EVAPCO AT Series Operation And Maintenance Instructions
Induced draft and forced draft cooling towers
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OPERATION AND MAINTENANCE INSTRUCTIONS
For EVAPCO Induced Draft and Forced Draft Cooling Towers
AT
EVAPCO, Inc. (World Headquarters) P.O. Box 1300, Westminster, Maryland 21158 USA
EVAPCO Europe
bvba
Heersterveldweg 19
Industrieterrein Oost
3700 Tongeren, Belgium
Phone: (32) 12 395029
Fax: (32) 12 238527
E-mail: evapco.europe@ evapco.be
EUROPEAN
UAT
For EVAPCO Authorized Parts and Service,
Contact Your Local Mr. GoodTower
or the EVAPCO Plant Nearest You
www.evapco.eu
EVAPCO Products are Manufactured Worldwide
Phone (410) 756-2600 - Fax (410) 756-6450
EVAPCO Europe S.r.l.
Via Ciro Menotti 10
I-20017 Passirana di Rho
Milan, Italy
Phone: (39) 02 9399041
Fax: (39) 02 93500840
Email: evapcoeurope@evapco.it
LSTE
EVAPCO Europe GmbH
Insterburger Straße, 18
D-40670 Meerbusch, Germany
Phone: (49) 2159-6956-0
Fax: (49) 2159-6956-11
Email: info@evapco.de
Bulletin 113-E Metric
LPT
PMTQ
Service Provider
®
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Summary of Contents for EVAPCO AT Series
- Page 1 Service Provider ® or the EVAPCO Plant Nearest You www.evapco.eu EVAPCO Products are Manufactured Worldwide EVAPCO, Inc. (World Headquarters) P.O. Box 1300, Westminster, Maryland 21158 USA Phone (410) 756-2600 - Fax (410) 756-6450 EVAPCO Europe EVAPCO Europe S.r.l. EVAPCO Europe GmbH...
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Page 2: Table Of Contents
Table of Contents Introduction ............................3 Safety Precautions / Remaining Risks ....................3 Installation Precautions ......................4 Storage Precautions ........................4 Label on the casing section(s) ....................4 Checklists ............................5 Initial and Seasonal Start-Up Checklist ..................5 Maintenance Checklist .......................6 Seasonal Shut-Down Checklist ....................7 Basic Cooling Tower Sequence of Operation ...................8 Fan System ............................9 Fan Motor Bearings ........................9... -
Page 3: Introduction
Introduction Congratulations on the purchase of your EVAPCO evaporative cooling unit. EVAPCO equipment is constructed of the highest quality materials and designed to provide years of reliable service when properly maintained. Evaporative cooling equipment is often remotely located and periodic maintenance checks are often overlooked. It is important to establish a regular maintenance program and be sure that the program is followed. -
Page 4: Installation Precautions
WARNING: Never use plastic sheets or tarps to protect a unit during storage. This practice can trap heat inside the unit and could potentially cause damage to plastic components. Label on the casing section(s) EVAPCO LOGO (both sides) RIGGING INSTRUCTIONS (both ends) WATER IN... -
Page 5: Checklists
General 1. Verify that the overall installation reflects the requirements of the installation guidelines found in EVAPCO Bulletin 311 - Equipment Layout Manual, available at www.evapco.eu. 2. For multi-speed fan motors, verify that 30 second or greater time delays are provided for speed changes when switching from high to low speed. Also check to see if interlocks are provided to prevent simultaneously energizing high and low speed and confirm both speeds turn in the same direction. -
Page 6: Maintenance Checklist
MAINTENANCE CHECKLIST PROCEDURE 1. Clean pan strainer – monthly or as needed 2. Clean and flush pan** – quarterly or as needed 3. Check bleed-off valve to make sure it is operative – monthly 4. Check operating level in pan and adjust float valve if necessary –... -
Page 7: Seasonal Shut-Down Checklist
MAINTENANCE CHECKLIST (optional accessories) PROCEDURE 1. Coupling/Shaft – Inspect flex elements and hardware for tightness, proper torque & crack/ deterioration – monthly 2. Heater Controller – Inspect controller and clean probe ends – quarterly 3. Heater – Inspect junction box for loose wiring and moisture –... -
Page 8: Basic Cooling Tower Sequence Of Operation
(usually about 27°C), at which time the bypass may be closed to cause total flow over the fill. EVAPCO does NOT recommend a partial water bypass due to the potential for freezing the heat transfer media during low ambient operation. Optional Defrost Cycle In more severe climates, the incorporation of a defrost cycle may be used to manage the ice formation in and on the unit. -
Page 9: Fan System
Feed grease slowly into the bearings or the seals may be damaged. A hand grease gun is recommended for this process. When introducing a new grease, all grease should be purged from the bearings. Most EVAPCO units are supplied with extended grease lines to allow easy lubrication of the fan shaft bearings. Unit Description Location of Lube Line Fittings Induced Draft Units – 2,4 m wide... -
Page 10: Fan Shaft Sleeve Bearings
Oil drippage may result from over-oiling or from using too light an oil. Should this condition persist with correct oiling, it is recommended that the next heavier weight oil be used. All bearings used on EVAPCO equipment are factory adjusted and self aligning. Do not disturb bearing alignment by tightening the sleeve bearing caps. -
Page 11: Fan And Motor Sheave Alignment
On induced draft belt driven units provided with externally mounted motors (2,4 and 2,6 m wide units), Figure 3, LSTE forced draft units, Figure 4, and PM forced draft units, Figure 7, both J-type adjustment bolts on the adjustable motor base should have an equal amount of exposed thread for proper sheave and belt alignment. -
Page 12: Fan System Capacity Control
Applications using a VFD for capacity control must also use an inverter duty motor built in compliance with IEC. This is an available option from EVAPCO. The standard fan motors supplied by EVAPCO are not intended for use with VFD’s. -
Page 13: Identify And Lock-Out Harmful Resonant Frequencies
Identify and Lock-out Harmful Resonant Frequencies A Variable Frequency Drive (VFD) fan system, unlike traditional fixed-speed systems, is designed to operate between 25% (13Hz) and 100% (50Hz) speeds, which creates an opportunity for operation where resonant frequencies exist. Sustained operation at resonant frequencies may lead to excessive vibration, fatigue of structural components and/or drive system noise and failure. -
Page 14: Suction Strainer Assembly
Cold Water Basin The cold water basin should be flushed out quarterly, and checked monthly or more often if necessary, to remove any accumulation of dirt or sediment which normally collects in the basin. Sediment can become corrosive and cause deterioration of basin materials. When flushing the basin, it is important to keep the suction strainers in place to prevent any sediment from entering the system. After the basin has been cleaned, the strainers should be removed and cleaned before refilling the basin with fresh water. -
Page 15: Water Make Up Valve
Pressurized Water Distribution Systems All EVAPCO cooling towers are supplied with wide orifice water diffusers. The water distribution system should be checked monthly to make sure it is operating properly. Always check the spray system with the pump on and the fans off (locked and tagged out). -
Page 16: Bleed-Off Valve
LPT and LSTE models in Figure 13 and as shown in Figure 14 for AT/UAT and PMTQ models. The top of the EVAPCO logo on the nozzle is parallel with the top of the water distribution pipe. -
Page 17: Water Treatment And Water Chemistry
Re-passivation may be required at any time in the service life of the equipment if an upset condition occurs which destabilizes the passivated zinc surface. For more information on passivation and white rust, please request a copy of EVAPCO’s Engineering Bulletin 36. -
Page 18: Water Chemistry Parameters
Chemicals should never be batch fed directly into the basin of the evaporative cooling equipment. Evapco does not recommend the routine use of acid due to the destructive consequences of improper feeding; however, if acid is used as part of the site specific treatment protocol, it should be pre-diluted prior to introduction into the cooling water and fed by automated equipment to an area of the system which ensures adequate mixing. -
Page 19: Gray Water And Reclaimed Water
Stainless steel is the most cost effective material of construction available to extend the life of an evaporative cooling unit. The stainless steel sheet material utilized by EVAPCO is Type 304L and Type 316L with a No. 2B unpolished finish. Type 304L stainless steel is a basic chromium-nickel austenitic stainless steel and is suitable for a wide range of applications. It is readily available throughout the world and is easy to form during the fabrication process. -
Page 20: Maintaining The Appearance Of Stainless Steel
When cleaning stainless steel, NEVER use coarse abrasives or steel wool, NEVER clean with mineral acids and NEVER leave stainless in contact with iron or carbon steel. For more information on cleaning stainless steel, please request a copy of EVAPCO’S Engineering Bulletin 40. -
Page 21: Cold Weather Operation
Prevailing winds can create icing conditions on the inlet louvers and fan screens adversely affecting airflow to the unit. For additional information on unit layout, please refer to EVAPCO’s Equipment Layout Manual - Bulletin 311. Unit Piping All external piping (water make up lines, equalizers, riser piping) that is not drained needs to be heat traced and insulated to make certain it does not freeze. All piping should be fitted with drain valves... - Page 22 When the ambient temperatures are below freezing, additional precautions must be taken to avoid the potential for damaging ice formation. It is very important to maintain close control of the cooling tower during winter operation. EVAPCO recommends that an absolute MINIMUM leaving water temperature of 6° C must be maintained;...
- Page 23 Forced Draft Unit Capacity Control The most common methods of capacity control are cycling the single speed fan motors, using two speed motors or pony motors and utilizing variable frequency drives to control the tower fans. Although capacity control methods for forced draft units are similar to those used for induced draft units, there are slight variations.
- Page 24 However, low speed fan operation or variable frequency drives maintain a positive pressure in the unit which helps prevent ice formation on the fan drive components. For more information on cold weather operation, please request a copy of EVAPCO’s Engineering Bulletin 23...
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Page 25: Troubleshooting
Troubleshooting Problem Possible Cause Remedy Overamping Fan Motors Reduction in air static 1. On a forced draft unit verify that the pump is on, and water is pressure flowing over the coil. If the pump is off, and the unit was not sized for dry operation, the motor may over-amp. - Page 26 Troubleshooting (Follows) Problem Possible Cause Remedy Fan Noise Blade rubbing inside of Adjust cylinder to provide blade tip clearance. fan cylinder (induced draft models) Scaled Inlet Louvers on Improper water This is not necessarily an indication that there is something wrong AT Units treatment, insufficient with the unit, or with the water treatment.
- Page 27 The rust spots can be removed with a good cleaning. EVAPCO recommends using a good stainless steel cleaner in conjunction with a Scotch-Brite pad. Maintenance of the unit’s surface should be done on a regular basis.
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Page 28: Replacement Parts
Replacement Parts EVAPCO has replacement parts available for immediate shipment. Most orders ship within 24 hours from time of order! To order replacement parts, please visit www.evapco.eu to find your local contact. -
Page 29: At/Uat - 1,2 M Wide Units
AT / UAT - 1,2 m WIDE UNITS ICT UNITS FAN SCREEN FAN & FILL CASING SECTION FAN CYLINDER DRIFT ELIMINATORS ACCESS DOOR WATER INLET CONNECTION FILL FAN MOTOR PAN SECTION MAKE-UP VALVE WITH ADJUSTABLE FLOAT AIR INLET LOUVER OUTLET CONNECTION SUCTION HOOD &... -
Page 30: At/Uat - 2,4 And 2,6 M Wide Cells
AT / UAT - 2,4 and 2,6 m WIDE CELLS AT / USS / UBT 8' & 8.5' WIDE CELLS FAN SCREEN FAN SCREEN FAN & FILL SUPPORT CASING SECTION BEARING SUPPORT FAN CYLINDER FAN SHAFT BEARING DRIFT ELIMINATORS SWING OUT MOTOR COVER TEFC FAN MOTOR FILL... -
Page 31: At/Uat - 3 And 3,6 M Wide Cells
AT / UAT - 3 m and 3,6 m WIDE CELLS AT / USS / UBT 12' & 14' WIDE CELLS FAN & FILL FAN SCREEN CASING SECTION FAN SCREEN SUPPORT MECHANICAL FAN CYLINDER EQUIPMENT SUPPORT DRIFT ELIMINATORS FILL ALUMINUM FAN SHEAVE SLIDING MOTOR BASE FAN BELT TEAO FAN MOTOR... -
Page 32: At/Uat - 4,2 M Wide Cells
AT / UAT - 4,2 m WIDE CELLS AT / USS / UBT 12' & 14' WIDE CELLS FAN SCREEN SUPPORT FAN & FILL FAN SCREEN CASING SECTION MECHANICAL FAN CYLINDER EQUIPMENT SUPPORT DRIFT ELIMINATORS WATER INLET CONNECTION FILL SLIDING MOTOR BASE WATER DISTRIBUTION TEAO FAN MOTOR SPRAY BRANCH... -
Page 33: Lpt - All Models
LPT UNITS LPT UNITS FILL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH DRIFT ELIMINATOR SUPPORT CASING FILL SUPPORT CHANNEL FILL WATER DISTRIBUTION WATER INLET SPRAY BRANCH SUPPORT CONNECTION PAN SECTION FAN SHEAVE FAN HOUSING FAN BELT FAN WRAPPER SUCTION HOOD SUCTION STRAINER MOTOR ACCESS DOOR TEFC FAN MOTOR... -
Page 34: Lste - 1,6 M Wide Units
LSTE UNITS - 1,2 and 1,6 m WIDE UNITS LSTA UNITS - 1,2 m WIDE UNITS FILL CASING SECTION DRIFT ELIMINATORS FILL SUPPORT CHANNEL FILL WATER INLET CONNECTION WATER DISTRIBUTION SPRAY BRANCH WATER DISTRIBUTION SPRAY BRANCH SUPPORT CASING PAN SECTION ACCESS DOOR MIGRATION... - Page 35 LSTE UNITS - 2,4 and 3 m WIDE UNITS LSTB UNITS FILL CASING SECTION DRIFT ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH FILL WATER INLET CONNECTION FILL SUPPORT CHANNEL CASING WATER DISTRIBUTION SPRAY BRANCH SUPPORT PAN SECTION MIGRATION BAFFLE FAN SCREENS NOT SHOWN FOR CLARITY OUTLET HOOD &...
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Page 36: Pmtq
PMTQ UNITS PMTQ Units FAN & FILL DRIFT CASING SECTION ELIMINATORS WATER DISTRIBUTION SPRAY BRANCH LIFTING EARS FILL WATER INLET CONNECTION CASING FILL SUPPORT CHANNEL WATER DISTRIBUTION SPRAY BRANCH SUPPORT PAN SECTION COLD WATER BASIN ACCESS DOOR FAN CYLINDER FAN BELT TEFC FAN MOTOR ADJUSTABLE MOTOR BASE SUPER LOW SOUND FAN... -
Page 37: At/Uat With Super Low Sound Fan - 2,4 And 2,6 M Wide Cells
AT / UAT WITH SUPER LOW SOUND FAN - 2,4 and 2,6 m WIDE CELLS UT 8.5' WIDE CELLS FAN & FILL CASING SECTION FAN SCREEN FAN SCREEN SUPPORT BEARING SUPPORT SUPER LOW SOUND FAN FAN CYLINDER FAN SHAFT FAN BEARING DRIFT ELIMINATORS SWING OUT MOTOR COVER... -
Page 38: At/Uat With Super Low Sound Fan - 3; 3,6 And 4,2 M Wide Cells
AT / UAT WITH SUPER LOW SOUND FAN - 3; 3,6 and 4,2 m WIDE CELLS UT 12' & 14' WIDE CELLS FAN & FILL FAN SCREEN FAN SCREEN CASING SECTION SUPPORT SUPER LOW SOUND FAN FAN CYLINDER MECHANICAL EQUIPMENT SUPPORT DRIFT ELIMINATORS FILL SLIDING MOTOR BASE... - Page 40 ©2012 EVAPCO Europe Bulletin 113-E 1216...
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