Field-erected cooling towers
YWCT has been designing and manufacturing field-erected cooling towers for over 50 years. In the past, all of our cooling towers were made of concrete. For the past 20 years, we have largely moved over to pultruded FRP cooling towers. In both cases, YWCT offers both counterflow and crossflow configurations.
Field-erected cooling towers
YWCT can offer our customers two alternatives for field-erected cooling towers (~1,000 m3hr-100,000 m3hr):
Pultruded FRP structure
Fiberglass field-erected cooling towers are high-quality cooling towers with powerful cooling capacity, designed to serve the heavy-duty heat removal demands of various industrial sectors.
Pultruded fiberglass structure is ideal for the wet, corrosive environments typical of cooling towers: It is strong yet light, doesn’t corrode when exposed to moisture or chemicals, and due to its UV resistance, won’t deteriorate when exposed to sunlight. Whether counterflow or crossflow design, they are structured of continuous composite fiberglass-pultruded sections that comply with CTI’s STD 37 and conform to ASTM E84D with a flame spread rating below 25.
YWCT provides our customers with scale drawings of the concrete cement basin, including locations and production drawings of all pipe fittings in 2D or 3D. The size of a single cell ranges from 6mx6m to 16mx16m. When the concrete basin is ready on site, YWCT sends one of its site managers to supervise erection (usually conducted using local teams).
Pultruded FRP cooling towers have become an alternative solution to traditional concrete cooling towers, as in many cases they cost less and their erection time is much shorter than that of cooling towers made entirely of concrete. In addition, pultruded FRP towers in many cases offer superior corrosion resistance.
Concrete cement cooling towers are designed for heavy industrial applications such as power plants; petrochemical and chemicals plants; and refineries of various kinds. YWCT provides our customers with scale drawings of the concrete cement structure, including locations and production drawings of all pipe fittings in 2D or 3D. The size of a single cell ranges from 6mx6m to 16mx16m. In most cases, our customers (who are familiar with the local market and regulations) choose to take over the civil engineering and the concrete work. Our engineering department guides the concrete construction process from beginning to completion, ensuring that on-site work meets all requirements. While construction is taking place, all relevant parts of the cooling tower are purchased or manufactured and delivered to the job site. When the structure is ready, YWCT sends one of its site managers to supervise the final stage of the cooling tower erection, which includes fitting of the cooling towers with fill, louvers, fan, motor unit, and fan stack (the work is usually conducted using local teams) until the cooling tower is operational.
Choosing a concrete structure ensures the end user long product life for the cooling tower, and may be the least costly solution for certain customers who already work with a concrete contractor, particularly in locations where labor is less costly.
As an option, YWCT can offer additional features for its field-erected cooling towers:
- Low-noise fans
- Complementary subsystems: filtration system, I&C, circulation pumps, water treatment systems, heat exchangers, VFD, and more
- Elevated basin for optimal use of space
- Rainfall attenuating
- Solutions for low-quality water
- Additional veil layers for increased corrosion resistance (for pultruded FRP structure)
Modular Cooling Towers
YWCT has developed a medium-size cooling tower (600 m3/hr-2,000 m3/hr per cooling tower) made of pultruded FRP with integral FRP basin. The cooling tower is delivered to site in modules (sections), reducing installation time on site to a few days instead of weeks.
Modular Cooling Towers
In many cases, installing a medium-size cooling tower (i.e., 30m2-120m2) is a challenging task. 6mx6m cells, for example, are too big to be transported as a single unit over land. One alternative would be shipping the cooling towers in components and installing them on site. Not only does this require a qualified team and enough space on site, but installation may take weeks. Such an installation process is not possible at small sites, and in many cases, it interferes with contractors’ other work. YWCT has designed a cooling tower that solves these problems.
Our cooling tower is designed in modules from the outset. The cooling tower components are sent to YWCT’s distributor’s premises in the customer’s destination country and assembled there (this reduces high sea freight costs associated with shipment of assembled cooling towers from the manufacturer‘s country). The cooling tower is tested and then disassembled into modules (sections), which are shipped to the job site on trucks. Assembly on site takes two to five days and requires a crew of five and a small crane. Two additional advantages of this modular cooling tower:
Materials. The cooling tower is made of pultruded FRP, which is on the one hand strong, light, and anti-corrosive; and on the other hand, inexpensive. FRP components are joined using SS hardware.
Integral basin. Unlike other solutions in the market, YWCT‘s modular cooling tower is fitted with an integral FRP basin of up to 2m depth
The bottom line: The customer gets a high-quality cooling tower, with low shipment and assembly cost and quick installation time, so the total cost of procurement is low.
YWCT can design any cooling tower (1,000 m3/hr-100,000 m3/hr) to fit an existing concrete basin. Erection of the new cooling tower can take place alongside the existing cooling tower. The new cooling tower can be lifted (entire cell or modules) to reduce downtime of the operating cooling tower.
YWCT specializes in tailor-made cooling towers that comply with any cooling challenge. Flexibility in production, diversified materials, and extensive cooling tower knowledge enables us to help you devise the cooling tower as per your specific requirements.
One of the most frequent challenges we encounter is replacement of old cooling towers in an operating plant. These challenges can be divided into two:
- Fitting a new cooling tower to an existing basin. YWCT specializes in designing custom-made cooling towers. In most cases, cooling towers of this size are made of pultruded FRP and designed for at least 25 years of service.In many cases, additional capacity is required due to growing demand of manufacturing process/es over the years. With modern technology, retrofitting is feasible in most cases. By converting crossflow configuration to counterflow, and choosing new fill types that were not available just a few years ago, we can significantly increase an existing cooling tower’s capacity.
- Minimum downtime. In many cases, stopping an operating cooling tower causes significant loss of output and revenues. To reduce downtime to a minimum, we have developed two methodologies to handle such situations:
- Lifting complete cooling tower cells. If there is enough space on site near the existing cooling tower, YWCT can design and build an entire cell alongside the existing cooling tower. On D-Day, one construction team demolishes the existing cooling tower (or one of its cells), and another team is responsible for lifting the new cell and positioning it in place. The process can take two to three days, although in many cases, post demolition of the existing cooling tower is a good time to reconstruct the concrete basin.
- Building cooling towers in modules. When there is no space on site or when the customer would like to reduce the duration of activities on site, building the cooling tower in modules is the way to go. The new cooling tower will be designed in modules that are built at a distant location. The modules (made of pultruded FRP) are designed to be transported on standard trucks. On D-Day, the modules are shipped to the site and assembled in a process that may take a few days, in place of the demolished cooling tower.
Packaged cooling towers
YWCT’s product line includes several series of packaged cooling towers made of steel or FRP, in counterflow or crossflow configurations. In addition, YWCT has the ability to design and build nearly any cooling tower that may be required by our customers or their needs.
Packaged cooling towers
Packaged cooling towers:
- P series. A built-to-last hand-laid FRP cooling tower with unique steel-free structure
- PIRD series. A premium crossflow series designed for harsh weather conditions or corrosive environments
- SIND series. Counterflow HDG steel structure cooling towers designed to minimize costs and maximize performance
- PIND series. Premium counterflow series, designed for harsh weather conditions. Combination of FRP and stainless steel maximizes capacity with minimum footprint.
One of YWCT’s main advantages is our ability to design nearly any cooling tower, from a small, packaged unit, to big field erected cooling tower, including:
- counterflow and crossflow
- induced-draft and forced-draft
- Hand-laid FRP
- Pultruded FRP
- HDG steel
- Stainless steel
- Super-low towers for underground parking
- Retrofitted towers to existing on-site basins or limited space
- Low-noise cooling towers
- Cooling towers for extremely hot inlet water
- Cooling towers adapted to brackish water/seawater
- Cooling towers designed for skyscrapers
In many cases, integrating a cooling tower with its subsystems requires more planning and attention than does the specification process of the cooling tower itself. Detecting a need in the market, YWCT has devised an end-to-end solution to this problem.
In many cases, integrating a cooling tower with its subsystems requires more planning and attention than does the specification process of the cooling tower itself. Detecting a need in the market, YWCT has devised an end-to-end solution to this problem: our skid-mounted plugNplay system that includes in addition to cooling towers, components such as pumps, heat exchangers, automatic filters, water treatment and bleeding systems, and electricity and control panels. Furthermore, a standard skid is designed for shipping in ordinary containers to the required location.
Our plugNplay systems are based on the following components (or combinations thereof):
- Cooling Tower. Our solution is ordinarily based on YWCT’s PIND cooling towers, whose capacity is between 120,000 and 800,000 kcal/hr (varying according to design conditions).
- Side stream filter. The tower can be fitted with a fully automatic self-cleaning filter or manual filter. The filter’s flow rate is usually designed to equal 10% of total water flow. In most cases, we use a filter with filtration degree of 50-100μ.
- Water treatment and bleeding system. The cooling tower can be equipped with a water treatment and bleeding system. The water treatment system is able to cover three aspects: corrosion, scale, and biological fouling, as offered by most reputable water treatment companies.
- Circulation pumps. As part of the cooling system, we can supply centrifugal circulation pumps, suitable for industrial applications, and having a very flat curve to guarantee constant pressure.
- Heat exchangers. A component that can be provided as part of the cooling system is a heat exchanger (PHE or tube & shell). The heat exchanger may be used for a second closed-circuit water system, or for any other fluid used in the production process.
- Electric and control panel. The system can be equipped with dedicated electricity and control panels.
- Skid. The components are rack mounted on a chassis made of hot galvanized profiles coated with protective paint. The solution includes piping connecting all components.