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 principal 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. Acceptable level generally satisfactory is "not in excess of 0.05%."

Trouble Shooting in Cooling Tower

No.	Trouble	Possible Cause	Remedy
1.	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.
2.	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
3.	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
4.	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
5.	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
6.	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
7.	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
8.	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
9.	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

Periodic maintenance: You may wish to have a contract with Clayton for regularly scheduled visits for the purpose of inspecting and reporting your tower's condition to make recommendations intended to prevent emergencies.

This service is not intended to replace the important function performed by your maintenance staff. Their attention assures the tower's routine operating performance and is invaluable.