Closed Circuit Cooling Towers

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1 VFL - C 35 Closed Circuit Cooling Towers Product Detail VFL Closed Circuit Cooling Tower... C36 Benefits... C38 Construction Details... C40 Custom Features and Options... C41 Accessories... C43 Engineering Data... C45 Structural Support... C50 Engineering Specifications... C51

2 VFL - C 36 VFL Closed Circuit Cooling Tower Capacity Single Model Capacity: 1 to 65 l/s General Description VFL Closed Circuit Cooling Towers deliver fully rated thermal performance over a wide range of flow and temperature requirements. The VFL can be installed indoors and minimize sound levels, and are available to accommodate limited ceiling or enclosure heights. The VFL design minimizes installation costs, provides year-round operating reliability, and simplifies maintenance requirements. Key Features Suitable for indoor and outdoor installations Suitable for high temperature applications Suitable for locations with limited ceiling or enclosure heights and roof top installations Low sound Single side air inlet Low energy consumption Low installed cost Easy maintenance Reliable year-round operation Long service life Baltimore Aircoil

3 ... because temperature matters VFL - C 37

4 VFL - C 38 Benefits Installation and Application Flexibility Indoor Installations Centrifugal fans can overcome the static pressure imposed by external ductwork, allowing this type of cooling towers to be installed indoors. Low Profile Models The fan section of low profile units is adjacent to the casing section to yield models suitable for use in height sensitive installations. Low profile models are available in heights of 1855 mm up to 2560 mm. Low Sound Centrifugal Fan - Centrifugal fans have inherently low sound characteristics. Low profile unit shown in contrast to a standard unit Single Side Air Inlet - Particularly sound-sensitive areas can be accommodated by facing the quiet side (back panel) to the sound-sensitive direction. Low Energy Consumption Evaporative Cooling Equipment minimizes the energy consumption of the entire system because it provides lower operating temperatures. The owner saves money while conserving natural resources and reducing environmental impact. Low Installed Cost Support All models mount directly on two parallel I-beams (supplied by others) and ship complete with motors and drives factoryinstalled and aligned. Modular Design All models without intake or discharge accessories ship in one piece to minimize field installation time and lifting time. Easy Maintenance Internal Access - The interior of the unit is easily accessible for adjusting the float valve, cleaning the strainer or flushing the basin. Modular Design Baltimore Aircoil

5 VFL - C 39 Reliable Year-Round Operation V-Belt Drive The fans, motor, and drive system are located outside of the moist discharge airstream, protecting them from moisture, condensation and icing hence allowing a safe year-round operation. Long Service Life Materials of Construction Various materials are available to meet the corrosion resistance, unit operating life, and budgetary requirements of any project (See section "Technical Resources, Materials of Construction" for more details) V-Belt Drive System... because temperature matters

6 VFL - C 40 Construction Details 1. Heavy Duty Construction Z600 hot-dip galvanized steel panels 2. Water Distribution System Plastic spray header and branches Large orifice, non-clog nozzles Grommetted for easy maintenance 3. Coil Continuous serpentine, steel tubing Hot-dip galvanized after fabrication (HDGAF) Sloped tubes for free drainage of fluid Designed for max. 10 bar operating pressure according to PED 4. Drift Eliminators UV resistant non-corrosive material, impervious to rot, decay and biological attack Three distinct changes in air direction to reduce drift loss significantly Assembled in easy to handle sections, which can be removed for access to the equipment interior 5. Fan Drive System V-belt drive Heavy-duty bearings and fan motor 6. Centrifugal Fan(s) Quiet Operation 7. Recirculating Spray Pump Close coupled, bronze fitted centrifugal pump Totally enclosed fan cooled (TEFC) motor Bleed line with metering valve installed from pump discharge to overflow 8. Access Door Circular access door 9. Strainer (Not Shown) Anti-vortexing design to prevent air entrainment Baltimore Aircoil

7 VFL - C 41 Custom Features and Options Construction Options Standard Construction: Steel panels and structural elements are constructed of Z600 heavy-gauge hot-dip galvanized steel protected with the Baltiplus Corrosion Protection on the outside of the unit. Optional BALTIBOND Corrosion Protection System: The BALTIBOND Corrosion Protection System, a hybrid polymer coating used to extend equipment life, is applied before assembly to all hot-dip galvanized steel components of the unit. Stainless Steel Cold Water Basin Optional Stainless Steel Construction: Steel panels and structural elements are constructed of stainless steel either type 304 or 316. Optional Water-Contact Stainless Steel Cold Water Basin: A cost-effective alternative to an all stainless steel unit. The critical components in the cold water basin and the cold water basin itself are provided in stainless steel. The remaining components are protected with the BALTIBOND Corrosion Protection System. Note: See section Technical Resources, Material Options for more details on the materials described above. Coil Configurations Standard Serpentine Coil: The standard condensing coil is constructed of continuous lengths of all prime surface steel, hot-dip galvanized after fabrication (HDGAF). Optional Extended Surface Coil: Coils are available with selected rows finned at 3 to 5 fins per inch for wet/dry applications. The coil is hot-dip galvanized after fabrication (HDGAF). Optional Stainless Steel Coil: Coils are available in Type 304L or 316L stainless steel for specialized applications. All coils are designed for low pressure drop with sloping tubes for free drainage of fluid. Fan Drive System The fan drive system provides the cooling air necessary to reject heat from the system to the atmosphere. Centrifugal fans, forwardly curved, are driven by matched V-belts with taper lock sheaves.... because temperature matters

8 VFL - C 42 Baltiguard Drive System The BALTIGUARD Drive System consists of two standard single-speed fan motors and drive assemblies. One drive assembly is sized for full speed and load, and the other is sized for approximately 2/3 speed and consumes only 1/3 of the design kilowatt power. This configuration allows the system to be operated like a two-speed motor, but with the reserve capacity of a standby motor in the event of failure. As a minimum, approximately 70% capacity will be available from the low kilowatt motor, even on a design wet-bulb day. Controls and wiring are the same, as those required for a two-speed, two-winding motor. Baltiguard Drive System Significant energy savings are achieved when operating at low speed during periods of reduced load and/or low wet-bulb temperatures. Low Sound Operation The low sound levels generated by BAC Products with centrifugal fans make them suitable for most installations. For situations when one direction is particularly sound sensitive, the unit can be oriented so that the side opposite the air inlet faces the soundsensitive direction. Units with centrifugal fans are also available with factory designed, tested and rated sound attenuation for both the air inlet and discharge. Remote Sump Execution Sound Attenuation at Air Inlet and Discharge The use of an auxiliary sump within a heated space is the most satisfactory way to protect sump water from freezing. When the circulating pump is shut off, all the water in the water distribution, in suspension and in the sump will drain freely to the auxiliary sump. Note: For detailed information on the calculation of the remote sump tank, please refer to the section "Technical Resources, Selection of Remote Sump Tank". Baltimore Aircoil

9 VFL - C 43 Accessories Electric Water Level Control Package The electric water level control replaces the standard mechanical make-up valve when a more precise water level control is required. This package consists of a float switch mounted in the basin and a solenoid activated valve in the makeup water line. The valve is slow closing to minimize water hammer. Extended Lubrication Lines Extended lubrication lines with grease fittings are available for lubrication of the fan shaft bearings. Basin Heaters Electric Water Level Control Package Units exposed to below freezing ambient temperatures require protection to prevent freezing of the water in the cold water basin when the unit is idle. Factory-installed heaters, which maintain the water temperature at 4 C, are a simple and inexpensive way of providing such protection. The heater package includes the heaters, a thermostat and a low level cut out switch to protect the heaters if the water level is too low. Standard electric heaters are selected for -18 C ambient temperature. Model No. VFL Heaters -18 C (kw) VFL 24X 1 x 3 VFL 36X 1 x 4 VFL 48X 1 x 5 VFL 72X 2 x 4 VFL 96X 2 x 5 Plume Abatement Coil The use of plume abatement coils is recommended to reduce significantly the formation of visible plume during wet operation and extend the dry operation capability of the closed circuit cooling tower. The combination of discharge air reheating and extended dry operation minimises plume formation during weather conditions with high relative humidities. Plume abatement coils are also an effective way to save water and water treatment costs. Capacity Control Dampers Plume Abatement Coil Modulating capacity control dampers are available to provide better leaving water temperature control than can be obtained from fan cycling alone. Fan discharge dampers consist of a single airfoil type damper blade located in the discharge of each fan housing. A standard electrical control package for dampers is available from BAC.... because temperature matters

10 VFL - C 44 Basin Sweeper Piping Basin sweeper piping provides an effective method of preventing sediment from collecting in the cold water basin of the unit. A complete piping system, including nozzles, is provided in the unit basin for connection to side stream filtration equipment (Refer to section "Technical Resources, Filtration"). Solid Bottom Panels Factory-installed bottom panels are required when intake air is ducted to the unit. Discharge Hoods Basin Sweeper Piping Discharge hoods reduce the risk of re-circulation in tight enclosures by increasing discharge air velocity, and can be used to elevate the unit discharge above adjacent walls to comply with layout guidelines. Discharge Hoods with Positive Closure Dampers BAC offers a full line of standard discharge hoods with and without positive closure dampers that are built, tested, and rated specifically for all Series V Closed Circuit Cooling Towers. The tapered hoods are designed to increase the discharge air velocity to avoid recirculation in extremely tight enclosures. Straight or tapered hoods can be used to elevate the unit discharge above adjacent walls. A larger fanmotor may be necessary when this option is provided. For details of hoods furnished with positive closure dampers see section Engineering Data Heat Loss Data. Positive Closure Damper Section Baltimore Aircoil

11 VFL - C 45 Engineering Data REMARK: Do not use for construction. Refer to factory certified dimensions & weights. This brochure includes data current at time of publication, which should be reconfirmed at the time of purchase. In the interest of product improvement, specifications, weights and dimensions are subject to change without notice. Up-to-date engineering data and more can be found at VFL 24 X - VFL 48 X 1. Fluid in ND100; 2. Fluid Out ND100; 3.Access Door; 4. Make Up ND25; 5. Overflow ND50 for VFL 24X - VFL 36x and ND80 for VFL 48X; 6. Drain ND50; 7. Vent ND15. Model No. VFL Operating Weight (kg) Shipping Weight (kg) Heaviest Section (kg) Air Flow (m³/s) Fan Motor (kw) Spray Water Flow (l/s) Pump Motor (kw) Coil Volume (L) H (mm) L (mm) W (mm) VFL 241-H VFL 242-H VFL 242-J VFL 243-J ,6 7,4 8,1 7, ,5 5,5 5,9 5,9 5,9 5,9 0,55 0,55 0,55 0,55 (1x) 176 (1x) 229 (1x) 229 (1x) VFL 361-L VFL 361-M VFL 362-M VFL 363-K VFL 363-M ,7 13,8 13,4 10,8 13, ,5 15 9,0 9,0 9,0 9,0 9,0 0,75 0,75 0,75 0,75 0,75 (1x) 258 (1x) 258 (1x) 338 (1x) 418 (1x) VFL 481-M VFL 482-L VFL 483-L VFL 483-M VFL 484-M ,1 13,6 13,4 14,6 14, ,1 12,1 12,1 12,1 12,1 (1x) 341 (1x) 448 (1x) 556 (1x) 556 (1x) because temperature matters

12 VFL - C 46 VFL 72 X - VFL 96 X 1. Fluid in ND100; 2. Fluid Out ND100; 3.Access Door; 4. Make Up ND50; 5. Overflow ND80; 6. Drain ND50; 7. Vent ND15. Model No. VFL Operating Weight (kg) Shipping Weight (kg) Heaviest Section (kg) Air Flow (m³/s) Fan Motor (kw) Spray Water Flow (l/s) Pump Motor (kw) Coil Volume (L) H (mm) L (mm) W (mm) VFL 721-L VFL 721-M VFL 721-O VFL 722-N VFL 722-O VFL 723-L VFL 723-O VFL 724-O ,0 21,8 24,6 22,8 24,0 19,3 23,4 22, , ,9 17,9 17,9 17,9 17,9 17,9 17,9 17,9 (2x) 258 (2x) 258 (2x) 258 (2x) 338 (2x) 338 (2x) 418 (2x) 418 (2x) VFL 961-P VFL 962-N VFL 962-O VFL 962-P VFL 963-O VFL 963-P VFL 964-P ,7 24,5 25,9 28,3 25,6 27,9 27, , ,2 24,2 24,2 24,2 24,2 24,2 24,2 2,2 2,2 2,2 2,2 2,2 2,2 2,2 (2x) 341 (2x) 448 (2x) 448 (2x) 448 (2x) 556 (2x) 556 (2x) General Notes 1. All location dimensions for coil connections are approximate and should not be used for prefabrication of connecting piping. 2. If discharge hoods with positive closure dampers are furnished, see table in section Engineering Data Straight Discharge Hood with PCD for added weight and height. 3. For external static pressure up to 125 Pa use next larger motor size. 4. For indoor applications of fluid coolers, the room may be used as a plenum with ductwork attached to the discharge only. If inlet ductwork is required, an enclosed fan section must be specified; consult your BAC Balticare representative for details. 5. Fan cycling results only in on-off operation. For additional steps of control, two-speed fan motors are available. More precise capacity control can be obtained with modulation fan discharge dampers or a BALTIGUARD Drive System 6. Make up, overflow, suction, drain connections and access door can be provided on side opposite to that shown; consult your BAC Balticare representative. 7. Shipping/operating weights indicated are for units without accessories such as sound attenuators, discharge hoods, plume abatement coils, etc. Consult factory certified prints to obtain weight additions and the heaviest section to be lifted. Baltimore Aircoil

13 VFL - C 47 Sound Attenuation HS Horizontal Intake Sound Attenuation 1.Discharge attenuator, 2. Access Door, 3. Intake Attenuator; W & H = Unit Dimensions (See Engineering Data). HD Horizontal Intake Sound Attenuation 1.Discharge attenuator, 2. Access Door, 3. Intake Attenuator; W & H = Unit Dimensions (See Engineering Data).... because temperature matters

14 VFL - C 48 VS Vertical Intake Sound Attenuation 1.Discharge attenuator, 2. Access Door, 3. Intake Attenuator, 4. Plenum; W & H = Unit Dimensions (See Engineering Data). Dimensions (mm) Maximum Weight (kg) Model No VFL L2 L1 Intake Attenuator + Solid Bottom Discharge Attenuator Total HS HD VS HS,HD,VS HS HD VS HS HD VS HS HD VS VFL 24X VFL 36X VFL 48X VFL 72X VFL 96X Note: All units with HS or VS attenuators ship in 2 pieces. All units with HD attenuators ship in 3 pieces. Baltimore Aircoil

15 VFL - C 49 Heat Loss Data Discharge Hoods with Positive Closure Dampers (PCD s) 1. Access Door. Model No. VFL Heat Loss Data (kw) (1) L W H Unit with Discharge Hood and Standard Unit PCD s VFL 241-H VFL 242-H VFL 242-J VFL 243-J 10,6 12,7 12,7 14,4 6,3 6,7 6,7 7, VFL 361-L VFL 361-M VFL 362-M VFL 363-K VFL 363-M 16,0 16,0 19,1 21,6 21,6 9,8 9,8 10,4 11,0 11, VFL 481-M VFL 482-L VFL 483-L VFL 483-M VFL 484-M 23,0 27,2 30,5 30,5 33,8 13,8 14,5 15,2 15,2 15, VFL 721-L VFL 721-M VFL 721-O VFL 722-N VFL 722-O VFL 723-L VFL 723-O VFL 724-O 40,1 40,1 40,1 46,4 46,4 51,5 51,5 56,6 17,8 17,8 17,8 18,6 18,6 19,3 19,3 20, VFL 961-P VFL 962-N VFL 962-O VFL 962-P VFL 963-O VFL 963-P VFL 964-P 47,9 56,3 56,3 56,3 63,0 63,0 69,7 20,1 21,0 21,0 21,0 21,9 21,9 23, (1) Heat loss data based on 10 C water and 14 C ambient temperature with 20 m/s wind velocity (fans and pump off). Remote Sump Data Refer to the "Technical Resources" section "Selection of Remote Sump" for Remote Sump Data.... because temperature matters

16 VFL - C 50 Structural Support REMARK: Do not use for construction. Refer to factory certified dimensions & weights. This brochure includes data current at time of publication, which should be reconfirmed at the time of purchase. In the interest of product improvement, specifications, weights and dimensions are subject to change without notice. Up-to-date engineering data and more can be found at The recommended support arrangement for units consists of parallel I-beams running the full length of the unit, spaced as shown in the following drawing. Besides providing adequate support, the steel also serves to raise the unit above any solid foundation to ensure access to the bottom of the unit. To support units in an alternate steel support arrangement, consult your BAC Balticare Representative. Units with and without Sound Attenuation Model No. VFL A (mm) B (mm) Maximum Allowable Beam Deflection (mm) VFL 24X VFL 36X VFL 48X VFL 72X VFL 96X Outline of Unit, 2. Support Beams, 3. Fan Side, 4. Mounting Holes Ø 22 mm. Notes: 1. The recommended support arrangement for VL units consists of two parallel I-beams extending the full length of the unit. Supports and anchor bolts are to be designed and furnished by others. 2. All supporting beams are to be flush and level at top and must be oriented relative to gage line as shown. 3. Recommended design loads for each unit support beam should be 70% of the total unit operating weight applied as a uniform load to each of the unit beams. Beams should be designed in accordance with standard structural practice. For the maximum allowable deflection of beams under the unit refer to above table. 4. All mounting holes have a diameter of 22 mm at the locations shown. 5. If vibration isolators are used, a rail or channel must be provided between the unit and the isolators to provide continuous unit support. Additionally the support beams must be designed to accommodate the overall length and mounting hole location of the isolators that may differ from those of the unit. Refer to vibration isolator drawings for these data. Baltimore Aircoil

17 VFL - C 51 Engineering Specifications 1.0 Closed Circuit Cooling Tower 1.0 General: Furnish and install factory assembled, forced draft, centrifugal fan, closed circuit cooling tower(s) with vertical air discharge, conforming in all aspects to the specifications and schedules as shown on the plans. Overall dimensions shall not exceed approximately mm long x mm wide x mm high. The total connected fan kw shall not exceed kw. The total connected pump kw shall not exceed kw. The closed circuit cooling tower(s) shall be Baltimore Aircoil Company Model(s) Thermal Capacity (water as heat transfer fluid): The closedcircuit cooling tower(s) shall be warranted by the manufacturer to cool l/s of water from C to C at C entering wet-bulb temperature. (Alternate1.2.) Thermal Capacity (aqueous glycol solution as heat transfer fluid): The closed circuit cooling tower(s) shall be warranted by the manufacturer to cool l/s of % by volume ethylene/propylene glycol solution from C to C at C entering wet-bulb temperature. Coil pressure drop shall not exceed bar Corrosion Resistant Construction: Unless otherwise noted in this specification, all steel panels and structural members shall be constructed of heavy-gauge Z600 metric hot-dip galvanized steel, with all sheared edges given a protective coating of zinc-rich compound and the exterior protected with the Baltiplus Corrosion Protection. (Alternate1.3.) Corrosion Resistant Construction: Unless otherwise noted in this specification, all steel panels and structural members shall be protected with the BALTIBOND Corrosion Protection System. The system shall consist of Z600 metric hot-dip galvanized steel prepared in a four-step (clean, pre-treat, rinse, and dry) process with an electrostatically sprayed, thermosetting hybrid polymer fuse-bonded to the substrate during a thermally activated curing stage and monitored by a 23-step quality assurance program Quality Assurance: The closed circuit cooling tower manufacturer shall have a management system certified by an accredited registrar as complying with the requirements of ISO- 9001:2000 to ensure consistent quality of its products and services Warranty: The manufacturer s standard equipment warranty shall be for a period of not less than one year from date of startup or eighteen months from date of shipment, whichever occurs first. 2.0 Construction Details 2.1.Tower Structure: The closed circuit cooling tower shall be constructed of heavy-gauge steel utilizing double-brake flanges for maximum strength and rigidity and reliable sealing of water-tight joints. All sheared edges shall be protected with a coating of zinc-rich compound Casing Assembly: The closed circuit cooling tower shall include a coil casing section consisting of a serpentine coil, spray water distribution system, and drift eliminators, as indicated by the manufacturer. Plastic drift eliminators shall be removable in easily handled sections. They shall incorporate a minimum of three changes in air direction Coil Assembly: The cooling coil shall be fabricated of continuous lengths of all prime surface steel at the manufacturer s own facility, and hot-dip galvanized after fabrication. The cooling coil shall be pneumatically tested at 15 bar. The cooling coil shall be designed for low pressure drop with sloping tubes for free drainage of fluid and shall be compliant to PED. Maximum allowable working pressure shall be 10 bar Water Distribution System: Water shall be distributed evenly over the coil at a minimum flow rate of 3,1 l/s/m² to ensure complete wetting of the coil at all times by large-diameter, non-clog, plastic 360 distribution nozzles, spaced across the coil face area in PVC spray branches by snap-in rubber grommets, allowing quick removal of individual nozzles or complete branches for cleaning or flushing. Nozzles shall utilize a two-stage diffusion pattern to provide overlapping, umbrella spray patterns that create multiple intersection points with adjacent nozzles Spray Pump System: The closed circuit cooling tower shall include a close-coupled, bronze-fitted centrifugal pump equipped with a mechanical seal, mounted on the basin and piped to the suction strainer and water distribution system. It shall be installed so that it can be drained when the basin is drained. The pump assembly shall include a metering valve and bleed line to control the bleed rate from the pump discharge to the overflow connection. The pump motor shall be totally enclosed fan cooled (TEFC) type with IP 55 protection and class B insulation suitable for outdoor service, kw, Volt, Hz, Phase. (Alternate 2.5.) Spray Pump System-Remote Sump: On installations requiring a remote sump, the closed circuit cooling tower shall be modified to accommodate the use of an independent basin and pump (both by others) for recirculating water Basin Assembly: The combination basin/fan section shall be constructed of heavy-gauge Z600 galvanized steel. The basin shall be provided with large area lift out strainers with perforated openings sized smaller than the water distribution nozzles and an anti-vortexing device to prevent air entrainment. The strainer and vortex device shall be constructed of the same material as the cold water basin to prevent dissimilar metal corrosion. 3.0 Mechanical Equipment 3.1. Fan System: The fans and motors shall be factory installed at the base of the unit in the dry entering air stream to provide greater reliability and ease of maintenance. The forwardly curved centrifugal fans shall be heavy-duty centrifugal flow types. Fan housings shall have curved inlet rings for efficient air entry and rectangular discharge cowls shall extend into the basin to increase fan efficiency and prevent water from entering the fans. Fans shall be mounted on a steel fan shaft supported by heavy-duty self-aligning, relubricatable ball bearings with cast iron housings and designed for a minimum L10 life of hours ( hrs average life). The fan shaft shall be protected with a two-part epoxy coating for corrosion protection Fan Motor/Drive System: Fan motor(s) shall be totally enclosed fan cooled (TEFC), IP-55, class F, selected for Pa static pressure. Fan motor(s) shall be suitable for volts, phase, Hz electrical service and shall be mounted on an easily adjusted, heavy-duty motor base. V-belt drives and all moving parts are protected with removable screens. (Alternate 3.2.) Baltiguard Fan System: Two single speed fan motors, one sized for full speed and load, the other sized for 2/3 speed and approximately 1/3 of full load kw shall be provided in each cell for capacity control and standby protection from drive or motor failure. Two-speed motor(s) is not an acceptable alternative.... because temperature matters

18 VFL - C Drift Eliminators 4.1 Drift Eliminators: Eliminators shall be constructed of specially formulated plastic material and be removable in easily handled sections. They shall have a minimum of three changes in air direction. 5.0 Access 5.1 Basin Access: Circular access doors shall be provided for easy access to the make-up water assembly and suction strainer for routine maintenance. 6.0 Sound 6.1 Sound Level: To maintain the quality of the local environment, the maximum sound pressure levels (db) measured 15 m from the cooling tower operating at full fan speed shall not exceed the sound levels detailed below. Location db(a) Discharge Air Inlet End Back Baltimore Aircoil

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