Training Overview Safety First What is a Cooling Tower Cooling Towers Components Structure Inspection Maintenance Summary Questions Discussion Safety First Identify potential hazards Plan ahead ID: 1003717
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1. Cooling Tower Maintenance Training
2. Training OverviewSafety FirstWhat is a Cooling TowerCooling TowersComponentsStructureInspection / Maintenance SummaryQuestions / Discussion
3. Safety FirstIdentify potential hazardsPlan aheadFollow safety and health regulationsUse personal protective equipment
4. What Is a Cooling Tower? A cooling tower is a piece of equipment that derives a primary cooling effect from the evaporation of water when brought into direct contact with air. Cooling towers are designed to expose the maximum transient water surface to the maximum air flow.
5. Types of Cooling TowersCrossflow towersCounterflow towers
6. Crossflow Cooling TowersCrossflow cooling towers use splash fill media through which the incoming cool air flows horizontally ACROSS the downward flow of hot water from the top distribution basins. These types of towers were predominantly used from the 1950’s through the 1970’s.
7. Crossflow Cooling Tower
8. Typical Crossflow Towers
9. Counterflow Cooling TowersIn counterflow cooling towers the incoming cool air moves vertically up through the fill media, COUNTER to the downward flow of hot water coming from the distribution laterals. These types of towers are commonly used in today’s applications.
10. Counterflow Cooling Tower
11. Typical Counterflow Towers
12. Other Types ofCooling Towers
13. Cooling Tower Components
14. Cooling Tower ComponentsCounterflow
15. Cooling Tower ComponentsCrossflow
16. Fan StacksCheck for cracksCheck & tighten any loose hardwareCheck & clean weep holes
17. Air Inlet LouversReduce splash out & water lossCheck for broken arms or rods after winter operation
18. Distribution SystemMaintenance interval: AnnuallyCheck lateral to header joints for bushing leakage
19. Distribution NozzlesMaintenance interval: Annual full inspectionMonthly ground level visualsUneven flowPlugged nozzlesRepair: clean out
20. Fill MediaMaintenance interval: AnnualInspect for plugging or biological foulingCheck for damage to top surfaceCheck bottom of fill for sagging caused by exceeding temperature limitation
21. Plugged Film Fill
22. Drift EliminatorsMaintenance interval: annual inspectionLook for damaged or plugged sectionsLook for gaps that permit water bypassRepair: replace damaged sections
23. Mechanical System
24. MotorsMaintenance interval: semi-annualGrease inboard & outboard bearingsMotor may have zerk and grease relief vent, or may have plugs
25. MotorsKeep drive shaft installed during operation
26. Motor LubricantUse a poly urea base grease with a good grade of petroleum oil, No. 2 consistencyIf grease vent plug is NOT removed, grease enter motor windings, causing premature motor failure
27. Drive Shaft & CouplingMaintenance interval: Annual or after high torque eventCheck alignmentInspect for corrosion, soft spots or cuts in shaftCheck flex coupling for protrusions or bumps on surface
28. Gear BoxesMaintenance interval: change oil after first 500 hours or 4 weeks, then every 2,500 hours or 6 monthsDuring shutdown periods: cool down gear box for 4 hours, then run 5 minutes/week until startupCheck oil weekly
29. Gear Box TipsTwo-speed motors: switching from High Speed to Low Speed requires coast-down to below Low Speed rpm before activating motor at Low SpeedCan be done manuallyRecommend timer in circuit to permit fan to coast for specified time before Low Speed is activated
30. Gear Box TipsVariable speed drive operation: Do not operate a standard gear box below 450 rpm due to lubrication problemsInspect case for excessive deposits which may cause overheating
31. Gear Box TipsFill gear box case with oil to top of case through oil breather port and cover with tarpBefore restart: Don’t forget to return oil to correct level prior to operationExtended Shutdown
32. Gear Box Vent LinesMaintenance interval: weekly checksLook for blockage in lineRepair: clean outBlockage causes pressure build up in case
33. Fan AssemblyMaintenance interval: by opportunityCheck fan tip clearanceVisually check leading edges for wearInspect surface for scale build-upCheck hub end of blades for cracksClean weep holes
34. Fan HubMaintenance interval: annualInspect connections between hub and bladesCheck for loose connection between hub and cover
35. Vibration SwitchesMaintenance interval: As required for trip delay set pointBrochures available from Midwest Towers
36. Cooling Tower Structure
37. What Can Go Wrong?
38. Deteriorated Structure
39. Over Tightened Hardware
40. Structural Failure
41. Delaminated Fan Deck
42. Structural Inspection TipsCheck for signs of biological or chemical attack annuallyCheck for cracks or deterioration annuallyCheck & tighten any loose hardware annuallyReplace any damaged structure immediately
43. Recommended Spare Parts(1) Gearbox(1) Drive Shaft (10) Nozzles(10) Louver Arms (If applicable)
44. Inspection/Maintenance SummaryCheck gear box oil level & drive vent tubeWeeklyCheck nozzles for uneven flow or pluggingMonthlyReplace motor bearing greaseSemi-Annually
45. Inspection/Maintenance SummaryInspect structure for cracks & deteriorationCheck, clean & if necessary replace distribution nozzlesCheck & clean fan blades & weep holesCheck fill for damage, plugging or biological growthAnnually
46. Inspection/Maintenance SummaryCheck drift eliminators for damaged sections or gapsInspect fan stacks for loose hardwareCheck drive shaft & coupling (also after high torque event)Check fan blades for wear, cracks, scale & tip clearance (also at any opportunity)Annually
47. Inspection/Maintenance SummaryChange gear box lubricant after first 500 hours or 4 weeks, then every 2,500 hours or 6 months of continuous operation
48. QuestionsIf you are unsure about what to check or have any questions or concerns, please feel free to contact your Midwest Towers representative to schedule a cooling tower inspection.
49. Corporate Office: Chickasha, OKTel 405.224.4622 Fax 405.224.4625www.mwcooling.comsales@mwcooling.comMidwestCOOLING TOWERS, INC