Precautions for cooling tower operation

 Note ： In order to fully understand the installation, use, operation and

maintenance of cooling towers, it is recommended that you read this manual
and the instructions for cooling towers, motors and fans carefully before
using them.
A．Install the point
1. It should be installed on the top of the pool or on the roof or where the air is
flowing smoothly. Otherwise, the performance and service life of the cooling
tower will be affected.
2. Avoid installation in places with soot and dust。
3. Keep away from hot places such as kitchen and boiler room.
4. The foundation of the cooling tower shall be horizontal, firm and not inclined,
and the center line of the cooling tower shall be perpendicular to the horizontal
plane, otherwise the operation of the motor will be affected.
5. The cooling tower fan is located on the reducer, and the fan must be firmly
fixed on the reducer. After fastening at any time during installation, rotate the fan
by hand. The fan shall rotate flexibly without jamming, otherwise it cannot be
started for trial operation. The fan blade shall be adjusted and balanced, and the
angle difference is not allowed to be too large. If any problem is found, it shall be
solved in time.
B．Precautions for equipment pre use inspection and startup
operation
 Note: As FRP and cooling tower packing are combustible goods, special
attention should be paid to fire prevention in the process of use and
maintenance, so as not to ignite the cooling tower and cause losses to you.
1. Preparation before operation of cooling tower
1.1 Clean the site to ensure that there are no sundries in and on the tower.
1.2 Recheck whether the installation position of each component meets the
installation requirements, whether each fastener is loose, and all pull rods
shall be tightened with adjustment allowance.
1.3 Check the insulation resistance of the motor to avoid burning the motor
during operation.
1.4 Before the operation of the cooling tower, the sundries in the pipeline
 must be cleaned to avoid blocking the nozzle, resulting in the wall clearance
controlled between 20-45mm. People are not allowed to walk on the blades.
The cover plate of the distribution tank and each access door shall be opened
flexibly.
1.5 When the cooling tower fan is driven by belt, check whether the bearing
has been greased, whether the V-belt tightness is appropriate, whether the
belt pulley is horizontal and whether the belt model is consistent, so as to
prevent the belt from loosening and slipping and ensure the smooth
operation of the fan.
1.6 When the cooling tower fan adopts gearbox, check whether the oil circuit
is unblocked, whether the oil pipe is kept on the same plane and whether the
oil level is at the specified position. The allowable deviation of motor output
shaft and gear input axial shaft is 0.1mm, the allowable deviation of coupling
parallel is 0.1-0.5mm, and the longitudinal and transverse direction and
horizontal error of adjusting seat shall not be greater than 0.12/1000 (see
the fan manufacturer's Manual for detailed data).
1.7 Check whether the stop fuse at the output end of the fan is installed
correctly.
 Note：The above conditions shall be comprehensively inspected and handled
as required. They can be put into operation only after there are no problems.
2. Commissioning of circulating water system
2.1 Gradually open the water inlet header valve and adjust the water volume
to the rated value through the valve.
2.2 When the rotating water distributor is used for water distribution in the
cooling tower, the rotation of the water distributor shall be observed. The
water distributor shall operate stably and distribute water evenly. In case of
any abnormality, it shall be eliminated according to the provisions of common
faults and troubleshooting. Add molybdenum disulfide grease to the bearing
and oil seal of the water distributor every 1-2 months.
2.3 The inlet pipe pressure of circular cooling tower is required to have
3.5m-5.0m water column at the inlet, and the inlet pipe pressure of square
cooling tower is required to have 6.5m-8.0m water column at the inlet. The
pressure should not be too high, otherwise the water floating phenomenon of
 the cooling tower is serious.
2.4 The cooling tower adopts pipeline water distribution. Check whether the
water distribution is uniform. If there is any abnormality, eliminate it
according to the provisions of common faults and troubleshooting.
2.5 Observe the ponding height of the sump, adjust the position of the
make-up water float ball and the height of the overflow pipe, and control the
ponding depth within the design range.
2.6 The water outlet of the cooling tower shall be unblocked, and the grid
shall be set at the water outlet.
2.7 Check whether the cooling tower body leaks. If there is any leakage, it
shall be sealed in time.
 Note：After the above items operate normally, close the header valve for the
next step.
3. Commissioning of fan system
3.1 Clean up the site
3.2 Recheck whether the installation position of each component meets the
installation requirements and whether the connectors of each fastener are
loose.
3.3 When the fan adopts gearbox, recheck whether the oil circuit is unblocked
and whether the oil level is at the specified position. When using belt
transmission, recheck whether the belt tightness is appropriate and whether
the bearing seat in the transmission device has been filled with grease.
3.4 Check whether the blade installation angle is correct and consistent, and
whether the horizontal position error of each blade is within the allowable
tolerance. Whether the impeller, blade and counterweight are installed
according to the corresponding number.
3.5 Check whether the impeller and blade are firmly installed, whether the
bolts are firm, whether the shaft end brake fuse is reliably installed, and
whether the shaft end pressing plate is firmly connected.
3.6 Check whether the insulation resistance of the motor meets the standard,
whether the cable is firmly laid and fixed, and whether the wiring is good.
3.7 Rotate the fan impeller by hand, and the fan shall operate smoothly and
evenly.
 3.8 Start the motor and check the rotation direction of the blades.
3.9 Run continuously for 1 hour, measure and record the current value and
voltage value of the motor. Check whether the gearbox and motor have
abnormal sound, abnormal heating and other abnormal phenomena.
3.10 When the fan is driven by belt, check whether the belt pulley operates
stably and whether the belt slips.
3.11 Observe the vibration of the tower.
3.12 If the above 3.9 is abnormal, shut down the fan and adjust the blade
installation angle until it meets the requirements.
3.13 After 4 hours of continuous operation
（1）Recheck whether the position of each component is loose
（2）Check whether all connectors and fasteners are loose
（3）Check whether each sealing part leaks oil
（ 4 ） Check whether the oil temperature of motor, bearing pedestal and
gearbox meets the requirements. See the fan manufacturer's Manual for
specific data of gearbox oil temperature.
After the above steps are normal, enter the following operation.
4.Water steam combined commissioning steps
4.1 Start the fan first. After the fan operates normally, open the water inlet
valve and gradually increase the water volume to the rated design value.
Check whether the water outlet of each water inlet pipe is uniform, and
whether the water inlet and ponding of the diverter are in order to prevent
short circuit of the air chamber.
4.2 Continue to detect fan vibration, power consumption, oil temperature and
oil level.
4.3 Continue to check the water distribution and splash of the air inlet
window.
4.4 Check the service effect of the water collector, and the floating water loss
at the air outlet shall be controlled below 0.01% of the total circulating water
volume.
4.5 After continuous operation for 72 hours, stop again and conduct
comprehensive inspection on the tower and fan. After confirming that there is
no abnormality, it can enter normal operation. Generally, 10-15 days after the
 first operation of the fresh air fan, clean the gearbox and replace with new oil
(see the fan manufacturer's Manual for specific operation).
After the cooling tower is put into normal operation, in order to ensure that it
is always in the best working state and can work effectively for a long time, it is
necessary to carefully read the precautions for the use of the cooling tower, pay
attention to various testing work, strictly implement the patrol inspection system
and carefully make records.
C．Precautions for putting into use
1. Before the use of the cooling tower, carefully remove the sundries and dirt on
the pipes, water collectors, filler surfaces and sump to avoid blockage.
2. When starting the cooling tower, the water pump must be started first and
then the fan. It is not allowed to operate the fan without water spraying,
otherwise the filler or water collector will be taken away by the wind; Check
whether the wind direction is upward.
3. The cooling tower shall be commissioned before use. Check whether the fan is
installed stably and whether all screws are tight. Whether the water distribution
of the nozzle is uniform, whether the moisture-proof measures of the motor are
tight, etc. The connector between the motor lead and the power line must be
waterproof to prevent damage to the motor and loss to you. Check whether the
power supply and motor voltage are consistent.
4. The fan of the cooling tower has high balance requirements. Please pay
attention to protection during use, and do not deform the blade, so as not to
cause unbalanced operation of the fan and damage the motor and reducer of the
cooling tower. When the cooling tower works normally, the fan shall rotate
clockwise (looking down) and the wind moves from bottom to top, otherwise the
motor lead shall be replaced or necessary inspection shall be made.
5. When the cooling tower is used, it shall be observed frequently to check
whether the fan rotates clockwise (looking down); The current shall be equal to
or less than about 85% of the rated current, and the current shall not be too large,
otherwise the motor will be damaged; Check the voltage, fan vibration, noise,
gear oil level, oil leakage or normal water distribution, etc.
6. Before starting the reducer, check whether the oil level reaches the center line
of the oil scale. During normal operation, the oil level of the oil gauge shall be
checked frequently. It is recommended to use No. 22 ~ 28 hyperbolic gear oil or
no. 90 ~ 120 industrial gear oil as lubricating oil, and use oil with high viscosity
in summer. In addition to continuously filling to the specified oil level at ordinary
times, it shall be replaced once at the beginning of continuous operation for 10 ~
15 days, and once at the second operation for 6 months. After that, it shall be
replaced at least once every year of continuous operation. In case of
deterioration of oil quality, it shall be replaced in time.
7. Turbine maintenance
7.1 Monthly inspection (routine appearance): when the water turbine is in
normal operation, the appearance inspection shall be carried out every month or
1000 hours of continuous operation.
 Mechanical damage
 Water and oil leakage
 Whether the operating speed is normal
7.2 Annual inspection (routine appearance)：
 According to the requirements of monthly inspection
 Inject grease into the upper and lower oil holes (high temperature bearing
grease, lithium base 5#)
 Surface coating paint maintenance
7.3 Replacement cycle of wearing parts
 The water seal and bearing need to be replaced every 20000 hours of
operation
 The oil seal needs to be replaced every 40000 hours of operation
8. Precautions for use of rotary atomizer：
The wear degree shall be checked frequently during normal operation；
High temperature bearing grease, lithium base 5#, is recommended for
lubricating oil. In addition to continuously filling to the specified oil level at
ordinary times, it shall be filled once at the beginning of continuous operation for
10 ~ 15 days. After that, it shall be filled at least once every 6 months of
continuous operation. In case of deterioration of oil quality, it shall be replaced
with new oil in time.
When the cooling tower is shut down for a long time, grease (high temperature
bearing grease, lithium base 5#) must be added from the oil hole. When running
again, after continuous operation for 2 hours, shut down and add lubricating
grease again.
9. After the cooling tower operates for a period of time, pay attention to check the
fastening of connecting parts and bolts, especially whether the nuts of fan and
motor are loose. If they are loose, they shall be handled in time.
10. The pressure of water inlet pipe of circular cooling tower is required to have
a lift of 3.5m ~ 5.0m at the water inlet; The inlet pipe pressure of square cooling
tower requires a head of 6.5m ~ 8.0m at the inlet. The pressure should not be too
high, otherwise the water floating phenomenon of the cooling tower is serious.
11. During the use of the cooling tower, the water quality management shall be
strengthened. The turbidity of the circulating water shall not be greater than 20
mg / L and 50 mg / L in the short term. At the same time, the circulating water
shall not contain errors and mechanical impurities. During operation, regular
sewage discharge or adding water quality stabilizer shall be considered
according to the water quality. When bacteria and algae are produced in
circulating water, water quality algicide can be added to remove them.
12. Under the freezing point temperature in winter, the tower is prone to icing.
Pay attention to the icing problems such as air inlet window, and take
corresponding measures to help melt the ice.
13. When the cooling tower stops working, stop the fan first and then the water
pump.
14. Performance of cooling tower: affected by cooling water volume, inlet and
outlet water temperature and meteorological parameters, pay attention to the
flow of cooling water and water temperature difference parameters regularly and
make records.
15. As an important cooling equipment, the cooling tower shall be managed by a
specially assigned person during operation, the working conditions shall be
observed frequently, and any abnormal conditions shall be eliminated in time.
D．Precautions for daily maintenance of motor
1. Frequent starting of the motor will cause overheating and will not win more
than 6 times per hour.
2. When using two speed motor, there shall be a 15 second delay when running
from high speed to low speed.
3. The operating environment shall be kept dry, the motor surface shall be kept
clean, and the air inlet shall not be obstructed by dust, fiber, etc.
4. When the thermal protection and short-circuit protection of the motor act
continuously, find out whether the fault is from the motor or overload or the
setting value of the protection device is too low. It can be put into operation only
after the fault is eliminated.
5. Good lubrication of the motor during operation shall be ensured. Generally, the
motor operates for about 5000h, that is, the lubricating grease shall be
supplemented or replaced (it is not necessary to replace the lubricating grease
within the service life of the closed bearing). After overheating or deterioration
of the bearing is found during operation, the lubricating grease shall be replaced
in time.
6. When the service life of the bearing ends, the vibration and noise of the motor
will increase significantly. Check that the radial clearance of the bearing reaches
the following values, that is, the bearing shall be replaced.

Bearing inner 20——30 35——50 55——80 85——120

diameter（mm）
Ultimate wear 0.10 0.15 0.20 0.30
clearance（mm）
E. Cooling tower cleaning
Because most of the cooling water contains calcium, magnesium ions and acid
carbonate, carbonate will be formed when the cooling water flows through the
metal surface. In addition, oxygen dissolved in cooling water will also cause
metal corrosion and rust. Secondly, due to the generation of scale and the growth
of algae, the heat transfer effect of cooling tower packing decreases. The packing
is seriously blocked, which directly makes the heat exchange effect ineffective.
The data show that scale deposits have a great impact on the loss of heat transfer.
With the increase of sediment, the maintenance cost will increase in the later
stage. Even if a thin layer of scale is generated, a lot of human and material
resources will be invested in maintenance. Therefore, keeping the cooling
channel free of mineral deposits can improve the efficiency and save the cost.
Prolong the service life of the equipment and save production time and cost at
the same time.
For a long time, traditional cleaning methods such as mechanical method
(scraping and brushing), high-pressure water and chemical cleaning (pickling)
have many problems in equipment cleaning: scale and other sediments cannot be
completely removed, acid solution causes corrosion to the equipment, forming
loopholes, residual acid causes secondary corrosion or under scale corrosion to
the materials, and finally leads to equipment replacement. In addition, the
cleaning waste liquid is toxic, A lot of money is needed for wastewater treatment.
In view of the above situation, efforts have been made at home and abroad to
develop cleaning agents with low corrosivity to metals, and the successfully
developed youshitaike cleaning agent. It has the characteristics of high efficiency,
environmental protection, safety and no corrosion. It not only has good cleaning
effect, but also has no corrosion to the equipment, which can ensure the
long-term use of the cooling tower. When bacteria and algae are produced in
circulating water, water quality sterilizer can be added to remove them.
Circulating water quality requirements (with water quality limit)
Project Make up water Circulating water
PH（25℃） 6-8 6-8
Conductivity（uv/CM） Below 200 Below500
Total hardness（CaCO3）p p m Below50 Below200
M alkalinity（CaCO3）p p m Below50 Below100
Chloride ion（CL）p p m Below50 Below200
Sulfate ion（SO4）p p m Below50 Below200
Iron（Fe）p p m Below0.3 Below10