Retroffiting and Repairing Cooling Tower Structure Within A Tide Deadline



Benny Dwika Leonanda (Jurusan Teknik Mesin Fakultas Teknik Universitas Andalas)


This project focused on the retrofitting of an aging cooling tower at PT. Sulfindo Adiusaha's Chlor Alkali Plant. The goal was to incorporate advanced technology and features into the cooling tower, in response to regulatory modifications and the need to upgrade older buildings to improve their resilience and performance. The existing wood structure of Cooling Tower T 9120 GH was replaced with a new FRP structure, and the Fill Pack was also replaced during the retrofit to restore the cooling capacity to the original design. The project was completed within a tight timeline of 10 days to ensure long-term reliability of operations at the plant.

Following the commissioning of the new cooling tower structure, the retrofitted T 9120 GH cooling tower was able to deliver a cooling capacity of 10.8 million Kcal with an efficiency of 78.6%, indicating good condition and close to the original design performance. The maximum vibration data on the motor and base frame were recorded at 10 mm/s2, which is within the satisfactory category based on the CTI Standard. Motor bearing temperature was recorded at 65°C, indicating good performance.

This project demonstrates the importance of timely upgrades to maintain plant operations and ensure long-term reliability. Retrofitting an aging cooling tower can improve its functionality, efficiency, and environmental impact. The success of this project also highlights that retrofitting can be done within a tight timeline, without compromising on safety or quality, provided proper planning and execution are in place.


Retrofitting, Cooling Tower, FRP

Full Text:



B. Yang, X. Liu1, Z. Zhao, J.Song1,C. Chen, "The analysis of the influence of packing and total pressure on cooling performance of the cooling tower," IOP Conf. Ser.: Earth Environ. Sci. 170 032020, 2018.

R. Abbond, "Improving Cooling Tower Water and Energy Efficencies Based on a Analytical Method," Master Thesis, Department of Energy Technology KTH, 2022.

S.T.Dehaghani, H. Ahmadikia, "Retrofit of a wet cooling tower in order to reduce water and fan power consumption using a wet/dry approach," Applied Thermal Engineering, Volume 125, October 2017, Pages 1002-1014.

J.K.Kim, R.Smith, "Automated retrofit design of cooling-water systems," AIChE Journal, 49(7):1712 – 1730, 2004.

J.C. Hensley, "Cooling Tower Fundamental," SPX Cooling Technology Inc., Kansas, 2009.

S. D. Anjarlekar, A. A. Ayare, D. R. Bakshi, S. T. Bhosale, and S. S. Goilkar, "Study and Design of Cooling Tower," International Journal of Engineering Science and Computing, vol. 8, no. 6, pp. 18244–18247, 2018.

B. B. Sai, I. Swathi,K. S. L. Prasanna, and K. S. Rao, "Design of Cooling Tower," International Journal of Scientific & Engineering Research, vol. 4, no. 5, pp. 1560–1563, 2013.

SPX Cooling Technologies, “Erection Sequence Marley Class 400 Counterflow Cooling Tower,“ SPX Cooling Technologies , Ing. Overland Park, KS 66213, 2010

A. Bardi, S. Montomolia , M. Pacib, A. Lenzia, L. Bertocchic, A. Garagiolac, A. Santini, L. Freire, “Hybrid Cooling Tower Retrofit in a Geothermal Power Plant: Outcomes from H2020 MATCHING Project”, Proceedings World Geothermal Congress 2020+1 Reykjavik, Iceland, April - October 2021

G. B. Hill, Cooling Tower principles and practice. London: Butterworth-Heinemann. 1990.

Basunanda dkk. (2014 ). “Modifikasi Cooling Tower Tipe Induce Draft Aliran Counter Flow”, Skripsi, Program Studi Teknik Mesin Fakultas Teknik Universitas Diponegoro.

StatisticsArticle Metrics

This article has been read : 49 times
PDF file viewed/downloaded : 5 times

Copyright (c) 2023 Benny Dwika Leonanda


View METAL's Stats


Creative Commons License

This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.