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Materials of Construction

Determining the appropriate material of construction for a project depends on several factors, including water quality, climate and environmental conditions, availability of time and manpower for maintenance, unit lifetime requirements, and budget. BAC provides the widest variety of material of construction options in the industry and has the ability to provide a solution to meet all conditions and budgets. Options such as the TriArmor® Corrosion Protection System and EVERTOUGH™ Construction provide superior corrosion resistance and durability at a tremendous value.

  • Standard Construction-G-235 mill galvanized steel is the heaviest commercially available galvanized steel, universally recognized for its strength and corrosion resistance. To assure long life, a G-235 mill galvanized steel frame with fiberglass reinforced polyester (FRP) casing panels and louvers is used as the standard material of construction. The structural integrity of the unit is provided by its strong steel frame. With proper maintenance and water treatment, G-235 galvanized steel and FRP will provide an excellent service life under the operating conditions normally encountered in refrigeration applications.
BFD Condenser Project 104

Standard Construction Installation

  • TriArmor® Corrosion Protection System (Option)-The TriArmor® Corrosion Protection System consists of heavy gauge G-235 mill galvanized steel panels fully encapsulated by a thermosetting hybrid polymer and further protected by a polyurethane barrier applied to all submerged surfaces of the cold water basin. The triple layers of protection form a completely seamless cold water basin for the most leak resistant and durable basin in the industry. Other components within the basin, such as the strainer and submerged structural supports, will be constructed of stainless steel. The TriArmor® Corrosion Protection System was specifically designed for evaporative cooling applications and released in 2006 after a decade of extensive R&D and field testing. To date, there are thousands of successful installations in North America. Every basin is leak tested at the factory and warranted against leaks and corrosion for five years.
TriArmorBasin

TriArmor® Corrosion Protection System Triple Layer Protection of the Basin

Application Application of TriArmor® Corrosion Protection System

Application Application of TriArmor® Corrosion Protection System

  • Evertough™ Construction (Option)-EVERTOUGH™ Construction combines the most corrosion resistant materials to provide the best value in corrosion protection for most water chemistries. EVERTOUGH™ Construction is backed by a comprehensive 5-year warranty which covers ALL components from the fan to the cold water basin, from louver to louver, including the motor (excluding the coil).
    • The following materials are used in EVERTOUGH™ Construction:
      • The basin is constructed with the TriArmor® Corrosion Protection System. The basin is leak tested at the factory and warranted against leaks and corrosion for 5 years.
      • Fiberglass reinforced polyester (FRP) casing panels are corrosion and UV resistant, ensuring long life.
      • Designated steel components above the basin are constructed of heavy-gauge G-235 mill galvanized steel and further protected with a thermosetting hybrid polymer. 
      • The distribution system is non-corrosive Schedule 40 PVC. 
      • Other components within the basin, such as the strainer and submerged structural supports, will be constructed of stainless steel.

        Standard FRP Panels

        Standard FRP Panels

  • Thermosetting Hybrid Polymer (Option)-A thermosetting hybrid polymer, used to extend equipment life, is applied to select G-235 mill galvanized steel components of the unit. The polymerized coating is baked onto the G-235 mill galvanized steel and creates a barrier to the already corrosion resistant galvanized steel. The thermosetting hybrid polymer has been tested to withstand 6,000 hours in a 5% salt spray without blistering, chipping, or losing adhesion.
Thermosetting Hybrid Polymer

Thermosetting Hybrid Polymer

  • Stainless Steel (Option)-Several stainless steel options are available.
  • Welded Stainless Steel Basin-A welded stainless steel basin is available. All steel panels and structural members of the basin are constructed from stainless steel. Seams between panels inside the basin are welded, providing an advantage over bolted stainless steel basins for minimizing susceptibility to leaks at basin seams. The basin is leak tested at the factory and welded seams are provided with a 5-year, leak-proof warranty.
Welded Stainless Steel Basin

Welded Stainless Steel Basin

  • All Stainless Steel Construction (Option)-All unit structural elements and the basin are constructed of stainless steel. Seams between panels inside the basin are welded, providing an extreme advantage over bolted basins for minimizing susceptibility to leaks at basin seams. The basin is leak tested at the factory and welded seams are provided with a 5-year, leak-proof warranty. Casing panels and air intake louvers are constructed of corrosion and UV-resistant fiberglass reinforced polyester (FRP).
  • Basinless Unit Construction (Option)-The basinless unit construction option enables CXVT Evaporative Condensers to be directly installed on new or existing basins.
    This custom feature reduces maintenance costs by eliminating the integral basin from traditional units. It simplifies piping and pumping requirements of multi-cell installations, eliminates concern for basin corrosion, and provides a cost-effective solution for many field-erected replacement projects. BAC is the only leading evaporative cooling equipment manufacturer to provide basinless construction for factory assembled equipment.

 

Basinless Unit Construction

  • Standard Fiberglass Reinforced Polyester (FRP) Casing Panels-Used with BAC’s durable steel frame construction, FRP casing panels offer a more durable corrosion resistant unit. FRP casing panels are a key component due to their corrosion resistant properties.
  • Steel Casing Panels and Louvers (Option)-Steel casing panels and louvers are available in G-235 mill galvanized steel, thermosetting hybrid polymer, and stainless steel.

Coil Configurations

BAC offers a large selection of coil configuration options to fulfill any thermal and pressure drop requirements.

  • Standard Serpentine Coil-The standard cooling coil is constructed of continuous lengths of all prime surface steel. The coil is hot-dip galvanized after fabrication (HDGAF) to apply a thick zinc corrosion barrier over the entire exterior surface of the coil. The coil is designed for low pressure drop with sloping tubes for free drainage of fluid. Each coil is pneumatically tested at 375 psig (2,586 kPa) and is fabricated per ASME B31.5 standards to ensure the highest quality and integrity.
Standard Coil Construction

Standard Coil Construction

  • Cleanable Header Coil (Option)-The cleanable header tube bundle provides removable cover plates on the intake and outlet header boxes to permit access to each serpentine tube circuit for solvent or air-pressure cleaning. Tubes are all prime surface steel tubing formed into a serpentine shape and welded into an assembly. Coil material options include carbon steel coils (hot-dip galvanized outside surface). Each coil is pneumatically tested at 125 psig (860 kPa).
  • Stainless Steel Coil (Option)-Coils are available in stainless steel for specialized applications. The coil is designed for low pressure drop with sloping tubes for free drainage of fluid. Each coil is pneumatically tested at 375 psig (2,586 kPa) and is fabricated per ASME B31.5 standards to ensure the highest quality and integrity.
  • Straight-Through Cleanable Coil (Option)-A header box with a removable cover plate at each end of the coil allows access to every tube end for mechanical cleaning or plugging. It is available in carbon steel (hot-dip galvanized inside and out). Each coil is pneumatically tested at 125 psig (860 kPa).
Straight-Through Cleanable Coil

Straight-Through Cleanable Coil

  • ASME U Designator Coil (Option)-BAC offers coils that are certified in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division I. ASME U designated coils are available for projects requiring ASME certified pressure vessels and involve 3rd party inspection and certification. Standard ASME U designated coils are rated at 340 psig (2,344 kPa) maximum allowable working pressure, and they
    are pneumatically tested at 375 psig (2,586 kPa).
  • Extended (Finned) Surface Coil (Option)-Coils are available with half or all rows finned at 5 fins per inch for seasonal wet/dry operation. The fins increase the surface area of the coil, therefore increasing the heat transfer capability. The coil is hot-dip galvanized after fabrication (HDGAF) to apply a thick zinc corrosion barrier over the entire exterior surface of the coil and fins. BAC coils are designed for low pressure drops and to be completely drainable with sloping tubes for free drainage of fluid. Each coil is pneumatically tested at 375 psig (2,586 kPa) and is fabricated per ASME B31.5 standards to ensure the highest quality and integrity.
  • Multiple Circuit Coils (Option)-Split coil configurations are available to allow separate process fluid loops through the same unit. Separate loops may be needed for multiple applications requiring different temperature processes or multiple types of process fluids.
Multiple Circuit Coils

Multiple Circuit Coils

Drive System Options

The fan drive system provides the cooling air necessary to reject unwanted heat from the system to the atmosphere. All BAC drive systems use premium efficient cooling tower duty motors and include BAC’s comprehensive 5-year motor and drive warranty. Cooling tower duty motors are specially designed for the harsh environment of a cooling tower and have permanently lubricated bearings, drastically decreasing the maintenance requirement of the motor. BAC belt drive systems are the most durable and maintenance friendly drive systems on the market, including single nut adjustment for belt tensioning to make belt tensioning simple.

  • Standard BALTIDRIVE® Power Train-The BALTIDRIVE® Power Train utilizes special corrosion resistant materials of construction and state-of-the-art technology to ensure ease of maintenance and reliable year-round performance. This BAC engineered drive system consists of a specially designed powerband and two cast aluminum sheaves located at minimal shaft centerline distances to maximize belt life. As compared to a gear drive system, this specially engineered belt drive system provides many advantages. The BALTIDRIVE® Power Train requires only periodic inspection of components and belt tensioning, which is simple with a single nut adjustment, and requires less downtime. Only fan bearing lubrication is required for routine maintenance. Belt drive systems also have the added advantage of being suitable for variable frequency drive (VFD) applications without requiring expensive optional accessories.
BALTIDRIVE® Power Train Fan System

BALTIDRIVE® Power Train Fan System

  • ENDURADRIVE™ Fan System (Option)-The ENDURADRIVE™ Fan System offers an energy efficient direct drive motor for large cooling tower applications. This system is designed to replace conventional gear drive designs and provides additional energy savings with the lowest maintenance, and highest reliability. Additionally this system comes with the industries best 7 year motor warranty and 5 year VFD (limited warranty).

ENDURADRIVE™ Fan System

ENDURADRIVE™ Fan System

  • BALTIGUARD™ Fan System (Option)
    The BALTIGUARD™ Fan System consists of two standard single-speed fan motor and drive assemblies. One drive assembly is sized for full speed and load, and the other is sized approximately 2/3 speed and consumes only 1/3 the design horsepower. This configuration provides the reserve capability of a standby motor in the event of failure. As a minimum, approximately 70% capacity will be available from the low horsepower motor, even on a design wet-bulb day. Controls and wiring are the same as those required for a two-speed, two-winding motor. Redundant motors are available by increasing the size of the standby fan motor of the BALTIGUARD™ Fan System to the size of the main motor. This provides 100% motor redundancy and the greatest level of reliability.
BALTIGUARD™ Fan System Used for VFD Applications

BALTIGUARD™ Fan System
Used for VFD Applications

  • BALTIGUARD PLUS™ Fan System (Option)-The BALTIGUARD PLUS™ Fan System builds on the advantages of the BALTIGUARD™ Fan System by adding a variable frequency drive (VFD) to either the pony or the main motor, depending on system requirements. This offers the benefits of additional capacity control and energy savings, along with the redundancy offered by the BALTIGUARD™ Fan System. Alternatively, a VFD can be added to both the pony and main motor for complete capacity control and redundancy under any load.
  • Gear Drive System, Close-Coupled Motor (Option)-A gear drive system is available. Both the gear drive and couplings are selected with a 2.0 service factor. Gear construction includes a nickel-alloy steel shaft, casehardened gears, self lubrication, and a single piece, gray iron housing. This drive system ships completely installed and aligned.
Extended Lubrication Lines with  Grease Fittings Located by the  Access Door

Extended Lubrication Lines with
Grease Fittings Located by the Access Door

  • Gear Drive System, Externally Mounted Motor (Option)-A gear drive system with a TEFC motor mounted outside the airstream is also available. A non-corrosive carbon-fiber composite drive shaft with stainless steel hubs is selected with a 2.0 service factor. The motor and drive shaft ship separately for easy field installation.

Cold Water Basin

The spray water collects in the cold water basin which is pumped back over the heat transfer coil. During operation, the FXV cold water basin helps eliminate any stagnant water zones, which are susceptible to biological growth.

  • Standard Mechanical Water Level Control-Mechanical make-up valves must operate continuously in the moist and turbulent environment existing within evaporative cooling equipment. Due to this environment, the operation of the valve must be simple, and the valve must be durable. BAC’s high quality mechanical water level control assembly is standard with all units, and has been specially designed to provide the most reliable operation while being easy to maintain. This accessory is omitted for remote sump applications.

    Mechanical Water Level Control

    Mechanical Water Level Control

  • Low and High Level Alarm Float Switches (Option)-Low and high level alarm float switches are available to provide added control to your equipment operation. Level alarms can alert operators to an abnormal operating condition to ensure the highest system efficiency with minimal water usage.

Water Distribution System

The FXV3 water distribution system is provided with BAC 360 Spray Nozzles. These nozzles are large orifice and non-clogging. The design of the FXV3 uses parallel air and water flow to allow for easy inspection and access to the top of the coil during full operation.

  • Standard Spray Water Pumps-The FXV3 comes standard with two integral spray water pumps sized to distribute the recirculating water over the coils maximizing capacity. The patented BAC 360 Spray Nozzles are non-clog, ensure even flow over the coil area, and are simple to remove for maintenance. Parallel flow of air and spray water over the coils allow for inspection and access to the top of the coils during full operation.

Standard Spray Water Pump

Fill

BACross® Fill, BAC’s patented crossflow hanging fill, was developed after years of extensive research. BACross® Fill is made of PVC and is optimized to provide the most efficient thermal capacity. PVC is virtually impervious to rot, decay, and biological attack. The fill is elevated above the cold water basin floor to facilitate cleaning and maintenance. The integral eliminators effectively strip entrained moisture from the leaving air stream with minimum pressure drop to prevent water loss with negligible impact on efficiency.

  • Standard Fill-Standard fill can be used in applications with spray water temperature up to 130°F (54.4°C). The fill and drift eliminators are formed from self-extinguishing PVC having a flame spread rating of 5 per ASTM E84.
BACross® Fill Manufacturing

BACross® Fill Manufacturing

Shipping and Rigging

BAC units are factory-assembled to ensure uniform quality with minimum field assembly. Each unit has been designed with rigging and assembly in mind and includes features to minimize the number of tools required and installation time.

  • Standard Rigging Guides-Rigging guides allow easy alignment and engagement of the coil sections, the fan (plenum) section, and lower section of units. The guides ensure proper placement of the coil sections to the fan section making rigging much simpler and reducing the time required.
Standard Rigging

Standard Rigging

  • Knockdown Units (Option)-Knockdown units are available for jobs where access to the cooling tower location is limited by elevators, doorways, or similar obstacles, where lifting methods impose very strict weight limits, or where the shipping cost of a fully assembled tower is excessive. All materials of construction and design features are the same as those of a factory assembled unit. Welded stainless steel cold water basins are excluded due to the need for in-plant assembly.

Sound Options

Recognition for the importance of sound reduction is growing and can be a very important design criterion for any project. BAC maintains the widest selection of sound mitigating options in the marketplace and can provide the most cost effective option to meet any requirement.

  • Standard Fan –The fan provided for all FXV3 Closed Circuit Cooling Towers is selected to optimize low sound levels and maximize thermal performance.
Standard Fan

Standard Fan

  • Low Sound Fan (Option)-The Low Sound Fan option reduces sound up to 9 dBA. Adding a high solidity fan decreases fan speeds, which proportionally decreases sound levels. The thermal performance with the Low Sound Fan has been certified in accordance with CTI Standard STD-201.
  • Sound Attenuation (Option)-Factory designed, tested, and rated sound attenuation options are available for both the air intake and discharge. Consult your local BAC Representative regarding available options.
Intake and Discharge Sound Attentuation

Intake and Discharge Sound Attenuation

Air  Discharge

  • PCD Hoods and Insulation (Option)-The innovative design of the FXV3 results in a low heat loss when the unit is idle. When additional heat loss prevention is desired, PCDs with stainless steel linkages and damper actuators can be provided. The motor actuators are easily accessible. The addition of factory mounted insulation to the hood and/or casing further reduces the heat loss by minimizing losses due to conduction. Per ASHRAE 90.1 -2010 either an automatic 3 way valve or PCDs are required on Closed Circuit Cooling Towers used on heat pump applications when used in heating applications.

PCD Hood and External Platform

Access Options

BAC provides a broad offering of access options. Our evaporative equipment is designed to be the most easily maintained for sustaining capacity over a longer life. All BAC platforms and ladders are OSHA compliant to ensure personnel safety and code compliance.

  • Motor Removal System (Option)-The removal system includes davit arm(s) to facilitate motor replacement.
  • External Platforms and Ladder Packages (Option)-Every external platform is preassembled and pre-fitted at the factory to ensure that every component will fit and function
    exactly as described. The platform will ship secured in the basin and attach quickly in the field with minimum fasteners. Safety gates are available for all handrail openings.

External Platform and Ladder Package

  • Access Door Platform and Ladder Packages (Option)-Access door platforms are available to access to the unit when installed on elevated supports. This allows for safe access to the unit, as well as a working platform to stage tools for maintenance.
  • Handrail Packages (Option)-Handrail packages are available to provide safe access to the top of the unit for maintenance to the distribution system. Fan deck extensions are available for passage around the fan on units designed with maximized fan diameters, or discharge sound attenuation. The specially designed handrail packages are secured for compact shipping in the cold water basin to minimize shipping costs and are ready for field assembly. Partial or full grating above the coil air intake is recommended with this option.
Handrail Package

Handrail Package

  • Internal Walkway (Option)-An internal walkway is available, allowing access to the spacious plenum area for maintenance and inspection of the cold water basin, make-up, fill, and drive system.
  • Internal Service Platform and Ladder Packages (Option) –For access to the motor and drive assemblies, an internal ladder and upper service platform with handrails is available on larger units. Safety gates are available for all handrail openings, and all components are designed to meet OSHA requirements. An internal walkway is required with this package.
External Motor Platform

External Motor Platform

Easy Access to the Coil

Easy Access to the Coil

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