Cooling_Tower_Instructions.pdf

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Academic Village Cooling Tower
Solicitation number
PSPW-25-10
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Broward County, Florida

About this file

This document is a comprehensive technical specification for cooling towers, specifically Section 236500, prepared for a cooling tower replacement project at the Pembroke Pines Charter School Academic Village Campus. The specification provides detailed requirements for open circuit, induced draft, crossflow cooling towers, with a basis of design from Baltimore Aircoil Company's Series 3000 model. The document outlines extensive technical requirements for components including cold water basins, water distribution systems, casing panels, fans, motors, drive systems, and accessories, offering multiple alternate construction options such as galvanized steel, stainless steel (304 and 316 grades), and hybrid polymer coatings.

The specification emphasizes high-performance characteristics, including energy efficiency, corrosion resistance, and durability. Key technical requirements include thermal performance certification per CTI STD-201, seismic design compliance, and comprehensive warranty provisions (one-year general warranty with extended five to seven-year coverage for specific mechanical components). Optional features include sound attenuation, velocity recovery stacks, vibration switches, access platforms, and safety equipment. The document provides detailed installation instructions, quality control procedures, and a schedule template for documenting specific tower characteristics, reflecting a comprehensive approach to cooling tower procurement that prioritizes long-term performance, maintenance accessibility, and operational reliability.

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R3.0 236500 - 1 Cooling Towers

SECTION 236500

COOLING TOWERS

PART 1 GENERAL

1.01 SECTION INCLUDES

A. Open circuit, induced draft, crossflow cooling towers.

1.02 REFERENCE STANDARDS

A. ASHRAE 90.1-2019 – Energy Standard for Buildings Except Low-Rise Residential Buildings.

B. ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products 2017.

C. ASTM A653/A653M - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process 2018.

D. ASTM B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus 2018.

E. ASTM E84 - Standard Test Method for Surface Burning Characteristics of Building Materials 2018b.

F. ASTM D2794 - Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact).

G. ABMA STD 9 - Load Ratings and Fatigue Life for Ball Bearings 2015.

H. ABMA STD 11 - Load Ratings and Fatigue Life for Roller Bearings 2014.

I. CTI STD-201 OM - Operations Manual for Thermal Performance Certification of Evaporative Heat Rejection Equipment 2017.

J. CTI STD-201 RS - Performance Rating of Evaporative Heat Rejection Equipment 2017.

K. CTI STD-111 - Gear Speed Reducers for Application on Industrial Water Cooling Towers;

2009. (Only for gear-driven products)

L. ISO 9001 - Quality management systems -- Requirements 2015.

M. NEMA MG 1 - Motors and Generators 2017.

N. ASCE/SEI 7 - Minimum Design Loads and Associated Criteria for Buildings and Other Structures.

1.03 SUBMITTALS

A. Product Data: Provide rated capacities, dimensions, weights and point loadings, accessories, required clearances, electrical requirements and wiring diagrams, and location and size of field connections.

B. Shop Drawings: Indicate suggested structural steel supports including dimensions, sizes, and locations for mounting bolt holes.

C. Manufacturer's Certificate: Certify that cooling tower performance, based on CTI STD-201 meets or exceeds specified requirements and submit performance curve plotting leaving water temperature against wet bulb temperature.

D. Manufacturer's Instructions: Submit manufacturer's complete installation instructions.

E. Operation and Maintenance Data: Include start-up instructions, maintenance data, controls, and accessories.

F. Warranty: Submit manufacturer's warranty and ensure forms have been filled out in Owner's name and registered with manufacturer.

R3.0 236500 - 2 Cooling Towers

1.04 QUALITY ASSURANCE

A. Manufacturer Qualifications: Company specializing in manufacturing the type of products specified in this section, with minimum 20 years of documented experience and ISO 9001 certification.

B. Installer Qualifications: Company specializing in performing the type of work specified in this section with minimum 20 years of experience and approved by manufacturer.

C. Product Performance:

1. Cooling tower must have a minimum energy rating of [_____] per ASHRAE 90.1, 189 and CA Title 24.

2. Structural and Seismic Performance: The structure will be designed, tested and certified in accordance with IBC regulations to meet a minimum unrestricted seismic design SDS = ___ g with an Importance Factor of ___ and wind load of __ psf. Units not provided with a certificate of IBC compliance will not be an acceptable alternative.

1.05 DELIVERY, STORAGE, AND HANDLING

A. Equipment will be factory-assembled, including a cold water basin, heat transfer section, water distribution, fan drive system, and casing panels. For shipping, disassemble into as large as practical sub-assemblies to minimize field work for re-assembly.

B. Comply with manufacturer's installation instructions for rigging, unloading, and transporting units.

1.06 WARRANTY

A. One-year warranty after start-up, or eighteen months from date of shipment, whichever occurs first. Warranty to include coverage for defects in material and workmanship.

B. Fans, fan shafts, bearings, sheaves, gearboxes, drive shafts, couplings, and mechanical equipment support must be warranted against defects in materials and workmanship for a period of five (5) years or seven (7) years, if motor space heater is properly wired.

C. For direct drive fan system: Fans, fan shafts, bearings, sheaves, gearboxes, drive shafts, couplings, and mechanical equipment support must be warranted against defects in materials and workmanship for a period of seven (7) from date of shipment. Included VFD will have 5-year warranty.

PART 2 PRODUCTS

2.01 MANUFACTURERS

A. Open Circuit, Induced Draft, Crossflow Cooling Towers:

1. Basis of Design: Baltimore Aircoil Company; Series 3000: www.baltimoreaircoil.com

#BAC

2.02 MANUFACTURED UNITS

A. Provide units suited for outdoor use, factory-assembled, induced draft with vertical discharge of air, and fan assemblies built into casing.

----- ALTERNATE for Knockdown Shipping -----

B. Provide units suited for outdoor use, induced draft with vertical discharge of air. Units will be shipped disassembled in protective crates. Crates and components must be clearly labeled with part numbers. Assembly of units will be completed onsite. Cold water basins will not have welded seams when shipped knocked down.

http://www.baltimoreaircoil.com/

R3.0 236500 - 3 Cooling Towers

2.03 COMPONENTS

A. Cold Water Basin:

1. Constructed with a minimum of 14-gauge galvanized steel with access doors at both ends of tower to air plenum. A removable anti-vortexing hood will be provided to prevent air entrainment. Large area lift out strainers will be provided with perforated openings sized smaller than the water distribution system nozzles. Provide sloped basin with drain/clean-out connection.

----- ALTERNATE for TriArmor Basin -----

2. Tri-layer protection system consisting of G-235 galvanized steel, a thermosetting hybrid polymer, and a polyurethane liner factory applied to all submerged surfaces. A Removable anti-vortexing hood will be provided to prevent air entrainment. Large area lift out strainers will be provided with perforated openings sized smaller than the water distribution system nozzles. Sloped with depressed section with drain/clean-out connection. A welded Type 316 stainless steel basin is an acceptable alternative.

----- ALTERNATE for 304 Stainless Steel -----

3. Type 304 welded stainless steel panels and structural members. A removable anti-vortexing hood will be provided to prevent air entrainment. Large area lift out strainers will be provided with perforated openings sized smaller than the water distribution system nozzles. Sloped with depressed section with drain/clean-out connection.

Basins with bolted seams or constructed of 301 stainless steel are not acceptable.

----- ALTERNATE for 316 Stainless Steel-----

4. Type 316 welded stainless steel panels and structural members. A removable anti-vortexing hood will be provided to prevent air entrainment. Large area lift out strainers will be provided with perforated openings sized smaller than the water distribution system nozzles. Sloped with depressed section with drain/clean-out connection.

Basins with bolted seams or constructed of 301 stainless steel are not acceptable.

-----ALTERNATE for Basinless Unit-----

5. The unit will be provided without an integral cold water basin. The unit will 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.

6. (Optional) Flume Box: Unit will be equalized with adjacent cell(s) through a factory-supplied flume box connection built into the cold water basin. Hardware, gaskets, and flume will be supplied. Size will be appropriate for the design flowrate of the tower.

7. (Optional) Equalizer Connection: An equalizer connection will be built into the cold water basin on the [bottom, side] with a pipe diameter appropriate for the design flowrate of the tower. See drawings for connection type.

8. (Optional) Bypass Connection: A bypass connection will be built into the cold water basin on the [bottom, side] with a pipe diameter appropriate for the design flowrate of the tower. See drawings for connection type.

B. Water Distribution System

1. The hot water distribution basins will be gravity-fed and accessible from the outside of the unit for service or inspection while unit is in operation. Included weir dams will accommodate a flow range of 50% to 100% of the design flow rate. Lift-off distribution covers will be constructed of steel and designed to withstand a 50 psf (244 kg/m2) live load or 200 pound (90.7 kg) concentrated load.

R3.0 236500 - 4 Cooling Towers

----- ALTERNATE for EVERTOUGH Construction-----

2. The hot water distribution basins will be gravity-fed and accessible from the outside of the unit for service or inspection while unit is in operation. Basins must be constructed of corrosion-resistant pultruded fiberglass reinforced polyester (PFRP) or type 316 stainless steel. Included weir dams will accommodate a flow range of 50% to 100% of the design flow rate. Lift-off distribution covers will be constructed of Type 304 stainless steel and designed to withstand a 50 psf (244 kg/m2) live load or 200 pound (90.7 kg) concentrated load.

C. Casing Panels and Framework:

1. Casing panels will be constructed of corrosion and UV-resistant fiberglass-reinforced polyester (FRP) or Type 304 stainless steel to minimize maintenance requirements and prolong equipment life.

----- ALTERNATE for Thermosetting Hybrid Polymer Panels-----

2. Casing panels will be constructed of galvanized steel protected by a thermosetting hybrid polymer. The polymer to consist of galvanized steel prepared in a four-step (clean, pre-treat, rinse, and dry) process with an electrostatically applied, 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:

a. When X-scribed to the steel substrate, unit to withstand 6000 hours of 5 percent salt spray per ASTM B117 without blistering, chipping, or loss of adhesion.

b. When X-scribed to the steel substrate, unit to withstand 6000 hours of exposure to acidic (pH=4.0) and alkaline (pH=11.0) water solutions at 95 degrees F (35 degrees C) without signs of chemical attack.

c. Unit to withstand impact of 160 in-lbs per ASTM D2794 without fracture or delamination of the polymer layer.

d. Unit to withstand 6000 hours of ultraviolet radiation equivalent to 120,000 hours of noontime sun exposure without loss of functional properties.

e. Unit to withstand 200 thermal shock cycles between minus 25 degrees F and 180 degrees F (minus 32 degrees C and 82 degrees C) without loss of adhesion or other deterioration.

f. Unit to withstand 6000 hours of exposure to 60 psi (42,184 kg/m^2) water jet without signs of wear or erosion.

g. Type 304 stainless steel may be supplied as an equal to eliminate the need for passivation, minimize maintenance requirements, and prolong equipment life.

----- ALTERNATE for Galvanized Steel Panels-----

3. Casing panels and framework will be constructed of G235 galvanized steel.

----- ALTERNATE for 304 Stainless Steel Panels-----

4. Casing panels, framework, and fasteners will be constructed of Type 304 stainless steel. Type 301 stainless steel is not an acceptable alternative.

----- ALTERNATE for 316 Stainless Steel Panels-----

5. Casing panels, framework, and fasteners will be constructed of Type 316 stainless steel. Type 301 or 304 stainless steel are not an acceptable alternative.

R3.0 236500 - 5 Cooling Towers

D. Air Inlet Louvers

1. Fiberglass Reinforced Polyester (FRP): Air Inlet louvers will be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers will prevent water splash out during fan cycling and be constructed of maintenance free, corrosion and UV resistant FRP.

----- ALTERNATE for Steel Louvers-----

2. Steel Louvers: Air inlet louvers will be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers will prevent water splash out during fan cycling. Material of construction must match steel grade of casing panels.

----- ALTERNATE for Combined Inlet Shields (PVC)----

3. PVC Inlet Shields: Louver sections will be individually removable sections. The combined inlet shields will be UV resistant PVC, installed on the air inlet face to minimize air resistance, prevent water splash out, and minimize sunlight exposure to reduce the potential for algae growth in the cold water basin.

4. (Optional) Air Intake Screens:

a. A removable galvanized steel wire mesh screen with 1”x1” openings will cover air intake areas.

----- ALTERNATE for Stainless Steel Screens----

b. A removable stainless steel wire mesh screen with 1”x1” openings will cover air intake areas.

E. Fans: Multi blade, axial type. Fans must factory test-mounted, balanced, and aligned to ensure reliable operation and ease of maintenance. Fan type will be selected to meet sound ratings published on equipment schedule.

F. Motors:

1. Single speed (1800 rpm) premium efficiency, cooling tower duty motor mounted on adjustable steel base. Fan motors will be inverter duty type designed per NEMA Standard MG1, Section IV Part 31. Motors will include an internal space heater that can be wired to remove condensation when motor is not in use.

----- ALTERNATE ENDURADRIVE Fan System -----

2. Direct Drive Motor: See Direct Drive Fan System (2.03 G)

G. Fan Drive System:

1. Direct Drive Fan System: The motor will be directly connected to the fan shaft within the airstream, eliminating the need for couplings, right-angle gears, belts, or sheaves.

a. Quality Assurance

1) Tower thermal performance must be certified per CTI STD-201.

2) Manufactured under ISO 9001 approved quality assurance program.

3) Seismic shake table tested per ICC-ES A156; must meet local Sds requirement but cannot be less than 0.50.

4) Tested and certified to operate continuously at 104°F ambient wet bulb temperature.

5) Compatible VFD supplied by tower manufacturer; see VFD specification for details.

R3.0 236500 - 6 Cooling Towers

b. (OPTIONAL) Factory Test: The motor will be wired and tested prior to shipping.

Testing done on-site is not acceptable. Testing will include:

(a) Installation of unit on a test stand for a visual/audible inspection to confirm no excess movement or unusual noises exist.

(b) Wiring of motor to a VFD.

(c) Running the motor to a specified speed/frequency and taking measurements of power draw to ensure appropriate loading is being achieved.

(d) Documentation of testing results supplied in the customer’s documents.

c. General

1) CSA Label and CE mark for safety compliance.

2) Totally Enclosed Air Over (TEAO) IP56 rating.

3) Interior permanent magnet rotor construction; synchronous design; magnets enclosed inside the rotor lamination; magnets with high temperature grade capable of 200°C conditions without loss of magnetization.

4) Compliance with NEMA MG 1 part 31 standards for definite-purpose inverter-fed motors suitable for 2000 volt peak at 10,000 volt per microsecond.

d. Components

1) Bearing isolator (seal) on motor shaft provided with shaft grounding device, utilizing two carbon grounding brushes to eliminate bearing currents.

2) Salient pole permanent magnet design rotor resulting in no I²R losses.

3) Stator consisting of low-loss C5a coated electrical steel.

4) Integral stator cooling fins, not a shaft mounted fan, for controlling rotor and stator temperatures during operation.

5) Class H insulation system rated at 1850 Volts peak, and thermally-rated wire when tested per ASTM D-2307 for 600,000 hours extrapolated life at 155°C minimum.

6) Shaft sealed by three O-rings, with two conductive O-rings to properly ground the bearing, eliminating damaging currents in the bearings.

7) Oversized conduit box with provisions for grounding inside.

8) Integral condensate drain system.

9) Three normally closed thermostats, one per phase.

10) Open ball bearings with a minimum L10 life of 100,000 hours.

11) Bearings sized to handle unbalanced loads based on an ISO Balance Grade of 6.3.

12) Re-greaseable bearing system including stainless steel inlet fitting and grease drain provided with square stainless-steel square head pipe plugs.

13) E-coat primer on cast iron parts prior to application of top coat.

14) Enhanced cooling tower duty paint that withstands 1000 hour salt fog test.

R3.0 236500 - 7 Cooling Towers

----- ALTERNATE Belt Drive -----

2. Belt Drive: Designed for minimum 150 percent motor nameplate power. Fan and motor sheave(s) will be fabricated from corrosion-resistant materials to minimize maintenance and ensure maximum drive and powerband operating life. Bearings must have a minimum L-10 life of 80,000 hours per ABMA STD 11. Belt tension must be easily adjusted in the field.

(Optional) Extended Grease Fittings: Extended grease lines are supplied that reach from the bearing to fittings on the exterior casing near the access doors. This facilitates easy periodic bearing maintenance without entering the tower.

----- ALTERNATE for BALTIGUARD™ Fan System-----

3. 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, will be provided for capacity control and stand-by protection from drive or motor failure. Two-speed motor(s) are not an acceptable alternative. Fan and motor sheave(s) will be fabricated from corrosion-resistant materials to minimize maintenance and ensure maximum drive and powerband operating life. Bearings must have a minimum L-10 life of 80,000 hours per ABMA STD 11. Belt tension must be easily adjusted in the field.

----- ALTERNATE Internal Gear Drive -----

4. Gear Drive with Internal Motor: Industrial duty, right angle gear designed in accordance with CTI STD-111. Gear must be rated for service factor of 2.0 with forward and reverse operation. Oil level fill port and sight glass are located on the gear. Gear connected to motor by flexible coupling.

----- ALTERNATE External Gear Drive -----

5. Gear Drive with External Motor: Industrial duty, right angle gear designed in accordance with CTI STD-111. Gear must be rated for service factor of 2.0 with forward and reverse operation. Oil level fill port and sight glass are located on the gear. Gear connected to motor with a drive shaft.

H. Fan Guard:

1. Welded steel rod and wire guard, hot dipped galvanized after fabrication. Installed over fan discharge.

-----ALTERNATE for stainless steel fan guard-----

2. Welded stainless steel rod and wire guard, placed over fan discharge.

I. (Optional) Motor Removal Davit: The unit will be equipped with a mechanical equipment removal davit. The motor will lower from the mechanical equipment supports down to grade.

Davit will attach to the unit without the need for tools. If tools are required for davit installation or removal, provide (1) davit for each motor provided.

J. Gravity-fed Distribution: Hot water basins will have removable covers for inspection while unit is in operation, weir dams and metering nozzles for at least 50 percent turndown capability. Gravity flow nozzles will be snap-in type for easy removal. Pressurized nozzles are not acceptable.

K. (Optional) Balancing Valves: Heavy-duty butterfly valves will be provided at the hot water inlet connections. These valves will include cast iron bodies, elastomer seat and steel operating lever.

R3.0 236500 - 8 Cooling Towers

-----Optional EASY CONNECT Single Inlet-----

L. Single Inlet Connection: Each tower cell will be furnished with a single water inlet connection complete with the means to automatically balance flow rates to the hot water basins.

(Optional Drain Valve on EASY CONNECT): The factory-supplied internal piping will include a manual drain valve positioned to drain the piping during shutdown to reduce risk of freezing.

M. Fill:

1. The fill and integral drift eliminators will be formed from self-extinguishing (per ASTM-

568) polyvinyl chloride (PVC) having a flame spread rating of 5 per ASTM E84 and will be impervious to rot, decay, fungus and biological attack. The fill is suitable for entering water temperatures up to and including 130°F (54.4°C). The fill must be manufactured, tested and rated by the cooling tower manufacturer and are elevated above the cold water basin floor to facilitate cleaning. If louvers are attached to fill, a spare set of fill sheets are required in case of icing and scaling damage.

----ALTERNATE for High-Temp Fill----

2. The fill and integral drift eliminators will be formed from self-extinguishing (per ASTM-

568) chlorinated polyvinyl chloride (CPVC) having a flame spread rating of 5 per ASTM E84 and will be impervious to rot, decay, fungus and biological attack. The fill is suitable for entering water temperatures up to and including 140°F (60.0°C). The fill must be manufactured, tested and rated by the cooling tower manufacturer and are elevated above the cold water basin floor to facilitate cleaning. If louvers are attached to fill, a spare set of fill sheets are required in case of premature icing and scaling.

N. Drift Eliminators: Three-pass design made of PVC material. Primary eliminators will be integrated into the fill media.

O. Basin Water Level Control:

1. Corrosion resistant PVC make-up valve with plastic float for easy adjustment of operating water level.

----- ALTERNATE for Electric Water Level Controller-----

2. Electric water level control with NEMA 4 enclosure, solid state controls, LED status light, and stainless steel water level sensing electrodes. Number and position of probes provided to sense the following: high water level, low water level, high water alarm level, low water alarm level, heater safety cutout, and automatic solenoid valve.

Include all necessary mounting hardware.

2.04 ACCESSORIES

A. (Optional) Electric Immersion Heaters: In pan suitable to maintain temperature of water in pan at 40 degrees F (4.4 degrees C) when outside temperature is 0 degrees F (-17.7 degrees C) [OR -20 degrees F (-28.9 degrees C)] and wind velocity is 15 mph (25 kph);

immersion thermostat and float control operate heaters on low temperature when the pan is filled. Heaters will be constructed of copper.

B. (Optional) Basin Sweeper Piping: The cold water basin of the cooling tower will be equipped with PVC sump sweeper piping with plastic eductor nozzles. The piping must be designed specifically for the size and shape of the basin to ensure full agitation.

C. (Optional) Fan Cylinder Extension: To extend the height of the tower equal to the surrounding enclosure, the cooling tower will be provided with _____inches (mm) of fan cylinder extension. The fan cylinder extension will match the construction of the fan deck.

R3.0 236500 - 9 Cooling Towers

D. (Optional) Vibration Switch

1. 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.

2. (ALTERNATE) Provide an electronic remote reset vibration switch with contact for BAS monitoring. Wiring will be by the installing contractor. The electronic vibration cutout switch will 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).

E. Access Packages: See submittal documents for access package requirements. Platforms and ladders must ship assembled from cooling tower manufacturer.

1. Plenum Access: Two hinged access doors must be provided for access into the plenum section. Include an internal walkway for inspection and maintenance. All working surfaces will 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, will not be considered an internal working surface. Cooling tower designs that utilize these surfaces as working platforms will not be acceptable. Cooling tower manufacturers that promote these surfaces to be used as a working platform will provide a two-year extended warranty to the Owner to repair any damage to these surfaces caused during routine maintenance.

2. (Optional) Fan Deck Ladder with Handrails: A ladder with steel safety cage and safety gate will be provided for access to the fan deck. Access door or service platforms are not acceptable. 1-1/4 inch (32 mm) galvanized steel pipe handrail will be provided around the perimeter of the cooling tower cells. The handrails will be provided with knee and toe rails and will conform to OSHA requirements applicable at the time of shipment. To comply with OSHA 1910.28(b)(9), fan deck ladders exceeding 24’ in total length must be designed to accept a ladder safety system. A ladder safety cage is not an acceptable alternative to a ladder safety system and will not be provided on ladders exceeding 24’ in total length.

3. (Optional) Louver Face External Platforms: Easy access to the hot water basins for inspection of spray water distribution, even during tower operation, will be provided by external platforms at the louver face. Fan deck ladders and handrails, which add to the overall height of the tower, are not acceptable. Platforms and ladders must ship assembled from cooling tower manufacturer. To comply with OSHA 1910.28(b)(9), louver face external platform ladders exceeding 24’ in total length must be designed to accept a ladder safety system. A ladder safety cage is not an acceptable alternative to a ladder safety system and will not be provided on ladders exceeding 24’ in total length.

4. (Optional. Available on Double Height Models) Internal Service Platform: An internal platform will be provided in the plenum section to provide for inspection and maintenance of internal components and drive system. All working surfaces will be able to withstand 50 psf (244 kg/m^2) live load or 200 pound (90.7 kg) concentrated load. Platforms and ladders must ship assembled from cooling tower manufacturer.

5. (Optional) Access Door Platform: An external galvanized steel access platform at the access door of the unit(s) provides access to the spray distribution system or internal plenum. An aluminum ladder and 1-1/4 inch (32 mm) galvanized steel pipe safety railing is included with the platform. This option meets pertinent OSHA standards.

Platforms and ladders must ship assembled from cooling tower manufacturer.

R3.0 236500 - 10 Cooling Towers

6. (Optional) Safety Gates: All handrail access openings will be provided with a self-closing safety gate for increased safety.

F. (Optional) Sound Attenuation:

1. Discharge Sound Attenuation: The unit will be equipped with straight discharge attenuation with sound absorbing fiberglass acoustical baffles to reduce sound levels from the top of the unit.

2. Intake Sound Attenuation: The unit will be equipped with attenuation at the unit’s air intake. Sound absorbing fiberglass acoustical baffles will reduce sound levels from the air intake side of the unit.

G. (Optional) Velocity Recovery Stacks: A conical shaped fan cowl extension will be provided that allows for increased cooling tower performance. Increase in thermal performance must be certified per CTI STD 201. VR stack material of construction will match unit.

PART 3 EXECUTION

3.01 INSTALLATION

A. Install in accordance with manufacturer's instructions.

B. Provide the services of the manufacturer's field representative to supervise rigging, hoisting, and installation, allowing for minimum of one eight-hour day per tower.

C. Install tower on structural steel beams as instructed by manufacturer.

D. Connect condenser water piping to tower. Pitch condenser water supply to tower and condenser water suction away from tower.

E. Connect make-up water piping to tower. Pitch to tower.

F. Connect overflow and drain to acceptable discharge point as required by jurisdiction.

3.02 FIELD QUALITY CONTROL

A. See Section Quality Requirements, for additional requirements.

B. Provide the services of the manufacturer's field representative to inspect tower after installation and submit report prior to start-up, verifying installation is in accordance with specifications and manufacturer's recommendations.

3.03 SYSTEM START-UP

A. Start-up tower in presence of and instruct Owner's operating personnel.

3.04 SCHEDULES

A. Cooling Towers

1. Drawing Code:

2. Location:

3. Manufacturer:

4. Model Number:

5. Cooling Capacity

a. Water Flow Rate:

b. Entering Water Temperature:

c. Leaving Water Temperature:

6. Entering Air WB Temperature:

7. Number of Fan Motors:

R3.0 236500 - 11 Cooling Towers

8. Motor Size: [______] HP

9. Motor Electrical Characteristics: [_____] Volts, Three-Phase, 60 Hz.

10. Basin Heaters No. and Type:

END OF SECTION

PART 1 GENERAL
1.01 SECTION INCLUDES
A. Open circuit, induced draft, crossflow cooling towers.
1.02 REFERENCE STANDARDS
A. ASHRAE 90.1-2019 – Energy Standard for Buildings Except Low-Rise Residential Buildings.
B. ASTM A123/A123M - Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products 2017.
C. ASTM A653/A653M - Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process 2018.
D. ASTM B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus 2018.
E. ASTM E84 - Standard Test Method for Surface Burning Characteristics of Building Materials 2018b.
F. ASTM D2794 - Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact).
G. ABMA STD 9 - Load Ratings and Fatigue Life for Ball Bearings 2015.
H. ABMA STD 11 - Load Ratings and Fatigue Life for Roller Bearings 2014.
I. CTI STD-201 OM - Operations Manual for Thermal Performance Certification of Evaporative Heat Rejection Equipment 2017.
J. CTI STD-201 RS - Performance Rating of Evaporative Heat Rejection Equipment 2017.
K. CTI STD-111 - Gear Speed Reducers for Application on Industrial Water Cooling Towers; 2009. (Only for gear-driven products)
L. ISO 9001 - Quality management systems -- Requirements 2015.
M. NEMA MG 1 - Motors and Generators 2017.
N. ASCE/SEI 7 - Minimum Design Loads and Associated Criteria for Buildings and Other Structures.
1.03 SUBMITTALS
A. Product Data: Provide rated capacities, dimensions, weights and point loadings, accessories, required clearances, electrical requirements and wiring diagrams, and location and size of field connections.
B. Shop Drawings: Indicate suggested structural steel supports including dimensions, sizes, and locations for mounting bolt holes.
C. Manufacturer's Certificate: Certify that cooling tower performance, based on CTI STD-201 meets or exceeds specified requirements and submit performance curve plotting leaving water temperature against wet bulb temperature.
D. Manufacturer's Instructions: Submit manufacturer's complete installation instructions.
E. Operation and Maintenance Data: Include start-up instructions, maintenance data, controls, and accessories.
F. Warranty: Submit manufacturer's warranty and ensure forms have been filled out in Owner's name and registered with manufacturer.
1.04 QUALITY ASSURANCE
A. Manufacturer Qualifications: Company specializing in manufacturing the type of products specified in this section, with minimum 20 years of documented experience and ISO 9001 certification.
B. Installer Qualifications: Company specializing in performing the type of work specified in this section with minimum 20 years of experience and approved by manufacturer.
C. Product Performance:
1. Cooling tower must have a minimum energy rating of [_____] per ASHRAE 90.1, 189 and CA Title 24.
2. Structural and Seismic Performance: The structure will be designed, tested and certified in accordance with IBC regulations to meet a minimum unrestricted seismic design SDS = ___ g with an Importance Factor of ___ and wind load of __ psf. Units n...
1.05 DELIVERY, STORAGE, AND HANDLING
A. Equipment will be factory-assembled, including a cold water basin, heat transfer section, water distribution, fan drive system, and casing panels. For shipping, disassemble into as large as practical sub-assemblies to minimize field work for re-ass...
B. Comply with manufacturer's installation instructions for rigging, unloading, and transporting units.
1.06 WARRANTY
A. One-year warranty after start-up, or eighteen months from date of shipment, whichever occurs first. Warranty to include coverage for defects in material and workmanship.
B. Fans, fan shafts, bearings, sheaves, gearboxes, drive shafts, couplings, and mechanical equipment support must be warranted against defects in materials and workmanship for a period of five (5) years or seven (7) years, if motor space heater is pro...
C. For direct drive fan system: Fans, fan shafts, bearings, sheaves, gearboxes, drive shafts, couplings, and mechanical equipment support must be warranted against defects in materials and workmanship for a period of seven (7) from date of shipment. I...
PART 2 PRODUCTS
2.01 MANUFACTURERS
A. Open Circuit, Induced Draft, Crossflow Cooling Towers:
1. Basis of Design: Baltimore Aircoil Company; Series 3000: www.baltimoreaircoil.com #BAC
2.02 MANUFACTURED UNITS
A. Provide units suited for outdoor use, factory-assembled, induced draft with vertical discharge of air, and fan assemblies built into casing.
----- ALTERNATE for Knockdown Shipping -----

B. Provide units suited for outdoor use, induced draft with vertical discharge of air. Units will be shipped disassembled in protective crates. Crates and components must be clearly labeled with part numbers. Assembly of units will be completed onsite...

2.03 COMPONENTS
A. Cold Water Basin:
1. Constructed with a minimum of 14-gauge galvanized steel with access doors at both ends of tower to air plenum. A removable anti-vortexing hood will be provided to prevent air entrainment. Large area lift out strainers will be provided with perforat...
----- ALTERNATE for TriArmor Basin -----
2. Tri-layer protection system consisting of G-235 galvanized steel, a thermosetting hybrid polymer, and a polyurethane liner factory applied to all submerged surfaces. A Removable anti-vortexing hood will be provided to prevent air entrainment. Large...
----- ALTERNATE for 304 Stainless Steel -----
3. Type 304 welded stainless steel panels and structural members. A removable anti-vortexing hood will be provided to prevent air entrainment. Large area lift out strainers will be provided with perforated openings sized smaller than the water distrib...
----- ALTERNATE for 316 Stainless Steel-----
4. Type 316 welded stainless steel panels and structural members. A removable anti-vortexing hood will be provided to prevent air entrainment. Large area lift out strainers will be provided with perforated openings sized smaller than the water distrib...
-----ALTERNATE for Basinless Unit-----
5. The unit will be provided without an integral cold water basin. The unit will 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.
6. (Optional) Flume Box: Unit will be equalized with adjacent cell(s) through a factory-supplied flume box connection built into the cold water basin. Hardware, gaskets, and flume will be supplied. Size will be appropriate for the design flowrate of t...
7. (Optional) Equalizer Connection: An equalizer connection will be built into the cold water basin on the [bottom, side] with a pipe diameter appropriate for the design flowrate of the tower. See drawings for connection type.
8. (Optional) Bypass Connection: A bypass connection will be built into the cold water basin on the [bottom, side] with a pipe diameter appropriate for the design flowrate of the tower. See drawings for connection type.
B. Water Distribution System
1. The hot water distribution basins will be gravity-fed and accessible from the outside of the unit for service or inspection while unit is in operation. Included weir dams will accommodate a flow range of 50% to 100% of the design flow rate. Lift-of...
----- ALTERNATE for EVERTOUGH Construction-----
2. The hot water distribution basins will be gravity-fed and accessible from the outside of the unit for service or inspection while unit is in operation. Basins must be constructed of corrosion-resistant pultruded fiberglass reinforced polyester (PFR...
C. Casing Panels and Framework:
1. Casing panels will be constructed of corrosion and UV-resistant fiberglass-reinforced polyester (FRP) or Type 304 stainless steel to minimize maintenance requirements and prolong equipment life.
----- ALTERNATE for Thermosetting Hybrid Polymer Panels-----
2. Casing panels will be constructed of galvanized steel protected by a thermosetting hybrid polymer. The polymer to consist of galvanized steel prepared in a four-step (clean, pre-treat, rinse, and dry) process with an electrostatically applied, ther...
a. When X-scribed to the steel substrate, unit to withstand 6000 hours of 5 percent salt spray per ASTM B117 without blistering, chipping, or loss of adhesion.
b. When X-scribed to the steel substrate, unit to withstand 6000 hours of exposure to acidic (pH=4.0) and alkaline (pH=11.0) water solutions at 95 degrees F (35 degrees C) without signs of chemical attack.
c. Unit to withstand impact of 160 in-lbs per ASTM D2794 without fracture or delamination of the polymer layer.
d. Unit to withstand 6000 hours of ultraviolet radiation equivalent to 120,000 hours of noontime sun exposure without loss of functional properties.
e. Unit to withstand 200 thermal shock cycles between minus 25 degrees F and 180 degrees F (minus 32 degrees C and 82 degrees C) without loss of adhesion or other deterioration.
f. Unit to withstand 6000 hours of exposure to 60 psi (42,184 kg/m^2) water jet without signs of wear or erosion.
g. Type 304 stainless steel may be supplied as an equal to eliminate the need for passivation, minimize maintenance requirements, and prolong equipment life.
----- ALTERNATE for Galvanized Steel Panels-----
3. Casing panels and framework will be constructed of G235 galvanized steel.
----- ALTERNATE for 304 Stainless Steel Panels-----
4. Casing panels, framework, and fasteners will be constructed of Type 304 stainless steel. Type 301 stainless steel is not an acceptable alternative.
----- ALTERNATE for 316 Stainless Steel Panels-----
5. Casing panels, framework, and fasteners will be constructed of Type 316 stainless steel. Type 301 or 304 stainless steel are not an acceptable alternative.
D. Air Inlet Louvers
1. Fiberglass Reinforced Polyester (FRP): Air Inlet louvers will be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers will prevent water splash out during fan cycling and ...
----- ALTERNATE for Steel Louvers-----
2. Steel Louvers: Air inlet louvers will be separate from the fill and removable to provide easy access for inspection of the air/water interface at the louver face. Louvers will prevent water splash out during fan cycling. Material of construction mu...
----- ALTERNATE for Combined Inlet Shields (PVC)----
3. PVC Inlet Shields: Louver sections will be individually removable sections. The combined inlet shields will be UV resistant PVC, installed on the air inlet face to minimize air resistance, prevent water splash out, and minimize sunlight exposure to...
4. (Optional) Air Intake Screens:
a. A removable galvanized steel wire mesh screen with 1”x1” openings will cover air intake areas.
----- ALTERNATE for Stainless Steel Screens----
b. A removable stainless steel wire mesh screen with 1”x1” openings will cover air intake areas.
E. Fans: Multi blade, axial type. Fans must factory test-mounted, balanced, and aligned to ensure reliable operation and ease of maintenance. Fan type will be selected to meet sound ratings published on equipment schedule.
F. Motors:
1. Single speed (1800 rpm) premium efficiency, cooling tower duty motor mounted on adjustable steel base. Fan motors will be inverter duty type designed per NEMA Standard MG1, Section IV Part 31. Motors will include an internal space heater that can b...
----- ALTERNATE ENDURADRIVE Fan System -----
2. Direct Drive Motor: See Direct Drive Fan System (2.03 G)
G. Fan Drive System:
1. Direct Drive Fan System: The motor will be directly connected to the fan shaft within the airstream, eliminating the need for couplings, right-angle gears, belts, or sheaves.
a. Quality Assurance
1) Tower thermal performance must be certified per CTI STD-201.
2) Manufactured under ISO 9001 approved quality assurance program.
3) Seismic shake table tested per ICC-ES A156; must meet local Sds requirement but cannot be less than 0.50.
4) Tested and certified to operate continuously at 104 F ambient wet bulb temperature.
5) Compatible VFD supplied by tower manufacturer; see VFD specification for details.
b. (OPTIONAL) Factory Test: The motor will be wired and tested prior to shipping. Testing done on-site is not acceptable. Testing will include:
(a) Installation of unit on a test stand for a visual/audible inspection to confirm no excess movement or unusual noises exist.
(b) Wiring of motor to a VFD.
(c) Running the motor to a specified speed/frequency and taking measurements of power draw to ensure appropriate loading is being achieved.
(d) Documentation of testing results supplied in the customer’s documents.
c. General
1) CSA Label and CE mark for safety compliance.
2) Totally Enclosed Air Over (TEAO) IP56 rating.
3) Interior permanent magnet rotor construction; synchronous design; magnets enclosed inside the rotor lamination; magnets with high temperature grade capable of 200 C conditions without loss of magnetization.
4) Compliance with NEMA MG 1 part 31 standards for definite-purpose inverter-fed motors suitable for 2000 volt peak at 10,000 volt per microsecond.
d. Components
1) Bearing isolator (seal) on motor shaft provided with shaft grounding device, utilizing two carbon grounding brushes to eliminate bearing currents.
2) Salient pole permanent magnet design rotor resulting in no I²R losses.
3) Stator consisting of low-loss C5a coated electrical steel.
4) Integral stator cooling fins, not a shaft mounted fan, for controlling rotor and stator temperatures during operation.
5) Class H insulation system rated at 1850 Volts peak, and thermally-rated wire when tested per ASTM D-2307 for 600,000 hours extrapolated life at 155 C minimum.
6) Shaft sealed by three O-rings, with two conductive O-rings to properly ground the bearing, eliminating damaging currents in the bearings.
7) Oversized conduit box with provisions for grounding inside.
8) Integral condensate drain system.
9) Three normally closed thermostats, one per phase.
10) Open ball bearings with a minimum L10 life of 100,000 hours.
11) Bearings sized to handle unbalanced loads based on an ISO Balance Grade of 6.3.
12) Re-greaseable bearing system including stainless steel inlet fitting and grease drain provided with square stainless-steel square head pipe plugs.
13) E-coat primer on cast iron parts prior to application of top coat.
14) Enhanced cooling tower duty paint that withstands 1000 hour salt fog test.
----- ALTERNATE Belt Drive -----
2. Belt Drive: Designed for minimum 150 percent motor nameplate power. Fan and motor sheave(s) will be fabricated from corrosion-resistant materials to minimize maintenance and ensure maximum drive and powerband operating life. Bearings must have a mi...
(Optional) Extended Grease Fittings: Extended grease lines are supplied that reach from the bearing to fittings on the exterior casing near the access doors. This facilitates easy periodic bearing maintenance without entering the tower.
----- ALTERNATE for BALTIGUARD™ Fan System-----
3. 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, will be provided for capacity control and stand-by protection from drive or motor failure. Two-speed moto...
----- ALTERNATE Internal Gear Drive -----
4. Gear Drive with Internal Motor: Industrial duty, right angle gear designed in accordance with CTI STD-111. Gear must be rated for service factor of 2.0 with forward and reverse operation. Oil level fill port and sight glass are located on the gear....
----- ALTERNATE External Gear Drive -----
5. Gear Drive with External Motor: Industrial duty, right angle gear designed in accordance with CTI STD-111. Gear must be rated for service factor of 2.0 with forward and reverse operation. Oil level fill port and sight glass are located on the gear....
H. Fan Guard:
1. Welded steel rod and wire guard, hot dipped galvanized after fabrication. Installed over fan discharge.
-----ALTERNATE for stainless steel fan guard-----
2. Welded stainless steel rod and wire guard, placed over fan discharge.
I. (Optional) Motor Removal Davit: The unit will be equipped with a mechanical equipment removal davit. The motor will lower from the mechanical equipment supports down to grade. Davit will attach to the unit without the need for tools. If tools are r...
J. Gravity-fed Distribution: Hot water basins will have removable covers for inspection while unit is in operation, weir dams and metering nozzles for at least 50 percent turndown capability. Gravity flow nozzles will be snap-in type for easy removal....
K. (Optional) Balancing Valves: Heavy-duty butterfly valves will be provided at the hot water inlet connections. These valves will include cast iron bodies, elastomer seat and steel operating lever.
-----Optional EASY CONNECT Single Inlet-----
L. Single Inlet Connection: Each tower cell will be furnished with a single water inlet connection complete with the means to automatically balance flow rates to the hot water basins.
(Optional Drain Valve on EASY CONNECT): The factory-supplied internal piping will include a manual drain valve positioned to drain the piping during shutdown to reduce risk of freezing.
M. Fill:
1. The fill and integral drift eliminators will be formed from self-extinguishing (per ASTM-568) polyvinyl chloride (PVC) having a flame spread rating of 5 per ASTM E84 and will be impervious to rot, decay, fungus and biological attack. The fill is su...
----ALTERNATE for High-Temp Fill----
2. The fill and integral drift eliminators will be formed from self-extinguishing (per ASTM-568) chlorinated polyvinyl chloride (CPVC) having a flame spread rating of 5 per ASTM E84 and will be impervious to rot, decay, fungus and biological attack. T...
N. Drift Eliminators: Three-pass design made of PVC material. Primary eliminators will be integrated into the fill media.
O. Basin Water Level Control:
1. Corrosion resistant PVC make-up valve with plastic float for easy adjustment of operating water level.
----- ALTERNATE for Electric Water Level Controller-----
2. Electric water level control with NEMA 4 enclosure, solid state controls, LED status light, and stainless steel water level sensing electrodes. Number and position of probes provided to sense the following: high water level, low water level, high w...
2.04 ACCESSORIES
A. (Optional) Electric Immersion Heaters: In pan suitable to maintain temperature of water in pan at 40 degrees F (4.4 degrees C) when outside temperature is 0 degrees F (-17.7 degrees C) [OR -20 degrees F (-28.9 degrees C)] and wind velocity is 15 mp...
B. (Optional) Basin Sweeper Piping: The cold water basin of the cooling tower will be equipped with PVC sump sweeper piping with plastic eductor nozzles. The piping must be designed specifically for the size and shape of the basin to ensure full agita...
C. (Optional) Fan Cylinder Extension: To extend the height of the tower equal to the surrounding enclosure, the cooling tower will be provided with _____inches (mm) of fan cylinder extension. The fan cylinder extension will match the construction of t...
D. (Optional) Vibration Switch
1. 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 ...
2. (ALTERNATE) Provide an electronic remote reset vibration switch with contact for BAS monitoring. Wiring will be by the installing contractor. The electronic vibration cutout switch will be set to trip at a point so as not to cause damage to the coo...
E. Access Packages: See submittal documents for access package requirements. Platforms and ladders must ship assembled from cooling tower manufacturer.
1. Plenum Access: Two hinged access doors must be provided for access into the plenum section. Include an internal walkway for inspection and maintenance. All working surfaces will be able to withstand 50 psf (244 kg/m²) live load or 200 pound (90.7 k...
2. (Optional) Fan Deck Ladder with Handrails: A ladder with steel safety cage and safety gate will be provided for access to the fan deck. Access door or service platforms are not acceptable. 1-1/4 inch (32 mm) galvanized steel pipe handrail will be p...
3. (Optional) Louver Face External Platforms: Easy access to the hot water basins for inspection of spray water distribution, even during tower operation, will be provided by external platforms at the louver face. Fan deck ladders and handrails, which...
4. (Optional. Available on Double Height Models) Internal Service Platform: An internal platform will be provided in the plenum section to provide for inspection and maintenance of internal components and drive system. All working surfaces will be abl...
5. (Optional) Access Door Platform: An external galvanized steel access platform at the access door of the unit(s) provides access to the spray distribution system or internal plenum. An aluminum ladder and 1-1/4 inch (32 mm) galvanized steel pipe saf...

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