ERECTION MANUAL Doc No.

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

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 ERECTION MANUAL Doc No.
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
INDEX
Sl. No. Particulars Page No.
1 Checking of Civil Work 3
1.1 Check for Dimensions 3
1.2 Check for Levels 3
1.3 Checking of Bolts 4
2 End wall derrick 4
3 Casing Installation Instruction 4
3.1 Assembly of Scaffolds 4
3.2 Sorting of Sheets 5
3.3 Installation of Sheets 5
Fig. 1 Placing details of corrugated sheets 5
4 Hot water manifold assy. Installation 6
5 Hot water distribution & spray system installation 6
6 Installation of fill 6
7 Installation of Eliminators 7
7.1 Blade & Spacer type 7
7.2 TU15 Eliminator pack Assy. 7
8 Assembly installations for FRP/GRP Fan cylinder 7
8.1 General 7
8.2 Assembly on ground 8
Fig. 2 Erection of Fan cylinder segments 9
Fig. 3 Ladder Installation 10
8.3 Hoisting Fan cylinder in Place 11
8.4 Installation of Tower 11
Fig. 4 Hoisting Fan cylinder in Place 12
Fig. 5 Installation of brackets 13
Fig. 6 Installation of brackets 13
9 Drive shaft Installation 14
9.1 General 14
9.2 Drive Shaft Installation 14
9.3 Alignment 14
10 Fan Assy. Installation Instruction 14
10.1 General 14
10.2 Fan Assembly 15
10.3 Setting Fan Blade Pitch 15
11 Post Erection Check 16
12 Guidelines for use of Sealants 16
13 Safety Precaution 17

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 ERECTION MANUAL Doc No.
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

1. CHECKING OF CIVIL WORK

1.1 Check for Dimensions :

Measure the following & make necessary rectification if required :-

a) Inside dimension of the channels for installation of screens.

b) Inside dimension of the channels for installation of slide-gate.

c) Centre to centre distance of fill supporting channel(S-S) / beam.

d) Centre to centre distance of eliminator supporting beams.

e) Inside dimensions of fan cylinder on the fan level area.

f) Inside dimensions of the access hatch opening.

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)

1.2 Check for Levels :

Check the levels for following :-

a) Fill supporting beams

b) Eliminator supporting beams
c) Motor & gear reducer foundation
d) Beam for End Wall Derrick
e) Overflow funnel
f) RCC conduit for hot water

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 ERECTION MANUAL Doc No.
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

1.3 Checking of Bolts:

Following to be maintained as per drawings :-

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.

1.3.3 Bolt Projection

Projection of the bolts must be maintained as per drawing.

1.3.4 Clean threaded portion of bolt projection after grouting.

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.

2.2 Ensure correct tightening of the bolts by using torque wrench.

2.3 Test the derrick at partial capacity and retighten the bolts before using for maximum designed
capacity.

3. CASING INSTALLATION INSTRUCTIONS - A C B / G R P Sheet Casing

( IF CASING HAS BEEN PROVIDED )

3.1 Assembly of Scaffolds

Prior to installation of casing, put up scaffolding as required for workmen and

materials.

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 ERECTION MANUAL Doc No.
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

3.2 Sorting of Sheets

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 Installation of Sheets

3.3.1 Use sealing agent at joints to prevent water leakage.

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.

3.3.4 Install sheets firmly & these should not be loose.

3.3.5 Install sheets at their correct locations as mentioned in the drawing, working downward from the
top.

3.3.6 Use packings where indicated in the drawing.

BOTTOM LEFT HAND

CORNER OF SHEET #2
MITRE CUT

1 2

3 4
BOTTOM LEFT
HAND
CORNER OF SHEET
#3 MITRE CUT PLACING DETAILS OF CORRUGATED SHEETS Fig. 1

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 ERECTION MANUAL Doc No.
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

4. HOT WATER MANIFOLD ASSEMBLY INSTALLATION

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. HOT WATER DISTRIBUTION & SPRAY SYSTEM INSTALLATION

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.

5.3 Spray nozzles should be oriented correctly. Use gasket if required.

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

6.1 For gluing follow the Fill Gluing Procedure

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.

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 ERECTION MANUAL Doc No.
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

7. INSTALLATION OF DRIFT ELIMINATORS

7.1 BLADE & SPACER TYPE

7.1.1 Assemble the eliminator pack assembly by using eliminator blade and spacer.

7.1.2 Follow the suggested installation procedure as outlined in installation drawing.

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.

7.1.4 Place expanded polyethylene if shown in drawings.

7.2 TU15 ELIMINATOR PACK ASSEMBLY

7.2.1 For gluing follow the procedure as down in Field Gluing Procedure for TU15
Eliminator

7.2.2 Follow the installation drawing for correct installation.

8 ASSEMBLY INSTRUCTIONS FOR FRP /GRP FAN CYLINDER

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.

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 ERECTION MANUAL Doc No.
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

8.2 Assembly on ground :

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.

B) Apply a few drops of LOCKTIGHT (bonding agent) to threads of each

installation bolt to prevent loosening by vibration during operation.

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 ERECTION MANUAL Doc No.
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

8.3 Hoisting Fan Cylinder in Place (see figure 4) :

8.3.1 Jig for hoisting

Fasten 7m long and thick wire ropes with eye splices at both ends to a ring
for use as a hoisting jig.

Note : one wire rope is required per two cylinder segment.

8.3.2 Installation of brackets (See Fig 5 & 6 )

Brackets are to be installed inside of cylinder to the holes provided to
overlaps of segments at the narrowest straight side ( 1100 - 1800 mm
from the bottom ). Countersink the bolt holes in diameter of 13mm and
install each bracket with two provisional bolts M12 x 50mm, using washers
on the outside.

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.

8.4 Installation on Tower :

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.

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 ERECTION MANUAL Doc No.
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

5. Apply sealing agent to the clearance between the cylinder bottom flange and the fan
deck in accordance with the drawing.

9. DRIVE SHAFT INSTALLATION

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.

9.2 DRIVE SHAFT INSTALLATION

For Installation follow the instruction as detailed in Installation manual.

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. FAN ASSEMBLY INSTALLATION INSTRUCTION

10.1 General

Each fan is individually balanced at the factory before shipping. The

assembly is given a serial number and each fan blade and clamps assy.

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 ERECTION MANUAL Doc No.
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
are given a number and the socket of the fan hub is correspondingly
numbered. The fan blades and clamps must be matched and assembled
as numbered to prevent vibration when fan is in operation.
In shipping usually the hub, fan blades and fan clamps are boxed
separately.Coat the geareducer output shaft with anti corrosive paint or
similar lubricants.

10.2 Fan Assembly

There is an arrow mark on each fan blade showing direction of fan-wheel

rotation; this arrow must be on the air-discharge side (usually upside) of
the fan.
Assemble each fan blade as far from the center of the fan as the safety
shoulder on the shank end of the blade will permit. This is necessary in
order to restore the original balanced conditions established at the factory
before shipping.
Tighten clamp bolt nuts barely enough to keep blades from turning freely
in their hub sockets, in order that each blade may be pitched to the
proper angle. Retighten the clamp bolt nuts after the blades are pitched
to the proper angle.

10.3 Setting Fan Blade Pitch

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.

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 ERECTION MANUAL Doc No.
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

11. POST ERECTION CHECKS

Following post erection checks should be carried out for the common
erection quality problems and if observed should be rectified :-

a) Erection tolerance exceed the limits permitted.

b) ACB/GRP sheets are punched for installing coach screws instead of drilling
holes in casing.

c) Incorrect cutting of ACB sheets at corners of joints.

d) Improper use of sealant.

12. GUIDELINES FOR USE OF SEALANTS

BUTYL RUBBER SEALANT ( Non-hardening flexible Compound )

In end wall casing at the overlapping function of sheets.

In between fancylinder segments in the vertical joint.

POLY SLUPHIDE SEALER ( 2 part compound, hardens after drying )

Inside of FRP fancylinder at junction with fandeck.

ETHA FOAM
To fill larger gaps.

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 ERECTION MANUAL Doc No.
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

13. SAFETY PRECAUTION

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.

Additionally following measures should be ensured :-

(a) In stockyard

Display of no smoking Boards and Sand / Water Buckets.

Fire extinguishers.
Water connection.

(b) Near Cooling Tower provide :

No smoking Boards & Sand / Water Buckets.

Fire extinguishers.
Water connection.

(d) Usage of

Safety belt, Safety Shoe, Safety Helmet, Safety Goggles etc.

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