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SECTION 15640 - PACKAGED COOLING TOWERS

PART 1 - GENERAL

0.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including Conditions of Contract and
Division 1 Specification Sections, apply to this Section.

0.2 SUMMARY

A. This Section includes factory-fabricated, mechanical-draft cooling towers.

B. Related sections include the following:

1. Division 15 Section "HVAC Water Treatment” for cooling towers water treatment.

0.3 DESIGN CRITERIA:

A. Free water drift loss shall not be greater than five hundredths of one percent of the water
circulated to tower.

B. Cooling tower selection and sizing shall be based on Design Ambient Temperatures of 46C
DB/30C WB

C. Sound levels at 15 meters (fifty feet) in any direction from the tower shall not exceed 90
dB(A). Provide sound attenuators if necessary to meet the noise criteria.

D. Performance Criteria:

1. Cooling Tower Institute (CTI) Certified Towers: These towers shall have been tested,
rated, and certified in accordance with Cooling Tower Institute (CTI) Standard 201,
and shall bear the CTI certification label, and shall be listed in the CTI directory of
certified cooling tower models by manufacturers.

E. Exposed moving parts, parts that produce high operating temperature, parts which may be
electrically energized, and parts that may be a hazard to operating personnel shall be
insulated, fully enclosed, guarded, or fitted with other types of safety devices. Safety
devices shall be installed so that proper operation of equipment is not impaired. Welding
and cutting safety requirements shall be in accordance with AWS Z49.1.

0.4 SUBMITTALS

A. Product Data: Include rated capacities, pressure drop, fan performance, sound level rating,
rating curves with selected points indicated, startup instructions, furnished specialties, and
accessories for each model indicated.

1. Sample Warranty: Copy of manufacturer's proposed warranty, stating obligations,

remedies, limitations, and exclusions.

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B. Shop Drawings: Certified by a qualified professional engineer. Detail equipment

assemblies and indicate dimensions, weights, loads, required clearances, method of field
assembly, components, and location and size of each field connection.

1. Design Calculations: Calculate requirements for selecting vibration isolators and

seismic restraints and for designing vibration isolation bases.
2. Vibration Isolation Base Details: Detail fabrication, including anchorages and
attachments to structure and to supported equipment.
3. Vibration isolation, including anchorages and attachments to structure and to
supported equipment.
4. Wiring Diagrams: Detail wiring for power, signal, and control systems and
differentiate between manufacturer-installed and field-installed wiring.

C. Coordination Drawings: Show structural supports, piping roughing-in requirements, wiring

roughing-in requirements (determine spaces reserved for electrical equipment), and access
requirements for service and maintenance.

D. Product Certificates: Signed by cooling tower manufacturer to include certified

performance curves plotting leaving-water temperature against wet-bulb temperature.

E. Field Test and Commissioning Reports: As specified in "Commissioning" Article in Part 3

of this Section. Indicate and interpret test results for compliance with performance
requirements.

F. Maintenance Agreement: As specified in this Section.

G. Maintenance Data: For each cooling tower to include in maintenance manuals specified in
Division 1. Include part lists for tower fill, water distribution system, fans, bearings, fan
drives, vibration isolators, controls, basin heaters, and accessories.

H. Warranties: Warranties specified in this Section.

0.5 QUALITY ASSURANCE

A. Manufacturer's Certification: Certify cooling tower's thermal performance according to CTI

201.

B. Electrical Components, Devices, and Accessories: Listed and labeled as defined in latest
and relevant IEC standard, by a testing agency acceptable to the Engineer.

0.6 WARRANTY

A. Manufacturer's Warranty: Provide written warranty, signed by the manufacturer agreeing to

repair or replace components of packaged cooling towers that fail in materials or
workmanship within specified warranty period.

B. Warranty Period: Two years from date of Substantial Completion.

0.7 MAINTENANCE SERVICE

A. Maintenance: Submit four copies of manufacturer's "Agreement for Continued Service and
Maintenance," before Substantial Completion, for the Employer's acceptance. Offer terms

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and conditions for furnishing consumables and providing continued testing, maintenance
and servicing to include replacing materials and components. Include one-year term of
agreement, commencing at date of Substantial Completion, with option for one-year
renewal.

0.8 COORDINATION

A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases.
Concrete, reinforcement, and formwork requirements are specified in Division 3 Section
"Cast-in-Place Concrete."

0.9 DELIVERY, STORAGE, AND HANDLING

A. Deliver cooling tower as a factory-assembled unit with protective crating and covering.

B. Rig units for unloading and moving as recommended by the equipment manufacturer.

PART 2 - PRODUCTS

0.1 STANDARD COMMERCIAL PRODUCTS

A. Materials and equipment shall be standard products of a manufacturer regularly engaged in

the manufacturing of such products, which are of a similar material, design and
workmanship. The standard products shall have been in satisfactory commercial or
industrial use for 5 years prior to bid opening. The 5 year use shall include applications of
equipment and materials under similar circumstances and of similar size. The 5 years
experience shall be satisfactorily completed by a product that has been sold or is offered for
sale on the commercial market through advertisements, manufacturer's catalogs, or
brochures. Products having less than a 5 year field service record shall not be acceptable.
Products shall be supported by a service organization. System components shall be
environmentally suitable for the indicated locations.

0.2 INDUCED-DRAFT, COUNTERFLOW COOLING TOWERS

A. Description: Induced-draft, counterflow cooling tower that is factory fabricated and

assembled.

B. Factory fabricated, factory-assembled towers that are shipped to the job site in separate cells
or modules shall be provided with all appropriate manufacturer's hardware for assembly in
the field. Factory fabricated, field-assembled towers shall be assembled and adjusted at the
job site by a factory representative.

C. Fan:

1. Cast aluminum, propeller with maximum tip speed of 55 meter per second (11,000
fpm). Fan blade assembly shall be both statically and dynamically balanced after
assembly of the cooling tower.
2. Fan hub shall be constructed of cast aluminum with adequate surface protection
against corrosion.

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3. Complete fan assembly (fan and mounting) shall be designed to give maximum fan
efficiency and long life when handling saturated air at high velocities.
4. Each cooling tower fan shall be provided with a ball and pedestal type vibration limit
switch, which shall stop the corresponding fan motor in the event of sensing
excessive fan vibration.
5. Tower fan for induced draft towers of 350 kW (100 tons) and less shall be belt driven.
6. For induced draft towers larger than 350 kW (100 tons), fan shall be driven through a
gear reducer.

D. Fan: ABS plastic, propeller.

1. Drive: Gear, with speed reducer.

2. Drive: Belt.
3. Bearings: Self-aligning ball bearings or bronze sleeve bearings.
4. Vibration Cutout Switch: De-energize fan motors if excessive vibration occurs.
5. Protective Cladding: Fiberglass-reinforced, chemical-resistant, air-leak proof, plastic
panels, attached to structure with galvanized steel fasteners.

E. Speed Reducers Gears and Drive Shaft:

1. Speed reducer gears shall be rated in accordance with CTI Std-111.

2. Gear reducers shall be of the spiral or helical, double reduction type. Reducer shall
be mounted in accordance with manufacturer's recommendations. Each reducer shall
be provided with an oil level cutoff switch interlocked to the fan motor. Each reducer
shall be provided with an oil level sight glass, fill, drain, and vent lines located in a
readily accessible position.
3. Drive shafts shall be the full floating type with flexible couplings at both ends and
have a service factor of 1.0 or greater. Drive shafts shall be of stainless steel, fitted
each end with flexible couplings (stainless steel plate type). Each drive shaft shall be
provided with a galvanized steel guard, to prevent damage to surrounding equipment
in case of shaft failure. Provision shall be made for lubrication of all bearings.
Bearings shall be accessible to the extent that each bearing can be lubricated without
dismantling fan.
4. Gear reducer drive: Specially designed for cooling tower operation, with dynamically
balanced drive shaft assembly or shock absorbent flexible coupling requiring no
lubrication, cast iron case with readily accessible oil drum and fill, and self -contained
oil reservoir sealed against water entrance.

F. Fan Deck and Cylinder:

1. Each fan shall be mounted in a fan cylinder (or stack) to elevate the fan discharge air.
Total extension height shall not exceed the fan diameter.
2. Each fan cylinder shall be provided with a PVC-coated steel 2.75 mm (12 gage) wire
mesh securely mounted to the top of the cylinder in accordance with manufacturer's
recommendations.
3. Fan decks shall be designed to withstand a live load of not less than 2.9 kPa (60 psf)
in addition to the concentrated or distributed loads of equipment mounted on the fan
decks.
4. Fan deck shall be constructed of FRP (fiber reinforced polymer) material, in multiple
sections, forming a complete, vibration-free base for mounting fan, speed reducer,
drive shaft, motor, and fan stacks. Fan cylinders (or stacks) shall be constructed of
precast, reinforced lightweight concrete in multiple sections, constrained with bands
of zinc-coated steel conforming to ASTM A 123/A 123M, not less than 3 x 75 mm

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(1/8 x 3 inches), and bolted to form a compressive load on stack perimeter. Fan
cylinder shall be secured in place on the fan deck with Class A mortar.

G. Hot-Water Distribution System: Water distribution shall be gravity-flow type system that
distributes waters evenly over the entire fill surface. Each tower cell shall be designed so
that a water flow of 140 percent capacity will not cause overflowing or splashing. The
distribution system for each cell shall include adjustable flow control valves. The entire
distribution system shall be self-draining and nonclogging.

1. Pipe Material: Schedule 40 PVC.

2. Pipe Material: Stainless steel.
3. Nozzles: Removable plastic, brass, or ceramic nozzles.
4. Maximum Pressure Drop: 83 kPa.
5. Gravity-Flow System: System shall be provided with open basins which include a
splash box or baffles to minimize splashing of incoming hot water and holes that
evenly distribute the water over the entire decking area. Holes used in a water basin
shall be provided with ceramic or plastic orifice inserts.
6. Basin Cover: Hot water distribution basins shall be provided with the tower
manufacturer's standard removable, [zinc-coated steel] [stainless steel] [FRP]
covers. Covers shall prevent airborne debris from entering the basin.

H. Casing: Fiberglass-reinforced polyester with UV inhibitors; cylindrically formed with

bolted sections.

I. Casing: Stainless steel.

1. Fasteners: Corrosion resistance equal to or better than the materials being fastened.
2. Joints: Sealed watertight.
3. Welded Connections: Continuous and watertight.
4. Rigging Supports: For handling cooling towers at construction site.

J. Collecting Basin:

1. Basin shall be completely watertight and constructed of high density, air-entrained

concrete.
2. Basin shall be constructed and installed to ensure that air will not be entrained in
outlets when operating and no water will overflow on shutdown.
3. Each individual sump shall be provided with an individual outlet. Each outlet shall
be provided with a 1/2 inch mesh, zinc-coated steel wire securely mounted to prevent
trash from entering the outlet.
4. Each basin shall be provided with overflow and valved drain connections. Each basin
shall be provided with a float-controlled, makeup water valve. The makeup water
shall discharge not less than 50 mm (2 inches) or two pipe diameters, whichever is
greater, above the top of the basin.

K. Fill:

1. Tower fill shall be the splash type. Fill material shall be free to expand or contract
without warping or cracking. No plasticized wood cellulose shall be provided for fill
material.
2. Fill shall be removable or otherwise made accessible for cleaning. Space supports
shall be corrosion resistant and shall prevent warping, sagging, misalignment, or
vibration of the fill material. Fill material and supports shall be designed to provide
for an even mixing of air and water.

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3. Fill material shall be constructed of PVC; resistant to rot, decay, and biological
attack; with maximum flame-spread rating of five according to ASTM E 84; and
fabricated, formed, and installed by the manufacturer to ensure that water breaks up
into droplets.

L. Drift-Eliminator Material: Eliminators shall be provided in the tower outlet to limit drift
loss to not over [0.02] [0.005] percent of the circulating water rate. Eliminators shall be
constructed of not less than 10 mm (3/8 inch) PVC; resistant to rot, decay, and biological
attack; with maximum flame-spread rating of five according to ASTM E 84.

M. Louver Material: PVC; resistant to rot, decay, and biological attack; with maximum flame-
spread rating of five according to ASTM E 84. Provide 25.4 mm (one inch) hot-dip
galvanized steel or copper air-inlet screens. Attach screens securely to air-intakes.

N. Water-Level Control: Manufacturer's standard mechanical makeup water valve, and plastic
or bronze float with an adjustable linkage.

O. Water-Level Control: Electric float switch and solenoid-operated, makeup water valve.

P. Ladder, Safety Cage and Handrails: Factory fabricated and supplied, for field assembly and
installation. Ladders installed inside the cooling tower basin shall be of stainless steel
construction.

Q. Fixing hardware used inside the cooling towers shall be in stainless steel.

0.3 MOTORS

A. Refer to Division 15 Section "Motors" for general requirements for factory-installed motors.

B. Motor Construction: general purpose, insulation class F, continuous duty, to be located

outside the discharge airstream. Motors shall be mounted according to manufacturer's
recommendations.

C. Enclosure Type: Totally enclosed, fan cooled, energy efficient.

D. Protect fan, bearings, and appurtenances from damage by weather, corrosion, water spray
and grit.

E. Lubrication fittings shall be readily accessible outside the wet air stream. Provide access
doors for inspection and cleaning.

F. Fans over 1500 mm (60 inches) in diameter: Include a vibration cutout switch installed in a
protected position and located to effectively monitor fan vibration. It shall stop fan motor
under excessive fan vibration.

G. Motor Speed: [Single speed], [Two Speed], [Suitable for variable-speed drive].

0.4 VIBRATION CONTROL

A. Direct isolation (no base) with rubber or fiberglass pads.

B. Direct isolation (no base) with rubber mounts.

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C. Direct isolation (no base) with restrained-spring isolators.

0.5 HANDRAILS AND LADDERS

A. Handrails: Fabricate galvanized-steel pipe rails. Pipe-rail materials and fabrication are
specified in Division 5 Section "Pipe and Tube Railings."

B. Ladders and Safety Cages: Fabricate steel ladders and safety cages. Materials and
fabrication are specified in Division 5 Section "Metal Fabrications."

0.6 SOURCE QUALITY CONTROL

A. Verification of Performance: Test and certify cooling towers according to CTI 201 and
ASME PTC 23.

PART 3 - EXECUTION

0.1 EXAMINATION

A. Examine proposed route of moving cooling towers into place and verify that it is free of
interferences.

B. Examine elements and surfaces to support cooling tower.

C. Verify piping and wiring roughing-in locations.

D. Verify suitability of branch-circuit wiring.

0.2 INSTALLATION

A. Install cooling towers according to manufacturer's written instructions.

B. Install cooling towers level and plumb, and fasten to supporting structure with vibration
isolators and seismic restraints.

C. Maintain recommended clearances for service and maintenance.

D. Install grade-mounted cooling towers on reinforced-concrete bases of sizes indicated, or

otherwise required. Concrete, formwork, and reinforcement are specified in Division 3
Section "Cast-in-Place Concrete."

E. Electrical Wiring: Install electrical devices furnished by cooling tower manufacturer that
are not factory mounted.

0.3 CONNECTIONS

A. Piping installation requirements are specified in other Division 15 Sections. Drawings

indicate general arrangement of piping, fittings, and specialties. The following are specific
connection requirements:

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1. Install piping adjacent to cooling towers to allow service and maintenance.

2. Install flexible pipe connections for towers mounted on vibration isolators.
3. Pitch piping down to drain into sump.
4. Connect overflow drain and bleed lines to sanitary sewage system.
5. Domestic Water Piping: Comply with applicable requirements of Division 15
Section "Water Distribution Piping." Connect to water-level control with shutoff
valve and union or flange at each connection.
6. Condenser-Water Piping: Comply with applicable requirements of Division 15
Section "Hydronic Piping." Connect to supply and return cooling-tower connections
with shutoff valve, flow control valve, and union or flange on supply connection to
the tower and shutoff valve and union or flange to return connection from the tower
to the chiller as shown on the drawings.

B. Electrical: Comply with applicable requirements in Division 16 Sections.

C. Ground equipment.

1. Tighten electrical connectors and terminals according to manufacturer's published

torque-tightening values. If manufacturer's torque values are not indicated, use those
specified in UL 486A and UL 486B.

0.4 STARTUP AND TESTING

A. Check tower installation, perform startup procedures recommended by the manufacturer,

and observe its operation. Take readings of water flow, temperatures, and power to verify
tower operation and its capacity. Submit recorded readings to the Engineer.

0.5 PERFORMANCE TESTS

A. CTI certified cooling towers shall be factory run tested, rated and certified for actual
conditions specified. A certified test report shall be submitted and approved by the
Engineer, prior to delivery of the cooling tower. The factory certified test report shall be
signed by an officer of the manufacturer. Reprinted certification will not be acceptable.
Certificate furnished to the Engineer shall be original. If the cooling tower fails to perform
within the allowable tolerance, the manufacturer will be allowed to make necessary
revisions to his equipment and retest as required at no additional cost to the Employer.

0.6 ADJUSTING

A. Set and balance condenser-water flow to each tower inlet.

B. Adjust water-level control for proper operating level.

0.7 CLEANING

A. After completing system installation, including outlet fittings and devices, inspect exposed
finish. Remove burrs, dirt, and construction debris, and repair damaged finishes including
chips, scratches, and abrasions.

0.8 COMMISSIONING

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A. Engage a factory-authorized service representative to perform startup service and report

results in writing.

B. Complete installation and startup checks according to manufacturer's written instructions

and do the following:

1. Clean entire unit and wash basins.

2. Ensure that accessories are properly installed.
3. Check makeup water float.
4. Check clearances for airflow and for tower servicing.
5. Check for vibration isolation and structural support.

C. Obtain wet-bulb, tower-size, and performance selection tables from the manufacturer.

D. Lubricate bearings on fans and shaft as recommended by the manufacturer.

E. Ensure fan wheels rotate in correct direction without vibration or binding.

F. Start cooling-tower and condenser-water pumps. Follow manufacturers written starting

procedures.

G. Check water level in tower basin.

H. Check operation of tower basin, makeup line, and controlling device.

I. Ensure that system chemical treatment is working, and measure chemical treatment levels.
Check operation of tower basin automatic blow-down, and controlling device.

J. Verify that tower discharge is not recirculating into air intakes.

0.9 DEMONSTRATION

A. Engage a factory-authorized service representative to train the Employer's maintenance

personnel to adjust, operate, and maintain cooling towers. Refer to Division 1 Section
"[Demonstration and Training] [Closeout Procedures]."

1. Schedule at least eight (8) hours of training.

END OF SECTION 15640

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