LIANG CEI FRP COOLING TOWER GPERATION AND SERVICE MANUAL MODEL LBC )) UAHG CHI INDUSTRY C8. 17D,PREFACE ‘The adequate knowledge of cooling tower maintenance and control is necessary for user to acquire the best performance under safe operation for a long time. In this manual, the construction ‘of equipment, function, actual operation and checking procedure will be described in the Following. (1) TOWER CONSTRUCTION 11 Type ‘Theoretically, the tower belonged to induced draft counter flow design with an axial flow fan mounted on top of tower to draft air out. The low intemal pressure loss and bottle shaped design ensure the best efficiency and space economy, 12 Casing The F.RP, (fiberglass reinforced polyester) is majorly composed of fiberglass mat in laminate and molded it with unseturated polyester resin. The high structural strength of material itself can be against focal impact without crack. The outer appearance is covered with gel coat to form smooth surface 1.3 Water Basin Also made of F.RP. raw material. The bowlshaped basin with a cylindrical suction sump (LBC-200—1500) can keep pump from cavitation to the minimum, The drain connection provided for removal of accumulated diet from water basin. 14 Tower Support Framewonk (a) EBC3-175 ‘The F.RP. base legs are with water basin in one ody without recoating. The adequate {design can withstand wind pressure and vibration, (B) LBC-200—1500 Provided with hotip galvanized steel to resist corrosion and rust. 1.5 Motor Support Framework Made of hotdip glavanized steel without corrosion and rust too. 1.6 Air Inlet Lower For cooling tower is exposed (0 wind on top of the roof, the P.V.C. plastic mesh is fitted on the air inlet to prevent foreign material into basin or water drip splashing out of basin 17 Filling Made of rigid polyvinyl chloride sheet being embossed and corrugated in honeycomb confirgura- tion. It provides maximum ait to water contact for highest thermal eff 1.8 Sprinkler Device Consist of a set of sprinkler pipe and one sprinkler head that is mounted on top of stand pipe of cooling tower. ‘The sprinkler will be in rotation by the motive force obtained from the water pressure of circulating water. There are numberous holes in few millimeter diameter on the iency.sprinkler pipe. The speedy water will be Jetting from holes acting as rotating force when pump operates. The specified revolution speed can be kept by adjusting the sprinkling angle accorded with water flow rate. Its classified into two kinds of sprinkler head by material: (A) LBC-3-60 (refer to Fig.1, page 5) The outer casing is made of nylon material; The sliding partis lubricated by water itself (B) LBC-70—1500(refer to Fie.2, page 5) ‘The whole body is made of aluminum alloy, itis fitted with sealed type bearings to take ‘thrust and radial loads. These bearings assure that the sprinkler head revolves smoothly. 1.9 Fan Blade ‘The cooling tower not only needs large air volume but considering the low sound noise level; Specifically, the axial flow fans are most sutful with special design for high efficiency. (A) LBC-3-30 made of reinforced plastic material, the blades are coupled with fan hub by bolts and PAC. paste (8) LBC-40—1500 ‘made of aluminum alloy, the blades are freely adjustable by pitch angle scale on fan hub. 3 LBC-1250 & LBC-1500 are available ONLY upon special request. @) PREPARATIONS FOR STARTING 2.1 Open the drain at the bottom of the water basin and wash dust and dirt away while scrubbing. the water basin with a brush, 22. Thal Cirewlation Water Fill water in the water basin to the level where the discharge from the ball tap stops. Slowly rotate the sprinkler by hand to check whether it is free, Start the circulating pump, and after washing the interior of the tower and the water pipes thoroughly, refill the circulating water, 23 Checking After the circulation test, check if there any dirt or foreign matter stick to the interior of the tower or the outlets of the sprinkling pipes. Check to see if the belt of speed reducer has been adjusted correctly. After confirming that the fan revolves smoothly turning it by hand, check the state of gap between the tip of the blades and the tower casing. Measure the supplied voltage and make sure that power supply is in regulation type. Revolve the fan for a short time and make sure that air is blown upward. Revolve the fan two or three hours to see if any vibration or abnormal sound is generated Slowly move the float of the ball tap up and down and make sure the discharge and control system of water is accurate, In case the tower has been left idle for a long time, check the following points and make sure that nothing is wrong, Confirm the insulation of the motor with a megger (See that itis 1 MSY or above using a SOOV. megger). See that no loose nuts are found at various important junctions such as the tightened places of fan driving motor and the junctions between the supporting base and the tower easing, Tum the sprinkler with hand and see if it operates smoothlyor (3) STARTING 3.1 Pump Driving 4m order to make the circulating water fill every part of the circulation system, revolve the Circulation pump for a short while, to drain the air out of the piping of the circulating water. Before entering steady operation, confirm again that the water basin is filled to the specified level, and then start the pump. After starting the pump, gradually open the adjusting valve and adjust it so that the water will reach the volume specified on the name plate of the cooling tower. When circulation of water becomes steady, check to see if the sprinkler is evolving smoothly and the revolution is proper, Revolution of the Sprinkler tae] 9 | 0] ee [soa [pee [ anes [sow] woe) os) er [ass | asa] my [amas | 3.2 Fan Driving Clean up the surroundings of the tower and make sure that no foreign matter are near the ai inlet and outlet. When the equipment goes into steady operation, measure phase voltages and phase curients to ‘see if the motor is operating at the rated current range indicated on the name plate (#) CAUTIONS DURING OPERATION 41. Performance Since the cooling performance will be affected by the volume of the circulating water, be sure ‘to maintain the regulation water flow for all the time, Keep the interior of the tower always clean and take care that no scale or moss grow. 42 Water Level When the level of the water in the water basin drops, air is sucked in and “Cavitation” may develop; Therefore, itis necessary to keep the water level proper for all the time, 43 Functioning Pay close attention to the vibration, noise, temperature of the cooling water and electric current uring operation and make sure that nothing goes wrong. The source of vibration or noise is ‘mainly from the moving parts consisting of the speed reducer and the fan, be careful not to ‘overlook even a slight defect.(3) MAINTENANCE AND CONTROL 5.1. Sprinkler Pipe The sprinker pipe must be clean without blockage. If there is some fo the pipe, deal it with following steps: (A) Loose the set screw or lock nut on sprinkler device, then remove sprinkler pipe out to clean, (B) Align the dot mark on sprinkler head in the line as installed it again. jgn material retarded in For LBC-3~15 model, it is fitted with type A and B pipe of which hole pitch is different to assure even water distribution, 5.2 Sprinkler Head ‘The sprinkler head will rotate slow down, even stop if scale sticked in itor less water flow rate In this case, check it as follows: (A) LBC-3-60 (refer to Fig, 1 page 5) a. remove set screw cap on top of sprinkler head. bv. loose nut and washer, then take head off, . lean it with fresh water and check if any component worn out or not. (B) LBC-70-1500 (sefer to Fig.2 page 5) as remove the cap out and take circlip of, bb. pull the rotary part off the fixing part for check and replacement. SPRINKLER HEAD tac] 3] 1s] 25] s0-] 70] 125-] 200- | 300. | s0o-| 800. MosetNo:| Yo | 20 | 40) 60 | 100] 178 | 250 | 400 | 700 | 1500 -040-|-050-|-06s- | -080- | -100- | -125- | -150- |-200- |-250- | -300- LsHt Model No: lem ation Noi | Description ["TSH—100 [LSH-125 LSH-200 | LSH—250 | LSH-300 1 | Cap Cirelip Bearing 630iz_| 63022 | 63022 | 63032 | 304 | 640s Bearing housing Center pole Bearing ‘6002 | 60032 | s003z | 60042 | c00sz | co06Z Oil seal Spring washer ‘Nat Headoew Lone L o Genter Pate Washer @ Pua ~ “@ tan one =o “Bhat Sere (EP ® i = Ht © \ Ls A om Ser \ Soi Path + LSH.100~1sH-300 Fie. 2 5.3 Tower Casing No coating is needed for the tower casing as it is made of F.RP. IF it becomes soiled, wipe it with soap, water soaked piece of cloth and then wash it thoroughly with water 54 Water Basin ‘As dust and dirt are liable to get into the water basin, open the drain at the bottom of the Grop-in tank from time to time and wash it clean. This applies also to the water basin, In Particular as sediments are liable to accumlate near the outlet, Keep the tank clean so that the strainer mesh will not be dogged, 5.5. Filling No special cae is needed ifthe control of the quality of water is adequate during operation. 5.6 Fan Watch the surface of the blades carefully to see that no damage develops andl make sure that Proper space is maintained between the internal wall of tower casing and the tip of blades. mS eee LSP | os 5 5.7 Coating It is desirable to give periodic recoating to the metal parts as they are easily subject to rusting. 3K LBC-1250 & LBC-1500 are available ONLY upon special request(6) V-BELT SPEED REDUCER With increasing public awareness of noise, our engineers have developed a V-belt drive to reduce ‘operating noise levels. This new drive produces much lower noise levels than those obtained from conventional gear drives of the equivalent size. The V-belt is a wide angle (60°C) which is made of a special polyurethane compound with polyester tension cords (tensile member). Very compact V-belt drives are possible With this belt. With proper maintenance, the V-belt drive is thereafter reliable and satisfactory in ‘operation, However, proper maintenance is essential and the following instructions are very important, 6.1 Bele Adjustment Before operation, open the adjustment access cover and check whether the washer on the adjusting bolt is aligned with the adjusting gauge. (Ref. Fig.A Tighten the adjusting fut if necessary.) Adjusting Nu & Lach \ __sasing ote Washer Avign washer with ioting gaoge FIG. A During operation the belt may stretch, allowing belt slip and abrasion. Hence the belt tension should be checked at the following conditions. (A) SO hours after commissioning. (B) Thereafter, carry out 3 checks, each at 100 hour interval (C) After the 4th check at 350 hours, regularly check each month, Off Season Shut Down—For a long-time shut down, slacken the adjusting nut 4-Smm to prevent bolt stretch. Re-adjust belts prior to putting the cooling tower back into servie. ‘Adjustment Precaution—If a gap exist between the adjusting gauge and the washer, the belts are too slack. If the washer and the adjusting nut overlaps the adjusting gauge, the belts are 100 tight. ‘The life of the belts depends on the maintenance of proper tension. The adjusting gauge is factory set and should not be altered. 6.2. Testing of Drive Operation After checking the belt adjustment, spin the fan by hand to see whether itis free. If i spins freely and smoothly, start the fan motor. After 2 to 4 hours operation, check amperage and voltage and compare the readings with motor nameplate data. Check the motor temperature and check noise and vibration 6.3 Maintenance ‘The following work should be performed, (A) Drive Section Clean out the inside of the driving section annually -6-(B) Motor Insulation Before putting the tower into service in each cooling season, check the motor insulation with a S00 Volt Megger. A resistance greater than 1 M&tis acceptable. (C) Bearings Although itis unnecessary to lubricate the sealed bearings,an annual change of grease will extend their life. To repack the bearings, remove the seal plates with a sharp toot inserted as indicated by the arrow in Fig.B. Replace the seal plates after repacking the bearings. (D) V-belts Maintain belt adjustment as described above, This drive uses high quality special V-belts, ‘The Vebelts are designed to operate $,000 to 10,000 hours. If slipping or belt abrasion becomes evident after operating over 5,000 hours then replace the belt sets, If after 5,000 hours, excessive adjustments of belt tension are requited due to belt stretch, the belts have reached the end of ther life and should be replaced with belts as recommended in the V-belt Table at page 9, Since V-belts arc not widely available , please contact, cour nearest distributor for replacement. Belts must alway's be replaced in matched sets ‘ig, both upper and lower sets must be replaced simultaneously, Hence one faulty belt requires the replacement of up to 10 belts To replace belts, remove the belt cover from the belt case, slacken the adjusting nut and push the intermediate pullgy assembly towards the motor (Refer Fig.C), Remove old belts and replace with new sets. tnd move intermediate Pulley Newt Paley Ned,MOTOR and_V-BELT SPEED REDUCER Ee] 3 oo aaa a g ei2 1a ——| oO ey] = [= Soins Ba g Ee Sa “ s ce 2 ‘0| Pulley No. T a Ti_| Wen Cppen S 8 | « [35 Housing Coe Wo? —] Tater Stal Ha Bearing 8 Tne 5 Hoag Ce Onset Crain e Terminal bo ering A Setter T V-BELT SPEED REDUCER BEARING TABLE Yeh Daarag Set | tac skewer | Mott |e Toa [a lc ]lplel]o Lm.ossc | 225 @ 250 | 63062 | 6308ze | 62072 | 63082 | 2112 | 6012 | siz Lpm.o7s | 300.8 350 | 206 | 63082r | 620s: | osloe | ezit2 | eor2 | s1112 Lam-t10 | 400 & 500 | 6308z | 630322 | eanse | eat0e | 62132 | ear | sins | Lam.iso | 600 & 700 | ea08zz | 630522 | 62092 | 6313 | NI3I3| Nu2is| sis Lpm-220 | 800 & 1000 | 3092 | 6attze | e2ise | atte | Nuai7| Nuai7| suit Lpm-300 | 1250 & 1500 | aie | oatzer | 62isz | aire | nuai7] Nyai7] sitELT TABLE (I) V-Belt Fan Belts No. | Belts No. | Speed unc) Fan V-belt oF ‘Of | Betts No. Reducer Model ‘Ps Model No. Upper Lower Total Model No. RPM Pulley | Pulley | ‘LBM-05: 225 & 250 (398 2STIMS— 800 t — 1 fe 3—11MS—800 = 1 1 | ‘LBM-075, 300 & 350 398 2=1IMS—800 ——. 2 2} * ° 3—11MS—800 1 = [a 2—11Ms—1400 | = 1 Lami | 400.8 s00 | 342 3=1IMs— 1400 | — H i | LBM-150 | 600 & 700 282 | 2=IMS—1400 1 . 2 q [3etis—1400 | 1 1 LBM-220 | 800 & 1000 | 265 EIMS= 1550 = 2 2 pee 31IMS—1550 1 1 2 LBM-300 1250 & 1500 260 2OUIMS— 1550. 2 2 4 - : 3—11MS—1550_ 1 2 3 V=BELT TABLE (II) v- y] Belts No. | Belts No Spd LBC Fans | vapet Of ON | Bets No. Reducer Model Speed | Model No. | Upper Lower Total Model No. RPM. Pulley Pulley Lum.ossc | 225.6280 | 398 | tim—s00 | 2 3 5 Lam.o7s | 300.6380 | 398 | M800 | 3 4 7 Lami | 400.850 | 342 | iM—140) 2 3 5 LBM-150 | 600.&700 | 282 | 11M—1400. 2 5s 7 LBM-220 800 & 1000 265 1IM—1550, 3 | 7 10 Lam300 [1250 € 1500 | 260 | 1im—1550) 10 a (7) PRECAUTIONS IN PROLONGED INDLENESS. Unless the circulation water is drained, it may freeze in winter and cause the pipes to crack, If the Grain of the drop-in tank is kept open, rain-water and snow water will not accumulate in it, Make sure that tightening bolts on the various parts of the tower, especially on the moving parts are tight. As the cooling tower is installed on top of the roof, its desirable to cover up the tower casing and the air exhaust outlet, 2 LBC-1250 & LBC-1500 are available ONLY upon special request. =(8) WATER TREATMENT A. Bacterial Contamination Bacterial contamination of recirculated water in cooling tower is possible 11 is therefore recommended that, after the cooling tower is commissioned, a regular ‘maintenance program be investigated. This should include treatment of the recirculated water. ‘As we are not experts in this fleld we strongly recommend that a reputable water treatment company be consulted for the treatment of the systems recirculated water. BL Water Quality Control Poor quality of recirculated water due to air pollution, corrosion, scale and algae growth, will impede the performance of water colled equipment, We recommend a periodical water analysis and blow-down be initiated to maintain the water quality within the water cooling system to the permissible water quality as follows, PERMISSIBLE VALUE OF WATER ANALYSIS (JCI CODE) PARAMETER Make-up water Growtating water PH OSC) os Cy Electric conductivity Guvjem) 200 below 500 below Total hardness (CaCOs)npm 50 alkalinity (ACOs ppm 30 Chlorineion ppm 50 | Sulphuric acid jon "Y ppm 30 Silicie acid (Si0;) ppm 30 Ferrie (Fe) ppm 03 ~10~TROUBLE ANALYSIS TABLE -— Trouble Causes Counter-Measures Rise in cooling water Excess or inadequate cooling [Adjust to the speeified flow. CCC eee>—=—eeee au temperature water flow. 2. Irregular flow of at. 2. Improve ventilation. 3, Recirculation of airexhausted | 3. Same as above or install from tower: baffles 4, lnrogular operation of 4, Remove dust and scale, sprinkler pipes. 5. Improper flow of ar. 5. Adjust the angle of fan blades, 6. Blocking of the filing. 6. Clean the blocked areas, }Drop in the volume of 1, Blocking of the sprinkler 1. See section for maintenance ‘cooling water pipe holes. and adjustment 2. Blocking of strainer mesh, | 2, Remove strainer and clean, 3. Drop in the waterlevel of | 3. Adjust float valve. water basin 4, Improper slection of water | 4, Replace the pump with one circulating pump. ‘matching planned volume of water, Noise and vibration 1, Fan blade tips touching fan | 1. Adjust the fan mounting, stack. 2. Improper mounting of fan | 2. Correct the blade angle blades, settings. - 3. Loose bolts 3. Tighten loose bolts 4. Shortage of speed reducer | 4. Supply oil up to the level oil specified. Excessive current draw | 1. Drop in voltage. 1. Check supply voltage. Notify ower company if necessary, 2, Irregularities in the angles | 2. Adjust fan blade angles. of the fan blades. 3. Overload through excess air | 3. Adjust fan blade angles, flow. Water carry over 1. Irregular operation of T. Adjust the angle of the sprinker pipes sprinkler pipes in the sprinkler head, 2. Blocking of the filing. 2. Bliminate blockage at the upper edge of the filling. 3. Defective eliminator. 3. Renew the eliminator. 4. Too much circulating water. | 4, Adjust the water flow by ‘means of the val,LIANG CHI FRP COOLING TOWER MODEL LBC CONSTRUCTION & INSTALLATION DATATHE BIGGEST MANUFACTURER OF COOLING TOWER IN TAIWAN WHOSE PRODUCTS ARE ALL OVER THE WORLD ‘The TAO-YUAN Factory of Liang Chi Industry Co., Ltd. ‘TAIWAN, REPUBLIC OF CHINA. ‘OFFICE: No, 292, CHANG CHUN ROKD, ‘Tipe, TAIWAN, PUBLIC OF CHINA ‘Yak: (02 5063588-96 (13 UNES) FAX (CABLE: "UAMGRING” TAPE! TUSK: 11076 FACTORY: NO. 291, SEC. 2. HAE SUN ROAC, NAG VKLAGE,TAOYUAN, TAIWAN, REPUBLIC OF CHA, Fax 9) deat | LIANG CHI INDUSTRY CO., LTD. | DisTRIBUTOR: 1 mf Seeeoo aaa ceeee eee ceeaaeel