2.

CODES & STANDARDS

2.1. The design, material, construction, manufacture, inspection, testing and performance of
Induced Draft auxiliary Cooling Tower shall comply with all the currently applicable
statuette, regulations and safety codes in the locality where the equipment is to be
installed. Nothing in this specification shall be construed to relieve the CONTRACTOR
of this responsibility. The equipment shall also conform to the latest applicable Indian
and / or British Standards and publications of the Cooling Tower Institute and the
Hydraulic Institute. Other National Standards are acceptable, if they are established to be
equal or superior.
2.2. Cooling tower shall be designed as per In particular the equipment shall conform to the
latest edition of the following:
(1). Cooling Tower Institute Publications.
(2). BS 4485-Specification for Water Cooling Towers.
2.3. The cooling tower basin shall be of RCC and shall be designed as per latest edition of IS
3370 / ACI 318, 2009. (Purchaser Scope. Required general arrangement and Loading data
drawings to be provided by vendor)
2.4. The structure shall be designed for wind and other loads as per IS:875 and earthquake
resistance as per IS:1893. Unless otherwise stated, equipment shall be designed for the
continuous operation throughout the year.
2.5. Monorail and Hoists
2.5.1. IS: 3832: -2005 AMD 1 Chain pulley blocks
2.5.2. IS: 2429-1987: Round steel short link chain
2.5.3. IS: 6216 -1982: Short link chain grade 80
2.5.4. IS:210 -2009: Cast Iron Castings
2.6. Drive equipment
2.6.1. IS: 3688 -1990: Dimensions for shaft ends.
2.6.2. IS: 3681-1995: General plan for spur & helical gears.
2.7. Electrical
2.7.1. IS: 325 1996-AMD 3: Three phase induction motors.
2.7.2. IS: 1554- 1988 AMD 5: PVC insulated (heavy duty) electric cables.
2.7.3. IS: 2309 -1989 AMD 1: Practice for the protection of the buildings And allied
structures against Lighting of practice.
2.7.4. IS: 3043 -1987 AMD 2: Code of practice of earthing.
2.7.5. IS: 5082- 1998 –AMD 2: Wrought aluminum and aluminum alloy bars, rods, tubes
and selections for electrical purpose.
2.7.6. IS: 12615- 2011: Energy Efficient Induction Motors
 3. DESIGN BASIS

3.1.1. The vendor shall strictly adhere to the following design inputs and other details
furnished hereunder while offering and while detail designing of auxiliary cooling
tower unless otherwise if any parameters are changed and agreed mutually.
Deviations if any considered on this detail must be brought to the notice of the EPC
contractor in the offer stage itself.

3.1.2. The Aux. Cooling Tower and the associated equipment shall be designed to meet the
following independent operating requirement.

Sl. No. Description Details

I Aux.cooling tower Details
FRP Type, Mechanical, Induced draft
1 Type
counter flow
2 Number of cells 3 (2W+1S)
3 Rated Cooling Water flow per cell 425 m3/hr
4 Total Cooling Tower capacity, 1275 m3/hr
4 Maximum permissible drift loss 0.05 % of design total flow
III Design working conditions
1 Design inlet air wet-bulb temp. 27.4 °C
2 Recirculation margin 0.6 °C
3 Design approach temperature 4 °C
4 Cold water outlet temperature 32 °C
5 Hot water inlet temperature 40 °C
6 Cooling range 8 °C
7 Cycles of concentration 5
8 Design relative humidity 50%
IV Fills PVC film flow type
Multi pass herringbone type / PVC
V Drift eliminators
Cellular type / Double pass blade type.
VI Hot Water Supply Header
Entire water distribution system shall be
1 System design
self-draining and non-clogging type.
2 Distribution piping PVC
3 Nozzle and splash plate material Low Pressure Non clog Polypropylene
VII Fans
Multi-blade propeller type with
1 Type
adjustable pitch.
Drive motor shall have at least 10%
2 Drive
margin over maximum fan power
Sl. No. Description Details
consumption.
3 Drive suitable for VFD Yes
VIII Gear Box
1 Gear box service factor 1.4
2 Type of Gear Box Spiral Bevel cum Helical Type
IX Material of Construction
1 Cold water basin RCC
2 Casing & superstructure FRP
3 Aux. cooling tower roof (top deck) FRP
4 Fan stack FRP
5 Supporting structures MSHDG (610 gm /sqm)
6 Hot water distribution basin FRP
7 Lateral distribution pipes PVC
8 Hot water distribution nozzles Polypropylene
9 Fills PVC
10 Fill Support Stainless steel (SS 304)
11 Louvers FRP
12 Drift eliminators PVC
13 Fan blades FRP
14 Fan hub Hot Dipped Galvanized (HDG) Steel
15 Fan drive shaft SS 304
17 Oil Lines SS 304 / Neoprene
18 CAT (Cage) ladder MS HDG
19 Handrails MSHDG
20 Screens Not applicable
21 Sluice gate Not applicable
22 Access doors Hot Dipped Galvanized (HDG) Steel
Bolts and Nuts including
23 SS 304
foundation bolts
24 Cable tray(s) as applicable Galvanized
X Design parameters
1 Water Loading 15 TPH / sq.m.
2 Air velocity at stack inlet 4.5 m/sec.
3 Air exit velocity at stack outlet Minimum 6 m/sec.
4 L/G Ratio 1.5
5 Average fill air velocity Minimum 1.8 m/sec
 Sl. No. Description Details
6 Velocity pressure ratio Minimum 5
7 Plenum pressure drop Above 10% of the system pressure drop
8 Tip Speed of fan Maximum 65 m/sec
Minimum 80%, if a circle is projected on
9 Fan Coverage the drift eliminator plan area at 45°
angle fan cylinder opening
10 Basin storage Volume 15 min of circulating cooling water flow.
XI Electrical Parameters
1 Voltage (V) 415V +/-10%
2 Frequency (Hz) 50HZ +/-5%
XII Control & Instrumentation
1 LT Power 230V AC
2 Frequency (Hz) 50HZ +/-5%

The bidder shall furnish the following:

1. Heat balance calculations and air requirements for cooling tower.

2. Available tower characteristics (KaV/L - as a function of air & water rates, fill geometry, hot
water temperature, air velocity etc.) based on field performance tests. The bidder shall also
submit an equation and / or curve defining the demand requirement at design approach,
range and wet bulb temperature. The design L/G value shall be identified.
3. Pressure drops in the air circuit of cooling tower to arrive at discharge pressure of fan.
4. Calculations for arriving at the design power consumption.
5. Calculations for pumping head
6. Tower Performance curves.
 SCOPE OF WORK & SERVICES

5.1 Intent of specification

5.1.1 Scope of the proposal shall cover following activities and services in respect of all the
equipment and works specified in various sections of this specification.
5.1.1.1 Basic engineering & detailed design of all equipment and equipment system(s).
5.1.1.2 Providing engineering drawings, data, instruction manuals, as built drawings and
other information for purchaser’s review, approval and records.
5.1.1.3 Compliance with statutory requirements and obtaining clearances from statutory
authorities, wherever required.
5.1.1.4 Complete manufacturing including shop testing. Final painting
5.1.1.5 Packing and transportation from the manufacturer’s works to the site including
customs clearance, port charges, if any.
5.1.1.6 Supervision of Erection, testing, pre-commissioning and commissioning and putting
into satisfactory operation all the equipment including successful completion of initial
operation.
5.1.1.7 Performance guarantee/acceptance tests after successful completion of initial
operation.
5.1.1.8 Guaranteeing equipment performance for a period of 12 months from the date of
commercial operation.
5.1.1.9 Supply of mandatory spares as per the requirement.
5.1.1.10 Vendor to furnish the optional offer for two year O & M spares as per the list given in
the specification.
5.1.1.11 Supply of any other equipment including special tools and tackles, commissioning
spares and services required for satisfactory completion of the project and operation
and maintenance of the same.;
5.1.1.12 Training of purchaser’s personnel nominated by the purchaser during erection,
testing and commissioning, and for operation and maintenance.
5.1.1.13 Reconciliation with customs authorities, in case of imported equipments.
5.1.1.14 Satisfactory conclusion of the contract.
5.1.1.15 Erection manuals, installation procedures and startup procedure.
5.1.1.16 8 sets of O & M manuals, documents & drawings (soft & hard copies).
5.1.1.17 All items and equipment though not specifically mentioned in the specification, but
needed to complete the system to meet the intent of the specification shall be deemed
to be included in the scope of the bidder.
5.1.1.18 It is not the intent to completely specify all details of design and construction, but
only to lay down broad sizing and quality criteria for the major equipment and
systems and it is expected that the equipments shall conform in all respects to high
standards of engineering, design and workmanship and shall be capable of
performing in continuous commercial operation up to the contractor’s guarantee in a
specified manner acceptable to the purchaser.

5.2 SCOPE OF SUPPLY AND SERVICES

5.2.1 Induced draft fan assemblies for each cell. The fan blades shall be of adjustable pitch type
and axial flow.
5.2.2 Fan drive motor along with base frame and Hood (Cover) for each cell, Motor shall be IE2
Energy efficient class.
5.2.3 Drive shaft assembly with flexible couplings & bearings for each cell if fan is gear box
driven.
5.2.4 Extended gear reducer, oil lines of SS material with dipstick assembly oil filter & drain for
each cell if fan is gear box driven.
5.2.5 Independent vibration switch and low oil level switch for each cell with 1 NO and 1 NC
contacts if fan is gear box driven.
5.2.6 Removable types Fills and spray nozzles with supporting arrangement.
5.2.7 Main distribution header and lateral pipes.
5.2.8 Drift Eliminators.
5.2.9 Hot water distribution header with lateral distribution pipes.
5.2.10 Cage Ladder for cooling tower from ground level to top of tower.
5.2.11 SS 304 bolts & nuts
5.2.12 Counter flanges with fastener at hot water inlet.
5.2.13 First fill of lubricants, oil, grease, etc,.
5.2.14 Domestic road-worthy packing.
5.2.15 Manual Door as required for maintenance.
5.2.16 Bird cage for fan at the top of Aux. cooling tower.
5.2.17 Complete lightening and protection up to ground level.
5.2.18 Foundation bolts, embedment in the foundations, packer plates, insert plates, sleeves etc.
for all the equipment supplied.
5.2.19 Instrument (signal) cable supply and routing up to and including junction box with IP55
protection.
5.2.20 Control cable supply and routing up to junction box and including junction box with IP55
protection. The cable tray required for the above cable routing is also included in the
scope.
5.2.21 Supplier shall provide two terminals for Earthing of all rotating and static equipment.
5.2.22 Supply of necessary commissioning spares.