Marley F400 counter flow cooling tower installation, maintenance
Contents
1. Multipliers are based on drift of 0 02 of the circulating water rate maintenance EXAMPLE 7000 gpm circulating rate 15 cooling range To maintain 4 concentrations the required blowdown is 38 or 0038 times 7000 GPM which is 26 6 gpm If tower is operated at 4 concentrations circulating water will contain four times as much dissolved solid as the make up water providing none of the solids form scale or are otherwise removed from the system CHEMICAL TREATMENT In some cases chemical treatment of the cir culating water is not required if adequate blowdown is maintained In most cases however chemical treatment is required to prevent scale formation and corrosion Sulfuric acid or one of the polyphosphates is most generally used to control calcium carbonate scale Various proprietary materials containing chromates phosphates or other compounds are available for corrosion control When water treatment chemicals are required the services of reliable water treating companies should be obtained Slime a gelatinous organic growth and algae a green moss may grow in the cooling tower or heat exchangers Their presence can interfere with cooling efficiencies Proprietary compounds are available from water treating compa nies for the control of slime and or algae however compounds which contain copper are not recommended Chlorine and chlorine containing compounds are effective algaecides and slimicides If used ch2. Cooling Tower 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 personnel must wear proper personal protective equip ment during decontamination Do NOT attempt any service unless the fan motor is locked out Operators of evaporative cooling equipment such as water cooling towers should follow maintenance programs which will reduce to an absolute minimum the opportunity for bacteriological contamination Public Health Service officials have recommended that good housekeeping procedures be followed such as regular inspections for concentrations of dirt scale and algae periodic flushing and cleaning and the following of acomplete water treatment program including biocidal treatment Visual inspection should take place at least once a week during the operating season Periodic flushing and cleaning should be done at least twice a year Nozzles should be checked for clogging Drift eliminators and easily acces sible fill surfaces should be cleaned by use of a moderate pressure water nozzle being careful not to cause physical damage A reliable water treatment program should be installed and maintained troubleshooting Trouble Cause Remedy Motor Will Not Start Power not available at motor terminals 1 Check power at starter Correct any bad connections be
3. 913 664 7400 F 913 664 7439 spxcooling spx com In the interest of technological progress all products are subject to design and or material change without notice ISSUED 08 2013 M93 1288B COPYRIGHT 2013 SPX Corporation F400 cooling tower user manual
4. Cooling Tower Inspection Check List in this manual Keep a continuous lubrication and maintenance record for each cooling tower HOT WATER DISTRIBUTION SYSTEM keep the circulating water and distribution system piping and nozzles clean and free of dirt algae and scale Algae and scale may clog nozzles eliminators fill and piping and may collect on the equipment served thus reducing its performance An access hatch in the fan deck with ladder to an intermediate platform pro vides means for inspection of the plenum area above the eliminators Removal of an access hatch at the plenum level allows access to the spray chamber for inspection and maintenance of the nozzles and top of fill Provide surface protection before walking on the fill DRIFT ELIMINATORS Eliminators should be kept clean Do not walk or step on the eliminator COLD WATER COLLECTION BASIN Inspect collection basin occasionally for leaks and repair if necessary Keep cold water outlets clean and free of debris Makeup and circulating water controls must operate freely and maintain the desired water quantity in the system DRIVE SHAFT Check drive shaft alignment and condition of couplings every six months Refer to the Driveshaft User Manual for correcting misalignment balancing or replacing parts 4 maintenance ELECTRIC MOTOR Lubricate and maintain each electric motor in accordance with the manufacturer s instructions If repair work is necessary contac
5. tower 1 Check driveshaft alignment Realign if necessary Refer to the Driveshaft User Manual 2 Check tightness of bolts in fan cylinder joints 3 Check the following bolted joints in the fan and drive assemblies a Fan hub clamp bolts Refer to the Fan User Manual for correct torque setting b Fan hub cover bolts if present c Geareducer and motor mounting bolts d Driveshaft coupling and guard bolts Note Note operation 4 Check Geareducer oil for sludge or water by draining off and testing a sample as outlined in the Geareducer User Manual Check Geareducer oil level at oil level mark on the side of the case Add oil as required The oil level placard must be adjusted so that its full mark is at the same elevation as the full mark on the side of the Geareducer case Check oil lines to be sure there are no leaks Refer to theGeareducer User Manual for oil filling procedure and list of recommended lubricants 5 Rotate fan by hand to be sure of free rotation and ample tip clearance Refer to theFan User Manual 6 Check motor insulation with a Megger Refer to the Maintenance Section of Marley Electric Motor User Manual 7 Lubricate the motor according to motor manufacturer s instructions 8 Test run each fan separately for a short time Check for excessive vibration or unusual noise If either is present see Troubleshooting Guide on pages 14 and 15 of this manual Fan must rotate cl
6. Check fan blade pitch See Fan Service Manual Check for drag in fan drive train as from damaged bearings Wrong motor RPM Check nameplate against power supply Check RPM of motor and gear ratio Bearings overgreased Remove grease reliefs Run motor up to speed to purge excessive grease Rotor rubs stator bore If not poor machining replace worn bearing Wrong lubricant in bearings Change to proper lubricant See motor manufacturer s instruction Stop motor and attempt to start it Motor will not start if single One phase open phased Check wiring controls and motor Clean motor and check ventilation openings Allow ample ventila Poor ventilation tion around motor Check with Ohmmeter Winding fault Straighten or replace shaft Bent motor shaft Remove plugs and regrease bearings Insufficient grease Flush bearings and relubricate Deterioration of or foreign material in grease Bearings damaged Replace bearings Incorrect fan blade pitch See Fan Service Manual for blade pitching instructions Voltage too low at motor terminals because Check transformer and setting of taps Use higher voltage on Motor Does Not Come Up To Speed 14 of line drop Broken rotor bars transformer terminals or reduce loads Increase wire size or reduce inertia Look for cracks near the rings A new rotor may be required Have Wrong sequence of phases motor
7. F400 counterflow cooling tower OPERATION MAINTENANCE M93 1288A ISSUED 05 2013 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT Marley N Warning A Caution Note Note contents The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product Indicates presence of a hazard which can cause severe personal injury death or substantial property damage if ignored Indicates presence of a hazard which will or can cause personal injury or property damage if ignored Indicates special instructions on installation operation or main tenance which are important but not related to personal injury hazards These instructions assist in obtaining efficient long life from Marley counterflow cooling towers Direct questions concerning cooling tower operation and maintenance to your Marley sales represen tative Always include your tower serial number when writing for information or ordering parts Look for this number on the sidewall casing Before Startup ciere ten GER an atu ad 3 OPS zio p 4 inani iem noi ESPERE anima 7 Water Treatment cce u au ndtv teats ater c n 9 Spare Parts saei ira desea e on
8. Needs immediate attention Comments Structure Casing Material Structural Material Fan Deck Material Stairway Material Ladder Material Handrails Material Interior Walkway Material Cold Water Basin Material Water Distribution System Distribution System Header Material Manifold Material Branch Arms ili Nozzles Orifice diameter inches Heat Transfer System Fill Inlet Face of Fill Eliminators Use this space to list specific items needing attention 16 inspection checklist Condition 1 Good 2 Keep an eye on it 3 Needs immediate attention Mechanical Equipment Gear Drive Units T 2 3 comments Manufacturer Model Ratio Oil Level Full LJ Add Immediately i Low check again soon i Oil Condition Good LJ Contains Water LL Contains Metal Contains Sludge J Oil Used type Seals Back Lash Fan Shaft End Play Any Unusual Noises No Yes U Action Required Drive Shafts Manufacturer Material PET pT Fans Manufacturer Fixed Pitch LJ Adjustable Pitch LL Diameter Number of Blades Blade Material Hub Material Hub Cover Material Blade Assembly Hardware Blade Tip Clearance Vibration Level min max Fan Oylinder Height Mech Eqpt Support Mat I Oil Fill amp Drain Lines Oil Level Si
9. ade tip clearance Fan Noise Blade rubbing inside of fan cylinder Check and tighten if necessary Loose bolts in blade clamps SAFETY FIRST The F400 cooling tower has been designed to provide a safe working environment while either operating or shut down The ultimate responsibility for safety rests with the operator and owner When water flow to the tower is shut off or when portions of the tower require maintenance temporary safety barricades may be required around openings and fall protection equipment should be utilized where appropriate for compliance with OSHA regulations standards and good safety practices Routine periodic maintenance must be performed on all personnel access and material handling accessories in accordance with the following schedule Ladders Stairways Walkways Handrails Covers Decks and Access Doors Davits Derricks and Hoists Inspect for General Condition Semi annually Semi annually Inspect and Repair for Safe Use Yearly Inspect and Repair Before Each Use As Required 15 inspection checklist Date Inspected Inspected By Owner Location Owner s Tower Designation Tower Manufacturer Model No Serial No Process Served by ___ Operation Continuous L Intermittent Seasonal L Design Conditions GPM HW F CW F WB F Number of Fan Cells Condition 1 Good 2 Keep an eye on it 3
10. d OR Tec eg Seasonal Shutdown Instructions TO wer Cle un Troubleshooting case seuss nett teet erri tege N Warning Note operation Before Start up Among other sources outbreaks of Legionnaires disease have reportedly been traced to cooling towers Maintenance procedures that prevent amplification and dissemination of Legionella and other airborne bacteria should be formulated and implemented BEFORE systems are operated and continued reqularly thereafter to avoid the risk of sickness or death CLEANING New installations should be cleaned and treated with biocides by a water treatment expert before startup Remove any dirt and trash which has accumulated in the cold water basin Remove any sediment from the cold water collection basin sump and screens Use a water hose to flush cold water collection basins OPERATE WATER SYSTEM Start the circulating water pumps Increase the flow of circulating water gradually to match design water flow rate Circulate water over the cooling tower continuously for several days before starting the mechanical equipment and placing the cooling tower into continuous operation When starting in cold weather follow procedures outlined in Cold Weather Operation INSPECTION It is imperative that all operating assemblies be inspected before they are placed in operation The following is a list of components to be checked before starting the
11. er has two speed motors operate the fans at half speed forward This reduces the cooling air rate heat transfer and increases the quantity of warm water at the air inlet 3 With no heat load on the circulating water icing cannot be controlled Towers must not be operated with reduced water rate and or no heat load during freezing weather If a bypass directly into the cold water basin is used all water must be bypassed Reverse operation of fans is not recommended See Fan Drive for fan speed change precautions INTERMITTENT OPERATION When the unit is operated intermittently dur ing freezing weather it is necessary that the water be drained from the tower piping to insure protection against freezing and possible rupture N Warning N Warning maintenance Always shut off electrical power to the tower fan motor prior to performing any inspections that may involve physical contact with the mechanical or electrical equipment in or on the tower Lock out and tag out any electrical switches to prevent others from turning the power back on Service personnel must wear proper personal protective clothing and equipment Well maintained equipment gives the best operating results and the least maintenance cost SPX recommends setting up a regular inspection schedule to insure effective safe operation of the cooling tower Use the schedule on page 19 to obtain continuously good performance with the least tower main tenance See
12. ght Glass Vibration Limit Switches Other Components Motor Manufacturer Name Plate Data hp RPM Phase Cycle Volts EL Amps Frame S F Special Info Last Lubrication Date Grease Used Type Any Unusual Noise Any Unusual Vibration Any Unusual Heat Build up No LJ Yes Action Required No No LJ Yes Action Required z Action Required inspection and maintenance schedule General Recommendations more frequent inspection and maintenance may be desirable Hot Water Distribution System Suction Screen 1 Inspect for clogging 2 Check for unusual noise or vibration 3 Inspect keys keyways and set screws 4 Make sure vents are open 5 Lubricate grease 6 Check oil seals 7 Check operating oil level 8 Check static oil level 9 Check oil for water and sludge 10 Change oil 11 Check fan blade tip clearance 12 Check water level 13 Check for leakage 14 Inspect general condition 15 Tighten loose bolts 16 Clean 17 Repaint 18 Rebalance 19 Inspect repair for safe use 20 Inspect and repair before each use D Daily W Weekly M Monthly Q Quarterly S Semiannually Y Yearly R as Required Lis gel gd d d d a4 1 Stairs Ladders Walkway Doors Handrails 18 WHERE IDEAS MEET INDUSTRY SPX COOLING TECHNOLOGIES INC 7401 W 129 STREET OVERLAND PARK KANSAS 66213 USA P
13. lfate should be kept below 1000 ppm expressed as Calcium Carbonate Generally will not form scale in the cooling tower if carbonate scaling does not occur in the condenser Exceptions If make up water contains surplus free carbon dioxide scaling may be inhibited in the condenser but may occur in the tower fill because of CO stripping Silicates and Oxides Silica scale is virtually impossible to remove Silica scale is unlikely if SiO is held below 150 ppm Oxides such as iron oxide can coat all parts of the system if soluble iron is present in concentrations above 0 5 ppm Iron oxides do not usually develop into thick scales but can accentuate the development of other scales maintenance Spare Parts SPX Cooling Technologies manufactures and maintains a stock of replacement parts for the mechanical equipment Shipment of these parts are normally made within ten days after an order is received If emergency service is necessary contact the local Marley representative for assistance To prevent prolonged shutdown periods in case of damage to the mechanical equipment it is suggested that the following parts be carried in the owner s stock One fan assembly One Geareducer assembly One driveshaft assembly Be sure to furnish the tower serial number when ordering parts Seasonal Shutdown Instructions Tower Drain all tower piping During shutdown clean the tower and make any necessary repairs Ap
14. lorine should be added as intermittent or shock treatment only as frequently as needed to control the slime and algae Chlorine and chlorine containing compounds should be added carefully since very high levels of chlorine may occur at or near the point of entry into the circulating water system FOAMING Heavy foaming sometimes occurs when a new tower is put into operation This type of foaming generally subsides after a relatively short pe riod of operation Persistent foaming can be caused by the concentrations of certain combinations of dissolved solids or by contamination of the circulating water with foam causing compounds This type of foaming can sometimes be minimized by increasing the blowdown but in some cases foam depressant chemicals must be added to the system Foam depressants are available from a number of chemical companies N Warning 10 maintenance MAINTENANCE OF FILL PERFORMANCE Owner must keep water clean by treatment screening or filtering to avoid the possibility of fill clogging and loss of thermal perfor mance Potential Causes of Fill Clogging Suspended materials trash etc Scale Can be sulfates silicates carbonates or oxides Scaling effects can be accentuated by suspended muds Algae and or Slime Can control with chlorine or non oxidizing biocides Possible Sources of Scale Calcium Sulfate From make up and sulfates produced by sulfuric acid for pH adjustment Calcium su
15. ockwise when viewed from above Recheck Geareducer oil level 9 Check functioning of make up water supply Make sure the blowdown will carry the proper amount of water Starting Procedure WATER SYSTEM Fill the cold water collection basin and circulating water system until the operating water level is reached Prime and start the circulat ing water pumps Increase the flow of circulating water gradually to design water flow rate to avoid water hammer which could damage the distribution piping system Clean the sump screens several times during the first weeks of operation After this clean sump screens weekly When starting in cold weather follow procedures outlined in Cold Weather Operation STARTING FAN Operate the fan for 30 minutes to permit the Geareducer oil to come up to operating temperature and check the motor load with watt meter or take operating volt and ampere readings and calculate motor hp Refer to the Fan User Manual for instructions Pitch fans if required to pull correct contract horsepower when circulating design water rate at design hot water temperature A Caution operation Entering water temperature in excess of 125 F may result in fill deformation TOWER PERFORMANCE Keep the cooling tower clean and water distribu tion uniform to obtain continued maximum cooling capacity The capacity of a cooling tower to cool water to a given cold water temperature varies with the wet bulb temperature and the hea
16. ply protective coating as required to all metal parts Particular attention should be given to mechanical equipment supports drive shaft and drive shaft guards Mechanical Equipment Geareducer shutdown for 3 months or less 1 Each month drain water condensate from the lowest point ofthe Geareducer andits oil system Check oil level and add oil if necessary Operate to recoat all interior surfaces with oil 2 At start up drain water condensate and check oil level Add oil if neces sary Refer to the Geareducer User Manual for maintenance and lubrication instructions 11 12 maintenance Geareducer shutdown for 3 months or more 1 If the motors have space heaters operate mechanical equipment one hour each month 2 If the motors do not have space heaters operate mechanical equipment one hour each week 3 At startup operate mechanical equipment one hour or until oil is warm then shut the equipment down Drain the oil and refill with new oil Refer to Geareducer Manual for instruction on changing oil Refer to the Downtime Instruction Manual for downtime exceeding six months Electric Motors 1 Do not start the motor without determining that there will be no interference with free rotation of the fan drive 2 Refer to the the Marley Motor User Manual 3 If shutdown period is longer than seasonal contact your Marley sales rep resentative for additional information N Warning maintenance
17. seconds minimum after de energizing the high speed winding and before energizing the low speed winding Tremendous stresses are placed on driven machinery and motors unless the motors are allowed to slow to low speed RPM or less before the low speed winding is energized A Caution operation FREEZING WEATHER OPERATION During periods of low temperature operation 35 F to 40 F or below ice will form on the relatively dry parts of the cooling tower that are in contact with the incoming air Primarily this includes the airinletand adjacent structural framing Your understanding of cold weather operation will be enhanced if you read Operating Cooling Towers in Freezing Weather Technical Report H 003 available at spxcooling com Ice forming characteristics on any given cooling tower will vary depending on velocity and direction of wind circulating water rate and heat load Excessive ice formation may be controlled by regulating air and water flow through the tower by one or more of the following procedures 1 Shut the fan down This reduces the cooling air rate to a minimum and in creases the quantity of warm water at the air inlet to a maximum However normal fan off operation causes reverse air flow by aspiration and may cause water blowout and therefore must be done with caution and moni toring For automatic operation a timer switch can be provided to shut the fan down for a few minutes each hour 2 When a cooling tow
18. service man check motor Change any two of the three motor leads troubleshooting Trouble Cause Remedy Wrong Rotation Motor Geareducer bearings If new see if noise disappears after one week of operation Drain Geareducer Noise Gears flush and refill Geareducer See Geareducer User Manual If still noisy replace Correct tooth engagement Replace badly worn gears Replace Loose bolts and cap screws gears with imperfect tooth spacing or form Tighten all bolts and cap screws on all mechanical equipment and Unusual Fan Drive Vibration Unbalanced drive shaft or worn supports Make sure motor and Geareducer shafts are in proper alignment and couplings Fan match marks properly matched Repair or replace worn couplings Rebalance drive shaft by adding or removing weights from balancing cap screws See Drive Shaft User Manual Make certain all blades are as far from center of fan as safety Worn Geareducer bearings devices permit All blades must be pitched the same See Fan User Manual Clean off deposit build up on blades Check fan and pinion shaft endplay Replace bearings as neces Unbalanced motor sary Disconnect load and operate motor If motor still vibrates rebal Bent Geareducer shaft ance rotor Check fan and pinion shaft with dial indicator Replace if necessary Loose fan hub cover Tighten hub cover fasteners Adjust cylinder to provide bl
19. t load applied to the cooling tower As the wet bulb temperature drops the cold water temperature also drops However the cold water temperature does not drop linearly with the wet bulb temperature A cooling tower will not contro heat load The flow rate of water circulated through the cooling tower will determine the temperature range of cooling in conjunction with a given heat load The hot water and cold water temperatures will increase with higher heat loads HOT WATER DISTRIBUTION SYSTEM Maintain uniform water distribution at the nozzles uniform spray cone The amount of water circulated should approximate the contract requirements and the nozzle pressure should be kept constant Lower pressures may indicate excessive losses in the piping system and or insufficient pump capacity greater pressures might indicate clogged nozzles and or overpumping If a greatly reduced water flow rate is desired it may be advisable to change nozzle sizes to obtain the desired pressure and maintain proper water distribution An SPX Cooling Technologies engineer can advise minimum and maximum flow rates for even distribution COLD WATER COLLECTION BASIN A suitable depth must be maintained to keep the pumps from pulling air into the line The amount of make up water required to keep the water in the collection basin at the required depth depends upon the evaporation loss and blowdown FAN DRIVE When using two speed motors allow a time delay of 20
20. t the nearest representative of the motor manufacturer See Warranty Section of the Marley Electric Motors User Manual FAN Inspect fan blade surfaces every six months For detailed maintenance information refer to the Fan User Manual GEAREDUCER Make weekly and monthly oil checks Inspect internal parts during seasonaloil change Refer to the Geareducer User Manual for detailed maintenance instructions PAINTING Periodically clean and if necessary recoat all metal parts subject to corrosion Water Treatment BLOWDOWN Blowdown or bleed off is the continuous removal of a portion of the water from the circulating system Blowdown is used to prevent the dissolved solids from concentrating to the point where they will form scale The amount of blowdown required depends upon the cooling range the dif ference between the hot and cold water temperatures and the composition of the make up water water added to the system to compensate for losses by blowdown evaporation and drift The following table shows the amount of blowdown required to maintain different concentrations with various cool ing ranges BLOWDOWN OF CIRCULATING RATE Number of Concentrations 1 5X 2 5X 3 0X 4 0X 5 F 2 78 C 78 38 25 18 11 08 10 F 5 56 C 1 58 78 5i 38 25 18 15 F 8 33 C 2 38 1 18 78 58 38 28 20 F 11 11 C 3 18 1 58 1 05 78 51 38 25 F 13 89 C 3 98 1 98 1 32 98 64 48 Cooling Range
21. tween the control apparatus and the motor 2 Check starter contacts and control circuit Reset overloads close contacts reset tripped switches or replace failed control switches 3 If power is not on all leads at starter make sure overload and short circuit devices are in proper condition Wrong connections Check motor and control connections against wiring diagrams Low voltage Check nameplate voltage against power supply Check voltage at motor terminals Open circuit in motor winding Check stator windings for open circuits Motor or fan drive stuck Disconnect motor from load and check motor and Geareducer for cause of problem Rotor defective Look for broken bars or rings Unusual Motor Noise Motor running single phase Stop motor and attempt to start it Motor will not start if single phased Check wiring controls and motor Motor leads connected incorrectly Check motor connections against wiring diagram on motor Ball bearings Check lubrication Replace bade bearings Electrical unbalance Check voltages and currents of all three lines Correct if required Air gap not uniform Check and correct bracket fits or bearing Rotor unbalance Rebalance Cooling fan hitting guard Reinstall or replace fan Motor Runs Hot Wrong voltage or unbalanced voltage Check voltage and current of all three lines against nameplate values Overload
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