TECHNICAL SPECIFICATION FOR PROCURING JET TYPE COOLING TOWER

1.0 Bharat Petroleum Corporation Ltd Kochi Refinery (BPCL-KR) propose to

install and commission a jet type fanless cooling tower for the cooling circuit of
our Gas Turbine unit.

2.0 Vendor to design, supply, erect and commission the cooling tower as per
datasheet and below mentioned conditions at BPCLs refinery at Kochi,
Ambalamugal, Kerala.

3.0 The scope of work shall include design, engineering, procurement,
manufacture, shop testing & inspection, supply of all items including materials
and equipments, mandatory and commissioning spares, consumables, special
tools and tackles, transportation, storage and handling at site, installation,
painting, commissioning, trial run and performance guarantee test run of
complete jet type cooling tower, as per datasheet/ documents attached and
below mentioned conditions.

4.0 Cooling tower shall comply with stipulations laid down in the latest edition of
following codes and standards


CTI Cooling tower institute
CTI ATC-105 Acceptance test code for water cooling tower
CTI STD-131 Fibreglass reinforced plastic panels for application
On industrial water cooling towers
NFC 214 Water cooling towers

5.0 All materials required for completing this job shall be in vendors scope. BPCL-
KR shall not provide any free issue material.

6.0 The particulars of cooling tower including the area available for installation,
shall be as per datasheet attached.

7.0 The material of construction of various items shall be as follows:

Structural members : IS 2062 structural steel with 2 mm FRP
coating
Louvers : FRP moulded
Spray nozzle : Nylon 6
Connecting rings and base frame : FRP coated steel
Bolts and nuts for structure : GI
Bolts and nuts for FRP Louvers : Glass filled nylon nut bolts
Piping and valves : As per piping material specification
A3A attached

8.0 The P&ID of the proposed Jet type fanless cooling tower is given as
attachment. Vendor shall supply level transmitters and temperature
transmitters given in P&ID. The piping and valves upto the scope shown in
P&ID shall also be supplied by the vendor.

Our existing pump specification for hot water return circuit is


9.0 Civil jobs including the construction of basin and civil foundation of the
structure are excluded from vendors scope. However, vendor shall provide all
details and drawings for the construction of RCC basin and foundation for the
cooling tower.



10.0 The hot water inlet header shall be routed to the bottom of the cooling tower
with block valve at operable level. Vendors scope of supply of piping shall be
upto the first isolation valve of the header at grade level. Piping of hot water
inlet shall conform to A3A specification of M/s EIL which is attached.


11.0 Vendor shall check minimum pressure requirement in return header with return
header pressure available at cooling tower grade as specified in clause no
below. Vendor to finalise the cooling tower height accordingly and design hot
water riser to suit the battery limit pressure conditions. Each riser with nozzle
shall be provided with isolation valve.

12.0 The structure works shall include pipe supports, cable supports, operating
/maintenance platforms, walkways, crossover, stairs, ladders, handrails, bolts
& nuts etc.

13.0 Basin and channel shall be so designed that full flow conditions can be
attained even at minimum water level in basin. The sluice gate should be able
to discharge the full cell capacity at minimum water level and levels of gate
shall be fixed accordingly

14.0 The main columns of the cooling tower framework shall be suitably designed
so as to transmit all loads to cooling tower foundation and shall be properly
braced by horizontal and diagonal members. All portions of the frame work
structure shall be bolted.

15.0 Air inlet louvers shall be suitably designed, supported and arranged so that
there will be minimum restriction to air flow and prevent downcoming water
from splashing out of tower. The material of construction shall be FRP. All FRP
materials shall have a flame spread of 50 or less as per ASTM E84.

16.0 Drift eliminators shall be provided to limit drift losses to a value not greater
than 0.05% of design water circulation rate. Drift eliminator section shall be
designed to permit easy removal and replacement.

For counter flow cooling tower shall have minimum 610 mm vertical clear space
between spray headers and drift eliminators.

17.0 All parts subjected to periodical maintenance and inspection such as drift
eliminators, nozzles etc shall be readily accessible and easily removable.
Access door shall be provided at basin level in each cell. The door shall have
easily operable shutter of leak proof design.

18.0 One stairway of width not less than 750 mm clear shall be provided on casing
side from ground level for access to top deck. Staircase shall be provided with
handrails of 1 meter height, GI pipe uprights at spacing not more than 1.5 M
intervals, knee rails and toe boards and suitable landings shall be provided on
stairways at intervals not more than 4 meters vertically. Stairways shall be at
45 deg maximum with horizontal. The riser shall not be more than 200 mm.
Construction detail of stairway shall be in accordance with IS standard. Knee
rails and toe board shall be provided with one coat of red oxide zinc chromate
primer and 2 coats of approved enamel paint.

19.0 Basin for cooling tower shall be or reinforced cement concrete construction.
The concrete structure shall be designed as per IS 456, IS 3370 (latest edition)
and other relevant IS codes. The basin including channel shall have a holding
capacity to retain 10 minutes of recirculating water between minimum and
normal water level. A minimum of 300 mm free board shall be provided in
basin and channel. Depth of basin below min water level shall be 300 mm
minimum. The basin shall be divided into compartments by providing concrete
partition wall designed for pressure on one side only. Top of basin kerb shall
be fixed by vendor depending on the size of basin and water depth to suit 10
min basin and channel capacity.

Basin shall have adequate provision for following and these facilities shall be
provided for all compartments.

a)Drain off and sludge removal arrangement with piping valves and flanges
etc.
b)Overflow arrangement
c)Necessary MS pipe with puddle flanges (150#) and MS inserts wherever
required

Three phase power supply will be provided free of cost at one location near the work
site and vendor shall make own arrangement to extend power supply to all lighting,
welding and other requirements for erection works.

Vendor shall provide a walkway and ladder for approaching the nozzles with suitable
handrails

The repair /replacement of nozzles shall be possible without shutting down the
equipment.


All underground pipelines shall be provided with suitable corrosion protection as per
EIL specification.

20.0 Commissioning of entire system within package battery limit shall include
testing and trial run for 30 days.

21.0 BPCL-KR or its authorized representative will have the right to inspect at any
stage of manufacture and construction, all materials, components and
workmanship and testing of materials. Vendor shall provide all facilities of
inspection and testing without any extra cost to BPCL-KR.

22.0 Performance guarantee & tests
The cooling tower shall be tested and guaranteed to meet performance
requirement when tested in accordance with the procedure set forth in latest
revisions of the test procedure ATC-105 of CTI. The performance guarantee
test shall be conducted for 72 hours running. If the performance test shows a
deficiency, vendor shall rectify the defects without any additional cost to BPCL-
KR

23.0 Commissioning spares shall be supplied by the vendor well before
commissioning of the equipment. If any additional spares are required during
commissioning, the same to be supplied by the vendor. Any left over spares
shall be handed over to BPCL-KR. Vendor shall submit a list of spares
required for 2 years continuous operation with unit prices indicated against
each item. The prices quoted shall be valid for order placement at the time of
completion of work.

24.0 Vendor shall submit the following documents along with their bid:
a)Cooling tower technical data sheet with all relevant data duly filled in
b)Cooling tower thermal design calculations
c)Manufacturers design performance curves as per ATC 105 of CTI with 90%,
100% and 110% of water flow rate and range of 40 deg F, 36 deg F and 32
deg F.
d)GA drawing of cooling tower and basin with all associated structurals
e)Recommended spares for 2 years operation

25.0 Vendor shall submit the following drawings/ documents for BPCL-KRs
approval after order placement.
a)Basin holdup capacity calculations
b)GA drawing of cooling tower and basin with associated structurals.
c)Civil details of foundations and basin

26.0 Fabrication drawings submitted to BPCL-KR shall indicate item number,
clients name, fabricators name, purchase order number, drawing number
etc., all in the lower right hand corner. All revisions shall be clearly marked by
encircling with revision marks. Submission of required drawing/documents
shall be the responsibility of the fabricator.


27.0 All drawings shall be thoroughly checked and duly signed by the vendor.
Unchecked drawings and drawings without revisions clearly marked shall be
returned without review. Successive review of the same fabrication drawing
shall apply only to BPCL-KRs latest data sheet/ comments on the previous
revision. Drawings and documents returned to the fabricator for revision shall
be resubmitted at the earliest. Vendor must ensure that all the vendor
documents are thoroughly checked and approved at vendor's end by vendor's
competent engineer and responsible engineering office in charge before the
same are submitted to BPCL-KR for review.

28.0 All the drawings shall be prepared on Auto CAD 2000 or later versions.
English language and metric units shall be used in all documents. Drawings
shall be prepared in prescribed sizes as standardized by Bureau of Indian
Standards (BIS).

29.0 Three sets of as built drawings and data, one set of reproducible and soft copy
of all drawings in autocad, shall be supplied by the successful bidder at the
time of handing over of the equipment. Soft copies of all drawings shall be
submitted to BPCL-KR in flash drive as part of final documentation.