Field-Erected Cooling Towers (FEP) Field-Erected Cooling Towers (FEP) are large-scale cooling systems constructed on-site, designed for heavy-duty industrial applications where high cooling capacity, customization, and long-term durability are required. Unlike factory-assembled (packaged) cooling towers, FEP towers are built piece-by-piece at the installation site, allowing for greater flexibility in design and capacity. Key Features of Field-Erected Cooling Towers (FEP) 1. Custom-Engineered Design Tailored to meet specific cooling requirements (capacity, footprint, materials).Designed for high heat loads (common in power plants, refineries, and heavy industries). 2. Large Cooling Capacity Typically used for 500+ tons of refrigeration.Can handle millions of gallons of water per hour. 3. Construction Materials Structural Framework: Hot-dip galvanized steel, stainless steel, or concrete.Fill Media: PVC, polypropylene, or advanced high-efficiency fills.Casing: Fiberglass-reinforced plastic (FRP), stainless steel, or concrete. 4. Airflow & Heat Transfer Configurations Natural Draft: Hyperbolic towers (no fans, rely on buoyancy).Mechanical Draft:Induced Draft (fan at top, most common).Forced Draft (fan at base, less common).Crossflow or Counterflow designs. 5. Water Distribution System Gravity-fed (crossflow) – Lower energy consumption.Pressurized spray (counterflow) – More compact but higher pumping cost. 6. Drift Eliminators & Water Conservation High-efficiency drift eliminators reduce water loss.Optional closed-circuit (hybrid) designs for water-sensitive environments. Types of Field-Erected Cooling Towers 1. Natural Draft Cooling Towers Hyperbolic shape for optimal airflow.No mechanical fans (low operating cost).Used in large power plants (nuclear, coal, gas). 2. Mechanical Draft Cooling Towers A. Induced Draft (Most Common) Fan at the top pulls air upward.Better airflow distribution, less recirculation .Applications: Petrochemical, steel, power plants. B. Forced Draft (Less Common) Fan at the base pushes air upward.Higher energy consumption, prone to icing.Applications: Where fan maintenance is easier. 3. Crossflow vs. Counterflow Designs Feature Crossflow FEP Counterflow FEP Air-Water Flow Air horizontal, water down Air up, water down Footprint Wider but shorter Taller, more compact Energy Use Lower (gravity-fed) Higher (pressurized spray) Maintenance Easier (accessible fill) More complex (fill access) 4. Hybrid (Wet/Dry) Cooling Towers Combines evaporative cooling with dry heat exchangers.Reduces water consumption while maintaining efficiency. Field-Erected Cooling Towers (FEP) Field-Erected Cooling Towers (FEP) are large-scale cooling systems constructed on-site, designed for heavy-duty industrial applications where high cooling capacity, customization, and long-term durability are required. Unlike factory-assembled (packaged) cooling towers, FEP towers are built piece-by-piece at the installation site, allowing for greater flexibility in design and capacity. Key Features of Field-Erected Cooling Towers (FEP) 1. Custom-Engineered Design Tailored to meet specific cooling requirements (capacity, footprint, materials).Designed for high heat loads (common in power plants, refineries, and heavy industries). 2. Large Cooling Capacity Typically used for 500+ tons of refrigeration.Can handle millions of gallons of water per hour. 3. Construction Materials Structural Framework: Hot-dip galvanized steel, stainless steel, or concrete.Fill Media: PVC, polypropylene, or advanced high-efficiency fills.Casing: Fiberglass-reinforced plastic (FRP), stainless steel, or concrete. 4. Airflow & Heat Transfer Configurations Natural Draft: Hyperbolic towers (no fans, rely on buoyancy).Mechanical Draft:Induced Draft (fan at top, most common).Forced Draft (fan at base, less common).Crossflow or Counterflow designs. 5. Water Distribution System Gravity-fed (crossflow) – Lower energy consumption.Pressurized spray (counterflow) – More compact but higher pumping cost. 6. Drift Eliminators & Water Conservation High-efficiency drift eliminators reduce water loss.Optional closed-circuit (hybrid) designs for water-sensitive environments. Types of Field-Erected Cooling Towers 1. Natural Draft Cooling Towers Hyperbolic shape for optimal airflow. No mechanical fans (low operating cost).Used in large power plants (nuclear, coal, gas). 2. Mechanical Draft Cooling Towers A. Induced Draft (Most Common) Fan at the top pulls air upward. Better airflow distribution, less recirculation. Applications: Petrochemical, steel, power plants. B. Forced Draft (Less Common) Fan at the base pushes air upward. Higher energy consumption, prone to icing. Applications: Where fan maintenance is easier. 3. Crossflow vs. Counterflow Designs Feature Crossflow FEP Counterflow FEP Air-Water Flow Air horizontal, water down Air up, water down Footprint Wider but shorter Taller, more compact Energy Use Lower (gravity-fed) Higher (pressurized spray) Maintenance Easier (accessible fill) More complex (fill access) 4. Hybrid (Wet/Dry) Cooling Towers Combines evaporative cooling with dry heat exchangers.Reduces water consumption while maintaining efficiency. |
| Cooling Tower Manufacturer in Djibouti |
| Advantages of Field-Erected Cooling Towers ◉ High Customization – Designed for exact project needs. ◉ Massive Cooling Capacity – Handles 1000+ tons easily. ◉ Long Lifespan – Durable materials (concrete, stainless steel). ◉ Energy Efficiency Options – Variable-speed fans, hybrid cooling. ◉ Lower Long-Term Costs – Better for 24/7 industrial operations. Disadvantages ◉ Higher Initial Cost – More expensive than packaged towers. ◉ Longer Installation Time – Requires on-site construction. ◉ Large Footprint – Needs significant space. Applications of Field-Erected Cooling Towers Power Generation (nuclear, coal, gas, solar thermal). Oil & Gas Refineries. Chemical & Petrochemical Plants.Steel & Metal Processing. Large HVAC for District Cooling. Selection Criteria for FEP Cooling Towers Cooling Load Requirements (tons of refrigeration, GPM flow rate). Site Constraints (available space, seismic conditions). Water Quality & Treatment (scale, corrosion, fouling resistance). Climate Considerations (freezing risk, humidity levels). Energy Efficiency Needs (VFD fans, hybrid cooling). Regulatory Compliance (environmental, noise, water usage laws). Comparison: Field-Erected vs. Factory-Assembled Cooling Towers Factor Field-Erected (FEP) Factory-Assembled (FAP) Customization High (fully tailored) Limited (standard designs) Capacity 500+ tons 5–500 tons Installation Time Months (on-site build) Days/weeks (pre-built) Cost Higher initial cost Lower initial cost Maintenance More complex Easier (modular design) Lifespan 30+ years (durable) 15–20 years |
