Operation & Maintenance

Manual

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TC SERIES
COOLING TOWER

TRUWATER COOLING TOWERS SDN BHD

(Company No: 188113-A)
EXECUTIVE SUITE 702, BLOCK B,
KELANA BUSINESS CENTRE
NO.97, JALAN SS7/2 KELANA JAYA,
47301 PETALING JAYA, SELANGOR DARUL EHSAN
TEL: +603 7880 8800 FAX: +603-7804 5519
EMAIL: [email protected],
WEBSITE: http://www.truwater.com.my
 TC SERIES
COOLING TOWER

Operation & Maintenance Manual

CONTENTS PAGE

1.0 INTRODUCTION 1

2.0 CONSTRUCTION 1

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2.1 GENERAL
2.2 TOWER BODY
2.3 FAN
2.4 INFILL
2.5
2.6
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DRIFT ELIMINATOR
WATER DISTRIBUTION SYSTEM
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3.0 PREPARATION FOR START UP & OPERATION 3
3.1 CLEANING
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3.2 ELECTRICAL WIRING

3.3 WATER FEEDING
3.4 INSPECTION
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4.0 OPERATION 5
4.1 PRECAUTION DURING OPERATION
4.2 CARES FOR LONG-TERM SHUT DOWN
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5.0 PREVENTIVE MAINTENANCE 7

5.1 V-BELT & PULLEY SYSTEM
5.2 GEAR DRIVE SYSTEM
5.3 MOTOR RE-LUBRICATION

6.0 WATER REPLENISHMENT 11

6.1 EVAPORATION LOSS
6.2 CARRY-OVER LOSS
6.3 BLOW-DOWN LOSS
6.4 MAKE-UP FLOW RATE

7.0 TROUBLESHOOTING 12
 Operation & Maintenance Manual - TC Series

1.0 INTRODUCTION
Dear Customer,
You have chosen a Truwater TC Series Cooling Tower for your plant, thank you for trusting us. This
instruction manual has been prepared to furnish the operator with detailed information necessary to
ensure continued efficient and safe operation of cooling tower at all times. Therefore, the operator is
urged to thoroughly read this manual not only at the time of installation, but also during routine
maintenance services to acquaint himself fully with the construction and operation of the equipment.

2.0 CONSTRUCTION
2.1 GENERAL
The major sections of the cooling tower are shown in Figure 1. The functional key points of the
cooling tower are the fan and filling. The cooling tower, which cools re-circulating water based on
the principles of heat exchange between water and air, is designed and built to the highest standard
of workmanship and efficiency, backed by the specialized experience of the industry’s most

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competent engineering staff.

2.2 TOWER BODY

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2.2.1 Main Frame Structure
i) Steel Fabricated Type (TCS) = The steel fabricated framework is Hot-dip-galvanized
to achieve a high resistance to corrosion.
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ii) FRP Pultruded Type (TCF) = FRP Pultruded construction ensures perfect resistance to
corrosion, chemicals and weather. It is also lighter than the steel fabricated type, and is
more superior in terms of durability.
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iii) Wooden Type (TCT) = The wooden material is carefully selected under stringent
quality control to ensure good structural integrity and long service life.
iv) Stainless Steel Type (TCX) = Stainless steel framework provides maintenance free
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operation.

2.2.2 Casing, Louvers & Basins

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The casing, louvers and basins are made of fiberglass reinforced plastic (FRP) which is
highly resistant to corrosion, chemicals and weather.
* PVC low-pressure drop inlet louvers are also available as option. Hot Dip Galvanized
Steel supporting framework supports cold-water basin floors.

2.2.3 Design Flexibility

The multi-cell modular design concept is very suitable for air-conditioning or for industrial
purposes. It has great flexibility in terms of space and energy saving.

2.3 MOTOR
The AC induction, three phase squirrel cage motors are totally enclosed fan cooled (TEFC)
enclosure installed outside the hot moist discharged air-stream. The protective class of outside frame
is IP55. The normal ambient temperature limits are -20oC to + 40oC. The maximum altitude is
1000m above sea level.

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 Operation & Maintenance Manual - TC Series

2.4 FAN
The specially designed low-noise axial fan is evolved from many years of constant research and
development efforts. The fan blades are made of Aluminum Alloy and are freely adjustable. The
manufacturer must be contacted for readjusting the blades to ensure proper fan balancing afterwards.
Fans will be driven by V-belt & Pulley System or Gear Reducer System.

2.5 INFILL
The performance of the cooling tower depends very much upon the efficiency of the filling used.
The high-density film filling is fabricated from rigid, corrugated PVC sheets that are conducive to
cooling tower and UV protected. The filling is resistance to rot, fungi, bacteria and organic/inorganic
acids and alkalis as commonly found in cooling towers.
* Polypropylene or wooden splash fillings are also available as option.

2.6 DRIFT ELIMINATOR

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The Drift Eliminator modules are specially designed utilizing a series of sinusoidal-shaped blades.
The high efficiency drift eliminator was developed to conform with these specifications where very
low drift levels are required.

2.7 WATER DISTRIBUTION SYSTEM

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Good water distribution is essential for the operation of the cooling tower. A Hot-dip-Galvanized
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Steel or PVC distribution pipe and lateral tubes equipped with large orifice, non-clogging spray
nozzles, made of polypropylene, distribute the water evenly over the surface area. Only small head is
required at the cooling tower inlet flange.
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No Parts
1 Fan Assembly
2 V-Belt & Pulley System
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3 Motor
4 Fan Cylinder
5 Main Frame Structure
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6 Casing
7 Ladder
8 Cold Water Basin floor
9 Cold Water Basin Frame
10 Cold Water Basin Sump
11 Louver
12 High Performance Film Fill Pack
13 Spray Nozzle
14 Water Distribution System
15 Drift Eliminator
16 Safety Maintenance Platform
17 Safety Handrail
18 Gearbox System (as optional)

Figure 1: Cooling Tower Structure

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 Operation & Maintenance Manual - TC Series

3.0 PREPARATION FOR START- UP & OPERATION

3.1 CLEANING
Remove any dirt and trash, which has accumulated in the hot and cold-water basin. Remove any
sediment from the hot and cold-water collection basin, sump, and screens.

3.2 ELECTRICAL WIRING

i) Connect the ground wire to an appropriate point.
ii) There are 6 connector bases on the connection board of the motors and marked as follow:

Phase Order A B C
Head U1 V1 W1
Tail U2 V2 W2

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iii) For motor horsepower 4HP and below, the wiring connection is Υ Connection and others is ∆
Connection as shown above.

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Note: The above wiring connection is only applicable for single speed motor, FEM brand, for
others type / brands motor, please refer attached Motor Service Manual.
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3.3 WATER FEEDING
i) Open the drain valve located at the sump and wash off the dust and dirt in the basin.
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ii) Feed water through the make-up water inlet pipe until the water level is near the top of the
overflow pipe.
iii) Run the circulating pump for a while to force air out of the pipes as well as to fill the pipes and
cold water basin with water.
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iv) Adjust the ball tap of the automatic make-up water inlet pipe so that the valve will close when
the water level is slightly below the overflow level.
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3.4 INSPECTION
3.4.1 Inspection of Fan
i) Turn the fan by hand to make sure that the blade tips do not touch the fan stack. Ensure
tip clearance is within the allowable range (5mm-40mm)
ii) Start the fan intermittently and check if the motor is operating in the proper direction of
rotation. Also check if any abnormal noise is developing or if vibration is occurring.
iii) Check and adjust the blade angle (if necessary) within a maximum tolerance of 1°. For
all CKD towers, pitch angle shall be adjusted at site by installer.
iv) If fan hub plate, center hub or one or more blades are replaced, the complete fan
assembly may require rebalancing.
v) Now start the fan intermittently and check if the motor is operating in the proper
direction of rotation. Also check if any abnormal noise is developing or if vibration is
occurring. The fan should never be exposed to a vibration level of more than
7.1mm/sec rms measured at the drive shaft bearings,

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3.4.2 Inspection of Motor

i) Ensure the capacity of the power source is sufficient and supply horsepower, phase,
voltage & frequency ratings are identical to those on the nameplate
ii) Make sure the switches, fuses and wires are suitable for the motor capacity.
iii) Keep the motor surface clean and ensure free ventilation airflow.
iv) Check the wiring connections, mounting and assembly bolts.
v) Ensure the frame and terminal box are grounded.
vi) Ensure the rotor freely without rubbing.
vii) Ensure the motor is properly assembled and aligned.
viii) Ensure the motor bearing have adequate grease before operating.
ix) Check carefully whether the motor is out of shape and damage, tight sets are hard up or
fall off duping transporter, operating the motor with hands to see it is nimble or not.
x) Measure insulation resistance with 500V Megger and must be not less than 1 megohm.

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Note: Windings should be discharged immediately after measurement to avoid risk of
electric shock.

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Always shut off the electrical power to the tower fan motor prior to entering the
tower or performing any work on the tower. Any electrical switches should be
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locked out and tagged out to prevent others from turning the power back on.
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Figure 2 Figure 3

3.4.3 Inspection of Drive Systems

(A) Check the V-belts for the following:
i) The type, quantity and length of the belts are all the same.
ii) The V-belt pulleys are properly aligned (refer to Figure 2)
iii) The belts are properly tensioned (refer to Figure 3).
iv) To adjust the belt tension, loosen the slide bolts (2 pieces), adjust adjusting bolts (4
pieces), and move the motor base parallel to the shaft of the fan. (Refer to Figure 2)
v) Ensure that all the oil or grease is thoroughly removed from the V-belt & pulley.
vi) Pay attention to Section 5.1 for belt tensioning.
Note: Excessive belt tension will damage bearings and can cause shaft breakage.

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(B) Check the gear reducer system for the following:

i) Free from noise when rotate by hand.
ii) Sufficient gear oil.
iii) Tighten with bolt and nuts.
iv) Check drive shaft alignment.
v) Check vibration switch & oil level switch.

3.4.4 Check tightness of bolts that attach mechanical equipment support to the tower framing.
Check tightness of bolts in fan cylinder joints and fan cylinder anchorage. Re-tighten if
necessary.

3.4.5 Check tightness of bolts at diagonals and columns, and grits and columns in the area
between fan and cold water basin.

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3.4.6 Check tightness of the following bolted joints in the fan and drive assemblies:
i) Fan hub clamp bolts.
ii) Fan shaft lock nuts.

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iii) Motor mounting bolts.

Check functioning of make-up water float valve.

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3.4.7

4.0 OPERATION
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i) Start the cooling water circulation pump. Adjust the flow rate with the flow control valve.
Inspect the water distribution system via the inspection door to ensure even spray pattern.
ii) Check to see if the water level of the cold water basin is kept at the operating water level.
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iii) Make sure the cooling water is not dirty and contaminated. If it is dirty, drain the tower and fill
it with clean water.
iv) The motor should bring the fan up to speed in less than 15 seconds. If it does not, check the
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connections, fuses, overloads and voltage at motor terminals during start-up period.
v) Do not cycle a motor on and off more than necessary. Generally, the total starting time should
not exceed 30 seconds each hour. Too frequent cycling may cause the windings to burn out.
vi) Run the fan to check the following points.
¾ The fan turns in normal direction (clockwise as viewed from the air delivery side)
¾ There is no unusual sound and vibration.
¾ The fan motor current is within the rated value, the excess of electric current may be
caused by low voltage.
¾ The supply voltage to the motor is proper.

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4.1 PRECAUTIONS DURING OPERATION

i) Several days after running the cooling tower, check the belt tension. Readjust, as required.
ii) The cooling tower performance depends on the circulating water flow rate. See if the flow rate
is in accordance with the design specifications.
iii) Make sure the water level of the cold water basin is kept at a proper level at all times. If the
level is too low, the pump may be damaged.
iv) Pay enough attention to noise, vibration, cooling water temperature, current, etc. and if a
trouble occurs, refer to the troubleshooting chart for proper correction.
v) Check the bearing condition of motor by listening for unusual noise, vibration measurement,
bearing temperature, inspection of spent grease or SPM bearing monitoring.
vi) The filling can resist temperatures of up to 50°C for the standard type. Care must be taken to
keep the cooling water temperature below the respective limits.
vii) Normal operating temperatures of electric motors can be hot enough to cause burns. Avoid any
unprotected contact with the operated motor surface.

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viii) Always maintain good cooling water quality. Please refer to Table 1& Table 2 for
recommended cooling water quality criteria.
ix) See if the casing, framework and louvers are dirty. Clean them up with fresh water, if required.

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Items Value of Criteria
Corrosion Scale
pH (at 25°C) 6.5 ~ 8.0
Electric conductivity ( s / cm) below 800
Items
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Chloride ion (mg C1¯ / l) below 200

to be
Sulfate ion (mg SO42¯ / l) below 200
controlled
M-alkalinity (mg CaCO3 / l) below 100
Total hardness (mg CaCO3 / l) below 200
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Iron (mg Fe / l) below 1.0

Items
Sulfide ion (mg S2¯ / l) not detectable
to be
Ammonium ion (mg NH4+ / l) below 1.0
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referred
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Silica ion (mg SiO2 / l) below 50

Table 1: Recommended Cooling Water Quality Criteria for Circulation Water

Items Value of Criteria

pH (at 25°C) 6.5 ~ 8.0
Electric conductivity ( s / cm) below 200
Items
Chloride ion (mg C1¯ / l) below 50
to be
Sulfate ion (mg SO42¯ / l) below 50
controlled
M-alkalinity (mg CaCO3 / l) below 50
Total hardness (mg CaCO3 / l) below 50
Iron (mg Fe / l) below 0.3
Items
Sulfide ion (mg S2¯ / l) not detectable
to be
Ammonium ion (mg NH4+ / l) below 0.2
referred
Silica ion (mg SiO2 / l) below 30
Table 2: Recommended Cooling Water Quality Criteria for Makeup Water

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4.2 CARES FOR LONG-TERM SHUT-DOWN

i) In cold climates, freezing in winter may crack the water pipes. For such conditions and also for
long-term shutdown, it is imperative to discharge the circulating water.
ii) Drain the water basin and clean the inside of the tower. Keep the drain cock and plug open to
avoid any standing water.
iii) Check all the bolts for looseness.
iv) Loosen the fan drive V belt free from excessive tension.
v) It is desirable to cover the tower, especially the suction and exhaust pipe.
vi) Check fan blades for dust and other deposits. Such deposit may cause the blades to become out
of balance.
vii) For long-term storage (in excess of 6 months) it is necessary to check the fan condition of the
rust preventive coating on all machine surfaces in order to prevent corrosion. Reapply or repair
where necessary, using Esso Rust ban 397 or equivalent.
viii) The motor should be run for three hours at least once a month. This serves to dry out windings

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and re-lubricate bearing surfaces.
ix) At start of new operating season, make sure bearing are adequately lubricated before returning
motor to service.

5.0 PREVENTIVE MAINTENANCE

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i) It is recommended that the circulating water be replaced with fresh water every month or so.
ii) Check the fan bearings and replenish their grease every three months or so (assuming a daily
operation of 8 to 10 hours). Shell Alvania Grease No. 2 or equivalent is recommended. The
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replenishment amount is about 10 grams per bearing.

iii) Check the fan bolts torque. De-energize the fan and make a visual inspection for deposits or
damages. Deposits shall be removed from fan and fan bearing housing using brushes and/or
water jet with a maximum water pressure of 3 bar or 45 Psi.
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iv) If the belt is elongated, use the adjusting bolts to shift the motor position for proper belt tension.
If required, all the belts should be replaced at the same time.
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v) For every 5000 operating hours, the lubricant grease of motor should be replenished or changed
(should not change lubricant grease when the close bearing is in life of operation). Lithium-base
grease is recommended. Please refer section 5.3 for the motor re-lubrication procedures.
Note: The above statement is only applicable for FEM motor, for others brands motor, please
refer attached Motor Service Manual for more information.
vi) Refer Table 3 as below for routine inspection schedule.

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Ladder, Handrail, Walkway

V-Belt & Bearing Housing

Davits, Derrick and Hoists

Drive Shafts & Guards

Structural Members
Louvers & Casing
Cold Water Basin
Drift Eliminator

Control Valves
Suction Screen
Gear Reducer

Fan Cylinder
Float Valve
Motor

Infill
Fan
1. Inspect for clogging M M W
2. Check for unusual noise or vibration D D D D
3. Inspects keys, key ways & set screws S S S S
4. Make sure vents are open S
5. Check Lubricate (Grease) S M S
6. Check oil seals

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M
7. Check operating oil level D
8. Check static oil level M
9. Check oil for water and sludge M

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10. Charge oil, at least S
11. Check fan blade tip clearance S
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12. Check water level D
13. Check for leakage W S S
14. Inspect general condition S S M S S Y S Y Y S S S Y S S S
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15. Tighten loose bolts S S S S Y R S

16. Clean R S R R R R R S R R R
17. Repaint R R R R
18. Rebalance R R
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19. Completely open and close S

20. Inspect/repair for safe use Y Y Y
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21. Inspect and repair before each use R

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22. Overheat unusual smell D D

Notes: D: Daily W: Weekly M: Monthly Q: Quarterly S: Six monthly Y: Yearly R: As required
Table 3: Inspection schedule for V-belt & Pulley Drive System

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5.1 V- BELT & PULLEY SISTEM

i.) Open the Pulley and V-belt cover
ii.) Measure the center distance between fan pulley and motor pulley
iii.) Confirm type of belt (Either SPZ, SPA, SPB or SPC)
iv.) Confirm the small pulley diameter and determine the force required to deflect belt
16mm per meter of span.
ii.) Use belt tension indicator to measure belt deflection
iii.) Check the tension, re-setting to design value if necessary
a. Sample calculation of belt deflection
b.

Belt tension

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Center distance indicator applied to
mid center distance

16mm deflection

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Belt Deflection
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Center distance (meter) x 16mm(deflection) = actual belt deflection

If Center Distance = 1000mm = 1meter
Deflection (l) = 16mm
Example:
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SPA Belt, small pulley diameter = 150mm

Force value should be 36N (Referring to Table 2)
If F<36, too loose
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F>36, too tight

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Force required to deflect belt 16mm per meter span

Belt Section
Small Pulley Diameter (mm) Newton (N) Kilogram-force (kg-f)

56 to 71 16 1.6

SPZ 75 to 90 18 1.8

95 to 125 20 20

over 125 22 2.2

80 to 100 22 2.2

106 to 140 30 3.0

SPA
150 to 200 36 3.7

over 200 40 4.0

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112 to 160 40 4.0

170 to 224 50 5.1

SPB

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236 to 355

over 355
62

65
6.3

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224 to 250 70 7.1

SPC 265 to 355 92 9.4

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Over 375 115 12

Table 4: TC Series Drive Tension
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5.2 GEAR DRIVE SYSTEM

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i.) Check oil level weekly with each unit slopped. Add oil if level is below oil level indicator.
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ii.) Daily visual inspections and observation for oil leaks and unusual noises and vibrations are
recommended. If any of these occurs, the unit should be shut down and the cause found and
corrected.
iii.) Periodic checks should be made of the alignment of all components of the system. External
fasteners should be check for tightness.
iv.) The original oil should be replaced after 500 hours of operation or 4 weeks, whichever come
first. Refer to Table 5 for recommended mineral oil. It is recommended that the oil be drained
when it is at or near operating temperature. Refill the drive with the recommended type and
amount of lubricant.
v.) The oil should change every 2500 hours or every six-month, whichever come first. Shorter
change intervals of 2 or 3 months may be required if the gear drive is subjected to unusual
operating conditions such as very moist atmosphere, rapid temperature changes, consistent high
operating temperature or any conditions that tend to contaminate the oil or promote the
formulation of sludge inside the gear.

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AMBIENT TEMPERATURE AT GEAR DRIVE 20OF to 120OF (-7oC to 49oC)

AGMA LUBRICANT NUMBER 5
ISO GRADE 220
Atlantic Richfield Co. Duro 220
Chevron Oil Co. Machine Oil A W 220
Cities Service Oil Co. Citigo Parcernaker 220
Conoco Hyroclear Multipurpose R & O Oil 220
Exxon Company Teresstic 220
Gulf Oil Corp. Harmony 220
Mobil Oil Corp. DTE Oil BB
Pennzoil Pennzbell TO 220
Philips Petroleum Co. Magnus 220
Shell Oil Co. Morlina 220
Sun Oil Co. Sunvis 9220
Texaco Inc. Regal 220 R & O, Code 1531

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Total Carter 220
Table 5: Recommended Mineral Oils

5.3 MOTOR RE-LUBRICATION

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i) Remove the fan guard.
ii) Remove grease fill and relief plugs at both shaft extension end and opposite end bearings and
remove hardened grease is forced out through relief openings.
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iii) Insert grease fittings in grease fill openings and add grease until grease is forced out through
relief openings.
iv) Replace fill plugs and operate mechanical equipment 30 minutes to one hour to purge excess
grease at grease relief opening.
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v) Reinstall grease relief plugs and reinstall guard.

vi) Resume normal tower operation.
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Note: Do not mix different types of grease. Incompatible lubricants may cause bearing damage.

6.0 WATER REPLENISHMENT

In cooling towers, the amount of circulating water reduces due to the following three factors. It is
therefore necessary to replenish water by the reduced amount.
i) Hot water is cooled down in the cooling water. Part of this cooling is by evaporation that results
a loss of circulating water.
ii) The fan air flow carries away air-borne fine water droplets. This is referred to as carry-over or
drift loss.
iii) Because of the evaporation loss, the concentration of the dissolved components and impurities
in the water increase. In order to prevent this, it is necessary to have a water bleed (or blow-
down). This bleed constantly carries out part of the circulating water.

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6.1 EVAPORATION LOSS

Evaporation loss (E), can be estimated from the following:
E(kg/h) = Q/575 = CR.L/575
E(%) = 100.CR/575
Where, Q : Amount of heat transferred from the water (Kcal/h).
CR : Cooling ranges (the difference between inlet & outlet water temperatures).
L : Circulating water mass flow rate (kg/h).
It is noted that the latent heat of vaporization is 575 Kcal/kg. Therefore, for a 6°C cooling range, the
evaporation loss is about 1% of the cooling water flow rate.

6.2 CARRY-OVER LOSS

The drift or carry-over (C) depends on the type of the tower and drift eliminator. Extensive
measurements recorded on these towers indicated a drift loss as low as 0.005% of the circulating

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water flow rate.

6.3 BLOW-DOWN

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The blow-down (D) is carried out in any of the following manners.
i) The drain valve is kept slightly open during the operation.
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ii) The water level is set somewhat higher to allow constant overflow from the overflow pipe.
iii) The whole circulating water is frequently replaced with fresh water at the time of cleaning the
cooling tower.
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The blow-down amount depends on the quality and concentration of the dissolved components in the
water. It usually ranges from 0.2 to 2% of the circulating water flow rate.
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6.4 MAKE-UP FLOW RATE

The amount of water to be replenished is determined from: L = E + C + D
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Let us take the following example:

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Evaporation Loss : E = 1%
Drift Loss : C = 0.005%
Blow-down amount : D = 0.5%
Hence we obtain a make-up of 1.505%. It is desirable; however, to increase this by a safety margin,
in this case, say, a make-up of 2% of the circulating water flow should be sufficient.

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7.0 TROUBLE SHOOTING

Some possible problems, their possible causes and remedies are given below:
TROUBLE POSSIBLE CAUSE REMEDY
Fan Blade tips & casing in contact. Centre the fan shaft.
Bolt loosened. Re-tighten the bolt.
Unusual sound
Defective motor or bearing. Replace the motor or bearing.
and vibration
Damaged fan. Replace the fan.
V-belt loosened. Tension the V-belt.
Voltage drop. Measure the voltage and contact the
electricity authority.
Fan blades pitch angle changed. Readjust the blade angle.
Over current
Motor defective. Repair or replace the motor.
Overload by excessive airflow. Readjust the fan blade pitch angle.

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Cold water basin water too low. Check and readjust the ball tap and make-
Circulating up water feed system.
water flow Strainer clogged. Clean off dirt from strainer.
reduction

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Circulating water pump defective or
Repair or replace the pump.
short of capacity.
Circulating water flow is excessive. Readjust to the design flow rate.
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Uneven water distribution. Clean up the spray nozzles.
Circulating Fan airflow rates not enough. Check and readjust the fan blade pitch
water
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angle and belts.

temperature
Exhaust air re-circulated. Improve the airflow conditions.
rises
Suction airflow deflected. Improve the airflow conditions.
Filling plugged. Clear up the plugged portion.
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Circulating water flow is excessive. Readjust the valve for proper volume.
Excessive
Drift eliminator defective. Repair or replace drift eliminator.
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Carry-over
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Airflow rate excessive. Readjust the fan blade pitch angle.

1) Check power at starter. Correct any
bad connections between the control
apparatus and the motor.
2) Check starter contacts and control
circuit. Reset the overloads, close
Power not available at motor terminals
contacts, reset tripped switches or
replace failed control switches.
3) If power is not on all leads at starter
Motor fails to make sure overload and short circuit
start devices are in proper condition.
Wrong connection Check motor and control connections
against wiring diagram.
Blown fuses Replace fuses with proper type and rating
Overload trips Check and reset overload in starter.
Low voltage Check nameplate voltage against power
supply. Check voltage at motor terminals.
Open circuit in motor winding Check stator windings for open circuits.

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Indicated by blown fuses. Motor must be

Short circuited stator
rewound. Removed end bells, locate with
Poor stator coil overloaded
test lamp.
Motor or fan drive stuck Disconnect motor from load and check
motor and gear reducer for cause of
problem.
Rotor defective Look for broken bars and rings.
Motor runs
Check for loose connections to line, to
and then dies Power failure
fuses and to control.
down
Motor running single-phase Stop motor and attempt to start it. Motor
will not start if single-phased. Check
wiring, control and motor.
Motor leads connected incorrectly Check motor connections against wiring
diagram on motor
Unusual motor Ball bearings Check lubrication. Replace bad bearings.

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noise Electrical unbalance Check voltage and currents of all three
lines. Correct if required.
Air gap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance

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Cooling fan hitting end bell guard
Motor overload, wrong voltage or
Reinstall or replace fan.
Check voltage and current of all three
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unbalanced voltage lines against nameplate values.
Wrong motor RPM Check nameplate against power supply.
Check RPM of motor and gear ratio.
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Bearing over-greased Remove grease reliefs. Run motor up to

speed to purge excessive grease.
Wrong lubricant in bearings Change to proper lubricant. Refer
attached motor service manual.
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One phase open Stop motor and attempt to start it. Motor
will not start if single phased. Check
wiring, controls and motor.
Poor ventilation Clean motor and check ventilation
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openings. Allow ample ventilation

Motor run hot around motor.
Winding fault Check with Ohmmeter
Bent motor shaft Straighten or replace shaft
Insufficient grease Remove plugs and re-grease bearings.
Too frequent starting Limit accumulative starting time to a total
of 30 seconds each hour.
Deterioration of or foreign material in Flush bearings and re-lubricate.
grease
Bearings damaged Replace bearing.
Incorrect fan blade pitch Measure actual fan pitch and compare to
that recommended. Correct if necessary.
Check for faulty leads, connections and
Unbalanced terminal voltage
transformers.
Check transformer and setting if taps. Use
Motor does Voltage too low at motor terminals
higher voltage on transformer terminals
not come up to because of line drop
or reduce loads. Increase wire size or
speed
reduce inertia.

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 Operation & Maintenance Manual - TC Series

Starting load too high Check load motor is supposed to carry at

start.
Broken rotor bars Look for cracks near the rings. A new
rotor may be required. Have motor
service man check motor.
Open primary circuit Locate fault with testing device and repair
Wrong
rotation Wrong sequence of phases Change any two of the three motor leads.
(motor)
Motor misaligned Realign.
Weak support Strengthen coupling.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Motor vibrates

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Bearing not in line Line up properly.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor.
rotor and coupling (half key – full key)

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Polyphases motor running single phase Check for open circuit.
Excessive end play Adjust bearing or add shim.
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Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
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Pulleys too far away Move pulley closer to motor bearing.

Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
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Insufficient grease Maintain proper quantity of grease in

Hot bearings bearing.
ball Deterioration of grease or lubricant Remove old grease, wash bearings
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contaminated thoroughly in kerosene and replace with

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new grease.
Excess lubricant Reduce quantity of grease; bearing should
not be more than ½ filled.
Overloaded bearing Check alignment, side and end thrust.
Replace bearing, first clean housing
Broken ball or rough races
thoroughly.
Blade rubbing inside of fan cylinder Adjust cylinder to provide blade tip
clearance.
Fan noise
Loose bolts in blade clamps Check and tighten if necessary. Check fan
blade pitch.

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Operation & Maintenance
Manual

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TXS SERIES
COOLING TOWER

TRUWATER COOLING TOWERS SDN BHD

(Company No: 188113-A)
EXECUTIVE SUITE 702, BLOCK B,
KELANA BUSINESS CENTRE
NO.97, JALAN SS7/2 KELANA JAYA,
47301 PETALING JAYA, SELANGOR DARUL EHSAN
TEL: +603 7880 8800 FAX: +603-7804 5519
EMAIL: [email protected],
WEBSITE: http://www.truwater.com.my
 TXS SERIES
COOLING TOWER

Operation & Maintenance Manual

CONTENTS PAGE

1.0 INTRODUCTION 1

2.0 CONSTRUCTION 1
2.1 GENERAL

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2.2 TOWER BODY
2.3 FAN
2.4 INFILL
2.5 WATER DISTRIBUTION SYSTEM

3.0
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PREPARATION FOR START UP & OPERATION 3
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3.1 CLEANING
3.2 ELECTRICAL WIRING
3.3 WATER FEEDING
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3.4 INSPECTION

4.0 OPERATION 54
4.1 PRECAUTION DURING OPERATION
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4.1 CARES FOR LONG-TERM SHUT DOWN

5.0 PREVENTIVE MAINTENANCE 75

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6.0 WATER REPLENISHMENT 10

8
6.1 EVAPORATION LOSS
6.2 CARRY-OVER LOSS
6.3 BLOW-DOWN LOSS
6.4 MAKE-UP FLOW RATE

7.0 TROUBLESHOOTING 10
12
 Operation & Maintenance Manual - TXS Series

1.0 INTRODUCTION

Dear Customer,
You have chosen a Truwater TXS Series Cooling Towers for your plant, thank you for trusting
us. This instruction manual has been prepared to furnish the operator with detailed information to
ensure continued efficient and safe operation of cooling tower at all times. Therefore, the
operator is urged to thoroughly read this manual not only at the time of star-up, but also during
routine maintenance services to acquaint himself fully with the construction and operation of the
equipment.

2.0 CONSTRUCTION
2.1 GENERAL
The major sections of the cooling tower are shown in Figure 1. The functional key points
of the cooling tower are the fan and infill. The cooling tower, which cools recirculating

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water based on the principles of heat exchange between water and air, is designed and
built to the highest standard of workmanship and efficiency, backed by the specialized
experience of the industry’s most competent engineering staff.

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2.2 TOWER BODY
2.2.1 Main Frame Structure
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The mainframe structure of the cooling tower is steel fabricated and is hot-dip-
galvanized to achieve a high resistance to corrosion.
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2.2.2 Casing, Louvers & Basins

The casing and louvers are made of PVC; while basins are made of fiberglass-
reinforced polyester (FRP) that is highly resistance to corrosion, chemicals and
weather.
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2.3 MOTOR
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The AC induction, three phase squirrel cage motors are totally enclosed fan cooled (TEFC)
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enclosure installed outside the hot moist discharged air-stream. The protective class of outside
frame is IP55. The normal ambient temperature limits are -20oC to + 40oC. The maximum
altitude is 1000m above sea level.

2.4 FAN
The specially designed low-noise axial fans are propeller-type, incorporating heavy-duty
blades of aluminum alloy. Blades are freely adjustable. The manufacturer must be
contacted for readjusting the blades to ensure proper fan balancing afterwards.

2.5 INFILL
The performance of the cooling tower depends very much upon the efficiency of the infill
used. The high-density film infill is fabricated from rigid, corrugated PVC sheets that are
conductive to cooling tower. The infill is resistance to rot, fungi, bacteria and acids and
alkalis as commonly found in cooling towers.

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 Operation & Maintenance Manual - TXS Series

2.6 WATER DISTRIBUTION SYSTEM

Good water distribution is essential for the operation of the cooling tower. The open
gravity type of water distribution system need only a low pump pressure to achieve a
more uniform water distribution. The sizes of the distribution holes are chosen such that
they cannot be easily clogged.

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2

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4

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No. Parts
1 V-Belt & Pulley System
2 Fan Assembly
3 Motor
4 Infill
5 Louver
6 PVC Casing
7 Inspection Door
8 Ladder
9 Cold Water Basin

FIGURE 1: Cooling Tower Structure

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 Operation & Maintenance Manual - TXS Series

3.0 PREPARATION FOR START- UP & OPERATION

3.1 CLEANING
Remove any dirt and trash, which has accumulated in the hot and cold-water basin.
Remove any sediment from the hot and cold-water collection basin, sump, and screens.

3.2 ELECTRICAL WIRING

i.) Connect the ground wire to an appropriate point.
ii.) There are 6 connector bases on the connection board of the motors and marked as
follow:

Phase Order A B C
Head U1 V1 W1
Tail U2 V2 W2

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iii.) For motor horsepower 4HP and below, the wiring connection is Y Connection and
others is ∆ Connection as shown above.

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Note: The above wiring connection is only applicable for single speed motor, FEM brand,
for others type / brands motor, please refer attached Motor Service Manual.
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3.3 WATER FEEDING
i.) Open the drain valve located at the sump and wash off the dust and dirt in the basin.
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iv.) Feed water through the make-up water inlet pipe until the water level is near the top
of the overflow pipe.
v.) Run the circulating pump for a while to force air out of the pipes as well as to fill the
pipes and cold-water basin with water.
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vi.) Adjust the ball tap of the automatic make-up water inlet pipe so that the valve will
close when the water level is slightly below the overflow level.
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3.4 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 tower:

3.4.1 Inspection of fan

i.) Turn the fan by hand to make sure that the blade tips do not touch the fan
stack. Ensure tip clearance is within the allowable range (5mm-40mm).
ii.) Check and adjust the blade angle (if necessary) within a maximum tolerance
of 1°:
For all modular class TX Tower range from 100 – 250 tons (CBU), the
pitch angle shall be preset by factory.
For all other CKD towers, pitch angle shall be adjusted at site by installer.
iii.) If fan hub plate, center hub or one or more blades are replaced, the complete
fan assembly may require rebalancing.

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 Operation & Maintenance Manual - TXS Series

iv.) Now start the fan intermittently and check if the motor is operating in the
proper direction of rotation. Also check if any abnormal noise is developing or
if vibration is occurring. The fan should never be exposed to a vibration level
of more than 7.1mm/sec rms measured at the drive shaft bearings,

3.4.2 Inspection of Motor

i) Ensure the capacity of the power source is sufficient and supply horsepower,
phase, voltage & frequency ratings are identical to those on the nameplate
ii) Make sure the switches, fuses and wires are suitable for the motor capacity.
iii) Keep the motor surface clean and ensure free ventilation airflow.
iv) Check the wiring connections, mounting and assembly bolts.
v) Ensure the frame and terminal box are grounded.
vi) Ensure the rotor freely without rubbing.
vii) Ensure the motor is properly assembled and aligned.
viii) Ensure the motor bearing have adequate grease before operating.

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ix) Check carefully whether the motor is out of shape and damage, tight sets are
hard up or fall off duping transporter, operating the motor with hands to see
it is nimble or not.

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x) Measure insulation resistance with 500V Meggar and must be not less than
1 megaohm
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Note: Windings should be discharged immediately after measurement to avoid
risk of electric shock.
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Always shut off the electrical power to the tower fan motor prior to entering the
tower or performing any work on the tower. Any electrical switches should be
locked out and tagged out to prevent others from turning the power back on.
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3.4.3 Check v-belts tensions. Re-adjust if necessary.

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(Refer to Section 5.3)

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3.4.4 Check tightness of bolts that attach mechanical equipment support to the tower
framing. Check tightness of bolts in fan cylinder joints and fan cylinder anchorage.
Re-tighten if necessary.

3.4.5 Check tightness of bolts at diagonals and columns, and grits and columns in the
area between fan and cold water basin.

3.4.5 Check tightness of the following bolted joints in the fan and drive
assemblies:
i.) Fan hub clamp bolts.
ii.) Fan shaft lock nuts.
iii.) Motor mounting bolts.

3.4.6 Check functioning of make-up water float valve.

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 Operation & Maintenance Manual - TXS Series

4.0 OPERATION
i.) Start the cooling water circulation pump. Adjust the flow rate with the flow control valve.
Inspect the water distribution system via the inspection door to ensure even water
distribution.
ii.) Check to see if the water level of the cold-water basin is kept at the operating water level.
iii.) Make sure the cooling water is not dirty and contaminated. If it is dirty, drain the tower and
fill it with clean water.
iv.) The motor should bring the fan up to speed in less than 15 seconds. The motor should bring
the fan up to speed in less than 15 seconds. If it does not, check the connections, fuses,
overloads and voltage at motor terminals during start-up period.
v.) Do not cycle a motor on and off more than necessary. Generally, the total starting time
should not exceed 30 seconds each hour. Too frequent cycling may cause the windings to
burn out.
vi.) Run the fan to check the following points.

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The fan turns in normal direction (clockwise as viewed from the air delivery side).
There is no unusual sound and vibration.
The fan motor is within the rated value; the excess of electric current may be caused by
low voltage.

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The supply voltage to the motor is proper.
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4.1 PRECAUTION DURING OPERATION
i.) Several days after running the cooling tower, check the belt tension. Readjust, as
required.
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ii.) The cooling tower performance depends on the circulating water flow rate. See if the
flow rate is in accordance with the design specifications.
iii.) Make sure the water level of the cold water basin is kept at a proper level at every
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time. If the level is too low, the pump may be damaged.

iv.) Pay enough attention to noise, vibration, cooling water temperature, current, etc. and
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if a trouble occurs, refer to the troubleshooting chart for proper correction.

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v.) Check the bearing condition of motor by listening for unusual noise, vibration
measurement, bearing temperature, inspection of spent grease or SPM bearing
monitoring.
vi.) The infill can resist temperatures of up to 50°C for the standard type. Care must be
taken to keep the cooling water temperature below the respective limits.

vii.) Normal operating temperatures of electric motors can be hot enough to cause burns.
Avoid any unprotected contact with the operated motor surface.
viii.) Always maintain good cooling water quality. See Table 1 and for recommended
cooling water quality criteria.
ix.) See if the casing, framework and louvers are dirty. Clean them up with fresh water, if
required.

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 Operation & Maintenance Manual - TXS Series

Items Value of Criteria Tendency

Corrosion Scale
pH (at 25°C) 6.5 ~ 8.0
Items Electric conductivity (µs / cm) below 800
To Chloride ion (mg C1¯ / l) below 200
Be Sulfate ion (mg SO42¯ / l) below 200
Controlled M-alkalinity (mg CaCO3 / l) below 100
Total hardness (mg CaCO3 / l) below 200

Items Iron (mg Fe / l) below 1.0

to Sulfide ion (mg S2¯ / l) not detectable
+
be Ammonium ion (mg NH4 / l) below 1.0
referred Silica ion (mg SiO2 / l) below 50

Table 1: Recommended Cooling Water Quality Criteria for Circulation Water

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Items Value of Criteria

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pH (at 25°C) 6.5 ~ 8.0
Items Electric conductivity (µs / cm) below 200
to Chloride ion (mg C1¯ / l) below 50
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be Sulfate ion (mg SO42¯ / l) below 50
controlled M-alkalinity (mg CaCO3 / l) below 50
Total hardness (mg CaCO3 / l) below 50
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Items Iron (mg Fe / l) below 0.3

to Sulfide ion (mg S2¯ / l) not detectable
+
be Ammonium ion (mg NH4 / l) below 0.2
referred Silica ion (mg SiO2 / l) below 30
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Table 2: Recommended Cooling Water Quality Criteria for Makeup Water

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4.2 CARES FOR LONG-TERM SHUT-DOWN

i.) In cold climates, the water pipes may become cracked by freezing in winter. For such
conditions and for long-term shutdown, it is imperative to discharge the circulating
water.
ii.) Drain the water basin and clean the inside of the tower. Keep the drain cock and plug
open to avoid any standing water.
iii.) Check all the bolts for looseness.
iv.) Loosen the fan drive V belt free from excessive tension.
v.) It is desirable to cover the tower, especially the suction and exhaust pipe.
vi.) Check fan blades for dust and other deposits. Such deposit may cause the blades to
become out of balance.

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 Operation & Maintenance Manual - TXS Series

vii.) For long-term storage (in excess of 6 months) it is necessary to check the fan
condition of the rust preventive coating on all machine surfaces in order to prevent
corrosion. Reapply or repair where necessary, using Esso Rust ban 397 or equivalent.
viii.) The motor should be run for three hours at least once a month. This serves to dry out
windings and re-lubricate bearing surfaces.
ix.) At start of new operating season, make sure bearings are adequately lubricated before
returning motor to service.

5.0 PREVENTIVE MAINTENANCE

i.) It is recommended that the circulating water be replaced with fresh water every month or so.
ii.) Check the fan bearings and replenish their grease every three months or so (assuming a daily
operation of 8 to 10 hours). Shell Alvania Grease No. 2 or equivalent is recommended. The
replenishment amount is about 10 grams per bearing.
iii.) Check the fan bolts torque. De-energize the fan and make a visual inspection for deposits or

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damages. Deposits shall be removed from fan and fan bearing housing using brushes and/or
water jet with a maximum water pressure of 3 bar or 45 Psi.
iv.) Refer Table 3 for routine inspection schedule.

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v.) If the belt is elongated, use the adjusting bolts to shift the motor position for proper belt
tension. If required, all the belts should be replaced at the same time.
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vi.) For every 5000 operating hours, the lubricant grease of motor should be replenished or
changed (should not change lubricant grease when the close bearing is in life of operation).
Lithium-base grease is recommended. Please refer section 5.3 for the motor re-lubrication
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procedures.
Note: The above statement is only applicable for FEM motor, for others brands motor,
please refer attached Motor Service Manual for more information.
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5.1 V- BELT TENSIONING

i.) Open the Pulley and V-belt cover
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ii.) Measure the center distance between fan pulley and motor pulley
iii.) Confirm type of belt (Either SPZ, SPA, SPB or SPC)
iv.) Confirm the small pulley diameter and determine the force required to deflect belt
16mm per meter of span.
vii.) Use belt tension indicator to measure belt deflection
viii.) Check the tension, re-setting to design value if necessary
a. Sample calculation of belt deflection

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 Operation & Maintenance Manual - TXS Series

Belt tension
Center distance indicator applied to
mid center distance

16mm deflection
per 1 meter of span

Belt Deflection
Center distance (meter) x 16mm(deflection) = actual belt deflection
If Center Distance = 1000mm = 1meter
Deflection (l) = 16mm
Example:
SPA Belt, small pulley diameter = 150mm
Force value should be 36N (Referring to Table 2)

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If F<36, too loose
F>36, too tight

Belt Section
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Force required to deflect belt 16mm per meter span
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Small Pulley Diameter (mm) Newton (N) Kilogram-force (kg-f)
56 to 71 16 1.6
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SPZ 75 to 90 18 1.8
95 to 125 20 20
over 125 22 2.2
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80 to 100 22 2.2
106 to 140 30 3.0
SPA
150 to 200 36 3.7
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over 200 40 4.0

112 to 160 40 4.0
170 to 224 50 5.1
SPB
236 to 355 62 6.3
over 355 65 6.6
224 to 250 70 7.1
SPC 265 to 355 92 9.4
Over 375 115 12

Table 2: Tensioning Forces Table

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 Operation & Maintenance Manual - TXS Series

Inspection item

General conditions

Bolt tightness

Cleaning

Recoating

Balance adjustment

Water level

Water leak

Abnormal vibrations

Overheat unusual smell

Device

Fan M S R R D

Motor M S R R D D

Infill M M

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Cold water basin Y M R D Q

Ball tap W

Water distribution W
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system
Valve S
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Sump S M Q D

Strainer M M
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Structural components S Y R Y
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Casing Y
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Louvers Y

Notes: D: Daily W: Weekly M: Monthly Q: Quarterly S: Six monthly Y:

Yearly R: As required

Table 3: Routine Inspection Schedule

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 Operation & Maintenance Manual - TXS Series

6.0 WATER REPLENISHMENT

In cooling towers, the amount of circulating water reduces due to the following three factors. It is
therefore necessary to replenish water by the reduced amount.
i.) Hot water is cooled down in the cooling water. Part of this cooling is by evaporation that
results a loss of circulating water.
ii.) The fan airflow carries away air-borne fine water droplets. This is referred to as carry-over
or drift loss.
iii.)Because of the evaporation loss, the concentration of the dissolved components and
impurities in the water increase. In order to prevent this, it is necessary to have a water
bleed (or blow-down). This bleed constantly carries out part of the circulating water.

6.1 EVAPORATION LOSS

Evaporation loss ( E ), can be estimated from the following:
E(kg/h) = Q/575 = CR.L/575

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E(%) = 100.CR/575
where, Q : Amount of heat transferred from the water (Kcal/h).
CR : Cooling range (the difference between inlet and outlet water
temperatures).
L
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: Circulating water mass flow rate (kg/h).
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It is noted that the latent heat of vaporization is 575 Kcal/kg. Therefore, for a 6°C
cooling range, the evaporation loss is about 1% of the cooling water flow rate.

6.2 CARRY-OVER LOSS

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The drift or carry-over ( C ) depends on the type of the tower and drift eliminator.
Extensive measurements recorded on these towers indicated a drift loss as low as 0.02%
of the circulating water flow rate.
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6.3 BLOW-DOWN
The blow-down ( D ) is carried out in any of the following manners.
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i.) The drain valve is kept slightly open during the operation.
ii.) The water level is set somewhat higher to allow constant overflow from the overflow
pipe.
iii.) The whole circulating water is frequently replaced with fresh water at the time of
cleaning the cooling tower.
The blow-down amount depends on the quality and concentration of the dissolved
components in the water. It usually ranges from 0.2 to 2% of the circulating water flow
rate.

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 Operation & Maintenance Manual - TXS Series

6.4 MAKE-UP FLOW RATE

The amount of water to be replenished is determined from :
L=E+C+D

Let us take the following example :

Evaporation Loss : E = 1%
Drift Loss : C = 0.02%
Blow-down amount : D = 0.5%

Hence we obtain a make-up of 1.52%. It is desirable, however, to increase this by a

safety margin, in this case, say, a make-up of 2% of the circulating water flow should be
sufficient.

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 Operation & Maintenance Manual - TXS Series

7.0 TROUBLE SHOOTING

Some possible problems, their possible causes and remedies are given below.

TROUBLE POSSIBLE CAUSE REMEDY

Fan Blade tips & fan stack in Centre the fan shaft.
contact.
Unusual
Bolt loosened. Re-tighten the bolt.
sound and
Defective motor or bearing. Replace the motor or bearing.
vibration
Damaged fan. Replace the fan.
V-belt loosened. Tension the V-belt.
Voltage drop. Measure the voltage and contact the
electricity authority.
Over current Fan blades pitch angle changed. Readjust the blade angle.
Motor defective. Repair or replace the motor.
Overload by excessive airflow. Readjust the fan blade pitch angle.
Cold water basin water too low. Check and readjust the ball tap and

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Circulating make-up water feed system.
water flow Strainer clogged. Clean off dirt from strainer.
reduction Circulating water pump defective Repair or replace the pump.
or short of capacity.

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Circulating water flow is excessive.
Uneven water distribution.
Readjust to the design flow rate.
Clean up the spray nozzles.
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Circulating
Fan airflow rates not enough. Check and readjust the fan blade pitch
water
angle and belts.
temperature
Exhaust air re-circulated. Improve the airflow conditions.
rises
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Suction airflow deflected. Improve the airflow conditions.

Filling plugged. Clear up the plugged portion.
Circulating water flow is excessive. Readjust the valve for proper volume.
Excessive
Drift eliminator defective. Repair or replace drift eliminator.
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Carry-over
Airflow rate excessive. Readjust the fan blade pitch angle.
Power not available at motor 1) Check power at starter. Correct any
terminals bad connections between the
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control apparatus and the motor.

2) Check starter contacts and control
circuit. Reset the 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
Motor fails to short circuit devices are in proper
start condition.
Wrong connection Check motor and control connections
against wiring diagram.
Blown fuses Replace fuses with proper type and
rating
Overload trips Check and reset overload in starter.
Low voltage Check nameplate voltage against
power supply. Check voltage at motor
terminals.

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 Operation & Maintenance Manual - TXS Series

Open circuit in motor winding Check stator windings for open

circuits.
Short circuited stator Indicated by blown fuses. Motor must
Poor stator coil overloaded be rewound. Removed end bells,
locate with test lamp.
Motor or fan drive stuck Disconnect motor from load and
check motor and gear reducer for
cause of problem.
Rotor defective Look for broken bars and rings.
Motor runs Power failure Check for loose connections to line, to
and then dies fuses and to control.
down
Motor running single-phase Stop motor and attempt to start it.
Motor will not start if single-phased.
Check wiring, control and motor.
Motor leads connected incorrectly Check motor connections against

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wiring diagram on motor
Ball bearings Check lubrication. Replace bad
Unusual
bearings.
motor noise
Electrical unbalance Check voltage and currents of all three

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lines. Correct if required.
Air gap not uniform Check and correct bracket fits or
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bearing.
Rotor unbalance Rebalance
Cooling fan hitting end bell guard Reinstall or replace fan.
Motor overload, wrong voltage or Check voltage and current of all three
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unbalanced voltage lines against nameplate values.

Bearing over-greased Remove grease reliefs. Run motor up
to speed to purge excessive grease.
Wrong lubricant in bearings
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Change to proper lubricant. Refer

attached motor service manual.
One phase open Stop motor and attempt to start it.
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Motor will not start if single phased.

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Check wiring, controls and motor.

Poor ventilation Clean motor and check ventilation
openings. Allow ample ventilation
around motor.
Motor run
Winding fault Check with Ohmmeter
hot
Bent motor shaft Straighten or replace shaft
Insufficient grease Remove plugs and re-grease bearings.
Too frequent starting Limit accumulative starting time to a
total of 30 seconds each hour.
Deterioration of or foreign material Flush bearings and re-lubricate.
in grease
Bearings damaged Replace bearing.
Incorrect fan blade pitch Measure actual fan pitch and compare
to that recommended. Correct if
necessary.
Unbalanced terminal voltage Check for faulty leads, connections
and transformers.

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 Operation & Maintenance Manual - TXS Series

Voltage too low at motor terminals Check transformer and setting if taps.
because of line drop Use higher voltage on transformer
terminals or reduce loads. Increase
wire size or reduce inertia.
Motor does Starting load too high Check load motor is supposed to carry
not come up at start.
to speed Broken rotor bars Look for cracks near the rings. A new
rotor may be required. Have motor
service man check motor.
Open primary circuit Locate fault with testing device and
repair
Wrong Wrong sequence of phases Change any two of the three motor
rotation leads.
(motor)
Motor misaligned Realign.
Weak support Strengthen coupling.

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Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearing not in line Line up properly.
Motor

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Balancing weights shifted Rebalance motor.
vibrates
Contradiction between balancing of Rebalance coupling or motor.
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rotor and coupling (half key – full
key)
Polyphases motor running single Check for open circuit.
phase
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Excessive end play Adjust bearing or add shim.

Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
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Pulleys too far away Move pulley closer to motor bearing.

Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
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Insufficient grease Maintain proper quantity of grease in

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bearing.
Hot bearings
Deterioration of grease or lubricant Remove old grease, wash bearings
ball
contaminated thoroughly in kerosene and replace
with new grease.
Excess lubricant Reduce quantity of grease; bearing
should not be more than ½ filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, first clean housing
thoroughly.
Blade rubbing inside of fan Adjust cylinder to provide blade tip
cylinder clearance.
Fan noise
Loose bolts in blade clamps Check and tighten if necessary. Check
fan blade pitch.

14 Rev-2 (Dec 2010)