RECORD OF REVISIONS

Date Revision Details Revision

Number

21.06.2012 Issued as Standard Specification 0

Contents
1. Purpose.............................................................................................................................1
2. Scope.................................................................................................................................1
3. Cost competitive engineering and design.........................................................................1
4. Conflicts and Deviations....................................................................................................1
5. Definitions:........................................................................................................................1
6. Abbreviations:...................................................................................................................1
7. Codes and Standards:.......................................................................................................2
8. Basic Design/Assembly/Methodology:.............................................................................2
9. Accessories:.......................................................................................................................6
10. Inspection and Testing:.....................................................................................................6
11. Preparation for shipment:.................................................................................................6
12. Vendor Data Requirement:...............................................................................................6
13. Attachments:.....................................................................................................................6
1. Purpose

This specification covers the minimum requirements for the design, material
selection, supply, fabrication, inspection, testing and painting of Cooling Towers.
2. Scope
2.1. The scope comprises of supply, installation, commissioning and providing
necessary services whenever required.
2.2. The Seller’s scope of supply shall include and not be limited to all the
items/facilities required for Cooling Towers designed to meet the requirements
specified in the data sheets and this specification
3. Cost competitive engineering and design
The equipment / system selection should be done based on life cycle cost. This
should be done without compromising any specification and design requirements.
4. Conflicts and Deviations
Any conflict between any requirements specified in this document and
requirements of any other relevant referenced document shall be resolved in the
following order of preference:
Statutory Regulations.
Data sheet
Sec.1. scope of supply & Sec.2. - Additional Requirement of MR.
Referred codes and standards.
Other referenced specifications.
The seller of any equipment shall bring any conflict or deviation to the notice of
the buyer or owner in writing and obtain a resolution in writing during the
quotation stage.

5. Definitions:
Buyer: means the engineering consultant or the buyer
Seller: means the material & services Seller as per this specification

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6. Abbreviations:
FRP: Fibreglass Reinforced Plastic
GRP: Glass Reinforced Plastic
HDG: Hot Dipped Galvanised
DFT: Dry Film Thickness
PVC: Poly Vinyl Chloride
TDS: Total Dissolved Salts
ISO : International Organisation for Standardization
HSE : Health Safety and Environment
7. Codes and Standards:
The latest edition of the following codes and standards shall be complied:
ASME B16.5 – 1996 Ed Flange connections.
AGMA American Gear Manufacturers associations.
CTI 111 Specification for gear speed reducers
ATP 105 Acceptance Test Procedure
IS Latest standard for FRP, PP nozzles & PVC
8. Basic Design/Assembly/Methodology:
The cooling tower shall be mechanical induced draft, counter flow type. The
cooling tower shall be designed to cool not less than the design flow rate of water
from the specified inlet temperature to outlet temperature at the designed
ambient wet bulb temperature. The cooling towers shall be designed in such a
way that 15 % additional water flow rate can be cooled to the desired outlet
temperature, if required.
8.1. STRUCTURE
The main structure or framework of the cooling tower shall be FRP. The members
of main framework/ structure shall be suitably designed and braced by horizontal
and diagonal members to withstand loads of all tower components, wind load,
loads due to earthquake etc. and transmit them to the cooling tower foundation.
The horizontal and diagonal bracings shall also aid in providing a rigid platform for
the mechanical equipment while minimizing obstruction to airflow.

EPCMD-1-SS-HV-008 Page 2 of 6
 Casing of the cooling tower shall be of UV protected FRP/GRP of adequate
thickness.
8.2. DESIGN
The design of cooling tower should aim at having improved contact time between
air and water, larger fill surface, better water distribution over the fill and larger
number of smaller water droplets in order to have an efficient cooling tower at
reduced cost. Vendor to furnish details of fill.
Air inlet shall be through HDG metal mesh, which shall be suitably designed,
supported and arranged so as to offer minimum restriction to airflow for air
intake. This shall also avoid the water splashing out of basin. Vendor may offer
alternate design with FRP/GRP louvers if applicable.
Vendor shall recommend inter cell distance requirement if any to achieve free air
intake and to avoid recirculation of air.
All mechanical components of cooling tower such as fan, gear reducer, drive shaft
and electric motor shall be designed to withstand the humid and corrosive
atmosphere in which they will operate. All carbon steel components which are
not galvanized shall be painted with 2 coats of primer followed by two coats of
epoxy paint 150 microns thickness DFT.
8.3. FILLS
The fill shall be film type with rigid PVC honeycomb structure supported on
GRP/FRP/HDG steel grids. The fill design should allow minimum clogging and easy
cleaning. It should have maximum heat transfer surface with minimum pressure
drop and pump head.
8.4. FAN STACK
Fan deck shall be of FRP/ GRP. Fan stack cylinder shall be eased inlet type and
made of FRP/GRP. The stack shall be designed to achieve optimum fan efficiency
with static pressure recovery and minimum tip clearance. Fan guard of HDG wire
mesh of suitable gauge reinforced with steel angle. A velocity pressure recovery
fan stack with flared end shall be provided to reduce power consumption.
8.5. DRIFT ELIMINATORS & BASIN
The drift eliminators shall be designed to limit the drift losses to a value not
greater than 0.2 % of the design water circulation rate.
Vendor shall provide FRP/GRP basin below the Fills. Vendor to provide make up
connection with float valve, over flow, drain and provision for equalizer in case of
multiple towers.
EPCMD-1-SS-HV-008 Page 3 of 6
 The basin shall be equipped with metering orifice-type polypropylene nozzles to
deliver incoming water by gravity to the fill. Nozzles shall be easily removable and
replaceable.
8.6. FAN
Cooling tower fan shall be axial flow, multi-blade type / propeller type. Each blade
shall be adjustable for angle or pitch and individually fastened to a common hub.
Fan blades shall be in cast aluminium / GRP construction and hub of cast iron /
HDG steel. Fan shall be designed as aerofoil section.
Fan drive shaft shall be of HDG for outdoor operation in highly humid
atmosphere. Coupling bolts shall be galvanized steel. All moving parts of the fan
and motor assembly shall be properly guarded for prevention of accidents.
The drive motor assembly shall be statically balanced. The drive shaft however
shall be dynamically balanced as well. Coupling guard shall be of aluminium / HDG
steel.
The motor and reduction gear shall be supported on a single hot dip galvanized
structural steel frame with all necessary bracing to prevent deflection,
misalignment and excessive vibration. The reduction gear and the motor shall be
accurately aligned on the support and securely bolted to it with SS bolts, nuts,
split washers and steel washers.
Fan shall be driven through right angle speed reduction unit (high efficiency spiral
and helical bevel gearbox) especially designed for humid, corrosive and high
(ambient) temperature cooling tower service. Speed reducing gear shall be very
heavy duty, oil lubricating type. It shall conform to applicable AGMA standards.
Lubrication, oil drain pipe and fill pipe shall be brought out of the air stream. The
gearbox enclosure shall be totally enclosed weatherproof design and should have
ribs for rigidity and heat dissipation. The gearbox shall have an oil level sight glass
at an accessible location outside the cell or fan stack. A low oil level switches to be
provided for each gearbox.
The drive motor for fan shall be “2 speed” type for energy saving during winter. It
shall be mounted outside the air stream and the kw rating shall have at least 15 %
margin over maximum fan power consumption. Fan motor shall be suitable for
cold start at 10 deg C. Vendor shall indicate speeds and power consumption for
both conditions.
One vibration switch with adjustment for sensitivity shall be provided for fan.
Same shall be mounted on the fan motor / gear reducer supports outside the fan
deck. Maximum allowable limit of vibration shall be furnished by vendor in their
offer.
EPCMD-1-SS-HV-008 Page 4 of 6
 Potential free contacts to give trip signal in purchaser’s PB station due to excess
vibration / low oil level shall be provided by vendor. Two earthing points for
connecting GI strip for motor shall be also provided by vendor.
8.7. PAINTING
Surfaces to be painted shall be thoroughly cleaned with suitable solvent for oil,
grease removal and sand blasted giving a clear dry and rust free surfaces. Two
coats of suitable primer of 35 micron DFT each shall be applied prior to applying
two coats of final epoxy paint totalling 150 micron DFT on all CS parts. The shade
shall be as per vendor’s standard practice. If any specific requirement of shade
from client, same will be intimated during evaluation.
All external un-machined surfaces shall be prepared and painted as specified prior
to dispatch to site. Machined surfaces shall be covered with grease or removable
varnish to inhibit the formation of rust during transport.
8.8. GENERAL
All bolts, nuts and washers shall be HDG steel/SS304. All carbon steel components
shall be HDG after fabrication.
MS HDG cage ladder of at least 750 mm width shall be provided for access from
terrace level to top of deck.
Vendor shall be fully responsible for the complete and satisfactory supply and
errection of all portions of cooling tower. Accordingly vendor shall arrange for the
following things to complete the job;
All tools and tackles.
All labour.
All hoisting equipments.
All necessary scaffolding.
All necessary transporting equipments.
Testing and commissioning equipment.
Site fabrication work shall be carried out with all safety precautions. Vendors shall
arrange their own safety equipment.
8.9. ENVIRONMENTAL CONCERNS

EPCMD-1-SS-HV-008 Page 5 of 6
 Water falling through the tower shall remain in the tower and not be allowed to
splash or be blown onto the adjacent area. This applies to all phases of operation
including fans on/off and varying wind direction. Basin width may need to be
extended to meet this requirement.
Make up water to the towers shall be treated water or a mixture of this water and
treated wastewater. Cycles of water concentration in the tower shall be between
5 and 6. Vendor shall advise any water quality limitations that may affect the
design such as system pH, TDS, free chlorine residual, etc.
8.10. PERFORMANCE GUARANTEE
Vendor shall guarantee parameters for cooling tower pumps for cooling
temperature, flow rate & power consumption.
9. Accessories:
All standard accessories are already included in the chiller specification and
requirements.
10. Inspection and Testing:
All materials, components and workmanship shall be subject to inspection by the
purchaser.
Vendor shall guarantee the tower to meet the specified performance conditions
when tested in accordance with CTI acceptance test procedure ATP-105.

11. Preparation for shipment:

All the imported Material/System should be supplied in seaworthy packing and
local material as per the relevant standard specified in order.
12. Vendor Data Requirement:
12.1. Vendor shall submit for approval and record all documents in required number
and form.
Vendor shall submit the GA drawing of cooling tower with the foundation details
for mounting.
Vendor shall furnish performance curves for 50, 75, 100 and 115 % of design rate
with variations in range and wet bulb temperatures above and below the design
values, in accordance with CTI, ATP-105.

EPCMD-1-SS-HV-008 Page 6 of 6
12.2. Following documents shall be submitted along with the bid :
12.2.1. Filled in data sheets as per format given with Material Requisition
12.2.2. General arrangements drawing showing approximate area.
12.2.3. Any non-compliance with material requisition and attached specifications
12.2.4. Quality assurance / ISO related documents
12.2.5. HSE policy documents
12.2.6. All documents specified as per Material requisition attachments shall be
submitted after award.
13. Attachments:
NIL

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