Cooling Tower Manual

Research-Cottrell Cooling Division A620-001-
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HAMON THERMAL (TIANJIN) Co.,Ltd. DATE: 2016-02-29
OPRATION&MAINTANCE MANUAL FOR:

COOLING TOWER
OPERATION&MAINTANCE MANUAL FOR

COOLING TOWER

HTT Document. Nr. : C1509811-101-A620-001-OMM
PROJECT INFORMATION/
PROJECT NAME/ Parkistan Bhikki 1180MW209HCCPP/1180MW209H

PLANT LOCATION/: Punjab provinceParkistan/ Punjab
CLIENT/CUSTOMER/Harbin electric international company limited/
REV DATE AUT. CHE. APP. Description of Revision Status

00 2016.2.26 KGF First Issue PREL
01
02
03
04
05
06
PREL: PRELiminary ; APR: APpRoved ; CRT: ceRTified ; CFC: Certified For Construction ; ASB: As Built
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Contents
1 BRIEF INFORMATION ON TOWER ...............................................................................................3
1.1 INFORMATION ON A COUNTER FLOW TOWER ................................................................................................ 3
2 OPERATIONAL SAFETY ...................................................................................................................4
2.1 COOLING TOWERS - PREVENTION INSTRUCTIONS ......................................................... 4
3 FUNCTION AND DESIGN OF SYSTEM .............................................................................11
3.1 WORKING PRINCIPLE ................................................................................................................................... 11

3.2 COOLING RANGE / HEAT LOAD / ........................................................................................................... 11
3.3 COLD WATER TEMPERATURE .................................................................................................................. 12
3.4 TECHNICAL DATA OF THE COOLING TOWER ................................................................................ 12
3.5 THERMAL DESIGN ........................................................................................................................................ 12
3.6 QUIPMENT DESIGN ...................................................................................................................................... 13
4 OPERATION INSTRUCTIONS .........................................................................................................14
4.1 SAFETY RECOMMENDATIONS ...................................................................................................................... 14

4.2 HYDRAULIC AND MOTOR CONNECTIONS ................................................................................ 14
4.3 FAN BLADE ANGLE SETTING AND ABSORBED POWER ......................................................... 15
4.4 SPECIFIC INSTRUCTIONS FOR FIRST START UP ..................................................................................... 16
4.5 START UP AND OPERATING INSTRUCTIONS WITH NON FREEZING CONDITIONS 18
4.6 START UP AND OPERATING INSTRUCTIONS WITH FREEZING CONDITIONSELLIPSIS..20
4.7 CELL SHUT DOWN FOR MAINTENANCE .................................................................................... 29
4.8 COOLING TOWER SHUT DOWN ................................................................................................................ 30
4.9ANNEX : FUNCTIONAL DIAGRAM FOR COOLING TOWER START UP AND OPERATION 31
5 MAINTENANCE INSTRUCTIONS ....................................................................................................33
5.1 GENERAL COMMENTS ............................................................................................................................................ 33

5.2 BASIN ................................................................................................................................................................ 33
5.3 FRAMEWORK ............................................................................................................................................... 34
5.4 FAN STACK .......................................................................................................................................................... 34
5.5 SHELL ............................................................................................................................................................. 34
5.6 FILLING ............................................................................................................................................................... 34
5.7 WATER DISTRIBUTION .................................................................................................................................... 35
5.8 DRIFT ELIMINATORS .......................................................................................................................................... 35
5.9 FAN DRIVING SYSTEM ............................................................................................................................. 36
5.10 CONCLUSION ....................................................................................................................................................... 37
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1 BRIEF INFORMATION ON TOWER
1.1 Information on a counter flow tower
The tower is mainly composed of:

a) A frame work and its cladding (1). 1
b) A system of fluid distribution and
dispersion above the fill (2).2
c) The exchange surfaces forming
the filling (3).3
d) A basin collecting the fluid cooled
and from which the circulating
pumps feed the various .
utilities(4)4
e) A fan moving the air necessary to
the heat exchange (5).
5
f) Drift eliminators which catch
practically all the water droplets
in the air before it is rejected to
the atmosphere (6) .6
NOTE: THE FAN (5).CONSISTS OF FAN BLADE, FAN BELL, GEARBOX AND MOTOR
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2 OPERATIONAL SAFETY
2.1 COOLING TOWERS - PREVENTION INSTRUCTIONS
HAZARDS LINKED TO THE SITE EXAMPLES OF MEANS TO BE USED

Presence of obstacles Designation of a duly authorized safety inspector
live electricity lines
Overhead piping
Buildings
Difficulty of access to the installation site Drawing up a traffic plan and defining the dangers and
means of safeguard
Explosiveness Explosion-proof tools
Strict management for combustion source
The installation of electrical equipment need to conform to the

requirement.
Asphyxia or other specific hazards due to gases Safety instructions.Training of staff in chemical hazards

Adapting the equipment and tools

Defining the individual and collective safety
equipment
Maintain good air circulation in the space

The chemicals need to be stored according to the
requirement, identifiable, check regularly

HAZARDS LINKED TO THE MATERIALS EXAMPLES OF MEANS TO BE USED
Fire/explosion / Hot spot work only to be carried out by specialists trained

in the knowledge of the hazards and equipped with the
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necessary protection (flame-retardant tarpaulins,

extinguishers, etc.) and one safety inspector per critical
site.

During the period of hot work, from the working area there
should not be combustible gas discharge within 30m, should not
be emissions flammable liquid within 15 m. And below the
working area, there should not be flammable solvent cleaning or

spraying operations at the same time within 10m.
30m
15m
10m

Fire and entry permit.

When using the welding machine and other moving or hand-held
electric tools, one brake and one Leakage protector should be
connected the
machine.

When the work finished, confirm there isnt any residue
Pollution of the water in the basin by Make access
kindling to leaving.
before the basin impossible
:

the circuit to be cooled (Process of use)

treatment against algae, scale, etc.)

strength of materials Don not try to stand on the filling directly. Light wooden
plate is necessary to lay on
it.
HAZARDS LINKED TO PEOPLE
EXAMPLES OF MEANS TO BE USED
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Ignorance of the structures Training in the maintenance of internal equipment

Locking and tagging error
Risk of confusion between several pieces of Training in mechanical and electrical hazards
equipment or electrical installations
Having in the immediate vicinity of each cooler cell, a pad
lockable, isolating device in isolating position and fitted
with breaking contacts
Physical state (dizziness, allergies to algae, wood, Medical fitness for working at heights, carrying loads,
etc. to products which may be used on site, dust, operating a cradle elevator.
etc.)

Medical inspection
To develop the PPE (allergies)
dress standard.
Non-compliance with safety instructions and
failure to wear individual protective Employment of trained and properly authorized

equipment responsible staff

HAZARDS LINKED TO USE EXAMPLES OF MEANS TO BE USED

Stoppage of the fan on tripping of detector Resetting the vibration controller and restarting after
meticulous examination of the mechanical assembly to
Faults on motor-fan set (broken blades, discover the real fault.
etc.)
Periodic check on the operation of the vibration detector

Keeping the maintenance record up to date

Fall into the basin (shock, drowning) Making access to the basin impossible and the setting the
identification of Deep Water. Be Careful!,

Rot in framework that could cause the equipment Annual inspection by a specialist experienced in coolers.
or the coolant to
fall. Prohibition of access to unauthorized
persons.
(1) Refer to the manufacturer's instructions
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HAZARDS LINKED TO ASSEMBLY EXAMPLES OF MEANS TO BE USED
Electricity Installation and connection according to the standards in

force.
Equipotential of earthing
The electrical line must match the load.

Protection against direct and indirect contacts

Safeguarding of accesses
Emergency shut-down device
Lightning protection
Installation of lighting
Electrical measurements relevant staff qualification

Quality of tools Ensuring good condition and conformity with local
regulation if any

Quality of individual Protection equipment Ensuring conformity of the machines and the validity of
the regulatory inspection date

Lifting loads
Ensuring a firm and even floor for the stability of the
machine

Marking out the work
area.

When there is great snow, rain, fog, 6 above wind,
shouldnt work
out.
Lifting members of staff Ensuring staff training

Ensuring the validity of staff qualification
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Use of ladders Ensuring that the rules for use are
followed.
The ladder should be checked before using. When the situation
was confirmed fine. The ladder can be
used.
Assembling and fitting work Compliance with local obligations.

Compliance with the speed limits within the confines of
the enterprise
Authorization from the employer for driving materials-
handling trucks
Training in gestures [signals] and postures

Compliance with the permissible load limits in manual
handling
Conformity of tools (validity of regulatory
inspections)
Authorization of staff for working at heights and for
operating the staff lift

Employment of authorized staff in framework assembly
and mechanical fitting
Use of regulatory fixed or movable flooring and
scaffolding
HAZARDS LINKED TO MAINTENANCE EXAMPLES OF MEANS TO BE USED

Hazard related to equipment operation Total isolationand energy dissipation of the equipment
(electrical, mechanical and
hydraulic)

Locking of the isolating equipment

Precise signalling of locking
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Separation of circuits
Issue of a certificate of isolation
Issue of the access permit
Biological hazards : Carry out analyses before action.

- Development of various bacteria Wear a breathing mask type P3 SL . P3 SL
Inform the company doctor.
- Amibia, Legionella, Inform the participants of the risks and initial symptoms
etc. of the disease.
Information to persons about health and safety rules
Risk of falling in roof access trap. Installation of handrails as soon as the trap is opened

Authorizing and appointing persons responsible for
opening and closing the trap (shutdown procedure).

Allowing access after installation of protection means,
favouring collective protection (scaffolding - flooring).
Use of grating (minimum dimensions 600 x 1800 mm)
above supporting beams (max. load/grating = 100 daN)
to move over the equipment.
Risk of the fan "feathering" (rotation without Preventing rotation by any suitable system
power)
Risk of vibration caused by operation of the checking the stability of the cooler and stopping the fan in
attached neighbouring cell the case of excessive vibrations.

Access to the upper part of the SGB type blower Compulsory wearing of safety harness and use on life-
coolers lines
Medical fitness for working at heights and with potential
hazards of site and authorizations
replacement of the internal fittings of the Work permits
Designation of work teams
coolers or dismantling (risk of staff falling or
Knowledge of the equipment
being crushed, release of dust, permanent
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draughts, inflammability of Formal prohibition against walking over materials without

materials) properly installed and inspected flooring.

Use of individual protective gear: helmet, gloves,
goggles, harness, safety shoes, safety belt and etc.

Writing servicing procedures defining all the hazards
associated with servicing and the means of protection to
be used.

Develop the emergency plan and perform the drill timely.
Above is summarized by Hamon based on experience of previous projects. The user should find a qualified

safety production consultation company to evaluate and provide safety instruction.

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3 FUNCTION AND DESIGN OF SYSTEM
3.1 WORKING PRINCIPLE
All cooling towers operate on the principle of removing heat from water to an air stream by evaporating a small
portion of the water flow.
Depending on the design of the cooling tower, the air stream could be counter-flow or cross-flow.
The humidity of the air crossing the cooling tower increases up to

saturation.
3.2 COOLING RANGE / HEAT LOAD /
The cooling range is the difference in temperature between the hot water entering the tower and the cold water
leaving the tower.
When the cooling tower operates with a closed water circuit, it remove all the heat load brought by the hot
water circuit if the heat cycle is balanced.
Heat load = water flow X cooling range X specific heat of the water. = x x
If the heat load to remove changes, the temperatures of the hot and cold water will change too (water flow rate
constant).
A high heat load corresponds to a high cooling range and a high cold water temperature.
If the heat load to remove decreases, the cold water temperature and the cooling range will decrease too.
The cooling tower operates with a range which changes according to the heat load to remove. The cold water
temperature is a function of the cooling range.
The cooling range is not the correct parameter to describe the good working of the tower.
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As a conclusion, the cooling range is a function of the heat load to remove by the cooling tower.
3.3 COLD WATER TEMPERATURE
This temperature depends on :

- the water flow
- the cooling range
- the wet-bulb temperature of the ambient air
When the water flow and the cooling range are constant (constant heat load), the cold water temperature
depends only on the design of the tower.
If one of the three above parameters changes, the cold water temperature will change too.
The wet-bulb temperature is the lowest temperature that water theoretically can reach by evaporation.
The smaller the difference in temperature between the hot water and the air is, the huger the cooling
tower.
The smaller the difference in temperature between the cold water and the air is, the huger the cooling tower.
3.4 TECHNICAL DATA OF THE COOLING TOWER
Cooling towers are characterised by the cold water temperature that is reached for
:
- one given water flow.
- one given cooling range.
- one given wet-bulb temperature.
The technical data of the cooling tower is specific for each job.
3.5 THERMAL DESIGN
PLEASE SEE C1509811-101-A630-001-CLC REV00 Thermal Design Report
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3.6 QUIPMENT DESIGN
PLEASE REFERTO MOTOR , GEARBOX AND FAN SUPPLIERS DOCUMENTS (INSTRUCTIONSDRAWINGS AND
MANUAL)
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4 OPERATION INSTRUCTIONS
4.1 SAFETY RECOMMENDATIONS
Safety recommendations during the running of the installations

- It is strictly forbidden to go inside the cooling tower, from the access hatch or what ever the way used,
during the running of the installation.
- It is strictly forbidden to run on the sides of the basin without a safety belt firmly fixed at an
external fixed point.
Safety recommendations during the shut down of the installations
- When required, it is recommended to go inside the cooling tower, always and at least, with a
second person.
- The basics safety rules given in our erection and maintenance manuals are a minimum and all other ways
to reinforce the safety will be appreciated.
- All local regulations must be respected
4.2 HYDRAULIC AND MOTOR CONNECTIONS
4.2.1 Hydraulic connections
- The external pipes must not apply loads on the inlet flanges and on the cooling tower.

- Make sure that all the connections are correctly made.
- Check the good operation (on / off position) of all valves, including the bypass valve.

4.2.2 Motor connections
- Check the motor nameplate voltage and the supply voltage.

- Consult the wiring diagram and motor supplier instructions.
- Motor wiring must be executed according to local regulations and good practice.

- If the motor has two speeds, check that the electric circuit is provided with the required time lag when
switching from high to low speed.
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- Make sure that the fan can rotate freely.

- Start the motor for several seconds and stop it. If the fan does not rotate in the right direction (clockwise
looking from air discharge side as normal. Please check with the manufacturers to further specific
information).

- When the gearbox is fitted with a backstop, check the rotation direction of the motor before coupling the
shaft.
Remarks
- At all times, the operating instructions of the motor supplier should be followed.

- Motor must be lubricated before it is switched on.
- After a long storage or a prolonged stopping of the motor, check the value of the insulation resistance
Usually it should not be inferior to 1 000 ohms per volt with a maximum of 1 megohm.
1
- A maximum number of starts per hour is allowed (see motor manufacturer data). Take care to respect this
limit.
-When electrical motor is driven by frequency inverter some precautions must be taken
:
- the minimum motor speed must be compatible with a good operation of the gearbox (see gearbox
manufacturer data).
- The maximum motor speed must not exceed the nominal speed.
- During first start up, check the motor speed range (from minimum to maximum value) to identify the
resonance frequencies corresponding to significant vibrations. The corresponding rotation speeds will not be
used to avoid all risks of deterioration.

4.3 FAN BLADE ANGLE SETTING AND ABSORBED POWER
The cooling tower has been designed to operate with motors absorbing a certain power . (see).
C1509811-101-A630-001-CLC REV00 Thermal Design
Report During installation of the fan, the blades are fastened with a pitch angle given for information
only by the fan supplier. (See the data of fan manufacturer, or motor fan set
drawing).
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After start up of the cooling tower , it is often necessary to adjust the pitch angle in order to obtain the required
power. ;
The correct criteria for the pitch angle is the absorbed motor power at design operating conditions (water
flow and heat load) and not the theoretical value given by the fan supplier .
;
If the pitch angle is modified after the start up of the cooling tower, all blades must be adjusted at the same
angle, otherwise the fan could be unbalanced which could damage the equipment very quickly.
;
This adjustment must be checked systematically. ;
It must also be noted that increasing the pitch angle has a greater effect on the power absorbed by the motor
than on the thermal performance.
;
If the absorbed power is increased to a higher value than the design one, it is at user's risk.
4.4 SPECIFIC INSTRUCTIONS FOR FIRST START UP
This first start up will be made with non-freezing conditions . Or when the ambient temperature drops to below
4C it is advisable to take some precautions in order to avoid ice formation in the fill.
. 4
4.4.1 Prior to start up
Consult the manual of each mechanical part. The operating instructions of the motor fan set (lubrication,
insulation resistance...) should be carefully followed especially after storage or a prolonged stand-by.

4.4.2 Checks before first start-up
- Perform a last check on driveshaft alignment. Maximum tolerance : 0,1 mm (angular misalignment). This
tolerance is more severe than that recommended by manufacturer but this ensures a good alignment after
several start-ups.
0.1mm;
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- Check the fan blade pitch angles. ;

- Check the oil level in gearbox. The correct oil level is the in the normal range of the gearbox.
;
- Manually rotate the fan (clockwise looking from air discharge side as normal, Please check with the
manufacturers to further specific information.) to check that the motor/fan unit turns freely.
,
/;
- Check that there is no debris or other material (i.e. boards, ladders, tools, etc.) inside the cells.
;
- Check that the vibration switch is energized.
4.4.3 Start-up of fans
The first start-up is generally done with no water flow.

It is normal if more power is required to drive the fan without water or with cold water on the tower than
with hot water. (Depending on the power demand, it may be necessary to adjust the fan blade pitch
angles.)

Check the power demand immediately after start-up and after 1 hour of running time at which time the
gear oil should be at its normal temperature.

If possible, check the motor and gearbox bearings for excessive noise and vibration.

Stop after 1 hour and check the temperature of all bearings.
If no over-heating is found, run for a further 4 hours and check the temperatures again. A
temperature increase of more than 40C above ambient temperature may be a sign of overheating.
Check vibration switch if any.

40C
Note : it is recommended that all readings be noted in a log book.
4.4.4 Start up of water circulation
The first start-up is done in order to flush the pipes and clean the installation.

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- Fill the basin and the circulating water system by opening the make-up valves .

- Open all the cell inlet valves and close the cell drain valves. Open the bypass valve (if any).

- Start-up the tower circulating water pumps against closed discharge valves. Open these valves slowly to
prevent water hammer .

- After 10 minutes, close the bypass valve (if any) . 10
- Once the cooling tower has been in operation for 10 minutes, the pumps should be stopped.

- At this time, the basin should be emptied (the water from the first start up may contain dirt, debris, )
and cleaned out. In addition, the pump pit , the screens and any clogged sprayers should be cleaned
out.

- Once the basin has been refilled, restart the pumps (in accordance with the above procedure) .

- Check that the water flow is between 90% and 110% of the design value Check also the balance of the
flow between the cells. The water flow may be controlled by the cell inlet valves.
90%
110%
Notes :
- Those verifications can be accomplished by checking the water level in each cell (in the header vent pipes
or in the external flumes depending from the type of tower) .

- An increase of maximum 20% of design flow per cell can be tolerated without damage to the pipes, nozzles or
fill and without overflow. 20%
4.5 START UP AND OPERATING INSTRUCTIONS WITH NON FREEZING CONDITIONS

We consider that there is no risk of freezing when ambient temperature is above 4C.In such conditions, no
specific precaution needs to be taken on that point of view. 4C
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4.5.2 Checks before start up
- check the gear-box oil level

- check for free rotation of the fan
- check that the vibration switches are energized
- check the water level in the basin
- check that nozzles are not clogged
- check that no extraneous material is present in cells
4.5.3 Start up
To start the cooling tower , the following procedure should be applied

:
- Open all the cell inlet valves and close the cell drain valves. Open the bypass valve.

prevent water harm

- Once the flow is established through the water circuit, close the bypass valve.

- Start up the fans at full speed.
Note : According to the characteristics of the project with years extreme ambient temperature is above
4C, it is not mandatory to use or to have a bypass for start up. To start the tower without bypass, follow the
above procedure ignoring the actions on bypass valve. 4C
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4.5.4 Operation
As long as the ambient temperature exceeds 4C, all the fans should run at full speed to maximize
the cooling capacity of the tower. 4C
,
Notes :
- The temperature of the hot water feeding the cooling tower can not be higher than 55C with the fans
in operation except in specific cases after the agreement of the manufacturer (see < C1509811-101-
A630-001-CLC REV00 Thermal Design Report >).

55 C (C1509811-101-A630-001-CLC REV00 Thermal Design Report )
- With an ambient temperature above 4C, as long as the limit on the hot water temperature is
respected, fan speed could be reduced or (some) fans could be stopped without risk for the cooling
tower. Of course, in such a case, the cooling capacity of the tower is reduced. 4C

But Hamon recommends that whenever water is flowing over the fill , the fan in that cell(s) be kept in
operation. This operating recommendation will virtually eliminate the loss of water through the air
inlets due to splashing, wind currents, and misting. Such losses normally increase substantially when
fans are taken out of service and the water is left flowing to the cell(s).

- With an ambient temperature above 4C, the flow per cell can be reduced below the design flow
without risk for the cooling tower. 4

4.6 START UP AND OPERATING INSTRUCTIONS WITH FREEZING

CONDITIONSellipsis
We consider that there is a risk of freezing when the ambient temperature is below 4C. 4C
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In such conditions, it is advisable to take some precautions in order to avoid ice formation in the cells as it could
lead to a deterioration of the fill and damage the tower structure and internal components.
Those precautions are :

The average temperature of the cold water in individual cells must not drop below 12C
. 12C
Indeed, in all cooling cells, certain areas are at a lower temperature than others and it is not unusual to find
areas where the temperature is 5 to 8C lower than the mean temperature. This is the primary reason that ice
formation occurs when the ambient temperature is below 0C even thought the basin water temperature is at an
elevated water temperature.
5 8C 0C
It is however an upper limit and with several winters experience and close control it may be possible to adjust
this temperature by a few
degrees.
Each cell should be feed with at least 90% of its nominal water flow and the water should be
distributed uniformly.( Check if the nozzles and pipes are not clogged.)
90%
During winter operation, it is critical that the water flow rate to each operating cell be within design limits
(minimum 90% to a maximum 120% of design water flow) and the water distribution to the fill area be uniform.
If too little water is supplied to a cell, the water distribution may become uneven.
90% 120%
The combination of low flow rate and/or uneven water distribution will result in an increased potential for icing.
Note that areas of light water flow due to clogged nozzles could result in large ice formations if the nozzles are
not
unclogged./
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4.6.2 Checks before start up
- check the gear-box oil level

- check for free rotation of the fan
- check that the vibration switches are energized
- check the water level in the basin
- check that no extraneous material is present in cells
- check that there is no ice inside the fan stack or on the fan blades. This ice would unbalance the fan.

4.6.3 Start up
To ensure that the water temperature remains above 0C in all parts of the cooling tower, the following
start up procedure should be followed.
0C
- Close the cell drain valves. Open the bypass valve .
prevent water hammer ;

- When the water temperature rises above 25C, close slowly the bypass valve . 25C

- When the water flow is established in the cells, start up the fans at full speed
.
If there was ice on fan stacks or fan blades, wait that the hot air melt the ice before starting the
fans.
Notes :
- With an ambient temperature below 4C, it is mandatory to use a bypass for start up in order to heat the
water before feeding the cells. Start up without by-pass is at client risk. 4C

- The design of the bypass must be such that in bypass mode, there is not water arriving in the cells. If it is not
the case, start with cell isolating valves closed to avoid that cold water from the basin arrive in the cells
and open them just before closing the bypass valve.
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In by-pass mode, the cells must be totally by-passed. A partial by-pass favours icing.

- The start up should be made with the full water flow. (100% of design flow)
(100% )
If the start up is made with a reduced flow, several cells must be taken out of operation (isolating valves
closed) such that the water flow per cell is not lower than its nominal value. (but not higher than 120% to
avoid overflow)
120%
4.6.4 Operation
The purpose of the regulation is to maintain the temperature of the cooled water above a
minimum value (12C) to avoid any winter damage for the tower
12C

Note : the average cold water temperature can be measured at basin outlet or more easily at
water pumps inlet or discharge .The procedure is described hereafter and also in the functional diagram
(see enclosure) .

Case 1 1 : If there is a bypass and if splash out through air inlets must be avoided
When the cooling tower is in normal operation (all cells in operation with fans at full speed)
and when the cold water temperature decrease below 12C, the procedure is the following

12C :
- If the cells are equipped with two speed motor or variable frequency drive, the rotation speed of
all the fans should be reduced. (With VFD, the rotation speed can be reduced step by step down to
the minimum rotation speed accepted by the gearbox see <C1509811-101-A630-001-CLC REV00
Thermal Design
Report>)

C1509811-101-A630-001-CLC REV00 Thermal Design Report
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- If after a while, the cold water temperature has not increased above 12C or if there is too much
splash out, all the fans should be stopped and the bypass should be open. (bypass mode)
12C

- If the cells are equipped with single speed motor, all the fans should be stopped and the bypass
should be open.(bypass
mode)

Once the cold water temperature rises above 25C, the above steps should be performed in reverse.
25C
Note :
When the cooling tower is in bypass mode, no water can arrive in the cells.

If necessary, the cell isolating valves will be closed and the drain valves will be opened.

In such a case, it is important that no water leaks past the inlet valves. A small leak through the valves
could result in severe damage to the cooling towers structure and fill.

Alternative procedure for case 1 (not represented in functional diagram). 1
When the cooling tower is in normal operation (all cells in operation with fans at full speed) and
when the cold water temperature decreases below 12C, the cells should be shut down one at
the time until the cold water temperature increases. Shut down means fan stopped, cell isolating
valve closed and drain valve
open.
12C
12C
When a cell is shut down, it is necessary to adjust the water flow in the remaining cells so that
they do not become flooded (water flow per cell not greater than 120% of its nominal water flow).
That means that the bypass valve opening must be adjusted as a function of the number of
operating cells to maintain the water flow per cell between 100% and 120% of its nominal value
120%
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100% 120%
Once the cold water temperature rises above 25C,the above steps should be performed in reverse :
the cells should be restarted one by one. 25C

Each time a cell is restarted, the water flow to the cooling tower must be readjusted by adjusting
the bypass valve opening
.

Notes :
- When a cell is shut down , the fan must always be stopped before stopping the water distribution.
When re-starting the cell , the fan must be started after start up of the water flow distribution.

- In case of cell shut down, it is important that no water leaks past the inlet valves. A small leak
through the valve could result in severe damage to the cooling towers structure and
fill.

Case 2 2 : If some splash out is acceptable or if there is no

bypass.
When the cooling tower is in normal operation (all cells in operation with fans at full
speed) and when the cold water temperature decrease below 12C, the procedure is the
following
12C :
- If the cells are equipped with two speed motor or variable frequency drive, the rotation
speed of all the fans should be reduced. (With VFD, the rotation speed can be reduced
step by step down to the minimum rotation speed accepted by the gearbox see Cooling
Tower Datasheet ) .

If after a while, the cold water temperature has not increased above 12C, all the fans should be
stopped. 12C
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- If the cells are equipped with single speed motor, all the fans should be stopped.

If with fans stopped, the cold water temperature doesnt increase above 12C, the bypass should be
open or , if no bypass, the water pumps should be stopped.
12C
Once the cold water temperature rises above 25C,the above steps should be performed in
reverse. 25C
Note :
The losses of water through the air inlets increase substantially when fans are taken out of service.
In winter time, splash out may be an issue since the water may accumulate and freeze outside the
tower and form large ice areas
.

Alternative procedure for case 2 (not represented in functional diagram) 2
In the recommended procedure described here above, all the cells are operating in the same mode
( all fans at full speed or all fans at reduced speed or all fans stopped). That means that the average
cold water temperature measured at basin outlet corresponds to the cold water temperature of the
individual cells.

With the alternative procedure described here after, all the cells are not necessarily in the same
operating mode. To respect the limit of the minimum cold water temperature (12C) for any individual
cell, that means that the average cold water temperature measured at basin outlet should be
maintained at an higher value than 12C (as the cooling capacity of the cells is different).This value
depends on the operation mode of each cell, the heat load and the ambient conditions. Such a
procedure requires a very close control and monitoring of the cooling tower.
12

12

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If ice appears in some cells (cells with fan at highest speed) , the level of the minimum cold water
temperature will be increased.

When the cooling tower is in normal operation (all cells in operation with fans at full
speed) and when the cold water temperature decrease below 12C, the procedure is the
following
12C :
- If the cells are equipped with two speed motor , the fan speed should be reduced one at
the time until the cold water temperature increases.

12C
If the cold water temperature has not increased above 12C after all the fans have
been switched to low speed, it will be necessary to stop fans one at the time until the cold
water temperature increases.
12C 12C
- If the cells are equipped with single speed motor, the fans should be stopped one at the time.

If with fans stopped, the cold water temperature doesnt increase above 12C, the bypass should be
open or , if no bypass, the water pumps should be stopped .

12C
Once the cold water temperature rises above 25C,the above steps should be performed in reverse.
25C
Notes :
- In all the procedures described here above, due to the inertia of the cooling system, a time lag is
required between each
step.
- If the fans are operated in cyclic on/off mode, do not exceed the motor manufacturers allowable
number of starts as damage to the motor and/or its control could result.
/

4.6.5 General comments
- The preceding instructions are intended for the trouble free operation of the cooling tower.

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They cannot, however, entirely replace an intelligent operator who appreciates the logic of these
instructions and of the following remarks.
- The application of the above procedures does not exclude frequent inspections of the cooling tower for
ice formation during freezing periods. (see 4.6.6)

- If despite all the recommendations ice formation occurs, it is imperative not to remove it by mechanical
means.

The best way to de-ice the fill is to increase the level of the water temperature even it is within the
prescribed limits and let hot water melt it. -

To increase the level of water temperature, refer to the above
procedures.
If the ice is localized in a particular cell, stop the fans or reduce the fans speed (if applicable) in order to
increase the temperature of the water in the concerned cell.

- Note that a reduction in heat load has the same effect as a reduction in ambient temperature.

The influence of any combination of these two items is a decrease of the cold water temperature which is
the main parameter to be controlled.

The heat load and the selected cold water temperatures are also factors in a towers potential to ice.
Decreasing the heat load, and/or lowering the required cold water temperature will increase the
probability of ice formation.
/

Higher water temperatures are achieved by escalating the heat load to the tower. This will reduce the
probability of ice formation within the fill.

4.6.6 Inspection
A vital part of operating a cooling tower in cold weather is operator knowledge of the physical
condition of the tower. At ambient conditions below freezing, a cooling tower cannot be safely
operated without continual visual inspections. Most cases of ice damage can be avoided if the tower
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is properly inspected. At ambient temperatures below 0 C, the frequency of the inspection should be
increased to every two hours.

0
An additional, but not insignificant, benefit of frequent inspections is the accumulation of valuable
knowledge by the operators with regard to the particular cold weather characteristics of the cooling
tower. Such knowledge will serve as a database which may permit a greater range of operation (i.e.
running at lower heat loads or at lower ambient temperatures) via skilled manipulation of the cooling
tower controls.

When changes in the hydraulic mode of operation are required, an operator should be on the tower
to visually check the isolated cells to be sure they do not have any water leaking into the fill section. A
small amount of water leaking into an inactive cell by way of a defective or not full closed cell inlet
valve may result in extensive ice damage.

When all the fans are not operated at
same speed , the tower should be inspected hourly until a minimum value of the cold water
temperature has been found to be effective in controlling the icing.

4.7 CELL SHUT DOWN FOR MAINTENANCE
A cell can be shut down without problem as far as the water flow to the cells remaining in operation
will not exceed the maximum acceptable value. ( 120% of the nominal cell water flow except if an
other value has been agreed). 120%

If it is not the case, it will be necessary to adjust the water flow in the remaining cells so that they do
not become flooded.

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That means that the bypass valve opening must be adjusted to maintain the water flow per cell
between 100% and 120% of its nominal value.
100120%
The procedure is the following :
- Stop the fan of the cell.
- If necessary (see above), adjust the water flow.
- Close the cell isolating valve and open the drain valve.
- Energize the space heaters (winding heaters) on the motor, if applicable.

When restarting the cell, the above steps should be performed in reverse.
4.8 COOLING TOWER SHUT DOWN
The procedure is the following :

- Stop all the fans
- Open the bypass valve, if applicable
- Stop the water pumps
- Check that the cell isolating valves are open
- Energize the space heaters (winding heaters) on the motors, if applicable
In winter time, to prevent possible basin frost heave, a water circulation could be maintained through
the bypass. In such a case, the cell isolating valves will be closed and the drain valves will be open.
If necessary, the basin will be drained.

Note :
Consult the operating manual of each mechanical part. The operating instructions of the motor fan set
(lubrication, insulation resistance...) should be carefully followed especially during a prolonged stand-
by.

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4.9 ANNEX : FUNCTIONAL DIAGRAM FOR COOLING TOWER START UP AND
OPERATION
DBT : ambient temperature (dry bulb)

CWT : cold water temperature
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Note : Normal Operation: by-pass closed + all fans full speed

+
* If applicable, when 2-speed motors or frequency inverters are provided, the fan speed should be reduced
first before stopping the fans (check the low speed limit on the Cooling Tower Data Sheet when inverter
frequency are used).
** Obviously, when fan speed is decreased, the inlet air speed is also decreased. This increases the
sensitivity of the air inlet area to wind. As a result, the risk of water splash out will increase. This will wetten
or even ice the vicinity of the cooling tower in winter conditions.
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5 MAINTENANCE INSTRUCTIONS
5.1 General comments
Except for the systematic maintenance of the mechanical parts, the various elements composing the cooling
tower require little maintenance if the qualities of the circulating water are such that they allow to
avoid:
a) scale formation and other deposits ;

b) formation of algae ;
c) corrosion ;
d) chemical or biological attack of the wooden parts ;
e) presence of solvents which may damage the plastic parts
We must however point out that the ambient conditions in which the cooling tower will be operating
may have an influence on the behavior of the various cooling tower parts and may condition the
maintenance of the latter.

We shall assume that the customer has given to the builder all information on the particular conditions
relating to the quality of the fluid to be cooled as well as the ambient conditions so that the cooling
tower design and the selection of materials answer to the best operating systems.

5.2 Basin
The air going through the cooling tower deposits a certain amount of dust which settles in the basin and causes
the formation of a muddy deposit which must be regularly
removed.
The frequency of this cleaning obviously depends on the quantity of dust contained in the air in the cooling
tower.
In general, cleaning once a year is enough.
In case where, besides the air dust, the operating condition induces additional materials which may settle, it is
obvious that more frequent cleanings shall be required ; such additional materials may arise either from the
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make-up or by the cooling

process.
5.3 Framework
The circulating water qualities required for each type of framework being fulfilled, no particular maintenance is
required for this part of the cooling
tower.
However, routine surveillance of the condition of this essential part of the cooling will establish if the quality of
the water is in accordance with the requirements or if corrections are
necessary.
5.4 Fan stack
As the fan stack is subjected to vibratory forces inherent to the fan it is necessary to examine the fixation at least
every six months. 6
5.5 Shell
Our shells normally require no particular maintenance. The damage which would have been accidentally caused
to the shell for, besides the water loss resulting from such damage the uncontrolled air intakes may have a bad
influence on the thermal efficiency of the tower. It is thus necessary to make the repairs as soon as possible.
5.6 Filling
The causes of deterioration of the fillings are generally of the following

nature:
a) those attributable to the quality of water (see para. General comments) ;
b) those attributable to deposits and overloads (i.e. ice) ;
c) those attributable to water concentration resulting from a defect in the water distribution system.

If these causes of deterioration are eliminated, our fillings do not require any particular
care.
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It is however recommended to examine the condition of the filling as possible that is when the tower is at a
standstill. N.B.: If it is necessary to walk on the filling, this should be done using boards to spread the
load.
5.7 Water distribution
Water must be uniformly distributed over the whole surface of the filling. The good working of a distribution
may be affected either by accumulation of deposits or remains which may completely obstruct certain nozzles,
or by deterioration of the splashing or distribution system giving rise to water concentrations in the place of the
defect.
These two causes of poor water distribution obviously also have a detrimental influence on the tower efficiency
as well as on the good optimum performance of the
filling.
After a certain time of operation, it may happen that splashing devices are damaged. These defects are revealed
by the fact that water concentration arise in certain
places.
Water concentration is baneful to the good efficiency of the tower and they may damage the filling and favor
the icing.
In short, it is absolutely necessary to check systematically if the fluid to be cooled is uniformly distributed. This
checking may be effected on the induced draft cooling tower from the air inlet. Any cause of disturbance must
be eliminated without delay.
5.8 Drift eliminators
It is simply recommended to keep the drift eliminators clean by removing mosses, algae or muds which might
accumulate thereon.
These accumulations increase the loss of pressure of the circuit and therefore are influent on the tower
efficiency.
If the drift eliminators were damaged by accident it would be necessary to make the repairs so as to avoid
important drift losses.
It is inadvisable to walk on the drift eliminators without planking to spread the
load.
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5.9 Fan driving system
5.9.1 Shaft and couplings
As regards the assembly, the adjustment, the alignment, the examination and the maintenance of the
driving shafts and their couplings, please refer to the manufacturer's instructions which are enclosing. In
any case it is recommended to examine the couplings every
year.

5.9.2 Gear reducer
The manufacturers instructions give the types and specifications of lubricants to be

used.
In order to facilitate the filling, checking and draining operations, the lube piping system necessary for
these operations is installed outside of the fan
stack.
This system is composed of a funnel, an oil level indicator and a drain valve, the whole system being
connected to the reducer by piping inclined
outwards.
When the first filling is performed, the guiding marks of the dipstick located on the reducer are transferred
to the oil level indicator located outside the stack. If during the maintenance it happens that the piping of
the lubrication system has been dismantled, it is absolutely necessary to recheck the position of the oil
level indicator with regard to the marks of the dipstick.

Each reducer is fitted with a strainer enabling the air expansion during the
heating.
Care must be taken that the strainer is not obstructed.
5.9.3 Fan
As a general rule, it is recommended to check the tightening of all bolts used for assembling the various fan
elements such as blades and hubs, and this during the second month after a new tower is put into
operation.

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This checking shall be effected by means of a torque wrench set according to the indications given in the
instructions.
It is advisable to effect this checking at least once a year.
It is forbidden to climb on the blades or to use them as a scaffolding support or working
platform.
The blades shall be kept clean in order to avoid unbalancing and vibrations which may give rise to
deterioration of the rotating
parts.
For the same reason, it is forbidden to keep a fan operating when one or several blades have been
accidentally damaged.
In case of vibration or switching off due to overload, it must be checked that the setting angle of the blades
has not changed and is identical for each of
them.
This setting angle is adjustable at still stand.
5.9.4 Motor
The motor shall be lubricated according to the manufacturer's

instructions.
The voltage at motor terminal shall also be checked during the starting and operation period. These
measures provide for good operation of the installation and an awareness of the power
consumption.
5.10 Conclusion
It is of the utmost important to comply strictly with the instructions of the manufacturers of the different parts
of the installation. Checking annually all those parts, repairing them if necessary and complying strictly with the
operating instructions will ensure a perfect operation of the cooling
tower.
Notes
One during every shift it is advisable to make a general inspection to prevent what might become an accident.
In the spirit it is recommended that :

- basin water level be checked ;
- gear box oil level be checked ;
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- locate and check any suspect noise or

vibration. It is recommended that a detailed
log book be kept.
The above list of checks, etc. is the minimum we consider necessary for trouble free
running.
Important remarks
If after installation, regular operation is delayed pending completion of plant construction or if there are long
idle periods between operating cycles it is necessary to start the motor/gearbox/fan group every week for a
period of 5 minutes to bring all inner parts of the gearbox and the ball bearings into contact with the
lubricant. If the motor is not electrically connected, the rotation must be done
manually./
/5
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Research-Cottrell Cooling Division A620-001-

OPRATION&MAINTANCE MANUAL FOR:

OPERATION&MAINTANCE MANUAL FOR

HTT Document. Nr. : C1509811-101-A620-001-OMM

PROJECT NAME/ Parkistan Bhikki 1180MW209HCCPP/1180MW209H

CLIENT/CUSTOMER/Harbin electric international company limited/

REV DATE AUT. CHE. APP. Description of Revision Status

OPRATION&MAINTANCE MANUAL FOR:

1.1 INFORMATION ON A COUNTER FLOW TOWER ................................................................................................ 3

2 OPERATIONAL SAFETY ...................................................................................................................4

2.1 COOLING TOWERS - PREVENTION INSTRUCTIONS ......................................................... 4

3 FUNCTION AND DESIGN OF SYSTEM .............................................................................11

3.1 WORKING PRINCIPLE ................................................................................................................................... 11

4 OPERATION INSTRUCTIONS .........................................................................................................14

4.1 SAFETY RECOMMENDATIONS ...................................................................................................................... 14

5 MAINTENANCE INSTRUCTIONS ....................................................................................................33

5.1 GENERAL COMMENTS ............................................................................................................................................ 33

OPRATION&MAINTANCE MANUAL FOR:

1 BRIEF INFORMATION ON TOWER

1.1 Information on a counter flow tower

The tower is mainly composed of:

OPRATION&MAINTANCE MANUAL FOR:

2.1 COOLING TOWERS - PREVENTION INSTRUCTIONS

HAZARDS LINKED TO THE SITE EXAMPLES OF MEANS TO BE USED

The installation of electrical equipment need to conform to the

HAZARDS LINKED TO THE MATERIALS EXAMPLES OF MEANS TO BE USED

Fire/explosion / Hot spot work only to be carried out by specialists trained

OPRATION&MAINTANCE MANUAL FOR:

necessary protection (flame-retardant tarpaulins,

should not be combustible gas discharge within 30m, should not

be emissions flammable liquid within 15 m. And below the

working area, there should not be flammable solvent cleaning or

OPRATION&MAINTANCE MANUAL FOR:

Ignorance of the structures Training in the maintenance of internal equipment

failure to wear individual protective Employment of trained and properly authorized

HAZARDS LINKED TO USE EXAMPLES OF MEANS TO BE USED

OPRATION&MAINTANCE MANUAL FOR:

Electricity Installation and connection according to the standards in

The electrical line must match the load.

Electrical measurements relevant staff qualification

OPRATION&MAINTANCE MANUAL FOR:

Assembling and fitting work Compliance with local obligations.

HAZARDS LINKED TO MAINTENANCE EXAMPLES OF MEANS TO BE USED

OPRATION&MAINTANCE MANUAL FOR:

Biological hazards : Carry out analyses before action.

OPRATION&MAINTANCE MANUAL FOR:

draughts, inflammability of Formal prohibition against walking over materials without

OPRATION&MAINTANCE MANUAL FOR:

3 FUNCTION AND DESIGN OF SYSTEM

3.1 WORKING PRINCIPLE

The humidity of the air crossing the cooling tower increases up to

3.2 COOLING RANGE / HEAT LOAD /

OPRATION&MAINTANCE MANUAL FOR:

3.3 COLD WATER TEMPERATURE

This temperature depends on :

3.4 TECHNICAL DATA OF THE COOLING TOWER

3.5 THERMAL DESIGN

PLEASE SEE C1509811-101-A630-001-CLC REV00 Thermal Design Report

OPRATION&MAINTANCE MANUAL FOR:

3.6 QUIPMENT DESIGN

OPRATION&MAINTANCE MANUAL FOR:

4.1 SAFETY RECOMMENDATIONS

Safety recommendations during the running of the installations