Installation & Maintenance Guide Square type counter flow FRP cooling tower 1
<I> NST-H series cooling tower s installation considerations 1.Environmental selection: The cooling tower shall be installed in the right position to get the desired cooling effect, When selecting the installation location, you should pay attention to the following points: (1). Avoid installing next to somewhere fire escape or walls are easy to echo, it is better to install on the roof or somewhere air circulating well. (2). A certain distance between the cooling tower and the parallel buildings is indeed needed to ensure smooth air intake and avoid the hot humid air going into the fresh air system of the building. 2. Installation essentials (1)To ensure the basic surface level and sturdy, the combination of upper and lower iron frame and steel structure should be smooth vertical and horizontal (except bracing diagonal supporting), the upper and lower frame surface should be level to ensure the overall stability and sprinkle evenly. See the figure below: (2) In order to ensure the water pump functioning, the pipe of circulating water should be facing down, the circulating pump should be lower than the body of tower,. See the figure 2
below: (3) When two or more cooling towers share one circulating pump, a parallel connection tube next to the tank is needed to make each cooling tower s water level same.the pump head should also suit the technical requirements. (4)The pipe size should be chosen in accordance with piping of the cooling tower components, It is better to install a shock absorbers to to prevent pump and pipes from damage caused by long-term vibration or unmatched connection pipe. 3. Foundation construction essentials: (1)User should make a plan of foundation construction work according to user manual or drawing of cooling tower supplied by manufacturer. Please contact manufacturer or distributor if anything unclear. (2)Mixing sand and cement by a proper ratio, do rebar and steel plate s pre-buried work well, the upper surface of pre-buried steel plate and the upper surface of cement foundation should be in the same level. welding the upper end of pre-buried rebar with the bottom of steel plate, the upper surface of steel plate with tower s lower frame legs. If the cooling tower installed on the top of building, the lower end of foundation pre-buried rebar should be connected with the rebar of the matched floor. (3)The foundation height of cooling tower normally should not be less than the one from supplier, user can increase the height as needed according to ventilation, multi-sets combination and pipelines need, but the foundation upper surface of the whole tower and the steel plate upper surface should be in the same level, and tolerance should be within 2mm. But for different cell of one cooling tower, the water level should be same so as to avoid water flows among tower s cells due to different water level. (4)The installation workers can stop construction temporarily when the foundation dimension provided by user is not correct or steel plate welding is undone. 4. Placement on site Appropriate position of cooling tower s parts plays a very important role in quality of installation, parts protection and safety for workers, which must be highly valued, the detailed rules and notes as below: (1)Placement concentrated, reasonable, orderly. (2)Fiber parts stacked by the heavy is prohibited, avoid deformation. (3)Heat dissipation infill, fiber, glue should be rain-proof, fireproofing, sunscreen, high 3
temperature prevention and dustproof. (4)Make sure all precious accessories and tools will be kept well if all technician will leave before installation work finished. (5)Make the fiber parts and heat dissipation infill well bundled and do enough protection work so as to avoid unnecessary damage due to typhoon.. <II> Main steps of installation work 1. Foundation work: Please read NST-H series cooling tower specification or foundation drawing and finish the foundation work in advance, and take notes of below points. (1)Choose a a appropriate position for installing. (2)Cement, gravel mixed by a certain percentage to ensure a solid foundation, If necessary, referring to the operating weight and safety factor of the cooling tower, checking security and Loaded foundation bearing capacity. (3)Pre-buried steel plate (200mm * 200mm * 12mm) and upper surface of cement foundation should be in the same level. (4)The customized height of foundation according to the actual situation is also available, which should not be less than the dimension provided by manufacturer. User can also use a full steel material foundation to replace the concrete foundation, but the related dimension still has to refer to diagram. (5)The strict fireproof regulations and power protection measures are needed to ensure construction work safe during installation. 2. Parts box(g1): Since goods received, please open the parts box first and find the installation guide, check and confirm all the components are received well. Revise the deformation steel components, for components that are with anti-corrosion layer damage must be be patched before assembly. Please contact supplier for replacement if any of the components are damaged severely. 3. Installation procedure: Read and understand well of the drawings before start installation work. (A) Lower frames combination: (1). Find out all the steel components which are marked with AXX iron parts(the left ones are for middle and upper frame combinations and motor rack combination and ladder etc.). (2). Finish the outer frame on the foundation, and ensure the frame level, make the channel pillar vertical and place the tower foot plate in the middle of embedded steel plate. For more convenient installation. You can join the vertical pillars and angle iron before 4
moving on to the foundation. (B) Basin and water vat: (1). Place basin and water vat successively and make the bottom of water vat situated in the middle of its foundation. The bolt holes of water vat and basin should be matched with the counterparts of lower frame, then put screws, gaskets and nuts into the holes and fasten it accordingly. (2). Leakproof processing. (See appendix 8) (C) Middle frame: (1). Install the angle column and channel column on the lower frame and water vat combination. Here should add a Leakage-proof rubber gasket to the connection bolts to tighten the channel column and basin, connecting the corresponding angle iron, and make sure all the frame in the same level. (2). Place the infill support channel iron and infill support pipe Between the edge of the center column and middle frame angle iron. Adjust well and tighten it. (D)Upper frame: (1). Install the channel columns on angle iron of the middle frame. Make the column vertical, connect the upper frame angle iron and adjust well( Pull the diagonal to ensure if necessary), make sure all the frame Horizontal flat vertical and fasten it. (2). Install the top frame angle iron and top frame inclined strut. And then, Install horizontal pipes and sprinkle pipe support, Install tension bar on to the sprinkle pipe support. (E) Infill, sprinkle system and water collector. 1. Fasten the infill support column onto the middle frame beam first, put the infill support layer by layer among the support columns, In order to make the installation convenient, Please install the infill support form bottom to top, after finish, put the infill into the infill support. When placing the infill, staggering the infill layer by layer to ensure the high cooling efficiency. (you can also install the infill support and infill before installing the tower shell. But you should lay wood plate to ensure the infill will not be compressed and deformation so as to make installation work more convenient.) 2. After horizontal pipes installed, connecting the horizontal pipe and sprinkle tube (to ensure the the connection without leak, each connection pipe is needed to paint some glass cement), put the horizontal pipe and sprinkle tube on the support angle iron, connecting them with fiber pipe. Adjust carefully and make sure all the pipe are installed well. After that, fasten the pipes with pipe clamp. 3. Connecting the nozzle and pipe clamp on the holes of sprinkle tube, adjust the nozzle position and make sure all the nozzles are vertical, and fasten the sprinkle system( here glass cement painting is needed between nozzle holder and sprinkle tube to avoid water leakage). 4. Install closed water film supporting tension bar, place the closed water film well, install the tension bar and Cyclotron buckle. 5. Install ladder combos next to coaming of the door of maintenance and water makeup combos beside water makeup blades. 5
(G) Air draft combination (1)Connect air ducts sequentially and makes inwall same height in each horizon, install the lower neck(bigger one comparatively) on upper frame bearing angle iron and pulling bearing angle iron, screw down after threading screws, gaskets and nuts and makes upper and lower screw holes matched exactly. (2)Connect holder, middle stand and motor rack well and form motor support combination, install connector, take off garment bag or gummed paper under the connector, paint corrosive oil on the axial surface, fans took inside through the door of maintenance, make the core of fan sleeve into the axial(please note the front and back sides), then fasten the connector, the serial number on blades should be consistent with the ones on the core of fan. (3)Adjust the motor rack combinations position carefully, make blades rotation without contact with inwall of air duct and the distance between blade and air duct is same. (4)Install motor and belt, adjust the pull and degree of tightness by using of mobile screw. (5)Install fan s safety guard on the middle neck of the motor rack combination and air duct. (H) Leakproof accessory fiber (1)After finishing all procedures, make sure the whole installation without leak, the floating ball combination and full water pipe s installation correct(the level of full water should be lower 30mm than foot plate of middle and outer frame, but the cut-off water level should be lower 25mm than full water level). (2)All screws s connection should be with galvanized gaskets, the connection between the basin and middle frame also needs leakproof rubber mat, loosen screw first and adjust it well during adjustment. (3)Clean all circulation water pipelines and inlet air lanes thoroughly(including water sprinkle system, heat dissipation infill, water absorption rubber mat, basin, water vat, filter net, outlet/inlet pipelines, inlet air blades etc.). Remarks: 1. Inspection before start (1) If all screws for cooling towers are tightened. (2) If all circulation water pipelines and inlet air lanes are clean, without sundries. (3) If heat dissipation fan runs normally, the distance with airduct is same. (4) To check if the 3 phase current matched with nameplate of the motor, the motor connection way(y or ) is right or not, the junction box installed well after wire connection. (5) If there is deformation or damage for the motor, loose or drooped tightened parts, the circuit is overload and phase missing running, connects to the earth when using. (6) The belts combination s installation is correct or not. (7) The basin and water vat s connection is appropriate or not, leak or not. (8) Start automatic water makeup, make the basin and throat pipes completely full, the cut-off water level should be 25mm lower than the level of full water. 6
2. Real time examination after start (1) If the fan rotating clockwise, the wind down and up. (2) The water level of sprinkle basin and two sides of airduct are paralleled with bottom surface, and the water level remains same. (3) Interval pump start, make the air inside the circulation water pipeline exhaust completely so as to avoid interruption during water sprinkling, meanwhile, check if the nozzle water sprinkling is even and water makeup operation is correct. (4) Adjust the standard flow rate for cooling tower. 3. Operation and maintenance (1)Clean the cooling tower frequently so as to make sure the circulation water pipelines and inlet air lanes smooth. (2) Check the tower s water pouring infill, nozzles, inlet/outlet pipelines flanges etc., replace it if any damage, meanwhile, clean the dirt and biological slime regularly, water quality stability and sterilization is needed if necessary, the quality of water should comply with industrial circulation water process design standard(gbj50-80). (3) After 2500 hours running for fan, its connector and running parts should be cleaned and examined, new lubricating oil needed at this moment, the frequency is half year, do not mix the different lubricating oil for use, motor overload operation is not allowed. (4) There should be one exclusively monitor the cooling tower while its running, pay attention to current and water temperature changes, stop the tower to check if there is strange sound. <III >Leakproof instructions for the joint fiber of the water vat and basin 1. Items provided by factory: (1). Resin-softened fiber mats chemical medicine, the same color to finished goods. (2). Fiber mats-its width divides in 125mm and 150mm, white. (3). Drier-MEKP, colorless, fiercely and dangerous chemical, you need to buy it by yourself if it is prohibited by local customs. 2. Prepared items for builders (1). Plastic vessel-brand new, wide-mouthed, with hand shank such as shell of the glue. 7
(2). Hand brush-brand new, 50-60mm. (3). Glass measure-there is cc or ml indication. (4). Brush-brand new, to clean basin and water vat. 3..Construction procedures: (1). Put on gloves first, clean sundries inside water vat and basin such as screws, nuts and heat dissipation infill via brush, use solvent to clean if oil stain, the joint of inwall of basin and water vat have to be clean, dry and without water(see attached photo 8 shadowed part). (2). Put appropriate amount of resin into the plastic vessel(water hull thereafter) (see right photo2, e.g 2kg.) (3). Put certain amount of drier into the water hull with resin(see photo3), the ratio of combination for resin and drier as No.5 following. (4). To mix two chemical items fully via hand brush(finished combination of two chemicals called mixed glue thereafter) (5). To paint the mixed glue 150mm between basin and water vat or connection joints of water vat itself(connection joint and bolt must be covered, see photo4), but one joint painted each time. (6). Put the 125mm fiber mat on the connection joint that is already with mixed glue(see photo5), to paint the mixed glue evenly on fiber mat via hand brush and pressing constantly so as to soften fiber mat and make the air among it exhaust completely as the first layer.(see photo6). (7). Deal with 150mm fiber mat with same procedure as No. 6 as second and third layers. (8). Repeat No.5 to No.7 for other connection joints until its finish completely. 4. Remarks: (1). Do not make the drier under the sun directly and keep it away from the fire and no touch with skin directly as it is fiercely dangerous chemical. (2). Do not mix all provided mixed glue for use, first layer finished, mix for the second layer, by parity of reasoning. (3). Do not do leakproof work for each connection joint at the same time, first joint finished, then the second one, parity of reasoning. (4). Do not do leakproof work if there is water vapor on the inwall of water vat or basin or raining. 5. The ratio of resin combination: 10cc(cubic centimeter) drier with 1kg resin when 30 degrees celsius, the amount of drier should be less comparatively when it is hot and more comparatively when it is cold, the amount of drier should be less for dry area and more for damp area. 8
<IV> NST-H Series Cooling Tower s Maintenance Instruction After cooling tower installation finished, please note below points: 1. Tips for pipes installation: To guarantee cooling tower inlet&outlet water balance and well-distributed, not only water inlet header pipe and water outlet header pipe with control valve, but also all water inlet branch pipes and water distributors with control valve. 2. Water quantity and water quality requirements: a. Water quantity into cooling tower is the 85%~105% of the design water flow. b. To avoid fouling and biological slime, please check infill, water inlet & outlet flange regularly, replace it in time if damaged, keep water quality stable and sterilization if necessary. To ensure water quality, customers could use static or electron water treater if possible. 3. Clean and Maintenance a. Casing: No need extra painting for fiber glass casing, just using water and cleaning agent to keep casing gloss. b. Water basin: When cleaning, close water inlet pipe valve, make-up water valve, open outlets to drain out the rest water, then using brush to clean the fouling, and wash the water strainer at the same time. c. Infill To avoid fouling jammed infill, water treatment equipment is needed to clean water basin and water distribution system. When maintenance, a big smooth space is needed to put the infill to avoid damage of the infill surface. 9
<V>NST-H Series Cooling Tower s Problem and Solution Description of problem water temperature rising Irregular circulating water Drift overlarge Noise Vibration Reason of Problem 1. water flow is too big 2. air flow is not enough 3. air has return circuit 4. water distribution blocked 5. infill blocked 6. belt gets loose 7. air intake has barrier 8. uneven distribution 1. water distribution blocked 2. water strainer blocked 3. water pump has air 4. water pump selected incorrectly 5. water outlet /inlet tubes blocked 1. Circulating water flow is too big 2. water baffle installed incorrectly 3. air flow is too large 4. Surface of infill broken 1. fan blade striking casing 2. motor bearing damaged 3. fan connector bearing damaged 4. screw looses 5. air flow is too large 6. water flow is too big 1. fan blade angle asymmetric 2. screw looses 3. fan damaged 4. motor damaged Solution 1. adjust to standard water flow 2. adjust fan blade angle 3. improve ventilation 4. clean distribution nozzles 5. clean or replace infill 6. adjust or replace belt 7. improve ventilation 8. adjust water inlet valve 1. clean water distribution system 2. clean water strainer 3. open up vent to release air 4. change water pump to match with the water flow 5. clean water tube 1. Adjust to standard water flow 2. adjust water baffle 3. adjust fan blade angle 4. replace new infill 1. adjust motor support correctly 2. replace bearing 3. replace bearing 4. fastening screw 5. adjust fan blade angle 6. adjust to standard water flow 1. adjust fan blade angle 2. fastening screw 3. replace fan 4. replace motor 10
make-up water overlarge current overlarge water basin leakage 1. make-up water equipment damaged 2. water inlet level higher than overflow level 3. water basin leakage 4. circulating pipe leakage 5. drift overlarge 1. power voltage declined 2. fan blade angle asymmetric 3. air flow overlarge 4. motor bearing damaged 5. fan connector bearing damaged 6. infill blocked 7. air intake has barrier 8. motor damaged 1.crack leak-proof improperly 2.water inlet/outlet connector burst 3. make-up water level too high 1. replace make-up water equipment 2. adjust carefully 3. Maintain water basin well 4. Maintain pipe well 5.maintain properly 1. check power voltage 2. adjust fan blade angle 3. adjust fan blade angle 4. replace bearing 5. replace bearing 6. clean or replace new infill 7. improve ventilation 8. replace motor 1. rehandle process in proper way 2. replace connector 3. readjust auto. make-up water system. 11
<VI> NST-H Series Cooling Towers Regular Checking & Maintenance Advice D--Day, W--Week, M--Month, Q--Quarter, S--Half year, Y--Year, R--when needed Remarks: 1. The location of cooling tower should keep a certain distance and direction with the building so as to avoid hot air entering fresh air system. 2. To avoid bacteria breeding, end users are responsible for hiring professional water treatment company to clean the water regularly. 12