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Related Manuals for BAC PCT Series
Summary of Contents for BAC PCT Series
- Page 1 PCT Cooling Towers OPERATION & MAINTENANCE MANUAL...
- Page 3 Construction Details Fan (not shown) Drive Train (not shown) Motor Base (not shown) Fan Shaft (not shown) Motor Eliminators Access Door (not shown) Fill Louvres Make Up Assembly Water Distribution System Cold Water Basin Drain & Overflow Figure 1. PCT Cooling Tower Strainer...
- Page 4 “critical speed” which could result in fan failure and possible personal injury or damage. Contact your local BAC Representative regarding any such applications. Additionally, inverter duty motors are required on installations that are to be controlled by VFDs.
- Page 5 Cautions • CAUTION: BAC units are typically installed immediately after shipment and many operate year round. However, if the unit is to be stored for a prolonged period of time either before or after installation, certain precautions should be observed. For instance, covering the unit with a clear plastic tarpaulin during storage can trap heat inside the unit, potentially causing damage to the fill and other components.
- Page 6 Recommended Maintenance Service Inspect and clean as necessary: Start-Up Monthly Quarterly Annually Shutdown Inspect general condition of the unit and check unit for unusual noise or vibration Inspect cold water basin Flush water distribution system/Inspect spray nozzles Drain basin and piping Inspect combined inlet shields Check and adjust water level in basin(s) Check operation of make-up valve...
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Page 7: Table Of Contents
Table of Contents OPERATIONS & MAINTENANCE » PCT Construction Details Warnings and Cautions PART 1 Operation and Maintenance Initial & Seasonal Start-Up Extended Shutdown PART 2 Detailed Component Maintenance Procedures Cold Water Basin Fan Drive System (Except Direct Drive Units) Fan Drive System (Direct Drive) Fan Motors Fan Shaft Bearings... -
Page 8: Operation And Maintenance
PCT COOLING TOWER Operation and Maintenance INITIAL AND SEASONAL START -UP EXTENDED SHUTDOWN... -
Page 9: Initial & Seasonal Start-Up
Operation and Maintenance Initial & Seasonal Start-Up Initial & Seasonal Start-Up General Cleaning General Inspection • If the unit is mounted on vibration isolators or isolation rails (by others), refer to the vibration isolation manufacturer’s guidelines before loading/unloading weight from the unit. •... - Page 10 Start-up WARNING: Check to ensure the controls for the fan motor are set • Prior to seasonal start-up, lubricate the motor base adjusting to allow a maximum of six on-off screw(s) and fan shaft bearings. At initial start-up, no bearing cycles per hour to prevent lubrication is required since the bearings are factory lubricated prior to the shipment.
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Page 11: Extended Shutdown
Operation and Maintenance Extended Shutdown Initial & Seasonal Start-Up Start-up Perform the following services whenever the unit is shutdown in excess Extended Shutdown of three days: • If the unit is mounted on vibration isolators or isolation rails (by others), refer to the manufacturer’s guidelines before loading/ unloading weight from the unit. -
Page 12: Part 2 Detailed Component Maintenance Procedures
PCT COOLING TOWER Detailed Component Maintenance Procedures COLD WATER BASIN FAN DRIVE SYSTEM (BELT DRIVE UNITS) FAN DRIVE SYSTEM (DIRECT DRIVE UNITS) FAN MOTORS FAN SHAFT BEARINGS LOCKING COLLARS FAN SHAFT ACCESS DOOR LOUVRES AND ELIMINATORS WATER DISTRIBUTION AND HEAT TRANSFER SECTION WATER LEVEL CONTROL... -
Page 13: Cold Water Basin
Detailed Component Cold Water Basin Maintenance Procedures Cold Water Basin As water circulating through the cooling tower is cooled, it collects in the Water Levels cold water basin and passes through the suction strainer into the system. Inspection & Maintenance Water Levels Model Number At Overflow Level (mm) -
Page 14: Fan
– Check each blade in the area of the shank for any signs of cracking. If cracking is found, the fan motor should be locked out immediately. Contact your local BAC Representative for assistance. • Tip Clearance: Check the clearance between the tip of the blade and the fan cowl. -
Page 15: Fan Drive System (Except Direct Drive Units)
Detailed Component Fan Drive System (Belt Drive Units) Maintenance Procedures Belt Drive Power Train Inspection & Maintenance Fan Drive System The drive train consists of SPB belts, a fan sheave and a motor sheave. (Belt Drive Units) The high efficiency belts provide the premium quality necessary for Belt Drive Power Train evaporative cooling equipment. - Page 16 NOTE: There should be no “chirp” • Belt tension adjustment (if required): or “squeal” when the fan motor 1. Loosen the motor pulley guard retaining nuts. 2. Loosen the lock nuts on the Motor Base Adjusting Screws. is started. 3. Turn the Motor Base Adjusting Screws clockwise to tension the belt, or counterclockwise to relieve belt tension.
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Page 17: Fan Drive System (Direct Drive)
Detailed Component Alignment Maintenance Procedures • Check the drive alignment annually to ensure maximum belt life. • Drive alignment check and adjustment: Fan Drive System (Belt Drive Units) – Place a straight edge across the driver and the driven sheaves as shown in Figure 5. -
Page 18: Fan Motors
Fan Motors Fan Drive System Descriptions Direct Drive Motors: For direct driven units the motor is TEAO epoxy coated IP66. Belt Drive Motor: The fan motor used on belt driven PCT units is a TEFC motor, with permanently lubricated ball bearings. The motor is installed fully outside of the wet air stream. -
Page 19: Fan Shaft Bearings
• Only lubricate the bearings with a manual grease gun. Do not use high-pressure grease guns since they may rupture the bearing seals. • Bearings come pre-packed with Castrol EPL2 grease. BAC recommends re-packing only with a compatible water resistant, mineral base grease with a lithium thickener. -
Page 20: Locking Collars
Locking Collars Each eccentric locking collar should be checked every six months to ensure that the inner bearing race is secured to the fan shaft. The locking collar can be set using the following procedure (See Figure 7). 1. Loosen the set screw. 2. -
Page 21: Access Door
Detailed Component Access Door Maintenance Procedures Locking Collars The large access door is easily removed to provide complete access to Fan Shaft drift eliminators, spray system and fill. Access Door To remove the door, take out the louvres from door side. Loosen and remove the knobs that hold the door in place. -
Page 22: Louvres And Eliminators
3. Repair or replace damaged or defective bundles. Replacement NOTE: When working on fill section bundles are available through your local BAC representative. or above fill section, fill bundle Heat trace and insulate all exposed water piping including pump piping... -
Page 23: Water Distribution And Heat Transfer Section
Detailed Component Water Level Control Maintenance Procedures Louvres and Eliminators There are two types of water level controls used on BAC cooling towers: Water Distribution and Heat Transfer Section • Mechanical make-up valve assembly • Optional electric water level control package... - Page 24 Optional Electric Water Level Control Package As an option, an electric water level control package is available in lieu of the mechanical make-up assembly. The package consists of a probe type liquid level control assembly and a slow-closing solenoid valve. Stainless steel electrodes, factory-set at predetermined lengths, extend from an electrode holder into the cold water basin.
- Page 25 Detailed Component Maintenance Procedures Water Level Control Mechanical Make-up Valve Assembly Optional Electric Water Level Control Package M A R 1 0 8 - 2 W W W . B A L T I M O R E A I R C O I L . C O M . A U...
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Page 26: Water Treatment
PCT COOLING TOWER Water Treatment BLEED RATE BLEED LINE CALCULATIONS... -
Page 27: Bleed Rate
(Note: The solenoid valve and conductivity meter may be supplied by BAC or others). 6. Alternatively, use a bleed line with a valve to continuously bleed from the system. In this arrangement, adjust the rate of bleed using the valve in the bleed line. -
Page 28: Bleed Line Calculations
Bleed Line Calculations Bleed rate is determined by the following formula; Bleed Rate = B = E/(n-1) Where: B = Bleed Rate (L/S) E* = Evaporation Rate (L/S) Q = Process Fluid Flow Rate (L/S) R = Range = Entering – Leaving Fluid Temperature (°C) n = Number of Cycles of Concentration = CR/CM CR = Concentration in Re-circulating Water CM = Concentration in Make-Up Water... - Page 29 Water Treatment Bleed Line Calculations M A R 1 0 8 - 2 W W W . B A L T I M O R E A I R C O I L . C O M . A U...
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Page 30: Part 4 Corrosion And Scale Control
PCT COOLING TOWER Corrosion and Scale Control CORROSION AND TREATMENTS CORROSION AND SCALE CONTROL... -
Page 31: Corrosion And Treatments
Legionella. Since the quality of the ambient air and make-up water varies significantly from job site to job site, BAC strongly recommends obtaining the services of a competent water treatment specialist prior to the initial start-up of the evaporative cooling equipment. Additionally, to protect against the risk of Legionella contamination, never operate the cooling equipment without adequate biological control. -
Page 32: Corrosion And Scale Control
Corrosion and Scale Control 1. To control corrosion and scale, maintain the water chemistry of the re-circulating water within certain parameters. The specific measures required vary from system to system and are dependent on the chemistry of the make-up water, the metallurgy of the piping and heat transfer devices exposed to the re-circulating water and the temperatures at which the system will be operating. - Page 33 Corrosion and Scale Control Chemical Treatment Programs Must Meet or Exceed the Following Requirements: Corrosion and Scale Control 1. The chemicals must be compatible with the unit materials of Passivation construction as well as other materials used in the system (pipe, heat exchanger, etc.).
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Page 34: Biological Control
Biological Control 1. The warm, oxygen and nutrient rich environment inside evaporative cooling equipment provides an ideal environment conducive to the growth of algae, slime, and other micro- organisms. Uncontrolled, this can reduce heat transfer, promote corrosion and the growth of potentially harmful organisms such as Legionella. - Page 35 Corrosion and Scale Control • Check the pH of the circulating water and, if necessary, adjust it to 7.0-7.6. Then, running the pump only, treat Biological Control the system with sodium hypochlorite to maintain a level of 4 to 5 mg/l (ppm) free chlorine (as Cl2) over a six hour period.
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Page 36: Factory Authorised Parts
PCT COOLING TOWER Factory Authorised Parts THE PERFECT FIT... -
Page 37: The Perfect Fit
They are fully warranted to ensure long, trouble free operation. BAC original equipment parts also help maintain the thermal performance of CTI Certified models of BAC evaporative cooling equipment. In addition, BAC quality parts and accessories are fully compatible with other manufacturers’... - Page 38 COOLING TOWERS CLOSED CIRCUIT COOLING TOWERS ICE THERMAL STORAGE EVAPORATIVE CONDENSERS HYBRID PRODUCTS PARTS & SERVICES w w w . B a l t i m o r e A i r c o i l . c o m . a u 120 Wisemans Ferry Road, Somersby NSW 2250 ›...