SPX Cooling Technologies Cooling Tower 160 User's Manual
Contents
1. 2 390 11 660 42 1 Y4 19 3 4 1 Last number of model indicates number of cells Change 2 Fan hp is usually less than shown here as appropriate for your selection Primary engineering data is 3 Height shown is from base of tower columns to fan deck Wood per cell basin if used elevates tower 6 If concrete basin is used subtract 1 6 for height above top of basin curb Steel Basin Support 7 gt lt E BAYS 4 0 L EACH ADDITIONAL CELL L lt TY OUT OF OUT OF BASIN COL PA E B COL COL BASIN AIR INLET FACE ji lt _ 75 lt A we COL D B gt 1 1 lt W OVERALL WIDTH OF BASIN gt gt Cc FACE C CASED FACE j A SUMP 4 ji OVERFLOW L ADDITIONAL SUMP WHEN REQUIRED FACE A CASED FACE B D C ADDITIONAL OVERFLOW WHEN REQUIRED A COL FACE D AIR INLET FACE 7 gt Note Two beams shown phantom are required on Models 1651 and 1661 only All dimensions are to centers of tower columns not centers of anchor bolts or beams Operating Weight lb C Single Cell Each Cell Add 1611 37 10 7 5 10 10 24 0 110 865 104 830 Dimensions 37 10 7 5 8 10 10 28 0 127 440 121 305 37 10 7 5 10 10 32 0 143 565 137 830 37 10 7 5 10 10 36 0 158 800 12. Welded unitized hot dip galvanized steel supports maintain alignment throughout the mechanical equipment system Marley torque tubes provide superior strength and stability Their cylindrical shape also keeps operating costs down by minimizing airflow restrictions and reducing air turbulence in the fan entrance region Water Distribution System The gravity flow water distribution system designed into the Class 160 tower essentially reduces pump head to its most basic component static lift saving you money on pump power You won t have to force water through internal piping and pressure spray nozzles as you would in a counterflow tower Warm water enters the system through a Marley galvanized crossover pipe Inlet connections for your piping are drilled to conform to Class 125 ANSI requirements Marley flow control valves balance the flow to both distribution basins of each cell Water flows from the valves through a splash suppression chamber and into the treated fir plywood distribution basins Polypropylene Marley Spiral Target nozzles in the basin floor then distribute the water uniformly over the fill All materials in the water distribution system offer long life and minimal maintenance Valves consist of cast iron bodies and grease lubricated stainless steel operating stems All plywood is treated exterior grade The nozzles are chemically and biologically inert so they ll last indefinitely Structure and Mate
3. 18 0 16 2 20 4 ae 16 5 94 ae 20 6 94 2 390 7 050 7 051 11 660 18 0 17 8 3 4 20 4 ga iray 200 20 6 at 2 390 7 050 7 051 11 660 Use this bulletin for preliminary layouts only Obtain current drawings from your Marley sales representative Pumping head contributed by the tower is static lift shown on page 7 Actual pumping head will vary according to tower circulating GPM Total pumping head will be furnished at time of proposal If your application requires a bypass system recommended location is through tower endwall into plenum area Review of the system by Marley engineering is required 18 0 10 18 8 3 4 20 4 Ye e 18 11 94 PROE 20 6 Marley piping terminates at face of a cast iron flat face flange Bolt circle conforms to class 125 lb ANSI B16 1 specifications Supports on tower for crossover piping are furnished by Marley Do not support the riser s dead load or operating load from the tower Do not brace the riser s seismic or thrust loads against the tower On Models 1611 through 1641 with a 32 or 3200 Geareducer the inlet diameter must be 20 Available Options Cell Partition Options Every Class 160 tower includes plenum partitions and hot water distribution basin partitions between adjacent cells Plenum partitions keep air from entering an operating cell through an adjacent idle fan assuring consi
4. Marley Class 160 Cooling Tower SP COOLING TECHNOLOGIES The Marley Difference You ll enjoy single source responsibility and reliability because we design and manufacture virtually all major cooling tower components All Marley components are designed and selected to be part of an integrated system For example the spray pattern from nozzles and the pressure drop through drift eliminators both affect a fill s heat transfer capacity So we include that impact in our thermal analysis Drift eliminators must be effective at the air velocities where fill is most efficient So we ve carefully designed both components to work together efficiently Class 160 Tower Advantage Guaranteed Performance Don t rely on outside agencies with limited enforcement powers We ll stand by our responsibility for reliable thermal performance We designed it We rate it We guarantee it Long Service Life We ve carefully chosen all the materials used in Class 160 towers for their corrosion resistance and suitability for cooling tower service Pressure treated lumber heavy galvanized steel stainless steel PVC and fiberglass keep your Class 160 tower working year after year Efficient Field Assembly Precise factory fabrication assures that every component in your Class 160 tower will fit as designed And SPX offers an unparalleled nationwide construction organization to build your tower quickly and economically Easy Ma
5. 53 115 40 10 7 5 6 11 7 5 4 Ye 36 0 175 740 169 640 42 10 7 5 7 6 V2 5 9 V2 36 0 181 620 175 390 1 Use this bulletin for preliminary layouts only All dimensions show 4 Maintain no less than 2 0 of clear space at cased faces for column locations not anchor bolt locations Obtain current construction purposes Air inlet faces must have unobstructed drawings from your Marley sales representative before designing air supply Consult your Marley sales representative if nearby supports obstructions may interfere 2 Other contractors or purchaser must design and erect support 5 Operating weight is wet weight of tower and wood basin ing steel including 6 of water in the cold water basin This is the recom 3 If steel beams are used they must include 7 dia holes to mended operating water level for all models accept anchor bolts provided by Marley If concrete beams or 6 For collection basin accessories information request Marley pilasters are used 3 4 dia anchor bolts imbedded in the con drawing 90 3231 from your Marley sales representative crete must be provided by others Concrete Basin _6 MN m gt lt 6 MIN z 6 gt x A BAYS 4 0 B PER CELL gt lt 6 o COL PA
6. CE une COL AIR INLET FACE U i I U UJ i U p f 4 4 m l y y z z 2 LL 5 5 O b z 8 8 ig z i fl i Hl il A FACE D E i AIR INLET FACE hogan z 2 RECOMMENDED OPERATING 1 6 WATER LEVEL 1 0 RECOMMENDED OPERATING 1 i WATER LEVEL 1 0 Y yo I k Flat Slab Basin Dimensions Deep Basin Operating Weight Ib WwW A B Single Cell Each Cell Add 37 6 24 0 70 970 67 980 37 6 3 28 0 80 840 77 850 37 6 4 32 0 90 075 86 855 37 6 40 6 42 6 y4 6 7 8 9 9 9 Use this bulletin for preliminary layouts only Do not use for construction Obtain current drawings from your Marley sales representative Concrete basin design and construction are by other contractors or purchaser Operating weight is total wet operating weight of tower only excluding water in concrete basin Maintain at least 2 O of clear space at cased faces for con struction purposes Air inlet faces must have unobstructed air supply Consult your Marley sales representative for recommen dations if nearby obstructions may interfere 36 0 98 910 105 570 108 700 95 900 102 540 105 590 Minimum basin depth is 17 6 Maximum basin depth is 5 6 Marley will provide at extra cost extended interior columns fo
7. for Deep Collection Basin Interior tower columns can be extended to permit concrete basin depth of up to 5 6 Some exceptions apply so consult your Marley sales representative Ladder Extension Used when tower is elevated appreciably above working level Extensions attach to the normal ladder and may require foot anchorage depending on length Cell Partition Extra partitions between fan cells for specific operating considerations See page 11 Stainless Steel Hardware All hardware including assembly hardware and some specialty items are series 300 stainless steel Vibration Limit Switches Robertshaw or Metrix single pole double throw vibration switches in NEMA 4 housing Double pole double throw models are also available Oil Level Gauge A brass oil level sight glass replaces the dip stick on the external oil fill and drain system Permits easy reading of oil level and also provides access for Geareducer oil changes Air Inlet Screen Galvanized wire mesh screens over the air inlets keep leaves and debris out of the tower Easily removable Choose either treated fir frames or galvanized steel U edge frames Fan Cylinder Extension Optional flared fan cylinder extensions improve fan efficiency to reduce your operating costs Distribution Basin Cover Removable treated fir plywood covers keep upper basins free of leaves and debris They also tend to retard gr
8. intenance Access The Class 160 s crossflow design gives you quick direct access to the open distribution basins plenum and mechanical components for regular inspection and service How many other cooling tower companies can offer you this assurance They may use Brand A nozzles with Brand B fill and Brand C drift eliminators When they all come together the whole may be less than the sum of the parts Our total system approach assures that all the parts work together to provide you the greatest total performance And because we design specifically for cooling towers all our components will provide many years of service with minimal maintenance From design through installation and on throughout your tower s life all of SPX will work for you Low Operating Costs Marley high efficiency fill and fans gravity flow water distribution and efficient Geareducer drive work together to offer maximum cooling with minimum power use Low Maintenance Costs Induced draft propeller fans on Marley rightangle Geareducer units TEFC 1 15 service factor motors and heavy duty mechanical equipment supports assure long service life with minimal maintenance All Season Reliability Class 160 towers perform as specified in the heat of summer They respond well to energy management techniques in the spring and fall They operate virtually ice free in the dead of winter And they offer simple maintenance all year long We guara
9. least one or more depressed side outlet sumps complete with plugged drains and hot dip galvanized or stainless steel debris screens Standard sumps are FRP construction or galvanized steel depending on outlet size Each basin includes an overflow cleanout connection consisting of a galvanized full coupling and normally installed standpipe which removes easily for flush out basin cleaning A float operated mechanical makeup valve automatically replenishes water lost from the system The valve is located in 11 the plenum chamber between fill banks just inside the endwall access door to facilitate adjustment and maintenance Fire Safety Options On specific jobs you may want to weigh the cost of various modifications against the cost and maintenance of a sprinkler system or the cost of higher insurance premiums One or more of the following tower modifications may negate the need for a sprinkler system Q Fire retardant fan cylinders offer flame spread less than 25 per ASTM E 84 Q AY thick fiber reinforced cement board FRC overlay on the fan deck acts as a fire stop and provides a nonskid walking surface QO A FRC overlay on the distribution basin covers acts as a fire stop Q Barrier walls keep fire from spreading between cells in multicell towers Specify barrier wall design by containment period such as a 20 minute fire wall Barrier walls consist of pressure treated fir plywood between cells Plyw
10. motors also help to control icing during wintertime operation See Marley Technical Report H 003 Operating Cooling Towers During Freezing Weather Normally two speed motors are provided in 1800 900 RPM single winding configuration which is the least expensive two speed option They are also available in other combinations including the more expensive double winding Q Frequency modulation devices work well on induced draft propeller fan cooling towers such as the Class 160 However their design must include the capability to lock out any critical fan speeds and the very low fan speed ranges Consult your Marley sales representative for specific recommendations when considering variable speed control In many cases for example you ll achieve the best results by using a single control to regulate the speed of several fans on a multicell tower System Cleanliness Cooling towers are very effective air washers Atmospheric dust able to pass through the relatively small louver openings will enter the circulating water system Increased concentrations can intensify system maintenance by clogging screens and strainers and smaller particulates can coat system heat transfer surfaces In areas of low flow velocity such as the cold water basin sedimentary deposits can provide a breeding ground for bacteria In areas prone to dust and sedimentation you should consider installing some means for keeping the cold water basin clean T
11. ntee it Single Source Parts Availability SPX designs manufactures guarantees and stocks all major components of the tower except motors and some fan sizes In fact we stock many of those parts too We ll have the parts if you ever need them Construction and Components Fill Louvers Drift Eliminators Marley high performance film fill is the heart of every Class 160 tower A repeating chevron pattern provides the wetted surface and air turbulence necessary for proper heat transfer while minimizing resistance to airflow so you ll save on fan power Molded protrusions on each fill sheet assure uniform spacing Fill sheets are vacuum formed 15 mil 015 thick PVC polyvinyl chloride capable of service at hot water temperatures up to 120 F Consult your Marley sales representative for applications where hot water temperatures are greater than 120 F yet less than 145 F to determine upgrade possibilities Stainless steel structural tubes resting in stainless steel hangers support the fill and PVC tubes control alignment This system also holds the bottom of the fill sheets above the cold water basin floor to simplify basin cleaning Fill sheets include both louvers and drift eliminators The louvers in this patented arrangement keep water on the fill sheets and in your tower and also assure proper heat transfer throughout wide variations in airflow Users find this fill operates ice free even in extremely cold weather I
12. ntegral drift eliminators prevent the costly nuisance of drift spotting on objects in the surrounding environment Their unique shape induces the air flow through three distinct direction changes as shown below The final turn directs air toward the fan to save you fan horsepower Moisture carried in the air stream can t make these abrupt turns so drift is less than 0 005 of the circulating water flow rate Mechanical Equipment The Marley Geareducer speed reducer used in the Class 160 line contributes a long record of dependability long service life and low maintenance Their designs meet or exceed the requirements of CTI STD 111 and AGMA Std 420 04 We run in every Geareducer unit under load prior to shipment to make sure that it will operate properly on your tower Housings are gray cast iron Gears are high strength case hardened alloy steel And all bearings are tapered roller bearings A variety of available horsepower capacities and reduction ratios lets us choose the optimum Geareducer model and fan speed for your job Service factors are always at least 2 0 as applied Splash type lubrication and integral cooling fins preclude the need for maintenance intensive oil pumps and coolers A constant oil bath or flow lubricates every bearing in forward or reverse motion at full or half speed All Marley Geareducer assemblies are rightangle type with motors located outside the tower s saturated airstream A galvanized
13. ood thickness and cost vary according to the specified containment time Q FRP casing having a flame spread rating of 25 or less If your insurance carrier insists on a sprinkler system for your tower consult your Marley sales representative We can provide a sprinkler system to fit your needs or work with your people to be sure that the sprinkler system and tower will meet your specification Non Standard Motors Although you can buy your Class 160 tower less motor at a cost reduction it is not normally recommended Motors supplied on Marley towers meet rigorous specifications developed from environmental chamber tests at our Development Center These specifications represent prudent minimum design requirements Unless otherwise specified motors provided are TEFC 1 15 service factor appropriate to the applied load 1800 RPM Other enclosures Such as Explosion Proof and motors specially wound for nonstandard voltages are available at extra cost Two speed motors are also available and their advantages are discussed on page 6 Available Options Accessory Description and Remarks Accessory Description and Remarks Plywood Collection Basin Pressure treated Douglas fir plywood collection basin for towers located above grade See page 11 Fire Protection Sprinkler systems and overlay materials let you choose from a range of fire protection options See page 11 Extended Columns
14. owth of algae by keeping ultraviolet radiation away from the warm water in the basins Covers may be used as a working surface for tower maintenance SP COOLING TECHNOLOGIES 7401 WEST 129 STREET OVERLAND PARK KANSAS 66213 UNITED STATES 913 664 7400 spxcooling spx com spxcooling com In the interest of technological progress all products are subject to design and or material change without notice 2008 SPX Cooling Technologies Inc Printed in USA CL160 06
15. r deep basins Perimeter columns remain at 1 6 below top of basin curb All anchor bolts complete with nut and washer must be fur nished by others Bolts must be diameter with 2 all thread projection Other contractors or purchaser must design locate construct and furnish sump s and overflow s to suit requirements The sump s should be designed according to the pump manu facturer s recommendations Other design sources ANSI HI specifications 1 1 1 5 for centrifigal pumps 2 1 2 5 for vertical pumps and 9 8 for pump intake design Inlet Piping Plan ti g o e F z w z z LL y k iI Y FACE OF A DIA INLET FLANGE PIPING SHOWN WITH D E a D TYPICAL MULTICELL HIDDEN LINES IS BY OTHERS coL 4 INLET INLET B DIA FLOW CONTROL VALVE AND CROSSOVER PIPE BASE OF TOWER COL GPM Dimensions per Cell Cc D E F G 1 500 7 050 7 051 8 640 12 0 iga 16 2 y4 ET 20 4 3 24 0 16 5 9A 19 6 20 6 1 850 7 050 7 051 10 080 2 120 7 050 7 051 11 520 14 0 16 0 16 2 20 4 y 16 5 20 6 16 2 20 4 16 5 20 6 28 0 19 6 19 6 2 390 7 050 7 051 11 660
16. rials Class 160 tower design conforms to the latest edition of the National Design Specification for Wood Construction NDS published by the National Forest Products Association as well as CTI standards STD 114 and STD 108 Wind load criterion is normally 30 pounds per square foot of projected area and the design meets criteria for UBC Zone 1 seismic loading based on a maximum water temperature of 120 F The primary structural elements of all Class 160 towers are the nominal 4 x 4 columns spaced on 4 0 longitudinal centers A system of nominal 4 x 4 tower diagonals carries loads in both tension and compression to heavy duty hot dip galvanized steel anchor plates Pressure treated Douglas Fir is the standard material for structural members in Class 160 towers because it offers predictably consistent structural strength and provides long service life in cooling towers Unless otherwise specified all lumber is pressure treated after fabrication Treatment in accordance with CTI Standard STD 112 is available on request All structural framing connections use diameter galvanized machine bolts with either fiber reinforced nylon shear connectors or FRP connector straps The fan deck is pressure treated exterior grade fir plywood designed for a uniform live load of 60 psf Access and Safety The Class 160 tower is designed to meet all OSHA requirements A 3 6 high guardrail system complete with top rails in
17. steel lube line runs from the Geareducer unit to a standpipe near the motor on each cell so you can check oil level and change or add oil while standing on the fan deck Class 160 towers offer the benefits of adjustable pitch propeller type fans All fans used on Class 160 towers include hollow GRE glass reinforced epoxy blades and epoxy coated cast iron or galvanized steel hubs Blades are adjustable in pitch so you can take full advantage of rated horsepower or adjust the pitch to compensate for unusual jobsite restrictions The true airfoil blades designed specifically for cooling towers offer efficient quiet operation and long service life Fans operate inside structural FRP fiber reinforced polyester eased inlet fan cylinders designed and applied to maximize fan performance Standard cylinder heights are 6 0 to 7 0 depending on fan diameter 10 0 cylinders are available as an option Marley manufactured driveshafts transmit power from the motor to the Geareducer assembly All Marley driveshafts include 304 stainless steel tubes with welded on stainless steel flanges and bonded neoprene flexible elements to transmit torque Marley driveshafts are full floating assemblies with non lubricated flexible couplings on each end Their tolerance to misalignment and torsional shock is unequalled in non specialized units All Marley driveshafts are dynamically balanced at the factory to minimize operating vibrations
18. stent thermal performance Basin partitions let you inspect and clean individual basins while the rest of the tower continues to operate Specify extra partitions carefully because excess partitions can sometimes discourage routine maintenance and good housekeeping procedures Two options are available to meet specific design goals Q Fill area partitions are available but usually not necessary The solid sheet design of film fill prevents water and air migration between the fill areas of adjacent cells in all operating modes Q Complete watertight partitions let you use adjacent cells to serve separate loads having incompatible system temperatures Watertight partitions consist of exterior grade pressure treated fir plywood sealed to cold water basin partitions made from the same material as the basin sides For concrete basin partitions Marley drawings specify the appropriate design dimensions Optional weir gates in wood basin partitions let you mix or segregate the water in the basin to meet your operating needs Cold Water Collection Basins If you plan to locate your tower above grade we can supply a treated Douglas fir cold water collection basin complete with the necessary operating accessories The basin floor is exterior grade pressure treated fir plywood supported on joists Basin sides are also plywood machined to fit the basin floor providing a watertight joint after sealing The standard wood basin includes at
19. termediate rails and toeboards surrounds the entire top perimeter of the tower Aluminum ladders attached to the tower endwalls provide access to the fan deck level Ladders begin at the cold water basin level and end at the top of the guardrail around the fan deck Each tower normally includes two ladders one at each endwall Hinged doors through the endwall casing permit access to the interior of the tower at the basin level Single cell towers have one door Multicell towers have doors in both endwalls plus accessways through any and all partition walls All mechanical equipment is accessible both from the interior of the tower and through the fan cylinder Every component of every tower is removable and replaceable Casing Tower endwalls are cased with gray 8 oz sq ft ribbed FRP sheets Water and corrosion proof FRP is immune to biological deterioration and requires no maintenance Casing ribs run vertically Vertical joints between sheets are overlapped one rib and are sealed in the fill areas Casing attaches to the structural members with stainless steel fasteners and neoprene bonded washers Corner trim pieces are 12 oz sq ft molded FRP Cold Water Basin Most Class 160 owners install their towers over concrete cold water basins provided by others or you can choose a wood collection basin as an option See page 11 Consult your Marley sales representative for detailed dimensional drawings and load schedules to help yo
20. u with your basin design Operating and Environmental Considerations Cooling towers are usually selected to produce a specific cold water temperature at the higher summertime wet bulb temperatures During the remainder of the year the cooling tower is capable of producing much colder water Unless your system will benefit from the coldest possible water temperature you may want to consider controlling cold water temperatures to higher levels You ll also save energy by using such control See Marley Technical Report H 001A Cooling Tower Energy and its Management Always control leaving water temperature by manipulating the quantity of air that the fan moves through the tower Varying the quantity of water flow is not normally recommended and can be harmful in freezing weather You can alternately start and stop single speed motors to keep water temperatures within an acceptable range But your flexibility is limited by the amount of starting time per hour allowed by the motor manufacturer Increased flexibility can simplify your operating procedures and save you money in the long run both on operation and on maintenance Here are two of the more popular options QO Two speed motors improve operating flexibility by increasing the number of potential operating modes Users in northern climates will find that the tower can carry winter loads at half speed reducing fan power requirements by 85 during that time Two speed
21. ypical devices include side stream filters and a variety of filtration media You should also plan ahead to develop a consistent effective program of water treatment A good water treatment program will help to assure long service life while keeping your tower free of potentially harmful biological growths ACaution The cooling tower must be located at such distance and direction to avoid the possibility of contaminated tower discharge air being drawn into building fresh air intake ducts The purchaser should obtain the services of a Licensed Professional Engineer or Registered Architect to certify that the location of the tower is in compliance with applicable air pollution fire and clean air codes Tower Schematic 5 _ gt COL lt A BAYS 4 0 L _ gt C DIA FAN Tower Plan TOP OF FAN CYLINDER TOP OF FAN DECK w gt lt ff BASE OF TOWER COL Endwall Elevation GPM Width Height Dimensions Maximum per Cell wW H B Motor hp 1 500 8 640 37 1 y 19 3 4 7 0 125 1 850 10 080 37 1 y 19 3 1 7 0 125 2 120 11 520 37 1 y 19 3 1 2 390 11 660 37 1 y 19 3 1 2 390 11 660 40 1 19 3 1
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