SPX Cooling Technologies 800 manual

>ViÊ N Ê>ÊÀ ÞÊ}Ê N Ê>ÀiÞ  }Ê / i V  }i à / Marley Class 800 Mechanical Draft Cooling T ower / Us er Manu al 95- 135 6A[...]

2 Notice The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to im- portant information concerning the life of the product. Indicates presence of a hazar d which can cause severe personal injury , death or substantial property damage if ignor ed. Indicates presence of[...]

3 General ................................................................................................... 4 Before Start-up ....................................................................................... 5 Initial Starting Procedur e ........................................................................ 7 Routine Starting Procedur e .[...]

4 General A cooling tower , like any heat exchanger , exchanges all heat imposed upon it from one fluid to another fluid. For a cooling tower , heat from the water is put into the air . The plant process replenishes the heat to the water , typically at another heat exchanger such as a condenser . A cooling tower differs fr om many heat exchangers[...]

5 Befor e Start-up Safety T emporary safety barricades should be placed around any exposed openings in the operating (or nonoperating) tower , safety harnesses should be worn by personnel wher e appropriate, and other safety precautions should be taken in compliance with OSHA r egulations and standards. Cleaning Clean any nozzles that are clogged. [...]

6 Befor e Start-up See Geareducer Service Manual for oil filling procedur e and list of recommended lubricants. • Rotate fan by hand to be sure of fr ee rotation and ample tip clearance. See Marley Fan Service Manual . • Check motor insulation with a “Megger .” See maintenance section of Marley Electric Motor Service Manual . • Lubricate[...]

7 Initial Starting Pr ocedure 1— Fill the cold water basin and circulating water system to a level 1/2” (13 mm) below the overflow . 2— Bypass valve should be closed unless start-up is in cold weather . (See Routine Starting Procedur e on page 8.) 3— Prime and start the circulating water pumps one at a time. Increase the flow of circulati[...]

8 Routine Starting Pr ocedure After periods of routine shutdown, the following restarting procedure should be followed: • Start the circulating water pump(s). Increase the flow of circulating water gradually to design water rate to avoid sur ges or water hammer which could damage the distribution piping. Circulating cold water over a tower in fr[...]

9 Operation ➠ T ower Performance The following is intended to serve as a guideline for the operation of this counterflow mechanical draft cooling tower . The owner may use this infor - mation to develop prelimin ary operating proce dures. As oper ational experi- ence with the system accumulates, more definitive r esponses to specific condition[...]

10 Operation When changing fan direction of rotation, allow a minimum of two minutes time delay before energizing the fan motor . Hot W ater Distribution System Hot water from the process flows thr ough an inlet to each cell, which sup- plies a distribution header and a system of branch arms and nozzles. Each distribution header may be equipped wi[...]

11 Fr eezing W eather Operation During periods of low ambient air temperatures, 35°F to 40°F (2°C to 4°C) or below , it is advisable to maintain the cold water temperature at or above 70°F (21°C) to retar d the formation of ice and to assist in its control. The methods used in Minimizing T ower Energy Use, described on page 13 are those which[...]

12 Fr eezing W eather Operation • Under extended extreme cold conditions, it may be necessary to operate the fan in reverse. This forces warm air out through the air inlets, melt- ing any accumulated ice. Reversal may be at either full or half speed; however , full speed is r ecommended if adequate heat load is available. Reverse operation of the[...]

13 T emperature Contr ol and Energy Management ➠ The wet-bulb temperature of the ambient air varies significantly on a daily basis, and considerably from season to season. As the wet-bulb temperature reduces, the tower becomes capable of producing colder and colder water—or it becomes capable of pr oducing a given cold water temperature at red[...]

14 T emperature Contr ol and Energy Management number of seconds it takes your fan to get to full-speed (by obser - vation) and divide that number into 30 to obtain the recommended maximum number of starts per hour . T wo-speed motors cycling be- tween half and full speeds permit a commensurately greater number of control cycles. V ariable fr equen[...]

15 Maintenance ➠ W ell maintained equipment gives the best operating results and the least maintenance cost. A regular inspection schedule is recommended to insure effective safe operation of the cooling tower . Use the Inspection and Maintenance Schedule on page 25 to obtain continuously good performance with least tower maintenance. See the Ins[...]

16 Maintenance sibility to institute a pr ogram of water treatment and maintenance that will minimize their impact. (See W ater T reatment on pages 18 and 19.) T ower Framework Inspect for cracks and spalling and repair if necessary . Keep bolts tight in the mechanical equipment supports. Maintain a positive Langelier index in your circulating wate[...]

17 Cleaning Any evaporative-type cooling tower must be thoroughly cleaned on a regular basis to minimize the growth of bacteria, including Legionella Pneumophilla, to avoid the risk of sickness or death. Service person- nel must wear proper personal pr otective equipment. Do NOT attempt any service unless the fan motor is locked out. Operators of e[...]

18 Blowdown Blowdown, or bleed-off is the continuous removal of a portion of the water from the cir culating system. It is used to prevent dissolved solids from concentrating to the point where they will form scale. The amount of blowdown required depends upon the cooling range (design hot water temperature minus design cold water temperatur e) and[...]

19 predict the corrosive tendencies of the tower water toward concrete. An explanation and method of calculating the Langelier index can be found in all books on water treatment. Maintaining a positive Langelier index provides excellent pr otection of concrete. Slime, a gelatinous organic growth, and algae, a green or brown plant growth, may grow i[...]

20 Seasonal Shutdown Instructions T ower Drain all tower piping. During shutdown, clean the tower and make any necessary repairs. Ap- ply protective coating as required to all metal parts. Particular attention should be given to mechanical equipment supports, drive shaft and drive shaft guards, Gear educers, and motors. See W ar ning note on page 1[...]

21 Spar e Parts and Accessories Spare Parts SPX Cooling T echnologies manufactures and maintains a stock of re- placement parts for all cooling tower mechanical equipment. Shipment of these parts is normally made within ten days after an or der is received. If emer gency service is necessary , contact the local Marley sales office or repr esentati[...]

22 T r oubleshooting Remedy 1. Check power at starter . Correct any bad connections be- tween the control apparatus and the motor . 2. Check starter contacts and control circuit. Reset overloads, close contacts, reset tripped switches, or r eplace failed control switches. 3. If power is not on all leads at starter make sure overload and short circu[...]

23 T r oubleshooting Remedy Cause T rouble Wr ong sequence of phases Geareducer bearings Gears Loose bolts and cap screws Unbalanced drive shaft or worn cou- plings Fan W orn Geareducer bearings Unbalanced motor Bent Geareducer shaft Loose fan hub cover Blade rubbing inside of fan cylinder Loose bolts in blade clamps Switch any two of the three mot[...]

24 The tower has been designed to provide a safe working environment while either operating or shut down. The ultimate r esponsibility for safety r ests with the Operator and Owner . When flow to the tower is shut of f or when portions of the tower requir e maintenance, temporary safety barricades may be required around openings. Other safety pr e[...]

25 Inspection and Maintenance Schedule Fan Motor Drive Shaft and Guards Geareducer Drift Eliminators Fill Cold W ater Basin Hot W ater System W ater Make-up System Suction Screen Control V alves or Gates Structural Members Casing and Louvers Fan Cylinder Stairs, Ladders, W alkway , Doors, Handrails Davits, Derricks, Hoists General Recommendations M[...]

26 Inspection Checklist Date Inspected Inspected By Owner Location Owner's Tower Designation Tower Manufacturer Model No. Serial No. Process Served by Tower Operation: Continuous ❏ Intermittent ❏ Seasonal ❏ Design Conditions GPM HW °F CW °F WB °F Cell No. Number of Fan Cells Tower Type: Counterflow Date Tower was installed Condition: [...]

27 Inspection Checklist Condition: 1—Good 2—Keep an eye on it 3—Needs immediate attention Mechanical Equipment 1 2 3 Comments Speed Reducer Type Belt ❏ Gear ❏ Direct Drive ❏ Belt Drive Unit Belt Designation Fan Sheave Designation Motor Sheave Designation Gear Drive Unit Manufacturer Model Ratio Oil Level Full ❏ Add Immediately ❏ Low[...]

Manual 95-1356A / 7401 W 129 Street // Overland Park, KS USA 66213 // +1 913 664 7400 // spxcooling@ct.spx.com // www .spxcooling.com / In the interest of technological progress, all products are subject to design and/or material change without notice . ©2006 SPX Cooling T echnologies, Inc. | Printed in USA Balcke | Hamon Dr y Cooling | Marl ey Co[...]