BAC PCT Series Operation & Maintenance Manual Download Page 7

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W W W . B A L T I M O R E A I R C O I L . C O M . A U

M A R 1 0 8 - 2

Table

of Contents

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

Fan Drive System (Except Direct Drive Units)

Fan Drive System (Direct Drive)

Fan Motors

Fan Shaft Bearings

Locking collars

Fan Shaft

PART 2

Detailed Component Maintenance Procedures cont.

Access Door

Louvres and Eliminators

Water Distribution and Heat Transfer Section

Water Level Control

PART 3

Water Treatment

Bleed Rate

Bleed Line Calculations

PART 4

Corrosion and Scale Control

Corrosion and Treatments

Corrosion and Scale Control

Biological Control

PART 5

Factory Authorised Parts

The Perfect Fit

OPERATIONS & MAINTENANCE »

PCT

Summary of Contents for PCT Series

Page 1: ...OPERATION MAINTENANCE MANUAL PCT Cooling Towers ...

Page 2: ......

Page 3: ...er Distribution System Cold Water Basin Louvres Strainer Motor Access Door not shown Eliminators Fan Shaft not shown Fill Fan not shown Drive Train not shown Drain Overflow Motor Base not shown Make Up Assembly Construction Details ...

Page 4: ...ed to support the weight of a person or to be used as a storage or work surface for any equipment or tools WARNING When the fan speed of the unit is to be changed from the factory set speed including changes achieved by the use of a variable fan speed device steps must be taken to avoid operation at or near the fan s critical speed which could result in fan failure and possible personal injury or ...

Page 5: ... screens access panels and access doors in place For the protection of authorised service and maintenance personnel install a lockable disconnect switch located within sight of the unit on each fan motor associated with the equipment CAUTION Mechanical and operational methods must be employed to protect these products against damage and or reduced effectiveness due to possible freeze up Contact yo...

Page 6: ...otor exterior Check fan motor for proper rotation Check general condition of the fan Check and unplug fan drain holes hollow blade fans Check fan for uniform pitch Check fan for rotation without obstruction Check and recoat steel shafts with RUST VETO Recommended Maintenance Service WARNING Do not perform any service on or near the fans motors and drives or inside the unit without first ensuring t...

Page 7: ...s 13 Fan Drive System Direct Drive 14 Fan Motors 15 Fan Shaft Bearings 16 Locking collars 16 Fan Shaft PART 2 Detailed Component Maintenance Procedures cont 17 Access Door 18 Louvres and Eliminators 19 Water Distribution and Heat Transfer Section 20 Water Level Control PART 3 Water Treatment 23 Bleed Rate 24 Bleed Line Calculations PART 4 Corrosion and Scale Control 27 Corrosion and Treatments 28 ...

Page 8: ...PCT COOLING TOWER Operation and Maintenance INITIAL AND SEASONAL START UP EXTENDED SHUTDOWN 1 ...

Page 9: ...ted dirt and debris Remove clean and replace the basin strainer Inspection Conduct external inspection of the equipment Check for leaks corrosion and any structural damage Conduct internal inspection of the equipment Check for anything unusual such as structural or mechanical component damage Inspect piping and connections Thoroughly inspect the fan s for any mechanical or physical damage At seaso...

Page 10: ...attern as described in Water Distribution System and Heat Transfer System on Page 18 Open the valve in the tower bleed line and adjust the bleed by closing or opening the valve Verify fan tip clearance is between 3mm and 13mm For initial start up bump the fan motor and note the direction of rotation Start the fan motor s and verify proper fan rotation without obstruction The fan s should rotate in...

Page 11: ...ng Clean all the debris such as leaves and dirt from the interior and exterior of the unit Leave the cold water basin drain open so rain and melting snow will drain from the tower Clean the basin strainer and re install Cover the fan discharge to keep out dirt and debris For PCT belt driven units lubricate the fan shaft bearings motor base and motor base adjusting screw Apply RUST VETO to steel sh...

Page 12: ...dures COLD WATER BASIN FAN 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 2 ...

Page 13: ...en necessary to maintain the recommended operating level Consult Water Level Control on Page 20 for information on how to set and maintain basin operating level Inspection Maintenance Inspect the cold water basin regularly Remove trash or debris accumulated in the basin or on the strainer Quarterly or more often if necessary drain clean and flush the entire cold water basin with fresh water This w...

Page 14: ... no play or slippage Inspect each blade for excessive scale build up that could cause vibration 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 The clearance should be between 3mm...

Page 15: ... then check drive alignment belt tensioning as per procedures outlined below Seasonal Start Up Readjust the tension on the belt Operation After the first 24 hours of operation readjust the belt tension on a new unit start up or installation of a new belt Thereafter check the belt condition monthly and adjust tension as necessary Readjust tension at least once every three months Belt tension check ...

Page 16: ...belt tension During adjustment of belt tension the drives should be rotated several times by hand to evenly distribute the tension throughout the belt 4 When the belt is properly tensioned retighten the locking nuts on the Motor Base Adjusting Screws 5 Tighten guard nuts Note There should be no chirp or squeal when the fan motor is started NOTE There should be no chirp or squeal when the fan motor...

Page 17: ...as shown in Figure 5 indicating that the drives are properly aligned There should be no more than 1 5mm deviation from four points of contact In case of realignment loosen the motor sheave and align it with the fan sheave Allow 6mm for draw up as the bushing screw is retightened Fan Drive System Direct Drive Units Drive Train The standard fan motor used on direct driven PCT towers is a TEAO Totall...

Page 18: ...n the motor terminal box 6 Turn on unit and check amp draw does not exceed nameplate rating Note If unit is not run for a prolonged time or motor is stored with tower in kit form the motor insulation should be checked with a megger insulation tester prior to starting the motor If motor is stored it should be in a clean dry place have the shaft rotated occasionally Storage areas should not be subje...

Page 19: ...itial Start up Normally no lubrication is required since the bearings have been lubricated at the factory prior to shipment However if the cooling tower has been stored at the job site for more than 1 year both bearings should be lubricated with new grease before initial operation When lubricating purge the old grease from the bearing by gradually adding grease until a bead of new grease appears a...

Page 20: ...le holding the shaft 3 Retighten the set screw Fan Shaft The fan shaft is fabricated from stainless steel 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 This involves 1 Removal of the protective coating wit...

Page 21: ...n and remove the knobs that hold the door in place Larger units are provided with convenient anchor points to assist in removing the door and securing the door to the unit when removed Figure 8 Access Door Anchor Points Detailed Component Maintenance Procedures Locking Collars Fan Shaft Access Door WARNING The access door should not be removed without first ensuring the fan and pump motors have be...

Page 22: ... access panel 2 Inspect and clean thoroughly to remove all debris and deposits such as algae scale etc 3 Repair or replace damaged or defective bundles Replacement bundles are available through your local BAC representative Heat trace and insulate all exposed water piping including pump piping below the overflow level external header cleanout and make up water lines with electrical heater tape NOT...

Page 23: ...t if necessary Inspect the valve annually for leakage Replace the valve seat if necessary Maintain the make up water supply pressure between 100 and 350 kPa for proper operation BAC recommends a surge protector provided by others for pressures over 350 kPa Set the initial basin water level by adjusting the wing nuts so that the make up valve is completely closed when the water level in the cold wa...

Page 24: ...ned lengths extend from an electrode holder into the cold water basin Clean the stainless steel electrodes periodically to prevent accumulations of scale corrosion sludge or biological growth which could interfere with the electrical circuit The water level is maintained at the recommended operating level regardless of the system thermal load Therefore it is not recommended that the operating leve...

Page 25: ... W W W B A L T I M O R E A I R C O I L C O M A U M A R 1 0 8 2 Detailed Component Maintenance Procedures Water Level Control Mechanical Make up Valve Assembly Optional Electric Water Level Control Package ...

Page 26: ...PCT COOLING TOWER Water Treatment BLEED RATE BLEED LINE CALCULATIONS 3 ...

Page 27: ...as the cycles of concentration Specifically cycles of concentration is the ratio of the concentration of dissolved solids for example chlorides sulphates etc in the re circulating water to the concentration of the same material in the make up water 3 In order to optimise heat transfer efficiency and maximise equipment life bleed or blow down a small amount of re circulating water from the system T...

Page 28: ...l Heat Rejection THR 2 The evaporation rate L hr is 6 3 x R C x water flow The following example illustrates a bleed rate calculation Closed Circuit Cooling Tower Process Fluid Flow Rate 50 L S Range 5 5 C Maximum Allowable Chloride Concentration 250 ppm Concentration of Chlorides in Make Up Water 45 ppm Solution E 6 3 x R x flow 6 3 x 5 5 x 50 1732 5 L hr n CR CM 250 45 ppm 5 55 Bleed Rate B E n ...

Page 29: ...23 W W W B A L T I M O R E A I R C O I L C O M A U M A R 1 0 8 2 Water Treatment Bleed Line Calculations ...

Page 30: ...PCT COOLING TOWER Corrosion and Scale Control CORROSION AND TREATMENTS CORROSION AND SCALE CONTROL 4 ...

Page 31: ...irt and cleaned with soap and water as necessary Also FRP components should be inspected for any penetration of gel coat or UV veil Such penetrations should be repaired immediately Corrosion and Treatments 1 Corrosion Red rust on steel components and white rust on galvanised surfaces will affect the longevity of the unit 2 Scale formation Scale not only reduces heat transfer and system efficiency ...

Page 32: ... raise the allowable level of dissolved solids without the risk of scale and corrosion 3 Keep the chemically treated water within the guidelines given in the below table Your water treatment specialist may recommend more conservative limits than those shown in the table Quality Guidelines for Chemically Treated Circulating Water Galvanised steel units require passivation in order to prevent white ...

Page 33: ...ter basin or water distribution system as this can severely damage areas directly contacted 3 When chlorine is added to the system free residual chlorine should not exceed 1 ppm except as noted in start up and shutdown section Exceeding this limit may accelerate corrosion Passivation 1 Passivation is the formation of a protective passive carbonate layer on galvanised steel surfaces 2 On the newly ...

Page 34: ...system circulating pump Diluted liquid biocides may be added directly to the cold water basin 4 If ozone water treatment is used at no point should concentrations exceed 0 5 ppm 5 Initial Start up Start up following a Shutdown Period To minimise the risk of biological contamination during a shut down period of three days or more it is recommended that the entire system evaporative cooling equipmen...

Page 35: ...est kits for measuring the free residual of chlorine are commercially available Start the fan only after this treatment period is completed When it is not practical to drain the system during shut down periods install a by pass line with shut off valves to permit the re circulating water to circulate throughout the system including the unit basin while bypassing the Prime Surface Coil section of t...

Page 36: ...PCT COOLING TOWER Factory Authorised Parts THE PERFECT FIT 5 ...

Page 37: ...atible with other manufacturers equipment For Service and Preventative Maintenance BAC products are designed for long trouble free operation and BAC factory authorised parts provide everything you need to service and maintain your evaporative equipment with confidence To ensure optimum performance and maximum service life it is important that a program of regular inspection and maintenance be comp...

Page 38: ... 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 Telephone Australia 1300 134 622 Telephone New Zealand 0800 225 842 ...

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