(123a) Can You Afford to NOT Upgrade Your Cooling Tower?

Chevron Phillips Chemical Company, LP (CPC) operates a 12-cell Marley 600 Series cross flow tower at an ethylene cracker on the Gulf Coast. The cells were originally constructed using Douglas fir wood framing beginning in 1976. In 2016, an external visual inspection identified deflection in the 54-inch return header and supporting structure. Further analysis suggested that degradation of the main wooden columns was a likely root cause, and could have an impact on their load carrying capabilities. A quick repair was performed to maintain the tower as fit-for-purpose.

The existing tower was then evaluated using structural analysis software to determine the required equivalent FRP member sizes. A thermodynamic model proved there were opportunities to increase the efficiency by installing the latest technology splash-fill. This paper presents the improvements in reliability, maintenance costs, and production after rebuilding the cells with pultruded FRP members and modern splash fill. The other cells are planned to be upgraded at the next scheduled opportunity.