Professional Documents
Culture Documents
Doc Date
:
:
EM-800/01
16.11.2002
FOR Rev : O
Rev Date : 16.11.2002
CLASS 800 COUNTERFLOW Issue Date : 16.11.2002
File Name : EREC_MANU
COOLING TOWER
ERECTION MANUAL
FOR
CLASS 800 COUNTERFLOW
COOLING TOWER
g) Dimension of the fan cylinder door opening to suit the fixing of fan cylinder
door.
h) Centre to centre distance of the holes provided in RCC conduit for fixing hot
water distribution pipes. (Applicable if RCC conduit has been provided)
1.3.1 The centre to centre distance of bolts for fixing weldment assembly for Gear Reducer & motor.
The centre to centre distance of the motor & Gear Reducer must match to drawings.
1.3.2 The expansion bolts / anchor bolts position for fixing endwall derrick.
1.3.5 Install nut in position and cover with greased paper / cloth and secure the same suitably.
2 Endwall Derrick
2.1 Before erection of the derrick, proper planking should be carried out.
2.3 Test the derrick at partial capacity and retighten the bolts before using for maximum designed
capacity.
Refer to the drawing and sort the sheets by the order in which they are installed.
Saw off corners of the overlapping sheets as shown in the drawing (refer figure
1).
3.3.2 Apply sealing agent around the bolts from the inside to prevent trickling of water drops.
3.3.3 Where coach screws are to be used for installation, predrill guide / nails in the columns and drive
in coach screws. In case of G R P sheets use roofing nails as per drawing.
3.3.5 Install sheets at their correct locations as mentioned in the drawing, working downward from the
top.
1 2
3 4
BOTTOM LEFT
HAND
CORNER OF SHEET
#3 MITRE CUT PLACING DETAILS OF CORRUGATED SHEETS Fig. 1
4.1 Install hot water pipe as per the installation drawing. Since PCT pipe supports are designed to
support only the weight of pipe and water within the limits of the inlet flange ensure that pipe
outside of the cooling tower are independently supported.
5.1 Install the hot water distribution & spray system as per installation drawing.
5.2 Ensure that the outer edge of the PVC distribution pipes go approx 10 mm inside from the inner
surface of the header pipe.
5.4 During fixing of end cap by PVC Solvent, roughen the inner surface of end cap and outer surface
of PVC pipe to be joined for better adhesion. Similarly roughen the outer surface of the
distribution pipes and inner surface of socket for better adhesion.
5.5 After installation ensure that the vent pipe is not blocked.
5.6 Notch the eliminators to allow for vent pipe to extend upto full height and ensure tight fit of
eliminators against vent pipe.
5.7 After installation of the spray system check the level of distribution pipes and correct by placing
shims.
6. INSTALLATION OF FILL
6.2 Follow the erection drawing to ensure proper installation at end wall, partition etc.
6.3 Field notch the fill packs to clear fouling with columns.
7.1.1 Assemble the eliminator pack assembly by using eliminator blade and spacer.
7.1.3 During installation of eliminator pack ensure that the 2 packs to be kept back to
back and the joint shall be over transverse beam only.
7.2.1 For gluing follow the procedure as down in Field Gluing Procedure for TU15
Eliminator
8.1 General
These fan cylinders are assembled on the ground using a light crane or hoist and are hoisted on
to the tower top with heavy crane using hoisting jigs.
Provisions must be made for hoisting jigs, stakes and ladder before starting assembly of fan
cylinder and an area of at least 10 m x 10m level ground is required adjacent to the cooling
tower for assembly of one set of fan cylinder, excluding the area required for movement and
placement of cranes.
If circumstances require assembly of the fan cylinder on tower top, place planks
across the fan opening in fan deck, hoist fan cylinder segments into place on the
tower and assemble them using the on-ground assembly procedure outlined
below.
8.2.1 Lay down a segment of fan cylinder on the ground and tie the top flange of fan cylinder segment
at two places with two ropes each, utilizing the holes drilled on the top flange.
8.2.2 Fasten C clamps at two places of the top flange & erect the fan cylinder segment with a light
crane (8-15 tons) and tie the end of the four ropes to stakes driven into the ground to hold the
segment in place as shown in Fig. 2.
8.2.3 Then erect the next segment by following the above procedure and bolt into the preceding
segment using bolts of prescribed size.
For bolting, install two ladders having the same height as the cylinder segment
to the erected segment from the inside and outside as shown in Fig. 3.
8.2.4 Repeat the above procedure until all the segments are assembled to form a cylinder.
To bolt on the last segment, hoist one side of the assembled cylinder with a light crane so as to
narrow or wider the size opening of the cylinder for proper fit up.
C clamps are used as hoist rings and it is advisable to place some pieces of material to the part
where the clamps are to be fixed so as to provide enough space for clamping.
Ropes tied to stakes may be unfastened when the segments become self-standing after assembly
of several segments.
CAUTIONS :
A) Several different cuts are made to cylinder segments. Segments for 5490
dia (216 inch) and 6700 dia (264 inch) narrow type cylinders have
additional vertical cut at the bottom part in order to avoid interference with
the cylinder of the adjacent cell. Consult drawing for proper assembly and
arrangement of cylinder segments.
8.3.3 Hoisting
Install a shackle ( 5/8 Inch Inch ) to the bracket and also a hoisting
jig referred to above in Paragraph (1) and then hoist the cylinder. When
lifting, hold the cylinder slightly off the ground for a while to make sure
nothing is wrong with bracket.
1. Install fan cylinder in place concentrically with the fan deck opening, paying attention
to orientation of openings made to the cylinder for steel support and drive shaft.
2. Remove hoisting jig and brackets. Then install pipe compass at the centre of fan
shaft and rotate it by hand and adjust the position of the cylinder such that the
clearance between the blade tip and the cylinder in all directions is uniform
(tolerance : 6 mm of standard value). The cylinder can be moved for adjustment
if 3 4 work crews lift the cylinder with hand levers.
3. Install anchor bolts to the cylinder with fan deck in accordance with the drawing.
4. Align the drive shaft and install fan blades. Then install seal plates in accordance
with the drawing.
5. Apply sealing agent to the clearance between the cylinder bottom flange and the fan
deck in accordance with the drawing.
9.1 GENERAL
Each drive shaft has been dynamically balanced at the factory before shipping and the
yokes and the intermediate shaft coupling flanges are match marked with the numerals
1-1 and 2-2.
The match mark relation must be retained during installation at the jobsite.
9.3 ALIGNMENT
Align drive shaft by measuring with dial indicator kit, installing in the balancing hole of
Flange / Yoke of drive shaft on both motor side and gear reducer side.
Change position of motor or geareducer for alignment in horizontal direction and shim
motor or geareducer for securing alignment in vertical direction.
Drive shaft is aligned by checking variation of indicator readings between Yoke and
flange faces (angular alignment) at both ends.
The indicator readings must not exceed 0.005 inch. in a round when the pointer is
adjusted O at the top point of a coupling. Tighten all hold down bolts and recheck
alignment. If the difference of indicator readings exceed the tolerance of 0.005, repeat
the above steps to adjust the alignment within the specified tolerance.
10.1 General
The trial pitch angle is calculated for design breake HP at design heat load
and water rate or air density. Set the bevel protractor on pitching boss at
the trial pitch angle and pitch blades uniformly at the same angle within
the tolerance of 0.15 degree.
Each blade must be pitched to the same angle.
Tighten blade clamp bolts to recommended torque.
Two to four clamp bolts are used for each fan blade. In either case,
tighten clamp bolts in alternating sequence for uniform tightening.
A big difference in pitch setting may cause vibration when fan is in
operation.
Following post erection checks should be carried out for the common
erection quality problems and if observed should be rectified :-
b) ACB/GRP sheets are punched for installing coach screws instead of drilling
holes in casing.
ETHA FOAM
To fill larger gaps.
Area around cooling tower should be declared as fire hazard area. Safety Permit
for hot work should be issued only after consent of PCT Site Incharge is
obtained.
(a) In stockyard
(d) Usage of