When it came to very large water circulation, industries had no other option but to opt for “RCC” constructed fan type cooling towers.

Some of the reasons for switching over to “RCC” as material of construction were;

  1. Sourcing and using quality wood as the only option for material of construction for cooling tower became increasingly difficult. Its revamping was always an issue and many times running cooling towers used to collapse including almost fatal incidents.

  2. With RCC construction, there was assured life of 20 to 30 years.

  3. Galvanized structure for cooling tower applications had serious quality & life issues.

  4. No other suitable MOC was experimented and made available to buyer / user with good viability.

RCC towers have become more or less a norm when it comes to Large Power Plants, Refineries, Fertilizer Plants & similarly Large Industrial Complexes. Every technology gets actually evaluated only after good many years of use only to realize the overall benefits vis a vis limitations.

Large number of users have realized that;

  1. Technologies are changing very fast.

  2. The RCC cooling towers envisaged, designed & installed 10 or 20 years back are becoming obsolete due to their “Old Design”.

  3. The newer cooling towers are more compact & more energy efficient.

  4. Older RCC cooling towers have regular revamp schedules + costs including RCC structure care.

  5. Many times such RCC towers work at reduced efficiency levels.

  6. In a multi-cell arrangement, at any given time, few cells are always under repairs & revamps due to constant aging and due to the moving parts, vibration & packing material.

In constantly changing & challenging industrial scenario what remains unchanged is the presence of these old & aging RCC towers. People may retire but it may be very difficult to retire old & obsolete RCC Cooling Towers. (The breaking / re-shifting / capacity improvement is not economically viable with RCC towers). Then, how does one help these aging cooling towers?

What is required is a low cost, flexible, adaptable modern technology which can support such cooling towers.

IAMS – INNOVATIVE Asset Management System for the existing RCC Cooling Towers

For a typical 30,000 m3/hr RCC Cooling Tower zone:

Jet Cooling Towers of 3000 m3/hr to 6000 m3/hr can be installed wherein;

  • No new basin is required to be constructed,

  • No space remains unutilized

  • No new pumps are added

  1. The hot water / return water pipe line is extended (by way of tapping) and hot water is given to Jet Towers.

  2. Valves are used to control / divert the required water flow.

  3. The Jet Towers are installed on non storage P CC/RCC slab.

  4. The slab will be on columns where the space below can be utilized for any other purpose including storage or installation of smaller equipments.

  5. The water falling in Jet Towers is diverted to main existing cold water basin by gravity through open channel / pipe

The Clear Benefits of IAMS:

  • Ease of maintenance schedule in which one cell / two cells of RCC can be taken for longer, better shutdown time so that repair, revamping is done with utmost care. During this schedule, the load is taken by Jet Towers.

  • Better cold water temperature in hot & humid season; Since most of “old towers” do sweat in peak season, during such times, the additional cooling can be achieved by Jet Cooling Tower, which can improve overall supply of cooling temperatures and create special buffer for peak season.

  • Continuous energy saving depending on heat load and operating conditions.

  • Quick return on investment.

Jet Cooling Towers can be used for longer duration. The equivalent “Fan Cells” can be operationally replaced / put more on rest. So that, huge amount of power saving can be achieved.

The reduction in auxiliary power (utilized for fan motor) can increase selling of more power (in case the power selling option is available). This will directly support the increased profitability of the unit.

This IAMS can be easily carried out in existing plants. For newer projects it can save huge capex as:

  • IAMS can work as stand by cell of only Jet Cooling Towers, rather than RCC Cooling Towers).

  • Costly & complicated civil expense associated with RCC cooling tower basin can be totally saved!!


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