sct assembly indtruction.pdf

7/25/2019 SCT Assembly indtruction.pdf

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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: 0422-2360523EMAIL: [email protected]

: [email protected]

: [email protected]


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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.


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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.


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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.


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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-to-

Horsepower 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


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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


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ASSEMBLY INSTRUCTION MANUAL


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INTRODUCTION


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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


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2. ASSEMBLY OF TOP & BOTTOM L-ANGLE:

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


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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:


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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


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5. ASSEMBLY OF FRP SHEET:

Qty: 12 NosMaterial : FRP

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

FINAL ASSEMBLY

FRP SHEETS - 12 NOS


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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.

FRPLOUVER 4 NOS


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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 -4Nos.Material - 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


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9. ASSEMBLY OF DISTRIBUTION HEADER & NOZZLE PIPE:

HeaderPipe: 1 Nos. Nozzle Pipe: 8 NosMaterial : FRP 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


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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.

NOZZLE PIPE

MOTOR

FAN


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12. FAN GUARD ASSEMBLY:

Quantity - 4 Nos.Material - 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.


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4. MAINTENANCE AND ADJUSTMENTS

4.1 NOZZLE HEAD

First check whether the flow rate is normal. If correct, dismantle the head for cleaningand 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 can also keep the

operation within the acceptable water quality.


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TROUBLE SHOOTING

TROUBLE CAUSE REMEDYRise in cooling water

temperature

1. Excessive or inadequate

cooling water.

2. Irregular flow of air3. Recirculation of air from

tower outer.

4. Improper flow of air from

fan.

5. Blocking of the fills

1. Adjust to the specified flow.

2. Improve ventilation.

3. Improve ventilation.

4. Adjust the angle of fan blades.

5. Clean the blocked area.

Abnormal water flow 1. Blocking of the nozzle holes.

2. Blocking of pipe.

1. Clean nozzle.

2. Clean header and nozzle pipes.Noise and vibration 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. 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.

Excessive current flow 1. Drop in voltage.

2.Irregularities in the angles ofthe fan blades

3. Damage in motor.

4. Overload through excessiveair flow.

1. Check supply voltage.

2. Make careful adjustment.3. Repair or replace motor from

manufacturer.

4. Adjust fan blade angle.

Water carry over 1.Block of the fill

2. Excessive circulating water.

3.Excessive air flow

1. Eliminate blockage at the upper

edge of the fill.2. Adjust the water flow with

valve.

3. Adjust fan blade angle.


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INSPECTION AND MAINTENANCE SCHEDULE

INSPECTIONARE

A

FAN

MOTOR

ELIMINATOR

PVCFILLS

WIRINGS

STRUTURAL

MEMBERS

FRPCASING

FLOATVALVE

BLEEDVALVE

FLOWC

ONTROL

VALVE

G A O

Inspect for clogging W W

Check for unusual noise or

vibration

D D Y D

Inspection keys and set screw S S

Lubricate Y

Check flow rate M

Check for leakage S

Inspect general condition Y Y Y S Y Y S

Clean R S R R S Y R W

Repaint R

Completely open and close S

D-Daily W-Weekly M-Monthly Q-Quarterly S-Semi annually

Y-Yearly

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

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