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Overview · Model Selection · Engineering Data · Layout Data · Sound Data Specifications · Operation and Maintenance · Rigging and Assembly Downloads: Brochures · Product Reports · Project Reports · CAD Drawings Engineering Specifications for Series 3000 Cooling Towers Detailed Series 3000 Specification formatted for word processor use 1.0 Cooling Tower 1.1 General: Furnish and install _____ factory-assembled, induced draft, crossflow cooling tower(s) with vertical air discharge, conforming in all aspects to the specifications, schedules and as shown on the plans. Overall dimensions shall not exceed approximately _____ ft (mm) long X ______ ft (mm) wide X _____ ft (mm) high. The total connected fan horsepower shall not exceed _____ HP (kW). The cooling tower(s) shall be Baltimore Aircoil Company Model _______. 1.2 Thermal Capacity: The cooling tower(s) shall be warranted by the manufacturer to cool _____ USGPM (lps) of water from ______ ºF(°C) to _____ ºF(°C) at _____ ºF(°C) entering wet bulb temperature. Additionally, the thermal performance shall be certified by the Cooling Technology Institute in accordance with CTI Certification Standard STD-201. Lacking such certification, a field acceptance test shall be conducted within the warranty period in accordance with CTI Acceptance Test Code ATC-105, by the Cooling Technology Institute or other qualified independent third party testing agency. Manufacturers’ performance guarantees or performance bonds without CTI Certification or independent field thermal performance test shall not be accepted. The cooling tower(s) shall comply with the energy efficiency requirements of ASHRAE Standard 90.1. 1.3 Corrosion Resistant Construction (standard): Unless otherwise noted in this specification, all steel basin panels and structural members shall be constructed of heavy-gauge G-235 (Z700 metric) hot-dip galvanized steel with all edges given a protective coating of zinc-rich compound. (Alternate) 1.3 unless otherwise noted in this specification, all steel panels and structural members shall be protected with a thermosetting hybrid polymer. The system shall consist of G-235 (Z700 metric) hot-dip galvanized steel prepared in a four-step (clean, pre-treat, rinse, dry) process with an electrostatically sprayed, thermosetting, hybrid polymer fuse-bonded to the substrate during a thermally activated curing stage and monitored by a 23-step quality assurance program. Other coatings must be submitted to the engineer for pre-approval. Approved equals must have undergone testing, resulting in the following results as a minimum:
Type 304 stainless steel shall be considered an acceptable alternative. Uncoated G-235 galvanized steel shall not be considered an acceptable alternative. (Alternate) 1.3 EVERTOUGH™ Construction: All steel panels and structural members shall be protected with a thermosetting hybrid polymer. In addition, the cold water basin shall be protected with the TriArmor™ Corrosion Protection System. The system shall consist of G-235 galvanized steel encapsulated with a thermosetting hybrid polymer further protected by a polyurethane barrier applied to all submerged surfaces exposed to circulating system water. The polyurethane barrier shall seal all factory seams in the cold water basin to ensure a corrosion resistant and water tight construction, and shall be warranted against leaks and corrosion for five (5) years. Standard basin accessories shall include: a brass make-up valve with large diameter polystyrene filled plastic float for easy adjustment of the operating water level, removable anti-vortexing device to prevent air entrainment, and large area lift out strainers with perforated openings sized smaller than the water distribution system nozzles. The strainer and anti-vortexing device shall be constructed from type 304 stainless steel to prevent corrosion. A welded type 316 stainless steel basin shall be an acceptable alternative; provided the basin is warranted against leaks and corrosion for a period of at least 5 years. A bolted Series 300 basin shall not be an acceptable alternative. The hot water basins shall be constructed of UV and corrosion resistant pultruded fiberglass reinforced polyester (PFRP) with type 304 stainless steel covers. A welded type 304 or 316 stainless steel basin shall be an acceptable alternative. The entire cooling tower, including fan motor, drive system, bearings, and structure, shall be backed by a comprehensive Louver-to-LouverSM Five-Year warranty. (Alternate) 1.3 JE PREMIER SERIES® Construction: All steel panels and structural members, including the structural frame, hot and cold water basins, distribution covers, fan deck and fan cylinder shall be constructed of type 304 stainless steel and assembled with type 304 stainless steel nut and bolt fasteners. All factory seams in the cold water basin shall be welded to ensure watertight assembly and welded seams shall be warranted against leaks for five (5) years. Stainless steel basins with bolted seams are not acceptable. The entire cooling tower, including fan motor, drive system, bearings, and structure, shall be backed by a comprehensive Louver-to-LouverSM Five-Year warranty. 1.4 Quality Assurance: The cooling tower manufacturer shall have a Management System certified by an accredited registrar as complying with the requirements of ISO9001:2000 to ensure consistent quality of products and services. Manufacturers that are not ISO9001 Certified shall not be acceptable. 1.5 Wind and Seismic Forces: When supported as recommended, the unit shall be suitable for applications requiring equipment anchorage to resist wind loads up to 30 psf (146.6 kg/m2) acting on the full vertical projected area with 16 psf (78.1kg/m2) acting simultaneously on the full horizontal weight acting in the horizontal direction, and 24% of the operating weight acting in the vertical direction applied at the center of gravity. Loads are appropriate for Seismic Zone 4 assuming an Importance Factor of 1.0, and soil profile SD, and rigid mounting to the supporting structure per the 1997 Uniform Building Code. 2.0 Construction Details 2.1 Structure: The cooling tower shall be constructed with a sturdy structural frame designed to transmit all wind, seismic and mechanical loads to the equipment anchorage. The frame shall be constructed of heavy-gauge steel angles and channels. 2.2 Casing Panels: Casing panels shall be constructed of corrosion and UV-resistant
fiberglass reinforced polyester (FRP) to minimize maintenance requirements
and prolong equipment life. Casing panels shall not provide structural support,
since the sturdy, structural frame of the tower accurately transfers all loads
to the equipment anchorage. (Alternate) 2.2 Casing Panels: Casing panels shall be constructed of galvanized steel protected with a thermosetting hybrid polymer. Corrosion resistant type 304 stainless steel casing panels are an acceptable alternative. (Alternate) 2.2 FM approval (Multi-cell): The cooling towers shall be constructed with galvanized steel casing panels and louvers that shall meet the requirements of FM. (Alternate) 2.2 FM Approval (Multi-cell): The cooling towers shall be constructed with type 304 stainless steel casing panels and louvers that shall meet the requirements of FM. 2.3 Cold Water Basin: The cold water basin shall be constructed of heavy-gauge steel panels and structural members. Basin shall include a depressed center section with drain/clean-out connection. The basin area under the fill shall be sloped toward the depressed center section to facilitate cleaning. Standard basin accessories shall include a brass make-up valve with large diameter plastic float for easy adjustment of the operating water level. (Alternate) 2.3 Cold Water
Basin: Protected with TriArmor™ Corrosion
Protection System: The cold water basin shall be protected with the TriArmor™ Corrosion
Protection System. The system shall consist of G-235 galvanized steel encapsulated
with a thermosetting hybrid polymer further protected by a polyurethane liner
factory applied to all submerged surfaces. The polyurethane barrier shall seal
all factory seams in the cold water basin to ensure a corrosion resistant and
water tight construction, and shall be warranted against leaks and corrosion
for five (5) years. Field applied polyurethane or polyurethane applied directly
to galvanized steel is not an acceptable alternative. (Alternate) 2.3 Cold Water Basin: The cold water basin shall be constructed of heavy-gauge type 304 stainless steel panels and structural members. All factory seams shall be welded to ensure watertight construction and welded seams shall be warranted against leaks for a period of five (5) years from date of shipment. Stainless steel basins with bolted seams are not acceptable. Basin shall include a depressed center section with drain/clean-out connection. The basin area under the fill shall be sloped toward the depressed center section to facilitate cleaning. Standard basin accessories shall include a brass make-up valve with large diameter plastic float for easy adjustment of the operating water level. (Alternate) 2.3 Cold Water Basin: The unit shall be provided without an integral cold water basin. The unit shall be mounted on a separate concrete cold water basin provided by others, to allow cooling water to pass directly from the fill into the basin. 2.4 Water Outlet: The water outlet connection shall be beveled for welding and grooved for mechanical coupling or bolt hole circle designed to accept an ASME Class 150 flat face flange. The outlet shall be provided with large-area lift out strainers with perforated openings sized smaller than the water distribution nozzles and an anti-vortexing device to prevent air entrainment. The strainer and vortex device shall be constructed of the same materials as the cold water basin to prevent dissimilar metal corrosion. 2.5 Water Distribution System: The hot water distribution basins shall be the open gravity type for easy cleaning, and constructed of heavy-gauge, G-235 (Z700) hot-dip galvanized steel. The basins must be accessible from outside the unit and serviceable during tower operation. Basin weirs and plastic metering orifices shall be provided to assure even distribution of the water over the fill. Lift-off distribution covers shall be constructed of heavy-gauge G-235 (Z700) hot-dip galvanized steel and designed to withstand a 50 psf (244 kg/m2) live load or 200 pound (90.7 kg) concentrated load. Gravity flow nozzles shall be snap-in type for easy removal. Should pressurized nozzles be used, they shall utilize grommets, which ensure easy removal. (Alternate) 2.5 Water Distribution System: The hot water distribution basins shall be open gravity type for easy cleaning, and constructed of pultruded fiberglass reinforced polyester (PFRP) or type 304 or 316 stainless steel. The basins must be accessible from outside the unit and serviceable during tower operation. Basin weirs and plastic metering devices shall be provided to assure the even distribution of water over the fill. Lift-off distribution covers shall be constructed of heavy-gauge type 304 stainless steel and designed to withstand 50 psf (244 kg/m2) live load or a 200 pound (90.7 kg) concentrated load. Gravity flow nozzles shall be snap-in type for easy removal. Should pressurized nozzles be used, they shall utilize grommets, which ensure easy removal. 2.6 EASY CONNECT® Piping Arrangement (optional): Each tower cell shall be furnished with a single water inlet connection complete with the means to automatically balance flow rates to the hot water basins. 3.0 Mechanical Equipment 3.1 Fan(s): Fan(s) shall be heavy-duty, axial flow with aluminum alloy blades selected to provide optimum cooling tower thermal performance with minimal sound levels. Air shall discharge through a fan cylinder designed for streamlined air entry and minimum tip clearance for maximum fan efficiency. The top of the fan cylinder shall be equipped with a conical, non-sagging removable fan guard. 3.2 Bearings: Fan(s) and shaft(s) shall be supported by heavy-duty, self-aligning, grease-packed ball bearings with moisture proof seals and integral slinger collars, designed for a minimum L10 life of 80,000 hours. 3.3 Fan Drive: The fan(s) shall be driven by a one-piece, multi-groove, solid back V- type powerband with taper lock sheaves designed for 150% of the motor nameplate horsepower. The powerband shall be constructed of neoprene reinforced polyester cord and be specifically designed for cooling tower service. 3.4 Sheaves: Fan and motor sheave(s) shall be fabricated from corrosion-resistant materials to minimize maintenance and ensure maximum drive and powerband operating life. (Alternate 3.2, 3.3 & 3.4)
Fan Drive: Fan(s) are driven by a (Close-Coupled (internal) TEAO fan motor
gear drive) (gear drive with the TEFC fan motor mounted outside the airstream).
The gear shall be a right angle, industrial duty, oil-lubricated, geared
speed reducer. Spiral bevel or spiral bevel/helical gears are designed in
accordance with the 3.5 Fan Motor: Fan motor(s) shall be totally enclosed air over (TEAO), reversible, squirrel cage, ball bearing type designed specifically for cooling tower service. The motor shall be furnished with special moisture protection on windings, shafts and bearings and labeled appropriately for cooling tower duty. (Alternate) 3.5 Fan Motor: Fan motor(s) shall be totally enclosed air over (TEAO), reversible, squirrel cage, ball bearing type designed specifically for cooling tower service. The motor shall be furnished with special moisture protection on windings, shafts and bearings and labeled appropriately for cooling tower duty. Fan motors shall be inverter duty type designed per NEMA Standard MG1, Section IV, Part 31. (Alternate) 3.5 Fan Motor: Fan motor(s) shall be totally enclosed fan cooled (TEFC) and mounted outside the airstream. (Alternate) 3.5 Fan Motor: Fan motor(s) shall be totally enclosed fan cooled (TEFC) and mounted outside the airstream. Fan motors shall be inverter duty type designed per NEMA Standard MG1, Section IV, Part 31. 3.6 Mechanical Equipment Warranty: The fan(s), fan shaft(s), sheaves, bearings, mechanical equipment support and fan motor shall be warranted against defects in materials and workmanship for a period of five (5) years from date of shipment. 3.7 ENERGY-MISER® Fan System (optional): Two single speed fan motors, one sized for full speed and load, the other sized for 2/3 speed and approximately 1/3 the full load horsepower shall be provided in each cell for capacity control and stand-by protection from drive or motor failure. Two-speed motor(s) are not an acceptable alternative. 3.8 BALTIGUARD PLUS™ Fan System: Two single speed fan motors, one sized for load, the other sized for 1/3 of the full load horsepower shall be provided in each cell for capacity control and standby protection from drive or motor failure. The manufacturer of the equipment shall supply controls for the larger motor, a VFD for the smaller motor and factory programmed logic controller to maximize energy saving for off peak load and wet-bulb conditions. 4.0 Fill and Drift Eliminators 4.1 Fill and Drift Eliminators: The fill and integral drift eliminators shall be formed from self-extinguishing (per ASTM-568) polyvinyl chloride (PVC) having a flame spread rating of 5 per ASTM E84 and shall be impervious to rot, decay, fungus and biological attack. The fill shall be suitable for entering water temperatures up to and including 130°F (54.4°C). The fill shall be manufactured, tested and rated by the cooling tower manufacturer and shall be elevated above the cold water floor to facilitate cleaning. Spacing between fill sheets shall be a minimum of 3/4 inches (19.1 mm) to reduce the tendency for fouling and ensure proper airflow for maximum cooling capacity. (Alternate) 4.1 Fill and Drift Eliminators: The high temperature fill and integral drift eliminators shall be formed from self extinguishing (per ASTM-568) polyvinyl chloride (PVC) having a flame spread rating of 5 per ASTM E84 and shall be impervious to rot, decay, fungus and biological attack. The high temperature fill shall be suitable for entering water temperatures up to and including 140°F (60.0°C). The fill shall be manufactured, tested and rated by the cooling tower manufacturer and shall be elevated above the cold water floor to facilitate cleaning. Spacing between fill sheets shall be a minimum of 3/4 inches (19.1 mm) to reduce the tendency for fouling and scaling, and to ensure proper airflow for maximum cooling capacity. 5.0 Air Inlet Louvers 5.1 Air Inlet Louvers: Air Inlet louvers shall be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers shall prevent water splash out during fan cycling and be constructed of maintenance free, corrosion and UV resistant, fiberglass reinforced polyester (FRP). (Alternate) 5.1 Air Inlet Louvers: Air inlet louvers shall be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers shall prevent water splash out during fan cycling and be constructed of galvanized steel. (Alternate) 5.1 Air Inlet Louvers: Air inlet louvers shall be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers shall prevent water splash out during fan cycling and be constructed of galvanized steel protected a thermosetting hybrid polymer. Corrosion resistant type 304 stainless steel is an acceptable alternative. (Alternate) 5.1 Air Inlet Louvers: Air inlet louvers shall be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers shall prevent water splash out during fan cycling and be constructed of corrosion resistant type 304 stainless steel. 6.0 Access 6.1 Plenum Access: Two hinged access doors shall be provided for access into the plenum section. 7.0 Sound 7.1 Sound Level: To maintain the quality of the local environment, the maximum sound pressure levels (dB) measured 50 ft (15240 mm) from the cooling tower operating at full fan speed shall not exceed the sound levels detailed below. If the tower exceeds these conditions the tower must be either oversized and reduced in horsepower, provided with a low sound fan, or provided with sound attenuation. 8.0 Accessories 8.1 Balancing Valves: Heavy-duty butterfly valves shall be provided at the hot water inlet connections. These valves shall include cast iron bodies, elastomer seat and steel operating stems. There shall be a locking handle to maintain the valve setting in any position. Wafer type field supplied spool piece is required between the inlet connection and the valve. 8.2 Basin Heater(s): The cooling tower cold water basin shall be provided with electric heater(s) to prevent freezing in low ambient conditions. The heater(s) shall be selected to maintain 40°F (4.44°C) basin water temperatures at _____°F (°C) ambient. The heater(s) shall be ______ V /____ phase/ ___Hz electric and shall be provided with low water cutout and thermostat. (Alternate) 8.2 Basin Heaters: A steam coil shall be factory installed in the depressed section of the cold water basin to prevent freezing during cold water shutdown. The steam coil shall be capable of maintaining 40°F (4.44°C) basin water temperature at a –20°F (-28.89°C) ambient temperature given 5 psig (34 Kpa) at the coil inlet connection. (Alternate) 8.2 Basin Heaters: A steam injector shall be factory installed in the cold water basin section to prevent freezing during cold water shutdown. Steam injector shall be capable of maintaining 40°F (4.44°C) basin water temperature at a ___°F (°C) ambient temperature given 10 psig (68 Kpa) at the inlet connection. 8.3 Basin Water Level Control: The cooling tower manufacturer shall provide an electric water level control (EWLC) system. The system shall consist of water level sensing and control units in quantities and locations as indicated on the drawings. Each water level sensing and control unit shall consist of the following: NEMA 4 enclosure with gasketed access cover; solid state controls including all necessary relays and contacts to achieve the specified sequence of operation; stainless steel water level sensing electrodes with brass holder; Schedule 40 PVC standpipe assembly with vent holes, and all necessary stainless steel mounting hardware. Provide PVC union directly below the control enclosure to facilitate the removal and access of electrodes and control enclosure. The number and position of water level sensing electrodes shall be provided to sense the following: high water level, low water level, high water alarm level, low water alarm level, and heater safety cutout. 8.4 Vibration Cutout Switch: Provide a mechanical local reset vibration switch. The mechanical vibration cutout switch will be guaranteed to trip at a point so as not to cause damage to the cooling tower. To ensure this, the trip point will be set in a frequency range of 0 to 3,600 RPM and a trip point of 0.2 to 2.0 g’s. (Alternate) 8.4 Vibration Cutout Switch: Provide an electronic remote reset vibration switch with contact for BAS monitoring. Wiring shall be by the installing contractor. The electronic vibration cutout switch shall be set to trip at a point so as not to cause damage to the cooling tower. To ensure this, the trip point will be set in a frequency range of 2 to 1000 Hertz and a trip point of 0.45 in/sec (0.0114 m/sec). 8.5 Basin Sweeper Piping: The cold water basin of the cooling tower shall be equipped with PVC sump sweeper piping with plastic eductor nozzles. 8.6 Air intake Option: Provide removable hot dip galvanized steel 1"x1" (25.4 mm x 25.4 mm) mesh air intake screens. (Alternate) 8.6 Air intake Option: Provide removable type 304 stainless steel 1"x1" (25.4 mm x 25.4 mm) mesh air intake screens. (Alternate) 8.6 Air intake Option: Provide removable UV and corrosion resistant PVC air intake screens. The screens shall shield the air inlet from sunlight. Type 304 stainless steel mesh screens are an acceptable alternative. 8.7 Ladder: An aluminum ladder (with galvanized steel safety cage) shall be provided for access to the fan deck. Access door or service platforms are not acceptable. 8.8 Handrails: 1-1/4" (31.75 mm) galvanized steel pipe handrail shall be provided around the perimeter of the cooling tower cells. The handrails shall be provided with knee and toe rails and shall conform to the requirements of OSHA applicable at the time of shipment. 8.9 Access Door Platform: A galvanized steel platform and aluminum ladder to grade shall be provided at all access doors to access the plenum section of the cooling tower. All working surfaces shall be able to withstand 50 psf (244 kg/m2) live load or 200 pound (90.72 kg) concentrated load. 8.10 Platform to Access External Motor (available on gear drives equipped with TEFC external motors only): A galvanized steel platform and ladder to grade shall be provided for access to the external fan motor. All working surfaces shall be able to withstand 50 psf (244 kg/m2) live load or 200 pound (90.72 kg) concentrated load. 8.11 Internal Walkway: An internal walkway shall be provided in the plenum section to provide for inspection and maintenance. All working surfaces shall be able to withstand 50 psf (244 kg/m2) live load or 200 pound (90.7 kg) concentrated load. Other components of the cooling tower, i.e. basin and fill/drift eliminators, shall not be considered an internal working surface. Cooling tower manufacturers that promote these surfaces to be used as a working platform shall provide a two-year extended warranty to the Owner to repair any damage to these surfaces caused during routine maintenance. 8.12 Internal Platform: An internal platform shall be provided in the plenum section to provide for inspection and maintenance. All working surfaces shall be able to withstand 50 psf live load or 200 pound concentrated load. Other components of the cooling tower, i.e. basin floor and fill/drift eliminators, shall not be considered an internal working surface. Cooling tower manufacturers that promote these surfaces to be used as a working platform shall provide a two-year extended warranty to the Owner to repair any damage to these surfaces caused during routine maintenance. 8.13 Louver Face Platform: Easy access to the hot water basins for inspection and maintenance of the basins, even during tower operation, shall be provided by louver face platforms. Fan deck ladders and handrails, which add to the overall height of the tower, are not acceptable. 8.14 Fan Cylinder Extension: To extend the height of the tower equal to the surrounding enclosure, the cooling tower shall be provided with _____ft (mm) of fan cylinder extension. The fan cylinder extension shall match the construction of the fan deck. 8.15 Mechanical Equipment Removal Davit: Provide the mechanical equipment removal option to aid in motor removal or gear drive. The davit shall be portable from cell to cell and the heaviest piece shall weigh 60 lbs. The davit shall lower the motor or gear drive from the mechanical equipment supports down to an internal metal working surface. 8.16 Externally Mounted Pre-wired Terminal Box: The cooling tower shall ship from the factory with the fan motor(s) (and vibration cutout switch) wired to terminal blocks encased in a type 304 stainless steel NEMA 3R enclosure, mounted on the outside of the tower. No casing penetrations shall be permitted in the field. 9.0 Equipment Controls (Optional) 9.1 Variable Frequency Drive(s): A variable frequency drive (VFD) shall be provided for each fan motor. The supplier of the VFD shall be the manufacturer of the evaporative cooling equipment. The VFD shall have a 3-contactor bypass, 3% input line reactor, a removable keypad, an RS232 terminal for PC connection, and a circuit breaker disconnect. Fuse protection will not be accepted. Control voltage shall be 24V to minimize the size of the enclosure which should not exceed _____ ft x _____ ft x ____ ft and the weight should not exceed ____ lbs. VFD shall be provided in a NEMA (1)(3R)(12) enclosure. The VFD shall be compatible with a (ModBus) (LonWorks) (Johnson N2) Building Automation System. OR 9.1 Enclosed Controls: An enclosed control panel shall be provided for each cell of the evaporative cooling equipment. The panel shall include full voltage, non-reversing (FVNR) fan motor and pump motor (if applicable) starters in a common enclosure. The panel shall be provided with a main a circuit breaker disconnect and a separate circuit breaker for each motor or speed. Fuse protection will not be accepted. Panels containing basin heaters shall have an Earth Leakage Breaker containing ground fault protection. Starters above 25 A shall be NEMA rated. IEC starters will be accepted for motors below 25 A. Panel shall include a 120V/60Hz control power transformer, Hand-Off-Auto switches for each starter or contactor, and pilot lights for each component. Enclosed controls shall be provided in a NEMA (1)(3R)(4)(4X)(12) enclosure. Optional enclosed control features: (A temperature sensor shall be provided with the enclosed controls.)(A temperature controller shall be provided with the enclosed controls.) (A basin heater contactor with circuit breaker shall be provided.)(A vibration cutout switch input shall be provided.) 9.2 Safety Switch (es): A heavy-duty, non-fusible safety disconnect switch
shall be provided by the manufacturer of the evaporative cooling equipment.
Switch shall be single-throw, 3-pole design, rated up to 600 VAC. Switch shall
have triple padlocking capability, a visible double break rotary blade mechanism,
a clearly visible On/Off handle, an interlocking mechanism to prevent door
opening with handle in On position, and a clear line shield. Safety switch
shall be provided in a NEMA (1) (3R) (12) enclosure. |
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