mentioned herein, which are usually not quantified hence not visible & not available.
Life Cycle Cost Analysis for Cooling Tower:
Armec Jet vs Wooden vs PVC FRP
Total Cooling Tower Capacity – 800 M3/Hr

Fan Motor Capacity of PVC FRP Counter Wooden Cross
42.3 KW 35.2 KW

Types Of Cooling Towers
Description Base Armec Jet PVC FRP Wood Cross Flow
Tower Purchase Cost As in 2007 A
Rs.
7,88,870.00 Rs.
5,52,209.00 Rs.
10,25,531.00
Life Of Tower (Based On Maintenance & Use Of OEM Parts) Survey X Years
15 Years
8 Years
10
Total
Life Time Power Consumption B
No Fan No Fills Nil Rs.
2,33,40,717.00 Rs.
1,94,23,008.00
Fill Replacement Cost, % Armec – Nil Wooden – 40 % PVC FRP – 10 % Fill Less Rs.
55,220.90 Rs.
4,10,212.40
Fill Replacement Frequency In Life Time Survey Fill Less 5 2
Total Life Time Fill Maintenance Cost C Nil Rs.
2,76,104.50 Rs.
8,20,424.80
Motor Rewinding Cost, % Wooden – 3 % PVC FRP – 4 % Fill Less Rs.
22,088.36 Rs.
30,765.93
Motor Rewinding Frequency Survey Fill Less 1 1
Total Life Time Motor Maintenance Cost D Nil 22,088.36 30,765.93
Blade Replacement Cost, % Wooden – 5 % PVC FRP – 7 % Fill Less 38,654.63 51,276.55
Blade Replacement Frequency Survey Nil 1 1
Life Time Blade Maintenance Cost E Nil 38,654.63 51,276.55
Louvers & Nozzles Replacement Cost, % Armec – 40 % Wooden – 10 % PVC FRP – 6 % 3,15,548.00 33,132.54 1,02,553.10
Louvers & Nozzles Replacement Frequency Survey 1.00 1.00 1.00
Life Time Louvers & Nozzles Maintenance Cost F 315,548.00 33,132.54 1,02,553.10
Replacement Cost for Oil + Gear Box / V Belt & Misc. Repair Charges % Armec – Nil Wooden – 15 % PVC FRP – 2% G Nil 11,044.18 1,53,829.65
Life Time Structure Refurbishing Armec -5% Wooden -10% PVC FRP -15% H 39,443.50 82,831.35 1,02,553.10
Life Time Man Power Cost @ Rs. 6,00,000/- p.a. + % Armec – 2 % of
6 Lac,
Wooden – 8 % of
6 Lac PVC FRP -10 % of
6 Lac I 1,80,000.00 4,80,000.00 4,80,000.00
Total Life Time Cost A+B+C+D+E+F+G+H+I 13,23,861.50 2,09,19,072.56 2,20,87,389.03
In Words Thirteen Lac, Twenty Three Thousand Eight Hundred Sixty One Only Two Crore, Nine Lac, Nineteen Thousand, Seventy Two Only Two Crore, Twenty Lac, Eighty Seven Thousand, Three Hundred Eighty Nine Only.
Note: – Above calculations are for illustration. You may do your own LCCA with your actual data.

Quick Payback Period Saving Table & Graph
When You Buy Armec Jet Cooling Tower Instead Of Fan Type Cooling Tower
MOTOR KW Unit rate @ Rs. 5.50
Saving of each year b/w 2007 & 2009 Unit rate @ Rs. 7.00
Saving of each year b/w
2010 & 2012 Unit rate @ Rs. 8.50
Saving of each year b/w
2013 & 2015 10 YEARS Saving Of FAN POWER Cost IN JET COOLING TOWER
Total Yrs 2007 2008 2009 2010 2011 2012 2013 2014 2015
1 48,150.00 48,150.00 48,150.00 61,320.00 61,320.00 61,320.00 74,460.00 74,460.00 74,460.00 5,51,790.00
10 4,81,500.00 4,81,500.00 4,81,500.00 6,13,200.00 6,13,200.00 6,13,200.00 7,44,600.00 7,44,600.00 7,44,600.00 55,17,900.00
20 9,63,000.00 9,63,000.00 9,63,000.00 12,26,400.00 12,26,400.00 12,26,400.00 14,89,200.00 14,89,200.00 14,89,200.00 1,10,35,800.00
30 14,44,500.00 14,44,500.00 14,44,500.00 18,39,600.00 18,39,600.00 18,39,600.00 22,33,800.00 22,33,800.00 22,33,800.00 1,65,53,700.00
35 16,94,880.00 16,94,880.00 16,94,880.00 21,58,464.00 21,58,464.00 21,58,464.00 26,20,992.00 26,20,992.00 26,20,992.00 1,94,23,008.00

42.3
20,36,745.00 20,36,745.00 20,36,745.00 25,93,836.00 25,93,836.00 25,93,836.00 31,49,658.00 31,49,658.00 31,49,658.00 2,33,40,717.00

ARMEC GROUP
MUMBAI: 022 28544125 – 26 /66996311 E-mail: armecsale@yahoo.in;
PUNE: +91 9850747403 E-mail: bhagwanharani@gmail.com;
CHENNAI: 044 65176904 E-mail: jetenergytower@gmail.com;
DELHI: 011 22162488 / 11 22160148 E-mail: armcedel@gamil.com

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