Cooling Tower Thermal Performance Improvement Through Installation of Additional Splash Fill

Abstract

This project evaluated and implemented the installation of additional splash fill in the air inlet region of each cooling tower cell at a thermoelectric power plant to improve cooling tower thermal performance. Historical operating data showed that elevated circulating water outlet temperatures under high ambient temperature and humidity conditions increased condenser pressure, reduced condenser vacuum, and negatively affected plant heat rate and overall unit efficiency. The modification consisted of installing eight feet of D-Bar splash fill below the existing fill configuration to improve air-water contact and increase heat rejection capability. Baseline conditions were established using plant distributed control system data, including cooling water temperatures, condenser pressure, wet-bulb temperature, unit load, and cooling tower fan operation. After implementation, the project achieved the expected thermal performance improvement by reducing circulating water outlet temperature, lowering condenser pressure, improving heat rate, and supporting more efficient and stable operation of auxiliary systems that rely on closed cooling water.