BAC HXI Series Operating And Maintenance Instructions Manual
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BAC HXI Series Operating And Maintenance Instructions Manual

Hybrid closed circuit cooling tower
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MHXIv10EN-SA
HXI Hybrid Closed Circuit Cooling Tower
OPERATING AND MAINTENANCE INSTRUCTIONS

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Summary of Contents for BAC HXI Series

  • Page 1 MHXIv10EN-SA HXI Hybrid Closed Circuit Cooling Tower OPERATING AND MAINTENANCE INSTRUCTIONS...
  • Page 2 Water sampling, test results and corrective actions should be recorded in the cooling system logbook. For more specific recommendations on keeping your cooling system efficient and safe, contact your local BAC Balticare service provider or representative. Name, e-mail and phone number can be found on the website www.BACService.eu.
  • Page 3 Inspections and Monitoring Start- Weekly Monthly Quarterly Every 6 Annually Shutdown Months Electric Water Level Control Package (option) TAB test (dip slides) Circulating water quality System overview Recordkeeping as per event Lubrication Start-Up Weekly Monthly Quarterly Every 6 Annually Shutdown Months Fan shaft bearings Motor bearings*...

  • Page 4: Table Of Contents

    Table of Contents OPERATING AND MAINTENANCE INSTRUCTIONS Construction Details Hybrid Closed Circuit Cooling Towers General Information Operating Conditions Connecting Pipework Safety Precautions Disposal Requirements Non-walking Surfaces Modifications by others Warranty Water Care About Water Care Biological Control Chemical Treatment Passivation Cold Weather Operations About Cold Weather Operation Protection Against Sump Water Freezing...

  • Page 5: Construction Details

    CONSTRUCTION DETAILS Hybrid Closed Circuit Cooling Towers 1. Air In 2. Air Out 3. Liquid In 4. Liquid Out 5. Wet Deck Surface 6. Cold Water Basin 7. Water Distribution System 8. Prime Surface coil 9. Spray Water Pump 10. Eliminators 11.

  • Page 6: General Information

    GENERAL INFORMATION Operating Conditions BAC cooling equipment is designed for the operating conditions specified below, which must not be exceeded during operation. • Wind Load: For safe operation of unshielded equipment exposed to wind speeds above 120 km/h installed at a height above 30 m from the ground, contact your local BAC-Balticare representative.

  • Page 7: Connecting Pipework

    PURGE REQUIREMENTS The installer of BAC closed circuit cooling towers must ensure a proper air purging of the system prior to operation. Entrained air can restrict the capacity of the cooler, resulting in higher process temperatures.

  • Page 8: Safety Precautions

    When the equipment is operated with a variable fan speed control device, steps must be taken to avoid operating at or near to the fan's «critical speed». For more information consult your local BAC Balticare representative. ELECTRICAL SAFETY Each fan and pump motor associated with this equipment should be installed with a lockable disconnect switch located within sight of the equipment.

  • Page 9: Disposal Requirements

    BAC will guarantee all products to be free from manufactured defects in materials and workmanship for a period of 12 months from the date of shipment. In the event of any such defect, BAC will repair or provide a replacement.

  • Page 10: Water Care

    WATER CARE About Water Care In all cooling equipment, operating in evaporative mode, the cooling is accomplished by evaporating a small portion of the re-circulating water as it flows through the equipment. When this water evaporates, the impurities originally present in the water remain. Unless a small amount of water is drained from the system, known as blow down, the concentration of dissolved solids will increase rapidly and lead to scale formation or corrosion or both.
  • Page 11 Baltiplus 800™/810™ Protection Conductivity 2400 µS/cm Chlorides 250 mg/l max. Sulfates* 250 mg/l max.* Total Suspended Solids 25 mg/l max. Chlorination (as free chlorine): continuous 1 mg/l max. Chlorination (as free chlorine): batch dosing for cleaning & 5-15 mg/l max. for 6 hours max. disinfection 25 mg/l max.

  • Page 12: Biological Control

    5. If it is proposed to operate a treatment programme outside the BAC Water Quality Control Guidelines, the BAC factory warranty may be invalidated if the water quality is persistently outside the Control Guidelines, unless specific prior written BAC approval.
  • Page 13 ® Stainless steel units and units protected by the BALTIBOND hybrid coating without galvanized coil, do not require passivation. In case you can't keep the pH below 8.2, a secondary approach is to conduct a chemical passivation using inorganic phosphate or film-forming passivation agents. Consult your water treatment specialist for specific recommendation.

  • Page 14: Cold Weather Operations

    COLD WEATHER OPERATIONS About Cold Weather Operation BAC equipment can be operated in subfreezing ambient conditions provided the proper measures are taken: 1. Protection against sump water freezing, when the system is idle. 2. Capacity control to prevent ice formation during operation.

  • Page 15: Protection Against Coil Freezing

    «critical speed» and below a minimum of 15 Hz for a belt driven unit (or direct driven fans) or 20 Hz for a unit with gear box. For more information consult your local BAC Balticare representative.
  • Page 16 If the process load is extremely light or shut off, it may be necessary to apply an auxiliary heat load during freezing conditions. Consult your local BAC Balticare representative for advice, if these conditions cannot be met. Draining of the coil(s) is not recommended as a normal method of freeze protection unless the coil(s) are constructed from stainless steel or are of the cleanable type.
  • Page 17 Full draining of the heat exchanger coil is not guaranteed because of rising coil circuiting on the finned discharge coil (optional) and the risk for coil freeze-up remains. The local BAC Balticare representative should be consulted for guidelines on the installation of an emergency coil drain system.

  • Page 18: Maintenance Procedures

    MAINTENANCE PROCEDURES Checks and Adjustments COLD WATER BASIN AND BASIN STRAINERS The cold water basin should be inspected regularly. Any debris which may have accumulated in the basin or on the strainers should be removed. Quarterly, or more often if necessary, the entire cold water basin should be drained, cleaned and flushed with fresh water to remove the silt and sediment which normally collects in the basin and under the wet deck surface during operation.
  • Page 19 Cold Water Basin and Basin Strainer OPERATING LEVEL AND MAKE-UP Before initial start up the straps, that prevent the float ball from moving during transport, as well as the protective bag around this ball, need to be removed. Fixation and wrapping of Float ball As the water circulating through the unit is cooled, it collects in the cold water basin and passes through the strainers into the system.
  • Page 20 Operating Level (measured from the pan bottom) Model No. (mm) HXI-4XX HXI-5XX HXIQ-5XX HXI-6XX HXIQ-6XX Cold Water Basin Operating Heights The "x" represents the variable numbers or characters in the model numbers. The operating water level in the cold water basin will vary somewhat with system thermal load (evaporation rate), the bleed rate employed and the make-up water supply pressure.
  • Page 21 Water Make-up Valve Assembly 1. Float Ball 2. All Threaded Rod 3. Wing Nuts 4. Float Arm Assembly 5. Float Valve Caution SUPPLY PRESSURE FOR MECHANICAL MAKE-UP VALVES SHOULD BE BETWEEN 1 AND 4,5 BAR. To check the operating level, proceed as follows: 1.
  • Page 22 Caution SUMP HEATERS CAN BE HOT Sump Heater DRIVE SYSTEM Belt Driven Units The drive system consists of a specially designed belt, a fan sheave and a motor sheave. The high efficiency belt provides the premium quality necessary for evaporative cooling equipment service. Together these components provide a highly reliable system with low maintenance requirements.
  • Page 23 Drive System 1. Fan Motor 2. Motor Sheave 3. Belt 4. Cast Aluminium Fan Sheave 5. Fans Belt Tensioning Check belt tension as follows: 1. Shut off fan(s). 2. Rotate the fan sheave half a turn to evenly distribute the tension in the belt before measuring. 3.
  • Page 24 Fan Belt Check and Adjustment 1. Fan Sheave 2. Belt 3. Motor Sheave 4. 10 mm/m Deflection = Proper Belt Tension 5. Straight Edge Deflection Force (kg) Diameter (mm) Belt Profile Motor Sheave Min. Max. 100 through 118 125 through 140 150 through 170 >180 Belt Tension Forces...
  • Page 25 Drive Alignment Proper drive alignment ensures maximum belt life. Alignment is checked for standard drives after correct belt tensioning by placing a straight-edge across both sheaves as shown in the Figure below. Sheave alignment standard drives 1. Motor Sheave 2. Fan Sheave 3.

  • Page 26: Inspections And Corrective Actions

    Unusual noise and/or vibration are the result of malfunctioning of mechanical components or operational problems (e.g. unwanted ice formation). If this occurs, a thorough inspection of the entire unit followed by immediate corrective action is needed. If required, consult your local BAC Balticare representative for assistance. Inspections and Corrective Actions...
  • Page 27 Selecting a coil cleaner is important since the cleaner must neutralise and remove deposits on the surface of the coil. BAC does not recommend the use of alkaline and acidic coil cleaners. These coil cleaners can cause foaming action (oxides or hydroxides of aluminium) resulting in the stripping away of minute layers of the base alloy and the attached soil.
  • Page 28 4. Clean water distribution from dirt and debris. Ensure spray branches and nozzles are in place and clean. Replace damaged or missing nozzles. 5. Start fan(s) and pump(s). Nozzle Spray Distribution Type for Closed Circuit Cooling Tower COMBINED INLET SHIELDS Combined inlet shields are installed at the air inlet side.
  • Page 29 2. To remove the combined inlet shields, lift each section and pull at the lower end. Remove Combined Inlet Shields 3. Reinstall the cleaned combined inlet shields. 4. The supporting steel strip does not need to be reinstalled because it is only required for safe transport purposes.
  • Page 30 FAN SHAFT The exposed areas of the fan shaft are coated with a soft seal for added corrosion protection. It is recommended that the coating be inspected for continuity quarterly or at least every 6 months. Any signs of surface corrosion must be treated.
  • Page 31 DO NOT RUN/START THE FAN MOTOR(S) WHEN THERE IS NO HEAT LOAD. SPRAY WATER PUMP The BAC pump contains a mechanical seal between pump housing and pump motor. This seal needs to be checked quarterly for proper operation and replaced if necessary.

  • Page 32: Lubrication

    ELECTRIC WATER LEVEL CONTROL PACKAGE (OPTIONAL) The electric water level control package (optional) maintains a constant water level in the cold water sump independent of cooling load changes and water supply pressure variations. Ensure every six months that all components (valve, float switches) are operational and clean. During commissioning the unit should be filled manually till overflow level (push float ball under) to prevent air suction of the pump during first start-up.
  • Page 33 For grease products see Table below. MOTOR BEARINGS Motor bearings are greased for bearing life. GREASE PRODUCTS Shell Alvania grease RL3 -20°C to +120°C Texaco Multifak Premium 3 -30°C to +140°C Klüber Isoflex LDS Special A -50°C to +120°C Mobil Mobilith SHC 100 -40°C to +175°C Total Fina Elf...

  • Page 34: Cleaning Procedures

    6 hours. Higher chlorine levels for a shorter period are possible, but require a higher level of corrosion protection than galvanized steel only. Consult your BAC Balticare representative for further information.

  • Page 35: Comprehensive Maintenance

    Remove and store fan belts and access door gaskets. • Hot dip galvanized and stainless steel coils of BAC closed circuit cooling towers are filled with a low pressure inert gas at the factory before shipping, to ensure an optimal internal corrosion protection. It is recommended to check the overpressure every six months (connect a manometer to the valve).

  • Page 36: Further Assistance & Information

    FURTHER ASSISTANCE & INFORMATION Balticare BAC has established a specialized independent total care company called Balticare. The BAC Balticare offering involves all elements required to ensure a safe and efficient operation of your evaporative cooling products. From a full range of risk assessment to selective water treatment, training, testing, record keeping and annual system overview.
  • Page 37 W W W . B A L T I M O R E A I R C O I L . C O . Z A...
  • Page 38 W W W . B A L T I M O R E A I R C O I L . C O . Z A...
  • Page 39 W W W . B A L T I M O R E A I R C O I L . C O . Z A...
  • Page 40 COOLING TOWERS CLOSED CIRCUIT COOLING TOWERS ICE THERMAL STORAGE EVAPORATIVE CONDENSERS HYBRID PRODUCTS PARTS & SERVICES www.BaltimoreAircoil.co.za info@BaltimoreAircoil.co.za Please refer to our website for local contact details. PO Box 32088 - 7808 Ottery, Cape Province, South Africa © Baltimore Aircoil International nv...

This manual is also suitable for:

Hxi-4 seriesHxi-5 seriesHxiq-5 seriesHxi-6 seriesHxiq-6 series

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