Construction of cooling towers

Professional design, supply, installation and commissioning of industrial cooling towers and water cooling systems of any complexity.

An efficient recirculating water supply system — is the key to stable operation of technological equipment and minimizing the enterprise’s costs for energy resources and water. LLC «Dalgakiran Compressor Ukraine» offers a comprehensive approach to the construction, reconstruction and modernization of industrial cooling towers (fan, dry/chillers, evaporative) «turnkey».

We carry out a full cycle of works: from thermal calculation and selection of
the optimal technology to construction and installation works, adjustment and service support.

Why is it worth ordering «turnkey» cooling tower construction?

• Comprehensive responsibility: One contractor is responsible for the entire scope of work — from engineering calculations to commissioning the facility.
• Energy efficiency and water savings: The use of modern fills, nozzles and variable-frequency drives reduces electricity consumption and water losses due to evaporation/carryover.
• Resistance to corrosion and aggressive environments: The use of modern composite materials (fiberglass, stainless steel, special polymers) ensures a long service life.
• Exact compliance with technological processes: Individual selection of parameters according to the temperature schedule and hydraulic load of your enterprise.

Stages of «turnkey» cooling tower construction

1. Thermohydraulic audit and calculation of cooling demand

The first stage of project implementation is determining the actual or calculated heat load of the enterprise and the parameters of the recirculating water supply.

• For operating enterprises (modernization/reconstruction): Our specialists analyze the operation of the existing recirculating water supply equipment, measure the actual water temperature at the inlet/outlet, water flow rate, hydraulic resistance, water quality and energy consumption of the pump-and-fan complex.
• For new facilities (construction from scratch): The required cooling capacity is calculated based on the technical data of the consumer equipment, technological regulations and climatic conditions of the region (temperature and humidity of atmospheric air).

Stage result: Determination of the types and number of cooling towers, temperature schedule, hydraulic load, required make-up water quality and parameters of pumping equipment.

2. Feasibility study (FS) and efficiency calculation

In case of replacing outdated cooling towers or switching from a once-through system to a recirculating one, the economic effect of implementing new solutions is calculated.

We perform a comparative analysis and calculate:

• Reduction in electricity consumption by fans and pumps (in particular through the use of variable-frequency drives);
• Reduction of water losses (elimination of droplet carryover and minimization of blowdown);
• Reduction of costs for chemical water treatment and maintenance;
• Return on investment (ROI) and overall reduction in the cost of finished products.

Stage result: The customer receives a detailed calculation of the investment payback period and a feasibility study of the project.

3. Development of project documentation

At this stage, a set of design and estimate documentation is developed in accordance with the construction and technological standards of Ukraine.

The project covers the main and auxiliary systems: cooling tower casing, fill layer, drift eliminators, nozzles, fan units, collection basin, pumping station, chemical water treatment system, automation and pipeline fittings.

Project documentation includes:

• General layout and placement of the cooling tower taking into account the wind rose and sanitary zones;
• Technological and hydraulic diagrams of the recirculating water supply;
• Construction and structural solutions (foundations, water collection basins, load-bearing frames);
• Power supply, automation and parameter control diagrams (temperature, flow rate, water level);
• Emergency protection and antifreeze protection solutions for the winter period.

Stage result: Approved project, full equipment specification, construction materials specification and work schedule.

4. Construction works and site preparation

The fourth stage provides for the performance of general construction and preparatory works directly at the facility.

• For new construction: Earthworks, installation of a reinforced concrete foundation, construction or waterproofing of a water collection basin, laying of underground or above-ground utilities, and preparation of sites for pumping equipment are carried out.
• During reconstruction: Worn-out elements of outdated cooling towers are dismantled, existing basins/foundations are repaired or reinforced, the anti-corrosion coating is replaced or restored, and supply mains are modernized.

Stage result: A completed construction part that corresponds to the design loads and is ready for installation of technological equipment.

5. Supply and installation of the cooling tower and equipment

The fifth stage includes prompt delivery of components, unloading and installation works.

Our specialists perform:

• Assembly and installation of the load-bearing frame and cooling tower casing (made of fiberglass, stainless or galvanized steel);
• Installation of high-efficiency fill blocks, drift eliminators and nozzles of the water distribution system;
• Installation of fan units, diffusers, electric motors and gearboxes;
• Installation and piping of pumping equipment, shut-off and control valves and filters;
• Installation of control cabinets, sensors (temperature, vibration, level) and automation systems.

Stage result: A fully assembled and connected cooling tower, tested for tightness of the water distribution and collection systems.

6. Commissioning works, adjustment and personnel training

The final stage — commissioning of the recirculating water supply system.

Engineers of «Dalgakiran Compressor Ukraine» carry out:

• Individual testing of fans, pumps and shut-off valves;
• Comprehensive testing of the cooling tower under hydraulic and thermal load;
• Adjustment of automatic control systems (balancing fan speeds depending on the temperature of the cooled water);
• Checking the operation of icing protection systems during the winter period;
• Monitoring of water quality indicators and outlet water temperature.

Personnel training: We provide instructions for the customer’s technical personnel on the rules for operating the cooling tower, adjusting parameters, monitoring the chemical composition of the water, scheduled maintenance and actions during the winter period.

Stage result: Commissioning of the cooling tower into normal operation, signing of completed work certificates and transfer of as-built documentation.

Additional solutions from «Dalgakiran Compressor Ukraine»

• Comprehensive water treatment systems: Supply of reagent dosing, water softening and iron removal units to prevent scale formation, corrosion and biofouling in the fill.
• Winter operation kits: Equipping cooling towers with automatically driven louver systems, bypass lines and basin heating elements for operation at sub-zero temperatures.
• Service and reconstruction: Scheduled inspection, replacement of fills, maintenance of fan units and supply of original spare parts throughout Ukraine.

Need to calculate the cooling tower capacity or order an audit of the water cooling system?

Contact our engineers from the water cooling equipment department to receive technical consultation and arrange a specialist’s visit to your facility.