EVAPCO AT Series Guida alla risoluzione dei problemi

Bulletin 113-E Metric

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 bvba

Heersterveldweg 19

Industrieterrein Oost

3700 Tongeren, Belgium

Phone: (32) 12 395029

Fax: (32) 12 238527

E-mail: evapco.europe@ evapco.be

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: [email protected]

EVAPCO Europe GmbH

Insterburger Straße, 18

D-40670 Meerbusch, Germany

Phone: (49) 2159-6956-0

Fax: (49) 2159-6956-11

Email: [email protected]

EUROPEAN

OPERATION AND MAINTENANCE INSTRUCTIONS

For EVAPCO Induced Draft and Forced Draft Cooling Towers

For EVAPCO Authorized Parts and Service,

Contact Your Local Mr. GoodTower®Service Provider

or the EVAPCO Plant Nearest You

www.evapco.eu

AT UAT LSTE LPT PMTQ

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

Fan Shaft Ball Bearings .............................................................................................................9

Recommended Bearing Lubricants.............................................................................9

Fan Shaft Sleeve Bearings...................................................................................................................10

Fan Belt Adjustment .............................................................................................................................10

Fan and Motor Sheave Alignment............................................................................................ 11

Fan System Capacity Control ..................................................................................................12

Fan Motor Cycling.....................................................................................................12

Two Speed Motors ....................................................................................................12

Variable Frequency Drives........................................................................................12

Identify and Lock-out Harmful Resonant Frequencies...................................................................13

Recirculated Water System Routine Maintenance ..........................................................................13

Suction Strainer Assembly .......................................................................................................14

Cold Water Basin .....................................................................................................................14

Operating Water Levels ...........................................................................................................14

Water Make Up Valve ..............................................................................................................15

Drift Eliminators........................................................................................................................15

Pressurized Water Distribution System....................................................................................15

Bleed-Off Valve ........................................................................................................................16

Water Treatment and Water Chemistry ............................................................................................17

Bleed or Blowdown ..................................................................................................................17

Galvanized Steel - Passivation ................................................................................................17

Water Chemistry Parameters...................................................................................................18

Control of Biological Contamination.........................................................................................18

Gray Water and Reclaimed Water ...........................................................................................19

Air Contamination ....................................................................................................................19

Stainless Steel ..................................................................................................................................19

Maintaining the Appearance of Stainless Steel........................................................................20

Cleaning Procedures for Stainless Steel .................................................................................20

Cold Weather Operation ....................................................................................................................21

Troubleshooting .................................................................................................................................25

Replacement Parts .............................................................................................................................28

 PartIdenticationDrawings

AT/UAT - 1,2 m Wide Units .......................................................................................29

AT/UAT - 2,4 and 2,6 m Wide Cells ..........................................................................30

AT/UAT - 3 and 3,6 m Wide Cells .............................................................................31

AT/UAT - 4,2 m Wide Cells .......................................................................................32

LPT - All Models........................................................................................................33

LSTE - 1,6 m Wide Units ..........................................................................................34

LSTE - 2,4 and 3 m Wide Units ................................................................................35

PMTQ .......................................................................................................................36

AT/UAT with Super Low Sound Fan - 2,4 and 2,6 m Wide Cells ..............................37

AT/UAT with Super Low Sound Fan - 3; 3,6 and 4,2 m Wide Cells ..........................38

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. This bulletin should

be used as a guide to establish a program. A clean and properly serviced unit will provide a long service life and

operateatpeakefciency.

This bulletin includes recommended maintenance services for unit start up, unit operation and unit shutdown and the

frequency of each. Please note: the recommendations of frequency of service are minimums. Services should be

performed more often when operating conditions necessitate.

Become familiar with your evaporative cooling equipment. Refer to the isometric drawings located on pages 30-39 for

information on the arrangement of components in your equipment.

If you should require any additional information about the operation or maintenance of this equipment,

contact your local EVAPCO representative. You may also visit www.evapco.eu for more information.

Safety Precautions / Remaining Risks

Qualiedpersonnelshouldusepropercare,proceduresandtoolswhenoperating,maintainingorrepairingthisequipment

in order to prevent personal injury and/or property damage. The warnings listed below are to be used as guidelines only.

WARNING: Evaporative cooling equipment is considered as “Partly completed machinery”. “Partly completed machinery” is

a totality which almost forms a machinery but in itself cannot fulfil any particular function. The considered cooling

equipment is missing the components to safely connect it to the source of energy and motion in a controlled way.

The considered cooling equipment is custom made but is not designed to address the specific needs and safety

measures for a specific application. Each application requires a unique designed and integrated operational,

control and safety strategy that links all components of the installation and eventually a back-up system in a safe

and controlled way.

WARNING: This equipment should never be operated without fan screens and access doors properly secured, locked and

in place.

WARNING: For assembling or disassembling the unit or unit sections, please follow the rigging instructions or the

instructions on the yellow labels on the individual unit sections.

WARNING: During maintenance operations, the worker must use adequate personal protection equipment (PPE - A

minimum, but not limited list of PPE are safety shoes, glasses, gloves, respiration protection, helmet) as

prescribed by local authorities.

WARNING: For any exceptional, non routine work to be carried out, protection and adequate safety measures should be

considered and a Last Minute Risks Assessment (LMRA) must be made by an authorized person in accordance

with safety requirements of the country.

WARNING: A lock-out / tag-out procedure, integrated with the Process Control System, must be foreseen by the

customer. Before performing any type of service or inspection of the unit, make certain that all power has

been disconnected and locked in the “OFF” position.

WARNING: The top horizontal surface of any unit is not intended to be used as a working platform. No routine service

work is required from this area. For any exceptional, non routine work to be carried out on top of the

unit, use ladders, PPE and adequate safety measures against the risk of a fall, in accordance with safety

requirements of the country in question.

WARNING: The recirculating water system may contain chemicals or biological contaminants including Legionella

Pneumophila, which could be harmful if inhaled or ingested. Direct exposure to the discharge airstream

and the associated drift generated during operation of the water distribution system and/or fans,

or mists generated while cleaning components of the water system, require respiratory protection

equipment approved for such use by governmental occupational safety and health authorities.

WARNING: To avoid water and air contamination as a result of biological fouling, the cooling equipment must be

maintained in accordance, but not limited to the operating and maintenance instructions. All local

legislation related to evaporative cooling equipment must be respected.

WARNING: Accessories like platform and ladders are optional. In case these options are not taken in consideration, the

customer must design the installation to comply with local safety and access requirements and legislation.

WARNING: Sound reducing options are available. In case these options are not taken in consideration, the customer

must design the installation to comply with local sound requirements and legislation.

Installation Precautions

WARNING: The water inlet and outlet connections are not designed to support piping. The piping always need to be

supported (by others).

Storage 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)

2A(2)

2(2)

17A

2 EVAPCO LOGO (both sides)

2A RIGGING INSTRUCTIONS (both ends)

33 WATER IN

17A WARNING ELIMINATORS

35 DO NOT COVER ELIMINATORS

Initial and Seasonal Start-Up Checklist

General

1. Verifythattheoverallinstallationreects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conrmbothspeedsturninthesamedirection.

3. Verify all safety interlocks work properly.

4. For units operating with a variable frequency drive, make certain that minimum speed requirements have

been set. Check with VFD manufacturer for recommended minimum speeds and recommendations on

locking out resonance frequencies.

5. Verify that the sensor used for fan sequencing and/or by-pass valve control is located downstream of the

point where the by-pass water mixes with the condenser supply water, if applicable.

6. Verify that a water treatment plan has been implemented including passivation of galvanized steel units. See

“Water Treatment” section for more details.

7. For units subject to freezing climates, high humidity climates, or idle periods lasting 24 hours or more,

motor space heaters are suggested and (if equipped) should be energized. Alternatively, fan motors may be

energized for 10 minutes, twice daily, to drive any moisture condensation out of the motor windings.

8. If the unit is going to sit idle for an extended period of time, follow all manufacturers’ fan motor and pump

instructions for long term storage. Plastic sheets or tarps should never be used to protect a unit during storage.

This practice can trap heat inside the unit, and could potentially cause damage to plastic components. See your

local EVAPCO representative for additional information on unit storage.

BEFORE BEGINNING ANY MAINTENANCE, BE CERTAIN THAT THE POWER IS

TURNED OFF AND THE UNIT IS PROPERLY LOCKED AND TAGGED OUT!

Initial and Seasonal Start-Up

1. Clean and remove any debris, such as leaves and dirt from the air inlets.

2. Flush the cold water basin (with the strainer screens in place) to remove any sediment or dirt.

3. Remove the strainer screen, clean and reinstall.

4. Checkmechanicaloatvalvetoseeifitoperatesfreely.

5. Inspect water distribution system nozzles and clean as required. Check for proper orientation. (This is not

required at initial start-up. The nozzles are clean and set at the factory).

6. Check to ensure drift eliminators are securely in place and in proper orientation.

7. Adjust fan belt tension as required. See “Fan Belt Adjustment” section.

8. Lubricate fan shaft bearings prior to seasonal start-up.

9. Turn the fan(s) by hand to insure it turns freely without obstructions.

10. Visually inspect the fan blades. Blade clearance should be approximately 10 mm (min. 6 mm) from tip of

blade to the fan cowl. The fan blades should be securely tightened to the fan hub.

11. If any stagnant water remains in the system including “dead legs” in the piping, the unit must be disinfected

prior to the fans being energized. Please refer to ASHRAE Guideline 12-2000 and CTI Guideline WTP-148

for more information and consult local legislation prior to start-up.

12.Fillthecoldwaterbasinmanuallyuptotheoverowconnection.

13. Allnewevaporativecoolingequipmentandassociatedpipingshouldbepre-cleanedandushedtoremove

grease, oil, dirt, debris and other suspended solids prior to operation. Any pre-cleaning chemistry should be

compatible with the cooling equipment’s materials of construction. Alkaline formulations should be avoided

for systems which include galvanized materials of construction [EU].

After the unit has been energized, check the following:

1. Adjustmechanicaloatvalveasrequired.

2. Unitbasinshouldbelledtotheproperoperatinglevel.See“RecirculatingWaterSystem–Operating

Levels” section for more details.

3. Verify fan is rotating in proper direction.

4. Measure voltage and current on all three power leads. The current must not exceed the

motor nameplate full load amp rating.

5. Adjustbleedvalvetoproperowrate.Maximumbleed-offis3,2l/minper100kW.

 Consultyourqualiedwatertreatmentpersontonetunetheminimunbleednecessary.

MAINTENANCE

CHECKLIST

PROCEDURE

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

1. Clean pan strainer – monthly or as needed

2. Clean and ush 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 oat

valve if necessary – monthly

5. Check water distribution system and spray

pattern – monthly

6. Check drift eliminators – quarterly

7. Check the fan blades for cracks, missing

balancing weights, and vibrations - quarterly

8. Check sheaves and bushings for corrosion.

Scrape and coat with ZRC - annually

9. Lubricate fan shaft bearings* - every 1000 hours

of operation or every three months

10. Lubricate fan motor bearings – see mfg’s

instructions. Typically for non-sealed bearings,

every 2-3 years

11. Check belt tension and adjust – monthly

12. Sliding motor base – Inspect and grease –

annually or as needed

13. Check fan screens, inlet louvers and fans.

Remove any dirt or debris - monthly

14. Inspect and clean protective nish – annually

- Galvanized: scrape and coat with ZRC

- Stainless: clean and polish with a stainless

steel cleaner.

15. Check water quality for biological contamination.

Clean unit as needed and contact a water

treatment company for recommended water

treatment program** – regularly

* See maintenance manual for start-up instructions and lubrication recommendations

** Cooling Towers must be cleaned on a regular basis to prevent the growth of bacteria including Legionella Pneumophila

MAINTENANCE

CHECKLIST

(optional accessories)

PROCEDURE

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

1. Coupling/Shaft – Inspect ex 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 – one month after start-up and

semi-annually

4. Heater – Inspect elements for scale build-up –

quarterly

5. Electronic Water Level Controller – Inspect

junction box for loose wiring and moisture –

semi-annually

6. Electronic Water Level Controller – Clean probe

ends of scale build-up – quarterly

7. Electronic Water Level Controller – Clean inside

the standpipe – annually

8. Solenoid Make-up Valve – Inspect and clean

valve of debris – as needed

9. Vibration Switch (mechanical) – Inspect

enclosure for loose wiring and moisture – one

month after start-up and monthly

10. Vibration Switch – Adjust the sensitivity – during

start-up and annually

11. Sump Sweeper Piping – Inspect and clean

piping of debris – semi-annually

DURING IDLE PERIODS:

1. Two or More Days: Energize motor space

heaters – or run motors for 10 minutes twice daily

2. One Month or longer: Rotate motor shaft/fan

10 turns – bi-weekly

3. One Month or longer: Megger test motor

windings – semi-annually

Seasonal Shut-Down Checklist

When the system is to be shut down for an extended period of time, the following services should be performed.

1. The evaporative cooling unit cold water basin should be drained.

2. Thecoldwaterbasinshouldbeushedandcleanedwiththesuctionstrainerscreensinplace.

3. The suction strainer screens should be cleaned and re-installed.

4. The cold water basin drain should be left open.

5. The fan shaft bearings and motor base adjusting screws should be lubricated. This should also be

performed if the unit is going to sit idle prior to start up.

6. The water make up valve needs to be closed. All water make-up piping needs to be drained, if not heat

traced and insulated.

7. Thenishoftheunitshouldbeinspected.Cleanandrenishasrequired.

8. The fan bearings and motor bearings need to be turned at least once a month by hand. This can be

accomplished by making sure the unit’s disconnect is locked and tagged out, and grasping the fan

assembly, rotating it several turns.

9. Energize motor space heaters.

Basic Cooling Tower Sequence of Operation

System Off / No Load

The system pumps and fans are off. If the basin is full of water a minimum basin water temperature of 4ºC must

be maintained to prevent freezing. This can be accomplished with the use of optional basin heaters. See the

“Cold Weather Operation” section of this bulletin for more details on cold weather operation and maintenance.

System / Condensing Temperature Rises

The system pump turns on. The unit will provide approximately 10% cooling capacity with only the pump running.

NOTE:Iftheloadissuchthatsimplyrunningthesystempumpwiththeunitfanmotoridleissufcient,

motor space heaters (if equipped) should be energized while the motor is idle. Alternatively, the motor can

be energized twiced daily for a minimum of 10 minutes to protect the motor insulation from damage.

If the system temperature continues to rise, the unit fan is cycled on. For a variable speed controller, the

fansareturnedontominimumspeed.Seethe“FanSystem–CapacityControl”sectionofthisbulletinfor

more details on fan speed control options. If the system temperature continues to rise, then the fan speed

is increased as required, up to full speed.

NOTE: During sub-freezing weather the minimum recommended speed for variable speed controllers

is 50%. ALL FANS IN OPERATING CELLS OF MULTIPLE CELL UNITS MUST BE CONTROLLED

TOGETHER TO PREVENT ICING ON THE FANS.

System Temperature Stabilizes

Control the leaving water temperature by modulating the fan speeds with variable speed drives or by

cycling fans on and off with single or two-speed drives.

System Temperature Drops

Decrease the fan speed, as required.

System Off / No Load

The system pump turns off. The starter interlock will energize any optional basin heaters in cold weather.

The recirculation pump should not be used as a means of capacity control, and should not be cycled

frequently. Excessive cycling can lead to scale build-up, and reduce wet and dry performance.

Bypass Mode

During winter months when cooling load is minimal, bypass mode may be used as a form of capacity

control. Bypass mode allows the water to “bypass” the tower’s water distribution system and deposits the

inlet water directly into the cold water basin. Alternatively, the incoming water bypass can be piped directly

to the return condenser header pipe. Please note: The location of the bypass valve should be 4,5 m

below the cooling tower cold water basin elevation to assure proper operation and prevent cavitation. This

bypass mode should be continued until the total water inventory reaches an acceptable temperature level

(usuallyabout27°C),atwhichtimethebypassmaybeclosedtocausetotalowoverthell.

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. During the defrost cycle, the cooling tower fan(s) are reversed at no more than half speed

whilethesystempumpowswaterthroughthecoolingtower’swaterdistributionsystem.Operatingthe

unit in “reverse” will melt any ice that has formed in the unit or on the intake louvers. All multi-speed or

VFD duty motors supplied by EVAPCO for induced draft units, are capable of reverse operation.

Defrost cycles are NOT recommended for forced draft cooling towers. In these units, allowing the leaving

water temperature set point to rise causes the fans to be off for very long periods of time, which increases

the fan drive component potential for freezing. In lieu of a defrost cycle, forced draft units should be

operated at low speed (with a 2-speed motor) or minimum speed (no lower than 25% with a variable

frequency drives) in order to maintain positive pressure inside the unit to help prevent ice formation on the

fan drive components.

NOTE: MINIMUM CONTROL POINT FOR WATER SHOULD NEVER BE LOWER THAN 5°C.

Fan System

The fan systems of both centrifugal and axial driven units are rugged, however, the fan system must

be checked regularly and lubricated at the proper intervals. The following maintenance schedule is

recommended.

Fan Motor Bearings

EVAPCO evaporative cooling units use either a T.E.A.O. (Totally Enclosed Air Over) or a T.E.F.C. (Totally

EnclosedFanCooled)fanmotor.Thesemotorsarebuiltto“CoolingTowerDuty”specications.Thefan

motor bearings for motors up to 30 kW are lubricated for the lifecycle of the bearings, higher motor powers

require relubrication (please see motor manual for more detail). All fan motors are supplied with special

moisture protection on the bearings, shaft and windings. After extended shut-downs, the motor should be

checked with an insulation tester prior to restarting the motor.

Fan Shaft Ball Bearings

Lubricate the fan shaft bearings every 1,000 hours of operation or every three months for induced draft units.

Lubricate the fan shaft bearings every 2,000 hours of operation or every six months for forced draft units. Use

any of the following synthetic waterproof, inhibited greases which are suitable for operation between -40°C

and 120°C. (For colder operating temperatures, contact the factory).

Chevron - Multifak Premium 3 Total - Ceran WR2 or similar

Shell Alvanias

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 Located just beside the fan casing

access door

InducedDraftUnits–2,6mwide Located just beside the fan casing

access door

InducedDraftUnits–3mwideand6mwide Located inside the fan casing

access door

InducedDraftUnits–3,6mwideand7,2mwide Located inside the fan casing

access door

InducedDraftUnits–4,2mwideand8,4mwide Located inside the fan casing

access door

LSTE Forced Draft Units Located on the front of the unit

LPT Forced Draft Units Located on the front of the unit

PMTQ Forced Draft Units Located on the front of the unit

Table 1 – Location of Grease Lube Line Fittings for Belt Driven Units

Please note, the removal of the fan screens is not necessary on forced draft units

to access the extended lube line ttings.

Fan Shaft Sleeve Bearings – (1,2 m wide LSTE units only)

Lubricate the intermediate sleeve bearing(s) before unit start up. The reservoir should be checked

severaltimesduringtherstweektoensurethattheoilreserveisbroughttofullcapacity.After

therstweekofoperation,lubricatethebearing(s)every1.000hoursofoperationorevery

threemonths(whicheveroccursrst).Hightemperaturesorpoorenvironmentalconditionsmay

necessitate more frequent lubrication. The oil reservoir consists of a large felt packed cavity within

thebearinghousing.Itisnotnecessarytomaintaintheoillevelwithinthellercup.

Use one of the following industrial grade, non-detergent mineral oils. Do not use a detergent

based oil or those designated heavy duty or compounded. Different oils may be required

when operating at temperatures below -1°C continuously. Table 2 provides a short list of approved

lubricants for each temperature range. Most automotive oils are detergent based and may not be

used. Detergent oils will remove the graphite in the bearing sleeve and cause bearing failure.

Ambient Temp. Texaco Mobil Exxon Total

-32°C to 0°C - DTE Heavy - -

-17°C to 43°C - - - -

0 to 38°C Regal R&O 220 DTE Oil BB Teresstic 220 -

Table 2 - Sleeve Bearing Lubricants

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.

Fan Belt Adjustment

Thefanbelttensionshouldbecheckedatstartupandagainaftertherst24hoursofoperation

to correct for any initial stretch. To properly adjust the belt tension, position the fan motor so that

thefanbeltwilldeectapproximately13mmwhenmoderatepressureisappliedmidwaybetween

the sheaves.

Figure1andFigure2showtwowaystomeasurethisdeection.Belttensionshouldbecheckedon

a monthly basis. A properly tensioned belt will not “chirp” or “squeal” when the fan motor is started.

Figure 1 – Method 1 Figure 2 – Method 2

BELT

DRIVER

SHEAVE

DRIVEN

SHEAVE

STRAIGHT EDGE

13 mm DEFLECTION =

PROPER BELT TENSION

BELT

DRIVER

SHEAVE

DRIVEN

SHEAVE

TAPE MEASURE

13 mm DEFLECTION =

PROPER BELT TENSION

Altri manuali per AT Series

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