WatcoGroupEngineeringGuide
EngineeringanddesignprinciplesforWCNWaconandAQUAFANCoolingTowers
WATCO Engineering Guide
This WATCO Engineering Guide
provides System Management
requirements and an indicative
selection reference including
discussionofdifferentairinletheights.
The component section covers
engineering criteria for the structure
with consideration to profiles,
handrails/ladders/platform, fan cones
and basins. Separate sections discuss
fans,geardrivesanddriveshafts,plus
electricmotorsandcontrolsaswellas
sections on water distribution and
nozzles,exchangemediafilltypesand
airinletprotection.
The WATCO manual also discusses
drift eliminators, vibration switches
and the WATCO blow down control
system. Essential considerations like
performance testing and guarantee
and site specific sound considerations
arecoveredindetail.
WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE
Finally, you will find coverage of
special case cooling towers that deal
with hot water, turbidity and water
contaminated with things like
bacterial growth and how to handle
salt water. Availability of specification
templatesisalsolisted.
Visitourwebsitesforadditionalwhite
papers on specific subjects related to
coolingtowers,suchas:
CommissioningofCoolingTowers
CoolingTowerthermalcapability
Counter flow vs Cross flow
CoolingTowers
Mechanically assembled Cooling
towerfills
PreventionofLegionellosis
INTRODUCTION


WACON Engineering Guide on WCN and AQUAFAN Counter Flow

Cooling Towers

OVERVIEW

Introduction
SystemDesignandManagement
o Systemdesign
o CoolingTowerCost
o SystemManagement
Selectionreference(indicative)
o ModularcounterflowsystemsWCN
o ModularturbinepoweredcounterflowsystemsAQUAFAN
Components
o Structureandfill
o Mechanics
o WACONAutomaticBlowdownControlSystem
Sound
CTItestingfortailormadecoolingtowers
Warrantyandperformanceguarantee
Manufacturingandlogistics
Specificationtemplates:
o WCN
o AQF
o Others
CompanyProfile

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE OVERVIEW



System Design Considerations Thermalefficiency,where:
and System Management HWT=HotWater
This section presents an overview of
the engineering steps needed for a
cooling tower design including Water
Quality Management, referring to
handling biological build up,
Evaporation Loss, Blowdown and
designparameters.
System Design performanceofthecooling
Watco always has an open mind for
thespecificdesignlimitationsthatare
dictatedbytheclient,suchaspractical
limitationsinaspectsfootprint,height
oradvancedrequirementsintermsof
energy use, noise standards or
maintenance.
Based on the limitations several
alternativesmaybeexploredwherea
basic choice for the operational
principle of the cooling tower with a
specific combination of the cooling
towercomponents(aspresentedover
the next paragraphs) will lead to a
specific tailored designed installation
thatmeetsthespecificlimitationsand
deliversonthedesigncriteria.
Calculation guidelines: TonsandCoolingTowerTons.
Range: Temperaturedifference
betweenthehotandcoldsystem
waterisreferredtoasrange.
Approach:Thedifference
betweenthespecifiedcoldwater
temperatureandthewetbulb
temperatureistheapproach.
Temperature
CWT=ColdWater
Temperature
WBT=designWetBulb
Temperature:(HWT/
CWT)/(HWT/WBT)x100%=
range
KAV/L:standardforthe
towersinfillanddeterminedby
thesizeandrelativesurfaceofthe
infillinrelationtothewater
volumeatspecificapproach
temperaturesandL/Grations.
L/G:Rationbetweenliquidand
gasinthecoolingtower
operation.Isused(withKAV/L)to
predictthecoolingbehaviour.
Coolingtowersizeparameters:
kWh:theheatthattheCTis
dissipatingcaneasilybe
expressedinkWhaccording
tofollowingformula:
RT
RTCT
ThedifferencebetweenChiller
When making such comparisons, it is
important to do so only for similar
design conditions. When applied
under different conditions (approach
temperature)theremaybesubstantial
differencesintheloadintonnagethat
aninstallationmaybeabletohandle.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SYSTEM DESIGN AND MANAGEMENT


Cooling tower cost: Consequential cost of

Truecosttoacoolingtowerpurchaser unscheduled down time
iswhatWATCOdefinesastheCost of The cost of unscheduled down time
Ownershipcomprisedof: can and probably will run up
Purchasepriceofthecooling substantially once kicking in. A blown
tower out gear drive or electromotor may
Costofinstallation not be an everyday event, but if it
Costofelectricity doeshappen,itisnotaneasythingto
Accumulatedcostofmaintenance fix. Apart from the possible delay in
Costofconsumables(chemicals availability of replacement parts, the
etc) repair itself may be difficult to
Consequentialcostof execute, especially when hoisting
unscheduleddowntime equipment may be required to have
Costofremovinginstallationat the parts available at the cooling
theendofitslifetime tower (high rise buildings).

WATCO design parameters are based
Cost of Electricity upon the Cost of Ownership
Evaluated over the full range of load philosophy which requires
conditions that the cooling tower is consideration of all the variables
expected to handle which includes beyondfirstcost.
pumpsandthefan.
Inprocesseswerethecoldwatertemp
belowcertainlevelarenonrewarding
or possibly harmful there are
opportunities for substantial energy
savings by optimal control of the
process.EspeciallytheAquafanwhere
pump and fan optimally cooperate,
offers the most flexible energy
management possibilities.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SYSTEM DESIGN AND MANAGEMENT


System Management and

Maintenance Microbiology
Microbiological contamination does
Water quality call for an effective control program
Consistent cooling water treatment is using biocides (required by law in
a must for smooth cooling tower many countries with regards to
operations.Mineralbuildup,dustand Legionelladangers).
other impurities together with
microbiological contamination affect Foreign matters
theoperation. In a closed loop system like a cooling
tower, handling the buildup in air
Evaporation Loss borne debris is an important design
Evaporation is the cooling engine consideration. Dust collecting in the
behind cooling tower principles heatexchangerandcoldwaterbasins
resultingin0.16%waterlossforevery will result in performance
centigrade degree of cooling which deterioration promote bacterial
needstobereplaced. growth. In more severe
environments, it will dictate infill
Blowdown selectionandmaycallforsidestream
Mineral buildup from evaporation filtration.
shouldbemaintainedbelowtheCycle
of Concentration (COC) which
compares the mineral concentration
to the concentration in the supply
water to avoid interference with the
heat exchanger because of higher
viscosity and hygroscopic properties.
An acceptable COC is maintained by
periodically blowing down part of the
system water and replacing this and
the evaporated water with fresh
(suppletion)water.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SYSTEM DESIGN AND MANAGEMENT


Quick Selections WCN Modular Counter Flow Conventional Cooling

Towers

FinalDesignDatato
beconfirmedby FootPrint Motor Fan
Wet
WACON Size Surface
Power 37/32/27 37/32/28 35/30/27 40/34/31 n
InternationalPTE
Ltd LxWxHm m2 kW rpm
C C C C
Type: FanDiam. APPROXIMATEWATERFLOWm3/h
(ft)

WCN8 6 2.4x2.4x4 5.8 5.5* 121 115 109 104 560
WCN9 6 2.4x3x4 7.2 7.5* 151 144 137 130 560
WCN10 7 3x3x3.5 9.0 11* 189 180 171 162 440
WCN11 7 3x3.6x4.5 10.8 11* 227 216 205 194 440
WCN12 8 3.6x3.6x4.5 13.0 15* 272 259 246 233 440
WCN13 8 3.6x4.8x4.5 17.3 18.5 363 346 328 311 330
WCN14 10 4.8x4.8x5 23.0 22 484 461 438 415 330
WCN15 10 4.8x6x5.5 28.8 30 605 576 547 518 300
WCN16 12 6x6x6 36.0 37 756 720 684 648 260
WCN17 12 6x7.2x6.5 43.2 45 907 864 821 778 260
WCN18 14 7.2x7.2x7 51.8 55 1089 1037 985 933 230
WCN19 14 7.2x8.4x8 60.5 55 1271 1210 1150 1089 230
WCN20 14 8.4x8.4x7.5 70.6 75 1482 1411 1341 1270 230
WCN21 14 8.4x9x6 75.6 75 1588 1512 1436 1361 230
WCN22 18 9x9x6.5 81.0 90 1701 1620 1539 1458 195
WCN23 18 9x9.6x6.5 86.4 90 1814 1728 1642 1555 195
WCN24 20 9.6x9.6x7 92.2 90 1935 1843 1751 1659 165
WCN25 20 9.6x10.8x7 103.7 90 2177 2074 1970 1866 165
WCN26 22 10.8x10.8x7.5 116.6 110 2449 2333 2216 2100 145
WCN27 22 10.8x12x7.5 129.6 110 2722 2592 2462 2333 145
WCN28 24 12x12x8 144.0 110 3024 2880 2736 2592 135
WCN29 24 12x12.6x8 151.2 110 3175 3024 2873 2722 135
WCN30 26 12.6x12.6x8.5 158.8 110 3334 3175 3016 2858 125
WCN31 26 12.6x13.2x8.5 166.3 132 3493 3326 3160 2994 125
WCB32 28 13.2x13.2x9 174.2 132 3659 3485 3311 3136 115
WCN33 28 13.2x14.4x9 190.1 132 3992 3802 3612 3421 115
WCN34 30 14.4x14.4x9.5 207.4 132 4355 4147 3940 3732 105
WCN35 30 14.4x15.6x9.5 224.6 160 4717 4493 4268 4044 105
WCN36 30 15.6x15.6x10 243.4 160 5111 4867 4624 4380 105
*DirectDrive(allotherswith5bladefan,angledgearreducer&compositeshaft)
DataonlyapplytospecificationsissuedafterMarch2015
Forreferenceonly

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE QUICK SELECTIONS


Quick Selections AQUAFAN Modular Counter Flow Turbine Powered

Cooling Towers
FootPrint Average Average
FinalDesignDatatobe Wet Fan
confirmedbyWACON Size Surface
Pressure
Diam.
37/32/27 37/32/28 35/30/27 40/34/31 n
AQUAFAN.
LxWxHm m2 mH2O m C C C C rpm

APPROXIMATEWATERFLOWm3/h

AQF4singlecell(*) 1.25x1.25x1.9 1.44 20 1.2 29 27 26 24 580

AQF7singlecell(*) 2.15x2.15x2.4 4.4 18 1.5 88 84 79 75 500

AQF81#1singlecell 2.7x2.7x4 5.8 18 1.8 115 109 104 98 480
AQF81#2doublecell 2.7x5.1x4.5 11.5 18 1.8 230 219 207 196 480
AQF81#3triplecell 2.7x7.5x5 17.3 18 1.8 346 328 311 294 480
AQF81#4quatrocell 2.7x9.9x5. 23 18 1.8 461 438 415 392 480

AQF101#1singlecell 3.3x3.3x4.5 9 18 2.1 180 171 162 153 390
AQF101#2doublecell 3.3x6.3x5 18 18 2.1 360 342 324 306 390
AQF101#3triplecell 3.3x9.3x5.5 27 18 2.1 540 513 486 459 390
AQF101#4quatrocell 3.3x12.3x5.5 36 18 2.1 720 684 648 612 390

AQF121#1singlecell 3.9x3.9x4.5 13 18 2.4 260 247 234 221 330
AQF121#2doublecell 3.9x7.5x5.0 26 18 2.4 520 494 468 442 330
AQF121#3triplecell 3.9x11.1x5.5 39 18 2.4 780 741 702 663 330
AQF121#4quatrocell 3.9x14.7x5.5 52 18 2.4 1040 988 936 884 330

AQF122#24cell 7.5x7.5x5 52 18 2.4 1037 985 933 881 330
AQF122#36cell 7.5x11.1x5.5 78 18 2.4 1555 1477 1400 1322 330
AQF122#48cell 7.5x14.7x6 104 18 2.4 2074 1970 1866 1763 330
AQF122#510cell 7.5x14.7x6 130 18 2.4 2592 2462 2333 2203 330

AQF123#39cell 11.1x11.1x5.5 117 18 2.4 2333 2216 2100 1983 330
AQF123#412cell 11.1x14.7x6 156 18 2.4 3110 2955 2799 2644 330
AQF123#515cell 11.1x18.5x6.5 194 18 2.4 3888 3694 3499 3305 330
AQF123#618cell 11.1x21.9x6.5 233 18 2.4 4666 4432 4199 3966 330

AQF124#412cell 14.7x14.7x6 207 18 2.4 4147 3940 3732 3525 330
AQF124#520cell 14.7x18.5x6.5 235 18 2.4 4704 4469 4234 3998 330
AQF124#624cell 14.7x21.9x7 311 18 2.4 6221 5910 5599 5288 330
AQF124#728cell 14.7x25.5x7 363 18 2.4 7258 6895 6532 6169 330

Forreferenceonly

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE QUICK SELECTIONS

Cooling Tower Components consideration.
Structure and Infill
Structural Parts (profiles and
cladding)
FRP is the preferred and
recommended materials of choice
bringing the advantages of flexibility,
durability and cost in a variety of
colours to the job using South East
Asia suppliers. All pultrusions meet
CTI137standards.
WATCO specifies glass and resin
rations appropriate to the applied
loadswithUVandmoisturemigration
protectionforlayeredstructuralbuild
up of the pultrusions. This is the
material of choice for pultruted
profiles, handrails/ladders/platforms
andlouvers.
Structures from Stainless Steel or
HDGS are offered on clients request.
Fan Cones
Fan Cones are a critical design
elementaffectingefficientairflowand
overall cooling tower
performance.Specialattentionispaid
to minimizing turbulence with a
smooth air inlet and maximizing
WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE
efficiency with a minimum tip
clearance. Personnel safety is prime
Fiberreinforcedplasticisthematerial
of choice because of its light weight,
durability and resistance to water.
Design parameters conform to CTI
standards. Available options include
silencers, mesh guards and enhanced
shapestoenablevelocityrecovery.
Basins
Supporting the cooling tower
structure is the basin which collects
thecooledliquidforreuseordisposal.
Proper design calls for a water buffer
in the basin or a separate sump for
collection of all foreign materials
entering the system from the
airstream. A blowdown arrangement
periodically allows the system to
purgeitselfofthismaterial.Optionally,
strainers, filters and/or traps may be
included.
Materials of construction may be FRP
for smaller installations or reinforced
concrete with design
recommendations available from
WATCO.
Structure options
Maintaining a high standard of
operatorsafety,WATCOdesignsfocus
on ladders with safety cages and full
accessibility with proper use of
handrails, walking grids, etc. Clients
STRUCTURE AND COMPONENTS

special requirements are
accommodated with walkways,
staircases,extraaccessdoors,etc.All
WATCOdesignsmeetorexceedOSHA
standards.
Air Inlets Louvers intheairstreamguaranteesmaximum
Mounted in easily removable SST
frames, inlet louvers are designed to
keep leaves and other debris out and
water inside the tower. Made of
flame retardant, UV stabilized FRP,
they allow maximum air flow in with
neartozero pressure loss. Special
attention is given to noise reduction
wherethatiscritical
Air Inlets Screens windowsandthehazardofinterfering
WATCO screen design optimizes air
flow into the tower with minimal
pressure loss. Design criteria includes
reduced noise, minimum splash out,
retardicegrowthandkeepleavesand
otherdebrisoutofthebasin.
Materials are flame retardant, UV
stabilizedPPorPVC,mountedineasily
removable FRP frames. A colour
choiceisavailableuponrequest.
Film Infill
Fill design is the business end of the
coolingtowerwherethewatermeets
the air. WATCO optimized surface
designisalightweight,selfsupporting
structure offering a selection of flute
sizes to provide the desired balance
WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE
between water quality and pressure
drop. Flame retardant PVC is the
conventionalchoice.
Special onsite welding/glueing is an
availableoption.
Splash Fill
Inapplicationswheredirtywatermay
negatively impact the operational life
time of a film fill, WATCO offers
various splash fill alternatives. Due to
the open structure, a splash fill
medium is resistant to clogging while
the long holdup time of the water in
combination with intense turbulence
performance.
Thefillscanbesiteassembledwithout
use of tools or adhesives and are
reusable(aftercleaning).
Drift Eliminators
Drift is the water entrained in air
leaving the cooling tower with the
nuisancepotentialofspottingcarsand
with downwind power lines,
substations and other sensitive areas
while minimizing water loss to less
than 0.005%. Drift does not include
watervapour.
WATCOdesigncriteriaseektobalance
water loss with pressure loss through
appropriate location within the tower
structure.Materialsarepreglued,UV
protected flame retardant PP or PVC
withaselectionofcoloursavailable.
STRUCTURE AND COMPONENTS


Mechanics conditionsthatpresenthumidity,dust,
chemical fumes and a variety of
weatherconditions.TEFCwithclassB
insulation is the normal enclosure of
choice. Heaters are included to
maintain motors above ambient
temperature,avoidingcondensation.

Source:Bockwoldtwithinlinevertical
geardriveorElectramo.

MotorControls.
Fans Combination starters with nonfused
Airflowthroughthecoolingtowerand disconnectsinNEMA4enclosuresare
fan efficiencies are an ongoing focus normally selected. Low voltage
ofWATCOR&D.Workingwithleading dynamicbraking(tokeepmotorsfrom
fan manufacturers like IVI IImed, rotating when inoperative which will
HowdenandAerotech,wecontinueto preventcondensation)areincludedin
optimize fan selection to provide the
theWATCOpackage.
best adjustable pitch machines which
combined with light weight blades
maximizes air flow and minimizes
noise and vibration with state of the
artefficiencies.

Gear Drives / Drive Shafts

Speed reduction is accomplished with
gear drives in preference to higher

maintenance and less efficient VBelt
drives. Design incorporates L10
bearing life and service factors are in
accordance with CTI Standard 111.
Remote oil level indicator is standard
withconvenientrefilllocations.

Preferred gear drive supplier is

Sumitomo (Japan or Chinese origin).
ABB/Siemensisanalternatesource.

Electric motors
Appropriate NEMA enclosures are
selected suitable for cooling tower

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE STRUCTURE AND COMPONENTS


Vibration Isolation and

Auxiliary Items
The constant rotational movement in
the tower causes vibration and this
has (if not limited) impact on the
operationallifetimeoftheequipment.
Vibrationcanbeisolatedbytheuseof
springs or synthetic rubbers. Isolators
canbeinstalledundertowerorunder
mechanicgroup.

Auxiliaryitemsincludeextendedoilfill
and gauge lines, mechanical,
equipment removal device, basin
heaters, filter systems, fan
brakes/back stops and vibration
controlswitch.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE STRUCTURE AND COMPONENTS


Thee relevance of CTI Th

hen, for HVAC insstallations the
Cerrtification
n in HVAC
C applied fo
ollowingapplies:
Coooling Tow wers In generaal HVAC in nstallations are
slightly/m
moderately overdesiggned
CTI is the bran
nch organizzation of th he fromtherrequireddeesigncondittions
cooling tower industry that plays an a In practice, cooling towers are
imp
portant rolee in the seelf regulatio on actually rarely subbjected to the
proccess of th he industryy and helps onditions (in
design co n terms of heat
(pottential) buyyers in makking the rigght loadandWWBT).
decisions in the processs of supplier
and
dequipmenttselection. Thhe inevitabble question
n then pressents
Coo
olingtowermanufacturerscanhavve itself: Whatt is the addded value e of
theiir installattions CTIcertified by suubjecting a
a newly installed coo oling
meaansofeitheerafactorytest(CTI10 05; ower that runs smoo
to othly and that
app
plicable to standard models of delivers on its promisee to a CTItest,
cooling towerss) or a fieeld test (CTTI coonsidering the ffinancial and
201
1). organizationalresourcesinvolved??
Ad C
CTI105: It may be a better app
proach to agree
Obvviously,thistestapplieestostandard onaCTIfielddtestasaw
waytoresollvea
mod dels ratherr than tailo
orengineereed disputeoncoolingtoweerperformaance
installations. raather thaan a sttep in the
In HVAC ap pplications jobspeciffic coommissioningprocess..
requ uirements often lead d to a tailor Foor the record, WATTCO does not
mad de solution n, based on availab ble in
ntend to dismiss the importance of
spacce and other architecturral field testing as a part of the
limitations. Deeviations from standard coommissioning process. The aim is i to
mod dels may be
b expected d in terms of addvocate using the tesst where it has
boxxsizing,airiinletsorinffillheight,faan re
eal relevan nce. That would be e in
mod del and po
ower etc. Such
S tailoreed sppecific indu
ustrial applications (po
ower
installations obviously cannot be b plants,chem micalindustrriesetc),where
subjjected to a factory tests, simp ply evvery bit of co ooling to ower
because of financial
f and practiccal performancee directly translates into
(plaanning,timeedelay)facttors. output.
Ad C
CTI201: n HVAC projects w
In where spe ecific
A field test seems the practiccal re
equirementts call forr tailor made
m
solu
ution for th
hese tailormmade coolinng soolutions, a pragmatic approach with
tow
wer solution ns. Howeveer, also heere
re
egardstoco oolingtoweerperformaance
pracctical reasoons of finaance (budgget
maybethep
m preferredch hoice.
for a field tesst @ US$ 25,000) an nd
plan
nning (limiited testing resourcees,
waittingperiod offewmonthsormo ore
mayy apply) come into the picturre.

WATCO GROUP PTE LTD

D COOLING TOWER
R ENGINEERING GUIDE C
CTI CERTIFICATIION IN HVAC



Waarranty annd Performance Standard W

Warranty
y Conditio
ons
Guaarantee
Our
O coolingg towers are care efully
WACON WCN and Aquafan coolin ng en t your reequirement and
ngineered to
towwer modules are desiggned to meeet built from m highest quality of
preccise and speciific client
coomponents..Provided thattheserrvice
specifications and in accoordance with
an nd mainteenance insstructions and
the requiremeents as desccribed by CTI
C
procedures, as laid down in the
andd Euroventt. General engineerin ng
stipulationsareefollowed andonlyto op operational manuals, are follo owed
branndmechanicalequipm mentisused. sttrictly they can have an operatiional
a always on the saafe
Ourr designs are liffetime that exceed ds 25 ye ears.
sidee as to exclude operation nal Our
O warrannty condittions are the
limitations. Wee thereforee guaranteee a fo
ollowing:
therrmalperforrmancecapabilityof10 00%
(witthallowableetoleranceof+/5%). 12montthsonallcomponents.
Where requireed we sup pport a joint 60 months on thee cooling toower
field
d perform mance test of th he structuree.
installationacccordingtotthetestcod de Warranttyprotectsaagainstmatterial
ATCC105 as puublished byy CTI. Wheere defects or d
deficiency in
suchh test dem
monstrates flaws in th he performance.
installation WATCO allocates Faulty maintenan nce, as well
necessary ressources to o bring th he unskilledd treatmeent of the
towwer in the range of the
t specifieed installation,notinaaccordance with
perfformance. operatioonal recomm mendations and
instructioonsexcludeesanywarrranty
claims.
Warranttyperiodsarefromdatteof
startupordateofsshipment(add6
months);whicheverrcomesfirstt.

WATCO GROUP
R PTE LTD COOLING TOWER ENGINEERING
G GUIDE SYSTEM WARR
RANTY



Ma
anufacturiing and Lo
ogistics
Logistics
Ma
anufacturiing
Options
O to ship in 20 vs. 40
WATCO GRO OUP PTE LTD is an a coontainers are
a discusseed with pro oject
enggineering coompany, raather than a paartners, deepending o on project size
man nufacturingg companyy. Followin ng an nd destinaation. With h components
the success of the Eu uropean car
c frrom differeent originss (partial) LCL
induustry we have established th hat shhipmentsm maybeused d.Airfreighttcan
worrking with a
a network of renowneed beahelpful tooltoavo oiddelaybyykey
suppliers in various
v co
ontinents we
w coomponents that need longer
keep our hand ds free to do
d that wh hat manufacturin
m ngtime.
we like and where our co ore Sh
hipment cost
c consid derations may
com
mpetence lies: installatio
on afffect deccisions towards pre
enggineering. asssembled vs. onsitee assemblyy of
With our project teams in Singapo ore co
oolingtoweerinfillattim
mes.
and
dHongKonggweareab bletosource
our materials from the workshop
w of Available coontainer sizzes can be e an
theworld,SoutthEastAsiaa. isssuewhensspecialrequ uirementsarein
WithourEurop peanroots andnetwo ork placeforpreeassembledcoolingtow wers
we have acccess to the leadin ng orcoolingtoowerparts((basins).Spe ecial
Euroopeancomponentsup ppliersasweell. soolutions aree then avaiilable, eithe
er in
Ourr supplier network has beeen
engineering or shipm ment
careefully builtt up overr the yearrs.
arrrangementts.
Havving access to reputed
d and reliab
ble
suppliers we can offeer the beest
solu
utionsforanyjob,anyywhereinth he
worrld.

WATCO GROUP
R PTE LTD COOLING TOW
WER ENGINEERIN
NG GUIDE MANUFACTURING
G AND SHIPMENT
T



The text presented on the following pages can be used
as a template for specification of the cooling tower
section for your projects.

(Wordversionsareavailableatrequest)

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SPECIFICATION TEMPLATES


1 TECHNICALSPECIFICATIONSWCNSERIES:
2 COOLINGTOWERPRICIPLE

3 InducedDraftModularCOUNTERFLOWEvaporativeCoolingTower.

4 DESIGNCONDITION
5 Eachunitshallhavethecapacitytocool: ____m3/h ____gpm
6 ofwaterfrom (HWT) ____C ____F
7 to (CWT) ____C ____F
8 atanairenteringconditionof(WBT) ____C ____F
9
10 CoolingTower(CTI)Standardsappliedtorelevantsectionsofthisspecification:
11 CTI105 AcceptanceTestCodeforWaterCoolingTowers
12 CTI111 GearSpeedReducers
13 CTI131 FiberglassReinforcedPanels
14 CTI136 ThermoplasticsusedforFilm&SplashFillandDrift
15 Eliminators
16 CTI137 FiberglassPultrutedStructuralComponents
17 CTI203 IndustrialCoolingTowerStandard
18 ESG152 StructuralDesignofFRPComponentsinCooling
19 Towers
20 ASTME84 TestMethodforSurfaceburningcharacteristicsof
21 buildingmaterials
22 NEMA/ICE Motorstandards
23 AMGA/DIN GearDrivestandards
24
25 MODELSELECTION
26 Manufactureasshownondrawingno:induceddraftcounterflowcoolingsquare
27 shapedcoolingtower(s).
28
29 STRUCTURE
30 ThestructureprofilesshallbemanufacturedinFRPpultrusion.Theprofilesare
31 boltedwithfastenersinSST(304or316).Theprofilesaremanufacturedaccording
32 appliedstandardsforflammabilityratingandUVprotection.Thestructureis
33 designedforawindspeedonanysideofthetowerof<30m/s.
34 TheapplieddesignstandardsareDIN&ASHRAEcodesforFRPstructuraldesigns.
35 Colorshallbelightgrey,equaltoRAL7035orasperrequirement.
36 Allhandrails,cageladderandstaircasesaredesignedaccordingOSHA/DIN
37 standards.
38
39 COOLINGTOWERDECK
40 ThecoolingtowerdeckshallbeofpultrutedFRPreinforcedpanelswithantislipdeck
41 surface.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SPECIFICATION TEMPLATES


42 EachcellisforeseenwithaSSTinspectionmanholewithinternalladderinFRP
43 minimum60x60cm,2'x2'.
44 FANBELLSECTION
45 Thefanbellshallbeventureshapedwithaninletradiusforoptimalfanperformance.
46 Colorshallbelightgrey,equaltoRAL7035.
47
48 (OPTIONAsafetymeshmaybeaddedwithfollowingtext):
49
50 Thefanconeshallbecoveredwithaheavygaugesteelwirefanguard.
51
52 MECHANICALGROUP
53
54 FAN
55 Thehighefficientaxialpropellerfanshallbeheavydutyandstatically
56 balanced.ThefansshallbemanufacturedeitherinaluminumalloyorFRP
57 pultrusionswithHDGShub.Theshaftconnectionshallbewithkeylockacc
58 DIN6885/2.Eachfanbladeshallbeindividuallyadjustableduringstandstill.
59 Thefanshallbeinstalledinacloselyfittedconewithventuriairinletfor
60 maximumfanefficiency.
61 PreferredBrands: IlmedIVIItaly
62 HowdenNetherlands/USA
63 AerotechIndia
64 MooreUSA
65
66 MOTORSHAFTSPEEDREDUCERUNIT
67
68 HORIZONTALANGLEDGEARDRIVE
69 Thedriveunitisengineeredwithamotor,aflexiblecompositeshaftandan
70 angledgeardriveunit.
71 Theangledgeardriveisasingle/doublestagepistonreducerwithspecial
72 designedcrownwheelstoabsorbshockloadse.gfanbladepassfrequency.
73 Thebearingsshallbedesignedforaminimumlifetimeof40.000operational
74 hours.Thegeardriveholdsamin.levelofoil.Theoillineisbroughtoutside
75 thewetairbyaSSTpipingsystemforfill,drainandlevelcontrol.Alldrive
76 equipmentshallbemanufacturedincastedsteelandprotectedwithepoxy
77 coating,atleast250m.
78 PreferredBrands: AmarilloUSA
79 SiemensGermany
80 SumitomoJapan
81
82 COMPOSITESHAFT
83 Thepowertransmissionbetweenthemotorandthegearboxisestablished
84 byacompositeshaft,dulydesignedfortheshockfreepowertransmissionto
85 thefan.ThecompositeshaftshallbeequippedwithSST304/316flexible
86 couplings.ServiceFactor>2.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SPECIFICATION TEMPLATES


87 PreferredBrands: ADDAR/RexnordUSA/EU
88
89 MOTOR
90 ThemotorshallbeTEFC/ICEclassIIefficiency,protectionIP55upwards,
91 insulationclassF5withenclosedballbearingsandaservicefactorof>1.12.
92 Themotorpowershallbe:____V;_____Hz.Bearinglifetime>40.000hrsof
93 operation.
94 PreferredBrands: ABBEU/Asia
95 ElectramoBelgium
96 BrookCromptonUK
97 WEGEU/America
98
99 DRIVEFRAME
100 TheframeforthemechanicalcomponentsisinHDGSorSSTandholdsthe
101 setuppointsformotorandgeardrive aswell1or2shaftprotectors.
102
103 (OPTIONInsteadoftraditionalmotorshaftgeardrivecombination,selection(of
104 smallerunits)maylookatanintegratedunitwhichwouldbebelowspecification
105 text):
106
107 COMPACTGEARINLINEDIRECTDRIVE
108 Thefandriveshallbeacompactangledgearreducerdrive(forfans1800
109 3360mm)withsinglestagecrownwheelandpistonwithdoublebearing.The
110 bearingsshallbedesignedforaminimumlifetimeof40.000operational
111 hours.Themotorisdirectlycoupledtothepistonshaft.Theinputandoutput
112 shaftareequippedwithtopbrandseals.Thegeardriveholdsamin.levelof
113 oil.Theoillevelistobecheckedwithaninternaldipstick.Followthe
114 operationalinstructionsforoilchange.Alldriveequipmentshallbe
115 manufacturedincastedsteelandprotectedwithepoxycoating,atleast250
116 m.ServiceFactor>2.
117 PreferredBrands: BockwoldtGermany
118
119 WATERDISTRIBUTIONSYSTEM
120 Thecoolingtowershallhaveaninletinternalpiping#40/PN10withDIN/ANSI
121 connectionflange,whichdividesthewaterequallyoverthewetsection.Thefillwill
122 bewateredbyasufficientnumberofnoncloggingspraynozzles.Thenozzlesshallbe
123 manufacturedbythecoolingtowersupplierforsinglesourceandresponsibility.
124 DependingoftheinlettemperaturesthepipingsystemismadeinPVC,ABS,FRPor
125 SST.
126
127 HEATEXCHANGEINFILL
128
129 CENTRAPACKforcleantreatedcoolingwater.
130 ThecoolingtowerfillshallbeinPVCorABS,crossflutedfilmtypedesignY15for
131 optimumheattransferefficiency.Thefillthicknessshallbeatleast280mandshall

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SPECIFICATION TEMPLATES


132 bemanufacturedbythecoolingtowermanufacturerforsinglesourceand
133 responsibility.Thefilmshallbeselfextinguishingforthefireresistancewithaflame
134 spreadratingof5perASTME8481a.Itshallalsoberesistanttorot,decayand
135 biologicalattack.Forstandardoperatingtemperaturesthefillshallbeableto
136 withstandacontinuouswatertemperatureof55CforPVCand80CforABS.
137
138 (OPTIONInsteadoffilmfill,selectionmaycallforsplashfillwithfollowingtext)
139
140 CENTRAFILLforcontaminatedcoolingwater.
141 Theinfillpackconsistsofacertainleveloftrianglecorrugatedprofiles.Thetriangle
142 barsareincrosssectiontowardseachotherinthetowerstructure.Duetothe
143 extremelabyrinthfunctionofthepositionsofthecorrugatedprofilestheairflows
144 withintenseturbulenceintheinfillstructure.Inthesametimethewaterdropletsdo
145 attachtotheprofilesandfreefallrandomlydowntolowerlevelswereitissplitover
146 theprofileangles.Thelargeholduptimeofthewaterinthetowercreateanefficient
147 exchangeoftheheatload.
148
149 ELIMINATORS
150 CENTRADECK
151 TheeliminatorsshallbeinUVprotectedPVCorABSdoubleanglelabyrinthdesignto
152 avoidwaterindropletsleavingthetowerviatheexhaustairstream.Theefficiency
153 ofthedrifteliminatorshallbe<0.005%ofthecirculatingwatervolume.
154
155 AIRINLETLOUVRES
156 LOUVERS:
157 TheairinletlouveravoidsplashoutofthewaterandshallbeofFRPinSST304or
158 316holders.Thelouversshallbeinsectionsandeasilyremovable.
159
160 (OPTIONInsteadoflouvers,selectionmaycallforPVCscreenswithfollowingtext)
161
162 SCREENS:
163 Theinletscreensavoidsplashoutofthewateraswellsunlightimpactandan
164 additionalnoisereductionofthefallingwaterandshallbeofaFRPfamewith
165 labyrinthelementsinPVC.
166
167 OPTIONALITEMS
168
169 WATERBASIN:
170 ThewaterbasinshallbemanufacturedinrigidFRPsectionalpartsforeasy
171 installation,longlifeanddurability.Standardbasinaccessoriesshallbeincludedas
172 inletflangewithstrainer,drainsocketandoverflowsocket.Thebasinisdesignedto
173 holdingaminimumrequiredwatervolumeforlowoperationweightandeasy
174 maintenance.Vitalpointsareslopedesignedforfulldrainage.Colorshallbelight
175 grey,equaltoRAL7035.
176

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SPECIFICATION TEMPLATES


177 (CAGE)LADDER/STAIRCASE,HANDRAIL:
178 TobemadefromFRPpultrutedprofilesaccordinginternationalDIN/OSHA.SAME
179 standards.
180
181 VIBRATIONSWITCHES.
182
183 FLOATVALVESorINDUCTIVELEVELCONTROLWITHFILLVALVE.
184

185 Disclaimer:

186 Due to continuous improvements in research & development of our products, the data shown in this catalog are
187 subject to change without notice. Please contact your local dealer or www.watco-group.com for updated
188 information. This paper was designed in October 2015.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SPECIFICATION TEMPLATES


TECHNICALSPECIFICATIONSAQUAFANSERIES:
ForthetechnicalspecificationsofAQUAFANTurbinePoweredCounterFlowcooling
towers,usethespecificationofWCNseriesinwhichthetextinlinenumbers52125
(SectionsMechanicalGroupandWaterDistributionSystem)isreplacedbythe
following:

FAN:
Thehighefficientaxialpropellerfanshallbeheavydutyandstaticallybalanced.The
fansshallbemanufacturedofABS(18002400mm)withstainlesssteel(304)hub
connectedtoaturbine.Eachfanbladeshallbeindividuallyadjustableduring
standstill.Thefanshallbeinstalledinacloselyfittedconewithventuriairinletfor
maximumfanefficiency.

TURBINE:
Thefanshallbeconnectedtoaturbinethroughwhichtheprocesswaterentersthe
coolingtower.Thepressureoftheincomingprocesswatershallturnthefanand
applythedesiredcoolingeffect.Thereshallbenoelectricalpartsinthetower.

WATERDISTRIBUTIONSYSTEM
Theincomingprocesswatershallbedistributedevenlyoverthewetsectionviathe
turbinespindle.Thewatershallhavesufficientpressurefromthesystempumpto
turnthefan.

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE SPECIFICATION TEMPLATES


Company Profile

CompanyName : WATCOGroupPTELTD
CompanyType : LimitedExemptPrivateCompany
Registeredin : Singapore
Registrationnumber : 201322647W
CompanyAddress : Tower1,RafflesPlace#4402
Singapore048616
Telephone+6531581332

Subsidiaries : WACONInternational(HK)Ltd
WACONGuangzhouTradingLtd

Directors/shareholders : HubertPoels,ManagingDirector
sg.linkedin.com/in/hubertpoels/

HenkJanssen,OperationsDirector
sg.linkedin.com/in/henkjanssen/

Employees : 12
AnnualTurnover : US$2,500,000
Activities : Industrialwatercoolingsolutions

Productlines : Coolingtowers
Motorlesshydropoweredcoolingtowers
Onlinebrushingsystemsforshellandtube
heatexchangers
Enthalpyrecoveryunits

BriefHistory : FoundedasWACONAQUAVENBVin1984in
Netherlands,specialistincoolingtowers.
In2002movedcompanyheadquartersto
HongKongwithfocusoncoolingtower
projectengineering,consultingand
componentsupply
In2013establishednewheadquartersin
Singapore

WATCO GROUP PTE LTD COOLING TOWER ENGINEERING GUIDE COMPANY PROFILE


Background : TheGrouuphasalonngexperiencceincoolingtower
engineerring.Inrecentyearstheedevelopm mentand
engineerringofenerggysavingteechnologiesshas
beengiveenprioritiessandresulttedinthelaaunchof
motorlessscoolingtoowersandh highperform mance
onlinecleaningsysttemsforheeatexchangers.

Mainmarketsarein nSouthEasttAsiaandM Middle
East.

Compan
nyWebsites : www.watcogroup.cco
www.wacon.co
www.aqu uafan.co
www.eqo obrush.co

WATCO GROUP
R PTE LTD COOLING TOWER
O ENGINEER
RING GUIDE COMPANY PROFILLE