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Summary of Contents for SPX MARLEY CLASS 800
- Page 1 Marley Class 800 Mechanical Draft Cooling Tower User Manual 95-1356A...
- Page 2 Warning Caution Note Notice The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning the life of the product. Indicates presence of a hazard which can cause severe personal injury, death or substantial property damage if ignored.
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Page 3: Table Of Contents
Contents General ...4 Before Start-up ...5 Initial Starting Procedure ...7 Routine Starting Procedure ...8 Operation ...9 Freezing Weather Operation ...11 Temperature Control and Energy Management ...13 Maintenance ...15 Cleaning ... 17 Water Treatment ...18 Seasonal Shutdown Instructions ...20 Spare Parts and Accessories ...21 Troubleshooting ...22 Safety ...24 Inspection and Maintenance Schedule ...25... -
Page 4: General
General A cooling tower, like any heat exchanger, exchanges all heat imposed upon it from one fluid to another fluid. For a cooling tower, heat from the water is put into the air. The plant process replenishes the heat to the water, typically at another heat exchanger such as a condenser. -
Page 5: Before Start-Up
Caution Before Start-up Safety Temporary safety barricades should be placed around any exposed openings in the operating (or nonoperating) tower, safety harnesses should be worn by personnel where appropriate, and other safety precautions should be taken in compliance with OSHA regulations and standards. - Page 6 Caution Before Start-up • Rotate fan by hand to be sure of free rotation and ample tip clearance. See Marley Fan User Manual. • Check motor insulation with a “Megger. ” See maintenance section of Marley Electric Motor Service Manual. • Lubricate the motor according to motor manufacturer’s instructions. • Test run each fan separately for a short time. Check for excessive vibration or unusual noise. If either is present, see Troubleshooting on pages 22 and 23 of this manual. Fan must rotate clockwise when viewed from above. Recheck Geareducer oil level.
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Page 7: Initial Starting Procedure
Caution Initial Starting Procedure 1— Fill the cold water basin and circulating water system to a level 1/2” (13 mm) below the overflow. 2— Bypass valve should be closed unless start-up is in cold weather. (See Routine Starting Procedure on page 8.) 3—... -
Page 8: Routine Starting Procedure
Caution Routine Starting Procedure After periods of routine shutdown, the following restarting procedure should be followed: • Start the circulating water pump(s). Increase the flow of circulating water gradually to design water rate to avoid surges or water hammer which could damage the distribution piping. Circulating cold water over a tower in freezing weather will cause ice to form, which may cause damage to the fill system. -
Page 9: Operation
Operation Tower Performance The following is intended to serve as a guideline for the operation of this counterflow mechanical draft cooling tower. The owner may use this information to develop preliminary operating procedures. As operational experience with the system accumulates, more definitive responses to specific conditions will be developed by the owner’s operating personnel. - Page 10 Operation Hot Water Distribution System Hot water from the process flows through an inlet to each cell, which supplies a distribution header and a system of branch arms and nozzles. Each distribution header may be equipped with a vent standpipe to minimize water hammer, to maintain a slightly pressurized water distribution system, and to provide vacuum release at pump shutdown.
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Page 11: Freezing Weather Operation
Note Freezing Weather Operation During periods of low ambient air temperatures, 35°F to 40°F (2°C to 4°C) or below, it is advisable to maintain the cold water temperature at or above 70°F (21°C) to retard the formation of ice and to assist in its control. - Page 12 Caution Caution Caution Freezing Weather Operation • Under extended extreme cold conditions, it may be necessary to operate the fan in reverse. This forces warm air out through the air inlets, melting any accumulated ice. Reversal may be at either full or half speed; however, full speed is recommended if adequate heat load is available. Reverse operation of the fan should be avoided, where possible, and should not exceed 15 to 20 minutes.
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Page 13: Temperature Control And Energy Management
Temperature Control and Energy Management The wet-bulb temperature of the ambient air varies significantly on a daily basis, and considerably from season to season. As the wet-bulb temperature reduces, the tower becomes capable of producing colder and colder water—or it becomes capable of producing a given cold water temperature at reduced airflow through the tower. - Page 14 Temperature Control and Energy Management Excessive cycling of motors causes overheating of the windings Caution and ultimate failure of the motor. The total amount of starting time (period of high inrush current) should not exceed 30 seconds per hour. On fans 20 feet diameter and smaller, this may allow 4 or 5 starts per hour.
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Page 15: Maintenance
Note Warning Caution Maintenance Well maintained equipment gives the best operating results and the least maintenance cost. A regular inspection schedule is recommended to insure effective safe operation of the cooling tower. Use the Inspection and Maintenance Schedule on page 25 to obtain continuously good performance with least tower maintenance. - Page 16 Maintenance to institute a program of water treatment and maintenance that will minimize their impact. (See Water Treatment on pages 18 and 19.) Tower Framework Inspect for cracks and spalling and repair if necessary. Keep bolts tight in the mechanical equipment supports. Maintain a positive Langelier index in your circulating water.
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Page 17: Cleaning
Cleaning Any evaporative-type cooling tower must be thoroughly cleaned on a Warning regular basis to minimize the growth of bacteria, including Legionella Pneumophilla, to avoid the risk of sickness or death. Service personnel must wear proper personal protective equipment. Do NOT attempt any service unless the fan motor is locked out. Operators of evaporative cooling equipment, such as water cooling towers, should follow maintenance programs which will reduce to an absolute minimum the opportunity for bacteriological contamination. -
Page 18: Water Treatment
Note Note Water Treatment Blowdown Blowdown, or bleed-off is the continuous removal of a portion of the water from the circulating system. It is used to prevent dissolved solids from concentrating to the point where they will form scale. The amount of blowdown required depends upon the cooling range (design hot water temperature minus design cold water temperature) and the composition of the make-up water (water added to the system to compensate for losses by blowdown, evaporation,... - Page 19 Caution Water Treatment these values it is possible to calculate the index and predict the corrosive tendencies of the tower water toward concrete. An explanation and method of calculating the Langelier index can be found in all books on water treatment. Maintaining a positive Langelier index provides excellent protection of concrete.
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Page 20: Seasonal Shutdown Instructions
Seasonal Shutdown Instructions Tower Drain all tower piping. During shutdown, clean the tower and make any necessary repairs. Apply protective coating as required to all metal parts. Particular attention should be given to mechanical equipment supports, drive shaft and drive shaft guards, Geareducers, and motors. -
Page 21: Spare Parts And Accessories
Spare Parts and Accessories Spare Parts SPX Cooling Technologies manufactures and maintains a stock of replacement parts for all cooling tower mechanical equipment. Shipment of these parts is normally made within ten days after an order is received. If emergency service is necessary, contact the local Marley sales office or representative for assistance. -
Page 22: Troubleshooting
Troubleshooting Trouble Cause Motor Will Not Start Power not available at motor terminals Wrong connections Low voltage Open circuit in motor winding Motor or fan drive stuck Rotor defectve Unusual Motor Noise Motor running single-phase Motor leads connected incorrectly Ball bearings Electrical unbalance Air gap not uniform Rotor unbalance... - Page 23 Troubleshooting Trouble Cause Wrong Rotation (Motor) Wrong sequence of phases Geareducer Noise Geareducer bearings Gears Unusual Fan Drive Loose bolts and cap screws Vibration Unbalanced drive shaft or worn couplings Worn Geareducer bearings Unbalanced motor Bent Geareducer shaft Fan Noise Loose fan hub cover Blade rubbing inside of fan cylinder Loose bolts in blade clamps...
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Page 24: Safety
Safety The tower has been designed to provide a safe working environment while either operating or shut down. The ultimate responsibility for safety rests with the Operator and Owner. When flow to the tower is shut off or when portions of the tower require maintenance, temporary safety barricades may be required around openings. -
Page 25: Inspection And Maintenance Schedule
Inspection and Maintenance Schedule General Recommendations More frequent inspection and maintenance may be desirable. 1. Inspect for clogging 2. Check for unusual noise or vibration 3. Inspect keys, keyways, and set screws 4. Make sure vents are open 5. Lubricate (grease) 6. -
Page 26: Inspection Checklist
Inspection Checklist Date Inspected Owner Owner's Tower Designation Tower Manufacturer Process Served by Tower Design Conditions Number of Fan Cells Condition: 1—Good Structure Casing Material Structural Material Fan Deck Material Stairway? Material Ladder? Material Handrails? Material Interior Walkway? Material Cold Water Basin Material Water Distribution System Distribution Basin Material Inlet Pipe Material... - Page 27 Inspection Checklist Condition: 1—Good Mechanical Equipment Gear Drive Units Manufacturer Oil Level: Full Oil Condition: Good Oil Used — Type Seals Backlash Fan Shaft Endplay Any Unusual Noises? Drive Shafts Manufacturer Fans Manufacturer Diameter Blade Material Hub Material Hub Cover Material Blade Assembly Hardware Tip Clearance "min.
- Page 28 7401 WEST 129 STREET OVERLAND PARK, KANSAS 66213 UNITED STATES 913 664 7400 spxcooling@ct.spx.com spxcooling.com In the interest of technological progress, all products are subject to design and/or material change without notice. ©2009 SPX Cooling Technologies, Inc. | Printed in USA Manual 95-1356A...
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