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User Manual
Clayton's interest in your cooling tower does not end with the sale. Having conceived, designed and manufactured the most reliable and long lasting cooling tower of its class, we want to make sure that you gain the maximum possible benefit from its purchase.
Therefore, the following services are available which are intended to assure the maximum possible service life under your operating conditions; tailor the operating characteristics to your specific needs; and maintain consistent optimum thermal performance capability.
They are available by contacting your Clayton Sales Engineer.
Cooling Tower Fundamentals
The basic principle bringing about the cooling in a cooling tower is the mechanism of evaporative cooling and the exchange of sensible heat. The air-water mixture releases latent heat of vaporization. The water exposed to cooling air steams, evaporates as the water changes to vapour. The heat is taken from the water that remains by lowering its temperature.
However, there is a penalty involved, and that is loss of water which goes up the cooling tower and is discharged into the atmosphere as hot moist water vapor. Under normal operating conditions this amounts to approximately one and two tenths percent (1%) for each 10* F (5.5* C) of cooling range. Sensible heat that changes temperature is also responsible for part of the cooling tower's operation. When water is warmer than the air, there is a tendency for the air to cool the water. The air then gets hotter as it gains the sensible heat of the water and the water is cooled as its sensible heat is transferred to the air.
Cooling due to the evaporative effect of the release of latent heat of vaporization amounts to approximately 75% while 25% of the heat exchange in the cooling tower is sensible heat transfer.
Complete drift elimination is possible in theory, but impractical in application. The acceptable level generally satisfactory is "not in excess of 0.05%."
Trouble | Possible Cause | Remedy |
|---|---|---|
Cold water too warm | Over pumping; fill improperly installed; not enough air | Adjust water flow to design conditions; make sure all fill sections are intact and properly installed; make certain motor hp is correct; see if fill or eliminators need cleaning; see if anything is obstructing inlets or discharge |
Excessive movement in speed-reducer pinion and low-speed shafts | Worn high speed and low speed bearings | Replace worn bearings and oil seals; check tooth contact of gears after replacing gears and/or bearings |
Excessive water drift | Broken or plugged distribution system; broken or missing drift eliminators; fan pitched above design; overpumping | Replace or clean nozzles; see that all fill and eliminator sections are in place and intact; pitch fan to design conditions; reduce water flow to tower design conditions |
Motor won't start | Line trouble; single-phasing at starter; improper connections; load too heavy (disconnect motor to see if it starts without load) | Check source of power supply and correct; check connections with circuit diagram; reduce load or, if necessary, replace motor with unit of greater capacity |
Motor, motor-bearing overheating | Overload (measure load, compare with nameplate rating); misalignment; excessive end thrust; too much grease (ball or roller bearing); insufficient lubricant | Check for excessive friction in motor drive or unit; check for overvoltage, improper connections; realign set; reduce thrust from drive or machine; relieve grease supply and boost oil to points set by manufacturer |
Noisy gears and bearings in speed reducer | Worn bearings or gear set; warped gearing; low oil level; contaminated oil; protective shield rubbing gear case; bearing fatigue | Check oil for level and contamination; adjust oil shield; replace worn bearings, oil seal or gear sets; check tooth contact of gears; add oil if necessary |
Uneven water distribution | Broken or plugged nozzles and/or distribution piping; distributing pan out of level; excessive or uneven water flow | Replace or repair defective parts; clean distribution system and pump suction screen; adjust water flow to design conditions. |
Unusual motor noise | Motor running single-phase; electrical unbalance; worn bearings | Stop motor, try to restart (unit won't start if single-phased); check wiring, controls, motor and all three lines-correct if required; check lubrication; replace bad bearings |
Vibration in couplings and drive shaft | Misalignment of couplings; foreign matter adhering to coupling; shaft out of balance, bent or off-center; worn bearings or bent shaft in motor or gear unit | Realign coupling and recheck alignment after 30 days; tighten motor and speed-reducer hold-down bolts |
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