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INSTRUCTION MANUAL

CUSTOMER: M/s. KIS


MODEL: SCT 250LE
TYPE: SQUARE TYPE

GEM EQUIPMENTS LIMITED


S.F.NO 103A,
ARASUR (PO)
COIMBATORE-641 407
INDIA
PHONE: 0422-2360013, 2360130, 2363800.
FAX: 0422-2360523
EMAIL: sales@gemindia.com
: export@gemindia.com
: info@gemindia.com

FORWARD

This manual contains information for Installation of FRP COOLING TOWER.

This unit has been designed in such a way that it is reliable and maintenance
free. Even then we feel that any machine or equipment has to be understood and
handled with care so that it gives a good service. This manual will help to keep your
Cooling Tower in its best condition. Please follow all instruction in this manual during
installation of the Cooling Tower. If you have any problem or doubt please ask our
service engineer, who would be able to guide you.

WARRANTY
This equipment is warranted to be free defective material or workmanship for a
period of 18 months from the date of shipment or 24 months from the date of
commissioning whichever occurs earlier. Any equipment, material or parts found
defective will be replaced free of charge.

INTRODUCTION
Adequate knowledge about cooling tower maintenance and operation will allow you to
perform inspections and service your own tower to ensure that performance and structural
integrity do not decline over the life of your cooling tower. This knowledge will allow you to
operate your cooling tower safely and with optimum performance. The following steps are
intended to provide you incite and allow you to prevent or foresee problems that may occur as a
result of normal operation.

1. Tower Construction
1.1 Type
The is an induced draft counter flow design with a propeller type Fan blade mounted on
the top of the cooling tower. The Square shaped tower provides High efficiency with proceeding
Large Fan.
1.2 Casing
The Fiberglass Reinforced Polyester (FRP) is composed of fiberglass mat laminated from
unsaturated polyester resin. The high structural strength of the material protects the unit against
impact and cracking. Gel coat is applied for UV protection and to provide a glossy finish.
2. Tower Support Framework

2.1 Motor Support Frame


Made of hot dipped galvanized steel or stainless steel depending on options you have
chosen.

2.2 Air Inlet Louver


The FRP louver is fitted on the air inlet to prevent foreign materials from falling into the
basin. The air inlet louvers are constructed of corrosion-free FRP (Fiber Reinforced Plastic).
They are minimizes splash out form cooling tower.
In these louver systems circulating water droplets tend to splash out, the water droplets are
captured on the inward sloping pass, minimizing splash out problems. This unique louver design
completely encloses the basin area. There by reducing the splash out water.

2.3 Filling
Made of rigid polyvinyl chloride sheets which is embossed and corrugated into a
honeycomb configuration that provides maximum air-to-water contact for higher levels of heat
exchange.

2.4 Water Distribution


Centre pipe header are Mounted in centre of the cooling tower for even distribution of
water over the fill material The branch pipe are fitted in the centre pipe for even distribution of
water . Numerous Non Clog Nozzle are fitted in the branch pipe with equal distance.

2.5 Fan Blade


Fan Blades are propeller design providing quiet operation and maximum airflow-toHorsepower ratios. It is important to check that fan blade is corrected properly. This can be
identified by arrow markings on the fan blade.

2.6 Motor
The fan motor is equipped with gear Box and it is mounted on rigid galvanizing steel
supports. The motor is totally enclosed IP55, flange type, 380 v, 3 ph, 50 Hz, induction weather
proof with extended shaft. Fan is driven by drive shaft which will be engaged in Gear box which
will reduce the fan rpm for required tip speed

TABLE OF CONTENTS.
1. INTRODUCTION
2. PREPARATION OF INSTALLATION
3. STARTING
4. OPERATIONAL CHECKS
5. ASSEMBLY INSTRUCTION MANUAL
6. MAINTENANCE & ADJUSTMENTS
7. TROUBLE SHOOTING
8. INSPECTION & MAINTENANCE SCHEDULE

ASSEMBLY INSTRUCTION MANUAL

INTRODUCTION

ASSEMBLY INSTRUCTION MANUAL

ASSEMBLY INSTRUCTION MANUAL


1. ASSEMBLY OF VERTICAL POST:
Quantity :4 Nos.
Material: HDG

Place the Vertical Post on the base frame as per Fig 1.

VERTICAL POST 4 NOS

2. ASSEMBLY OF TOP & BOTTOM L-ANGLE:


9

Place H1 L Angle on the First row of all Vertical Post using Bolt& Nut.

Place H2 L Angle on the Second row of all Vertical Post using Bolt& Nut.

TOP L-ANGLE (H2) 4 NOS

BOTTOM L-ANGLE (H1) 4 NOS

3. ASSEMBLY OF TOP HOOD:


Quantity: 4Nos.
Material: FRP
The Top support sheet is placed on the Top hood L angle & above that Top Hood is placed in
Centre of the Tower.

TOP HOOD 4 NOS


FINAL VIEW OF TOP HOOD:

4. ASSEMBLY OF FILLS RING SUPPORT ANGLE & FILLS RING BED:


Quantity - 3 Nos. (Support Angle.)
Material - HDG.

FILLS RING SUPPORT ANGLE - 3 NOS

Quantity - 2 Nos. (Fills Ring Bed)


Material - HDG.

FILLS RING BED - 2 Nos

5. ASSEMBLY OF FRP SHEET:


Qty: 12 Nos
Material : FRP

FRP Sheet is outer portion of the tower, which is placed between all the vertical Posts.

FINAL ASSEMBLY
FRP SHEETS - 12 NOS

6. LOUVER ASSEMBLY:
Quantity: 4 Nos.
Material: FRP
Louvers are placed below the fill ring bed to avoid over flow of water away the cooling tower.

FRP LOUVER 4 NOS

7. ASSEMBLY OF FILLS:
Qty

: 175 Nos

Material: PVC
PVC Fills are C-12 with Honey comb packing are placed above the fill ring bed. They have high
contact surface area .
PVC FILLS 175 NOS

8. DRIFT ELIMINATOR & PVC FILLS


Quantity
Material

-4Nos.
- PVC

Method of Assembly:Drift Eliminator are placed above the drift support, they are used reduce the drift loss of water.

DRIFT ELIMINATOR 4 NOS

9. ASSEMBLY OF DISTRIBUTION HEADER & NOZZLE PIPE:


Header Pipe:
Material
:

1 Nos.
FRP

Nozzle Pipe: 8 Nos


Material: PVC

The Centre pipe is placed between the motor bed post and it must suit to inlet sheet of FRP
.Branch Pipe are fitted in the Centre pipe with 2 Nozzle.
DRIFT SUPPORT ANGLE 2 NOS

CENTER PIPE 1NO

HOLDING CLAMP 2 NOS

NOZZLE PIPE 8 NOS

NOZZLE SUPP.ANGLES 6 NOS

10. ASSEMBLY OF MOTOR BED:


Quantity: 1Nos.
Material: HDG
Motor bed is placed on top hood as shown in the fig.
MOTOR BED ASSEMBLY 1 NO

11. ASSEMBLY MOTOR & FAN:


Quantity: 1Nos.
Motor is placed on motor bed.

MOTOR
FAN

NOZZLE PIPE

12. FAN GUARD ASSEMBLY:


Quantity
Material

4 Nos.
MS HDG

The FAN GUARD (G19) is mounted on the top of the fan inside the Motor Bed

13. LADDER ASSEMBLY:

Ladder

Quantity (L)

1 Nos.

Ladder is placed in front of the tower.

4. MAINTENANCE AND ADJUSTMENTS


4.1 NOZZLE HEAD
First check whether the flow rate is normal. If correct, dismantle the head for cleaning
and check.

4.2 HEADER & NOZZLE PIPES


The header pipe and the nozzle pipes must be kept clean to prevent any blockage in
flow. For cleaning, remove the nozzle and loosen the nozzle pipes.

4.3 CASING
No coating is needed for the casing as it is made of FRP. If it becomes soiled, wash it
with soap and water.

4.4 FILLS
No specific attention is necessary for fills with proper water quality control. Remember
do not walks or stand directly on the fills, always place plywood or hardboard over the fills
while repairing.

4.5 WATER QUALITY CONTROL:


Poor quality cooled water or air pollution causes corrosion, scale & algae growth, which
not only impedes the performance of equipments but also damages the equipments.
1. Make quality analysis of circulating & make up water.
2. Water treatment is strongly recommended. Periodic blow down
operation within the acceptable water quality.

can also keep the

TROUBLE SHOOTING
TROUBLE
Rise in cooling water
temperature

Abnormal water flow


Noise and vibration

Excessive current flow

Water carry over

CAUSE
1. Excessive or inadequate
cooling water.
2. Irregular flow of air
3. Recirculation of air from
tower outer.
4. Improper flow of air from
fan.
5. Blocking of the fills
1. Blocking of the nozzle holes.
2. Blocking of pipe.
1. Fan blade tips touching
casing.
2. Bending of fan shaft.
3. Loose bolts.
4. Motors bearing damages.
5. Damage in fan and/or motor.
6. Check Gearbox oil level.

1. Drop in voltage.
2.Irregularities in the angles of
the fan blades
3. Damage in motor.
4. Overload through excessive
air flow.
1.Block of the fill
2. Excessive circulating water.
3.Excessive air flow

REMEDY
1. Adjust to the specified flow.
2. Improve ventilation.
3. Improve ventilation.
4. Adjust the angle of fan blades.
5. Clean the blocked area.

1. Clean nozzle.
2. Clean header and nozzle pipes.
1. Adjust the fan mounting.
2. Adjust bend at special shop.
3. Tighten loose bolts.
4. Repair or replace motor.
5. Replace fan and/ or motor.
6. Fill the gearbox with oil as
required.
1. Check supply voltage.
2. Make careful adjustment.
3. Repair or replace motor from
manufacturer.
4. Adjust fan blade angle.
1. Eliminate blockage at the upper
edge of the fill.
2. Adjust the water flow with
valve.
3. Adjust fan blade angle.

Check for unusual noise or


vibration

Inspection keys and set screw

Lubricate

GEAR BOX

FLOW CONTROL
VALVE
D
S

Check flow rate

Check for leakage

Inspect general condition

Clean

Repaint

S
R

S
Y

Completely open and close

D-Daily

BLEED VALVE

FLOAT VALVE

FRP CASING

STRUTURAL
MEMBERS

WIRINGS

PVC FILLS

Inspect for clogging

ELIMINATOR

MOTOR

FAN

INSPECTION AREA

INSPECTION AND MAINTENANCE SCHEDULE

W-Weekly

W
S

M-Monthly

Q-Quarterly

S-Semi annually

Y-Yearly
R- As required more frequent inspection and maintenance might be desirable.

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