FORWARD
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
2.3 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.
2.6 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
INTRODUCTION
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.
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.
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
-4Nos.
- PVC
Method of Assembly:Drift Eliminator are placed above the drift support, they are used reduce the drift loss of water.
1 Nos.
FRP
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
MOTOR
FAN
NOZZLE PIPE
4 Nos.
MS HDG
The FAN GUARD (G19) is mounted on the top of the fan inside the Motor Bed
Ladder
Quantity (L)
1 Nos.
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.
TROUBLE SHOOTING
TROUBLE
Rise in cooling water
temperature
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.
Lubricate
GEAR BOX
FLOW CONTROL
VALVE
D
S
Clean
Repaint
S
R
S
Y
D-Daily
BLEED VALVE
FLOAT VALVE
FRP CASING
STRUTURAL
MEMBERS
WIRINGS
PVC FILLS
ELIMINATOR
MOTOR
FAN
INSPECTION AREA
W-Weekly
W
S
M-Monthly
Q-Quarterly
S-Semi annually
Y-Yearly
R- As required more frequent inspection and maintenance might be desirable.