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Product Information…

PANWATER PET 300 & 400 FC Series Cooling Towers

Types:

The PET 300 & 400 FC Series cooling towers are field erected induced draft cross flow type previously constructed of timber are now constructed with engineering materials replacing all timber components such as the mainframe structure and the splash bars system. They share all the advantages of timber cooling tower with the addition of longer tower life span, lighter operating weight and less maintenance required with the use of FRP Pultrusion for tower structure and extruded plastic splash bar and drift eliminator system.

Applications:

PET 300 & 400 FC Series cooling towers are designed and constructed for heavy duty continuous industrial processes where circulation cooling water is contaminated and/or untreated. Raw water or untreated water is used for make-up water supply. Bacteria growth or scaling is anticipated in the fill packing section. Circulation water with very high inlet water temperature or anticipate unusually high temperature during operation. The cooling tower is suitable to operate in environment with unavoidable air pollution where airborne particle such as dust and fibrous materials is constantly present in the surroundings. Typical applications include direct cooling water for quenching, barometric water in vacuum system, waste water treatment plant, biomass power plant, heat exchangers and condensers, equipment water jackets and cooling coil for process equipment.

Features:

Robust construction using FRP pultrusions provides long life span and trouble free operation. Extruded polypropylene splash bars construction withstands high temperature circulating water. Extruded polypropylene profile splash bar is less susceptible to clogging & increase efficiency. Smooth extruded splash bars fill packing section allows easier cleaning during tower operation. Extruded polypropylene splash bars can withstand hjigh operating temperature of up to 85ºC. Extruded polyvinyl chloride drift eliminator system reduce algae growth and easier cleaning. Gravity type hot water distribution systems provide direct access for maintenance and low pump head. Heavy duty type fan machineries provide trouble free operation and minimum maintenance.

Tower Mainframe Structure

The entire cooling tower mainframe structure is constructed of FRP Pultrusion profiles of various shapes and sizes for different structural members due to its higher flexural strength than timber and has significantly higher strength-to-weight ratio. Moreover, FRP Pultrusion materials has remarkably low water absorption properties which is almost negligible, when used for cooling tower construction, final overall operating weight is very much reduced compare to the cooling tower constructed of timber with the same model.

With this extremely superior quality, the final supporting system such as the foundation or the supporting structure required for the operating weight of the cooling tower is very much reduced while providing a very robust and strong framework to support all the cooling tower components.

As FRP is an engineered material, it is also possible the FRP pultrusion used for cooling tower construction is manufactured with the proper selection of resin system for corrosion resistant properties to cater for any specific water condition it may anticipate. Thus, cooling tower constructed of FRP pultrusion is suitable for the most demanding industrial application handling corrosive water such as the waste water treatment plant of many industrial processes and cooling water of barometric system in oil refineries where cooling water is very corrosive and contaminated.

As a standard, all FRP materials used for the construction of cooling tower shall be manufactured with fire retardant capability conforming to ASTM E-84 with flame spread rate of 25 or less with self extinguishing properties.

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email: panwater@panwater.com Website: www.panwater.com

Product Information…

Hot Water Distribution

The hot water distribution system is the open basin type located on top of the cooling tower with polypropylene nozzles embedded on the FRP basin floor to distribute hot water by gravity to the fill packing section below evenly. For multiple cells cooling tower, each cell will be provided with a single inlet pipe connection to regulate the hot water to each cell while distribution of the hot water within the tower cell will be provided with a hot dip galvanized cross over pipe with all flow control valves attached at discharge outlets to regulate volumetric flow. Water levels of all individual hot water basins are regulated and maintained at similar level by the cast iron flow control valves at each pipe discharge outlet. Hot water discharge from the flow control valves enter into the FRP splash boxes to ensure even distribution as well as prevent water splashing out of the cooling tower. Since performance of the cooling tower is very dependent upon the distribution of the hot water over all the splash bars, a very efficient splash box of FRP design has been developed to provide even distribution and prevented water which may contain water treatment chemicals from splashing to the tower surroundings or onto the personnel operating the cooling tower.

Fill Packing System

The fill packing system for the PET 300 & 400 FC Series consist of extruded polypropylene splash bars supported on grids made of heavy gauge SS304 stainless steel. The splash bars are installed in the cooling tower extending from the operating water level in the cold water basin to the hot water basin above and cover the entire air inlet area along the longitudinal sides of the tower. Each piece of splash bars is supported by 3 pieces of supporting grids and each grid is directly attached to tower framework member using grid hangers with SS304 stainless steel fasteners. Grids are welded at all contact points to ensure the dimension and shape is always maintained and rigid to prevent deformation or distortion of the grids when splash bars become very heavy when they become contaminated.

All splash bars are installed and with fixed configuration on the supporting grids to evenly expose maximum surface area for hot water and ambient air interaction to allow for efficient evaporation to take place. The newly developed splash bars with thetriangular profile has proven to be very efficient in providing extended surface area for heat exchange as well as reducing therate of sludge build up rate compare with the timber splash bars due to its smooth surface and profile shape. Life expectancy ofthe PP splash bars is also expected to be longer than timber splash bars since the PP splash bars are not subject to decaying erosion. Maximum continuous operating temperature of the PP splash bars is 80ºC while intermittent maximum temperature is 85ºC. This temperature limits exceeds most cooling water temperature in the industrial processes.

Drift Eliminator System

Since PET Series cooling towers are specifically designed to handle all kinds of industrial cooling water including very dirty and contaminated water, the drift eliminator systems installed are capable of allowing high deposition of muck commonly found in most cooling tower as well as allowing the drift eliminator system to be cleaned without damaging the materials easily. The drift eliminator system is installed inside the tower at the entire air exit plane after air passing through the fill packing system. The drift eliminator system is designed with a two pass drift elimination to remove all the larger water droplets carried by the moving air stream and to eliminate the drift loss to as small as 0.01% of the total circulation flow rate.

Drift eliminator panels are assembled from extruded PVC profile which provides features which restrain airborne water droplets as airflow passing through the eliminator panels. The extruded materials used for the eliminator panels are made to provide the rigidity and durability for the application. Moreover, eliminators are factory assembled into panels which are readily to be installed into the cooling tower withease thus making installation, maintenance and replacement becomes very easy. This innovative drift eliminator system has completely address many problems previously encounter with using timber drift eliminator such as algae growth due to exposure to sunlight and missing and broken timber eliminators each time after cleaning. This drift eliminator system had also successfully proven itself far more superior to PVC drift eliminator system made of thin PVC film formed into honeycomb shape type in terms of life span and durability.

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email: panwater@panwater.com Website: www.panwater.com

Product Information…

Mechanical Equipment

The mechanical equipment consisting of the fan assembly, gear speed reducer, drive shaft and electric motor forming the fan machinery to produce the airflow required for the tower is supported on a common sturdy base. It is located on top of the cooling tower along the tower axis and housed within a FRP fan stack to operate efficiently and safely.

The fan machinery consist of energy efficient axial flow adjustable pitch propeller fan with the fan blades made of hollow FRP construction and the fan hub made hot dip galvanized steel construction dynamically balanced with the fan blades tip speed operating not exceeding 60 m/s. The fan assembly is mounted on a spiral bevel gear speed reducer and operates at an optimum speed to achieve best tower performance. Gear speed reducer used is specifically designed for cooling tower application and has power rating at least 2.0 the power of the motor power rating. Gear speed reducer is oil-lubricated type with the lubrication pipelines extended to the external of fan stack to facilitate inspection and maintenance.

Electric motors of various voltages, frequencies and operating speeds can be supplied but only reputable manufacturer approved by Panwater will be used on the cooling tower in order to enjoy the standard cooling tower warranty provided by Panwater. Electric motors conforms to IEC Standards and is totally enclosed fan cooled type with IP55 protection and Class 'F' insulation as minimum requirement to provide complete protection against contact with dust and the effects of water. Materials of construction should have cast iron frame frames, terminal box, end shields with oil seals, and polypropylene cooling fan. Motor is located outside the humid air stream discharge by the fan and seated on the unitized mechanical equipment support common to the gear speed reducer to avoid contamination of electric motor by the saturated and humid discharge air from the cooling tower. All hold down bolts used for the motor are of stainless steel material. Electric motor is designed to operate with at least power rating 1.15 times to maximum brake horsepower of the fan at duty.

Mechanical torque from the electric motor is transmitted to the gear speed reducer via a floating type drive shaft. The drive shaft is designed with mechanical power rating of at least 2 times the power rating of the electric motor and is constructed from carbon composite. Flexible elements of the drive shaft are also made from carbon composite while all hardwares of the drive shaft are made of SS 316 stainless steel. The drive shaft is dynamically balanced at its operating speed and no lubrication of any parts is required.

Having all the mechanical components carefully designed and put together as an complete fan machinery, it is very important that all these mechanical components are mounted on a well designed and constructed mechanical supporting base to ensure the entire fan machinery is operating efficiently and safely to maintain a long life span. Mechanical support for PCG Series fanmachinery are mounted onto an independent mechanical support fabricated from carbon steel and hot-dip galvanized after all fabrication is completed. Emphasis has been given to the design of the mechanical support to ensure alignment of the drive shaft is maintained within tolerance at all time during operation.

Fan Stack

The entire fan assembly system is housed within an aerodynamically bell mouth FRP fan stack to minimize velocity pressure loss as airflow passing through the fan stack as well as providing a safe casing protection for both the operator and the fan machinery .

FRP fan stack are designed with box profile reinforcement ribs and molded with thick layers of FRP materials to ensure very strong hoop stress to maintain rigidity during operation and very long life span as well as to provide safety protection to operator.

Velocity recovery stacks for large diameter fans are also available for high efficiency fan performance for optimum power consumption. The fan stake is assembled from multiple panels of similar design forming into a circular cylinder with all flanged joints located at the outside for easy assembly and dismantling.

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email: panwater@panwater.com Website: www.panwater.com

Product Information…

Tower Access

PET Series cooling towers internals are accessible through the FRP doors installed at the end wall and partition. All the cooling towers are provided with internal walkway extending the entire length of the cooling tower for inspection and to carry out maintenance routines. Areas accessible are the drift eliminators, splash bars section after removal of drift eliminators, towerstructures and mechanical equipment.

The fan deck level of the cooling tower is accessible by ladder or stairway installed at the end-wall and the entire fan deck issurrounded by safety handrail in compliance with OSHA requirement. Areas accessible at the fan deck level are fan machinery, hot water distribution basin and flow control valves. This safe and easy access allows periodic inspection and maintenance works for the mechanical system such as checking of lubrication system, detection of abnormal vibration caused by the rotating equipment, tightening of loosened fasteners and to carry out preventive maintenance requirement. Access to the flow distribution system allows operation of the flow control valves to balance flow to all the hot water basins are maintained and cleaning of the hot water basin and the nozzles is done periodically so that cooling tower is performing efficiently. All towers are installed with perimeter handrail surrounding the tower at the fan deck level to ensure accessing to the various areas on the fan deck is safe.

Tower Cladding & Air Inlet Louvers

The entire external of the cooling tower consisting of the cladding walls and air inlet louvers are constructed with FRP panels. FRP cladding panels are molded with box rib designs overlapped at all joints to ensure complete sealing to prevent water and air leakages and are firmly secured directly to tower structure to withstand wind load. Cladding at the tower end wall extends from the fan deck level to the base of the tower and below the operating water level. No air leakage is allowed at the end wall cladding. Access door made of FRP materials is provided at both end walls and at each cell partition. All doors are hinged and can be operated at any time with ease. FRP louver panels are freely supported on louver holders to prevent water from splashing and diverting water back to cold water basin. They are made easily removable for access into the fill packing section for cleaning and maintenance.

Cold Water Basin & Foundation

The cold water from the cooling tower is collected by the cold water basin below. Cold water basin for the PET Series cooling tower are normally construct with the reinforce concrete with all the tower foundation and supporting columns being constructed within the basin. Although other basin materials have been used for some special application, concrete basin is highly recommended for most industrial applications due to various reasons and advantages.

The most obvious advantage of the concrete basin over the others is due to its long life span and requires minimum maintenance or repair during its entire service life. A sufficiently large basin retention volume is a pre-requisite for the safe and efficient operation of many continuous industrial processes especially any interruption of supply of make-up water may cause major plant shut down. Moreover, in most industrial

processes, a complete plant shut down requires all equipments in the plant to be shut down in stages and requires the cooling water to be circulated through all the equipment during the entire shut down process. Thus having an adequately designed basin with sufficiently large retention volume for the cooling tower will ensure cooling water will be available and adequate for a sufficiently predetermined duration to allow for emergency measures to be taken.