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Cooling Tower Installation Manual
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    Tower Tech, Inc . 5400 N.W. 5th Street Oklahoma City, Oklahoma 73127 USA TEL: 405.290.7788 FAX: 405.979.2131 Sales@TowerTechInc.com ▪ Service@TowerTechInc.com www.TowerTechInc.com Installation, Operation and Maintenance Manual TTXL Series Modular Cooling Tower  ™   Ver. MK9000-12 Orig. 09/22/2015 © 2015-2016 Tower Tech, Inc. All Rights Reserved.      Tower Tech Modular Cooling Tower ™  Date: 09/22/2015 MK9000-12 Page 1 of 130 TTXL Series Installation, Operation and Maintenance Manual Outperform    ™   Table of Contents   Chapter One:   About This Manual ............................................................ 5  1.1 Scope ........................................................................................................... 5 1.2 Use .............................................................................................................. 5 1.3 Reference .................................................................................................... 6 1.4 Customer Service Support .......................................................................... 6 Chapter Two:   TTXL Series Features ....................................................... 7  2.1 Model Nomenclature .................................................................................. 7 2.2 Modular Design .......................................................................................... 7 2.3 Sump Design ............................................................................................. 11 2.4 Make-Up Connection / Float Valve .......................................................... 12 2.5 Rotary Spray Nozzle ................................................................................. 13 2.6 Motors ....................................................................................................... 16 2.7 Fans ........................................................................................................... 16 2.8 Fan Shroud ................................................................................................ 24 2.9 Fill Media .................................................................................................. 24 2.10 Drift Eliminators ....................................................................................... 26 2.11 Safety Point Brackets ................................................................................ 27 2.12 Power and Control Wiring ........................................................................ 27 Chapter Three:   Materials of Construction ............................................ 31  3.1 Background ............................................................................................... 31 3.2 Tower Walls .............................................................................................. 31 3.3 Fan Shroud ................................................................................................ 32    Tower Tech Modular Cooling Tower ™  Date: 09/22/2015 MK9000-12 Page 2 of 130 TTXL Series Installation, Operation and Maintenance Manual Outperform    ™   3.4 Fan Motor Support .................................................................................... 32 3.5 Tower Internals ......................................................................................... 32 Chapter Four:   Optional Equipment ....................................................... 34  4.1 Sub-Structure (Leg) Kit ............................................................................ 34 4.2 T9900 Motor Control Panel ...................................................................... 35 4.3 T2100 Motor Protection Panel .................................................................. 39 4.4 Variable Frequency Drive ......................................................................... 39 4.5 Immersion Basin Heater ........................................................................... 40 4.6 Vibration Control ...................................................................................... 44 4.7 Ultrasonic Liquid Level Sensor ................................................................ 44 Chapter Five:   Preparing for Installation ............................................... 47  5.1 Limitations ................................................................................................ 48 5.2 Tower Location ......................................................................................... 49 5.2.1 Environmental Safety Considerations.......................................... 49 5.2.2 Re-Circulation Considerations ..................................................... 49 5.2.3 Interference Considerations ......................................................... 50 5.3 Tolerances ................................................................................................. 50 5.3.1 Leveling ....................................................................................... 50 5.3.2 Foundation/Slab or Pier Requirements ........................................ 50 5.3.3 Positioning ................................................................................... 51 5.3.4 Piping ........................................................................................... 51 5.3.5 Layout Recommendations ........................................................... 51 5.4 Sub-Structure Installation   ………...………………………………..…….42  5.4.1 Installation of Sub-Structures Taller Than One Foot (30.5 cm) .. 53 5.4.2 Installation of One-Foot (30.5 cm) Sub-Structure ....................... 54  Chapter Six: Rigging & Handling ……………………………………...45   6.1 Introduction ............................................................................................... 56    Tower Tech Modular Cooling Tower ™  Date: 09/22/2015 MK9000-12 Page 3 of 130 TTXL Series Installation, Operation and Maintenance Manual Outperform    ™   6.2 Accessory Location Checklist................................................................... 57 6.3 Procedure .................................................................................................. 57  Chapter Seven: Tower & Peripherals Installation…..………………...49  7.1 Sump Attachment...................................................................................... 61 7.1.1 Procedure ..................................................................................... 61 7.2 Piping Connections ................................................................................... 63 7.2.1 Inlet Connection ........................................................................... 64 7.2.2 Discharge Connection .................................................................. 65 7.2.3 Make-Up Connection ................................................................... 66 7.2.4 Overflow/Equalization Connection ............................................. 66 Chapter Eight:   Tower Start-Up .............................................................. 67  8.1 Filling System with Water ........................................................................ 71 8.2 Controlling Water Level ........................................................................... 81 8.3 Hydraulics ................................................................................................. 83 8.3.1 Single Pump Operation Procedure ............................................... 84 8.3.2 Multiple Pump Operation Procedure ........................................... 84 8.3.3 VFD Pump Operation Procedure ................................................. 84 8.4 Initial Fan Start-Up ................................................................................... 86 8.5 Flow Balancing ......................................................................................... 87 Chapter Nine:   Operation ......................................................................... 89  9.1 Water Flow Control .................................................................................. 89 9.2 Water Temperature ................................................................................... 89 9.3 Fan Control ............................................................................................... 90 9.4 Cold Weather ............................................................................................ 91 9.4.1 Tower Offline During Cold Weather ............................................ 91 9.4.2 Cold Weather Operations .............................................................. 91 9.4.3 Basin Heater Installation, Testing, Start-up and Operation .......... 91 9.5 Water Treatment ..................................................................................... 103 9.5.1 Scale Control ............................................................................... 103 9.5.2 Solids Control ............................................................................. 104
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