TECHNICAL SPECIFICATION FOR PROCURING JET TYPE COOLING TOWER

1.0Bharat 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.

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

3.0The 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.

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

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

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

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

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

Structural members : IS 2062 structural steel with 2 mm FRP coatingLouvers : FRP mouldedSpray nozzle: Nylon 6Connecting rings and base frame: FRP coated steelBolts and nuts for structure: GIBolts and nuts for FRP Louvers: Glass filled nylon nut boltsPiping and valves: As per piping material specification A3A attached

8.0The 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

9.0Civil 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.

10.0The 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.

11.0Vendor 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.

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

13.0Basin 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

14.0The 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.

15.0Air 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.

16.0Drift 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.

17.0All 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.

18.0One 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.

19.0Basin 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 arrangementc)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.

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

21.0BPCL-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.

22.0Performance guarantee & testsThe 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

23.0Commissioning 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.

24.0Vendor shall submit the following documents along with their bid:a)Cooling tower technical data sheet with all relevant data duly filled inb)Cooling tower thermal design calculationsc)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 structuralse)Recommended spares for 2 years operation

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

26.0Fabrication 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.

27.0All 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.

28.0All 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).

29.0Three 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.