A Reliable Upgrade for Industrial Cooling: Replacing Crossflow Towers with Multi-EC Fan Counterflow Technology
Project Overview
Contractor: L&T Construction
End User: Toyota Kirloskar (TKAP), Bidadi, Karnataka
Application: Industrial Process Cooling
Cooling Tower Configuration: Counterflow Cooling Tower with Multi-EC Fans
Water Flow Rate: 410 CMH across a 4-cell cluster
Cooling Capacity: 4,067,800 kcal/hr
The Challenge
Toyota Kirloskar Auto Parts Pvt. Ltd., a Toyota-affiliated automotive component manufacturer based in Bidadi, Karnataka, required modernization of its existing cooling tower system. The existing installation consisted of a competitor crossflow cooling tower with an axial fan arrangement. To improve cooling performance, operational efficiency, accessibility, and long-term reliability, the existing system was replaced with a new-generation counterflow cooling tower equipped with Multi-EC fans. This project an important example of our ability to deliver reliable cooling solutions for demanding industrial applications.
The Solution
We designed and supplied a 4-cell counterflow cooling tower cluster with Multi-EC fan technology, delivering a water flow rate of 410 CMH and a total cooling capacity of 4,067,800 kcal/hr. The modernization was designed not merely as a replacement, but as an upgrade aimed at improving the overall performance, accessibility, and maintainability of the cooling system.
This project demonstrates how modernization of an existing cooling tower can go beyond simply replacing equipment. The successful implementation reinforces our commitment to delivering energy-efficient, durable, and maintainable cooling solutions tailored to the requirements of modern industrial facilities.
Multi-EC Fans for Reliable, Efficient Operation
We are the first in India to offer CTI-certified cooling towers with EC fan technology. One of the key upgrades was the replacement of the conventional axial fan arrangement with Multi-EC fans. The EC fans offer the advantage of continuous 24×7 operation, ensuring reliable performance with minimal risk of breakdown. With multiple fans working as an integrated system, the arrangement also provides operational flexibility and helps minimize the impact of an individual fan-related issue. The Multi-EC fans have been successfully installed as part of the upgraded cooling system, providing a modern and reliable fan solution for continuous industrial operation.
Improved Accessibility and Maintenance
To improve safety and ease of maintenance, handrails have been provided on all four sides of the cooling tower. This provides operators and maintenance personnel with convenient and safer access for routine inspection, operation, and maintenance activities. This improved accessibility can be particularly valuable in industrial installations where regular inspection and cleaning are essential for maintaining cooling performance over the long term.
Key Takeaways
The modernization delivered a significant upgrade to the existing cooling infrastructure:
• 410 CMH water flow rate across the 4-cell cluster.
• 4,067,800 kcal/hr total cooling capacity.
• Replacement of the existing crossflow tower with a counterflow configuration.
• Upgrade from conventional axial fans to Multi-EC fan technology.
• FRP pultruded air inlet louvers for corrosion resistance and durability.
• Handrails on all four sides for safer operation and maintenance
• Improved access to the fill area for inspection, cleaning, and maintenance.
