and fans, and direct connection to city water supplies for makeup water to keep the system filled and provide emer- gency water in case of equipment or power failures. Tis was not the case at Chassix, which wanted the
new cooling tower and pumps installed adjacent to the old tower that was being taken out of service. Tis allowed an easy connection to the existing plant cooling water piping, electrical network and control interface, but it posed a challenge. “Te installation site was a tiny space adjacent to the old cooling tower and hemmed in by that tower and by the scrap yard with its rail spur,” explained Mark Foster, site supervisor, EMSCO. “Te only access was by a narrow alleyway. Another obstacle was a drainage culvert that ran through the only spot where the new cooling tower could be placed.” Because the old cooling system had to be completely
shut down before the new system could be connected, a full plant shutdown was required. Tat shutdown had to be as brief as possible to minimize its effect on casting pro- duction. Installation was scheduled for a holiday weekend. To meet the space and time challenges, every step of
the installation process was carefully planned. Rail tracks were removed, and footings for the cooling tower were placed to avoid the drainage culvert. To simplify handling and speed assembly at the Chassix site, the three pumps were delivered and moved as modular units complete with their own piping and electrical connections. And for the assembly work at the site, a just-in-time delivery schedule was set up, and equipment lay-down and staging locations were cleared and prepared. Special compact material han- dling equipment was used to move everything as needed in the small working space. When it was time to shut down the old cooling system and the entire metalcasting opera- tion, all that remained to be done was to make the new connections to the plant pipes, power and controls. Te project was completed on time and within budget.
According to Roop, the new cooling system continues to work flawlessly. “It does what we were told it would do,” he said. “Te new system has the capacity we need and the water is staying cooler,” said James. “We have not had to shut down due to water over temperature. We can run all of our equipment all of the time, even in summer. Produc- tion is no longer impacted by cooling problems.” As melt maintenance supervisor, Shawn J. Murray is
responsible for keeping everything running, including the cooling system. “With the old cooling system, we could not run all the furnaces at once,” he said. “And we still were having 50 to 60 high temp alarms per day. Now, with the new cooling system, we can run everything all the time. It has greatly reduced furnace trips and completely eliminated the need to shut down due to a lack of water at the right temperature. With the new cooling system, I can keep our furnace temperatures under control and all of our equipment running.” ■
Tis article is based on a paper (14-030) presented at the 2014 Metalcasting Congress.
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION September 2014
并不是Chassix公司才有这种情况，想把新的冷却 塔和水泵毗邻安装在即将淘汰的旧塔旁。这样可以方 便的连接到现有厂房的冷却水管道、电网和控制接 口，但也提出了挑战。
“毗邻旧冷却塔的安装地点是个狭小的空间，并且 旧塔周围环绕着废料场与铁路支线，”EMSCO 公司 现场监理Mark Foster解释说，“唯一的通道是条狭 窄的小巷。另一个障碍是排水涵洞，恰好通过新冷却 塔可以唯一放置的地方。”
因为新的系统接入之前，旧冷却系统必须完全关 闭，必须要求全厂停产。由于停产时间必须尽可能的 短，以减少对铸造生产的影响。安装工作安排在周末 假期。
为了应对空间和时间的挑战，安装过程中的每一步 都经过周密策划。移开铁轨，使冷却塔支撑架的位置 避开了排水涵洞。为了简化在Chassix公司现场的操 作和提高组装的速度，3台泵在运输和交付时已完成 自身的管道和电气连接的模块化配置。在现场的组装 工作，按原定的时间表及时完成，设备的卸下，分批 就位清晰有序。在狭小的空间内，使用特殊器具固定 设备。当关闭旧的冷却系统和全部铸造作业的时间来 临，所要做的工作就是把新系统接入设备管网、电源 和控制柜。
项目在预计的时间和预算范围完成。据Roop介 绍，新的冷却系统运行得很好，“这确实与我们所预 期的一样”。
“新系统符合我们所要求的性能而且循环水持续冷
却，”James说，“我们还没遇到因水温度过高而跳 闸的情况。我们甚至能在整个夏季运行所有的设备。 生产不再因冷却的问题而受影响。
据负责熔炼车间所有设备包括冷却塔维护的维修主 管Shawn J. Murray介绍。“使用旧的冷却系统时， 我们不能同时运行所有的炉子，”他说，“每天仍然 有50〜60次的高温警报。现在，随着新冷却系统投 入使用，我们可以全天候的运行所有设备。这极大地 减少了炉体故障而且完全消除了因水温过高而导致的 停机。新的冷却系统能让炉体水温受控，并且保持所 有设备正常运行。” ■
本文摘自发表于2014年铸造大会上的一篇论文（14-030 ）。
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