REF.

6813-19
March 27th, 2019

Cairo Oil Refinery Co.

TECHNICAL SPECIFICATION FOR COLING TOWERS

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In the industrial refrigeration field the open induced draft cooling towers are usual requested
due to their high efficiency and easy maintenance. In particular for refinery facilities,
complete FRP field erected cooling towers of large size are the best solution in order to
balance economical and technical aspects.
For a refinery tender in Oil & Gas in Egypt, three cooling tower groups are needed to cool
process facilities. The basic design data for the No. 3 new cooling towers installation are the
following ones:

Item CT001 CT002 CT003

Total Water Flow Rate 3000 mc/h 3000 mc/h 7000 mc/h
Water Inlet Temperature 40°C 40°C 40°C
Water Outlet Temperature 30°C 30°C 30°C
Air Wet Bulb Temperature 26°C 26°C 26°C
Available space To be defined To be defined 10 x 60 mt

In the following specification, there are indicated the compulsory requirements of the cooling
towers for this tender to be complied fully as required. The towers should be in FRP with a
modular conception. These models must be characterized by a defined CTI standards and
are supplied with a pultruded fiberglass composite, with dimensions that are compatible with
the road transport and space between the structural coloumns fixed at 1,8 mt. The ventilation
units will be designed for a long durability and high quality of the components with a very
simple maintenance program.

VENTILATION UNITS
The electric motors will be indirect driven outside the flow of saturated air (with gear shafts
and speed reduction), wherein light alloy or glass reinforced plastic fans are keyed, diffusers
with dynamic recovery, and bearings lubrification taken outside the diffuser are the main
features.

Axial Flow Fans : With multiblade solution, has the main function of ensuring the cooling
tower with the necessary air volume. The axial flow fan is placed on hight section of the cell,
(fan deck) and it is directly coupled on low speed ax of the gear box. The blades are shaped
with “NACA” aereonautic profile statically balanced with master blade system; all the blades
are equipped with the adjustable incidence solution to adjust the best performances
configuration. The materials are HDGS for the hub and FRP for the blades. The blades
holder hub must have an unprecedented innovative design, engineered to reduce vibrations
to a minimum and it allows the mounting of a blade at a time, for an easy and fast
maintenance.
The forces on the fan blades are alternating ones because of the turbulences that occur
during the normal service. This type of inserts (backups inside the blades) and fastening
systems allow the slight oscillation of it and then allow to absorb the vibrations generated.
The blades fit is possible when the impeller is still through simple registers that allow the
inclination of these.

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Drive shafts : They transmit the movement from the electric motor to the gear-box. The
supplied floating type has the primary function to accommodate the slight shaft
misalignments which can happen in service; to absorb shocks, vibrations and pulsations;
minimise installation and maintenance difficulties.

Electric motors: Are designed for severe conditions

Cooling Towers continuous S1 service IEC 3
premium EFF 1 according to new european norm
IEC 60034-30. The motors are located outside the
wet steam air flowing in the GRP fan stack, but they
they have special protection to be safe and reliable
against water infiltration. To avoid this problem,
issued a dedicated specification “SPMS” and, on
this base, modifies all the standard engines of the
towers. The operations are part of the company
know-how and make the engine reliable, safe and
subject to a minor maintenance.
Here are the compulsory improvements to comply the tender:

- improvement of protection with tropycalization,

- improvement of seals,
- sealing of some exposed parts with special materials,
- bolts replacement,
- terminal board elimination,
- better painting cycle,
- bearings replacement with an high
quality optimized one type 2RSC3 with
hermetic seal, forever oiled,
- space heaters,
- at discretion, elimination of the cooling
fan

The motors must be CANTONI or SCAM TPE

brands.

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Gear boxes : The gear box is geared to reduce speed of the electric motor to speed required
by axial flow fan. The box is perfectly waterproof to avoid any entering of water; seals on
slow shaft and high velocity shaft are of labyrinth type. The box is properly stiffened to resist
to the stresses that are occurring during running, and to reject heat without any auxiliary
cooling system. The construction and sizing is in accordance with AGMA codes (at least 2
on the absorbed power). The brand should be high quality coming from europe or USA.
Gear box from China are rejected.

OIL & GREASE PIPES : The mechanical system is provided with the following oil and
grease pipes:
 Reducer breather which is extended outside the fan stack to prevent oil
contamination from water and steam coming out the cooling tower.
 Pipe for oil filling and draining; the same pipe is used for both operations with
the help of a discharge valve on the fan deck.
 Level indicator on the fan deck which is perfectly aligned with the glass
indicator existing on the box of the gear reducer.

Vibration switch :
All cells/ventilation units are equipped with a switch cutting the
supply power line in case of excessive vibrations and it is
located outside the fan stack on the gear box tank.

The vibraswitches must be METRIX brand model 5550-011-040

for remote re-hung.

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FAN STACKS
Mechanical equipment in each cell of the tower
has a fiberglass reinforced polyester fan stack.
Each stack has a belled inlet and conical,
diverging exit for reduced air pressure drop
losses and pressure recovery for high axial flow
fan efficency. Fan stack sections are connected
via lap joints allowing field adjustment of the
stack diameter and control of the fan blade tip
clearence maximixing fan performances. The
axial flow fan stacks are secured to the structure
through bolts attached to deck joints. Each stack
has a removable access panel opening for
maintenance on the fans and gears.

DISTRIBUTION SYSTEM
Inside the cooling tower upper section is placed
the distribution system of “pressure” type (0.5 –
1 bar g). Low pressure fed of towers is
compulsory for saving energy. In case of
pressure feed requirement over 1 bar g, the
proposal of towers is rejected. The water
distribution must be composed by a main
channel whereon the dynamic spray nozzles
“RSN” type ROTARY SPRAY NOZZLE (one for
each cell) are placed in order to ensure a water
uniform distribution upon a wide dispersion section. The number of nozzles must be very
reduced to save costs of stock spare parts. The towers endowed with many standard
nozzles with variable shape flow will be rejected due to the low efficiency linked to the old
technology. The nozzles must be very close to the filling plain, less than 100 mm. This
innovative rotating spray nozzle is Tower Tech Inc. patented and it has been planned to
achieve the following main goals :

 Large water distribution (approximately 4 m2) thanks

to the centrifugal movement caused by the action of the
coming out water that passes through the nozzle
orifices, is nebulized and provides the rotatory dynamic
motion similar to that of an hydraulic turbine;
 Very low distance between nozzle and filling (about 2”)
in order to reduce the pumping geodesic height of the
water entering the tower (energy savings);
 Uniform hydraulic load in order to avoid any air bypass
where the load is low and not equally distributed.

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  Variable spraying capacity with regard to the applied
hydraulic pressure thanks to its spring-loaded
mechanism, automatic (without electric or pneumatic
parts), which modulates the water spraying passage;
 Anti clogging.
 Easy care thanks to the threaded end wherewith it is
fixed to the cylinder of the main pipe.
 The nozzle must be Tower Tech brand NPT threaded
for connection;

The features of the spraying nozzles are fundamental and compulsory to get the best cooling
efficiency by avoiding air by-pass, no dry zone of filling and low energy costs to pump water.
Other kind of nozzles will be rejected for this tender.

COOLING TOWER STRUCTURE

The tower frame work shall consist of structural shapes of pultruded fiberglass composite,
stiffened with diagonal braces to transfer wind, earthquake and other live loads to the basin.
A large area of the fan deck will be walkable and design to allow an easy maintenance of
the tower, accessible from ground level via stair/ladder and completely surrounded by
handrails.
The FRP has the following characteristics:

High Strength / Light Weight : FRP approximately has the same strength of steel in tension
and a 80% less in compression; moreover it has a major strength in tension and a 30% less
than aluminum;
Corrosion Resistance: FRP is impermeable to the vast majority of corrosive materials and it
is immune to deterioration;

Quality Construction: Cut and predrilled according to the exact specifications from our
manufacturing / fabrication facilities, fiberglass pultruded materials are not deformed,
warped or torn after fabrication and this simplifies field assembly and makes construction
operations safe, reliable and efficient using pultruded structural components.

Fire Retardant : FRP pultruded materials will be supplied with a flame resistance below 25.

The basin must be in concrete and the vendor must supply the civil drawing complete of
foundation loading to support in the manufacturing of the basin. Each concrete pillar
supporting the tower must be 1,8 meters each other. Other distance steps are not permitted
and the offer will be rejected in case of other clearance step of concrete pillars.

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The continuous improvement process of cooling towers led to the development of
SCAM/SHIELD internal plastic coating, a thermoplastic sheet which covers the internal walls
of the tower body, wrapping the dispersion elements and ensuring multiple benefits. This
plastic protection inside the tower is compulsory to reduce the aging of the equipment. In
case of absence of this layer inside the tower, the offer will be rejected.

The advantages of SCAM/ SHIELD protection are:

- reduction of “by-pass on wall” phenomenon of the spray

water with the consequent increase in the cooling
efficiency of the tower;
- the elimination of possible water losses from the tower
walls;
- the complete isolation of the hydraulic circuit from the
contact with the structure of the tower.

LADDER AND HANDRAILS

All cells of FEC SERIES are equipped with the following items, designed in accordance with
the most updated safety regulations to satisfy the
plant standards:
 Mechanical system frame
 Fan deck Handrails
 Stair and ladder
 Inspection Trap

INCLUSIONS AND EXCLUSIONS

INCLUSION
 Thermal & Hydraulic design
 Basic design and water collecting
tank loads design.
 Detailed calculations for cooling tower structure.
 Internals and equipments drawing.
 Mechanical groups drawing.
 Quality Certificates.
 Structure.
 Casing.
 Fan Stack.
 Filling.

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  Drift Eliminators.
 Distibution Pipes.
 Nozzles.
 Accessories (Vibration switches and Lubrification system).
 Electric motors.
 Reducers.
 Driving Shafts.
 Axial flow fans.
 Ladder from the basin to the fan deck.
 Inspection ladders from fan deck to drift eliminators system.
 Protection on electric motor couplings.
 Inspection trap doors on the cell deck.
 First Oil filling of the reducers.

EXCLUSIONS
 Concrete basin
 Erection
 Our technician supervision and assistance during assembly.
 Spare parts for 2 years operations.
 Water treatment equipment
 Hot water piping from Cooling tower backwards, (expansion joints, risers, main return
line, valves).
 Chemical products and chlorine injection.
 Blow down make up connection (valves excluded).
 Pumps
 Lightning and grounding.
 Lifting devices.
 All that not clearly specified in the inclusions.

BATTERY LIMIT
Hydraulic: Water inlet flange
Electrical: Motor terminal box.
Instrumentation: Not wired instrumentation into dedicated JB.
Civil: Basin surface (fixation bolts and supporting steel basin beams excluded).