Marley AV Series Cooling Tower - Engineering
Contents
1. 1 2 DIA ANCHOR BOLTS 4 REQD 148 1 2 1 8 1 2 MIN 8 O 1 2 MIN 1 1 S re 1 23 l lt m 5 TT Sy 1 10 1 4 lt i gou L f Ew C Lo TOWER COLLECTION TOWER COLLECTION BASIN AIR INLET FACE BASIN AIR INLET FACE SUPPORTING STEEL SUPPORTING STEEL OPTION THREE OPTION FOUR r MINIMUM BEARING WIDTH MUST BE PROVIDED BY BEAM FLANGE OR BEARING PLATE AT EACH ANCHOR BOLT LOCATION 3 1 2 MAX TO CLEAR LARGES BOTTOM OUTLET FLANGE TOWER NOTE 1 2 COLLECTION TOWER BASIN 1 2 WASHER REQD COLLECTION 1 2 WASHER REQD BY OTHERS BASIN BY OTHERS NORMAL SUPPORT SUPPORT NORMAL GAUGE ee BY OTHERS VIEW B BY OTHERS S GAUGE ANCHOR BOLT LOCATION RELATIVE TO BEAM ORIENTATION IS OPTIONAL VIEW C Use this bulletin for preliminary layouts only Obtain current drawings from your Marley sales representative for final design Grillage anchorage Option Three is not intended for use with the Bottom Outlet Option Multicell installations shall conform to arrangements shown The standard spacing between the side face anchor bolts is 5 Purchaser to provide tow2. They are also used in the cool ing of jacket water for engines and air compressors and are widely applied to dissipate waste heat in a variety of industrial and manufacturing processes Choosing the all stainless steel construction option the AV Series can be confidently applied in unusually corrosive processes and operating environments However no single product line can answer all problems and selective judgement should be exercised in the following situations Applications Requiring Alternative Cooling Tower Selections Certain types of applications are incompatible with any cooling tower with PVC film fill whether AV Series or a competitive tower of similar manufacture PVC is subject to distortion in high water temperatures and the narrow pas sages typical of film type fill are easily clogged by turbid or debris laden water Some of the applications which call for alternative tower designs are e Water temperatures exceeding 125 F will adversely affect the service life and performance of normal PVC fill Ethylene glycol content can plug fill passages as slime and algae accumulate to feed on the available organic materials Fatty acid content found in processes such as soap and detergent manufacturing and some food process ing fatty acids pose a serious threat for plugging fill passages Particulate carry over often found in steel mills and ce ment plants can both cause fill plugging and can build up
3. 100 class 125 ANSI pipe flange specifications All outlet ar 3000 19 38 57 75 113 150 rangements include easily removable debris screens 4000 25 50 75 100 150 200 Multicell towers intended to operate together as a com 5000 32 63 94 125 188 250 mon unit are joined by steel flumes between the collection 6000 38 75 113 150 225 300 basins These flumes equalize the operating water level 8000 50 100 150 200 300 400 between basins and also provide a flow passage from cells not equipped with outlets or makeup valves often eliminat NOTE ing the need to specify an outlet and makeup valve for If circulating water is to be maintained at 2 concentrations instead of each cell on a multicell installation Refer to sales drawings 3 multiply table GPM values by 1 36 before sizing makeup valve to obtain flow values of suctions and bottom outlets for multicell installations The best choice for a tower used with a remote or indoor storage tank see page 1 1 or on a concrete cold Makeup Valve Flow Capacities GPM water basin is usually a bottom outlet with or without Basen A Vets rst 1 Diamter 0 Diameter screen while flowing psig Valve Valve 10 56 90 Makeup 20 78 120 The amount of water constantly evaporated from a 30 92 143 cooling tower varies directly with the heat load applied E 40 106 160 In addition to evaporation water is normally lost to the blowdown bleed off necessary to maintain dissolved 9d pud 167 solids concentration at a
4. 15 11168 5706 AV62041 259 20 11212 5749 AV62051 275 25 11314 5851 AV63001 190 7 9893 5421 3066 AV63011 204 10 9920 5448 3093 AV63021 232 8 4 15 21 8 774 14 6 e 15 39 15 10197 5726 3285 AV63031 248 20 10278 5807 3366 AV63041 264 25 10370 5899 3458 AV64001 201 7 10467 5688 3066 AV64011 217 10 10494 5715 3093 AV64021 246 15 10785 6002 3285 8 4 16 7 e 7 15 11 6 16 8 A0 AV64031 263 20 10865 6087 3365 AV64041 285 25 10958 6180 3458 AV64051 302 30 11024 6246 3524 AV65001 242 10 11976 6386 3470 AV65011 270 15 12076 6486 3570 AV65021 288 20 12402 6813 3771 9 10 1671548 10 172 15 11740 16 8 6 AV65031 311 25 12506 6917 3875 AV65041 329 30 12541 6952 3910 AV65051 345 40 12709 7120 4078 AV66001 279 15 13263 6901 3947 AV66011 305 20 13335 6973 4019 AV66021 322 11 10 15 2 12 174 14 6 e 15 374 25 13710 7347 4262 AV66031 343 30 13743 7380 4295 AV66041 355 40 13912 7549 4464 AV67001 293 15 14009 7224 3947 AV67011 320 20 14081 7296 4019 AV67021 344 11 10 16 719 121 110 157 1176 16 8 A0 25 14186 7401 4124 AV67031 365 30 14510 7724 4295 AV67041 390 40 14679 7894 4464 NOTE 1 Use this bulletin for preliminary layouts only Obtain current 4 Standard overflow is a 4 dia connection in the collection basin drawings from your Marley sales representative All table data wall on the air inlet side of the tower A 3 dia drain connection is per cell is located below the overflow See page 7 for details 2 Las
5. 3 I beam side rails and 1 25 diameter serrated rungs shall extend from the base of the tower to the top of the handrail Ladder Extension Add the following to the end of the Hot Water Basin Access Platform paragraph Provide a ladder extension for connection to the foot of the external ladder This extension shall be long enough to rise from the roof grade level The installing contractor shall be responsible for cutting the ladder to length attaching it to the foot of the tower ladder and anchoring it at its base Ladder Safety Cage Add the following to the end of the Hot Water Basin Access Platform paragraph A heavy gauge galvanized steel safety cage shall surround the ladder extending from a point 7 O to 8 O above the foot of the ladder to the top of the distribution basin access platform handrail 24 Specification Value E Periodic inspection and maintenance of a cooling tower distribution system is fundamental to preserv ing maximum cooling system efficiency All cooling towers crossflow or counterflow are subject to clogging to varying degrees by waterborne contam inants such as pipe scale and sediment Therefore safe and easy access to these components is of significant value to the operator Access can be provided in a number of ways including portable lad ders or scaffolding but for maximum safety and convenience a factory installed Marley access platform with guardrails makes thi
6. A 3 diameter drain and a 4 diameter overflow shall be provided in each cell of the tower The basin shall include a depressed section into which accumulated silt can be flushed to permit cleaning The basin floor adjacent to the depressed section shall slope toward the depressed section to prevent buildup of silt under the fill area Towers of more than one cell shall include stainless steel flumes for flow and equalization between cells All steel items which project into the basin columns diagonals anchor clips etc shall also be made of stainless steel Replace paragraph 8 1 with the follow ing A stainless steel open basin above the bank of fill shall receive hot water piped to each cell of the tower The distri bution basin shall be installed and sealed at the factory and shall be equipped with removable stainless steel covers to keep out leaves and debris and to retard the growth of algae All Stainless Cooling Tower Replace paragraph 5 1 with the follow ing Except where otherwise specified all components of the cooling tower shall be fabricated of heavy gauge series 300 stainless steel The tower shall be capable of withstanding water having a chloride content NaCl up to 750 ppm a sulfate content SO4 up to 1200 ppm a calcium content CaCO3 up to 800 ppm silica SiO2 up to 150 ppm and design operating ranges up to 50 F The circulat ing water shall contain no oil grease fatty acids or organic s
7. ask your Marley sales representative for a copy During shutdown water collects in the cold water basin and may freeze solid You can prevent freezing by adding heat to the water left in the tower or you can drain the tower and all exposed pipework at shutdown Electric Basin Heaters An automatic basin water heater system is available con sisting of the following components Stainless steel electric immersion heater s Threaded couplings are provided in the side of the collection basin NEMA 4 enclosure containing Magnetic contactor to energize heater Transformer to convert power supply to 24 volts for control circuit Solid state circuit board for temperature and low water cutoff Enclosure may be mounted on the side of the tower Control probe in the collection basin to monitor water temperature and level Heater components are normally shipped separately for installation by others Note any exposed piping that is still filled with water at shutdown including the makeup water line should be electrically traced and insulated by others Freeze Prevention Steam Jet Heater Penberthy Houdaille bronze steam jet heaters to 34 are available for freeze protection installation by others Injectors install in a coupling provided in the side of the col lection basin Live steam as required is injected directly into the water Condensed steam adds water to the basin and t
8. beam side rails and 1 25 diameter serrated rungs shall extend from the cold water basin to the top of the handrail Wi Periodic inspection and maintenance of cooling tower fans motors and other rotating equipment is fundamental to preserving maximum cooling system efficiency All mechanical draft cooling towers forced or induced draft are subject to vibration and wear Therefore safe and easy access to these components for inspection and maintenance is of significant value to the operator Access can be provided in a number of ways including portable lad ders or scaffolding but for maximum safety and convenience a factory installed Marley access platform with guardrails makes this task as safe and user friendly as possible See graphic below It also saves the owner time and money in that maintenance personnel may devote their time to inspection rather than searching for ladders or erection of portable scaf folding AV Series Cooling Tower Specifications Options 26 Specifications Specification Value Miscellaneous Options Fan Cylinder Extensions Insert the following after the first sen tence Fan cylinder extensions shall be provided to elevate the fan discharge to a height of ft above the top of the standard fan cylinder Equalizer Flume Weir Gates Ada the following paragraph under Cold Water Collection Basin The intercon necting flume between cells sh
9. for a stainless steel tower or if your water or air quality suggests that the use of stainless steel is prudent see stainless steel options on page 21 AV Series Cooling Tower Specifications Base Specifications Fill Louvers and Drift Eliminators Fill shall be film type thermoformed of 15 mil thick PVC with louvers formed as part of each fill sheet Fill shall be suspended from hot dip galvanized structural tubing supported from the tower structure and shall be elevated above the floor of the cold water basin to facilitate cleaning The air inlet face of the tower shall be free of water splash out Drift eliminators shall be PVC triple pass and shall limit drift losses to 0 005 or less of the design water flow rate Louvers Fill Sheets 18 Specification Value E Louvers integral with the fill keep the flowing water within the confines of the fill The separate external louvers used by others permit water to escape the fill and form ice or produce an unsightly situation adjacent to the tower If you plan to use your tower in the wintertime particularly for free cooling integral louvers will put your operating concerns to rest Wi Drift rate varies with design water loading and air rate as well as drift eliminator depth and number of directional changes A drift rate of 0 001 is readily available on many standard models If a lower rate is required please discuss with your Marley sales represen
10. slots shall be provided in the basin side supports to allow handling of the tower at grade level 15 Specification Value CTI Certification means that the tower has been tested under operating condi tions and found to perform as rated by the manufacturer under those circum stances It assures the buyer that the tower is not intentionally or inadvertently undersized by the manufacturer However CTI certification alone is not sufficient to assure you that the tower will perform satisfactorily in your situation Certification is estab lished under relatively controlled conditions and towers seldom operate under such ideal circumstances They are affected by nearby structures machinery enclosures effluent from other towers etc Responsible and knowledgeable bidders will take such site specific effects into consider ation in selecting the tower but the specifier must insist by the written specification that the designer manufacturer guarantee this real world performance Any reluctance on the part of the bidder should cause you some concern 95 90 o a o 8 45 F RANGE lt gt 10 F RANGE 15 F RANGE Q eg COLD WATER TEMP F E a 2 a 2 3 a a 50 55 60 65 70 75 80 WET BULB TEMP F M The design wind and seismic loads at the left are the minimum allow ables for any model in the line under accepted design standards Some models ca
11. to po tentially damaging levels on tower structure Pulp carry over typical of the paper industry and food pro cessing where vacuum pumps or barometric con densers are used Causes fill plugging which may be intensified by algae Alternative Selections In addition to the AV Series we offer a full scope of Marley products in various designs and capacities to meet the special demands of specific applications Corrosion Resistance e QuadraFlow fiberglass and stainless steel construc tion assures long service life in virtually any environment Five year full product warranty Efficient PVC film fill Uniquely different and architecturally attractive Sigma Series available in wood fiberglass HDG steel or stainless steel structure Field erected for medium to large projects Available in a wide range of sizes Ef ficient PVC film fill Splash Fill Towers Series 10 Series 15 wood structure fiberglass cas ing with splash type fill Similar capacities to Sigma series towers Proven in hundreds of installations Excel lent in dirty water situations AV Series Cooling Tower Specifications Base Specifications Specification Value Base Provide an induced draft crossflow type factory assembled film fill industrial duty galvanized steel cooling tower situated as shown on the plans The limiting overall dimensions of the tower shall be wide long and high to the top of the fan guard Total op
12. AL ql sava COUPLING GROOVE SUCTION HOOD REMOVABLE n 1053 8 md TRASH SCREEN SUCTION CONNECTION SEE TABLE FOR SIZE 15 8 OUT OF TOWER TOWER SECTION OUTLET SEE TABLE FOR SIZE Maximum GPM Outlet TOWER COLLECTION mi PASIN PLOGR Bottom Outlet Side Suction Side Suction Bottom Outlet pump flow REMOVABLE pump flow pump flow m fl uve w anti vortex TRASH SCREEN OUTLET air inlet face cased face plate or CONNECTION Outlet Dia pie Av62 Section 7 aves 2786 Ali Models All Models All Models thru RIZ a O NOTE BOTTOM OUTLET IS AV65 m ALSO AVAILABLE WITHOUT BASE OF TRASH SCREEN TOWER 4 71 164 BOTTOM OUTLET CONNECTION 8 1595 1568 287 658 10 2562 453 1038 121 3500 644 1476 14 788 1807 MAKEUP i A SE 1 MNPT 13 4 ko Tower OVERFLOW Mb Ee 1 Dimensions 4 FNPT Tower Model A B DRAIN 7 T 2 FNPT 1 2 3 p 21 7 AV61 1 9 3 10 AV62 3 6 5 7 3 5 8 7 AV63 1 9 3 10 AV64 1 9 3 10 pisi 2 3 OUT OF TOWER AV65 2 6 4 7 TOWER AV66 3 6 5 7 AIR INLET FACE SECTION T m OVERFLOW DRAIN AND MAKEUP CONNECTION NOTE 1 For gravity flow situations as to an indoor tank use bottom 2 GPM limits are based on single cell or multicell towers with a single outlet Side outlet suction is not recommended for gravity flow outlet per cell For multicell towers connected with collection basin flumes and less than one outlet p
13. Lenntech info lenntech com Tel 431 152 610 900 www lenntech com Fax 431 152 616 289 AV Series Cooling Tower Engineering Data amp Specifications m Marley n AN SPX BRAND AV Series Cooling Tower Table of Contents Engineering Data Schematic 4 Support 8 Hoisting Info 10 Freeze Prevention 11 Environmental 12 Application 13 Specifications Base Base 14 Thermal Performance 15 Performance Warranty 15 Design Loading 15 Construction 16 Mechanical Equipment 17 Fill Louvers and Drift Eliminators 18 Hot Water Distribution System 19 Access 20 Specifications Options Stainless Steel Options Stainless Steel Collection Basin 21 All Stainless Steel Cooling Tower 21 Control Options Fan Motor Starter Control Panel 22 Vibration Limit Switch 23 Basin Heater 23 Convenience and Safety Options Hot Water Basin Access Platform 24 Ladder Extension 24 Ladder Safety Cage 24 Mechanical Equipment Access Platform 25 Miscellaneous Options Fan Cylinder Extensions 26 Equalizer Flume Weir Gates 26 Marley Control Valve 26 FM Approval 27 Low Noise Tower 27 AV Series Cooling Tower A Series towers are galvanized steel factory assembled general purpose crossflow cooling towers designed to serve normal air conditioning and refrigeration systems as well as light industrial loads They evolve from a singleflow concept of towers pioneered by Marley in the 1950s and incorporate all of the design advancements that o
14. The UPDATE web based selection software available at spxcooling com provides AV model recommendations based on customer s LEER AA specific design requirements d X j A TX N MARLEY HC VALVE INLET INLET FACE INLET SS OPTION SHORT RADIUS ELBOW BY OTHERS ae PEDES NM L av l 4 d iacu es X 8 INLET PIPING T J PIPING 8 INLET me n BASE OF BY OTHERS TOWER BY OTHERS d E INLET PIPING DETAILS f 1 156 INLET FACE a H INSTALLED HEIGHT BASE OF TOWER HINGED ACCESS DOOR AV Series Cooling Tower Engineering Data Schematic Tower Nominal Dimensions Design se Motor Operating Model Tons h Wt Cell Note 2 Note 3 L H A s P hs S Weight Heaviest Cell Section AV61001 117 3 8078 4237 AV61011 138 5 8126 4276 AV61021 157 8 4 12 3 6 7 11 6 6 12 3 6 7 8156 4306 AV61031 167 10 8335 4485 AV61041 195 15 8435 4585 AV62001 172 5 10771 5308 AV62011 193 7 10801 5338 AV62021 213 10 10829 5366 11 10 12 3346 12 1 11 6 6 12 3 540 AV62031 229
15. all be equipped with a removable cover plate to permit the shutdown of one cell for maintenance purposes or to permit inde pendent cell operation Marley Control Valve Add the following paragraph under Hot Water Distribution System A heavy duty industrial grade flow control valve shall be provided at the inlet to the hot water basin The valve shall permit both flow balancing on multicell towers and tempo rary shut off for maintenance of selected cells Valve shall have a machined cast iron body with stainless steel operating stem and heavy duty locking handle Premium Efficiency Motor Replace paragraph 6 3 with the follow ing The fan and fan drive assembly for each cell shall be supported by a rigid welded hot dip galvanized steel structural support that resists misalignment The mechanical equipment assembly shall be warranted against any failure caused by defects in materials and workmanship for no less than five 5 years following the date of tower shipment This war ranty shall cover the fan speed reducer motor drive shaft and couplings and the mechanical equipment support The bear ing assemblies and V belts shall be war ranted for 18 months E Extensions are available in 11 increments to a maximum extension height of 6 1074 Such extensions may be considered necessary in order to elevate the discharge beyond the bounds of an enclosure Discuss applicability with your local Marley sales representa
16. box shall include lockable stainless steel snap latch door fasteners terminal blocks marked with wire numbers sub pan and a wiring diagram Complete assembly shall be built to UL 508A standards Conduit entry and exit points shall be the bottom of the enclosure preventing water collection in the enclosure Vibration Limit Switch Add the following paragraph in the Mechanical Equipment section A single pole double throw vibration limit switch in a NEMA 4 housing shall be installed on the mechanical equipment support for wiring into the owner s control panel The purpose of this switch will be to interrupt power to the motor in the event of exces sive vibration It shall be adjustable for sensitivity and shall require manual reset Basin Heaters Add the following paragraph in the Cold Water Basin section Provide a system of electric immersion heater prevent freezing of water in the collection basin during periods of shutdown The system shall consist of one or more stainless steel electric immersion heaters installed in threaded couplings provided in the side of the basin A NEMA 4 enclosure shall house a magnetic contactor to energize heaters a transformer to provide 24 volt control circuit power and a solid state cir cuit board for temperature and low water cutoff A control probe shall be located in the basin to monitor water level and tem perature The system shall be capable of maintaining 40 F water temperature a
17. d for cooling tower duty Speed and electrical characteristics shall be RPM single winding phase hertz volts The fan and fan drive assembly for each cell shall be supported by a rigid welded hot dip galvanized steel structural support that resists misalignment The mechanical equipment assembly shall be warranted against any failure caused by defects in materials and workmanship for no less than five 5 years following the date of tower shipment This warranty shall cover the fan speed reducer drive shaft and couplings and the mechanical equipment support The electric motor shall carry a manufacturer s warranty of at least one year The bearing assemblies and V belts shall be warranted for 18 months Wi Propeller type fans require only half the operating hp of blower type fans However they should be readily adjustable to permit compensation for job site conditions that may tend to overload the motor The fans of one manufacturer require the purchase of special positioners for each incre ment of fan blade pitch Unless otherwise specified motor speed will be 1800 RPM in 60 Hertz areas and 1500 RPM in 50 Hertz areas If you prefer the operating flex ibility of two speed operation please specify the RPM to be 1800 900 1500 750 in 50 Hertz regions Incidentally two speed motors are a far better choice than separate pony motors which simply double the prob lems indicated above If your preference is
18. d scale but biological contamination can only be controlled with biocides An acceptable water treatment program must be compat ible with the variety of materials incorporated in a cooling tower ideally the pH of the circulating water should fall between 6 5 and 8 0 Batch feeding of chemicals directly into the cooling tower is not a good practice since localized damage to the tower is possible Specific startup instructions and additional water quality recommendations can be found in the AV Series User Manual which accompanies the tower and also is available from your local Marley sales representative For complete water treatment recommendations consult a competent qualified water treatment supplier N CAUTION 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 AV Series Cooling Tower Application Typical Applications The AV Series tower can be used in normal applications requiring cold water for the dissipation of heat This includes condenser water cooling for air conditioning refrigeration and thermal storage systems as well as their utilization for free cooling in all of those systems
19. er so it can operate continuous ly at half 900 RPM motor speed even at the highest design wet bulb temperature A typical sound reduction is 10 dBA at 1 2 fan speed but larger reductions are often possible Extreme cases may require special fans or inlet and discharge sound attenuator sections however the static pressure loss imposed by attenuators may necessitate an increase in tower size This is the least desirable approach because of the significant cost impact and because of the obstruction to normal maintenance procedures Your Marley sales representative can help you meet your sound requirements Lenntech info lenntech com Tel 431 152 610 900 www lenntech com Fax 431 152 616 289 SP COOLING TECHNOLOGIES 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 2010 SPX Cooling Technologies Inc Printed in USA AV TS 10
20. er support complete with holes and anchor bolts Do not use studs Anchor points must be framed flush and level at top Design operating weight occurs with collection basin full to overflow level Actual operating weight varies with GPM and piping scheme Anchorage for Supporting Steel Options One and Two are designed for 30 psf wind and or 7g seismic loading for AV61 and AV62 20 psf wind and or 3g for AV63 thru AV65 and 20 psf wind and or 46g for AV66 and AV67 Anchorage capacity for Supporting Steel Options Three and Four are less and will vary with the beam spacing Tower may be placed on a flat concrete slab Side outlet must be specified See pages 6 and 7 and consult your Marley ap plication sales representative Tower may be supported from piers at each anchor bolt loca tion as a support alternative AV Series Cooling Tower Engineering Data Hoisting OFFSET REQUIRED FOR BALANCED LIFT 10 O MIN 15 O MIN SLING LENGTH NOTE 1 All hoisting clip holes are 174 2 Overall length of shackle pins should not exceed 5 4 3 For overhead lifts or where additional safety is required add slings beneath the tower unit AV Series Cooling Tower Engineering Data When the ambient air temperature falls below 32 F the water in a cooling tower can freeze Marley Technical Report H 008 Operating Cooling Towers in Freezing Weather describes how to prevent freezing during operation Available at spxcooling com or
21. er tower cell consult your Marley sales representative for more specific information AV Series Cooling Tower Engineering Data Support 8 k L OVERALL OF BASIN OVERALL OF BASIN D 1 D ANCHOR ANCHOR ANCHOR ANCHOR G 2 BOLT BOLT BOLT BOLT 7 m dl SS R 49 9 ve I l 7 l Sa Ga 29 z 9 HOLES FOR HOLES FOR 1 2 DIA ANCHOR 1 2 DIA ANCHOR BOLTS 4REQD BOLTS 4REQD 11 8 1 4 Yo i 1 8 12 11 4 1 2 l l l w a 2 v o Zo Te 1 sA ta 2 i vou bw p TOWER COLLECTION BASIN AIR INLET FACE TOWER COLLECTION BASIN AIR INLET FACE OPTION ONE OPTION TWO TOWER Dimensions Design Operating Design Operating rer cia Tower Model Wt Cell Load at Anchor m 1 i S Ib lb nw AV61000 8 4 8 2 8435 2815 EE kt n 5 BY OTHERS BY OTHERS AV62000 11 10 11 8 11314 3824 k NORMAL GAUGE AV63000 8 4 8 2 10370 3436 AV64000 8 4 8 2 11024 3636 SECTION A AV65000 9 10 9 8 12709 4203 AV66000 11 10 11 8 13912 4709 AV67000 11 10 11 8 14791 4939 AV Series Cooling Tower Engineering Data Support 9 L L OVERALL OF BASIN OVERALL OF BASIN 4 1 1 ANCHOR ANCHORQ EANCHOR ANCHOR BOLT BOLT BOLT BOLT E 5 1 10 1 4 HOLES FOR 1 2 DIA ANCHOR BOLTS 4REQD HOLES FOR
22. erating horsepower of all fans shall not exceed hp consisting of hp motor s Tower shall be similar and equal in all respects to Marley Model Wi Your specification base establishes the type configuration base material and physical limitations of the cooling tower to be quoted During the planning and layout stages of your project you will have focused your attention on a cooling tower selection that fits your space allotment and whose power usage is acceptable Limitations on physical size and total operating horsepower avoid the introduction of unforeseen operational and site related influences Specifying the number of cells and the maxi mum fan hp cell will work to your advantage The benefit of crossflow towers is that they are inherently easy to oper ate access and maintain Unlike counterflow towers they have a spa cious full height plenum for easy access to all of the tower s internal components and the water distribution system is readily open to view and cleaning If your preference is for a stainless steel tower or if your water or air quality suggests that the use of stainless steel is prudent see stainless steel options on page 21 Ladder and access platform are optional accessories See Page 24 for specification wording The ladder can be located on either end of the platform by simple field rearrangement of handrails and posts AV Series Cooling Tower Specificat
23. fill area Towers of more than one cell shall include flumes for flow and equaliza tion between cells M The access doors on competitive towers may be 18 wide or smaller which is unreasonably small for a human being Specifying the size of the door will cause those bidders to take exception alert ing you to a potential maintenance headache Two doors are standard on all towers so that access between cells of multicell towers is assured E Choose from side suctions and bottom outlets to accommodate a significant variety of piping schemes Unless so specified the tower you may be asked to approve may only be available with one type of suction connection requiring you to rede sign your piping layout If your preference is for a stainless steel tower or if your water or air quality suggests that the use of stainless steel is prudent see stainless steel options on page 21 AV Series Cooling Tower Specifications Options 21 Specifications Specification Value Stainless Steel Options Stainless Steel Collection Basin Replace paragraph 11 1 with the fol lowing The cold water basin shall be heavy gauge Series 300 stainless steel and shall include the number and type of suction connections required to accommodate the outflow piping system shown on the Plans Suction connections shall be equipped with stainless steel debris screens A factory installed float operated mechanical makeup valve shall be included
24. he excess will exit the overflow of the tower Indoor Storage Tank With this type of system water flows from an indoor tank hrough the load system and back to the tower where it is cooled The cooled water flows by gravity from the tower to he tank located in a heated space At shutdown all exposed water drains into the tank where it is safe from freezing The amount of water needed to successfully operate he system depends on the tower size and GPM and on the volume of water contained in the piping system to and from he tower You must select a tank large enough to contain hose combined volumes plus a level sufficient to maintain a flooded suction on your pump Control makeup water accord ing to the level where the tank stabilizes during operation AV Series Cooling Tower Environmental Sound Control Sound produced by an AV Series tower operating in an unobstructed environment will meet all but the most restrictive noise limitations and will react favorably to natural attenu ation Where the tower has been sized to operate within an enclosure the enclosure itself will have a damping effect on sound Sound also declines with distance by about 5 dBA each time the distance doubles Where noise at a critical point is likely to exceed an acceptable limit several options are available listed below in ascending order of cost impact n many cases noise concerns are limited to nighttime when ambient noise levels a
25. he following paragraph in the Mechanical Equipment section A factory installed terminal box shall be furnished and mounted to the outside of the tower where applicable The fan motor and optional components including the vibration switch and water level probes shall be factory wired to terminal points inside the terminal box Optional tower components which ship loose including the oil level switch and immersion heaters shall be field wired to the terminal If it is your opinion that the control system for the cooling tower should be part of the tower manufacturer s responsibility we are in wholehearted agreement with you Who better to determine the most efficient mode and manner of a tower s operation and to apply a system most compat ible with it than the designer and manufacturer of the cooling tower The Marley TF Terminal Box simplifies all electrical connections to the cooling tower motor and optional control accessories Eliminates wiring errors in the field Reduces field wiring labor and materials Provides an external access location to internal cooling tower wiring NEMA 4X fiberglass enclosure suitable for corrosive applications Terminal points are well identified UL 508 assembly 11 2 AV Series Cooling Tower Specifications Options 23 Specifications Specification Value box Enclosure shall be NEMA 4X fiberglass with hinged and lockable door meeting UL 508 CSA and IEC standards Terminal
26. ions Base Specifications Thermal Performance The tower shall be capable of cooling GPM of water from F to F at a design entering air wet bulb temperature of F and its thermal rating shall be Certified by the Cooling Tower Institute Performance Warranty CTI Certification notwithstanding the cooling tower manufacturer shall guar antee that the cooling tower supplied will meet the specified performance conditions when the tower is installed according to plan If because of a sus pected thermal performance deficiency the owner chooses to conduct an on site thermal performance test under the supervision of a qualified disinterested third party in accordance with CTI or ASME standards during the first year of operation and if the tower fails to per form within the limits of test tolerance then the cooling tower manufacturer will pay for the cost of the test and will make such corrections as are appropriate and agreeable to the owner to compensate for the performance deficiency Design Loading The tower structure and anchorage shall be designed to withstand a wind load of 20 psf as well as 3g seismic load while operating The tower shall be designed to withstand shipping and hoisting loads of 2g horizontal and 3g vertical Handrails where specified shall be capable of with standing a 200 Ib concentrated live load in any direction and shall be designed in accordance with OSHA guidelines Fork lift
27. n acceptable level in the circulat ing water system NOTE f makeup water pressure exceeds 50 psig use pressure reducer ahead of valve For flow requirements exceeding the above limitations use mul tiples of the same size valve The AV tower is equipped with a float operated me chanical makeup valves to automatically replenish this lost water The following tables calculated for a concentration of 3 times normal indicate the rate of water loss and the size of valve s required If your installation s cold water basin will drain by gravity to a remote storage tank or if you plan a separate means of controlling makeup water we offer a price reduction for deleting the makeup valve AV Series Cooling Tower Engineering Data Schematic WELDING MECHANIC
28. n withstand greater loads as listed below Model Wind Seismic AV61 and AV62 30 psf 7g AV63 thru AV65 20 psf 3g AV66 and AV67 20 psf 46g If your application requires higher loads consult your Marley sales rep resentative These standards give you assurance that the tower can be shipped handled hoisted and ultimately operated in a normal cooling tower environment AV Series Cooling Tower Specifications Base 16 Specifications Specification Value Construction Except where otherwise specified all components of the cooling tower shall be fabricated of heavy gauge steel protected against corrosion by G 235 galvanizing The tower shall be capable of withstand ing water having a pH of 6 5 to 8 0 a chloride content NaCl up to 500 ppm a sulfate content SO4 up to 250 ppm a calcium content CaCO3 up to 500 ppm silica SiO2 up to 150 ppm and design hot water temperatures up to 125 F The circulating water shall contain no oil grease fatty acids or organic solvents The specifications as written are intend ed to indicate those materials that will be capable of withstanding the above water quality in continuing service as well as the loads described in paragraph 4 1 They are to be regarded as minimum require ments Where component materials pecu liar to individual tower designs are not specified the manufacturers shall take the above water quality and load carrying capabilities into account in the selec
29. olvents M The cold water basin is the only part of the tower that is subject to periods of stagnant water concentrated with treatment chemicals and customary contaminants It is also the most expensive and difficult part of any tower to repair or replace For these reasons many customers particularly those who are replacing older towers choose to specify stainless steel cold water basins Also see the notes on page 20 regarding the standard Cold Water Collection Basin They apply equally well to the stainless steel basin M The corrosion potential of contaminated water increases with tempera ture and these basins see the hottest water in the tower If your design hot water temperature is over 125 F or if your operating system can produce excursions beyond that point you would be well advised to con sider this option It would also be advisable to change the fill support tubes in Para 7 1 from galvanized structural tubing to 300 stainless steel structural tubing See notes regarding Section 8 0 on page 19 E Where water quality falls outside the limits indicated in Paragraph 5 1 an all stainless tower is worthy of your consideration AV Series Cooling Tower Specifications Options 22 Specifications Specification Value Control Options Fan Motor Starter Control Panel Add the following paragraph in the Mechanical Equipment section Each cell of the cooling tower shall be equipped with a UL CUL 508 lis
30. out losing the ability of limited operations and capacity Sound produced by a AV Series tower operating in an unobstructed environment will meet all but the most restrictive noise limitations and will react favorably to natural attenuation Where the tower has been sized to operate within an enclosure the enclosure itself will have a damping effect on sound Sound also declines with distance by about 5 or 6 dBA each time the distance doubles Where noise at a critical point is likely to exceed an acceptable limit you have several options listed below in ascending order of cost impact Where only a slight reduction in noise will satisfy and the source of concern is in a particular direction merely turning the tower may be the answer Less sound emanates from the cased face of the tower than does from the air intake face In many cases noise concerns are limited to nighttime when ambient noise levels are lower and neighbors are trying to sleep You can usu ally resolve these situations by using two speed motors in 1800 900 configuration and operating the fans at half speed without cycling after hours The natural nighttime reduction in wet bulb temperature makes this a very feasible solution in most areas of the world but the need to avoid cycling may cause the cold water temperature to vary significantly e Where noise is a concern at all times for example near a hospital the best solution is to oversize the tow
31. re lower and neighbors are trying to sleep You can usually resolve these situations by using a two speed motor in an 1800 900 configu ration operating the fans at half speed without cycling after hours The natural nighttime reduction in wet bulb temperature makes this a very feasible solution in most areas of the world but the need to avoid cycling may cause the cold water temperature to vary significantly e Where noise is a concern at all times for example near a hospital the best solution is to oversize the tower so it can operate continuously at reduced 900 RPM motor speed Typical sound reductions at half speed are 10 dBA Extreme cases may require inlet and discharge sound attenuator sections however the static pressure loss imposed by attenuators may necessitate an increase in tower size This is the least desirable approach because of the significant cost impact and because of the ob struction to normal maintenance procedures Your Marley sales representative will help you meet your sound requirements Enclosure Occasionally cooling towers are located inside architec tural enclosures for aesthetic reasons Although AV Series towers adapt well to enclosures the designer must realize the potential impact of a poorly arranged enclosure on the tower s performance and operation The designer must take care to provide generous air inlet paths and the tower s fan cylinder discharge height should not be lower
32. s task as safe and user friendly as possible Further its location on the side of the tower does not add to the height of the unit preserving architectural integrity See graphic Page 14 It also saves the owner time and money in that maintenance personnel may devote their time to inspection rather than searching for ladders or erection of portable scaffolding E Many towers are installed such that the base of the tower is 2 0 or more above the roof or grade level This makes it difficult to get up to the foot of the attached ladder The ladder extension alleviates this problem Marley ladder extensions are available in standard 5 0 and 11 0 lengths E To meet OSHA guidelines towers whose distribution basin access plat forms are 20 0 or more above roof or grade and which are equipped with external ladders should have safety cages surrounding the ladders AV Series Cooling Tower Specifications Options 25 Specification Value Mechanical Equipment Access Platform Available only on AV63000 models and larger Add the following paragraph in the Access section Provide an internal platform approximately 7 below the level of the fan for access to the mechanical equipment The platform shall be galva nized steel bar grating supported by gal vanized steel framework attached to the tower The platform shall be surrounded by a handrail and kneerail A permanently attached 1 6 wide aluminum ladder with 3 I
33. t an ambient air temperature of __ F Wi Unless specified otherwise a Marley M 5 vibration switch will be provided The requirement for manual reset assures that the cooling tower will be visited to determine the cause of excessive vibration M The basin heater components described at left are recommended for a reliable automatic system for the prevention of basin freezing They are normally shipped separately for installation at the job site by the installing contractor When purchased in conjunction with the enhanced Control System option however they are customarily factory mounted and tested Submerged in basin water in which zinc ions are present copper immer sion heaters must not be used Insist upon stainless steel The ambient air temperature that you fill in should be the lowest 1 level of winter temperature prevalent at site Ask for appropriate Marley drawing IND AV Series Cooling Tower Specifications Options Specifications Convenience and Safety Options Hot Water Basin Access Platform Add the following paragraph in the Access section Provide an external platform near the top of the louver face for access to the hot water distribution system The platform shall be galvanized steel bar grating supported by galvanized steel framework attached to the tower The platform shall be surrounded by a handrail kneerail and toeboard A per manently attached 1 6 wide aluminum ladder with
34. t numeral of model number indicates number of cells 5 Outlet sizes vary according to GPM and arrangement See Change as appropriate for your selection pages 6 and 7 for outlet sizes and details 3 Nominal tons are based upon 95 F HW 85 F CW 78 F WB 6 Makeup water connection may be 1 or 2 dia depending upon and 3 GPM ton tower heat load water pressure and desired connections See page 6 for additional information AV Series Cooling Tower Engineering Data Schematic 6 Outlet and Makeup Piping Details p Fiping Makeup Water Flow Required GPM to Maintain Three 3 Concentrations Unless otherwise specified single cell towers normally ER T 5 i Tower Cooling Range hot water minus cold water have a side outlet suction appropriate for the design water PM G 5 10 F 151E 20 F 30 F 40 F flow rate see page 7 This usually assures the lowest 200 2 3 4 5 8 10 possible installed tower elevation Side suction connection pipes extend roughly 3 outside the basin and are beveled ave 8 10 15 20 for weld connection and also grooved for a mechanical 999 g le 18 29 W coupling 800 5 10 15 20 30 40 Outlet piping can be kept below the cold water basin 1080 f 1 19 5 Bs 5 level by choosing a bottom outlet connection in lieu of the i200 ig 18 ZE se 807 Side suction Bottom outlet design conform to standard 2000 18 25 38 50 75
35. tative Drift Eliminators AV Series Cooling Tower Specifications Base 19 Specifications Specification Value Hot Water Distribution System An open basin above the bank of fill shall receive hot water piped to each cell of the tower The distribution basin shall be installed and sealed at the factory and shall be equipped with removable galva nized steel covers to keep out leaves and debris and to retard the growth of algae The basin shall include an inlet hole and bolt circle to accept a 125 flange con nection per ANSI B16 1 Removable interchangeable polypropylene nozzles installed in the floor of these basins shall provide full coverage of the fill by gravity flow Casing Fan Deck and Fan Cylinder The casing and fan deck shall be heavy gauge galvanized steel and shall be capable of withstanding the loads described in paragraph 4 1 The fan cyl inder shall be molded FRP and shall be through bolted to the fan deck to provide a consistently stable operating shroud for the fan The top of the fan cylinder shall be equipped with a conical non sagging removable fan guard fabricated of welded 6 and 7 gauge rods and hot dip galvanized after fabrication E Gravity flow distribution basins are a feature of crossflow type towers resulting in operating pump heads of from 10 to 20 feet less than that encountered in counterflow towers with pressurized spray systems Also these basins are out where the
36. ted control panel in a NEMA 8R or 4X outdoor enclosure capable of controlling single speed or two speed motors as required and designed specifically for cooling tower applications The panel shall include a main circuit breaker or main fused disconnect with an external operating handle lockable in the off position for safety Full voltage non reversing mag netic starter shall be controlled with a thermostatic or solidstate temperature controller Door mounted selector switch es shall be provided to enable automatic or manual control and wired for 120VAC control Control circuit to be wired out to terminal blocks for field connection to a remote vibration switch overload trip alarms and remote temperature control devices The temperature controller shall be adjustable for the required cold water temperature If a thermostatic controller is used it shall be mounted on the side of the tower with the temperature sens ing bulb installed in the cold water basin using a suspension mounting bracket If a solid state temperature controller is used the controller will be door mounted on the control panel The solid state temperature controller will display two temperatures one for outgoing water and the other for set point Water temperature input shall be obtained using a three wire RTD with dry well in the outlet water piping and wired back to the solid state temperature controller in the control panel Marley TF Terminal Box Add t
37. than the elevation of the top of the enclosure Obtain a copy of Marley Technical Report H 004 External Influences on Cooling Tower Performance from your Marley sales representative As suggested in the aforementioned Technical Report it may also be advisable to specify a design wet bulb tempera ture 1 F higher than normal to compensate for potential recir culation initiated by the enclosure You ll benefit from discuss ing your project with your Marley sales representative System Cleanliness Cooling towers are very effective air washers Atmospheric dust able to pass through the relatively small louver openings will enter the circulating water system Increased concentra tions can intensify system maintenance by clogging screens and strainers and smaller particulates can coat system heat transfer surfaces In areas of low flow velocity such as the cold water basin sedimentary deposits can provide a breed ing ground for bacteria In areas prone to dust and sedimentation you should con sider installing some means for keeping the cold water basin clean Typical devices include side stream filters and a variety of filtration media Water Treatment To control the buildup of dissolved solids resulting from water evaporation as well as airborne impurities and biologi cal contaminants including Legionella an effective consistent water treatment program is required Simple blowdown may be adequate to control corrosion an
38. tion of their materials of manufacture E In the history of cooling towers no other coating for carbon steel has exhibited the success and longevity of galvanization in exposure to the normal cooling tower water quality defined at left No paints or electro statically applied coatings however exotic they may be can approach galvanization s history of success Except for those unusual operating situations where the circulating water may be so laden with suspended solids algae fatty acids product fibers active organisms reflected in BOD and the like that plugging of the fill is a probability reasonable attention to the construction materials and or their coatings is all that is normally required If your preference is for a stainless steel tower or if your water or air quality suggests that the use of stainless steel is prudent see stainless steel options on page 21 AV Series Cooling Tower Specifications Base 17 Specifications Specification Value Mechanical Equipment Fan s shall be propeller type incorporat ing wide chord aluminum alloy blades and galvanized hubs Blades shall be individu ally adjustable Fan s shall be driven through an industrial grade system of V belts pulleys and tapered roller bear ings Bearings shall be rated at an L10A service life of 40 000 hours or greater Motor s shall be hp maximum Totally Enclosed 1 15 service factor vari able torque and specially insulate
39. tive E Where it is your intention to be able to operate other cells of the tower while the flume cover plate is installed separate outlet connections float valves and overflows must be provided for each cell Likewise this would require separate sensors and controls for basin heater systems if installed E NEMA premium efficiency motor with a five year warranty enhances the standard five year mechanical equipment warranty of the AV cooling tower AV Series Cooling Tower Specifications Options Specifications Specification Value FM Approval Available only on multi cell towers Ada the following paragraph in the Construction section The tower shall include all design and material modifica tions necessary to meet the fire rating requirements of Factory Mutual The product proposed shall be listed in the FM Approval Guide latest edition Low Noise Tower Ada the following paragraph under Base The cooling tower shall be quiet operating and shall produce an overall level of sound no higher than dBA measured at the critical location indicated on the Plans M This could have a very beneficial effect upon your fire insurance premi ums Towers not able to meet FM requirements may require the inclusion of a fire protection sprinkler system to achieve a comparable level of insurance premium cost Even if you are not insured by FM this require ment ensures that each cell will contain any fire that may occur with
40. ur customers have found valuable They represent the current state of the art in this cooling tower category This booklet not only relates the language to use in describing an appropriate AV Series cooling tower but also defines why certain items and features are important enough to specify with the intention of insisting upon compliance by all bidders The left hand column of pages 14 thru 27 provides appropriate text for the various specification paragraphs whereas the right hand column comments on the meaning of the subject matter and explains its value Pages 14 thru 20 indicate those paragraphs which will result in the purchase of a basic cooling tower one that accomplishes the specified thermal performance but which will lack many operation and maintenance enhancing accessories and features that are usually desired by those people who are responsible for the continued and continuing operation of the system of which the tower is part It will also incorporate those standard materials which testing and experience has proven to provide acceptable longevity in normal operating conditions Pages 21 thru 27 provide paragraphs intended to add those features components and materials that will customize the tower to meet the user s requirements AV Series Cooling Tower Engineering Data Schematic Use this data for preliminary layouts only Obtain current drawing from your sales representative
41. y can be easily inspected even maintained while the tower is in operation Spray systems of counterflow towers sandwiched between the top of the fill and the drift eliminators are extremely awkward to access and maintain If your preference is for a stainless steel tower or if your water or air quality suggests that the use of stainless steel is prudent see stainless steel options on page 21 c AV Series Cooling Tower Specifications Base 20 Specification Value Access Large galvanized steel access doors 30 wide and a minimum of 42 high shall be located in both endwalls for entry into the cold water basin and fan plenum area Access doors shall be operable from inside as well as outside the tower Cold Water Collection Basin The cold water basin shall be heavy gauge galvanized steel and shall include the number and type of suction connec tions required to accommodate the out flow piping system shown on the Plans Suction connections shall be equipped with galvanized debris screens A factory installed float operated mechani cal makeup valve shall be included A 3 diameter drain and a 4 diameter overflow shall be provided in each cell of the tower The basin shall include a depressed section into which accumulat ed silt can be flushed to permit cleaning The basin floor adjacent to the depressed section shall slope toward the depressed section to prevent buildup of silt under the
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