WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
SI. Description
NO.
1 GENERAL
2 Manufacturer's Name M/s. GACTEL TURNKEY PROJECT LTD.
3 No. of Towers 2 Nos.
4 No. of Cells 14 Nos (13W+1SB)
5 Cooling Tower structure RCC
6 Hot inlet water Temperature 42.4 deg C(max) (Inlet to cooling tower)
7 Cold Water Temperature 33 deg C(nor) (Outlet form cooling tower) Worst Condition
7 Dry Bulb Temperature 30.13 Deg C
8 Wet Bulb Temperature 29 Deg C
9 Approach to wet Bulb temperature 4 deg C
10 Cycles of Concentration 2
11 Design Wind Load , KN/m² 2.52 KN/m2 AS PER IS 875
12 Wind Velocity , m/sec 55.55 m/sec (Max) AS PER BID
13 Design Seismic Load Zone IV & IS 4326 AS PER IS 1893
14 Earthquake factor IS 1893:2005
16 Total Power Consumption at Fan 189 for 2 nos. working Fans only
shaft in KW(Guaranteed)
17 Weight of heaviest piece of 1150
maintenance ,Kgf
TOWER DATA( FOR EACH CELL)
18 Type of cooling tower Induced draft Counter current Flow
19 Circulating water flow, M³/hr 40000
20 Guaranteed Drift Loss(% of 0.10%
Circulation flow)
21 Evaporation loss(at design) <1.5%
22 Drift Loss Consumption, M³/hr 3 M3/HR (0.10% OF 3000 M3/HR)
23 Evaporation loss consumption, 42 M3/HR
M³/hr
24 Blow Down 42 M3/HR
25 Make up water quantity, m³/hr 87 /CELL
26 Active Tower Volume , M³ (Per 980
Cell)
27 Flat Surface, M² 494.48
28 Total Wetted Surface m2 294
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
29 Minimum static pressure head
required in rising main at 1 mtr
above FGL, Mtr 16
30 Water Area/Cell, M² 196
31 Air Area/Cell, M² 196
32 Water flow/, M², of Water area 15.3
Overall Dimensions
33 Total Length, M (COLUMN CENTRE TO 42
CENTRE)
34 Total Width, M (COLUMN CENTRE TO 13.8
CENTRE)
35 Hight above basin curb, M (upto to 14.33
deck)
36 Fan Stack height, M 3.5
Diameter of fan Stack at
37 Stack base -M 10.60
38 Outlet -M 10.95
39 Overall tower Hight -M(above basin 17.83
curb)
40 Air Entry Direction COUNTER FLOW
Basin:-
41 Storage Capacity -M³(Excluding 556.51 (UP TO MAX LVL)/CELL
Channel)/CELL
42 Length ×Width× Depth/Cell - 13.85 × 13.8 × 3.2(INSIDE CLEAR) UP TO CURB.LVL
M×M×M Mtr
43 Maximum, minimum & normal Max:- 2.9, Min:- 0.3, Nor: - 2.6(FRM TOC OF BASIN BOTTOM REF
operation depth of water ;Mtr 103.00MTR LVL )REFER MECHANICAL GA
44 Free Board -mm 300
Cold water channel :-
45 capacity of cold water channel/Cell 10.15 M3/CELL (UP TO MAX LVL)
m³
46 Dimensions of cold water channel- 2m × 1.750m × 3m(TOTAL INSIDE CLEAR)
M with beffle wall(W x L x H)Mtr
Hot water distribution system
47 Type (Description) Gravity
48 Height of hot water inlet above 10.8
basin curb -M
49 Nozzle diameter ;mm 32
50 Nos of Nozzles 972
51 Nozzle material PP
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
52 Specification of all flanges 26" & ABOVE AWWA STANDARD AND 24"& BELOW ANSI B 16.5
#150
53 Nominal diameter and number of 28" NB, 1 PER CELL
hot water inlet
54 No of valves and Sizes 1 PER CELL/28" NB
Filling surface
55 Pure film/splash SPLASH
56 Flat/corrugated/tringular FLAT(RACTANGULAR)
Internal fill Details:-
57 Make & Model GAMMON
58 Fill Volume of one cell - M³ 980
59 Fill Depth -M 5
60 No. of Layers 26
61 Orientation Horizontal Spacing
62 PVC SHEET Thickness - mm N.A.
63 Surface Area -M²/M³ NA
64 Weight -Kg/M³ 8
65 Gantry & lifting tackles END WALL DERRICK AT DECK LEVEL
MATERIAL OF CONSTRUCTION
66 Frame work of members RCC
67 Casing RCC
68 Partitions RCC
69 Fills PP
70 Fills support grid PP
71 Grid Decks RCC
72 Fan deck RCC
73 Fan stack(Fan cylinders) RCC
74 Fan Rings for Fan stacks RCC
75 Drift Eliminators PVC
76 Nozzles and splash Plates PP
77 Distribution Header PVC
78 Butter Fly Valves CI
79 Bolts, Nuts,washers SS 304
80 Anchor Bolts SS 304
81 Chain Pulleyblock, Monorail U MS EPOXY PAINTED
Clamp(for lifting screens)
82 Trolley,Chain PulleyBlock,Tripod- MS EPOXY PAINTED
for-Fans Motors etc.
83 Track MS HDG
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
84 Platforms MS HDG
85 Ladders, stairway and handrail MS HDG/RCC/GI
86 Vibration switch enclosure IP 55
87 Mechanical Equpment AS PER MFR
88 Other Hardware & steel fittings MS HDG
89 Cooled Water Basin , Channel, Pits RCC
and Columns for fixing Monorail
90 Metal inserts and cable trays MS HDG
FAN DETAILS DOC NO.S2087-5M-4DOC002 REV 00
91 Fan Manufacturers & Model No. PARAG/(PARAG-MAP-9144-8HV-P30)
92 Number of Fans per Cell 1
93 Type Axial Flow
94 Materials of Fan FRP
95 Material of Fan Hub MSHDG
96 Diameter of Fan-mm 9144
97 Number of blades 8
98 Blade Angle of Incidence 15.6 Nominalº
99 Net Discharge Area ;M² 79.8
100 Hub Diameter -mm 1200
101 Total Differential Pressure Drop - 15.072
mm H20
102 static Pressure through Cooling 11.682
tower -mm H20
103 Drop through louvers -mm H20
104 Drop Through filling -mm H20
105 Drop Through Eliminators mm H20
106 Drop across rain mmH20
107 Velocity pressure -mm (H20) REFER ATTACHED CALCULATION
108 Total efficiency of Fan 82%
109 Fan Air flow Rate/Cell - 1825111 M3/Hr or 506.975 m3/sec
110 Fan Speed R.P.M. 119 / 116 NOMINAL/ACTUAL
111 Fan Tip Speed, M/Min < 3600
112 Fan B.H.P.(Metric) 124.283
113 Horse Power to drive each fan i.e. 127.47
actual B.H.P. of Motor(Metric)
114 Material of fan drive shafts SS 304
115 Noise level of Fan at rated pitch & 85 dbA AT 1 Mtr. Dist.
speed
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
116 Total Power consumption at motor 100.49KW FOR EACH MOTOR
inlet - KW (Guaranteed)
117 Fan Balancing YES(STATIC BALANCING ONLY)
118 Air density at Fan
-Kg Dry air per M³, Kg/m3 1.03552
3
-Kg Mixture per M³, Kg/m 1.08912
119 Tempreture of outgoing Mixed 41.28 oC
Air(Exit WBT)
VIBRATION SWITCH
20 Type /Nos of switches/material ELECTRONIC TYPE/ 1 PER CELL
121 Make/Model MAKE : ACD
122 Location OUTDOOR
123 Maximum vibration at which it trips 0-300 µ
motor
124 Normal vibration allowed in tower 120µ
GEAR REDUCERS (DOC-:S2087-5M-4DOC003 REV 00)
125 Type /Nos of switches/material BEVEL HELICAL
126 Make PREMIUM GREAVES
127 Model B 232
128 Reduction ratio Nominal / Actual 12.60 /12.735
129 Input speed 1500/1485 Ideal/Actual
Service factor(AGMA) of gear 2.5/3.19 Min/Available Over Motor Power
boxes
131 AGMA Mechanical KW Rating 351
132 FullLoad Efficiency @Design Power 97.5%
133 No. of stages of speed reductions 2
134 Design bearing life O/P BRG >100000 OPERATING HRS
I/P BRG >100000
135 Oil Cooling arrangement CONVECTION/RADIATION
136 Lubrication SPLASH
DRIVE SHAFT
137 Number per cell 1
138 Type/Dia/Length TYPE - SINGLE SPAN / DIA- AS PER MFR / LENGTH - 3.97 Mtr
139 Make/Model SPANCRETE
140 Material SS 304
Rated KW 110
COUPLINGS
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
142 Coupling make /model SPANCRETE
143 Type FLEXIBLE
144 Coupling Material MS HDG
145 Coupling Rated KW 110
MOTOR
146 Number per cell 1
147 Type SQUIRREL CAGE
148 Model 315L
149 Make Crompton Greaves Ltd
150 Mounting FOOT
151 Speed, RPM/Rated Power, KW 1485 RPM / 110 KW Dual Speed
152 Duty CONTINUOUS
153 Max nos Of start per hr. 3 COLD OR 2 HOT
154 Connections STAR/DELTA OR DOL
155 Efficiency 94 (FULL LOAD)
156 Space heater provision yes
FITTINGS IN RCC BASIN &
WATER CHANNEL :
157 Valves REFER MECH GA
158 Pipes REFER MECH GA
Sluice Gate
159 Size, mm 900×900
160 Material CS FABRICATED
161 Lifting arrangment CPB
162 Spindle dia, mm AS PER (BANKIM) DESIGN
Screen at basin
163 Material MESH: SS 304,FRAME: MSHDG
164 Mesh size, mm REFER MECH GA
165 Weight of screen, Kg APP. 100 Kg
166 Lifting arrangment CPB
167 Oil Skimming Facility YES
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
BASIC DESIGN PARAMETER BASED ON 4 DEG APPROACH
Sr.
No. Technical Parameters Unit Parameter
1 No. of Cooling Towers Nos 1
2 Water Flow M³/hr 9000
3 Heat Load Kcal/hr 106860600
4 Range of Cooling ºC 12
5 Cold Water Temperature (normal) ºC 33
6 Re-Circulating Allowance ºC 0
7 Design Wet Bulb Temperature ºC 29
8 Design Relative Humidity % 92
9 Terminal Pressure available at Hot Water Header MWC 25
10 Quality of Water Treated
11 Length of Cooling Tower Mtr 42
12 Diameter of Riser Pipes NB 28"
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
THERMAL CALCULATION
1 DUTY CONDITIONS
Water Flow 9000 m³/hr
No of working cells 2 nos
No of standby cells 1 no
Cell length 14 mtrs
Cell width 14 mtrs
Air inlet height 5.5 mtrs
Cell orientation In Line
Re-circulation 0 Deg C
Design inlet WBT 29 Deg C
Design RH 92 %
HWT 45 Deg C
CWT 33 Deg C
Approach 4 Deg C
Range 12 Deg C
Operating pressure available at hot water header 25 mwc
Total guaranteed power at fan shaft 189 kw
Design L/G 1.575
Fill Splash
Fill
Fill depth 5 mtrs
2 INLET AIR PROPERTIES
Inlet WBT 29 Deg C
RH 92 %
Enthalpy 94.9078 KJ/Kg
Moisture content 0.02528 kg/kg
Specific volume 0.8952 m³/kg
Wet density (pw1) 1.14534 kg/m³
Dry density (pd1) 1.11707 kg/m³
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
3 EXIT AIR PROPERTIES
Exit WBT 41.28 Deg C
RH 98.49 %
Enthalpy 177.89 KJ/Kg
Moisture content 0.05284 kg/kg
Specific volume 0.9684 m³/kg
Wet density (pw2) 1.08722 kg/m³
Dry density (pd2) 1.03263 kg/m³
4a Air flow
L 8905050 kg/hr
L/G 1.575
G 5654000 kg/hr
G 1884667 kg/hr per cell
Dry air density (Inlet) 1.11707 kg/m³
Air flow at inlet and rain zone, G/(3600*pd1) 468.65 m³/sec per cell
4b Average density dry (p'd) 1.07485 kg/m³
Average density wet (p'w) 1.11628 kg/m³
Air flow at fill, G/(3600*p'd) 487.06 m³/sec per cell
4c Dry air density at fan (pd2) 1.03263 kg/m³
Air flow at fan, G/(3600*pd2) 506.98 m³/sec per cell
L/G and KaV/L
L/G 1.575
Fill Equation 2.831 * (L/G)- 0.8
Based on above equation for fill depth, 5.0 mtrs
KaV/L fill 1.546
KaV/L water distribution 0.253
KaV/L rain zone (below fill) 0.17
Total KaV/L (Blue Book) 1.969
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
Tower Characteristic Curve attached vide Annexure 'A'
5 Pressure Loss Calculations
Location Wet Specific Pressure
Air Flow Velocity Density Volume Drop
(m³/s) (m/s) (kg/m³) (m³/kg) (mmWC)
Inlet 468.65 2.40 1.14534 0.8952 1.03
Rain Zone 468.65 2.40 1.14534 0.8952 1.22
Fill Top 487.06 2.49 1.11628 0.9318 8.27
Drift Eliminator + Others 506.98 2.59 1.11628 0.9318 1.52
Fan Velocity Pressure 506.98 7.79 1.11628 0.9318 3.39
Recovery 506.98 1.11628 0.9318 0.358
FAN TOTAL PRESSURE 15.072
6 Fan Power Calculations
Attached vide Annexure 'B'
7 Heat Balance Calculations
Attached vide Annexure 'C'
8 Velocity Pressure Ratio Calculation
Air Inlet Area of Tower to calculate velocity pressure = 195 m²
ratio
Air Flow considered = 468.65 m³/s
Velocity of Air = 2.40 m/s
Density of Inlet Air = 1.14534 kg/m³
Static pressure of inlet velocity = 1.03 mmWC
Pressure loss in air path from inlet to drift eliminator = 12.04 mmWC
Velocity Pressure Ratio = 11.689 mmWC
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
ANNEXU
ANNEXURE
XURE B FAN POWER CALCULATIONS
L = 9000 x 989.45 = 8905050 kg/hr
No of cells = 3
L per cell = 8905050 ÷ 3 = 2968350 kg/hr
Dry Density of Air @ 39.55 = 1.03263 kg/m³
deg C
Wet Density of Air @ 39.55 = 1.08722 kg/m³
deg C
L/G = 1.575
Air Flow, (G) = 506.98 m³/s
Total Pressure = 15.072 mmWC = 147.86 N/m²
Fan Total Efficiency = 82 %
Power Required at Fan = Air Flow (G) * Total Pressure = 91.41 kw
Shaft
10 * Fan Total Efficiency
Power Required at Gearbox = 91.41 ÷ 0.975 = 93.76 kw
Input Shaft
Power Required at Motor = 93.76 ÷ 0.933 = 100.49 kw
Inlet Terminals
MOTOR RATING = 110 kw
PROVIDED
MOTOR MARGIN = 117.32 %
AVAILABLE
GEARBOX RATING = 351 kw Unit Size B232
SELECTED 1
SERVICE FACTOR = 351/100.49 = 3.49
AVAILABLE
1
As mentioned in the gearbox manufacturers catalogue cooling tower gearboxes are positioned in the draft of air stream of
fan, as such thermal ratings are not relevant, mechanical ratings are overriding
WO S2931
CUSTOMER APNRL COOLING TOWER DATA
CONSULTANT DCPL SHEET
DOC. NO. S2931-5M-4DOC006
ANNEXUR C HEAT
HEAT BALANCE CALCULATIONS
Heat Lost by Water = Heat Gained by Air
Heat Lost by Water = L x (T1 - T2) + EvT2
L = 9000 x 989.45 = 8905050 kg/hr
T1 - T2 = 45 - 33 = 12 Deg C
Ev = 133576 kg/hr
Ev x T2 = 4408000
L x (T1-T2) = 106860600 Kcal/hr
L x (T1-T2) + EvT2 = 111268600 Kcal/hr
Moisture Content at Exit, Me = 0.05284
Moisture Content at Inlet, Mi = 0.02528
Heat Gained by Air = G (H2 - H1)
G = 5654000 kg/hr
H1 = 22.67 Kcal/kg
H2 = 42.49 Kcal/kg
G (H2 - H1) = 112062044 Kcal/hr
Heat Gained by Air = 112062044 > Heat Lost by Water = 111268600
MYA MYA NC 02/02/2010 0
PREPARED CHECKED APPROVED DATE OF ISSUE REVISION
