Spx Cooling Technologies Tower 160 Users Manual
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2015-02-06
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/ Marley Class 160 Cooling Tower / / The Marley Difference / You’ll enjoy single source responsibility and reliability How many other cooling tower companies can offer you because we design and manufacture virtually all major cooling this assurance? They may use Brand “A” nozzles with Brand tower components. “B” fill and Brand “C” drift eliminators. When they all come All Marley components are designed and selected to be together, the whole may be less than the sum of the parts. part of an integrated system. For example, the spray pattern Our total system approach assures that all the parts work from nozzles and the pressure drop through drift eliminators together to provide you the greatest total performance. both affect a fill’s heat transfer capacity. So, we include that And because we design specifically for cooling towers, impact in our thermal analysis. all our components will provide many years of service with Drift eliminators must be effective at the air velocities minimal maintenance. From design through installation and on where fill is most efficient. So, we’ve carefully designed both throughout your tower’s life, all of SPX will work for you. components to work together efficiently. / Class 160 Tower Advantage / ■ Guaranteed Performance. Don’t rely on outside agencies ■ Low Operating Costs. Marley high-efficiency fill and fans, with limited enforcement powers. We’ll stand by our gravity-flow water distribution, and efficient Geareducer® responsibility for reliable thermal performance. We designed drive work together to offer maximum cooling with it. We rate it. We guarantee it! minimum power use. ■ Low Maintenance Costs. Induced-draft propeller fans on ■ Long Service Life. We’ve carefully chosen all the materials used in Class 160 towers for their corrosion resistance Marley rightangle Geareducer units; TEFC, 1.15 service and suitability for cooling tower service. Pressure-treated factor motors; and heavy-duty mechanical equipment lumber, heavy-galvanized steel, stainless steel, PVC and supports assure long service life with minimal maintenance. fiberglass keep your Class 160 tower working year after ■ All-Season Reliability. Class 160 towers perform as specified year. in the heat of summer. They respond well to energy management techniques in the spring and fall. They ■ Efficient Field Assembly. Precise factory fabrication assures that every component in your Class 160 tower will fit as operate virtually ice-free in the dead of winter. And they designed. And SPX offers an unparalleled nationwide offer simple maintenance all year long. construction organization to build your tower quickly and We guarantee it! economically. ■ Single Source Parts Availability. SPX designs, manufactures, ■ Easy Maintenance Access. The Class 160’s crossflow design guarantees, and stocks all major components of the tower gives you quick, direct access to the open distribution except motors and some fan sizes. In fact, we stock many basins, plenum and mechanical components for regular of those parts, too. We’ll have the parts if you ever need inspection and service. them. 2 / Construction and Components / ■ Fill/Louvers/Drift Eliminators Marley high-performance film fill is the heart of every Class 160 tower. A repeating chevron pattern provides the wetted surface and air turbulence necessary for proper heat transfer, while minimizing resistance to airflow so you’ll save on fan power. Molded protrusions on each fill sheet assure uniform spacing. Fill sheets are vacuum formed 15 mil (.015″) thick PVC (polyvinyl chloride) capable of service at hot water temperatures up to 120°F. Consult your Marley sales representative for applications where hot water temperatures are greater than 120°F yet less than 145°F to determine upgrade possibilities. Stainless steel structural tubes resting in stainless steel hangers support the fill, and PVC tubes control alignment. This system also holds the bottom of the fill sheets ■ Mechanical Equipment above the cold water basin floor to simplify basin cleaning. The Marley Geareducer speed reducer used in the Class Fill sheets include both louvers and drift eliminators. The louvers in this patented arrangement keep water on the 160 line contributes a long record of dependability, long service fill sheets and in your tower, and also assure proper heat life, and low maintenance. Their designs meet or exceed the transfer throughout wide variations in airflow. Users find this fill requirements of CTI STD-111 and AGMA Std. 420.04. We run- operates ice-free even in extremely cold weather. in every Geareducer unit under load prior to shipment to make sure that it will operate properly on your tower. Integral drift eliminators prevent the costly nuisance of Housings are gray cast iron. Gears are high-strength, drift spotting on objects in the surrounding environment. Their unique shape induces the air flow through three distinct case hardened alloy steel. And all bearings are tapered roller direction changes as shown below. The final turn directs air bearings. A variety of available horsepower capacities and toward the fan to save you fan horsepower. Moisture carried reduction ratios lets us choose the optimum Geareducer model in the air stream can’t make these abrupt turns, so drift is less and fan speed for your job. Service factors are always at least than 0.005% of the circulating water flow rate. 2.0 as applied. Splash-type lubrication and integral cooling fins preclude the need for maintenance-intensive oil pumps and coolers. A constant oil bath or flow lubricates every bearing in forward or reverse motion—at full or half speed. All Marley Geareducer assemblies are rightangle type with motors located outside the tower’s saturated airstream. A galvanized steel lube line runs from the Geareducer unit to a standpipe near the motor on each cell, so you can check oil level and change or add oil while standing on the fan deck. 3 ■ Water Distribution System Class 160 towers offer the benefits of adjustable pitch propeller type fans. All fans used on Class 160 towers include The gravity-flow water distribution system designed into the hollow GRE (glass-reinforced epoxy) blades and epoxy-coated Class 160 tower essentially reduces pump head to its most cast iron or galvanized steel hubs. Blades are adjustable in basic component—static lift—saving you money on pump pitch, so you can take full advantage of rated horsepower or power. You won’t have to force water through internal piping adjust the pitch to compensate for unusual jobsite restrictions. and pressure spray nozzles, as you would in a counterflow The true airfoil blades, designed specifically for cooling towers, tower. offer efficient, quiet operation and long service life. Warm water enters the system through a Marley galvanized crossover pipe. Inlet connections for your piping are drilled to conform to Class 125 ANSI requirements. Marley flow-control valves balance the flow to both distribution basins of each cell. Water flows from the valves through a splash-suppression chamber and into the treated fir plywood distribution basins. Polypropylene Marley “Spiral Target” nozzles in the basin Fans operate inside structural FRP (fiber-reinforced polyester) eased-inlet fan cylinders designed and applied to maximize fan performance. Standard cylinder heights are 6′-0″ to 7′-0″, depending on fan diameter. 10′-0″ cylinders are floor then distribute the water uniformly over the fill. available as an option. All materials in the water distribution system offer long life Marley-manufactured driveshafts transmit power from the and minimal maintenance. Valves consist of cast iron bodies motor to the Geareducer assembly. All Marley driveshafts and grease-lubricated stainless steel operating stems. All include 304 stainless steel tubes with welded-on stainless plywood is treated exterior grade. The nozzles are chemically steel flanges and bonded neoprene flexible elements to and biologically inert, so they’ll last indefinitely. transmit torque. Marley driveshafts are full-floating assemblies with non-lubricated flexible couplings on each end. Their ■ Structure and Materials tolerance to misalignment and torsional shock is unequalled in non-specialized units. All Marley driveshafts are dynamically Class 160 tower design conforms to the latest edition of balanced at the factory to minimize operating vibrations. the National Design Specification for Wood Construction (NDS) published by the National Forest Products Association, as well Welded unitized hot dip galvanized steel supports maintain alignment throughout the mechanical equipment system. as CTI standards STD-114 and STD-103. Wind load criterion Marley torque-tubes provide superior strength and stability. is normally 30 pounds per square foot of projected area and Their cylindrical shape also keeps operating costs down by the design meets criteria for UBC Zone 1 seismic loading, minimizing airflow restrictions and reducing air turbulence in based on a maximum water temperature of 120°F. the fan entrance region. 4 The primary structural elements of all Class 160 towers Hinged doors through the endwall casing permit access to are the nominal 4″ x 4″ columns spaced on 4′-0″ longitudinal the interior of the tower at the basin level. Single-cell towers centers. A system of nominal 4″ x 4″ tower diagonals carries have one door. Multicell towers have doors in both endwalls, loads in both tension and compression to heavy-duty hot dip plus accessways through any and all partition walls. galvanized steel anchor plates. All mechanical equipment is accessible both from the Pressure-treated Douglas Fir is the standard material for interior of the tower and through the fan cylinder. Every structural members in Class 160 towers because it offers component of every tower is removable and replaceable. predictably consistent structural strength and provides long service life in cooling towers. ■ Casing Unless otherwise specified, all lumber is pressure treated Tower endwalls are cased with gray 8 oz/sq ft ribbed FRP after fabrication. Treatment in accordance with CTI Standard sheets. Water and corrosion-proof FRP is immune to biological STD-112 is available on request. deterioration and requires no maintenance. All structural framing connections use ¹⁄₂″ diameter Casing ribs run vertically. Vertical joints between sheets galvanized machine bolts with either fiber-reinforced nylon are overlapped one rib and are sealed in the fill areas. Casing shear connectors or FRP connector straps. attaches to the structural members with stainless steel The fan deck is pressure treated exterior grade fir plywood fasteners and neoprene bonded washers. Corner trim pieces designed for a uniform live load of 60 psf. are 12 oz/sq ft molded FRP. ■ Access and Safety ■ Cold Water Basin The Class 160 tower is designed to meet all OSHA Most Class 160 owners install their towers over concrete requirements. A 3′-6″ high guardrail system complete with top cold water basins provided by others—or you can choose a rails, intermediate rails and toeboards, surrounds the entire top wood collection basin as an option. See page 11. perimeter of the tower. Consult your Marley sales representative for detailed Aluminum ladders attached to the tower endwalls provide dimensional drawings and load schedules to help you with access to the fan deck level. Ladders begin at the cold water your basin design. basin level and end at the top of the guardrail around the fan deck. Each tower normally includes two ladders—one at each endwall. 5 / Operating and Environmental Considerations / ■ System Cleanliness Cooling towers are usually selected to produce a specific cold water temperature at the higher summertime wet-bulb Cooling towers are very effective air washers. Atmospheric temperatures. During the remainder of the year, the cooling dust able to pass through the relatively small louver tower is capable of producing much colder water. Unless openings will enter the circulating water system. Increased your system will benefit from the coldest possible water concentrations can intensify system maintenance by clogging temperature, you may want to consider controlling cold water screens and strainers; and smaller particulates can coat temperatures to higher levels. You'll also save energy by using system heat transfer surfaces. In areas of low flow velocity such control. See Marley Technical Report (such as the cold water basin), sedimentary deposits can #H-001A, “Cooling Tower Energy and its Management”. provide a breeding ground for bacteria. Always control leaving water temperature by manipulating In areas prone to dust and sedimentation, you should the quantity of air that the fan moves through the consider installing some means for keeping the cold water tower. Varying the quantity of water flow is not normally basin clean. Typical devices include side stream filters and a recommended and can be harmful in freezing weather. You variety of filtration media. can alternately start and stop single-speed motors to keep You should also plan ahead to develop a consistent, water temperatures within an acceptable range. But your effective program of water treatment. A good water treatment flexibility is limited by the amount of starting time per hour program will help to assure long service life, while keeping your allowed by the motor manufacturer. tower free of potentially harmful biological growths. Increased flexibility can simplify your operating procedures and save you money in the long run, both on operation and on maintenance. Here are two of the more popular options: ❑ Two-speed motors improve operating flexibility by increasing the number of potential operating modes. Users in northern climates will find that the tower can carry winter Caution loads at half-speed; reducing fan power requirements by 85+% during that time. Two-speed motors also help The cooling tower must be located at such distance and direction to avoid the possibility of contaminated tower discharge air being drawn into building fresh air intake ducts. The purchaser should obtain the services of a Licensed Professional Engineer or Registered Architect to certify that the location of the tower is in compliance with applicable air pollution, fire, and clean air codes. to control icing during wintertime operation. See Marley Technical Report #H-003, “Operating Cooling Towers During Freezing Weather”. Normally, two-speed motors are provided in 1800/900 RPM, single winding configuration, which is the least expensive two-speed option. They are also available in other combinations including the more expensive double winding. ❑ Frequency modulation devices work well on induced draft, propeller fan cooling towers such as the Class 160. However, their design must include the capability to lock out any critical fan speeds and the very low fan speed ranges. Consult your Marley sales representative for specific recommendations when considering variable speed control. In many cases, for example, you'll achieve the best results by using a single control to regulate the speed of several fans on a multicell tower. 6 W OUT TO OUT OF TOWER / Tower Schematic / C DIA. FAN A BAYS @ 4a-0q= L 5q 5q CL COL. COL. CL Tower Plan TOP OF FAN CYLINDER B H TOP OF FAN DECK BASE OF TOWER COL. Endwall Elevation 4OWER -ODEL 1. '0PER #ELL 7IDTH ,ENGTH (EIGHT 7 , ( $IMENSIONS ! " # -AXIMUM -OTOR HP 3TATIC ,IFT a 6Mq a q a 56 q a q q a a 6Mq a q a 56 q a q q a a 6Mq a q a 56 q a q q a a 6Mq a q a 56 q a q q a a 6Mq a q a 56 q a q q a a 6Mq a q a 56 q a q q a Last number of model indicates number of cells. Change as appropriate for your selection. Primary engineering data is per cell. 2. 3. 7 Fan hp is usually less than shown here. Height shown is from base of tower columns to fan deck. Wood basin, if used, elevates tower 6¹⁄₄″. If concrete basin is used, subtract 1′-6″ for height above top of basin curb. / Steel Basin Support / E BAYS @ 4a-0q= L EACH ADDITIONAL CELL= L CL COL. 756Oq OUT OF BASIN COL.CL COL.CL FACE “B” AIR INLET FACE ADDITIONAL SUMP WHEN REQUIRED OVERFLOW FACE “A” CASED FACE D C C SUMP ADDITIONAL OVERFLOW WHEN REQUIRED CL COL. D FACE “C” CASED FACE B B A W OVERALL WIDTH OF BASIN A 7 6 q 756Oq OUT OF C COL. BASIN L 7 6 q FACE “D” AIR INLET FACE Two beams shown phantom are required on Models 1651 and 1661 only. All Note: dimensions are to centers of tower columns—not centers of anchor bolts or beams. 4OWER -ODEL 1. 2. 3. $IMENSIONS # $ /PERATING 7EIGHT LB 3INGLE #ELL %ACH #ELL !DD 7 ! " % , a q a 6 q a q a q a q a 6 q a q a q a q a 6 q a q a q a q a 6 q a q a q a q a 6 q a (6 q a 56 q a q a q a 6 q a 56Oq a 56Oq a q Use this bulletin for preliminary layouts only. All dimensions show column locations, not anchor bolt locations. Obtain current drawings from your Marley sales representative before designing supports. Other contractors or purchaser must design and erect supporting steel. If steel beams are used, they must include ⁷⁄₈″ dia. holes to accept anchor bolts provided by Marley. If concrete beams or pilasters are used, ³⁄₄″ dia. anchor bolts imbedded in the concrete must be provided by others. 4. 5. 6. 8 Maintain no less than 2′-0″ of clear space at cased faces for construction purposes. Air inlet faces must have unobstructed air supply. Consult your Marley sales representative if nearby obstructions may interfere. Operating weight is wet weight of tower and wood basin, including 6″ of water in the cold water basin. This is the recommended operating water level for all models. For collection basin accessories information request Marley drawing 90-3231 from your Marley sales representative. 6q MIN. 6q MIN. A BAYS @ 4a-0q= B PER CELL 6q RECOMMENDED OPERATING WATER LEVEL 1a-6q 6q COL.CL FACE “B” AIR INLET FACE FACE “A” CASED FACE FACE “C” CASED FACE CL COL. FACE “D” AIR INLET FACE 6q MIN. W IN TO IN OF BASIN WALLS 6q MIN. / Concrete Basin / RECOMMENDED OPERATING WATER LEVEL 1a-6q 1a-0q Flat Slab Basin 4OWER -ODEL 1. 2. 3. 1a-0q Deep Basin $IMENSIONS 7 ! " a 6Mq a q /PERATING 7EIGHT LB 3INGLE #ELL %ACH #ELL !DD a 6Mq a q a 6Mq a q a 6Mq a q a 6Mq a q a 6Mq a q Use this bulletin for preliminary layouts only. Do not use for construction. Obtain current drawings from your Marley sales representative. Concrete basin design and construction are by other contractors or purchaser. Operating weight is total wet operating weight of tower only, excluding water in concrete basin. Maintain at least 2′-0″ of clear space at cased faces for construction purposes. Air inlet faces must have unobstructed air supply. Consult your Marley sales representative for recommendations if nearby obstructions may interfere. 4. 5. 6. 9 Minimum basin depth is 1′-6″. Maximum basin depth is 5′-6″. Marley will provide (at extra cost) extended interior columns for deep basins. Perimeter columns remain at 1′-6″ below top of basin curb. All anchor bolts, complete with nut and washer, must be furnished by others. Bolts must be ³⁄₄″ diameter with 2″ all-thread projection. Other contractors or purchaser must design, locate, construct, and furnish sump(s) and overflow(s) to suit requirements. The sump(s) should be designed according to the pump manufacturer’s recommendations. Other design sources: ANSI/HI specifications 1.1-1.5 for centrifigal pumps, 2.1-2.5 for vertical pumps, and 9.8 for pump intake design. E F MINIMUM FAN CL TOWER CL TOWER / Inlet Piping Plan / FACE OF A DIA. INLET FLANGE C D TYPICAL MULTICELL CL COL. CL INLET PIPING SHOWN WITH HIDDEN LINES IS BY OTHERS CL INLET B DIA. FLOW CONTROL VALVE CL INLET AND CROSSOVER PIPE G BASE OF TOWER COL. 4OWER -ODEL 1. 2. 3. '0PER #ELL $IMENSIONS ! q q q q q q q q q q q q " q q q q q q q q q q q q # $ a q a q a q a q a q a q a q a q a q a q a q a q Use this bulletin for preliminary layouts only. Obtain current drawings from your Marley sales representative. Pumping head contributed by the tower is static lift shown on page 7. Actual pumping head will vary according to tower circulating GPM. Total pumping head will be furnished at time of proposal. If your application requires a bypass system, recommended location is through tower endwall into plenum area. Review of the system by Marley engineering is required. 4. 5. 6. 10 % a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq a 6Mq & a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q ' a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q a 6 q Marley piping terminates at face of a cast iron flat face flange. Bolt circle conforms to class 125 lb. ANSI B16.1 specifications. Supports on tower for crossover piping are furnished by Marley. Do not support the riser’s dead load or operating load from the tower. Do not brace the riser’s seismic or thrust loads against the tower. On Models 1611 through 1641 with a 32 or 3200 Geareducer the inlet diameter must be 20″. / Available Options / ■ Cell Partition Options the plenum chamber between fill banks, just inside the endwall access door to facilitate adjustment and maintenance. Every Class 160 tower includes plenum partitions and hot water distribution basin partitions between adjacent cells. Plenum partitions keep air from entering an operating cell ■ Fire Safety Options through an adjacent idle fan—assuring consistent thermal On specific jobs you may want to weigh the cost of various performance. Basin partitions let you inspect and clean modifications against the cost (and maintenance) of a sprinkler individual basins while the rest of the tower continues to system—or the cost of higher insurance premiums. One or operate. more of the following tower modifications may negate the need Specify extra partitions carefully because excess partitions for a sprinkler system: can sometimes discourage routine maintenance and good ❑ Fire-retardant fan cylinders offer flame spread less than 25 housekeeping procedures. Two options are available to meet per ASTM E-84. specific design goals: ❑ A ¹⁄₄″ thick fiber-reinforced cement board (FRC) overlay on ❑ Fill area partitions are available, but usually not necessary. the fan deck acts as a fire stop and provides a nonskid The solid sheet design of film fill prevents water and air walking surface. migration between the fill areas of adjacent cells in all operating modes. ❑ A ¹⁄₄″ FRC overlay on the distribution basin covers acts as a fire stop. ❑ Complete watertight partitions let you use adjacent cells to serve separate loads having incompatible system ❑ Barrier walls keep fire from spreading between cells in temperatures. Watertight partitions consist of exterior multicell towers. Specify barrier wall design by containment grade, pressure-treated fir plywood, sealed to cold water period, such as a “20-minute fire wall”. Barrier walls consist basin partitions made from the same material as the basin of pressure-treated fir plywood between cells. Plywood sides. For concrete basin partitions, Marley drawings thickness (and cost) vary according to the specified specify the appropriate design dimensions. containment time. Optional weir gates in wood basin partitions let you mix or ❑ FRP casing having a flame spread rating of 25 or less. segregate the water in the basin to meet your operating If your insurance carrier insists on a sprinkler system for needs. your tower, consult your Marley sales representative. We can provide a sprinkler system to fit your needs, or work with your people to be sure that the sprinkler system and tower will meet ■ Cold Water Collection Basins your specification. If you plan to locate your tower above grade, we can supply a treated Douglas fir cold water collection basin, complete with ■ Non-Standard Motors the necessary operating accessories. The basin floor is exterior grade, pressure-treated fir plywood, supported on joists. Although you can buy your Class 160 tower “less motor” Basin sides are also plywood, machined to fit the basin floor, at a cost reduction, it is not normally recommended. Motors providing a watertight joint after sealing. supplied on Marley towers meet rigorous specifications The standard wood basin includes at least one or more developed from environmental chamber tests at our depressed, side-outlet sumps, complete with plugged drains Development Center. These specifications represent prudent and hot dip galvanized or stainless steel debris screens. minimum design requirements. Standard sumps are FRP construction or galvanized steel Unless otherwise specified, motors provided are TEFC, depending on outlet size. 1.15 service factor (appropriate to the applied load), 1800 Each basin includes an overflow/cleanout connection RPM. Other enclosures (such as Explosion Proof) and motors consisting of a galvanized full coupling and normally-installed specially wound for nonstandard voltages are available at extra standpipe which removes easily for flush-out basin cleaning. cost. A float operated, mechanical makeup valve automatically Two-speed motors are also available, and their advantages replenishes water lost from the system. The valve is located in are discussed on page 6. 11 / Available Options / Accessory Description and Remarks Accessory Description and Remarks Plywood Collection Basin Pressure-treated Douglas fir plywood collection basin for towers located above grade. See page 11. Fire Protection Sprinkler systems and overlay materials let you choose from a range of fire protection options. See page 11. Extended Columns for Deep Collection Basin Interior tower columns can be extended to permit concrete basin depth of up to 5’-6”. Some exceptions apply, so consult your Marley sales representative. Ladder Extension Used when tower is elevated appreciably above working level. Extensions attach to the normal ladder and may require foot anchorage (depending on length). Cell Partition Extra partitions between fan cells for specific operating considerations. See page 11. Stainless Steel Hardware All hardware, including assembly hardware and some specialty items, are series 300 stainless steel Vibration Limit Switches Robertshaw or Metrix single-pole, doublethrow vibration switches in NEMA 4 housing. Double-pole, double-throw models are also available. Oil Level Gauge A brass oil level sight glass replaces the dip stick on the external oil fill and drain system. Permits easy reading of oil level and also provides access for Geareducer oil changes. Air Inlet Screen Galvanized wire mesh screens over the air inlets keep leaves and debris out of the tower. Easily removable. Choose either treated fir frames or galvanized steel U-edge frames. Distribution Basin Cover Fan Cylinder Extension Optional flared fan cylinder extensions improve fan efficiency to reduce your operating costs. Removable, treated fir plywood covers keep upper basins free of leaves and debris. They also tend to retard growth of algae by keeping ultraviolet radiation away from the warm water in the basins. Covers may be used as a working surface for tower maintenance. 7401 WEST 129 STREET OVERLAND PARK, KANSAS 66213 UNITED STATES 913 664 7400 spxcooling@spx.com spxcooling.com In the interest of technological progress, all products are subject to design and/or material change without notice. ©2008 SPX Cooling Technologies, Inc. Printed in USA | CL160-06
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