Maxim Power – HR Milner Cooling Tower Replacement
Gas Liquids Engineering Ltd. (GLE) designed a replacement cooling tower for the HR Milner Coal Fired Power Plant located in Grande Cache Alberta. The existing 4-cell tower had suffered a failure and could no longer be used. The key project driver was to procure and install a new tower as quickly as possible to minimize the plant down-time. The design reuses as much of the existing infrastructure as possible including portions of the existing inlet piping, basin, sump, cooling water pumps and electrical infrastructure. An 850 MMbtu/hr, 14-cell pre-fabricated tower design was selected as the replacement option because it could be pre-fabricated off-site at lower cost and at a significantly shorter delivery than a replacement in-kind solution. The project included:
- Laser scanning to accurately model the existing facility structures and piping to incorporate the new tower design. The existing drawings could not be used reliably as many drawings were not available or were from the original plant construction in 1969.
- Line locating and hydro-vac to expose existing undergrounds. The pilings and support structure for the new tower had to be designed to avoid a number of underground piping systems including: intakes to the pump sumps; fire water lines; and supply water lines from the main plant.
- Piping design and stress analysis of 42” low pressure water piping to the new tower.
- Electrical and controls integrated into the existing plant systems.
- To reduce evaporation coming off the cooling tower basin and subsequent icing of the tower inlet, the tower basin was fitted with a ball cover consisting of 60,000 4” black plastic floating balls.