ISO 9001 : 2008

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1. GENERAL

1.1 We thank you very much for going in for HIMGIRI FRP Cooling Tower and
are sure that you will be more than satisfied with its performance. You will
get a better performance and longer life of the cooling tower if the instruction
as mentioned below are followed.

1.2 The operating and maintenance instructions as given below are of

general nature. In case you have any specific queries please do
not hesitate to contact “HIMGIRI”

1.3 The major details and parameters of the HIMGIRI FRP Cooling Tower supplied
to you are as per Our Quotation.

2. PREPARATIONS FOR STARTING

2.1 Cleaning.

Open the drain of the cooling water dirt while scrubbing the water tank with a
brush will flow out.

2.2 Trial Circulation of Water.

Fill the water basin until the float valve cuts off. Start the circulating pump
and make up the water level in the basin as necessary. ( Refer also to pump
starting instruction-part 3.1 )

2.3 Checks.

After the circulations test, check for dirt or foreign matter stuck to the inside
of the tower. Rotate the fan by hand to check that it is free and check the fan
blade tip clearance. Measure the supply voltage and check that the power
supply suits the fan motor. Run the fan momentarily to check the direction of
rotation (it should be anti clock wise when viewed from top side of fan deck.).
Then run the fan for two to three hours to check that no vibration or
abnormal sound develops.

Move the float of the float valve, up and down, to check its discharge and
control of the water level.

Should the tower be idle for some months (either prior to commissioning or
due to shut down ) the following extra checks should be made.

a) Check the insulation of the motor with a megger.

b) Check for loose nuts, especially at fan motor mountings and at the
attachment of the casing and the tank.
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3. STARTING

3.1 Pump Start Up

Run the Pump intermittently for 5 minutes to drive any air out of the water
piping. Again check the water level in the basin before operating the tower.
Start the pump, and adjust the necessary valves until the required water flow
rate is obtained.

3.2 Fan Start Up

(Direction of rotation should be anti clock wise when viewed from top side of
fan deck.)Check that there is no foreign matter near the air inlet and outlet
that could interfere with the fan operation . After Starting the fan, check the
phase currents and voltages to ensure that the motor is operating in
accordance with name plate data.

4. OPERATIONAL CHECKS

4.1.1 Performance

The specified water flow must be maintained to obtain rated cooling capacity.
Be sure that the tower interior is kept clean and that scale and algae do not
form.

4.2 Water Level

If the water level in the water basin drops, air may be drawn, causing
cavitation in the pump. Hence, it is important to maintain the water level.

4.3 Make regular checks for vibration and noise.

Also, regularly check the cooling water temperatures and the electric current
to the fan. As the source of vibration or noise is usually the fan, be careful
not to overlook even a slightest defect.

5. MAINTENANCE

5.1 Casing

No painting is needed for the casing as it is made of F.R.P. when it is soiled;

wash it with soap and water.
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5.2 Water Tank

Scrub the water tank when it is dirty. Flush any dirt out through the drain.

5.3 Nozzles

Ensure that there is adequate water spray and the nozzles are not blocked. If
nozzles are blocked remove them through the inspection window, clean them
and refit them. Broken spray nozzles should be replaced.

5.4 Fill

PVC fills do not deteriorate and no attention is necessary provided proper

water quality control is maintained. In case some scaling is observed clean
the fill packs after removing them from the inspection / service window. The
fill packs may be cleaned by a pressurized jet of water. If the scale is still not
removed the packs may be cleaned by dipping them in dilute solution of HCL
acid (Commercial grade).

5.5 Fan

Check and tighten Blade Clamping Hardware after about a week of

Commissioning and at least at 6 monthly intervals thereafter visually inspect
fan every month and clean the Blades if any dirt has accumulated on them.
Dirt accumulation on Blades could affect balance and result in excessive
vibration.

5.6 Fan Motor

STORAGE - The Motors are to be stored properly in a clean, dry place. It is

preferable to store the motors indoor. Rotate the shaft periodically to avoid
the grease settling down.

INSTALLATION – While installing a motor, the statutory and regulatory

requirements, of any of the country where it is being installed have to be
observed.

FOUNDATION – The foundation of the motor has to be made to minimize

vibration and maintain alignment between the motor and the load.
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5.7 GEAR BOX (Not applicable for small Cooling Tower, where Fan is directly
coupled to motor shaft)

STORAGE - The GEAR are to be stored properly in a clean, dry place. It is

preferable to store the GEAR indoor ABOVE FLOOR LEVEL. Rotate the shaft
periodically to avoid the grease settling down.

INSTALLATION – While installing a GEAR BOX, CHECK THE LEVEL OF

GREASE / OIL AND THEN TAKE IT INTO OPERATION.

FOUNDATION – They are normally vertical mounted . They shall be checked

for proper leveling to sit on perfect plane to minimize vibration and maintain
alignment between the motor and the load.

CONNECTION LOAD (EQUIPMENT) – The motor may be connected to the

equipment to be driven directly or by means of belt and pulley arrangement,
coupling or through a gear system. After connecting the motor to the
equipment, the alignment of the overall system has to be checked.

ELECTRICAL CONNECTION AND INSULATION RESISTANCE – Before the

motor is put into the service, the insulation resistance of the winding – both
between phases and phases to earth must be checked by means of a 500
volts megger. The insulation resistance should not be lower than ten mega
ohms when the motor is cold. It is lower; it may be due to moisture inside the
enclosure, which must be dried out before the motor is put into service.

The supply connections to be made to the motor are given on the nameplate,
or indicated in a separate connection diagram provided along with the motor.
Check phase sequence of incoming supply and the direction of rotation. To
change the direction of rotation, interchange any two of the line leads.

Proper cable glands of appropriate size must be used at the cable entry of the
terminal box of the motor. For motor of IP 55 higher protection double
compression pressure gland are must.

BEARINGS – Motors are provided with grease lubricated ball/roller bearings.

While regreasing, mixing of different base grease should be avoided as the
essential lubricating properties may be lost.

For removing bearings, properly designed draw-off tackle is to be used. Use

tabular drift for fitting bearing, to ensure correct alignment.

MOTOR PROTECTION – Motors are to be protected with fuses of suitable

rating. Also, suitable protections are to be provided with reference to
overload, single phasing and under voltage.
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6. PERFORMANCE

The performance of the cooling tower depends on – (a) water flow, (b) water
temperatures inlet and outlet), (c) ambient wet bulb temperature and (d) air flow.
A large temperature difference in the circulating water does not necessarily mean
that the tower is of high performance. Similarly, a small temperature difference
does not mean that it is of low performance.

The temperature difference is small if the heat load is low. A similar result is seen
when a large volume of water is flowing.

On the other hand, a higher heat load, a reduced water flow or the higher water
inlet temperature makes the temperature difference larger. The relevant factors
may be checked if the performance is not met.

7. CIRCULATING WATER MAKE UP

Loss of water from the cooling tower consists of evaporation and carries over,
which is scattered about by the fan as drift. As continued evaporation of the
circulating water results in increased hardness, corrosion of the circulating
system is possible and scale may form. For this reason, blow-down, in which part
of the circulating water is bled off, is necessary.

7.1 Evaporation Loss

Evaporation loss (E) can be calculated with the following equation:

t
E (%) = --------- x 100
600
Where

t : water temperature range dig’s

600 : latent heat of evaporation in kcal / kg

7.2 Carry over volume

It is very small in volume, and though it is affected by the construction of the

tower proper to a certain extent, it is normally 0.2 to 0.3 % of the volume of
the circulating water flow.
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7.3 Blow-down volume

In order to drain part of the circulating water periodically or continuously, it

is effective to leave the drain slightly open during operation, or to let the water
overflow constantly by raising the operating water level or to change the water
completely from time to time when the water basin is cleaned.

The blow-down volume differs depending on the quality of the water or the
degree of hardness. In most of the cases of air conditioning, about 0.3 %
blow-down is usually necessary. For proper quantity of blow down, please
send the analysis of make water, water circulation quantity and temperature
range to HIMGIRI so that the desired blow down quantity can be informed to
you.
TYPICAL RECOMMENDATION FOR INSPECTION & MAINTENANCE
SCHEDULE

DISTRIBUTION SYSTEM
GEAR BOX (OPTIONAL)

FAN SHAFT BEARINGS

STRUCTURAL MEMBERS

FLOW CONTROL VALVE

DRIFT ELIMINATORS

COLD WATER BASIS

SUCTION SCREEN
MOTOR / GEAR

FLOAT [Link]
BLEED RATE
CASING
FILLS
FAN

INSPECT FOR CLOSING W W W W

CHECK FOR UNUSUAL NOISE & D W D Y

VIBRATION / OIL-GREASE LEVEL
INSPECT KEYS & SET SCREWS S S

LUBRICATE Q Q S

CHECK WATER LEVEL D D

CHECK FLOW RATE M

CHECK FOR LEAKAGE S S S

INSPECT GENERAL CONDITION Y Y Y S Y S Y

TIGHTEN LOOSE BOLTS S S S Y R

CLEAN R S R Y S R R R W

REPAINT R R R R R

COMPLETELY OPEN & CLOSE S

OIL CHANGE / GREASE CHANGE Y

SHELF LIFE OF POLYESTER RESIN

BEFORE LINING – 45 DAYS ONLY.
CLEANING OF FILLS - MANDATORY Y

REPLACEMENT OF FILLS 3
Y
MAIN REASON FOIR REDUCED
EFFICIENCY – FILLS CLOGGING.
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NOTATIONS:

D - DAILY
W - WEEKLY
M - MONTHLY
Q - QUARTERLY
S - SEMI ANUALLY
Y - YEARLY
R - AS REQUIRED.

TROUBLE SHOOTING

Cause & Remedy

PROBLEM CAUSE REMEDY

LOWERING OF TEMPERATURE
DROP ACROSS COOLING FILLS CONDITION IS POOR REPLACE / CLEAN FILLS
TOWER (weight per block of 600 x 150 x 300
mm shall not increase 4 - 5 kg. max).
FAN NOT IN OPERATION CHECK MOTOR, PUT FAN
(Check directio) Should be anti clock wise when IN OPERATION IN
viewed from Top of Fan deck. CORRECT DIRECTION

DISTRIBUTION OF WATER THROUGH CLEAN THE NOZZLES

NOZZLES ON FILLS NOT CORRECT

CHANGE IN DESIGN PARAMETERS AS CHECK PUMP FLOW RATE, PLANT

WATER FLOW RATE, AIR FLOW RATE LOAD, CLEAN HEAT TRANSFER
SURFACES WHEREVER POSSIBLE
ADJUST FAN BLADE ANGLE.

WET BULB TEMPERATURE HIGHER CHECK DESIGN CONDITION, TRY TO

AVOID SATURATED
AIR RECIRCULATION.

MOTOR NOT WORKING IMPROPER POWER SUPPLY CONSULT SUPPLY TERMINALS.

PHASE SUPPLY IMPROPER CHACK PHASE POWER, CONSULT

POWER SUPPLY TERMINAL

STARTER NOT PERFORMING PROPERLY REPLACE STARTER,

CONNECT PHASE FAILURE SAFETY
DEVICES.

MOTOR WINDING DAMAGED SEND OUT FOR REPAIR WITH

SPECIFIC EXPLAINATION AS PER
MOTOR QUALITY.

BEARING JAMMED CLEAN / REPLACE BEARING

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FLUCTUATING WATER NOZZLES CLOGGED CLEAN NOZZLES

FLOW OBSERVED

PUMP PERFORMING AT HIGHER/ LOWER CHECK PUMP GRAPH, CHECK PUMP

DISCHRGE PRESSURE POWER, REMOVE AIR TRAP, REPLACE
PUMP

SUMP WATER LEVEL LOW MAKEUP SUFFICIENT WATER IN BASIN

VALVES, PUMP BAFFELS, FILTERS PERFORM CLEANING ACTIVITY

CHOCKED

WATER CARRY AWAY FROM WATER FLOW MORE THAN DESIGN PUT THE CORRECT PUMP
TOP OF TOWER PARAMETER

NOZZLES CLOGGED, NOT IN POSITION CLEAN NOZZLES, PUT IN CORRECT

DIRECTION

FILLS CHOCKED CLEAN / REPLACE FILLS

MOTOR RPM HIGHER PUT THE CORRECT MOTOR WITH

COMPARATIVELY LOWER RPM

AIR FLOW NOT SUFFICIENT FILLS CLOGGED CLEAN / REPLACE FILLS

FAN ANGLE OF ATTACK INCREASE FAN ANGLE

IN NOT CORRECT

FAN SPEED NOT CORRECT CHECK MOTOR POWER SUPPLY

VOLTAGE, BEARING CONDITION

EXCESS VIBERATION & FAN NOT IN GOOD CONDITION REPLACE / REPAIR FAN
NOISE THROUGH FAN

BALANCING NOT DONE DO STATIC & DYNAMIC BALANCING OF

FAN

MOTOR NOT PERFORMING CHECK MOTOR BEARING

IN GOOD CONDITION

MOTOR MOUNTING FRAME NOT IN GOOD PUT A GOOD MOTOR SUPPORT

CONDITION FRAME.

FAN TOUCHING CASING CREAT PROPER CLEARENCE BETWEEN

FAN TIP AND CASING.

GEAR BOX NOISE LEVEL ON GREASE / OIL

ABNORMAL VIBRATION MOTOR MOUNTING/ FAN CONDITION

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HIMGIRI COOLING TOWERS
SALES OFFICE : 22 & 320 MAHESH INDL. ESTATE, OPP. SILVER PARK, MIRA ROAD (E), DIST. THANE - 401 104.
FACTORY : Plot No. 144/1/1/2, [Link]. 162, Athal Indl. Estate, Village Athal, Dadra Nagar Haveli, Silvassa– 396 230
[Link]. : 28117392 / 28110937 / 28118581 FAX NO. : 28118220
EMAIL : contact@[Link]./ himgiric@[Link]
Website – [Link]