1. Inspection requirements
In addition to daily inspections and troubleshooting in emergencies, the following periodic inspections are designed to identify potential risks and failures and prepare for risk and troubleshooting in advance.
The inspection process should be non-essential to avoid touching the equipment with hands as much as possible, especially valves, main circulation pumps, running radiator fans, etc., to protect personal and equipment safety. Inspectors should be professionally qualified and trained in the use of products and troubleshooting in emergency situations.
Should be observed daily to record the operation of the equipment, record work, and comparative analysis, timely discovery of abnormal small changes in the situation and the trend of change, predict the possible risks of operation, take targeted measures in advance.
2. Inspection item:
2.1 Observe all operating parameters through the cooling system control panel cabinet for any abnormalities.
2.2 Check the main circulation pump, instrumentation and equipment for any abnormalities in the operating parameters。
3. Regular inspection item:
3.1 Routine inspection items
Cooling system: water pump, make-up tank level, piping, valve status, pressure gauge, pressure sensor, temperature sensor, flow sensor, power and control cabinet, LCD display, container fan。
Cooling tower and external pipeline: fan, pump, pool level, cooling pipe scale, pipe connection, valve status, etc.。
See Annex II "ANTSPACE Cooling System Inspection Record Form"
4. Key inspection item
Cooling system professional inspection (station duty) work standardization operation card
Index | Key component | Quality standards and requirements | Risk Identification and Preventive Measures | Frequency |
1 | In-valve water cooling system professional inspection | |||
1.1 | Main circulation pump |
1) There should be no obvious oil leakage or water leakage; 2) There should be no abnormal noise and vibration; 3) The bearing should be free of abnormal noise and jamming; 4) The inlet and outlet pressure difference should be within the normal range; 5) No leakage near the main circulation pump is dry; 6) No abnormal temperature rise when the pump body is measured by infrared temperature. |
(1) Inspection tour should maintain a sufficient safety distance from live equipment. 2)When inspecting, no other work should be done, and no moving away from or over the cover fence. (3) Open and close the equipment door should be careful to prevent excessive vibration. 4)Entering the equipment area, you must wear a helmet, no slippers or high heels, and dress in accordance with the requirements. (5) Strictly in accordance with the inspection route, inspection of equipment is prohibited to change the maintenance site security measures, prohibit the change of maintenance equipment state. (6) before the inspection, check the safety instruments used intact. |
Once every half month |
1.2 | Main Filter |
1) Good sealing performance of the tank, no leakage, water overflow phenomenon; 2) The main filter fixed bolts should be free of looseness and internal noise; 3) The pressure difference between the front and rear of the main filter should be within the normal range. |
Once every half month | |
1.3 | Voltage stabilization system |
1) The expansion tank pressure should not be lower than the normal value; 2) Pipeline joints and exhaust valves should be free of leakage; |
Once every half month | |
1.4 | Hydration device |
1) The level of the make-up water tank should be within the normal range; 2) The power supply of the make-up water pump should be free of abnormalities; 3) The valve position of the make-up water circuit should be normal; 4) The mechanical seal position of the make-up water pump should be free of water leakage. |
Once every month | |
1.5 | Sensors |
1) The sensor connector should be free of looseness and water leakage; 2) Sensor panel display value should be normal and no black screen phenomenon; 3)The local display is consistent with the remote transmission data. |
Once every month | |
1.6 | Piping, flanges and valves |
1) No abnormal vibration of the pipeline; 2) Pipeline and flange joints, drainage valves are not broken, no water leakage phenomenon; 3) Pipeline and flange should be free of deformation and distortion; 4) The connection bolts shall be free of looseness, gaskets shall be free of deformation, and the torque line shall not be shifted; 5) The valve position should be consistent with the mode of operation, the opening degree has not been displaced; 6) The valve position indication is normal. |
Once every half month | |
1.7 | Power supply cabinet |
1) No alarm signal, no abnormal sound; 2) Normal position of the power switch, all kinds of control handles and knobs in the correct position; 3) The cabinet status indication is correct, consistent with the actual state of the equipment; 4) Components and cables without aging phenomenon, no burn paste traces; 5) Power cable, switchgear components for infrared temperature measurement, there should be no local overheating phenomenon; 6) Terminal wiring without falling off, no abnormal opening of the terminal; 7) Inverter panel display without black screen, bad screen phenomenon, signal indicator is normal, control mode in normal position; 8) The radiator fan runs normally, no abnormal sound or stopping phenomenon, the filter is not blocked; 9) Ventilation style window without foreign matter coverage, good ventilation; 10) Cabinet without water, condensation phenomenon; 11) Lighting function should be normal; 12) Cabinet door sealing good, close normal, cable hole sealing tight. |
Once every month | |
1.8 | Control and protection cabinet |
1) No alarm signal, no abnormal sound; 2) Normal position of the power switch, all kinds of control handles and knobs in the correct position; 3) The host is well fixed, the fasteners are complete and intact, the appearance is intact without damage; 4) Normal operation of the host fan, no abnormal sound; 5) The host of the status indicators indicate normal; 6) Each input and output module and slot connection should be solid and reliable, no bending, deformation, extrusion phenomenon, no dust accumulation;; 7) The cabinet status indication is correct, consistent with the actual state of the equipment; 8) Components and cables without aging phenomenon, no burn paste traces; 9) Infrared temperature measurement should be no local overheating phenomenon; 10) Terminal wiring without falling off, no abnormal opening of the terminal; 11) Radiator fan running normally, no abnormal sound or stall phenomenon, no blockage of the filter; 12) Cabinet without water, condensation phenomenon; 13) The cabinet lighting function should be normal; 14) Cabinet door sealing good, close normal, cable hole sealing tight. |
Once every month |
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2 | Professional inspection of water cooling system outside the valve | |||
2.1 | Piping, valves |
1) The appearance should be free of rust and corrosion, and no scaling; 2) Pipeline should be free of sand eyes, no water leakage; 3) Pipeline water flow direction indication, valve opening and closing indication is clear; 4) Valve position should be consistent with the mode of operation, the opening degree has not been displaced; 5) Valve locking device is intact, the lock is not damaged, rust and corrosion. |
Once every month | |
2.2 | Meters | 1) No damage to the meter's appearance and no loose joints; | Once every month | |
2.3 | Control cabinet |
1) No alarm signal on the display, no abnormal sound in the cabinet; 2) Normal position of the power switch; 3) The host, input and output modules, power modules and other indicators are normal; 4) The cabinet status indication is correct, and the actual state of the equipment; 5) Components and cables without aging phenomenon, no burn traces; 6) Infrared temperature measurement should be no local overheating phenomenon; 7) Terminal wiring without falling off, no abnormal opening of the terminal; |
Once every month | |
2.4 | Cooling Towers |
1) Cooling tower body without leakage, deformation, damage and rust and other phenomena; 2) Cooling tower fan motor speed, turning normal, bearing rotation even, no abnormal sound; 3) Cooling tower fan blade no deformation, no cracks, no breakage, normal running noise; 4) No blockage of the spray pipe, no breakage, uniform water flow, into, return water without overflow and suction empty phenomenon; 5) The import and export of cooling water, water replenishment, sewage and other valve position indication is correct, the valve locking device is normal; 6) Fan junction box, safety switch sealing and rainproof situation is good, internal wiring without overheating, aging, loose phenomenon; 7) Cooling tower grille without deformation, water overflow. |
Once every month |
5. Cooling Tower
Cooling tower operation process need to do routine inspection, if found fault, please do replacement for parts.。
5.1 Spray pumps
5.1.1 Spray pump dimensional drawing
Outline | Installation Size | Liquid inlet and outlet flange size | ||||||||||||||
L1 | H | H1 | L2 | L3 | L7 | L9 | L5 | L4 | L8 | L6 | R | D1 | D2 | D3 | n | dl |
700 | 462 | 232 | 510 | 195 | 402 | 350 | 150 | 170 | 310 | 135 | 6 | 150 | 240 | 285 | 8 | 22 |
5.1.2 Exploded of spray pump
1. Pump body | 11.Moto | 25.Nut | 34. Impeller spacer | 7 Protection plate | 13. Key (motor) |
3. Impeller | 12. Bolts, washers, nuts | 26. Pipe Plugging | 38. Pump head | 4. Pump shaft | |
5. Mechanical Seals | 15.Base | 30. Bolts, washers | 39. Bolts, washers | 22. Set screws | |
6. Post Circle | 23.Key | 33.Spring washers | 16. Crossed pan head screws | 18.Nut, washers |
5.1.3. Solutions to pump problems
Failure phenomenon | Cause | Exclusion method |
Motor does not start |
1. Power supply failure 2. Control circuit is faulty |
1. Check the power supply - container control cabinet power on and off. 2. Check the in and out line - three-phase circuit connection sequence is normal, container abnormal tips. |
Insufficient pump flow |
1.The pipeline is blocked 2. Air inlet pipe 3.Water leakage at the connection of motor impeller |
1. Check the pump - whether the impeller disk of the pump is rotating normally. 2.Check the pipeline - after removing the water tank strainer, visually inspect the pipeline to see if there are any foreign objects in the pump head, the water tank level is detected by the level meter without replenishment, and there is no vortex in the water tank to absorb the empty situation. 3. Replace the wear ring wear, see the instructional video for details. |
Excessive pump power consumption |
1. Flow rate is too large 2. Motor bearings are badly worn |
1. Check whether there is overload and deal with the corresponding overload item. 2. After the manufacturer confirms the wear and tear, replace the whole pump. |
Excessive noise |
1.Damaged parts in the pump 2.Motor bearing wear 3.Air in the pump |
1. Replace the parts inside the pump - impeller. 2. Replace the whole pump after the manufacturer confirms the wear and tear. 3. Exhaust the water through the pump flange side exhaust bolt to the bolt hole, see the exploded diagram for details. |
Motor is hot |
1. Excessive current overload 2. Insufficient water inlet |
1. Check the system alarm message, the operating current should not exceed 5% of the rated current. 2. Check the water level of the sink: the supplemental sink water level meter detects that the system prompts normal, and the sink has no eddy current to absorb the empty situation. |
5.1.4. Regular pump maintenance.
Seal testing and replacement - once every six months [such as downtime, winter, use of harsher working conditions than the technical standards need to be shortened as appropriate] - machine seal corresponding to the No. 5 parts. (Seal brand is TG, specification is 108-28)
Bearing rotation without abnormal inspection - once every six months [such as downtime, winter, use of harsher working conditions than the technical standards need to be shortened as appropriate] - bearings in the motor out of the shaft end, the motor inside. (Bearing brand NSK, specifications are 6308ZZ C3/5C and 6309ZZ C3/5C)
5.2 Cooling tower fans
5.2.1 Fan composition:
The wind machine consists of ④ impeller (including two parts: blade and hub), transmission system (including bearing seat, belt and pulley), fan guide barrel ⑧, protective net ⑩ and motor ⑫. Each blade in the factory are torque balance after assembling the whole set of wind blade after dynamic balance test, so in the use of maintenance process can not be decomposed, disassembly and repair blade, so as not to affect the balance accuracy of the blade.
Whether the fan is mounted on the frame or foundation, the frame or foundation should have sufficient strength, rigidity and stability to absorb and isolate vibration to prevent resonance. The foundation not only bears the full weight of the fan static load, but also by the fan rotation of the unbalanced inertial force caused by the power load and pneumatic load.
1. Bolt locking washers | 4. Impeller | 7. Motor fixing nut | 10.Protection grid | 13. Motor fixing bolts |
2. Impeller shaft head bolts | 5. Bushing | 8. Dampers | 11. Protective net fixing bolts | |
3. Impeller fixing nut | 6. Impeller fixing bolt | 9. Protective net fixing nuts | 12 Motor |
5.2.2 Fan operating instructions
5.2.2.1 Operation after running
1). Check the vibration level, check the vibration speed of the left and right, front and back, and top and bottom of the fan shaft respectively. Vibration level should not exceed the limit value of 7mm/s root mean square value (overall) specified by the device where the fan is installed, if it exceeds, it must stop immediately to find out the cause of vibration. can be through the noise, the whole machine heat dissipation preliminary determination of the fan whether there are serious abnormalities before further inspection of vibration]
Note: If the vibration is within the range of 7-12mm/s root mean square value (overall) with the vibration tester, the fan can run for a period of time to solve the vibration problem.
2). After the fan works for 50-75 hours, check if the wind blade U-bolt ② is loose.
3). Preventive maintenance measures
(1). Periodically check the fan assembly condition
The inspection interval depends on the operating conditions of the turbine and can range from a minimum of two weeks to a maximum of six months.
Inspection includes
* Bolt torque
* Fastener corrosion condition
* General condition of the blade and blade shaft
When necessary, the fan blade surface dirt should be cleaned to ensure the correct balance of the fan and to avoid excessive dirt leading to improper operation. If the surface dirt accumulation thickness exceeds 1mm, you need to use a shovel to shovel the surface dirt to prevent excessive dirt accumulation affect the normal operation of the fan。
(2).To strictly avoid ice on the surface of the fan blades in operation. If icing occurs on the blades in stationary, the ice must be removed before running the fan. Clean the snow on the fan blades regularly.
(3). If the fan is shut down for a long time, it is recommended to run the machine for 10~15 minutes every month, so that the bearing grease can evenly wrap the steel ball and play the role of protecting the bearing. Before running again must check all bearings before running, if found to have inflexible operation or stuck phenomenon, must first replace the bearings before starting to run. Daily inspection of the motor once every three months 。
(4). Don't remind: When encountering extreme weather effects, such as typhoons, sandstorms, strong convective weather, heavy rain, hail, etc., the running fan must be shut down to reduce the external environmental factors that cause fatal damage to the fan and seriously affect the normal service life of the fan.
4). Common causes of fan failure and its troubleshooting methods
Failure | Causes | Exclusion method |
Fan vibration and abnormal sound |
1.The balance block on the wheel hub is dislodged or the balance is not calibrated after overhaul. (See the exploded view for the location of the wheel balancing block) |
Wheel rebalancing, or on-site balancing test |
2.The blade installation angle is not consistent, the blade height difference exceeds the requirements. | Visualize whether the blade is deformed | |
3.Uneven adhesion on the surface of the blade | Cleaning of the blade surface | |
4.Uneven clearance between impeller and wind cylinder | First check whether the impeller and wind cylinder friction, impeller to wind cylinder spacing uniform (error not more than 5MM) | |
5.Spindle bearing damage | Replace the bearings or the whole machine after confirmation by the manufacturer | |
Three-phase current imbalance | 1.Power supply voltage imbalance | Measure the power supply voltage and find out the cause |
2.Windings failure | Identify the cause, repair if necessary (three resistance values are consistent) | |
Motor rated current is too high | 1.Motor failure itself | Identify the cause and fix if necessary |
2.The power supply voltage is higher than the standard voltage | Measure power supply voltage to find the cause and select a better quality grid | |
Too low airflow | 1.Impeller turning opposite | Adjust the wiring phase sequence until the fan blade rotates in the direction shown by the arrow |
Annex I. Reference torque comparison table
Carbon Steel Bolt Torque Table | ||
External hexagon bolts S(mm) |
Bolt diameter M(mm) |
Bolt strength grade 4.8 Ma (Nm) |
10 | M6 | 3.92 |
13 | M8 | 9.48 |
17 | M10 | 19.1 |
19 | M12 | 32.6 |
22 | M14 | 52 |
24 | M16 | 79.9 |
Stainless steel bolt torque meter | ||
External hexagon bolts S(mm) |
Bolt diameter M(mm) |
Bolt strength grade A2-70 Ma(Nm) |
10 | M6 | 5.6 |
13 | M8 | 13.6 |
17 | M10 | 26.9 |
19 | M12 | 46.9 |
24 | M16 | 117 |
Note: 1. S - the distance between the two parallel sides of the outer hexagon; 2. Ma - the bolt torque (N-m); |
Annex II
ANTSPACE Cooling System Inspection Record Sheet |
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Date: | Ambient temperature: | Ambient Humidity: |
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Category | Inspection Projects | Result | Remark |
Cooling System | Main Pump | ||
Water refill tank | |||
Piping, valves and limit markings | |||
Pressure gauges | |||
Pressure sensors | |||
Temperature sensors | |||
Flow sensors | |||
Power and control cabinets | |||
LCD display | |||
Container fans | |||
Cooling tower and external piping | Fans | ||
Spray water pump | |||
Pool level | |||
Pipe connection port | |||
Valve status | |||
Inspection results:
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Inspector: Checker:
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