Series

9KF

PULTRUDED FRP INDUCED DRAFT COUNTERFLOW COOLING TOWERS

9KF 13-Apr-2015
 PAHARPUR SERIES 9KF FIBREGLASS COUNTERFLOW COOLING TOWER

Paharpur's series 9KF induced draft cooling tower represents the culmination of more than 50
years of counter flow design experience. With polyvinyl chloride fill and glass reinforced polyester
structural, basin and casing, the series 9KF continues a tradition of excellence.

Improvements and innovations in structure and component designs produce in the series 9KF a
heavy-duty, energy efficient and dependable cooling tower unrivaled in the industry. Perhaps most
importantly, all major components responsible for this breakthrough have been developed,
manufactured, applied and guaranteed by one single source company – Paharpur. Without
question, the series 9KF establishes a new state of the art in counter flow cooling tower design.

PAHARPUR'S INTEGRATED SYSTEMS DESIGN

Although Paharpur's original motivation in the design and manufacture of all major cooling tower
components was to assure dependability and longevity, a secondary benefit quickly became of
prime importance. That benefit was the ability to coordinate a variety of components of known
design characteristics into a cooling tower of assured thermal performance predictability.

Paharpur's philosophy of component design has been – and continues to be – to assess the value
of a development only in terms of its effect upon the total cooling tower system. Particular fills, fans,
fan cylinders, etc., tend to optimize within a very narrow range of tower configurations and design
parameters. Consequently, a considerable variety of individual components is required in order to
achieve a near-ideal combination for any operating circumstance. And it is imperative that these
components be designed and rated within a cooling tower system context.

Paharpur has all such variety of components. Their capabilities are well known because they were
designed and manufactured by Paharpur.
STRUCTURE: Structural components are glass fibre pultruded composite. Columns are 65 X 65
nominal box section with a minimum 5 mm wall thickness and carry loads to anchor castings.
Columns are spaced on no greater than 1520 mm centres both longitudinally and transversely.
Diagonal and other structural connectors are through bolted.

Structure is designed based on wind load of 150 kg/m 2 and in accordance with CTI standard ESG-
152.

Pultruded FRP is far superior to HDG steel in terms of corrosion-resistance and, therefore, life of
the cooling tower. In fact, FRP is ideal for wet, corrosive conditions encountered during cooling
tower operation. The pultrusion process produces fibreglass components of extremely high
standard, with consistent strength and performance, and a strength-weight ratio much higher than
that of steel in the length-wise direction. The final strength in compression and tension is
approximately equal to that of steel. FRP also reduces the hazard of electrical shock compared
with steel structure towers. Finally, for the environmentally conscious, the carbon footprint of the
pultruded FRP production process is lower than that of steel’s.

Pultruded FRP structure cooling towers are now the standard worldwide and especially in USA.
We have multiple installations in India and countries across the world, such as UAE (Dubai), Saudi
Arabia, Kazakhstan, Chile and New Caledonia.

FILL: Vacuum formed 0.3 mm thick polyvinyl chloride (PVC) sheets with a flute size of 12 mm are
solvent welded into a cross corrugated configuration to provide maximum heat transfer surface
with minimum pressure drop and pump head. These have a flame spread rating less than 25 mm
as per ASTM D635.

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ELIMINATOR: Drift eliminator panels are formed from 0.5 mm thick PVC sheets into a cellular
configuration which forces exhaust air into three complete directional changes to eliminate water
droplets from the air stream. The 3-pass eliminator provides maximum efficiency in elimination up
to 0.005% of circulating water flowrate at the very minimum in horse power consumption. These
also have a flame spread rating less than 25 mm as per ASTM D635.

SPEED REDUCER: Designed and manufactured to furnish extended service life in industrial water
cooling applications, Paharpur gear reducers have an overall mechanical efficiency of 95%. They
are rated in accordance with CTI STD-111 and have a service factor of over 2.0. Their rugged
design has been proven by years of field operational experience worldwide.

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FAN: Designed, tested and manufactured by Paharpur. Fan materials include cast aluminium
alloy, glass reinforced polyester, and glass reinforced epoxy. Fan sizes and materials are selected
to provide the most efficient solution to any cooling tower application requirement. Fan assembly
is balanced per balance quality grade G 6.3 as mentioned in the standard ISO 1940.

DRIVE SHAFT: Utilizing floating tubular shafts and neoprene flexible elements. Paharpur
designed and manufactured drive shafts do not require lubrication and are dynamically balanced
prior to shipment.

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DISTRIBUTION SYSTEM: Uniform hot water distribution is guaranteed by Paharpur's injection
moulded polypropylene nozzle, incorporating a unique diffusion ring for spray development
distribution. This nozzle system is specially designed to function under low operating heads for
greater energy efficiency. Large diameter orifices contribute to overall reduced maintenance costs.

FAN CYLINDER: Fan cylinders are Paharpur designed and manufactured glass reinforced
polyester (GRP), molded to provide a large entrance flair, smooth approach to the fan, and close
tip clearances for maximum efficiency and reduced operating costs.

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 Typical tower schematic
(Single Cell)

For detailed engineering data refer Table 1

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 Table 1
Tower Engineering Data

Tower Length Width Height Total Motor Fan Gear box Drive No. of No. of
Model (mm) (mm) up to Height up HP Shaft water inlets
(Only fan deck to fan distri- &
TB) (mm) guard bution outlet
H1 (mm) nozzles s
H2
Type Dia No. of Speed Sr. Ratio Sr.
(Inch) blades (rpm)
91441 7.5 6
91442 2546 2546 4181 4702 10 H-3 72 535 20T 2.71 6Q 16 1
8
91443 15
91451 7.5
91452 10
3146 2546 4181 4702 H-3 72 8 535 20T 2.71 6Q 20 1
91453 15
91454 20
91552 10
91553 15
3146 3146 4181 4733 H-3 96 8 444 20T 3.27 6Q 25 1
91554 20
91555 25
91562 10
91563 15
91564 3766 3146 4181 4733 20 H-3 96 8 444 20T 3.27 6Q 30 1
91565 25
91566 30
91662 10
91663 15
266 5.50
91664 20
3766 3766 4181 4733 H-3 120 9 22.2 6Q 36 1
91665 25
91666 30
320 4.56
91667 40
91672 10
91673 15
266 5.50
91674 20
4366 3766 4181 4733 H-3 120 9 22.2 6Q 42 2
91675 25
91676 30
320 4.56
91677 40
91772 10
91773 15
91774 20
91775 4366 4366 4181 4812 25 H-3 144 9 320 22.2 4.56 6Q 49 2
91776 30
91777 40
91778 50
91782 10
91783 15
91784 20
91785 4986 4366 4181 4812 25 H-3 144 9 320 22.2 4.56 6Q 56 2
91786 30
91787 40
91788 50
91882 10
91883 15
91884 20
4986 4986 4181 4812 H-3 168 12 266 22.2 5.50 175 64 2
91885 25
91886 30
91887 40

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Tower Length Width Height Total Motor Fan Gear box Drive No. of No. of
Model (mm) (mm) up to Height up HP Shaft water inlets
(Only fan deck to fan distri- &
TB) (mm) guard bution outlet
H1 (mm) nozzles s
H2
Type Dia No. of Speed Sr. Ratio Sr.
(Inch) blades (rpm)
91888 50
4986 4986 4181 4812 H-3 168 12 266 22.2 5.50 175 64 2
91889 60
91892 10
91893 15
91894 20
91895 25
5586 4986 4181 4812 H-3 168 12 266 22.2 5.50 175 72 2
91896 30
91897 40
91898 50
91899 60
91992 10
91993 15
91994 20
91995 5586 5586 4181 4812 25 H-3 168 12 266 22.2 5.50 175 81 2
91996 30
91997 40
91998 50

Tower Only (‘TO’) models are also available. Multi cell models are available in both ‘TO’ and ‘TB’ configurations.
Details are available on request.

Optional Extras: 1) Fixed type HDG steel ladder.

2) Lube line with sight gauge options.
3) Vibration Limit Switch.
4) Low Oil Level Switch for Gear Reducers.
5) Perimeter Handrail.
6) SS304/SS316 Structural Hardware.
7) FRP fan blade in lieu of cast aluminium alloy fan blade.

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OPERATING AND ENVIRONMENTAL CONSIDERATIONS

ENCLOSURES
Occasionally, cooling towers are located inside architectural enclosures for aesthetic reason. Although the
Paharpur cooling towers adapt well to enclosures, the designer must realise the potential impact of a
poorly arranged enclosure on the tower's performance and operation. The designer must take care to
provide generous air inlet paths, and the minimum distance specified should be observed.

NOISE LEVEL
Sound produced by a series 9KF tower operating in an unobstructed environment will meet all but the
most restrictive noise limitations and will react favourably to natural attenuation. Where the tower has
been designed to operate within an enclosure, the enclosure itself will usually have a dampening effect on
sound. Sound also declines with distance by about 5 dBA each time the distance doubles. Where noise at
critical point is likely to exceed an acceptable limit, you have several options listed below in ascending
order of cost impact:

 In many cases, noise concerns are limited to night-time, when ambient noise levels are lower. Such
situations are tackled by using two (2) speed motors in either 1500/1000 or 1500/750 rpm
configuration; and operating the fans at reduced speed without cycling "after hours". This is a relatively
inexpensive solution and pays for itself quickly in reduced energy costs.
 Where noise is a concern at all times (for example, near a hospital) the best solution is to oversize the
tower so it can operate continuously at reduced (1000 or 750 rpm) motor speed. Typical sound
reductions are 7 dBA at two-third fan speed or 10 dBA at half speed.
 Extreme cases may require inlet and discharge sound attenuator sections; however, the static pressure
loss imposed by attenuators may necessitate an increase in tower size. This is the least desirable
approach because of significant cost impact and because of obstruction to normal maintenance
procedures.

APPROPRIATE 9KF APPLICATIONS

TYPICAL APPLICATIONS

Although the 9KF is a premium-value cooling tower targeted for those applications that demand a high
degree of corrosion resistance-as well as an aesthetically pleasing appearance-it is routinely applied in
virtually all normal systems requiring cold water for the dissipation of heat. Some common applications
include:
 Condenser water service for air conditioning and refrigeration systems. (They are especially adaptable
to Free Cooling applications).
 Jacket water cooling for engines and air compressors.
 Chemical and industrial processes.
 Batch cooling.
 Welder cooling.
 Plastic industry processes.
 Dairy, citrus, and other food industry processing where water contamination is not likely to occur.

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 PAHARPUR 9KF COOLING TOWER SPECIFICATIONS

DESCRIPTION line shall extend from the gear reducer to the

Supply and install an induced draught, motor enclosure, and shall be equipped with an
counterflow, field-erected FRP cooling tower of easily visible oil sight glass. The mechanical
............... cells, as shown on plan. Tower shall be equipment for each cell shall rest on a rigid HDG
similar and equal in all respect to Paharpur 9KF steel support that resists misalignment between
model............... the motor and the gear reducer.

PERFORMANCE FILL & DRIFT ELIMINATORS

The tower shall be capable of cooling............... Fill shall be film type, vacuum-formed PVC sheets
USGPM of water from ...............° C to ...............° C with a flute size of 12 mm are solvent welded into
at a design wet bulb temperature of ...............° C. a cross corrugated configuration to provide
The cooling tower manufacturer shall guarantee maximum heat transfer surface with minimum
the performance of the tower as installed pressure drop and pump head. These have a flame
according to plans. spread rating less than 25 mm as per ASTM D635.
Air inlet faces of the tower shall be free of water
CONSTRUCTION splash-out, and guaranteed drift losses shall not
The cold water basin, fan deck, fan cylinder and exceed 0.005% of the design water flow rate. Drift
access door shall be formed of inert fibre- eliminator panels are formed from PVC sheets into
reinforced polyester (FRP). All hardware shall be a cellular configuration which forces exhaust air
fabricated of HDG Steel. Structural columns will be into three complete directional changes i.e. 3-pass
of pultruded FRP. Mechanical equipment support to eliminate water droplets from the air stream.
structure, fan guards will be of HDG steel. Louvers shall be of FRP.

MECHANICAL EQUIPMENT HOT WATER DISTRIBUTION SYSTEM

Fan(s) shall be propeller type, incorporating heavy The FRP hot water distribution basin shall be
duty blades of cast aluminium alloy or high equipped with metering orifice-type
strength, inert composite material (FRP). Blades polypropylene nozzles to deliver incoming water
shall be individually adjustable. Fan(s) shall be by pressure to the fill. Nozzles shall be easily
driven through a right angle, industrial-duty, oil- removable and replaceable.
lubricated, geared speed reducer. Speed reducers
employing pulleys and belts will not be acceptable. COLD WATER BASIN & ACCESSORIES
Minimum service factor of speed reducers should The FRP cold water basin shall be sealed
be 2. Motor(s) shall be............... HP, TEFC weather watertight and shall include a float-operated
proof, squirrel cage induction type. Speed and mechanical make-up valve, a 100 mm diameter
electrical characteristics shall be 1500 RPM, single drain-cum-overflow connection and an HDG steel
winding, 3 phase, ............... hertz ............... volts. debris screen with side outlet.
Motor shall be located outside the humid interior
of tower, in a corner on the fan deck. Dual speed SCOPE OF WORK
motor(s) should be offered as an option at extra The cooling tower manufacturer shall be
price. The motor shall be connected to the gear responsible for the design, fabrication, and
reducer by a dynamically balanced HDG steel delivery of materials to the project site, and for the
driveshaft equipped with neoprene flexible erection of the tower over RCC foundation
coupling elements. A neoprene oil gauge and drain provided by others.

Note: FRP cold water basin can be substituted by concrete basin (by purchaser). In this case, basin accessories will also be deleted from
Paharpur's scope and Louvers will be deleted and the purpose of the same will be served by extended RCC basin (not in Paharpur’s scope).

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